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Instruction Manual

Operator Manual
for Portable Compressors
English

XAHS 38 Kd APP - XAHS 70 KD8 APP


XAS 58 Kd APP - XAS 120 KD8 APP Engine
XAS 68 Kd APP - XAS 135 KD8 APP Kubota V1505
XAS 48 G Kd APP - XAS 90 G KD8 APP
XAS 48 G Kd APP - XAS 90 G KD8 APP
XATS 68 Kd APP - XATS 135 KD8 APP
Engine
XAS 78 Kd APP - XAS 160 KD8 APP
Kubota V1505-T
XAS 88 Kd APP - XAS 175 KD8 APP
XAS 68 G Kd APP - XAS 135 G KD8 APP
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Operator Manual
for Portable Compressors

XAHS 38 Kd
XAS 58 Kd
XAS 68 Kd
XAS 48 G Kd
XATS 68 Kd
XAS 78 Kd
XAS 88 Kd
XAS 68 G Kd

Original instructions

Printed matter N°
2954 9520 01 ATLAS COPCO - PORTABLE ENERGY DIVISION
12/2016 www.atlascopco.com

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Warranty and Liability Limitation
Use only authorized parts.
Any damage or malfunction caused by the use of unauthorized parts is not covered by Warranty or Product
Liability.
The manufacturer does not accept any liability for any damage arising from modifications, additions or
conversions made without the manufacturer's approval in writing.
Neglecting maintenance or making changes to the setup of the machine can result in major hazards, including
fire risk.
While every effort has been made to ensure that the information in this manual is correct, Atlas Copco does not
assume responsibility for possible errors.

Copyright 2016, Atlas Copco Airpower n.v., Antwerp, Belgium.


Any unauthorized use or copying of the contents or any part thereof is prohibited.
This applies in particular to trademarks, model denominations, part numbers and drawings.

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Preface Table of contents 5 Maintenance ............................................. 28
Follow the instructions in this booklet and we 5.1 Daily maintenance compressor before
guarantee you years of troublefree operation. It is a 1 Safety precautions ...................................... 7 starting a job............................................... 28
solid, safe and reliable machine, built according to 1.1 Introduction .................................................. 7 5.2 Daily maintenance undercarriage before
the latest technology.
1.2 General safety precautions ........................... 8 a roadgoing job........................................... 28
Always keep the manual available near the machine. 5.3 Oil............................................................... 29
1.3 Safety during transport and installation ....... 9
In all correspondence always mention the 1.4 Safety during use and operation ................. 10 5.3.1 Oil level check ....................................... 29
compressor type and serial number, shown on the 5.3.2 Engine oil............................................... 29
data plate. 1.5 Safety during maintenance and repair........ 11
5.3.3 Compressor oil....................................... 29
1.6 Tool applications safety ............................. 12
The company reserves the right to make changes 5.4 Coolant ....................................................... 31
without prior notice. 1.7 Specific safety precautions......................... 13
5.4.1 Coolant level check................................ 31
2 Leading particulars .................................. 15 5.5 Battery........................................................ 31
2.1 Safety pictograms used .............................. 15 5.5.1 Recharging a battery .............................. 31
2.2 General description .................................... 15 5.5.2 Periodic battery service.......................... 31
5.6 Air filter engine/compressor ...................... 32
2.3 Markings and information labels ............... 17
5.7 Cleaning ..................................................... 32
3 Main Parts................................................. 18 5.7.1 Cleaning coolers .................................... 32
5.7.2 Cleaning hardhat .................................... 32
4 Operating instructions ............................. 20 5.7.3 Spillage-free frame ................................ 33
4.1 Parking, towing and lifting instructions ..... 20 5.8 Storage ....................................................... 33
4.1.1 Parking instructions ............................... 20 5.9 Options ....................................................... 33
4.1.2 Towing instructions ............................... 21
4.1.3 Lifting instructions................................. 23 6 Problem solving ........................................ 34
4.2 Operating the compressor .......................... 24
4.2.1 Prevent low loads................................... 24 7 Technical specifications ........................... 36
4.2.2 Before starting........................................ 24 7.1 Compressor / engine specifications............ 36
4.2.3 Control panel.......................................... 25 7.2 Dimensions................................................. 44
4.2.4 During operation .................................... 26
4.2.5 Stopping procedure ................................ 26 8 Dataplate ................................................... 48
4.2.6 Fault situations and protective devices .. 26
9 Disposal ..................................................... 49
4.2.7 Generator (option).................................. 27
10 Maintenance Log...................................... 50

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Safety precautions
To be read attentively and acted accordingly before towing, lifting, operating, performing
maintenance or repairing the unit.

INTRODUCTION

The policy of Atlas Copco is to provide the users of It is the responsibility of management to appoint Take necessary steps to keep unauthorized persons
their equipment with safe, reliable and efficient operators with the appropriate training and skill for away from the unit and eliminate all possible sources
products. Factors taken into account are among each category of job. of danger at the unit.
others: When handling, operating, overhauling and/or
Skill level 1: Operator
- the intended and predictable future use of the performing maintenance or repair on Atlas Copco
products, and the environments in which they are An operator is trained in all aspects of operating the
unit with the push-buttons, and is trained to know the equipment, the mechanics are expected to use safe
expected to operate, engineering practices and to observe all relevant local
safety aspects.
- applicable rules, codes and regulations, safety requirements and ordinances. The following
- the expected useful product life, assuming proper Skill level 2: Mechanical technician list is a reminder of special safety directives and
service and maintenance, A mechanical technician is trained to operate the unit precautions mainly applicable to Atlas Copco
- providing the manual with up-to-date the same as the operator. In addition, the mechanical equipment.
information. technician is also trained to perform maintenance and These safety precautions apply to machinery
repair, as described in the instruction manual, and is processing or consuming air. Processing of any other
Before handling any product, take time to read the
allowed to change settings of the control and safety gas requires additional safety precautions typical to
relevant instruction manual. Besides giving detailed
system. A mechanical technician does not work on the application and are not included herein.
operating instructions, it also gives specific live electrical components.
information about safety, preventive maintenance, Neglecting the safety precautions may endanger
etc. Skill level 3: Electrical technician people as well as environment and machinery:
Keep the manual always at the unit location, easy An electrical technician is trained and has the same - endanger people due to electrical, mechanical or
accessible to the operating personnel. qualifications as both the operator and the mechanical chemical influences,
technician. In addition, the electrical technician may - endanger the environment due to leakage of oil,
See also the safety precautions of the engine and
carry out electrical repairs within the various solvents or other substances,
possible other equipment, which are separately sent enclosures of the unit. This includes work on live
along or are mentioned on the equipment or parts of - endanger the machinery due to function failures.
electrical components.
the unit. All responsibility for any damage or injury resulting
These safety precautions are general and some Skill level 4: Specialist from the manufacturer from neglecting these precautions or by non-
statements will therefore not always apply to a This is a skilled specialist sent by the manufacturer or observance of ordinary caution and due care required
particular unit. its agent to perform complex repairs or modifications in handling, operating, maintenance or repair, also if
to the equipment. not expressly mentioned in this instruction manual, is
Only people that have the right skills should be
allowed to operate, adjust, perform maintenance or In general it is recommended that not more than two disclaimed by Atlas Copco.
repair on Atlas Copco equipment. people operate the unit, more operators could lead to
unsafe operating conditions.

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The manufacturer does not accept any liability for any GENERAL SAFETY PRECAUTIONS 9 Care shall be taken to avoid damage to safety
damage arising from the use of non-original parts and valves and other pressure-relief devices,
for modifications, additions or conversions made 1 The owner is responsible for maintaining the unit especially to avoid plugging by paint, oil coke or
without the manufacturer’s approval in writing. in a safe operating condition. Unit parts and dirt accumulation, which could interfere with the
If any statement in this manual does not comply with accessories must be replaced if missing or functioning of the device.
unsuitable for safe operation.
local legislation, the stricter of the two shall be 10 Pressure and temperature gauges shall be checked
applied. 2 The supervisor, or the responsible person, shall at regularly with regard to their accuracy. They shall
Statements in these safety precautions should not be all times make sure that all instructions regarding be replaced whenever outside acceptable
machinery and equipment operation and tolerances.
interpreted as suggestions, recommendations or
maintenance are strictly followed and that the
inducements that it should be used in violation of any 11 Safety devices shall be tested as described in the
applicable laws or regulations. machines with all accessories and safety devices, maintenance schedule of the instruction manual
as well as the consuming devices, are in good
to determine that they are in good operating
repair, free of abnormal wear or abuse, and are
condition.
not tampered with.
12 Mind the markings and information labels on the
3 Whenever there is an indication or any suspicion
unit.
that an internal part of a machine is overheated,
the machine shall be stopped but no inspection 13 In the event the safety labels are damaged or
covers shall be opened before sufficient cooling destroyed, they must be replaced to ensure
time has elapsed; this to avoid the risk of operator safety.
spontaneous ignition of oil vapour when air is 14 Keep the work area neat. Lack of order will
admitted. increase the risk of accidents.
4 Normal ratings (pressures, temperatures, speeds, 15 When working on the unit, wear safety clothing.
etc.) shall be durably marked. Depending on the kind of activities these are:
5 Operate the unit only for the intended purpose and safety glasses, ear protection, safety helmet
within its rated limits (pressure, temperature, (including visor), safety gloves, protective
speeds, etc.). clothing, safety shoes. Do not wear the hair long
and loose (protect long hair with a hairnet), or
6 The machinery and equipment shall be kept clean,
wear loose clothing or jewellery.
i.e. as free as possible from oil, dust or other
deposits. 16 Take precautions against fire. Handle fuel, oil and
anti-freeze with care because they are
7 To prevent an increase in working temperature,
inflammable substances. Do not smoke or
inspect and clean heat transfer surfaces (cooler
approach with naked flame when handling such
fins, intercoolers, water jackets, etc.) regularly. substances. Keep a fire-extinguisher in the
8 All regulating and safety devices shall be vicinity.
maintained with due care to ensure that they
function properly. They may not be put out of
action.

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SAFETY DURING TRANSPORT AND - check that the wheels are secure and that the 7 Lifting hooks, eyes, shackles, etc., shall never be
INSTALLATION tyres are in good condition and inflated bent and shall only have stress in line with their
correctly, design load axis. The capacity of a lifting device
Transport of the unit has to be done by authorized/ - connect the signalisation cable, check all lights diminishes when the lifting force is applied at an
experienced people. and ascertain that the signalisation cable can angle to its load axis.
When towing, lifting or transporting the compressor not drag on the ground when towing the unit, 8 For maximum safety and efficiency of the lifting
in any way, the battery switch must always be - attach the safety break-away cable or safety apparatus all lifting members shall be applied as
switched off. chain to the towing vehicle, near to perpendicular as possible. If required, a
To lift a unit, all loose or pivoting parts, e.g. doors and lifting beam shall be applied between hoist and
- remove wheel chocks, if applied, and load.
tow bar, shall first be securely fastened. disengage the parking brake,
Do not attach cables, chains or ropes directly to the 9 Never leave a load hanging on a hoist.
- check whether springs on wheelchocks are
lifting eye; apply a crane hook or lifting shackle missing or broken. 10 A hoist has to be installed in such a way that the
meeting local safety regulations. Never allow sharp object will be lifted perpendicular. If that is not
bends in lifting cables, chains or ropes. 2 To tow a unit use a towing vehicle of ample possible, the necessary precautions must be taken
capacity. Refer to the documentation of the to prevent load-swinging, e.g. by using two
Helicopter lifting is not allowed. towing vehicle. hoists, each at approximately the same angle not
It is strictly forbidden to dwell or stay in the risk zone 3 If the unit is to be backed up by the towing exceeding 30° from the vertical.
under a lifted load. Never lift the unit over people or vehicle, disengage the overrun brake mechanism
residential areas. Lifting acceleration and retardation 11 Locate the unit away from walls. Take all
(if it is not an automatic mechanism). precautions to ensure that hot air exhausted from
shall be kept within safe limits.
4 Never exceed the maximum towing speed of the the engine and driven machine cooling systems
1 Before towing the unit: unit (mind the local regulations). cannot be recirculated. If such hot air is taken in
- ascertain that the pressure vessel(s) is (are) 5 Place the unit on level ground and apply the by the engine or driven machine cooling fan, this
depressurized, parking brake before disconnecting the unit from may cause overheating of the unit; if taken in for
the towing vehicle. Unclip the safety break-away combustion, the engine power will be reduced.
- check the towbar, the brake system and the
towing eye. Also check the coupling of the cable or safety chain. If the unit has no parking 12 Before moving the compressor, switch it off.
towing vehicle, brake or jockey wheel, immobilize the unit by
- check the towing and brake capability of the placing chocks in front of and/or behind the
towing vehicle, wheels. When the towbar can be positioned
vertically, the locking device must be applied and
- check that the towbar, jockey wheel or stand kept in good order. The unit must always be used/
leg is safely locked in the raised position, parked/stored in a non publicly accessible area,
- keep hands/fingers away from the coupling locked away from access by unauthorized
device and all other potential pinch points. persons.
Keep feet away from the towbar to avoid 6 To lift heavy parts, a hoist of ample capacity,
injury if it should slip, tested and approved according to local safety
- ascertain that the towing eye can swivel freely regulations, shall be used.
on the hook,

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SAFETY DURING USE AND OPERATION 8 Do not use compressed air from any type of effective. A door should be kept open for a short
compressor, without taking extra measures, for period only e.g. for inspection or adjustment.
1 When the unit has to operate in a fire-hazardous breathing purposes as this may result in injury or 15 Periodically carry out maintenance works
environment, each engine exhaust has to be death. For breathing air quality, the compressed according to the maintenance schedule.
provided with a spark arrestor to trap incendiary air must be adequately purified according to local
sparks. legislation and standards. Breathing air must 16 Stationary housing guards are provided on all
always be supplied at stable, suitable pressure. rotating or reciprocating parts not otherwise
2 The exhaust contains carbon monoxide which is a
protected and which may be hazardous to
lethal gas. When the unit is used in a confined 9 Distribution pipework and air hoses must be of personnel. Machinery shall never be put into
space, conduct the engine exhaust to the outside correct diameter and suitable for the working operation, when such guards have been removed,
atmosphere by a pipe of sufficient diameter; do pressure. Never use frayed, damaged or before the guards are securely reinstalled.
this in such a way that no extra back pressure is deteriorated hoses. Replace hoses and flexibles
created for the engine. If necessary, install an before the lifetime expires. Use only the correct 17 Noise, even at reasonable levels, can cause
extractor. Observe any existing local regulations. type and size of hose end fittings and connections. irritation and disturbance which, over a long
Make sure that the unit has sufficient air intake period of time, may cause severe injuries to the
10 If the compressor is to be used for sand-blasting nervous system of human beings. When the sound
for operation. If necessary, install extra air intake
or will be connected to a common compressed-air pressure level, at any point where personnel
ducts.
system, fit an appropriate non-return valve (check normally has to attend, is:
3 When operating in a dust-laden atmosphere, place valve) between compressor outlet and the
the unit so that dust is not carried towards it by the connected sand-blasting or compressed-air - below 70 dB(A): no action needs to be taken,
wind. Operation in clean surroundings system. Observe the right mounting position/ - above 70 dB(A): noise-protective devices
considerably extends the intervals for cleaning direction. should be provided for people continuously
the air intake filters and the cores of the coolers. being present in the room,
11 Before removing the oil filler plug, ensure that the
4 Close the compressor air outlet valve before pressure is released by opening an air outlet - below 85 dB(A): no action needs to be taken
connecting or disconnecting a hose. Ascertain valve. for occasional visitors staying a limited time
that a hose is fully depressurized before only,
12 Never remove a filler cap of the cooling water
disconnecting it. Before blowing compressed air - above 85 dB(A): room to be classified as a
system of a hot engine. Wait until the engine has
through a hose or air line, ensure that the open end sufficiently cooled down. noise-hazardous area and an obvious warning
is held securely, so that it cannot whip and cause shall be placed permanently at each entrance
injury. 13 Never refill fuel while the unit is running, unless to alert people entering the room, for even
5 The air line end connected to the outlet valve otherwise stated in the Atlas Copco instruction relatively short times, about the need to wear
must be safeguarded with a safety cable, attached book. Keep fuel away from hot parts such as air ear protectors,
next to the valve. outlet pipes or the engine exhaust. Do not smoke
- above 95 dB(A): the warning(s) at the
when fuelling. When fuelling from an automatic entrance(s) shall be completed with the
6 No external force may be exerted on the air outlet pump, an earthing cable should be connected to
valves, e.g. by pulling on hoses or by installing recommendation that also occasional visitors
the unit to discharge static electricity. Never spill
auxiliary equipment directly to a valve, e.g. a shall wear ear protectors,
nor leave oil, fuel, coolant or cleansing agent in or
water separator, a lubricator, etc. Do not step on around the unit. - above 105 dB(A): special ear protectors that
the air outlet valves. are adequate for this noise level and the
14 All doors shall be shut during operation so as not spectral composition of the noise shall be
7 Never move a unit when external lines or hoses
to disturb the cooling air flow inside the provided and a special warning to that effect
are connected to the outlet valves, to avoid
bodywork and/or render the silencing less shall be placed at each entrance.
damage to valves, manifold and hoses.

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18 The unit has parts, which may be accidentally 25 Remember that where there is visible dust, the SAFETY DURING MAINTENANCE AND
touched by personal, of which the temperature finer, invisible particles will almost certainly be REPAIR
can be in excess of 80°C (176°F). The insulation present too; but the fact that no dust can be seen
or safety guard, protecting these parts shall not be is not a reliable indication that dangerous, Maintenance, overhaul and repair work shall only be
removed before the parts have cooled down to invisible dust is not present in the air. carried out by adequately trained personnel; if
room temperature. As it is technically not 26 Never operate the unit at pressures or speeds required, under supervision of someone qualified for
possible to insulate all hot parts or to install safety below or in excess of its limits as indicated in the the job.
guards around hot parts (e.g. exhaust manifold, technical specifications. 1 Use only the correct tools for maintenance and
exhaust turbine), the operator / service engineer repair work, and only tools which are in good
must always be aware not to touch hot parts when 27 Do not use aerosol types of starting aids such as
ether. Such use could result in an explosion and condition.
opening a machine door.
personal injury. 2 Parts shall only be replaced by genuine Atlas
19 Never operate the unit in surroundings where Copco replacement parts.
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
20 If the working process produces fumes, dust or is stopped. Steps shall be taken to prevent
vibration hazards, etc., take the necessary steps to inadvertent starting. In addition, a warning sign
eliminate the risk of personal injury. bearing a legend such as ”work in progress; do
21 When using compressed air or inert gas to clean not start” shall be attached to the starting
down equipment, do so with caution and use the equipment. On engine-driven units the battery
appropriate protection, at least safety glasses, for shall be disconnected and removed or the
the operator as well as for any bystander. Do not terminals covered by insulating caps. On
apply compressed air or inert gas to your skin or electrically driven units the main switch shall be
direct an air or gas stream at people. Never use it locked in open position and the fuses shall be
to clean dirt from your clothes. taken out. A warning sign bearing a legend such
22 When washing parts in or with a cleaning solvent, as ”work in progress; do not supply voltage” shall
provide the required ventilation and use be attached to the fuse box or main switch.
appropriate protection such as a breathing filter, 4 Before dismantling any pressurized component,
safety glasses, rubber apron and gloves, etc. the compressor or equipment shall be effectively
23 Safety shoes should be compulsory in any isolated from all sources of pressure and the entire
workshop and if there is a risk, however small, of system shall be relieved of pressure. Do not rely
falling objects, wearing of a safety helmet should on non-return valves (check valves) to isolate
be included. pressure systems. In addition, a warning sign
bearing a legend such as ”work in progress; do
24 If there is a risk of inhaling hazardous gases,
not open” shall be attached to each of the outlet
fumes or dust, the respiratory organs must be
valves.
protected and depending on the nature of the
hazard, so must the eyes and skin. 5 Prior to stripping an engine or other machine or
undertaking major overhaul on it, prevent all
movable parts from rolling over or moving.

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6 Make sure that no tools, loose parts or rags are left 15 Protect the engine, alternator, air intake filter, 23 Make sure that oil, solvents and other substances
in or on the machine. Never leave rags or loose electrical and regulating components, etc., to likely to pollute the environment are properly
clothing near the engine air intake. prevent moisture ingress, e.g. when steam- disposed of.
7 Never use flammable solvents for cleaning (fire- cleaning. 24 Before clearing the unit for use after maintenance
risk). 16 When performing any operation involving heat, or overhaul, check that operating pressures,
8 Take safety precautions against toxic vapours of flames or sparks on a machine, the surrounding temperatures and speeds are correct and that the
cleaning liquids. components shall first be screened with non- control and shutdown devices function correctly.
flammable material.
9 Never use machine parts as a climbing aid.
17 Never use a light source with open flame for
10 Observe scrupulous cleanliness during inspecting the interior of a machine.
maintenance and repair. Keep away dirt, cover
the parts and exposed openings with a clean cloth, 18 Disconnect –battery-clamp before starting TOOL APPLICATIONS SAFETY
paper or tape. electrical servicing or welding (or turn battery-
switch in “off” position). Apply the proper tool for each job. With the
11 Never weld on or perform any operation
involving heat near the fuel or oil systems. Fuel 19 When repair has been completed, the machine knowledge of correct tool use and knowing the
and oil tanks must be completely purged, e.g. by shall be barred over at least one revolution for limitations of tools, along with some common sense,
steam-cleaning, before carrying out such reciprocating machines, several revolutions for many accidents can be prevented.
operations. Never weld on, or in any way modify, rotary ones to ensure that there is no mechanical Special service tools are available for specific jobs
pressure vessels. Disconnect the alternator cables interference within the machine or driver. Check and should be used when recommended. The use of
during arc welding on the unit. the direction of rotation of electric motors when these tools will save time and prevent damage to
starting up the machine initially and after any parts.
12 Support the towbar and the axle(s) securely if alteration to the electrical connection(s) or switch
working underneath the unit or when removing a gear, to check that the oil pump and the fan
wheel. Do not rely on jacks. function properly.
13 Do not remove any of, or tamper with, the sound- 20 Maintenance and repair work should be recorded
damping material. Keep the material free of dirt in an operator’s logbook for all machinery.
and liquids such as fuel, oil and cleansing agents. Frequency and nature of repairs can reveal unsafe
If any sound-damping material is damaged, conditions.
replace it to prevent the sound pressure level from
increasing. 21 When hot parts have to be handled, e.g. shrink
fitting, special heat-resistant gloves shall be used
14 Use only lubricating oils and greases and, if required, other body protection shall be
recommended or approved by Atlas Copco or the applied.
machine manufacturer. Ascertain that the
selected lubricants comply with all applicable 22 When using cartridge type breathing filter
safety regulations, especially with regard to equipment, ascertain that the correct type of
explosion or fire-risk and the possibility of cartridge is used and that its useful service life is
decomposition or generation of hazardous gases. not surpassed.
Never mix synthetic with mineral oil.

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SPECIFIC SAFETY PRECAUTIONS Pressure vessels Safety valves
Maintenance/installation requirements: 1 All adjustments or repairs are to be done by an
Batteries authorized representative of the valve supplier.
1 The vessel can be used as pressure vessel or as
When servicing batteries, always wear protecting separator and is designed to hold compressed air 2 Only trained and technically competent personnel
clothing and glasses. for the following application: should consider overhaul, re-set or performance
1 The electrolyte in batteries is a sulphuric acid - pressure vessel for compressor, testing of safety valves.
solution which is fatal if it hits your eyes, and
- medium AIR/OIL, 3 The safety valve is supplied with either a lead
which can cause burns if it contacts your skin.
and operates as detailed on the data plate of the security seal or crimped cover to deter
Therefore, be careful when handling batteries, unauthorised access to the pressure regulation
e.g. when checking the charge condition. vessel:
device.
2 Install a sign prohibiting fire, open flame and - the maximum working pressure ps in bar (psi),
- the maximum working temperature Tmax in 4 Under no circumstances should the set pressure of
smoking at the post where batteries are being the safety valve be altered to a different pressure
charged. °C (°F),
than that stamped on the valve without the
3 When batteries are being charged, an explosive - the minimum working temperature Tmin in °C permission of the installation designer.
gas mixture forms in the cells and might escape (°F),
- the capacity of the vessel V in l (US gal). 5 If the set pressure must be altered then use only
through the vent holes in the plugs. Thus an
correct parts supplied by Atlas Copco and in
explosive atmosphere may form around the 2 The pressure vessel is only to be used for the accordance with the instructions available for the
battery if ventilation is poor, and can remain in applications as specified above and in accordance valve type.
and around the battery for several hours after it with the technical specifications. Safety reasons
has been charged. Therefore: prohibit any other applications. 6 Safety valves must be frequently tested and
regularly maintained.
- never smoke near batteries being, or having 3 National legislation requirements with respect to
recently been, charged, re-inspection must be complied with. 7 The set pressure should be periodically checked
for accuracy.
- never break live circuits at battery terminals, 4 No welding or heat treatment of any kind is
because a spark usually occurs. permitted to those vessel walls which are exposed 8 When fitted, the compressors should be operated
to pressure. at pressures not less than 75% of the set pressure
4 When connecting an auxiliary battery (AB) in
to ensure free and easy movement of internal
parallel to the unit battery (CB) with booster 5 The vessel is provided and may only be used with parts.
cables: connect the + pole of AB to the + pole of the required safety equipment such as
CB, then connect the – pole of CB to the mass of manometer, overpressure control devices, safety 9 The frequency of tests is influenced by factors
the unit. Disconnect in the reverse order. valve, etc. such as the severity of the operating environment
and aggressiveness of the pressurised medium.
6 Draining of condensate shall be performed daily
when vessel is in use. 10 Soft seals and springs should be replaced as part
of the maintenance procedure.
7 Installation, design and connections should not be
changed. 11 Do not paint or coat the installed safety valve.
8 Bolts of cover and flanges may not be used for
extra fixation.
9 (Pressure) vessel maintenance is to be performed
by Atlas Copco.

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SAFETY PRECAUTIONS FOR GENERATORS Safety precautions during operation Safety precautions during maintenance
1 Never operate the generator in excess of its limits Before clearing the generator for operation after
This generator is designed to produce an as indicated in the technical specifications. maintenance work or an overhaul, submit it to a test
alternating current! 2 Never operate the generator in a humid run and check that the AC supply is correct and that
atmosphere. Excessive moisture has a detrimental the control and shut-down devices function correctly.
1. The total length of all electric cables connected to impact on the generator insulation.
the generator must not exceed 150 m. 3 Never touch the power terminals during operation
2. If several generators are used or if the mains is of the machine.
also employed, the networks must not be 4 Periodically check that:
connected to each other. - all guards are in place and properly fastened.
3. Do not ground neutral conductor. For that reason, - all hoses, cables and pipes inside are in good
do not use generator as feed point for construction condition, secure and are not rubbing.
site distribution centres. - there are no leaks.
4. Equipment with protective conductor may be - all connection elements are properly secured.
connected. We recommend, however, to use
equipment with full protective insulation - all the wiring is secure and in good order.
whenever possible. 5 If an abnormal situation arises, e.g. excessive
vibration, noise, odour etc., switch the circuit
5. Repair and maintenance of generator's electric
breakers to position 0 and stop the engine. Correct
parts by qualified electricians only. the fault before re-starting.
6 Check the electric cables regularly. If damaged
Safety precautions during installation cables or hazardous conditions are observed,
1 The electrical connections must comply with the switch the circuit breakers to position 0 and stop
local regulations. the engine. Replace the damaged cables or
eliminate the hazardous situation before
2 Damaged cables and inadequately connections restarting.
may cause electric shocks. Replace damaged
cables and ensure that all electric connections are 7 Avoid overloading the generator. The generator is
correct. provided with circuit breakers for overload
protection. When a circuit breaker has tripped,
reduce the load before re-starting.
8 Never connect the generator to an installation
which is also connected to the mains.
9 Before connecting a load, check to see whether
the frequency, voltage, and power comply with
the ratings of the generator.

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Leading particulars QR CODE GENERAL DESCRIPTION

SAFETY PICTOGRAMS USED

This symbol draws your attention to


dangerous situations. The operation
concerned may endanger persons and
cause injuries.

This symbol is followed by


supplementary information.

The unit is equipped with a QR code label. You will The compressors type XAHS 38 - XAHS 70 ranging
find the QR code next to the operating panel. to XAS 88 - XAS 175 are silenced, single-stage, oil-
Scanning the code with your smartphone or tablet will injected screw compressors, built for a nominal
lead you to a website with additional information effective working pressure of 7 bar (102 psi) to 12 bar
about your compressor. (175 psi) (see chapter Technical specifications).
The compressor is equipped with a PE canopy.
Some parts of this website may be
password protected. PE is very robust, can't corrode and will keep its shape
and color during the full lifetime of the machine. It is
fully recyclable to keep the environmental impact as
low as possible. Its low weight (below 750 kg) makes
it possible to tow it with a standard European driver's
license.
The canopy has openings at the shaped front and rear
end for the intake and outlet of cooling air. The
canopy is internally lined with sound-absorbing
material.

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Engine Regulation Fuel system
The compressor is driven by a liquid-cooled diesel The compressor is provided with a continuous The fuel feed lines and fuel filtration are designed in
engine. pneumatic regulating system and a blow-down valve such a way that after running the fuel tank dry, air
which is integrated in the unloader assembly. The pockets can't reach the engine and smooth starting is
The engine's power is transmitted to the compressor
valve is closed during operation by outlet pressure of ensured.
through a gear box.
the compressor element and opens by air receiver
pressure when the compressor is stopped. Safety devices
Compressor element
When the air consumption increases, the air receiver A thermal shut-down switch protects the compressor
The compressor casing houses two screw-type rotors,
pressure will decrease and vice versa. against overheating. The air receiver is provided with
mounted on ball and roller bearings. The male rotor,
driven by the engine, drives the female rotor. The a safety valve.
This receiver pressure variation is sensed by the
element delivers pulsation-free air. regulating valve which, by means of control air to the The engine is equipped with low oil pressure and high
Injected oil is used for sealing, cooling and unloader and engine speed regulator, matches the air coolant temperature shut-down switches.
lubricating purposes. output to the air consumption. The air receiver
pressure is maintained between the pre-selected Frame and axles
Compressor oil system working pressure and the corresponding unloading The machine is equipped with a spillage-free frame.
pressure.
The oil is boosted by air pressure. The system has no The base frame which is made out of a single metal
oil pump. Cooling system sheet, can contain up to 110% of all the liquids in the
The entire oil system is equipped with screwed oil compressor. A drain plug is installed to drain the
The engine is provided with a liquid cooler and the frame and safely capture all the spilled liquids.
hoses to ensure higher quality and less failures. compressor is provided with an oil cooler.
The oil is removed from the air, in the air/oil vessel The bumper is designed in such a way that it protects
The top tank of the engine cooler is integrated in the the rear bottom of the frame if the machine would be
first by centrifugal force, secondly by the oil separator cooler to reduce the amount of connections. This tilted on its rear.
element. A Spin-on oil separator assures for quick results in higher general robustness and less engine
service. failures. The compressor/engine unit is supported by rubber
buffers in the frame.
The cooling air is generated by a fan, driven by the
engine. The unit can be delivered with or without wheels. If
equipped with wheels it has an adjustable or fixed tow
bar with or without brakes. The tow bar can be
equipped with a ball coupling or various towing eyes.
The tow bar can be equipped with a jockey wheel or
support leg.

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MARKINGS AND INFORMATION LABELS
For location of the labels refer to the spare parts manual.

Danger, outlet gases. Runlamp. Use diesel fuel only.

2.7 bar
Danger, hot surface. Airfilter. (39 psi)
Tyre pressure.

Electrocution hazard. Compressor temperature too high. Service.

Atlas Copco mineral compressor oil. Compressor oil level. Engine coolant.
MAX.

MIN.

Sound power level in accordance


Atlas Copco synthetic compressor oil. Rotation direction. with Directive 2000/14/EC
(expressed in dB (A)).

Read the instruction manual before Horizontal towbar position required in


Atlas Copco mineral engine oil.
starting. case of coupling.

Manual. Service every 24 hours. Start engine.

Read the instruction manual before


Warning! Part under pressure. Preheating.
working on the battery.

On / off button. Do not stand on outlet valves. Towing eye load.

Do not run the compressor with open


Hours, time. Flammable substances.
doors.

Prohibition to open air valves without


Lifting device.
connected hoses.

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Main Parts

(ET)
(FF)
(F) (EB)
(E) (OC) (OFce)
(TB)
(AFc) (AFe)
(RV)
(FCeo)

(SV)
(AR)

(CP)
(FU) (OS)
(FFp) (GB)
(SR) (B)
(D) (S)

(DPec)

(FP)

(AOV)
(UV) (FCft) (G) (DSe)
(SB) (VV)
(CE) (EP)
(FT) (SL)

(OFe)

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Reference Name Reference Name
AFc Air Filter (compressor) FT Fuel Tank
AFe Air Filter (engine) FU Fuel Pump
AOV Air Outlet Valves G Generator (option)
AR Air Receiver GB Gear Box
B Battery OC Oil Cooler
CE Compressor Element OFce Oil Filter (compressor element)
CP Control Panel OFe Oil Filter (engine)
D Data Plate OS Oil Separator
DPec Drain Plug (engine oil cooler) RV Regulating Valve
DSe Dipstick (engine oil) S Starting Motor
E Engine SB Socket Box (option)
EB Electronic Box (option) SL Support Leg
EP Exhaust Pipe SR Speed Regulator
ET Expansion Tank SV Safety Valve
F Fan TB Towbar
FCeo Filler Cap (engine oil) UV Unloader Valve
FCft Filler Cap (fuel tank) VV Vacuator Valve
FF Fuel Filter
FFp Fuel pre filter
FP Filler Plug

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Operating instructions PARKING INSTRUCTIONS

PARKING, TOWING AND LIFTING


INSTRUCTIONS

Safety precautions

The operator is expected to apply all (1) (2)


relevant Safety precautions. (A)
(3)

Attention
After the first 100 km travel:
Check and retighten the wheel nuts (B)
and towbar bolts to the specified
torque. See section Compressor /
Fixed towbar with support leg and brakes (A) Parking position of jockey wheel (adjustable towbar)
engine specifications.
(B) Rear-end of compressor upwind

When using a towing vehicle to When parking a compressor, secure support leg (1) or Locate the rear-end of the compressor upwind, away
manoeuver the unit, take care that the jockey wheel (2) to support the compressor in a level from contaminated wind-streams and walls. Avoid
support leg is lifted maximally. position. recirculation of exhaust gas and warmed-up cooling
When the jockey wheel is on the ground, Apply parking brake by pulling parking brake handle air. This causes overheating and engine power
the unit may only be manoeuvered by decrease. Do not obstruct air evacuation from the
(3) upwards. Place the compressor as level as
hand. cooling system. The compressor oil lifetime will be
possible; however, it can be operated temporarily in
an out-of-level position not exceeding 15°. If the shortened when the compressor inlet air is
contaminated.
compressor is parked on sloping ground, immobilize
the compressor by placing wheel chocks (available as
an option) in front of or behind the wheels.

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TOWING INSTRUCTIONS

(1)

(3)

(2) (2)

Label on towbar, towing instructions Fixed towbar with support leg and brakes Towing position of jockey wheel

Before towing the compressor, ensure For both non-adjustable - and adjustable towbar, the
that the towing equipment of the vehicle towbar should be as level as possible and the
matches the towing eye or ball compressor and towing eye end in a level position.
connector, and ensure that the hood is Push the hand brake lever (3) completely downwards
closed and locked properly. and connect breakaway cable to the vehicle. Secure
jockey wheel (2) or support leg (1) in the highest
possible position.

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HEIGHT ADJUSTMENT
(with adjustable towbar)
 Remove spring pin (1).
 Release locking nut (2).
 Adjust required height of the towbar.
600 mm
 Tighten locking nut (2) by hand.
(3)
(2)  Secondly tighten locking nut (2) using an
extension tube (3) and handforce of 45 N/ 100 lbf.
(1)  Fix locking nut (2) with spring pin (1).

Attention:

 Height adjustment should be undertaken on


levelled ground and in coupled condition.
 When readjusting, make sure that the front point
of the towbar is horizontal with the coupling
Before towing the compressor, make point.
sure that the joints of the towbar are
secured with maximum strength without  Before starting a trip, ensure that the adjustment
damaging the towbar. Be sure that there shaft is secure, so that stability and safety is
is no clearance between the teeth of the guaranteed while driving. If necessary, tighten the
joints. locking nut (2). See above.

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BALL COUPLING (OPTION) LIFTING INSTRUCTIONS

Coupling:
Open coupling jaw by pulling the lever vigorously (1)
upwards in the direction of the arrow. Lower the
opened coupling onto the ball of the vehicle coupling
and the lever will automatically be lowered. Closing
and locking are carried out automatically. Check the
"+" (see figure) position!
Connect the breakaway cable and electrical plug
(option) to the towing vehicle. Raise the support leg
up fully and secure by firmly clamping it. Release
parking brake before setting off.
Visual check: the ball should no longer be visible
in coupled condition.

Uncoupling: When lifting the compressor, the hoist has to be


The handle of the ball coupling and the placed in such a way that the compressor, which must
handbrake lever may never be used as a Lower the support leg. Disconnect breakaway cable
and electrical plug. Pull the lever vigorously upwards be placed level, is lifted vertically. Keep lifting
manoeuvring aid; internal components acceleration and retardation within safe limits.
may get damaged! in the direction of the arrow and hold. Lift the
compressor off the ball of the towing vehicle. The lifting eye should preferably be used. The lifting
The coupling (ball coupling) on the tow bar is type Secure the compressor by means of a wheel chock. eye is accessible when lifting the rubber flap (1).
approved. The maximum load at the coupling may not
be exceeded. Lifting acceleration and retardation
must be kept within safe limits (max.
When coupling lower the support leg to the ground. 2xg).
Reverse the car up to the compressor or, in the case of
a small compressor, manoeuvre the compressor up to Helicopter lifting is not allowed.
the car's trailer coupling. Lifting is not allowed when the unit is
running.

Preferably use a lifting rope to avoid


damage to the lifting beam structure and
canopy.
Use a rope of ample capacity, that is
tested and approved according to local
safety regulations.

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OPERATING THE COMPRESSOR BEFORE STARTING
1. Before initial start-up, prepare battery for 5. Check that the fuel tank contains sufficient diesel
PREVENT LOW LOADS operation if not already done. See section fuel. Top up, if necessary. For priming the engine,
Recharging a battery. the fuel must be electrically pumped up by
Low loads may lead to: holding the start switch in the "preheat" position,
2. With the compressor standing level, check the
 High oil consumption: prolonged no-load/low level of the engine oil. Add oil, if necessary, up to
for max. 20 seconds. If necessary, return to "0"
load operation of the engine may cause it to blue/ the upper mark on the dipstick. See section position and repeat. See further starting
grey smoke at low rpm with an associated increase instructions.
Engine oil level check.
in oil consumption. 6. Drain leaking fluid from the frame.
3. Check the level of the compressor oil. Add oil if
 Low combustion temperature: this will result in necessary. See section Compressor oil level 7. Check the air filter vacuum indicators (if present).
insufficiently burned fuel, which will cause check. If the yellow piston reaches the red marked
diluting of the lube oil. Also, unburned fuel and service range, have the filter element replaced.
lube oil can enter the exhaust manifold and 4. Check the coolant level at the level gauge on the
After replacing, reset the indicator by pushing the
eventually leak out through joints in the exhaust radiator. If necessary top up with coolant. See
section Topping up of coolant. reset button.
manifold.
8. Press vacuator valves of the air filter to remove
 Risk for fire. dust.
Reduce low load periods to a minimum. 9. Open air outlet valve to allow air flow to the
It is recommended that a unit is always used with a atmosphere.
load 30% of nominal. Actions should be taken if due
to circumstances this minimum load capacity cannot
be obtained.
For more info, please contact your Atlas
Copco Service Center.
Please note that when a failure occurs and is deemed
due to low load operation, repair is not covered by
warranty!

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CONTROL PANEL STARTING PROCEDURE

Before operating the unit first read the manual.


(P1) (H2) (PG) (F1) (S1)
5 1. Open air outlet valve, do not connect a hose yet.
2. Open the hood and switch the main switch at the
MAX
10 SEC
back of the control panel to ON.
1 6 3. Turn the start switch S1 clockwise to position 1,
lamp H2 (temperature alarm lamp) will go on.
4. To preheat turn the start switch S1 clockwise to
position 2 for 20 sec (also to allow the fuel pump
2 7
priming).
5. Turn start switch S1 further clockwise into
ON position 3. The general alarm lamp H1 will go on.
(H1) The starter motor will set the engine in motion.
3 8 The maximum allowed starter time, where the
starter motor is running continuously, is
10 seconds. If the engine does not catch, a new
Reference Name attempt can be made after waiting 30 seconds.
3 MIN
General alarm lamp H1 will go out as soon as the
P1 Hour meter 4 9 engine has been started.
F1 Main switch
1638 2148 00

6. The start switch automatically springs back to


PG Working pressure gauge 20 SEC
position 1 and both lamps will be off.
H1 General alarm lamp (red) 7. Close the air outlet valve(s).
H2 Temperature alarm lamp (red) 8. Let the engine warm up for 3 minutes.
S1 Start switch with pre-heating 9. After warming up the air hose can be connected
position and the unit is ready for operation.

Lamp H2 will only come on when the


The main switch is a protection against compressor outlet temperature is too
unintended starting of the compressor. high.

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DURING OPERATION STOPPING PROCEDURE

When the engine is running, the air Do not open the air outlet valve when
outlet valves (ball valves) must always be machine is shut down. Remaining air
in a fully opened or fully closed position. inside the vessel will automatically be
evacuated via a blow down valve!
The hood must be closed during If pressure is released from the vessel too
operation and may be opened for short quickly, oil will start creating foam. This
periods only. 1 3
foam could reach the oil separator
Be aware not to touch hot parts when the element resulting in oil carry over.
hood is open. Failures caused by incorrectly shutting
down the compressor will not be covered
 Check that the regulating valve is correctly 2 4 by warranty!
functioning, i.e. starts decreasing the engine speed
when reaching the working pressure. OFF
 Check on abnormal noise. 3 MIN
FAULT SITUATIONS AND PROTECTIVE
 Check the alarm lamps. DEVICES
NEED
HELP
 A fault involving the engine, either oil pressure
SCAN
(too low), coolant temperature (too high), will
ME
AIR OUTLET PRESSURE always and immediately cause the engine to cut
? out and the alarm lamp H1 will light up.
The air outlet pressure is set in the factory.
 When the air outlet temperature is too high the
Modifying the set point above the 1638 2153 00
alarm lamp H2 will light up. The alarm lamp will
nominal working pressure can affect the stay on, until the compressor has been restarted
correct working of the unit and result in (start switch to position 3), or the contact is
failure. Only the Atlas Copco customer 1. Close the air outlet valves (AOV). turned off (start switch to position 0; also when,
center or an authorized distributor may 2. Run unloaded for 3 minutes. due to cooling off, the thermocontact has closed
work on, or adjust the regulating valve! again (= memory function).
3. Turn the start switch S1 counterclockwise (CCW)
Incorrect use/operation of the machine, to position 0.
including modifying the working
pressure above the nominal pressure, Be aware not to touch hot parts when the
will void warranty. hood is open.

4. Open the hood and switch the main switch at the


back of the control panel to “OFF”.

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GENERATOR (OPTION)

Using switch (2) you can switch on the automatic


(2) (3) (4) control system. As soon as the generator is switched
on, the automatic control system will continuously
check for electric load in order to rev up the engine
from idle to nominal speed only when needed. This
saves fuel and reduces emissions. If a consumer is
disconnected, the engine goes on for 60 secs. before

min 400
falling back to idle speed.
With the current continuously monitored, a consumer
having just been switched on is temporary
disconnected from the generator to be re-connected as
soon as the engine reaches nominal speed. This safety
mechanism prevents load at too low speed.
(1)
Turning the generator switch (3) to position "0" cuts
off the power from the sockets. The lamp in the
switch is off.
Reference Name Before switching on the generator,
always place the earth pin in position.
1 Sockets Check the cable connection between Faults
2 Switch automatic control function earth pin and the GND-terminal on the
unit. In case of an overload or an earth fault the circuit
3 Switch generator function breakers or earth fault relay will trip and the power to
Avoid high inductive loads (e.g. the sockets is turned off.
4 Terminal earth cable
welding). High inductive loads can When this occurs, first disconnect the consumers
damage the generator. from the sockets and manually reset the circuit
The built-in generator is driven by a multi V-belt breakers / earth fault relay in the electronic box.
drive. The generated current can be drawn via
3 sockets (see chapter Technical specifications). The Generator operation Do not use the consumers connected previously
generator is also equipped with an automatic control before the cause of the fault is cleared.
system to save fuel when no electric power is used. Start the unit in accordance with the normal
The compressor and the generator may be used procedure. Let the motor warm up until it reaches
simultaneously. operational temperature. Turn the generator switch
(3) to position "1". The normal control system is
switched off and the motor speed increases to reach
the maximum. The green lamp in the switch is
activated, showing that sockets are live.

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Maintenance DAILY MAINTENANCE COMPRESSOR BEFORE STARTING A JOB

Drain condensate and water from spillage-free frame see Spillage-free frame
Unauthorised modifications can result in
injuries or machine damage. Empty air filter vacuator valves see Air filter engine/compressor
Check engine oil level (if necessary top up) see Engine oil level check
Always keep the machine tidy to prevent Check compressor oil level (if necessary top up) see Compressor oil level check
fire hazard.
Check coolant level see Coolant level check
Poor maintenance can void any Check/Fill fuel level after a day’s work
warranty claims. Check air intake vacuum indicators
The operator is only allowed to execute Check on abnormal noise
the daily maintenance. All other
maintenance/repair is to be done by Check control panel see Control panel
authorized personnel.

DAILY MAINTENANCE UNDERCARRIAGE BEFORE A ROADGOING JOB


LIABILITY

The manufacturer does not accept any liability for any Check towbar, handbrake lever, spring actuator,
damage arising from the use of non-original parts and reversing lever, linkage and all movable parts for ease
for modifications, additions or conversions made of movement
without the manufacturer’s written approval.
Check coupling head for damage
Check height of adjusting facility see Height adjustment
Check tyre pressure see Technical specifications
Check safety cable for damage

For fluids to be used and their ordering


numbers refer to the spare parts manual.

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OIL ENGINE OIL COMPRESSOR OIL

It is strongly recommended to use Atlas


Copco branded lubrication oils for both
compressor and engine. If you want to
use another brand of oil, consult Atlas 50° C 122° F 50° C 122° F
Copco.
40° C 104° F 40° C 104° F

PAROIL M Xtreme

PAROIL M Xtreme
30° C 86° F 30° C 86° F
PAROIL E xtra

PAROIL E xtra
PAROIL E

PAROIL E
Never mix synthetic with mineral oil.

PAROIL S

PAROIL S
20° C 68° F 20° C 68° F

10° C 50° F 10° C 50° F

-0° C 32° F -0° C 32° F


OIL LEVEL CHECK
-10° C 14° F -10° C 14° F

Never mix oils of different brands or -20° C -4° F -20° C -4° F


types. -30° C -22° F -30° C -22° F
Use only non-toxic oils where there is a
risk of inhaling delivered air. -40° C -40° F -40° C -40° F

Let the engine cool down for about 10 minutes. With


the compressor standing level, check the level of the
engine oil. Add oil, if necessary, up to the upper mark
on the dipstick. Choose your engine oil based on the ambient Choose your compressor oil based on the ambient
temperatures in the actual operating area. temperatures in the actual operating area.
For ordering numbers refer to the spare parts list. For ordering numbers refer to the spare parts list.
ENGINE OIL LEVEL CHECK

Check engine oil level in accordance to the


instructions in the Engine Operation Manual and if
necessary, top up with oil.

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COMPRESSOR OIL LEVEL CHECK DAILY CHECK CHECK AFTER A LONGER PERIOD
WITHOUT RUNNING THE COMPRESSOR
Check the compressor oil level daily, after running
the compressor. 1. Check the oil level via the oil sight glass (3). The
level must be in the upper half of the glass.
The compressor oil level needs to be 2. If the oil level is too low, remove the oil filler plug
(4) checked with the compressor in an (2) and check if there is still oil in the vessel.
horizontal position after running the
compressor to warm up so that the  No oil in the vessel: Top up the compressor
thermostatic valve is open. with oil until the oil level is at the upper level
(1) as indicated on the label and follow the steps
1. Stop the compressor with closed air outlet valve as described above in Daily check.
(3) and let it rest for a short period, to allow the
 Oil in the vessel: Start up the unit to warm up
system to relief pressure inside the vessel and
and give time for the thermostatic valve to
settle down the oil.
open. Stop the compressor with closed outlet
2. Check the oil level via the oil sight glass (1). The valve (4) and follow the steps described above
oil level must be in the upper half of the glass. If in Daily check.
(2) the oil level is too low, add oil via the oil filler plug
(2). At temperatures below 0°C, you have to
load the compressor to be sure that the
Before removing the oil filler plug, compressor thermostat will be open.
ensure that the pressure is released by
opening the air outlet valve (4) and
(3) checking the vessel pressure on the
controller or the pressure gauge.
3. Top up with oil until the oil level is at the upper
level as indicated on the label (1).
4. Reinstall and tighten the filler plug.

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COOLANT COOLANT LEVEL CHECK BATTERY

It is strongly recommended to use Atlas  Check the coolant level at the level gauge on the RECHARGING A BATTERY
Copco branded coolant. radiator. If necessary top up with coolant. See
section Topping up of coolant. Before and after charging a battery, always check the
Never mix different coolants and mix the  Low coolant level can lead to engine overheating, electrolyte level in each cell; if required, top up with
coolant components outside the cooling and will eventually result in permanent engine distilled water only. When charging batteries, each
system. damage. cell must be open, i.e. plugs and/or cover removed.
Use a commercial automatic battery
charger in accordance with the
PARCOOL EG manufacturer’s instructions.
TOPPING UP OF COOLANT
PARCOOL EG is a ready to use Ethylene Glycol
based coolant, premixed in an optimum 50/50 Never remove the cooling system filler
dilution ratio, for antifreeze protection guaranteed to cap while coolant is hot. PERIODIC BATTERY SERVICE
-40°C (-40°F).
The system may be under pressure.
For ordering numbers refer to the spare parts list. Remove the cap slowly and only when  Keep the battery clean and dry.
Liquid-cooled engines are factory-filled with this coolant is at ambient temperature. A  Keep the electrolyte level at 10 to 15 mm above
type of coolant mixture. sudden release of pressure from a heated the plates or at the indicated level; top up with
cooling system can result in personal distilled water only. Never overfill, as this will
injury from the splash of hot coolant. cause poor performance and excessive corrosion.
If doubtful conditions are noticed or malfunctions
 Always top-up with PARCOOL EG. arise, keep in mind that the cause may be in the
 Topping up the coolant with water only, changes electical system, e.g.loose terminals, voltage
the concentration of additives and is therefore not regulator maladjusted, poor performance of
allowed. compressor, etc...

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AIR FILTER ENGINE/COMPRESSOR CLEANING CLEANING HARDHAT
Optimal cleaning of the HardHat can be achieved by
(1)
CLEANING COOLERS high pressure cleaning in combination with liquid
soap.
Keep the coolers clean to maintain the cooling
efficiency. Open the hood and clean the coolers with Do not use water with a temperature
a fibre brush and compressed air. >50°C (122°F).
Remove any dirt from the coolers with a
fibre brush. Never use a wire brush or
metal objects.

Steam cleaning in combination with a cleansing agent


may be applied.
(5)(2) (3) (4) (7)
(6) To avoid damaging the coolers, angle
(8) between jet and coolers should be
approx. 90 °.

1. Snap clips 5. Vacuator valve


2. Dust trap cover 6. Vacuum indicator Protect the electrical and controlling
equipment, air filters, etc. against
3. Filter element 7. Reset button penetration of moisture.
4. Filter housing 8. Yellow indicator
Never leave spilled liquids such as fuel,
oil, water and cleansing agents in or
CLEANING THE DUST TRAP around the compressor.

To remove dust from the dust trap squeeze the


vacuator valve (5) several times.

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SPILLAGE-FREE FRAME STORAGE OPTIONS
Run the compressor regularly, e.g. twice a week, until Multi-approved vessel
warm.
Standard the machine comes with a CE approved
Load and unload the compressor a few times to vessel. The multi approved vessel includes ASME,
operate the unloading and regulating components. CRN, MOM, AS1210 and ML approval.
Close the air outlet valves after stopping.
Additional fuel filter
If the compressor is going to be stored
without running regularly, protective When bad fuel quality is a risk, an additional fuel
measures must be taken. filter with water separator is recommended.
Contact Atlas Copco for correct Safety cartridge
measures.
In case of highly polluted / dusty environments a
safety cartridge is recommended. This gives extra
protection in case of a rupture in the filter element.
(1)
Toolbox
The compressor is fitted with a leak-proof A toolbox is located inside the bodywork above the
undercarriage in order to protect the environment. battery and can be easily removed to access the
battery below if required.
Any leaking fluid is collected in case of malfunctions.
This fluid can be removed via a drain (1), normally Non-return valve
secured by caps.
A non-return valve can be installed between vessel
Tighten the cap firmly and check for leakages. and air outlet valves to prevent air of flowing back to
Please observe the locally applicable environmental the vessel when using pressurized equipment.
regulations when removing the leaked liquid.
Cold weather equipment
With cold weather equipment we guarantee starting
down to -20°C.

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Problem solving
It is assumed that the engine is in good condition.
If it’s not possible to solve the problem
with this problem solving table, please
consult Atlas Copco.

Problem Possible faults Corrective actions


1. Lamp does not light up when turning Discharged or defective battery. Check electrolyte level and charge battery.
the start switch to position 1.
2. General alarm lamp does not light up Lamp (H2) blown. Consult authorized technician/Atlas Copco.
when turning the start switch to
position 2.
3. Engine does not start after turning (S1) a. Low battery output. a. See remedy 1a.
to position 1.
b. Main switch is OFF. b. Switch main switch to ON.
c. Fuel tank is empty. c. Refuel and prime fuel pump.
4. Starter motor cranks engine when Low battery output. See 1a.
turning start switch to position 3, but
engine does not fire.
5. Engine is running, but shuts down a. Start switch (S1) released too soon. a. Restart once. If the engine does not start, stop at once and
immediately after the start switch has consult authorized technician/Atlas Copco.
been released. b. Insufficient engine oil pressure. b. Stop at once, consult authorized technician/Atlas Copco.
c. Fuel tank contains insufficient fuel. c. Fill fuel tank.
6. General alarm lamp remains alight for a. Insufficient engine oil pressure or too high engine a. Stop at once, consult authorized technician/Atlas Copco.
over 5 seconds after starting. coolant temperature.
b. Engine oil pressure switch, or compressor temperature b. Stop at once, consult authorized technician/Atlas Copco.
switch defective.
7. Hour meter does not count running Hour meter defective. Consult authorized technician/Atlas Copco.
time.

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Problem Possible faults Corrective actions
8. Compressor capacity or pressure Air consumption exceeds capacity of the compressor. Check equipment connected.
below normal.
9. Overheating; alarm lamp goes on. a. Insufficient compressor cooling. a. Relocate compressor.
b. Oil / coolant cooler clogged externally. b. Clean cooler; see section Cleaning coolers.
10. Engine keeps running at maximum Consult authorized technician/Atlas Copco.
speed when closing the air outlet
valves; safety valve blows.
11. Working pressure rises during Consult authorized technician/Atlas Copco.
operation and causes safety valve to
blow.
12. Oil mist being discharged from air Consult authorized technician/Atlas Copco.
outlet valve(s).
13. Compressor shuts down without Consult authorized technician/Atlas Copco.
apparent cause.
14. Air and oil mist expelled from air filter Consult authorized technician/Atlas Copco.
after stopping.
15. No air output. Consult authorized technician/Atlas Copco.
Generator (option)
16. No voltage at sockets. a. Generator not switched on. a. Switch generator on.
b. Circuit breakers are off. b. Switch on circuit breakers.
17. When an electrical device is a. Electrical device is defective. a. Have electrical device replaced or repaired.
connected, the circuit breakers switch
off.
18. Circuit breakers are off. a. Short circuit or overload. a. Remedy fault. Switch on circuit breakers.
19. Green lamp H3 is deactivated. a. Circuit breakers are off. a. Switch on circuit breakers.
b. Serious electrical fault. b. Consult Atlas Copco.

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Technical specifications
COMPRESSOR / ENGINE SPECIFICATIONS

REFERENCE CONDITIONS

Designation XAHS 38 Kd XAS 58 Kd XAS 68 Kd XAS 48 G Kd XATS 68 Kd XAS 78 Kd XAS 88 Kd XAS 68 G Kd


Absolute inlet pressure bar 1 1 1 1 1 1 1 1
psi 14.5 14.5 14.5 14.5 14.5 14.5 14.5 14.5
Relative air humidity % 0 0 0 0 0 0 0 0
Air inlet temperature °C 20 20 20 20 20 20 20 20
°F 68 68 68 68 68 68 68 68
Nominal effective working bar 12 7 7 7 10.3 7 7 7
pressure psi 175 100 100 100 150 100 100 100
The inlet conditions are specified at the air inlet grating outside the canopy.

LIMITATIONS

Designation XAHS 38 Kd XAS 58 Kd XAS 68 Kd XAS 48 G Kd


Minimum effective receiver pressure bar 2 2 2 2
psi 30 30 30 30
Maximum effective receiver pressure, bar 13.5 8.8 8.8 8.8
compressor unloaded psi 200 125 125 125
Maximum ambient temperature without aftercooler °C 50 50 50 50
at sea level °F 122 122 122 122
with aftercooler °C 45 45 45 45
°F 113 113 113 113
Minimum starting temperature °C -10 -10 -10 -10
°F 14 14 14 14
Minimum starting temperature, with coldstart equipment °C -20 -20 -20 -20
°F -4 -4 -4 -4

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Designation XATS 68 Kd XAS 78 Kd XAS 88 Kd XAS 68 G Kd
Minimum effective receiver pressure bar 2 2 2 2
psi 30 30 30 30
Maximum effective receiver pressure, bar 13.5 8.8 8.8 8.8
compressor unloaded psi 200 125 125 125
Maximum ambient temperature without aftercooler °C 50 50 50 50
at sea level °F 122 122 122 122
with aftercooler °C 45 45 45 45
°F 113 113 113 113
Minimum starting temperature °C -10 -10 -10 -10
°F 14 14 14 14
Minimum starting temperature, with coldstart equipment °C -20 -20 -20 -20
°F -4 -4 -4 -4

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ALTITUDE UNIT PERFORMANCE CURVES

Max. allowable working pressure as a function altitude and ambient temperature.

TEMPERATURE °F

14 24 34 44 54 64 74 84 94 104
3000 9842

2400 7873.6
ALTITUDE m

ALTITUDE ft

1800 5905.2

1200 3936.8
12 bar (25 psi)

600 1968.4

0 0
-10 -5 0 5 10 15 20 25 30 35 40 45
TEMPERATURE °C

All units

Graphic represents working conditions, for starting conditions please contact your Atlas Copco contact.

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PERFORMANCE DATA

At reference conditions, if applicable, and at normal shaft speed, unless otherwise stated.

Designation XAHS 38 Kd XAS 58 Kd XAS 68 Kd XAS 48 G Kd


Engine shaft speed, normal and maximum r/min 3000 3000 3000 3000
Engine shaft speed, compressor unloaded r/min 1850 1850 1850 1850
Free air delivery 1) without aftercooler l/s 33 50 58 42
m3/min 2.0 3.0 3.5 2.5
cfm 80 120 135 90
with aftercooler l/s 32 49 57 40
m3/min 1.9 2.9 3.4 2.4
cfm 77 117 132 87
Fuel consumption - at 100% FAD kg/h 6.44 6.44 6.44 6.44
lb/h 14.2 14.2 14.2 14.2
- at 75% FAD kg/h 5.23 5.23 5.23 5.23
lb/h 11.5 11.5 11.5 11.5
- at 50% FAD kg/h 3.87 3.87 3.87 3.87
lb/h 8.5 8.5 8.5 8.5
- at 25% FAD kg/h 3.51 3.51 3.51 3.51
lb/h 8.5 8.5 8.5 8.5
- at unload kg/h 2.57 2.57 2.57 2.57
lb/h 5.7 5.7 5.7 5.7
Specific fuel consumption - at 100% FAD g/m3 29.9 29.9 29.9 29.9
lb/1000 cu.ft 1.9 1.9 1.9 1.9
Engine oil consumption (maximum) g/h 17 17 17 17
oz/h 0.6 0.6 0.6 0.6

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Designation XAHS 38 Kd XAS 58 Kd XAS 68 Kd XAS 48 G Kd
Compressed air temperature at without aftercooler °C 58.5 58.5 58.5 58.5
outlet valves °F 138 138 138 138
with aftercooler °C 35 35 35 35
°F 95 95 95 95
- Sound pressure level (Lp), measured according to dB(A) 70 70 70 70
ISO 2151 under free field conditions at 7 m distance
- Sound power level (Lw) complies with 2000/14/EC dB(A) 98 98 98 98

Designation XATS 68 Kd XAS 78 Kd XAS 88 Kd XAS 68 G Kd


Engine shaft speed, normal and maximum r/min 3000 3000 3000 3000
Engine shaft speed, compressor unloaded r/min 1850 1850 1850 1850
Free air delivery 1) without aftercooler l/s 58 75 83 58
m3/min 3.5 4.5 5.0 3.5
cfm 135 160 175 135
with aftercooler l/s 57 74 82 57
m3/min 3.4 4.4 4.9 3.4
cfm 132 158 173 132
Fuel consumption - at 100% FAD kg/h 6.44 6.44 6.44 6.44
lb/h 14.2 14.2 14.2 14.2
- at 75% FAD kg/h 5.23 5.23 5.23 5.23
lb/h 11.5 11.5 11.5 11.5
- at 50% FAD kg/h 3.87 3.87 3.87 3.87
lb/h 8.5 8.5 8.5 8.5
- at 25% FAD kg/h 3.51 3.51 3.51 3.51
lb/h 8.5 8.5 8.5 8.5
- at unload kg/h 2.57 2.57 2.57 2.57
lb/h 5.7 5.7 5.7 5.7

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Designation XATS 68 Kd XAS 78 Kd XAS 88 Kd XAS 68 G Kd
3
Specific fuel consumption - at 100% FAD g/m 29.9 29.9 29.9 29.9
lb/1000 cu.ft 1.9 1.9 1.9 1.9
Engine oil consumption (maximum) g/h 17 17 17 17
oz/h 0.6 0.6 0.6 0.6
Compressed air temperature at without aftercooler °C 58.5 58.5 58.5 58.5
outlet valves °F 138 138 138 138
with aftercooler °C 35 35 35 35
°F 95 95 95 95
- Sound pressure level (Lp), measured according to dB(A) 70 70 70 70
ISO 2151 under free field conditions at 7 m distance
- Sound power level (Lw) complies with 2000/14/EC dB(A) 98 98 98 98

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DESIGN DATA

Compressor

Number of compression stages: 1

Engine

Designation XAHS 38 Kd XAS 58 Kd XAS 68 Kd XAS 48 G Kd XATS 68 Kd XAS 78 Kd XAS 88 Kd XAS 68 G Kd


Make Kubota Kubota Kubota Kubota Kubota Kubota Kubota Kubota
Type V1505 V1505 V1505 V1505-T* V1505-T V1505-T V1505-T V1505-T
Coolant Liquid Liquid Liquid Liquid Liquid Liquid Liquid Liquid
Number of cylinders 4 4 4 4 4 4 4 4
Bore mm 78 78 78 78 78 78 78 78
in 3.07 3.07 3.07 3.07 3.07 3.07 3.07 3.07
Stroke mm 78.4 78.4 78.4 78.4 78.4 78.4 78.4 78.4
in 3.09 3.09 3.09 3.09 3.09 3.09 3.09 3.09
Swept volume l 1.498 1.498 1.498 1.498 1.498 1.498 1.498 1.498
cu in 91.4 91.4 91.4 91.4 91.4 91.4 91.4 91.4
Output according to kW 26.5 26.5 26.5 33 33 33 33 33
ISO 9249 G at normal shaft BHP 36 36 36 45 45 45 45 45
speed
- Load factor % 100 100 100 100 100 100 100 100
Capacity of oil sump:
- Refill (max.) with filter change l 5.5 5.5 5.5 5.5 5.5 5.5 5.5 5.5
US gal 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5
Capacity of cooling system l 7.2 7.2 7.2 7.2 7.2 7.2 7.2 7.2
US gal 1.9 1.9 1.9 1.9 1.9 1.9 1.9 1.9
* V1505: 6 kVA generator
V1505-T: 12 kVA generator

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Unit

Designation All units


Capacity of compressor oil l 7.7
system US gal 2.0
Net capacity of air receiver l 16.7
US gal 4.4
Capacity of fuel tank l 60
US gal 16
Air volume at inlet grating m3/s 0.93
(approx.) 1) cuft/s 32.8
1) Air required for engine and compressor cooling, for combustion and for compression.

Alternator

XAS 48 G + XAS 68 G
Voltage AC V 110 230/400 230/400
Rated output kVA 6 6 12
Model S16F T16F T20FS
Protection Earth fault relay Earth fault relay IT relay Earth fault relay IT relay
Sockets 1x 110V/1ph/32A 1x 400V/3ph/10A 2x 400V/3ph/16A
2x 110V/1ph/16A 2x 230V/1ph/10A 1x 230V/1ph/16A
Protection rating IP 23
Standard IEC 34-1

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DIMENSIONS

9822 0106 00 - Adjustable tow bar no brakes


2802 [110,3]
2306 [90,8]

2514 [99,0]

1435 [56,5]
1171 [46,1]
888 [34,9]
186 [7,3] 1140 [44,9] 235 [9,3]
940 [37,0]
3106 [122,3]
1130 [44,5]
1346 [53,0]

9822 0105 00 - Adjustable tow bar with brakes


3152 [124,1]

2204 [86,8]
2514 [99,0]
1497 [58,9]

1435 [56,5]
884 [34,8]
401[15,8]
186 [7,3]

940 [37,0] 1140 [44,9]


1130 [44,5] 3403 [134,0]
1346 [53,0] Weight (maximum): see indication on dataplate

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9822 0109 00 - Fixed tow bar no brakes

2765 [108,9]

2514 [99,0]

1435 [56,5]
438 [17,2]
940 [37,0] 186 [7,3] 1196 [47,1]
1130 [44,5]
1345 [53,0]

9822 0108 00 - Fixed tow bar with brakes


2763 [108,8]
2514 [99,0]

1435 [56,5]
446 [17,6]

940 [37,0] 1229 [48,4]


186 [7,3]
1130 [44,5]
1345 [53,0] Weight (maximum): see indication on dataplate

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9822 0107 00 - Box

1935 [76,2]

2514 [99,0]

1066 [42,0]
1139 [44,8]
1720 [67,7]
940 [37,0]
2327 [91,6]
1173 [46,2]

9822 0110 00 - Support mounted

1931 [76,0]
2325 [91,5]

1091 [43,0]
1246 [49,1)

845 [33,3] 1720 [67,7]


940 [37,0] 2327 [91,6]
1168 [46,0] Weight (maximum): see indication on dataplate

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9822 0122 00 - Extended support mounted

1931 [76,0]

2470 [97,2]

1091 [43,0]
1391 [54,8]
860 [33,9] 1720 [67,7]
940 [37,0] 2327 [91,6]

1168 [46,0]

Weight (maximum): see indication on dataplate

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Dataplate
Weight 1 Company code
(1) (2) (3) 2 Product code
Weight ready to operate see dataplate 3 Unit serial number
(4) 4 Name of the manufacturer
(5) 5 EEC or national type approval number
(6) 6 Vehicle identification number
Air outlet A kg
B kg 7 Undercarriage
(7)
Air outlet valves 3 x 3/4
C kg A Maximum permitted total weight of the
D kg
Compressor (8)
vehicle
Pmax(e)working Bar
(9) B Maximum permitted load on the towing eye
Speed
Pengine
Rpm
kW (10) C Maximum permitted load on axle (or front
Wheels axle on dual axle units)
(11)
D Maximum permitted load on rear axle (on dual
Tyre pressure bar 2.7 S/N: Manuf. Year: (12) axle units)
MADE IN BELGIUM
8 Model
psi 39 Atlas Copco Airpower n.v.
Ingberthoeveweg 7
B-2630 Aartselaar
9 Working pressure
Wheel bolt torque Nm 85 10 Speed
lbf.ft 63 11 Engine power
(13) (14) 12 Manufacturing year
13 CE mark in accordance with Machine Directive
89/392 EC
14 Register number or number of notified body

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Disposal
GENERAL DISPOSAL OF MATERIALS
When developing products and services, Atlas Copco Dispose of contaminated substances and material
tries to understand, address, and minimize the separately, in accordance with locally applicable
negative environmental effects that the products and environmental legislation.
services may have, when being manufactured,
Before dismantling a machine at the end of its
distributed, used and disposed.
operating lifetime drain and dispose of all fluids of
Recycling and disposal policy are part of the according the applicable local disposal regulations.
development of all Atlas Copco products. Atlas
Remove the batteries. Do not throw batteries into the
Copco company standards determine strict fire (explosion risk) or residual waste. Separate the
requirements.
machine into metal, electronics, wiring, hoses,
Material selection, substantial recyclability, insulation and plastic parts.
disassembly possibilities and separability of materials
Dispose of all components in accordance with
and assemblies are considered, as well as
applicable disposal regulations.
environmental perils and dangers to health during the
recycling and disposal of the unavoidable rates of Remove spilled fluid mechanically; pick up the rest
non-recyclable materials. using an absorbing agent (for example sand, sawdust)
and dispose of it in accordance with applicable local
Your Atlas Copco compressor consists for the most
disposal regulations. Do not drain into the sewage
part of metallic materials, that can be remelted in
system or surface water.
steelworks and smelting works and are therefore
almost infinitely recyclable. The plastic used is
labelled; sorting and fractioning of the materials for
recycling in the future is foreseen.

This concept can only succeed with your


help. Support us by disposing
professionally. By assuring correct
disposal of the product you help prevent
possible negative consequences for
environment and health as a result of
inappropriate waste handling.
Recycling and re-usage of material help
preserve natural resources.

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Maintenance Log

Compressor ........................................................................................................ Customer ......................................................................................................................

Serial number...................................................................................................... .......................................................................................................................................

Service hours Maintenance action Date By: initials

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Service hours Maintenance action Date By: initials

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Service hours Maintenance action Date By: initials

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Service hours Maintenance action Date By: initials

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Following documents are provided with this unit:
- Test Certificate
- EC Declaration of Conformity:

1
EC DECLARATION OF CONFORMITY
2 We, Atlas Copco Airpower n.v., declare under our sole responsibility, that the product
3 Machine name :
4 Commercial name :
5 Serial number :

6 Which falls under the provisions of article 12.2 of the EC Directive 2006/42/EC on the approximation of the
laws of the Member States relating to machinery, is in conformity with the relevant Essential Health and
Safety Requirements of this directive.

The machinery complies also with the requirements of the following directives and their amendments as
indicated.

7 Directive on the approximation of laws of the Harmonized and/or Technical Att’


Member States relating to Standards used mnt
a. Pressure equipment 97/23/EC X

EN ISO 12100-1
b. Machinery safety 2006/42/EC EN ISO 12100-2
EN 1012-1
c. Simple pressure vessel 87/404/EEC X
EN 61000-6-2
d. Electromagnetic compatibility 2004/108/EC
EN 61000-6-4
EN 60034
e. Low voltage equipment 2006/95/EC EN 60204-1
EN 60439
f. Outdoor noise emission 2000/14/EC ISO 3744 X

8.a The harmonized and the technical standards used are identified in the attachments hereafter
8.b Atlas Copco Airpower n.v. is authorized to compile the technical file

9 Conformity of the product to the


Conformity of the specification to the
10
specification and by implication to the
Directives
directives
11
12 Issued by Product engineering Manufacturing
13
14 Name
15 Signature

16 Place , Date
Form 5009 0600 00
ed. 09, 2010-03-15

Atlas Copco Airpower n.v. A company within the Atlas Copco Group

Postal address Visitors address Phone: +32 (0)3 870 21 11 Com. Reg. Antwerp 44651
P.O. Box 100 Boomsesteenweg 957 Fax: +32 (0)3 870 24 43 V.A.T. 403.992.231
B-2610 Wilrijk-Antwerp B-2610 Wilrijk-Antwerp
Belgium Belgium For info, please contact your local Atlas Copco representative
www.atlascopco.com
p.1(1)

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