Atlas Copco XRVS 1000 CD8 T4F HOP Instruction Manual Download

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Reference

Name

After Cooler

AFe

Air Filter (engine)

AOV

Air Outlet Valves

Air Receiver

Battery

Brake Handle

Battery Switch

Compressor Element

Coolant Tank

DPar

Drain Plug Air Receiver

DPce

Drain Plug Compressor Ele-
ment

DPgc

Drain Plug Gear Casing

DPoc

Drain Plug Oil Cooler

DPr

Drain Plug Radiator

Engine

Exhaust Pipe

Fan

Fuel Cooler

FFC

Fuel Filter Caterpillar

FCft

Filler Cap (fuel tank)

FCc

Filler Cap (coolant)

Reference

Name

Flash Light

Fuel Tank

Intercooler

Loading Valve

Oil Cooler

OFce

Oil Filter (compressor ele-
ment)

OFe

Oil Filter (engine)

Radiator

Safety Valve

Towbar

Unloader Valve

Vacuator Valve

Water Separator

Summary of Contents for XRVS 1000 CD8 T4F HOP

Page 1: ...Engine Caterpillar C13 XRVS 1000 CD8 T4F HOP Instruction Manual for Portable Compressors English ...

Page 2: ......

Page 3: ...ATLAS COPCO PORTABLE ENERGY DIVISION www atlascopco com Printed matter Nr 1310 3018 04 01 2017 Instruction Manual for Portable Compressors XRVS 1000 CD8 T4F HOP Original instructions ...

Page 4: ...ufacturer does not accept any liability for any damage arising for modifications additions or conversions made without the manufacturer s approval in writing Copyright 2017 Atlas Copco Compressors LLC RockHill SC USA 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 ...

Page 5: ...uctions 25 3 4 Lifting Instructions 28 3 5 Before Starting 28 3 6 Basic Operation Of The Machine 29 4 Starting Stopping 30 4 1 Battery Switch 30 4 2 Control Panel 31 4 2 1 Overview Icons 32 4 2 2 Starting 35 4 2 3 Stopping 40 4 2 4 Shutdown 41 4 2 5 Power Off 41 4 2 6 Diesel Particulate Filter Regeneration 41 4 2 7 Automatic Dpf Regeneration Default 42 4 2 8 Inhibit Dpf Regeneration 42 4 2 9 Incre...

Page 6: ...t And The Safety Cartridge 69 6 1 4 Air Receiver 69 6 1 5 Safety Valve 69 6 2 Fuel System 70 6 2 1 Priming Instructions 70 6 3 Replacing Filter Elements 70 6 4 Cleaning Crankcase Breather Filter 70 6 5 Rubber Torsion Suspension 71 6 6 Inspection 71 6 7 Brake Drum Inspection 71 6 8 Bearing Inspection 71 6 9 Bearing Lubrication 71 6 9 1 Bearing Lubrication oil 71 6 9 2 Seal Inspection And Replacemen...

Page 7: ...the unit When handling operating overhauling and or performing maintenance or repair on Atlas Copco equipment the mechanics are expected to use safe engineering practices and to observe all relevant local safety requirements and ordinances The following list is a reminder of special safety directives and precautions mainly applicable to Atlas Copco equipment These safety precautions apply to machi...

Page 8: ...wing vehicle remove wheel chocks if applied and disengage the parking brake 2 To tow a unit use a towing vehicle of ample capacity Refer to the documentation of the towing vehicle 3 Never exceed the maximum towing speed of the unit mind the local regulations 4 Place the unit on level ground and apply the parking brake before disconnecting the unit from the towing vehicle Unclip the safety break aw...

Page 9: ...ch entrance to alert people entering the room for even relatively short times about the need to wear ear protectors above 95 dB A the warning s at the entrance s shall be completed with the recommendation that also occasional visitors shall wear ear protectors above 105 dB A special ear protectors that are adequate for this noise level and the spectral composition of the noise shall be provided an...

Page 10: ...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...

Page 11: ...tamped on the valve without the permission of the installation designer If the set pressure must be altered then use only correct parts supplied by Atlas copco and in accordance with the instructions available for the valve type Safety valves must be frequently tested and regularly maintained The set pressure should be periodically checked for accuracy When fitted the compressors should be operate...

Page 12: ...cooled exhaust gas regeneration process Safety devices A thermal shut down sensor protects the compressor against overheating The air receiver is provided with a safety valve The engine is equipped with low oil pressure and high coolant temperature shut down sensors The electric system is equipped with a 24V main switch Frame and axles The compressor engine unit is supported by rubber buffers in a...

Page 13: ... 13 Main parts ...

Page 14: ...t DPgc Drain Plug Gear Casing DPoc Drain Plug Oil Cooler DPr Drain Plug Radiator E Engine EP Exhaust Pipe F Fan FC Fuel Cooler FFC Fuel Filter Caterpillar FCft Filler Cap fuel tank FCc Filler Cap coolant Reference Name FL Flash Light FT Fuel Tank IC Intercooler LV Loading Valve OC Oil Cooler OFce Oil Filter compressor ele ment OFe Oil Filter engine R Radiator SV Safety Valve TB Towbar UV Unloader ...

Page 15: ... 15 Regulating system OVERVIEW ...

Page 16: ...AXiv DrillAirXpert Inlet Valve DAXsm DrillAirXpert Stepper Motor DE Dust Evacuator DP Drain Plug E Engine EW Electrical Wiring F Fan MPV Minimum Pressure Valve OC Oil Cooler OFc Oil Filter compressor OFe Oil Filter engine Reference Name OSE Oil Separator Element OSV Oil Stop Valve PSai Pressure Sensor air inlet PSlp Pressure Sensor low pressure SC Safety Cartridge SL Scavenge Line SV Safety Valve ...

Page 17: ...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 restrict...

Page 18: ... 18 Flow diagram exhaust after treatment ...

Page 19: ...e lifetime of a filter it converts particulate matter into CO2 and ash Atlas Copco engines use high temperature regeneration that includes a fuel burner in the exhaust stream that intermittently raises the temperature above 600º C 1100 F A separate High Pressure Fuel Pump HPFP supplies fuel to the burner in the active regeneration system Active regeneration decreases in the higher load cycles of t...

Page 20: ... 20 Electric system CIRCUIT DIAGRAM INDEX 1310 3200 95_01 ...

Page 21: ... 21 Electric system WIRING DIAGRAM 1310 3200 95_02 ...

Page 22: ... 22 Electric system WIRING DIAGRAM 1310 3200 95_03 ...

Page 23: ... 23 Electric system WIRING DIAGRAM 1310 3200 95_04 ...

Page 24: ... 24 Electric system WIRING DIAGRAM 1310 3200 95_05 ...

Page 25: ...Q1 XC CONTROLLER 15A Q2 ECU FUSE 1 25A Q3 ECU FUSE 2 25A Q4 FUEL PUMP 15A Q7 DEF TANK PWR 1 20A Q8 DEF TANK PWR 2 20A Q13 ALTERNATOR 100A Q5 Q6 NOT USED N A Q9 Q10 Q11 NOT USED N A Q12 Q14 NOT USED N A R1 FUEL PUMP RELAY N A R2 STARTER RELAY N A ...

Page 26: ...urs Warning Part under pressure Do not stand on outlet valves Start Stop indication of switch Do not run the compressor with open doors Lifting permitted Use diesel fuel only 9 5 bar 138 psi Tyre pressure Wagon 7 5 bar 109 psi Tyre pressure Tandem EU 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...

Page 27: ...e jack to the highest position Attach safety chains cables in a crisscross manner to the tow vehicle This will help prevent the drawbar from contacting ground in event of a breakaway If applicable your compressor will be fitted with a emergency breakaway system which is simply a small battery on your trailer and a switch connected to a cable Secure the cable to your vehicle s trailer hitch In case...

Page 28: ...eration Man ual for the type of fuel 7 Drain any water and sediment from the fuel filters until clean fuel flows from the drain cock 8 Empty the dust trap of each air filter AF See sec tion Replacing the filter element and the safety car tridge 9 Clogged air filter s will be indicated on the display of the control panel see section Fault codes If indi cated replace the filter elements 10 Check coo...

Page 29: ...ompressor can be controlled in 4 different modes Local Operation Mode locally at the Operating Panel Remote Operation Mode via remote switch input located at the bottom of the Control panel Automatic Operation Mode via pressure sensor data from the customer s installation PC Operation Mode with software running on a PC In this section is described how to operate the machine in Local Operation Mode...

Page 30: ...for stopping Always first shut off the control unit and wait until the display is dark before switching the battery switch to position OFF Turn the battery switch BS off 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 Please ...

Page 31: ...ing on actual status command the compressor to switch to Not Loaded when in Load MEASUREMENTS VIEW button By pressing this button you can toggle between Measurements View and Main View SETTINGS VIEW button By pressing this button you can toggle between Settings View and Main View ALARMS VIEW button By pressing this button you can toggle between Alarms View and Main View NAVIGATION buttons These bu...

Page 32: ... LOADED 1300RPM 22 4bar 41 1286h 1 2 3 0 Reference Name 1 Compressor status 2 Vessel pressure indication or info text 3 Compressor info Main View Indication Measuring View Indication Settings View Indication Alarm View Indication ...

Page 33: ...he controller will show its dedicated icon Reference Name OPERATION MODE Local OPERATION MODE Remote OPERATION MODE PC Control OPERATION MODE Automatic OPERATION MODE Automatic Mode is active but the Auto Start and Auto Stop function are both inactive OPERATION MODE Block Mode ALARM Active not acknowledged Shutdown Alarm ALARM Active not acknowledged Non Shutdown Alarm ALARM Active acknowledged Al...

Page 34: ... can be selected and entered to access the sublist MAIN VIEW LOADED 1300RPM 22 4bar 41 1286h 22 4 MEASUREMENTS LOADED 1300RPM 22 4bar 41 1286h Running Hours 1286h ECU Engine rpm 1300 rpm ECU Requested Speed 1300 rpm Vessel Pressure 22 4 bar HP Element Temperature 101 C Ambient Temperature 27 C SETTINGS LOADED 1300RPM 22 4bar 41 1286h 1000 GENERAL SETTINGS 2000 DIGITAL INPUTS 3000 VOLTAGE INPUTS 40...

Page 35: ...pening the blow down valve After power up the vessel pressure normally is low enough to proceed with the starting procedure The display now shows The machine is now ready to be started and is waiting for a start command Xc3003 v1 00 0 r7307 If the Power switch is turned to the OFF position while the vessel is blowing down it will not power down for as long as the vessel pressure is higher than 1 5...

Page 36: ...l preheat according to the parameters of the engine controller Active Buttons Stop Button to cancel Start command Load Button to activate Automatic Load Measurement View Button Settings View Button Alarms View Button MAIN VIEW PREPARING FOR START 0 0 RPM 0 0bar 41 1286h MAIN VIEW READING ENGINE DATA 0 0 RPM 0 0bar 41 1286h Active Buttons Stop Button to cancel Start command Load Button to activate ...

Page 37: ... display shows The engine will run at minimum rpm until the engine s coolant temperature reaches 40 C with a minimum time of 15 seconds and a maximum time of 300 seconds 800RPM 324RPM 0RPM MAIN VIEW ENGINE CRANKING 324RPM 0 0bar 41 1286h Active Buttons Stop Button to cancel Start command Load Button to initiate Automatic Load Measurement View Button Settings View Button Alarms View Button 120s 54s...

Page 38: ...ttons Stop Button to cancel Start command Load Button to cancel Load command Measurement View Button Settings View Button Alarms View Button MAIN VIEW ENGINE WARMING UP 1200RPM 2 9 bar 41 1286h 15s 7s 0s Active Buttons Stop Button to cancel Start command Load Button to cancel Load command Measurement View Button Settings View Button Alarms View Button MAIN VIEW READY TO LOAD 4 6 1200RPM 4 6bar 41 ...

Page 39: ...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 sys tem to speed up starting Active Buttons Stop Button to cancel Start command Load Button to cancel Load command Measurement View Button Settings View Button Alarms View Button MAIN VIEW PREPARING TO LOAD 4 7 1800RPM 4 7bar 41 1286h Active Buttons Stop Button to ca...

Page 40: ...own and run at minimum rpm for 3 minutes before it will stop If the Soot Load in the diesel particulate filter is above 30 when a stop command is given the controller will ask the user if it is allowed to perform a complete DPF Regeneration cycle before stopping When ENTER is pressed the HEST icon will appear See paragraph Always first shut off the controller and wait until the display is dark bef...

Page 41: ...ntil the display is dark before switching the battery switch to position OFF Diesel Particulate Filter Regeneration DIESEL PARTICULATE FILTER REGENERATION When the Diesel Particle Filter regeneration process is kept at its default AUTOMATIC setting then the DPF regeneration will be performed automatically when the Soot Load exceeds 60 The controller display will indicate an ongoing DPF Regeneratio...

Page 42: ...ll ask If Enter is pressed within 10 seconds then the controller will allow the DPF regeneration to be completed before the engine is stopped If Enter is not pressed within 10 seconds then the engine will be stopped after cooling down INHIBIT DPF REGENERATION When running in an environment where an elevated exhaust temperature is not allowed it might be necessary to inhibit DPF regeneration This h...

Page 43: ... PLEASE FORCE DPF REGEN ERATION warning press Enter while in the Main View 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 SOOT LOAD REACHES 92 When still no DPF regeneration is forced the next warning alarm will pop up Additionally the machine will be prevented to Load Requir...

Page 44: ...the DPF Regeneration settings will be back to default and an Automatic DPF Regeneration will take place at the soonest appropriate moment Machine is running Press the Settings View Button Enter the 1000 GENERAL SETTINGS menu Scroll one line down and Enter the 1140 ECU DPF REGENERATION menu OR Scroll down and Enter the MODE parameter Scroll down and Enter the AUTOMATIC setting Press the Back button...

Page 45: ... re back in the Main View or in the menu you require Set Language Press the SETTINGS VIEW button scroll to 1000 GENERAL SETTINGS press ENTER scroll to 1300 LANGUAGES ENTER the LANGUAGES menu ENTER the SETTINGS parameter scroll to the preferred language press ENTER Now press BACK until you re back in the Main View or in the menu you require Set Units Press the SETTINGS VIEW button scroll to 1000 GE...

Page 46: ...ENTER the Diagnostics menu ENTER the ENABLE parameter scroll to ON and press ENTER Now the ECU will get power and one can perform ECU diagnostics read DM1 List DM2 List ECU values perform engine diagnostics Now press BACK until you re back in the Main View or in the menu you require To leave Diagnostics press the STOP button ...

Page 47: ... COOLANT LEVEL LOW SHUTDOWN Shutdown Xc 2090 Δp 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 ...

Page 48: ...hutdown 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 6709 DRAINING 2 Warning Xc 6749 OILTRONIX FUNCTIONALITY DISABLED Warning Xc 6760 OILTRONIX COUPLING FAILU...

Page 49: ...rminated by the emergency stop itself hardware as well as by the software When the emergency stop button 1 is pressed the operator can unlock the emergency stop by turning it counterclockwise The emergency stop button is only to be used in emergency situations not for stopping procedures 1 ...

Page 50: ...lection 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 uptime of the unit The order numbers of the Service Kits are listed in the Atlas Copco Parts List ASL 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 c...

Page 51: ...ered at a reduced price compared to individual components Refer to the parts list for more information on the contents of the service kits Drain water from fuel filter x Drain condensate and water from spillage free frame or catch basin 10 x Empty air filter vacuator valves x Check engine oil level if necessary top up x Check compressor oil level if necessary top up x Check coolant level x Check F...

Page 52: ...eck functioning of regulating valve x x x Test safety valve 9 x x x Replace bleed off valve unloader x x x Check rubber flexibles 11 x x x Clean after cooler option 1 x x x Replace DD PD QD filter option x x x Clean oil stop valve x x x Change compressor oil 1 7 x x x Replace oil separator element x x x Clean fuel cooler x x x Clean crankcase breather filter and check for obstructions x x x Replac...

Page 53: ...lve as specified in the parts list 6 Gummed or clogged filters means fuel starvation and reduced engine performance 7 See section Oil specifications 8 The following part numbers can be ordered from Atlas Copco to check on inhibitors and freezing points 2913 0028 00 refractometer 2913 0029 00 pH meter 9 See section Safety valve 10 See section BEFORE STARTING 11 Replace all rubber flexibles every 6 ...

Page 54: ...ing of the overrun brake x x x Check brake system if installed and adjust if necessary x x x Oil or grease brake lever and moving parts such as bolts and joints x x x Check Adjust lateral play of wheel bearing x x x Check tyres for uneven wear x x Grease sliding points on height adjusting parts x x Check safety cable for damage x x Check Bowden cable on height adjustable connection device for dama...

Page 55: ... PRESSURE ECU FUEL FILTER PRESSURE ECU WATER IN FUEL ECU OIL LEVEL ECU OIL FILTER PRESSURE ECU OIL PRESSURE ECU TURBO BOOST PRESSURE ECU TURBO OIL PRESSURE ECU INTAKE MANIFOLD TEMPERATURE ECU AIR INLET PRESSURE ECU COOLANT TEMPERATURE ECU COOLANT LEVEL ECU SUPPLY VOLTAGE ECU AMBIENT AIR TEMPERATURE ECU AIR INLET TEMPERATURE ECU FUEL TEMPERATURE ECU OIL TEMPERATURE ECU ENGINE SPEED ECU INJECTOR 1 E...

Page 56: ... year Related instructions can be found in the following subsections In principle damaged parts have to be repaired or replaced Any other inspection jobs have to be carried out regularly by an expert at 6 month intervals Inspection list for the expert 1 To be performed by skill level 2 Mechanical technician 2 To be performed by skill level 3 Electrical technician Inspection jobs After the first ev...

Page 57: ...tection 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 Stage IIIB 3 2 TIER 4 Interim 3 2 engines running on low sulphur diesel for lower oil and fuel consumption PAROIL E xtra is a Synthetic ultra high performance diesel engine oil with a hig...

Page 58: ...thetic compressor oil PAROIL S Mineral compressor oil PAROIL S xtreme Liter US gal Order number can 5 1 3 1630 0160 00 can 20 5 3 1630 0161 00 barrel 210 55 2 1630 0162 00 container 1000 264 1630 0163 00 Liter US gal Order number can 20 5 3 1630 0180 00 barrel 210 55 2 1630 0181 00 container 1000 264 1630 0182 00 ...

Page 59: ...ra PAROIL E MISSION GREEN PAROIL E xtra PAROIL E MISSION GREEN Synthetic engine oil PAROIL E xtra Mineral engine oil PAROIL E Mission Green Liter US gal Order number can 5 1 3 1630 0135 00 can 20 5 3 1630 0136 00 Liter US gal Order number can 5 1 3 1630 0471 00 can 20 5 3 1630 0472 00 barrel 210 55 2 1630 0473 00 ...

Page 60: ...e frequent oil drain intervals Increase overall operating costs Failures that result from the use of improper fuels will not be covered by warranty Oil and oil filter change ENGINE OIL ANPreventive maintenance scheduleD OIL FILTER CHANGE See section Preventive maintenance schedule TOPPING UP THE COMPRESSOR OIL 1 Stop the compressor Wait a few minutes until the pressure is released through the auto...

Page 61: ... that no dirt gets into the system Reinstall and tighten the filler plug 6 Start the compressor 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 DIESEL EXHAUST FLUID In this case contact Atlas Copco Never add more oil Overfilling results in oil consumption DEF meeti...

Page 62: ...a new oil separator screw on new compressor oil filter s and close the oil vessel according to the instructions 6 Fill the oil vessel with the minimum amount of replacement oil run the compressor under light load conditions for 30 minutes 7 Thoroughly drain the system when the oil is warm leaving as little oil in the system as possible espe cially in dead areas if possible blow out remaining oil b...

Page 63: ... PARCOOL EG inhibits corrosion deposit formation is minimized This effectively eliminates flow restriction problems through the engine coolant ducts and the radiator minimizing the risk of 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 you...

Page 64: ...olant check In order to guarantee the lifetime and quality of the product thus optimising engine protection regular coolant condition analysis is recommended The quality of the product can be determined by three parameters Visual check Verify the appearance of the coolant with regard to its colour and make sure that no loose particles are floating around pH measurement Check the pH value of the co...

Page 65: ...on tank at low level this quantity is to be filled without draining from the cooling system 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 Liter PARCOOL EG Concentrate PN 1604 8159 00 4 0 0 0 5 1 0 1 5 2 0 2 5 3 0 3 5 4 0 4 5 5 0 5 5 6 0 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 Engin...

Page 66: ...ration In case of expansion tank at normal level this quantity is to be drained from the cooling system 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 Liter PARCOOL EG Concentrate PN 1604 8159 00 4 8 12 16 20 24 28 32 36 40 44 48 52 56 60 64 68 72 76 80 84 0 0 2 5 5 0 7 5 10 0 12 5 1...

Page 67: ...until normal engine operation tem perature is reached Turn off the engine and allow to cool Recheck coolant level and add if necessary Cleaning coolers Keep the coolers 1 2 and 3 clean to maintain the cooling efficiency Service doors 4 are provided on both sides of the fan cowl to allow easy access to the fan side surface of the coolers Clean by air jet in the direction of the arrow Steam cleaning...

Page 68: ...perating conditions i e temperatures number of starts running time between start and stop etc If a battery starts to need excessive make up water this points to overcharging Most common causes are high temperatures or a too high voltage regulator setting If a battery does not need any make up water at all over a considerable time of operation an undercharged battery condition may be caused by poor...

Page 69: ...lar inspections in conformity with local regulations SAFETY VALVE Following checks must be carried out A check of the opening of the lifting gear twice a year This can be done by screwing the cap of the valve anti clockwise An annual check of the set pressure according to local regulations This check cannot be done on the compressor and must be carried out on a proper test bench 1 Snap clips 4x 4 ...

Page 70: ... misfires operate at low idle until the engine is running smoothly If the engine cannot be started continue to prime the fuel system for 30 more sec onds Replacing filter elements Replacing the filter elements Installation instructions 1 Drain fuel from the bowl 2 Remove filter 3 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 ...

Page 71: ... and oil from the bearing cone using a suitable solvent Dry the bearing with clean lint free cloth and inspect the rollers completely If any pitting spalling or corrosion is present then replace the bearing The bearing cup inside the hub must be inspected also ALWAYS REPLACE THE BEARINGS AND CUP IN SETS 1 When replacing the bearing cup proceed as follows 2 Place the hub on a flat work surface with...

Page 72: ... 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 represen...

Page 73: ...ews 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 overheating Fuel tank ...

Page 74: ...ent 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 st...

Page 75: ...ate the valve Rotate the white coupling of the valve manually until the blind hole 2 in the coupling is in line with the threaded hole 3 in the housing Block the valve by screwing a bolt M5 x 20 through the housing and in the blind hole in the coupling Check the correct position of the blind hole with a 4 mm pin Contact Atlas Copco for a thorough scan and repair 1 3 2 ...

Page 76: ...el tank to get larger intervals between two fuel supply actions INLET SHUTDOWN 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 pneumatically controlled solenoid valve closes off the air inlet and the fuel supply to the engine is cut FORK LIFT SLOTS With fork lift slots the compressor...

Page 77: ...fter cooler is used in an application where the temperature is critical the air outlet temperature can be monitored by the compressor controller A warning can be set at a value between 0 C and 115 C default value and a shut down can be set at a value between 0 C and 120 C default value The operator has authority to modify these values so the process can be guarded and kept in a safe condition unde...

Page 78: ...10 154 98 M16 345 254 61 Assemblies Torque value Nm lbf ft Axles to frame Wheel nuts 270 199 26 Bolts front axle frame 205 151 29 Bolts rear axle frame 205 151 29 Compressor to frame Bolts elements gear casing 46 33 95 Bolts elements support 80 59 04 Bolts support buffer 205 151 29 Bolts buffer frame 80 59 04 Engine to frame Bolts engine support 205 151 29 Bolts support buffer 46 33 95 Bolts buffe...

Page 79: ... Nominal effective working pressure bar e 25 16 35 02 psi 365 508 Designation Units XRVS 1000 CD8 T4F 365 psi 508 psi Minimum effective receiver pressure bar e 21 02 21 02 psi 305 305 Maximum effective receiver pressure compressor unloaded bar e 35 02 35 02 psi 508 508 Maximum ambient temperature at sea level C 50 50 F 122 122 Minimum starting temperature C 23 33 23 33 F 10 10 Minimum starting tem...

Page 80: ... Fuel KG KW hr DEF Consumption gph DEF DEF to Fuel Ratio Unloaded Idle 0 116 1400 4 23 55 7 0 038 0 130 3 07 Loaded Idle 0 508 1400 12 70 18 6 0 115 0 342 2 69 25 1062 365 1900 22 02 10 7 0 200 0 618 2 81 30 981 437 1775 21 17 11 1 0 192 0 591 2 79 35 911 508 1650 20 32 11 6 0 185 0 618 3 04 Compressed Air Conditions Standard Outlet ppm 5 Typical oil content of compressed air F 1062 911 Compressed...

Page 81: ...236 Service Level Engine Oil Change hrs 500 ChangeService Level Compressor Oil Change hrs 1000 Designation All units Dimensions L x W x H in 205 X 88 X 101 mm 5207 X 2235 2 x 2565 2 Weight with fuel lbs 16815 kg 7627 15 1 At reference conditions if applicable and at normal shaft speed unless otherwise stated 2 Free air delivery is measured according to ISO 1217 ed 3 1996 annex D Tolerance 5 25 l s...

Page 82: ...TITUDEUNIT PERFORMANCE CURVE Max achievable working pressure in relation to altitude and ambient temperature Graph represents working conditions for starting conditions please contact your Atlas Copco contact ...

Page 83: ... 83 Unit Dimensions ...

Page 84: ...ycling in the future is foreseen Disposal of materials Dispose of contaminated substances and material separately in accordance with locally applicable environmental legislation Before dismantling a machine at the end of its operating lifetime drain and dispose of all fluids of according the applicable local disposal regulations Remove the batteries Do not throw batteries into the fire explosion r...

Page 85: ... 85 Maintenance Log Compressor Customer Serial number Service hours Maintenance action Date By initials ...

Page 86: ... 86 Maintenance Log Compressor Customer Serial number Service hours Maintenance action Date By initials ...

Page 87: ......

Page 88: ...www atlascopco com ...

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