Page 1 B7-41/1000 Engine C7.1 T3 INSTRUCTION BOOK 06/2020 Printed matter no. : 2960 2900 02...
Page 3 Instruction book B7-41/1000 Engine C7.1 T3...
Page 5 Atlas Copco B7-41/1000 Engine C7.1 T3 Instruction book Original instructions Copyright Notice. Any unauthorized use or copying of the contents or any part thereof is prohibited. This applies in particular to trademarks, model denominations, part numbers and drawings This instruction book is valid for CE as well as non-CE labelled machines. It meets the requirements for instructions specified by the applicable European directives as identified in the Declaration of Conformity.
Page 6: Table Of Contents
Instruction book Table of contents Introduction ......................... 6 Competency requirements ....................6 Safety precautions ....................... 7 Safety icons ..................................7 General safety precautions ............................... 7 Personal protective equipment (PPE) ..........................8 Safety during transport and installation ........................... 9 Safety during use and operation ............................9 Safety during maintenance and repair ..........................
Page 7 Instruction book Transporting ................................... 32 Lifting .................................... 32 Installation..................................33 Control panel .................................. 34 6.4.1 Operating buttons ..............................34 Overview screen icons ..............................35 6.5.1 Top bar icons ................................36 6.5.2 Bottom bar icons ............................... 37 6.5.3 Main screen ................................37 Operations overview ..............................
Page 8 Instruction book 6.14.5 Go to DIAGNOSTICS .............................. 73 6.14.6 Resetting the initial overhaul timer ........................... 74 6.14.7 Setting the fuel level alarm ............................76 6.14.8 Selecting high altitude mode ............................. 77 6.14.9 Quick setpoint menu ..............................79 6.15 Switching operation mode ............................. 81 6.16 Automatic booster loading .............................
Page 9 Instruction book 8.1.2 Cleaning the dust trap ..............................94 8.1.3 Replacing the filter element and the safety cartridge ....................95 Safety valve ..................................95 Fuel system ..................................96 8.3.1 Priming instructions ..............................96 8.3.2 Replacing the filter elements ............................. 96 8.3.3 Draining instructions ..............................
Page 10: Introduction
Instruction book Introduction The policy of Atlas Copco is to provide the users of their equipment with safe, reliable and efficient products. Factors taken into account are among others: • The intended and predictable future use of the products, and the environments in which they are expected to operate;...
Page 11: Safety Precautions
• Keep a fire extinguisher in the vicinity The following list is a reminder of special safety directives and precautions mainly applicable to Atlas Copco equipment. These safety precautions apply to machinery processing or consuming air. Processing of any other gas requires additional safety precautions typical to the application and are not included herein.
Page 12: Personal Protective Equipment (Ppe)
Instruction book The supervisor, or the responsible person, shall at all times make sure that all instructions regarding machinery and equipment operation and maintenance are strictly followed and that the machines with all accessories and safety devices, as well as the consuming devices, are in good condition, free of abnormal wear or abuse, and are not tampered with.
Page 13: Safety During Transport And Installation
Instruction book Safety during transport and installation When towing, lifting or transporting the booster in any way, the battery switch must always be in the "OFF" position. Refer to section 3.3 Personal protective equipment (PPE) To lift a unit, all loose or pivoting parts, e.g. doors, shall first be securely fastened. Do not attach cables, chains or ropes directly to the lifting eyes;...
Page 14 DO NOT apply compressed air or inert gas to your skin or direct an air or gas stream at people When the unit has to operate in a fire-hazardous environment, the spark arrestor option (by Atlas Copco) to trap incendiary sparks for each engine exhaust is a mandatory Refer to section 3.3 Personal protective equipment (PPE)
Page 15: Safety During Maintenance And Repair
Instruction book 13. Stationary housing guards are provided on all rotating or reciprocating parts not otherwise protected and which may be hazardous to personnel. Machinery shall never be put into operation, when such guards have been removed, before the guards are securely reinstalled. 14.
Page 16 If any sound-damping material is damaged, replace it to prevent the sound pressure level from increasing. 12. Use only lubricating oils and greases recommended or approved by Atlas Copco. • Ensure that the selected lubricants comply with all applicable safety regulations, especially with regard to explosion or fire-risk and the possibility of decomposition or generation of hazardous gases.
Page 17: Tool Application Safety
Instruction book 17. When repair has been completed: • The machine shall be barred over at least one revolution for reciprocating machines, several revolutions for rotary ones to ensure that there is no mechanical interference within the machine or driver. •...
Page 18: Safety Valves
Instruction book 3.8.3 Safety valves DO NOT adjust or restrict safety valves Only trained and technically competent personnel should consider overhaul, re-set or performance testing of safety valves The safety valve is supplied with either a lead security seal or crimped cover to deter unauthorized access to the pressure regulation device •...
Page 19: Disposal
Your Atlas Copco machinery equipment consists for the most part of metallic materials that can be remelted in steelworks and smelting works and are therefore almost infinitely recyclable. The plastic used is labelled; sorting and fractioning of the materials for recycling in the future is foreseen.
Page 20: Leading Particulars
Instruction book Leading particulars Illustrations used in this manual are for reference only. Actual unit may differ according to product variations. Scope of supply Reference Name Lifting yoke Control panel Emergency stop button (S20) Forklift slots Suction Discharge Skid 2960 2900 02...
Page 21 Refers to booster Refers to the diesel engine Refers to booster cylinders Refers to booster stages Refers to discharge pressure (psi) Booster – C7.1 T3 Caterpillar engine- 4 pistons – single stage - 1000 psi discharge pressure B7-41/1000 2960 2900 02...
Page 22: Main Parts
Instruction book Main parts Reference Name Battery box stage cooler Control box Control panel Suction cooler Suction scrubber Emergency stop button 2960 2900 02...
Page 23 Instruction book Reference Name Air filter Back pressure regulator Engine cooler Engine exhaust Fuel tank Unloading valve 2960 2900 02...
Page 24: Unit Data Plate Overview
Instruction book 4.2.1 Unit data plate overview The booster is furnished with a unit data plate (1) showing the product code, the unit serial number and the working pressure. 2960 2900 02...
Page 25 Instruction book Reference Name Name of the manufacturer Waste electrical and electronic equipment (WEEE) symbol Maximum weight of the unit Booster model Maximum discharge pressure Engine speed Engine power Maximum suction pressure Manufacturing year QR code Unit serial number 2960 2900 02...
Page 26: Control Box Overview
Instruction book 4.2.2 Control box overview Reference Name ANfl Antenna FleetLink Control panel Flasher light Pressure gauge discharge Pressure gauge suction Emergency stop button 2960 2900 02...
Page 27: Working Principle
Instruction book Working principle Overview The booster allows for single-stage operation mode where air is compressed to the required discharge pressure. Single-stage mode The intake compressed air is fed via the suction valve into the suction cooler. The condensate from the feed air is separated in the suction scrubber where the liquid is manually drained.
Page 28: Drain Valves And Filler Caps
Instruction book Back Pressure Regulator (BPR) The booster is equipped with BPR set at 40 bar (580 psi) installed at the downstream of 1 stage cooler that guarantees an internal minimum pressure. Unloading valve The unloading valve regulator at the suction scrubber is set at 5.5 bar (80 psi) providing the pressure to operate the unloading valve.
Page 29 Instruction book Reference Name Drain valve suction scrubber Filler cap engine coolant Reference Name Dipstick pumper oil FCft Filler cap fuel tank Filler cap pumper oil 2960 2900 02...
Page 30 Instruction book Reference Name Dipstick engine oil Filler cap engine oil Reference Name DVc1 Drain valve 1 stage cooler DVcs Drain valve suction cooler 2960 2900 02...
Page 31: External Fuel Tank Connection (Option)
Instruction book External fuel tank connection (option) The "External fuel tank connection" allows to bypass the internal fuel tank and to connect an external fuel tank to the unit. 4.5.1 Auxiliary fuel tanks Auxiliary fuel tanks, service tanks and day tanks are secondary fuel tanks located in between the main fuel tank and the engine.
Page 32: Connecting The External Fuel Tank
Instruction book • The tank should be close enough to the engine so that the total suction lift to the transfer pump with the fuel at low level, plus the line loss of the supply line, is less than the fuel pump's maximum suction lift capability. This figure should be minimized for better starting.
Page 33: Fuel Feed Pipe Connections
Instruction book Step Action Put the selector switch in vertical position to select the external fuel tank Always connect the return line to the external fuel tank as well. This will allow the air to escape from the internal tank, and will prevent spillage when there is an overfill. 4.5.3 Fuel feed pipe connections Quick couplings: •...
Page 34: Markings And Information Labels
Read the instruction book before working on the battery Electrocution hazard Service point Warning! Part under pressure Start-Stop indication of switch Atlas Copco PAROIL E Mission Green Use diesel fuel only Atlas Copco PAROIL E Fork lifting permitted Atlas Copco PARCOOL EG Suction...
Page 35: Important Safety Signs
Instruction book Reference Description Reference Description Rotation direction Lifting permitted Circuit breaker Do not lift here Do not run the unit when the baffles are Tie down point not in the right position Read the instruction book before starting Important safety signs Look for these signs, which point out potential hazards to your safety and others.
Page 36: Operating Instructions
Instruction book Operating instructions Transporting Refer to section 3.4 Safety during transport and installation. The units must be transported horizontally. During transport, they must be fastened to the transporting vehicle. When towing, lifting or transporting the booster in any way, the battery switch must always be in the "OFF" position.
Page 37: Installation
Instruction book Installation Refer to section 3.4 Safety during transport and installation. Step Action Ensure unobstructed air intake for the cooler pack, diesel engine and pumper NOTE: Take into account the coolers' air flow direction when performing the above. See figure below. •...
Page 38: Control Panel
Instruction book Control panel 6.4.1 Operating buttons Reference Description Power ON/OFF switch Switches the control panel on and off Start button Starts the booster Stop button Stops the booster in a controlled manner Load button Pressing this button will: • initiate the Auto Load function, or command the booster to load (depending on actual status) •...
Page 39: Overview Screen Icons
Instruction book Reference Description Navigation buttons These buttons are used to navigate through the display panel Enter button Confirms or stores the selection or change Back button Moves back one level or ignores the change Overview screen icons Reference Description Top bar: booster status View, overhaul, auto load, preset, active operation mode indication, and navigation 2960 2900 02...
Page 40: Top Bar Icons
Instruction book Reference Description Main screen: Pressure indication and engine speed Bottom bar: Alarm indication , running hours, engine rpm, and fuel tank level 6.5.1 Top bar icons Reference Description Reference Description Preset Depending of which Pressure (and/or Main view indication Flow) setting is active, the controller will show its dedicated icon Preset...
Page 41: Bottom Bar Icons
Instruction book 6.5.2 Bottom bar icons Reference Description Reference Description Running hours Running on internal fuel tank Active (acknowledged and unacknowledged) Running on internal fuel tank and fuel alarms in alarms list pump is energized Running on external fuel tank, and Engine rpm internal fuel tank level is shown Running on external fuel tank, internal...
Page 42 Instruction book View 2 is the digital view screen Icons shown on digital view screen View 3 is the pumper view screen Icons shown on pumper view screen 2960 2900 02...
Page 43 Instruction book b. Settings view Step Action Use the Up and Down navigation buttons to scroll through the full list of settings Use the Enter button to enter the selected submenu Use the Back button to leave the entered submenu Icons shown on settings view screen Measurement view Step...
Page 44 Instruction book d. Alarms view Step Action Use the Up and Down navigation buttons to scroll through the full list of alarms NOTE: • Red-colored tag indicates shutdown alarm • Green-colored tag indicates acknowledged (active) alarm • Amber-colored tag indicates warning Icons shown on alarms view screen 2960 2900 02...
Page 45: Operations Overview
Instruction book Operations overview It is possible to control the booster locally with the Control Box, remotely with the remote switch inputs located on the back of the Control Box, or with software running on a PC with a CAN interface (PC Control Mode). The way one ends up in each status can differ from how the Control Box is controlled, but the function of each status stays the same.
Page 46: Fuel Venting Procedure
Instruction book Fuel venting procedure Perform the following procedure when: • Putting in operation for the first time; • Running out of fuel; • Changing the fuel filter; • After cleaning/ draining the fuel tank. Step Action Loosen the vent screw (1) on the fuel filter Operate the hand pump (2) at the filter until fuel comes out of the bore for the vent screw, and air is completely removed from the fuel system Fasten the vent screw (1)
Page 47: Before Starting The Booster
Instruction book Before starting the booster ENSURE suction hose is free from debris or dirt. Failure to do so may result in clogged/ damaged concentric valves DO NOT operate without safety cables on air hoses DO NOT operate with safety devices by-passed DO NOT set booster within 2.5 m (8 feet) of other machinery, buildings, or any obstructions that may hamper cooling air flow to and from booster.
Page 48: Initializing Sequence
Instruction book 6.10.1 Initializing sequence The instrument panel will now perform a self-test; the following display will be shown and the controller is initialized. During initializing all buttons/ inputs/ outputs/ alarms are inactive. This view will be shown for approximately 10 seconds. 6.10.2 Ready-to-start sequence The display now shows the following: The booster is now ready to be started and waiting for a start command.
Page 49: Pre-Start Sequence
Instruction book Active button Description Settings view button Toggles between Settings View and Main View Alarms view button Toggles between Alarms View and Main View 6.10.3 Pre-start sequence Step Action Press the start button to enter the pre-start sequence The following display shows: NOTE: the horn and flasher light will activate for 5 seconds to notify that it will start Active button Description...
Page 50: Reading Engine Data Sequence
Instruction book Active button Description Settings view button Toggles between Settings View and Main View Alarms view button Toggles between Alarms View and Main View 6.10.4 Reading engine data sequence The following display shows: The engine control unit (ECU) will be powered up. As soon as communication between booster controller and engine controller is established, the machine will preheat according to the parameters of the engine controller.
Page 51: Engine Cranking Sequence
Instruction book Active button Description Alarms view button Toggles between Alarms View and Main View 6.10.5 Engine cranking sequence The engine now starts cranking and the display shows: The engine cranks until 800 rpm is reached. If 800 rpm is not reached within 30 seconds, the starting procedure is cancelled and the engine will rest for some time (resting time depends on cranking time).
Page 52: Warming Up Sequence
Instruction book Active button Description Stop button Cancels the Start command Load button Activates Automatic load Measurements view button Toggles between Measurements View and Main View Settings view button Toggles between Settings View and Main View Alarms view button Toggles between Alarms View and Main View 6.10.6 Warming up sequence The engine now starts running at idle speed and the display shows: The engine will run at minimum rpm, until the engine’s coolant temperature reaches 40°C, with a minimum time...
Page 53 Instruction book Active button Description Load button Activates Automatic load Measurements view button Toggles between Measurements View and Main View Settings view button Toggles between Settings View and Main View Alarms view button Toggles between Alarms View and Main View 2960 2900 02...
Page 54: Setting The Discharge Pressure
Instruction book 6.10.7 Setting the discharge pressure There are three (3) presets available to determine the following parameters: • Discharge pressure • Flow • Engine speed The three parameters only work together under the same preset It is recommended to determine all parameters within the same preset before doing it for another preset Step Action Press the Settings View button...
Page 55 Instruction book Step Action Enter the pressure setting value • Scroll up/ down to edit the figure • Use left/ right button to shift between editable figures Example of display: Press Enter to confirm the value Press Back to return to the Main View or any other menu required Example of Main View: 2960 2900 02...
Page 56: Setting The Engine Speed
Instruction book 6.10.8 Setting the engine speed Step Action Press the Settings View button The following display shows: Scroll to 1000 General Settings Press Enter Scroll to 1061 RPM Setpoint 1 Press Enter 2960 2900 02...
Page 57 Instruction book Step Action Enter the pressure setting value • Scroll up/ down to edit the figure • Use left/ right to shift between editable figures Example of display: Press Enter to confirm the value Press Back to return to the Main View or any other menu required Example of Main View: 2960 2900 02...
Page 58: Setting The Flow
Instruction book 6.10.9 Setting the flow Step Action Press the Settings View button The following display shows: Scroll to 1000 General Settings Press Enter Scroll to 1030 Flow Setpoint 1 Press Enter 2960 2900 02...
Page 59 Instruction book Step Action Enter the pressure setting value • Scroll up/ down to edit the figure • Use left/ right button to shift between editable figures Example of display: Press Enter to confirm the value Press Back to return to the Main View or any other menu required Example of Main View: 2960 2900 02...
Page 60: Selecting Operation Mode Command
Instruction book 6.10.10 Selecting operation mode command The operation mode command can be selected on: • Local operation mode to allow starting, loading, and stopping the booster via the unit controller • Block operation mode command to disable starting, loading, and stopping the booster via the unit controller •...
Page 61 Instruction book Step Action At operation mode setting, scroll up and down to select the desired operation mode command Press Enter to confirm the selection 2960 2900 02...
Page 62: Not Loaded Sequence
Instruction book Step Action Press Back to return to the Main View or any other menu required 6.10.11 Not loaded sequence After warming up the booster is ready to be loaded and is waiting for a load command; the display shows: Step Action Press the load button...
Page 63: Suction Pressure Load Prevention Sequence
Instruction book Active button Description Measurements view button Toggles between Measurements View and Main View Settings view button Toggles between Settings View and Main View Alarms view button Toggles between Alarms View and Main View 6.10.12 Suction pressure load prevention sequence The suction pressure is checked and the following display shows: Active button Description...
Page 64: Loaded Sequence
Instruction book Active button Description Alarms view button Toggles between Alarms View and Main View Step Action Ensure suction valve is in open position Ensure bypass valve is in closed position Ensure feeding compressor is delivering flow 6.10.13 Loaded sequence During loading the following display is shown.
Page 65: Stopping The Booster
Instruction book Active button Description Settings view button Toggles between Settings View and Main View Alarms view button Toggles between Alarms View and Main View 6.11 Stopping the booster 6.11.1 Cooldown sequence • DO NOT use emergency stop button for normal stopping •...
Page 66: Stop Sequence
Instruction book 6.11.2 Stop sequence After cooling down, the engine will stop and the following display will show: The engine is stopped, and the controller will do a double check if the engine is really stopped. Active button Description Start button Initiates Start command Load button Activates Automatic load...
Page 67: Powering Off
Instruction book 6.12 Powering off Step Action Switch the Power to “OFF” position to switch off the controller NOTE: always perform this first before switching off the battery Wait until the display is dark before proceeding to the next step When the booster is not in use, switch the battery to “OFF”...
Page 68 Instruction book Step Action The following display shows: Press the Enter button to acknowledge the alarm Slowly open drain valve suction scrubber 2960 2900 02...
Page 69: Alarm Activation
Instruction book 6.13.2 Alarm activation Step Action When an alarm activates, there are several possible displays: • In measurements view and settings view, a red alarm icon is shown at the bottom left corner of the screen: • In main view, a notification banner appears: 2960 2900 02...
Page 70 Instruction book Step Action • In alarms view, the current alarm is highlighted: To acknowledge the alarm, perform either step 1 OR step 2: Press the Enter button to acknowledge the alarm Press the Alarms View button and press the Enter button to acknowledge the alarm NOTE: •...
Page 71: Settings
Instruction book 6.14 Settings Refer to section 6.4 Control panel for buttons to be used. 6.14.1 Setting the clock Step Action Press the Settings View button The following display shows: Scroll to 1000 General Settings Press Enter Scroll to 1290 Date / Time Enter the DATE/TIME menu 2960 2900 02...
Page 72: Setting The Language
Instruction book Step Action Scroll to the parameter to be changed • Scroll up/ down and press Enter to change • Use left/ right to shift between editable figures Press Back to return to the Main View or any other menu required 6.14.2 Setting the language Step Action...
Page 73 Instruction book Step Action Press Enter Scroll to 1300 Language Enter the Language menu Scroll to the preferred language Press Enter Press Back to return to the Main View or any other menu required 2960 2900 02...
Page 74: Setting The Units
Instruction book 6.14.3 Setting the units Step Action Press the Settings View button The following display shows: Scroll to 1000 General Settings Press Enter Scroll to the unit to be changed: • 1340 Temperature Units • 1350 Pressure Units • 1360 Fuel Flow Units •...
Page 75: Changing Display Settings
Instruction book Step Action Scroll to the preferred setting Press Enter Press Back to return to the Main View or any other menu required 6.14.4 Changing display settings Step Action Press the Settings View button The following display shows: Scroll to 1000 General Settings 2960 2900 02...
Page 76 Instruction book Step Action Press Enter Scroll to 1310 Display Backlight Enter the Display Backlight menu Scroll to the setting be changed Press Enter • Edit the red-marked figure to change a setting • Scroll up/ down and press Enter to change •...
Page 77: Go To Diagnostics
Instruction book 6.14.5 Go to DIAGNOSTICS Step Action Press the Settings View button The following display shows: Scroll to 1000 General Settings Press Enter Scroll to 1150 Diagnostics Enter the ENABLE parameter Scroll to ON and press Enter NOTE: Now the Engine Control Unit (ECU) will get Power after Contact (PAC) - ignition and one can perform ECU diagnostics (read DM1 List, DM2 List, ECU values, perform engine diagnostics, etc.) 2960 2900 02...
Page 78: Resetting The Initial Overhaul Timer
Instruction book Step Action Press Back to return to the Main View or any other menu required Press the Stop button to leave DIAGNOSTICS 6.14.6 Resetting the initial overhaul timer Step Action NOTE: When the initial overhaul alarm appears, initial overhaul needs to be performed to the machine. When the Initial Overhaul is performed, the Initial Overhaul warning can be reset as following: Press the Settings View button Scroll to the 1000 General Settings...
Page 79 Instruction book Step Action Scroll to 1510 Initial Overhaul Reset Enter the Operation Mode Command menu Enter the RESET parameter Scroll to ON Press Enter NOTE: if the initial overhaul alarm has been acknowledged, the alarm and icon will disappear Press Back to return to the Main View or any other menu required 2960 2900 02...
Page 80: Setting The Fuel Level Alarm
Instruction book 6.14.7 Setting the fuel level alarm Step Action Press the Settings View button The following display shows: Scroll to 3000 Voltage Inputs Press Enter Scroll to 3000 Fuel Level Low 1 Press Enter 2960 2900 02...
Page 81: Selecting High Altitude Mode
Instruction book Step Action Scroll to Setting • Scroll up/ down and press Enter to change • Use left/ right to shift between editable figures Press Back to return to the Main View or any other menu required 6.14.8 Selecting high altitude mode High altitude mode is selected when operating on a high elevation to protect the engine by ensuring the correct engine speed Step...
Page 82 Instruction book Step Action Scroll to 1000 General Settings Press Enter Scroll to 1240 High Altitude Press Enter Select “On” to enable Press Enter to confirm the selection Press Back to return to the Main View or any other menu required 2960 2900 02...
Page 83: Quick Setpoint Menu
Instruction book 6.14.9 Quick setpoint menu The quick setpoint menu shows all setpoints under different Presets Step Action At Main View, press and hold Enter button for 2 seconds Use right/ left button to toggle between different setpoints Example of displays: 2960 2900 02...
Page 84 Instruction book Step Action At the setpoint, use up/ down button to adjust the value Scroll up/down to toggle between Presets 2960 2900 02...
Page 85: Switching Operation Mode
Instruction book 6.15 Switching operation mode The booster allows for switching operation mode between bypass and single-stage operation mode. Below is the procedure to switch from bypass to single-stage operation mode. Step Action NOTE: • In bypass mode the air from the feeding compressor(s) is routed from booster suction to discharge. •...
Page 86: Automatic Booster Loading
Instruction book 6.16 Automatic booster loading Step Action Press the load button to load NOTE: • Booster will begin to build pressure when there is sufficient restriction downstream at the recipient • Booster will automatically unload and load according to the pressure setting 6.17 Manual booster unloading Step Action...
Page 87: Pilot Valve And Blow Off Valve
Instruction book 6.18.2 Pilot valve and blow off valve The pilot valve (PV) is set at 27 bar (391 psi). Reference Name Blow off valve Pilot valve 2960 2900 02...
Page 88: Maintenance
Instruction book Maintenance Liability Atlas Copco does not accept any liability for any damage arising from the use of non-original parts and for modifications, additions or conversions made without the manufacturer’s approval in writing. Service packs A Service Pack is a collection of parts to be used for a specific maintenance task, e.g. after 250, 500, 1000 and after 2000 running hours.
Page 89: Daily Checks Activities
Instruction book Daily checks activities Refer to Appendix-1 Maintenance log Step Action Check pumper oil, engine oil, and coolant level Drain suction scrubber Check and take service readings (air, cylinder, engine, oil temperatures, and pressures) Check for air, fuel, coolant, and oil leakage Check fixation of hoses, cables and pipes Check air filter restriction indicator via the controller Check all critical bolt connections...
Page 90: Engine
Instruction book 7.7.1 Engine Refer to Engine Operation manual for engine maintenance Replace coolant every three years or 3000 hrs (whichever earlier) Service packs/ hrs Service pack Service pack Service pack Activities 2912468300 2912468600 2912468700 250 hrs 500 hrs 1000 hrs 2000 hrs Check oil level / add engine oil Replace engine oil...
Page 91: Oil Specifications
Re-drain the synthetic oil and refill with new synthetic oil. To set correct oil levels, follow the normal instructions It is strongly recommended to use Atlas Copco brand lubrication oils for both booster and engine It is recommended to use high-quality, mineral, hydraulic or synthesized hydrocarbon oil with rust and...
Page 92: Paroil
Instruction book 7.8.1 PAROIL PAROIL from Atlas Copco is the ONLY oil tested and approved for use in all engines built into Atlas Copco boosters. Extensive laboratory and field endurance tests on Atlas Copco equipment have proven PAROIL to match all lubrication demands in varied conditions.
Page 93: Engine And Booster Oil
Instruction book 7.8.2 Engine and booster oil Choose the oil based on the actual ambient temperatures in the operating environment Refer to Parts Online for the recommended oil Refer to the Engine operation manual for oil specifications 7.8.3 Oil level check Consult the Engine Operation manual for the oil specifications, viscosity recommendations, and oil change intervals Step...
Page 94: Parcool
PARCOOL is the only coolant that has been tested and approved by all manufacturers of engines currently used in Atlas Copco compressors. Atlas Copco PARCOOL EG extended life coolant is the new range of organic coolants purpose-designed to meet the needs of modern engines. PARCOOL EG can help prevent leaks caused by corrosion. PARCOOL EG is also fully compatible with all sealants and gasket types developed to join different materials used within an engine.
Page 95: Coolant Quality Check
Instruction book Handling PARCOOL EG PARCOOL EG should be stored at ambient temperatures, while periods of exposure to temperatures above 35°C (95°F) should be minimized. PARCOOL EG can be stored for a minimum of 5 years in unopened containers without any effect on the product quality of performance. PARCOOL EG is compatible with most other coolants based on ethylene glycol, but the benefits of 5 years protection are only achieved when it is used on its own.
Page 96: Glycol Concentration Measurement
Instruction book 7.10.3 Glycol concentration measurement Glycol concentration measurement might provide incorrect values when using a mix of different coolant products To optimize the unique engine protection features of the PARCOOL EG, the concentration of the Glycol in the water should always be above 33 vol.%. Mixtures exceeding a 68 vol.% mix ratio in water are not recommended, as this will lead to high engine operating temperatures.
Page 97: Cleaning The Coolers
NOTE: steam cleaning in combination with a cleansing agent may be applied (do not use jet at maximum power) Close the service door(s) if available 7.13 Battery care • The battery is maintenance-free • Contact Atlas Copco for any services required for the battery 2960 2900 02...
Page 98: Adjustments And Servicing Procedures
Instruction book Adjustments and servicing procedures Air filter(s) 8.1.1 Main parts • The Atlas Copco air filters are specially designed for the application • The use of non-genuine air filters may lead to severe damage of the engine Reference Name...
Page 99: Replacing The Filter Element And The Safety Cartridge
Instruction book 8.1.3 Replacing the filter element and the safety cartridge The safety cartridge cannot be cleaned • Replace the filter element and the safety cartridge at the same time • New elements should be inspected for tears and punctures before installation Step Action Release the snap clips (1) and remove the dust trap cover (2)
Page 100: Fuel System
Instruction book Fuel system 8.3.1 Priming instructions • Fuel leaked or spilled onto hot surfaces or electrical components can cause fire • To help prevent possible injury, turn the power switch off when changing fuel filters or water separator elements. Clean up fuel spills immediately. Refer to the Engine operation manual for fuel priming instructions Step Action...
Page 101: Draining Instructions
Instruction book 8.3.3 Draining instructions Step Action Open bowl drain valve (1) Operate hand pump (5) and pump water out Close drain valve (1) Cleaning crankcase breather filter Step Action After switching off the engine, let it cool down for about 30 minutes Open the clasps (1) and carefully separate the bowl (2) from the head.
Page 102: Fault Codes List
Instruction book Fault codes list This section is to be updated. There are several parameters that are continuously watched. When one of these parameters exceeds its specified limit the booster will react depending the present status of the control box. Alarm code Alarm text Fail class...
Page 103 Instruction book Alarm code Alarm text Fail class 6011 MACHINE DATA CHANGED Controlled Stop 6190 CHARGE MONITORING FAIL Indication 6327 START FAILURE Shutdown 6329 STARTER SPEED TOO LOW Shutdown 6388 VESSEL PRESSURE TOO LOW TO LOAD Indication 6426 UNINTENTIONAL RUN Shutdown 6427 RUN FAILURE...
Page 104 Instruction book • ECU - TURBO BOOST PRESSURE • ECU - TURBO OIL PRESSURE • ECU - INTAKE MANIFOLD TEMPERATURE • ECU - AIR INLET PRESSURE • ECU - COOLANT TEMPERATURE • ECU - COOLANT LEVEL • ECU - SUPPLY VOLTAGE •...
Page 105: Technical Specifications
Instruction book 10 Technical specifications 10.1 Reference conditions Designation Value 1 bar Absolute suction pressure 14.5 psi Relative air humidity 20˚C Air suction temperature 68˚F 10.2 Limitations Designation Value 24 bar Maximum suction pressure 350 psi 69 bar Maximum discharge pressure 1000 psi 50˚C Maximum ambient temperature...
Page 106: Fluid Capacities
Instruction book 10.3.2 Fluid capacities Designation Value 9.8 l Pumper oil 2.6 US gal 15 l Engine oil 4 US gal 36 l Coolant system 9.5 US gal 295 l Fuel tank 78 US gal NOTE: includes filter 10.3.3 Pumper Designation Value 127 mm...
Page 107: Shutdown And Alarm Set Points
Instruction book 10.3.6 Shutdown and alarm set points Value Designation Alarm Shutdown 180°C 190 °C First-stage temperature high 356°F 374 °F 76 bar 80 bar Discharge pressure high 1102 psi 1160 psi 1.6 bar 1.4 bar Pumper oil pressure low 23.2 psi 20.3 psi Fuel level low...
Page 108: Capacity Chart
Instruction book 10.4 Capacity chart 10.4.1 Single-stage mode Maximum capacity 63 m /min (1050 l/s) 2250 cfm Maximum suction 24 bar 350 psi Maximum discharge 69 bar 1000 psi Operating speed 1250 rpm - 1800 rpm Capacity (cfm) at various pressure and operating speed Maximum Suction pressure discharge...
Page 109: Piping And Instrumentation Diagram
Instruction book 10.5 Piping and instrumentation diagram Refer to Atlas Copco Toolbox for latest drawing 2960 2900 02...
Page 110: Dimensional Drawing
Instruction book 10.6 Dimensional drawing Refer to Atlas Copco Toolbox for latest drawing 2960 2900 02...
Page 111: Electrical Diagram
Instruction book 10.7 Electrical diagram Refer to Atlas Copco Toolbox for latest drawing Sheet 01 of 08 - Index and Legend 2960 2900 02...
Page 112 Instruction book Sheet 02 of 08-Legend 2960 2900 02...
Page 113 Instruction book Sheet 03 of 08-Main Circuit 2960 2900 02...
Page 114 Instruction book Sheet 04 of 08-XC 4004 Connector 2960 2900 02...
Page 115 Instruction book Sheet 05 of 08-XC 4004 Connector 2960 2900 02...
Page 116 Instruction book Sheet 06 of 08-XC 4004 Controller 2960 2900 02...
Page 117 Instruction book Sheet 07 of 08-Engine Plug Connector 2960 2900 02...
Page 118 Instruction book Sheet 08 of 08-Optional Equipment 2960 2900 02...
Page 119: Appendix-1 Maintenance Log
Instruction book Appendix-1 Maintenance log Booster :................................Serial number : ................................Customer :................................. Service hours Maintenance action Date By: initials 2960 2900 02...
Page 121 We make performance stand the test of time. This is what we call – Sustainable Productivity. Atlas Copco Airpower nv Ingberthoeveweg 7, 2630 Aartselaar, Belgium Phone: +32 (0)3 870 21 11 Reg. no: BE 0403 992 231 www.atlascopco.com...