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Atlas Copco XAXS 600 Cud Export PNE Instruction Manual

Engine 6cta 8.3
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Instruction Manual
for Portable Compressors
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XAXS 600 Cud Export PNE
Engine 6CTA 8.3

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Summary of Contents for Atlas Copco XAXS 600 Cud Export PNE

  • Page 1 Instruction Manual for Portable Compressors English XAXS 600 Cud Export PNE Engine 6CTA 8.3...
  • Page 3 Instruction Manual for Portable Compressors XAXS 600 Cud Export PNE Engine 6CTA 8.3 Printed matter No. 2954 9760 00 ATLAS COPCO - PORTABLE ENERGY DIVISION www.atlascopco.com 12/2018...
  • Page 4 The manufacturer does not accept any liability for any damage arising for modifica- tions, additions or conversions made without the manufacturer's approval in writing. Copyright 2018, Atlas Copco (India) Ltd. Any unauthorized use or copying of the contents or any part thereof is prohibited.

  • Page 5: Table Of Contents

    Table of contents Preface Before starting ........31 Starting / Stopping .......32 Please read the following instructions 4.3.1 Control panel ........32 carefully before starting to use your Operations overview......34 Safety precautions ....... 7 compressor. Specific start procedure ....... 34 Introduction ...........
  • Page 6 5.10 Cleaning coolers ......... 47 7.3.1 Priming instructions ......55 5.11 Battery care ......... 48 7.3.2 Replacing fuel filter elements ..55 5.11.1 Electrolyte ........48 7.3.3 Exhaust System ....... 55 5.11.2 Activating a dry-charged battery ..48 Problem solving ......... 56 5.11.3 Recharging a battery .......

  • Page 7: Safety Precautions

    Safety precautions To be read attentively and acted accordingly before towing, lifting, operating, performing maintenance or repairing the compressor. INTRODUCTION The policy of Atlas Copco is to provide the mentioned on the equipment or parts of the safety system. mechanical users of their equipment with safe, reliable unit.

  • Page 8: General Safety Precautions

    1 The owner responsible on Atlas Copco equipment, the mechanics modifications, additions or conversions maintaining the unit in a safe operating are expected to use safe engineering made without the manufacturer’s approval condition. Unit parts and accessories practices and to observe all relevant local in writing.

  • Page 9: Safety During Transport And Installation

    oil, dust or other deposits. 13 In the event the safety labels are SAFETY DURING TRANSPORT damaged or destroyed, they must be AND INSTALLATION 7 To prevent an increase in working replaced to ensure operator safety. temperature, inspect and clean heat Transport of the unit has to be done by transfer surfaces...

  • Page 10: Safety During Use And Operation

    - remove wheel chocks, if applied, and 7 Lifting hooks, eyes, shackles, etc., shall contact Atlas Copco. disengage the parking brake, never be bent and shall only have stress in line with their design load axis. The...
  • Page 11 If measures for breathing purposes as this Atlas Copco Instruction Book (AIB). necessary, install extra air intake ducts. may result in injury or death. For Keep fuel away from hot parts such as quality breathing air, the compressed air outlet pipes or the engine exhaust.
  • Page 12 17 Noise, even at reasonable levels, can provided and a special warning to 23 Safety shoes should be compulsory in cause irritation and disturbance which, that effect shall be placed at each any workshop and if there is a risk, over a long period of time, may cause entrance.

  • Page 13: Safety During Maintenance And Repair

    2 Parts shall only be replaced by genuine machine or undertaking major overhaul on jacks. Atlas Copco replacement parts. on it, prevent all movable parts from 13 Do not remove any of, or tamper with, 3 All maintenance work, other than rolling over or moving.

  • Page 14: Tool Applications Safety

    15 Protect the engine, alternator, air intake 21 When hot parts have to be handled, e.g. TOOL APPLICATIONS SAFETY filter, electrical regulating shrink fitting, special heat-resistant Apply the proper tool for each job. With components, etc., to prevent moisture gloves shall be used and, if required, the knowledge of correct tool use and ingress, e.g.

  • Page 15: Specific Safety Precautions

    9 (Pressure) vessel maintenance is to be in the plugs. Thus an explosive plate of the vessel: performed by Atlas Copco. atmosphere may form around the - the maximum working pressure ps in battery if ventilation is poor, and can...
  • Page 16 Safety valves When fitted, the lifting device should be operated at pressures not less than 75% of Operating & Maintenance the set pressure to ensure free and easy Only trained and technically competent movement of internal parts. personnel should consider overhaul, re-set The frequency of tests is influenced by or performance testing of safety valves.

  • Page 17: Leading Particulars

    Leading particulars DESCRIPTION OF SAFETY GENERAL DESCRIPTION oil vessel at first by centrifugal force, secondly through the oil separator element. PICTOGRAMS USED IN THIS The compressor XAXS 600 is silenced, MANUAL The vessel is provided with an oil level single-stage, oil-injected screw indicator.
  • Page 18 Cooling system Bodywork Control panel The engine is provided with a liquid-cooler The bodywork has openings at the rear of The control panel grouping the air pressure and the compressor is provided with an oil unit for the intake and outlet of cooling air gauge, control switch etc., is placed at the cooler.

  • Page 19: Markings And Information Labels

    Loading valve Danger, hot surface. Run the compressor for 2 min on unload Use diesel fuel only. Service point. Door opening, closing. Atlas Copco mineral Paroil Read the instruction manual Sxtreme before starting. Tyre pressure. Manual. Do not tow with Warning! Part under pressure.

  • Page 20: Main Parts

    Main parts - 20 -...
  • Page 21 Reference Name Reference Name Oil Level Gauge Alternator Radiator AFce Air Filter (compressor element) Regulating Valve Air Filter (engine) Starting Motor Air Outlet Valves Safety Valve Air Receiver Unloading Valve Battery VIce Vacuum Indicator (compr. element) Compressor Element Vacuator Valve Coolant Tank Data Plate Engine...

  • Page 22: Regulating System

    REGULATING SYSTEM OVERVIEW - 22 -...

  • Page 23: Air Flow

    AIR FLOW OIL SYSTEM then by-passes the filter without being filtered. For this reason, the oil filter must Air drawn through the airfilter (AFce) into The lower part of the air receiver (AR) be replaced at regular intervals (see section compressor element (CE)

  • Page 24: Continuous Regulating System

    CONTINUOUS REGULATING SYSTEM The compressor is provided with a 2. Air inlet throttling. Part of the control air is vented to continuous regulating system and a blow- atmosphere, condensate If the air consumption is equal to or off valve (BOV) which is integrated in the discharged, through the vent holes.

  • Page 25: Electric System

    ELECTRIC SYSTEM - CIRCUIT DIAGRAM - 9097 3811 00_00 - 25 -...
  • Page 26 WIRE HARNESS DIAGRAM - 9097 3812 01_00 - 26 -...
  • Page 27 - 27 -...

  • Page 28: Operating Instructions

    Operating instructions PARKING, TOWING AND LIFTING INSTRUCTIONS Safety precautions PARKING INSTRUCTIONS The operator is expected to apply relevant Safety precautions. Attention Before putting the compressor in to use, check the brake system. After the first 100 km travel: Check and retighten the wheel nuts and towbar bolts to the Locate the unit away from restriction Uncouple vehicle.

  • Page 29: Towing Instructions

    TOWING INSTRUCTIONS Before towing the compressor, ensure that towing equipment vehicle matches the towing eye. The towbar should be as level as possible and the compressor and towing eye in a level position. The towbar should be as level as possible and the compressor and towing eye end in a level position.

  • Page 30: Lifting Instructions

    LIFTING INSTRUCTIONS To lift the compressor, use a lift truck or Lifting acceleration crane with sufficient capacity. retardation must be kept within safe limits (max. 2xg). Helicopter lifting is not allowed. See to it that the compressor will be lifted vertically and remains level Lifting is not allowed when the unit is running.

  • Page 31: Before Starting

    BEFORE STARTING the amount of condensate depends on marked service range, replace the filter the operating condition. element. Reset the indicator by pushing the reset button. Before draining, ensure that the 9. Check coolant level in engine coolant pressure is released. top tank integrated in radiator.

  • Page 32: Starting / Stopping

    STARTING / STOPPING CONTROL PANEL Ammeter Key Switch Air Pressure Gauge Loading valve Air Temperature Gauge PGeo Pressure Guage Engine Oil Hour Meter/RPM Push Button Indicator Lamp TGew Temperature Gauge Engine Water - 32 -...
  • Page 33 Safety precautions 6. Release the start button (S) & key switch (KS) to “ON” position when Never push the start button engine tires. when the engine is running. 7. Run the compressor for two minutes on unload 8. Push the loading valve (LV) button to When the compressor is put in load the compressor.

  • Page 34: Operations Overview

    • Switch the “ON/OFF” switch to OPERATIONS OVERVIEW SPECIFIC START PROCEDURE position ”ON”. The instrument panel will now perform a brief selftest. During operation • Push the start button and the starter When the engine is running, the motor will automatically try to start the air outlet valves (ball valves) engine.

  • Page 35: Maintenance

    1000 and after 2000 running hours. repair. The order numbers of the Service Kits are It guarantees that all necessary parts are listed in the Atlas Copco Parts List (ASL). replaced at the same time keeping down time to a minimum. Contact Atlas Copco.

  • Page 36: Preventive Maintenance Schedule For The Compressor

    4153 1367 15 For the most important subassemblies, Atlas Copco has developed service kits that combine all wear parts. These service kits offer you the benefits of genuine parts, save on administration costs and are offered at reduced price, compared to the loose components.
  • Page 37 Maintenance schedule 1000 hours 2000 hours Daily Weekly (continuation of page 36) Air filter Primary (1) (14) Replace Replace Air filter Safety Replace Replace Fuel filter water / sediment Drain Alternator charge lamp Check (During Charge if starting) necessary Electrolyte level and terminals of battery Check Charge if necessary...
  • Page 38 Maintenance schedule 1000 hours 2000 hours Daily Weekly (continuation of page 37) Valve Unloader kit Replace Minimum Pressure Valve Kit Replace Oil stop/Check valve kit Replace Thermostatic Valve Replace Regulating Valve Kit Replace Wiper of Actuating Cylinder Replace Piston Seal of Actuating Cylinder Replace Rubber flexible (11) Check...
  • Page 39 Fuel moisture Separator bowl assembly Clean Fuel filter & Water separator (3)(6)(13) Refer Engine Clean manual Fuel tank Clean Inspection by Atlas Copco Service Inspection Technician (15) Engine service hours 250 hours / 1500 hours / Every 6 months Every 1 year...
  • Page 40 Technical specifications. 4. Check coolant. 5. Use Atlas Copco oil filters, with by-pass valve, as specified in the parts list. 6. Replace the fuel filters regularly. Gummed or clogged filters mean fuel starvation and reduced engine performance. The quality of the fuel determines the frequency of renewal.

  • Page 41: Oil Specifications

    OIL SPECIFICATIONS It is strongly recommended to Never mineral with use Atlas copco “paroil”. This is synthetic oil. special screw compressor which keeps the Remark: compressor excellent When changing from mineral to condition. synthetic oil (or the other way around), you will need to do an...

  • Page 42: Oil Level Check

    OIL LEVEL CHECK CHECK COMPRESSOR OIL LEVEL 3. If the oil level is too low, add oil by removing the oil filler plug (2) (DAILY AFTER RUNNING THE Never mix oils of different COMPRESSOR) Before removing the oil filler brands or types. plug, ensure that the pressure is Use only non- toxic oils where The compressor oil level needs to be...

  • Page 43: Check Compressor Oil Level (Daily After Running The Compressor)

    CHECKING COMPRESSOR OIL OIL AND OIL FILTER CHANGE TOPPING UP THE COMPRESSOR LEVEL AFTER A LONGER PERIOD WITHOUT RUNNING THE ENGINE OIL AND OIL FILTER COMPRESSOR CHANGE 1. Check the oil level via the pointer of the For replacing the engine oil filter (1), oil level gauge (1).

  • Page 44: Compressor Oil And Oil Filter Change

    Reinstall and tighten lifetime. For more information consult humidity conditions, it is recommended to the filler plug. Atlas Copco Service dept. change the oil more frequently. 6. Start the compressor and let it run Aged oil can be recognized best by using unloaded for a few minutes.
  • Page 45 3. Open the oil vessel and remove the oil separator element. Instructions on replacing the oil separator element are available 4. Check the interior of the oil vessel (see from Atlas Copco Service dept. pictures). If varnish deposits are discovered, contact...

  • Page 46: Coolant Specifications

    COOLANT SPECIFICATIONS COOLANT CHECK TOPPING UPCOOLANT Never remove the cooling system Never remove the cooling system For topping up / replacing filler cap while coolant is hot. filler cap while coolant is hot. coolant consult engine operation The system may be under The system may be under manual.

  • Page 47: Replacing The Coolant

    REPLACING THE COOLANT CLEANING COOLERS Clean by air jet in the direction of the arrow. Drain Steam cleaning in combination with a • Completely drain the entire cooling cleansing agent may be applied (do not use system. jet at max. power). •...

  • Page 48: Battery Care

    BATTERY CARE The solution must be made up before being RECHARGING A BATTERY introduced into the battery. Before and after charging a battery, always Before handling batteries, read Always pour the sulphuric acid check the electrolyte level in each cell; if the relevant safety precautions carefully into the distilled water;...

  • Page 49: Battery Maintenance

    1. Snap clips (3x) 4. Filter element 2. Dust trap cover 5. Filter housing 3. Safety cartridge 6. Vacuator valve The Atlas Copco air filters are specially designed application. The use of non- genuine air filters may lead to severe damage of the engine and/or compressor elements.

  • Page 50: Air Filters Engine / Compressor

    CLEANING THE DUST TRAP REPLACING THE FILTER ELEMENT Replace the filter element and AND THE SAFETY CARTRIDGE Remove dust daily. the safety cartridge at the same time. New elements should be To remove dust from the dust trap pinch inspected tears the vacuator valve (6) several times.

  • Page 51: Engine Preservation

    Engine preservation 3. Do not stack any material on engine box 2. Prepare the engine to fit on the to avoid damage to engine/engine box. equipment. Install the engine on the equipment and ensure the connections Customer center or end user If engine is to be stored without engine box are fitted completely.

  • Page 52: Storage Of The Engine That Is Installed On The Equipment

    6. Put a tag to the engine which must PREPARE THE STORED ENGINE The above procedure is to be indicate: FOR PUTTING IN SERVICE done repeatedly at the end of every six months during the • Engine preservation process date. 1.

  • Page 53: Adjustments And Servicing Procedures

    Adjustments and servicing procedures ADJUSTMENT OF THE CONTINUOUS REGULATING SYSTEM - 53 -...

  • Page 54: Pressure System

    PRESSURE SYSTEM AIR RECEIVER SAFETY VALVE The working pressure is determined by the All adjustments or repairs are to tension of the spring in the regulating valve be done by an authorized (RV). This tension can be increased to representative of the safety valve raise the pressure and decreased to lower it (2) supplier, see section Specific by turning the adjusting wheel clockwise...

  • Page 55: Fuel System

    FUEL SYSTEM REPLACING FUEL FILTER EXHAUST SYSTEM ELEMENTS PRIMING INSTRUCTIONS Fuel leaked or spilled onto hot surfaces electrical components can cause a fire. To help prevent possible injury, turn the “ON/OFF” switch in position “OFF” when changing fuel filters or water separator elements.

  • Page 56: Problem Solving

    Choked air filter elements (AF). Remove and inspect elements. Clean or replace, if necessary. Regulating valve (RV) defective. Have regulating valve removed and inspected by an Atlas Copco Service representative. Blow down valve stuck in open position. Check and correct as necessary.
  • Page 57 Problem: Pressure in air receiver rises above maximum and causes safety valve to blow. Possible faults Corrective actions Regulating valve (RV) opens too late or its ball valve Have regulating valve removed and inspected by an Atlas Copco Service spring is broken. representative. Air leaks in regulating system.
  • Page 58 Remove valve and check for proper opening and closing. Replace if out of position. order. Fan blade(s) broken. Check and correct if necessary. Oil stop valve malfunctioning. Remove and inspect valve. Oil separator element (OS) clogged. Have element removed and inspected by an Atlas Copco Service representative. - 58 -...
  • Page 59 Alternator precautions 1. Never reverse the polarity of the battery or the alternator. 2. Never break any alternator or battery connections while the engine is running. 3. When recharging the battery, disconnect it from the alternator. Before using booster cables to start the engine, be sure of the polarity and connect the batteries correctly.

  • Page 60: Technical Specifications

    Technical specifications TORQUE VALUES GENERAL TORQUE VALUES For hexagon screws and nuts with strength grade 12.9 The following tables list the recommended torques applied for Thread size Torque value (Nm / general applications at assembly of the compressor. lbf.ft) 15 (11.07) For hexagon screws and nuts with strength grade 8.8 39 (28.78) Thread size...

  • Page 61: Compressor / Engine Specifications

    COMPRESSOR / ENGINE SPECIFICATIONS REFERENCE CONDITIONS Designation Unit XAXS 600 Absolute inlet pressure bar(e) 14.5 Relative air humidity Air inlet temperature °C °F Nominal effective working pressure bar(e) The inlet conditions are specified at the air inlet grating outside the canopy. LIMITATIONS Designation Unit...

  • Page 62: Performance Data

    PERFORMANCE DATA At reference conditions, if applicable, and at normal shaft speed, unless otherwise stated. Designation Unit XAXS 600 Engine shaft speed, normal and maximum r/min 2200 Engine shaft speed, compressor unloaded r/min 1200 Free air delivery 281.7 596.89 Free air delivery Fuel consumption: at full load 100% FAD 43.2...

  • Page 63: Design Data

    Noise level - Sound pressure level (LP), measured under free field conditions at 7 m distance dB(A) • +/- 5% 25 l/s (53 cfm) < FAD < 250 l/s (530 cfm) Tolerance: • +/- 4% 250 l/s (530 cfm) < FAD •...
  • Page 64 DESIGN DATA Engine Designation Unit XAXS 600 Make Cummins Type 6CTA 8.3 Coolant EG 50-50 DCA4 Premix Number of cylinders Bore 4.48 Stroke 5.31 Displacement US gal 2.19 Output power at 2500 rpm according to BS 5514 Capacity of oil sump 23.8 US gal 6.28...
  • Page 65 DESIGN DATA Unit Shipping dimension (approx) Length meter Designation Unit XAXS 600 Width meter Fuel tank capacity Height meter US gal 75.02 Air volume at inlet grating (approx;) ) Air required for engine and compressor cooling, combustion Overall Dimensions with Under carriage (Approx) and for compression.
  • Page 66 ALTITUED UNIT PERFORMANCE CURVE - 66 -...

  • Page 67: Disposal

    Disposal GENERAL DISPOSAL OF MATERIALS When developing products and services, This concept can only succeed Atlas Copco tries to understand, address, with your help. Support us by Dispose contaminated substances and and minimize the negative environmental disposing professionally. material separately, according to local...

  • Page 68: Maintenance Log

    Maintenance Log Compressor Customer............................Serial number............................... Service hours Maintenance action Date By initials - 68 -...
  • Page 69 Maintenance Log Compressor Customer............................Serial number............................... Service hours Maintenance action Date By initials - 69 -...
  • Page 70 Maintenance Log Compressor Customer............................Serial number............................... Service hours Maintenance action Date By initials - 70 -...

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