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Atlas Copco XRVS 1000 CD7 IT4 HOP Instruction Manual

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Instruction Manual
for Portable Compressors
English
Engine CAT C13
XRVS 1000 CD7 IT4

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Summary of Contents for Atlas Copco XRVS 1000 CD7 IT4 HOP

  • Page 1 Instruction Manual for Portable Compressors English Engine CAT C13 XRVS 1000 CD7 IT4...
  • Page 3 Instruction Manual for Portable Compressors XRVS 1000 CD7 IT4 HOP Original instructions Printed matter Nr 1310 3012 85 ATLAS COPCO - PORTABLE ENERGY DIVISION 04/2014 www.atlascopco.com...
  • Page 4 The manufacturer does not accept any liability for any damage arising for modifications, additions or conversions made without the manufacturer's approval in writing. Copyright 2014, Atlas Copco Compressors LLC, RockHill SC USA. Any unauthorized use or copying of the contents or any part thereof is prohibited.

  • Page 5: Table Of Contents

    ..........39 Preface Table of contents 4.2.4 Shutdown ..........39 4.2.5 Power Off Please read the following instructions carefully before ....39 4.2.6 Diesel Particulate Filter Regeneration starting to use your compressor. Safety Precautions For Portable ..40 4.2.7 Automatic Dpf Regeneration (Default) Compressor ..........7 It is a solid, safe and reliable machine, built according to ......40 4.2.8...
  • Page 6 ..........62 ..........76 5.15 Coolant Check 9.1 Torque Values ........76 5.15.1 Topping Up Without Draining From The Cooling 9.1.1 General Torque Values ............. 63 ........76 System 9.1.2 Critical Torque Values 5.15.2 Topping Up After Limited Quantity Draining From ....77 9.2 Compressor / Engine Specifications ........

  • Page 7: Safety Precautions For Portable Compressor

    Introduction electrical components. operating, maintenance or repair, also if not expressly The policy of Atlas Copco is to provide the users of their mentioned in this instruction manual, is disclaimed by Skill level 3: Electrical technician equipment with safe, reliable and efficient products.

  • Page 8: Safety During Transport And Installation

    - check that the wheels are secure and that the tyres are See the Preventive maintenance schedule. vehicle lights up, please contact Atlas copco. in good condition and inflated correctly, 12 Mind the markings and information labels on the unit.

  • Page 9: Safety During Maintenance And Repair

    Wait until the engine has sufficiently 18 The unit has parts, which may be accidentally touched cooled down. 2 Parts shall only be replaced by genuine Atlas copco by personnel, of which the temperature can be in exess replacement parts.

  • Page 10: Tool Applications Safety

    14 Use only lubricating oils and greases recommended or applications as specified above and in accordance with approved by Atlas copco or the machine manufacturer. prevented. the technical specifications. Safety reasons prohibit...
  • Page 11 If the set pressure must be altered then use only correct parts supplied by Atlas copco and in accordance with the instructions available for the valve type. Safety valves must be frequently tested and regularly maintained.

  • Page 12: Leading Particulars

    Leading particulars Cooling system Control panel General description The engine is provided with a liquid-cooler and The control panel is located at the back on the left hand The XRVS 1000 CD7 is a silenced, two-stage, oil injected, intercooler and the compressor is provided with an oil side of the canopy.

  • Page 13: Regulating System

    Regulating system OVERVIEW - 13 -...
  • Page 14 Reference Name Reference Name Air Filter Element Oil Separator Element Air Filter (compressor) Oil Stop Valve Air Filter (engine) Oiltronix Air Filter Switch PSai Pressure Sensor (air inlet) Air Outlet Valve PSlp Pressure Sensor (low pressure) Air Receiver Safety Cartridge BVof Bypass Valve oil filter Scavenge Line...

  • Page 15: Air Flow

    OIL SYSTEM Oiltronix Air flow The lower part of the air receiver (AR) serves as an oil The oil system of XRYS and XRXS units is equipped with Air drawn through the airfilter (AFce) into the compressor tank. the Oiltronix system, a system that electronically element (CElp CEhp) is compressed.

  • Page 16: Flow Diagram Exhaust After Treatment

    Flow diagram exhaust after treatment - 16 -...

  • Page 17: Exhaust Gas After Treatment

    Extending the lifetime of a filter, it converts particulate matter into CO2 and ash. Atlas Copco engines use high temperature regeneration that includes a fuel burner in the exhaust stream that intermittently raises the temperature above 600º C / 1100°...

  • Page 18: Electric System

    Electric system CIRCUIT DIAGRAM 1310 3002 56 - 18 -...
  • Page 19 Electric system CIRCUIT DIAGRAM - 19 -...
  • Page 20 Electric system CIRCUIT DIAGRAM - 20 -...
  • Page 21 Electric system CIRCUIT DIAGRAM - 21 -...
  • Page 22 Electric system CIRCUIT DIAGRAM - 22 -...

  • Page 23: Fuse Box

    Fuse box Reference Name Main circuit breaker Engine control module CAT regeneration system Fuel priming pump Refuel pump Internal lights Preheater/Nordic Roof actuator Charging alternator - 23 -...

  • Page 24: Markings And Information Labels

    Compressor oil drain. Fork lifting permitted. Read the instruction manual before Electrocution hazard. starting. Don’t lift here. Atlas Copco synthetic compressor oil. Service every 24 hours. Read the instruction manual before lifting. Atlas Copco mineral engine oil. Warning! Part under pressure.

  • Page 25: Operating Instructions

    Operating instructions The compressor oil lifetime will be shortened when the Parking, towing and lifting instructions compressor air inlet air is contaminated. Safety precautions TOWING INSTRUCTIONS The operator is expected to apply all Before towing the compressor, make sure the towing relevant Safety precautions.

  • Page 26: Lifting Instructions

    Check that the fuel tank contains sufficient fuel. Top LIFTING INSTRUCTIONS BEFORE STARTING up, if necessary. Consult the Engine Operation Man- ual for the type of fuel Make sure the unit is in a level position not exceeding 8° before refuelling. Drain any water and sediment from the fuel filters until clean fuel flows from the drain cock.

  • Page 27: Basic Operation Of The Machine

    1. Select fuel supply mode. Do not switch the fuel selecting lever when the unit is in operation! • Internal supply. Move the lever of the fuel selection supply valve upwards. • External supply. Connect the supply and return hose to the fuel nip- ples at the fuel funnel.

  • Page 28: Starting / Stopping

    Starting / Stopping Safety precautions Control panel Do not disconnect power supply to control box in any way when the control box is switched on. This will cause memory loss. Do not switch off the circuit breaker when the control box is switched on. This will cause memory loss.
  • Page 29 Reference Name LOAD button. Pressing this button will: • initiate the Auto Load function, or commands the compressor to load (depending on actual status). • command the compressor to switch to Not Loaded (when in Load). MEASUREMENTS VIEW button By pressing this button you can toggle between Measurements View and Main View.

  • Page 30: Overview Icons

    OVERVIEW ICONS Reference Name Compressor status Vessel pressure indication or info text Compressor info Main View Indication Measuring View Indication Settings View Indication Alarm View Indication DPF REGENERATION MAIN VIEW High Exhaust System Temperature. Means that the Diesel Particle Filter is being regenerated.
  • Page 31 Reference Name Reference Name Reference Name DPF REGENERATION OPERATION MODE FUELTANK Diesel Particle Filter Regeneration Local Running at internal fueltank. Inhibited. OPERATION MODE FUELTANK Means that the DPF regeneration is Remote Running at internal fueltank & Fuelpump inhibited, even if all criteria to activate a is energized.
  • Page 32 Possible views Setup View Alarm View Main View ALARMS SETTINGS LOADED LOADED 3450 BATTERY LOW ALARM 1000 GENERAL SETTINGS 2070 COOLANT LEVEL LOW 2000 DIGITAL INPUTS 3010 FUEL LEVEL LOW 3000 VOLTAGE INPUTS ECU DM1 LIST 4000 TEMPERATURE INPUTS ECU DM2 LIST 5000 RELAY OUTPUTS EVENT LOG LIST 5300 SEMICONDUCTOR OUTPUTS...

  • Page 33: Starting

    STARTING The display now shows Switch on the battery switch. MAIN VIEW Switch the controller on by switching the Power switch to VESSEL BLOWING DOWN MAIN VIEW the position “ON”. PREPARING FOR START The instrument panel will now perform a selftest; the following display will be shown and the controller is initialized: 1286h...
  • Page 34 The display now shows The display now shows MAIN VIEW MAIN VIEW MAIN VIEW ENGINE PREHEATING PREPARING FOR START READING ENGINE DATA 1286h --RPM 0.0bar 1286h --RPM 0.0bar 1286h --RPM 0.0bar After pressing the START button the machine will Active Buttons activate its horn and flasher light for 5 seconds, to notify The engine electronics (ECU) will be powered up.
  • Page 35 The engine starts running at idle speed. The display shows The display now shows The engine starts running at idle speed. The display shows MAIN VIEW MAIN VIEW MAIN VIEW ENGINE RESTING ENGINE WARMING UP ENGINE CRANKING 120s 13˚C 40˚C 25˚C 0RPM 800RPM...
  • Page 36 The display now shows After warming up the machine is ready to be loaded and is Press the load button, the display will show waiting for a load command; the display shows MAIN VIEW MAIN VIEW ENGINE WARMING UP MAIN VIEW BUILDING UP VESSEL PRESSURE READY TO LOAD 1286h...
  • Page 37 During operation The engine will now run at maximum rpm, the display will During loading the following display is shown (default show display The doors must be closed during operation and may be opened for short periods for inspection and adjustments only. Be aware not to touch hot parts when the MAIN VIEW MAIN VIEW...

  • Page 38: Stopping

    Press ENTER to confirm the new setting. Some additional control features are available from Atlas Copco, such as dual pressure switch, remote start, auto start, remote pressure setting. If interested, please consult your Atlas Copco representative for more information. - 38 -...

  • Page 39: Shutdown

    SHUTDOWN POWER OFF After cooling down the engine will stop and the display will show When the machine is shutdown due to a critical alarm or Switch the controller off by switching the Power switch to an emergency stop the display will show the position “OFF”.

  • Page 40: Automatic Dpf Regeneration (Default)

    AUTOMATIC DPF REGENERATION (DEFAULT) INHIBIT DPF REGENERATION In specific cases, when the engine speed is constant at When running in an environment where an elevated MAIN VIEW Minimum RPM, it can happen that the DPF regeneration exhaust temperature is not allowed, it might be necessary LOADED already starts from 30% Soot Load (LSR - Low Speed to inhibit DPF regeneration.

  • Page 41: Increasing Soot Load

    INCREASING SOOT LOAD SOOT LOAD REACHES 90% (ONLY WHEN DPF SOOT LOAD REACHES 92% REGENERATION IS INHIBITED) When the DPF Regeneration is Inhibited, or when the When still no DPF regeneration is forced the next warning engine does not get sufficient possibility to automatically When still no DPF regeneration is forced the next warning alarm will pop-up.

  • Page 42: Soot Load Reaches 98

    • Press the Back button 3 times to get back to the Main Required Action: View Contact Atlas Copco for further actions to • Acknowledge the ‘ECU DPF SOOT LOAD HIGH’ be taken. DPF Regeneration setting will now be AUTOMATIC warning (press Enter while in the Main View).

  • Page 43: Settings

    SETTINGS unacknowledged alarms can be seen by pressing the Set Units ALARM VIEW button For buttons to be used see “Control Panel” Press the SETTINGS VIEW button, Pressing the ALARM VIEW button again, will bring you • scroll to ‘1000 GENERAL SETTINGS’ Acknowledge an Alarm back to the Main View.
  • Page 44 Go To Diagnostics Press the SETTINGS VIEW button • scroll to ‘1000 GENERAL SETTINGS’ • press ENTER • scroll to ‘1150 DIAGNOSTICS’ • ENTER the Diagnostics menu, • ENTER the ‘ENABLE’ parameter • scroll to ‘ON’ and press ENTER. Now the ECU will get power and one can perform ECU diagnostics (read DM1 List, DM2 List, ECU values, perform engine diagnostics, …).

  • Page 45: Fault Codes

    FAULT CODES When one of these parameters exceeds its specified limit the compressor will react depending the present status of There are several parameters that are continuously the control box. watched. Alarmcode Alarmtext Failclass Trigger 1231 FUEL FILL CHECK Warning 1503 INITIAL OVERHAUL REQUIRED Warning...
  • Page 46 Alarmcode Alarmtext Failclass Trigger 4000 L.P. ELEMENT TEMPERATURE HIGH Warning 4010 L.P. ELEMENT TEMP. ALARM 2 Controlled Stop 4020 L.P. ELEMENT TEMP. ALARM 3 Shutdown 4040 L.P. ELEMENT TEMP. SENSOR CIRCUIT Shutdown 4070 AMBIENT TEMPERATURE SENSOR CIRCUIT Warning 4100 AIR DISCHARGE TEMPERATURE ALARM 1 Warning 4110 AIR DISCHARGE TEMPERATURE ALARM 2...

  • Page 47: Emergency Stop

    EMERGENCY STOP The emergency stop button is only to be used in emergency situations; not for stopping procedures. When an emergency stop button (1) is pressed, power to all outputs is terminated, by the emergency stop itself (hardware) as well as by the software. When the emergency stop button (1) is pressed the operator can unlock the emergency stop by turning it counterclockwise.

  • Page 48: Maintenance

    If the compressor is going to be stored maintenance of both compressor and engine. without running from time to time, Service Paks minimize downtime and keep your protective measures must be taken. maintenance budget low. Order Service Paks at your local Atlas Copco dealer. - 48 -...

  • Page 49: Preventive Maintenance Schedule

    XRVS 1000 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 a reduced price, compared to individual components. Refer to the parts list for more information on the contents of the service kits.
  • Page 50 Clean fuel cooler Clean crankcase breather filter and check for obstructions Replace air filter element (1) Check external fuel connection (option) Inspection by Atlas Copco service technician Adjust engine inlet and outlet valves (2) Inspect alternator Replace spring check valve...
  • Page 51 6. Gummed or clogged filters means fuel starvation and reduced engine performance. 7. See section Oil specifications. 8. The following part numbers can be ordered from Atlas Copco to check on inhibitors and freezing points: • 2913 0028 00 : refractometer •...
  • Page 52 Daily 50 km Every Every Every Yearly Maintenance schedule (km) after initial 500 km 1000 km 2000 km (continuation of page 51) start-up Drain ABS vessel (option) Check coupling head Check tyre pressure Check height of adjusting facility Check torque of wheel nuts Grease coupling head, tow bar bearings at the housing of the overrun brake Check brake system (if installed) and adjust if necessary Oil or grease brake lever and moving parts such as bolts and joints...
  • Page 53 Trigger 7110 PLEASE FORCE DPF REGENERATION ! Inhibit Load 7120 LOAD PREVENTION - HIGH DPF SOOT LOAD Controlled Stop 7130 SOOT LOAD TOO HIGH - CALL ATLAS COPCO Warning 7222 COMBO COMMUNICATION FAILURE Warning 7223 COMBO PA SENSOR WARNING Warning...

  • Page 54: Inspection Schedule For Undercarriage Eu

    Inspection schedule for Undercarriage EU Inspection includes regular checks of individual After 50,000 km i.e. after 12 months of running, the The following details refer to normal use of the components and related action based on these checks. undercarriage of the compressor has to be inspected on its compressor based on a maximum of 50,000 km per year.

  • Page 55: Oil Specifications

    Oil specifications PAROIL from Atlas Copco is the ONLY oil tested and 'standard' ambient conditions from -10°C (14°F) onward. It is strongly recommended to use Atlas approved for use in all engines built into Atlas Copco...

  • Page 56: Compressor Oil

    COMPRESSOR OIL Synthetic compressor oil PAROIL S Liter US gal Order number 1630 0160 00 1630 0161 00 barrel 55.2 1630 0162 00 container 1000 1630 0163 00 Mineral compressor oil PAROIL S xtreme Liter US gal Order number 1630 0180 00 barrel 55.2 1630 0181 00...

  • Page 57: Engine Oil

    Synthetic engine oil PAROIL E xtra ENGINE OIL Liter US gal Order number 1630 0135 00 1630 0136 00 Mineral engine oil PAROIL E Mission Green Liter US gal Order number 1630 0471 00 1630 0472 00 barrel 55.2 1630 0473 00 Choose your engine oil based on the ambient temperatures in the actual operating area.

  • Page 58: Oil Level Check

    DIESEL FUEL RECOMMENDATIONS Oil level check Oil and oil filter change CHECK ENGINE OIL LEVEL ENGINE OIL ANPreventive maintenance scheduleD OIL FILTER CHANGE Also consult the Engine Operation Manual for the oil specifications, viscosity recommendations and oil change See section Preventive maintenance schedule. intervals.

  • Page 59: Compressor Oil And Oil Filter Change

    When operating in high ambient temperatures, in very the upper part of the green area. dusty or high humidity conditions, it is recommended to change the oil more frequently. Never add more oil. Overfilling results in oil consumption. In this case, contact Atlas Copco. - 59 -...

  • Page 60: Compressor Oil Flushing Procedure

    Whenever aged oil is discovered, eg. when changing the oil separator, contact Atlas Copco Service dept. to have your compressor cleaned and flushed. 1. First thoroughly drain the system when the oil is warm,...

  • Page 61: Coolant Specifications

    It reduces water pump seal wear and has excellent stability ambient temperature. A sudden release of Atlas Copco's PARCOOL EG extended life coolant is the pressure from a heated cooling system can when subjected to sustained high operating temperatures.

  • Page 62: Handling Parcool Eg

    The mixed coolants will be considered as one suring device. concentration of additives and is therefore not product. • The pH-meter can be ordered from Atlas Copco with allowed. part number 2913 0029 00. The use of distilled water is recommended. If you have •...

  • Page 63: Topping Up Without Draining From The Cooling System

    TOPPING UP WITHOUT DRAINING FROM THE COOLING SYSTEM The quantity of PARCOOL EG Concentrate to be topped up can be estimated with the following formula and/or graph: Corrections concentrate in measured system towards 50% volume by using PARCOOL EG Concentrate Example: PN: 1604 8159 00 Total volume coolant =...

  • Page 64: Topping Up After Limited Quantity Draining From The Cooling System

    TOPPING UP AFTER LIMITED QUANTITY DRAINING FROM THE COOLING SYSTEM The quantity of PARCOOL EG Concentrate to be topped up after draining a calculated volume from the cooling system, can be estimated with the following formula and/or graph: Corrections concentrate in measured system towards 50% volume by using PARCOOL EG Concentrate Example: PN: 1604 8159 00 Total volume coolant =...

  • Page 65: Replacing The Coolant

    • Using the Atlas Copco Instruction book, determine Never leave spilled liquids such as fuel, oil, the amount of PARCOOL EG required and pour into coolant and cleansing agents in or around the compressor.

  • Page 66: Battery Care

    If the battery is still dry, it must be activated as described must be open, i.e. plugs and/or cover removed. to be done by Atlas Copco. This guarantees the use of in section Activating a dry-charged battery. Use a commercial automatic battery genuine parts and correct tools with care and precision.

  • Page 67: Adjustments And Servicing Procedures

    Daily drain condensate. cover (2). Clean the inside of the cover. Withdraw the filter element (4) and safety cartridge The Atlas Copco air filters are specially SAFETY VALVE (3) from the housing (5). designed for the application. The use of non- Discard the filter element when damaged.

  • Page 68: Fuel System

    Manual switch priming (if equipped) Fuel system CLEANING CRANKCASE BREATHER The manual switch is located on the primary filter base/ FILTER PRIMING INSTRUCTIONS electric priming pump assembly. Fuel leaked or spilled onto hot surfaces or 1. Hold the manual switch in the up position until fuel has electrical components can cause a fire.

  • Page 69: Rubber Torsion Suspension

    drum surface, the maximum re-bore diameter for a 12 1/4” RUBBER TORSION SUSPENSION BEARING LUBRICATION brake drum is 12.340”. The machined inner surface of the The RUBBER TORSION suspension system is a torsion Along with bearing adjustment, proper lubrication is brake drum that contacts the Brake magnet is called the arm type suspension, which is completely self-contained essential to the current function and reliability of your...

  • Page 70: 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 71 Corrective actions Regulating valve (RV) opens too late or its ball valve spring is broken. Have regulating valve removed and inspected by an Atlas Copco Service representative. Air leaks in regulating system. Check hoses and their fittings. Stop leaks; replace leaking hoses.
  • Page 72 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. Alternator precautions 1. Never reverse the polarity of the battery or the alternator.

  • Page 73: Oiltronix Failure

    Check the correct position of the blind hole with a ∅ 4 mm pin. Block the valve by screwing a bolt (M5 x 20) through the housing and in the blind hole in the coupling. Contact Atlas Copco for a thorough scan and repair. - 73 -...

  • Page 74: Available Options

    Available options SUPPORT MOUNTED / LARGE FUELTANKS INLET SHUTDOWN VALVE FORK LIFT SLOTS With the option “Support mounted” it is possible to fix the compressor to a truck for more flexibility or to a frame when it is to be used permanently in an installation. In combination with the support mounted it is also The inlet shut down valve is a safety device preventing the With fork lift slots the compressor can easily be moved...
  • Page 75 AFTER-COOLER A warning can be set at a value between 0°C and 115°C (=default value) and a shut-down can be set at a value between 0°C and 120°C (= default value). The operator has authority to modify these values so the process can be guarded and kept in a safe condition under all circumstances.

  • Page 76: Technical Specifications

    Technical specifications CRITICAL TORQUE VALUES Torque values Assemblies Torque value (Nm / lbf.ft) GENERAL TORQUE VALUES Axles to frame: The following tables list the recommended torques applied for general applications Wheel nuts 270 (199.26) during assembly of the compressor. Bolts, front axle/frame 205 (151.29) For hexagon screws and nuts with strength grade 8.8 Bolts, rear axle/frame...

  • Page 77: Compressor / Engine Specifications

    Compressor / engine specifications REFERENCE CONDITIONS Designation XRVS 1000 Absolute inlet pressure bar(e) 1.013 14.7 Relative air humidity Air inlet temperature °C °F Nominal effective working pressure bar(e) 25.16-35.16 365-510 The inlet conditions are specified at the air inlet grating outside the canopy. LIMITATIONS Designation XRVS 1000...

  • Page 78: Performance Data

    PERFORMANCE DATA At reference conditions, if applicable, and at normal shaft speed, unless otherwise stated. Designation XRVS 1000 Engine shaft speed, normal and maximum 1950 Engine shaft speed, compressor unloaded 1300 Free air delivery 1000 Fuel consumption gal/h 20.71 -at 90% Load gal/h 12.59 -at 75% Load...

  • Page 79: Design Data

    DESIGN DATA Compressor Designation Number of compression stages 2 (TWIN) Engine Designation XRVS 1000 Make Caterpillar Type C13 IT4 Coolant Ethylene glycol mix w/SCA package Number of cylinders Bore 5.12 Stroke 6.18 Displacement 12.2 cu.in 762.8 Engine Horse power 354.2 Lube System refill Cooling system 4.94...
  • Page 80 Unit Designation All units Capacity of compressor oil system US gal 21.7 Net capacity of air receiver US gal 37.8 Capacity of fuel tank (tandem) US gal Service Level - Engine Oil Change ChangeService Level - Compressor Oil Change 1000 Physical Data Designation All units...
  • Page 81 ALTITUDEUNIT PERFORMANCE CURVE Max. achievable working pressure in relation to altitude and ambient temperature. Graph represents working conditions, for starting conditions please contact your Atlas Copco contact. - 81 -...
  • Page 82 Unit Dimensions - 82 -...

  • Page 83: Disposal

    Remove spilled fluid mechanically; pick up the rest using Your Atlas Copco compressor consists for the most part of an absorbing agent (for example sand, sawdust) and metallic materials, that can be remelted in steelworks and dispose of it in accordance with local disposal regulations.

  • Page 84: Maintenance Log

    Maintenance Log Compressor Customer..................................................Serial number..................................................... Service hours Maintenance action Date By initials - 84 -...
  • Page 85 Maintenance Log Compressor Customer..................................................Serial number..................................................... Service hours Maintenance action Date By initials - 85 -...
  • Page 86 - 86 -...
  • Page 88 www.atlascopco.com...

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