X MD Presentation

Service training ‘98
X-Md range
Bob Rigouts
Portable Air GAC 41

Agenda
• Definitions & Product range
• Air, oil & fuel system
• Regulating system
• Electrical system
• Maintenance
• Trouble shooting
• Service info
• Key figures
Portable Air GAC 41
Definitions
actual pressure
+
effective
pressure
atmospheric
pressure absolute
pressure
vacuum
zero pressure -
(perfect vacuum)
Portable Air GAC 41
Definitions
• NO LOAD : machine runs with air receiver

NOT pressurized, no air is taken in
• UNLOAD : machine runs with air receiver

pressurized, no air is taken in
• LOAD : air is taken in and compressed

Portable Air GAC 41
Definitions
• FREE AIR DELIVERY
= measured, actually delivered volume of air,
converted to the same pressure and temperature
prevailing at the inlet
= only correct way to give the delivery capacity
of a compressor, taking into account internal
leakages
Portable Air GAC 41

Definitions
Pressure indication :
Working principle
A : single stage single stage : two stage :
compressor standard pressure : 7 bar 17 bar
R : two stage M : medium pressure : 8.6 bar
compressor H : high pressure : 12 bar 20 bar
V : very high pressure 14 bar 25 bar
Product range
X : oil injected
portable Silencing
compressor S : the S means that
the unit is silenced
X A M S 3 6 5 M d
Type of drive :
d : Diesel engine
E : Electric motor
Capacity
Approximate
compressor Engine manufacturer :
capacity in liters M : Mercedes
per second D : KHD Deutz
G : Detroit Diesel
Cu : Cummins
Portable Air GAC 41

Product range
• Portable, oil injected screw compressors

• Pressures : 7 25 bar
• Capacities : 265 615 l/s
• Driven by Mercedes engines
• 4 different engine types => ‘Md 1 / 2 / 3 / 4’
Portable Air GAC 41

Md 1 : OM 366 LA
• 6 in Line
• 1500 - 2400 rpm
• 151 kW DIN
• 163 kW SAE
• Turbocharged &
aftercooled
Portable Air GAC 41

Md 2 : OM 441 LA
• 6 in V
• 1000 - 1600 rpm
• 206 kW DIN
• 218 kW SAE
• Turbocharged &
aftercooled
Portable Air GAC 41
Md 3: OM 441 LA
• 6 in V
• 1000 - 1800 rpm
• 224 kW DIN
• 236 kW SAE
• Turbocharged &
aftercooled
Portable Air GAC 41
Md 4: OM 442 LA
• 8 in V
• 1000 - 1700 rpm
• 313 kW DIN
• 329 kW SAE
• Turbocharged &
aftercooled
Portable Air GAC 41
Product range
X Md RANGE Md 1 Md 2 Md 3 Md 4
engine type OM 366 LA OM 441 LA OM 441 LA OM 442 LA
6 cyl in line 6 cyl in V 6 cyl in V 8 cyl in V
SAE Power 163 kW 218 kW 236 kW 329 kW
DIN Power 151 kW 206 kW 224 kW 312 kW
max speed 2400 rpm 1600 rpm 1800 rpm 1700 rpm
Portable Air GAC 41

Product range
7 bar XAS 365 405 495 555 -

8.6 bar XAMS 295 355 445 505 615
12 bar XAHS 285 365 425 515
14 bar XAVS 265 335 375 465
17 bar XRS - - 415 -
20 bar XRHS - - 385 485
25 bar XRVS - - 345 455
Portable Air GAC 41

Air system : flow
• Air filters
• Unloader valve
• Compressor element(s)
• Check valve
• Air receiver
• Minimum pressure valve
Portable Air GAC 41

Air system : Air filters
• Solid polluants cause wear on bearings, rotors and
gears when suspended in oil.
• Sour, gaseous polluants cause internal corrosion.
==> beware for exhaust gas recirculation
• Pressure drop reduces compressor flow :
10 mbar ==> - 1 %
CLEAN AIR IS THUS EXTREMELY IMPORTANT

Portable Air GAC 41
• 3 to 5 dry-type heavy duty filters

• 3 stage filters
• 16 or 21 m³/min
Portable Air GAC 41
• Cyclone centrifugal pre-cleaner removes up to

85 % of the incoming dust
• Dust collects in the dust trap : clean daily
• Paper filter element removes up to 99.9 % (2µ)
• Safety cartridge protects air inlet when paper
element is removed : oil coating catches dust
• Saf. cartr. oil coating ages : replace after 2 years
Portable Air GAC 41
• Filters are monitored by a vacuum switch

– 35 mbar switch : Md 2
– 65 mbar switch : Md 1, 3, 4
– only service filters when warning lamp lights up
– more often disassembling and cleaning leads to
damage and improper sealing : avoid it !
• Press. drop over new element = 15 - 20 mbar
Portable Air GAC 41

Portable Air GAC 41

Air system : Throttle valve
• Spring-loaded piston valve

• Normal open position
• Throttles compressor air intake from 100 %
to 0 %
• Operated by means of control air (from reg.
valve) at the back side of the piston
Portable Air GAC 41

Air system : Throttle valve
• Small air passage during off load

maintains the pressure in the
air receiver to ensure lubrication
when no air is taken in
• Some air is taken in and bled off :
– Calibrated hole in piston
– Bleed-off valve
Portable Air GAC 41

Compressor element
• Oil injected screw compressor :

– positive displacement compressor with built-in
pressure ratio
• Output = proportional to speed
• Lifetime is determined by bearings
– clean air and good oil are a must
• Thermal expanion limits the maximum
operating temperature
Portable Air GAC 41
LP - compressor element
Portable Air GAC 41

Compressor element
• HIGH PRESSURE VARIANTS :

– two stage compression for better efficiency
– compressor elements : ‘size II short + HP’
(p/n LP 2934 9988 36
+ HP 2934 9988 23)
– XRS - XRHS - XRVS
– working pressure : 17/20/25 bar
safety valve :
Portable Air GAC 41 20 - 30 psi
HP
compressor
element
Portable Air GAC 41

Air system : Check valve
• Prevents blow back of compressed air
• On 2-stage : 2 valves in parallel :
– 1 normal check
valve
– 1 by-pass valve to
protect LP-
element
Portable Air GAC 41
Air system : Air receiver
• HAS 3 FUNCTIONS
– Air receiver
• evens pulsations
• stabilizes regulating
– Oil separator
– Oil tank
Portable Air GAC 41

Air system :
Minimum pressure valve
• Normally closed, opens by receiver pressure
• Prevents pressure from dropping below
minimum, necessary for :
– Cooling & lubrication
– Prevent foaming of oil in case of pressure drop
• Contains also a check valve to prevent
• blow back from the air net
Portable Air GAC 41
Air system :
Portable Air GAC 41

Air system :
Compressor type Minimum pressure
XAS 4 bar
XAMS 4 bar
XAHS 4 bar
XAVS 4 bar
XRS 12 bar
XRHS 12 bar
XRVS 15 bar
Portable Air GAC 41
Air system : Blow down valve
• Only XR
• Depressurizes air receiver
• Closed during operation
• by outlet pressure of
• compressor element
• Opens by air receiver pressure at shut-down
• Connected to oil stop valve
Portable Air GAC 41
Oil system
• OIL SERVES FOR :

• Cooling : compression heat
• Lubrication : rotors, bearings & gears
• Sealing : clearance compressor chamber &
rotor shaft ends
• Consequently corrosion protection : steel
OIL IS THUS EXTREMELY IMPORTANT !
Portable Air GAC 41
Oil system : flow
• Oil tank
• Oil cooler
• Oil filters
• Oil stop valve
• Compressor oil gallery
• Oil separator
Portable Air GAC 41

Oil system : Oil tank
• Combined with air receiver

• Contains most, but not all oil in the system
• The air pressure drives the oil out
• Minimum pressure required for adequate
lubrication & cooling
=> no oil pump necessary
Portable Air GAC 41

Oil system : Oil cooler
• Dissipates compression heat

• Thermostatic by-pass :
– closed below 70 °C
– completely open above 85 °C
– others can be fitted
• Setting is 80 °C on reheater
• Versions
Portable Air GAC 41
Oil system : thermostatic valve
Start of opening Completely open Part number

60 °C 75 °C 1202 5869 02
65 °C 80 °C 1202 5869 03
70 °C 85 °C 1202 5869 01
75 °C 90 °C 1202 5869 04
80 °C 95 °C 1202 5869 05
Portable Air GAC 41

Oil system : Oil filters
Portable Air GAC 41

Oil system : Oil filters
• Remove contamination
• 3 filters in parallel :
– low pressure version on XAS, XAMS
for max. 14 bar
– high pressure version on XAHS, XAVS, all XR
for max. 30 bar
• By-pass valve set at 2.5 bar
Portable Air GAC 41
Oil system : Oil stop valve
• Spring loaded valve

• Prevents elements
from flooding with
oil after shut down
• Closed by spring force and oil pressure
• Opened by discharge air from element
• Drain : lowest point of element
Portable Air GAC 41
Oil system : Oil separator
• Oil separation :
– centrifugal : 85 %
– shield : change of direction : 99 %
– separator element : 3 ppm
• Too high oil level :
– excess of oil is taken out with discharge air
– soaks separator => reduces efficiency
Portable Air GAC 41

Oil system : Oil separator
2 separator sizes : do not mix up
– Md 1 : 1615 5485 00 gasket

use kit 2911 0018 00
kit
separator
– Md 2, 3, 4 : 1615 6038 00
use kit 2911 0019 00 gasket
Portable Air GAC 41

Oil system : scavenging line
• Evacuates separated oil from separator

element
• Flow by pressure difference between air
receiver and compressor element
• Restrictor to minimize air leak back to
compressor element
Portable Air GAC 41

2 sizes of scavenge lines : do not mix up
– Md 1 : 1615 5487 01
length = 465 mm
– Md 2, 3, 4 : 1615 6052 02 L
length = 565 mm
Portable Air GAC 41

+
restrictor : 1615 9643 00
pipe : 1615 9642 00
Portable Air GAC 41
Fuel system
Portable Air GAC 41

Fuel system
injectors
3/3
1/3
fuel pre feed fine injection
tank filter pump filter pump
2/3
fuel fuel
FUEL FLOW tank cooler
Portable Air GAC 41
Fuel system
• 30 µ pre filter : p/n 2914 8070 00

• 10 µ fine filter : p/n 2914 8071 00
• 1.3 - 1.8 bar(e) = feed pump pressure
• 0.1 - 0.3 bar(e) = normal vacuum in suction lines
• 0.8 - 1.2 bar(e) = normal overpressure in pressure
lines
• 0.2 bar(e) = max filter pr. drop
Portable Air GAC 41

Fuel Cooling
• Only 1/3 of the circulated

fuel is used for combustion
• 2/3 is circulated for cooling
of injectors & pump
• 1% power increase for
each 5°C above 30°C
ambient.
Portable Air GAC 41
Portable Air GAC 41
Regulating system
• Serves to match air delivery to air demand

• Controls air delivery through :
– Engine speed variation
– Air intake throttling
• Components :
– Regulating valve
– Speed regulator
– Throttle valve
Portable Air GAC 41
Regulating valve
• Translates receiver pressure

in control pressure
• Supplies control pressure of
0 - 2 bar
• Control range :
– 8.6 bar : 1 bar
– 12 bar : 2 bar
Portable Air GAC 41

Regulating valve
Portable Air GAC 41

Regulating system
W.P. U.P. C.R.

p unloading pressure : U.P. XAS 7 8 1
XAMS 8,6 9,6 1
control range : C.R.
XAHS 12 14 2
XAVS 14 16 2
working pressure : W.P.
XRS 17 19 2
XRHS 20 22 2
XRVS 25 27 2
(values in bar(e) )
Portable Air GAC 41

Regulating valve
• Turning adjusting wheel clockwise

increases pressure set point
• Turning adjusting wheel anti-clockwise
decreases pressure set point
• Adjust during unload
• Set pressure 1 bar above working pressure
on XA/XAM; 2 bar on XAH/XR
Portable Air GAC 41
Regulating system
regulating
pressure
vacuum
speed
100%
max.
2
speed
min.
regulating
pressure
vacuum receiver
0 0 pressure
Portable Air min. working

GAC 41 unloading
Speed regulator
• Change engine speed between
minimum & maximum.
Compressor output changes
linear with the drive speed
• Spring loaded linear cylinder
• Connected to speed lever of injection pump
• In maximum speed position by spring force
• Operated by control air from regulating valve
Portable Air GAC 41

Speed regulator
• Maximum speed when pressure = between

minimum pressure and working pressure
• Variable speed when pressure = between
working pressure and unloading pressure
• Minimum speed when pressure = unloading
pressure
Portable Air GAC 41

Unloader valve
• Controls amount of air taken in by taking

any position between open and closed
• Spring forced in open position
• Operated (closes) by control air from
regulating valve
• Completely closed with 2 bar control
pressure
Portable Air GAC 41
Electrical system
• Power supply
• Starting system
• Shut-down system
• Control & indication system
Portable Air GAC 41

Power system
• 24 Volt DC : 2 batteries in series :

– Md 1 : 12 V - 110 Ah - 450 A (DIN)
– Md 2, 3, 4 : 12 V - 143 Ah - 540 A (DIN)
• Alternator with built-in rectifier and voltage
regulator
• Conventional instr. panel : 10 A thermic fuse
• Electronic instr. panel : self protecting
MOSFETs
Portable Air GAC 41
Starting system
• Starter solenoid built-in starter motor

• Safety relay connected to alternator output
cuts starter relay when alternator delivers
• Start prevention switch on air receiver
– set at 1,6 bar(e)
– prevents overload
– limit starting time (MB allows max. 20 sec)
Portable Air GAC 41

Starting system
• Extra fuel solenoid

on injection pump of
OM 441/442 LA
• Injects more fuel for
better starting while
p/n 2914 8104 00
starter motor is
engaged
Portable Air GAC 41
Shut down system
• Protects engine and compressor :

– low coolant level
– high coolant temperature (+105 °C)
– low engine oil pressure (-0.8 bar)
– low fuel level
– high LP or HP element outlet temperature
(Md1/2 : 120 °C - Md 3/4 : 130 °C)
Portable Air GAC 41

Shut down system
engine oil pressure

coolant temperature
switch
sensor
Portable Air GAC 41

Shut down system
coolant level sensor coolant level module

p/n 1089 0393 01 p/n 1089 0394 12
Portable Air GAC 41
Control & indication
• Till serial no AIP 286729 : Conventional

– F&M module for fault indication (not shut
down)
– F&M STD on Md 3/4, optional on Md 1/2
– Coolant module for coolant level monitoring
• From s/no AIP 286830 : Electronic
– Logic is programmed
– F&M indication is STD
Portable Air GAC 41
Control & indication
Fault indication & memory module : p/n 1615 5902 00

Portable Air GAC 41
Electronic instrument panel
• New features
– No override button
– F&M indication STD
– Automatic load feature
– Stand by in no load
– Warm-up & Cooldown
– Diagnostics
Portable Air GAC 41

No override
button
Additional indication :
Wait
Automatic load
Running loaded
Portable Air GAC 41
• Max. starting time = 20 sec.

• Warmup after start :
– Minimum warmup time = 30 sec
– Maximum warmup time = 5 min
– Warmup will be finished if coolant
temperature reaches 35 °C
– During warmup compressor cannot
be loaded
Portable Air GAC 41
• Loading :
max 5 min
during
warmup
after
warmup
Portable Air GAC 41

 Cool Down & Stop
– Press ‘Stop’ => compressor goes to no load to cool
down. After 30 seconds machine stops
Portable Air GAC 41

• DIAGNOSTICS FUNCTION:
– Switch machine on
– During lamptest press start and load button
• During 20 msec all outputs will be activated
• Shorted or open circuits are checked
• Malfunction will be indicated
• Module goes to off state after 60 min
Portable Air GAC 41
DURING
hourmeter gauges
LAMPTEST
starter warning load fuel

motor lamp solenoid solenoid
PUSH
Portable Air GAC 41
Maintenance
• Systematic preventive maintenance = basis

for long trouble free life
• First maintenance at
– Md 1 : 30 hours
– Md 2, 3, 4 : 50 hours
• Maintenance intervals :
– Md 1 : every 400 hours
– Md 2, 3, 4 : every 500 hours
Portable Air GAC 41
Maintenance : service kits
Type of kit XAS/XAMS XAHS/XAVS XRS/XRHS/
XRVS
Oil stop valve 2910 3001 00 2910 3001 00 2910 3001 00

Unloading valve 2910 3003 00 2910 3003 00 2910 3003 00
Speed regulator 2910 3006 00 2910 3006 00 2910 3006 00
Regulating valve 2910 3012 00 2910 3005 00 2910 3005 00
LP Element mounting 2910 4044 00 2910 4044 00 2910 4041 00
HP Element mounting - - 2910 4043 00
Min. press. valve 2911 0000 00 2911 0000 00 2911 3043 00
Oil separator Md 1 2911 0018 00 2911 0018 00 -
Oil separator Md 2, 3, 4 2911 0019 00 2911 0019 00 2911 0019 00
LP Element overhaul 2911 0063 00 2911 0063 00 2911 0063 00
HP Element overhaul - - 2910 4050 00
Gear casing 2911 0066 00
Portable Air GAC 41

Maintenance
• Reduce service intervals :
– when operating in extremely dusty conditions
– when operating at high ambient temperatures
Portable Air GAC 41

Maintenance : Daily
• Check oil levels (compressor + engine)

• Check coolant level
• Empty filter dust traps
• Drain fuel filter waterseparators
Portable Air GAC 41

Maintenance : Daily
engine oil level compressor oil air filter dust

level traps
Portable Air GAC 41

Maintenance : Daily
fuel filter waterseparators
check coolant level
Portable Air GAC 41

Maintenance : first 30/50 hours
• After a run in period of 30 hours on Md1,

50 hours on Md 2/3/4 :
– Change engine oil & oil filter
– Change compressor oil filters
– Adjust engine valve clearance
• The necessary parts are delivered with the
machine in the initial Service Pak kit
Portable Air GAC 41
Maintenance : valve clearance
• Check on cold engine, at least 20 minutes

after shutting off (max 50 °C coolant temp)
• Inlet valve clearance = 0.40 mm
• Exhaust valve clearance = 0.60 mm
• crank engine by hand at fan pulley
Portable Air GAC 41

• Crank engine to TDC mark on flywheel

• Check if CYL 1 is in ignition TDC (inlet &
exhaust valve closed)
==> adjust valves marked with 
if CYL 1 is in overlap TDC
==> adjust valves marked with 
Portable Air GAC 41

flywheelside
OM 366 LA OM 441 LA OM 442 LA

Portable Air GAC 41
TDC
mark
crank engine
measure adjust
Portable Air GAC 41

Maintenance : every 50 hours
• Lubricate all flexible joints
• Check pressure and condition of tyres
• Check electrolyte & battery terminals
• Check condition of belts, hoses, dampers
• Check condition & routing of wires & hoses
• Service air filters
• Check for air, oil, fuel or coolant leaks
• Check tightness of bolts & nuts
Portable Air GAC 41
Maintenance : every 50 hours
flexible joints tires
batteries belts
Portable Air GAC 41

Maintenance : 400 / 500 hours
• Same as ‘every 50 hours’

• Change engine oil & oil filter
• Change fuel filters
• Grease axle and towbar
• Drain water/sediment from fuel tank
• Check regulating system
• Check brake system
Portable Air GAC 41
drain engine oil drain oil filter change filter
Portable Air GAC 41

grease towbar drain sediments check regulating

and axle from fuel tank system
Portable Air GAC 41

• Same as 400/500 hours

• Change compressor oil
– drain cooler, receiver, check valve, oil stop
valve and gearbox
• Replace compressor oil filters
• Replace air filters
• Replace filter of regulating valve
Portable Air GAC 41
• Measure pressure drop separator element :

replace if pressure drop > 0.8 bar
• Clean restrictor scavenging line
• Test safety valve
• Test safety switches
Portable Air GAC 41

change air
& oil filters
drain gearbox, cooler,

o.s.v., c.v., vessel
Portable Air GAC 41
Maintenance
• Use of pirate parts holds

no certainty towards quality :
no warranty
• Service Pak contains all parts
for normal maintenance
• Use oil, fuel and coolant as specified
• Be alert for noise, temp. and vibration signals
Portable Air GAC 41
Maintenance : PAROIL
Portable Air GAC 41

(compressor)
• Md 1/2 : use mineral oil or synthetic oil
(Synthetic oil offers extended service
intervals + suited for high/low ambients)
• Md 3/4 : use only synthetic oil
• (Use only viscosity VG 46 : lower = too
thin oil film, higher = high engine load)
Portable Air GAC 41

(compressor)
• When filling the compressor system :
– first fill up to the upper edge of the filler pipe
– run shortly at no load to circulate the oil
– top up to the maximum level in the sight glass
• The quantity of oil also determines the
outlet temperature and lifetime of the oil
Portable Air GAC 41

Size Mineral Synthetic Engine
5 l can 1615 5947 00 1615 5950 00 1615 5953 00

20 l can 1615 5948 00 1615 5951 00 1615 5954 00
barrel 1615 5949 00 1615 5952 00 1615 5955 00
Portable Air GAC 41

Maintenance : Engine oil
• Use approved oil

• Use proper viscosity
class depending on
the ambient
temperature
Portable Air GAC 41

Maintenance : Coolant
• provide good heat transfer

• protect against cavitation damage
• corrosion/erosion resistant environment
• prevent scale or sludge deposits formation
• provide adequate frost protection
• be compatible with used materials
Portable Air GAC 41

• Use a 50% antifreeze - 50% water mixture

• Never use more than 55% or less than 40%
of antifreeze
• Tolerance : freezing point -45°C .. -25°C)
• Use antifreeze also when it doesn’t freeze
Portable Air GAC 41

• Use normal drinking water

• Never add water only
• Premix outside the coolant system
• Renew coolant every 2 years
• Never mix different coolants
Portable Air GAC 41

• When filling up the coolant

system:
– first fill to the maximum

– let the engine run shortly
to circulate the coolant
– top up again to the maximum
Portable Air GAC 41

Maintenance : fuel
• Use only commercial-grade diesel fuel

• If fuel can be contaminated by water, a
water separator must be installed
• If sulphur content is more than 0.5 %,
service intervals must be halved
Portable Air GAC 41

Maintenance : fuel
• Adding gasoline (winter) increases the

combustion temperature :
– never add premium gasoline
– never add more than 30 % of regular gasoline
Portable Air GAC 41

Maintenance : Engine speed
• Maximumspeed = sealed on injection pump

• Minimum speed = adjustable
• Minimum speed must be high enough to :
– avoid vibrations that can cause coupling failure
– supply sufficient torque and power for driving
the compressor so that the engine doesn’t stall
Portable Air GAC 41

Portable Air GAC 41

Max. engine speed 2400 - 2500 1600 - 1665 1800 - 1875 1700 - 1775
Min. unloaded speed XAS/XAMS 1500 - 1550 950 - 1000 1000 - 1040 1000 - 1040
Min. unloaded speed XAHS 1600 - 1650 950 - 1000 1000 - 1040 1050 - 1100
Minimum unloaded speed 1800 - 1850 950 - 1000 1000 - 1040 1050 - 1100
XAVS/XRS/XRHS/XRVS
Portable Air GAC 41

• Check speed with

digital tacho
• Adjust tachometer
on the instrument
panel if necessary
adjustment screw
Portable Air GAC 41
Maintenance : Discharge pipe
• Discharge pipe contains

flexible part
• FML : free moveable length
• Check FML when installing
• Durability depends on
correct mounting
Portable Air GAC 41

Maintenance : Discharge pipe
• FML is stamped on the pipe : length in mm,
measured under pressure
• FML = length of the visible wire braiding,
measured parallel to the centerline of the flexible
• Before assembly : length must be equal to
FML -2 / +0 mm
• After assembly : length must be equal to
FML -2 / +3 mm
Portable Air GAC 41

Maintenance : pressure switch
CONTACTS
NC=2 NO=4
C= 1
Portable Air GAC 41

Maintenance : pressure switch
• switch is adjustable
• load prevention switch :
– set at 5 bar
– switched normally open (terminal 1 & 4)
• start prevention switch :
– set at 1.6 bar
– normally closed switch
Portable Air GAC 41
Maintenance : fan belt tension
• Automatic belt
tensioner is fitted
• Check belt tension
regularly and adjust if
necessary
• Keep arrow between
min & max mark
Portable Air GAC 41
Maintenance : Tire pressure
• Md 1/2 standard : 4.5 bar

• Md 1 pneumatic
brakes & tandem : 5 bar
• Md 2 pneumatic
brakes & tandem : 4.5 bar
• all Md 3/4 : 6 bar
Portable Air GAC 41

Thermostatic valve
Position of valve
! & spring = critical !
• When valve is fitted
in the wrong way, oil
will be continuously
cooled, creating a lot
of condensate
Portable Air GAC 41

Thermostatic valve
• Spring = conical • Spring fits in 2

directions
• Smallest side must

be inserted in the
valve
Portable Air GAC 41

Thermostatic valve
1615 6439 00
1615 6440 00
XA filter housing
Portable Air GAC 41
Thermostatic valve
1615 6398 00
XR filter housing
Portable Air GAC 41
Trouble Shooting
Some other field problems

then described in AIB
Portable Air GAC 41

Trouble shooting
• Electric fault finding

• Oil consumption
• Loading problems : 6 off
• Engine stalls : 3 off
• Shutdown on water level
• Gearbox leaks oil
• Insufficient capacity
Portable Air GAC 41
Electrical fault finding
• Analyse situation :
– Exclude not starting or shutting down

through engaged safety device (e.g. high
temp, low level)
– Exclude other reasons for malfunctioning
(e.g. dirty filters, squeezed hoses)
Portable Air GAC 41

• Make sure :
– batteries are well connected and battery

terminals are not corroded
– emergency stop is not locked
– thermic fuse is reset
Portable Air GAC 41

• Shut downs switches :

– low engine oil pressure
– low engine coolant level
– high engine coolant temperature
– low fuel level
– high compressor discharge air temperature
Portable Air GAC 41

• Warning :
– high air filter vacuum
– low fuel level
• Load prevention : overheating protection
• Start prevention : starter motor protection
Portable Air GAC 41

Setting of switches :
– Engine oil pressure 0.8 - 1.14 bar (adjustable)
– Coolant temperature 105 °C
– Air filters Md 1,3,4 : 65 mbar
Md 2 : 35 mbar
– Compressor temp. 120 °C on XA - 130 °C on XR
(adjustable : red arrow)
– Load prevention 5 bar (adjustable)
– Start prevention 1.6 bar (adjustable)
Portable Air GAC 41

• Faulty safety switch :

– contact continuously open
– contact continuously closed or shorted
• Measure condition of switches on
connectors X1 and X2 according to table
• Least probable cause = circuit board
Portable Air GAC 41

Wires numbered :1 to 20
Connectors : X1 & X2 X1 X2
X1 X2
Portable Air GAC 41

Measuring method Power Open contact Closed contact

Volt-meter ON 24 V 0V
Ohm-meter OFF  0
Portable Air GAC 41

• Use Volt meter :

– Open contact = 24 V
– Closed contact = 0 V
• Resistance measurement can damage
circuit board : therefore :
– On instrument panel NO resistance measurement
– On wiring only when disconnected from
instrument panel
Portable Air GAC 41
Safety switch Name Machine not in operation Machine in operation Contacts Shut down when
Method Status Method Status Pos. Earth Disconnected Shorted
Fuel level warning S37:2 V-meter open V-meter open X2-11 X2-16 no no
Fuel level shut off S37:1 V-meter open V-meter open X1-8 X2-16 no yes
Engine oil pressure S5 -meter open V-meter closed X1-5 X1-6 yes no
Coolant temperature S14 V-meter open V-meter open X2-17 X2-16 no yes
Air filter vacuum S10 V-meter open V-meter open X1-10 X2-16 no no
Coolant level N6 V-meter closed V-meter open N6-5 X2-16 no yes
Compressor temp. S7 -meter closed V-meter closed X1-6 X1-7 yes no
Load prevention S13 V-meter open V-meter closed X2-13 X2-16 no (can't load) no
Start prevention S18 -meter closed V-meter open 1 2 no (can't start) no
Conventional instrument panel X Md

Portable Air GAC 41
Electronic instrument panel X Md

Portable Air GAC 41
Sensors Name Contacts Shut down when

(+) (-) Disconnected Shorted
Coolant level sensor B12 X1-9 X2-16 yes no

Oil pressure sensor B7 X2-19 X2-16 no no
Fuel level sensor B6 X2-20 X2-16 no yes
Coolant temperature sensor B8 X2-14 X2-16 no no
Portable Air GAC 41

Oil consumption
• clogged restrictor in scavenge line

• overfilled receiver : above sight
• glass level
• wrong oil type : foaming of oil
• shut down with open air outlet valve
• scavenge pipe bended or too short : 5 to 10
mm from bottom
Portable Air GAC 41
Engine does not start 1
• Problem : Machine does not start when

pressing the start button, no fault indication
• Reason :
– Air receiver pressurized
– start prevention switch disconnected
• Remedy :
– wait till air receiver is depressurized
– check start prevention switch and wiring
Portable Air GAC 41
Engine does not start 2
• Problem : Machine does not start when

pressing the start button
• Reason : safety system
• Remedy :
– check fault indication lights : correct indicated
fault
– if H1 flashes : wire D+ on alternator broken
Portable Air GAC 41

Loading problem 1
• Problem : machine does not

load or loads immediately
• Reason : load solenoid stuck
by deposits (salt, …)
• Remedy : clean valve
Portable Air GAC 41

Loading problem 2
• Problem : machine does not load

• Reason : Membrane in regulating valve
cracked, so that receiver pressure closes the
unloader valve
• Remedy : replace membrane
Portable Air GAC 41

Loading problem 3
• Problem : Machine with new instrument

panel loads only after 5 minutes
• Reason : Temperature sensor bad or
disconnected
• Remedy : Check connector,
wiring and switch
Portable Air GAC 41

Loading problem 4
• Problem : machine does not unload

• Reason : venting holes in regulating system
plugged or not installed
• Remedy : check for venting holes at
unloader, speed regulator or tee coupling in
regulating lines
Portable Air GAC 41

Loading problem 5
• Problem : XR does not build up sufficient
pressure to load (< 5 bar)
• Reason : air leaks in regulating system
• Remedy :
– check for air leaks at couplings
– check venting holes for size : max 1 x 2.2 mm or
2 x 1.6 mm
– check size of regulating lines : 6 mm
Portable Air GAC 41

Loading problem 6
• Problem : XR does not build up sufficient

pressure to load (< 5 bar)
• Reason : air leaks in regulating system
• Remedy :
NORDIC VERSIONS ONLY : 4.5
lower setting of load prevention
pressure switch to 4.5 bar
bar
Portable Air GAC 41
Engine stalls 1
• Problem : engine stalls when loading

• Reason : engine gets unsufficient fuel
• Remedy :
– check fuel lines for squeezed hoses
– air in the fuel system : prime
– check for air leaks : untight fuel filters
Portable Air GAC 41

Engine stalls 2

• Reason : too low unloaded speed
• Remedy :
– check engine speed during unload
– use digital tachometer
– adjust speed setting
– if required adjust tachometer on instr. panel
Portable Air GAC 41
Engine stalls 3

• Reason : fuel solenoid has weakened
• Remedy :
– although fuel solenoid engages, it does not pull
up completely :
– adjust spring or lever system
– force too weak => replace
Portable Air GAC 41

Shut down on water level
• Problem : machine stops for low water level
• Reason :
– level too low
– air in system
– resistance in electric circuit too high
– sensor dirty
• Remedy :
– check level, sensor, see ‘improvements’
Portable Air GAC 41

XR gearbox leaks oil
• Problem : Gear box relief valve leaks oil

• Reason : Overpressure in gearbox
(setting = 1.3 - 2.5 bar)
• Remedy :
– check if oil injection nozzles are fitted and
don’t leak (o-ring)
– check if suction pipe is not blocked or leaks air
through welds
Portable Air GAC 41
XR gearbox leaks oil
suction
injection
Portable Air GAC 41
Insufficient capacity
• Problem : machine delivers insufficient

capacity (PTO, small XA)
• Reason : air flows back to inlet
• Remedy :
– check if scavenge line restriction is fitted
– check if bleed off valve in unloader is fitted
Portable Air GAC 41

Service info
• Element kits
• Mercedes engine parts
• Pressure gauges : dual reading
• Special torques
• Technical video
Portable Air GAC 41

Element kits
Mounting kit Overhaul kit

LP short old 2910 4041 00 2910 4040 00
LP short new 2910 4041 00 2911 0063 00
LP long 2910 4044 00 2911 0063 00
HP 2910 4043 00 2910 4050 00
Portable Air GAC 41

Mercedes engine parts
OM 366 LA
Injection nozzle, complete 001 017 52 21 2914 8040 00

V-belt set 009 997 78 92 2914 8076 00
Turbo charger 366 096 29 99 2914 8022 00
Fuel stop solenoid 442 066 01 02 2914 8024 00
Starter motor, overhauled 004 151 59 01 2914 8033 00
Fuel filter element 000 090 01 51 2914 8003 00
Fuel filter set 352 470 00 92 2914 8007 00
Gasket, rocker cover 366 016 03 21 2914 8006 00
Oil filter set 366 180 00 09 2914 8008 00
Portable Air GAC 41

OM 441 LA

V-belt set 003 997 31 92 2914 8077 00
Turbo charger 004 096 92 99 2914 8023 00
Oil filter element 402 180 00 09 2914 8012 00
Gasket, turbo oil press. pipe 442 187 01 80 2914 8048 00
Gasket, turbo oil return 442 187 00 80 2914 8047 00
Filter, prime pump 000 090 07 51 2914 8013 00
Prime pump 000 090 60 50 2914 8025 00
Oil cooler cover 403 180 39 38 2914 8072 00
Gasket, oil cooler 442 188 05 80 2914 8073 00
Waterpump 403 200 71 01 2914 8074 00
Portable Air GAC 41

OM 442 LA

V-belt set 003 997 30 92 2914 8049 00
Turbo charger 003 096 08 99 2914 8050 00
Oil filter element 402 180 00 09 2914 8012 00
Gasket, turbo oil press. pipe 442 187 01 80 2914 8048 00
Gasket, turbo oil return 442 187 00 80 2914 8047 00
Filter, prime pump 000 090 07 51 2914 8013 00
Portable Air GAC 41

OM 442 LA (continued)
Prime pump 000 090 60 50 2914 8025 00

Cylinder liner 442 030 05 37 2914 8059 00
Seal ring 442 011 00 59 2914 8060 00
O-ring 015 997 90 48 2914 8061 00
O-ring 015 997 91 48 2914 8062 00
Gasket kit 444 010 01 20 2914 8063 00
Con rod 442 030 02 20 2914 8064 00
Oil cooler cover 403 180 39 38 2914 8072 00
Gasket, oil cooler 442 188 05 80 2914 8073 00
Waterpump 403 200 71 01 2914 8074 00
Gasket, inlet manifold 442 141 14 80 2914 8090 00
Portable Air GAC 41

Pressure gauges with dual
reading (bar - psi)
range (bar) range (psi) size (mm) part number

-1 - 15 -15 - 210 60 1615 7260 00
0 - 16 0 - 230 60 1615 7264 00
0 - 16 0 - 230 80 1615 7265 00
0 - 25 0 - 350 60 1615 7261 00
0 - 25 0 - 350 80 1615 7263 00
0 - 40 0 - 550 60 1615 7262 00
0 - 40 0 - 550 80 1615 7266 00
Portable Air GAC 41

Special torques Md 1/2
Axles to frame 205 Nm M16
Wheels to axle Md 120 Nm
Towbar to front axle : Wagon 120 Nm
Towbar to front axle : Tandem 205 Nm
Towbar to frame : Tandem 205 Nm
Buffers engine to frame 80 Nm M12
Buffers compressor to frame 80 Nm M12
Center bolts in buffers 205 Nm M16
Supports to element 80 Nm M12
Gear casing to engine Md 2 46 Nm M10
Spacer to engine Md1 46 Nm M10
Coupling ring to engine Md 1 46 Nm M10
Compressor element to gear casing 46 Nm M10
Rubber coupling to hub Md 1 123 Nm M12
Rubber coupling to hub Md 2 135 Nm M12
Locking plate to drive gear 46 Nm M10
Washer to gear element 145 Nm M12
Portable Air GAC 41

Oil stop valve to element 46 Nm M10
Check valve to element 80 Nm M12
Air receiver cover fixation bolts 205 Nm M16
Discharge pipe to element 80 Nm M12
Discharge pipe to air receiver 80 Nm M12
Outlet pipe to MPV 80 Nm M12
Air receiver to frame 80 Nm M12
Lifting support to frame 205 Nm M16
Lifting support to lifting beam 205 Nm M16
Fan pulley to engine Md 1 46 Nm M10
Fan pulley to engine Md 2 23 Nm M8
Fan shaft to fan support 80 Nm M12
Fan pulley to fan axle 80 Nm M12
Fan to fan support 46 Nm M10
Top cooler assy to fan support 205 Nm M16
Fan support to coooler support 205 Nm M16
Belt tensioner fixation bolts 80 Nm M12
Portable Air GAC 41

Axles to frame 205 Nm M16
Wheels to axle 200 Nm
Towbar to front axle : Wagon 120 Nm
Towbar to front axle : Tandem 205 Nm
Towbar to frame : Tandem 205 Nm
Buffers engine to frame 80 Nm M12
Buffers compressor to frame 80 Nm M12
Center bolts in buffers 205 Nm M16
Supports to element 80 Nm M12
Gear casing to engine Md 4 46 Nm M10
Spacer to engine Md 3 46 Nm M10
Compressor element to gear casing 46 Nm M10
Rubber coupling to hub 135 Nm M12
Drive gear to drive shaft 145 Nm M12
Retainer to coupling housing 46 Nm M10
Oil stop valve to element 46 Nm M10
Portable Air GAC 41

Check valve to element 46 Nm M10
Connection pipe LP-HP element 80 Nm M12
Oil connection LP-HP element 46 Nm M10
Air receiver cover fixation bolts 395 Nm M20
Discharge pipe to element 80 Nm M12
Discharge pipe to air receiver 80 Nm M12
Outlet pipe to MPV 80 Nm M12
Air receiver to frame 80 Nm M12
Lifting support to frame 205 Nm M16
Lifting support to lifting beam 205 Nm M16
Fan pulley to engine 23 Nm M8
Fan shaft to fan support 80 Nm M12
Fan pulley to fan axle 80 Nm M12
Fan to fan support 46 Nm M10
Top cooler assy to fan support 205 Nm M16
Fan support to coooler support 205 Nm M16
Belt tensioner fixation bolts 80 Nm M12
Portable Air GAC 41

Technical video
• Presents basic technical aspects of the

X-Md compressors
• Duration 9 minutes
• To be ordered by fax, memo or letter to
Roger Van der Schoot
Portable Air GAC 41

Technical video
• Specify video system :

– VHS, Umatic, Betamax
– PAL, SECAM, NTSC
• Specify language :
– English 2937 0002 36
– Spanish 2937 4002 36
Portable Air GAC 41

Key Figures
Portable Air GAC 41

Specs Pressure
Full load
Unload
FAD FAD FAD Engine
Type
Engine Speed
Power DIN Full load
Power SAE Unload
Key figures
Fuel cons. Temp.
Full load Max. amb.
Unload (sea level)
Altitude Capacity Capacity Capacity Capacity
Max. Oil comp. Coolant
Oil engine
Fueltank Battery
Setting
Saf. vlv.
Tyre size
Standard
Pneu. br.
Tyre press.
Standard
Pneu. br.
Outlet
valves
UNIT bar l/s m³/min cfm kw rpm kg/h °C m L L L Ah bar bar

XAHS 285 Md 12 283 17,0 600 Mercedes 151 2400 32,6 50 4000 66 45 320 2x110 16 6.5 R 16 4,5 1x2"
14 OM 366 LA 163 1600 15,5 18 7.00 R 16 5
XAMS 295 Md 8,6 292 17,5 619 Mercedes 151 2400 26,8 50 4000 66 45 320 2x110 12 6.5 R 16 4,5 1x1"
9,6 OM 366 LA 163 1500 12,4 18 7.00 R 16 5 1x2"
XAMS 355 Md 8,6 350 21,0 742 Mercedes 151 2400 32 50 4000 66 45 320 2x110 12 6.5 R 16 4,5 1x1"
9,6 OM 366 LA 163 1500 14,9 18 7.00 R 16 5 1x2"
XAS 405 Md 7 393 23,6 833 Mercedes 151 2400 31,4 50 4000 66 45 320 2x110 10,5 6.5 R 16 4,5 1x1"
8 OM 366 LA 163 1500 14,6 18 7.00 R 16 5 1x2"
XAHS 365 Md 12 358 21,5 759 Mercedes 206 1600 38,6 50 4000 66 54 334 2x143 16 6.5 R 16 4,5 1x2"
14 OM 441 LA 218 950 17,8 15 225/75R16 4,5
XAMS 445 Md 8,6 435 26,1 922 Mercedes 206 1600 38,6 50 4000 66 54 334 2x143 12 6.5 R 16 4,5 1x1"
9,6 OM 441 LA 218 950 17,6 15 225/75R16 4,5 1x2"
XAS 495 Md 7 480 28,8 1017 Mercedes 206 1600 38,5 50 4000 66 54 334 2x143 10,5 6.5 R 16 4,5 1x1"
8 OM 441 LA 218 950 17,6 15 225/75R16 4,5 1x2"
XAHS 425 Md 12 400 24,0 848 Mercedes 224 1800 46,2 50 5000 83 54 545 2x143 16 205/75R17.5 6 1x2"
14 OM 441 LA 236 1000 18 18 215/75R17.5 6
XAMS 505 Md 8,6 500 30,0 1059 Mercedes 224 1800 46,4 50 5000 83 54 545 2x143 12 205/75R17.5 6 1x2"
9,6 OM 441 LA 236 1000 17,9 18 215/75R17.5 6
XAS 555 Md 7 560 33,6 1187 Mercedes 224 1800 47,9 50 5000 83 54 545 2x143 10,5 205/75R17.5 6 1x2"
8 OM 441 LA 236 1000 17,8 18 215/75R17.5 6
XRS 415 Md 17 409 24,5 867 Mercedes 224 1800 45,8 50 5000 83 54 545 2x143 22 205/75R17.5 6 1x2"
19 OM 441 LA 236 1000 17,2 18 215/75R17.5 6
XRHS 385 Md 20 371 22,3 786 Mercedes 224 1800 43,8 50 5000 83 54 545 2x143 25 205/75R17.5 6 1x2"
22 OM 441 LA 236 1000 16,7 18 215/75R17.5 6
XRVS 345 Md 25 331 19,9 701 Mercedes 224 1800 44,7 50 5000 83 54 545 2x143 30 205/75R17.5 6 1x2"
27 OM 441 LA 236 1000 17,6 18 215/75R17.5 6
XAHS 515 Md 12 500 30,0 1059 Mercedes 313 1700 57 50 5000 83 65 665 2x143 16 205/75R17.5 6 1x2"
14 OM 442 LA 329 1050 31,7 30 215/75R17.5 6
XAMS 615 Md 8,6 570 34,2 1208 Mercedes 313 1700 53,1 50 5000 83 65 665 2x143 12 205/75R17.5 6 1x2"
9,6 OM 442 LA 329 1050 24,5 30 215/75R17.5 6
XRHS 485 Md 20 480 28,8 1017 Mercedes 313 1700 56,1 50 5000 83 65 665 2x143 25 205/75R17.5 6 1x2"
22 OM 442 LA 329 1050 23,3 30 215/75R17.5 6
XRVS 455 Md 25 450 27,0 954 Mercedes 313 1700 58 50 5000 83 65 665 2x143 30 205/75R17.5 6 1x2"
27 OM 442 LA 329 1050 24,6 30 215/75R17.5 6
Portable Air GAC 41

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Service training ‘98

Portable Air GAC 41

• NO LOAD : machine runs with air receiver

• UNLOAD : machine runs with air receiver

• LOAD : air is taken in and compressed

Portable Air GAC 41

Portable Air GAC 41

• Portable, oil injected screw compressors

Portable Air GAC 41

Portable Air GAC 41

Portable Air GAC 41

7 bar XAS 365 405 495 555 -

Portable Air GAC 41

Portable Air GAC 41

CLEAN AIR IS THUS EXTREMELY IMPORTANT

• 3 to 5 dry-type heavy duty filters

• Cyclone centrifugal pre-cleaner removes up to

• Filters are monitored by a vacuum switch

Portable Air GAC 41

Portable Air GAC 41

• Spring-loaded piston valve

Portable Air GAC 41

• Small air passage during off load

Portable Air GAC 41

• Oil injected screw compressor :

Portable Air GAC 41

• HIGH PRESSURE VARIANTS :

Portable Air GAC 41

Portable Air GAC 41

Portable Air GAC 41

• OIL SERVES FOR :

Portable Air GAC 41

• Combined with air receiver

Portable Air GAC 41

• Dissipates compression heat

Start of opening Completely open Part number

Portable Air GAC 41

Portable Air GAC 41

• Spring loaded valve

Portable Air GAC 41

– Md 1 : 1615 5485 00 gasket

Portable Air GAC 41

• Evacuates separated oil from separator

Portable Air GAC 41

Portable Air GAC 41

Portable Air GAC 41

• 30 µ pre filter : p/n 2914 8070 00

Portable Air GAC 41

• Only 1/3 of the circulated

• Serves to match air delivery to air demand

• Translates receiver pressure

Portable Air GAC 41

Portable Air GAC 41

W.P. U.P. C.R.

Portable Air GAC 41

• Turning adjusting wheel clockwise

Portable Air min. working

Portable Air GAC 41

• Maximum speed when pressure = between

Portable Air GAC 41

• Controls amount of air taken in by taking

Portable Air GAC 41