Professional Documents
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Registration code
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Tab: 38
2
INSTRUCTION MANUAL
3
XAS66 DDG / DDG IT
4
1. SAFETY PRECAUTIONS FOR PORTABLE COMPRESSORS WITH GENERATOR
To be read attentively and acted accordingly before towing, lifting, operating, performing maintenance or repairing the unit
1.1 INTRODUCTION
The policy of Atlas Copco is to provide the users of their equipment with The manufacturer does not accept any liability for any damage arising from
safe, reliable and efficient products. Factors taken into account are among the use of non-original parts and for modifications, additions or conversions
others: made without the manufacturer’s approval in writing.
- the intended and predictable future use of the products, and the
If any statement in this manual does not comply with local legislation, the
environments in which they are expected to operate,
stricter of the two shall be applied.
- applicable rules, codes and regulations,
- the expected useful product life, assuming proper service and Statements in these safety precautions should not be interpreted as
maintenance, suggestions, recommendations or inducements that it should be used in
- providing the manual with up-to-date information. violation of any applicable laws or regulations.
Before handling any product, take time to read the relevant instruction
manual. Besides giving detailed operating instructions, it also gives specific
information about safety, preventive maintenance, etc.
Keep the manual always at the unit location, easy accessible to the operating 1.2 GENERAL SAFETY PRECAUTIONS
personnel.
See also the safety precautions of the engine and possible other equipment, 1 The owner is responsible for maintaining the unit in a safe operating
which are separately sent along or are mentioned on the equipment or parts condition. Unit parts and accessories must be replaced if missing or
of the unit. unsuitable for safe operation.
These safety precautions are general and some statements will therefore not 2 The supervisor, or the responsible person, shall at all times make sure
always apply to a particular unit. that all instructions regarding machinery and equipment operation and
Only people that have the right skills should be allowed to operate, adjust, maintenance are strictly followed and that the machines with all
perform maintenance or repair on Atlas Copco equipment. It is the accessories and safety devices, as well as the consuming devices, are in
responsibility of management to appoint operators with the appropriate good repair, free of abnormal wear or abuse, and are not tampered with.
training and skill for each category of job. 3 Whenever there is an indication or any suspicion that an internal part of
Skill level 1: Operator a machine is overheated, the machine shall be stopped but no inspection
covers shall be opened before sufficient cooling time has elapsed; this to
An operator is trained in all aspects of operating the unit with the push- avoid the risk of spontaneous ignition of oil vapour when air is admitted.
buttons, and is trained to know the safety aspects.
4 Normal ratings (pressures, temperatures, speeds, etc.) shall be durably
Skill level 2: Mechanical technician marked.
A mechanical technician is trained to operate the unit the same as the
operator. In addition, the mechanical technician is also trained to perform 5 Operate the unit only for the intended purpose and within its rated limits
maintenance and repair, as described in the instruction manual, and is (pressure, temperature, speeds, etc.).
allowed to change settings of the control and safety system. A mechanical 6 The machinery and equipment shall be kept clean, i.e. as free as possible
technician does not work on live electrical components. from oil, dust or other deposits.
Skill level 3: Electrical technician 7 To prevent an increase in working temperature, inspect and clean heat
An electrical technician is trained and has the same qualifications as both the transfer surfaces (cooler fins, intercoolers, water jackets, etc.) regularly.
operator and the mechanical technician. In addition, the electrical technician See the maintenance schedule.
may carry out electrical repairs within the various enclosures of the unit. 8 All regulating and safety devices shall be maintained with due care to
This includes work on live electrical components. ensure that they function properly. They may not be put out of action.
Skill level 4: Specialist from the manufacturer 9 Care shall be taken to avoid damage to safety valves and other pressure-
This is a skilled specialist sent by the manufacturer or its agent to perform relief devices, especially to avoid plugging by paint, oil coke or dirt
complex repairs or modifications to the equipment. accumulation, which could interfere with the functioning of the device.
In general it is recommended that not more than two people operate the unit, 10 Pressure and temperature gauges shall be checked regularly with regard
more operators could lead to unsafe operating conditions. Take necessary to their accuracy. They shall be replaced whenever outside acceptable
steps to keep unauthorized persons away from the unit and eliminate all tolerances.
possible sources of danger at the unit.
11 Safety devices shall be tested as described in the maintenance schedule
When handling, operating, overhauling and/or performing maintenance or of the instruction manual to determine that they are in good operating
repair on Atlas Copco equipment, the mechanics are expected to use safe condition.
engineering practices and to observe all relevant local safety requirements
12 Mind the markings and information labels on the unit.
and ordinances. The following list is a reminder of special safety directives
and precautions mainly applicable to Atlas Copco equipment. 13 In the event the safety labels are damaged or destroyed, they must be
replaced to ensure operator safety.
These safety precautions apply to machinery processing or consuming air.
Processing of any other gas requires additional safety precautions typical to 14 Keep the work area neet. Lack of order will increase the risk of
the application and are not included herein. accidents.
Neglecting the safety precautions may endanger people as well as 15 When working on the unit, wear safety clothing. Depending on the kind
environment and machinery: of activities these are: safety glasses, ear protection, safety helmet
- endanger people due to electrical, mechanical or chemical influences, (including visor), safety gloves, protective clothing, safety shoes. Do not
- endanger the environment due to leakage of oil, solvents or other wear the hair long and loose (protect long hair with a hairnet), or wear
substances, loose clothing or jewelry.
- endanger the machinery due to function failures.
All responsibility for any damage or injury resulting from neglecting these
precautions or by non-observance of ordinary caution and due care required
in handling, operating, maintenance or repair, also if not expressly
mentioned in this instruction manual, is disclaimed by Atlas Copco.
5
16 Take precautions against fire. Handle fuel, oil and anti-freeze with care 11 Locate the unit away from walls. Take all precautions to ensure that hot
because they are inflammable substances. Do not smoke or approach air exhausted from the engine and driven machine cooling systems
with naked flame when handling such substances. Keep a fire- cannot be recirculated. If such hot air is taken in by the engine or driven
extinguisher in the vicinity. machine cooling fan, this may cause overheating of the unit; if taken in
17a Portable compressors with generator (with earthing pin): for combustion, the engine power will be reduced.
Earth the generator as well as the load properly. 12 The electrical connections shall correspond to local codes. The
machines shall be earthed and protected against short circuits by fuses or
17b Portable compressors with generator IT: circuit breakers.
Note: This generator is built to supply a sheer alternating current IT
13 Never connect the generator outlets to an installation which is also
network.
Earth the load properly. connected to a public mains.
14 Before connecting a load, switch off the corresponding circuit breaker,
and check whether frequency, voltage, current and power factor comply
with the ratings of the generator.
1.3 SAFETY DURING TRANSPORT AND
INSTALLATION
1.4 SAFETY DURING USE AND OPERATION
To lift a unit, all loose or pivoting parts, e.g. doors and towbar, shall first be
securely fastened.
1 When the unit has to operate in a fire-hazardous environment, each
Do not attach cables, chains or ropes directly to the lifting eye; apply a crane engine exhaust has to be provided with a spark arrestor to trap
hook or lifting shackle meeting local safety regulations. Never allow sharp incendiary sparks.
bends in lifting cables, chains or ropes.
2 The exhaust contains carbon monoxide which is a lethal gas. When the
Helicopter lifting is not allowed. unit is used in a confined space, conduct the engine exhaust to the
It is strictly forbidden to dwell or stay in the risk zone under a lifted load. outside atmosphere by a pipe of sufficient diameter; do this in such a
Never lift the unit over people or residential areas. Lifting acceleration and way that no extra back pressure is created for the engine. If necessary,
retardation shall be kept within safe limits. install an extractor. Observe any existing local regulations. Make sure
1 Before towing the unit: that the unit has sufficient air intake for operation. If necessary, install
- ascertain that the pressure vessel(s) is (are) depressurized, extra air intake ducts.
- check the towbar, the brake system and the towing eye. Also check 3 When operating in a dust-laden atmosphere, place the unit so that dust is
the coupling of the towing vehicle, not carried towards it by the wind. Operation in clean surroundings
- check the towing and brake capability of the towing vehicle, considerably extends the intervals for cleaning the air intake filters and
- check that the towbar, jockey wheel or stand leg is safely locked in the cores of the coolers.
the raised position,
4 Close the compressor air outlet valve before connecting or
- ascertain that the towing eye can swivel freely on the hook,
disconnecting a hose. Ascertain that a hose is fully depressurized before
- check that the wheels are secure and that the tyres are in good
disconnecting it. Before blowing compressed air through a hose or air
condition and inflated correctly,
line, ensure that the open end is held securely, so that it cannot whip and
- connect the signalisation cable, check all lights and connect the
cause injury.
pneumatic brake couplers,
- attach the safety break-away cable or safety chain to the towing 5 The air line end connected to the outlet valve must be safeguarded with
vehicle, a safety cable, attached next to the valve.
- remove wheel chocks, if applied, and disengage the parking brake. 6 No external force may be exerted on the air outlet valves, e.g. by pulling
2 To tow a unit use a towing vehicle of ample capacity. Refer to the on hoses or by installing auxiliary equipment directly to a valve, e.g. a
documentation of the towing vehicle. water separator, a lubricator, etc. Do not step on the air outlet valves.
3 If the unit is to be backed up by the towing vehicle, disengage the 7 Never move a unit when external lines or hoses are connected to the
overrun brake mechanism (if it is not an automatic mechanism). outlet valves, to avoid damage to valves, manifold and hoses.
4 Never exceed the maximum towing speed of the unit (mind the local 8 Do not use compressed air from any type of compressor, without taking
regulations). extra measures, for breathing purposes as this may result in injury or
death. For breathing air quality, the compressed air must be adequately
5 Place the unit on level ground and apply the parking brake before
purified according to local legislation and standards. Breathing air must
disconnecting the unit from the towing vehicle. Unclip the safety break-
always be supplied at stable, suitable pressure.
away cable or safety chain. If the unit has no parking brake or jockey
wheel, immobilize the unit by placing chocks in front of and/or behind 9 Distribution pipework and air hoses must be of correct diameter and
the wheels. When the towbar can be positioned vertically, the locking suitable for the working pressure. Never use frayed, damaged or
device must be applied and kept in good order. deteriorated hoses. Replace hoses and flexibles before the lifetime
expires. Use only the correct type and size of hose end fittings and
6 To lift heavy parts, a hoist of ample capacity, tested and approved
connections.
according to local safety regulations, shall be used.
10 If the compressor is to be used for sand-blasting or will be connected to
7 Lifting hooks, eyes, shackles, etc., shall never be bent and shall only
a common compressed-air system, fit an appropriate non-return valve
have stress in line with their design load axis. The capacity of a lifting
(check valve) between compressor outlet and the connected sand-
device diminishes when the lifting force is applied at an angle to its load
blasting or compressed-air system. Observe the right mounting position/
axis.
direction.
8 For maximum safety and efficiency of the lifting apparatus all lifting
11 Before removing the oil filler plug, ensure that the pressure is released
members shall be applied as near to perpendicular as possible. If
by opening an air outlet valve.
required, a lifting beam shall be applied between hoist and load.
12 Never remove a filler cap of the cooling water system of a hot engine.
9 Never leave a load hanging on a hoist.
Wait until the engine has sufficiently cooled down.
10 A hoist has to be installed in such a way that the object will be lifted
13 Never refill fuel while the unit is running, unless otherwise stated in the
perpendicular. If that is not possible, the necessary precautions must be
Atlas Copco Instruction Book (AIB). Keep fuel away from hot parts
taken to prevent load-swinging, e.g. by using two hoists, each at
such as air outlet pipes or the engine exhaust. Do not smoke when
approximately the same angle not exceeding 30° from the vertical.
fuelling. When fuelling from an automatic pump, an earthing cable
should be connected to the unit to discharge static electricity. Never spill
nor leave oil, fuel, coolant or cleansing agent in or around the unit.
6
14 All doors shall be shut during operation so as not to disturb the cooling 30 Never touch the power terminals during operation of the machine.
air flow inside the bodywork and/or render the silencing less effective.
31 Whenever an abnormal condition arises, e.g. excessive vibration, noise,
A door should be kept open for a short period only e.g. for inspection or
odour, etc., switch the circuit breakers to OFF and stop the engine.
adjustment.
Correct the faulty condition before restarting.
15 Periodically carry out maintenance works according to the maintenance
32 Check the electric cables regularly. Damaged cables and insufficient
schedule.
lightening of connections may cause electric shocks. Whenever
16 Stationary housing guards are provided on all rotating or reciprocating damaged wires or dangerous conditions are observed, switch the circuit
parts not otherwise protected and which may be hazardous to personnel. breakers to OFF and stop the engine. Replace the damaged wires or
Machinery shall never be put into operation, when such guards have correct the dangerous condition before restarting. Make sure that all
been removed, before the guards are securely reinstalled. electric connections are securely tightened.
17 Noise, even at reasonable levels, can cause irritation and disturbance 33 Avoid overloading the generator. The generator is provided with circuit
which, over a long period of time, may cause severe injuries to the breakers for overload protection. When a breaker has tripped, reduce the
nervous system of human beings. concerned load before restarting.
When the sound pressure level, at any point where personnel normally
34 If the generator is used as stand-by for the mains supply, it must not be
has to attend, is:
operated without control system which automatically disconnects the
below 70 dB(A): no action needs to be taken,
generator from the mains when the mains supply is restored.
above 70 dB(A): noise-protective devices should be provided for
people continuously being present in the room, 35 Never remove the cover of the output terminals during operation. Before
below 85 dB(A): no action needs to be taken for occasional visitors connecting or disconnecting wires, switch off the load and the circuit
staying a limited time only, breakers, stop the machine and make sure that the machine cannot be
above 85 dB(A): room to be classified as a noise-hazardous area and started inadvertently or there is any residual voltage on the power
an obvious warning shall be placed permanently at circuit.
each entrance to alert people entering the room, for 36 Running the generator at low load for long periods will reduce the
even relatively short times, about the need to wear lifetime of the engine.
ear protectors,
above 95 dB(A): the warning(s) at the entrance(s) shall be completed
with the recommendation that also occasional
visitors shall wear ear protectors,
above 105 dB(A): special ear protectors that are adequate for this noise 1.5 SAFETY DURING MAINTENANCE AND REPAIR
level and the spectral composition of the noise shall
be provided and a special warning to that effect shall Maintenance, overhaul and repair work shall only be carried out by
be placed at each entrance. adequately trained personnel; if required, under supervision of someone
18 Insulation or safety guards of parts the temperature of which can be in qualified for the job.
excess of 80 °C (175 °F) and which may be accidentally touched by 1 Use only the correct tools for maintenance and repair work, and only
personnel shall not be removed before the parts have cooled to room tools which are in good condition.
temperature.
2 Parts shall only be replaced by genuine Atlas Copco replacement parts.
19 Never operate the unit in surroundings where there is a possibility of
taking in flammable or toxic fumes. 3 All maintenance work, other than routine attention, shall only be
undertaken when the unit is stopped. Steps shall be taken to prevent
20 If the working process produces fumes, dust or vibration hazards, etc., inadvertent starting. In addition, a warning sign bearing a legend such as
take the necessary steps to eliminate the risk of personnel injury. ”work in progress; do not start” shall be attached to the starting
21 When using compressed air or inert gas to clean down equipment, do so equipment.
with caution and use the appropriate protection, at least safety glasses, On engine-driven units the battery shall be disconnected and removed or
for the operator as well as for any bystander. Do not apply compressed the terminals covered by insulating caps.
air or inert gas to your skin or direct an air or gas stream at people. On electrically driven units the main switch shall be locked in open
Never use it to clean dirt from your clothes. position and the fuses shall be taken out. A warning sign bearing a
legend such as ”work in progress; do not supply voltage” shall be
22 When washing parts in or with a cleaning solvent, provide the required
attached to the fuse box or main switch.
ventilation and use appropriate protection such as a breathing filter,
safety glasses, rubber apron and gloves, etc. 4 Before dismantling any pressurized component, the compressor or
equipment shall be effectively isolated from all sources of pressure and
23 Safety shoes should be compulsory in any workshop and if there is a
the entire system shall be relieved of pressure. Do not rely on non-return
risk, however small, of falling objects, wearing of a safety helmet should
valves (check valves) to isolate pressure systems. In addition, a warning
be included.
sign bearing a legend such as ”work in progress; do not open” shall be
24 If there is a risk of inhaling hazardous gases, fumes or dust, the attached to each of the outlet valves.
respiratory organs must be protected and depending on the nature of the
5 Prior to stripping an engine or other machine or undertaking major
hazard, so must the eyes and skin.
overhaul on it, prevent all movable parts from rolling over or moving.
25 Remember that where there is visible dust, the finer, invisible particles
6 Make sure that no tools, loose parts or rags are left in or on the machine.
will almost certainly be present too; but the fact that no dust can be seen
Never leave rags or loose clothing near the engine air intake.
is not a reliable indication that dangerous, invisible dust is not present in
the air. 7 Never use flammable solvents for cleaning (fire-risk).
26 Never operate the unit at pressures or speeds below or in excess of its 8 Take safety precautions against toxic vapours of cleaning liquids.
limits as indicated in the technical specifications. 9 Never use machine parts as a climbing aid.
27 Never operate the generator in excess of its limits as indicated in the 10 Observe scrupulous cleanliness during maintenance and repair. Keep
technical specifications and avoid long no-load sequences. away dirt, cover the parts and exposed openings with a clean cloth,
28 Never operate the generator in a humid atmosphere. Excessive moisture paper or tape.
causes worsening of the generator insulation. 11 Never weld on or perform any operation involving heat near the fuel or
29 Do not open electrical cabinets, cubicles or other equipment while oil systems. Fuel and oil tanks must be completely purged, e.g. by
voltage is supplied. If such cannot be avoided, e.g. for measurements, steam-cleaning, before carrying out such operations. Never weld on, or
tests or adjustments, have the action carried out by a qualified electrician in any way modify, pressure vessels. Disconnect the alternator cables
only, with appropriate tools, and ascertain that the required bodily during arc welding on the unit.
protection against electrical hazards is applied.
7
12 Support the towbar and the axle(s) securely if working underneath the 1.7 SPECIFIC SAFETY PRECAUTIONS
unit or when removing a wheel. Do not rely on jacks.
13 Do not remove any of, or tamper with, the sound-damping material. Batteries
Keep the material free of dirt and liquids such as fuel, oil and cleansing
agents. If any sound-damping material is damaged, replace it to prevent When servicing batteries, always wear protecting clothing and glasses.
the sound pressure level from increasing. 1 The electrolyte in batteries is a sulphuric acid solution which is fatal if it
14 Use only lubricating oils and greases recommended or approved by hits your eyes, and which can cause burns if it contacts your skin.
Atlas Copco or the machine manufacturer. Ascertain that the selected Therefore, be careful when handling batteries, e.g. when checking the
lubricants comply with all applicable safety regulations, especially with charge condition.
regard to explosion or fire-risk and the possibility of decomposition or 2 Install a sign prohibiting fire, open flame and smoking at the post where
generation of hazardous gases. Never mix synthetic with mineral oil. batteries are being charged.
15 Protect the engine, alternator, air intake filter, electrical and regulating 3 When batteries are being charged, an explosive gas mixture forms in the
components, etc., to prevent moisture ingress, e.g. when steam-cleaning. cells and might escape through the vent holes in the plugs.
16 When performing any operation involving heat, flames or sparks on a Thus an explosive atmosphere may form around the battery if
machine, the surrounding components shall first be screened with non- ventilation is poor, and can remain in and around the battery for several
flammable material. hours after it has been charged. Therefore:
- never smoke near batteries being, or having recently been, charged,
17 Never use a light source with open flame for inspecting the interior of a - never break live circuits at battery terminals, because a spark usually
machine. occurs.
18 When repair has been completed, the machine shall be barred over at 4 When connecting an auxiliary battery (AB) in parallel to the unit battery
least one revolution for reciprocating machines, several revolutions for (CB) with booster cables: connect the + pole of AB to the + pole of CB,
rotary ones to ensure that there is no mechanical interference within the then connect the - pole of CB to the mass of the unit. Disconnect in the
machine or driver. Check the direction of rotation of electric motors reverse order.
when starting up the machine initially and after any alteration to the
electrical connection(s) or switch gear, to check that the oil pump and
the fan function properly. Pressure vessels
19 Maintenance and repair work should be recorded in an operator’s (according to directive 87/404/EEC annex II § 2)
logbook for all machinery. Frequency and nature of repairs can reveal Maintenance/installation requirements:
unsafe conditions.
1 The vessel can be used as pressure vessel or as separator and is designed
20 When hot parts have to be handled, e.g. shrink fitting, special heat- to hold compressed air for the following application:
resistant gloves shall be used and, if required, other body protection - pressure vessel for compressor,
shall be applied. - medium AIR/OIL,
21 When using cartridge type breathing filter equipment, ascertain that the
correct type of cartridge is used and that its useful service life is not and operates as detailed on the data plate of the vessel:
surpassed. - the maximum working pressure ps in bar,
- the maximum working temperature Tmax in °C,
22 Make sure that oil, solvents and other substances likely to pollute the - the minimum working temperature Tmin in °C,
environment are properly disposed of. - the capacity of the vessel V in l.
23 Before clearing the unit for use after maintenance or overhaul, check 2 The pressure vessel is only to be used for the applications as specified
that operating pressures, temperatures and speeds are correct and that above and in accordance with the technical specifications. Safety
the control and shutdown devices function correctly. Submit the reasons prohibit any other applications.
generator to a testrun, check that the AC power performance is correct.
3 National legislation requirements with respect to re-inspection must be
complied with.
4 No welding or heat treatment of any kind is permitted to those vessel
walls which are exposed to pressure.
1.6 TOOL APPLICATIONS SAFETY
5 The vessel is provided and may only be used with the required safety
Apply the proper tool for each job. With the knowledge of correct tool use equipment such as manometer, overpressure control devices, safety
valve, etc.
and knowing the limitations of tools, along with some common sense, many
accidents can be prevented. 6 Draining of condensate shall be performed regularly when vessel is in
Special service tools are available for specific jobs and should be used when use.
recommended. The use of these tools will save time and prevent damage to 7 Installation, design and connections should not be changed.
parts.
8 Bolts of cover and flanges may not be used for extra fixation.
Safety valves
All adjustments or repairs are to be done by an authorized representative of
the valve supplier (see maintenance schedule 4.2).
8
INSTRUCTION MANUAL
2. LEADING PARTICULARS
2.1 DESCRIPTION OF SAFETY PICTOGRAMS USED IN When the air consumption increases, the air receiver pressure will
THIS MANUAL decrease and vice versa.
This receiver pressure variation is sensed by the regulating valve
which, by means of control air to the unloader and engine speed
This symbol draws your attention to dangerous regulator, matches the air output to the air consumption. The air
situations. The operation concerned may endanger receiver pressure is maintained between the pre-selected working
persons and cause injuries. pressure and the corresponding unloading pressure.
– Safety devices
A thermal shut-down switch protects the compressor against
overheating. The air receiver is provided with a safety valve.
The engine is equipped with low oil pressure and high oil temperature
shut-down switches.
66
S – Frame and axle
XA
The compressor/engine unit is supported by rubber buffers in the
1
0
frame.
The standard unit has a non-adjustable towbar with a towing eye.
As an option the unit can be equipped with an adjustable towbar, an
overrun and parking brake and towing eyes type AC, DIN, ball, ITA,
GB, NATO (for available options see chapter 7).
The new braking system consists of an integrated parking brake and
overrunbrake. When driving backwards the overrunbrake is not
engaged automatically.
Fig. 2.1 General view of XAS66 DdG, DdGIT with open door
(adjustable towbar with brakes and jockey wheel are options)
– Bodywork
The bodywork has openings at the shaped front and rear end for the
2.2 GENERAL DESCRIPTION intake and outlet of cooling air and hinged doors for maintenance and
service operations. The bodywork is internally lined with sound-
The XAS66 DdG, DdG IT is a silenced, single-stage, oil-injected absorbing material.
screw compressor, built for a nominal effective working pressure of
7 bar. – Lifting eye
A lifting eye is accessible when a small door at the top of the unit is
– Engine unlocked.
The compressor is driven by a oil-cooled diesel engine.
The engine’s power is transmitted to the compressor through a heavy- – Control panel
duty drive belt. The control panel grouping the air pressure gauge, control switch etc.,
is placed at the right hand/ rear end corner.
– Compressor
The compressor casing houses two screw-type rotors, mounted on ball – Data plate
and roller bearings. The male rotor, driven by the engine, drives the
female rotor. The element delivers pulsation-free air. The compressor is furnished with a data plate showing the product
Injected oil is used for sealing, cooling and lubricating purposes. code, the unit serial number and the working pressure (see chapter 10).
9
XAS66 DDG / DDG IT
Warning!
Electrocution hazard.
Part under pressure.
Atlas Copco mineral engine oil. Do not run the motor with open doors.
Compressor loaded.
0 = OFF
Generator
Runlamp. 1 = ON
Airfilter.
Insulation fault.
Rotation direction.
10
INSTRUCTION MANUAL
66
AS
X CPg
BH
OFe
A
EP JW
E
S F TB
G
VI
AR
RV
SV
FP
OLG
DPec
AV
FC 2
DS e
SN
FC1
OF c FU
SVa
CE FF
VV
CP DB FT AF
Fig. 2.2 Main parts of XAS66 DdG, DdG IT (adjustable towbar, jockey wheel, brakes and roadsignalisation are options)
A Alternator E Engine OFc Oil Filter (compressor)
AF Air Filter (for engine and compressor) EP Exhaust Pipe OFe Oil Filter (engine)
AR Air Receiver F Fan OLG Oil Level Gauge
AV Air outlet valves FC1 Filler Cap (engine oil) RV Regulating Valve
BH Brake Handle FC2 Filler Cap (fuel tank) S Starting Motor
CE Compressor Element FF Fuel Filter SN Serial Number
CP Control Panel (compressor) FP Filler Plug (compressor oil) SV Safety Valve
CPg Control Panel (generator) FT Fuel Tank SVa Solenoid Valve (generator action)
DB Drive Belt FU Fuel Pump TB Towbar
DPec Drain Plug Engine Oil Cooler G Generator VI Vacuum Indicator
DSe Engine Oil Level Dipstick JW Jockey Wheel VV Vacuator Valve
11
XAS66 DDG / DDG IT
SVa
VV
RV
PG FR SV
E OC
OS SR
SL
UA DB
UV
AR
FP BDV VH
CV
AV
OF
F
SL
TS DP
FN
CE
OLG
DP
Fig. 2.3 DP
AF Air Filter DP Drain Plug OLG Oil Level Gauge SVa Solenoid valve
AR Air Receiver E Engine OS Oil Separator (generator action)
AV Air Outlet Valves F Fan PG Pressure Gauge TS Temperature Switch
BDV Blow Down Valve FN Flow Nozzle RV Regulating Valve UA Unloader Assembly
CE Compressor Element FP Filling Plug SL Scavenge Line UV Unloader Valve
CV Check Valve FR Flow Restrictor SR Speed Regulator VH Vent Hole
DB Drive Belt OC Oil Cooler SV Safety Valve VI Vacuum Indicator
OF Oil Filter VV Vacuator Valve
12
INSTRUCTION MANUAL
13
XAS66 DDG / DDG IT
2.8.1 CIRCUIT DIAGRAM (GENERATOR DDG 110V) The compressor is equipped with a negative earthed system.
0 1 2 3
S1
0
12V DC S1 1
2
3 1
10A F1 5 31 2
22 23 30 33 3 13 K3
32 4 10 11
S5 14´
18 0
K4 15´
15 16
K4 19 8 3 3 3 3 9 9 9 11 13´
K0
17
6 S2 8´
G2 G1 5´ V1 0
+ B+ 7 35 7´
D- D+ 6´ S3 13
Auxiliary p 1´
2´
34
P1 27
14
K0 12´ V2 Y1 3´ K3 14 9 K2 25 H1 29 H2 K1 5
h
26
4´ 12 7 24 Temp 28 General 3 M1 M
15 10 alarm
1 2
4 K1 K2 8 20 S4
(Lamp-
6 21 tester)
12 12 12 12 12 12 12 12 12
9´,10´,11´
S7
3
X1 X2 X3 b3
52 51
L1 L2 L1 L2 L1 L2 b3 b3 b3
32A 16A 16A 13 13 13
L1
L2
1L1
1L2
2L1
2L2
N13
e0 e0 e54 c0 c0 c54 c0 c0 c54 10 1 30mA 7
6
Q2 Q3 b3 14 I n 5
16A 16A 11 3 40msec. 4
I >> I >> I >> I >>
P R Y2 A1
K5
B A2
e0 L1 12 12 12
e0 L2 b6 b6 b6 b6 12
b0 L2
b0 L1
H3
1 3
K5
2 4
T13
1 b0 15
2 b0 16
3 b0 17
4 b0 18
W1
V1
e0 e0
Q1
I >> I >>
40A
e0 e0
W
V
V W e54
G3
G
EARTHING PIN
Fig. 2.4 Circuit diagram (No. 9822 0797 01 + No. 9822 0834 06)
F1 Circuit Breaker (10A) K2 Blocking Relay Q3 Circuit breaker 2-pole T13 Current transformer for N13
G1 Alternator K3 Override Start Relay S1 Contact Switch (Off-On- V1 Diode
G2 Battery K4 Start Relay Override-start) V2 Diode
G3 Generator K5 Contactor S2 Temperature Switch Engine X1 Socket outlet
H1 Temperature Alarm Lamp M1 Starter Motor S3 Oil Pressure Switch Engine X2 Socket outlet
H2 General Alarm Lamp N13 Earth faultcurrent relay S4 Temperature Lamptest Switch X3 Socket outlet
H3 Lamp (Power ON) P1 Hourmeter S5 Temperature Switch Y1 Fuel solenoid Valve
K0 Starter Solenoid (part of M1) Q1 Main circuit breaker 2-pole Compressor Y2 Solenoid valve (Generator
K1 Shut-down Relay Q2 Circuit breaker 2-pole S7 Switch (Generator-compressor) action)
14
INSTRUCTION MANUAL
2.8.2 DESCRIPTION
(GENERATOR DDG 110V)
15
XAS66 DDG / DDG IT
S1
0
S1 1
12V DC 2
3 1
10A 5 31 2
33 13
22
F1 23 30
32
3
10
K3
4 11
18
S5 14´
K4 15´
15 16
K4 19 8 3 3 3 3 9 9 9 11 13´
K0
17
6 S2 8´
G2 G1 5´
V1 0
7´
+ B+
D+
7 35
6´ 13
D-
Auxiliary
S3 1´
p
2´
34
P1 27 14
K0 12´ Y1 3´ K3 14 9 K2 25 H1 29 H2 K1 5
h V2
26
4´ 12 7 24 Temp 28 General 3 M1 M
15 10 alarm
1 2
4 K1 K2 8 20 S4
(Lamp-
6 21 tester)
12 12 12 12 12 12 12 12 12
9´,10´,11´
L2
L1
L2
L3
N
N
1 3 5 7 S7
K5 2 4 6 8 b0 b3 3
Q1 16 52 51
EA
b3
b0 b0 b3
I I I I
>> >> >> >>
W1 16 13
34
10A 16A 10A 16A
14 12 11 A1 K6 b6 b0 b3 b3
N N L2 15 13
b6 b0
b0 b6 R<
W1 16
H3 D1A1 K5 P R 9 Y2
A2
35
R T PE L A2 B
b6 b6 b6
b54 b54
b54 b0 b6
12 12 12 12
N
b0
W
U
V
G3 U1 V1 W1 N
G
S6
0
Fig. 2.5 Circuit diagram (No. 9822 0797 01 + No. 9822 0834 00)
16
INSTRUCTION MANUAL
2.8.4 DESCRIPTION
(GENERATOR DDG IT 230/400V)
17
XAS66 DDG / DDG IT
S1
0
S1 1
12V DC 2
3 1
10A 5 31 2
33 13
22
F1 23 30
32
3
10
K3
4 11
18
S5 14´
K4 15´
15 16
K4 19 8 3 3 3 3 9 9 9 11 13´
K0
17
6 S2 8´
G2 G1 5´
V1 0
7´
+ B+
D+
7 35
6´ 13
D-
Auxiliary
S3 1´
p
2´
34
P1 27 14
K0 12´ Y1 3´ K3 14 9 K2 25 H1 29 H2 K1 5
h V2
26
4´ 12 7 24 Temp 28 General 3 M1 M
15 10 alarm
1 2
4 K1 K2 8 20 S4
(Lamp-
6 21 tester)
12 12 12 12 12 12 12 12 12
9´,10´,11´
X1.1 X1.2 X1.3
L1
L2 L1 L2 L1 L2
L3
16A 16A 16A
L2
L1
L1
L2
L1
L2
L3
S7
b0 b3 3
Q1 16 52 51
EA
b3
b0 b0 b3
I I I
>> >> >>
1V1 16 13
34
16A 16A 16A
14 12 11 A1 K6 b0 b0 b3 b3
b0 1W1 L2 L1 15 13
b0
b0 b6 R<
c0 c0 c0 H3 D1A1 K5 P R 9 Y2
1W1
1U1
1V1
1V1 16 A2 B
35
R T PE L A2
1 3 5 b6 b6 b6
b54 b54
K5 b54 b0 b6
2 4 6
c0 c0 c0 12 12 12
W1 b0
W1
U1
V1
G3 U1 V1 W1
W2 U2 V2
G L3 16
S6
0
Fig. 2.6 Circuit diagram (No. 9822 0797 01 + No. 9822 0834 04)
18
INSTRUCTION MANUAL
2.8.6 DESCRIPTION
(GENERATOR DDG IT 230V)
19
XAS66 DDG / DDG IT
3. OPERATING INSTRUCTIONS
3.1 PARKING, TOWING AND LIFTING INSTRUCTIONS
Safety precautions. 6 6
The operator is expected to apply all relevant safety
precautions, including those mentioned on the pages
5 - 8 of this book.
2
Attention: 2
– Before putting the compressor in to use, check the brake system
as described in section 5.6.
Fig. 3.3 Parking position of jockey wheel
– After the first 100 km travel:
– Check and retighten the wheel nuts and towbar bolts to the
specified torque. See section 3.1.3 and 9.1.
– Check the brake adjustment. See section 5.6.
S S
XA XA
1
3.1.2 TOWING INSTRUCTIONS
5
Fig. 3.1 Non-adjustable towbar with standard prop without brakes
2
3
20
INSTRUCTION MANUAL
B
2
A
3
2
Fig. 3.9 Lifting eye
1
When lifting the compressor, the hoist has to be placed in such a way
that the compressor, which must be placed level, will be lifted
vertically. Keep lifting acceleration and retardation within safe limits.
Preferably use the lifting eye (1) after opening the small door (2).
Fig. 3.7
4. Check that the fuel tank contains sufficient fuel. Top up, if
– Height adjustment should be undertaken on levelled ground and
necessary. Consult the Engine Operation Manual for the type of
in coupled condition.
fuel.
– When readjusting, make sure that the front point of the drawbar
5. Drain any water and sediment from the fuel filter until clean fuel
is horizontal to the coupling point.
flows from the drain cock.
– Before starting a trip, make sure that the adjustment shaft is
6. Press vacuator valve (Fig. 2.3, VV) of the air filter to remove
secure, so that the stability and safety is guaranteed while
dust.
driving. If necessary tighten the locking nut (2) corresponding to
table (Fig. 3.8). 7. Check the air filter vacuum indicator (Fig. 2.3, VI). If the yellow
piston reaches the red marked service range, replace the filter
element. Reset the indicator by pushing the reset button.
8. Open air outlet valve to allow air flow to the atmosphere.
21
XAS66 DDG / DDG IT
3.3 STARTING/STOPPING
3.3.1 GENERAL
Before starting, first operate the circuit breaker button (F1) at the left
side of the control panel (open left-hand service door first).
To start, the start button is turned clockwise to position 1, lamp H2
(general alarm) will go on. When the button is turned further to
position 3, the starter motor will set the engine in motion. Lamp H2
P1 will go out as soon as the engine has been started. The start button
automatically springs back to position 1. Lamp H1 only produces a
signal when the compressor outlet temperature is too high. Correct
operation of the lamp itself can be checked by operating the lamp
test button S4 located on the control panel.
When the start button is in position 1 and the engine is not running,
F1 the lamp test can be used. Lamp H1 will go on and will
automatically go out when the group is started.
PG
Shutting-down is simply done by turning the start button anti-
clockwise to position 0 (with valves closed).
The control panel in addition indicates receiver pressure (PG) and
accumulated operating hours (P1).
P1 Hourmeter
F1 Circuit breaker button
PG Working pressure gauge
H1 Temperature alarm lamp (red)
H2 General alarm lamp (red)
S1 Contact switch
S4 Lamp test
22
INSTRUCTION MANUAL
3.3.2 FUNCTION OF GENERATOR DDG Start the unit in accordance with the normal procedure
(see section 3.3.1). Let the motor warm up until it reaches operational
temperature. Turn the green switch S7 to position 1.
The normal control system is switched off and the motor speed
increases to reach the maximum.
0 1
The green lamp H3 in the switch S7 is activated, showing that sockets
X1, X2 and X3 are under tension.
S7 / H3
The generator can be switched off by turning the green switch S7 to
position 0.
X3 X3
Q1 Q2 Q3
1 2 3 4 5 6 7 8 9 10
X2 X2
X1 X1
Before connecting an electrical device, always check
the data listed on the rating plate.
Fig. 3.11 Control panel (generator) Fault situations and protective devices:
– When switching on the generator by means of the switch S7, the
H3 Lamp (green) green lamp H3 is not activated. Open the left machine door and
S7 Switch check if the circuit breakers are down.
X1 Socket 110 V/ 32 A
If so, put them up (switch them on). If the circuit breakers are up,
X2 Socket 110 V/ 16 A
it can be indicative of a serious electrical fault.
X3 Socket 110 V/ 16 A
– When the electrical device is connected, the green lamp H3 is
always deactivated. This indicates a fault in the electrical device.
min 400
23
XAS66 DDG / DDG IT
0 1
S7 / H3
40 50 60
30 70
20 80
14
Q1 Q2Q1 Q3
1 2 3 4 5 6 7 8 9 10
X1.3 X1.3
Start the unit in accordance with the normal procedure The doors must be closed during operation and may be
(see section 3.3.1). Let the motor warm up until it reaches operational opened for short periods only.
temperature. Turn the green switch S7 to position 1.
The normal control system is switched off and the motor speed
Regularly carry out following checks:
increases to reach the maximum.
1. That regulating valve (RV) is correctly adjusted, i.e. starts
The green lamp H3 in the switch S7 is activated, showing that sockets decreasing the engine speed when reaching the preset working
X1.1, X1.2 and X1.3 are under tension. pressure in the receiver.
The generator can be switched off by turning the green switch S7 to 2. Check the air filter vacuum indicator (VI, Fig. 2.3). If the yellow
position 0. piston reaches the red marked service range, replace the filter
element. Reset the indicator by pushing the reset button.
3. On compressors with aftercooler, check that the automatic drain
of the water separator is operative without air leakage.
24
INSTRUCTION MANUAL
4. MAINTENANCE
4.1 USE OF SERVICE PAKS 4.2 PREVENTIVE MAINTENANCE SCHEDULE FOR THE
COMPRESSOR
Service Paks include all genuine parts needed for normal maintenance
of both compressor and engine. The schedule contains a summary of the maintenance instructions.
Read the respective section before taking maintenance measures.
Service Paks minimise downtime and keep your maintenance budget
low. When servicing, replace all disengaged packings, e.g. gaskets,
O-rings, washers.
Order Service Paks at your local Atlas Copco dealer.
For engine maintenance refer to Engine Operation Manual.
The maintenance schedule has to be seen as a guideline for units
operating in a dusty environment typical to compressor applications.
Maintenance schedule can be adapted depending on application
environment and quality of maintenance.
Keep the bolts of the housing, the lifting eye, the towbar and the axle securely tightened.
Refer to section 9 ’Technical specifications’ and section 3.1.3 for the torque values.
25
XAS66 DDG / DDG IT
Remark:
3
When changing from mineral to synthetic oil (or the
other way around), you will need to do an extra rinse:
After doing the complete change procedure to synthetic
oil, run the unit for a few minutes to allow good and
Fig. 4.1 Check compressor oil level
complete circulation of the synthetic oil. Then drain the
synthetic oil again and fill again with new synthetic oil.
To set correct oil levels, proceed as in normal With the unit standing level, check the level of the compressor oil. The
instruction. pointer of the oil level gauge (1) must register in the upper extremity
of the green range. Add oil if necessary.
26
INSTRUCTION MANUAL
4.5 OIL AND OIL FILTER CHANGE 6. Run the unit at no load for a few minutes to circulate the oil and
to evacuate the air trapped in the oil system.
7. Stop the compressor. Let the oil settle for a few minutes. Check
that the pressure is released by opening an air outlet valve (5).
2 Screw out filler plug (2) and add oil until the pointer of the oil
level gauge (4) again registers in the upper extremity of the green
range. Reinstall and tighten the filler plug.
4
Never add more oil. Overfilling results in oil
consumption.
AS
0
1
X
5 3
2
Fig. 4.2 Oil filters 1
Fig. 4.3 Compressor oil cooler (1) and engine oil cooler (2)
4.5.2 COMPRESSOR OIL AND OIL FILTER CHANGE
Keep the oil coolers (1) and (2) clean to maintain the cooling
The quality and the temperature of the oil determine the oil change efficiency.
interval.
The fan side surface of compressor- and engine oil cooler is accessible
The prescribed interval (see section 4.2) is based on an oil temperature by removing the fan cowl upper part.
of up to 100 °C and normal operating conditions.
When operating in high ambient temperatures, in very dusty or high Remove any dirt from the coolers with a fibre brush.
humidity conditions, it is recommended to change the oil more Never use a wire brush or metal objects.
frequently.
Steam cleaning in combination with a cleansing agent may be
In this case, contact Atlas Copco. applied.
1. Run the compressor until warm. Close the outlet valve(s) (5) and To avoid damaging the coolers, angle between jet and
stop the compressor. Wait until the pressure is released through coolers should be approx. 90 °.
the automatic blow-down valve. Unscrew the oil filler plug (2)
one turn. This uncovers a vent hole, which permits any pressure Protect the electrical and controlling equipment, air
in the system to escape. filters, etc. against penetration of moisture.
2. Drain the oil by removing all relevant drain plugs. Drain plugs
are located at the air receiver and compressor element. Catch the Close the service door(s).
oil in a drain pan. Screw out the filler plug to speed up draining.
Never leave spilled liquids such as fuel, oil, water and
Tighten the plugs after draining.
cleansing agents in or around the compressor.
3. Remove the oil filter (3), 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.
5. Fill the air receiver until the pointer of the oil level gauge (4)
registers in the upper extremity of the green range. Take care that
no dirt drops into the system. Reinstall and tighten the filler plug.
27
XAS66 DDG / DDG IT
4.7.1 ELECTROLYTE
Before and after charging a battery, always check the electrolyte level
in each cell; if required, top up with distilled water only. When
charging batteries, each cell must be open, i.e. plugs and/or cover
removed. 4.11 COMPRESSOR ELEMENT OVERHAUL
Use a commercial automatic battery charger according
to its manufacturer’s instructions. When a compressor element is due for overhaul, it is recommended to
have it done by Atlas Copco. This guarantees the use of genuine parts
Apply with preference the slow charging method and adjust the charge and correct tools with care and precision.
current according to the following rule of thumb:
Battery capacity in Ah divided by 20 gives safe charging current in
Amp.
4.12 LIABILITY
4.7.4 BATTERY MAINTENANCE The manufacturer does not accept any liability for any damage arising
from the use of non-original parts and for modifications, additions or
– Keep the battery clean and dry. conversions made without the manufacturer’s approval in writing.
– Keep the electrolyte level at 10 to 15 mm above the plates or at
the indicated level; top up with distilled water only.
– Keep the terminals and clamps tight, clean, and lightely covered
with petroleum jelly.
28
INSTRUCTION MANUAL
VI AF
SVa
VV
RV
PG FR SV
E OC
OS SR
SL
UA DB
UV
AR
FP BDV VH
CV
AV
OF
F
SL
TS DP
FN
CE
OLG
DP
DP
Fig. 5.1
29
XAS66 DDG / DDG IT
1 To remove dust from the dust trap pinch the vacuator valve (6) several
times.
7
6 2 3 4 5
Fig. 5.2 Air filter 9
1 Snap clips
2 Dust trap
3 Safety cartridge (option)
4 Filter element Fig. 5.3 Vacuum indicator
5 Filter housing
6 Vacuator valve 7 Air filter contamination indicator
8 Reset button
9 Yellow indicator
5.2.2 RECOMMENDATIONS
The Atlas Copco air filters are specially designed for
5.3 AIR RECEIVER
the application. The use of non-genuine air filters may
lead to severe damage of engine and/or compressor The air receiver is tested according to official standards. Regularly
element. have inspections carried out in conformity with local regulations.
New elements must also be inspected for tears or punctures before 5.4 SAFETY VALVE
installation.
Discard the element (4) when damaged. All adjustments or repairs are to be done by an
authorized representative of the valve supplier.
In heavy duty applications it is recommended to install a safety
cartidge which can be ordered with
part no.: 2914 9309 00 Following checks must be carried out:
A dirty safety cartridge (3) is an indication of a mal-functioning air – A check of the opening of the lifting gear, twice a year.
filter element. Replace the element and the safety cartridge in this case. This can be done by screwing the cap of the valve anti-clockwise.
The safety cartridge cannot be cleaned. – A check of the set pressure once a year according to the local
regulations. This check cannot be done on the machine and must
be carried out on a proper test bench.
30
INSTRUCTION MANUAL
5 1 3 2
Replacing the filter element:
Fig. 5.5 Brake shoe adjustment
1. Unscrew the filter element (1) from the adapter head.
1 Adjusting bolt
2. Clean the adapter head sealing surface. Lightly oil the gasket of 2 Axle
the new element and screw the latter onto the header until the 3 Brake cable
gasket is properly seated, then tighten with both hands. 4 Pin ∅ 4 mm
5 Plug
3. Check for fuel leaks once the engine has been restarted.
31
XAS66 DDG / DDG IT
5.6.2 TEST PROCEDURE OF BRAKE CABLE ADJUSTMENT 5.6.3 BRAKE CABLE ADJUSTMENT
1. Check if the towing eye rod of the overrun brake mechanism is
1 6 4 2
in the outmost position.
2. Check if the adjustable towbar (= option) is in the actual towing
position.
3. Apply the hand brake lever.
4. Push the compressor a few centimeters backwards 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 Fig. 5.6 A,B,C,D.
1 2 3 4 2 5
1 Fig. 5.7 Brake cable arrangement
2
1 Brake cable
2 Lock nut
3 Adjusting nut
4 Brake cable nut
5 Main brake cable
6 Equalizer
A. Adjusted correctly
1. With the towing eye pulled out in the outmost position and the
hand brake lever in the downward position (Fig. 5.8), loosen the
lock nuts (Fig. 5.7, 2). Turn adjusting nuts and brake cable nuts
(Fig. 5.7, 4) clockwise until there is no slack in the brake
mechanism.
The equalizer (Fig. 5.7, 6) must remain perpendicular to the main
brake cable (Fig. 5.7, 5).
2. Apply the hand brake lever several times and repeat the
adjustment. Tighten the nuts with their lock nuts (Fig. 5.7, 2).
Remove the jack and the blocks.
3. Road test the compressor and brake several times. Check brake
shoe and brake cable adjustment and if necessary adjust.
B. Acceptable
C. Too loose;
adjust brake cables
(Section 5.6.3)
Fig. 5.8 Hand brake lever downward - brake not operated
32
INSTRUCTION MANUAL
1. Lamps (H1, H2) do not a. Discharged or defective battery. a. Check electrolyte level and charge battery.
light up when switching If no cells are shorted and battery is
(S1) to ” I ” and applying discharged, trace cause and correct.
lamp test. b. Loose battery cable(s) or oxidised terminals. b. Check and correct if necessary.
c. Loose connection or damaged wiring. c. Check wiring and connections; correct if
necessary.
d. Contact switch (S1) defective. d. With (S1) switched in ” I ”, check voltage
between earth and respectively each of the
terminals of (S1). Voltage must register at
each of the terminals; if not, replace (S1).
e. Circuit breaker (F1) defective. e. Replace circuit breaker.
4. Starter motor (S) does not a. Low battery output. a. See remedy 1a.
crank engine (E) after b. Contact switch (S1) defective. b. With (S1) in ” ”, check voltage between
switching startbutton (S1) earth and respectively each of the terminals
to ” ”. of (S1). Voltage must register at each of the
terminals; if not, replace (S1).
c. Alternator output relay (K4) defective. c. Replace (K4).
d. Starter solenoid (K0) or starter motor defective. d. Check start solenoid (K0). Have starter
motor repaired.
5. Starter motor (S) cranks a. Contact switch (S1) defective. a. See remedy 1d.
engine (E) when switching b. Fuel solenoid (Y1) defective. b. Check solenoid and its valve, correct or
(S1) to ” ”, but engine replace if necessary.
does not fire. c. Low battery output. c. See 1a.
33
XAS66 DDG / DDG IT
6. Engine fires, but general a. Alternator drive belt broken or slipping. a. Check and correct if necessary.
alarm lamp (H2) remains b. Alternator (A)/regulator defective. b. Have assembly repaired.
alight; engine stops when
releasing (S1).
7. Engine is running, but shuts a. Contact switch (S1) released too soon. a. Release button after engine oil pressure has
down immediately after built up above the minimum allowed value.
(S1) has been released. b. Insufficient engine oil pressure. b. Stop at once, consult the Engine Operation
Manual.
c. Fuel tank contains insufficient fuel. c. Fill fuel tank.
d. Engine oil pressure shutdown switch (S3), d. Remove and test switches.
engine temperature switch (S2) or compressor Replace if out of order.
temperature switch (S5) defective.
8. General alarm lamp (H2) a. Insufficient engine oil pressure or too high a. Stop at once, consult Engine Operation
remains alight for over 5 engine oil temperature. Manual.
seconds after starting. b. Engine oil pressure switch (S3), or compressor b. Stop at once, test switches, replace if
temperature switch (S5) defective. necessary.
c. Relay (K1) defective. c. Replace (K1).
10. Compressor does not a. Air leaks in regulating system. a. Check and repair.
unload and engine keeps b. Regulating valve (RV) incorrectly set or b. Adjust or repair regulating valve; see
running at maximum speed defective. section 5.1.
when closing the air outlet c. Unloading valve (UV) or its actuating piston c. Repair unloading valve assembly.
valves; safety valve blows. stuck.
11. Compressor capacity or a. Air consumption exceeds capacity of a. Check equipment connected.
pressure below normal. compressor.
b. Choked air filter elements (AF). b. Replace air filter element (AF).
c. Unloading valve (UV) not completely open. c. Speed regulation cable maladjusted; see
section 5.1.
d. Engine does not run at maximum speed. d. Check the maximum speed, service the fuel
filter.
e. Oil separator element (OS) clogged. e. Have element removed and inspected by an
Atlas Copco Service representative.
13. Working pressure rises a. See faults 10. a. See remedies 10.
during operation and causes b. Safety valve (SV) opens too soon. e. Have safety valve adjusted;
safety valve to blow. consult Atlas Copco.
34
INSTRUCTION MANUAL
14. Excessive compressor oil a. Restrictor in oil scavenging line (SL) clogged. a. Dismount, clean and refit restrictor.
consumption. Oil mist b. Oil separator element (OS) defective. b. Replace element.
being discharged from air c. Oil level too high. c. Check for overfilling. Release pressure and
outlet valve(s). drain oil to correct level.
15. Compressor shuts down a. Alternator V-belt broken or slipping. a. Re-tense or replace V-belt.
through a shutdown switch. b. Compressor overheating. b. See condition 17.
c. Engine oil pressure too low. c. Check lubricating system.
d. Engine temperature too high. d. Check engine oil system; see Engine
Operation Manual.
16. Air and oil mist expelled a. Unloader valve (UV) defective. a. Repair valve.
from air filter after b. Wrong oil type with no foam-retarding b. Consult Atlas Copco.
stopping. additives.
Generator DdG:
18. Circuit breakers are off a. Short circuit or overload. a. Remedy fault. Switch on circuit breakers.
(down). b. Circuit breakers switched off. b. Switch on circuit breakers.
19. Green lamp H3 is a. Circuit breakers are off. a. Switch on circuit breakers.
deactivated. b. Serious electrical fault. b. Consult Atlas Copco.
20. Circuit breakers Q1 are off a. Short circuit. a. Remedy fault. Switch on circuit breakers.
(down). b. Temperature in generator too high. b. Check generator cooling.
21. Green lamp H3 is a. Circuit breakers are off. a. Switch on circuit breakers.
deactivated. b. Serious electrical fault. b. Consult Atlas Copco.
22. The red lamp H4 is active. a. Insulation fault. a. Disconnect the electrical device, stop and
restart the unit.
The red lamp is deactivated:
Insulation fault in the electrical device.
The red lamp is again activated:
Consult Atlas Copco.
35
XAS66 DDG / DDG IT
7. AVAILABLE OPTIONS
The XAS66 DdG, DdG IT can be delivered with following options:
36
INSTRUCTION MANUAL
8. INSTALLATION
RECOMMENDATIONS FOR FRAME
SUPPORT For support mounted portable compressors we
Instrument panel this end recommend the use of Atlas Copco option „Support
mounted“. If for technical reasons, this option can not
be used, the following recommendations should be
followed ensuring a safe installation:
5
80
22
16
5
0
32
0
64
ø15
• 2 blocks of 50 mm x 50 mm x 425 mm
(2 holes with a diameter of 15 mm)
=
25
=3
50
5
32
ø15
• 2 blocks of 50 mm x 50 mm x 325 mm
(2 holes with a diameter of 15 mm)
=
25
=2
50
0
26
ø15
• 1 block of 50 mm x 50 mm x 260 mm
=
60
50
ø1
3
M12
37
XAS66 DDG / DDG IT
Measure the thickness of the truck bed or floor in order to determine Put blocks of 50 x 50 mm on the bed or floor of the truck according
how long the bolts must be. the pattern shown in Fig. 8.1.
Make sure that the bolts do not protrude from the Slowly lower the compressor onto the blocks, making sure these are
truck bed or floor by more than 75 mm not displaced.
(check, see Fig. 8.3). Too long bolts may puncture the
Tighten the M12 bolts (correct length!), from the lower side, into the
fuel tank.
nuts welded to the interior of the compressor bottom.
(For the recommended tightening torques of the bolts, see section 9
M12 Bolt Frame
’Technical Specifications’).
Once again make sure that the bolts used are sufficiently long to
correctly fasten the compressor without contacting the fuel tank.
max.
75 mm
washer
Truck bed or floor Block
38
INSTRUCTION MANUAL
For hexagon screws and nuts with strength grade 12.9 Limitations
Thread size M6 M8 M10 M12 M14 M16 1. Minimum effective receiver pressure bar(e) 2.9
Nm 15 39 78 135 210 345 2. Maximum effective receiver pressure bar(e) 8.5
3. Maximum ambient temperature °C 45
4. Minimum starting temperature °C -15
5. Altitude capability (see separate curve below) m
9.1.2 FOR IMPORTANT ASSEMBLIES Altitude unit performance curve
Max. allowable working pressure as a function of altitude and ambient
Assemblies Unit Torque value
temperature.
Wheel nuts Nm 80 +10/-0
Bolts, axle/beams Nm 80 +/- 10 Generator DdG Generator DdG IT
Bolts, towbar/axle Nm 80 +/- 10
ATMOSPHERE ATMOSPHERE
Bolts, towbar/bottom Nm 80 +/- 10 ALTITUDE PRESSURE ALTITUDE PRESSURE
Bolts, towing eye/towbar Nm 80 +/- 10 m mbar m mbar
Bolts, lifting eye/flywheel housing Nm 205 + 20 4000 616 4000 616
7bar(e)
Note: 6bar(e)
Secure the tank cap and drain cock of the fuel tank handtight.
1000 899 1000 7bar(e) 899
SAFETY VALVES
TEMPERATURE C° TEMPERATURE C°
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XAS66 DDG / DDG IT
Design data The international standard ISO 1217 corresponds to following national standards:
- British BSI 1571 part 1
Compressor
- German DIN 1945 Part 1
1. Number of compression stages 1 - Swedish SS-ISO 1217
Engine - American ANSI PTC9
1. Make Deutz Free air delivery = volume flow rate
3) complying with British Gas Spec. TIN 12
2. Type F3M1011
4) complying with ISO 8528/8 - DIN 6280/10
3. Coolant OIL
4. Number of cylinders 3
5. Bore mm 91
9.4 CONVERSION LIST OF SI UNITS INTO
6. Stroke mm 112 BRITISH UNITS
7. Swept volume l 2.184
8. Output according to DIN ISO 3046 IFN 1 bar = 14.504 psi
at normal shaft speed kW 33.2 1g = 0.035 oz
9. Capacity of oil sump: 1 kg = 2.205 lb
– Initial fill l 8.5 1 km/h = 0.621 mile/h
– Refill (max.) l 6 1 kW = 1.341 hp (UK and US)
10. Capacity of cooling system l 1.2 1l = 0.264 US gal
1l = 0.220 Imp gal (UK)
Generator DdG 1l = 0.035 cu.ft
1. Electric power 110V/50Hz3) kVA 4.4 1m = 3.281 ft
2. Rated current A 40 1 mm = 0.039 in
3. Power factor 1 1 m3/min = 35.315 cfm
4. Sockets A 1x32 1 mbar = 0.401 in wc
A 2x16
1N = 0.225 lbf
1 Nm = 0.738 lbf.ft
Generator DdG IT
t °F = 32 + (1.8 x t °C)
1. Electric power 230/400V/50Hz4)
1 phase / 3 phases kVA 4/6.5 t °C = (t °F - 32)/1.8
2. Power factor 0.8 – A temperature difference of 1 °C = a temperature difference of 1.8 °F.
3. Sockets A 3x16
Unit
10. DATA PLATE
1. Capacity of compressor oil system l 6.5
2. Net capacity of air receiver l 14
3. Capacity of fuel tank l 58
4. Air volume at inlet grating (approx.) m3/s 0.93
(Air required for engine, compression and for
engine- and compressor cooling)
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