Instruction Manual

for Portable Compressors

English

XAS 67 DD - XAS 130 DD7

XATS 67 DD - XATS 125 DD7 Engine Deutz
XAS 77 DD - XAS 150 DD7 D2011L03
XAS 97 DD - XAS 185 DD7
 Instruction Manual
for Portable Compressors

XAS 67 DD - XAS 130 DD7

XATS 67 DD - XATS 125 DD7
XAS 77 DD - XAS 150 DD7
XAS 97 DD - XAS 185 DD7

Original instructions

Printed matter N°
2954 2150 04 ATLAS COPCO - PORTABLE AIR DIVISION
10/2010 www.atlascopco.com
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 2010, 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
Follow the instructions in this booklet and we
guarantee you years of troublefree operation. It is a
solid, safe and reliable machine, built according to
the latest technology.
Always keep the manual available near the machine.
In all correspondence always mention the
compressor type and serial number, shown on the
data plate.
The company reserves the right to make changes
without prior notice.
Table of contents 3.2.6 Generator DDG IT 230V, 6 kVA .......... 36
3.2.7 Generator DDG IT 230/400V, 12 kVA
1 Safety precautions (generator).................. 7 without automatic control system 38
1.1 Introduction .................................................. 7 3.2.8 Generator DDG IT 230/400V, 12 kVA with
automatic control system 40
1.2 General safety precautions ........................... 8
3.2.9 Generator DDG IT 230V, 12 kVA ........ 42
1.3 Safety during transport and installation ....... 9
3.2.10 Circuit diagram refinary equipment 9822
1.4 Safety during use and operation ................... 9 0909 00 (all types) 44
1.5 Safety during maintenance and repair........ 11
3.3 Markings and information labels ............... 46
1.6 Tool applications safety ............................. 12
1.7 Specific safety precautions......................... 13 4 Operating instructions............................. 47
4.1 Parking, towing and lifting instructions..... 47
2 Leading particulars .................................. 14 4.1.1 Parking instructions ............................... 47
2.1 Safety pictograms used .............................. 14 4.1.2 Towing instructions ............................... 48
2.2 General description .................................... 14 4.1.3 Height adjustment .................................. 49
4.1.4 Spillage-Free Instruction ....................... 49
3 Main Parts................................................. 16 4.1.5 Instructions ball coupling (option)......... 50
3.1 Compressor regulating system ................... 18 4.1.6 Lifting instructions................................. 50
3.1.1 Overview................................................ 18 4.1.7 Diesel particle filter (option) ................. 51
3.1.2 Air flow.................................................. 20 4.1.8 Aftercooler (option) ............................... 51
3.1.3 Oil system .............................................. 21 4.1.9 Anti-Frost Device (option) .................... 52
3.1.4 Continuous pneumatic regulating system ... 4.2 Starting / Stopping ..................................... 52
22
4.3 Before starting............................................ 52
3.2 Electric system ........................................... 24 4.3.1 Starting procedure (with cold start; option)
3.2.1 Circuit diagram (standard) (9822 0991 32) 53
24 4.3.2 Starting procedure (without cold start) .. 55
3.2.2 Generator DDG 110V without automatic 4.3.3 During operation .................................... 57
control system 28 4.3.4 Stopping procedure ................................ 57
3.2.3 Generator DDG 110V with automatic 4.3.5 Fault situations and protective devices .. 57
control system 30 4.4 Functional description of generator (option) ..
3.2.4 Generator DDG IT 230/400V, 6 kVA
58
without automatic control system 32
4.4.1 DDG 110V without automatic control
3.2.5 Generator DDG IT 230/400V, 6 kVA with system 58
automatic control system 34

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4.4.2 DDG 110V with automatic control system 5.17 Service paks ............................................... 75 9 Technical specifications ........................... 94
(option) 59 5.18 Service kits ................................................. 75 9.1 Torque values............................................. 94
4.4.3 DDG 230/400V and 230V - 3ph without 5.19 Compressor element overhaul.................... 75 9.1.1 General torque values ............................ 94
automatic control system 60 5.20 Liability ...................................................... 75 9.1.2 Critical torque values ............................. 94
4.4.4 DDG 230/400V and 230V - 3ph with 9.2 Settings of shutdown switches and safety
automatic control system (option) 61 6 Adjustments and servicing procedures .. 76 valves 95
6.1 Adjustment of the continuous pneumatic 9.3 Compressor / engine specifications............ 96
5 Maintenance.............................................. 63
regulating system 76 9.3.1 Reference conditions ............................. 96
5.1 Preventive maintenance schedule............... 63
6.2 Air filter engine/compressor ...................... 78 9.3.2 Limitations............................................. 97
5.2 Use of service paks..................................... 63 6.2.1 Cleaning the dust trap ............................ 78 9.3.3 Altitude unit performance curves .......... 98
5.3 Maintenance schedule compressor............. 63 6.2.2 Recommendations.................................. 78 9.3.4 Performance data ................................. 100
5.4 Diesel particle filter .................................... 66 6.2.3 Replacing the air filter element.............. 78 9.3.5 Design data .......................................... 101
5.5 Maintenance schedule undercarriage ......... 67 6.3 Air receiver................................................. 79 9.3.6 Design data for generator..................... 103
5.6 Lubrication oils........................................... 68 6.4 Drive Belt (XAS 67 DD - XAS 130 DD7,
5.7 Oil specifications........................................ 69 XATS 67 DD - XATS 125 DD7) 79 10 Dataplate ................................................. 106
5.7.1 Compressor oil ....................................... 69 6.5 Safety valve ................................................ 79 11 Disposal ................................................... 107
5.8 Oil level check............................................ 70 6.6 Fuel system................................................. 79 11.1 General ..................................................... 107
5.8.1 Check engine oil level............................ 70 6.7 Brake (= option) adjustment....................... 80 11.2 Disposal of materials................................ 107
5.8.2 Check compressor oil level .................... 70 6.7.1 Brake shoe adjustment ........................... 80
5.9 Oil and oil filter change.............................. 71 6.7.2 Brake cable adjustment .......................... 80 12 Maintenance Log.................................... 108
5.9.1 Engine oil and oil filter change .............. 71 6.7.3 Test procedure brake cable adjustment.. 81
5.9.2 Compressor oil and oil filter change ...... 71 6.8 Wheels........................................................ 82
5.10 Compressor Oil Flushing Procedure .......... 72 6.8.1 Wheel check........................................... 82
5.11 Cleaning coolers ......................................... 73 6.8.2 Lubrication............................................. 82
5.12 Cleaning fuel tank ...................................... 73 6.8.3 Wheel bolts check .................................. 83
5.13 Cleaning hardhat......................................... 74 6.8.4 Wheel bearing adjustment...................... 84
5.14 Battery care................................................. 74 6.9 Towbar and overrun brake ......................... 85
5.14.1 Electrolyte .............................................. 74 6.9.1 Towbar and overrun brake check........... 85
5.14.2 Activating a dry-charged battery............ 74 6.9.2 Lubrication............................................. 86
5.14.3 Recharging a battery .............................. 74
7 Problem solving ........................................ 88
5.14.4 Battery maintenance............................... 74
5.15 Changing tyres............................................ 75 8 Available options ...................................... 93
5.16 Storage........................................................ 75

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Safety precautions (generator)
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
their equipment with safe, reliable and efficient
products. Factors taken into account are among
others:
- the intended and predictable future use of the
products, and the environments in which they are
expected to operate,
- applicable rules, codes and regulations,
- the expected useful product life, assuming proper
service and maintenance,
- providing the manual with up-to-date
information.
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 personnel.
See also the safety precautions of the engine and
possible other equipment, which are separately sent
along or are mentioned on the equipment or parts of
the unit.
These safety precautions are general and some
statements will therefore not always apply to a
particular unit.
Only people that have the right skills should be
allowed to operate, adjust, perform maintenance or
repair on Atlas Copco equipment.
It is the responsibility of management to appoint
operators with the appropriate training and skill for
each category of job.
Skill level 1: Operator
An operator is trained in all aspects of operating the
unit with the push-buttons, and is trained to know the
safety aspects.
Skill level 2: Mechanical technician
A mechanical technician is trained to operate the unit
the same as the operator. In addition, the mechanical
technician is also trained to perform maintenance and
repair, as described in the instruction manual, and is
allowed to change settings of the control and safety
system. A mechanical technician does not work on
live electrical components.
Skill level 3: Electrical technician
An electrical technician is trained and has the same
qualifications as both the operator and the mechanical
technician. In addition, the electrical technician may
carry out electrical repairs within the various
enclosures of the unit. This includes work on live
electrical components.
Skill level 4: Specialist from the manufacturer
This is a skilled specialist sent by the manufacturer or
its agent to perform complex repairs or modifications
to the equipment.
In general it is recommended that not more than two
people operate the unit, more operators could lead to
unsafe operating conditions.
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Take necessary steps to keep unauthorized persons
away from the unit and eliminate all possible sources
of danger at the unit.
When handling, operating, overhauling and/or
performing maintenance or repair on Atlas Copco
equipment, the mechanics are expected to use safe
engineering practices and to observe all relevant local
safety requirements and ordinances. The following
list is a reminder of special safety directives and
precautions mainly applicable to Atlas Copco
equipment.
These safety precautions apply to machinery
processing or consuming air. Processing of any other
gas requires additional safety precautions typical to
the application and are not included herein.
Neglecting the safety precautions may endanger
people as well as environment and machinery:
- endanger people due to electrical, mechanical or
chemical influences,
- endanger the environment due to leakage of oil,
solvents or other substances,
- 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.
The manufacturer does not accept any liability for any
damage arising from the use of non-original parts and
for modifications, additions or conversions made
without the manufacturer’s approval in writing.
If any statement in this manual does not comply with
local legislation, the stricter of the two shall be
applied.
Statements in these safety precautions should not be
interpreted as suggestions, recommendations or
inducements that it should be used in violation of any
applicable laws or regulations.
GENERAL SAFETY PRECAUTIONS
1 The owner is responsible for maintaining the unit
in a safe operating condition. Unit parts and
accessories must be replaced if missing or
unsuitable for safe operation.
2 The supervisor, or the responsible person, shall at
all times make sure that all instructions regarding
machinery and equipment operation and
maintenance are strictly followed and that the
machines with all accessories and safety devices,
as well as the consuming devices, are in good
repair, free of abnormal wear or abuse, and are
not tampered with.
3 Whenever there is an indication or any suspicion
that an internal part of a machine is overheated,
the machine shall be stopped but no inspection
covers shall be opened before sufficient cooling
time has elapsed; this to avoid the risk of
spontaneous ignition of oil vapour when air is
admitted.
4 Normal ratings (pressures, temperatures, speeds,
etc.) shall be durably marked.
5 Operate the unit only for the intended purpose and 15 When working on the unit, wear safety clothing.
within its rated limits (pressure, temperature, Depending on the kind of activities these are:
speeds, etc.). safety glasses, ear protection, safety helmet
6 The machinery and equipment shall be kept clean, (including visor), safety gloves, protective
i.e. as free as possible from oil, dust or other clothing, safety shoes. Do not wear the hair long
deposits. and loose (protect long hair with a hairnet), or
wear loose clothing or jewelry.
7 To prevent an increase in working temperature,
inspect and clean heat transfer surfaces (cooler 16 Take precautions against fire. Handle fuel, oil and
fins, intercoolers, water jackets, etc.) regularly. anti-freeze with care because they are
See the Preventive maintenance schedule. inflammable substances. Do not smoke or
approach with naked flame when handling such
8 All regulating and safety devices shall be substances. Keep a fire-extinguisher in the
maintained with due care to ensure that they vicinity.
function properly. They may not be put out of
action. 17a Portable compressors with generator (with
earthing pin):
9 Care shall be taken to avoid damage to safety
valves and other pressure-relief devices, Earth the generator as well as the load properly.
especially to avoid plugging by paint, oil coke or 17b Portable compressors with generator IT:
dirt accumulation, which could interfere with the Note: This generator is built to supply a sheer
functioning of the device. alternating current IT network.
10 Pressure and temperature gauges shall be checked Earth the load properly.
regularly with regard to their accuracy. They shall
be replaced whenever outside acceptable
tolerances.
11 Safety devices shall be tested as described in the
maintenance schedule of the instruction manual
to determine that they are in good operating
condition. See the Preventive maintenance
schedule.
12 Mind the markings and information labels on the
unit.
13 In the event the safety labels are damaged or
destroyed, they must be replaced to ensure
operator safety.
14 Keep the work area neet. Lack of order will
increase the risk of accidents.
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SAFETY DURING TRANSPORT AND
INSTALLATION
To lift a unit, all loose or pivoting parts, e.g. doors and
towbar, shall first be securely fastened.
Do not attach cables, chains or ropes directly to the
lifting eye; apply a crane hook or lifting shackle
meeting local safety regulations. Never allow sharp
bends in lifting cables, chains or ropes.
Helicopter lifting is not allowed.
It is strictly forbidden to dwell or stay in the risk zone
under a lifted load. Never lift the unit over people or
residential areas. Lifting acceleration and retardation
shall be kept within safe limits.
1 Before towing the unit:
- ascertain that the pressure vessel(s) is (are)
depressurized,
- check the towbar, the brake system and the
towing eye. Also check the coupling of the
towing vehicle,
- check the towing and brake capability of the
towing vehicle,
- check that the towbar, jockey wheel or stand
leg is safely locked in the raised position,
- ascertain that the towing eye can swivel freely
on the hook,
- check that the wheels are secure and that the
tyres are in good condition and inflated
correctly,
- connect the signalisation cable, check all lights
and connect the pneumatic brake couplers,
- attach the safety break-away cable or safety
chain to the towing vehicle,
- remove wheel chocks, if applied, and
disengage the parking brake.
2 To tow a unit use a towing vehicle of ample
capacity. Refer to the documentation of the
towing vehicle.
3 If the unit is to be backed up by the towing
vehicle, disengage the overrun brake mechanism
(if it is not an automatic mechanism).
4 Never exceed the maximum towing speed of the
unit (mind the local regulations).
5 Place the unit on level ground and apply the
parking brake before disconnecting the unit from
the towing vehicle. Unclip the safety break-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 the
wheels. When the towbar can be positioned
vertically, the locking device must be applied and
kept in good order.
6 To lift heavy parts, a hoist of ample capacity,
tested and approved according to local safety
regulations, shall be used.
7 Lifting hooks, eyes, shackles, etc., shall never be
bent and shall only have stress in line with their
design load axis. The capacity of a lifting device
diminishes when the lifting force is applied at an
angle to its load axis.
8 For maximum safety and efficiency of the lifting
apparatus all lifting members shall be applied as
near to perpendicular as possible. If required, a
lifting beam shall be applied between hoist and
load.
9 Never leave a load hanging on a hoist.
10 A hoist has to be installed in such a way that the
object will be lifted perpendicular. If that is not
possible, the necessary precautions must be taken
to prevent load-swinging, e.g. by using two
hoists, each at approximately the same angle not
exceeding 30° from the vertical.
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11 Locate the unit away from walls. Take all
precautions to ensure that hot air exhausted from
the engine and driven machine cooling systems
cannot be recirculated. If such hot air is taken in
by the engine or driven machine cooling fan, this
may cause overheating of the unit; if taken in for
combustion, the engine power will be reduced.
12 The electrical connections shall correspond to
local codes. The machines shall be earthed and
protected against short circuits by fuses or circuit
breakers.
13 Never connect the generator outlets to an
installation which is also 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.
SAFETY DURING USE AND OPERATION
1 When the unit has to operate in a fire-hazardous
environment, each engine exhaust has to be
provided with a spark arrestor to trap incendiary
sparks.
2 The exhaust contains carbon monoxide which is a
lethal gas. When the unit is used in a confined
space, conduct the engine exhaust to the outside
atmosphere by a pipe of sufficient diameter; do
this in such a way that no extra back pressure is
created for the engine. If necessary, install an
extractor. Observe any existing local regulations.
Make sure that the unit has sufficient air intake
for operation. If necessary, install extra air intake
ducts.
3 When operating in a dust-laden atmosphere, place
the unit so that dust is not carried towards it by the
wind. Operation in clean surroundings
considerably extends the intervals for cleaning
the air intake filters and the cores of the coolers.
4 Close the compressor air outlet valve before
connecting or disconnecting a hose. Ascertain
that a hose is fully depressurized before
disconnecting it. Before blowing compressed air
through a hose or air line, ensure that the open end
is held securely, so that it cannot whip and cause
injury.
5 The air line end connected to the outlet valve
must be safeguarded with a safety cable, attached
next to the valve.
6 No external force may be exerted on the air outlet
valves, e.g. by pulling on hoses or by installing
auxiliary equipment directly to a valve, e.g. a
water separator, a lubricator, etc. Do not step on
the air outlet valves.
7 Never move a unit when external lines or hoses
are connected to the outlet valves, to avoid
damage to valves, manifold and hoses.
8 Do not use compressed air from any type of
compressor, without taking extra measures, for
breathing purposes as this may result in injury or
death. For breathing air quality, the compressed
air must be adequately purified according to local
legislation and standards. Breathing air must
always be supplied at stable, suitable pressure.
9 Distribution pipework and air hoses must be of
correct diameter and suitable for the working
pressure. Never use frayed, damaged or
deteriorated hoses. Replace hoses and flexibles
before the lifetime expires. Use only the correct
type and size of hose end fittings and connections.
10 If the compressor is to be used for sand-blasting
or will be connected to a common compressed-air
system, fit an appropriate non-return valve (check
valve) between compressor outlet and the
connected sand-blasting or compressed-air
system. Observe the right mounting position/
direction.
11 Before removing the oil filler plug, ensure that the
pressure is released by opening an air outlet
valve.
12 Never remove a filler cap of the cooling water
system of a hot engine. Wait until the engine has
sufficiently cooled down.
13 Never refill fuel while the unit is running, unless
otherwise stated in the Atlas Copco Instruction
Book (AIB). Keep fuel away from hot parts such
as air outlet pipes or the engine exhaust. Do not
smoke when 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.
14 All doors shall be shut during operation so as not
to disturb the cooling air flow inside the
bodywork and/or render the silencing less
effective. A door should be kept open for a short
period only e.g. for inspection or adjustment.
15 Periodically carry out maintenance works
according to the maintenance schedule.
16 Stationary housing guards are provided on all
rotating or reciprocating parts not otherwise
protected and which may be hazardous to
personnel. Machinery shall never be put into
operation, when such guards have been removed,
before the guards are securely reinstalled.
17 Noise, even at reasonable levels, can cause
irritation and disturbance which, over a long
period of time, may cause severe injuries to the
nervous system of human beings. When the sound
pressure level, at any point where personnel
normally has to attend, is:
- 10 -
- below 70 dB(A): no action needs to be taken,
- above 70 dB(A): noise-protective devices
should be provided for people continuously
being present in the room,
- below 85 dB(A): no action needs to be taken
for occasional visitors staying a limited time
only,
- above 85 dB(A): room to be classified as a
noise-hazardous area and an obvious warning
shall be placed permanently at each entrance
to alert people entering the room, for even
relatively short times, about the need to wear
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 level and the
spectral composition of the noise shall be
provided and a special warning to that effect
shall be placed at each entrance.
18 Insulation or safety guards of parts the
temperature of which can be in excess of 80 °C
(175 °F) and which may be accidentally touched
by personnel shall not be removed before the
parts have cooled to room temperature.
19 Never operate the unit in surroundings where
there is a possibility of taking in flammable or
toxic fumes.
20 If the working process produces fumes, dust or
vibration hazards, etc., take the necessary steps to
eliminate the risk of personnel injury.
21 When using compressed air or inert gas to clean
down equipment, do so with caution and use the
appropriate protection, at least safety glasses, for
the operator as well as for any bystander. Do not
 apply compressed air or inert gas to your skin or
direct an air or gas stream at people. Never use it
to clean dirt from your clothes.
22 When washing parts in or with a cleaning solvent,
provide the required ventilation and use
appropriate protection such as a breathing filter,
safety glasses, rubber apron and gloves, etc.
23 Safety shoes should be compulsory in any
workshop and if there is a risk, however small, of
falling objects, wearing of a safety helmet should
be included.
24 If there is a risk of inhaling hazardous gases,
fumes or dust, the respiratory organs must be
protected and depending on the nature of the
hazard, so must the eyes and skin.
25 Remember that where there is visible dust, the
finer, invisible particles will almost certainly be
present too; but the fact that no dust can be seen
is not a reliable indication that dangerous,
invisible dust is not present in the air.
26 Never operate the unit at pressures or speeds
below or in excess of its limits as indicated in the
technical specifications.
27 Never operate the generator in excess of its limits
as indicated in the technical specifications and
avoid long no-load sequences.
28 Never operate the generator in a humid
atmosphere. Excessive moisture causes
worsening of the generator insulation.
29 Do not open electrical cabinets, cubicles or other
equipment while voltage is supplied. If such
cannot be avoided, e.g. for measurements, tests or
adjustments, have the action carried out by a
qualified electrician only, with appropriate tools,
and ascertain that the required bodily protection
against electrical hazards is applied.
30 Never touch the power terminals during operation
of the machine.
31 Whenever an abnormal condition arises, e.g.
excessive vibration, noise, odour, etc., switch the
circuit breakers to OFF and stop the engine.
Correct the faulty condition before restarting.
32 Check the electric cables regularly. Damaged
cables and insufficient lightening of connections
may cause electric shocks. Whenever damaged
wires or dangerous conditions are observed,
switch the circuit breakers to OFF and stop the
engine. Replace the damaged wires or correct the
dangerous condition before restarting. Make sure
that all electric connections are securely
tightened.
33 Do not use aerosol types of starting aids such as
ether. Such use could result in an explosion and
personal injury.
34 Avoid overloading the generator. The generator is
provided with circuit breakers for overload
protection. When a breaker has tripped, reduce
the concerned load before restarting.
35 If the generator is used as stand-by for the mains
supply, it must not be operated without control
system which automatically disconnects the
generator from the mains when the mains supply
is restored.
36 Never remove the cover of the output terminals
during operation. Before connecting or
disconnecting wires, switch off the load and the
circuit breakers, stop the machine and make sure
that the machine cannot be started inadvertently
or there is any residual voltage on the power
circuit.
37 Running the generator at low load for long
periods will reduce the lifetime of the engine.
- 11 -
SAFETY DURING MAINTENANCE AND
REPAIR
Maintenance, overhaul and repair work shall only be
carried out by adequately trained personnel; if
required, under supervision of someone qualified for
the job.
1 Use only the correct tools for maintenance and
repair work, and only tools which are in good
condition.
2 Parts shall only be replaced by genuine Atlas
Copco replacement parts.
3 All maintenance work, other than routine
attention, shall only be undertaken when the unit
is stopped. Steps shall be taken to prevent
inadvertent starting. In addition, a warning sign
bearing a legend such as ”work in progress; do
not start” shall be attached to the starting
equipment. On engine-driven units the battery
shall be disconnected and removed or the
terminals covered by insulating caps. On
electrically driven units the main switch shall be
locked in open 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 attached to the fuse box or main switch.
4 Before dismantling any pressurized component,
the compressor or equipment shall be effectively
isolated from all sources of pressure and the entire
system shall be relieved of pressure. Do not rely
on non-return valves (check valves) to isolate
pressure systems. In addition, a warning sign
bearing a legend such as ”work in progress; do
not open” shall be attached to each of the outlet
valves.
5 Prior to stripping an engine or other machine or
undertaking major overhaul on it, prevent all
movable parts from rolling over or moving.
6 Make sure that no tools, loose parts or rags are left
in or on the machine. Never leave rags or loose
clothing near the engine air intake.
7 Never use flammable solvents for cleaning (fire-
risk).
8 Take safety precautions against toxic vapours of
cleaning liquids.
9 Never use machine parts as a climbing aid.
10 Observe scrupulous cleanliness during
maintenance and repair. Keep away dirt, cover
the parts and exposed openings with a clean cloth,
paper or tape.
11 Never weld on or perform any operation
involving heat near the fuel or oil systems. Fuel
and oil tanks must be completely purged, e.g. by
steam-cleaning, before carrying out such
operations. Never weld on, or in any way modify,
pressure vessels. Disconnect the alternator cables
during arc welding on the unit.
12 Support the towbar and the axle(s) securely if
working underneath the unit or when removing a
wheel. Do not rely on jacks.
13 Do not remove any of, or tamper with, the sound-
damping material. 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 the sound pressure level from
increasing.
14 Use only lubricating oils and greases
recommended or approved by Atlas Copco or the
machine manufacturer. Ascertain that the
selected lubricants comply with all applicable
safety regulations, especially with regard to
explosion or fire-risk and the possibility of
decomposition or generation of hazardous gases.
Never mix synthetic with mineral oil.
15 Protect the engine, alternator, air intake filter, 22 Make sure that oil, solvents and other substances
electrical and regulating components, etc., to likely to pollute the environment are properly
prevent moisture ingress, e.g. when steam- disposed of.
cleaning. 23 Before clearing the unit for use after maintenance
16 When performing any operation involving heat, or overhaul, check that operating pressures,
flames or sparks on a machine, the surrounding temperatures and speeds are correct and that the
components shall first be screened with non- control and shutdown devices function correctly.
flammable material. Submit the generator to a testrun, check that the
AC power performance is correct.
17 Never use a light source with open flame for
inspecting the interior of a machine.
18 When repair has been completed, the machine
shall be barred over at least one revolution for
reciprocating machines, several revolutions for TOOL APPLICATIONS SAFETY
rotary ones to ensure that there is no mechanical
interference within the machine or driver. Check
Apply the proper tool for each job. With the
the direction of rotation of electric motors when knowledge of correct tool use and knowing the
starting up the machine initially and after any
limitations of tools, along with some common sense,
alteration to the electrical connection(s) or switch many accidents can be prevented.
gear, to check that the oil pump and the fan
function properly. Special service tools are available for specific jobs
and should be used when recommended. The use of
19 Maintenance and repair work should be recorded these tools will save time and prevent damage to
in an operator’s logbook for all machinery.
parts.
Frequency and nature of repairs can reveal unsafe
conditions.
20 When hot parts have to be handled, e.g. shrink
fitting, special heat-resistant gloves shall be used
and, if required, other body protection shall be
applied.
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 surpassed.
- 12 -
SPECIFIC SAFETY PRECAUTIONS
Batteries
When servicing batteries, always wear protecting
clothing and glasses.
1 The electrolyte in batteries is a sulphuric acid
solution which is fatal if it hits your eyes, and
which can cause burns if it contacts your skin.
Therefore, be careful when handling batteries,
e.g. when checking the charge condition.
2 Install a sign prohibiting fire, open flame and
smoking at the post where batteries are being
charged.
3 When batteries are being charged, an explosive
gas mixture forms in the cells and might escape
through the vent holes in the plugs. Thus an
explosive atmosphere may form around the
battery if ventilation is poor, and can remain in
and around the battery for several hours after it
has been charged. Therefore:
- never smoke near batteries being, or having
recently been, charged,
- never break live circuits at battery terminals,
because a spark usually occurs.
4 When connecting an auxiliary battery (AB) in
parallel to the unit battery (CB) with booster
cables: connect the + pole of AB to the + pole of
CB, then connect the - pole of CB to the mass of
the unit. Disconnect in the reverse order.
Pressure vessels Safety valves
Maintenance/installation requirements: All adjustments or repairs are to be done by an
authorized representative of the valve supplier (see
1 The vessel can be used as pressure vessel or as
also Preventive maintenance schedule).
separator and is designed to hold compressed air
for the following application:
- pressure vessel for compressor,
- medium AIR/OIL,
and operates as detailed on the data plate of the
vessel:
- the maximum working pressure ps in bar (psi),
- the maximum working temperature Tmax in
°C (°F),
- the minimum working temperature Tmin in °C
(°F),
- the capacity of the vessel V in l (US gal).
2 The pressure vessel is only to be used for the
applications as specified above and in accordance
with the technical specifications. Safety reasons
prohibit any other applications.
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.
5 The vessel is provided and may only be used with
the required safety equipment such as
manometer, overpressure control devices, safety
valve, etc.
6 Draining of condensate shall be performed daily
when vessel is in use.
7. Installation, design and connections should not be
changed.
8. Bolts of cover and flanges may not be used for
extra fixation.
- 13 -
Leading particulars
SAFETY PICTOGRAMS USED GENERAL DESCRIPTION

This symbol draws your attention to

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

This symbol is followed by

supplementary information.

General view metal canopy General view HardHat

The compressors type XAS 67 DD - XAS 130 DD7, Engine

XATS 67 DD - XATS 125 DD7, XAS 77 DD - XAS
150 DD7 and XAS 97 DD - XAS 185 DD7 are
silenced, single-stage, oil-injected screw
compressors, built for a nominal effective working
pressure, ranging from 7 bar (102 psi) up to 10.3 bar
(150 psi) (see chapter Technical specifications).
The compressor is available with metal or PE canopy
(HardHat).
The compressor is driven by an oil-cooled diesel
engine.
The engine’s power is transmitted to the compressor
through a heavy-duty drive belt (XAS 67 DD - XAS
130 DD7, XATS 67 DD - XATS 125 DD7) or a
heavy-duty coupling (XAS 77 DD - XAS 150 DD7,
XAS 97 DD - XAS 185 DD7).

- 14 -
Compressor element
The compressor casing houses two screw-type rotors,
mounted on ball and roller bearings. The male rotor,
driven by the engine, drives the female rotor. The
element delivers pulsation-free air.
Injected oil is used for sealing, cooling and
lubricating purposes.
Compressor oil system
The oil is boosted by air pressure. The system has no
oil pump.
The oil is removed from the air, in the air/oil vessel at
first by centrifugal force, secondly through the oil
separator element.
The vessel is provided with an oil level indicator.
Regulation
The compressor is provided with a continuous
pneumatic regulating system and a blow-down valve
which is integrated in the unloader assembly. The
valve is closed during operation by outlet pressure of
the compressor element and opens by air receiver
pressure when the compressor is stopped.
When the air consumption increases, the air receiver
pressure will 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 regulator, matches the air
output to the air consumption. The air receiver
pressure is maintained between the pre-selected
working pressure and the corresponding unloading
pressure.
Cooling system
Engine and compressor are provided with an oil
cooler.
The cooling air is generated by a fan, driven by the
engine.
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.
Frame and axles
The compressor/engine unit is supported by rubber
buffers in the frame. The standard unit has a none
adjustable towbar with support leg and one of the
following towing eyes AC, DIN, ball, ITA, GB or
NATO.
As an option the unit can be equipped with an
adjustable towbar, a jockey wheel and/or overrun
parking brake (for options see chapter Available
options).
The braking system consists of an integrated parking
brake and overrunbrake. When driving backwards the
overrunbrake is not engaged automatically.
Bodywork
The bodywork has openings at the shaped front and
rear end for the intake and outlet of cooling air and a
hood for maintenance and service operations. The
bodywork is internally lined with sound-absorbing
material.
- 15 -
Lifting eye
A lifting eye is accessible when the small door at the
top of the unit is unlocked.
Control panel
The control panel grouping the air pressure gauge,
control switch etc., is placed in the center at the rear
end.
Data plate
The compressor is furnished with a data plate (D)
showing the product code, the unit number and the
working pressure (see chapter Dataplate).
Serial number
The serial number is located on the right-hand front
side of the frame.
Generator (option for XAS 67 DD - XAS 130
DD7 and XAS 97 DD - XAS 185 DD7)
The built-in generator is driven by a multi V-belt
drive. The generated current can be drawn via 3
sockets (see chapter Technical specifications).
The compressor and the generator of the XAS 67
DDG - XAS 130 DD7G / DDG IT may be used
simultaneously. The compressor and the generator of
the XAS 97 DDG - XAS 185 DD7G / DDG IT may
not be used simultaneously.
As an option the generator can be equipped with an
automatic control system to save fuel when no
electric power is used.
Main Parts
(H) (EP)
(OFe)
(A)
(F)
(BH)

(G) (AFD)
(E)
(CPG) (S)
(VI) (TB)
(RV) (AR)

(FP) (SV)
(JW)

(OLG) (SN)

(D)

(DPec)
(FCeo)
(FCft)

(AOV) (DSe)

(CP) (FU)
(DPft) (FF)
(OFce)
(FT) (VV)
(CE) (AF)
(DB/C)

- 16 -
Reference Name Reference Name
A Alternator FF Fuel Filter
AF Air Filter FP Filler Plug (compressor oil)
AFD Anti-Frost Device (option) FT Fuel Tank
AOV Air Outlet Valves FU Fuel Pump
AR Air Receiver G Generator
BH Brake Handle H Hood
C Coupling JW Jockey wheel
(XAS 77 DD - XAS 150 DD7, OFce Oil Filter (compressor element)
XAS 97 DD - XAS 185 DD7)
OFe Oil Filter (engine)
CE Compressor Element
OLG Oil Level Gauge (compressor
CP Control Panel element)
CPG Control Panel (generator), (option) RV Regulating Valve
D Data Plate S Starting Motor
DB Drive Belt SN Serial Number
(XAS 67 DD - XAS 130 DD7,
XATS 67 DD - XATS 125 DD7) SV Safety Valve
DPec Drain Plug Engine Oil Cooler TB Towbar
DPft Drain Plug Fuel Tank VI Vacuum Indicator
DSe Engine Oil Level Dipstick VV Vacuator Valve
E Engine
EP Exhaust Pipe
F Fan
FCeo Filler Cap (engine oil)
FCft Filler Cap (fuel tank)

- 17 -
COMPRESSOR REGULATING SYSTEM

OVERVIEW

(VI) With generator 67 DDG 6.5 kVA

(AF) 67 DDG 12 kVA
(SVsr)
(RV) 97 DDG 6.5 kVA
Without generator
(FR)
(SV)
(VV)
(RV)
(SVuv)
(FR)
(SV)

(SL)
(PG)
(OS) (E) (OCce) (FP) (BDV)
(CV)
(SL)
(UA) With generator 97 DDG 12 kVA
(PG) (SR) (SVsr)
(UV) (RV)
(AR)
(FP) (BDV) (VH)
(CV) (FR)
(DB/C) (SV)
(AOV)
(OF)

(SL)
(TS)
(FN) (CE) (SL)
(OLG) (DP) (F) (PG)
(DP)
(FP) (BDV)
(CV)

- 18 -
Reference Name Reference Name
AF Air Filter PG Pressure Gauge
AOV Air Outlet Valves RV Regulating Valve
AR Air Receiver SL Scavenge Line
BDV Blow Down Valve SR Speed Regulator
C Coupling SV Safety Valve
(XAS 77 DD - XAS 150 DD7, SVsr Solenoid Valve (Speed regulator)
XAS 97 DD - XAS 185 DD7)
SVuv Solenoid Valve (Unloader valve)
CE Compressor Element
TS Temperature Switch
CV Check Valve
UA Unloader Assembly
DB Drive Belt
(XAS 67 DD - XAS 130 DD7, UV Unloader Valve
XATS 67 DD - XATS 125 DD7) VH Vent Hole
DP Drain Plug VI Vacuum Indicator
E Engine VV Vacuator Valve
F Fan
FN Flow Nozzle
FP Filler Plug
FR Flow Restrictor
OCce Oil Cooler (compressor element)
OF Oil Filter
OLG Oil Level Gauge
OS Oil Separator

- 19 -
AIR FLOW

Air drawn through the airfilter (AF) into the

compressor element (CE) is compressed. At the
element outlet, compressed air and oil pass into the air
receiver/oil separator (AR/OS).
(AF)
The check valve (CV) prevents blow-back of
compressed air when the compressor is stopped. In
the air receiver/oil separator (AR/OS), most of the oil
is removed from the air/oil mixture; the remaining oil
is removed by the separator element.
The oil collects in the receiver and on the bottom of
the separator element.
The air leaves the receiver via a flow nozzle (FN)
which prevents the receiver pressure from dropping
below the minimum working pressure (specified in
section Limitations), even when the air outlet valves
(OS)
are open. This ensures adequate oil injection and
prevents oil consumption.
A temperature switch (TS) and a working pressure
(PG) gauge (PG) are comprised in the system.
(AR)
(BDV) A blow-down valve (BDV) is fitted in the unloader
(CV) assembly to automatically depressurise the air
receiver (AR) when the compressor is stopped.

(TS)
(FN) (CE)

- 20 -
OIL SYSTEM

The lower part of the air receiver (AR) serves as oil

tank.
Air pressure forces the oil from the air receiver/oil
separator (AR/OS) through the oil cooler (OCce) and
oil filter (OF) to the compressor element (CE).
The compressor element has an oil gallery in the
bottom of its casing. The oil for rotor lubrication,
cooling and sealing is injected through holes in the
gallery.
(FR) Lubrication of the bearings is ensured by oil injected
into the bearing housings.
The injected oil, mixed with the compressed air,
leaves the compressor element and re-enters the air
receiver, where it is separated from the air as
(OS) (OCce) described in section Air flow. The oil that collects in
the bottom of the oil separator element is returned to
the system through a scavenging line (SL), which is
provided with a flow restrictor (FR).

(AR)
The oil filter by-pass valve opens when the pressure
drop over the filter is above normal because of a
clogged filter. The oil then by-passes the filter
without being filtered. For this reason, the oil filter
(OF) must be replaced at regular intervals (see section
Preventive maintenance schedule).
(SL)
When cold start equipment is installed, a thermostatic
(CE) valve will bypass the compressor oil (oil will not pass
through oil cooler OCce), until the working
temperature is reached.

- 21 -
CONTINUOUS PNEUMATIC REGULATING SYSTEM

With generator 67 DDG 6.5 kVA

(SVsr) 67 DDG 12 kVA
97 DDG 6.5 kVA
Without generator

(RV)
(SVuv)

(UA) With generator 97 DDG 12 kVA

(UV) (SR) (SVsr)
(AR)
(VH)

(CE)

- 22 -
The compressor is provided with a continuous
pneumatic regulating system. This system is provided
with a blow-down valve which is integrated in the
unloader assembly (UA). The valve is closed during
operation by outlet pressure of the compressor
element and opens by air receiver pressure when the
compressor is stopped.
When the air consumption increases, the air receiver
pressure will decrease and vice versa. This receiver
pressure variation is sensed by the regulating valve
which, by means of control air to the unloader,
matches the air output to the air consumption. The air
receiver pressure is maintained between the pre-
selected working pressure and the corresponding
unloading pressure.
When starting the compressor, the unloader valve
(UV) is kept open by spring force, the engine runs at
maximum speed. The compressor element (CE) takes
in air and pressure builds up in the receiver (AR).
The air output is controlled from maximum output
(100%) to no output (0%) by:
1. Speed control of the engine between maximum
load speed and unloading speed (the output of a
screw compressor is proportional to the rotating
speed).
2. Air inlet throttling.
If the air consumption is equal to or exceeds the
maximum air output, the engine speed is held at
maximum load speed and the unloading valve is fully
open.
If the air consumption is less than the maximum air
output, the regulating valve supplies control air to
unloader valve (UV) to reduce the air output and
holds air receiver pressure between the normal
working pressure and the corresponding unloading
pressure of approx. 1.5 bar (22 psi) above the normal
working pressure.
When the air consumption is resumed, the unloader
valve (UV) gradually opens the air intake and the
speed regulator (SR) increases the engine speed.
The construction of the regulating valve (RV) is such
that any increase (decrease) of the air receiver
pressure above the pre-set valve opening pressure
results in a proportional increase (decrease) of the
control pressure to the unloading valve and the speed
regulator.
Part of the control air is vented to the atmosphere, and
any condensate discharged, through the vent holes
(VH).
Generator
When the generator is switched on, the solenoid valve
(SVsr) via the speed regulator (SR) controls the
engine and allows it to reach maximum speed (the
normal control system is switched off).
The integrated solenoid valve (SVuv) makes it
possible to simultaneously use the compressor and
generator on the types XAS 67 DDG - XAS 130
DD7G (6.5 and 12 kVA) and XAS 97 DDG - XAS
185 DD7G (6.5 kVA).
- 23 -
ELECTRIC SYSTEM

CIRCUIT DIAGRAM (STANDARD) (9822 0991 32)

- 24 -
(Coldstart Option)

Reference Name Reference Name

F1 Circuit Breaker (10 A) V2 Diode
G1 Alternator X1 Connector
G2 Battery X3 Auxiliary Connection
H1 Temperature Alarm Lamp Y1 Fuel Solenoid Valve
H2 General Alarm Lamp
K0 Starter Solenoid (part of M1) The compressor is equipped with a negative earthed
K1 Relay Temperature Alarm system.
K2 Relay Temperature Alarm Hold
K3 Override Start Relay
K4 Relay
K5 Relay Heater Plug (coldstart
option)
M1 Starter Motor
N1 Starter Protection Relay
P1 Hourmeter
R1 Heater Plug (coldstart option)
S1 Contact Switch (Off-On-
Override-start)
S2 Temperature Switch Engine
S3 Oil Pressure Switch Engine
S4 Lamptest Switch
S5 Temperature Switch Compressor
S6 Coldstart Switch (coldstart
option)
V1 Diode

- 25 -
Operation of the electric circuit in detail

Start switch S1 position 2:

(K1) (K2) Line 3 on 12V (overwrite function) hourmeter P1 and
fuel solenoid Y1 excited. Thermocontact engine S2
normally closed, oil pressure contact S3 open.

Start switch S1 position 3:

(K3) (K4)
Start relay K0 is excited and starter motor is running,
engine builds up oil pressure and oil pressure contact
S3 closes. K3 excited and contact K3 changes over to
(30-87). Relay K2 no longer excited, contact K2
opens, lamp H1 goes out. Alternator also commences
supplying voltage and K4 is no longer excited and
contact K4 changes over to (30-87a). Lamp H2 goes
out, one can release start switch S1 and it returns to
position 1. Exciting the safety devices occurs no
longer across line 3 but across line 2 to line 4 and this
Start switch S1 position 1: way to line 3.
Line 2 on 12V contact K3 closed (30-87a), lamp H2
is on. K4 excites contact K4 (30-87). Thermocontact
element S5 normally closed, K1 excites contact K1
(30-87).

Use of lamp test:

Start switch S1 position 1 press lamp test S4, across
K3 and line 9 lamp H1 and relay K2 are excited. After
releasing lamp test button S4, lamp H1 remains on, S4
taken over by contact K2.

- 26 -
Engine is running normally:
Oil pressure contact S3 opens, K3 no longer excited.
K3 changes over (30-87a), engine cuts out because
fuel solenoid Y1 no longer excited and lamp H2 goes
on simultaneously.
Thermocontact S2 opens, K3 no longer excited. K3
changes over (30-87a), engine cuts out because fuel
solenoid Y1 no longer excited and lamp H2 goes on
simultaneously.
Thermocontact S5 opens, K1 no longer excited.
Contact K1 changes over (30-87a). K3 no longer
excited. K3 changes over (30-87a), engine cuts out
because fuel solenoid Y1 no longer excited and lamp
H2 and H1 go on simultaneously. Take-over relay K2
is excited simultaneously with H1 and contact K2
closes (30-87).
Thermocontact S5 cools off and closes, K1 excited
again and contact K1 changes over (30-87).
However, lamp H1 remains on across line 9 and
contact K2 (30-87).
A fault in the alternator part causes terminal D+ to go
to 0V and K4 to be excited. Contact K4 changes over
to (30-87), engine cuts out because fuel solenoid Y1
no longer excited and lamp H2 goes on
simultaneously.
N1 prevents the starter motor from being used when
the engine is running.

- 27 -
GENERATOR DDG 110V WITHOUT AUTOMATIC CONTROL SYSTEM

Circuit diagram (9822 1055 27) (Not on HardHat)

Reference Name
D1 Diode
X1 X2 X3
L1 L2 L1 L2 L1 L2
G3 Generator
32A 16A 16A H3 Lamp (Power ON)

2L1
2L2
1L1

1L2

3L1
3L2
e0 e0 e54 c0 c0 e54 c0 c0 e54 K5 Contactor
Q2 Q3 Q4
N13 Earth faultcurrent relay
32A 16A 16A
Q1 Main circuit breaker 2-pole
L1
e0 Q2 Circuit breaker 2-pole
L2
e0
Q3 Circuit breaker 2-pole
Q4 Circuit breaker 2-pole
e0 e0 e0 e0
1 3 5 7 S7 Switch (Generator-compressor)
K5 2 4 6 8
e0 e0 T13 Current transformer for N13
S7
f0 f0
b3 52 51
3
b3 X1 Socket outlet
W1
V1

N13 13
X2 Socket outlet
1 T13 4 1 34
b3 13 b3 b3
2 10
3
5 30mA
6 I n b3 14 To Circuit diagram X3 Socket outlet
4 40msec 11 13 13
7 3
D1A1 K5
9822 0797 01 Y2 Solenoid valve (Generator action)
Q1
b6 PR Y2 H3 35
12
A2
b6 B b6 b6 b6
50A
12 12 12 12

f0 f0
W
V

V W
G3
e54

EARTHING PIN
G
The compressor is equipped with a negative earthed
system.
For location of relais K1, K2, K3, K4, see paragraph
Electric system.

- 28 -
Operation of the electric circuit in detail
Compressor function:
See Circuit diagram (standard) (9822 0991 32)
(pages 24 and 26).

Generator function:
Turn switch S7 to position 1. The solenoid valve Y2
via the speed regulator controls the motor and allows
it to reach maximum speed (the normal control
system is switched off). Lamp H3 is activated and
sockets X1, X2, X3 are under tension.
The generator can be switched off by turning switch
S7 to position 0.
An insulation fault is detected when a leakage current
is flowing. Contactor K5 will no longer be exited
through the earth faultcurrent relay N13.

- 29 -
GENERATOR DDG 110V WITH AUTOMATIC CONTROL SYSTEM

Circuit diagram (9822 1055 91) (Not on HardHat)

Reference Name
D1 Diode
X1 X2 X3
L1 L2 L1 L2 L1 L2
E1 Ecologiser
32A 16A 16A
G3 Generator
1L1
1L2

2L1
2L2

3L1
3L2
e0 e0 e54 c0 c0 e54 c0 c0 e54
H3 Lamp (Power ON)
Q2 Q3 Q4
32A 16A
H4 Lamp automatic control system
16A
K5 Contactor
L1
L2
e0
E1 K7 Time relais
e0
K8 Time relais
7 6 5 4 3 2 1
N13 Earth faultcurrent relay
e0 e0 e0 e0
b6 b3 b3 b6 b3 Q1 Main circuit breaker 2-pole
9 11
1 3 5 7 H4
K5 2 4 6 8 S8
b3 b6
Q2 Circuit breaker 2-pole

3 4
e0 e0
b3 S7
3
Q3 Circuit breaker 2-pole
f0 f0 52 51 b3
b3 13 13 Q4 Circuit breaker 2-pole
W1

N13
V1

13 b3 b3
T13 34
1
2
4
5 30mA
1
10
b3 13 A1 K8
To Circuit S7 Switch (Generator-compressor)
3 6 I n
S8 Switch automatic control system
A2
4 7
40msec 11 b3 14 A1 K7 b3
b3
diagram
3 15
b3 A2 9822 0797 01
Q1
b6
12 D1
PR Y2
H3 35 T13 Current transformer for N13
A1 K5 B b6 b6 b6
50A
A2
b6
b6
12 12
b6
12 12 12
X1 Socket outlet
f0 f0
12 X2 Socket outlet
X3 Socket outlet
W
V

V W
G3
e54
Y2 Solenoid valve (Generator action)

EARTHING PIN
G
The compressor is equipped with a negative earthed
system.
For location of relais K1, K2, K3, K4, see paragraph
Electric system.

- 30 -
Operation of the electric circuit in detail
Compressor function:
See Circuit diagram (standard) (9822 0991 32)
(pages 24 and 26).

Generator function:
Turn switch S7 to position 1. The solenoid valve Y2
via the speed regulator controls the motor and allows
it to reach maximum speed (the normal control
system is switched off). Lamp H3 is activated. Time
relay K7 disconnects the sockets from the generator
during 4 sec, after which the sockets X1, X2, X3 are
under tension.
The generator can be switched off by turning switch
S7 to position 0.
If switch S7 is turned on, lamp H4 and ecologiser E1
are activated. E1 senses continuously the current to
the sockets. If no current is sensed, time relay K8 is
activated. This time relay deactivates the solenoid
valve Y2 so that the speed regulator is again
controlled by the normal compressor control system.
When in this condition E1 senses current to the
sockets, the solenoid valve Y2 is re-activated
immediately by K8. Time relay K7 disconnects the
sockets from the generator during 4 sec, after which
the sockets X1, X2, X3 are under tension.

- 31 -
GENERATOR DDG IT 230/400V, 6 kVA WITHOUT AUTOMATIC CONTROL SYSTEM

Circuit diagram (9822 1055 25) (Not on HardHat)

Reference Name
X1.2 X1.3 D1 Diode
X1.1
L2 L1
G3 Generator
16A
L3 N
L2 N L2 N
H3 Lamp (Power Control)
16A 16A
K5 Contactor/4-pole

L2

L2
L1
L2
L3

N
N

c0 c0 c0 c6 c54 c0 c6 c54 c0 c6 c54 K6 Insulation monitoring relay

Q1 Main circuit breaker 4-pole + shunt
tripcoil

1 3 5 7
S6 Thermalcontact
K5 2 4 6 8
S7 Switch (Generator-compressor)
C0 C0 C0 C6
S7 X1.1 Socket outlet
W1
U1
V1

b0 b3 3
16 52 51 b3
X1.2 Socket outlet
Q1 EA 34
b6 b0 b0 b3 b3 b3 b3 X1.3 Socket outlet
16 W1 16 13
10A 16A 10A 16A 13 13 13
To Circuit diagram Y2 Solenoid valve (Generator action)
K6 14 12 11 A1 9822 0797 01
H3 D1 K5
A1 PR Y2 35
N R<
b6 b6 A2
b0 R T PE L A2 b6 B b6 b6
W1 b54 b54 b6 12 12 12 12
b0
W1 12

b54
b0
N
W
U

N
V

U1 V1 W1 N
G3

S6 The compressor is equipped with a negative earthed

u system.
For location of relais K1, K2, K3, K4, see paragraph
Electric system.

- 32 -
Operation of the electric circuit in detail
Compressor function:
See Circuit diagram (standard) (9822 0991 32)
(pages 24 and 26).

Generator function:
Turn switch S7 to position 1. The solenoid valve Y2
via the speed regulator controls the motor and allows
it to reach maximum speed (the normal control
system is switched off). Lamp H3 is activated and
sockets X1.1, X1.2, X1.3 are under tension.
The generator can be switched off by turning switch
S7 to position 0.
In the case of an insulation fault, the yellow LED on
the insulation monitoring relay K6 of the system is
activated. When the yellow LED of K6 is active, a
reset can only occur by halting and restarting the
assembly.

- 33 -
GENERATOR DDG IT 230/400V, 6 kVA WITH AUTOMATIC CONTROL SYSTEM

Circuit diagram (9822 1055 90) (Not on HardHat)

Reference Name
D1 Diode
X1.1 X1.2 X1.3
L2 L1
E1 Ecologiser
16A L2 N L2 N
L3 N
16A 16A G3 Generator
H3 Lamp (Power Control)

L2
L2
L1
L2
L3

N
N
N

c0 c0 c0 c6 c54 c0 c6 c54 c0 c6 c54

H4 Lamp automatic control system
K5 Contactor/4-pole
E1 K6 Insulation monitoring relay
K7 Time relais
7 6 5 4 3 2 1
K8 Time relais
L1
L2
L3
N

c0 c0 c0 c6 b6 b3 b3 b6 b3

K5
1 3 5 7 9 11
b3 H4 b6
Q1 Main circuit breaker 4-pole + shunt
2 4 6 8
S8 tripcoil

3 4
C0 C0 C0 C6
S6 Thermalcontact
W1

S7
U1
V1

b3
N

b0 b3 3
16 52 51 b3

Q1
13
b3
13
b3 S7 Switch (Generator-compressor)
EA 34
b6
16
b0
W1
b0 b3
16 13
b3 A1 K7 A1 K8
To Circuit S8 Switch automatic control system
A2 15 A2
10A 16A 10A 16A
K6 14 12 11A1
13
b3 b3 b3 diagram X1.1 Socket outlet
H3 D1 K5 9822 0797 01
Y2
N R<
A1 PR
35 X1.2 Socket outlet
b6 b6 A2 B
R T PE L b6 b6 b6 b6 b6
X1.3 Socket outlet
b0 A2
W1 b54 b54 b6 12 12 12 12 12 12
b54
b0
12
Y2 Solenoid valve (Generator action)
N b0
W

W1
U

N
V

U1 V1 W1 N
G3

S6 The compressor is equipped with a negative earthed

u system.
For location of relais K1, K2, K3, K4, see paragraph
Electric system.

- 34 -
Operation of the electric circuit in detail
Compressor function:
See Circuit diagram (standard) (9822 0991 32)
(pages 24 and 26).

Generator function:
Turn switch S7 to position 1. The solenoid valve Y2
via the speed regulator controls the motor and allows
it to reach maximum speed (the normal control
system is switched off). Lamp H3 is activated. Time
relay K7 disconnects the sockets from the generator
during 4 sec, after which the sockets X1.1, X1.2, X1.3
are under tension.
The generator can be switched off by turning switch
S7 to position 0.
If switch S7 is turned on, lamp H4 and ecologiser E1
are activated. E1 senses continuously the current to
the sockets. If no current is sensed, time relay K8 is
activated. This time relay deactivates the solenoid
valve Y2 so that the speed regulator is again
controlled by the normal compressor control system.
When in this condition E1 senses current to the
sockets, the solenoid valve Y2 is re-activated
immediately by K8. Time relay K7 disconnects the
sockets from the generator during 4 sec, after which
the sockets X1, X2, X3 are under tension.

- 35 -
GENERATOR DDG IT 230V, 6 kVA

Circuit diagram (9822 1055 26) (Not on HardHat)

Reference Name
X1.2 X1.3 D1 Diode
X1.1
L1 G3 Generator
L2 L1 L2 L1 L2
L3
16A 16A
H3 Lamp (Power Control)
32A
K5 Contactor/4-pole

1L1
1L2

L1
L2
L1
L2
L3

c0 c0 c0 e54 c0 c0 c54 c0 c0 c54 K6 Insulation monitoring relay

L1 c0
L2 c0
Q1 Main circuit breaker 4-pole + shunt
tripcoil
S6 Thermalcontact
1 3 5
K5 2 4 6 S7 Switch (Generator-compressor)
c0 c0 c0
S7 X1.1 Socket outlet
1W1
1U1
1V1

b0 3
16 52 51 b3 X1.2 Socket outlet
Q1 EA
b0 b0 b3 b3 b3 b3
34 X1.3 Socket outlet
16A 16A 16A V1 16 13 13 13 13
To Circuit diagram Y2 Solenoid valve (Generator action)
b6 K6 9822 0797 01
14 12 11 A1 H3 D1 K5
b0
W1 A1 P R Y2 35
b0 R< A2
16 b6 b6 B b6 b6
V1 R T PE L A2
b0 12 12 12 12
b54 b54 b6
V1
b54 12

b0
c0 c0 c0 W1
W1
U1
V1

G3 U1 V1 W1

W2 U2 V2

S6 The compressor is equipped with a negative earthed

u system.
For location of relais K1, K2, K3, K4, see paragraph
Electric system.

- 36 -
Operation of the electric circuit in detail
Compressor function:
See Circuit diagram (standard) (9822 0991 32)
(pages 24 and 26).

Generator function:
Turn switch S7 to position 1. The solenoid valve Y2
via the speed regulator controls the motor and allows
it to reach maximum speed (the normal control
system is switched off). Lamp H3 is activated and
sockets X1.1, X1.2, X1.3 are under tension.
The generator can be switched off by turning switch
S7 to position 0.
In the case of an insulation fault, the yellow LED on
the insulation monitoring relay K6 of the system is
activated. When the yellow LED of K6 is active, a
reset can only occur by halting and restarting the
assembly.

- 37 -
GENERATOR DDG IT 230/400V, 12 kVA WITHOUT AUTOMATIC CONTROL SYSTEM

Circuit diagram (9822 1055 28) (Not on HardHat)

Reference Name
D1 Diode
L2 L1
X1.1 X1.2 X1.3 G3 Generator
L2 L1
16A
L3 N
16A
L3 N
L3 N
H3 Lamp (Power Control)
16A
K5 Contactor/4-pole
L1
L2
L3

L1
L2
L3

L2
N

N
c0 c0 c0 c6 c54 c0 c0 c0 c6 c54 c0 c6 c54 K6 Insulation monitoring relay
Q1 Main circuit breaker 4-pole + shunt
tripcoil
S6 Thermalcontact

K5
1 3 5 7 S7 Switch (Generator-compressor)
2 4 6 8
X1.1 Socket outlet
W1

S7
U1
V1

b0 3
C0 C0 C0 C6 16 52 51 b3 X1.2 Socket outlet
Q1 EA
b6 b0 b0 b3 b3 b3 b3
34 X1.3 Socket outlet
W1 16 13
16A 16A 16A 16A
16
13 13 13 To Circuit diagram Y2 Solenoid valve (Generator action)
K6 14 12 11A1
H3 D1 K5 9822 0797 01
A1 PR Y2 35
N R<
A2
b6 b0 R T PE L A2 b6 b6 B b6 b6
W1 b54 b54 b6 12 12 12 12
b0
W1 12

b54
b0
C0 C0 C0 C6 N
W
U

N
V

U1 V1 W1 N
G3

S6 The compressor is equipped with a negative earthed

u system.
For location of relais K1, K2, K3, K4, see paragraph
Electric system.

- 38 -
Operation of the electric circuit in detail
Compressor function:
See Circuit diagram (standard) (9822 0991 32)
(pages 24 and 26).

Generator function:
Turn switch S7 to position 1. The solenoid valve Y2
via the speed regulator controls the motor and allows
it to reach maximum speed (the normal control
system is switched off). Lamp H3 is activated and
sockets X1.1, X1.2, X1.3 are under tension.
The generator can be switched off by turning switch
S7 to position 0.
In the case of an insulation fault, the yellow LED on
the insulation monitoring relay K6 of the system is
activated. When the yellow LED of K6 is active, a
reset can only occur by halting and restarting the
assembly.

- 39 -
GENERATOR DDG IT 230/400V, 12 kVA WITH AUTOMATIC CONTROL SYSTEM

Circuit diagram (9822 1055 92) (Not on HardHat)

Reference Name
D1 Diode
L2 L1
X1.1
L2 L1
X1.2 X1.3 E1 Ecologiser
16A 16A
L3 N L3 N
16A
L3 N
G3 Generator
H3 Lamp (Power Control)

L2
L1
L2
L3
L1
L2
L3

N
N
N

c0 c0 c0 c6 c54 c0 c0 c0 c6 c54 c0 c6 c54 H4 Lamp automatic control system

K5 Contactor/4-pole
E1 K6 Insulation monitoring relay
K7 Time relais
1 3 5 7
7 6 5 4 3 2 1 K8 Time relais
K5 b6 b3 b3 b6 b3
2 4 6 8
Q1 Main circuit breaker 4-pole + shunt
W1
U1
V1

9 11 H4
tripcoil
N

b3 b6
b0
S8

3 4
16
Q1
C0 C0 C0 C6
b3 S7 S6 Thermalcontact
EA
3
b6
16
b0
W1
b0 b3
16 13 13 13 52 51 b3 S7 Switch (Generator-compressor)
b3 b3
16A 16A 16A 16A
K6 14 12 11 A1 b3 A1 K7 A1 K8
34
S8 Switch automatic control system
To Circuit
N R< 13 b3 A2
15
b3 b3
A2
diagram X1.1 Socket outlet
b6 b0 R T PE L A2 D1 9822 0797 01
W1
b0
b54 b54 b6 H3 A1 K5 PR Y2 35
X1.2 Socket outlet
12
X1.3 Socket outlet
W1 b6 A2
b6 b6 B b6 b6 b6
12 12 12 12 12 12
b54
b0
Y2 Solenoid valve (Generator action)
C0 C0 C0 C6 N
W
U

N
V

U1 V1 W1 N
G3

S6 The compressor is equipped with a negative earthed

u system.
For location of relais K1, K2, K3, K4, see paragraph
Electric system.

- 40 -
Operation of the electric circuit in detail
Compressor function:
See Circuit diagram (standard) (9822 0991 32)
(pages 24 and 26).

Generator function:
Turn switch S7 to position 1. The solenoid valve Y2
via the speed regulator controls the motor and allows
it to reach maximum speed (the normal control
system is switched off). Lamp H3 is activated. Time
relay K7 disconnects the sockets from the generator
during 4 sec, after which the sockets X1.1, X1.2, X1.3
are under tension.
The generator can be switched off by turning switch
S7 to position 0.
If switch S7 is turned on, lamp H4 and ecologiser E1
are activated. E1 senses continuously the current to
the sockets. If no current is sensed, time relay K8 is
activated. This time relay deactivates the solenoid
valve Y2 so that the speed regulator is again
controlled by the normal compressor control system.
When in this condition E1 senses current to the
sockets, the solenoid valve Y2 is re-activated
immediately by K8. Time relay K7 disconnects the
sockets from the generator during 4 sec, after which
the sockets X1.1, X1.2, X1.3 are under tension.

- 41 -
GENERATOR DDG IT 230V, 12 kVA

Circuit diagram (9822 1055 29) (Not on HardHat)

Reference Name
D1 Diode
L1
X1.1 X1.2 X1.3 G3 Generator
L2
L3
L1 L2 L1 L2
H3 Lamp (Power Control)
16A 16A
32A
K5 Contactor/4-pole

1L1
1L2

1L1
1L2
Q2
L1
L2
L3

e0 e0 e0 e54 c0 c0 c54 c0 c0 c54 K6 Insulation monitoring relay

L1 c0 16A Q1 Main circuit breaker 3-pole + shunt
L2 c0 16A tripcoil
1 3 5
Q2 Circuit breaker 2-pole
K5 2 4
e0 e0 e0
6
S6 Thermalcontact
S7 S7 Switch (Generator-compressor)
1W1
1U1
1V1

b0 3

Q1
16 52 51 b3
X1.1 Socket outlet
EA
b0 b0 b3 b3 b3 b3
34
X1.2 Socket outlet
To Circuit diagram
32A 32A 32A V1 16 13 13 13 13 X1.3 Socket outlet
b6 K6 14 12 11 A1 H3 D1 K5
9822 0797 01
b0
W1 A1 PR Y2
35
Y2 Solenoid valve (Generator action)
b0 R< A2
16 b6 b6 B b6 b6
V1 R T PE L A2
b0 12 12 12 12
b54 b54 b6
V1
12
b54
b0
e0 e0 e0 W1
W1
U1
V1

G3 U1 V1 W1

W2 U2 V2

S6 The compressor is equipped with a negative earthed

u system.
For location of relais K1, K2, K3, K4, see paragraph
Electric system.

- 42 -
Operation of the electric circuit in detail
Compressor function:
See Circuit diagram (standard) (9822 0991 32)
(pages 24 and 26).

Generator function:
Turn switch S7 to position 1. The solenoid valve Y2
via the speed regulator controls the motor and allows
it to reach maximum speed (the normal control
system is switched off). Lamp H3 is activated and
sockets X1.1, X1.2, X1.3 are under tension.
The generator can be switched off by turning switch
S7 to position 0.
In the case of an insulation fault, the yellow LED on
the insulation monitoring relay K6 of the system is
activated. When the yellow LED of K6 is active, a
reset can only occur by halting and restarting the
assembly.

- 43 -
CIRCUIT DIAGRAM REFINARY EQUIPMENT 9822 0909 00 (ALL TYPES)

0
1
S1 2
12V DC 3 1
10A 5 2 2
3 3 30 K3
F1
4 4 87 87a

S5 87a
30 u
K4 30
87 87a
K9
30 87
86
3A K0
K4 86 2 8 3 3 9 9 9 11 30

85
6 S2 87a
G2 G1 20 u
B+ V1 30
D+ 7
3 4 1 8 13
D- W
S3 87a
p
N1 2 5 6 7 30

21 22 23 14
P1 M1
K9 86 K0 Y1 86 K3 86 86 K2 H1 H2 K1 86
V2
h M
85 85 85 85 85
S32 87 Y20 86 15 10
30 87 87a
85
30 K1 K2 30 87 S4
87 30
12 12 12 12 12 12 12 12 12 12 12 12

- 44 -
Reference Name
F1 Circuit Breaker (10 A)
G1 Alternator
G2 Battery
H1 Temperature Alarm Lamp
H2 General Alarm Lamp
K0 Starter Solenoid (part of M1)
K1 Shut-down Relay
K2 Blocking Relay
K3 Override Start Relay
K4 Start Relay
K9 Auxilary Relay Safety Circuit
M1 Starter Motor
N1 Overspeed Module
P1 Hourmeter
S1 Contact Switch (Off-On-
Override-start)
S2 Temperature Switch Engine
S3 Oil Pressure Switch Engine
S4 Temperature Lamptest Switch
S5 Temperature Switch Compressor
S32 Test Button Overspeed
Y1 Fuel Solenoid Valve
Y20 Solenoid for Overspeed
Protection Valve
V1 Diode
V2 Diode

- 45 -
MARKINGS AND INFORMATION LABELS
Manual override switch. Warning! Part under pressure.
Compressor outlet temperature too
high.
Hours, time. Do not stand on outlet valves.

Compressor outlet temperature.

Prohibition to open air valves without
Start-Stop indication of switch.
connected hoses.
Compressor outlet pressure.
Do not run the compressor with open
Compressor loaded.
doors.
Danger, outlet gases.
Runlamp. Lifting device.
Danger, hot surface.
Airfilter. Use diesel fuel only.
Electrocution hazard.
2.7 bar
Compressor temperature too high. (39 psi)
Tyre pressure.
Atlas Copco mineral compressor oil.
Sound power level in accordance
Atlas Copco synthetic compressor oil. Rotation direction. with Directive 2000/14/EC
(expressed in dB (A)).
Sound power level in accordance
Atlas Copco mineral engine oil.
Inlet. with Directive 2000/14/EC
(expressed in dB (A)).
Atlas Copco synthetic engine oil.
Horizontal towbar position required in
Outlet.
case of coupling.
Manual.

Compressor oil drain. Earthing connections.

Read the instruction manual before
working on the battery.
Read the instruction manual before 0 = OFF
Generator
Reset fuse. starting. 1 = ON

On / off button. Service every 24 hours. Insulation fault.

- 46 -
Operating instructions
PARKING, TOWING AND LIFTING
INSTRUCTIONS
Safety precautions
The operator is expected to apply all
relevant Safety precautions (generator).
Attention
Before putting the compressor in to use,
check the brake system as described in
section Brake shoe adjustment.
After the first 100 km travel:
Check and retighten the wheel nuts and
towbar bolts to the specified torque. See
section Compressor / engine
specifications.
Check the brake adjustment. See section
Brake shoe adjustment.
PARKING INSTRUCTIONS
(2)
(2)
(A)
(1)
(B)
Non-adjustable towbar with standard support leg without (A) Parking position of jockey wheel (adjustable towbar)
brakes (B) Rear-end of compressor upwind
When parking a compressor, secure support leg (1) or
jockey wheel (2) to support the compressor in a level
position. Be sure that the jockey wheel (2) is blocked
(3)
by the blocking pin (4).
Apply parking brake by pulling parking brake handle
(3) upwards. Place the compressor as level as
possible; however, it can be operated temporarily in
an out-of-level position not exceeding 15°. If the
compressor is parked on sloping ground, immobilize
the compressor by placing wheel chocks (available as
option) in front of or behind the wheels. Locate the
(4) rear-end of the compressor upwind, away from
(2)
contaminated wind-streams and walls. Avoid
recirculation of exhaust air from the engine. This
causes overheating and engine power decrease.
Adjustable towbar with jockey wheel and brakes
- 47 -
TOWING INSTRUCTIONS
Label on towbar, towing instructions
Before towing the compressor, ensure
that the towing equipment of the vehicle
matches the towing eye or ball
connector, and ensure that the hood is
closed and locked properly.
(3)
(4)
(4)
(1) (2)
Non-adjustable towbar with standard support leg without Adjustable towbar with jockey wheel and brakes
brakes
For both non-adjustable - and adjustable towbar, the
towbar should be as level as possible and the
compressor and towing eye end in a level position.
Push the hand brake lever (3) completely downwards
and connect breakaway cable (4) to the vehicle.
Secure jockey wheel (2) or support leg (1) in the
highest possible position. The jockey wheel is
prevented from turning.
(2)
(2)
Towing position of jockey wheel
- 48 -
HEIGHT ADJUSTMENT SPILLAGE-FREE INSTRUCTION
(with adjustable towbar)
• Remove spring pin (1). This compressor is fitted with a leak-proof
• Release locking nut (2). undercarriage in order to protect the environment.
(B) Any leaking fluid is collected in case of malfunctions.
• Adjust required height of the towbar.
This fluid can be removed via outlets, normally
(A) • Tighten locking nut (2) by hand. secured by caps.
(3) • Secondly tighten locking nut (2) with a tightening Tighten the caps firmly and check for leakages.
(2) torque corresponding to table. With an extension
Please observe the locally applicable environmental
tube (3) (”A” corresponding to table) and
handforce (”B” corresponding to table) easy regulations when removing the leaking liquid.
(1)
tightening is possible.
• Fix locking nut (2) with spring pin (1).
X
XX

Attention:

• Height adjustment should be undertaken on

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

For specific instruction see below!

Type (XXX) M [Nm/lbf.ft.] ”A” [mm/in] ”B” [N/lbf]

ZV 2000 250 - 300 / 185 - 220 600 / 23.4 420 - 500 / 95 - 110
ZV 2500 350 - 400 / 260 - 295 600 / 23.4 580 - 660 / 130 - 145

- 49 -
INSTRUCTIONS 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 jockey wheel
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
handbrake lever may never be used as a
manoeuvring aid; internal components
may get damaged!
The coupling (ball coupling) on the tow bar is type
approved. The maximum load at the coupling may not
be exceeded.
When coupling lower the jockey wheel to the ground.
Reverse the car up to the compressor or, in the case of
a small compressor, manoeuvre the compressor up to
the car's trailer coupling.
Lower the jockey wheel. Disconnect breakaway cable
and electrical plug. Pull the lever vigorously upwards
in the direction of the arrow and hold. Wind down
jockey wheel (option) and lift the compressor off the
ball of the towing vehicle.
Secure the compressor by means of a wheel chock
and/or by applying the parking brake.
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 after opening the small
door (1).
Lifting acceleration and retardation
must be kept within safe limits (max.
2xg).
Helicopter lifting is not allowed.
Lifting is not allowed when the unit is
running.

- 50 -
DIESEL PARTICLE FILTER (OPTION)
(1) (2) (3)
(6) (5) (4)
In order to be able to comply with local regulations
regarding exhaust gas, the machine can be equipped
with a diesel particle filter with control unit and
display.
When a diesel particle filter is installed,
only use diesel with less than 50 ppm
sulphur.
This display (1) is especially designed for off-road
machinery operated under severe conditions and is
integrated into the unit's control panel.
The display has three LED bars, the upper bar (2) for
temperature indication, the middle bar (3) for
pressure indication and the bottom bar (4) for alarms.
A triangle shaped general alarm LED (6) and an
acknowledge sensor (5) complete the display.
The pressure and temperature indicating LEDs are
controlled by parameters stored in a data logger unit.
AFTERCOOLER (OPTION)
After starting, the LEDs of the temperature and
pressure bar will change from red via yellow to green,
starting from the left. Yellow and finally red
indicators on the right side of the bars will indicate
rising values. Clogging of the filter will be indicated
first by LED's and secondly by a buzzer.
The particle filter is self-cleaning up to a certain
degree. When backpressure rises, increasing engine
load will result in a temperature rise so the soot will
burn and subsequently backpressure will be lowered.
Using low SAP oil (less sulphur) will create longer
intervals between cleanings.
In the bottom bar (4), alarms will be displayed while
an additional LED will submit additional information (1)
in respect to temperature or backpressure.
In case of an alarm, a triangle shaped LED (6) will The aftercooler option also includes a by-pass valve
start flashing. By just touching the sensor (5) the error (1) when operating at ambient temperatures below
will be acknowledged and the LED will be off. 10° C (50° F). The by-pass valve has to be open in
In case an alarm is only acknowledged, without any order to prevent the system from freezing. Frost can
actions taken to eliminate the problem, the alarm will damage the aftercooler.
be repeated two more times at intervals of 10 minutes.
After the third acknowledgement the triangle shaped
LED will be off while the corresponding alarm LED
is continuously lighted.
A sounding buzzer in combination with the yellow
LED lit at the right of the pressure bar (3) means that
the machine has to be switched to full until the alarm
is off.
For Error Codes refer to the paragraph Problem
solving.
It is recommended to operate the
machine at full load for at least 25% of a
daily shift, in order to prevent clogging
of the particle filter.
- 51 -
ANTI-FROST DEVICE (OPTION)
(1)
The anti-frost device consist of a manualy operated
by-pass valve (1) on the oil cooler to prevent freezing
of the pneumatic tools at low ambient temperatures
(partial by-pass).
As soon as the ambient temperature drops below
20° C (68° F) it is recommended to open the valve and
by-pass the oil cooler. The outlet air temperature will
increase with 13 - 16° C (23 - 29° F) and condensation
in the air will be reduced.
It is also recommend to use the by-pass valve in case
the compressor is used at partial load for a long time.
STARTING / STOPPING
BEFORE STARTING
1. Before initial start-up, prepare battery for
operation if not already done. See section
Recharging a battery.
2. With the compressor standing level, check the
level of the engine oil. Add oil, if necessary, to the
upper mark on dipstick. Consult the Engine
Operation Manual for type and viscosity grade of
the engine oil.
3. Check the level of the compressor oil. The pointer
of oil level gauge (OLG) should register in the
green range. Add oil if necessary. See section Oil
level check for the oil to be used.
Before removing oil filler plug (FP),
ensure that the pressure is released by 5. In case of start up of the unit, after running out of
opening an air outlet valve. fuel, pump up the fuel manually with the fuel hand
pump before starting.
4. Check that the fuel tank contains sufficient fuel. 6. Drain any water and sediment from the fuel filters
Top up, if necessary. Consult the Engine until clean fuel flows from the drain cock.
Operation Manual for the type of fuel.
7. Drain leaking fluid from the frame.
8. Press vacuator valves (VV) of the air filter to
remove dust.
9. Check the air filter vacuum indicators (VI). If the
yellow piston reaches the red marked service
range, replace the filter element. Reset the
indicator by pushing the reset button.
10. Open air outlet valve to allow air flow to the
atmosphere.
- 52 -
STARTING PROCEDURE (WITH COLD START; OPTION)

The control panel indicates receiver

(P1) (PG) (H1) (F1) (S1) (S4) pressure (PG) and accumulated
operating hours (P1).

Before starting open the air outlet valve(s) (AOV) and

push circuit breaker button (F1) once (open hood
first). Circuit breaker button should now be in
position B.

(F1)

A
(H2) (S6)
B

Reference Name
P1 Hourmeter
F1 Circuit breaker button
PG Working pressure gauge
H1 Temperature alarm lamp (red)
H2 General alarm lamp (red)
S1 Start switch The circuit breaker button is a
protection against unintended starting
S4 Lamp test button
of the compressor.
S6 Cold start button
To preheat if necessary push the cold start button S6
for a short period.

- 53 -
Starting procedure

1 2 3 4 5 6

1. Open air outlet valve. The temperature alarm lamp H1 and the general
alarm lamp H2 will go out as soon as the engine
2. Press circuit breaker F1. For cold start press
button S6. has been started.
The start switch automatically springs back to
3. Turn start switch S1 clockwise to position 1, lamp
H2 (general alarm lamp) will go on. position 1.
Lamp H1 only will go on when the compressor
4. Check correct operation of alarm lamps H1 and
H2 by pushing lamp test button S4. Both alarm outlet temperature is too high.
lamps (red) should go on. 6. Close the air outlet valve(s) (AOV).
5. Turn start switch S1 further clockwise into
position 3.
The starter motor will set the engine in motion.
The maximum allowed starter time, where the
starter motor is running continuously is 20
seconds.
If the engine does not catch, a new attempt can be
made after 30 seconds waiting.

- 54 -
STARTING PROCEDURE (WITHOUT COLD START)

The control panel indicates receiver

(P1) (PG) (H1) (F1) (S1) pressure (PG) and accumulated
operating hours (P1).

Before starting open the air outlet valve(s) (AOV) and

push circuit breaker button (F1) once (open hood
first). Circuit breaker button should now be in
position B.

(F1)

A
(H2) (S4)
B

Reference Name
P1 Hourmeter
F1 Circuit breaker button
PG Working pressure gauge
H1 Temperature alarm lamp (red)
H2 General alarm lamp (red)
S1 Start switch The circuit breaker button is a
protection against unintended starting
S4 Lamp test button
of the compressor.

- 55 -
Starting procedure

1 2 3 4 5 6

1. Open air outlet valve. The temperature alarm lamp H1 and the general
alarm lamp H2 will go out as soon as the engine
2. Press circuit breaker F1.
has been started.
3. Turn start switch S1 clockwise to position 1, lamp
The start switch automatically springs back to
H2 (general alarm lamp) will go on.
position 1.
4. Check correct operation of alarm lamps H1 and
Lamp H1 only will go on when the compressor
H2 by pushing lamp test button S4. Both alarm
lamps (red) should go on. outlet temperature is too high.
6. Close the air outlet valve(s) (AOV).
5. Turn start switch S1 further clockwise into
position 3.
The starter motor will set the engine in motion.
The maximum allowed starter time, where the
starter motor is running continuously is 20
seconds.
If the engine does not catch, a new attempt can be
made after 30 seconds waiting.

- 56 -
DURING OPERATION
When the engine is running, the air
outlet valves (ball valves) must always be
put in a fully opened or fully closed
position.
The hood must be closed during
operation and may be opened for short
periods only.
Regularly carry out following checks:
1. That the regulating valve (RV) is correctly
adjusted, i.e. starts decreasing the engine speed
when reaching the preset working pressure in the
receiver.
2. Check the air filter vacuum indicators (VI). If the
yellow piston reaches the red marked service
range, replace the filter element. Reset the
indicators by pushing the reset button.
3. On compressors with aftercooler, check that the
automatic drain of the water separator is operative
without air leakage.
STOPPING PROCEDURE FAULT SITUATIONS AND PROTECTIVE
DEVICES
• A fault which occurs with the engine, either: oil
pressure (too low), oil temperature (too high) or
alternator voltage (too low) will always and
3 min immediately cause the engine to cut out and the
control lamp H2 will light up. By doing some
simple checks, it can be determined what it was
1 2 3 4 that caused the engine to fail: low oil level,
clogged-up cooler, slack alternator belt tension or
broken belt.
1. Close the air outlet valves (AOV).
• When the outlet temperature of the element
2. Run unloaded for 3 minutes. becomes too high, a thermocontact will also
3. Turn the start switch S1 counterclockwise (CCW) switch off the group immediately. Both control
to position 0. lamps H1 and H2 will light up. Both control lamps
will remain on until the group has been restarted
4. Push the circuit breaker button (F1) once (open (start switch to position 3) or the contact is turned
hood first). Circuit breaker button should now be off (start switch to position 0); also when, due to
in position A. cooling off, the thermocontact has closed again (=
memory function).
(F1)
A
B
- 57 -
FUNCTIONAL DESCRIPTION OF GENERATOR (OPTION)

DDG 110V WITHOUT AUTOMATIC CONTROL SYSTEM

min 400
(X1) (X2) (X3) (H3/S7) (GND)

Control panel (generator) Earth pin Generator control box

H3 Lamp (green, power ON) Start the unit in accordance with the normal Q1 Main circuit breaker 2-pole
S7 Switch (generator - compressor) procedure (see section Starting / Stopping). Let the Q2 Circuit breaker 2-pole
motor warm up until it reaches operational
X1 Socket 110 V/ 32 A Q3 Circuit breaker 2-pole
temperature. Turn the green switch S7 to position 1.
X2 Socket 110 V/ 16 A Q4 Circuit breaker 2-pole
X3 Socket 110 V/ 16 A The normal control system is switched off and the
motor speed increases to reach the maximum. Before connecting an electrical device,
GND Terminal earth cable
The green lamp H3 in the switch S7 is activated, always check the data listed on the rating
Before switching on the generator, showing that sockets X1, X2 and X3 are under plate.
always place the earth pin in position. tension.
Check the cable connection between The generator can be switched off by turning the
earth pin and the GND-terminal on the Protective device
green switch S7 to position 0.
unit. The generator is protected by circuit breakers that
Avoid high inductive loads (e.g. switch off if a connected electrical device has an
welding). High inductive loads can electrical fault.
damage the generator.

- 58 -
DDG 110V WITH AUTOMATIC CONTROL SYSTEM (OPTION)

Operation with automatic control switch S8

“OFF”
• Switch generator main switch S7 “ON”.
• Generator is disconnected from socket.
• Engine reaches nominal speed.

min 400
• Generator is re-connected after 4 secs.
• Power is now available until the generator main
switch S7 is turned “OFF”.
(X1) (X2) (X3) (H4/S8) (H3/S7) (GND)
Operation with automatic control switch S8
“ON”
• Switch generator main switch S7 “ON”.
Control panel (generator) Earth pin • Generator is disconnected from socket.
• Engine reaches nominal speed.
H3 Lamp (green, power ON) As soon as the generator is switched on, the automatic
control system will continuously check for electric • Generator is re-connected after 4 secs.
S7 Switch (generator - compressor)
H4 Lamp automatic control system load in order to rev up the engine from idle to nominal • If a consumer is connected, the engine goes on for
speed only when needed. This saves fuel and reduces 60 secs. before falling back to idle speed.
S8 Switch automatic control system emissions.
X1 Socket 110 V/ 32 A • Generator is in standby. As soon as any consumer
What is more, with the current continuously is switched on, the routine is repeated from step 2.
X2 Socket 110 V/ 16 A
monitored, a consumer having just been switched on
X3 Socket 110 V/ 16 A is temporary disconnected from the generator to be
GND Terminal earth cable re-connected as soon as the engine reaches nominal
speed. This is a safety mechanism to protect generator
Before switching on the generator, and engine below nominal speed.
always place the earth pin in position.
Check the cable connection between Avoid high inductive loads (e.g.
earth pin and the GND-terminal on the welding). High inductive loads can
unit. damage the generator.

- 59 -
 DDG 230/400V AND 230V - 3PH WITHOUT AUTOMATIC CONTROL SYSTEM

(X1.1) (X1.2) (X1.3) (H3/S7) (GND)

Generator control box Control panel (generator) Generator control box

Q1 Main circuit breaker 2-pole Generator DDG 230/400V: Generator DDG 230/400V:
Q2 Circuit breaker 2-pole S7 Switch Q1 Main circuit breaker 4-pole + shunt trip coil
Q3 Circuit breaker 2-pole H3 Lamp (green) K6 Insulation monitoring relay
Q4 Circuit breaker 2-pole X1.1 Socket 400 V/ 16 A
X1.2 Socket 230 V/ 16 A* Generator DDG 230V:
Before connecting an electrical device, X1.3 Socket 230 V/ 16 A Q1 Main circuit breaker 3-pole + shunt trip coil
always check the data listed on the rating GND Terminal earth cable
plate. Q2 Circuit breaker 2-pole (for 12.5 kVA only)
K6 Insulation monitoring relay
Generator DDG 230V:
Protective device S7 Switch
Before connecting an electrical device,
The generator is protected by circuit breakers that H3 Lamp (green) always check the data listed on the rating
switch off if a connected electrical device has an X1.1 Socket 230 V/ 16 A** plate.
electrical fault. X1.2 Socket 230 V/ 16 A
X1.3 Socket 230 V/ 16 A * For 6 kVA.
GND Terminal earth cable For 12.5 kVA: Socket 400V / 16A.
** For 6 kVA.
For 12.5 kVA: socket 230V / 32A.

- 60 -
 DDG 230/400V AND 230V - 3PH WITH AUTOMATIC CONTROL SYSTEM (OPTION)

Start the unit in accordance with the normal Generator DDG 230V:
procedure (see section Starting / Stopping). Let the H3 Lamp (green, power ON)
motor warm up until it reaches operational S7 Switch (generator - compressor)
temperature. Turn the green switch S7 to position 1.
H4 Lamp automatic control system
The normal control system is switched off and the S8 Switch automatic control system
engine speed increases to reach the maximum. X1.1 Socket 230 V/ 16 A**
The green lamp H3 in the switch S7 is activated, X1.2 Socket 230 V/ 16 A
showing that sockets X1.1, X1.2 and X1.3 are under X1.3 Socket 230 V/ 16 A
tension.
GND Terminal earth cable
The generator can be switched off by turning the (X1.1) (X1.2) (X1.3) (H4/S8) (H3/S7) (GND)
green switch S7 to position 0.
* For 6 kVA.
For 12.5 kVA: Socket 400V / 16A.
Protective device
Control panel (generator) ** For 6 kVA.
The generator is protected by circuit breakers that For 12.5 kVA: socket 230V / 32A.
switch off if a connected electrical device has an
electrical fault. Generator DDG 230/400V:
H3 Lamp (green, power ON)
The insulation is monitored by relay K6. As soon as the generator is switched on, the automatic
S7 Switch (generator - compressor) control system will continuously check for electric
When the yellow LED on the insulation monitoring H4 Lamp automatic control system load in order to rev up the engine from idle to nominal
relay K6 is activated, it means that a serious insulation S8 Switch automatic control system speed only when needed. This saves fuel and reduces
fault has occured. emissions.
X1.1 Socket 400 V/ 16 A
The insulation monitoring relay K6 is adjusted to X1.2 Socket 230 V/ 16 A* What is more, with the current continuously
10 kΩ. This adjustment may not be changed. X1.3 Socket 230 V/ 16 A monitored, a consumer having just been switched on
The generator temperature is monitored by a thermal GND Terminal earth cable is temporary disconnected from the generator to be
contact (S6). re-connected as soon as the engine reaches nominal
speed. This is a safety mechanism to protect generator
Avoid high inductive loads (e.g. and engine below nominal speed.
welding). High inductive loads can
damage the generator.

- 61 -
Operation with automatic control switch S8 Protective device
“OFF” The generator is protected by circuit breakers that
• Switch generator main switch S7 “ON”. switch off if a connected electrical device has an
electrical fault.
• Generator is disconnected from socket.
The insulation is monitored by relay K6.
• Engine reaches nominal speed.
When the yellow LED on the insulation monitoring
• Generator is re-connected after 4 secs. relay K6 is activated, it means that a serious insulation
• Power is now available until the generator main fault has occured.
switch S7 is turned “OFF”. The insulation monitoring relay K6 is adjusted to
10 kΩ. This adjustment may not be changed.
Operation with automatic control switch S8
“ON” The generator temperature is monitored by a thermal
contact (S6).
• Switch generator main switch S7 “ON”.
• Generator is disconnected from socket. Generator control box Avoid high inductive loads (e.g.
welding). High inductive loads can
• Engine reaches nominal speed. damage the generator.
Generator DDG 230/400V:
• Generator is re-connected after 4 secs.
Q1 Main circuit breaker 4-pole + shunt trip coil
• If a consumer is connected, the engine goes on for K6 Insulation monitoring relay
60 secs. before falling back to idle speed.
• Generator is in standby. As soon as any consumer Generator DDG 230V:
is switched on, the routine is repeated from step 2. Q1 Main circuit breaker 3-pole + shunt trip coil
Q2 Circuit breaker 2-pole (for 12.5 kVA only)
K6 Insulation monitoring relay

Before connecting an electrical device,

always check the data listed on the rating
plate.

- 62 -
Maintenance
PREVENTIVE MAINTENANCE SCHEDULE USE OF SERVICE PAKS
Unauthorised modifications can result in
injuries or machine damage. The schedule contains a summary of the maintenance Service Paks include all genuine parts needed for
instructions. Read the respective section before taking normal maintenance of both compressor and engine.
maintenance measures. Service Paks minimize downtime and keep your
Always keep the machine tidy to prevent
fire hazard. When servicing, replace all disengaged packings, e.g. maintenance budget low.
gaskets, O-rings, washers. Order Service Paks at your local Atlas Copco dealer.
For engine maintenance refer to Engine Operation
Poor maintenance can void any
Manual.
warranty claims.
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.

MAINTENANCE SCHEDULE COMPRESSOR

To determine the maintenance intervals, use service hours, or calendar time, whichever occurs first.
Daily Initially or 50 hours Yearly or every
after initial start-up 500 hours
Service pak - 2912 4392 06
XAS 67 DD - XAS 130 DD7, XATS 67 DD - XATS 125 DD7,
XAS 77 DD - XAS 150 DD7
Service pak XAS 97 DD - XAS 185 DD7 - 2912 4393 06
For the most important subassemblies, Atlas Copco has developed service kits that combine all wear parts. These service kits offer you the benefits
of genuine parts, save on administration costs and are offered at reduced price, compared to the loose components. Refer to the parts list for more
information on the contents of the service kits.
Check engine oil level x
Check compressor oil level x
Check fuel level x
(to be continued on page 64)

- 63 -
Maintenance schedule Daily Initially or 50 hours Yearly or every
(continuation of page 63) after initial start-up 500 hours
Empty air filter vacuator valves x
Drain water from fuel filter x
Check air intake vacuum indicators x
For spillage free: drain fluids out of frame x
Check general conditions (leaks, damaged parts, loose bolts, trouble x
in previous operation)
Check during operation: meters and lamps, noise, colour exhaust x
fumes
Check electrolyte level and terminals of battery x x
Check tyre pressure x x
Check for leaks in air-, oil- or fuel system x x
Check oil coolers x
Check engine minimum and maximum speeds x x
Check torque of wheel nuts x x
Check brake system (if installed) and adjust if necessary x x
Test safety valve x
Grease door hinges x
Grease coupling head and all its moving parts / shaft x
Check joints of height adjustment adjustable towbar x
Check rubber flexibles (2) x
Check shutdown switches x
Adjust fan V-belt (3) x
Clean fuel tank x
Change compressor oil x
(to be continued on page 65)

- 64 -
 Maintenance schedule Daily Initially or 50 hours Yearly or every
(continuation of page 64) after initial start-up 500 hours
Replace compressor oil filter x
Replace air filter element (1) x
Replace safety cartridges (1) (option) x
Change engine oil (3) (4) (5) x
Replace engine oil filter (3) x
Replace fuel filter (3) (6) (8) x
Adjust engine inlet and outlet valves (3) x (7)
Replace PD / QD filter (option) x
Replace separator element After 1000 running hours or after max. 2 years

Notes

1. More frequently when operating in a dusty environment. Keep the bolts of the housing, the lifting
2. Replace all rubber flexibles each 6 years, according to DIN 20066. eye, the towbar and the axle securely
tightened.
3. Refer to the Deutz operation manual.
Refer to section Technical specifications
4. 500 hours only valid when using PAROIL E. and section Height adjustment for the
5. Also drain engine oil from engine oil cooler torque values.
(see chapter Main Parts, DPec = Drain plug engine oil cooler).
6. In case of poor fuel quality, replace fuel filter more frequently.
7. The valves need to be adjusted for the first time before 500 running hours.
8. Option, additional fuel filter: heavy duty filter element 2914 8092 00, to be ordered separately.
9. Consult Atlas Copco.

- 65 -
DIESEL PARTICLE FILTER
every 500 hrs every 1500 hrs
Diesel particle filter * clean replace

*
Soot is toxic. It must be handled
according local regulations for toxic
waste. Cleaning and replacing of the
diesel particle filter may only be done by
qualified and authorised personnel.

- 66 -
MAINTENANCE SCHEDULE UNDERCARRIAGE
Maintenance schedule Initially Interval
Wheels
Tyre pressure Before each run
Check wheel bolts for firm seating Before first run
Check hub caps for firm seating 2,500km/annually
Check tyres for uneven wear 2,500km/annually
Check lateral play of bearings After 500 km 2,500km/annually
Check brake lining wear 5,000km/annually

Towbar
Check coupling head for wear, operation and fastening Before first run 5,000km/annually
Check brake play After first run 2,500km/annually
Check height adjustment facility Before each run, during first 5,000km/annually
500 km
Check reversing lever for ease of motion 2,500 km 5,000km/annually
Check safety cable and bowden cable for damage 5,000km/annually
Check/adjust brake system (if installed) Before first run 2,500km/annually

Lubrication
Coupling head and all its moving parts/shaft Before first run 2,500km/annually
Overrun brake Before first run 5,000km/annually
Reversing lever Before first run 5,000km/annually
Overrun coupling Before first run 5,000km/annually
Joints of height adjustable towbar 5,000km/annually
Bearings (conventional bearings only) 5,000km/annually

- 67 -
LUBRICATION OILS
High-quality, mineral, hydraulic or synthesized hydrocarbon oil with rust and oxidation inhibitors and anti-foam
and anti-wear properties is recommended. The viscosity grade should correspond to the ambient temperature and
ISO 3448, as follows:
Type of lubricant
between 30°C (86°F) and 40°C (104°F)
between 30°C (86°F) and -5°C (23°F)
between -5°C (23°F) and -20°C (-4°F)
PAROIL from Atlas Copco is the ONLY oil tested
and approved for use in all engines built into Atlas
Copco compressors and generators.
Extensive laboratory and field endurance tests on
Atlas Copco equipment have proven PAROIL to
match all lubrication demands in varied conditions. It
meets stringent quality control specifications to
ensure your equipment will run smoothly and
reliably.
The quality lubricant additives in PAROIL allow for
extended oil change intervals without any loss in
performance or longevity.
PAROIL provides wear protection under extreme
conditions. Powerful oxidation resistance, high
chemical stability and rust- inhibiting additives help
reduce corrosion, even within engines left idle for
extended periods.
PAROIL contains high quality anti-oxidants to
control deposits, sludge and contaminants that tend to
build up under very high temperatures.
PAROIL’s detergent additives keep sludge forming
particles in a fine suspension instead of allowing them
to clog your filter and accumulate in the valve/rocker
cover area.
*
If you want to use another brand of oil,
consult the engine instruction manual.
Compressor** Engine*
PAROIL S PAROIL E **
It is strongly recommended to use Atlas
PAROIL M PAROIL E Copco branded lubrication oils for the
PAROIL S compressor. If you want to use another
PAROIL S PAROIL E xtra brands of oil, consult Atlas Copco.
PAROIL releases excess heat efficiently, whilst
maintaining excellent bore-polish protection to limit
oil consumption.
PAROIL has an excellent Total Base Number (TBN)
retention and more alkalinity to control acid
formation.
PAROIL prevents Soot build-up
PAROIL is optimized for the latest low emission
EURO -3 & -2, EPA TIER II & III engines running on
low sulphur diesel for lower oil and fuel consumption.
PAROIL E xtra is a Synthetic ultra high performance
diesel engine oil with a high viscosity- index. Atlas
Copco PAROIL E xtra is designed to provide
excellent lubrication from start-up in temperatures as
low as -20°C (-4°F).
PAROIL E is a mineral based high performance
diesel engine oil with a high viscosity- index. Atlas
Copco PAROIL E is designed to provide a high level
of performance and protection in ‘standard’ ambient
conditions as from -5°C (23°F).
- 68 -
OIL SPECIFICATIONS COMPRESSOR OIL

Mineral compressor oil PAROIL M

Liter US gal Order number
Never mix synthetic with mineral oil.
Remark: can 5 1.3 1615 5947 00

When changing from mineral to can 20 5.3 1615 5948 00

synthetic oil (or the other way around), barrel 210 55.2 1615 5949 00
you will need to do an extra rinse:
After doing the complete change Synthetic compressor oil PAROIL S
procedure to synthetic oil, run the unit
for a few minutes to allow good and Liter US gal Order number
complete circulation of the synthetic oil.
can 5 1.3 1615 5950 01
Then drain the synthetic oil again and
fill again with new synthetic oil. To set can 20 5.3 1615 5951 01
correct oil levels, proceed as in normal barrel 210 55.2 1615 5952 01
instruction.
Mineral engine oil PAROIL E

Liter US gal Order number

can 5 1.3 1615 5953 00
can 20 5.3 1615 5954 00
barrel 210 55.2 1615 5955 00

Synthetic engine oil PAROIL E xtra

Liter US gal Order number
can 5 1.3 1604 6060 01
can 20 5.3 1604 6059 01

- 69 -
OIL LEVEL CHECK CHECK COMPRESSOR OIL LEVEL

Never mix oils of different brands or

types. (2)

Use only non-toxic oils where there is a

risk of inhaling delivered air. (1)

CHECK ENGINE OIL LEVEL

Also consult the Engine Operation Manual for the oil

specifications, viscosity recommendations and oil
change intervals.
For intervals, see Preventive maintenance schedule.
Check engine oil level according to the instructions in
the Engine Operation Manual and if necessary top up
with oil.
(3)

With the unit standing horizontal, check the level of

the compressor oil. The pointer of the oil level gauge
(1) must register in the upper extremity of the green
range. Add oil if necessary.
Before removing the oil filler plug (2),
ensure that the pressure is released by
opening an air outlet valve (3).

- 70 -
OIL AND OIL FILTER CHANGE COMPRESSOR OIL AND OIL FILTER CHANGE
ENGINE OIL AND OIL FILTER CHANGE
(1)
(3)
See section Preventive maintenance schedule. (2)
(4)
(5)
The quality and the temperature of the oil determine
the oil change interval.
The prescribed interval is based on normal operating
conditions and an oil temperature of up to 100 °C
(212 °F) (see section Preventive maintenance
schedule).
When operating in high ambient temperatures, in very
dusty or high humidity conditions, it is recommended
to change the oil more frequently.
In this case, contact Atlas Copco.
- 71 -
1. Run the compressor until warm. Close the outlet
valve(s) (5) and stop the compressor. Wait until
the pressure is released through the automatic
blow-down valve. Unscrew the oil filler plug (2)
one turn. This uncovers a vent hole, which permits
any pressure in the system to escape.
2. Drain the compressor oil by removing all relevant
drain plugs. Drain plugs are located at the air
receiver (DPar) and compressor element (DPcv,
DPosv). Catch the oil in a drain pan. Screw out the
filler plug to speed up draining. After draining,
place and tighten the drain plugs.
3. Remove the oil filters (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) is in the upper part of the green area. Be
sure that no dirt gets into the system. Reinstall and
tighten the filler plug.
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). 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.
Never add more oil. Overfilling results in
oil consumption.
COMPRESSOR OIL FLUSHING PROCEDURE

Not respecting compressor oil changing 4. Check the interior of the oil vessel (see pictures).
intervals according to the maintenance If varnish deposits are discovered, contact Atlas
schedule, can lead to serious problems, Copco Service dept. and do not continue.
including fire hazard! The manufacturer 5. Put in a new oil separator, screw on new
does not accept any liability for damage compressor oil filter(s) and close the oil vessel
arising from not following the according to the instructions.
maintenance schedule or not using
genuine parts. 6. Fill the oil vessel with the minimum amount of
replacement oil, run the compressor under light
To avoid problems when changing over to a new type load conditions for 30 minutes.
of oil (see table) a special Compressor Oil Flushing 7. Thoroughly drain the system when the oil is
Procedure has to be followed. The table is only valid warm, leaving as little oil in the system as feasible,
in case the replaced oil has not exceeded its lifetime. especially in dead areas, if possible blow out
For more information consult Atlas Copco Service Vessel cover
remaining oil by pressurising the oil. contaminated clean
dept.
8. Fill the system with the final oil charge.
Aged oil can be recognized best by using an oil
sampling analysis program. Indicators for aged oil are 9. Run the compressor under light load conditions
strong smell, or contamination like sludge and for 15 minutes and check for leakage.
varnish inside the oil vessel and oil stop valve or a 10. Check the oil level and top up if necessary.
brownish colour of the oil.
11. Collect all waste lubricant used during the
Whenever aged oil is discovered, eg. when changing flushing process and dispose of it in accordance
the oil separator, contact Atlas Copco Service dept. to with the applicable procedures for managing
have your compressor cleaned and flushed. waste lubricant.
1. First thoroughly drain the system when the oil is
warm, leaving as little oil in the system as feasible
especially in dead areas, if possible blow out
remaining oil by pressurising the oil system. Vessel
Check the instruction manual for detailed contaminated clean
description.
2. Remove the compressor oil filter(s). PAROIL M PAROIL S PAROIL Sxtreme
3. Open the oil vessel and remove the oil separator PAROIL M draining * flushing flushing
element. PAROIL S draining ** draining * draining
Instructions on replacing the oil PAROIL Sxtreme draining ** draining draining *
separator element are available from
* When changing over to the same oil within the oil changing interval, draining is sufficient
Atlas Copco Service dept.
** Change over not recommended

- 72 -
CLEANING COOLERS CLEANING FUEL TANK

Steam cleaning in combination with a cleansing agent

may be applied in order to remove also the dirt
(1)
sticking to the cooler fins.
(2) To avoid damaging the coolers, angle
between jet and coolers should be
approx. 90 °.
Protect the electrical and controlling
equipment, air filters, etc. against
penetration of moisture.
Close the service door(s).
Never leave spilled liquids such as fuel,
oil, water and cleansing agents in or
around the compressor.
Observe all relevant environmental and
safety precautions.
Place an appropriate drain pan under the drainplug
(see chapter Main Parts, DPec) of the fuel tank.
Remove the drain plug.
Lift the towbar (see chapter Main Parts, TB) and tilt
the compressor approx. 15° to remove all fuel, dirt
and water.
Clean the fuel tank and fix the drain plug handtight.
Never leave spilled liquids such as fuel,
oil, water and cleansing agents in or
around the compressor.
Refill the fuel tank with clean fuel.

Keep the oil-coolers (1) and (2) clean to maintain the

cooling efficiency.
The fan side surface of compressor- and engine oil
cooler is accessible by removing the fan cowl upper
part.
The opposite surface of compressor- and engine oil
cooler is accessible by removing the centre part of the
front baffles.
Remove any dirt from the coolers with a
fibre brush. Never use a wire brush or
metal objects.

- 73 -
CLEANING HARDHAT
Optimal cleaning of the HardHat can be obtained by
applying high pressure cleaning in combination with
liquid soap.
BATTERY CARE
Before handling batteries, read the
relevant safety precautions and act
accordingly.
If the battery is still dry, it must be activated as
described in section Activating a dry-charged
battery.
The battery must be in operation within 2 months
from being activated; if not, it needs to be recharged
first.
ELECTROLYTE
Read the safety instructions carefully.
Electrolyte in batteries is a sulphuric acid solution in
distilled water.
The solution must be made up before being
introduced into the battery.
ACTIVATING A DRY-CHARGED BATTERY
• Take out the battery.
• Battery and electrolyte must be at equal
temperature above 10 °C (50 °F).
• Remove cover and/or plug from each cell.
• Fill each cell with electrolyte until the level
reaches 10 mm (0.4 in) to 15 mm (0.6 in) above
the plates, or to the level marked on the battery.
• Rock the battery a few times so that possible air
bubbles can escape; wait 10 minutes and check the
level in each cell once more; if required, add
electrolyte.
• Refit plugs and/or cover.
• Place the battery in the compressor.
- 74 -
RECHARGING A BATTERY
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.
Use a commercial automatic battery
charger according to its manufacturer’s
instructions.
Apply with preference the slow charging method and
adjust the charge current according to the following
rule of thumb:
Battery capacity in Ah divided by 20 gives safe
charging current in Amp.
BATTERY MAINTENANCE
• Keep the battery clean and dry.
• Keep the electrolyte level at 10 mm (0.4 in) to 15
mm (0.6 in) 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.
CHANGING TYRES
When changing a tyre, please observe that the arrow
on the tyre in top position points in the driving
direction (to the towbar).
STORAGE
Run the compressor regularly, e.g. twice a week, until
warm.
Load and unload the compressor a few times to
operate the unloading and regulating components.
Close the air outlet valves after stopping.
If the compressor is going to be stored
without running from time to time,
protective measures must be taken.
SERVICE PAKS
A Service Pak is a collection of parts to be used for a
specific maintenance measure.
It guarantees that all necessary parts are replaced at
the same time keeping down time to a minimum.
The order number of the Service Paks are listed in the
Atlas Copco Parts List (ASL).
- 75 -
SERVICE KITS
A Service Kit is a collection of parts to fit a specific
repair or rebuilding task.
It guarantees that all necessary parts are replaced at
the same time which improves the uptime of the unit.
The order numbers of the Service Kits are listed in the
Atlas Copco Parts List (ASL).
Contact Atlas Copco.
COMPRESSOR ELEMENT OVERHAUL
When a compressor element is due for overhaul, it
needs to be done by Atlas Copco. This guarantees the
use of genuine parts and correct tools with care and
precision.
LIABILITY
The manufacturer does not accept any liability for any
damage arising from the use of non-original parts and
for modifications, additions or conversions made
without the manufacturer’s approval in writing.
Adjustments and servicing procedures
ADJUSTMENT OF THE CONTINUOUS PNEUMATIC REGULATING SYSTEM

With generator
(SVsr)

Without generator

(RV)
(SVuv)

(E)

With generator
(SR) (SVsr)

(AOV)

(FP)

- 76 -
The working pressure is determined by the tension of X Y Z1 – Z2
the spring in the regulating valve (RV). This tension bar(e) bar(e) bar(e) bar(e)
can be increased to raise the pressure and decreased to
lower it by turning the adjusting wheel clockwise and XAS 67 DD - XAS 130 DD7 8.5 7 8.3 – 8.7
anti-clockwise respectively. XATS 67 DD - XATS 125 DD7 11.8 10.3 11.6 – 12
To adjust the normal working pressure, proceed as XAS 77 DD - XAS 150 DD7 8.5 7 8.3 – 8.7
follows:
XAS 97 DD - XAS 185 DD7 8.5 7 8.3 – 8.7
1. Start and warm up the engine (see section
Starting / Stopping).
2. With the outlet valves (AOV) closed, pull out the
knob, adjust the regulating valve (RV) until a
pressure of X bar(e) is reached (see table).
3. Check the minimum speed of the engine. Adjust
minimum speed stop screw if necessary.
4. Open an outlet valve (AOV) just enough to let the
engine (E) run at maximum speed. The working
pressure must be Y bar(e) (see table); adjust if
necessary with regulating valve (RV).
5. Check the engine maximum speed. Adjust the
maximum speed by means of adjusting eccentric
nut on top of speed regulator (SR).
6. Close the outlet valves (AOV), check that the
pressure is between Z1 and Z2 bar(e) (see table).
Lock the regulating valve (RV) by pushing the
knob down.
7. Check the operation of the solenoid valve (SVsr)
when equipped with a generator.

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AIR FILTER ENGINE/COMPRESSOR RECOMMENDATIONS REPLACING THE AIR FILTER ELEMENT
1. Release the snap clips (1) and remove the dust trap
The Atlas Copco air filters are specially (2). Clean the trap.
(1)
designed for the application. The use of
non-genuine air filters may lead to 2. Remove the element (4) from the housing (5).
severe damage of engine and/or 3. Reassemble in reverse order of dismantling. Make
compressor element. sure the vacuator valve (6) points down.
Never run the compressor without air 4. Inspect and tighten all air intake connections.
filter element.
5. Reset the vacuum indicator (7).
The filter element must be cleaned or
replaced when the yellow indicator (9)
has reached the bottom of the vacuum
(6)(2) (3)(4) (5) (8) indicator.
(7)
(9) New elements must also be inspected for tears or
punctures before installation.

1. Snap clips 6. Vacuator valve Discard the element (4) when damaged.
2. Dust trap cover 7. Vacuum indicator In heavy duty applications it is recommended to
3. Safety cartridge 8. Reset button install a safety cartridge which can be ordered with
(option) XAS 67 DD - XAS 130 DD7,
4. Filter element 9. Yellow indicator XATS 67 DD - XATS 125 DD7,
5. Filter housing XAS 77 DD - XAS 150 DD7 - part no.: 2914 9309 00
XAS 97 DD - XAS 185 DD7 - part no.: 2914 9311 00
A dirty safety cartridge (3) is an indication of a
CLEANING THE DUST TRAP malfunctioning air filter element. Replace the element
and the safety cartridge in this case.
To remove dust from the dust trap pinch the vacuator The safety cartridge cannot be cleaned.
valve (6) several times.

- 78 -
AIR RECEIVER
The air receiver is tested according to official
standards. Regularly have inspections carried out in
conformity with local regulations.
DRIVE BELT (XAS 67 DD - XAS 130 DD7,
XATS 67 DD - XATS 125 DD7)
Never retense or reuse the drive belt
between engine and compressor.
Consult Atlas Copco for replacement of
drive belt.
SAFETY VALVE FUEL SYSTEM
All adjustments or repairs are to be done
by an authorized representative of the
valve supplier.
Following checks must be carried out:
• a check of the opening of the lifting gear, twice a
year. This can be done by screwing the cap of the
valve anti-clockwise.
• 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.
(1)
Replacing the filter element
1. Unscrew the filter element (1) from the adapter
head.
2. Clean the adapter head sealing surface. Lightly oil
the gasket of the new element and screw the latter
onto the header until the gasket is properly seated,
then tighten with both hands.
3. Check for fuel leaks once the engine has been
restarted.
- 79 -
BRAKE (= OPTION) ADJUSTMENT BRAKE CABLE ADJUSTMENT

Before jacking up the compressor,

connect it to a towing vehicle or attach a (4) (1) (6) (4) (2)
weight of minimum 50 kg (110 lb) to the
towbar.
(2)

BRAKE SHOE ADJUSTMENT

Check the thickness of the brake lining. Remove both

black plastic plugs (5), one on each wheel. When the
brake lining has been worn to a thickness of 2 mm
(0.079 in) or less, the brake shoes have to be replaced.
After inspection and/or replacement re-insert both
plugs. (5) (1) (3) (1) (2) (3) (4) (2) (5)
Brake shoe adjustment re-establishes the brake
lining-to-drum clearance and compensates for lining
wear. 1. Adjusting bolt 4. Pin (∅ 4 mm) 1. Brake cable 4. Brake cable nut
2. Axle 5. Plug 2. Lock nut 5. Main brake cable
Lift and support the compressor. Make sure that all
brakes are off (overrunbrake and hand brake lever). 3. Brake cable 3. Adjusting nut 6. Equalizer
The brake cables must be free from tension. Lock the
swivel cams of the wheel brake from the outside by Check the position of the equalizer (see section 1. With the towing eye pulled out in the outmost
means of a pin ∅ 4 mm (4) through the hole as shown Brake cable adjustment, 6) with the parking brake position and the hand brake lever in the downward
in the figure. actuated. position, loosen the lock nuts (2). Turn adjusting
Turn the adjusting bolt (1) clockwise with a wrench nuts and brake cable nuts (4) clockwise until there
Perpendicular position of equalizer = identical
till the wheel locks up. Center the brake shoes by clearance of wheel brakes. is no slack in the brake mechanism.
actuating the parking brake several times. The equalizer (6) must remain perpendicular to
Re-adjust the brake shoes, if necessary.
Turn the adjusting bolt anti-clockwise until the wheel main brake cable (5).
is running free in direction of travel (approx. 1 full To test, slightly apply the parking brake and check
2. Apply the hand brake lever several times and
turn of the adjusting bolt). identical brake torque on left and right side.
repeat the adjustment. Tighten the nuts with their
Remove locking pin (4). Remove clearance from lock nuts (2). Remove the jack and the blocks.
brake cables.
3. Road test the compressor and brake several times.
Check all lock nuts (see section Brake cable Check brake shoe and brake cable adjustment and
adjustment, 2). if necessary adjust.

- 80 -
TEST PROCEDURE BRAKE CABLE ADJUSTMENT

Correct and wrong position of markings

1. Check if the towing eye rod of the overrun brake
mechanism is in the outmost position.

1
2. Check if the adjustable towbar (= option) is in the
actual towing position.
2
3. Apply the hand brake lever.
4. Push the compressor a few centimeters backwards
B. Acceptable so that the brake lever is automatically pulled
further up.
5. Check the position of the arrow marking ”1” at the
catch lock in combination with the arrow marking
”2” at the toothed sector, according to A,B,C,D.

C. Too loose;
adjust brake cables
(Section Brake
A. Adjusted correctly cable adjustment)

D. Too tight;
adjust brake cables
(Section Brake
cable adjustment)

- 81 -
WHEELS LUBRICATION

WHEEL CHECK

• Check wheel bolts for firm seating (initially)

• Check hub caps for firm seating (every 2,500 km
or anually)
• Check tyres for uneven wear (every 2,500 km or
anually)
• Check lateral play of wheel bearing. If necessary,
readjust.
Compact bearings (every 2 years)
Conventional bearings (after 500 km, every 2,500
km or anually) Tapered type hub cap Greasing bearing race

Taper roller bearings and deep groove ball Fill the hub caps to 3/4 full with grease.
bearing
Fit wheel hubs, adjust the bearing play and fit the hub
Axles fitted with taper roller bearings are caps.
recognizable by a tapered type hub cap, see Figure.
Remove wheels and wheel hubs.
Mark dismounted wheel hubs and bearing races so
that their identity is not mistaken during reassembly.
Clean wheel hubs thoroughly inside and outside.
Remove old grease totally.
Clean taper roller bearings and seals (using diesel oil)
and check for reuseability.
Work BPW special longlife grease ECO_Li 91 into
the cavities between the taper roller and cage. Smear
grease into the hub's outer bearing race.

- 82 -
 WHEEL BOLTS CHECK
Tightening torques of wheel bolts

Spanner Thread Tightening

width (mm) torque
17 (19) M 12x1.5 80 100 Nm
19 M 14x1.5 110 120 Nm
24 M 18x1.5 270 280 Nm

Cylindrical hub cap shape Wheel bolts tightening

Compact bearings After the first run, likewise after each

Compact bearings are recognizable by cylindrical hub wheel change.
cap shape, see Figure.
Tighten wheel bolts crosswise using a torque wrench
Compact bearings are maintenance-free due to to the tightening torque in compliance with the table.
permanent lubrication and are designed for high
mileages.
Therefore, there is no grease change or regreasing
necessary.

- 83 -
WHEEL BEARING ADJUSTMENT

Conventional taper roller bearings Compact bearings

Taper roller bearings are recognisable by the conical Compact bearings are recognizable by their
profile of the hub cap. cylindrical hub cap shape.
• Lever off hub cap. Remove split pin from axle nut
and tighten so that rotation of the wheel is slightly If noticeable bearing play is felt, the
braked. compact bearings should be replaced.
• Turn back the axle nut to the next possible split pin
hole, by a maximum of 30 degrees.
• Insert split pin and bend ends slightly outwards.
• Check wheel rotation, fit hub cap.

Bearing play Important:

Jack up the compressor, release brakes. The grease in the hub cap and bearing must not be
contaminated with dirt during this job!
Turn wheels manually and rock.
If any bearing play is perceivable, adjust the bearings.

- 84 -
TOWBAR AND OVERRUN BRAKE

TOWBAR AND OVERRUN BRAKE CHECK

Check coupling head

Initially, then every 5,000 kilometres or
annually.
(x)
Check coupling head for wear and correct operation.
Check the wear indicator (use within the "+" range
only).
Check the coupling head fastenings (see arrows,
Figure) at regular intervals for firm seating.
Check the coupling head fastenings Brake play check

Check height adjustment facility Brake play check

Initially, before every journey, after 500 After the first run, then every 2,000 -
kilometres, then every 5,000 kilometres 3,000 kilometres.
or annually.
The check is carried out visually on the stroke (x) of
After every adjustment the clamping nuts must be the overrun coupling.
screwed up tight and secured with the spring
As soon as this is more than 50 mm when the brakes
elements.
are applied, adjust the wheel brakes.
Tightening torque:
Check towbar, handbrake lever, spring actuator,
M 24 = 250 - 350 Nm reversing lever, linkage and all movable parts for ease
M 32 = 350 - 400 Nm of movement.

Check tight fit of the clamping nuts and correct

positioning of the adjustment facility.

- 85 -
 LUBRICATION

(1)

(2)

Towbar Lubrication coupling head Greasing towbar

Initially, then every 5,000 kilometres or
annually.
Check safety cable (1) for damage; every 5,000
kilometres or annually.
Check Bowden cable (2) on height-adjustable
connection devices for damage; every 5,000
kilometres or annually.
Lubricate the coupling head Towbar bushes on the housing of the
overrun coupling
At regular intervals.
Initially, after 2,000 - 3,000 kilometres,
every 5,000 kilometres.
Oil ball coupling at regular intervals at the specified
locations and moving parts. Apply general purpose grease via the grease nipples
until fresh grease can be seen emerging from the
Grease the contact surface of the ball of the towing
bushes.
vehicle.

- 86 -
 (1)

Reversing lever Lubrication points Heigth adjusting device

Reversing lever
Initially, after 2,000 - 3,000 kilometres,
every 5,000 kilometres.
Check reversing lever (1) for ease of motion.
If fitted, apply general purpose grease via the grease
nipple until fresh grease can be seen emerging from
the bush.
If grease nipples are not fitted, then apply oil to the
reversing lever bush.
Lubricate all moving parts and pivot pins at
the overrun coupling
Initially, after 2,000 - 3,000 kilometres,
every 5,000 kilometres.
All moving parts of drawbar, handbrake lever, spring
actuator, reversing lever, linkages etc. to be oiled or
greased as required.
Grease sliding locations on the height-
adjusting device
For the first time after 2,000 - 3,000
kilometres travelled, then every 5,000
kilometres.
Oil threaded parts and grease toothed parts.

- 87 -
Problem solving
It is assumed that the engine is in good condition and
that there is adequate fuel flow to the filter and
injection equipment.
An electrical fault must be traced by an
electrician.
Make sure that the wires are not damaged and that
they are clamped tight to their terminals.
If it’s not possible to solve the problem
with this problem solving table, please
consult Atlas Copco.
Alternator precautions
1. Never reverse the polarity of the battery or the
alternator.
2. Never break any alternator or battery connections
while the engine is running.
3. When recharging the battery, disconnect it from
the alternator. Before using booster cables to start
the engine, be sure of the polarity and connect the
batteries correctly.
4. Never operate the engine without the main or
voltage sensing cables connected in the circuit.

Problem Possible faults Corrective actions

1. Lamps (H1, H2) do not light up when
switching (S1) to ”I” and applying
lamp test.
2. General alarm lamp (H2) does not
light up when switching (S1) to ”I”;
lamp (H1) lights up when applying
lamptest.
a. Discharged or defective battery.
b. Loose battery cable(s) or oxidised terminals.
c. Loose connection or damaged wiring.
d. Contact switch (S1) defective.
e. Circuit breaker (F1) defective.
a. Lamp (H2) blown.
b. Alternator (A)/regulator defective.
a. Check electrolyte level and charge battery. If no cells are
shorted and battery is discharged, trace cause and
correct.
b. Check and correct if necessary.
c. Check wiring and connections; correct if necessary.
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. Replace circuit breaker.
a. Replace lamp.
b. Disconnect the wire from alternator terminal D+ and
connect it to terminal D–. If (H1) lights up, replace the
alternator; if not, test (S1); see remedy 1d.

- 88 -
Problem
3. Temperature alarm lamp (H1) does not
light up when switching (S1) to ”I”
and applying lamp test.
4. Starter motor (S) does not crank
engine (E) after switching startbutton
(S1) to ” ”.
5. Starter motor cranks engine when
switching start switch (S1) to ” ”,
but engine does not fire.
6. Engine fires, but general alarm lamp
(H2) remains alight; engine stops
when releasing start switch (S1).
7. Engine is running, but shuts down
immediately after (S1) has been
released.
8. General alarm lamp (H2) remains
alight for over 5 seconds after starting.
9. Hourmeter (P1) does not count
running time.
10. Compressor does not unload and
engine keeps running at maximum
speed when closing the air outlet
valves; safety valve blows.
Possible faults Corrective actions
a. Lamp (H1) blown. a. Replace lamp.
b. See fault 1d. b. See 1d.
a. Low battery output. a. See remedy 1a.
a. Contact switch (S1) defective. a. See remedy 1d.
b. Fuel solenoid (Y1) defective. b. Check solenoid and its valve, correct or replace if
necessary.
c. Low battery output. c. See 1a.
a. Alternator drive belt broken or slipping. a. Check and correct if necessary.
b. Alternator (A)/regulator defective. b. Have assembly repaired.
a. Contact switch (S1) released too soon. a. Release switch after engine oil pressure has built up
above the minimum allowed value.
b. Insufficient engine oil pressure. b. Stop at once, consult the Engine Operation Manual.
c. Fuel tank contains insufficient fuel. c. Fill fuel tank.
a. Insufficient engine oil pressure or too high engine oil a. Stop at once, consult Engine Operation Manual.
temperature.
b. Engine oil pressure switch (S3), or compressor b. Stop at once, test switches, replace as necessary.
temperature switch (S5) defective.
c. Relay (K1) defective. c. Replace (K1).
a. Hourmeter (P1) defective. a. Replace.
a. Air leaks in regulating system. a. Check and repair.
b. Regulating valve (RV) incorrectly set or defective. b. Adjust or repair regulating valve; see section
Adjustment of the continuous pneumatic regulating
system.
c. Unloading valve (UV) or its actuating piston stuck. c. Repair unloading valve assembly.
- 89 -
Problem
11. Compressor capacity or pressure
below normal.
12. Working pressure rises during
operation and causes safety valve to
blow.
13. Excessive compressor oil
consumption. Oil mist being
discharged from air outlet valve(s).
14. Compressor shuts down through a
shutdown switch.
15. Air and oil mist expelled from air filter
after stopping.
16. Compressor overheating.
Possible faults
a. Air consumption exceeds capacity of compressor.
b. Choked air filter elements (AF).
c. Unloading valve (UV) not completely open.
d. Engine does not run at max. speed.
e. Oil separator element (OS) clogged.
a. See faults 10.
b. Safety valve (SV) opens too soon.
a. Restrictor in oil scavenging line (SL) clogged.
b. Oil separator element (OS) defective.
c. Oil level too high.
a. Alternator V-belt broken or slipping.
b. Compressor overheating.
c. Engine oil pressure too low.
d. Engine temperature too high.
a. Unloader valve (UV) defective.
b. Wrong oil type (without foam-retarding additives).
a. Insufficient compressor cooling.
b. Oil cooler (OC) clogged externally.
c. Oil system clogged internally.
d. Oil level too low.
- 90 -
Corrective actions
a. Check equipment connected.
b. Replace air filter element (AF).
c. Speed regulation cable maladjusted; see section
Adjustment of the continuous pneumatic regulating
system.
d. Check the maximum speed, service the fuel filter.
e. Have element removed and inspected by an Atlas Copco
Service representative.
a. See remedies 10.
b. Have safety valve adjusted; consult Atlas Copco.
a. Dismount, clean and refit restrictor.
b. Replace element.
c. Check for overfilling. Release pressure and drain oil to
correct level.
a. Re-tense or replace V-belt.
b. See condition 16.
c. Check lubricating system.
d. Check engine oil system; see Engine Operation Manual.
a. Repair valve.
b. Consult Atlas Copco.
a. Relocate compressor.
b. Clean cooler; see section Cleaning coolers.
c. Consult Atlas Copco.
d. See section Oil level check.
Problem
XAS 67 DD - XAS 130 DD7, XATS 67 DD - XATS 125 DD7:
17. No air output.
Generator DDG 110V:
18. No voltage at sockets.
19. When the electrical device is
connected, the circuit breakers switch
always off.
20. Circuit breakers are off (down).
21. Green lamp H3 is deactivated.
Generator DDG IT 230/400V:
22. No voltage at sockets.
23. When the electrical device is
connected, the circuit breakers switch
always off.
24. Circuit breakers Q1 are off (down).
25. Green lamp H3 is deactivated.
26. Yellow LED on insulation monitoring
relay K6 is activated.
Possible faults
a. Drive belt broken.
a. Generator not switched on.
b. Circuit breakers are off.
a. Electrical device is defective.
a. Short circuit or overload.
b. Circuit breakers switched off.
a. Circuit breakers are off.
b. Serious electrical fault.
a. Generator not switched on.
b. Circuit breakers are off.
a. Electrical device is defective.
a. Short circuit.
b. Temperature in generator too high.
a. Circuit breakers are off.
b. Serious electrical fault.
a. Serious insulation fault.
- 91 -
Corrective actions
a. See section Drive Belt (XAS 67 DD - XAS 130 DD7,
XATS 67 DD - XATS 125 DD7).
a. Switch generator on.
b. Switch on circuit breakers.
a. Have electrical device replaced or repaired.
a. Remedy fault. Switch on circuit breakers.
b. Switch on circuit breakers.
a. Switch on circuit breakers.
b. Consult Atlas Copco.
a. Switch generator on.
b. Switch on circuit breakers.
a. Have electrical device replaced or repaired.
a. Remedy fault. Switch on circuit breakers.
b. Check generator cooling.
a. Switch on circuit breakers.
b. Consult Atlas Copco.
a. Switch off the engine and restart.
Problem Possible faults Corrective actions
Diesel particle filter
No LED, triangle flashes. No Communikation between CB and PB. Consult Atlas Copco.
All Alarm LED flash, triangle shaped Non compatible SW-Versions of CB and PB. Consult Atlas Copco.
flashes.
Pressure 1 / Alarm 2 flash, triangle shaped Lower Pressure Limit.
flashes.
Pressure 1 / Alarm 4 flash triangle shaped No change of pressure within 10 minutes. a. Start engine.
flashes.
b. Have pressure line cleaned.
Temp. 1 / Alarm 5 flash, triangle shaped No change of temperature within 10 minutes. Check if engine is running and pressure sensor is correctly
flashes. fitted.
Temp. 1 / Alarm 6 flash, triangle shaped Damage of temperature probe.
flashes.
Pressure 8 / Alarm 1 flash, triangle shaped Upper Pressure Limit. Switch to full load.
flashes.
Alarm 3 flashes, triangle shaped flashes. No RPM-Signal from the generator.
Alarm 7 flashes, triangle shaped flashes. Date and Time not correct, no recording of data. Consult Atlas Copco.
Alarm 1 flashes, triangle shaped flashes Error Additive-Dosing. Consult Atlas Copco.
(Pressure 8 off).
Alarm 8 flashes, triangle shaped flashes. Level Additive-Tank.
Alarm 4 flashes, triangle shaped flashes Error PLC (Slave).
(Pressure 1 off).
Alarm 5 flashes, triangle shaped flashes Error GSM (Slave).
(Temp.1 off).
Alarm 4-8 flash, triangle shaped flashes. Glass Cover dirty. Clean glass cover.
Filter does not regenerate spontaneously. Consult Atlas Copco.

- 92 -
Available options
Pressure vessel approval: CE Safety: Wheel chocks
ASME Safety cartridge
Undercarriage: Adjustable towbar with brakes Spark arrestor 1)
Fixed towbar with brakes Safety chain CE/ASME
Support (without undercarriage) 1) Anti-theft 3)
Simplified bumper 1) Hose reel 1)
Towing eyes: Loose ball coupling Inlet shutdown valve 1)
Towbar support: Jockey wheel Spillage free frame
Road lights system: Reflectors only Exhaust particle filter 1)
Road lights system Non return valve
24 V adaptor Additional literature set
Air quality equipment: Aftercooler + water separator Fueltank with metal fillerneck
Aftercooler + water separator + PD filter Additional fuel filter
Aftercooler + water separator + PD/QD Cold start: Cold start - 20 °C
filters Generator 4): 230/400 V - 6.5 kVA
Aftercooler + water separator + reheater 1) 230/400 V - 6.5 kVA Automatic
Aftercooler + water separator + PD filter + 230 V - 3 ph - 6.5 kVA
reheater 1)
110 V - 6 kVA
Aftercooler + water separator + PD/QD
filters + reheater 1) 110 V - 6 kVA Automatic
Lubricator 2) 230 V - 3 ph - 12 kVA
Anti-frost device 2) 230/400 V - 12 kVA
By-pass 2) 230/400 V - 12 kVA Automatic
Tool box: Single Canopy colour: single
Twin double 1)
3)
1)
Not in combination with HardHat In order to obtain a spare key at the local ABUS dealer, the key code card must
2)
be presented. Please keep this card available.
Not on XATS 67 DD - XATS 125 DD7. 4)
Only for XAS 67 DD - XAS 130 DD7 and XAS 97 DD - XAS 185 DD7 with
metal canopy.

- 93 -
Technical specifications
TORQUE VALUES

GENERAL TORQUE VALUES CRITICAL TORQUE VALUES

The following tables list the recommended torques applied for general applications
at assembly of the compressor. Assemblies Torque value (Nm / lbf.ft)
Wheel nuts 80 (59) +10/-0 %
Bolts, axle/beams 80 (59) +/- 10 %
For hexagon screws and nuts with strength grade 8.8 Bolts, towbar/axle 80 (59) +/- 10 %
Thread size Torque value (Nm / lbf.ft) Bolts, towbar/bottom 80 (59) +/- 10 %
M6 9 (6.5) Bolts, towing eye/towbar 80 (59) +/- 10 %
M8 23 (17) Bolts, lifting eye/flywheel housing 80 (59) +/- 10 %
M10 46 (35) Bolts, engine/drive housing (M12) 80 (59) +/- 10 %
M12 80 (59) Bolts, engine/drive housing (M14) 125 (92) +/- 10 %
M14 125 (92) Bolts, compressor element/drive 80 (59) +/- 5 %
housing
M16 205 (151)
Safety switches 35 (26) +/- 5 %
For hexagon screws and nuts with strength grade 12.9 Joints adjustable towbar (M24) 275 (205) +/- 10 %
Joints adjustable towbar (M32) 375 (280) +/- 10 %
Thread size Torque value (Nm / lbf.ft)
M6 15 (11)
M8 39 (29) Secure the drain cock and tank cap of the fuel tank handtight.
M10 78 (58)
M12 135 (100)
M14 210 (155)
M16 345 (255)

- 94 -
SETTINGS OF SHUTDOWN SWITCHES AND SAFETY VALVES

Designation XAS 67 DD - XATS 67 DD - XAS 77 DD - XAS 97 DD -

XAS 130 DD7 XATS 125 DD7 XAS 150 DD7 XAS 185 DD7
Engine oil pressure bar(e) 1.2 1.2 1.2 1.2
psi 17.4 17.4 17.4 17.4
Engine oil temperature °C 127 - 133 127 - 133 127 - 133 127 - 133
°F 260 - 270 260 - 270 260 - 270 260 - 270
Compressor temperature °C 116 - 120 116 - 120 116 - 120 116 - 120
°F 241 - 248 241 - 248 241 - 248 241 - 248
Safety valve opening pressure
- EC type bar(e) 10.5 14.5 10.5 10.5
- ASME type psi 160 210 160 160

- 95 -
COMPRESSOR / ENGINE SPECIFICATIONS

REFERENCE CONDITIONS

Designation XAS 67 DD - XAS 67 DDG - XATS 67 DD - XAS 77 DD - XAS 97 DD -

XAS 130 DD7 XAS 130 DD7G/ XATS 125 DD7 XAS 150 DD7 XAS 185 DD7
DDG IT
Absolute inlet pressure bar(e) 1 1 1 1 1
psi 14.5 14.5 14.5 14.5 14.5
Relative air humidity % 0 0 0 0 0
Air inlet temperature °C 20 20 20 20 20
°F 68 68 68 68 68
Nominal effective working pressure bar(e) 7 7 10.3 7 7
psi 102 102 150 102 102
The inlet conditions are specified at the air inlet grating outside the canopy.

- 96 -
LIMITATIONS

Designation XAS 67 DD - XAS 67 DDG - XATS 67 DD - XAS 77 DD - XAS 97 DD -

XAS 130 DD7 XAS 130 DD7G/ XATS 125 DD7 XAS 150 DD7 XAS 185 DD7
DDG IT
Minimum effective receiver pressure bar(e) 2.9 3 4 3.3 4
psi 42 43 58 48 58
Maximum effective receiver pressure, bar(e) 8.7 8.7 11.8 8.7 9
compressor unloaded psi 126 126 171 126 130
Maximum ambient temperature no aftercooler °C 45 45 45 45 45
at sea level 1) °F 113 113 113 113 113
with aftercooler °C 40 40 40 40 40
°F 104 104 104 104 104
Minimum starting temperature °C -10 -10 -10 -10 -10
°F 14 14 14 14 14
Minimum starting temperature, °C -20 -20 -20 -20 -20
with coldstart equipment 2) °F -4 -4 -4 -4 -4
Altitude capability see curves
1)
For Hose Reel application: maximum ambient temperature 30°C (86°F).
2) Cold start equipment not available at time of release.

- 97 -
ALTITUDE UNIT PERFORMANCE CURVES
Max. allowable working pressure as a function altitude and ambient temperature.

TEMPERATURE °F TEMPERATURE °F TEMPERATURE °F

14 32 50 68 86 104 122 14 32 50 68 86 104 122 14 32 50 68 86 104 122

5000 16.405 5000 16.405 5000 16.405

5.0 bar(e) 7.0 bar(e) 102 psi

73 psi

4000 13.124 4000 13.124 4000 13.124

6.0 bar(e) 87 psi 4.0 bar(e) 58 psi

5.0 bar(e) 73 psi

3000 7.0 bar(e) 9.843 3000 9.843 3000 9.843
ALTITUDE m

ALTITUDE m

ALTITUDE m
ALTITUDE ft

ALTITUDE ft

ALTITUDE ft
102 psi
6.0 bar(e) 87 psi

7.0 bar(e)
2000 6.562 2000 102 psi 6.562 2000 6.562

1000 3.281 1000 3.281 1000 3.281

0 0 0 0 0 0
-10 0 10 20 30 40 50 -10 0 10 20 30 40 50 -10 0 10 20 30 40 50

TEMPERATURE °C TEMPERATURE °C TEMPERATURE °C

XAS 67 DD - XAS 130 DD7 XAS 67 DDG - XAS 130 DD7G 6kVA XAS 67 DDG - XAS 130 DD7G 12kVA

- 98 -
Max. allowable working pressure as a function altitude and ambient temperature.

TEMPERATURE °F TEMPERATURE °F TEMPERATURE °F

14 32 50 68 86 104 122 14 32 50 68 86 104 122 14 32 50 68 86 104 122

5000 16.405 5000 16.405 5000 16.405

4.0 bar(e)
58 psi
7.3 bar(e) 106 psi
4000 13.124 4000 13.124 4000 13.124
4.0 bar(e)
8.3 bar(e) 58 psi
121 psi
5.0 bar(e)
73 psi
9.3 bar(e)
3000 135 psi 9.843 3000 9.843 3000 9.843
ALTITUDE m

ALTITUDE m

ALTITUDE m
ALTITUDE ft

ALTITUDE ft

ALTITUDE ft
5.0 bar(e)
6.0 bar(e)
73 psi
10.3 bar(e)
150 psi
87 psi

2000 6.562 2000 6.562 2000 6.0 bar(e) 6.562

7.0 bar(e) 87 psi
102 psi
7.0 bar(e)
1000 3.281 1000 3.281 1000 102 psi 3.281

0 0 0 0 0 0
-10 0 10 20 30 40 50 -10 0 10 20 30 40 50 -10 0 10 20 30 40 50

TEMPERATURE °C TEMPERATURE °C TEMPERATURE °C

XATS 67 DD - XATS 125 DD7 XAS 77 DD - XAS 150 DD7 XAS 97 DD - XAS 185 DD7

- 99 -
PERFORMANCE DATA

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

Designation XAS 67 DD - XAS 67 DDG - XATS 67 DD - XAS 77 DD - XAS 97 DD - XAS 97 DDG -

XAS 130 DD7 XAS 130 DD7G/ XATS 125 DD7 XAS 150 DD7 XAS 185 DD7 XAS 185 DD7G/
DDG IT DDG IT
Engine shaft speed, normal and maximum r/min 2400 2750 2750 2300 2750 2750
Engine shaft speed, compressor unloaded r/min 1850 1850 1850 1850 1850 1850
Engine shaft speed, generator at maximum load r/min - 2700 - - - 2700
Free air delivery 1) no aftercooler l/s 62 58 58 72 89 89
cfm 131 123 123 153 189 189
with aftercooler l/s 57 53 53 67 84 84
cfm 121 112 112 142 178 178
Typical oil content of compressed air mg/m3 <5 <5 <5 <5 <5 <5
oz/1000 cu.ft < 0.005 < 0.005 < 0.005 < 0.005 < 0.005 < 0.005
Engine oil consumption (maximum) g/h 17 20 37 17 37 37
oz/h 0.6 0.7 1.3 0.6 1.3 1.3
Compressed air temperature at no aftercooler °C 89 94 90 89 90 90
outlet valves °F 192 201 194 192 194 194
with aftercooler °C 30 30 30 30 30 30
°F 86 86 86 86 86 86
Noise level
- Sound pressure level (LP), measured acc. to dB(A) 70 70 72 70 72 72
ISO 2151 under free field conditions at 7 m distance
- Sound power level (LW) complies with dB(A) 98 98 98 98 98 100
2000/14/EC
1) Free Air Delivery (volume flow rate) is measured according to ISO 1217 ed.3 1996 annex D

Tolerance: The international standard ISO 1217 corresponds to following national standards:
• +/- 5% 25 l/s (53 cfm) < FAD < 250 l/s (530 cfm) • British BSI 1571 part 1 • Swedish SS-ISO 1217
• +/- 4% 250 l/s (530 cfm) < FAD • German DIN 1945 Part 1 • American ANSI PTC9

- 100 -
DESIGN DATA

Compressor

Number of compression stages 1

Engine

Designation XAS 67 DD - XAS 67 DDG - XATS 67 DD - XAS 77 DD - XAS 97 DD - XAS 97 DDG -

XAS 130 DD7 XAS 130 DD7G/ XATS 125 DD7 XAS 150 DD7 XAS 185 DD7 XAS 185 DD7G/
DDG IT DDG IT
Make Deutz
Type D2011L03
Coolant Oil
Number of cylinders 3 3 3 3 3 3
Bore mm 94 94 94 94 94 94
in 3.7 3.7 3.7 3.7 3.7 3.7
Stroke mm 112 112 112 112 112 112
in 4.4 4.4 4.4 4.4 4.4 4.4
Swept volume l 2.332 2.332 2.332 2.332 2.332 2.332
cu.in 142.3 142.3 142.3 142.3 142.3 142.3
Output acc. to ISO 9249 G at normal shaft speed kW 32.5 36 36 31.5 36 36
hp 43.6 48.3 48.3 42.2 48.3 48.3
- Load factor % 50 50 50 50 50 50
Capacity of oil sump:
- Initial fill l 8.5 8.5 8.5 8.5 8.5 8.5
US gal 2.25 2.25 2.25 2.25 2.25 2.25
- Refill (max.) 1) l 6 6 6 6 6 6
US gal 1.59 1.59 1.59 1.59 1.59 1.59
Capacity of cooling system l - - - - - -
US gal - - - - - -
1)
With filter change.

- 101 -
Unit

Designation XAS 67 DD - XAS 67 DDG - XATS 67 DD - XAS 77 DD - XAS 97 DD - XAS 97 DDG -

XAS 130 DD7 XAS 130 DD7G/ XATS 125 DD7 XAS 150 DD7 XAS 185 DD7 XAS 185 DD7G/
DDG IT DDG IT
Capacity of compressor oil system l 8 8 8 8 8 8
US gal 2.1 2.1 2.1 2.1 2.1 2.1
Net capacity of air receiver l 16.7 16.7 16.7 16.7 16.7 16.7
US gal 4.4 4.4 4.4 4.4 4.4 4.4
Capacity of fuel tank l 80 80 80 80 80 80
US gal 21.1 21.1 21.1 21.1 21.1 21.1
Air volume at inlet grating (approx.) 1) m3/s 0.85 0.85 0.85 0.93 1.2 0.81
cuft/s 30 30 30 33 42.4 29
1)
Air required for engine and compressor element cooling, for combustion and for compression.

- 102 -
DESIGN DATA FOR GENERATOR

Alternator

Designation DDG 110V - 6 kW DDG IT 230V - DDG IT 230V - DDG IT 230/400V - DDG IT 230/400V -
3 ph - 6 kVA 3 ph - 12.5 kVA 3 ph - 6 kVA 3 ph - 12.5 kVA
(XAS 67 DDG - XAS 130 DD7G/DDG IT, XAS 97 DDG - XAS 185 DD7G/DDG IT)
Standard IEC 34-1 IEC 34-1 IEC 34-1 IEC 34-1 IEC 34-1
Make MECC ALTE MECC ALTE MECC ALTE MECC ALTE MECC ALTE
Model MR-1 -180/2 TR-1 -160/2 TR-2 -200/2 TR-1 -160/2 TR-2 -200/2
Rated output kVA 6 6 6 6 6
Degree of protection IP 23 23 23 23 23
Insulation - stator class H H H H H
- rotor class H H H H H
Number of phases 1 3 3 3 3
Number of leads 4 6 6 6 6

Electrical power circuit

Designation DDG 110V - 6 kW DDG IT 230V - DDG IT 230V - DDG IT 230/400V - DDG IT 230/400V -
3 ph - 6 kVA 3 ph - 12.5 kVA 3 ph - 6 kVA 3 ph - 12.5 kVA
(XAS 67 DDG - XAS 130 DD7G/DDG IT, XAS 97 DDG - XAS 185 DD7G/DDG IT)
Rated continuous active power COP kW 5.5 4.8 9.6 4.8 9.6
Rated power factor (lagging) 1 0.8 0.8 0.8 0.8
Rated continuous apparent power 1 ph COP kVA 5.5 4 4 4 4
Rated voltage 1ph line to line V 110 230 230 230 230
Rated current 1ph A 50 16 16 16 16
Frequency droop % <5 <5 <5 <5 <5
Rated continuous apparent power 3 ph COP kVA - 6 12 6 12
Rated voltage 3ph line to line V - 230 230 400 400
Rated current 3ph A - 15 30.1 8.7 17.4

- 103 -
Circuit breaker

Designation DDG 110V - 6 kW DDG IT 230V - DDG IT 230V - DDG IT 230/400V - DDG IT 230/400V -
3 ph - 6 kVA 3 ph - 12.5 kVA 3 ph - 6 kVA 3 ph - 12.5 kVA
(XAS 67 DDG - XAS 130 DD7G/DDG IT, XAS 97 DDG - XAS 185 DD7G/DDG IT)
Number of poles 2 3 3 4 4
Rated current In 1ph A 50
In 1ph/3ph A 16/16 16/32 16/10 16/16
Thermal release It 1ph A 50
It 1ph/3ph A 16/16 16/32 16/10 16/16
Magnetic release Im A 3..5 In 3..5 In 3..5 In 3..5 In 3..5 In

Fault current protection

Designation DDG 110V - 6 kW DDG IT 230V - DDG IT 230V - DDG IT 230/400V - DDG IT 230/400V -
3 ph - 6 kVA 3 ph - 12.5 kVA 3 ph - 6 kVA 3 ph - 12.5 kVA
(XAS 67 DDG - XAS 130 DD7G/DDG IT, XAS 97 DDG - XAS 185 DD7G/DDG IT)
Insulation resistance kOhm 10-80 10-80 10-80 10-80
Residual current release Idn A 0.03

- 104 -
Unit dimensions

Designation XAS 67 DD - XAS 130 DD7 XAS 77 DD - XAS 150 DD7

XATS 67 DD - XATS 125 DD7 XATS 67 DD - XATS 125 DD7

without brakes towbar towbar

fixed adjustable fixed adjustable
Length mm 2827 - 2827 -
in 111.3 - 111.3 -
Width mm 1410 1410 1410 1410
in 55.5 55.5 55.5 55.5
Height mm 1258 1258 1258 1258
in 49.5 49.5 49.5 49.5
Weight (ready-to-operate) kg 880 - 890 -
lb 1940 - 1962 -

with brakes towbar towbar

fixed adjustable fixed adjustable
Length mm 2970 3302 - 3470 2970 3302 - 3470
in 117 130 - 137 6548 130 - 137
Width mm 1410 1410 1410 1410
in 55.5 55.5 55.5 55.5
Height mm 1258 1258 1258 1258
in 49.5 49.5 49.5 49.5
Weight (ready-to-operate) kg 915 930 925 940
lb 2017 2050 2040 2073

- 105 -
Dataplate
1 Company code
(1) (2) (3)
2 Product code
3 Unit serial number
Atlas Copco Airpower n.v. (4)
4 Name of the manufacturer
(5)
5 EEC or national type approval number
A kg (6) 6 Vehicle identification number
1- B kg
2- C kg (7) 7 A Maximum permitted total weight of the
D kg vehicle
(8) B Maximum permitted axle load
(9) C Maximum permitted load on the towing eye
(10) 8 Model
(11) 9 Working pressure
10 Speed
S/N Manuf. year (12) 11 Engine power
12 Manufacturing year
0038
Atlas Copco Airpower n.v.
Boomsesteenweg 957 13 CE mark in accordance with Machine Directive
B-2610, WILRIJK
89/392 EC
(13) (14) 14 Register number or number of notified body

- 106 -
Disposal
GENERAL DISPOSAL OF MATERIALS
When developing products and services, Atlas Copco Dispose contaminated substances and material
tries to understand, address, and minimize the separately, according to local applicable
negative environmental effects that the products and environmental legislations.
services may have, when being manufactured,
Before dismantling a machine at the end of its
distributed, and used, as well as at their disposal.
operating lifetime drain all fluids and dispose 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 into the residual waste.
requirements.
Separate the machine into metal, electronics, wiring,
Selecting materials the substantial recyclability, the hoses, insulation and plastic parts.
disassembly possibilities and the separability of
Dispose all components according to the applicable
materials and assemblies are considered as well as the
disposal regulations.
environmental perils and dangers to health during the
recycling and disposal of the unavoidable rates of not Remove spilled fluid mechanically; pick up the rest
recyclable materials. with absorbing agent (for example sand, sawdust) and
dispose it according the applicable local disposal
Your Atlas Copco compressor consists for the most
regulations. Do not drain into the sewage system or
part of metallic materials, that can be remelted in
surface water.
steelworks and smelting works and that is therefore
almost infinite recyclable. The plastic used is
labelled; sorting and fractioning of the materials for
recycling in the future is forseen.

This concept can only succeed with your

help. Support us by disposing
professionally. By assuring a correct
disposal of the product you help to
prevent possible negative consequences
for environment and health, that can
occur with an inappropriate waste
handling.
Recycling and re-usage of material helps
to preserve natural resources.

- 107 -
Maintenance Log

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

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

Service hours Maintenance action Date By initials

- 108 -
Following documents are provided with this unit:
- Test Certificate
- EC Declaration of Conformity:
1
EC DECLARATION OF CONFORMITY

E
2 We, Atlas Copco Airpower n.v., declare under our sole responsibility, that the product
3 Machine name : Compressor (≥ ≥ 350 kW)
4 Machine type :
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

L
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

P
a. Pressure equipment 97/23/EC x
EN ISO 12100-1
EN ISO 12100-2
EN 1012-1
EN 294
EN 349
EN 418
b. Machinery safety 2006/42/EC
EN 563
EN 842

M
EN 953
EN 1037
EN 1050
EN 13478
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

A
EN 60439

Atlas Copco Airpower n.v. is authorized to compile the technical file

8 The harmonized and the technical standards used are identified in the attachments hereafter

9 Conformity of the product to the

Conformity of the specification to the
10
specification and by implication to the

X
Directives
directives
11
12 Issued by Product engineering Manufacturing
13
14 Name
15 Signature

16 Date

E
Form 5009 0603 04
ed. 00, 2010-01-01

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
Be lgiu m Belg ium For info, please contact your local Atlas Copco representative
www.atlascopco.com
p.1(2)

- 109 -
Notes

- 110 -