Atlas Copco Instruction Manual - Northern Hire Group
Atlas Copco Instruction ManualInstruction Manualfor Portable CompressorsEnglishXAS 97 DD - XAS 185 DD7Engine Deutz D2011L03Engine Deutz F3M2011
Instruction Manualfor Portable CompressorsXAS 97 DD - XAS 185 DD7Printed matter N 9829 3095 0011/2008ATLAS COPCO - PORTABLE AIR DIVISIONwww.atlascopco.com
Warranty and Liability LimitationUse only authorized parts.Any damage or malfunction caused by the use of unauthorized parts is not covered by Warranty or ProductLiability.The manufacturer does not accept any liability for any damage arising for modifications, additions orconversions made without the manufacturer's approval in writing.While every effort has been made to ensure that the information in this manual is correct, Atlas Copco does notassume responsibility for possible errors.Copyright 2008, Atlas Copco Airpower n.v., Antwerp, Belgium.Any unauthorized use or copying of the contents or any part thereof is prohibited.This applies in particular to trademarks, model denominations, part numbers and drawings.-2-
PrefacePlease read the following instructions carefullybefore starting to use your compressor.It is a solid, safe and reliable machine, builtaccording to the latest technology. Follow theinstructions in this booklet and we guarantee youyears of troublefree operation.Always keep the manual available near the machine.In all correspondence always mention thecompressor type and serial number, shown on thedata plate.The company reserves the right to make changeswithout prior notice.Table of contents11.11.21.31.41.51.61.722.1Safety precautions . 5Introduction . 5General safety precautions . 6Safety during transport and installation . 7Safety during use and operation . 7Safety during maintenance and repair. 9Tool applications safety . 10Specific safety precautions. 112.2Leading particulars . 12Description of safety pictogramsused in this manual. 12General description . 1233.13.1.13.1.23.1.33.1.43.23.3Main Parts.Compressor regulating system .Overview.Air flow.Oil system .Continuous regulating system.Electric system .Markings and information labels .14161618192022274Operating instructions . 284.1Parking, towing and lifting instructions . 284.1.1Parking instructions . 284.1.2Towing instructions . 294.1.3Spillage-Free Instruction. 304.1.4Height adjustment . 304.1.5Lifting instructions. 314.1.6Anti-Frost Device (option). 31-3-4.2Starting / Stopping .4.3Before starting.4.3.1Starting procedures .4.3.2During operation .4.3.3Stopping procedure .4.3.4Fault situations and protective devices 125.135.145.15Maintenance .Use of service paks .Preventive maintenance schedulefor the compressor.Lubrication oils .Oil specifications.Compressor oil.Oil level check .Check engine oil level .Check compressor oil level.Oil and oil filter change .Engine oil and oil filter change.Compressor oil and oil filter change.Cleaning coolers.Cleaning fuel tank .Battery care .Electrolyte.Activating a dry-charged battery .Recharging a battery .Battery maintenance .Changing tyres .Storage .Service paks .Service kits.Compressor element 343444444444444
66.16.6.3Adjustments and servicing procedures .Adjustment of the continuousregulating system.Air filter engine/compressor.Main parts .Cleaning the dust trap .Replacing the air filter element .Air receiver.Safety valve .Fuel system.Brake adjustment.Brake shoe adjustment .Test procedure of brake cableadjustment .Brake cable adjustment .7Problem solving . 508Available options . al specifications .9.1Torque values .9.1.1General torque values.9.1.2Critical torque values .9.2Settings of shutdown switchesand safety valves .9.3Compressor / engine specifications.9.3.1Reference conditions.9.3.2Limitations .9.3.3Altitude unit performance curve .9.3.4Performance data.9.3.5Design data.1045454646464747474848481111.111.2Disposal . 63General . 63Disposal of materials. 6312Maintenance Log . 6449495454545455565657585960Dataplate . 62-4-
Safety precautionsTo be read attentively and acted accordingly before towing, lifting, operating, performingmaintenance or repairing the compressor.INTRODUCTIONThe policy of Atlas Copco is to provide the users oftheir equipment with safe, reliable and efficientproducts. Factors taken into account are amongothers:- the intended and predictable future use of theproducts, and the environments in which they areexpected to operate,- applicable rules, codes and regulations,- the expected useful product life, assuming properservice and maintenance,- providing the manual with up-to-dateinformation.Before handling any product, take time to read therelevant instruction manual. Besides giving detailedoperating instructions, it also gives specificinformation about safety, preventive maintenance,etc.Keep the manual always at the unit location, easyaccessible to the operating personnel.See also the safety precautions of the engine andpossible other equipment, which are separately sentalong or are mentioned on the equipment or parts ofthe unit.These safety precautions are general and somestatements will therefore not always apply to aparticular unit.Only people that have the right skills should beallowed to operate, adjust, perform maintenance orrepair on Atlas Copco equipment.It is the responsibility of management to appointoperators with the appropriate training and skill foreach category of job.Skill level 1: OperatorAn operator is trained in all aspects of operating theunit with the push-buttons, and is trained to know thesafety aspects.Skill level 2: Mechanical technicianA mechanical technician is trained to operate the unitthe same as the operator. In addition, the mechanicaltechnician is also trained to perform maintenance andrepair, as described in the instruction manual, and isallowed to change settings of the control and safetysystem. A mechanical technician does not work onlive electrical components.Skill level 3: Electrical technicianAn electrical technician is trained and has the samequalifications as both the operator and the mechanicaltechnician. In addition, the electrical technician maycarry out electrical repairs within the variousenclosures of the unit. This includes work on liveelectrical components.Skill level 4: Specialist from the manufacturerThis is a skilled specialist sent by the manufacturer orits agent to perform complex repairs or modificationsto the equipment.In general it is recommended that not more than twopeople operate the unit, more operators could lead tounsafe operating conditions.-5-Take necessary steps to keep unauthorized personsaway from the unit and eliminate all possible sourcesof danger at the unit.When handling, operating, overhauling and/orperforming maintenance or repair on Atlas Copcoequipment, the mechanics are expected to use safeengineering practices and to observe all relevant localsafety requirements and ordinances. The followinglist is a reminder of special safety directives andprecautions mainly applicable to Atlas Copcoequipment.These safety precautions apply to machineryprocessing or consuming air. Processing of any othergas requires additional safety precautions typical tothe application and are not included herein.Neglecting the safety precautions may endangerpeople as well as environment and machinery:- endanger people due to electrical, mechanical orchemical influences,- endanger the environment due to leakage of oil,solvents or other substances,- endanger the machinery due to function failures.All responsibility for any damage or injury resultingfrom neglecting these precautions or by nonobservance of ordinary caution and due care requiredin handling, operating, maintenance or repair, also ifnot expressly mentioned in this instruction manual, isdisclaimed by Atlas Copco.
The manufacturer does not accept any liability for anydamage arising from the use of non-original parts andfor modifications, additions or conversions madewithout the manufacturer’s approval in writing.If any statement in this manual does not comply withlocal legislation, the stricter of the two shall beapplied.Statements in these safety precautions should not beinterpreted as suggestions, recommendations orinducements that it should be used in violation of anyapplicable laws or regulations.GENERAL SAFETY PRECAUTIONS12345678The owner is responsible for maintaining the unitin a safe operating condition. Unit parts andaccessories must be replaced if missing orunsuitable for safe operation.The supervisor, or the responsible person, shall atall times make sure that all instructions regardingmachinery and equipment operation andmaintenance are strictly followed and that themachines with all accessories and safety devices,as well as the consuming devices, are in goodrepair, free of abnormal wear or abuse, and arenot tampered with.Whenever there is an indication or any suspicionthat an internal part of a machine is overheated,the machine shall be stopped but no inspectioncovers shall be opened before sufficient coolingtime has elapsed; this to avoid the risk ofspontaneous ignition of oil vapour when air isadmitted.Normal ratings (pressures, temperatures, speeds,etc.) shall be durably marked.Operate the unit only for the intended purpose andwithin its rated limits (pressure, temperature,speeds, etc.).The machinery and equipment shall be kept clean,i.e. as free as possible from oil, dust or otherdeposits.To prevent an increase in working temperature,inspect and clean heat transfer surfaces (coolerfins, intercoolers, water jackets, etc.) regularly.See the Preventive maintenance schedule forthe compressor.All regulating and safety devices shall bemaintained with due care to ensure that theyfunction properly. They may not be put out ofaction.-6-910111213141516Care shall be taken to avoid damage to safetyvalves and other pressure-relief devices,especially to avoid plugging by paint, oil coke ordirt accumulation, which could interfere with thefunctioning of the device.Pressure and temperature gauges shall be checkedregularly with regard to their accuracy. They shallbe replaced whenever outside acceptabletolerances.Safety devices shall be tested as described in themaintenance schedule of the instruction manualto determine that they are in good operatingcondition. See the Preventive maintenanceschedule for the compressor.Mind the markings and information labels on theunit.In the event the safety labels are damaged ordestroyed, they must be replaced to ensureoperator safety.Keep the work area neet. Lack of order willincrease the risk of accidents.When working on the unit, wear safety clothing.Depending on the kind of activities these are:safety glasses, ear protection, safety helmet(including visor), safety gloves, protectiveclothing, safety shoes. Do not wear the hair longand loose (protect long hair with a hairnet), orwear loose clothing or jewelry.Take precautions against fire. Handle fuel, oil andanti-freeze with care because they areinflammable substances. Do not smoke orapproach with naked flame when handling suchsubstances. Keep a fire-extinguisher in thevicinity.
SAFETY DURING TRANSPORT ANDINSTALLATIONWhen towing, lifting or transporting the compressorin any way, the battery switch must always be in the“OFF” position!To lift a unit, all loose or pivoting parts, e.g. doors andtowbar, shall first be securely fastened.Do not attach cables, chains or ropes directly to thelifting eye; apply a crane hook or lifting shacklemeeting local safety regulations. Never allow sharpbends in lifting cables, chains or ropes.Helicopter lifting is not allowed.It is strictly forbidden to dwell or stay in the risk zoneunder a lifted load. Never lift the unit over people orresidential areas. Lifting acceleration and retardationshall be kept within safe limits.1 Before towing the unit:- ascertain that the pressure vessel(s) is (are)depressurized,- check the towbar, the brake system and thetowing eye. Also check the coupling of thetowing vehicle,- check the towing and brake capability of thetowing vehicle,- check that the towbar, jockey wheel or standleg is safely locked in the raised position,- ascertain that the towing eye can swivel freelyon the hook,- check that the wheels are secure and that thetyres are in good condition and inflatedcorrectly,- connect the signalisation cable, check all lightsand connect the pneumatic brake couplers,- attach the safety break-away cable or safetychain to the towing vehicle,- remove wheel chocks, if applied, anddisengage the parking brake.2 To tow a unit use a towing vehicle of amplecapacity. Refer to the documentation of thetowing vehicle.3 If the unit is to be backed up by the towingvehicle, disengage the overrun brake mechanism(if it is not an automatic mechanism).4 Never exceed the maximum towing speed of theunit (mind the local regulations).5 Place the unit on level ground and apply theparking brake before disconnecting the unit fromthe towing vehicle. Unclip the safety break-awaycable or safety chain. If the unit has no parkingbrake or jockey wheel, immobilize the unit byplacing chocks in front of and/or behind thewheels. When the towbar can be positionedvertically, the locking device must be applied andkept in good order.6 To lift heavy parts, a hoist of ample capacity,tested and approved according to local safetyregulations, shall be used.7 Lifting hooks, eyes, shackles, etc., shall never bebent and shall only have stress in line with theirdesign load axis. The capacity of a lifting devicediminishes when the lifting force is applied at anangle to its load axis.8 For maximum safety and efficiency of the liftingapparatus all lifting members shall be applied asnear to perpendicular as possible. If required, alifting beam shall be applied between hoist andload.9 Never leave a load hanging on a hoist.10 A hoist has to be installed in such a way that theobject will be lifted perpendicular. If that is notpossible, the necessary precautions must be takento prevent load-swinging, e.g. by using two-7-hoists, each at approximately the same angle notexceeding 30 from the vertical.11 Locate the unit away from walls. Take allprecautions to ensure that hot air exhausted fromthe engine and driven machine cooling systemscannot be recirculated. If such hot air is taken inby the engine or driven machine cooling fan, thismay cause overheating of the unit; if taken in forcombustion, the engine power will be reduced.12 Before moving the compressor, switch it off.13 If the warning light on the ABS module or in thevehicle lights up, please contact Atlas Copco.SAFETY DURING USE AND OPERATION123When the unit has to operate in a fire-hazardousenvironment, each engine exhaust has to beprovided with a spark arrestor to trap incendiarysparks.The exhaust contains carbon monoxide which is alethal gas. When the unit is used in a confinedspace, conduct the engine exhaust to the outsideatmosphere by a pipe of sufficient diameter; dothis in such a way that no extra back pressure iscreated for the engine. If necessary, install anextractor. Observe any existing local regulations.Make sure that the unit has sufficient air intakefor operation. If necessary, install extra air intakeducts.When operating in a dust-laden atmosphere, placethe unit so that dust is not carried towards it by thewind. Operation in clean surroundingsconsiderably extends the intervals for cleaningthe air intake filters and the cores of the coolers.
4Close the compressor air outlet valve beforeconnecting or disconnecting a hose. Ascertainthat a hose is fully depressurized beforedisconnecting it. Before blowing compressed airthrough a hose or air line, ensure that the open endis held securely, so that it cannot whip and causeinjury.5 The air line end connected to the outlet valvemust be safeguarded with a safety cable, attachednext to the valve.6 No external force may be exerted on the air outletvalves, e.g. by pulling on hoses or by installingauxiliary equipment directly to a valve, e.g. awater separator, a lubricator, etc. Do not step onthe air outlet valves.7 Never move a unit when external lines or hosesare connected to the outlet valves, to avoiddamage to valves, manifold and hoses.8 Do not use compressed air from any type ofcompressor, without taking extra measures, forbreathing purposes as this may result in injury ordeath. For breathing air quality, the compressedair must be adequately purified according to locallegislation and standards. Breathing air mustalways be supplied at stable, suitable pressure.9 Distribution pipework and air hoses must be ofcorrect diameter and suitable for the workingpressure. Never use frayed, damaged ordeteriorated hoses. Replace hoses and flexiblesbefore the lifetime expires. Use only the correcttype and size of hose end fittings and connections.10 If the compressor is to be used for sand-blastingor will be connected to a common compressed-airsystem, fit an appropriate non-return valve (checkvalve) between compressor outlet and the
ATLAS COPCO - PORTABLE AIR DIVISION www.atlascopco.com Printed matter N 9829 3095 00 11/2008 Instruction Manual for Portable Compressors XAS 97 DD - XAS 185 DD7
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Press release from Atlas Copco AB Atlas Copco Group Center Atlas Copco AB Visitors address: Telephone: 46 8 743 8000 A Public Company (publ) SE-105 23 Stockholm Sickla Industriväg 19 www.atlascopcogroup.com Reg. . Corporate income tax amounted to MSEK -1 170 (-1 204), corresponding to an effective tax rate of 23.4% (24.5). Profit for the .
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