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Atlas Copco XAS 38 Kd APP Instruction Manual
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Atlas Copco XAS 38 Kd APP Instruction Manual

Atlas Copco XAS 38 Kd APP Instruction Manual

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Operator Manual
for Portable Compressors
English
XAS 38 Kd APP
XAS 48 Kd APP
XAS 48 LRC Kd APP
Instruction Manual
D722
Engine Kubota
D902
Engine Kubota

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Summary of Contents for Atlas Copco XAS 38 Kd APP

  • Page 1 Instruction Manual Operator Manual for Portable Compressors English D722 XAS 38 Kd APP Engine Kubota XAS 48 Kd APP D902 Engine Kubota XAS 48 LRC Kd APP...
  • Page 3 Operator Manual for Portable Compressors XAS 38 Kd APP XAS 48 Kd APP XAS 48 LRC Kd APP Original instructions Printed matter No. 2954 9510 02 ATLAS COPCO - PORTABLE ENERGY DIVISION www.atlascopco.com 08/2023...
  • Page 4 Neglecting maintenance or making changes to the setup of the machine can result in major hazards, including fire risk. While every effort has been made to ensure that the information in this manual is correct, Atlas Copco does not assume responsibility for possible errors.

  • Page 5: Table Of Contents

    Table of contents Preface 5.4.1 Prevent low loads........31 5.4.2 Before starting ........31 Follow the instructions in this booklet and we 5.4.3 Control panel ......... 32 guarantee you years of troublefree operation. It is a Safety precautions ........7 solid, safe and reliable machine, built according to 5.4.4 Starting procedure........
  • Page 6 6.17.1 Coolant level check ........ 45 Electrical drawings........73 6.17.2 Replacing the coolant......46 Data plate ..........76 6.18 Battery ............47 6.18.1 Electrolyte ..........47 Disposal ............. 77 6.18.2 Activating a dry-charged battery.... 47 6.18.3 Recharging a battery ......47 Maintenance log ........

  • Page 7: Safety Precautions

    INTRODUCTION Skill level 3: Electrical technician The policy of Atlas Copco is to provide the users of These safety precautions are general and some their equipment with safe, reliable and efficient statements will therefore not always apply to a An electrical technician is trained and has the same products.

  • Page 8: General Safety Precautions

    Atlas Copco GENERAL SAFETY PRECAUTIONS Care must be taken to prevent damage to safety equipment. valves other pressure-relief devices, The owner is responsible for maintaining the unit especially to avoid plugging by paint, oil coke or These safety precautions apply to machinery in a safe operating condition.

  • Page 9: Safety During Transport And Installation

    SAFETY DURING TRANSPORT AND - check that the wheels are secure and that the Lifting hooks, eyes, shackles, etc., shall never be tyres are in good condition and inflated bent and shall only have stress in line with their INSTALLATION correctly, design load axis.

  • Page 10: Safety During Use And Operation

    13 Never refill fuel while the unit is running, unless injury. to alert people entering the room, for even otherwise stated in the Atlas Copco instruction relatively short times, about the need to wear The air line end connected to the outlet valve book.

  • Page 11: Safety During Maintenance And Repair

    18 The unit has parts, which may be accidentally 25 Remember that where there is visible dust, the SAFETY DURING MAINTENANCE AND touched by personal, of which the temperature finer, invisible particles will almost certainly be REPAIR can be in excess of 80°C (176°F). The insulation present too;...

  • Page 12: Tool Applications Safety

    Atlas Copco or the applied. machine manufacturer. Ascertain that the 22 When using cartridge type breathing filter selected lubricants comply with all applicable equipment, ascertain that the correct type of...

  • Page 13: Specific Safety Precautions

    If the set pressure must be altered then use only has been charged. Therefore: applications as specified above and in accordance correct parts supplied by Atlas Copco and in with the technical specifications. Safety reasons - never smoke near batteries being, or having accordance with the instructions available for the prohibit any other applications.

  • Page 14: Leading Particulars

    Leading particulars GENERAL DESCRIPTION Engine This symbol draws your attention to The compressor is driven by a liquid-cooled diesel dangerous situations. The operation engine. concerned may endanger persons and The engine's power is transmitted to the compressor cause injuries. through a gear box. Compressor element This symbol...
  • Page 15 Regulation Fuel system Lifting eye The compressor is provided with a continuous The fuel feed lines and fuel filtration are designed in A lifting eye is accessible through a rubber flap pneumatic regulating system and a blow-down valve such a way that after running the fuel tank dry, air covered hole at the top of the unit.

  • Page 16: Markings And Information Labels

    Rotation direction. with Directive 2000/14/EC oil. (expressed in dB (A)). Read the instruction manual Horizontal towbar position Atlas Copco mineral engine oil. before starting. required in case of coupling. Atlas Copco synthetic engine oil. Service every 24 hours. Start engine.

  • Page 17: Main Parts

    Main parts - 17 -...
  • Page 18 Reference Name Reference Name Air Filter Compressor Fuel pre filter Air Filter Engine Filler Plug Air Outlet Valves Fuel Tank Air Receiver Fuel Pump Battery Gear Box Brake Handle Oil Cooler Compressor Element OFce Oil Filter (compressor element) Control Panel Oil Filter (engine) Data Plate Oil Separator...

  • Page 19: Overview

    Overview - 19 -...

  • Page 20: Air Flow

    AIR FLOW OIL SYSTEM Air drawn through the compressor airfilter (AFc) into The lower part of the air receiver (AR) serves as an oil the compressor element (CE) is compressed. At the tank. element outlet, compressed air and oil pass into the air Air pressure forces the oil from the air receiver/oil receiver/oil separator (AR/OS).

  • Page 21: Continuous Pneumatic Regulating System

    CONTINUOUS PNEUMATIC REGULATING SYSTEM The compressor is provided with a continuous If the air consumption is less than the maximum air pneumatic regulating system. This system is provided output, the regulating valve supplies control air to with a blow-down valve, which is integrated in the unloader assembly (UA) to reduce the air output and unloader assembly.

  • Page 22: Operating Instructions

    Operating instructions PARKING, TOWING AND LIFTING PARKING INSTRUCTIONS INSTRUCTIONS Safety precautions The operator is expected to apply all relevant Safety precautions. Attention After the first 100 km travel: Check and retighten the wheel nuts and towbar bolts to the specified torque. section Compressor/engine specifications.

  • Page 23: Towing Instructions

    TOWING INSTRUCTIONS Label on towbar, towing instructions Towing position of jockey wheel Adjustable towbar with support leg and brakes For both non-adjustable and adjustable towbar, the Before towing the compressor, make towbar should be as level as possible and the sure that the towing equipment of the compressor and towing eye end in a level position.

  • Page 24: Height Adjustment

    HEIGHT ADJUSTMENT (with adjustable towbar) 8. When readjusting, make sure that the front point of the towbar is horizontal with the coupling point. 9. Before starting a trip, ensure that the adjustment shaft is secure, so that stability and safety is guaranteed while driving.

  • Page 25: Lifting Instructions

    BALL COUPLING (OPTION) LIFTING INSTRUCTIONS Coupling: Open coupling jaw by pulling the lever vigorously upwards in the direction of the arrow. Lower the opened coupling onto the ball of the vehicle coupling and the lever will automatically be lowered. Closing and locking are carried out automatically.

  • Page 26: Towbar Adjustment

    TOWBAR ADJUSTMENT To securely tighten the adjustable braked towbar, follow the torque values. Ball coupling Slotted towing eye Towbar diameter Weight range Screw Quality Towbar Sheet Molding Horizontal screw Vertical screw Ø35.5x5.2 900 kg 60-5 Nm Ø45x5 1400 kg 10.9 65-5 Nm 95-5 Nm 95-5 Nm...
  • Page 27 Bolt and Screw Hexagon bolts with metric regular thread Gag of height-adjustable overrun devices according to DIN 931, DIN 933 or Bolts and DIN EN ISO 4014/4017 MA [Nm] L [mm] F [kg] tension nut Screw Quality MA [Nm] M16x1.5 1000 M20x1.5 1000...

  • Page 28: Shipping The Compressor

    SHIPPING THE COMPRESSOR Specified shipping vehicle Use only these shipping vehicles to transport the unit to the required location: 1. Curtain Trailers 2. Open Trailers 3. Winch Trucks - 28 -...

  • Page 29: Fixation Tools

    FIXATION TOOLS Removing the Lashing belts Use only CE-approved lashing belts (ratchet straps). The lashing belt set has two separate belts- the fixed belt and the adjusting belt. 1. Open the ratchet handle (3). The lashing belts (ratchet straps) must be of type LC 2000 daN and Stf 350 daN.

  • Page 30: Securing The Unit To The Shipping Vehicle

    SECURING THE UNIT TO THE SHIPPING VEHICLE 1. Place the unit in centre position into the shipping vehicle so that the canopy is parallel to the edges of the shipping vehicle. 2. For tie points 1 to 4, hook the four adjusting belts to the eyes of the unit and four fixed belts to the eyes on the shipping vehicle.

  • Page 31: Operating The Compressor

    OPERATING THE COMPRESSOR BEFORE STARTING 5. Check that the fuel tank contains sufficient diesel 1. Before initial start-up, prepare battery for fuel. Top up, if necessary. For priming the engine, PREVENT LOW LOADS operation if not already done. See section the fuel must be electrically pumped up by Recharging a battery.

  • Page 32: Control Panel

    CONTROL PANEL STARTING PROCEDURE Before operating the unit first read the manual. 1. Open air outlet valve, do not connect a hose yet. (P1) (H2) (PG) (F1) (S1) 2. Open the hood and switch the main switch at the back of the control panel to ON. 3.

  • Page 33: During Operation

    1. Close the air outlet valves (AOV). turned off (start switch to position 0; also when, failure. Only the Atlas Copco customer due to cooling off, the thermocontact has closed center or an authorized distributor may 2.

  • Page 34: Maintenance

    QR CODE FLEETLINK The schedule contains a summary of the maintenance Scan the QR code to access into the Atlas Copco instructions. Read the respective section before taking The compressor is equipped with the FleetLink as an Spare Part list (ASL).

  • Page 35: Daily Maintenance Compressor Before Starting A Job

    DAILY MAINTENANCE COMPRESSOR BEFORE STARTING A JOB Drain water from fuel filter Drain condensate and water from spillage-free frame see Spillage-free frame Empty air filter vacuator valves see Air filter engine/compressor see Engine oil level check Check engine oil level (if necessary top up) Check compressor oil level (if necessary top up) see Compressor oil level check Check coolant level...

  • Page 36: Maintenance Schedule Compressor

    1000 hrs 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 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/service paks and their ordering numbers.
  • Page 37 Maintenance schedule (running hrs) 50 hrs after Every Every Every Every Yearly 2 Yearly initial start-up 250 hrs 500 hrs 750 hrs 1000 hrs Clean flow restrictor in oil scavenge line Grease hinges Check/Test glow plugs - grid heater Replace bleed-off valve unloader Check rubber flexibles (3) (7) Analyse coolant...
  • Page 38 4. Use Atlas Copco oil filters, with by-pass valve as specified in the parts list. 5. Gummed or clogged filters means fuel starvation and reduced engine performance. 6. See section Oil. 7. The following part numbers can be ordered from Atlas Copco to check on inhibitors and freezing points  2913 0028 00: refractometer ...

  • Page 39: Maintenance Schedule Undercarriage

    MAINTENANCE SCHEDULE UNDERCARRIAGE Maintenance schedule (km) Every 2000 km Yearly 50 km after initial start-up Check tyre pressure Check tyres for uneven wear Check torque of wheel nuts Check coupling head Check height adjusting facility Check towbar handbrake lever spring actuator, reversing lever, linkage and all movable parts for ease of movement Grease coupling head, towbar bearings at the housing of the overrun brake...

  • Page 40: Adjustment Of The Continuous Pneumatic Regulating System

    Only the pressure must be Y bar (see table); adjust if Atlas Copco customer center or an necessary with regulating valve (RV). To adjust the normal working pressure, proceed as authorized distributor may work on the follows: 5.

  • Page 41: Oil

    ENGINE OIL LEVEL CHECK COMPRESSOR OIL Check engine oil level in accordance to the It is strongly recommended to use Atlas instructions in the Engine Operation Manual and if Copco branded lubrication oils for both necessary, top up with oil. compressor and engine.

  • Page 42: Compressor Oil Level Check

    COMPRESSOR OIL LEVEL CHECK DAILY CHECK CHECK AFTER A LONGER PERIOD WITHOUT RUNNING THE COMPRESSOR Check the compressor oil level daily, after running 1. Check the oil level by opening an oil filler plug the compressor. (2). The oil level must always be above the bend The compressor oil level needs to be of the elbow.

  • Page 43: Compressor Oil And Oil Filter Change

    Never add more oil. Overfilling results in to change the oil more frequently. oil consumption. In this case, contact Atlas Copco. 1. Run the compressor until warm. Close the outlet valve(s) (2) and stop the compressor. Wait until the pressure is released through the automatic blow-down valve.

  • Page 44: Compressor Oil Flushing Procedure

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

  • Page 45: Coolant

     Check the pH value of the coolant using a pH system. damage. measuring device.  The pH-meter can be ordered from Atlas Copco PARCOOL EG TOPPING UP OF COOLANT with part number 2913 0029 00. PARCOOL EG is a ready to use Ethylene Glycol ...

  • Page 46: Replacing The Coolant

    REPLACING THE COOLANT Drain  Completely drain the entire cooling system.  Used coolant must be disposed of or recycled in accordance with legislation and local regulations. Flush  Flush twice with clean water. Used coolant must be disposed or recycled in accordance with laws and local regulations.

  • Page 47: Battery

    BATTERY MAKE-UP DISTILLED WATER ACTIVATING A DRY-CHARGED BATTERY Before handling batteries, read the 1. Take out the battery. The amount of water evaporating from batteries is relevant safety precautions and act largely dependant on the operating conditions, i.e. 2. Battery and electrolyte must be at an equal accordingly.

  • Page 48: Air Receiver

    1. Unscrew the filter element (2) from the adapter When a compressor element is due for overhaul, it head. needs to be done by Atlas Copco. This guarantees the use of genuine parts and correct tools with care and 2. Clean the adapter head sealing surface. Lightly oil precision.

  • Page 49: Air Filter Engine/Compressor

    AIR FILTER ENGINE/COMPRESSOR CLEANING To avoid damaging the coolers, angle CLEANING COOLERS between jet and coolers should be approximately 90°. Protect the electrical and controlling equipment, air filters, etc. against penetration of moisture. Close the service door(s). Never leave spilled liquids such as fuel, oil, water and cleansing agents in or around the compressor.

  • Page 50: Replacing The Air Filter Element

    REPLACING THE AIR FILTER ELEMENT The Atlas Copco air filters are specially designed for the application. The use of non-original air filters may lead to severe damage engine and/or compressor element. Never run the compressor without air filter element. The filter element must be cleaned or...

  • Page 51: Wheels

    WHEELS Wheel bearing maintenance 1. Remove wheels and wheel hubs. Wheel bolts check 2. Mark dismounted wheel hubs and bearing races so Tighten the wheel bolts crosswise using a torque that their identity is not mistaken during wrench. Tighten the bolts in compliance with the reassembly.

  • Page 52: Towbar And Overrun Brake

    TOWBAR AND OVERRUN BRAKE Height adjustment facility check After every adjustment the clamping nuts must be tightened and secured with the spring elements. Tightening torque: M 24 = 250 - 350 Nm M 32 = 350 - 400 Nm Check tight fit of the clamping nuts and correct positioning of the adjustment facility.

  • Page 53: Towbar Lubrication

    TOWBAR LUBRICATION Moving parts and pivot pins at overrun Coupling head coupling Oil moving parts of ball coupling at regular intervals. All moving parts of drawbar, handbrake lever, spring Grease the contact surface of the ball of the towing actuator, reversing lever, linkages etc. are to be oiled vehicle.

  • Page 54: Spillage-Free Frame

    SPILLAGE-FREE FRAME STORAGE Run the compressor regularly, e.g. twice a week, until warm. Load and unload the compressor a few times to operate the unloading and regulating components. Close the air outlet valves after stopping. If the compressor is going to be stored without running regularly, protective measures must be taken.

  • Page 55: Available Options

    AVAILABLE OPTIONS Special color Special Color Orange - ICO 3220 Undercarriage Adjustable towbar with brakes Special Color Red - ICO 4308 Adjustable towbar without brakes Special Color White - ICO 1001 Fixed towbar with brakes Special Color Blue - ICO 5507 Fixed towbar without brakes Special Color Green - ICO 6903 Support mounted...
  • Page 56 Road light system Hose reel The right hand traffic road light system includes rear The hose which is 16 m long, winded on a reel. Do not lights, stop lights, direction indicators, license plate run over the hose while it is under pressure. Hose reel light, fog light and rear reflector and a 7-pin connector must be winded up and hose end must be put in the to connect the lights to the towing vehicle.

  • Page 57: Problem Solving

    4. Never operate the engine without the main or stay on, until the compressor has been restarted consult Atlas Copco. voltage sensing cables connected in the circuit. (start switch to position 3), or the contact is turned off (start switch to position 0;...
  • Page 58 Check and repair. keeps running at maximum speed when b. Regulating valve (RV) incorrectly set or defective. b. Consult Atlas Copco. closing the air outlet valves; safety valve c. Unloader valve (UV) or its actuating piston stuck. c. Repair unloader valve assembly.
  • Page 59 Engine does not run at maximum speed. d. Check the maximum speed, service the fuel filter. e. Oil separator element (OS) clogged. e. Have element removed and inspected by an Atlas Copco Service representative. 10. Overheating; alarm lamp goes on.

  • Page 60: Technical Specifications

    Technical specifications TORQUE VALUES GENERAL TORQUE VALUES CRITICAL TORQUE VALUES The following tables list the recommended torques applied for general applications during assembly of the compressor. Assemblies Torque value, Nm (lbf.ft) For hexagon screws and nuts with strength grade 8.8 Wheel bolts See section Wheels Thread size...

  • Page 61: Compressor/Engine Specifications

    COMPRESSOR/ENGINE SPECIFICATIONS REFERENCE CONDITIONS Designation Unit XAS 38 Kd APP XAS 48 Kd APP XAS 48 LRC Kd APP Absolute inlet pressure 14.5 14.5 14.5 Relative air humidity Air inlet temperature °C °F Nominal effective working pressure The inlet conditions are specified at the air inlet grating outside the canopy.
  • Page 62 ALTITUDE UNIT PERFORMANCE CURVES Maximum achievable working pressure in relation to altitude and ambient temperature. XAS 38 Kd APP XAS 48 Kd APP XAS 48 LRC Kd APP - 62 -...

  • Page 63: Performance Data

    PERFORMANCE DATA At reference conditions, if applicable, and at normal shaft speed, unless otherwise stated. Designation Unit XAS 38 Kd APP XAS 48 Kd APP XAS 48 LRC Kd APP Free air delivery /min Compressed air temperature at outlet valve without °C...

  • Page 64: Design Data

    Designation Unit XAS 38 Kd APP XAS 48 Kd APP XAS 48 LRC Kd APP Noise Level - Sound pressure level (Lp), dB(A) measured according to ISO 2151 - Sound power level (Lw) dB(A) complies with 2000/14/EC DESIGN DATA Compressor...
  • Page 65 Engine Designation Unit XAS 38 Kd APP XAS 48 Kd APP XAS 48 LRC Kd APP Make Kubota Kubota Kubota Type D722 D902 D902 Coolant PARCOOL PARCOOL PARCOOL Number of cylinders Bore 2.61 2.81 2.81 Stroke 73.6 73.6 2.65 2.87 2.87...
  • Page 66 Unit Designation Unit XAS 38 Kd APP XAS 48 Kd APP XAS 48 LRC Kd APP Air volume at inlet grating (approximately) 0.93 0.93 0.93 Capacity of compressor oil system US gal Net capacity of air receiver US gal Capacity of fuel tanks 28.5...

  • Page 67: Dimension Drawings

    Dimension drawings 9822 0088 00-01 - Adjustable unbraked towbar - 67 -...
  • Page 68 9822 0089 00-01 - Adjustable braked towbar - 68 -...
  • Page 69 9822 0090 00-01 - Fixed unbraked towbar Center of gravity Net Mass Wet Mass mm / mm / mm / mm / mm / mm / Kg/Lbs Kg/Lbs [Inches] [Inches] [Inches] [Inches] [Inches] [Inches] 533/1172,6 667/[26,2] 412/[16,2] 282/[11,8] 569/1251,8 654/[25,7] 398/[15,6] 277/[10,9] 525 [20,7] 190 [7,5] 595 [23,4]...
  • Page 70 9822 0091 00-01 - Fixed braked towbar - 70 -...
  • Page 71 9822 0093 00-04 - Support mounted - 71 -...
  • Page 72 9822 0168 00-01 - Extended support - 72 -...

  • Page 73: Electrical Drawings

    Electrical drawings 9822108210-02-1 - 73 -...
  • Page 74 9822108210-02-2 CONTROL CIRCUIT - 74 -...
  • Page 75 9822108210-02-3 FLEETLINK - 75 -...

  • Page 76: Data Plate

    2-D Maximum permitted load on rear axle (on Wheel bolt torque (12) S/N: Manuf. date: dual axle units) MADE IN BELGIUM lbf.ft 0343 Atlas Copco Airpower n.v. Model name Boomsesteenweg 957 B-2610 Wilrijk 0038 Working pressure in bar 10 Speed in RPM (13) (14) (15)

  • Page 77: Disposal Of Materials

    For more information check with your local waste Your Atlas Copco compressor consists for the most disposal regulations. Do not drain into the sewage authority, customer center or distributor.

  • Page 78: Maintenance Log

    Maintenance log Compressor ......................Customer ........................Serial number................................................Service hours Maintenance action Date By: initials - 78 -...
  • Page 79 Following documents are provided with this unit: - Test Certificate - EC Declaration of Conformity: EC DECLARATION OF CONFORMITY We, Atlas Copco Airpower n.v., declare under our sole responsibility, that the product Machine name Commercial name : Serial number Which falls under the provisions of article 12.2 of the EC Directive 2006/42/EC on the approximation of the laws of the Member States relating to machinery, is in conformity with the relevant Essential Health and Safety Requirements of this directive.
  • Page 80 UK Declaration of Conformity - 80 -...
  • Page 82 Scan the QR code to access into the Atlas Copco Spare Part List (ASL). XAS 48 KD APP XAS 38 KD APP...

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