Atlas Copco XAS 97 DD, XAS 185 DD7 Instruction Manual
Atlas Copco Instruction Manual
Instruction Manual
for Portable Compressors
English
XAS 97 DD - XAS 185 DD7
Engine Deutz D2011L03
Engine Deutz F3M2011
Instruction Manual
for Portable Compressors
XAS 97 DD - XAS 185 DD7
Printed matter N°
9829 3095 00
11/2008
ATLAS COPCO - PORTABLE AIR DIVISION
www.atlascopco.com
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...................................... 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 . ... ............................................ 16
3.1.2 Air flow.................................................. 18
3.1.3 Oil system .................. ... ......................... 19
3.1.4 Continuous regulating system................ 20
3.2 Electric system ........................................... 22
3.3 Markings and information labels ............... 27
4 Operating instructions.......... ................... 28
4.1 Parking, towing and lifting instructions..... 28
4.1.1 Parking instructions ............................... 28
4.1.2 Towing instructions ............................... 29
4.1.3 Spillage-Free Instruction........................ 30
4.1.4 Height adjustment .................................. 30
4.1.5 Lifting instructions................................. 31
4.1.6 Anti-Frost Device (option)..................... 31
4.2 Starting / Stopping ..... ................................ 32
4.3 Before starting............................................ 32
4.3.1 Starting procedures ................................ 32
4.3.2 During operation.............. ... ................... 34
4.3.3 Stopping procedure................................ 34
4.3.4 Fault situations and protective devices.. 34
5 Maintenance ............................................. 35
5.1 Use of service paks .... ... ............................. 35
5.2 Preventive maintenance schedule
for the compressor...................................... 35
5.3 Lubrication oils .......................................... 38
5.4 Oil specifications........................... ... .......... 39
5.4.1 Compressor oil....................................... 39
5.5 Oil level check ........ ... ... .... ......................... 40
5.5.1 Check engine oil level ........................... 40
5.5.2 Check compressor oil level.................... 40
5.6 Oil and oil filter change ................... .... ...... 41
5.6.1 Engine oil and oil filter change.............. 41
5.6.2 Compressor oil and oil filter change...... 41
5.7 Cleaning coolers......... ... ............................. 42
5.8 Cleaning fuel tank... ... ... ............................. 42
5.9 Battery care ................................................ 43
5.9.1 Electrolyte.............................................. 43
5.9.2 Activating a dry-charged battery ........... 43
5.9.3 Recharging a battery..... ... ... ................... 43
5.9.4 Battery maintenance ..... ... ...................... 43
5.10 Changing tyres .............. ............................. 44
5.11 Storage ....... .... ...................................... ... ... 44
5.12 Service paks ............................................... 44
5.13 Service kits................................................. 44
5.14 Compressor element overhaul. ... ................ 44
5.15 Liability............................. ... ...................... 44
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6 Adjustments and servicing procedures .. 45
6.1 Adjustment of the continuous
regulating system........................................ 45
6.2 Air filter engine/compressor....................... 46
6.2.1 Main parts ........................................ ...... 46
6.2.2 Cleaning the dust trap ............................ 46
6.2.3 Replacing the air filter element.............. 47
6.3 Air receiver................................................. 47
6.4 Safety valve................................................ 47
6.5 Fuel system................................................. 48
6.6 Brake adjustment...................... .................. 48
6.6.1 Brake shoe adjustment ........................... 48
6.6.2 Test procedure of brake cable
adjustment ............................... ... ............ 49
6.6.3 Brake cable adjustment .......................... 49
7 Problem solving ............... ... ...................... 50
8 Available options............................. ... ...... 53
9 Technical specifications ........................... 54
9.1 Torque values ............................................. 54
9.1.1 General torque values............................. 54
9.1.2 Critical torque values ............................. 54
9.2 Settings of shutdown switches
and safety valves ........................................ 55
9.3 Compressor / engine specifications............ 56
9.3.1 Reference conditions.............................. 56
9.3.2 Limitations .................... ... .... .................. 57
9.3.3 Altitude unit performance curve ............ 58
9.3.4 Performance data.................................... 59
9.3.5 Design data.... .... ... .................................. 60
11 Disposal .................. .... ............................... 63
11.1 General................................. ...................... 63
11.2 Disposal of materials.................................. 63
12 Maintenance Log............................. ... ...... 64
10 Dataplate .......................... ......................... 62
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Safety precautions
To be read attentively and acted accordingly before towing, lifting, operating, performing
maintenance or repairing the compressor.
INTRODUCTION
The policy of Atlas Copco is to provide the 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 require d
handlin
in
not expressly mentioned in this instruction manual, is
disclaimed by Atlas Copco.
g, operating, maintenance or repair, also if
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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 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-extinguishe
nity.
vici
r in the
- 6 -
SAFETY DURING TRANSPORT AND INSTALLATION
When towing, lifting or transporting the compressor
in any way, the battery switch must always be in the
“OFF” position!
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 the un it from
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 Before moving the compressor, switch it off.
13 If the warning light on the ABS module or in the
vehicle lights up, please contact Atlas Copco.
SAFETY DURING USE AND OPERATION
When the unit has to operate
1
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.
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.
in a fire-hazardous
- 7 -
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 (AIB). 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 entr
to alert people
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 The unit has parts, which may be accidentally
touched by personnel, of which the temperature
can be in exess of 80 °C (176 °F). The insulation
or safety guard, protecting these parts shall not be
removed before the parts have cooled down 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
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.
entering the room, for even
ance
- 8 -
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 Do not use aerosol types of starting aids such as
ether. Such use could result in an explosion and
personal injury.
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.
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.
Do not remove an
13
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 ga ses.
Never mix synthetic with mineral oil.
y of, or tamper with, the sound-
- 9 -
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 Disconnect –battery-clamp before starting
electrical servicing or welding (or turn batteryswitch in “off” position).
19 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.
20 Maintenance and repair work should be recorded
in an operator’s logbook for all machinery.
Frequency and nature of repairs can reveal unsafe
conditions.
21 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.
22 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.
23 Make sure that oil, solvents and other substances
likely to pollute the environment are properly
disposed of.
24 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.
- 10 -
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
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 (p si),
- 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 daily
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
Operating & Maintenance
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 unauthorised access to
the pressure regulation device.
Under no circumstances should the set pressure of the
safety valve be altered to a different pressure than that
stamped on the valve without the permission of the
installation designer.
If the set pressure must be altered then use only
correct parts supplied by Atlas Copco and in
accordance with the instructions available for the
valve type.
Safety valves must be frequently tested and regularly
maintained.
The set pressure should be periodically checked for
accuracy.
When fitted, the compressors should be operated at
pressures not less than 75% of the set pressure to
ensure free and easy movement of internal parts.
The frequency of tests is influenced by factors such as
the severity of the operating environment and
aggressiveness of the pressurised medium.
Soft seals and springs should be replaced as part of the
maintenance procedure.
Do not paint or coat the installed safety valve (see also
Preventive maintenance schedule for the
compressor).
- 11 -
Leading particulars
DESCRIPTION OF SAFETY PICTOGRAMS USED IN THIS MANUAL
This symbol draws your attention to
dangerous situations. The operation
concerned may endanger persons and
cause injuries.
This symbol is followed by
supplementary information.
GENERAL DESCRIPTION
The compressors type XAS 97 DD - XAS 185 DD7
are silenced, single-stage, oil-injected screw
compressors, built for a nominal effective working
pressure, ranging from 7 bar (102 psi) up to 10 .3 bar
(150 psi) (see chapter Technical specifications).
Engine
The compressor is driven by an oil-cooled diesel
engine.
The engine’s power is transmitted to the compressor
through a heavy-duty coupling.
Compressor element
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 through the oil
separator element.
The vessel is provided with an oil level indicator.
- 12 -
Regulation
(D)
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 outlet pressure of the
compressor element and opens by air receiver
pressure 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.
Cooling system
Engine and compressor are provided 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 axles
The compressor/engine unit is supported by rubber
buffers in the frame. The standard unit has a none
adjustable towbar with support leg and one of the
following towing eyes AC, DIN, ball, ITA, GB or
NATO.
As an option the unit can be equipped with an
adjustable towbar, a jockey wheel and/or overrun
parking brake (for options 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 a
hood for maintenance and service operations. The
bodywork is internally lined with sound-absorbing
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 (D)
showing the product code, the unit number and the
working pressure (see chapter Dataplate).
- 13 -
Main Parts
(SV)
(A)
(VI)
(AR)
(RV)
(FP)
(OLG)
(AOV)
(CP)
(C)
(AF) (VV)
(FF)
(FU)
(CE)
(F)
(EP)
(FT)
(D)
(FCeo)
(FCft)
(DPec)
(DSe)
(OFe)
(OFce)
(TB)
(H)
(DPft)
(S)
(E)
(AFD)
- 14 -
Reference Name
A Alternator
AF Air Filter
AFD Anti-Frost Device (option)
AOV Air Outlet Valves
AR Air Receiver
C Coupling
CE Compressor Element
CP Control Panel
D Data Plate
DPec Drain Plug Engine Oil Cooler
DPft Drain Plug Fuel Tank
DSe Engine Oil Level Dipstick
E Engine
EP Exhaust Pipe
FFan
FCeo Filler Cap (engine oil)
FCft Filler Cap (fuel tank)
FF Fuel Filter
FP Filler Plug (compressor oil)
FT Fuel Tank
FU Fuel Pump
Reference Name
HHood
OFce Oil Filter (compressor element)
OFe Oil Filter (engine)
OLG Oil Level Gauge (compressor
element)
RV Regulating Valve
S Starting Motor
SV Safety Valve
TB Towbar
VI Vacuum Indicator
VV Va cua tor Valve
- 15 -
COMPRESSOR REGULATING SYSTEM
(BOV)
(AF)
(DP)
(FN)
(UV)
(UA)
(VH)
(BDV)
(CV)
(AOV)
(RV)
(SR)
(VV)
(VI)
(SV)
(FR)
(PG)
(AR)
(DP)
(OLG)
(SL)
(FP)
(SL)
(OF)
(CE)
(DP)
(TS)
(F)
(OCce)
(E)
(SC)
(OS)
OVERVIEW
- 16 -
Reference Name
AF Air Filter
AOV Air Outlet Valves
AR Air Receiver
BDV Blow Down Valve
BOV Blow Off Valve
CE Compressor Element
CV Check Valve
DP Drain Plug
E Engine
FFan
FN Flow Nozzle
FP Filler Plug
FR Flow Restrictor
OCce Oil Cooler (compressor element)
OF Oil Filter
OLG Oil Level Gauge
OS Oil Separator
Reference Name
PG Pressure Gauge
RV Regulating Valve
SC Safety Cartridg e (op tio n)
SL Scavenge Line
SR Speed Regulator
SV Safety Valve
TS Temperature Switch
UA Unloader Assembly
UV Unloader Valve
VH Vent Hole
VI Vacuum Indicator
VV Va cua tor Valve
- 17 -
(AF)
(FN)
(BDV)
(CV)
(PG)
(AR)
(CE)
(TS)
(OS)
AIR FLOW
Air drawn through the airfilter (AF) into the
compressor element (CE) is compressed. At the
element outlet, compressed air and oil pass into the air
receiver/oil separator (AR/OS).
The check valve (CV) prevents blow-back of
compressed air when the compressor is stopped. In
the air receiver/oil separator (AR/OS), 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 flow nozzle (FN)
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 (PG) 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.
- 18 -
OIL SYSTEM
(FR)
(AR)
(SL)
(OF)
(OCce)
(OS)
(CE)
(SL)
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).
When the compressor is stopped and / or there is no
pressure in the system, the oil stop valve (OSV)
prevents the oil from flowing back into the
compressor element.
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 a scavenging line (SL), which is
provided with a flow restrictor (FR).
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).
When cold start equipment is installed, a thermostatic
valve will bypass the compressor oil (oil will not pass
through oil cooler OCce), until the working
temperature is reached.
- 19 -
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