Instruction Manual

Instruction Manual
for Portable Compressors
English

XAXS 600 WUX

XAVS 650 WUX
XAHS 750 WUX Engine DCEC QSB6.7-C260
XATS 800 WUX
XAMS 850 WUX
 Instruction Manual
for Portable Compressors

XAXS 600 WUX

XAVS 650 WUX
XAHS 750 WUX
XATS 800 WUX
XAMS 850 WUX

Original instructions

Printed matter Nr.

9829 3582 15 ATLAS COPCO - PORTABLE ENERGY DIVISION
07/2021 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 from modifications, additions or
conversions made without the manufacturer's approval in writing.
Neglecting maintenance or making changes to the setup of the machine can result in major hazards, including
fire risk.
While every effort has been made to ensure that the information in this manual is correct, Atlas Copco does not
assume responsibility for possible errors.

Copyright 2021, Atlas Copco (Wuxi) Compressor Co., Ltd.

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 Table of contents 4.3.3 Overview icons ...................................... 34
Please read the following instructions carefully 4.3.4 Starting................................................... 37
before starting to use your compressor. 1 Safety precautions ...................................... 7 4.3.5 Stopping................................................. 42
It is a solid, safe and reliable machine, built 1.1 Introduction .................................................. 7 4.3.6 Shutdown ............................................... 43
according to the latest technology. Follow the 1.2 General safety precautions ........................... 8 4.3.7 Power off ............................................... 43
instructions in this booklet and we guarantee you 1.3 Safety during transport and installation ....... 9 4.3.8 Diesel particulate filter regeneration ..... 43
years of troublefree operation. 4.3.9 Automatic DPF regeneration (default) .. 44
1.4 Safety during use and operation ................... 9
Always keep the manual available near the machine. 4.3.10 Inhibit DPF regeneration ....................... 44
1.5 Safety during maintenance and repair........ 11
In all correspondence always mention the 4.3.11 Increasing soot load ............................... 45
1.6 Tool applications safety ............................. 12
compressor type and serial number, shown on the 4.3.12 Turning regeneration back to auto......... 45
data plate. 1.7 Specific safety precautions......................... 13 4.3.13 Force DPF regeneration......................... 45
The company reserves the right to make changes 2 Leading particulars .................................. 14 4.3.14 Service regeneration .............................. 45
without prior notice. 4.3.15 Settings .................................................. 46
2.1 General description .................................... 14
4.3.16 Fault codes ............................................. 48
3 Main Parts................................................. 16
5 Maintenance ............................................. 52
3.1 Compressor regulating system ................... 18
5.1 Liability...................................................... 52
3.1.1 Overview................................................ 18
3.1.2 Air flow .................................................. 20 5.2 Service paks ............................................... 52
3.1.3 Oil system .............................................. 21 5.3 Service kits................................................. 52
3.1.4 Continuous pneumatic regulating 5.4 Storage ....................................................... 52
system .................................................... 22 5.5 Preventive maintenance schedule .............. 53
3.2 Electric system ........................................... 24 5.5.1 Maintenance schedule compressor ........ 53
3.2.1 Dimension drawing................................ 27 5.6 Oil specifications........................................ 56
3.3 Markings and information labels ............... 28 5.6.1 Compressor oil....................................... 57
5.6.2 Engine oil............................................... 58
4 Operating instructions ............................. 29 5.7 Oil level check ........................................... 59
4.1 Parking, towing and lifting instructions ..... 29 5.7.1 Check engine oil level ........................... 59
4.1.1 Parking instructions ............................... 29 5.7.2 Check compressor oil level.................... 59
4.1.2 Towing instructions ............................... 30 5.7.3 Engine oil and oil filter change.............. 59
4.1.3 Lifting instructions................................. 30 5.7.4 Topping up the compressor oil .............. 60
4.2 Starting / Stopping...................................... 31 5.8 Compressor Oil Flushing Procedure .......... 61
4.3 Before starting ............................................ 31 5.9 Coolant specifications ................................ 62
4.3.1 Battery switch ........................................ 32 5.9.1 PARCOOL EG ...................................... 62
4.3.2 Control panel.......................................... 33 5.9.2 Handling PARCOOL EG ...................... 63

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5.10 Coolant check ............................................. 63 7 Problem solving ........................................ 74
5.11 Topping up/replacing coolant..................... 63
8 Available options ...................................... 77
5.11.1 Topping up without draining from the
cooling system ........................................64 9 Technical specifications ........................... 78
5.11.2 Topping up after limited quantity draining 9.1 Torque values ............................................. 78
from the cooling system .........................65 9.1.1 General torque values ............................ 78
5.11.3 Replacing the coolant............................. 66 9.1.2 Critical torque values ............................. 78
5.11.4 Cleaning coolers..................................... 66 9.2 Compressor / engine specifications............ 79
5.12 Battery care................................................. 67 9.2.1 Reference conditions.............................. 79
5.12.1 Electrolyte .............................................. 67 9.2.2 Limitations ............................................. 80
5.12.2 Activating a dry-charged battery............ 67 9.2.3 Altitude unit performance curve ............ 81
5.12.3 Recharging a battery .............................. 67 9.2.4 Performance data ................................... 83
5.12.4 Make-up distilled water.......................... 67 9.2.5 Design data............................................. 86
5.12.5 Periodic battery service .......................... 68
5.13 Compressor element overhaul .................... 68 10 Data plate .................................................. 88

6 Adjustments and servicing procedures .. 69 11 Legislation ................................................ 89

6.1 Adjustment of the continuous pneumatic 12 Disposal ..................................................... 90
regulating system ........................................69 12.1 General ....................................................... 90
6.2 Air filter engine/compressor....................... 70 12.2 Disposal of materials.................................. 90
6.2.1 Servicing ................................................ 70
6.2.2 Main parts .............................................. 70 13 Maintenance Log ...................................... 91
6.2.3 Cleaning the dust trap ............................ 70
6.2.4 Cleaning instructions filter element ....... 70
6.2.5 Replacing the air filter element .............. 71
6.2.6 Air receiver............................................. 72
6.3 Safety valve ................................................ 72
6.4 Fuel system................................................. 72
6.4.1 Priming instructions ............................... 72
6.4.2 Draining instructions.............................. 73

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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 It is the responsibility of management to appoint Take necessary steps to keep unauthorized persons
their equipment with safe, reliable and efficient operators with the appropriate training and skill for away from the unit and eliminate all possible sources
products. Factors taken into account are among each category of job. of danger at the unit.
others: Skill level 1: Operator When handling, operating, overhauling and/or
- the intended and predictable future use of the performing maintenance or repair on Atlas Copco
products, and the environments in which they are An operator is trained in all aspects of operating the
unit with the push-buttons, and is trained to know the equipment, the mechanics are expected to use safe
expected to operate, engineering practices and to observe all relevant local
- applicable rules, codes and regulations, safety aspects.
safety requirements and ordinances. The following
- the expected useful product life, assuming proper Skill level 2: Mechanical technician list is a reminder of special safety directives and
service and maintenance, A mechanical technician is trained to operate the unit precautions mainly applicable to Atlas Copco
- providing the manual with up-to-date the same as the operator. In addition, the mechanical equipment.
information. technician is also trained to perform maintenance and These safety precautions apply to machinery
Before handling any product, take time to read the repair, as described in the instruction manual, and is processing or consuming air. Processing of any other
relevant instruction manual. Besides giving detailed allowed to change settings of the control and safety gas requires additional safety precautions typical to
operating instructions, it also gives specific system. A mechanical technician does not work on the application and are not included herein.
information about safety, preventive maintenance, live electrical components.
etc. Neglecting the safety precautions may endanger
Skill level 3: Electrical technician people as well as environment and machinery:
Keep the manual always at the unit location, easy An electrical technician is trained and has the same - endanger people due to electrical, mechanical or
accessible to the operating personnel. qualifications as both the operator and the mechanical chemical influences,
See also the safety precautions of the engine and technician. In addition, the electrical technician may - endanger the environment due to leakage of oil,
possible other equipment, which are separately sent carry out electrical repairs within the various solvents or other substances,
along or are mentioned on the equipment or parts of enclosures of the unit. This includes work on live - endanger the machinery due to function failures.
the unit. electrical components. All responsibility for any damage or injury resulting
These safety precautions are general and some Skill level 4: Specialist from the manufacturer from neglecting these precautions or by non-
statements will therefore not always apply to a This is a skilled specialist sent by the manufacturer or observance of ordinary caution and due care required
particular unit. its agent to perform complex repairs or modifications in handling, operating, maintenance or repair, also if
Only people that have the right skills should be to the equipment. not expressly mentioned in this instruction manual, is
allowed to operate, adjust, perform maintenance or disclaimed by Atlas Copco.
In general it is recommended that not more than two
repair on Atlas Copco equipment. people operate the unit, more operators could lead to
unsafe operating conditions.

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The manufacturer does not accept any liability for any GENERAL SAFETY PRECAUTIONS 9 Care shall be taken to avoid damage to safety
damage arising from the use of non-original parts and valves and other pressure-relief devices,
for modifications, additions or conversions made 1 The owner is responsible for maintaining the unit especially to avoid plugging by paint, oil coke or
without the manufacturer’s approval in writing. in a safe operating condition. Unit parts and dirt accumulation, which could interfere with the
accessories must be replaced if missing or functioning of the device.
If any statement in this manual does not comply with
unsuitable for safe operation. 10 Pressure and temperature gauges shall be checked
local legislation, the stricter of the two shall be
applied. 2 The supervisor, or the responsible person, shall at regularly with regard to their accuracy. They shall
all times make sure that all instructions regarding be replaced whenever outside acceptable
Statements in these safety precautions should not be
machinery and equipment operation and tolerances.
interpreted as suggestions, recommendations or
maintenance are strictly followed and that the 11 Safety devices shall be tested as described in the
inducements that it should be used in violation of any
machines with all accessories and safety devices, maintenance schedule of the instruction manual
applicable laws or regulations.
as well as the consuming devices, are in good to determine that they are in good operating
repair, free of abnormal wear or abuse, and are condition. See the Preventive maintenance
not tampered with. schedule.
3 Whenever there is an indication or any suspicion 12 Mind the markings and information labels on the
that an internal part of a machine is overheated, unit.
the machine shall be stopped but no inspection
covers shall be opened before sufficient cooling 13 In the event the safety labels are damaged or
time has elapsed; this to avoid the risk of destroyed, they must be replaced to ensure
spontaneous ignition of oil vapour when air is operator safety.
admitted. 14 Keep the work area neat. Lack of order will
4 Normal ratings (pressures, temperatures, speeds, increase the risk of accidents.
etc.) shall be durably marked. 15 When working on the unit, wear safety clothing.
5 Operate the unit only for the intended purpose and Depending on the kind of activities these are:
within its rated limits (pressure, temperature, safety glasses, ear protection, safety helmet
speeds, etc.). (including visor), safety gloves, protective
clothing, safety shoes. Do not wear the hair long
6 The machinery and equipment shall be kept clean, and loose (protect long hair with a hairnet), or
i.e. as free as possible from oil, dust or other wear loose clothing or jewellery.
deposits.
16 Take precautions against fire. Handle fuel, oil and
7 To prevent an increase in working temperature, anti-freeze with care because they are
inspect and clean heat transfer surfaces (cooler inflammable substances. Do not smoke or
fins, intercoolers, water jackets, etc.) regularly. approach with naked flame when handling such
See the Preventive maintenance schedule. substances. Keep a fire-extinguisher in the
8 All regulating and safety devices shall be vicinity.
maintained with due care to ensure that they
function properly. They may not be put out of
action.

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SAFETY DURING TRANSPORT AND - remove wheel chocks, if applied, and hoists, each at approximately the same angle not
INSTALLATION disengage the parking brake. exceeding 30° from the vertical.
2 To tow a unit use a towing vehicle of ample 11 Locate the unit away from walls. Take all
When towing, lifting or transporting the compressor capacity. Refer to the documentation of the precautions to ensure that hot air exhausted from
in any way, the battery switch must always be in the towing vehicle. the engine and driven machine cooling systems
“OFF” position! cannot be recirculated. If such hot air is taken in
3 If the unit is to be backed up by the towing
To lift a unit, all loose or pivoting parts, e.g. doors and vehicle, disengage the overrun brake mechanism by the engine or driven machine cooling fan, this
tow-bar, shall first be securely fastened. (if it is not an automatic mechanism). may cause overheating of the unit; if taken in for
Do not attach cables, chains or ropes directly to the combustion, the engine power will be reduced.
4 Never exceed the maximum towing speed of the
lifting eye; apply a crane hook or lifting shackle unit (mind the local regulations). 12 Before moving the compressor, switch it off.
meeting local safety regulations. Never allow sharp 13 If the warning light on the ABS module or in the
bends in lifting cables, chains or ropes. 5 Place the unit on level ground and apply the
parking brake before disconnecting the unit from vehicle lights up, please contact Atlas Copco.
Helicopter lifting is not allowed. the towing vehicle. Unclip the safety break-away
It is strictly forbidden to dwell or stay in the risk zone cable or safety chain. If the unit has no parking SAFETY DURING USE AND OPERATION
under a lifted load. Never lift the unit over people or brake or jockey wheel, immobilize the unit by
residential areas. Lifting acceleration and retardation placing chocks in front of and/or behind the 1 When the unit has to operate in a fire-hazardous
shall be kept within safe limits. wheels. When the towbar can be positioned environment, each engine exhaust has to be
vertically, the locking device must be applied and provided with a spark arrestor to trap incendiary
1 Before towing the unit:
kept in good order. sparks.
- ascertain that the pressure vessel(s) is (are) de-
6 To lift heavy parts, a hoist of ample capacity, 2 The exhaust contains carbon monoxide which is a
pressurized,
tested and approved according to local safety lethal gas. When the unit is used in a confined
- check the towbar, the brake system and the regulations, shall be used. space, conduct the engine exhaust to the outside
towing eye. Also check the coupling of the atmosphere by a pipe of sufficient diameter; do
towing vehicle, 7 Lifting hooks, eyes, shackles, etc., shall never be
bent and shall only have stress in line with their this in such a way that no extra back pressure is
- check the towing and brake capability of the design load axis. The capacity of a lifting device created for the engine. If necessary, install an
towing vehicle, diminishes when the lifting force is applied at an extractor. Observe any existing local regulations.
angle to its load axis. Make sure that the unit has sufficient air intake
- check that the towbar, jockey wheel or stand for operation. If necessary, install extra air intake
leg is safely locked in the raised position, 8 For maximum safety and efficiency of the lifting ducts.
- ascertain that the towing eye can swivel freely apparatus all lifting members shall be applied as
near to perpendicular as possible. If required, a 3 When operating in a dust-laden atmosphere, place
on the hook, the unit so that dust is not carried towards it by the
lifting beam shall be applied between hoist and
- check that the wheels are secure and that the wind. Operation in clean surroundings
load.
tyres are in good condition and inflated considerably extends the intervals for cleaning
correctly, 9 Never leave a load hanging on a hoist. the air intake filters and the cores of the coolers.
- connect the signalisation cable, check all lights 10 A hoist has to be installed in such a way that the
and connect the pneumatic brake couplers, object will be lifted perpendicular. If that is not
possible, the necessary precautions must be taken
- attach the safety break-away cable or safety
to prevent load-swinging, e.g. by using two
chain to the towing vehicle,

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4 Close the compressor air outlet valve before 11 Before removing the oil filler plug, ensure that the - below 85 dB(A): no action needs to be taken
connecting or disconnecting a hose. Ascertain pressure is released by opening an air outlet for occasional visitors staying a limited time
that a hose is fully depressurized before valve. only,
disconnecting it. Before blowing compressed air 12 Never remove a filler cap of the cooling water - above 85 dB(A): room to be classified as a
through a hose or air line, ensure that the open end system of a hot engine. Wait until the engine has noise-hazardous area and an obvious warning
is held securely, so that it cannot whip and cause sufficiently cooled down. shall be placed permanently at each entrance
injury. to alert people entering the room, for even
13 Never refill fuel while the unit is running, unless
5 The air line end connected to the outlet valve otherwise stated in the Atlas Copco Instruction relatively short times, about the need to wear
must be safeguarded with a safety cable, attached Book (AIB). Keep fuel away from hot parts such ear protectors,
next to the valve. as air outlet pipes or the engine exhaust. Do not - above 95 dB(A): the warning(s) at the
6 No external force may be exerted on the air outlet smoke when fuelling. When fuelling from an entrance(s) shall be completed with the
valves, e.g. by pulling on hoses or by installing automatic pump, an earthing cable should be recommendation that also occasional visitors
auxiliary equipment directly to a valve, e.g. a connected to the unit to discharge static shall wear ear protectors,
water separator, a lubricator, etc. Do not step on electricity. Never spill nor leave oil, fuel, coolant - above 105 dB(A): special ear protectors that
the air outlet valves. or cleansing agent in or around the unit. are adequate for this noise level and the
7 Never move a unit when external lines or hoses 14 All doors shall be shut during operation so as not spectral composition of the noise shall be
are connected to the outlet valves, to avoid to disturb the cooling air flow inside the provided and a special warning to that effect
damage to valves, manifold and hoses. bodywork and/or render the silencing less shall be placed at each entrance.
8 Do not use compressed air from any type of effective. A door should be kept open for a short 18 The unit has parts, which may be accidentally
compressor, without taking extra measures, for period only e.g. for inspection or adjustment. touched by personal, of which the temperature
breathing purposes as this may result in injury or 15 Periodically carry out maintenance works can be in excess of 80 °C (176 °F). The insulation
death. For breathing air quality, the compressed according to the maintenance schedule. or safety guard, protecting these parts shall not be
air must be adequately purified according to local 16 Stationary housing guards are provided on all removed before the parts have cooled down to
legislation and standards. Breathing air must rotating or reciprocating parts not otherwise room temperature. As it is technically not
always be supplied at stable, suitable pressure. protected and which may be hazardous to possible to insulate all hot parts or to install safety
9 Distribution pipe work and air hoses must be of personnel. Machinery shall never be put into guards around hot parts (e.g. exhaust manifold,
correct diameter and suitable for the working operation, when such guards have been removed, exhaust turbine), the operator / service engineer
pressure. Never use frayed, damaged or before the guards are securely reinstalled. must always be aware not to touch hot parts when
deteriorated hoses. Replace hoses and flexibles opening a machine door.
17 Noise, even at reasonable levels, can cause
before the lifetime expires. Use only the correct irritation and disturbance which, over a long 19 Never operate the unit in surroundings where
type and size of hose end fittings and connections. period of time, may cause severe injuries to the there is a possibility of taking in flammable or
10 If the compressor is to be used for sand-blasting nervous system of human beings. When the sound toxic fumes.
or will be connected to a common compressed-air pressure level, at any point where personnel 20 If the working process produces fumes, dust or
system, fit an appropriate non-return valve (check normally has to attend, is: vibration hazards, etc., take the necessary steps to
valve) between compressor outlet and the - below 70 dB(A): no action needs to be taken, eliminate the risk of personal injury.
connected sand-blasting or compressed-air - above 70 dB(A): noise-protective devices 21 When using compressed air or inert gas to clean
system. Observe the right mounting position/ should be provided for people continuously down equipment, do so with caution and use the
direction. being present in the room, appropriate protection, at least safety glasses, for

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 the operator as well as for any bystander. Do not SAFETY DURING MAINTENANCE AND 6 Make sure that no tools, loose parts or rags are left
apply compressed air or inert gas to your skin or REPAIR in or on the machine. Never leave rags or loose
direct an air or gas stream at people. Never use it clothing near the engine air intake.
to clean dirt from your clothes. Maintenance, overhaul and repair work shall only be 7 Never use flammable solvents for cleaning (fire-
22 When washing parts in or with a cleaning solvent, carried out by adequately trained personnel; if risk).
provide the required ventilation and use required, under supervision of someone qualified for
the job. 8 Take safety precautions against toxic vapours of
appropriate protection such as a breathing filter, cleaning liquids.
safety glasses, rubber apron and gloves, etc. 1 Use only the correct tools for maintenance and
repair work, and only tools which are in good 9 Never use machine parts as a climbing aid.
23 Safety shoes should be compulsory in any
workshop and if there is a risk, however small, of condition. 10 Observe scrupulous cleanliness during
falling objects, wearing of a safety helmet should 2 Parts shall only be replaced by genuine Atlas maintenance and repair. Keep away dirt, cover
be included. Copco replacement parts. the parts and exposed openings with a clean cloth,
paper or tape.
24 If there is a risk of inhaling hazardous gases, 3 All maintenance work, other than routine
fumes or dust, the respiratory organs must be attention, shall only be undertaken when the unit 11 Never weld on or perform any operation
protected and depending on the nature of the is stopped. Steps shall be taken to prevent involving heat near the fuel or oil systems. Fuel
hazard, so must the eyes and skin. inadvertent starting. In addition, a warning sign and oil tanks must be completely purged, e.g. by
bearing a legend such as “work in progress; do steam-cleaning, before carrying out such
25 Remember that where there is visible dust, the operations. Never weld on, or in any way modify,
finer, invisible particles will almost certainly be not start” shall be attached to the starting
equipment. On engine-driven units the battery pressure vessels. Disconnect the alternator cables
present too; but the fact that no dust can be seen during arc welding on the unit.
is not a reliable indication that dangerous, shall be disconnected and removed or the
invisible dust is not present in the air. terminals covered by insulating caps. On 12 Support the towbar and the axle(s) securely if
electrically driven units the main switch shall be working underneath the unit or when removing a
26 Never operate the unit at pressures or speeds locked in open position and the fuses shall be wheel. Do not rely on jacks.
below or in excess of its limits as indicated in the taken out. A warning sign bearing a legend such
technical specifications. 13 Do not remove any of, or tamper with, the sound-
as “work in progress; do not supply voltage” shall damping material. Keep the material free of dirt
27 Do not use aerosol types of starting aids such as be attached to the fuse box or main switch. and liquids such as fuel, oil and cleansing agents.
ether. Such use could result in an explosion and 4 Before dismantling any pressurized component, If any sound-damping material is damaged,
personal injury. the compressor or equipment shall be effectively replace it to prevent the sound pressure level from
isolated from all sources of pressure and the entire increasing.
system shall be relieved of pressure. Do not rely 14 Use only lubricating oils and greases
on non-return valves (check valves) to isolate recommended or approved by Atlas Copco or the
pressure systems. In addition, a warning sign machine manufacturer. Ascertain that the
bearing a legend such as “work in progress; do selected lubricants comply with all applicable
not open” shall be attached to each of the outlet safety regulations, especially with regard to
valves. explosion or fire-risk and the possibility of
5 Prior to stripping an engine or other machine or decomposition or generation of hazardous gases.
undertaking major overhaul on it, prevent all Never mix synthetic with mineral oil.
movable parts from rolling over or moving.

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15 Protect the engine, alternator, air intake filter, 23 Make sure that oil, solvents and other substances
electrical and regulating components, etc., to likely to pollute the environment are properly
prevent moisture ingress, e.g. when steam- disposed of.
cleaning. 24 Before clearing the unit for use after maintenance
16 When performing any operation involving heat, or overhaul, check that operating pressures,
flames or sparks on a machine, the surrounding temperatures and speeds are correct and that the
components shall first be screened with non- control and shut-down devices function correctly.
flammable material.
17 Never use a light source with open flame for TOOL APPLICATIONS SAFETY
inspecting the interior of a machine.
18 Disconnect –battery-clamp before starting Apply the proper tool for each job. With the
electrical servicing or welding (or turn battery- knowledge of correct tool use and knowing the
switch in “off” position). limitations of tools, along with some common sense,
many accidents can be prevented.
19 When repair has been completed, the machine
shall be barred over at least one revolution for Special service tools are available for specific jobs
reciprocating machines, several revolutions for and should be used when recommended. The use of
rotary ones to ensure that there is no mechanical these tools will save time and prevent damage to
interference within the machine or driver. Check parts.
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.

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SPECIFIC SAFETY PRECAUTIONS Pressure vessels Safety valves
Maintenance/installation requirements: Operating & Maintenance
Batteries
1 The vessel can be used as pressure vessel or as Only trained and technically competent personnel
When servicing batteries, always wear protecting separator and is designed to hold compressed air should consider overhaul, re-set or performance
clothing and glasses. for the following application: testing of safety valves.
1 The electrolyte in batteries is a sulphuric acid - pressure vessel for compressor, The safety valve is supplied with either a lead security
solution which is fatal if it hits your eyes, and seal or crimped cover to deter unauthorised access to
which can cause burns if it contacts your skin. - medium AIR/OIL,
the pressure regulation device.
Therefore, be careful when handling batteries, - and operates as detailed on the data plate of the
e.g. when checking the charge condition. vessel: Under no circumstances should the set pressure of the
safety valve be altered to a different pressure than that
2 Install a sign prohibiting fire, open flame and - the maximum working pressure ps in bar (psi), stamped on the valve without the permission of the
smoking at the post where batteries are being installation designer.
- the maximum working temperature Tmax in
charged.
°C (°F), If the set pressure must be altered then use only
3 When batteries are being charged, an explosive correct parts supplied by Atlas Copco and in
- the minimum working temperature Tmin in °C
gas mixture forms in the cells and might escape accordance with the instructions available for the
(°F),
through the vent holes in the plugs. Thus an valve type.
explosive atmosphere may form around the - the capacity of the vessel V in l (US gal, Imp
battery if ventilation is poor, and can remain in gal, cu.ft). Safety valves must be frequently tested and regularly
and around the battery for several hours after it 2 The pressure vessel is only to be used for the maintained.
has been charged. Therefore: applications as specified above and in accordance The set pressure should be periodically checked for
- never smoke near batteries being, or having with the technical specifications. Safety reasons accuracy.
recently been, charged, prohibit any other applications. When fitted, the compressors should be operated at
- never break live circuits at battery terminals, 3 National legislation requirements with respect to pressures not less than 75% of the set pressure to
because a spark usually occurs. re-inspection must be complied with. ensure free and easy movement of internal parts.
4 When connecting an auxiliary battery (AB) in 4 No welding or heat treatment of any kind is The frequency of tests is influenced by factors such as
parallel to the unit battery (CB) with booster permitted to those vessel walls which are exposed the severity of the operating environment and
cables: connect the + pole of AB to the + pole of to pressure. aggressiveness of the pressurised medium.
CB, then connect the - pole of CB to the mass of 5 The vessel is provided and may only be used with Soft seals and springs should be replaced as part of the
the unit. Disconnect in the reverse order. the required safety equipment such as maintenance procedure.
manometer, overpressure control devices, safety Do not paint or coat the installed safety valve (see also
valve, etc. Preventive maintenance schedule).
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.

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Leading particulars
GENERAL DESCRIPTION Compressor Regulation
The compressor casing houses two screw-type rotors, The compressor is provided with a continuous
mounted on ball and roller bearings. The male rotor, pneumatic regulating system and a blow-off valve
driven by the engine, drives the female rotor. The which is integrated in the unloader assembly. The
compressor delivers pulsation-free air. valve is closed during operation by air receiver
pressure and opens by air receiver pressure via the
Injected oil is used for sealing, cooling and
compressor element when the compressor is stopped.
lubricating purposes.
When air consumption increases, the air receiver
Compressor oil system pressure will decrease and vice versa.
The oil is boosted by air pressure. The system has no This receiver pressure variation is sensed by the
oil pump. regulating valve which, by means of control air to the
The oil is removed from the air, in the air/oil vessel unloader and an electronic engine speed regulator,
first by centrifugal force, secondly by the oil separator matches the air output to the air consumption. The air
element. receiver pressure is maintained between the pre-
selected working pressure and the corresponding
The vessel is provided with an oil level indicator. unloading pressure.

Cooling system
The XA(X\V\H\T\M)S 600-850 are a silenced,
single-stage, oil-injected screw compressor, built for The engine is provided with a liquid-cooler and
a nominal effective working pressure of 8.6 bar to17 intercooler and the compressor is provided with an oil
bar (124.7 psi to 246.5 psi). See Technical cooler. For available options see chapter Available
specifications. options.
The XRHS 650 is a silenced, double stage oil-injected The cooling air is generated by a fan, driven by the
screw compressor, built for a nominal effective engine.
working pressure of 20 bar (300 psi) See Technical
specifications. Safety devices
A thermal shut-down sensor protects the compressor
Engine against overheating. The air receiver is provided with
The compressors XA(X\V\H\T\M)S 600-850 are a safety valve.
driven by 6 cylinder in-line liquid-cooled diesel The engine is equipped with low oil pressure and high
engines. coolant temperature shut-down sensors.
The engine’s power is transmitted to the compressor The electric system is equipped with a 24V main
element through a heavy-duty coupling. switch.

- 14 -
Frame and axles Serial number
The compressor/engine unit is supported by rubber
buffers in the frame.
The standard compressor has an adjustable or fixed
towbar with brakes.
The braking system consists of an integrated parking
brake and overrunbrake. When driving backwards the
overrunbrake is not engaged automatically. (For
available options see chapter Available options.)

Bodywork
The bodywork has openings at the shaped front and
rear end 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 eye
A lifting eye is accessible when a small door at the top The serial number (SN) is located on the right-hand
of the unit is unlocked. side towards the front on the upper edge of the frame.

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 Altitude unit
performance curve).

- 15 -
Main Parts

- 16 -
Reference Name Reference Name
A Alternator FT Fuel Tank
AFce Air Filter (compressor element) IC Intercooler
AFe Air Filter (engine) MPV Minimum Pressure Valve
AOV Air Outlet Valves OC Oil Cooler
AR Air Receiver OFce Oil Filter (compressor element)
B Battery OFe Oil Filter (engine)
BS Battery Switch OLG Oil Level Gauge
C Cubicle R Radiator
CE Compressor Element RV Regulating Valve
CP Control Panel S Silencer
DP Data plate SL Support Leg
E Engine SN Serial Number
EP Exhaust Pipe SV Safety Valve
ES Emergency Stop TB Towbar
F Fan UV Unloading Valve
FCft Filler Cap (fuel tank)
FCc Filler Cap (coolant)
FF Fuel Filter
FLS Fuel Level Sensor
FPco Filler Plug (oil compressor element)

- 17 -
COMPRESSOR REGULATING SYSTEM

OVERVIEW

- 18 -
Reference Name Reference Name
AFE Air Filter Element OSV/CV Oil Stop Valve / Check Valve
AFc Air Filter (compressor) RPS Regulating Pressure Sensor
AFe Air Filter (engine) RV Regulating Valve
AOV Air Outlet Valves AFSC Air filter Safety Cartridge
AR/OS Air Receiver / Oil Separator SL Scavenge Line
BOV Blow Off Valve SV Safety Valve
BVof Bypass Valve oil filter TBV Thermostatic Bypass Valve
CB Cubicle TS Temperature Sensor
CE Compressor Element UA Unloader Assembly
CH Coupling Housing VI Vacuum Indicator
CU Control Unit WPS Working Pressure Sensor
CV Check Valve
DP Drain Plug
E Engine
EW Electrical Wiring
F Fan
LV Loading Valve
MPV Minimum Pressure Valve
OC Oil Cooler
OFc Oil Filter (compressor)
OSE Oil Separator Element

- 19 -
AIR FLOW

Air drawn through the air filter (AFce) 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 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 Limitations). This ensures adequate oil
injection and prevents oil consumption. The
minimum pressure valve (MPV) also functions as a
check valve.
The system comprises of temperature sensors (TS),
regulating pressure sensors (RPS) and a working
pressure sensor (WPS).

- 20 -
OIL SYSTEM

The lower part of the air receiver (AR) serves as an oil

tank.
Air pressure forces the oil from the air receiver/oil
separator (AR/OS) through the oil cooler (OC), the oil
filters (OFc) and the oil stop valve (OSV) 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 thermostatic by-pass valve (TBV) starts opening
when the oil temperature is 70°C (158°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 Air flow. The oil that collects on
the bottom of the oil separator element is returned to
the system through a scavenging line (SL), which is
provided with a flow restrictor.
The oil filter by-pass valve opens when the pressure
drop over the filter is above normal because of a
clogged filter. The oil then by-passes the filter
without being filtered. For this reason, the oil filter
must be replaced at regular intervals (see section
Preventive maintenance schedule).

- 21 -
CONTINUOUS PNEUMATIC REGULATING SYSTEM

- 22 -
The compressor is provided with a continuous If the air consumption is less than the maximum air
pneumatic regulating system and a blow-off valve output, air receiver pressure increases and the
(BOV), which is integrated in the unloader assembly regulating valve supplies control air to throttle valve
(UA). The blow-off valve is kept closed by receiver to reduce the air output and holds air receiver pressure
pressure and opens by compressor element outlet between the normal working pressure and the
pressure when the compressor is stopped. corresponding unloading pressure. Unloading
pressure = normal working pressure + 1 bar
When the air consumption increases, the air receiver
(14.5 psi).
pressure will decrease and vice versa. This receiver
pressure variation is sensed by the regulating valve When the air consumption is resumed, the blow off
(RV) which, by means of control air to the unloader valve (BOV) closes and the throttle valve gradually
assembly (UA), matches the air output to the air opens the air intake and the electronic speed regulator
consumption. The air receiver pressure is maintained increases the engine speed.
between the pre-selected working pressure and the The construction of the regulating valve (RV) is such
corresponding unloading pressure. that any increase (decrease) of the air receiver
When starting the compressor, the throttle valve is pressure above the pre-set valve opening pressure
kept closed via receiver pressure. The compressor results in a proportional increase (decrease) of the
element (CE) takes in air and pressure builds up control pressure to the throttle valve and the
inside the receiver (AR). The throttle valve is closed. electronic speed regulator.
The air output is controlled from maximum output Part of the control air is vented into the atmosphere,
(100%) to no output (0%) by: and any condensate discharged, through the vent
1. Speed control of the engine between maximum holes.
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 is fully
open.

- 23 -
ELECTRIC SYSTEM

Circuit diagram - 9829 3800 86

- 24 -
 Circuit diagram Circuit Diagram PREHEATER (optional)

Reference Name
F1 Circuit breaker
F2 Circuit breaker
G1 Battery
K0 Start relay
LS1 Level switch-coolant level
LT1 Fuel level switch
M1 Starter motor
N1 Control module-Xc2003
PT1 Pressure sensor-Regulating pressure
PT2 Pressure sensor-Vessel pressure
PT3 Pressure interstage pressure
PT4 Pressure OSV pressure
S0 Battery Switch
Reference Name Reference Name
S2 Emergency Stop
F3 Fuse F4 Fuse 10A
TS1 LP Element pressure
G2 Alternator R4 Resistor 470 Ohm 3W
TS2 HP Element pressure
K1 Relay - Starter motor N7 Eberspacher Timer
Y1 Loading valve
K2 K2 - Glow Relay N8 Eberspacher Preheater
N2 Electronic control unit - 4pin M4 Fuel pump
N3 Electronic control unit - 60pin S2b Emergency stop
N6 Diagnostic connector
R3 Grid heater
R2 Excitation resistor
D1 Excitation diode

- 25 -
Fuse box

Sr Nr Functional Description Data

Q1 Controller Xc2003 10A
PN: 1089 9206 31
Q2 Engine Controller 25A
PN: 1089 9206 21
Q3 Air Inlet Heater (Optional) 10A
PN: 1089 9206 09

- 26 -
DIMENSION DRAWING - 9829 3582 02

- 27 -
MARKINGS AND INFORMATION LABELS

Sound power level in accordance with

Dangerous outlet gases. Outlet. Directive 2000/14/EC (expressed in
dB (A)).

Danger, hot surface. Compressor oil drain. Fork lifting permitted.

Read the instruction manual before

Electrocution hazard. Don’t lift here.
starting.

Atlas Copco synthetic compressor oil. Service every 24 hours. Read the instruction manual before
lifting.

Atlas Copco mineral engine oil. Warning! Part under pressure. Filler cap coolant.

Manual. Do not stand on outlet valves. Read the instruction manual before
topping up with coolant.

Read the instruction manual before

Start-Stop indication of switch. Service point.
working on the battery.

Do not run the compressor with open

Reset fuse. Circuit breaker.
doors.

On / off button. Do not run the compressor when the

Lifting permitted.
baffles are not in the right position.

Prohibition to open air valves without

connected hoses. Use diesel fuel only.

Rotation direction. 4 bar (58 psi) Tyre pressure.

Inlet. 6 bar (87 psi) Tyre pressure.

- 28 -
Operating instructions PARKING INSTRUCTIONS

When parking a compressor, secure the support leg(2)

PARKING, TOWING AND LIFTING to support the compressor in a level position.
INSTRUCTIONS Place the compressor as level as possible; however, it
can be operated temporarily in an out-of-level
Safety precautions position not exceeding 15°. If the compressor is
parked on sloping ground, immobilize the compressor
The operator is expected to apply all by placing wheel chocks (available as an option) in
relevant Safety precautions. front of or behind the wheels. Locate the rear-end of
the compressor upwind away from contaminated
wind-streams and walls. Do not obstruct air
Attention evacuation from the cooling system. Avoid
recirculation of exhaust air from the engine. This can
Before putting the compressor into use, cause overheating and engine power decrease.
check the brake system as described in The compressor oil lifetime will be shortened when
section Brake shoe adjustment. the compressor air inlet air is contaminated.
Fixed towbar
After the first 100 km travel:
Check and re-tighten the wheel nuts and
towbar bolts to the specified torque. See
section Compressor / engine
specifications.
Check the brake adjustment. See section
Brake shoe adjustment.

When the engine is running, the air

outlet valves (ball valves) must always be
put in fully opened or fully closed
position.

When towing, lifting or transporting the

compressor in any way, the battery Rear-end of the compressor upwind
switch must always be in the “OFF”
position!

- 29 -
TOWING INSTRUCTIONS LIFTING INSTRUCTIONS

Label on towbar When lifting the compressor, the hoist has to be

placed in such a way that the compressor, which must
Before towing the compressor, ensure be placed level, is lifted vertically. Keep lifting
that the towing equipment of the vehicle acceleration and retardation within safe limits.
matches the towing eye or ball connector
The lifting eye (1) should preferably be used after
and ensure that the service doors are
opening the small door (2).
closed and locked properly.
The towbar should be as level as possible Lifting acceleration and retardation
and the compressor and towing eye end must be kept within safe limits (max.
in the level position. 2xg).
Helicopter lifting is not allowed.
Lifting is not allowed when the unit is
running.

- 30 -
STARTING / STOPPING 9. Attach the air line(s) to the closed air outlet
valve(s). Connect the safety chain.
BEFORE STARTING No external force may be applied to the
air outlet valve(s), e.g. by pulling hoses
1. Before initial start-up, prepare battery for or by connecting equipment directly to
operation if not already done. See section the valve(s).
Recharging a battery.
2. With the compressor standing level, check the
level of the engine oil. Add oil, if necessary, up to Safety precautions
the upper mark on the dipstick. Also check the
engine coolant level. Consult the Engine
Operation Manual for the type of coolant and type Do not disconnect power supply to
and viscosity grade of the engine oil. control box in any way when the control
3. Check the level of the compressor oil. The pointer box is switched on. This will cause
of oil level gauge (OLG) should register in the memory loss.
green range. Add oil if necessary. See section
Engine oil for the oil to be used.
Make sure the fuel tank is filled up.
Before removing oil filler plug (FP),
ensure that pressure is released by When the compressor is put in operation
opening an air outlet valve. for the first time and after running out of
fuel or changing the fuel filter, follow the
4. Check that the fuel tank contains sufficient fuel. specific start procedure as described in
Top up, if necessary. Consult the Engine section Priming instructions.
Operation Manual for the type of fuel. Do not switch off the circuit breaker
when the control box is switched on. This
5. Drain any water and sediment from the fuel filters will cause memory loss.
until clean fuel flows from the drain cock. See
section Priming instructions.
6. Empty the dust trap of each air filter (AF). See
section Cleaning the dust trap.
7. Clogged air filter(s) will be indicated on the
display of the control panel, see section Fault
codes. If indicated, replace the filter elements.
8. Check coolant level in engine coolant top tank.
Top up, if necessary. Consult the Engine
Operation Manual for coolant specifications.

- 31 -
BATTERY SWITCH

The compressor is equipped with a battery switch.

When the compressor is not in use this switch must
always be in the “OFF” position.
It is not allowed to use this switch as an
emergency switch or for stopping the
compressor. It will cause damage in the
control unit when using this switch for
stopping.

Always first shut off the control unit and wait until the
display is dark before switching the battery switch to
position “OFF”.
To switch the electric system “ON”, turn the handle
(1) of the battery switch clockwise.
To switch the electric system “OFF”, turn the handle
(1) of the battery switch counter-clockwise.
Please be aware that when the electric
system is switched “OFF” the batteries
are still under tension.
Please be aware that the (optional)
preheater unit is still “live” with the
battery switch in “OFF” position.

- 32 -
CONTROL PANEL Reference Name
MEASUREMENTS VIEW
BUTTON: This button will enter the
Measurements View when not
already in the Measurements View, or
when already in the Measurements
View it will enter the Main View.
SETTINGS VIEW BUTTON: This
button will enter the Settings View
when not already in the Settings
View, or when already in the Settings
Reference Name View it will enter the Main View.
START BUTTON: This button will ALARMS VIEW BUTTON: This
initiate the starting sequences if the button will enter the Alarms View
controller is in Ready To Start when not already in the Alarms View,
Sequence, or will re-enter the normal or when already in the Alarms View it
running sequence when in Cooldown will enter the Main View.
Sequence.
NAVIGATION BUTTONS: These
STOP BUTTON: This button will buttons are used to navigate through
initiate the cool down/stopping the display menu’s.
sequences if the controller is in
normal running sequence.
ENTER BUTTON: Confirms/stores
LOAD BUTTON: This button will:- the selection/change.
initiate the Auto Load function when
the controller is in normal running
sequence, but not ready to be loaded. BACK BUTTON: Moves back one
- initiate the loading sequences when level or ignores the change.
the controller is ready to be loaded.
- initiate the not loaded sequence
when the controller is running in
Loaded Sequence

- 33 -
OVERVIEW ICONS

Reference Name
0 1 Compressor status
2 Vessel pressure indication or info text
3 Compressor info

Main View Indication

Measuring View Indication

MAINVIEW

LOADED
Settings View Indication
1

Alarm View Indication

2
DPF REGENERATION
High Exhaust System Temperature.
Means that the Diesel Particle Filter
is being regenerated.
3 41% 1286h 1300RPM 22.4bar DPF REGENERATION NEEDED
Means that the Diesel Particle Filter
needs to be regenerated.
Please force DPF Regeneration.

- 34 -
Reference Name Reference Name Reference Name
DPF REGENERATION OPERATION MODE FUELTANK
INHIBITED Local Running at internal fuel tank.
Diesel Particle Filter
Regeneration OPERATION MODE FUELTANK
Inhibited. Remote Running at internal fuel tank &
Means that the DPF regeneration Fuelpump is energized.
is
inhibited, even if all criteria to OPERATION MODE FUELTANK
activate a regeneration are met. PC Control Running at external fueltank, but
internal fueltank level is shown.
OVERHAUL
Initial Overhaul required. OPERATION MODE FUELTANK
Automatic Running at external fueltank, but
internal fueltank level is shown &
OVERHAUL
OPERATION MODE fuelpump is energized.
Minor Overhaul required.
Automatic Mode is active, but the OIL FILL
Auto Start and Auto Stop function Oilpump is energized.
OVERHAUL are both inactive.
Major Overhaul required.
OPERATION MODE
Block Mode
AUTO LOAD
This icon will be shown if the
Auto Load functionality is ALARM
enabled, or by means of a Active & not-acknowledged
parameter setting, or by means Shutdown Alarm.
of pressing the load button ALARM
before the machine is ready to be Active & not-acknowledged
loaded. Non-Shutdown Alarm.
PRESET ALARM
Depending of which Pressure Active & acknowledged Alarm.
(and/or Flow) setting is active,
the controller will show its
dedicated icon.
PRESET
Depending of which Pressure
(and/or Flow) setting is active,
the controller will show its
dedicated icon.

- 35 -
Possible views

Main View Setup View Alarm View

Use the Up and Down navigation buttons to scroll Use the Up and Down navigation buttons to scroll
Measuring View through the full list of settings. through the full list of alarms.
Use the Enter button to enter the selected submenu. The DM Lists and the Log Lists can be selected and
MEASUREMENTS Use the Back button to leave the entered (sub) menu. entered to access the sublist.
LOADED

Running Hours 1286h

ECU Engine r pm 1300 r pm
ECU Requested Speed 1300 r pm
ECU DPF Soot Load 24 %
Vessel Pressure 22.4 bar
HP Element Temperature 1 01 C
Ambient Temperature 27 C

41% 1286h 1300RPM 22.4bar

Use the Up and Down navigation buttons to scroll

through the full list of measurements.

- 36 -
STARTING
Switch on the battery switch if so equipped. The actual vessel pressure is shown. If the measured The machine is now ready to be started and is waiting
Switch the controller on by pressing the power button. vessel pressure is higher than 1.5 bar, the unit will not for a start command.
start. The vessel pressure has to be lowered by
The instrument panel will now perform a self test; the opening the blow down valve. After power up, the
following display will be shown and the controller is Active Buttons
vessel pressure normally is low enough to proceed
initialized: with the starting procedure. Start Button
(to initiate Start command)

Active Buttons Measurement View Button

Measurement View Button

Settings View Button

Xc2003 Settings View Button

Alarms View Button
v1.00.05
Alarms View Button

During initializing all buttons/inputs/outputs/alarms

The display now shows
are inactive.
This view will be shown for about 2 seconds, after
which the display will show the Main View.

- 37 -
The display now shows The display now shows The engine starts cranking, the display shows

VUE PRINCIPALE

DÉMARRAGE MOTEUR

0RÉGIME 800RÉGIME
324RÉGIME

40% 1286h 324RÉGIME 0,0bar

After pressing the START button, the engine The engine cranks until 800 rpm is reached.
electronics (ECU) will be powered up. Active Buttons
If 800 rpm is not reached within 30 seconds, the
As soon as communication between compressor
Stop Button starting procedure is cancelled and the engine will
controller and engine controller is established, the
(to cancel Start command) rest for some time. (Resting time depends on cranking
machine will preheat according to the parameters of
time).
the engine controller.
Measurement View Button

Settings View Button

Alarms View Button

- 38 -
The display now shows The engine starts running at idle speed. The display The display now shows
shows

VUE PRINCIPALE
VUE PRINCIPALE
RÉCHAUFFAGE DU MOTEUR
MOTEUR AU REPOS
VUE PRINCIPALE

RÉCHAUFFAGE DU MOTEUR

0s 30s
0s 120s 7s
54s
13°C 40°C
25°C
0s 300s
76s 40% 1286h 1200RÉGIME 2,7bar
40% 1286h 324RÉGIME 0,0bar

40% 1286h 1200RÉGIME 0,0bar

Active Buttons
Active Buttons The engine will run at minimum rpm, until the
engine’s coolant temperature reaches 40° C (104° F), Stop Button
Stop Button (to cancel Start command)
(to cancel Start command) with a minimum time of 15 seconds and a maximum
time of 300 seconds.
Measurement View Button
Measurement View Button

Settings View Button

Settings View Button

Alarms View Button

Alarms View Button

- 39 -
After warming up the machine is ready to be loaded The engine will now run at maximum rpm, the display During loading the following display is shown
and is waiting for a load command; the display shows will show (default display)

The loading valve will be energized and pressure The controller controls the speed of the engine in
starts building up. order to meet the requested working pressure, at the
Active Buttons
most economical fuel usage.
Stop Button Active Buttons
(to cancel Start command) Stop Button Active Buttons
(to cancel Start command)
Load Button Stop Button
(to initiate Automatic Load) (to cancel Start command)
Load Button
(to cancel Load command)
Load Button
Measurement View Button (to cancel Load command)
Measurement View Button

Settings View Button Measurement View Button

Settings View Button

Alarms View Button Settings View Button

Alarms View Button
Alarms View Button

- 40 -
During operation
The doors must be closed during
operation and may be opened for
short periods for inspection and
adjustments only.

Be aware not to touch hot or moving

parts when the door is open.

When the engine is running, the air

outlet valves (ball valves) must
always be put in a fully opened or
fully closed position.

Regularly carry out following checks:

1. Ensure that the regulating valve (RV) is cor-
rectly adjusted, i.e. starts decreasing the engine
speed when reaching the preset working pres-
sure in the receiver.
2. Check the air outlet temperature of the com-
pressor element.
3. Check the engine oil pressure, the coolant tem-
perature and display of control box.
4. Avoid the engine running out of fuel. Neverthe-
less, if this happens, fill the fuel tank and prime
the fuel system to speed up starting.

- 41 -
STOPPING

After pressing the STOP button the display will show: After cooling down the engine will stop and the
Active Buttons display will show
Start Button
(to initiate Start command) MAIN VIEW

ENGINE STOPPING

Measurement View Button

Settings View Button

Alarms View Button 41% 1286h --RPM 5.3bar

After a Stop command, or in case of a controlled stop

alarm, the machine will cool down and run at The engine is stopped, and the controller will do a
minimum rpm for 1 minute before it will stop. double check to see if the engine is really stopped.

Active Buttons
Start Button
(to initiate Start command)

Measurement View Button

Settings View Button

Alarms View Button

- 42 -
SHUTDOWN POWER OFF DIESEL PARTICULATE FILTER
Switch the controller off by pressing the Power REGENERATION
When the machine is shutdown due to a critical alarm
button. When the Diesel Particle Filter regeneration process
or an emergency stop the display will show
If the compressor is equipped with a battery switch: is kept at its default ‘AUTOMATIC’ setting, then the
DPF regeneration will be performed automatically
When the compressor is not in use, this switch must
when the Soot Load exceeds 60%.
always be in the “OFF” position.
The controller display will indicate an ongoing DPF
It is not allowed to use this switch as an emergency
Regeneration by showing the HEST icon (High
switch or for stopping the compressor.
Exhaust System Temperature):
It can damage the controller or the engine’s
Electronic Control Unit when using the battery switch
HEST Icon
for stopping.
Always first shut off the controller and wait until the
display is dark before switching the battery switch to
position “OFF”.

Active Buttons

Measurement View Button

Settings View Button

Alarms View Button

The DPF regeneration process will continue, until the

Enter Button Soot Load has become as low as possible, or until the
(to acknowledge the shown alarm)
engine is stopped.
When the DPF regeneration process is stopped, the
HEST icon will disappear from the display.

- 43 -
AUTOMATIC DPF REGENERATION If Enter is pressed within 10 seconds then the INHIBIT DPF REGENERATION
(DEFAULT) controller will allow the DPF regeneration to be When running in an environment where an elevated
In specific cases, when the engine speed is constant at completed before the engine is stopped. exhaust temperature is not allowed, it might be
Minimum RPM, it can happen that the DPF A full DPF Regeneration can take up necessary to inhibit DPF regeneration. This has to be
regeneration already starts from 30% Soot Load (LSR to an hour. done at Customer Service Level. Go to General
- Low Speed Regeneration). settings 1000.Parameter 1142 ECU DPF
If Enter is not pressed (within 10 seconds), then the
This can happen in following situations: Regeneration Enable - Set to "OFF". The controller
engine will be stopped after cooling down.
has now put the DPF Regeneration in a FORCED
• Warming Up
OFF mode, which is Inhibit DPF Regeneration.
• Not Loaded
• Loaded (when running in Unload condition - The compressor controller will communicate with the
minimum RPM) engine controller and the (RED) Inhibit DPF
• Cooldown
regeneration icon will appear:
When an LSR is ongoing while the soot load is less
than 60%, and the engine speed changes (engine is DPF Regeneration Inhibited.
stopped, machine gets loaded, …), then the DPF
Regeneration process will be stopped.
If the Soot Load is higher than 30% when cooling
down should start (then an LSR is expected to be
started) the controller will ask:

When the controller gets powered down, it will (at

next power up) fall back to its default settings,
meaning AUTOMATIC DPF regeneration.

- 44 -
INCREASING SOOT LOAD TURNING REGENERATION BACK TO AUTO SERVICE REGENERATION
When the DPF Regeneration is Inhibited, or when the Machine is not running: Machine is running:
engine does not get sufficient possibility to Power the controller down. At next power up, the • Press the Settings View Button
automatically perform a full DPF Regeneration, the DPF Regeneration settings will be back to default, • Enter the '7000 ENGINE' menu
Soot Load will exceed the normal levels. and an Automatic DPF Regeneration will take place • Go to parameter '7140 SERVICE REGEN-
The controller will show the DPF Regeneration at the soonest appropriate moment. ERAION'
Machine is running: • Scroll to Enable and change to "ON"
Needed Icon. In case of Inhibited DPF Regeneration,
the DPF Regeneration Needed Icon will overwrite the • Make sure parameter '1142 ECU DPF REGEN- Unit will not regenerate if soot level is
ERATION ENABLE' is set to "ON" not high enough.
DPF Inhibited Icon.
• Scroll down and Enter the 'MODE' parameter
• Scroll down and Enter the 'AUTOMATIC' set-
DPF Regeneration needed ting
• Press the Back button 3 times to get back to the
Main view

FORCE DPF REGENERATION

Machine is running:
• Press the Settings View Button
• Enter the '1000 GENERAL SETTINGS' menu
• Go to parameter '1130 STATIONARY
REGENERATION'
• Scroll to Enable and change to "ON"
• Go to parameter '1140 ECU DPF REGENERA-
TION'
• Scroll to Enable and change to "ON"
Unit will not regenerate if soot level is
Required Action: not high enough.
• Force DPF Regeneration, see paragraph
FORCE DPF REGENERATION
When DPF Regeneration is started, the DPF
Regeneration Needed icon will disappear and the
HEST icon will pop-up.

- 45 -
SETTINGS As soon as the fuel level is higher than the warning Set Language
level, the alarm icon will automatically disappear. Press the SETTINGS VIEW button.
For buttons to be used see “Control Panel”
As long as there is an alarm icon in the middle of the • scroll to ‘1000 GENERAL SETTINGS’
Acknowledge an Alarm bottom part of the view, all active acknowledged / • press ENTER
unacknowledged alarms can be seen by pressing the • scroll to ‘1300 LANGUAGES’
If an alarm becomes active, for example a Low Fuel
ALARM VIEW button • ENTER the LANGUAGES menu,
Level Warning:
Pressing the ALARM VIEW button again, will bring • ENTER the ‘SETTINGS’ parameter
you back to the Main View. • scroll to the preferred language
• press ENTER.
Set Clock Now press BACK until you’re back in the Main View
Press the SETTINGS VIEW button (or in the menu you require).
• Scroll to ‘1000 GENERAL SETTINGS’
• Press ENTER Set Units
• Scroll to ‘1290 DATE/TIME’ Press the SETTINGS VIEW button,
• ENTER the Date/Time menu • Scroll to ‘1000 GENERAL SETTINGS’
• Scroll to the parameter you want to change • Press ENTER
• ENTER this parameter. • Scroll to the unit you would like to change:
To change the ‘Month’, scroll to the preferred month ‘1340 TEMPERATURE UNITS’
then this alarm can be acknowledged by pressing the and press ENTER. ‘1350 PRESSURE UNITS’
ENTER button. If the fuel level is still low, the view To change any other setting, the highlighted figure is ‘1360 FUEL FLOW UNITS’
will change to: editable. • ENTER the preferred menu
• ENTER the ‘SETTINGS’ parameter
Scroll up/down and press ENTER to change. Use left/
• Scroll to the preferred setting
right to shift between editable figures.
• Press ENTER.
Now press BACK until you’re back in the Main View
Now press BACK until you’re back in the Main View
(or in the menu you require).
(or in the menu you require).

- 46 -
Change Display Settings Go To Diagnostics
Press the SETTINGS VIEW button Press the SETTINGS VIEW button
• Scroll to ‘1000 GENERAL SETTINGS’ • Scroll to ‘1000 GENERAL SETTINGS’
• Press ENTER • Press ENTER
• Scroll to ‘1310 DISPLAY BACKLIGHT’ • Scroll to ‘1150 DIAGNOSTICS’
• ENTER the DISPLAY BACKLIGHT menu • ENTER the Diagnostics menu,
• Scroll to the setting you would like to change • ENTER the ‘ENABLE’ parameter
• Press ENTER. • Scroll to ‘ON’ and press ENTER.
To change a setting, the highlighted figure is editable. Now the ECU will get power and one can perform
Scroll up/down and press ENTER to change. Use left/ ECU diagnostics (read DM1 List, DM2 List, ECU
right to shift between editable figure. values, perform engine diagnostics, …).
Now press BACK until you’re back in the Main View Now press BACK until you’re back in the Main View
(or in the menu you require). (or in the menu you require).
To leave Diagnostics, press the STOP button.
• ECU warning 7009 will be active while in diag-
nostics.

- 47 -
FAULT CODES When one of these parameters exceeds its specified
There are several parameters that are continuously limit the compressor will react depending the present
watched. status of the control box.

Alarm code Alarm text Fail class Trigger

1231 FUEL FILL CHECK Warning Xc
1503 INITIAL OVERHAUL REQUIRED Warning Xc
1522 MINOR OVERHAUL WITHIN ** H Warning Xc
1523 MINOR OVERHAUL WITHIN ** D Warning Xc
1524 MINOR OVERHAUL REQUIRED Warning Xc
1552 MAJOR OVERHAUL WITHIN ** H Warning Xc
1553 MAJOR OVERHAUL WITHIN ** D Warning Xc
1554 LOAD PREVENTION - FIRE RISK Inhibit Load Xc
1558 COMP. OIL CHANGE WITHIN ** H Warning Xc
1559 COMP. OIL CHANGE WITHIN ** D Warning Xc
2000 EMERGENCY STOP INPUT Shutdown Xc
2040 REMOTE EMERGENCY STOP Shutdown Xc
2070 COOLANT LEVEL LOW WARNING Warning Xc
2080 COOLANT LEVEL LOW SHUTDOWN Shutdown Xc
2090 DP AIRFILTERS HIGH Warning Xc
2100 NO PROJECTFILE DOWNLOADED Warning Xc
2752 NAM OILTRONIX BYPASS CIRCUIT Shutdown After Stop Xc
2762 NAM OILTRONIX CLOSED CIRCUIT Shutdown After Stop Xc
2772 NAM AIRXPERT OPENED CIRCUIT Shutdown Xc
2782 NAM AIRXPERT CLOSED CIRCUIT Shutdown Xc
3000 FUEL LEVEL LOW WARNING Warning Xc
3010 FUEL LEVEL LOW SHUTDOWN Controlled Stop Xc
3020 FUEL LEVEL SENSOR CIRCUIT Warning Xc
3050 VESSEL PRESSURE HIGH WARNING Controlled Stop Xc
3060 VESSEL PRESSURE HIGH SHUTDOWN Shutdown Xc
3070 VESSEL PRESSURE SENSOR CIRCUIT Shutdown Xc
3120 REGULATING PRESSURE SENSOR CIRCUIT Shutdown Xc

- 48 -
 Alarm code Alarm text Fail class Trigger
3170 AIR DISCHARGE PRESSURE SENSOR CIRCUIT Warning Xc
3320 INLET PRESSURE SENSOR CIRCUIT Shutdown Xc
3450 BATTERY LOW ALARM Indication Xc
3460 BATTERY HIGH ALARM Warning Xc
3660 FIRE RISK - CHECK OILSTOPVALVE Shutdown Xc
3680 OSV PRESSURE SENSOR CIRCUIT Controlled Stop Xc
3720 INTERSTAGE PRESSURE SENSOR CIRCUIT Warning Xc
4000 L.P. ELEMENT TEMPERATURE HIGH Warning Xc
4010 L.P. ELEMENT TEMP. ALARM 2 Controlled Stop Xc
4020 L.P. ELEMENT TEMP. ALARM 3 Shutdown Xc
4040 L.P. ELEMENT TEMP. SENSOR CIRCUIT Shutdown Xc
4070 AMBIENT TEMPERATURE SENSOR CIRCUIT Warning Xc
4100 AIR DISCHARGE TEMPERATURE ALARM 1 Warning Xc
4110 AIR DISCHARGE TEMPERATURE ALARM 2 Controlled Stop Xc
4120 A.D. TEMPERATURE SENSOR CIRCUIT Warning Xc
4150 H.P. ELEMENT TEMPERATURE ALARM 1 Warning Xc
4160 H.P. ELEMENT TEMPERATURE ALARM 2 Controlled Stop Xc
4170 H.P. ELEMENT TEMPERATURE ALARM 3 Shutdown Xc
4190 H.P. ELEMENT TEMP. SENSOR CIRCUIT Shutdown Xc
4220 AFTERCOOLER AIR TEMP SENSOR CIRCUIT Warning Xc
4230 AFTERCOOLER FREEZING DANGER Indication Xc
5200 AIR SHUT OFF Shutdown Xc
6190 CHARGE MONITORING FAIL Indication Xc
6327 START FAILURE Shutdown Xc
6329 STARTER SPEED TOO LOW Shutdown Xc
6388 VESSEL PRESSURE TOO LOW TO LOAD Indication Xc
6426 UNINTENTIONAL RUN Shutdown Xc
6427 RUN FAILURE Shutdown Xc
6428 STOP FAILURE Shutdown Xc
6708 DRAINING 1 Warning Xc

- 49 -
 Alarm code Alarm text Fail class Trigger
6709 DRAINING 2 Warning Xc
6749 OILTRONIX FUNCTIONALITY DISABLED Warning Xc
6760 OILTRONIX COUPLING FAILURE Shutdown After Stop Xc
6769 OILTRONIX COMPONENT FAILURE Shutdown Xc
6981 INLET VALVE POS. FAILURE Shutdown Xc
7002 ECU COMMUNICATION Shutdown Xc
7007 ECU RED LAMP Shutdown ECU
7008 ECU AMBER LAMP Warning ECU
7009 ECU PROTECT LAMP Warning ECU
7010 ECU ENGINE SPEED TOO LOW Shutdown Xc
7020 ECU ENGINE SPEED ALARM 2 Shutdown Xc
7030 ECU ENGINE COOLANT TEMP. ALARM Controlled Stop Xc
7050 ECU ENGINE AIR INLET TEMP. ALARM 1 Controlled Stop Xc
7100 ECU DPF SOOT LOAD HIGH Warning Xc
7110 PLEASE FORCE DPF REGENERATION ! Inhibit Load Xc
7120 LOAD PREVENTION - HIGH DPF SOOT LOAD Controlled Stop Xc
7130 SOOT LOAD TOO HIGH - CALL ATLAS COPCO Warning Xc
7222 COMBO COMMUNICATION FAILURE Warning Xc
7223 COMBO PA SENSOR WARNING Warning Xc
7224 COMBO RHA SENSOR WARNING Warning Xc
7225 COMBO TA SENSOR WARNING Warning Xc

- 50 -
Details of ECU triggered alarms can be monitored via the ECU DM1 LIST menu

In case of ECU AMBER LAMP or ECU PROTECT For following alarms, the Xc controller also shows ECU - AMBIENT AIR TEMPERATURE
LAMP: full text next to the SPN code: ECU - AIR INLET TEMPERATURE
Only possible when engine is running or if ECU - FUEL FILTER PRESSURE ECU - FUEL TEMPERATURE
Diagnostics Mode is active. ECU - INTERCOOLER TEMPERATURE ECU - OIL TEMPERATURE
Access the ECU DM1 LIST menu via Alarm ECU - FUEL PRESSURE ECU - ENGINE SPEED
View. ECU - FUEL FILTER PRESSURE ECU - INJECTOR 1
ECU - WATER IN FUEL ECU - INJECTOR 2
In case of ECU RED LAMP: ECU - OIL LEVEL ECU - INJECTOR 3
Do NOT acknowledge the ECU RED LAMP ECU - OIL FILTER PRESSURE ECU - INJECTOR 4
alarm. ECU - OIL PRESSURE ECU - INJECTOR 5
DM1 alarms are automatically copied into the ECU - TURBO BOOST PRESSURE ECU - INJECTOR 6
Alarm View, and can be read there. ECU - TURBO OIL PRESSURE ECU - INJECTOR 7
ECU - INTAKE MANIFOLD TEMPERATURE ECU - INJECTOR 8
For all ECU triggered alarms, the respective SPN ECU - AIR INLET PRESSURE ECU - SOOT LOAD
code is shown in the ECU DM1 LIST ECU - COOLANT TEMPERATURE
A full list of supported SPN codes is provided by the ECU - COOLANT LEVEL
engine manufacturer. ECU - SUPPLY VOLTAGE

- 51 -
Maintenance
LIABILITY SERVICE KITS

The manufacturer does not accept any liability for any A service kit is a collection of parts to fit a specific
damage arising from the use of non-original parts and repair or rebuilding task.
for modifications, additions or conversions made It guarantees that all necessary parts are replaced at
without the manufacturer’s approval in writing. the same time which improves the uptime of the unit.
The order numbers of the Service Kits are listed in the
SERVICE PAKS
Atlas Copco Parts List (ASL).
A Service Pak is a collection of parts to be used for a
specific maintenance task, e.g. after 400 and after Contact Atlas Copco.
1000 running hours.
It guarantees that all necessary parts are replaced at
STORAGE
the same time keeping down time to a minimum.
The order number of the Service Paks are listed in the Run the compressor regularly, e.g. twice a week, until
Atlas Copco Parts List (ASL). warm.
Load and unload the compressor a few times to
Use of service paks operate the unloading and regulating components.
Service Paks include all genuine parts needed for Close the air outlet valves after stopping.
normal maintenance of both compressor and engine.
If the compressor is going to be stored
Service Paks minimize downtime and keep your without running from time to time,
maintenance budget low. protective measures must be taken.
Order Service Paks at your local Atlas Copco dealer.

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PREVENTIVE MAINTENANCE SCHEDULE

The schedule contains a summary of the maintenance The maintenance schedule has to be seen as a
Unauthorised modifications can lead to
instructions. Read the respective section before taking guideline for compressors operating in a dusty
risk for injury or machine damage.
maintenance measures. environment typical for compressor applications.
Maintenance schedule can be adapted depending on
When servicing, replace all disengaged packings, e.g.
Always keep the machine tidy in order to application, environment and quality of maintenance.
gaskets, O-rings, washers.
prevent fire hazard.
For engine maintenance refer to Engine Operation
Manual.
Poor maintenance can void any
warranty claims.

MAINTENANCE SCHEDULE COMPRESSOR

To determine the maintenance intervals, use of service hours, or calendar time, whichever occurs first.
Maintenance schedule (running hrs) Daily Normal Yearly
Every 400 hours Or every 1000 hours
Service Paks 3002 6084 40 3002 6084 50
For the most important subassemblies, Atlas Copco has developed service kits that combine all wear parts. These service kits offer you the benefits of genuine parts,
save administration costs and are offered at a reduced price, compared to individual components. Refer to the parts list for more information on the contents of the
service kits.
Engine oil level Check
Compressor oil level Check
Coolant level (3) Check
Coolant (7) Analyse Analyse
Air filter vacuator valves Empty
Fuel filter water drain Drain
Air intake vacuum indicators Check
Electrolyte level and terminals of battery Check Check
Tyre pressure Check Check
Leaks in air-, oil- or fuel system Check Check
Coolers (Oil, Coolant, Inter-) Check Clean

- 53 -
MAINTENANCE SCHEDULE COMPRESSOR
To determine the maintenance intervals, use of service hours, or calendar time, whichever occurs first.
Maintenance schedule (running hrs) Daily Normal Yearly
Every 400 hours Or every 1000 hours
Engine minimum and maximum speeds Check Check
Torque of wheel nuts Check Check
Brake system (if installed) Check/Adjust Check/Adjust
Safety valve Test
Door hinges Grease Grease
Towing eye shaft or ball coupling and its shaft Grease Grease
Joints of height adjustment adjustable towbar Grease Grease
Shutdown switches Check
Pressure drop over separator element (2) Measure Replace(6)
Fan V-belts (3) Adjust Adjust
Fuel tank Clean Clean
Compressor oil Change
Compressor oil filter Replace
Air filter elements (1) Replace
Safety cartridges (1) Replace
Engine oil (3) (4) Change
Engine oil filter (3) Replace
Fuel filter (3) (5) Replace
Fuel prefilter (3) Replace
Engine inlet and outlet valves (3) Check
Flow restrictor in oil scavenge line Clean
Fan adaptor and bolts Check
Engine valve cover bolts Check/Adjust Check/Adjust
Engine thermostat valve Check
Vessel water drain Drain

- 54 -
Notes
1. More frequently when operating in a dusty
environment.
2. Replace the element when the pressure drop exceeds 0.8 bar.
3. Refer to the Cummins operation manual.
4. 400 hours only valid when using PAROIL SAE 15 W 40.
5. In case of poor fuel quality, replace fuel filter more frequently.
6. Clean retainer when replacing element.
7. The following part numbers can be ordered from Atlas Copco to check on inhibitors and freezing
point:
• 2913 0028 00: Refractometer
• 2913 0029 00: pH-meter
8. Replace all rubber flexibles each 6 years, according to DIN 20066.
9. Change coolant every 2 years (Or every 2000 hours).
10. Whatever occurs first.

- 55 -
OIL SPECIFICATIONS

It is strongly recommended to use Atlas PAROIL from Atlas Copco is the ONLY oil tested PAROIL releases excess heat efficiently, whilst
Copco branded lubrication oils for both and approved for use in all engines built into Atlas maintaining excellent bore-polish protection to limit
compressor and engine. Copco compressors and generators. oil consumption.
Extensive laboratory and field endurance tests on PAROIL has an excellent Total Base Number (TBN)
Atlas Copco equipment have proven PAROIL to retention and more alkalinity to control acid
Only use mineral based compressor oil match all lubrication demands in varied conditions. It formation.
PAROIL M Xtreme. meets stringent quality control specifications to PAROIL prevents soot build-up
ensure your equipment will run smoothly and
reliably. PAROIL is optimized for the latest low emission
High-quality, mineral, hydraulic or synthesized
The quality lubricant additives in PAROIL allow for EURO -3 & -2, EPA TIER II & III engines running on
hydrocarbon oil with rust and oxidation inhibitors,
extended oil change intervals without any loss in low sulphur diesel for lower oil and fuel consumption.
anti-foam and anti-wear properties is recommended.
The viscosity grade should correspond to the ambient performance or longevity. PAROIL E xtra is a synthetic ultra high performance
temperature and ISO 3448, as follows: PAROIL provides wear protection under extreme diesel engine oil with a high viscosity- index. Atlas
conditions. Powerful oxidation resistance, high Copco PAROIL E xtra is designed to provide
chemical stability and rust- inhibiting additives help excellent lubrication from start-up at temperatures as
Never mix synthetic with mineral oil. reduce corrosion, even within engines left idle for low as -25° C (-13° F).
Remark: extended periods. PAROIL E is a mineral based high performance
When changing from mineral to PAROIL contains high quality anti-oxidants to diesel engine oil with a high viscosity- index. Atlas
synthetic oil (or the other way around), control deposits, sludge and contaminants that tend to Copco PAROIL E is designed to provide a high level
you will need to do an extra rinse: build up under very high temperatures. PAROIL's of performance and protection under ‘standard’
detergent additives keep sludge forming particles in a ambient conditions from -5°C (23°F) onward.
After a complete change over to fine suspension, instead of allowing them to clog your
synthetic oil, run the unit for a few filter and accumulate in the valve/rocker cover area.
minutes to allow proper and complete
circulation of the synthetic oil.
Then drain the synthetic oil again and
fill again with new synthetic oil. To set
correct oil levels, follow the normal
instructions.

- 56 -
COMPRESSOR OIL

Synthetic compressor oil PAROIL S

Liter US gal Order number
50˚ C 122˚ F can 5 1.3 1615 5950 01

40˚ C 104˚ F
can 20 5.3 1615 5951 01
PAROIL S xtreme

PAROIL S xtreme
barrel 210 55.2 1515 5952 01
30˚ C 86˚ F
container 1000 265 1604 7422 00
20˚ C 68˚ F
PAROIL S

PAROIL S
10˚ C 50˚ F Mineral compressor oil PAROIL M
-0˚ C 32˚ F Liter US gal Order number
-10˚ C 14˚ F can 5 1.3 1615 5947 00
-20˚ C -4˚ F can 20 5.3 1615 5948 00
-30˚ C -22˚ F barrel 210 55.2 1615 5949 00
-40˚ C -40˚ F container 1000 265 1630 0310 00

Choose your compressor oil based on the ambient

temperatures in the actual operating area.

- 57 -
ENGINE OIL

Synthetic engine oil PAROIL E xtra 1

6
Liter US gal Order number
PAROIL E MISSION GREEN
50˚ C 122˚ F can 5 1.3 1630 0135 01

PAROIL E MISSION GREEN

40˚ C 104˚ F
can 20 5.3 1630 0136 01
barrel 210 55.2 1626 0102 00
30˚ C 86˚ F
PAROIL E xtra

PAROIL E xtra
20˚ C 68˚ F Mineral engine oil PAROIL E
10˚ C 50˚ F
Liter US gal Order number
-0˚ C 32˚ F can 5 1.3 1615 5953 00
-10˚ C 14˚ F can 20 5.3 1615 5954 00
-20˚ C -4˚ F barrel 210 55.2 1615 5955 00
-30˚ C -22˚ F container 1000 264.17 1630 0096 00
-40˚ C -40˚ F

Choose your engine oil based on the ambient

temperatures in the actual operating area.

- 58 -
OIL LEVEL CHECK CHECK COMPRESSOR OIL LEVEL ENGINE OIL AND OIL FILTER CHANGE

See section Preventive maintenance schedule.

CHECK ENGINE OIL LEVEL

Consult the Engine Operation Manual for the oil

specifications, viscosity recommendations and oil
change intervals.
For intervals, see Preventive maintenance schedule.
Check engine oil level in accordance to the
instructions in the Engine Operation Manual and if
necessary, top up with oil.

With the unit standing horizontal, check the level of

the compressor oil.The level of oil must register in the
upper extremity of the middle of the oil level gauge
(3). Add oil if the level of the oil lower than the
middle of the oil level gauge (3) and should be lower
than the level of the oil level gauge (2).
Before removing the oil filler plug (1),
ensure that the pressure is released by
opening the air outlet valve (4).

Level of the compressor oil must register

in the upper extremity of the middle of
the oil level gauge (3) to assure the
cooling of element.

- 59 -
TOPPING UP THE COMPRESSOR OIL COMPRESSOR OIL AND OIL FILTER 1. Run the compressor until warm. Close the outlet
CHANGE valve (3) and stop the compressor. Wait until the
pressure is released through the automatic blow-
down valve. Unscrew the oil filler plug (2) by a
single turn. This uncovers a vent hole, which
permits any pressure in the system to escape.
2. Drain the compressor oil by removing all relevant
drain plugs. Drain plugs are fitted at the air
receiver (drain plug (4)), compressor element and
compressor oil cooler. Catch the oil in a drain pan.
Unscrew the filler plug (2) to speed up the
draining. After draining, repositon and tighten the
drain plugs
3. Remove the oil filter (1), e.g. by means of a
special tool. Catch the oil in a drain pan.
4. Clean the filter seat on the manifold, taking care
that no dirt drops into the system. Oil the gasket of
the new filter element. Screw it into place until the
gasket contacts its seat, then tighten one half turn
The quality and temperature of the oil determine the only
oil change interval.
5. Fill the air receiver until the level of compressor
The prescribed interval is based on normal operating oil reaches the middle of the oil level gauge (5).
1. Stop the compressor and make sure that all conditions and an oil temperature of up to 100°(212°F Be sure that no dirt gets into the system. Reinstall
pressure is released by opening the filler plug (1) ). (See section Preventive maintenance schedule). and tighten the filler plug (2).
on turn.
When operating in high ambient temperatures, in very 6. Start the compressor and let it run unloaded for a
2 Wait for few minutes until the oil level is constant dusty or high humidity conditions, it is recommended few minutes.
(oil level gauge (2)&(3)). to change the oil more frequently
7. Stop the compressor, wait a few minutes and top
up with oil until the level of compressor oil
In this case, contact Atlas Copco. reaches the middle of the oil level gauge (5).
Never add more oil. Overfilling results in
oil consumption.

- 60 -
COMPRESSOR OIL FLUSHING PROCEDURE

Not respecting compressor oil changing 4. Check the interior of the oil vessel (see pictures).
intervals in accordance with the If varnish deposits are discovered, contact Atlas
maintenance schedule, can lead to Copco Service dept. and do not continue.
serious problems, including fire hazard! 5. Put in a new oil separator, screw on new
The manufacturer does not accept any compressor oil filter(s) and close the oil vessel
liability for damage arising from not according to the instructions.
following the maintenance schedule or
not using genuine parts. 6. Fill the oil vessel with the minimum amount of
replacement oil, run the compressor under light
To avoid problems when changing over to a new type load conditions for 30 minutes.
of oil (see table) a special Compressor Oil Flushing 7. Thoroughly drain the system when the oil is
Procedure has to be followed. The table is only valid warm, leaving as little oil in the system as
when the replaced oil has not exceeded its lifetime. possible, especially in dead areas, if possible blow
For more information consult Atlas Copco Service Vessel cover
out remaining oil by pressurising the oil. contaminated clean
dept.
8. Fill the system with the final oil charge.
Aged oil can be recognized best by using an oil
sampling analysis program. Indicators for aged oil are 9. Run the compressor under light load conditions
strong smell, or contamination such as sludge and for 15 minutes and check for leakage.
varnish inside the oil vessel and oil stop valve or a 10. Check the oil level and top up if necessary.
brownish colour of the oil.
11. Collect all waste lubricant used during the
Whenever aged oil is discovered, eg. when changing flushing process and dispose of it in accordance
the oil separator, contact Atlas Copco Service dept. to with the applicable procedures for managing
have your compressor cleaned and flushed. waste lubricant.
1. First thoroughly drain the system when the oil is
warm, leaving as little oil in the system as
possible, especially in dead areas, if possible blow
out remaining oil by pressurising the oil system. Vessel
Check the instruction manual for detailed contaminated clean
description.
2. Remove the compressor oil filter(s).
PAROIL S PAROIL M
3. Open the oil vessel and remove the oil separator
element. PAROIL S draining * draining
PAROIL M draining draining *
Instructions on replacing the oil
separator element are available from * When changing over to the same oil within the oil changing interval, draining is sufficient
Atlas Copco Service dept. ** Change over not recommended

- 61 -
COOLANT SPECIFICATIONS PARCOOL EG

PARCOOL EG is the only coolant that has been Because PARCOOL EG inhibits corrosion, deposit
It is strongly recommended to use Atlas tested and approved by all manufacturers of formation is minimized. This effectively eliminates
Copco branded coolant. engines currently used in Atlas Copco flow restriction problems through the engine coolant
The use of the correct coolant is important for proper compressors and generators. ducts and the radiator, minimizing the risk of engine
heat transfer and protection of liquid-cooled engines. overheating and possible failure.
Atlas Copco's PARCOOL EG extended life coolant is
Coolants used in these engines must be mixtures of the new range of organic coolants purpose-designed It reduces water pump seal wear and has excellent
good quality water (distilled or de-ionised), special to meet the needs of modern engines. PARCOOL EG stability when subjected to sustained high operating
coolant additives and anti-freeze, if required. Coolant can help prevent leaks caused by corrosion. temperatures.
that is not to manufacturer's specification will result PARCOOL EG is also fully compatible with all
in mechanical damage of the engine. PARCOOL EG is free of nitride and amines to protect
sealants and gasket types developed to join different your health and the environment. Longer service life
The freezing point of the coolant must be lower than materials used within an engine. reduces the amount of coolant produced and disposal
the freezing point that can occur in the area. The PARCOOL EG is a ready to use Ethylene Glycol requirements, which limits environmental impact.
difference must be at least 5°C (9°F). If the coolant based coolant, premixed in an optimum 50/50
freezes, it may crack the cylinder block, radiator or dilution ratio, for antifreeze protection guaranteed to
coolant pump. -40°C (-40°F).
Consult the engine's operation manual and follow the
manufacturer's directions.
PARCOOL EG
Never mix different coolants and mix the
coolant components outside the cooling Liter US gal Order number
system. can 5 1.3 1604 5308 01
can 20 5.3 1604 5307 02
barrel 210 55.2 1604 5306 01
To ensure protection against corrosion, cavitation and formation of deposits, the concentration of the additives
in the coolant must be kept to certain limits, as stated by the manufacturer's guidelines. Topping up the coolant
with water only, changes the concentration and is therefore not allowed.
Liquid-cooled engines are factory-filled with this type of coolant mixture.

PARCOOL EG Concentrate
Liter US gal Order number
can 5 1.3 1604 8159 01

- 62 -
HANDLING PARCOOL EG COOLANT CHECK Glycol concentration measurement

PARCOOL EG should be stored at ambient Never remove the cooling system filler  To optimise the unique engine protection features
temperatures, while periods of exposure to cap while coolant is hot. of the PARCOOL EG, the concentration of the
temperatures above 35°C (95°F) should be Glycol in the water should always be above 33
The system may be under pressure. vol.%.
minimized. PARCOOL EG can be stored for a Remove the cap slowly and only when
minimum of 5 years in unopened containers without coolant is at ambient temperature. A  Mixtures exceeding a 68 vol.% mix ratio in water
any effect on the product quality of performance. sudden release of pressure from a heated are not recommended, as this will lead to high
PARCOOL EG is compatible with most other cooling system can result in personal engine operating temperatures.
coolants based on ethylene glycol, but you only get injury from the splash of hot coolant.  A refractometer can be ordered from Atlas Copco
the benefits of 5 years protection when its used on its with part number 2913 0028 00.
own. Exclusive use of PARCOOL EG is In order to guarantee the lifetime and quality of the
recommended for optimum corrosion protection and In case of a mix of different coolant
product, thus optimising engine protection, regular products this type of measuring might
sludge control. coolant-condition-analysis is recommended. provide incorrect values.
For simple density-measuring of Ethylene Glycol and The quality of the product can be determined by three
Propylene Glycol in general the standard available parameters:
‘density’ measuring devices are used to measure the
concentration of EG. In case a device is used to Visual check TOPPING UP/REPLACING COOLANT
measure EG, no PG can be measured afterwards as a
result of the difference in the density. More specific  Verify the appearance of the coolant with regard to  Verify whether the engine cooling system is in a
measurements can be done by the use of a its colour and make sure that no loose particles are good condition (no leaks, clean,...).
refractometer. This device can measure both EG and floating around.
PG. A mix of both products will be show unreliable  Check the condition of the coolant.
results! pH measurement  If the condition of the coolant is no longer up to
Mixed EG coolants with identical glycol type can be  Check the pH value of the coolant using a pH- standard, the complete coolant should be replaced
measured by use of a refractometer as well as the measuring device. (see section Replacing the coolant).
‘density’ system. The mixed coolants will be  The pH-meter can be ordered from Atlas Copco  Always top-up with PARCOOL EG Concentrate /
considered as one product. with part number 2913 0029 00. PARCOOL EG.
The use of distilled water is recommended. If you  Typical value for EG = 8.6.  Topping up the coolant with water only, changes
have exceptionally soft water it would be acceptable, the concentration of additives and is therefore not
as well. Basically, the engine metals are going to  If the pH-level is below 7 or above 9.5, the coolant allowed.
corrode to some extent no matter what water you use, should be replaced.
and hard water will encourage the resulting metal
salts to precipitate.
PARCOOL EG comes as a pre-mixed coolant to
safeguard the quality of the complete product.
It is recommended that topping up of the cooling
system is always done with PARCOOL EG.

- 63 -
 TOPPING UP WITHOUT DRAINING FROM THE COOLING SYSTEM

The quantity of PARCOOL EG Concentrate to be topped up can be estimated with the following formula and/or graph:

Corrections concentrate in measured system towards 50% volume by using PARCOOL EG Concentrate

PN: xxxx xxxx xx Example:

Total volume coolant = 14 Liter
Measured concentration = 33 Vol %
50- 33 = 17 * 14 / 50 = 4,8 Liter PARCOOL EG Concentrate

Top-up volume PARCOOL EG Concentrate without drainage

In case of expansion tank at low level, this quantity is to

be filled without draining from the cooling system.
6,0

5,5 1

5,0 2
4,5
Top-up volume (liter)

4,0

3,5
3
3,0

2,5

2,0
4
1,5
1 Refractometer indication -20° C (-4° F) (33%)
2 Refractometer indication -22° C (-7.6° F)
1,0

0,5
5 3 Refractometer indication -25° C (-13° F)
0,0
4 5 6 7 8 9 10 11 12 13 14 15 16 4 Refractometer indication -30° C (-22° F)
5 Refractometer indication -36° C (-32.8° F)

Engine coolant capacity (liter)

- 64 -
 TOPPING UP AFTER LIMITED QUANTITY DRAINING FROM THE COOLING SYSTEM

The quantity of PARCOOL EG Concentrate to be topped up after draining a calculated volume from the cooling system, can be
estimated with the following formula and/or graph:
Corrections concentrate in measured system towards 50% volume by using PARCOOL EG Concentrate
PN: xxxx xxxx xx Example:
Total volume coolant = 80 Liter
Measured concentration = 33 Vol %
50- 33 = 17 * 80 / 67 = 20 Liter PARCOOL EG Concentrate

100- 33 = 67
Top-up volume PARCOOL EG Concentrate with drainage
In case of expansion tank at normal level, this quantity is to
25,0 be drained from the cooling system.
22,5 1

20,0 2

17,5
Top-up volume (liter)

15,0 3

12,5

10,0
4
7,5

5,0
1 Refractometer indication -20° C (-4° F) (33%)
2,5
5 2 Refractometer indication -22° C (-7.6° F)
0,0 3 Refractometer indication -25° C (-13° F)
4 8 12 16 20 24 28 32 36 40 44 48 52 56 60 64 68 72 76 80 84
4 Refractometer indication -30° C (-22° F)
5 Refractometer indication -36° C (-32.8° F)

Engine coolant capacity (liter)

- 65 -
REPLACING THE COOLANT CLEANING COOLERS

Drain Steam cleaning in combination with a cleansing agent

 Completely drain the entire cooling system. may be applied (do not use jet at max. power).
 Used coolant must be disposed of or recycled in To avoid damaging the coolers, angle
accordance with legislation and local regulations. between jet and coolers should be
approx. 90 °.
Flush
 Flush twice with clean water. Used coolant must Close the service door(s).
be disposed or recycled in accordance with laws
Protect the electrical and controlling
and local regulations.
equipment, air filters, etc. against
 Using the Atlas Copco Instruction book, penetration of moisture.
determine the amount of PARCOOL EG required
Never leave spilled liquids such as fuel,
and pour into the radiator top tank.
oil, coolant and cleansing agents in or
 It should be clearly understood that proper around the compressor.
cleaning reduces contamination risks.
 In case of "other" coolant residues inside the Keep the compressor oil cooler and engine liquid
system, the coolant with the lowest properties cooler clean to maintain the cooling efficiency.
influences the quality of the ‘mixed’ coolant.
Remove any dirt from the coolers with a
Fill fibre brush. Never use a wire brush or
metal objects.
 To assure proper operation and the release of
trapped air, run the engine until normal engine Clean by air jet in the direction of the arrow.
operation temperature is reached. Turn off the
engine and allow to cool.
 From the Atlas Copco Instruction book, determine
the amount of PARCOOL EG required.
 Mix concentrate and water before filling.
 Fill with a maximum rate of 10 l/min (0.35 cu.ft/
min).
 Recheck coolant level and add coolant mixture if
necessary.

Caution: do not top up when the engine

is hot.

- 66 -
BATTERY CARE ACTIVATING A DRY-CHARGED BATTERY MAKE-UP DISTILLED WATER

Before handling batteries, read the  Take out the battery. The amount of water evaporating from batteries is
relevant safety precautions and act largely dependant on the operating conditions, i.e.
 Battery and electrolyte must be at equal
accordingly. temperatures, number of starts, running time between
temperature above 10 °C (50 °F).
start and stop, etc.
If the battery is still dry, it must be activated as  Remove cover and/or plug from each cell.
If a battery starts to need excessive make-up water,
described in section Activating a dry-charged  Fill each cell with electrolyte until the level this points to overcharging. Most common causes are
battery. reaches 10 mm (0.4 in) to 15 mm (0.6 in) above high temperatures or a too high voltage regulator
The battery must be in operation within 2 months the plates, or to the level marked on the battery. setting.
from being activated; if not, it needs to be recharged  Rock the battery a few times so that possible air If a battery does not need any make-up water at all
first. bubbles can escape; wait 10 minutes and check the over a considerable time of operation, an
level in each cell once more; if required, add undercharged battery condition may be caused by
ELECTROLYTE electrolyte. poor cable connections or a too low voltage regulator
 Refit plugs and/or cover. setting.

 Place the battery in the compressor.

Read the safety instructions carefully.

RECHARGING A BATTERY
Electrolyte in batteries is a sulphuric acid solution in
distilled water. Before and after charging a battery, always check the
electrolyte level in each cell; if required, top up with
The solution must be made up before being distilled water only. When charging batteries, each
introduced into the battery. cell must be open, i.e. plugs and/or cover removed.
Use a commercial automatic battery
charger according to its manufacturer’s
instructions.
Preferably use the slow charging method and adjust
the charge current according to the following rule of
thumb: battery capacity in Ah divided by 20 gives
safe charging current in Amp.

- 67 -
PERIODIC BATTERY SERVICE COMPRESSOR ELEMENT OVERHAUL

 Keep the battery clean and dry. When a compressor element is due for overhaul, it
needs to be done by Atlas Copco. This guarantees the
 Keep the electrolyte level at 10 to 15 mm above
use of genuine parts and correct tools with care and
the plates or at the indicated level; top up with
precision.
distilled water only. Never overfill, as this will
cause poor performance and excessive corrosion.
 Record the quantity of distilled water added.
 Keep the terminals and clamps tight, clean, and
lightely covered with petroleum jelly.
 Carry out periodic condition tests. Test intervals
of 1 to 3 months, depending on climate and
operating conditions, are recommended.
If doubtful conditions are noticed or malfunctions
arise, keep in mind that the cause may be in the
electrical system, e.g.loose terminals, voltage
regulator maladjusted, poor performance of
compressor, etc.

- 68 -
Adjustments and servicing procedures
ADJUSTMENT OF THE CONTINUOUS PNEUMATIC REGULATING SYSTEM
The working pressure is determined by the tension of
the spring in the regulating valve (RV). This tension
can be increased to raise the pressure and decreased
by turning the adjusting wheel clockwise and anti-
clockwise respectively.
To adjust the normal working pressure, proceed as
follows:

Be aware not to touch hot parts when the

door is open.

1. Loosen the lock nut of the regulating valve.

2. Release Regulating Valve (turn out).
3. With the outlet valves (AOV) closed, adjust the
regulating valve (RV), until a pressure is reached
of nominal pressure + 1.5 bar (+ 22 psi).
4. Lock the regulating valve (RV) by fixing the lock
nut.

- 69 -
AIR FILTER ENGINE/COMPRESSOR MAIN PARTS CLEANING THE DUST TRAP

Remove dust daily.

The Atlas Copco air filters are specially
designed for the application. The use of To remove dust from the dust trap squeeze the
non-originals air filters may lead to vacuator valve (6) several times.
severe damage of engine and/or
compressor element. CLEANING INSTRUCTIONS FILTER
Never run the compressor without air ELEMENT
filter element.
If element cleaning can not be avoided, care should be
taken that the filter element (4) is not washed out.
SERVICING Please note that engine damage can cause
considerable costs, which makes the cost of a new
Always select the service point according to the filter element seam insignificant.
vacuum indicator or display message. A regular
inspection or cleaning as it is sometimes practiced in Safety cartridges (3) can not be cleaned but must be
the field is more likely to be damaging than useful as exchanged.
there is a risk that the element will be damaged and Please note that a cleaned element will never match
dust will gain access to the engine. the service life and performance of a new element.
Atlas Copco always recommends exchanging 1. Snap clips 4. Filter element Take the element from the air filter housing (5) (see
rather than cleaning the filter element in order to 2. Dust trap cover 5. Filter housing section Replacing the air filter element).
avoid damage and ensure maximum engine 3. Safety cartridge 6. Vacuator valve
protection. (option)

- 70 -
 REPLACING THE AIR FILTER ELEMENT

New elements must also be inspected for tears or

punctures before installation.
Discard the element (4) when damaged.
A dirty safety cartridge (3) is an indication of a mal-
functioning air filter element. In that case replace the
element and safety cartridge.
The safety cartridge cannot be cleaned.

1. Release the snap clips (1) and remove the dust trap
(2). Clean the trap.
2. Remove the element (4) and the safety cartridge.
In order to clean, position a pipe with an end bent by 3. Reassemble in reverse order of dismantling. Make
approx. 90° on the end of a compressed-air pistol. The sure the vacuator valve (5) points down.
pipe must be long enough to reach the bottom of the 4. Inspect and tighten all air intake connections.
filter element. Carefully blow out the filter element
with dry compressed air (max. 5 bar (72.5 psi)) from
the inside to the outside until there is no more
development of dust. The end of the pipe must not
touch the element.
Next carefully examine the element for possible
damage. Never beat or knock the element as this will
damage it and there will be a danger of damage to the
engine.
Carefully clean the inside of the housing and put the
element in the housing (see section Replacing the air
filter element).

- 71 -
AIR RECEIVER SAFETY VALVE FUEL SYSTEM

All adjustments or repairs are to be done PRIMING INSTRUCTIONS

by an authorized representative of the
valve supplier, see section Specific safety Fuel leaked or spilled onto hot surfaces
precautions. or electrical components can cause a fire.
To help prevent possible injury, turn the
“ON/OFF” switch in position “OFF”
Following checks must be carried out on the safety when changing fuel filters or water
valve (2): separator elements. Clean up fuel spills
 A check of the opening of the lifting gear, twice a immediately.
year.
This can be done by screwing the cap of the valve Prime the fuel system in order to fill the fuel filter.
anti-clockwise. Prime the fuel system in order to purge trapped air.
 an annual check of the set pressure according to The fuel system should be primed under the following
local regulations. This check cannot be done on conditions:
the machine and must be carried out on a proper  Compressor is put in operation for the first time
test bench.
 Running out of fuel
 Storage
 Replacement of the fuel filter
The air receiver (1) is tested according to official
standards. Carry out regular inspections in conformity Do not loosen the fuel lines at the fuel
with local regulations. manifold. The fittings may be damaged
and/or a loss of priming pressure may
Daily drain condensate. occur when the fuel lines are loosened.

- 72 -
DRAINING INSTRUCTIONS

Replacing the filter elements:

Installation instructions:
1. Drain fuel from the bowl.
2. Remove filter (2, 3), filter element (4) and
separate bowl (2) from element (3).
3. Apply film of gas oil to new bowl seat.
4. Screw bowl (2) to new element (3) tightly by
hand.
5. Apply film of gas oil to new element seals.
6. Screw on filter (2, 3) and filter element (4) tightly
by hand.
7. Open head vent and operate pump (5). Close vent
when fuel begins to purge.
1. Open bowl drain valve (1), operate pump (5) and
pump water out. 8. Check for leaks, re-tighten if necessary.
2. Close drain valve (1).

- 73 -
Problem solving
It is assumed that the engine is in good condition and Make sure that the wires are not damaged and that
that there is adequate fuel flow to the filter and they are clamped tight to their terminals.
injection equipment. For denomination of switches, relays, etc., see
Electric system.
An electrical fault must be traced by an See also section Control panel.
electrician.

Problem: Compressor capacity or pressure below normal.

Possible faults Corrective actions

Air consumption exceeds capacity of compressor. Check equipment connected.
Choked air filter elements (AF). Remove and inspect elements. Clean or replace, if necessary.
Regulating valve (RV) defective. Have regulating valve removed and inspected by an Atlas Copco Service representative.
Blow down valve stuck in open position. Check and correct as necessary.
Loading valve (LV) leaking past O-ring. With compressor running at max. load speed, disconnect hose leading to unloader. If air leaks
from the hose, remove and inspect loading valve. Replace damaged or worn O-rings.
Oil separator element clogged. Have element removed and inspected by an Atlas Copco Service representative.
Air intake throttle valve remains partially closed. Remove air filters, air intake manifold and throttle valve spring seat. Withdraw the valve and
inspect. Replace parts where necessary. Caution: the spring seat is fixed with 4 short and 2 long
setscrews: first remove the short screws, then release the spring tension unscrewing the long
ones.
Safety valve (SV) leaking. Remove and inspect. Replace if not airtight after re-installation.
Blow-off valve leaking. Remove and inspect. Replace if necessary.

- 74 -
Problem: Pressure in air receiver rises above maximum and causes safety valve to blow.

Possible faults Corrective actions

Regulating valve (RV) opens too late or its ball valve spring is broken. Have regulating valve removed and inspected by an Atlas Copco Service representative.
Air leaks in regulating system. Check hoses and their fittings. Stop leaks; replace leaking hoses.
Air intake throttle valve does not close for some reason. Remove air filters, air intake manifold and throttle valve spring seat. Withdraw the valve and
inspect. Replace parts where necessary. Caution: the spring seat is fixed with 4 short and 2 long
setscrews: first remove the short screws, then release the spring tension unscrewing the long
ones.
Minimum pressure valve malfunctioning. Remove and inspect valve.
Blow-off valve malfunctioning. Remove and inspect valve.

Problem: After working some time, the unit stops through a shutdown switch.

Possible faults Corrective actions

Engine oil pressure too low. Refer to the engine instruction manual.
Compressor or engine overheating. See corrective actions “Compressor overheating”.
Fuel tank contains insufficient fuel. Fill fuel tank.
Low coolant level. Top up cooling system.

Problem: Air and oil mist expelles from air filters immediately after stopping.

Possible faults Corrective actions

Check valve at element outlet. Remove and inspect. Replace if necessary. Replace air filter elements and safety cartridges.
Check the oil level and add oil if necessary. Run the compressor for a few minutes, stop and
recheck oil level.
Plunger of oil stop valve jammed. Remove and inspect. Replace if necessary. Replace air filter elements and safety cartridges.
Check the oil level and add oil if necessary. Run the compressor for a few minutes, stop and
recheck oil level.

- 75 -
Problem: Compressor overheating.

Possible faults Corrective actions

Insufficient compressor cooling. Locate compressor away from walls; when banked with other compressors, leave space
between them.
Oil cooler clogged externally. Clean oil cooler. Refer to section Cleaning coolers.
Oil cooler clogged internally. Consult Atlas Copco.
Oil filters clogged. Replace oil filters.
Oil level too low. Check oil level. Top up with recommended oil if necessary.
Thermostatic by-pass valve remains stuck in opened position. Remove valve and check for proper opening and closing. Replace if out of order.
Fan blade(s) broken. Check and correct if necessary.
Oil stop valve malfunctioning. Remove and inspect valve.
Oil separator element (OS) clogged. Have element removed and inspected by an Atlas Copco Service representative.

Alternator precautions
1. Never reverse the polarity of the battery or the alternator.
2. Never break any alternator or battery connections while the engine is running.
3. When recharging the battery, disconnect it from the alternator. Before using booster cables to start the engine, be sure of the polarity and connect the batteries correctly.
4. Never operate the engine without the main or voltage sensing cables connected in the circuit.

- 76 -
Available options
Support Spark arrestor Customer colour canopy (1 colour)
A rigid support mounted version for rough The spark arrestor option prevents burning particles Special colour will apply on all external canopy parts
construction conditions with the possibility to be leaving the exhaust system. This reduces the fire or all internal parts visible from the outside, and
mounted on a truck. The installation allows the unit to hazard in dry conditions to protect the environment wheel rims. The undercarriage, towbar and frame will
be put on and taken off the truck daily. It is possible and also enables units to be operated in closed be painted in black.
to handle the unit with a forklift. environments where there is a fire risk.
Customer colour canopy (2 colours)
Fix height towbar with brakes Inlet shutdown Same to Customer colour (1) option, but with two (2)
A fix towbar with integrated parking brake. The inlet shutdown provides protection to the diesel colours for which the customer will provide details.
engine against over speeding caused by failure of the
Adjustable height towbar with brakes engine regulator, burning oil from the engine sump Customer colour frame (1 colour)
A dual-hinged articulating towbar assembly, with due to overfilling or aspiration of combustible fumes Customer colour for undercarriage, towbar and
integrated parking brake. in hazardous environments. The inlet shutdown frame.
system is fully electronic.
DIN/NATO/ITA eye COSMOS
Refinery package
Towing eye according to DIN, NATO or ITA Comprehensive Service and Monitoring System for
specification. The refinery package is a combination of the Spark global remote monitoring and fleet management.
arrestor and Inlet shutdown options.
Road signalization FuelXpert
Aftercooler
A road signalisation option compliant with European The FuelXpert optimizes the fuel consumption during
regulations. The rear lights are protected by the The aftercooler option includes a bypass valve when operation at partial load conditions.
canopy or the bumper bar against external damage. operating at ambient temperatures at below 10° C
(50° F). The bypass valve must be open to prevent the
Road signalization USA system from freezing. Frost can damage the
aftercooler.
Additional side mounted lights to meet North
American road signalization requirements.

- 77 -
Technical specifications
TORQUE VALUES CRITICAL TORQUE VALUES

GENERAL TORQUE VALUES

Assemblies Torque value (Nm / lbf.ft)
The following tables list the recommended torques applied for general applications Axles to frame:
during assembly of the compressor. Wheel nuts 270 (199.26)
For hexagon screws and nuts with strength grade 8.8 Bolts, front axle/frame 205 (151.29)
Thread size Torque value (Nm / lbf.ft) Bolts, rear axle/frame 205 (151.29)
Compressor to frame:
M6 8 (6) +/-25 %
Bolts, elements/gear casing 46 (33.95)
M8 20 (15) +/-25 %
Bolts, elements/support 80 (59.04)
M10 41 (30) +/-25 %
Bolts, support/buffer 205 (151.29)
M12 73 (54) +/-25 %
Bolts, buffer/frame 80 (59.04)
M14 115 (85) +/-25 %
Engine to frame:
M16 185 (137) +/-25 %
Bolts, engine/support 205 (151.29)
For hexagon screws and nuts with strength grade 12.9 Bolts, support/buffer 46 (33.95)
Bolts, buffer/frame 23 (16.97)
Thread size Torque value (Nm / lbf.ft) Lifting beams to frame:
M6 14 (10) +/-21 % Bolts, lifting beams/yoke (M12) 125 (92.25)
M8 34 (25) +/-23 % Bolts, lifting beams/yoke (M16) 205 (151.29)
M10 70 (52) +/-24 % Bolts, lifting beams/A-Frames 205 (151.29)
M12 120 (89) +/-25 % Bolts, A-Frames/frame 205 (151.29)
M14 195 (144) +/-23 % Hose clamps:
M16 315 (233) +/-23 % Pebra hose clamps on all IC/radiator 12 (8.85)
hoses

Secure the drain cock and tank cap of the fuel tank handtight.

- 78 -
COMPRESSOR / ENGINE SPECIFICATIONS
REFERENCE CONDITIONS

Designation Unit XAXS 600 XAVS 650 XAHS 750 XATS 800 XAMS 850
Absolute inlet pressure bar(e) 1 1 1 1 1
psi 14.5 14.5 14.5 14.5 14.5
Relative air humidity % 0 0 0 0 0
Air inlet temperature °C 20 20 20 20 20
°F 68 68 68 68 68
Nominal effective working pressure bar(e) 17 14 12 10.3 8.6
psi 250 200 175 150 125

The inlet conditions are specified at the air inlet grating outside the canopy.

- 79 -
LIMITATIONS

Designation Unit XAXS 600 XAVS 650 XAHS 750 XATS 800 XAMS 850
Minimum effective receiver pressure bar(e) 12 4 4 4 4
psi 174 58 58 58 58
Maximum effective receiver pressure, bar(e) 18.5 15.5 13.5 11.8 10.1
compressor unloaded
psi 268.25 224.75 195.75 171.1 146.45
Maximum ambient With °C 45 45 45 45 45
temperature at sea level
aftercooler °F 113 113 113 113 113
Without °C 50 50 50 50 50
aftercooler °F 122 122 122 122 122
Minimum starting temperature °C -10 -10 -10 -10 -10
°F 14 14 14 14 14
Minimum starting temperature, with coldstart °C -25 -25 -25 -25 -25
equipment
°F -13 -13 -13 -13 -13
Altitude capability See curve

- 80 -
ALTITUDE UNIT PERFORMANCE CURVE

XAXS 600 XAVS 650 XAHS 750

- 81 -
XATS 800 XAMS 850

- 82 -
PERFORMANCE DATA1)

At reference conditions, if applicable, and at normal shaft speed, unless otherwise stated.

Designation Unit XAXS 600 XAVS 650 XAHS 750 XATS 800 XAMS 850
Engine shaft speed, normal and maximum r/min 2000 2000 2000 2000 2000
Engine shaft speed, compressor unloaded r/min 1300 1300 1300 1300 1300
Free air delivery 2) l/s 277 307 343 372 403
cfm 587 651 727 788 854
m3/min 17 18 21 22 24
Fuel consumption
- at 100% FAD Fuel expert kg/h 38.92 38.92 38.92 38.92 38.92
lb/h 85.8 85.8 85.8 85.8 85.8
No Fuel expert kg/h 38.92 38.92 38.92 38.92 38.92

lb/h 85.8 85.8 85.8 85.8 85.8

- at 75% FAD Fuel expert kg/h 28.28 28.28 28.28 28.28 28.28
lb/h 62.3 62.3 62.3 62.3 62.3
No Fuel expert kg/h 34.60 34.60 34.60 34.60 34.60
lb/h 76.3 76.3 76.3 76.3 76.3
- at 50% FAD Fuel expert kg/h 22.68 22.68 22.68 22.68 22.68
lb/h 50 50 50 50 50
No kg/h 28.80 28.80 28.80 28.80 28.80
Fuel expert lb/h 63.5 63.5 63.5 63.5 63.5
- at 25% FAD Fuel expert kg/h 19.59 19.59 19.59 19.59 19.59
lb/h 43.2 43.2 43.2 43.2 43.2
No Fuel expert kg/h 22.12 22.12 22.12 22.12 22.12
lb/h 48.8 48.8 48.8 48.8 48.8
- at unload Fuel expert kg/h 16.44 16.44 16.44 16.44 16.44
lb/h 36.2 36.2 36.2 36.2 36.2

- 83 -
 Designation Unit XAXS 600 XAVS 650 XAHS 750 XATS 800 XAMS 850
No Fuel expert kg/h 16.44 16.44 16.44 16.44 16.44
lb/h 36.2 36.2 36.2 36.2 36.2
g/m3 39.0 29.1 29.1 29.1 26.8
Specific fuel consumption at 100% FAD lb/1000 2.44 1.81 1.81 1.81 1.67
cu.ft
mg/m3 <5 <5 <5 <5 <5
Typical oil content of compressed air oz/ <0.005 < 0.005 < 0.005 < 0.005 < 0.005
1000
cu.ft
g/h 11 11 11 11 11
Engine oil consumption (maximum)
oz/h 0.39 0.39 0.39 0.39 0.39
Compressed air temperature at °C 71 71 71 71 71
outlet valve
°F 160 160 160 160 160
Noise level
- Sound pressure level (LP), measured acc. to ISO dB(A) - - - - -
2151 under free field conditions at 7 m distance
- Sound power level (LW) complies with ISO 3744 dB(A) 97 97 97 97 97
84/533/EEC and 85/406/EEC limits dB(A) 110 110 110 110 110

1. Free Air Delivery (volume flow rate) is measured according to ISO 1217 ed.4 2009 annex D.
Tolerance:
 +!- 5% 25 1/s (53 cfm) < FAD < 250 1/s (530 cfm)
 +/- 4% 250 1/s (530 cfm) < FAD

- 84 -
DESIGN DATA

Compressor element

Designation XAXS 600, XAVS 650, XAHS

750, XATS 800, XAMS 850

Number of compression stages 1

Engine

Designation Unit XAXS 600, XAVS 650, XAHS 750, Designation Unit XAXS 600, XRHS 650,
XATS 800, XAMS 850 XAVS 650, XAHS 750,
XATS 800, XAMS 850
Make Cummins
Type QSB6.7-C260 Capacity of oil sump:
Coolant Liquid (glycol 50%) - Initial fill l 17.8
Number of cylinders 6 US gal 4.70
Bore mm 107 - Refill (max.)3) l 16.7
in 4.21 US gal 4.41
Stroke mm 124
in 4.88
Swept volume l 6.7
cu.in 408.86
Output acc. to SAE J1995 kW 194
at normal shaft speed BHP 260.15
- Load factor % 88

- 85 -
Compressor Unit

The international standard ISO 1217 corresponds to following national standards:

Designation Unit XAXS 600, XAVS 650,
XAHS 750, XATS 800, - British BSI 1571 part 1
XAMS 850 - German DIN 1945 Part 1
Capacity of oil sump l 21
- Swedish SS-ISO 1217
Initial fill US gal 5.55
- American ANSI PTC9
Capacity of cooling system l 35.5
3. With filter change.
US gal 9
4. Air required for engine and compressor cooling, combustion and for
Capacity of compressor oil l 60
compression.
system US gal 15.85
Net capacity of air receiver l 63.5
Compressor dimensions with brakes and adjustable towbar
US gal 16.77
Air volume at inlet grating m³/s 9.5
(approx.) 5) Designation Unit All units
cuft/s 335.49
2) Length mm 4945
Capacity of fuel tank l 320
m 197.8
US gal 85
Width mm 1987
1. At reference conditions, if applicable, and at normal shaft speed unless m 79.5
otherwise stated .
Height mm 2059
2.
m 82.4
Data Measured according Tolerance Weight (ready-to-operate) See indication on dataplate

Free air delivery ISO 1217 ed. 3 1996 annex D +/- 5% 251/s<FAD<2501/s
+/ - 4% 2501/s <FAD

- 86 -
Data plate

1. Name of the manufacturer

2. Product code
3. Model
4. Unit serial number
5. Working pressure
6. Speed
7. Engine power
8. Manufacturing year

- 87 -
Legislation Size 2 LP
PARTS, SUBJECTED TO PRESSURE EQUIPMENT DIRECTIVE 97/23/EC, CAT. II AND ABOVE
Safety valve: cat. IV

Designation Unit XAXS 600 XAVS 650 XAHS 750 XATS 800 XAMS 850
Set pressure bar(e) 21 18 18 16 16
psi 304 261 261 232 232
Design temperature °C 130 130 130 130 130
°F 266 266 266 266 266
PARTS, SUBJECTED TO SIMPLE PRESSURE VESSEL DIRECTIVE 87/404/EC
Air Oil separator

Designation Unit Standard Cold start equipment

Design pressure bar(e) 26 26
psi 377 377
Design temperature max. °C 130 130
°F 266 266
Design temperature min. °C -10 -25
°F 14 -13
Volume l 92 92
US gal 24.3 24.3
PARTS, SUBJECTED TO CAT. I AND COVERED BY THE MACHINE DIRECTIVE 89/392/EC
All other parts
PARTS, SUBJECTED TO ART. I, PARAGRAPH 3.3
All other parts

- 88 -
Disposal
GENERAL DISPOSAL OF MATERIALS

When developing products and services, Atlas Copco Dispose of contaminated substances and material
tries to understand, address, and minimize the separately, in accordance with locally applicable
negative environmental effects that the products and environmental legislation.
services may have, when being manufactured, Before dismantling a machine at the end of its
distributed, used and disposed. operating lifetime drain and dispose of all fluids of
Recycling and disposal policy are part of the according the applicable local disposal regulations.
development of all Atlas Copco products. Atlas Remove the batteries. Do not throw batteries into the
Copco company standards determine strict fire (explosion risk) or residual waste. Separate the
requirements. machine into metal, electronics, wiring, hoses,
Material selection, substantial recyclability, insulation and plastic parts.
disassembly possibilities and separability of materials Dispose of all components in accordance with
and assemblies are considered, as well as applicable disposal regulations.
environmental perils and dangers to health during the
recycling and disposal of the unavoidable rates of Remove spilled fluid mechanically; pick up the rest
non-recyclable materials. with absorbing agent (for example sand, sawdust) and
dispose of it in accordance with applicable local
Your Atlas Copco compressor consists for the most disposal regulations. Do not drain into the sewage
part of metallic materials, that can be remelted in system or surface water.
steelworks and smelting works and are therefore
almost infinitely recyclable. The plastic used is
labelled; sorting and fractioning of the materials for
recycling in the future is foreseen.

This concept can only succeed with your

help. Support us by disposing
professionally. By assuring correct
disposal of the product you help prevent
possible negative consequences for
environment and health as a result of
inappropriate waste handling.
Recycling and re-usage of material help
preserve natural resources.

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Maintenance Log

Compressor .......................................................................................... Customer ...............................................................................................

Serial number........................................................................................ ................................................................................................................

Service hours Maintenance action Date By: initials

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