Size1.5 and Size 2 - Module Controlled

Size 1.
5 – Size 2
Geert Paelinckx
Portable Air GAC 41

Size 1.5
Size 2
Portable Air GAC 41

Content
• Range • Control unit
• Product features • External software
• Engines • Undercarriage
• Air system • Maintenance
• Oil system • Pending problems
• Regulating system • Questions and
• Electrical system remarks
Portable Air GAC 41 3/176

Range
Portable Air GAC 41

Product designation
Engine supplier
Working principle C : Caterpillar
Product range A : Single stage D : Deutz
X : Oil injected compressor Silencing G : Detroit Diesel Prime mover
portable R : Two stage : Un-silenced M : Mercedes d : diesel engine
compressor compressor S : Silenced Y : Yanmar E : electric motor
X A H S 306 Md
Working pressure Capacity (FAD)
Single stage Two stage Liter/sec
: standard pressure 7 bar 17 bar CFM (US-version)
M : medium pressure 8.6 bar -
T : “ten” pressure 10.3 bar -
H : high pressure 12 bar 20 bar
V : very high pressure 14 bar 25 bar

Size 1.5 - range
• Mercedes variants:
7 bar 8,6 bar 12,0
PG418
OM904LA-4LL XAMS 286 Md XAHS 236 Md
125kW@2300rpm
• Caterpillar variants:
7 bar 8,6 bar 12,0
PG418
CAT 3126B XAS 756 Cd XAMS 606 Cd XAHS 506 Cd
149kW@2300rpm XAS 336 Cd

Size 2 - range
• Mercedes variants:
Single Stage Two Stage
7 bar 8,6 bar 10,5 bar 12 bar 17 bar 20 bar 25 bar
PG410
OM906LA-6L XAS 426 XAMS 376 XAHS 306
170kW@2200rpm
PG411 / PG412
OM926LA-6L XAMS 486 XAHS 416 XRHS 396 XRVS 346
230kW@2100rpm
PG413
OM501LA-6V XAMS 586 XAHS 546 XRHS 486 XRVS 466
317kW@1800

Size 2 - range
• Caterpillar variants:
100 psi 125 psi 150 psi 175 psi 250 psi 300 psi 350 psi
PG410
3126B XAS 896 XAMS 796 XAHS 646
168kW@2200rpm
PG411 / PG412
C9-6L XAMS1026 XAHS 836 XRHS 836 XRVS 716
224kW@2100rpm
PG413
C12-6L XAMS 1256 XAHS 1146 XRHS 1096 XRVS 976
317kW@1800

Product features
Portable Air GAC 41

General lay-out Size 2
AIR OUTLET
AIR INLET
METAL FUEL
TANKS SPILLAGE FREE
FORKLIFT SLOTS FRAME
Reduced noise emission
• Super-silenced
baffling in doors to
reduce noise
emission from
engine and
compressor element

Reduced noise emission
• Extra baffling in air
outlet compartment
to reduce noise
emission from fan
and cooling air.

Closed roof design
• Double roof to
reduce noise.
• Complete closed
roof with air outlet
louvers to prevent
rain water from
entering..

Access to separator element
• Hinged door in the
roof to give access
to the separator top.

Air outlet louvers
• Cooling air outlet
sealed with louvers.
• Louvers will open
to a 90° angle
controlled by
compressor oil
pressure.

External fuel tanks
External
Filler plug
Easy drainage
Side protection plate

Forklift slots

Service access LH

Service access RH

Service access Front

Service access Rear

Regulating valve
• Regulating pressure
adjustable while
checking the
pressure on the user
interface.

Engines
Portable Air GAC 41

Mercedes: power range
Power (kW)
400
230 - 448 kW
308 - 601 hp
OM 501 LA
OM 502 LA
300
322 hp
240 kW OM 926 LA
7,2 12.0 - 16.0
200
101 - 275 hp
75 - 205 kW
OM 904 LA
OM 906 LA
100
4.3 - 6.4
5 10 15 20 Displacement (Li)
OM 904 LA
Three Valves Technology Electronic Engine
Management
Oil and Fuel Filters

OM 906/926 LA Electronic Engine
Management
Three Valves Technology


Series 900 : engine features
• High pressure injection (1600 bar) with unit pumps.
• Direct injection with 8-or 6-hole injection nozzle, centrally
located.
• Three valves technology (2 intake, one exhaust).
• Full electronic engine management.
• Low fuel consumption
• Compliance with Euro 2/3 exhaust emission legislation.
• Easy to maintain engine oil filter and fuel filter located on
front face.
• Maintenance free belt drive.

OM 501 LA
Four Valves Technology
Electronic Engine Management

Series 500 : engine features
• High pressure injection (1800 bar) with unit pumps.
• Direct injection with 8-hole injection nozzle, centrally
located.
• Four valves technology (2 intake, 2 exhaust).
• Full electronic engine management.
• Low fuel consumption
• Compliance with Euro 2 exhaust emission legislation.
• Easy to maintain engine oil filter and fuel filter located on
front face.

3126B

C9

C12

Air system
Portable Air GAC 41

Air system
• Air filters
• Unloader valve
• Compressor element
• Check valve
• Air receiver
• Minimum pressure
valve

Air filters
Air inlet Centrifugal separation
Vacuum switch Filter element
Dust trap
to compressor element
Air filters
• Solid pollutants cause wear on bearings,

rotors and gears when suspended in oil.
• Sour, gaseous pollutants cause internal
corrosion.
 beware for exhaust gas re-circulation
• Pressure drop reduces compressor flow :
10 mbar  - 1 %
CLEAN AIR IS THUS EXTREMELY IMPORTANT
Air filters
• 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
• Press. drop over a new element = 15 - 20 mbar
Air filters
• Filters are monitored by a vacuum switch
– Part number: 1089 0607 02
– Setting: 50  3 mbar
normally open

Unloader
• Air intake is completely pneumatically regulated
from 100% to 0% by means of regulating air at the
back of the piston
– Closes by regulating air
– Opens by under pressure from element air inlet
• Some air is taken in and bled off during unload
– Calibrated hole in piston
– Bleed-off valve
• NO spring

Unloader
• Small air passage during unload maintains
the pressure in the air receiver to ensure
lubrication during off-load periods
• Match air delivery to air demand
– capacity regulation between 0 and 100 %
• Control air delivery through :
– Engine speed regulation
– Air intake regulation (0%  100%)

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 expansion limits the maximum
operating temperature

Compressor element
Size 1,5
– Single stage compression
– O.I.S. M-01 (S1,5-L)
– Part number: 1616 6551 90
– Working pressures 8.6 bar
12 bar

Compressor element
Size 2
– Single stage compression
– O.I.S. O-01 (S2-L)
– Part number: 1616 5288 50
– Working pressures 7 bar
8.5 / 10.5 bar
12 bar

Compressor element
Size 2
– Two stage compression
– LP- stage:
– O.I.S. N-02 (S2-S)
– Part number: 2934 9988 36
– HP-stage:
– O.I.S. J-23 (S1-S)
– Part number: 1616 7098 91
– Working pressures 17 / 20 bar
25 bar

Compressor element
Size 2
– Two stage compression
– Gear casing safety valve:
– Part number
– 2253 2423 80
– Setting
– 1.3 bar  2.5 bar

Check valve
• Prevents blow back of compressed air

• On two stage : 2 valves in parallel :
– 1 check valve
• Spring 1615 9687 00
– 1 by-pass valve to
protect the LP-element
• Spring 2254 8075 00

Air receiver
• 3 FUNCTIONS
– Air receiver
• evens pulsations
• stabilizes regulating
– Oil separation
– Oil tank

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

• Size 1.5 + Size 2 PG410
– Part number 1604 1339 00
– Setting 4 bar
– Service kit 2911 0131 00
• Size 2 LP PG411/412/413
– Part number 1604 2601 01
– Setting 4 bar
– Service kit 2911 0132 00
• Kits available from July 2003 on

• Size 2 HP XRHS...
– Part number 1604 2524 01
– Setting 12 bar
– Service kit 2911 0133 00
• Size 2 HP XRVS...
– Part number 1604 3602 00
– Setting 15 bar
– Service kit 2911 0133 00
• Kits available from July 2003 on

Oil system
Portable Air GAC 41

Oil system
• OIL SERVES FOR :

– Cooling compression heat
– Lubrication rotors, bearings & gears
– Sealing clearance compressor chamber
& rotor shaft ends
– Corrosion protection

Oil system : Flow
• Oil tank
• Oil filters
• Oil cooler
• Oil stop valve
• Oil separator
• Louvers

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

Oil filters
• Remove contamination
• Size 1.5
– 2 filters in parallel
• Size 2
– 3 filters in parallel
• Low pressure variant
– Max. pressure 15 bar
( working pressure)
– 1613 6105 90
– For XAS, XAMS

Oil filters
• High pressure variant

– Max. pressure 30 bar
( working pressure)
– 1202 8040 90
– For XAHS, XAVS, XRHS &
XRVS
• By-pass valve set at 2.5 bar

Thermostatic valve
Start of opening Completely open Part number Used in

40 °C 60 °C 1619 7560 00 Size 1,5
60 °C 75 °C 1202 5869 02
65 °C 80 °C 1202 5869 03
70 °C 85 °C 1202 5869 01 Size 2, except XRVS
75 °C 90 °C 1202 5869 04
80 °C 95 °C 1615 9720 00 XRVS

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

Thermostatic valve
• Spring = conical
• Spring fits in 2
directions
• Smallest side must be

inserted in the valve

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

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

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

Louvres
• Compressor oil pressure controls opening of
louvers.

Regulating system
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

Regulating valve
• Translates receiver pressure

in control pressure
• Supplies control pressure
of 0 - 2 bar

Regulating valve
• Turning adjusting wheel clockwise

increases pressure set point
• Turning adjusting wheel anti-clockwise
decreases pressure set point
• Adjust during unload
• Set pressure 1.5 bar above working pressure

Speed regulation
• Change of engine speed between minimum &
maximum electronically controlled.
• Compressor output changes linear with the drive
speed
• 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

Unloader valve
• Controls amount of air taken in by taking

any position between open and closed
• Operated (closes) by control air from
regulating valve

Electrical system
Portable Air GAC 41

Ingress Protection
IP-class sensors/connectors: 66
Degree of protection Digit "x" Protection against ingress Digit "y"
against ingress of solids of liquids
No protection 0 No protection 0
Protected against large solid Protected against vertically falling
objects up to 50mm (eg hands) 1 drops of water 1
Protected against small solid Protection against drops of liquid
objects up to 12.5 mm (eg fingers) falling at an angle up to 15 from
2 vertical 2
Protected against solid objects up Protection against rain falling at any
to 2.5 mm (eg tools) 3 angle up to 60 from vertical 3
Protected against solid objects up Protection against splashing from all
to 1 mm (eg wires) 4 directions 4
Protected against ingress of dust in Protection against water jets from
an amount sufficient to interfere with any direction
the satisfactory operation of the
equipment 5 5
Totally protected against the ingress Protection against strong water jets
of dust 6 from all direction 6
x Protected against immersion
x between 15 mm and 1 m in depth 7
x x Protected against lengthy
immersion under pressure 8

Circuit diagram
Unit types Circuit diagram

S1,5 Md 9822 0937 10
S1,5 Cd 9822 0937 12
S2 Md LP 9822 0975 28
S2 Md HP 9822 0975 23
S2 Cd 3126B/C9 LP 9822 0963 15
S2 Cd C9 HP 9822 0963 16
S2 Cd C12 LP 9822 0963 17
S2 Cd C12 HP 9822 0963 18

Circuit diagram
Size 1.5 Md
9822 0937 10

Circuit diagram
Size 2 Md HP
9822 0975 23

Temperature sensors
Temperature sensors:
• Part number 1089 0574 40
• Type PT1000
• Temperature range -40°C to 270°C

Temperature sensors
Temperature sensors:
• Positive temperature coefficient (PTC)
–TR
• Resistance change
  4.0  / °C Temp. RPT1000
-25°C 902 
0 °C 1000 
20 °C 1078 
100 °C 1385 
130 °C 1498 
Pressure sensors
Pressure transducers:
• Translates regulating pressure into electrical signal

Pressure sensors
• Pressure transducers
– Specifications
• Supply voltage 5 ± 0.25 V DC
• Output voltage 0.5  4.5 V DC
proportional to pressure
– Located away from regulating valve to damp
small pressure fluctuations

Pressure sensors
Supply voltage
– Principle:
5V
Signal
Air 0.5 V – 4.5 V
Pressure
Piezo electrical
element
Pressure sensors
– Connections:
• 18 digital ground
• x signal
X
• 29 +5VDC supply
• 28 +24VDC supply (NA)
X
Pressure sensors
Overview pressure transducers:
1-stage units 2-stage units
Vessel 1089 0575 45 1089 0575 38
Regulating pressure 1089 0660 10 1089 0660 10
Interstage pressure - 1089 0575 45
Manifold 1089 0575 45 1089 0575 38
transducer range (bar)

1089 0660 10 0 to 3
1089 0575 45 0 to 17
1089 0575 38 0 to 35

Fuel level sensor
Fuel level sensors:
– Size 1.5
• Part number 1089 0659 05
• Type ITS 60 L 540
– Size 2
• Part number 1089 0659 03
X
• Type ITS 60 L 480
– Supply voltage
24 VDC
– Output voltage
• Empty tank 0.5 VDC = 0%
• Full tank 4.5 VDC = 100%

Fuel level sensor
Fuel level sensors:

– Connections:
• 18 digital ground
• 15 signal
X
• 29 +5VDC supply (NA)
• 28 +24VDC supply

Control unit
Portable Air GAC 41

Control unit: Hardware
Display Size 1.5:

Display Size 1.5:
1. Pressure gauge.
2. Fuel level gauge.
3. Power ON/OFF switch.
4. Start button.
5. Stop button.
6. Load-Noload button.
7. Display (2 rows, 40 characters / row).

Display Size 2:

Display Size 2:
1. Pressure gauge.
2. Fuel level gauge.
3. Power ON/OFF switch.
4. Start button.
5. Stop button.
6. F1 Function button.
7. F2 Function button.
8. Arrow Up button.
9. Arrow Down button.
10. Display (4 rows, 40 characters / row).

Part numbers:
Size 1.5 1900 1005 25

Size 2 LP 1900 1003 45
Size 2 HP 1900 1003 46
Spares:
No internal spares available

Power supply:
– 24 V
– minimum voltage: 12 V
– maximum voltage: 34 V
Ambient conditions:
– -30°C to + 60°C @ RH 100%
Ingress Protection:
– IP66

Inputs:
– Digital: 19
– 6 reserved for remote operation
– 6 reserved for display buttons
– low or high voltage
– active when pulled to GND
– Analog: 7
– Range from 0 to 5 V with digital GND as reference
– Temperature: 6
– for reading PT 1000 temperature sensor

Outputs:
– digital high 10
– Active high: 24 V
– digital low 3
– Active high: GND
– Open collector output
CAN J-1939
– According SAE J-1939

Power supply:

Connectors:
– Main connector (1)
– Remote connector (2)
– 9-pin
– CAN connector (3)
3 2 1
Control unit: Software
Latest versions available on CD-ROM

Inputs
Digital:
• Coolant level Shutdown input
– Active when coolant level OK
• Airfilter Switch input
– Active when too high vacuum
• Spare digital inputs
Analogue:
• Regulating Pressure Sensor input
– RPM steering
– Offset fault adjustable with ‘vessel pressure sensor calibration’- parameter.
– 0 bar  3 bar

Analogue:
• Vessel Pressure Sensor input
– Offset fault adjustable with ‘vessel pressure sensor calibration’-
parameter.
– Sensor range single stage units
• 0 bar  17 bar
– Sensor range two stage units
• 0 bar  35 bar
• Interstage Pressure Sensor Input
– For two stage units only, otherwise spare input
– Sensor range
• 0 bar  17 bar

Analogue:
• Air Discharge Pressure Sensor Input
– For Size 1.5, spare input
– Sensor range single stage units Size 2
• 0 bar  17 bar
– Sensor range two stage units Size 2
• 0 bar  35 bar
• Fuel Level Sensor input
– Fuel level warning setting
– Fuel level shutdown setting
– Linear signal:
• Empty 0.5 V 0%
• Full 4.5 V 100%
– Signal averaged over 8 seconds for peak values

Analogue:
• Spare pressure inputs
– Limits to be programmed with external software
Temperature:
• Air Discharge Temperature Sensor input
– Air temperature in outlet manifold
– Air discharge temperature warning setting
• LP Element Temperature Sensor input
– Air temperature in compressor element
– Element temperature warning setting
– Element temperature shutdown setting

Temperature:
• HP Element Temperature Sensor input
– For two stage units only, otherwise spare input
– Air temperature in compressor element
– Element temperature warning setting
– Element temperature shutdown setting
• Ambient Temperature Sensor input
– Only for Size 2
– Ambient temperature warning
• Spare temperature inputs

Inputs
Battery voltage
• U < 22.5V & RPM < start detection rpm
– Battery voltage low warning
• U < 22.5V & RPM > start detection rpm
– Battery not charging warning
• Battery voltage not checked
– Cranking status
– Coldstart activated
• Battery voltage reset
– When Ubat < 12 V
– All digital outputs disabled and back to initialisation status

Outputs
Digital low:
• Spare digital low outputs
Digital high:
• Power After Contact output
– Powers engine electronics
– Active when power-switch is in ON-position
• Starter Motor output
• Loading Valve output
• Flash Lights output
– Only for Size 2
– During cranking
– When warning occurs
– When shutdown occurs

Outputs
Digital high:
• Horn output
– Only for Size 2
– During cranking
– When shutdown occurs
• Spare digital high outputs
• Cold start output
– Only Cat engines
• Controls preheat relay
– For MB engines
• Spare output

Communication CAN J-1939:
– Engine to AC control unit:
• Engine Oil Pressure
• Engine Oil Temperature
• Fuel Pressure
• Fuel Temperature
• Fuel Consumption
• Engine Load
• Coolant temperature
• Air Inlet temperature
• Engine RPM
• Engine shutdown and warning codes

Communication CAN J-1939:
– AC control unit to engine:

• RPM setpoint
 RPM setpoint – RPM engine > 200rpm
• More than 5 sec
Engine not responding shutdown
• More than 20 sec in warm-up status
Engine not responding shutdown

Shutdown status:
– Apparatus shutdowns:
– Fuel level sensor failure
– Vessel pressure sensor failure
– Regulating pressure sensor failure
– LP element temperature sensor failure
– HP element temperature sensor failure (only 2 stage unit)
– Loading valve failure
– CAN J1939 communication link failure
– Starter relay failure (NA for MB, controlled by MR)
– Engine not responding

Shutdown status:
– Engine shutdowns:
– Coolant temperature sensor failure
– Oil pressure sensor failure
– Fuel pressure sensor failure
– Fuel temperature sensor failure
– Fuel temperature high
– Fuel pressure low
– Coolant temperature high
– Oil pressure low
– Injector X failure
– PLD communication failure (only MB)
– PLD failure (only MB)
Shutdown status:
– Engine shutdowns:
– ADM communication failure (only MB)
– ADM failure (only MB)
– ADEM failure (only Cat)
– Starter motor failure (only MB)
– Process shutdowns:
– Fuel level shutdown
– LP element temperature shutdown
– HP element temperature shutdown (only 2 stage unit)
– Coolant level shutdown
– Vessel pressure shutdown

Shutdown status:
– Shutdown history:
– 10 last shutdowns are saved together with process data of
that moment (visible by ACCIP):
• Compressor status
• Control mode
• Engine rpm setpoint
• All analogue input data
• All temperature input data
• All digital input data
• All digital output data
• All monitored engine data
• Battery voltage
Emergency stop status:
– (Not displayed at ‘soft emergency stop’)

Info status (Size 2):
– Compressor type
– Control mode
– Battery voltage
– Ambient temperature
– Software version
– Compressor serial number
– Engine serial number
– Fleet number (only displayed if not ‘000000’)

Options status:
• Language
• Pressure UM ( Unit of measurement)
• Temperature UM
• Flow UM
• Service

Test status:
– To be activated by external software
– Tested by temporary change of settings:
• Fuel level warning
• Fuel level shutdown
• LP/HP Element temperature warning
• LP/HP Element temperature shutdown
• Vessel pressure start prevention
• Vessel pressure shutdown
• Safety valve
• Static pressure test (opens/closes loading valve)
• Overspeed shutdown (tested at rpmmin + 100)
Process info:
• Compressor status • All temperature input data
• Running hours • All digital input data
• Engine RPM • All digital output data
• Engine RPM setpoint • All monitored engine data
• All analogue input data • Battery voltage

Warnings: Blue; is also start prevention
Italic; shutdown in some statuses
Apparatus warnings:
– Fuel level sensor failure
– Vessel pressure sensor failure
– Regulating pressure sensor failure
– LP/HP element temperature sensor failure
– Loading valve failure
– CAN J1939 communication link failure
– Starter relay failure (NA for MB, controlled by MR)
– EEPROM failure
– Ambient temperature sensor failure (Size 2 only)
– Air discharge temperature sensor failure
– Flash lights failure
– Horn failure
– Default mode

– Process warnings:
– Fuel level shutdown
– LP/HP element temperature shutdown
– Coolant level shutdown
– Vessel pressure start prevention
– Fuel level warning
– LP/HP element temperature warning
– Battery voltage low
– Battery not charging
– Airfilter warning
– Air discharge temperature warning

– Engine warnings:
– Coolant temperature sensor failure
– Oil pressure sensor failure
– Fuel pressure sensor failure
– Fuel temperature sensor failure
– Fuel temperature high
– Fuel pressure low
– Coolant temperature high
– Injector X failure
– PLD communication failure (only MB)
– PLD failure (only MB)
– ADM communication failure (only MB)
– ADM failure (only MB)

– Engine warnings:
– ADEM failure (only Cat)
– Starter motor failure (only MB)
– Oil pressure low
– Engine oil temperature sensor failure
– Air intake manifold temperature sensor failure
– Air intake manifoldtemperature high
– Turbo boost pressure sensor failure
– Turbo boost pressure high

Enable parameters:
– Disable lock
• Procedure can’t be used
• Operator can’t enable
– Disable
• Procedure can’t be used
• Operator can enable
– Enable lock
• Procedure is used
• Operator can’t disable
– Enable
• Procedure is used
• Operator can disable
Reset:
– STOP-button pushed while turning on power
– Reset to default values

Service:

Custom service tasks:
– 8 custom service tasks
• Description 16 characters max
• Running hours and/or time interval defineable

Service options:
– Confirmation task
– Confirmation task in advance (max 50 hours)

Features:
– Automatic start
– Automatic stop
– Remote control
– Coldstart (MB only)
– Air shut-off valve

ACCIPX
Atlas Copco Compressor Interface Program
Portable Air GAC 41

ACCIPX
Requirements:
• Microsoft windows based operating system
• CAN-card
• 2913 0014 00 PCMCIA CANcard2
IP € 1.431
Or
• 2913 0042 00 CANUSB
IP € 520,00
• 2913 0015 00 cable
IP € 44.05

ACCIPX
Requirements:
• Priority technician hardware key  Parallel port

1604 3684 00 IP € 92,70
• Priority technician hardware key  USB port
1604 5372 00 IP € 85,00

ACCIPX
Download tool 2913 0040 00:
• IP €200
• To prepare control unit
at the office
Simulation box 2913 0041 00:

• IP €2500
• To prepare, test and simulate
the control unit

ACCIPX
CAN-card de-installation:
• Find and delete all files related to the cancard by the keyword CAN and
CANCARD
• Find file REGEDIT
• Start-up file REGEDIT and you are coming to REGISTRY EDITOR
• Select EDIT
• Select FIND and delete all files related to the cancard by the keyword
CANCARD
• Shutdown computer
• Restart computer

ACCIPX
External software installation:
• Run ‘9822 1005 xx.exe’
• Click ‘UNZIP’
• Go to ‘C:\ 9822 1005 xx \144MB\DISK1’
• Run ‘Setup.exe’
• Follow the installation guidelines
Hardware key installation:

• Open the external software
• Click ‘Tools’
• Click "HASP4 driver“
• Click ‘install’

ACCIPX
Latest version ACCIPX available on CD ROM:
Updates of the program will be sent or provided on request.

ACCIPX
User manual ACCIPX (2950 2370 01) available
on CD-ROM

Maintenance
Portable Air GAC 41

Maintenance
• First maintenance at 50 hours
• Minor maintenance intervals :
– Size 1.5 Md OM904LA 500 hours
– Size 1.5 Cd 3126B 250 hours
– Size 2 Md OM906LA / OM926LA 500 hours
– Size 2 Md OM501LA 200 hours
– Size 2 Cd 3126B, C9 and C12 250 hours
• Major maintenance intervals :

– 1000 hours

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

Maintenance : 50 hours
• Necessary parts are delivered with the

machine in the initial Service Pak:
– Compressor oil filters

Maintenance schedule
MAINTENANCE SCHEDULE Daily Initially 6 months Yearly
Size 1.5 Md Engine oil level

Compressor oil level
Check
Check
around 50 hours or every 500 hours or every 1000 hours
Coolant level Check
OM 904LA:
Coolant Analyse Replace
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 cooler Clean Clean
Water cooler Clean Clean
Torque of wheel nuts Check Check Check
Brake system (if installed) Check/Adjust Check/Adjust Check/Adjust
Safety valve Test
Door Hinges Grease Grease
Towing eye shaft or ball coupling and its shaft Grease Grease
Shut-down switches Check
Pressure drop over separator element Measure Replace
Fan V-belts Adjust Adjust Adjust
Fueltank Clean Clean
Compressor oil Change
Compressor oil filter Replace Replace
Air filter elements Replace
Engine oil Change Change
Engine oil filter Replace Replace
Primary fuel filter (AC filter) Replace Replace
Fuel prefilter (MB filter) Replace Replace
Fuel filter (MB filter) Replace Replace
Engine inlet and outlet valves Adjust
Inspection by Atlas Copco Service technician !

MAINTENANCE SCHEDULE Daily Initially Yearly
Size 1.5 Cd
Engine oil level Check
Compressor oil level Check
Coolant level Check
Coolant Analyse Replace
3126B: Air filter vacuator valves

Fuel filter water drain
Air intake vacuum indicators
Empty
Drain
Check
Safety valve Test
Fan drive bearing Grease Grease
Fuel prefilter (Cat filter) Replace Replace
Fuel filter (Cat filter) Replace Replace
Engine crankcase breather Clean Clean

Size 2 Md
Coolant level Check
OM 906/926LA: Fuel filter water drain

Air intake vacuum indicators
Electrolyte level and terminals of battery
Drain
Check
Check Check Check
Intercooler Clean Clean
Safety valve Test
Coolant Analyse Change
Fuel prefilter (MB filter) Replace Replace
Filter element regulating valve Replace
Flow restrictor in oil scavenging line Clean

Size 2 Md
OM 501LA:
Coolant level Check
Safety valve Test

Size 2 Cd MAINTENANCE SCHEDULE Daily Initially
around 50 hours or every 250 hours
Yearly
or every 1000 hours
3126B, C9, C12:

Coolant level Check
Safety valve Test
Fuel pre-filter Replace Replace
Fuel filter Replace Replace

Maintenance
• Use of pirate parts:
– 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

Service PAKs
• Size 1.5:
2912 4350 04 2912 4350 05 2912 4350 06 2912 4351 04 2912 4351 06 2912 4352 05 2912 4352 06 2912 4353 06
50 h 500 h 1000 h 50 h 1000 h 250 h 1000 h 1000 h
XAMS 286 Md x x x
XAHS 236 Md x x x
XAS 756 Cd x x x
XAMS 606 Cd x x x
XAHS 506 Cd x x x

Service PAKs
• Size 2 Md:
500 h 1000 h 1000 h 200 h 1000 h 1000 h 1000 h 1000 h
2912 4356 05 2912 4356 06 2912 4357 06 2912 4358 05 2912 4358 06 2912 4359 06 2912 4360 06 2912 4361 06
XAS 426 Md X X
XAMS 376 Md X X
XAHS 306 Md X X
XAMS 486 Md X X
XAHS 416 Md X X
XRHS 396 Md X X
XRVS 346 Md X X
XAMS 586 Md X X
XAHS 546 Md X X
XRHS 486 Md X X
XRVS 466 Md X X
Engine cover head gaskets (are NOT included in PAKS):

OM906/926LA 2914 8258 00
OM501LA 2914 8261 00 (6 needed per engine)
Service PAKs
• Size 2 Cd:
50 h 250 h 1000 h 250 h 1000 h 50 h 1000 h 1000 h 250 h 1000 h 1000 h
2912 4356 04 2912 4382 05 2912 4382 06 2912 4383 05 2912 4383 06 2912 4357 04 2912 4384 06 2912 4385 06 2912 4386 05 2912 4386 06 2912 4387 06
XAS 896 Cd X X X
XAMS 796 Cd X X X
XAHS 646 Cd X X X
XAMS 1026 Cd X X X
XAHS 836 Cd X X X
XRHS 836 Cd X X X
XRVS 716 Cd X X X
XAMS 1256 Cd X X X
XAHS 1146 Cd X X X
XRHS 1096 Cd X X X
XRVS 976 Cd X X X

Service KITs
• Size 1.5:
part number designation
2911 0109 00 oil stop valve
2911 0110 00 unloader
2911 0111 00 regulating valve
2911 0112 00 oil separator kit
2911 0113 00 element overhaul
2911 0114 00 kit element mounting

Service KITs
• Size 2:
part number designation
2911 0118 00 oil stop valve
2910 3003 00 unloader
2910 3005 00 regulating valve
2911 0112 00 oil separator kit PG410
2911 0116 00 oil separator kit PG411, 412 & 413 LP
(XAHS 416 < 389 563)
2911 0117 00 oil separator kit PG411, 412 & 413 HP
(XAHS 416 > 389 968)
2911 0119 00 kit element mounting OIS O-01
2910 4041 00 kit element mounting OIS N-02
2911 0120 00 kit element mounting OIS J-23
2911 0063 00 element overhaul LP + HP
2910 4050 02 element overhaul HP
2911 0066 00 gear casing HP units

Compressor oil
• Size 1.5: PAROIL M
PAROIL S  extended service interval
 suited for high/low ambient
temperatures

Compressor oil
• Size 2 Md:
PG410
OM906LA-6L XAS 426 XAMS 376 XAHS 306
170kW@2200rpm
PG411 / PG412
OM926LA-6L XAMS 486 XAHS 416 XRHS 396 XRVS 346
230kW@2100rpm
PG413
OM501LA-6V XAMS 586 XAHS 546 XRHS 486 XRVS 466
317kW@1800
PAROIL M
PAROIL S

Compressor oil
• Size 2 Cd:
PG410
3126B XAS 896 XAMS 796 XAHS 646
168kW@2200rpm
PG411 / PG412
224kW@2100rpm
PG413
317kW@1800
PAROIL M
PAROIL S

Compressor oil
• 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

Part numbers Oil
PAROIL M PAROIL S ENGINE OIL

5 l 1615 5947 00 1615 5950 00 1615 5953 00
20 l 1615 5948 00 1615 5951 00 1615 5954 00
209 l 1615 5949 00 1615 5952 00 1615 5955 00

Coolant
• Correct coolant is important
– Good heat transfer
– Protection of engine
• Cavitation
• Corrosion
• Formation of deposites
• Freezing
– Freezing point at least 5°C lower than the lowest possible
temperature

Coolant
• Mixture:
– 50% antifreeze/anticorrosion - 50% water
– Good quality water (distilled or de-ionized)
– Never use more than 55% or less than 40% of
antifreeze/anticorrosion
• Use antifreeze/anticorrosion also when it
doesn’t freeze

Coolant
• Mix coolant outside the coolant system
• Renew coolant every 3 years
• Never mix different coolants
• 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

Fuel quality
• Use only commercial-grade diesel fuel

• If sulphur content is more than 0.3 %,
service intervals must be halved
• Adding gasoline (winter) increases the
combustion temperature :
– never add premium gasoline
– never add more than 30 % of regular gasoline

Fan belt tension
• Automatic belt
tensioner is fitted
• Check belt tension
regularly and adjust if
necessary
• Keep arrow between
min & max mark

Drains
• Color coded drains :
– red : compressor oil
– blue : coolant
– black : engine oil

Questions?
Remarks?
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Portable Air GAC 41

Portable Air GAC 41

Portable Air GAC 41 3/176

Portable Air GAC 41

Portable Air GAC 41 5/176

Portable Air GAC 41 6/176

Portable Air GAC 41 7/176

Portable Air GAC 41 8/176

Portable Air GAC 41

Portable Air GAC 41 11/176

Portable Air GAC 41 12/176

Portable Air GAC 41 13/176

Portable Air GAC 41 14/176

Portable Air GAC 41 15/176

Side protection plate

Portable Air GAC 41 16/176

Portable Air GAC 41 17/176

Portable Air GAC 41 18/176

Portable Air GAC 41 19/176

Portable Air GAC 41 20/176

Portable Air GAC 41 21/176

Portable Air GAC 41 22/176

Portable Air GAC 41

Oil and Fuel Filters

Portable Air GAC 41 25/176

Oil and Fuel Filters

Portable Air GAC 41 26/176

Portable Air GAC 41 27/176

Electronic Engine Management

Portable Air GAC 41 28/176

Portable Air GAC 41 29/176

Portable Air GAC 41 30/176

Portable Air GAC 41 31/176

Portable Air GAC 41 32/176

Portable Air GAC 41

Portable Air GAC 41 34/176

Vacuum switch Filter element

• Solid pollutants cause wear on bearings,

Portable Air GAC 41 38/176

Portable Air GAC 41 39/176

Portable Air GAC 41 40/176

Portable Air GAC 41 41/176

Portable Air GAC 41 42/176

Portable Air GAC 41 43/176

Portable Air GAC 41 44/176

Portable Air GAC 41 45/176

• Prevents blow back of compressed air

Portable Air GAC 41 46/176

Portable Air GAC 41 47/176

• Normally closed, opens by receiver pressure

Portable Air GAC 41 48/176

• Kits available from July 2003 on

Portable Air GAC 41 49/176

• Kits available from July 2003 on

Portable Air GAC 41 50/176

Portable Air GAC 41

• OIL SERVES FOR :