Atlas Copco XRHS 506, XRHS 1100 CD6, XRVS 476, XRVS 1000 CD6, XRVS 476 Cd C13 Instruction Manual
...
Instruction Manual for Portable Compressors
English
XRHS 506 - XRHS 1100 CD6
XRVS 476 - XRVS 1000 CD6
Engine C13 Tier 3
Instruction Manual
for Portable Compressors
XRHS 506 - XRHS 1100 CD6
XRVS 476 - XRVS 1000 CD6
ATLAS COPCO - PORTABLE AIR DIVISION
www.atlascopco.com
Printed matter N°
2954 2510 03
04/2007
Instruction Manual
4
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 2007, 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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Table of contents
1 SAFETY PRECAUTIONS ...................................................................................... 9
1.1 Introduction ....................................................................................................... 9
1.2 General safety precautions ................................................................................ 10
1.3 Safety during transport and installation ............................................................... 11
1.4 Safety during use and operation ......................................................................... 13
1.5 Safety during maintenance and repair.................................................................. 15
1.6 Tool applications safety..................................................................................... 16
1.7 Specific safety precautions ................................................................................ 16
2 LEADING PARTICULARS ................................................................................... 18
2.1 General description ........................................................................................... 18
2.2 Markings and information labels ......................................................................... 20
2.3 Main parts ....................................................................................................... 22
2.4 Regulating system ............................................................................................ 24
2.4.1 Overview .................................................................................................... 24
2.4.2 Air flow ...................................................................................................... 26
2.4.3 Oil system................................................................................................... 27
2.4.4 Continuous regulating system ........................................................................ 27
2.5 Electric system................................................................................................. 28
3 OPERATING INSTRUCTIONS.............................................................................. 30
3.1 Parking, towing and lifting instructions ................................................................ 30
3.1.1 Parking instructions ...................................................................................... 31
3.1.2 Towing instructions ...................................................................................... 32
3.1.3 Towbar levelling (option) ............................................................................... 33
3.1.4 Lifting instructions........................................................................................ 33
3.2 Preheater (option) ............................................................................................. 34
3.2.1 Description heating operation......................................................................... 34
3.2.2 Operations overview ..................................................................................... 35
3.3 Before starting ................................................................................................. 38
3.4 Starting / Stopping ........................................................................................... 39
3.4.1 Control panel ............................................................................................... 40
3.4.2 Operations overview ..................................................................................... 41
3.4.3 Battery switch ............................................................................................. 41
3.4.4 Specific start procedure ................................................................................ 42
3.4.5 Power ON / OFF........................................................................................... 43
3.4.6 Starting....................................................................................................... 44
3.4.7 Warming up................................................................................................. 45
3.4.8 Loading....................................................................................................... 46
3.4.9 Fault codes.................................................................................................. 47
3.4.10 Stopping ..................................................................................................... 50
3.4.11 Emergency stop ........................................................................................... 51
3.4.12 Info ............................................................................................................ 52
3.4.13 Options....................................................................................................... 53
3.4.14 Service task confirmed.................................................................................. 54
3.4.15 Service in advance ....................................................................................... 55
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4 MAINTENANCE................................................................................................ 56
4.1 Liability ........................................................................................................... 56
4.2 Service paks .................................................................................................... 56
4.3 Service kits ..................................................................................................... 56
4.4 Storage ........................................................................................................... 56
4.5 Preventive maintenance schedule for the compressor ............................................ 57
4.6 Oil specifications .............................................................................................. 59
4.6.1 Compressor oil............................................................................................. 59
4.6.2 Engine oil .................................................................................................... 60
4.7 Oil level check ................................................................................................. 61
4.7.1 Check engine oil level ................................................................................... 61
4.7.2 Check compressor oil level ............................................................................ 61
4.8 Oil and oil filter change ..................................................................................... 62
4.8.1 Engine oil and oil filter change ....................................................................... 62
4.8.2 Topping up the compressor oil ....................................................................... 62
4.8.3 Compressor oil and oil filter change ................................................................ 63
4.9 Coolant specifications ....................................................................................... 65
4.9.1 PARCOOL EG .............................................................................................. 66
4.9.2 Handling PARCOOL EG ................................................................................. 67
4.10 Coolant check.................................................................................................. 68
4.11 Topping up/replacing coolant ............................................................................. 69
4.11.1 Topping up without draining from the cooling system ....................................... 70
4.11.2 Topping up after limited quantity draining from the cooling system..................... 71
4.11.3 Replacing the coolant ................................................................................... 72
4.12 Cleaning coolers............................................................................................... 73
4.13 Battery care..................................................................................................... 74
4.13.1 Electrolyte................................................................................................... 74
4.13.2 Activating a dry-charged battery .................................................................... 74
4.13.3 Recharging a battery .................................................................................... 75
4.13.4 Battery maintenance..................................................................................... 75
4.14 Compressor element overhaul ............................................................................ 75
5 ADJUSTMENTS AND SERVICING PROCEDURES .................................................. 76
5.1 Adjustment of the continuous regulating system .................................................. 76
5.2 Air filters engine / compressor............................................................................ 77
5.2.1 Main parts................................................................................................... 77
5.2.2 Cleaning the dust trap .................................................................................. 77
5.2.3 Replacing the filter element and the safety cartridge......................................... 78
5.2.4 Air receiver ................................................................................................. 79
5.3 Safety valve .................................................................................................... 79
5.4 Fuel system ..................................................................................................... 80
5.4.1 Priming instructions ...................................................................................... 80
5.4.2 Replacing filter elements ............................................................................... 81
5.5 Brake adjustments ............................................................................................ 82
5.5.1 Brake shoe adjustment (no ABS) .................................................................... 82
5.5.2 ABS braking system ..................................................................................... 82
5.5.3 Brake adjustment wagon ABS........................................................................ 83
5.5.4 Brake adjustment wagon without ABS ............................................................ 84
5.5.5 Brake adjustment tandem ABS....................................................................... 85
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5.5.6 Brake adjustment tandem without ABS ........................................................... 86
6 PROBLEM SOLVING.......................................................................................... 87
7 AVAILABLE OPTIONS ....................................................................................... 90
8 TECHNICAL SPECIFICATIONS.......................................................................... 101
8.1 Torque values ................................................................................................ 101
8.1.1 General torque values ................................................................................. 101
8.1.2 Critical torque values .................................................................................. 101
8.2 Compressor / engine specifications ................................................................... 102
8.2.1 Reference conditions .................................................................................. 102
8.2.2 Limitations ................................................................................................ 103
8.2.3 Performance data ....................................................................................... 104
8.2.4 Design data ............................................................................................... 105
9 DATAPLATE .................................................................................................. 107
10 LEGISLATION ................................................................................................ 108
10.1 Parts, subjected to Pressure Equipment Directive 97/23/EC, cat. II and above ........ 108
10.2 Parts, subjected to Simple Pressure Vessel Directive 87/404/EC........................... 108
10.3 Parts, subjected to cat. I and covered by the Machine Directive 89/392/EC ........... 108
10.4 Parts, subjected to art. I, paragraph 3.3 ............................................................ 108
11 DISPOSAL ..................................................................................................... 109
11.1 General ......................................................................................................... 109
11.2 Disposal of materials....................................................................................... 109
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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.
1 Safety precautions
1.1 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.
To be read attentively and acted accordingly before towing, lifting, operating,
performing maintenance or repairing the compressor.
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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 required in handling, operating, maintenance or repair,
also if not expressly mentioned in this instruction manual, is disclaimed by Atlas Copco.
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.
1.2 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.
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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 4.5 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 4.5 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.
1.3 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.
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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 disconnecting the unit 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.
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1.4 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.
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 (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.
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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 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.
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.
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1.5 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 left 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 gases. 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 steam-cleaning.
16 When performing any operation involving heat, flames or sparks on a machine, the surrounding
components shall first be screened with non-flammable material.
17 Never use a light source with open flame for inspecting the interior of a machine.
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18 Disconnect –battery-clamp before starting electrical servicing or welding (evt. turn battery-
switch 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.
1.6 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.
1.7 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.
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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 (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 devices, 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 Seetru 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 lifting device 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 4.5 Preventive maintenance schedule for the compressor).
Instruction Manual
18 2954 2510 03
2 Leading particulars
2.1 General description
The XRHS 506 - XRHS 1100 CD6 is a silenced, two-stage, oil-injected screw compressor, built for
a nominal effective working pressure of 20 bar (290 psi).
The XRVS 476 - XRVS 1000 CD6 is a silenced, two-stage, oil-injected screw compressor, built for
a nominal effective working pressure of 25 bar (363 psi).
• Engine
The compressors are driven by a liquid-cooled diesel engine.
The engine’s power is transmitted to the compressor element 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 compressor 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.
• Regulation
The compressor is provided with a continuous regulating system and a blow-off 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 an electronic 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
The engine is provided with a liquid-cooler and intercooler and the compressor is provided with
an oil cooler. (For available options see chapter 7 Available options.)
The cooling air is generated by a fan, driven by the engine.
Instruction Manual
2954 2510 03 19
• Safety devices
A thermal shut-down sensor protects the compressor against overheating. The air receiver is
provided with a safety valve.
The engine is equipped with low oil pressure and high coolant temperature shut-down sensors.
The electric system is equipped with a 24V main switch.
• Frame and axles
The compressor/engine unit is supported by rubber buffers in a spillage-free frame.
The standard compressor has a towbar with parking brakes.
For available options see chapter 7 Available options.
• Bodywork
The bodywork has openings for the intake and outlet of cooling air and hinged doors for
maintenance and service operations. The bodywork is internally lined with sound-absorbing
material.
• Lifting beam
A lifting beam is accessible when a small door at the top is opened.
• Control panel
The control panel grouping the air pressure gauge, control switch etc., is placed at the left hand/
rear end corner.
• Data plate
The compressor is furnished with a data plate showing the product code, the unit serial number
and the working pressure (see chapter 9 Dataplate).
• Serial number
The serial number is stamped in at the front of the compressor on the upper edge of the frame
behind the right door. It is also mentioned on the data plate and inside the control box.
Instruction Manual
20 2954 2510 03
2.2 Markings and information labels
Dangerous outlet gases.
Danger, heat flat.
Electrocution hazard.
Atlas Copco synthetic compressor oil.
Atlas Copco mineral engine oil.
Manual.
Read the instruction manual before working on the battery.
Reset fuse.
On / off button.
Prohibition to open air valves without connected hoses.
Rotation direction.
Inlet.
Outlet.
Compressor oil drain.
Read the instruction manual before starting.
Service every 24 hours.
Instruction Manual
2954 2510 03 21
Warning! Part under pressure.
Do not stand on outlet valves.
Start-Stop indication of switch.
Do not run the compressor with open doors.
Lifting permitted.
Use diesel fuel only.
5.5 bar (80 psi)
Tyre pressure.
Sound power level in accordance with Directive 2000/14/EC
(expressed in dB (A)).
Fork lifting permitted.
Don’t lift here.
Read the instruction manual before lifting.
Filler cap coolant.
Read the instruction manual before topping up with coolant.
Service point.
Circuit breaker.
Do not run the compressor when the baffles are not in the right position.
ABS braking system, emergency relay valve. See section 5.5.2.
Instruction Manual
22 2954 2510 03
2.3 Main parts
(AFce)
(AFe)
(AOV)
(AR)
(CElp)
(CEhp)
(R)
(E)
(EP)
(ES)
(F)
(OFe)
(FT)
(IC)
(FCc)
(LV)
(MPV)
(OC)
(OFce)
(OLG)
(RV)
(SV)
(AFS)
(B)
(FFpc)
(ES)
(FPco)
(RS)
(WPS)
(FCft)
(CU)
(CP)
(FLG)
(S)
(A)
(FFc)
(DSe)
(FCeo)
(BH)
(TB)
(CBE)
(CB)
(F1)
(SN)
(RPS)
(FLS)
(CT)
(CLS)
(DPeo)
(DPoc)
(DPr)
(DPce)
(DPar)
(ETS)
(IPS)
(ATS)
(H)
(FL)
(BS)
Reference Name
AAlternator
AFce Air Filter (compressor element)
AFe Air Filter (engine)
AFS Air Filter Switch
AOV Air Outlet Valves
AR Air Receiver
ATS Ambient Temperature Sensor
BBattery
BH Brake Handle
BS Battery Switch
CB Circuit Breaker
CBE Cubicle for Electrical devices
CEhp Compressor Element (high pressure)
CElp Compressor Element (low pressure)
Instruction Manual
2954 2510 03 23
CLS Coolant Level Switch
CP Control Panel
CT Coolant Tank
CU Control Unit
DPar Drain Plug Air Receiver
DPce Drain Plug Compressor Element
DPeo Drain Plug Engine Oil
DPoc Drain Plug Oil Cooler
DPr Drain Plug Radiator
DSe Engine Oil Level Dipstick
E Engine
EP Exhaust Pipe
ES Emergency Stop
ETS Element Temperature Sensor
FFan
F1 Fuse
FCeo Filler Cap (engine oil)
FCft Filler Cap (fuel tank)
FCc Filler Cap (coolant)
FFc Fuel Filter Caterpillar
FFpc Fuel Prefilter Caterpillar
FL Flash Light
FLG Fuel Level Gauge
FLS Fuel Level Sensor
FPco Filler Plug (oil compressor element)
FT Fuel Tank
HHorn
IC Intercooler
IPS Interstage Pressure Sensor
LV Loading Valve
MPV Minimum Pressure Valve
OC Oil Cooler
OFce Oil Filter (compressor element)
OFe Oil Filter (engine)
OLG Oil Level Gauge
RRadiator
RPS Regulating Pressure Sensor
RS Roadsignalisation
RV Regulating Valve
S Starting Motor
SN Serial Number
SV Safety Valve
TB Towbar
WPS Working Pressure Sensor
Reference Name
Instruction Manual
24 2954 2510 03
2.4 Regulating system
2.4.1 Overview
(AFS)
(DP)
(TBV)
(E)
(F)
(C)
(UA)
(BOV)
(OC)
(OSV)
(MPV)
(SV)
(CU)
(TV)
(OLG)
(FPco)
(CEhp)
(CElp)
(FR)
(OS)
(AR)
(RV)
(LV)
(SC)
(CV)
(RPS)
(AFce)
(AFe)
(AOV)
(SL)
(SV)
(WPS)
(WPG)
(TS)
(TS)
(DP)
(DP)
(VH)
(PS)
(PS)
(CBE)
(F1)
(BVof)
(OFce)
(VV)
Reference Name
AFce Air Filter (compr. element)
AFe Air Filter (engine)
AFS Air Filter Switch
AOV Air Outlet Valves
AR Air Receiver
BOV Blow Off Valve
BVof Bypass Valve oil filter
Instruction Manual
2954 2510 03 25
C Coupling
CBE Cubicle for Electrical devices
CEhp Compressor Element (high pressure)
CElp Compressor Element (low pressure)
CU Control Unit
CV Check Valve
DP Drain Plug
E Engine
FFan
F1 Fuse
FPco Filler Plug (oil compressor element)
FR Flow Restrictor
LV Loading Valve
MPV Minimum Pressure Valve
OC Oil Cooler
OFce Oil Filter (compressor element)
OLG Oil Level Gauge
OS Oil Separator
OSV Oil Stop Valve
PS Pressure Sensor
RPS Regulating Pressure Sensor
RV Regulating Valve
SC Safety Cartridge
SL Scavenge Line
SV Safety Valve
TBV Thermostatic Bypass Valve
TS Temperature Sensor
TV Throttle Valve
UA Unloader Assembly
VH Vent hole
VV Vacuator Valve
WPG Working Pressure Gauge
WPS Working Pressure Sensor
Reference Name
Instruction Manual
26 2954 2510 03
2.4.2 Air flow
Air drawn through the airfilter (AFce) into the compressor element (CEhp CElp) 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 oil collects in the receiver and on the bottom of the separator element.
The air leaves the receiver via a minimum pressure valve (MPV) which prevents the receiver
pressure from dropping below the minimum working pressure, even when the air outlet valves are
open (specified in section 8.2.2 Limitations). This ensures adequate oil injection and prevents oil
consumption. The minimum pressure valve (MPV) also functions as a check valve.
The system comprises temperature sensors (TS), pressure sensors (PS) and a working pressure
sensor (WPS).
(CElp)
(OS)
(AR)
(AFce)
(TS)
(TS)
(PS)
(PS)
(MPV)
(CV)
(WPS)
(OSV)
(FR)
(SL)
(TBV)
(BVof)
(OFce)
(OC)
(CEhp)
(UA)
(BOV)
(TV)
(RV)
(VH)
Instruction Manual
2954 2510 03 27
2.4.3 Oil system
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 (OC), the
oil filters (OF) and the oil stop valve (OSV) to the compressor element (CEhp CElp).
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 thermostatic by-pass valve (TBV) starts opening when the oil temperature is 80 °C (176 °F)
(when no Oiltronix is installed). With installed Oiltronix, the thermostatic by-pass valve starts
opening when the oil temperature is 40 °C (104 °F).
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 2.4.2 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 4.5 Preventive maintenance schedule for the
compressor).
2.4.4 Continuous regulating system
The compressor is provided with a continuous regulating system and a blow-off valve (BOV) which
is integrated in the unloader assembly (UA). 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 (RV) which, by means of control air to
the unloader assembly (UA), 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.
When starting the compressor, the throttle valve (TV) is kept closed via receiver pressure. The
compressor element (CEhp CElp) takes in air and pressure builds up in the receiver (AR). The throttle
valve (TV) is closed. The air output is controlled from maximum 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.
If the air consumption is equal to or exceeds the maximum air output, the engine speed is held at
maximum load speed and the throttle valve (TV) is fully open.
If the air consumption is less than the maximum air output, air receiver pressure increases and the
regulating valve supplies control air to throttle valve (TV) to reduce the air output and holds air
receiver pressure between the normal working pressure and the corresponding unloading pressure.
Unloading pressure = normal working pressure + 1 bar (14.504 psi).
When the air consumption is resumed, the blow off valve (BOV) closes and the throttle valve (TV)
gradually opens the air intake and the electronic speed regulator 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 throttle valve and the electronic speed regulator.
Part of the control air is vented to atmosphere, and any condensate discharged, through the vent
holes (VH).
Instruction Manual
28 2954 2510 03
2.5 Electric system
Circuit diagram (9822 0963 18 - C13 HP)
+
-
G1
+
-
G2
K0
M
M1
K0
B-
B+
G3
S1
24
24
24
24
24M
24M
24M
3
19
S2
19 19U
19
19
28
20
21
18
36
35
191919
28191835362120
24VDC
K1
87
30
24M
3
ECM
J1/P1-52 J1/P1-70
J1/P1-50
J1/P1-34
J1/P1-42
J1/P1-9
J1/P1-8
J1/P1-61
J1/P1-63
J1/P1-65
N2
J1/P1-48
24
27M
X1
F1
15A
1
8
ABC
CBA
DEF G
R1
Instruction Manual
2954 2510 03 29
TT1
P
U
V+ 24VDC
V+ 5VDC
V-
SIG
24M
19
28
20
21
18
18
18
29
18
4
9
55
4
K1
86
85
TT2
18
10
9
10
19
1
1
27M
Y1
PS1
LS1
19
19
19
30
34
31
2
34
31
28
28
2
3019
CONTROLLER
A16
B3
C8
B8
D7
D11
D12
D13
A1B1
C16
A4
A3
B16
A7
C9
N1
C7
D9
11
B9
A9
D1
D16
D15
C6
C2
C3
B4
C4
B5
B6
B10
C10
A11
A12
A13
B14
C14
B15
C15
LS2
19
19
H4-5 H6
32
33
33
32
29
28
18
29
28
PT1
P
U
V+ 24VDC
V+ 5VDC
V-
SIG
V+ 24VDC
V-
SIG
V+ 24VDC
V-
SIG
PT2
66
B7
18
29
28
P
U
V+ 24VDC
V+ 5VDC
V-
SIG
PT3
18
29
28
L
U
L
Z
L
Z
V+ 24VDC
V+ 5VDC
V-
SIG
LT1
1515
V-IN 07
D-IN 06
D-IN 04
D-IN 07
D-IN 05
V-IN 06
T-IN 05
T-IN 06
L-OUT 01
L-OUT 02
L-OUT 03
H-OUT 09
H-OUT 10
H-OUT 07
A15
H-OUT 08
H-OUT 06
C1
V-IN 04
T-IN 01
2
3
4
5
TT3
18
11
6
7
C1 Spare I/O (female contacts)
F1 Fuse 15A
G1 Battery
G2 Battery
G3 Alternator
H4-5 Warning flasher lights
H6 Horn
K0 Relay, Starter motor
K1 Relay, Aux. starter
LS1 Level Switch, Coolant level Warning
LS2 Level Switch, Coolant level Shutdown
LT1 Level sensor, Fuel level
M1 Starter motor
N1 Compressor Control Module
N2 Engine Control Modu le (Caterpillar)
PS1 Pressure Switch, Airfilter
PT1 Pressure sensor, Vessel pressure
PT2 Pressure sensor, Regulating pressure
PT3 Pressure sensor, Interstage pressure
R1 Termination resistor
S1 Emergency Stop
S2 Battery switch
TT1 Temperature sensor, PT1000, LP
element temperature
TT2 Temperature sensor, PT1000, HP
element temperature
TT3 Temperature sensor, PT1000, Ambient
temperature
X1 Caterpillar service tool connection
Y1 Loading Valve
1 24 VDC (power supply box) for Spare
I/O's and options
2 Fused 24 VDC after Emergency Stop for
Spare I/O's and options
3 Fused 24 VDC for Spare I/O's and
options
4 Power After Contact for Spare I/O's and
options
5 5 VDC for Spare I/O's and options
6 Digital Ground for Spare I/O's and
options
7 Ground for Spare I/O's and options
8 Ground (power supply box) for Spare
I/O's and options
Instruction Manual
30 2954 2510 03
3 Operating instructions
3.1 Parking, towing and lifting instructions
Safety precautions
Attention
The operator is expected to apply all relevant 1 Safety precautions.
• Before putting the compressor in to use, check the brake system as
described in section 5.5.1 Brake shoe adjustment (no ABS).
• After the first 100 km travel:
Check and retighten the wheel nuts and towbar bolts to the specified
torque. See section 8.1 Torque values.
Check the brake adjustment. See section 5.5.1 Brake shoe adjustment (no
ABS).
When towing, lifting or transporting the compressor in any way, the battery
switch must always be in the “OFF” position!
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