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Atlas Copco XAS96JD, Instruction Book

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Atlas Copco XAS96JD Instruction Book Download Page 12

12

1310 3011 08

Fig. 2.3 Compressor Regulating System

AF

Air Filter

AR

Air Receiver

AV

Air Outlet Valves

BDV Blow Down Valve
CE

Compressor Element

CV

Check Valve

DB

Drive Belt

DP

Drain Plug

E

Engine

F

Fan

FN

Flow Nozzle

FP

Filling Plug

FR

Flow Restrictor

OC

Oil Cooler

OF

Oil Filter

OLG Oil Level Gauge
OS

Oil Separator

PG

Pressure Gauge

RV

Regulating Valve

SL

Scavenge Line

SR

Speed Regulator

SV

Safety Valve

TS

Temperature Switch

UA

Unloader Assembly

UV

Unloader Valve

VH

Vent Hole

VI

Vacuum Indicator

2.4

 

Air Flow (See Fig. 2.3)

The system comprises:

AF

Air filter

AR/OS

Air receiver/oil separator

CE

Compressor element

UA/UV

Unloader assembly with unloader valve

BDV

Blow-down valve

FN

Flow nozzle

Air drawn through the airfilter (AF) into the compressor
element is compressed.  At the element outlet, compressed
air and oil pass into the air receiver/oil separator (AR/OS).

The check valve prevents blow-back of compressed air when the
compressor is stopped.  In the air receiver/oil separator AR//OS),
most of the oil is removed from the air/oil mixture: the remaining
oil is removed by the separator element.

The oil collects in the receiver and on the bottom of the separator
element.

The air leaves the receiver via a flow nozzle (FN) which prevents
the receiver pressure from dropping below the minimum working
pressure, even when the air outlet valves are open.  This ensures
adequate oil injection and prevents oil consumption.

A temperature switch (TS) and a working pressure gauge (PG) are
comprised in the system.

A blow-down valve (BDV) is fitted in the unloader assembly to
automatically depressurize the air receiver (AR) when the
compressor is stopped.

Summary of Contents for XAS96JD

Page 1: ...thorized use or copying of the contents or any part of this book is prohibited This applies in particular to trademarks model denominations part numbers and drawings No 1310 3011 08 Ed 0 1998 06 Atlas Copco Portable Compressors XAS96 Instruction Book 1310 3011 08 Ed 0 1998 06 ...

Page 2: ... Service plan First start up date Selected Lubricants Compressor Capacity Bearing grease type electric motor Printed Matter Nos Atlas Copco instruction book rev Atlas Copco logbook Atlas Copco parts list rev Engine parts list Local Atlas Copco Representative Name Address Telephone Contact persons Service Telefax Parts ...

Page 3: ... regulating system see Fig 2 3 13 2 7 Electrical System 14 3 Operating Instructions 16 3 1 Parking Towing And Lifting Instructions 16 3 2 Before Starting 16 3 3 Starting Stopping 17 3 4 During Operation 17 4 Maintenance 18 4 1 Use of Service Paks 18 4 2 Preventive Maintenance Schedule For The Compressor 18 4 3 Lubrication oils 19 4 4 Oil Level Check 19 4 5 Oil And Oil Filter Change 20 4 6 Cleaning...

Page 4: ...hine manufacturer Ascertain that the selected lubricants comply with all applicable safety regulations especially with regard to explosion or fire risk and the possibility of decomposition or generation of hazardous gases 3 The supervisor or the responsible person shall at all times make sure that all instructions regarding machinery and equipment operation and maintenance are strictly followed an...

Page 5: ...or stay in the risk zone under a lifted load Never lift the unit over people or residential areas Lifting acceleration and retardation shall be kept within safe limits 1 Before towing the unit ascertain that the pressure vessel s is are depressurized check the drawbar the brake system and the towing eye Also check the coupling of the towing vehicle check that the pivot wheel or stand leg is safely...

Page 6: ... equipment is in good working order all guards and air conducting baffles are in place and securely fastened all hoses and or pipes inside the unit are in good condition secure and not rubbing there are no fuel oil or coolant leaks all fasteners are tight all electrical leads are secure and in good order the engine exhaust system is in good condition air outlet valves and manifold hoses couplings ...

Page 7: ...all if something lets go 20 Wear approved eye protection when using percussion tools or when scraping chipping shaving or grinding 21 Wear protective gloves when holding a chisel or punch 1 6 Batteries 1 The electrolyte in batteries is a sulphuric acid solution which is fatal if it hits your eyes and which can cause burns if it contacts your skin Therefore be careful when handling batteries e g wh...

Page 8: ... required bodily protection against electrical hazards is applied 3 Noise even at reasonable levels can cause irritation and disturbance which over a long period of time may cause severe injuries to the nervous system of human beings When the sound pressure level at any point where personnel normally has to attend is below 70 dB A no action needs to be taken above 70 dB A noise protective devices ...

Page 9: ...ander Do not apply compressed air or inert gas to your skin or direct an air or gas stream at people Never use it to clean dirt from your clothes 15 Before blowing compressed air or inert gas through a hose ensure that the open end is held securely so that it cannot whip and cause injury 16 When washing parts in or with a cleaning solvent provide the required ventilation and use appropriate protec...

Page 10: ...essure of the compressor element and opens by air receiver pressure when the compressor is stopped When the air consumption increases the air receiver pressure will decrease and vice versa This receiver pressure variation is sensed by the regulating valve which by means of control air to the unloader and engine speed regulator matches the air output to the air consumption The air receiver pressure...

Page 11: ...CV Check Valve DB Drive Belt DP Drain Plug E Engine F Fan FN Flow Nozzle FP Filling Plug FR Flow Restrictor OC Oil Cooler OF Oil Filter OLG Oil Level Gauge OS Oil Separator PG Pressure Gauge RV Regulating Valve SL Scavenge Line SR Speed Regulator SV Safety Valve TS Temperature Switch UA Unloader Assembly UV Unloader Valve VH Vent Hole VI Vacuum Indicator ...

Page 12: ...he airfilter AF into the compressor element is compressed At the element outlet compressed air and oil pass into the air receiver oil separator AR OS The check valve prevents blow back of compressed air when the compressor is stopped In the air receiver oil separator AR OS most of the oil is removed from the air oil mixture the remaining oil is removed by the separator element The oil collects in ...

Page 13: ... compressor is stopped When the air consumption increases the air receiver pressure will decrease and vice versa This receiver pressure variation is sensed by the regulating valve which by means of control air to the unloader matches the air output to the air consumption The air receiver pressure is maintained between the pre selected working pressure and the corresponding unloading pressure When ...

Page 14: ...Temperature alarm H2 General alarm K0 Starter solenoid part of M1 K1 Relay K2 Relay K3 Relay K4 Relay M1 Starter motor P1 Hour meter S1 Contact switch Off On Override start S2 Temperature switch engine S3 Oil pressure switch engine S4 Temperature Lamp test switch S5 Temperature switch compressor Y1 Fuel solenoid valve R1 Resistor V2 Diode ...

Page 15: ...Lamp H2 goes out one can release start button S1 and it returns to position 1 Exciting the safety devices occurs no longer across line 3 but across line 2 to line 4 and this way to line 3 Explanation of shutdowns Oil pressure contact S3 opens K3 no longer excited K3 changes over 13 11 engine cuts out because fuel solenoid Y1 no longer excited and lamp H2 goes on simultaneously Thermocontact S2 ope...

Page 16: ...or which must be placed level will be lifted vertically Preferably use the lifting bale ù ù Lifting acceleration and retardation must be kept within safe limits max 2xg Helicopter lifting is not allowed 3 2 Before Starting ù ù If the compressor is to be connected to a common compressed air system fit an appropriate check valve between compressor outlet and air system Observe the right mounting pos...

Page 17: ...tton counter clockwise to position 0 with valves closed The control panel in addition indicates receiver pressure PG and accumulated operating hours P1 Fault situations and protective devices The starter motor is protected against prolonged starting or against attempts to start when the unit is already running A fault which occurs with the engine either oil pressure too low oil temperature too hig...

Page 18: ...Fuel filter water drain Drain Air intake vacuum indicator Check Electrolyte level and terminals of battery Check Check Check Tire pressure Check Check Check Leaks in air oil or fuel system Check Check Check Oil cooler package Clean Clean Engine minimum and maximum speeds Check Check Check Torque of wheel nuts Check Check Check Brake system if installed Check Adjust Check Adjust Check Adjust Safety...

Page 19: ... mix oils of different brands or types 4 4 1 Check Engine Oil Level Consult also the Engine Operation Manual for the oil specifications viscosity recommendations and oil change intervals See schedule Check engine oil level according to the instructions in the Engine Operation Manual and top up with oil if necessary 4 4 2 Check Compressor Oil Level With the unit standing level engine stopped check ...

Page 20: ...the filler plug 6 Run the unit at no load for a few minutes to circulate the oil and to evacuate the air trapped in the oil system 7 Stop the compressor Let the oil settle for a few minutes Check that the pressure is released by opening an air outlet valve 5 Screw out filler plug 2 and add oil until the pointer of the oil level gauge 4 again registers in the upper extremity of the green range Rein...

Page 21: ... Keep the battery clean and dry Keep the electrolyte level at 10 to 15 mm above the plates or at the indicated level top up with distilled water only Keep the terminals and clamps tight clean and lightely covered petroleum jelly 4 8 Storage Run the compressor regularly e g twice a week until warm Load and unload the compressor a few times to operate the unloading and regulating components Close th...

Page 22: ...ne see section 3 3 2 With the outlet valves AV closed pull out the knob adjust the regulating valve RV until a pressure of 8 5 bar s 123 psig is reached 3 Check the minimum speed of the engine Adjust minimum speed stop screw if necessary 4 Open an outlet valve just enough to let the engine run at maximum speed The working pressure must be 7 bar e 102 psig adjust if necessary with regulating valve ...

Page 23: ...he vacuator valve 6 several times 5 2 4 Replacing The Air Filter Element 1 Release the snap clips 1 and remove the dust trap 2 Clean the trap 2 Remove the element 3 from the housing 5 If the element is to be serviced for immediate re use reinstall the dust trap to protect the air intake system while cleaning the element 3 Reassemble in reverse order of dismantling 4 Inspect and tighten all air int...

Page 24: ... the adapter head 2 Clean the adapter head sealing surface Lightly oil the gasket of the new element and screw the latter onto the header until the gasket is properly seated then tighten with both hands 3 Prime fuel system with manual prime lever on fuel pump 4 Check for fuel leaks once the engine has been restarted ...

Page 25: ...ged trace cause and correct b Check and correct as necessary c Check wiring and connections correct as necessary d With S1 switched in I check voltage between ground and respectively each of the terminals of S1 Voltage must register at each of the terminals if not replace S1 e Replace circuit breaker 2 General alarm lamp H2 does not light up when switching S1 to 1 lamp H1 lights up when applying l...

Page 26: ...ompressor does not unload and engine keeps running at maximum speed when closing the air outlet valves safety valve blows a Air leaks in regulating system b Regulating valve RV incorrectly set or defective c Unloading valve UV or its actuating piston stuck a Check and repair b Adjust or repair regulating valve see section 5 1 c Repair unloading valve assembly 11 Compressor capacity or pressure bel...

Page 27: ...6 Air and oil expelled from air filter after stopping a Unloader valve defective b Wrong oil type with no foam retarding additives a Repair valve b Consult Atlas Copco 17 Compressor overheating a Insufficient compressor cooling b Oil cooler OC clogged externally c Oil system clogged internally d Oil level too low e Cooling fan F defective f Oil separator element clogged g Oil filter clogged a Relo...

Page 28: ... at l s 87 normal working pressures cfm 185 and maximum loading speed 1 Engine Make John Deere Model 4045D Type 4CYL Maximum operating speed rpm 2100 20 Minimum operating speed rpm 1600 20 Battery One BCI Group size 31 12V 625CCA Capacities Compressor oil system liter 10 US gals 2 5 Engine lube oil system with filter liter 8 5 approximately US gals 2 3 Fuel tank liter 98 5 US gals 26 Engine coolin...

Page 29: ... Rating F78 14 Effective tire pressure Inflate to manufacturers recommended pressure as embossed on tire Overall length approximately mm 3200 in 126 Overall width approximately mm 1626 in 64 Overall height approximately mm 1397 in 55 Gross weight wet approximately kg 1205 lb 2650 Gross weight dry approximately kg 1091 lb 2400 Wheel nut s torque ft lb 94 Towbar bolt torque ft lb 70 ...

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