Atlas Copco XA(S) 137 DD, XAHS 107 DD, XA(S) 300 DD7, XA(S) 137 DDG, XAHS 250 DD7 Instruction Manual
...
Atlas Copco Instruction Manual
XA(S) 137 DD - XA(S) 300 DD7
Engine Deutz
XA(S) 137 DDG - XA(S) 300 DD7G
BF4M2011
XAHS 107 DD - XAHS 250 DD7
Instruction Manual
for Portable Compressors
English
ATLAS COPCO - PORTABLE AIR DIVISION
www.atlascopco.com
Printed matter N°
2954 3170 01
04/2008
Instruction Manual
for Portable Compressors
XA(S) 137 DD - XA(S) 300 DD7
XA(S) 137 DDG - XA(S) 300 DD7G
XAHS 107 DD - XAHS 250 DD7
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Warranty and Liability Limitation
Use only authorized parts.
Any damage or malfunction caused by the use of unauthorized parts is not covered by Warranty or Product
Liability.
The manufacturer does not accept any liability for any damage arising for modifications, additions or
conversions made without the manufacturer's approval in writing.
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.
Copyright 2008, Atlas Copco Airpower n.v., Antwerp, Belgium.
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 .
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Preface
Please read the following instructions carefully
before starting to use your compressor.
It is a solid, safe and reliable machine, built
according to the latest technology. Follow the
instructions in this booklet and we guarantee you
years of troublefree operation.
Always keep the manual available near the machine.
In all correspondence always mention the
compressor type and serial number, shown on the
data plate.
The company reserves the right to make changes
without prior notice.
Table of contents
1 Safety precautions for portable
compressors with generator ...................... 5
1.1 Introduction.................................................. 5
1.2 General safety precautions ........................... 6
1.3 Safety during transport and installation....... 7
1.4 Safety during use and operation................... 7
1.5 Safety during maintenance and repair.......... 9
1.6 Tool applications safety ............. .... ... ... ...... 10
1.7 Specific safety precautions......... .... ............ 11
2 Leading particulars...................... ............ 12
2.1 Description of safety pictograms
used in this manual............................... ... ... 12
2.2 General description .................................... 12
3Main Parts.............................. ... ................ 14
3.1 Compressor regulating system ................... 16
3.1.1 Overview (Load condition) ... .... ... ......... 16
3.1.2 Air flow.................................................. 17
3.1.3 Oil system ..................... ... ... ... ................ 17
3.1.4 Continuous regulating system................ 18
3.2 Electrical system ........................................ 20
3.2.1 Description.................... ... ... ... ................ 23
3.3 Markings and information labels ............... 24
4 Operating instructions....... ... ................... 25
4.1 Parking, towing and lifting instructions..... 25
4.1.1 Parking instructions ............................... 25
4.1.2 Towing instructions ............................... 26
4.1.3 Height adjustment .................................. 27
4.1.4 Lifting instructions................................. 27
4.2 Starting/Stopping ....................................... 28
4.2.1 Before starting ....................................... 28
4.2.2 Control panel (with cold start; option)... 28
4.2.3 Control panel (without cold start).......... 30
4.2.4 Generator function
(XAS 137 D
DG - XA(S) 300 DD7G)... 32
4
.2.5 During operation........... ... ...................... 33
4.2.6 Stopping procedure................................ 33
5 Maintenance .................... ......................... 34
5.1 Use of service paks .............. ... ... ... ............. 34
5.2 Preventive maintenance schedule
for the compressor...................................... 34
5.3 Lubrication oils .......................................... 36
5.4 Oil level check ..................... ...................... 38
5.4.1 Check engine oil level ........................... 38
5.4.2 Check compressor oil level.................... 38
5.5 Oil and oil filter change ............................. 39
5.5.1 Engine oil and oil filter change.............. 39
5.5.2 Compressor oil and oil filter change...... 39
5.6 Cleaning coolers......... ................................ 40
5.7 Battery care............................................. ... 40
5.7.1 Electrolyte........................... ... ................ 40
5.7.2 Activating a dry-charged battery ........... 41
5.7.3 Recharging a battery.............................. 41
5.7.4 Battery maintenance .............................. 41
5.8 Storage ................. ...................................... 41
5.9 Service paks ............................................... 41
5.10 Service kits................................................. 41
5.11 Compressor element overhaul. ... ................ 41
5.12 Liability............................. ... ...................... 41
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6 Adjustments and servicing procedures .. 42
6.1 Adjustment of the continuous
regulating system........................................ 42
6.2 Air filter engine/compressor.................... ... 44
6.2.1 Servicing ........... ... ... ............................... 44
6.2.2 Main parts ........................................... ... 44
6.2.3 Cleaning the dust trap ............................ 44
6.2.4 Cleaning instructions filter element....... 44
6.2.5 Replacing the air filter element.............. 45
6.3 Air receiver................................................. 46
6.4 Safety valve................................................ 46
6.5 Fuel system................................................. 46
6.6 Brake (= option) adjustment....................... 47
6.7 Brake shoe adjustment................. ............... 47
6.7.1 Test procedure of brake cable
adjustment ........................................ ...... 48
6.7.2 Brake cable adjustment .......................... 49
7 Problem solving ........................................ 50
8 Available options...................................... 53
9 Technical specifications ..... .... ... ............... 54
9.1 Torque values ............................................. 54
9.1.1 For general applications ......................... 54
9.1.2 For important assemblies ....................... 54
9.2 Settings of shutdown switches
and safety valves ........................................ 55
9.3 Compressor/Engine/Generator
specifications.............................................. 56
9.3.1 Reference conditions.............................. 56
9.3.2 Limitations ....................... .... ... ... ............ 57
9.3.3 Performance data.................................... 59
9.3.4 Design data . ... ...................................... ... 62
9.3.5 Design data for generator.................... ... 64
10 Data plate...................................... ............ 65
11 Disposal............ ... ... ................................... 66
11.1 General....................................................... 66
11.2 Disposal of materials.................................. 66
12 Maintenance Log...................... .... ............ 67
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Safety precautions for portable compressors with generator
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,
- applicable rules, codes and regulations,
- the expected useful product life, assuming proper
service and maintenance,
- providing the manual with up-to-date
information.
Before handling any product, take time to read the
relevant instruction manual. Besides giving detailed
operating instructions, it also gives specific
information about safety, preventive maintenance,
etc.
Keep the manual always at the unit location, easy
accessible to the operating personnel.
See also the safety precautions of the engine and
possible other equipment, which are separately sent
along or are mentioned on the equipment or parts of
the unit.
These safety precautions are general and some
statements will therefore not always apply to a
particular unit.
Only people that have the right skills should be
allowed to operate, adjust, perform maintenance or
repair on Atlas Copco equipment.
It is the responsibility of management to appoint
operators with the appropriate training and skill for
each category of job.
Skill level 1: Operator
An operator is trained in all aspects of operating the
unit with the push-buttons, and is trained to know the
safety aspects.
Skill level 2: Mechanical technician
A mechanical technician is trained to operate the unit
the same as the operator. In addition, the mechanical
technician is also trained to perform maintenance and
repair, as described in the instruction manual, and is
allowed to change settings of the control and safety
system. A mechanical technician does not work on
live electrical components.
Skill level 3: Electrical technician
An electrical technician is trained and has the same
qualifications as both the operator and the mechanical
technician. In addition, the electrical technician may
carry out electrical repairs within the various
enclosures of the unit. This includes work on live
electrical components.
Skill level 4: Specialist from the manufacturer
This is a skilled specialist sent by the manufacturer or
its agent to perform complex repairs or modifications
to the equipment.
In general it is recommended that not more than two
people operate the unit, more operators could lead to
unsafe operating conditions.
Take necessary steps to keep unauthorized persons
away from the unit and eliminate all possible sources
of danger at the unit.
When handling, operating, overhauling and/or
performing maintenance or repair on Atlas Copco
equipment, the mechanics are expected to use safe
engineering practices and to observe all relevant local
safety requirements and ordinances. 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.
Neglecting the safety precautions may endanger
people as well as environment and machinery:
- endanger people due to electrical, mechanical or
chemical influences,
- endanger the environment due to leakage of oil,
solvents or other substances,
- endanger the machinery due to function failures.
All responsibility for any damage or injury resulting
from neglecting these precautions or by nonobservance of ordinary caution and due care requir ed
in handling, operating, maintenance or repair, also if
not expressly mentioned in this instruction manual, is
disclaimed by Atlas Copco.
To be read attentively and acted accordingly before towing, lifting, operating, performing
maintenance or repairing the unit.
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The manufacturer 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.
If any statement in this manual does not comply with
local legislation, the stricter of the two shall be
applied.
Statements in these safety precautions should not be
interpreted as suggestions, recommendations or
inducements that it should be used in violation of any
applicable laws or regulations.
GENERAL SAFETY PRECAUTIONS
1 The owner is responsible for maintaining the unit
in a safe operating condition. Unit parts and
accessories must be replaced if missing or
unsuitable for safe operation.
2 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
repair, free of abnormal wear or abuse, and are
not tampered with.
3 Whenever there is an indication or any suspicion
that an internal part of a machine is overheated,
the machine shall be stopped but no inspection
covers shall be opened before sufficient cooling
time has elapsed; this to avoid the risk of
spontaneous ignition of oil vapour when air is
admitted.
4 Normal ratings (pressures, temperatures, speeds,
etc.) shall be durably marked.
5 Operate the unit only for the intended purpose and
within its rated limits (pressure, temperature,
speeds, etc.).
6 The machinery and equipment shall be kept clean,
i.e. as free as possible from oil, dust or other
deposits.
7 To prevent an increase in working temperature,
inspect and clean heat transfer surfaces (cooler
fins, intercoolers, water jackets, etc.) regularly.
See the maintenance schedule. See the
Preventive maintenance schedule for the
compressor.
8 All regulating and safety devices shall be
maintained with due care to ensure that they
function properly. They may not be put out of
action.
9 Care shall be taken to avoid damage to safety
valves and other pressure-relief devices,
especially to avoid plugging by paint, oil coke or
dirt accumulation, which could interfere with the
functioning of the device.
10 Pressure and temperature gauges shall be checked
regularly with regard to their accuracy. They shall
be replaced whenever outside acceptable
tolerances.
11 Safety devices shall be tested as described in the
maintenance schedule of the instruction manual
to determine that they are in good operating
condition. See the Preventive maintenance
schedule for the compressor.
12 Mind the markings and information labels on the
unit.
13 In the event the safety labels are damaged or
destroyed, they must be replaced to ensure
operator safety.
14 Keep the work area neet. Lack of order will
increase the risk of accidents.
15 When working on the unit, wear safety clothing.
Depending on the kind of activities these are:
safety glasses, ear protection, safety helmet
(including visor), safety gloves, protective
clothing, safety shoes. Do not wear the hair long
and loose (protect long hair with a hairnet), or
wear loose clothing or jewelry.
16 Take precautions against fire. Handle fuel, oil and
anti-freeze with care because they are
inflammable substances. Do not smoke or
approach with naked flame when handling such
substances. Keep a fire-extinguisher in the
vicinity.
17 Portable compressors with generator (with
earthing pin):
Earth the generator as well as the load properly.
18 Portable compressors with generator IT:
Note: This generator is built to supply a sheer
alternating current IT network.
Earth the load properly.
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SAFETY DURING TRANSPORT AND
INSTALLATION
To lift a unit, all loose or pivoting parts, e.g. doors and
towbar, shall first be securely fastened.
Do not attach cables, chains or ropes directly to the
lifting eye; apply a crane hook or lifting shackle
meeting local safety regulations. Never allow sharp
bends in lifting cables, chains or ropes.
Helicopter lifting is not allowed.
It is strictly forbidden to dwell or stay in the risk zone
under a lifted load. Never lift the unit over people or
residential areas. Lifting acceleration and retardation
shall be kept within safe limits.
1 Before towing the unit:
- ascertain that the pressure vessel(s) is (are)
depressurized,
- check the towbar, the brake system and the
towing eye. Also check the coupling of the
towing vehicle,
- check the towing and brake capability of the
towing vehicle,
- check that the towbar, jockey wheel or stand
leg is safely locked in the raised position,
- ascertain that the towing eye can swivel freely
on the hook,
- check that the wheels are secure and that the
tyres are in good condition and inflated
correctly,
- connect the signalisation cable, check all lights
and connect the pneumatic brake couplers,
- attach the safety break-away cable or safety
chain to the towing vehicle,
- remove wheel chocks, if applied, and
disengage the parking brake.
2 To tow a unit use a towing vehicle of ample
capacity. Refer to the documentation of the
towing vehicle.
3 If the unit is to be backed up by the towing
vehicle, disengage the overrun brake mechanism
(if it is not an automatic mechanism).
4 Never exceed the maximum towing speed of the
unit (mind the local regulations).
5 Place the unit on level ground and apply the
parking brake before disconne cting th e unit fr om
the towing vehicle. Unclip the safety break-away
cable or safety chain. If the unit has no parking
brake or jockey wheel, immobilize the unit by
placing chocks in front of and/or behind the
wheels. When the towbar can be positioned
vertically, the locking device must be applied and
kept in good order.
6 To lift heavy parts, a hoist of ample capacity,
tested and approved according to local safety
regulations, shall be used.
7 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.
8 For maximum safety and efficiency of the lifting
apparatus all lifting members shall be applied as
near to perpendicular as possible. If required, a
lifting beam shall be applied between hoist and
load.
9 Never leave a load hanging on a hoist.
10 A hoist has to be installed in such a way that the
object will be lifted perpendicular. If that is not
possible, the necessary precautions must be taken
to prevent load-swinging, e.g. by using two
hoists, each at approximately the same angle not
exceeding 30° from the vertical.
11 Locate the unit away from walls. Take all
precautions to ensure that hot air exhausted from
the engine and driven machine cooling systems
cannot be recirculated. If such hot air is taken in
by the engine or driven machine cooling fan, this
may cause overheating of the unit; if taken in for
combustion, the engine power will be reduced.
12 The electrical connections shall correspond to
local codes. The machines shall be earthed and
protected against short circuits by fuses or circuit
breakers.
13 Never connect the generator outlets to an
installation which is also connected to a public
mains.
14 Before connecting a load, switch off the
corresponding circuit breaker, and check whether
frequency, voltage, current and power factor
comply with the ratings of the generator.
SAFETY DURING USE AND OPERATION
1 When the unit has to operate in a fire-hazardous
environment, each engine exhaust has to be
provided with a spark arrestor to trap incendiary
sparks.
2 The exhaust contains carbon monoxide which is a
lethal gas. When the unit is used in a confined
space, conduct the engine exhaust to the outside
atmosphere by a pipe of sufficient diameter; do
this in such a way that no extra back pressure is
created for the engine. If necessary, install an
extractor. Observe any existing local regulations.
Make sure that the unit has sufficient air intake
for operation. If necessary, install extra air intake
ducts.
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3 When operating in a dust-laden atmosphere, place
the unit so that dust is not carried towards it by the
wind. Operation in clean surroundings
considerably extends the intervals for cleaning
the air intake filters and the cores of the coolers.
4 Close the compressor air outlet valve before
connecting or disconnecting a hose. Ascertain
that a hose is fully depressurized before
disconnecting it. Before blowing compressed air
through a hose or air line, ensure that the open end
is held securely, so that it cannot whip and cause
injury.
5 The air line end connected to the outlet valve
must be safeguarded with a safety cable, attached
next to the valve.
6 No external force may be exerted on the air outlet
valves, e.g. by pulling on hoses or by installing
auxiliary equipment directly to a valve, e.g. a
water separator, a lubricator, etc. Do not step on
the air outlet valves.
7 Never move a unit when external lines or hoses
are connected to the outlet valves, to avoid
damage to valves, manifold and hoses.
8 Do not use compressed air from any type of
compressor, without taking extra measures, for
breathing purposes as this may result in injury or
death. For breathing air quality, the compressed
air must be adequately purified according to local
legislation and standards. Breathing air must
always be supplied at stable, suitable pressure.
9 Distribution pipework and air hoses must be of
correct diameter and suitable for the working
pressure. Never use frayed, damaged or
deteriorated hoses. Replace hoses and flexibles
before the lifetime expires. Use only the correct
type and size of hose end fittings and connections.
10 If the compressor is to be used for sand-blasting
or will be connected to a common compressed-air
system, fit an appropriate non-return valve (check
valve) between compressor outlet and the
connected sand-blasting or compressed-air
system. Observe the right mounting position/
direction.
11 Before removing the oil filler plug, ensure that the
pressure is released by opening an air outlet
valve.
12 Never remove a filler cap of the cooling water
system of a hot engine. Wait until the engine has
sufficiently cooled down.
13 Never refill fuel while the unit is running, unless
otherwise stated in the Atlas Copco Instruction
Book. Keep fuel away from hot parts such as air
outlet pipes or the engine exhaust. Do not smoke
when fuelling. When fuelling from an automatic
pump, an earthing cable should be connected to
the unit to discharge static electricity. Never spill
nor leave oil, fuel, coolant or cleansing agent in or
around the unit.
14 All doors shall be shut during operation so as not
to disturb the cooling air flow inside the
bodywork and/or render the silencing less
effective. A door should be kept open for a short
period only e.g. for inspection or adjustment.
15 Periodically carry out maintenance works
according to the maintenance schedule.
16 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.
17 Noise, even at reasonable levels, can cause
irritation and disturbance which, over a long
period of time, may cause severe injuries to the
nervous system of human beings.
When the sound pressure level, at any point where
personnel normally has to attend, is:
- below 70 dB(A): no action needs to be taken,
- above 70 dB(A): noise-protective devices
should be provided for people continuously
being present in the room,
- below 85 dB(A): no action needs to be taken
for occasional visitors staying a limited time
only,
- above 85 dB(A): room to be classified as a
noise-hazardous area and an obvious warning
shall be placed permanently at each entrance
to alert people entering the room, for even
relatively short times, about the need to wear
ear protectors,
- above 95 dB(A): the warning(s) at the
entrance(s) shall be completed with the
recommendation that also occasional visitors
shall wear ear protectors,
- above 105 dB(A): special ear protectors that
are adequate for this noise level and the
spectral composition of the noise shall be
provided and a special warning to that effect
shall be placed at each entrance.
18 Insulation or safety guards of parts the
temperature of which can be in excess of 80 °C
(175 °F) and which may be accidentally touched
by personnel shall not be removed before the
parts have cooled to room temperature.
19 Never operate the unit in surroundings where
there is a possibility of taking in flammable or
toxic fumes.
20 If the working process produces fumes, dust or
vibration hazards, etc., take the necessary steps to
eliminate the risk of personnel injury.
21 When using compressed air or inert gas to clean
down equipment, do so with caution and use the
- 9 -
appropriate protection, at least safety glasses , for
the operator as well as for any bystander. Do not
apply compressed air or inert gas to your skin or
direct an air or gas stream at people. Never use it
to clean dirt from your clothes.
22 When washing parts in or with a cleaning solvent,
provide the required ventilation and use
appropriate protection such as a breathing filter,
safety glasses, rubber apron and gloves, etc.
23 Safety shoes should be compulsory in any
workshop and if there is a risk, however small, of
falling objects, wearing of a safety helmet should
be included.
24 If there is a risk of inhaling hazardous gases,
fumes or dust, the respiratory organs must be
protected and depending on the nature of the
hazard, so must the eyes and skin.
25 Remember that where there is visible dust, the
finer, invisible particles will almost certainly be
present too; but the fact that no dust can be seen
is not a reliable indication that dangerous,
invisible dust is not present in the air.
26 Never operate the unit at pressures or speeds
below or in excess of its limits as indicated in the
technical specifications.
27 Never operate the generator in excess of its limits
as indicated in the technical specifications and
avoid long no-load sequences.
28 Never operate the generator in a humid
atmosphere. Excessive moisture causes
worsening of the generator insulation.
29 Do not open electrical cabinets, cubicles or other
equipment while voltage is supplied. If such
cannot be avoided, e.g. for measurements, tests or
adjustments, have the action carried out by a
qualified electrician only, with appropriate tools,
and ascertain that the required bodily protection
against electrical hazards is applied.
30 Never touch the power terminals during operation
of the machine.
31 Whenever an abnormal condition arises, e.g.
excessive vibration, noise, odour, etc., switch the
circuit breakers to OFF and stop the engine.
Correct the faulty condition before restarting.
32 Check the electric cables regularly. Damaged
cables and insufficient lightening of connections
may cause electric shocks. Whenever damaged
wires or dangerous conditions are observed,
switch the circuit breakers to OFF and stop the
engine. Replace the damaged wires or correct the
dangerous condition before restarting. Make sure
that all electric connections are securely
tightened.
33 Avoid overloading the generator. The generator is
provided with circuit breakers for overload
protection. When a breaker has tripped, reduce
the concerned load before restarting.
34 If the generator is used as stand-by for the mains
supply, it must not be operated without control
system which automatically disconnects the
generator from the mains when the mains supply
is restored.
35 Never remove the cover of the output terminals
during operation. Before connecting or
disconnecting wires, switch off the load and the
circuit breakers, stop the machine and make sure
that the machine cannot be started inadvertently
or there is any residual voltage on the power
circuit.
36 Running the generator at low load for long
periods will reduce the lifetime of the engine.
SAFETY DURING MAINTENANCE AND
REPAIR
Maintenance, overhaul and repair work shall only be
carried out by adequately trained personnel; if
required, under supervision of someone qualified for
the job.
1 Use only the correct tools for maintenance and
repair work, and only tools which are in good
condition.
2 Parts shall only be replaced by genuine Atlas
Copco replacement parts.
3 All maintenance work, other than routine
attention, shall only be undertaken when the unit
is stopped. Steps shall be taken to prevent
inadvertent starting. In addition, a warning sign
bearing a legend such as ”work in progress; do
not start” shall be attached to the starting
equipment.
On engine-driven units the battery shall be
disconnected and removed or the terminals
covered by insulating caps.
On electrically driven units the main switch shall
be locked in open position and the fuses shall be
taken out. A warning sign bearing a legend such
as ”work in progress; do not supply voltage” shall
be attached to the fuse box or main switch.
4 Before dismantling any pressurized component,
the compressor or equipment shall be effectively
isolated from all sources of pressure and the entire
system shall be relieved of pressure. Do not rely
on non-return valves (check valves) to isolate
pressure systems. In addition, a warning sign
bearing a legend such as ”work in progress; do
not open” shall be attached to each of the outlet
valves.
5 Prior to stripping an engine or other machine or
undertaking major overhaul on it, prevent all
movable parts from rolling over or moving.
- 10 -
6 Make sure that no tools, loose parts or rags are lef t
in or on the machine. Never leave rags or loose
clothing near the engine air intake.
7 Never use flammable solvents for cleaning (fire-
risk).
8 Take safety precautions against toxic vapours of
cleaning liquids.
9 Never use machine parts as a climbing aid.
10 Observe scrupulous cleanliness during
maintenance and repair. Keep away dirt, cover
the parts and exposed openings with a clean cloth,
paper or tape.
11 Never weld on or perform any operation
involving heat near the fuel or oil systems. Fuel
and oil tanks must be completely purged, e.g. by
steam-cleaning, before carrying out such
operations. Never weld on, or in any way modify,
pressure vessels. Disconnect the alternator cables
during arc welding on the unit.
12 Support the towbar and the axle(s) securely if
working underneath the unit or when removing a
wheel. Do not rely on jacks.
13 Do not remove any of, or tamper with, the sound-
damping material. Keep the material free of dirt
and liquids such as fuel, oil and cleansing agents.
If any sound-damping material is damaged,
replace it to prevent the sound pressure level from
increasing.
14 Use only lubricating oils and greases
recommended or approved by Atlas Copco or the
machine manufacturer. Ascertain 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 g ases.
Never mix synthetic with mineral oil.
15 Protect the engine, alternator, air intake filter,
electrical and regulating components, etc., to
prevent moisture ingress, e.g. when steamcleaning.
16 When performing any operation involving heat,
flames or sparks on a machine, the surrounding
components shall first be screened with nonflammable material.
17 Never use a light source with open flame for
inspecting the interior of a machine.
18 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. Check
the direction of rotation of electric motors when
starting up the machine initially and after any
alteration to the electrical connection(s) or switch
gear, to check that the oil pump and the fan
function properly.
19 Maintenance and repair work should be recorded
in an operator’s logbook for all machinery.
Frequency and nature of repairs can reveal unsafe
conditions.
20 When hot parts have to be handled, e.g. shrink
fitting, special heat-resistant gloves shall be used
and, if required, other body protection shall be
applied.
21 When using cartridge type breathing filter
equipment, ascertain that the correct type of
cartridge is used and that its useful service life is
not surpassed.
22 Make sure that oil, solvents and other substances
likely to pollute the environment are properly
disposed of.
23 Before clearing the unit for use after maintenance
or overhaul, check that operating pressures,
temperatures and speeds are correct and that the
control and shutdown devices function correctly.
TOOL APPLICATIONS SAFETY
Apply the proper tool for each job. With the
knowledge of correct tool use and knowing the
limitations of tools, along with some common sense,
many accidents can be prevented.
Special service tools are available for specific jobs
and should be used when recommended. The use of
these tools will save time and prevent damage to
parts.
- 11 -
SPECIFIC SAFETY PRECAUTIONS
Batteries
When servicing batteries, always wear protecting
clothing and glasses.
1 The electrolyte in batteries is a sulphuric acid
solution which is fatal if it hits your eyes, and
which can cause burns if it contacts your skin.
Therefore, be careful when handling batteries,
e.g. when checking the charge condition.
2 Install a sign prohibiting fire, open flame and
smoking at the post where batteries are being
charged.
3 When batteries are being charged, an explosive
gas mixture forms in the cells and might escape
through the vent holes in the plugs. Thus an
explosive atmosphere may form around the
battery if ventilation is poor, and can remain in
and around the battery for several hours after it
has been charged. Therefore:
- never smoke near batteries being, or having
recently been, charged,
- never break live circuits at battery terminals,
because a spark usually occurs.
4 When connecting an auxiliary battery (AB) in
parallel to the unit battery (CB) with booster
cables: connect the + pole of AB to the + pole of
CB, then connect the - pole of CB to the mass of
the unit. Disconnect in the reverse order.
Pressure vessels
(according to directive 87/404/EEC annex II § 2)
Maintenance/installation requirements:
1 The vessel can be used as pressure vessel or as
separator and is designed to hold compressed air
for the following application:
- pressure vessel for compressor,
-medium AIR/OIL,
and operates as detailed on the data plate of the
vessel:
- the maximum working pressure ps in bar (psi),
- the maximum working temperature Tmax in
°C (°F),
- the minimum working temperature Tmin in °C
(°F),
- the capacity of the vessel V in l (US gal, Imp
gal, cu.ft).
2 The pressure vessel is only to be used for the
applications as specified above and in accordance
with the technical specifications. Safety reasons
prohibit any other applications.
3 National legislation requirements with respect to
re-inspection must be complied with.
4 No welding or heat treatment of any kind is
permitted to those vessel walls which are exposed
to pressure.
5 The vessel is provided and may only be used with
the required safety equipment such as
manometer, overpressure control de vices, safety
valve, etc.
6 Draining of condensate shall be performed
regularly when vessel is in use.
7 Installation, design and connections should not be
changed.
8 Bolts of cover and flanges may not be used for
extra fixation.
Safety valves
All adjustments or repairs are to be done by an
authorized representative of the valve supplier (see
also Preventive maintenance schedule for the
compressor).
- 12 -
Leading particulars
DESCRIPTION OF SAFETY PICTOGRAMS
USED IN THIS MANUAL
GENERAL DESCRIPTION
The compressors type XA(S) 137 DD - XA(S) 300
DD7, XA(S) 137 DDG - XA(S) 300 DD7G and
XAHS 107 DD - XAHS 250 DD7 are silenced,
single-stage, oil-injected screw compressors, built for
a nominal effective working pressu re, ranging from
7 bar (102 psi) up to 12 bar (175 psi) (see chapter
Technical specifications).
Engine
The compressors are driven by an oil-cooled diesel
engine.
The engine’s power is transmitted to the compressor
through a heavy-duty coupling.
Compressor
The compressor casing houses two screw-type rotors,
mounted on ball and roller bearings. The male rotor,
driven by the engine, drives the female rotor. The
element delivers pulsation-free air.
Injected oil is used for sealing, cooling and
lubricating purposes.
Compressor oil system
The oil is boosted by air pressure. The system has no
oil pump.
The oil is removed from the air, in the air/oil vessel at
first by centrifugal force, secondly by the oil separator
element.
The vessel is provided with an oil level indicator.
Regulation
The compressor is provided with a continuous
regulating system and a blow-down valve which is
integrated in the unloader assembly. The valve is
closed during operation by air receiver pressure and
opens by air receiver pressure via the compressor
element when the compressor is stopped.
When the air consumption increases, the air receiver
pressure will decrease and vice versa.
This receiver pressure variation is sensed by the
regulating valve which, by means of control air to the
unloader and engine speed regulator, matches the air
output to the air consumption. The air receiver
pressure is maintained between the pre-selected
working pressure and the corresponding unloading
pressure.
This symbol draws your attention to
dangerous situations. The operation
concerned may endanger persons and
cause injuries.
This symbol is followed by
supplementary information.
- 13 -
Cooling system
The engine is equipped with an oil cooler. All
compressors are equipped with an oil cooler.
The cooling air is generated by a fan, driven by the
engine.
Safety devices
A thermal shut-down switch protects the compressor
against overheating. The air receiver is provided with
a safety valve.
The engine is equipped with low oil pressure and high
oil temperature shut-down switches.
Frame and axle
The compressor/engine unit is supported by rubber
buffers in the frame.
The standard unit has a non-adjustable towbar with a
towing eye.
As an option the unit can be equipped with an
adjustable towbar, an overrun and parking brake and
towing eyes type DIN, ball, ITA, GB, NATO, AC
(France), (see chapter Available options).
The braking system consists of an integrated parking
brake and overrunbrake. When driving backwards the
overrunbrake is not engaged automatically.
Bodywork
The bodywork has openings at the shaped front and
rear end for the intake and outlet of cooling air and
hinged door for maintenance and service operations.
The bodywork is internally lined with soundabsorbing material.
Lifting eye
A lifting eye is accessible when the small door at the
top of the unit is unlocked.
Control panel
The control panel grouping the air pressure gauge,
control switch etc., is placed in the center at the rear
end.
Data plate
The compressor is furnished with a data plate
showing the product code, the unit number and the
working pressure (see chapter Data plate).
Serial number
The serial number is located on the right-hand side
towards the front on the upper edge of the frame and
also on the data plate.
Generator - XA(S) 137 DDG - XA(S) 300 DD7G
The built-in generator is driven by a multi V-belt
drive. The generated current can be drawn via
3 sockets (3 x 16 A, 2 x 3 phases, 1 x 1 phase).
The compressor and the generator of the XA(S) 137
DDG - XA(S) 300 DD7G may be used
simultaneously.
- 14 -
Main Parts
(E)
(EP)
(AOV)
(VI)
(SV)
(OLG)
(FPco)
(RV)
(AR)
(CP)
(OFce)
(CE)
(FT)
(AF)
(FCft)
(A)
(FF)
(DSe)
(FCeo)
(OCce/OCe)
(BH)
(TB)
(F)
(D)
(VV)
(G)
(CPg)
XA(S) 137 DDG - XA(S) 300 DD7G, XA(S) 137 DD - XA(S) 300 DD7
and XAHS 107 DD - XAHS 250 DD7 with some options
- 15 -
Reference Name
A Alternator
AF Air Filter
AOV Air Outlet Valves
AR Air Receiver
BH Brake Handle
CE Compressor Element
CP Control Panel
CPg Control Panel Generator
D Data plate
DSe Engine Oil Level Dipstick
E Engine
EP Exhaust Pipe
FFan
FCeo Filler Cap (engine oil)
FCft Filler Cap (fuel tank)
FF Fuel Filter
FPco Filler Plug (oil compressor element)
FT Fuel Tank
G Generator
Reference Name
OCce Oil Cooler (compressor element)
OCe Oil Cooler (engine)
OFce Oil Filter (compressor element)
OLG Oil Level Gauge (compressor
element)
R V Regulating Valve
SV Safety Valve
TB Towbar
VI Vacuum Indicator
VV Va c uato r Valv e
- 16 -
COMPRESSOR REGULATING SYSTEM
OVERVIEW (LOAD CONDITION)
(AFE)
(AFce)
(VI)
(CV)
(RV)
(AR)
(SV)
(OSE)
(R)
(AOV)
(DP)
(BV)
(OFC)
(SL)
(CP)
(OC)
(E)
(F)
(TSE)
(SRE)
(PSE)
(UA)
(OFE)
(BDV)
(CH)
(CE)
(EW)
Air Atmospheric Pressure
Air Regulating Pressure
Air Working Pressure
Air/Oil Mixture
Oil
Reference Name
AFce Air Filter Compressor/Engine
AFE Air Filter Element
AOV Air Outlet Valves
AR Air Receiver/Oil Separator
BDV Blow Down Valve
BV By-Pass Valve Oil Filter
CE Compressor Element
CH Coupling Housing
CP Control Panel
CV Check Valve
DP Drain Plug
EEngine
EW Electrical Wiring
F Cooling Fan
OC Oil Cooler
OFC Oil Filter Compressor
OFE Oil Filter Engine
OSE Oil Separator Element
PSE Pressure Switch Engine
R Restrictor
R V Regulating Valve
- 17 -
AIR FLOW
The system comprises:
AFce Air filter compressor/engine
AR/OSE Air receiver/oil separator element
CE Compressor element
UA/UV Unloader assembly with unloader valve
BDV Blow-down valve
Air drawn through the airfilter (AFce) into the
compressor element (CE) is compressed. At the
element outlet, compressed air and oil pass into the air
receiver/oil separator (AR/OSE).
The check valve (CV) prevents blow-back of
compressed air when the compressor is stopped. In
the air receiver/oil separator (AR/OSE), most of the
oil is removed from the air/oil mixture; the remaining
oil is removed by the separator element.
The oil collects in the receiver and on the bottom of
the separator element.
The air leaves the receiver via a restriction which
prevents the receiver pressure from dropping below
the minimum working pressure (specified in section
Limitations), even when the air outlet valves are
open. This ensures adequate oil injection and prevents
oil consumption.
A temperature switch (TS) and a working pressure
gauge (WPG) are comprised in the system.
A blow-down valve (BDV) is fitted in the unloader
assembly to automatically depressurise the air
receiver (AR) when the compressor is stopped.
OIL SYSTEM
The system comprises:
AR/OSE Air receiver/oil separator
OC Oil cooler
OF Oil filter
The lower part of the air receiver (AR) serves as oil
tank.
Air pressure forces the oil from the air receiver/oil
separator (AR/OS) through the oil cooler (OCce) and
oil filter (OF) to the compressor element (CE).
The compressor element has an oil gallery in the
bottom of its casing. The oil for rotor lubrication,
cooling and sealing is injected through holes in the
gallery.
Lubrication of the bearings is ensured by oil injected
into the bearing housings.
The injected oil, mixed with the compressed air,
leaves the compressor element and re-enters the air
receiver, where it is separated from the air as
described in section Air flow. The oil that collects in
the bottom of the oil separator element is returned to
the system through scavenging line (SL), which is
provided with a flow restrictor.
The oil filter by-pass valve opens when the pressure
drop over the filter is above normal because of a
clogged filter. The oil then by-passes the filter
without being filtered. For this reason, the oil filter
must be replaced at regular intervals (see section
Preventive maintenance schedule for the
compressor).
Reference Name
SL Scavenge Line
SRE Speed Regulator Element
SV Safety Valve
TSE Temperature Switch Engine
UA Unloader Assembly
VI Vacuum Indicator
- 18 -
CONTINUOUS REGULATING SYSTEM
(BOV)
(UV)
(UA)
(VH)
(RV)
(AR)
(CE)
(SVa)
(SR)
- 19 -
The system comprises:
RV Regulating valve
UA Unloader assembly
SR Speed regulator
The compressor is provided with a continuous
regulating system. This system is provided with a
blow-down valve which is integrated in the unloader
assembly (UA). The valve is closed during operation
by air receiver pressure and opens by air receiver
pressure via the compressor element when the
compressor is stopped.
When the air consumption increases, the air receiver
pressure will decrease and vice versa. This receiver
pressure variation is sensed by the regulating valve
which, by means of control air to the unloader,
matches the air output to the air consumption. The air
receiver pressure is maintained between the preselected working pressure and the corresponding
unloading pressure.
When starting the compressor, the unloader valve
(UV) is kept open by spring force, the engine runs at
maximum speed. The compressor element (CE) takes
in air and pressure builds up in the receiver (AR).
The air output is controlled from maximu m output
(100%) to no output (0%) by:
1. Speed control of the engine between maximum
load speed and unloading speed (the output of a
screw compressor is proportional to the rotating
speed).
2. Air inlet throttling.
3. Blow off valve (BOV).
If the air consumption is equal to or exceeds the
maximum air output, the engine speed is held at
maximum load speed and the unloading valve is fully
open.
If the air consumption is less than the maximum air
output, the regulating valve supplies control air to
unloader valve (UV) to reduce the air output and
holds air receiver pressure between the normal
working pressure and the corresponding unloading
pressure of approx. 1.5 bar (22 psi) above the normal
working pressure.
When the air consumption is resumed, the blow off
valve (BOV) closes and the unloader valve (UV)
gradually opens the air intake and the speed re gulator
(SR) increases the engine speed.
The construction of the regulating valve (RV) is such
that any increase (decrease) of the air receiver
pressure above the pre-set valve opening pressure
results in a proportional increase (decrease) of the
control pressure to the unloading valve and the speed
regulator.
Part of the control air is vented to atmosphere, and
any condensate discharged, through the vent holes
(VH).
XA(S) 137 DDG - XA(S) 300 DD7G:
When the generator is switched on, the solenoid valve
(SVa) via the speed regulator (SR) controls the motor
and allows it to reach maximum speed (the normal
control system is switched off).
- 20 -
ELECTRICAL SYSTEM
All compressors are equipped with a negative earthed system.
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Cold Start Option.
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