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Xas 137 DD
Xas 137 DD
Xas 137 DD
Instruction Manual
for Portable Compressors
English
Printed matter N°
2954 3170 01 ATLAS COPCO - PORTABLE AIR DIVISION
04/2008 www.atlascopco.com
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INTRODUCTION
The policy of Atlas Copco is to provide the users of It is the responsibility of management to appoint Take necessary steps to keep unauthorized persons
their equipment with safe, reliable and efficient operators with the appropriate training and skill for away from the unit and eliminate all possible sources
products. Factors taken into account are among each category of job. of danger at the unit.
others: When handling, operating, overhauling and/or
Skill level 1: Operator
- the intended and predictable future use of the performing maintenance or repair on Atlas Copco
products, and the environments in which they are An operator is trained in all aspects of operating the
unit with the push-buttons, and is trained to know the equipment, the mechanics are expected to use safe
expected to operate, engineering practices and to observe all relevant local
- applicable rules, codes and regulations, safety aspects.
safety requirements and ordinances. The following
- the expected useful product life, assuming proper Skill level 2: Mechanical technician list is a reminder of special safety directives and
service and maintenance, A mechanical technician is trained to operate the unit precautions mainly applicable to Atlas Copco
- providing the manual with up-to-date the same as the operator. In addition, the mechanical equipment.
information. technician is also trained to perform maintenance and These safety precautions apply to machinery
Before handling any product, take time to read the repair, as described in the instruction manual, and is processing or consuming air. Processing of any other
relevant instruction manual. Besides giving detailed allowed to change settings of the control and safety gas requires additional safety precautions typical to
operating instructions, it also gives specific system. A mechanical technician does not work on the application and are not included herein.
information about safety, preventive maintenance, live electrical components.
etc. Neglecting the safety precautions may endanger
Skill level 3: Electrical technician people as well as environment and machinery:
Keep the manual always at the unit location, easy An electrical technician is trained and has the same - endanger people due to electrical, mechanical or
accessible to the operating personnel. qualifications as both the operator and the mechanical chemical influences,
See also the safety precautions of the engine and technician. In addition, the electrical technician may - endanger the environment due to leakage of oil,
possible other equipment, which are separately sent carry out electrical repairs within the various solvents or other substances,
along or are mentioned on the equipment or parts of enclosures of the unit. This includes work on live - endanger the machinery due to function failures.
the unit. electrical components. All responsibility for any damage or injury resulting
These safety precautions are general and some Skill level 4: Specialist from the manufacturer from neglecting these precautions or by non-
statements will therefore not always apply to a This is a skilled specialist sent by the manufacturer or observance of ordinary caution and due care required
particular unit. its agent to perform complex repairs or modifications in handling, operating, maintenance or repair, also if
Only people that have the right skills should be to the equipment. not expressly mentioned in this instruction manual, is
allowed to operate, adjust, perform maintenance or disclaimed by Atlas Copco.
In general it is recommended that not more than two
repair on Atlas Copco equipment. people operate the unit, more operators could lead to
unsafe operating conditions.
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(CPg)
(F)
(G) (EP)
(E)
(VI)
(RV) (BH)
(SV)
(TB)
(CP)
(FPco)
(OCce/OCe)
(OLG) (FF)
(A)
(AR) (D)
(FCeo)
(AOV) (DSe)
(OFce) (FCft)
(CE) (VV)
(FT)
(AF)
XA(S) 137 DDG - XA(S) 300 DD7G, XA(S) 137 DD - XA(S) 300 DD7
and XAHS 107 DD - XAHS 250 DD7 with some options
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Reference Name
AFce Air Filter Compressor/Engine
AFE Air Filter Element
AOV Air Outlet Valves
(AFE) AR Air Receiver/Oil Separator
(AFce)
(VI) BDV Blow Down Valve
(CV) (OC) BV By-Pass Valve Oil Filter
(RV) CE Compressor Element
(AR) CH Coupling Housing
(SV)
(OSE) CP Control Panel
(E) CV Check Valve
(R) (F)
(AOV) DP Drain Plug
(TSE)
(SRE) E Engine
(DP) (PSE) EW Electrical Wiring
(UA)
(BV) F Cooling Fan
(OFC) (OFE)
(SL) (BDV) OC Oil Cooler
(CP) (CH) OFC Oil Filter Compressor
(CE)
(EW)
OFE Oil Filter Engine
OSE Oil Separator Element
Air Atmospheric Pressure PSE Pressure Switch Engine
Air Regulating Pressure
R Restrictor
Air Working Pressure
Air/Oil Mixture
RV Regulating Valve
Oil
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(SVa)
(RV)
(BOV)
(UV)
(UA) (SR)
(VH)
(AR)
(CE)
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F1 5 30 31 2
33 3
K3
1 1 1 32 4 2 2
S5 S6
K4
K4
6 8 3 3 3 3 9 9 9 11 16 16 1 1
G2 + G1
B+ 7
V1 S2
D+
- D-
13
K0 S3
Auxiliary P
M1 14
K0 P1 Y1 K3 K2 H1 H2 K1 K5 K6 K5 K6
M h V2
15 10 17 18
P2 P3
K2 S4
K1
12 12 12 12 12 12 12 12 12 12 12
b3 b3 c1 a8 a8 d7 d6 d6
d10 d10
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L1
L2
L3
N
N
1 3 5 7
K5 2 4 6 8
W1
S7
U1
V1
b0 3
c0 c0 c0 c6 16 52 51 b3
Q1 MX b3
34
b6 b0 b0 b3 b3 b3
16 W1 16 13
To Circuit diagram
16A 16A 16A 16A 13 13 13 9822 0797 01
K6 14 12
11 A1
D1
H3 A1 K5 PR Y2 35
N R<
b6 b0 R T PE L A2 b6 A2 b6 B b6 b6
W1 b54 b54 b6 12 12 12 12
b0
12
W1
b54
c0 c0 c0 c6 b0
N
W
U
N
V
U1 V1 W1 N
G3
S6
u
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Atlas Copco mineral compressor oil. Compressor temperature too high. Use diesel fuel only.
4.75 bar
Atlas Copco synthetic compressor oil. Rotation direction. (69 psi)
Tyre pressure.
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Safety precautions
(4) (4)
The operator is expected to apply all
relevant safety precautions, including
those mentioned on the pages 5 - 11 of
this book.
(2)
(2)
Attention:
Before putting the compressor in to use, (1)
check the brake system as described in
section Brake (= option) adjustment.
Non-adjustable towbar with standard support leg without Parking position of jockey wheel
After the first 100 km travel: brakes
Check and retighten the wheel nuts and
towbar bolts to the specified torque. See When parking a compressor, secure support leg (1) or
section Height adjustment and section (3) jockey wheel (2) to support the compressor in a level
Torque values. position. Be sure that the jockey wheel (2) is blocked
by the blocking pin (4).
Check the brake adjustment. See section
Brake (= option) adjustment. Apply parking brake by pulling parking brake handle
(3) upwards. Place the compressor as level as
possible; 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.
(2)
(4)
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(1)
(3)
(2)
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Attention:
When lifting the compressor, the hoist has to be
Before towing the compressor, make placed in such a way that the compressor, which must
sure that the joints of the towbar are • Height adjustment should be undertaken on be placed level, will be lifted vertically. Keep lifting
secured with maximum strength without levelled ground and in coupled condition. acceleration and retardation within safe limits.
damaging the towbar. Be sure that there • When readjusting, make sure that the front point Preferably use the lifting eye (1) herefore open the
is no clearance between the teeth of the of the towbar is horizontal to the coupling point. small door (2).
joints.
• Before starting a trip, ensure that the adjustment Lifting acceleration and retardation
shaft is secure, so that the stability and safety is must be kept within safe limits (max. 2g).
guaranteed while driving. If necessary tighten the
locking nut (2) corresponding to table. Helicopter lifting is not allowed.
Lifting is not allowed when the unit is
For specific instruction see below! running.
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BEFORE STARTING
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(F1)
H2 0 1 2 3 S4 A
B
Reference Name
P1 Hourmeter
F1 Circuit breaker button
PG Working pressure gauge
H1 Temperature alarm lamp (red)
H2 General alarm lamp (red)
S1 Start switch
The circuit breaker button is a
S4 Lamp test button protection against unintended starting
of the compressor.
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1. To start, turn start switch S1 clockwise to position 4. The start switch automatically springs back to
1, lamp H2 (general alarm lamp) will go on. position 1.
2. Check correct operation of alarm lamps H1 and Lamp H1 only will go on when the compressor
H2 by pushing lamp test button S4. Both alarm outlet temperature is too high.
lamps (red) should go on. 5. Close the air outlet valve(s) (AOV).
3. Turn start switch S1 further clockwise into
position 3.
The starter motor will set the engine in motion.
The maximum allowed starter time, where the
starter motor is running continuously is 20
seconds.
If the engine does not catch, a new attempt can be
made after 30 seconds waiting.
The temperature alarm lamp H1 and the general
alarm lamp H2 will go out as soon as the engine
has been started.
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X1.1 Socket 400 V/16 A X1.3 Socket 230 V/16 A Q1 Main circuit breaker 4-pole
X1.2 Socket 400 V/16 A S1 ON/OFF switch K8 Insulation monitoring relay
K1 Earthing clamp
Before connecting an electrical device,
Start the unit in accordance with the normal always check the data listed on the rating
procedure. Let the motor warm up until it reaches plate.
operational temperature.
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A
B
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Maintenance schedule Daily Initially Every 500 hours Every 1000 hours
Service pak
XA(H)(S) 107-137 / 250-300 DD(7)G 2912 4490 05 2912 4491 06
Standard
Service pak
XA(H)(S) 107-137 / 250-300 DD(7)G 2912 4492 05 2912 4493 06
Heavy duty filter system (option)
Engine oil level Check
Compressor oil level Check
Air filter vacuator valves Empty
Fuel filter water drain Drain
Air intake vacuum indicators Check
Electrolyte level and terminals of battery Check Check Check
Tyre pressure Check Check Check
Leaks in air-, oil- or fuel system Check Check Check
Oil coolers Clean Clean
Engine minimum and maximum speeds Check Check Check
(to be continued on page 35)
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(1)
CHECK ENGINE OIL LEVEL
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ENGINE OIL AND OIL FILTER CHANGE 2. Drain the oil by removing all relevant drain plugs.
(2) Drain plugs are located at the air receiver,
For replacing the engine oil filter, see section compressor element and compressor oil cooler.
Preventive maintenance schedule for the Catch the oil in a drain pan. Screw out the filler
compressor. plug to speed up draining. Tighten the plugs after
draining.
3. Remove the oil filter (1), e.g. by means of a
special tool. Catch the oil in a drain pan.
4. Clean the filter seat on the manifold, taking care
that no dirt drops into the system. Oil the gasket of
the new filter element. Screw it into place until the
gasket contacts its seat, then tighten one half turn
only.
(1) (3)
5. Fill the air receiver until the pointer of the oil level
gauge (3) registers in the upper extremity of the
The quality and the temperature of the oil determine green range. Take care that no dirt drops into the
the oil change interval. system. Reinstall and tighten the filler plug.
The prescribed interval (see section Preventive 6. Run the unit at no load for a few minutes to
maintenance schedule for the compressor) is based circulate the oil and to evacuate the air trapped in
on an oil temperature of up to 100 °C (212 °F) and the oil system.
normal operating conditions. 7. Stop the compressor. Let the oil settle for a few
When operating in high ambient temperatures, in very minutes. Check that the pressure is released by
dusty or high humidity conditions, it is recommended opening an air outlet valve. Screw out filler plug
to change the oil more frequently. (2) and add oil until the pointer of the oil level
gauge (3) again registers in the upper extremity of
In this case, contact Atlas Copco. the green range. Reinstall and tighten the filler
plug.
1. Run the compressor until warm. Close the outlet
valve(s) and stop the compressor. Wait until the Never add more oil. Overfilling results in
pressure is released through the automatic blow- oil consumption.
down valve. Unscrew the oil filler plug (2) one
turn. This uncovers a vent hole, which permits any
pressure in the system to escape.
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Steam cleaning in combination with a cleansing agent Before handling batteries, read the
may be applied. relevant safety precautions and act
(1) accordingly.
To avoid damaging the coolers, angle
between jet and coolers should be If the battery is still dry, it must be activated as
approx. 90 °. described in section Activating a dry-charged
(do not use jet at max. power) battery.
Protect the electrical and controlling The battery must be in operation within 2 months
equipment, air filters, etc. against from being activated; if not, it needs to be recharged
penetration of moisture. first.
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(SVa)
(RV)
(E)
(SR)
(AOV)
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To adjust the normal working pressure, proceed as 6. Close the outlet valves (AOV), check that the
follows: pressure is between Z1 and Z2 bar(e) (see table).
Lock the regulating valve (RV) by fixing the lock
1. Start and warm up the engine (see section
nut.
Starting/Stopping).
2. With the outlet valves (AOV) closed, loosen the
regulating valve’s lock nut and adjust the
regulating valve (RV) until a pressure of X bar(e)
is reached (see table).
3. Check the minimum speed of the engine. Adjust
minimum speed stop screw if necessary.
4. Open an outlet valve (AOV) just enough to let the
engine (E) run at maximum speed. The working
pressure must be Y bar(e); adjust if necessary with
regulating valve (RV) (see table).
5. Check the engine maximum speed. Adjust the
maximum speed by means of adjusting eccentric
nut on top of speed regulator (SR).
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The Atlas Copco air filters are specially Remove dust daily.
designed for the application. The use of (1) To remove dust from the dust trap pinch the vacuator
non-genuine air filters may lead to valve (6) several times.
severe damage of engine and/or
compressor element.
CLEANING INSTRUCTIONS FILTER
Never run the compressor without air ELEMENT
filter element.
If element cleaning can not be avoided, care should be
taken that the filter element (4) is not washed out.
SERVICING Please note that engine damage can cause
considerable costs, which makes the cost of a new
Always select the service point according to the
filter element seam insignificant.
vacuum indicator or display message. A regular (6)(2) (3)(4) (5) (8)
inspection or cleaning as it is sometimes practiced in (7) Safety cartridges (3) can not be cleaned but must be
the field is more likely to be damaging than useful as (9) exchanged.
there is a risk that the element will be damaged and Please note that a cleaned element will never match
dust will gain access to the engine.
the service life and performance of a new element.
Atlas Copco always recommends exchanging 1. Snap clips 6. Vacuator valve Take the element from the air filter housing (5) (see
rather than cleaning the filter element in order to 2. Dust trap cover 7. Vacuum indicator section Replacing the air filter element).
avoid damage and ensure maximum engine
3. Safety cartridge 8. Reset button
protection.
(option)
4. Filter element 9. Yellow indicator
5. Filter housing
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1. Release the snap clips (1) and remove the dust trap
(2). Clean the trap.
(6) (2) (3)(4) (5)
2. Remove the element (4) and the safety cartridge.
3. Reassemble in reverse order of dismantling. Make
sure the vacuator valve (6) points down.
4. Inspect and tighten all air intake connections.
5. Reset the vacuum indicator by pressing the reset
button (5).
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The air receiver (1) is tested according to official Replacing the filter element
standards. Regularly have inspections carried out in
1. Unscrew the filter element (1) from the adapter
conformity with local regulations. 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. Check for fuel leaks once the engine has been
restarted.
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1
2. Check if the adjustable towbar (= option) is in the
actual towing position.
2
3. Apply the hand brake lever.
4. Push the compressor a few centimeters backwards
B. Acceptable so that the brake lever is automatically pulled
further up.
5. Check the position of the arrow marking ”1” at the
catch lock in combination with the arrow marking
”2” at the toothed sector, according to A,B,C,D.
C. Too loose;
adjust brake cables
(Section Brake
A. Adjusted correctly cable adjustment)
D. Too tight;
adjust brake cables
(Section Brake
cable adjustment)
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Alternator precautions
1. Never reverse the polarity of the battery or the
alternator.
2. Never break any alternator or battery connections
while the engine is running.
3. When recharging the battery, disconnect it from
the alternator. Before using booster cables to start
the engine, be sure of the polarity and connect the
batteries correctly.
4. Never operate the engine without the main or
voltage sensing cables connected in the circuit.
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The following tables list the recommended torques applied for general applications
at assembly of the compressor. Assemblies Torque value (Nm / lbf.ft)
Wheel nuts 120 (88.56) +/- 15
Bolts, axle/beams 205 (151.29) +/- 20
For hexagon screws and nuts with strength grade 8.8 Bolts, towbar/axle 80 (59.04) +/- 10
Bolts, towbar/bottom 205 (151.29) +/- 20
Thread size Torque value (Nm / lbf.ft)
Bolts, towing eye/towbar 80 (59.04) +/- 10
M6 9 (6.64)
Bolts, lifting eye/flywheel housing 205 (151.29) + 20
M8 23 (16.97)
Bolts, engine/drive housing (M12) 80 (59.04) +/- 10
M10 46 (34.69
Bolts, engine/drive housing (M14) 125 (92.25) +/- 10
M12 80 (59.04)
Bolts, compressor element/drive 80 (59.04) +/- 5
M14 125 (92.25) housing
M16 205 (151.29) Safety switches 35 (25.83) +/- 5
Joints adjustable towbar (M24) 275 (202.95) +/- 25
For hexagon screws and nuts with strength grade 12.9
Joints adjustable towbar (M32) 375 (276.75) +/- 25
Thread size Torque value (Nm / lbf.ft)
M6 15 (11.07) Secure the drain cock and tank cap of the fuel tank handtight.
M8 39 (28.78)
M10 78 (57.56)
M12 135 (99.63)
M14 210 (154.98)
M16 345 (254.61)
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REFERENCE CONDITIONS
The inlet conditions are specified at the air inlet grating outside the canopy.
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ALTITUDE IN FT
ALTITUDE IN FT
ALTITUDE IN M
ALTITUDE IN M
ALTITUDE IN M
102 psi 174 psi
0 0 ft 0 0 ft 0 0 ft
-10,0 0,0 10,0 20,0 30,0 40,0 50,0 -10,0 0,0 10,0 20,0 30,0 40,0 50,0 -10,0 0,0 10,0 20,0 30,0 40,0 50,0
TEMPERATURE IN °C TEMPERATURE IN °C TEMPERATURE IN °C
XAS 137 Dd XAS 137 DdG XAHS 107 Dd
XAS 300 DD7 27/jul/07 XAS 300 DD7G 3/aug/07 XAHS 250 DD7 27/jul/07
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At reference conditions, if applicable, and at normal shaft speed, unless otherwise stated.
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1) Free Air Delivery (volume flow rate) is measured according to ISO 1217 ed.3 1996 annex D
Tolerance:
• +/- 5% 25 l/s (53 cfm) < FAD < 250 l/s (530 cfm)
• +/- 4% 250 l/s (530 cfm) < FAD
The international standard ISO 1217 corresponds to following national standards:
• British BSI 1571 part 1
• German DIN 1945 Part 1
• Swedish SS-ISO 1217
• American ANSI PTC9
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Compressor
Designation
Number of compression stages 1
Engine
Designation XA(S) 137 DD - XA(S) 300 DD7 Designation XA(S) 137 DD - XA(S) 300 DD7
XA(S) 137 DDG - XA(S) 300 DD7G XA(S) 137 DDG - XA(S) 300 DD7G
XAHS 107 DD - XAHS 250 DD7 XAHS 107 DD - XAHS 250 DD7
Make Deutz Capacity of oil sump:
Type BF4M2011 - Initial fill l 11
Coolant Oil US gal 2.91
Number of cylinders 4 - Refill (max.) 1) l 6.5
Bore mm 94 US gal 1.72
in 3.70 1)
With filter change.
Stroke mm 112
in 4.41
Swept volume l 3.1
cu.in 189.7
Output according to DIN 6271 kW 58
at normal shaft speed BHP 77.8
- Load factor % 50
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Circuit-breaker
Fault current protection
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