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Xas 96 JD
Xas 96 JD
Xas 96 JD
XAS96
Instruction Book
1310 3011 08 Ed. 0 1998-06
Selected Lubricants
Compressor: Capacity:
Name:
Address:
Telefax: Parts:
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1.2 General Safety Precautions 11 Maintenance and repair work should be recorded in an
operators logbook for all machinery. Frequency and nature of
1 The owner is responsible for maintaining the unit in a repairs can reveal unsafe conditions.
safe operating condition. Unit parts and accessories 12 The machinery and pneumatic equipment shall be kept clean,
must be replaced if missing or unsuitable for safe i.e. as free as possible from oil, dust or other deposits.
operation.
13 To prevent an increase in working temperature, inspect and
clean heat transfer surfaces (cooler fins, intercoolers, water
jackets, etc.) regularly. For every machine establish a suitable
time interval for cleaning operations.
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20 Observe scrupulous cleanliness during maintenance - Apply safety chains to tow vehicle.
and repair. Keep away dirt by covering the parts and 2 If the unit is to be backed up by the towing vehicle, disengage
exposed openings with clean cloth, paper or tape. the overrun brake mechanism (if equipped).
21 Protect the engine, alternator, air intake filter, 3 Never exceed the maximum towing speed of the unit.
electrical and regulating components, etc. to prevent
moisture ingress, e.g. when steam-cleaning. 4 Place the unit on level ground and chock the wheels before
disconnecting the unit from the towing vehicle. Unclip the
22 When performing any operation involving heat, safety break-away cable
flames or sparks on a machine, the surrounding
components shall first be screened with non- 5 When the unit has to operate in a fire-hazardous environment,
flammable material. each engine exhaust has to be provided with a spark arrestor
to trap incendiary sparks.
23 Never use a light source with open flame for
inspecting the interior of a machine, pressure vessel, 6 The exhaust contains carbon monoxide which is a lethal gas.
etc. When the unit is used in a confined space, conduct the engine
exhaust to the outside atmosphere by a pipe of sufficient
24 On portable units, support the drawbar and axle(s) diameter (min. 4 inches); do this in such a way that no extra
securely if working underneath the units or when back pressure is created for the engine. If necessary, install an
removing a wheel. Do not rely on jacks. extractor.
25 Prior to stripping a compressor, engine or other 7 When operating in a dust-laden atmosphere, place the unit so
machine or undertaking major overhaul on it, prevent that dust is not carried towards it by the wind. Operation in
all movable parts with a mass exceeding 15 kg (30 clean surroundings considerably extends the intervals for
lbs) from rolling over or moving. cleaning the air intake filters and the cores of the coolers.
26 When repair has been completed, make sure that no 8 Locate the unit away from walls. Take all precautions to
tools, loose parts or rags are left in, or on, the ensure that hot air exhausted from the engine and driven
machine, the prime mover or the driving gear. The machine cooling systems cannot be recirculated. If such hot
machine shall be barred several revolutions to ensure air is taken in by the engine or driven machine cooling fan,
that there is no mechanical interference within the this may cause overheating of the unit; if taken in for
machine or driver. combustion, the engine power will be reduced.
9 No external force may be exerted on the air outlet valves, e.g.
1.3 Safety during use and operation by pulling on hoses or by installing auxiliary equipment
directly to a valve, e.g. a water separator, a lubricator, etc.
To lift a unit, all loose or pivoting parts, e.g. doors shall
first be securely fastened. Do not attach cables, chains or 10 Distribution pipework and air hoses must be of correct size
ropes directly to the lifting eye; apply a crane hook or and suitable for the working pressure. Never use frayed,
lifting shackle meeting local safety rules. damaged or deteriorated hoses. Replace hoses and flexibles
Helicopter lifting using the lifting eye is forbidden. of which the lifetime expired. Use only the correct type and
size of hose end fittings and connections.
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11 Never move a unit when external lines or hoses are - all fasteners are tight
connected to the outlet valves, to avoid damage to - all electrical leads are secure and in good order,
valves and/or manifold and hoses.
- the engine exhaust system is in good condition,
12 Never refill fuel while the unit is running. Keep fuel
away from hot parts such as air outlet pipes or the - air outlet valves and manifold, hoses, couplings, etc. are in
engine exhaust. Do not smoke when fueling. When good repair, free of wear or abuse,
fueling from an automatic pump, a ground cable - the wheel nuts are tightened to the proper torque.
should be connected to the unit to discharge static
electricity. Never spill nor leave oil, fuel, coolant or When more than one compressor is connected to a common
cleansing agent in or around the unit. header, be sure each compressor has a non-return valve (check
valve) to prevent reverse rotation when stopping.
1.4 Safety During Maintenance and 6 Scrupulously observe cleanliness during maintenance and
Repair when performing repairs. Keep dirt away by covering the
parts and exposed openings with a clean cloth, paper or tape.
Maintenance and repair work shall only be carried out by
adequately trained personnel: if required, under 7 Never weld on or perform any operation involving heat near
supervision of someone qualified for the job. the fuel or oil systems. Fuel and oil tanks must be completely
purged, e.g. by steam-cleaning, before carrying out such
1 Use only the correct tools for maintenance and repair operations.
work.
Never weld on, or in any way modify, pressure vessels.
2 Use only genuine spare parts. Disconnect the alternator cables during arc welding on the
3 All maintenance work, other than routine attention, unit.
shall only be undertaken when the unit is stopped. 8 Support the drawbar and the axle securely if working
Ensure that the unit cannot be started inadvertently. underneath the unit or when removing a wheel. Do not rely
4 Before removing any pressurized component, on jacks.
effectively isolate the compressor from all sources of 9 Make sure that no tools, loose parts or rags are left in or on the
pressure and relieve the entire system of pressure. Do unit.
not rely on non-return valves (check valves) to isolate
pressure systems. 10 Before clearing the unit for use after maintenance or overhaul,
check that operating pressures, temperatures and speeds are
5 Never use flammable solvents or carbon tetrachloride correct and that the control and shutdown devices function
for cleaning parts. Take safety precautions against correctly.
toxic vapors of cleaning liquids.
11 Do not remove any of, or tamper with, the sound damping
material. Keep the material free of dirt and liquids such as
fuel, oil and cleansing agents.
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+ This symbol is followed by supplementary When the air consumption increases, the air receiver pressure will
decrease and vice versa.
Information.
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 is maintained between the pre-selected working
pressure and the corresponding unloading pressure.
— Cooling System
Engine and compressor are provided with a radiator and oil cooler.
The cooling air is generated by a fan, driven by the engine.
— Safety Devices
A thermal shut-down switch 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 switches and an alternator V-belt
protection.
— Frame and Axle
Fig. 2.1 General view of XAS 96 JD The compressor/engine unit is supported by rubber buffers in the
frame.
The standard XAS 96 JD has an adjustable drawbar with a towing
2.2 General Description eye.
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The operator is expected to apply all relevant safety ù Lifting acceleration and retardation must be kept within
precautions, including those mentioned on the Inside of safe limits (max. 2xg).
the cover of this book.
Helicopter lifting is not allowed.
Attention:
— Check and retighten the wheel nuts and drawbar bolts 3.2 Before Starting
to the specified torque. See section 7.
ù If the compressor is to be connected to a common
3.1.1 Parking Instructions compressed air system, fit an appropriate check valve
between compressor outlet and air system. Observe the
When parking a compressor, secure prop (1) or nose right mounting position/direction!
wheel to support the compressor in a level position. Place
the compressor as level as possible; however, it can be 1. Before initial start-up, prepare battery for operation if not
operated temporarily in an out-of-level position not already done. See section 4.7.
exceeding 15°. If the compressor is parked on sloping 2. With the compressor standing level, check the level of the
ground, immobilize the compressor by placing wheel engine oil. Add oil, if necessary, to the upper mark on
chocks in front of or behind the wheels. Locate the dipstick. Consult the Engine Operation Manual for the type
compressor upwind, away from contaminated wind- and viscosity grade of the engine oil.
streams and walls. Avoid recirculation of exhaust air
from the engine. This causes overheating and engine 3. Check the level of the compressor oil. The pointer of oil level
power decrease. gauge (OLG- Fig. 2.3) should register in the green range.
Add oil if necessary. See section 4.3 for the oil to be used.
3.1.2 Towing Instructions ù Before removing oil filler plug (FP1- Fig. 2.3), ensure
that the pressure is released by opening an air outlet
valve.
4. Check that the fuel tank contains sufficient fuel. Top up, if
necessary. Consult the Engine Operation Manual for the type
of fuel.
5. Drain any water and sediment from the fuel filter until clean
fuel flows from the drain cock.
6. Press vacuator valve (VV- Fig. 2.2) of the air filter to remove
dust.
7. Check the air filter service indicator (VI- Fig. 2.2). If the red
part shows completely, service or replace the filter element.
Reset the indicator.
Fig. 3.1 Drawbar
8. Open an air outlet valve (AV-fig. 2.2to allow air flow to the
atmosphere.
Before towing the compressor, make sure that the towing
equipment of the vehicle matches the towing eye or ball
connector
The drawbar should be as level as possible and the
compressor and towing eye end in a level position.
Secure nose prop (1) in the highest position.
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(1) More frequently when operating in a dusty (2) Replace the element when the pressure drop
environment. exceeds 11.5 psi.
(3) Refer to the John Deere instruction manual.
ù Keep the bolts of the housing, the lifting eye, the towbar and the axle securely tightened. A Refer to ‘Technical
specifications for the torque values.
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Apply with preference the slow charging method and adjust 4.9 Service Kits
the charge current according to the following rule of thumb:
battery capacity in Ah divided by 20 gives safe charging A service kit is a collection of parts to fit a specific repair or
current in Amp. rebuilding task.
It guarantees that all necessary parts are replaced at the same
4.7.3 Battery Maintenance time which improves the uptime of the unit.
Keep the battery clean and dry The order numbers of the Service Kits are listed in the Atlas
Copco Parts List (ASL).
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The working pressure is determined by the tension of the 3. Check the minimum speed of the engine. Adjust
spring in the regulating valve. This tension can be increased minimum speed stop screw if necessary.
to raise the pressure and decreased to lower it by turning the
4. Open an outlet valve just enough to let the engine run at
adjusting wheel clockwise and counter-clockwise respectively.
maximum speed. The working pressure must be 7 bar(e)
To adjust the normal working pressure, proceed as follows: (102 psig); adjust if necessary with regulating valve (RV).
1. Start and warm up the engine (see section 3.3). 5. Check the engine maximum speed. Adjust the maximum
speed by means of adjusting eccentric nut on top of speed
2. With the outlet valves (AV) closed, pull out the knob,
regulator (SR).
adjust the regulating valve (RV) until a pressure of 8.5
bar(s) (123 psig) is reached. 6. Close the outlet valves, check that the pressure is between
8.3 and 8.7 bar(e) (120 and 126 psig). Lock the
regulating valve by pushing the knob down.
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1 Snap clips
2 Dust trap
3 Filter element
4 Safety cartridge (option)
5 Filter housing
6 Vacuator valve
5.2.2 Recommendations
ù The Atlas Copco air filters are specially designed for
the application. The use of non-genuine air filters
may lead to severe damage of engine and/or Fig. 5.3 Vacuum indicator
compressor element.
Never run the compressor without air filter element. 7 Air filter contamination indicator
New elements must also be inspected for tears or punctures 8 Reset button
before installation. 9 Red indicator
Discard the element (3) when damaged.
In heavy duty applications it is recommended to install a 5.3 Air Receiver
safety cartridge. The air receiver is tested according to official standards.
A dirty safety cartridge (4) is an indication of a mal- Regularly have inspections carried out in conformity with
functioning air filter element. Replace the element and the local regulations.
safety cartridge in this case.
Replace the safety cartridge together with the filter element. 5.4 Safety Valve
The safety cartridge cannot be cleaned.
ù All adjustments or repairs are to be done by an
authorized representative of the valve supplier.
5.2.3 Cleaning The Dust Trap
Following checks must be carried out:
To remove dust from the dust trap pinch the vacuator valve (6)
several times. - a check of the opening of the lifting gear, twice a year. This
can be done by lifting the ring.
5.2.4 Replacing The Air Filter Element - a check of the set pressure once a year according to the local
1. Release the snap clips (1) and remove the dust trap (2). regulations. This check cannot be done on the machine and
Clean the trap. must be carried out on a proper test bench.
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