Atlas Copco XRHS 1100 CD6 Instruction Manual Download Page 1

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Instruction Manual for Portable Compressors
English

XRHS 506 - XRHS 1100 CD6
XRVS 476 - XRVS 1000 CD6

Engine C13 Tier 3

Summary of Contents for XRHS 1100 CD6

Page 1: ...Instruction Manual for Portable Compressors English XRHS 506 XRHS 1100 CD6 XRVS 476 XRVS 1000 CD6 Engine C13 Tier 3 ...

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Page 3: ...Instruction Manual for Portable Compressors XRHS 506 XRHS 1100 CD6 XRVS 476 XRVS 1000 CD6 ATLAS COPCO PORTABLE AIR DIVISION www atlascopco com Printed matter N 2954 2510 03 04 2007 ...

Page 4: ... modifications additions or conversions made without the manufacturer s approval in writing While every effort has been made to ensure that the information in this manual is correct Atlas Copco does not assume responsibility for possible errors Copyright 2007 Atlas Copco Airpower n v Antwerp Belgium Any unauthorized use or copying of the contents or any part thereof is prohibited This applies in p...

Page 5: ...ous regulating system 27 2 5 Electric system 28 3 OPERATING INSTRUCTIONS 30 3 1 Parking towing and lifting instructions 30 3 1 1 Parking instructions 31 3 1 2 Towing instructions 32 3 1 3 Towbar levelling option 33 3 1 4 Lifting instructions 33 3 2 Preheater option 34 3 2 1 Description heating operation 34 3 2 2 Operations overview 35 3 3 Before starting 38 3 4 Starting Stopping 39 3 4 1 Control p...

Page 6: ...70 4 11 2 Topping up after limited quantity draining from the cooling system 71 4 11 3 Replacing the coolant 72 4 12 Cleaning coolers 73 4 13 Battery care 74 4 13 1 Electrolyte 74 4 13 2 Activating a dry charged battery 74 4 13 3 Recharging a battery 75 4 13 4 Battery maintenance 75 4 14 Compressor element overhaul 75 5 ADJUSTMENTS AND SERVICING PROCEDURES 76 5 1 Adjustment of the continuous regul...

Page 7: ...8 2 1 Reference conditions 102 8 2 2 Limitations 103 8 2 3 Performance data 104 8 2 4 Design data 105 9 DATAPLATE 107 10 LEGISLATION 108 10 1 Parts subjected to Pressure Equipment Directive 97 23 EC cat II and above 108 10 2 Parts subjected to Simple Pressure Vessel Directive 87 404 EC 108 10 3 Parts subjected to cat I and covered by the Machine Directive 89 392 EC 108 10 4 Parts subjected to art ...

Page 8: ...Instruction Manual 8 2954 2510 03 ...

Page 9: ...e providing the manual with up to date information Before handling any product take time to read the relevant instruction manual Besides giving detailed operating instructions it also gives specific information about safety preventive maintenance etc Keep the manual always at the unit location easy accessible to the operating personnel See also the safety precautions of the engine and possible oth...

Page 10: ...nances The following list is a reminder of special safety directives and precautions mainly applicable to Atlas Copco equipment These safety precautions apply to machinery processing or consuming air Processing of any other gas requires additional safety precautions typical to the application and are not included herein Neglecting the safety precautions may endanger people as well as environment a...

Page 11: ...regularly with regard to their accuracy They shall be replaced whenever outside acceptable tolerances 11 Safety devices shall be tested as described in the maintenance schedule of the instruction manual to determine that they are in good operating condition See the 4 5 Preventive maintenance schedule for the compressor 12 Mind the markings and information labels on the unit 13 In the event the saf...

Page 12: ... by placing chocks in front of and or behind the wheels When the towbar can be positioned vertically the locking device must be applied and kept in good order 6 To lift heavy parts a hoist of ample capacity tested and approved according to local safety regulations shall be used 7 Lifting hooks eyes shackles etc shall never be bent and shall only have stress in line with their design load axis The ...

Page 13: ...ses 8 Do not use compressed air from any type of compressor without taking extra measures for breathing purposes as this may result in injury or death For breathing air quality the compressed air must be adequately purified according to local legislation and standards Breathing air must always be supplied at stable suitable pressure 9 Distribution pipework and air hoses must be of correct diameter...

Page 14: ... 176 F The insulation or safety guard protecting these parts shall not be removed before the parts have cooled down to room temperature 19 Never operate the unit in surroundings where there is a possibility of taking in flammable or toxic fumes 20 If the working process produces fumes dust or vibration hazards etc take the necessary steps to eliminate the risk of personnel injury 21 When using com...

Page 15: ...e left in or on the machine Never leave rags or loose clothing near the engine air intake 7 Never use flammable solvents for cleaning fire risk 8 Take safety precautions against toxic vapours of cleaning liquids 9 Never use machine parts as a climbing aid 10 Observe scrupulous cleanliness during maintenance and repair Keep away dirt cover the parts and exposed openings with a clean cloth paper or ...

Page 16: ...the control and shutdown devices function correctly 1 6 Tool applications safety Apply the proper tool for each job With the knowledge of correct tool use and knowing the limitations of tools along with some common sense many accidents can be prevented Special service tools are available for specific jobs and should be used when recommended The use of these tools will save time and prevent damage ...

Page 17: ...ons should not be changed 8 Bolts of cover and flanges may not be used for extra fixation Safety valves Operating Maintenance Only trained and technically competent personnel should consider overhaul re set or performance testing of safety valves The safety valve is supplied with either a lead security seal or crimped cover to deter unauthorised access to the pressure regulation device Under no ci...

Page 18: ...rom the air in the air oil vessel at first by centrifugal force secondly through the oil separator element The vessel is provided with an oil level indicator Regulation The compressor is provided with a continuous regulating system and a blow off valve which is integrated in the unloader assembly The valve is closed during operation by air receiver pressure and opens by air receiver pressure via t...

Page 19: ...e bodywork has openings for the intake and outlet of cooling air and hinged doors for maintenance and service operations The bodywork is internally lined with sound absorbing material Lifting beam A lifting beam is accessible when a small door at the top is opened Control panel The control panel grouping the air pressure gauge control switch etc is placed at the left hand rear end corner Data plat...

Page 20: ... Atlas Copco synthetic compressor oil Atlas Copco mineral engine oil Manual Read the instruction manual before working on the battery Reset fuse On off button Prohibition to open air valves without connected hoses Rotation direction Inlet Outlet Compressor oil drain Read the instruction manual before starting Service every 24 hours ...

Page 21: ...0 psi Tyre pressure Sound power level in accordance with Directive 2000 14 EC expressed in dB A Fork lifting permitted Don t lift here Read the instruction manual before lifting Filler cap coolant Read the instruction manual before topping up with coolant Service point Circuit breaker Do not run the compressor when the baffles are not in the right position ABS braking system emergency relay valve ...

Page 22: ...PS FLS CT CLS DPeo DPoc DPr DPce DPar ETS IPS ATS H FL BS Reference Name A Alternator AFce Air Filter compressor element AFe Air Filter engine AFS Air Filter Switch AOV Air Outlet Valves AR Air Receiver ATS Ambient Temperature Sensor B Battery BH Brake Handle BS Battery Switch CB Circuit Breaker CBE Cubicle for Electrical devices CEhp Compressor Element high pressure CElp Compressor Element low pr...

Page 23: ...l FCft Filler Cap fuel tank FCc Filler Cap coolant FFc Fuel Filter Caterpillar FFpc Fuel Prefilter Caterpillar FL Flash Light FLG Fuel Level Gauge FLS Fuel Level Sensor FPco Filler Plug oil compressor element FT Fuel Tank H Horn IC Intercooler IPS Interstage Pressure Sensor LV Loading Valve MPV Minimum Pressure Valve OC Oil Cooler OFce Oil Filter compressor element OFe Oil Filter engine OLG Oil Le...

Page 24: ...SV MPV SV CU TV OLG FPco CEhp CElp FR OS AR RV LV SC CV RPS AFce AFe AOV SL SV WPS WPG TS TS DP DP VH PS PS CBE F1 BVof OFce VV Reference Name AFce Air Filter compr element AFe Air Filter engine AFS Air Filter Switch AOV Air Outlet Valves AR Air Receiver BOV Blow Off Valve BVof Bypass Valve oil filter ...

Page 25: ...Restrictor LV Loading Valve MPV Minimum Pressure Valve OC Oil Cooler OFce Oil Filter compressor element OLG Oil Level Gauge OS Oil Separator OSV Oil Stop Valve PS Pressure Sensor RPS Regulating Pressure Sensor RV Regulating Valve SC Safety Cartridge SL Scavenge Line SV Safety Valve TBV Thermostatic Bypass Valve TS Temperature Sensor TV Throttle Valve UA Unloader Assembly VH Vent hole VV Vacuator V...

Page 26: ...e oil collects in the receiver and on the bottom of the separator element The air leaves the receiver via a minimum pressure valve MPV which prevents the receiver pressure from dropping below the minimum working pressure even when the air outlet valves are open specified in section 8 2 2 Limitations This ensures adequate oil injection and prevents oil consumption The minimum pressure valve MPV als...

Page 27: ...e of the compressor element and opens by air receiver pressure when the compressor is stopped When the air consumption increases the air receiver pressure will decrease and vice versa This receiver pressure variation is sensed by the regulating valve RV which by means of control air to the unloader assembly UA matches the air output to the air consumption The air receiver pressure is maintained be...

Page 28: ...P G1 G2 K0 M M1 K0 B B G3 S1 24 24 24 24 24M 24M 24M 3 19 S2 19 19U 19 19 28 20 21 18 36 35 19 19 19 28 19 18 35 36 21 20 24VDC K1 87 30 24M 3 ECM J1 P1 52 J1 P1 70 J1 P1 50 J1 P1 34 J1 P1 42 J1 P1 9 J1 P1 8 J1 P1 61 J1 P1 63 J1 P1 65 N2 J1 P1 48 24 27M X1 F1 15A 1 8 A B C C B A D E F G R1 ...

Page 29: ...rn K0 Relay Starter motor K1 Relay Aux starter LS1 Level Switch Coolant level Warning LS2 Level Switch Coolant level Shutdown LT1 Level sensor Fuel level M1 Starter motor N1 Compressor Control Module N2 Engine Control Modu le Caterpillar PS1 Pressure Switch Airfilter PT1 Pressure sensor Vessel pressure PT2 Pressure sensor Regulating pressure PT3 Pressure sensor Interstage pressure R1 Termination r...

Page 30: ...pressor in to use check the brake system as described in section 5 5 1 Brake shoe adjustment no ABS After the first 100 km travel Check and retighten the wheel nuts and towbar bolts to the specified torque See section 8 1 Torque values Check the brake adjustment See section 5 5 1 Brake shoe adjustment no ABS When towing lifting or transporting the compressor in any way the battery switch must alwa...

Page 31: ...however it can be operated temporarily in an out of level position not exceeding 15 If the compressor is parked on sloping ground immobilize the compressor by placing wheel chocks available as option in front of or behind the wheels Locate the rear end of the compressor upwind away from contaminated wind streams and walls Avoid recirculation of exhaust air from the engine This can cause overheatin...

Page 32: ...ing the unit without connecting the brake pressure lines pressure has to be released from the ABS brake system by pushing button 3 If the ABS vessel is under pressure it is possible to put pressure back on the brakes by pulling button 3 Before towing the compressor ensure that the towing equipment of the vehicle matches the towing eye The height of the towing device of the vehicle must be 815 845 ...

Page 33: ...ise to decrease the spring load for lowering the towbar 3 Slide the bellows 1 over the nut 3 1 4 Lifting instructions To lift the compressor use a lift truck or crane with sufficient capacity weight see indication on 9 Dataplate See to it that the compressor will be lifted vertically and remains level Lifting positions of unit 2 1 Lifting acceleration and retardation must be kept within safe limit...

Page 34: ...130 sec The signal lamp will stay lit during the control interval and also the waterpump continues to run If the heater does not ignite within 90 seconds after fuel pumping has started the start procedure must be repeated If the heater once again fails to ignite after 90 seconds a fault shut down is effected It is possible to override a fault shut down by briefly switching the heater off and then ...

Page 35: ...ge more rapidly With this mini clock you can set and activate three pre set times Each pre set time is deactivated after the set heating period has ended It has to be activated again for each new heating action 5 6 7 4 8 3 1 2 Reference Name 1 Button Mode 2 Button Time down 3 Button Time up 4 Button ON OFF select pre set time 5 Time pre set time and heating time 6 Symbol pre set time is active 7 S...

Page 36: ...imes you will select pre set time 1 2 or 3 The display shows e g pre set time 1 and symbol 1 Set the pre set period with buttons 2 or 3 With button 4 you can activate or deactivate the pre set period When activated the symbol ON appears and the symbol 1 2 or 3 Operation Switching ON the heater Press button 4 The heating period lasts minutes The display shows remaining heating time and symbol 7 Swi...

Page 37: ... electrical contact Check electrical wiring Blocked air duct or exhaust gas duct Check combustion air duct and exhaust gas duct Glow plug defective Replace glow plug Fan motor defective Replace fan motor Possible faults Corrective actions Overheating Cool down and start again Possible faults Corrective actions Upper or lower voltage limit is reached Check power Possible faults Corrective actions D...

Page 38: ... the level of the compressor oil See section 4 7 2 Check compressor oil level The pointer of oil level gauge OLG should register in the green range Add oil if necessary See section 4 6 1 Compressor oil for the oil to be used Before removing oil filler plug FP ensure that the pressure is released by opening an air outlet valve 6 Check that the fuel tank contains sufficient fuel Top up if necessary ...

Page 39: ...g hoses or by connecting equipment directly to the valve s DPar Do not disconnect power supply to control box in any way when the control box is switched on This will cause memory loss Do not switch off the circuit breaker when the control box is switched on This will cause memory loss When the compressor is put in operation for the first time and after running out of fuel or changing the fuel fil...

Page 40: ... 1 2 3 4 5 F1 F2 6 O I ON OFF Reference Name 1 Emergency stop 2 Display 4 rows 40 characters row 3 Pressure gauge 4 Arrow Up button 5 Arrow Down button 6 Fuel level gauge F1 F1 Function button F2 F2 Function button 0 Stop button I Start button ON OFF Power ON OFF switch ...

Page 41: ...hen reaching the preset working pressure in the receiver 2 Check the air outlet temperature of the compressor element 3 Check the engine oil pressure the coolant temperature and display of control box 4 Avoid the engine running out of fuel Nevertheless if this happens fill the fuel tank and prime the fuel system to speed up starting see section 3 4 4 Specific start procedure 3 4 3 Battery switch T...

Page 42: ...e instrument panel will now perform a brief selftest Push the start button and the starter motor will automatically try to start the engine After cleaning draining the fuel tanks the system is filled with air Before starting the engine operate the fuelpump on the fuelfilter to fill the fuelsystem Loosen the vent screw 1 on the fuel filter Operate the hand pump 2 at the filter until fuel comes out ...

Page 43: ...OFF switch to the position ON The instrument panel will now perform a brief selftest The display will show By pressing the button F1 the user goes to the INFO status F1 ON OFF Do not disconnect power supply during operation When disconnecting power supply during operation the user will be prompted to this by the next display ...

Page 44: ...he attempt will be indicated on the display as 1 1 If the engine failed to start the display will show the cause of the failure When the stopping procedure has ended the time message disappears and the F1 function appears Reset The display will show O I To cool down the starting motor the system will wait 1 minute before the next attempt can be made meanwhile do not leave the compressor ...

Page 45: ...will first warm up before automatically switching to LOAD The display will show If the button F1 is pressed after warming up the compressor immediately will enter the LOAD status The pressure will rise till it the reaches setting If the Warm up Temperature has not been reached after 5 minutes the Warm up procedure will be ended and the Control Box will proceed to the NOT LOADED status After warmin...

Page 46: ...ton F1 the compressor will be loaded The pressure will rise till it reaches the setting The engine rpm is shown on the display The display will show F1 The setting of the regulating valve with shut valves should be 2 bar 29 psi higher than the required working pressure ...

Page 47: ...RE X X X STARTER RELAY FAILURE X X ENGINE NOT RESPONDING X X STARTER MOTOR BURNING DANGER X X ENGINE OVERSPEED PROTECTION X X AMBIENT TEMPERATURE SENSOR FAILURE X INTERSTAGE PRESSURE SENSOR FAILURE X FLASH LIGHTS FAILURE X HORN FAILURE X OPERATING ON DEFAULT PARAMETERS X FUEL LEVEL TOO LOW X X X LP ELEMENT TEMPERATURE TOO HIGH X X X HP ELEMENT TEMPERATURE TOO HIGH X X X COOLANT LEVEL TOO LOW X X X...

Page 48: ...MPERATURE HIGH X ENGINE TURBO BOOST PRESS SENSOR FAILURE X ENGINE TURBO BOOST PRESSURE HIGH X Options COLDSTART RELAY FAILURE X AFTERCOOLER AIR DISCHARGE TEMP HIGH X AMBIENT TEMP TOO COLD FOR AFTERCOOLER X AFTERCOOLER AIR DISCHARGE TEMP TOO HIGH X X AFTERCOOLER AIR DISCH PRESS SENSOR FAIL X AFTERCOOLER AIR DISCH TEMP SENSOR FAIL X AIR SHUT OFF VALVE RELAY FAILURE X BLOW OFF VALVE FAILURE X AIR DIS...

Page 49: ...e of exceeding a parameter setting e g compressor temperature the display shows and than After the stopping procedure has ended press F1 to continue Restarting before the parameter is within its limits is impossible because of the parameter check before the cranking procedure ...

Page 50: ...on 0 The engine will run some time at min speed to cool down and will stop finally The remaining time is shown in the display Meanwhile the air receiver is depressurised Switch the ON OFF switch to the position OFF Wait until the display is dark Switch the battery switch in the OFF position O ON OFF ...

Page 51: ...uts is terminated by the emergency stop itself hardware as well as by the software The display will show When the emergency stop button 1 is unlocked the operator can reset the emergency stop by pressing the button F1 1 F1 The emergency stop button is only to be used in emergency situations not for stopping procedures ...

Page 52: ...rolling down at the last topic displays the first scrolling up at the first topic displays the last Text in capitals is the text that appears on the display max 19 characters The characters XXXX XXXX in the upper right corner stand for compressor type COMPRESSOR TYPE CONTROL MODE BATTERY VOLTAGE AMBIENT TEMPERATURE SOFTWARE VERSION COMPR SERIAL NR ENGINE SERIAL NR FLEET NR Optional The F2 button r...

Page 53: ...g shutdown history The F1 button enters a menu or confirms a new parameter setting To select a menu the button function text is F1 SELECT To go back the button function text is F2 BACK If the F1 button is pressed the topic next to is selected For example if the operator wishes to change the language to NEDERLANDS he would press the F1 button when LANGUAGE is next to From there the operator has ent...

Page 54: ... 3 4 14 Service task confirmed The following confirmation is displayed for 10 seconds or until the F1 button is pressed When the display shows the Option status again the service task that has been confirmed is no longer displayed because it is confirmed F1 ...

Page 55: ...thin 50 running hours the user can choose NEXT SERVICE TASK Next to the next standard service task all active custom service tasks are always displayed When a service task is selected pressing the button F1 this service task is triggered and confirmed This confirmation is also displayed When pressing the button F2 EXIT the user goes straight to READY TO START F1 F2 ...

Page 56: ...ks include all genuine parts needed for normal maintenance of both compressor and engine Service Paks minimize downtime and keep your maintenance budget low Order Service Paks at your local Atlas Copco dealer 4 3 Service kits A service kit is a collection of parts to fit a specific repair or rebuilding task It guarantees that all necessary parts are replaced at the same time which improves the upt...

Page 57: ...arly or every 1000 hours XRHS 506 XRHS 1100 CD6 XRVS 476 XRVS 1000 CD6 supplied with unit 2912 4432 05 2912 4432 06 Engine oil level Check Condensate 11 Drain Compressor oil level Check Coolant level Check Air filter vacuator valves Empty Fuel filter water drain Drain ABS vessel drain Drain Electrolyte level and terminals of battery Check Check Check Tyre pressure Check Check Check Leaks in air oi...

Page 58: ...drop exceeds 0 8 bar 11 6 psi 3 Refer to the engine operation manual 4 500 hours is only valid when using PAROIL 15W40 5 Change coolant every 5 years 6 Use Atlas Copco oil filters with by pass valve as specified in the parts list 7 Replace the fuel filters regularly Gummed or clogged filters mean fuel starvation and reduced engine performance The quality of the fuel determines the frequency of ren...

Page 59: ...0 C and 30 C PAROIL S PAROIL 15W40 between 30 C and 50 C PAROIL S68 PAROIL 15W40 Never mix synthetic with mineral oil Remark When changing from mineral to synthetic oil or the other way around you will need to do an extra rinse After doing the complete change procedure to synthetic oil run the unit for a few minutes to allow good and complete circulation of the synthetic oil Then drain the synthet...

Page 60: ...to clog your filter and accumulate in the valve rocker cover area PAROIL releases excess heat efficiently whilst maintaining excellent bore polish protection to limit oil consumption PAROIL has an excellent Total Base Number TBN retention and more alkalinity to control acid formation PAROIL prevents Soot build up PAROIL is optimized for the latest low emission EURO 3 2 EPA TIER II III engines runn...

Page 61: ...eck engine oil level according to the instructions in the Engine Operation Manual and if necessary top up with oil 4 7 2 Check compressor oil level Check compressor oil level With the compressor standing horizontal check the level of the compressor oil The pointer of the oil level gauge 1 must register in the upper extremity of the green range Add oil if necessary 1 2 3 Before removing the oil fil...

Page 62: ...ssor oil 1 2 1 Stop the compressor Wait a few minutes until the pressure is released through the automatic blow down valve Make sure that all pressure is released by loosening the filler plug 1 one turn 2 Wait 10 minutes so that the oil level is constant 3 Remove the filler plug 1 and top up with oil until the pointer of the oil level gauge 2 is in the upper part of the green area 4 Reinstall and ...

Page 63: ...e automatic blow down valve Unscrew the oil filler plug 2 one 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 4 Catch the oil in a drain pan Screw out the filler plug 2 to speed up draining After draining place and tighten the drain plugs 4 3 Remove the oil filters 1 e g by means of a special tool Cat...

Page 64: ...ompressor and let it run unloaded for a few minutes 7 Stop the compressor wait a few minutes and top up with oil until the pointer of the oil level gauge is in the upper part of the green area Never add more oil Overfilling results in oil consumption ...

Page 65: ...he freezing point that can occur in the area The difference must be at least 5 C 9 F If the coolant freezes it may crack the cylinder block radiator or coolant pump Consult the engine s operation manual and follow the manufacturer s directions Never remove the cooling system filler cap while coolant is hot The system may be under pressure Remove the cap slowly and only when coolant is at ambient t...

Page 66: ...oolant ducts and the radiator minimizing the risk for engine overheating and possible failure It reduces water pump seal wear and has excellent stability when subjected to sustained high operating temperatures PARCOOL EG is free of nitride and amines to protect your health and the environment Longer service life reduces the amount of coolant produced and needing disposal to minimise environmental ...

Page 67: ...ncentration of EG In case a device is used to measure EG no PG can be measured afterwards as a result of the difference in the density More specific measurements can be done by the use of a refractometer This device can measure both EG and PG A mix of both products will be show unreliable results Mixed EG coolants with identical glycol type can be measured by use of a refractometer as well as the ...

Page 68: ... 5 the coolant should be replaced Glycol concentration measurement To optimise the unique engine protection features of the PARCOOL EG the concentration of the Glycol in the water should be always above 33 vol Mixtures with more than 68 vol mix ratio in water are not recommended as this will lead to high engine operating temperatures A refractometer can be ordered from Atlas Copco with part number...

Page 69: ...s clean Check the condition of the coolant If the condition of the coolant is outside the limits the complete coolant should be replaced see section 4 11 3 Replacing the coolant Always top up with PARCOOL EG Concentrate PARCOOL EG Topping up the coolant with water only changes the concentration of additives and is therefore not allowed ...

Page 70: ...20 C 33 2 Refractometer indication 22 C 3 Refractometer indication 25 C 4 Refractometer indication 30 C 5 Refractometer indication 36 C 14 33 33 17 14 50 4 8 50 Total volume coolant Measured concentration In case of expansion tank at low level this quantity is to be filled without draining from the cooling system Liter Vol Liter PARCOOL EG Concentrate 4 0 0 0 5 1 0 1 5 2 0 2 5 3 0 3 5 4 0 4 5 5 0 ...

Page 71: ...1 Refractometer indication 20 C 33 2 Refractometer indication 22 C 3 Refractometer indication 25 C 4 Refractometer indication 30 C 5 Refractometer indication 36 C 80 33 33 33 17 67 80 67 20 50 100 Total volume coolant Measured concentration In case of expansion tank at normal level this quantity is to be drained from the cooling system Liter Vol Liter PARCOOL EG Concentrate 4 8 12 16 20 24 28 32 3...

Page 72: ...e amount of PARCOOL EG required and pour into the radiator top tank It should be clearly understood that the risk for contamination is reduced in case of proper cleaning In case a certain content of other coolant remains in the system the coolant with the lowest properties influences the quality of the mixed coolant Fill To assure proper operation and the release of trapped air run the engine unti...

Page 73: ...direction of the arrow Steam cleaning in combination with a cleansing agent may be applied do not use jet at max power Close the service door s 1 2 3 4 Remove any dirt from the coolers with a fibre brush Never use a wire brush or metal objects To avoid damaging the coolers angle between jet and coolers should be approx 90 Protect the electrical and controlling equipment air filters etc against pen...

Page 74: ...te must be at equal temperature above 10 C 50 F Remove cover and or plug from each cell Fill each cell with electrolyte until the level reaches the mark on the battery If there is no mark on the battery the level must be above the plates for at least 10 mm 0 4 in to 15 mm 0 6 in Rock the battery a few times so that possible air bubbles can escape wait 10 minutes and check the level in each cell on...

Page 75: ...20 gives safe charging current in Amp 4 13 4 Battery maintenance Keep the battery clean and dry Keep the electrolyte level above the plates or at the indicated level Level above plates at least 10 mm 0 4 in to 15 mm 0 6 in Top up with distilled water only Keep the terminals and clamps tight clean and lightely covered with petroleum jelly 4 14 Compressor element overhaul When a compressor element i...

Page 76: ...d to raise the pressure and decreased to lower it by turning the adjusting wheel clockwise and anti clockwise respectively To adjust the normal working pressure proceed as follows 1 Loosen the lock nut of the regulating valve 1 2 Release Regulating Valve turn out 3 With the outlet valves 2 closed adjust the regulating valve 1 until a pressure is reached of nominal pressure 2 bar 29 psi 4 Lock the ...

Page 77: ...ust trap pinch the vacuator valve 6 several times 6 1 2 3 4 5 Reference Name 1 Snap clips 4x 2 Dust trap cover 3 Safety cartridge 4 Filter element 5 Filter housing 6 Vacuator valve The Atlas Copco air filters are specially designed for the application The use of non genuine air filters may lead to severe damage of the engine and or compressor elements ...

Page 78: ...r 2 Clean the inside of the cover 2 Withdraw the filter element 4 and safety cartridge 3 from the housing 5 Discard the filter element when damaged A dirty safety cartridge 3 is an indication of a malfunctioning filter element Replace the filter element and the safety cartridge at the same time New elements should be inspected for tears and punctures before installation The safety cartridge cannot...

Page 79: ...f the opening of the lifting gear twice a year This can be done by screwing the cap of the valve 2 anti clockwise A check of the set pressure once a year according to the local regulations This check cannot be done on the compressor and must be carried out on a proper test bench Daily drain condensate 1 2 All adjustments or repairs are to be done by an authorized representative of the safety valve...

Page 80: ...essor is put in operation for the first time Running out of fuel Storage Replacement of the fuel filter Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire To help prevent possible injury turn the ON OFF switch in position OFF when changing fuel filters or water separator elements Clean up fuel spills immediately Do not loosen the fuel lines at the fuel manifold The ...

Page 81: ... 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 filterelement 4 tightly by hand 7 Open head vent and operate pump 5 Close vent when fuel begins to purge 8 Check for leaks retighten if necessary Step Action 1 Open bowl drain valve 1 operate pump 5 and...

Page 82: ...en play on both wheel brakes Re adjust brakes if necessary As a check apply the parking brake slightly and check that the braking effect on the wheels in the direction of travel is the same on the right and on the left 5 5 2 ABS braking system Pneumatic setting on the relay valve The pre dominance of the pneumatic braking system is pre set and is not to be changed Pre set pre dominance for compres...

Page 83: ...arking brake lever several times by hand with a force of 200 to 300 N and put it back into the not engaged tooth 1 position Adjust the turnbuckle 8 as described above Testing the parking brake For testing the parking brake apply the parking brake lever The nominal brake power must be reached between the 16th and 23rd tooth of the toothed segment Z W Y 8 11 11 l 1 Z 16 23 10 Z W 9 7 Y Tighten all l...

Page 84: ...ed Apply the parking brake lever several times by hand with a force of 200 to 300 N and put it back into the not engaged tooth 1 position Adjust the turnbuckle 8 as described above Testing the parking brake For testing the parking brake apply the parking brake lever Brake power must be reached between the 6th and 14th tooth of the toothed segment Z 10 Z 9 7 Y Y 11 11 8 Z 14 6 1 Tighten all lock nu...

Page 85: ...l are visible in the inner part of the turnbuckle Apply the parking brake lever several times by hand with a force of 200 to 300 N and put it back into the not engaged tooth 1 position Adjust the turnbuckle 3 2 as described above Testing the parking brake For testing the parking brake apply the parking brake lever The nominal brake power must be reached between the 6th and 12th tooth of the toothe...

Page 86: ... are visible in the inner part of the turnbuckle Apply the parking brake lever several times by hand with a force of 200 to 300 N and put it back into the not engaged tooth 1 position Adjust the turnbuckle 6 2 as described above Testing the parking brake For testing the parking brake apply the parking brake lever The nominal brake power must be reached between the 6th and 12th tooth of the toothed...

Page 87: ...moved 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 inspect...

Page 88: ...nd 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 Possible faults Corrective actions Engine oil pressure too low Refer to the engine instruction manual Compressor or engine overheating See corrective actions Compressor overhe...

Page 89: ...housing Block the valve by screwing a bolt M5 x 20 through the housing and in the blind hole in the coupling 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 4 12 Cleaning coolers Oil cooler clogged internally Consult Atlas ...

Page 90: ...engine speed and the air inlet to optimise fuel consumption depending on the working conditions and the output required Additional fuelfilter In dusty environments or in situations where the fuel quality is not up to the normal standard this additional fuel filter gives an extra protection to the fuel combustion system ...

Page 91: ...peeds compliant to 98 12 EC External fuel connection When a compressor is operated on site for a longer period it is advisable to supply the fuel through external fuel connections When using this option the regular refuelling by tanker it is no more needed Consequently there is also less risk for contamination when refuelling ...

Page 92: ...heels are also equipped with brakes operated from the brake handle on the tow bar Skid The skid is ideal in circumstances where the site is impossible to reach by truck It allows transportation by crane or fork lift truck When on the ground it can be pushed into the exact location Truck mounted version With the option Support mounted it is possible to fix the compressor to a truck for more flexibi...

Page 93: ... level device The tow bar levelling device is an ergonomic device making it easier for the operating personnel to couple the compressor to a towing vehicle As the tow bar itself is rather heavy the levelling device compensates most of this weight so the operator has less weight to carry saving his back Road signalisation On road bumper bars and lights can be specified in accordance with local legi...

Page 94: ...e the compressor in hazardous environments like refineries where there is a possibility that inflammable fumes can be released The spark arrestor prevents any hot burning particles from getting into the open air Inlet shut down valve The inlet shut down valve is a safety device preventing the engine from over speeding when sucking in combustible fumes When the engine max RPM is exceeded a pneumati...

Page 95: ... able to start the engine at temperatures between 10 C 14 F and 25 C 13 F Engine preheater The preheater is a device for preheating the cooling fluid before starting when operating at low temperatures The engine will start more easy Additionally the preheater will lengthen the life span of the engine as there are no cold starts see also section 3 2 Preheater option ...

Page 96: ... filter For applications that demand quality air a fine filtration unit can be specified with the aftercooler package This will remove oil and particles down to 0 01 mg m3 Aftercooler package fine filter charcoal filter For purer but not breathing air an active charcoal filtration unit can be specified with the aftercooler package This removes oil and oil vapour content to 0 003 mg m3 ...

Page 97: ... at ambient 60 C Refuel pump The electric refuel pump makes it easy to refuel the compressor on site when refuelling from tanks or containers This option also contains a suction hose with strainer Large fuel tanks for truck mounted version In combination with the support mounted it is also possible to integrate larger fuel tank to get larger intervals between two fuel supply actions ...

Page 98: ... additional no load function COSMOS COSMOS allows technicians to arrive at the right location at the right time with the right information and service materials so enabling you to give better customer service more up time and more accurate invoicing than previously possible COSMOS provides information on time to maintenance operational history running hours fuel levels events utilization data visu...

Page 99: ...nnections Additional manifold For more flexibility it is possible to have additional outlets installed Additional sensors in outlet For applications were the air outlet temperature is important additional sensors can be installed in the manifold ...

Page 100: ...ssure It will limit the operating pressure to 7 bar and allow the operation of hand held pneumatic tools Oiltronix The OILTRONIX is an Electronic Oil Management System for compressors providing an optimal oil injection temperature that reduces the condensation of water in the oil This will result in a longer life of components in the compressor system ...

Page 101: ...rque values Axles to frame Compressor to frame Thread size Torque value Nm lbf ft M6 9 6 64 M8 23 16 97 M10 46 34 69 M12 80 59 04 M14 125 92 25 M16 205 151 29 Thread size Torque value Nm lbf ft M6 15 11 07 M8 39 28 78 M10 78 57 56 M12 135 99 63 M14 210 154 98 M16 345 254 61 Assemblies Torque value Nm lbf ft Wheel nuts 270 199 26 Bolts front axle frame 205 151 29 Bolts rear axle frame 205 151 29 As...

Page 102: ...7 Assemblies Torque value Nm lbf ft Bolts lifting beams yoke M12 125 92 25 Bolts lifting beams yoke M16 205 151 29 Bolts lifting beams A Frames 205 151 29 Bolts A Frames frame 205 151 29 Assemblies Torque value Nm lbf ft Pebra hose clamps on all IC radiator hoses 12 8 85 Secure the drain cock and tank cap of the fuel tank handtight Designation XRHS 506 XRHS 1100 CD6 XRVS 476 XRVS 1000 CD6 Absolute...

Page 103: ...inimum effective receiver pressure bar e 12 5 15 5 psi 182 225 Maximum effective receiver pressure compressor unloaded bar e 22 27 psi 319 392 Maximum ambient temperature at sea level Standard C 50 50 F 122 122 Aftercooler option C 45 45 F 113 113 Minimum starting temperature C 10 10 F 14 14 Minimum starting temperature with coldstart equipment C 25 25 F 13 13 50 616 701 795 899 0 1000 2000 3000 4...

Page 104: ... Fuel expert kg h 55 4 55 4 lb h 122 1 122 1 50 FAD Fuel expert kg h 38 8 39 2 lb h 85 5 86 4 No Fuel expert kg h 46 8 47 2 lb h 103 2 104 1 25 FAD Fuel expert kg h 33 9 34 6 lb h 74 7 76 3 No Fuel expert kg h 35 9 36 7 lb h 79 2 80 9 unload Fuel expert kg h 29 30 2 lb h 63 9 66 6 No Fuel expert kg h 29 30 2 lb h 63 9 66 6 Specific fuel consumption g m3 34 6 37 5 dram cu ft 55 10 6 59 6 10 6 Typic...

Page 105: ... Typical average load factor 2 With filter change Designation Number of compression stages 2 Designation XRHS 506 XRHS 1100 CD6 XRVS 476 XRVS 1000 CD6 Make Caterpillar Type C13 Tier 3 Coolant Liquid Number of cylinders 6 Bore mm 130 in 5 1 Stroke mm 157 in 6 2 Swept volume l 12 5 US gal 3 4 Imp gal 2 7 cu in 764 Output according to DIN 6271 at normal shaft speed kW 317 8 hp 426 2 Load factor 1 70 ...

Page 106: ... of compressor oil system l 75 US gal 19 8 Imp gal 16 5 cu ft 2 6 Net capacity of air receiver l 143 US gal 37 7 Imp gal 31 5 cu ft 5 Capacity of fuel tanks wagon tandem l 796 538 US gal 210 142 Imp gal 175 119 cu ft 27 8 19 0 Air volume at inlet grating approx 1 m3 s 14 6 cfm 3 0 x 104 Designation All Units Length mm 5640 in 220 Width mm 2100 in 81 9 Height mm 2460 in 95 9 Weight ready to operate...

Page 107: ...ype approval number 6 Vehicle identification number 7 A Maximum permitted laden weight of the vehicle B Maximum permitted road weight of the front axle C Maximum permitted road weight of the rear axle 8 Model 9 Working pressure 10 Speed 11 Engine power 12 Manufacturing year 13 CE mark in accordance with Machine Directive 89 392 EC 14 Register number or number of notified body ...

Page 108: ...Machine Directive 89 392 EC All other parts 10 4 Parts subjected to art I paragraph 3 3 All other parts XRHS 506 XRHS 1100 CD6 XRVS 476 XRVS 1000 CD6 Set pressure bar e 25 30 psi 363 435 Design temperature C 130 130 F 266 266 XRHS 506 XRHS 1100 CD6 XRVS 476 XRVS 1000 CD6 Standard Cold start equipment Design pressure bar e 30 30 psi 435 435 Design temperature max C 130 130 F 266 266 Design temperat...

Page 109: ...ioning of the materials for recycling in the future is forseen Note 11 2 Disposal of materials Dispose contaminated substances and material separately according to local applicable environmental legislations Before dismantling a machine at the end of its operating lifetime drain all fluids and dispose of according the applicable local disposal regulations Remove the batteries Do not throw batterie...

Page 110: ...Instruction Manual 110 2954 2510 03 Maintenance Log Compressor Customer Serial number Service hours Maintenance action Date By initials ...

Page 111: ......

Page 112: ...Printed in Belgium 04 2007 2954 2510 03 www atlascopco com ...

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