Atlas Copco XRX 1350 Cud PNE Instruction Manual
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Atlas Copco XRX 1350 Cud PNE Instruction Manual

Atlas Copco XRX 1350 Cud PNE Instruction Manual

Portable compressors
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Instruction Manual
for Portable Compressors
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Engine KTA 1150 C
XRX 1350 Cud PNE

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Summary of Contents for Atlas Copco XRX 1350 Cud PNE

  • Page 1 Instruction Manual for Portable Compressors English Engine KTA 1150 C XRX 1350 Cud PNE...
  • Page 3 Instruction Manual for Portable Compressors XRX 1350 Cud PNE Engine: KTA 1150C Printed Matter No. 2954 9720 00 ATLAS COPCO - PORTABLE ENERGY DIVISION www.atlascopco.com 07/2016...
  • 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 2016, 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 Preventive maintenance schedule for the compressor ..........40 Please read the following instructions Oil specifications........44 carefully before starting to use your Oil level check ........45 Safety precautions ........7 compressor. Check compressor oil level (daily after Introduction ..........
  • Page 6 Dataplate ..........68 Disposal........... 69 10.1 General ............ 69 10.2 Disposal of materials ....... 69 Maintenance Log ........70 Maintenance Log ........71 Maintenance Log ........72 - 6 -...

  • 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 non-original parts maintaining the unit in a safe operating are expected to use safe engineering modifications, additions or conversions condition.

  • Page 9: Safety During Transport And Installation

    6 The machinery and equipment shall be 12 Mind the markings and information SAFETY DURING TRANSPORT kept clean, i.e. as free as possible from labels on the unit. AND INSTALLATION oil, dust or other deposits. 13 In the event the safety labels are Transport of the unit has to be done by 7 To prevent an increase in working damaged or destroyed, they must be...

  • 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 extra measures, for breathing purposes Atlas Copco Instruction Book (AIB). necessary, install extra air intake ducts. as this may result in injury or death. For Keep fuel away from hot parts such as breathing air quality, 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 Compressor oil system PICTOGRAMS USED IN THIS The oil is boosted by air pressure. The The compressor XRX 1350 is two-stage, MANUAL system has no oil pump. oil-injected screw compressor, built for a nominal effective working pressure of 25 The oil is removed from the air, in the air/ This...
  • Page 18 Regulation This receiver pressure variation is sensed Frame and axles by the regulating valve which, by means of The compressor is provided with a The compressor/engine unit is supported control air to the unloader and engine continuous regulating system and a blow- by rubber buffers in the frame.
  • Page 19 Serial number Data plate The compressor is furnished with a data plate showing the product code, the unit serial number and the working pressure (see chapter Dataplate). The serial number is mentioned on the data plate and frame. Control panel The control panel grouping the air pressure gauge, control switch etc., is placed at the right hand side.

  • Page 20: Main Parts

    Main parts - 20 -...
  • Page 21 Reference Name Reference Name Oil Cooler Alternator OFce Oil Filter (compressor AFce Air Filter (compressor element) element) Oil Filter (engine) Air Filter (engine) Oil Level Gauge Air Outlet Valves Radiator Air Receiver Regulating Valve Battery Starting Motor CEhp Compressor Element (High Pressure) Solenoid Valve CElp...

  • Page 22: Markings And Information Labels

    Danger, hot surface. Read the instruction manual before topping up with coolant. Compressor oil drain. Electrocution hazard. Service point. Engine oil drain. Atlas Copco synthetic compressor oil. Circuit breaker. Coolant outlet Manual. Lifting not permited Read the instruction manual Battery charge indication before working on the battery.

  • Page 23: Regulating System

    REGULATING SYSTEM OVERVIEW - 23 -...
  • Page 24 AIR FLOW OIL SYSTEM provided with a flow restrictor (FR). The oil filter by-pass valve opens when the Air drawn through the airfilter (AFce) into The lower part of the air receiver (AR) pressure drop over the filter is above the compressor element (CEhp CElp) is serves as oil tank.
  • Page 25 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 26: Electric System

    ELECTRIC SYSTEM Circuit Diagram - 9097 1137 00 _00 - 26 -...
  • Page 27 Wiring Diagram - 9097 1136 00 _00 - 27 -...
  • Page 28 - 28 -...
  • Page 29 Wiring Diagram (Instument panel) - 9097 1138 00 _00 - 29 -...
  • Page 30 - 30 -...

  • Page 31: Operating Instructions

    Operating instructions LIFTING INSTRUCTIONS 6. Lifting hooks, eyes, shackles, etc., shall never be bent and shall only have stress in line with their design load axis. The capacity of a lifting device diminishes when the lifting force is applied at an angle to its load axis.
  • Page 32 Locate the unit away from restriction surfaces such as walls. Locate the rear-end of the compressor upwind,away from contaminated windstreams and walls. The minimum distance for air intake should be 3000 mm and machine should be parallel with ground for proper airflow in front and rear.

  • Page 33: Starting / Stopping

    STARTING / STOPPING CONTROL PANEL Ammeter Lamp Switch Air Pressure Gauge Loading Switch Bypass Switch PGeo Pressure Guage Engine Oil Circuit Breaker Button TGeo Temperature Gauge Engine Oil Gauge Engine R.P.M. TGew Temperature Gauge Engine Water Key Switch - 33 -...
  • Page 34 DUAL PRESSURE SETTING 7. Dual pressure - Dual pressure settings available on this machine are 25 Bar & 1. Ensure that the Air receiver pressure is 30 Bar. fully released before starting. (Recommended Default pressure setting of 2. Switch on the MCB, Start the prime this machine is 25 bar) mover by pressing the bypass button and turn the key switch.
  • Page 35 8. For stopping the machine unload the machine and then switch off through key. START-UP INSTURCTION This compressor has Starter Protection Unit installed to protect the starter motor from damage. Following instructions are to be followed- 1. Engine can not be cranked more than 20 seconds continuously. 2.
  • Page 36 Safety precautions 8. Press & hold start button (S) & key Fault situations protective switch (KS) position “start” devices (Also refer to chapter Never push the start button simultaneously. 6.Problem Solving): when the engine is running. 9. Starter motor will set the engine in •...

  • Page 37: Before Starting

    BEFORE STARTING experience, as the amount of condensate 8. Check the air filter vacuum indicators. depends on the operating condition. If the yellow piston reaches the red marked service range, replace the filter Before draining, ensure that the element. Reset the indicator by pushing pressure is released.

  • Page 38: Operations Overview

    OPERATIONS OVERVIEW After cleaning /draining the fuel tanks, the system is filled with During operation air. When the engine is running, the Before starting engine air outlet valves (ball valves) operate the fuelpump on the must always be put in fully fuelfilter to fill the fuelsystem.

  • Page 39: Maintenance

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

  • Page 40: Preventive Maintenance Schedule For The Compressor

    9095 0503 73 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. Refer to the parts list for more information on the contents of the service kits.
  • Page 41 Service hours 500 hours 1000 hours 2000 hours Calendrial Daily Fuel filter water / sediment Drain Electrolyte level and terminals of battery Check Check Check Leaks in air-, oil- or fuel system (11) Check Check Check Oil cooler Clean externally Clean externally, Clean externally, internally also if...
  • Page 42 Wheel nut tightness Under carriage components Fuel moisture Separator bowl assembly Clean Weekly Fuel filter & Water separator (3) (6) (13) Refer Engine manual Fuel tank Clean Clean Clean Inspection by Atlas Copco Service Technician (15) Inspection - 42 -...
  • Page 43 Check coolant. Pressure drop (delta P) across oil Use Atlas Copco oil filters, with by-pass valve, as specified in the parts list. separator element, can be measured as shown. Replace the fuel filters regularly. Gummed or clogged filters mean fuel starvation and reduced engine performance.

  • Page 44: Oil Specifications

    OIL SPECIFICATIONS It is strongly recommended to Never synthetic with use Atlas Copco “PAR OIL S mineral oil. Xtreme”. This is a special oil for screw compressor which keeps Remark: the compressor in excellent When changing from mineral to condition...

  • Page 45: Oil Level Check

    OIL LEVEL CHECK CHECK COMPRESSOR OIL LEVEL 2. Check the oil level via the pointer of the oil level gauge (1). The pointer must (DAILY AFTER RUNNING THE Never mix oils of different register in the green area. COMPRESSOR) brands or types. 3.

  • Page 46: Oil And Oil Filter Change

    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 For replacing the engine oil filter (1), 1. Check the oil level via the pointer of the oil level gauge (1).
  • Page 47 3. Remove the filler plug (2) and top up section Preventive maintenance 5. Fill the air receiver until the pointer of with oil until the pointer of the oil level schedule for the compressor). the oil level gauge is in the upper part of gauge (1) is in the upper part of the the green area.

  • Page 48: Coolant Specifications

    COOLANT SPECIFICATIONS VISUAL CHECK Flush • Remove filter cap(1) • Verify the outlook of the coolant Never remove the cooling system regarding colour and make sure that no • Flush twice with clean water. filler cap(1) while coolant is hot. loose particles are floating around.

  • Page 49: Cleaning Coolers

    CLEANING COOLERS Steam cleaning in combination with a cleansing agent may be applied (do not use jet at max. power). To avoid damaging the coolers, angle between jet and coolers should be approx. 90 °. Close the service doors. Protect electrical controlling equipment,...

  • Page 50: Battery Care

    BATTERY CARE ACTIVATING A DRY-CHARGED RECHARGING A BATTERY BATTERY Before and after charging a battery, always check the electrolyte level in each cell; if Before handling batteries, read • Take out the battery. required, top up with distilled water only. the relevant safety precautions •...

  • Page 51: Compressor Element Overhaul

    BATTERY MAINTENANCE COMPRESSOR ELEMENT OVERHAUL • Keep the battery clean and dry. When a compressor element is due for • Keep the electrolyte level above the overhaul, it needs to be done by Atlas plates or at the indicated level. Level Copco.

  • Page 52: Air Filters Engine / Compressor

    AIR FILTERS ENGINE / COMPRESSOR should be repeated for both air filters engine and air filters compressor. MAIN PARTS The Atlas Copco air filters are 1. Remove the dust trap cover (1). Clean specially designed the inside of the cover.

  • Page 53: Adjustments And Servicing Procedures

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

  • Page 54: Air Receiver

    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 / lbf.ft) general applications at assembly of the compressor. 15 (11.07) For hexagon screws and nuts with strength grade 8.8 39 (28.78) 78 (57.56)

  • Page 61: Compressor / Engine Specifications

    COMPRESSOR / ENGINE SPECIFICATIONS REFERENCE CONDITIONS Designation XRX 1350 29.3 Absolute inlet pressure bar(e) 14.5 14.5 Relative air humidity Air inlet temperature °C °F Nominal effective working pressure bar(e) 29.3 The inlet conditions are specified at the air inlet grating outside the canopy. - 61 -...
  • Page 62 LIMITATIONS Designation XRX 1350 Minimum effective receiver pressure bar(e) Maximum effective receiver pressure, compressor unloaded bar(e) 26.5 30.8 Maximum ambient temperature at sea level °C °F Minimum starting temperature °C °F Maximum ambient temperature at sea level with after cooler °C °F Altitude capability (without deration)
  • Page 63 PERFORMANCE DATA At reference conditions, if applicable, and at normal shaft speed, unless otherwise stated. Designation XRX 1350 Engine shaft speed, normal and maximum r/min 1950 1950 Engine shaft speed, compressor unloaded r/min 1300 1300 Free air delivery 1263 1263 Fuel consumption at 100% FAD (Full Load) kg/h...
  • Page 64 DESIGN DATA Compressor Engine Designation XRX 1350 Total Capacity of oil sump Number of compression stages US gal 10.03 - Initial fill Engine - Refill (max.) US gal Designation XRX 1350 Capacity of cooling system Make Cummins US gal 15.5 Type KTA 1150C Coolant...
  • Page 65 Designation XRX 1350 4582 Overall Dimensions without Under Carriage (Approx) 2237 2336 Net weight DRY with Under Carriage (approx) Net weight DRY with Under Carriage & After cooled (approx) Net weight WET with Under Carriage (approx) Net weight WET with Under Carriage & After cooled (approx) Net weight DRY Stationary (approx) 5100...
  • Page 66 At reference conditions, if applicable, and at normal shaft speed unless otherwise stated Free air delivery is measured according to ISO 1217 ed.3 1996 annex D • +/- 5% 25 l/s (53 cfm) < FAD < 250 l/s (530 cfm) Tolerance: •...

  • Page 67: Altitude Unit Performance Curve

    ALTITUDE UNIT PERFORMANCE CURVE Max. allowable working pressure as a function altitude and ambient temperature. - 67 -...

  • Page 68: Dataplate

    Dataplate Unit serial number Name of the manufacturer Vehicle identification number* A Maximum permitted laden weight of the vehicle* B Maximum permitted road weight of the vehicle* C Maximum permitted laden weight of the towing eye* Model Working pressure Speed Engine power Manufacturing year 3 &...

  • Page 69: 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 70: Maintenance Log

    Maintenance Log Compressor ..............Customer ................. Serial number................................Service hours Maintenance action Date By initials - 70 -...

  • Page 71: Maintenance Log

    Maintenance Log Compressor ..............Customer ................. Serial number................................Service hours Maintenance action Date By initials - 71 -...

  • Page 72: Maintenance Log

    Maintenance Log Compressor ..............Customer ................. Serial number................................Service hours Maintenance action Date By initials - 72 -...

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