2954 6220 00 - XA (H) S 107-137 KD (G) - EN

Instruction Manual
for Portable Compressors

English
XAS 127 Kd - XAS 275 KD7

Engine
XA(S) 137 Kd - XA(S) 300 KD7
Kubota V3800
XA(S) 137 KdG - XA(S) 300 KD7G
Com 2
XAHS 107 Kd - XAHS 225 KD7
XAS137 Kd - XAS 300 KD7 Engine
XAS 137 KdG - XAS 300 KD7G Kubota V3307
XAHS 107 Kd - XAHS 225 KD7 Com 3
Instruction Manual
for Portable Compressors

XA(S) 137 Kd - XA(S) 300 KD7
Original instructions
Printed matter N°
2954 6220 00 ATLAS COPCO - PORTABLE ENERGY DIVISION
03/2012 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 2012, Atlas Copco Airpower n.v., Antwerp, Belgium.

Any unauthorized use or copying of the contents or any part thereof is prohibited.
This applies in particular to trademarks, model denominations, part numbers and drawings.
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Preface Table of contents 4.1.4 Lifting instructions................................. 33
Please read the following instructions carefully 4.2 Control panel.............................................. 34
before starting to use your compressor. 1 Safety precautions for portable 4.3 Starting/Stopping ....................................... 34
It is a solid, safe and reliable machine, built compressors with generator ...................... 7 4.3.1 Before starting ....................................... 34
according to the latest technology. Follow the 1.1 Introduction .................................................. 7 4.3.2 Starting procedure.................................. 35
instructions in this booklet and we guarantee you 1.2 General safety precautions ........................... 8 4.3.3 During operation .................................... 36
years of troublefree operation. 4.3.4 Stopping procedure ................................ 36
1.3 Safety during transport and installation ....... 9
Always keep the manual available near the machine. 4.3.5 Generator function (XA(S) 137 KdG -
1.4 Safety during use and operation ................... 9
In all correspondence always mention the XA(S) 300 KD7G) and DdG ................. 37
1.5 Safety during maintenance and repair........ 11
compressor type and serial number, shown on the
data plate. 1.6 Tool applications safety ............................. 12 5 Maintenance ............................................. 38
1.7 Specific safety precautions......................... 13 5.1 Liability...................................................... 38
The company reserves the right to make changes
without prior notice. 5.2 Service paks ............................................... 38
2 Leading particulars .................................. 14
5.3 Service kits................................................. 38
2.1 Description of safety pictograms used
5.3.1 Storage ................................................... 38
in this manual ............................................. 14
5.3.2 Safety precautions.................................. 38
2.2 General description .................................... 14
5.4 Preventive maintenance schedule .............. 39
3 Main Parts................................................. 16 5.5 Maintenance schedule compressor............. 39
3.1 Compressor regulating system ................... 20 5.6 Oil specifications........................................ 44
3.1.1 Overview (Load condition)................... 20 5.6.1 Compressor oil....................................... 45
3.1.2 Air flow.................................................. 21 5.6.2 Engine oil............................................... 46
3.1.3 Oil system .............................................. 21 5.7 Oil level check ........................................... 47
3.1.4 Continuous pneumatic regulating 5.7.1 Check engine oil level ........................... 47
system .................................................... 22 5.7.2 Check compressor oil level.................... 47
3.2 Electrical system ........................................ 24 5.8 Oil and oil filter change ............................. 47
3.2.1 Description............................................. 29 5.8.1 Engine oil and oil filter change.............. 47
3.3 Markings and information labels ............... 30 5.8.2 Compressor oil and oil filter change...... 48
5.9 Compressor Oil Flushing Procedure .......... 49
4 Operating instructions ............................. 31 5.10 Coolant specifications ................................ 50
4.1 Parking, towing and lifting instructions ..... 31 5.10.1 PARCOOL EG ...................................... 50
4.1.1 Parking instructions ............................... 31 5.10.2 Handling PARCOOL EG ...................... 51
4.1.2 Towing instructions ............................... 32 5.11 Coolant check............................................. 51
4.1.3 Height adjustment .................................. 33 5.12 Topping up/replacing coolant .................... 51
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5.12.1 Replacing the coolant............................. 52 7 Problem solving ........................................ 68
5.12.2 Cleaning coolers..................................... 52
5.13 Battery care................................................. 53 8 Available options ...................................... 71
5.13.1 Electrolyte .............................................. 53
9 Technical specifications ........................... 72
5.13.2 Activating a dry-charged battery............ 53
9.1 Torque values ............................................. 72
5.13.3 Recharging a battery .............................. 53
5.13.4 Make-up distilled water.......................... 53 9.1.1 For general applications......................... 72
9.1.2 For important assemblies ....................... 72
5.13.5 Periodic battery service .......................... 54
5.14 Compressor element overhaul .................... 54 9.2 Compressor/Engine/Generator
specifications.............................................. 73
6 Adjustments and servicing procedures .. 55 9.2.1 Reference conditions.............................. 73
6.1 Adjustment of the continuous 9.2.2 Limitations ............................................. 74
pneumatic regulating system ...................... 55 9.2.3 Performance data ................................... 78
9.2.4 Design data............................................. 81
6.2 Air filter engine/compressor....................... 57
6.2.1 Servicing ................................................ 57 9.2.5 Design data for generator....................... 84
6.2.2 Main parts .............................................. 57
10 Data plate .................................................. 85
6.2.3 Cleaning the dust trap ............................ 57
6.2.4 Cleaning instructions filter element ....... 57 11 Disposal ..................................................... 86
6.2.5 Replacing the air filter element .............. 58 11.1 General ....................................................... 86
6.3 Air receiver................................................. 59 11.2 Disposal of materials.................................. 86
6.4 Safety valve ................................................ 59
6.5 Fuel system................................................. 59 12 Maintenance Log ...................................... 87
6.6 Brake (= option) adjustment....................... 60
6.7 Brake shoe adjustment................................ 60
6.7.1 Brake cable adjustment .......................... 61
6.7.2 Brake adjustment check ......................... 61
6.8 Wheels ........................................................ 62
6.8.1 Wheel check ........................................... 62
6.8.2 Lubrication ............................................. 62
6.8.3 Wheel bolts check .................................. 63
6.8.4 Wheel bearing adjustment...................... 64
6.9 Towbar and overrun brake check ............... 65
6.9.1 Towbar and overrun brake lubrication... 66
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Safety precautions for portable compressors with 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 It is the responsibility of management to appoint Take necessary steps to keep unauthorized persons
their equipment with safe, reliable and efficient operators with the appropriate training and skill for away from the unit and eliminate all possible sources
products. Factors taken into account are among each category of job. of danger at the unit.
others: When handling, operating, overhauling and/or
Skill level 1: Operator
- the intended and predictable future use of the performing maintenance or repair on Atlas Copco
products, and the environments in which they are An operator is trained in all aspects of operating the
unit with the push-buttons, and is trained to know the equipment, the mechanics are expected to use safe
expected to operate, engineering practices and to observe all relevant local
- applicable rules, codes and regulations, safety aspects.
safety requirements and ordinances. The following
- the expected useful product life, assuming proper Skill level 2: Mechanical technician list is a reminder of special safety directives and
service and maintenance, A mechanical technician is trained to operate the unit precautions mainly applicable to Atlas Copco
- providing the manual with up-to-date the same as the operator. In addition, the mechanical equipment.
information. technician is also trained to perform maintenance and These safety precautions apply to machinery
Before handling any product, take time to read the repair, as described in the instruction manual, and is processing or consuming air. Processing of any other
relevant instruction manual. Besides giving detailed allowed to change settings of the control and safety gas requires additional safety precautions typical to
operating instructions, it also gives specific system. A mechanical technician does not work on the application and are not included herein.
information about safety, preventive maintenance, live electrical components.
etc. Neglecting the safety precautions may endanger
Skill level 3: Electrical technician people as well as environment and machinery:
Keep the manual always at the unit location, easy An electrical technician is trained and has the same - endanger people due to electrical, mechanical or
accessible to the operating personnel. qualifications as both the operator and the mechanical chemical influences,
See also the safety precautions of the engine and technician. In addition, the electrical technician may - endanger the environment due to leakage of oil,
possible other equipment, which are separately sent carry out electrical repairs within the various solvents or other substances,
along or are mentioned on the equipment or parts of enclosures of the unit. This includes work on live - endanger the machinery due to function failures.
the unit. electrical components. All responsibility for any damage or injury resulting
These safety precautions are general and some Skill level 4: Specialist from the manufacturer from neglecting these precautions or by non-
statements will therefore not always apply to a This is a skilled specialist sent by the manufacturer or observance of ordinary caution and due care required
particular unit. its agent to perform complex repairs or modifications in handling, operating, maintenance or repair, also if
Only people that have the right skills should be to the equipment. not expressly mentioned in this instruction manual, is
allowed to operate, adjust, perform maintenance or disclaimed by Atlas Copco.
In general it is recommended that not more than two
repair on Atlas Copco equipment. people operate the unit, more operators could lead to
unsafe operating conditions.
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The manufacturer does not accept any liability for any 4 Normal ratings (pressures, temperatures, speeds, 13 In the event the safety labels are damaged or
damage arising from the use of non-original parts and etc.) shall be durably marked. destroyed, they must be replaced to ensure
for modifications, additions or conversions made 5 Operate the unit only for the intended purpose and operator safety.
without the manufacturer’s approval in writing. within its rated limits (pressure, temperature, 14 Keep the work area neat. Lack of order will
If any statement in this manual does not comply with speeds, etc.). increase the risk of accidents.
local legislation, the stricter of the two shall be 6 The machinery and equipment shall be kept clean, 15 When working on the unit, wear safety clothing.
applied. i.e. as free as possible from oil, dust or other Depending on the kind of activities these are:
Statements in these safety precautions should not be deposits. safety glasses, ear protection, safety helmet
interpreted as suggestions, recommendations or 7 To prevent an increase in working temperature, (including visor), safety gloves, protective
inducements that it should be used in violation of any inspect and clean heat transfer surfaces (cooler clothing, safety shoes. Do not wear the hair long
applicable laws or regulations. fins, intercoolers, water jackets, etc.) regularly. and loose (protect long hair with a hairnet), or
See the Preventive maintenance schedule. wear loose clothing or jewellery.
8 All regulating and safety devices shall be 16 Take precautions against fire. Handle fuel, oil and
maintained with due care to ensure that they anti-freeze with care because they are
function properly. They may not be put out of inflammable substances. Do not smoke or
GENERAL SAFETY PRECAUTIONS approach with naked flame when handling such
action.
substances. Keep a fire-extinguisher in the
1 The owner is responsible for maintaining the unit 9 Care shall be taken to avoid damage to safety vicinity.
in a safe operating condition. Unit parts and valves and other pressure-relief devices,
accessories must be replaced if missing or especially to avoid plugging by paint, oil coke or 17 Portable compressors with generator (with
unsuitable for safe operation. dirt accumulation, which could interfere with the earthing pin):
2 The supervisor, or the responsible person, shall at functioning of the device. Earth the generator as well as the load properly.
all times make sure that all instructions regarding 10 Pressure and temperature gauges shall be checked 18 Portable compressors with generator IT:
machinery and equipment operation and regularly with regard to their accuracy. They shall Note: This generator is built to supply a sheer
maintenance are strictly followed and that the be replaced whenever outside acceptable alternating current IT network.
machines with all accessories and safety devices, tolerances.
as well as the consuming devices, are in good Earth the load properly.
11 Safety devices shall be tested as described in the
repair, free of abnormal wear or abuse, and are maintenance schedule of the instruction manual
not tampered with. to determine that they are in good operating
3 Whenever there is an indication or any suspicion condition. See the Preventive maintenance
that an internal part of a machine is overheated, schedule.
the machine shall be stopped but no inspection 12 Mind the markings and information labels on the
covers shall be opened before sufficient cooling unit.
time has elapsed; this to avoid the risk of
spontaneous ignition of oil vapour when air is
admitted.
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SAFETY DURING TRANSPORT AND 2 To tow a unit use a towing vehicle of ample 11 Locate the unit away from walls. Take all
INSTALLATION capacity. Refer to the documentation of the precautions to ensure that hot air exhausted from
towing vehicle. the engine and driven machine cooling systems
To lift a unit, all loose or pivoting parts, e.g. doors and 3 If the unit is to be backed up by the towing cannot be recirculated. If such hot air is taken in
towbar, shall first be securely fastened. vehicle, disengage the overrun brake mechanism by the engine or driven machine cooling fan, this
Do not attach cables, chains or ropes directly to the (if it is not an automatic mechanism). may cause overheating of the unit; if taken in for
lifting eye; apply a crane hook or lifting shackle combustion, the engine power will be reduced.
4 Never exceed the maximum towing speed of the
meeting local safety regulations. Never allow sharp unit (mind the local regulations). 12 The electrical connections shall correspond to
bends in lifting cables, chains or ropes. local codes. The machines shall be earthed and
5 Place the unit on level ground and apply the protected against short circuits by fuses or circuit
Helicopter lifting is not allowed. parking brake before disconnecting the unit from breakers.
It is strictly forbidden to dwell or stay in the risk zone the towing vehicle. Unclip the safety break-away
under a lifted load. Never lift the unit over people or cable or safety chain. If the unit has no parking 13 Never connect the generator outlets to an
residential areas. Lifting acceleration and retardation brake or jockey wheel, immobilize the unit by installation which is also connected to a public
shall be kept within safe limits. placing chocks in front of and/or behind the mains.
1 Before towing the unit: wheels. When the towbar can be positioned 14 Before connecting a load, switch off the
vertically, the locking device must be applied and corresponding circuit breaker, and check whether
- ascertain that the pressure vessel(s) is (are) kept in good order. frequency, voltage, current and power factor
depressurized, comply with the ratings of the generator.
6 To lift heavy parts, a hoist of ample capacity,
- check the towbar, the brake system and the tested and approved according to local safety
towing eye. Also check the coupling of the regulations, shall be used.
towing vehicle,
7 Lifting hooks, eyes, shackles, etc., shall never be
- check the towing and brake capability of the bent and shall only have stress in line with their
towing vehicle, SAFETY DURING USE AND OPERATION
design load axis. The capacity of a lifting device
- check that the towbar, jockey wheel or stand diminishes when the lifting force is applied at an 1 When the unit has to operate in a fire-hazardous
leg is safely locked in the raised position, angle to its load axis. environment, each engine exhaust has to be
- ascertain that the towing eye can swivel freely 8 For maximum safety and efficiency of the lifting provided with a spark arrestor to trap incendiary
on the hook, apparatus all lifting members shall be applied as sparks.
- check that the wheels are secure and that the near to perpendicular as possible. If required, a 2 The exhaust contains carbon monoxide which is a
lifting beam shall be applied between hoist and lethal gas. When the unit is used in a confined
tyres are in good condition and inflated
load. space, conduct the engine exhaust to the outside
correctly,
9 Never leave a load hanging on a hoist. atmosphere by a pipe of sufficient diameter; do
- connect the signalisation cable, check all lights
10 A hoist has to be installed in such a way that the this in such a way that no extra back pressure is
and connect the pneumatic brake couplers,
object will be lifted perpendicular. If that is not created for the engine. If necessary, install an
- attach the safety break-away cable or safety extractor. Observe any existing local regulations.
possible, the necessary precautions must be taken
chain to the towing vehicle, Make sure that the unit has sufficient air intake
to prevent load-swinging, e.g. by using two
- remove wheel chocks, if applied, and hoists, each at approximately the same angle not for operation. If necessary, install extra air intake
disengage the parking brake. exceeding 30° from the vertical. ducts.
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3 When operating in a dust-laden atmosphere, place system, fit an appropriate non-return valve (check When the sound pressure level, at any point
the unit so that dust is not carried towards it by the valve) between compressor outlet and the where personnel normally has to attend, is:
wind. Operation in clean surroundings connected sand-blasting or compressed-air - below 70 dB(A): no action needs to be taken,
considerably extends the intervals for cleaning system. Observe the right mounting position/
the air intake filters and the cores of the coolers. direction. - above 70 dB(A): noise-protective devices
should be provided for people continuously
4 Close the compressor air outlet valve before 11 Before removing the oil filler plug, ensure that the being present in the room,
connecting or disconnecting a hose. Ascertain pressure is released by opening an air outlet
that a hose is fully depressurized before valve. - below 85 dB(A): no action needs to be taken
for occasional visitors staying a limited time
disconnecting it. Before blowing compressed air 12 Never remove a filler cap of the cooling water only,
through a hose or air line, ensure that the open end system of a hot engine. Wait until the engine has
is held securely, so that it cannot whip and cause - above 85 dB(A): room to be classified as a
sufficiently cooled down.
injury. noise-hazardous area and an obvious warning
13 Never refill fuel while the unit is running, unless shall be placed permanently at each entrance
5 The air line end connected to the outlet valve otherwise stated in the Atlas Copco Instruction to alert people entering the room, for even
must be safeguarded with a safety cable, attached Book. Keep fuel away from hot parts such as air relatively short times, about the need to wear
next to the valve. outlet pipes or the engine exhaust. Do not smoke ear protectors,
6 No external force may be exerted on the air outlet when fuelling. When fuelling from an automatic - above 95 dB(A): the warning(s) at the
valves, e.g. by pulling on hoses or by installing pump, an earthing cable should be connected to entrance(s) shall be completed with the
auxiliary equipment directly to a valve, e.g. a the unit to discharge static electricity. Never spill recommendation that also occasional visitors
water separator, a lubricator, etc. Do not step on nor leave oil, fuel, coolant or cleansing agent in or shall wear ear protectors,
the air outlet valves. around the unit.
- above 105 dB(A): special ear protectors that
7 Never move a unit when external lines or hoses 14 All doors shall be shut during operation so as not are adequate for this noise level and the
are connected to the outlet valves, to avoid to disturb the cooling air flow inside the spectral composition of the noise shall be
damage to valves, manifold and hoses. bodywork and/or render the silencing less provided and a special warning to that effect
8 Do not use compressed air from any type of effective. A door should be kept open for a short shall be placed at each entrance.
compressor, without taking extra measures, for period only e.g. for inspection or adjustment.
18 The unit has parts, which may be accidentally
breathing purposes as this may result in injury or 15 Periodically carry out maintenance works touched by personal, of which the temperature
death. For breathing air quality, the compressed according to the maintenance schedule. can be in excess of 80 °C (176 °F). The insulation
air must be adequately purified according to local 16 Stationary housing guards are provided on all or safety guard, protecting these parts shall not be
legislation and standards. Breathing air must rotating or reciprocating parts not otherwise removed before the parts have cooled down to
always be supplied at stable, suitable pressure. protected and which may be hazardous to room temperature. As it is technically not
9 Distribution pipework and air hoses must be of personnel. Machinery shall never be put into possible to insulate all hot parts or to install safety
correct diameter and suitable for the working operation, when such guards have been removed, guards around hot parts (e.g. exhaust manifold,
pressure. Never use frayed, damaged or before the guards are securely reinstalled. exhaust turbine), the operator / service engineer
deteriorated hoses. Replace hoses and flexibles 17 Noise, even at reasonable levels, can cause must always be aware not to touch hot parts when
before the lifetime expires. Use only the correct irritation and disturbance which, over a long opening a machine door.
type and size of hose end fittings and connections. period of time, may cause severe injuries to the 19 Never operate the unit in surroundings where
10 If the compressor is to be used for sand-blasting nervous system of human beings. there is a possibility of taking in flammable or
or will be connected to a common compressed-air toxic fumes.
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20 If the working process produces fumes, dust or cannot be avoided, e.g. for measurements, tests or SAFETY DURING MAINTENANCE AND
vibration hazards, etc., take the necessary steps to adjustments, have the action carried out by a REPAIR
eliminate the risk of personal injury. qualified electrician only, with appropriate tools,
21 When using compressed air or inert gas to clean and ascertain that the required bodily protection Maintenance, overhaul and repair work shall only be
down equipment, do so with caution and use the against electrical hazards is applied. carried out by adequately trained personnel; if
appropriate protection, at least safety glasses, for 30 Never touch the power terminals during operation required, under supervision of someone qualified for
the operator as well as for any bystander. Do not of the machine. the job.
apply compressed air or inert gas to your skin or 31 Whenever an abnormal condition arises, e.g. 1 Use only the correct tools for maintenance and
direct an air or gas stream at people. Never use it excessive vibration, noise, odour, etc., switch the repair work, and only tools which are in good
to clean dirt from your clothes. circuit breakers to OFF and stop the machine. condition.
22 When washing parts in or with a cleaning solvent, Correct the faulty condition before restarting. 2 Parts shall only be replaced by genuine Atlas
provide the required ventilation and use 32 Check the electric cables regularly. Damaged Copco replacement parts.
appropriate protection such as a breathing filter, cables and insufficient lightening of connections 3 All maintenance work, other than routine
safety glasses, rubber apron and gloves, etc. may cause electric shocks. Whenever damaged attention, shall only be undertaken when the unit
23 Safety shoes should be compulsory in any wires or dangerous conditions are observed, is stopped. Steps shall be taken to prevent
workshop and if there is a risk, however small, of switch the circuit breakers to OFF and stop the inadvertent starting. In addition, a warning sign
falling objects, wearing of a safety helmet should engine. Replace the damaged wires or correct the bearing a legend such as ”work in progress; do
be included. dangerous condition before restarting. Make sure not start” shall be attached to the starting
24 If there is a risk of inhaling hazardous gases, that all electric connections are securely equipment.
fumes or dust, the respiratory organs must be tightened. On engine-driven units the battery shall be
protected and depending on the nature of the 33 Avoid overloading the generator. The generator is disconnected and removed or the terminals
hazard, so must the eyes and skin. provided with circuit breakers for overload covered by insulating caps.
protection. When a breaker has tripped, reduce On electrically driven units the main switch shall
25 Remember that where there is visible dust, the
finer, invisible particles will almost certainly be the concerned load before restarting. be locked in open position and the fuses shall be
taken out. A warning sign bearing a legend such
present too; but the fact that no dust can be seen 34 If the generator is used as stand-by for the mains as ”work in progress; do not supply voltage” shall
is not a reliable indication that dangerous, supply, it must not be operated without control
invisible dust is not present in the air. be attached to the fuse box or main switch.
system which automatically disconnects the
generator from the mains when the mains supply 4 Before dismantling any pressurized component,
26 Never operate the unit at pressures or speeds
below or in excess of its limits as indicated in the is restored. the compressor or equipment shall be effectively
isolated from all sources of pressure and the entire
technical specifications. 35 Never remove the cover of the output terminals system shall be relieved of pressure. Do not rely
27 Never operate the generator in excess of its limits during operation. Before connecting or on non-return valves (check valves) to isolate
as indicated in the technical specifications and disconnecting wires, switch off the load and the pressure systems. In addition, a warning sign
avoid long no-load sequences. circuit breakers, stop the machine and make sure bearing a legend such as ”work in progress; do
28 Never operate the generator in a humid that the machine cannot be started inadvertently not open” shall be attached to each of the outlet
atmosphere. Excessive moisture causes or there is any residual voltage on the power valves.
worsening of the generator insulation. circuit.
5 Prior to stripping an engine or other machine or
29 Do not open electrical cabinets, cubicles or other 36 Running the generator at low load for long undertaking major overhaul on it, prevent all
equipment while voltage is supplied. If such periods will reduce the lifetime of the engine. movable parts from rolling over or moving.
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6 Make sure that no tools, loose parts or rags are left 15 Protect the engine, alternator, air intake filter, 23 Before clearing the unit for use after maintenance
in or on the machine. Never leave rags or loose electrical and regulating components, etc., to or overhaul, check that operating pressures,
clothing near the engine air intake. prevent moisture ingress, e.g. when steam- temperatures and speeds are correct and that the
7 Never use flammable solvents for cleaning (fire- cleaning. control and shutdown devices function correctly.
risk). 16 When performing any operation involving heat,
8 Take safety precautions against toxic vapours of flames or sparks on a machine, the surrounding
cleaning liquids. components shall first be screened with non-
flammable material.
9 Never use machine parts as a climbing aid. TOOL APPLICATIONS SAFETY
17 Never use a light source with open flame for
10 Observe scrupulous cleanliness during inspecting the interior of a machine.
maintenance and repair. Keep away dirt, cover Apply the proper tool for each job. With the
the parts and exposed openings with a clean cloth, 18 When repair has been completed, the machine knowledge of correct tool use and knowing the
paper or tape. shall be barred over at least one revolution for limitations of tools, along with some common sense,
reciprocating machines, several revolutions for many accidents can be prevented.
11 Never weld on or perform any operation rotary ones to ensure that there is no mechanical
involving heat near the fuel or oil systems. Fuel Special service tools are available for specific jobs
interference within the machine or driver. Check and should be used when recommended. The use of
and oil tanks must be completely purged, e.g. by the direction of rotation of electric motors when
steam-cleaning, before carrying out such these tools will save time and prevent damage to
starting up the machine initially and after any parts.
operations. Never weld on, or in any way modify, alteration to the electrical connection(s) or switch
pressure vessels. Disconnect the alternator cables gear, to check that the oil pump and the fan
during arc welding on the unit. function properly.
12 Support the towbar and the axle(s) securely if 19 Maintenance and repair work should be recorded
working underneath the unit or when removing a in an operator’s logbook for all machinery.
wheel. Do not rely on jacks. Frequency and nature of repairs can reveal unsafe
13 Do not remove any of, or tamper with, the sound- conditions.
damping material. Keep the material free of dirt 20 When hot parts have to be handled, e.g. shrink
and liquids such as fuel, oil and cleansing agents. fitting, special heat-resistant gloves shall be used
If any sound-damping material is damaged, and, if required, other body protection shall be
replace it to prevent the sound pressure level from applied.
increasing.
21 When using cartridge type breathing filter
14 Use only lubricating oils and greases equipment, ascertain that the correct type of
recommended or approved by Atlas Copco or the cartridge is used and that its useful service life is
machine manufacturer. Ascertain that the not surpassed.
selected lubricants comply with all applicable
safety regulations, especially with regard to 22 Make sure that oil, solvents and other substances
explosion or fire-risk and the possibility of likely to pollute the environment are properly
decomposition or generation of hazardous gases. disposed of.
Never mix synthetic with mineral oil.
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SPECIFIC SAFETY PRECAUTIONS Pressure vessels Safety valves
(according to directive 87/404/EEC annex II § 2) All adjustments or repairs are to be done by an
Batteries authorized representative of the valve supplier (see
Maintenance/installation requirements:
When servicing batteries, always wear protecting also Preventive maintenance schedule).
clothing and glasses. 1 The vessel can be used as pressure vessel or as
separator and is designed to hold compressed air
1 The electrolyte in batteries is a sulphuric acid for the following application:
solution which is fatal if it hits your eyes, and
which can cause burns if it contacts your skin. - pressure vessel for compressor,
Therefore, be careful when handling batteries, - medium AIR/OIL,
e.g. when checking the charge condition. and operates as detailed on the data plate of the
2 Install a sign prohibiting fire, open flame and vessel:
smoking at the post where batteries are being - the maximum working pressure ps in bar (psi),
charged. - the maximum working temperature Tmax in
3 When batteries are being charged, an explosive °C (°F),
gas mixture forms in the cells and might escape - the minimum working temperature Tmin in °C
through the vent holes in the plugs. Thus an (°F),
explosive atmosphere may form around the - the capacity of the vessel V in l (US gal, Imp
battery if ventilation is poor, and can remain in gal, cu.ft).
and around the battery for several hours after it
has been charged. Therefore: 2 The pressure vessel is only to be used for the
applications as specified above and in accordance
- never smoke near batteries being, or having with the technical specifications. Safety reasons
recently been, charged, prohibit any other applications.
- never break live circuits at battery terminals, 3 National legislation requirements with respect to
because a spark usually occurs. re-inspection must be complied with.
4 When connecting an auxiliary battery (AB) in 4 No welding or heat treatment of any kind is
parallel to the unit battery (CB) with booster permitted to those vessel walls which are exposed
cables: connect the + pole of AB to the + pole of to pressure.
CB, then connect the - pole of CB to the mass of
5 The vessel is provided and may only be used with
the unit. Disconnect in the reverse order.
the required safety equipment such as
manometer, overpressure control devices, safety
valve, etc.
6 Draining of condensate shall be performed
regularly 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
DESCRIPTION OF SAFETY PICTOGRAMS GENERAL DESCRIPTION Compressor
USED IN THIS MANUAL The compressor casing houses two screw-type rotors,
mounted on ball and roller bearings. The male rotor,
This symbol draws your attention to driven by the engine, drives the female rotor. The
dangerous situations. The operation element delivers pulsation-free air.
concerned may endanger persons and Injected oil is used for sealing, cooling and
cause injuries. lubricating purposes.
This symbol is followed by Compressor oil system

supplementary information. 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 by the oil separator
element.
The vessel is provided with an oil level indicator.
The compressors type XAS 127 Kd - XAS 275 KD7, Regulation

XA(S) 137 Kd - XA(S) 300 KD7, XA(S) 137 KdG - The compressor is provided with a continuous
XA(S) 300 KD7G and XAHS 107 Kd - XAHS 225 pneumatic regulating system and a blow-down valve
KD7 are silenced, single-stage, oil-injected screw which is integrated in the unloader assembly. The
compressors, built for a nominal effective working valve is closed during operation by air receiver
pressure, ranging from 7 bar (102 psi) up to 12 bar pressure and opens by air receiver pressure via the
(175 psi) (see chapter Technical specifications). compressor element when the compressor is stopped.
Engine When the air consumption increases, the air receiver
pressure will decrease and vice versa.
The compressors are driven by a liquid-cooled diesel
engine. This receiver pressure variation is sensed by the
regulating valve which, by means of control air to the
The engine’s power is transmitted to the compressor unloader and engine speed regulator, matches the air
through a heavy-duty coupling. output to the air consumption. The air receiver
pressure is maintained between the pre-selected
working pressure and the corresponding unloading
pressure.
- 14 -
Cooling system Bodywork Generator - XA(S) 137 KdG - XA(S) 300 KD7G
The engine is equipped with a liquid cooler. All The bodywork has openings at the shaped front and The built-in generator is driven by a multi V-belt
compressors are equipped with an oil cooler. rear end for the intake and outlet of cooling air and drive. The generated current can be drawn via
The cooling air is generated by a fan, driven by the hinged door for maintenance and service operations. 3 sockets (3 x 16 A, 2 x 3 phases, 1 x 1 phase).
The bodywork is internally lined with sound-
engine. The compressor and the generator of the XA(S) 137
absorbing material.
KdG - XA(S) 300 KD7G may be used
Safety devices simultaneously.
Lifting eye
A thermal shut-down switch protects the compressor
A lifting eye is accessible when the small door at the
against overheating. The air receiver is provided with
top of the unit is unlocked.
a safety valve.
The engine is equipped with low oil pressure and high Control panel
oil temperature shut-down switches. The control panel grouping the air pressure gauge,
control switch etc., is placed in the center at the rear
Frame and axle
end.
The compressor/engine unit is supported by rubber
buffers in the frame. Data plate
The standard unit has a non-adjustable towbar with a The compressor is furnished with a data plate
towing eye. showing the product code, the unit number and the
working pressure (see chapter Data plate).
As an option the unit can be equipped with an
adjustable towbar, an overrun and parking brake and Serial number
towing eyes type DIN, ball, ITA, NATO, AC
(France), (see chapter Available options). The serial number is located on the right-hand side
towards the front on the upper edge of the frame and
The braking system consists of an integrated parking
also on the data plate.
brake and overrunbrake. When driving backwards the
overrunbrake is not engaged automatically.
- 15 -
Main Parts
(WLI)
(EP) (E) (F) (R) (OC) (SL) (BH)
(A)
(CPg) (AFce)
(G) (VI)
(B)
(AR) (RV) (TB)

(FPco) (AR) (FFa)
(SV) (FFp)
(OFce) (FCft)
(UV) (VV)
(BDV) (DP)
(OLG)
(CH) (FT)
(AOV)
(CE)
(SR)
(OFe)
(FCeo)
(CP)
(DSE)
XAS 127 Kd - XAS 275 KD7, XA(S) 137 Kd - XA(S) 300 KD7, XA(S) 137 KdG - XA(S) 300 KD7G
and XAHS 107 Kd - XAHS 225 KD7 with some options (Engine Kubota V3800)
- 16 -
Reference Name Reference Name
A Alternator G Generator
AFce Air Filter Compressor/Engine OC Oil Cooler
AOV Air Outlet Valve OFce Oil Filter (compressor element)
AR Air Receiver OFe Oil Filter (engine)
B Battery OLG Oil Level Gauge (compressor
BDV Blow Down Valve element)
BH Brake Handle R Radiator
CE Compressor Element RV Regulating Valve
CH Coupling Housing SL Support Leg
CP Control Panel SR Speed Regulator
CPg Control Panel Generator SV Safety Valve
DP Data Plate TB Towbar
DSE Engine Oil Level Dipstick UV Unloading Valve
E Engine VI Vacuum Indicator
EP Exhaust Pipe VV Vacuator Valve
F Fan WLI Water Level Indicator
FCeo Filler Cap (engine oil)
FCft Filler Cap (fuel tank)
FFp Primary Fuel Filter
FFa Additional Fuel Filter
FPco Filler Plug (compressor oil)
FT Fuel Tank
- 17 -
(EP) (E) (F) (R) (WLI) (OC) (SL) (BH)
(B)
(CPg)
(G) (VI) (AFce)
(AR)
(FPco)
(RV) (TB)
(AR) (FFa)
(SV) (FFp)
(OLG) (OFce) (FCft)
(UV) (VV)
(BDV) (DP)
(CH) (FT)
(SR)
(AOV) (SR)
(CE) (OFe)
(DSE)
(CP) (FCeo)
XAS 137 Kd - XAS 300 KD7, XAS 137 KdG - XAS 300 KD7G
and XAHS 107 Kd - XAHS 225 KD7 with some options (Engine Kubota V3307)
- 18 -
Reference Name Reference Name
A Alternator G Generator
AFce Air Filter Compressor/Engine OC Oil Cooler
AOV Air Outlet Valve OFce Oil Filter (compressor element)
AR Air Receiver OFe Oil Filter (engine)
B Battery OLG Oil Level Gauge (compressor
BDV Blow Down Valve element)
BH Brake Handle R Radiator
CE Compressor Element RV Regulating Valve
CH Coupling Housing SL Support Leg
CP Control Panel SR Speed Regulator
CPg Control Panel Generator SV Safety Valve
DP Data Plate TB Towbar
DSE Engine Oil Level Dipstick UV Unloading Valve
E Engine VI Vacuum Indicator
EP Exhaust Pipe VV Vacuator Valve
F Fan WLI Water Level Indicator
FCeo Filler Cap (engine oil)
FCft Filler Cap (fuel tank)
FFp Primary Fuel Filter
FFa Additional Fuel Filter
FPco Filler Plug (compressor oil)
FT Fuel Tank
- 19 -
COMPRESSOR REGULATING SYSTEM
OVERVIEW (LOAD CONDITION)
Reference Name
AFce Air Filter Compressor/Engine
(OC)
AFE Air Filter Element
(AFce)
(AFE) AFSC Air Filter Safety Cartridge
(AFSC) AOV Air Outlet Valve
(VI)
(SOV) AR Air Receiver/Oil Separator
BDV Blow Down Valve
(RV)
(CV) BV By-Pass Valve Oil Filter
(AR) CE Compressor Element
(SV)
(OSE) CH Coupling Housing
CP Control Panel
(R) CV Check Valve
(AOV)
(SRE) DP Drain Plug
(DP) (F) E Engine
(BV) (UA) EW Electrical Wiring
(OFC) (OFE)
F Cooling Fan
(SL) (E)
(EW) (CH) OC Oil Cooler
(CE) OFC Oil Filter Compressor
OFE Oil Filter Engine
(CP)
(TSE) OSE Oil Separator Element
(BDV) PSE Pressure Switch Engine
(PSE) R Restrictor
(TSC)
RV Regulating Valve
- 20 -
AIR FLOW OIL SYSTEM
Reference Name The system comprises: The system comprises:

SL Scavenge Line AFce Air filter compressor/engine AR/OSE Air receiver/oil separator element
SOV Solenoid Valve (Generator option) AR/OSE Air receiver/oil separator element OC Oil cooler
SRE Speed Regulator Engine CE Compressor element OF Oil filter
SV Safety Valve UA/UV Unloader assembly with unloader valve
The lower part of the air receiver (AR) serves as an oil
TSE Temperature Switch Engine BDV Blow-down valve tank.
TSC Temperature Switch Compressor Air pressure forces the oil from the air receiver/oil
Air drawn through the airfilter (AFce) into the
UA Unloader Assembly compressor element (CE) is compressed. At the separator (AR/OSE) through the oil cooler (OCce)
element outlet, compressed air and oil pass into the air and oil filter (OF) to the compressor element (CE).
VI Vacuum Indicator
receiver/oil separator (AR/OSE). The compressor element has an oil gallery in the
The check valve (CV) prevents blow-back of bottom of its casing. The oil for rotor lubrication,
compressed air when the compressor is stopped. In cooling and sealing is injected through holes in the
the air receiver/oil separator (AR/OSE), most of the gallery.
oil is removed from the air/oil mixture; the remaining Lubrication of the bearings is ensured by oil injected
oil is removed by the separator element. into the bearing housings.
The oil collects in the receiver and on the bottom of The injected oil, mixed with the compressed air,
the separator element. leaves the compressor element and re-enters the air
The air leaves the receiver via a restriction which receiver, where it is separated from the air as
prevents the receiver pressure from dropping below described in section Air flow. The oil that collects on
the minimum working pressure (specified in section the bottom of the oil separator element is returned to
Limitations), even when the air outlet valves are the system through a scavenging line (SL), which is
open. This ensures adequate oil injection and prevents provided with a flow restrictor.
oil consumption. The oil filter by-pass valve opens when the pressure
The system comprises of a temperature switch (TS) drop over the filter is above normal because of a
and a working pressure gauge (WPG). clogged filter. The oil then by-passes the filter
without being filtered. For this reason, the oil filter
A blow-down valve (BDV) is fitted in the unloader must be replaced at regular intervals (see section
assembly to automatically depressurise the air Preventive maintenance schedule).
receiver (AR) when the compressor is stopped.
- 21 -
CONTINUOUS PNEUMATIC REGULATING SYSTEM
(RV)
(SOV)
(UA)
(BOV)
(VH)
(BDV) (SR)
(TV)
(CE)
(AR)
- 22 -
The system comprises: The air output is controlled from maximum output The construction of the regulating valve (RV) is such
RV Regulating valve (100%) to no output (0%) by: that any increase (decrease) of the air receiver
pressure above the pre-set valve opening pressure
1. Speed control of the engine between maximum
UA Unloader assembly results in a proportional increase (decrease) of the
load speed and unloading speed (the output of a
SR Speed regulator screw compressor is proportional to the rotating control pressure to the unloading valve and the speed
regulator.
speed).
The compressor is provided with a continuous Part of the control air is vented into atmosphere, and
pneumatic regulating system. This system is provided 2. Air inlet throttling.
any condensate discharged, through the vent holes
with a blow-down valve (BDV), which is integrated 3. Blow off valve (BOV). (VH).
in the unloader assembly (UA). The valve is closed
If the air consumption is equal to or exceeds the
during operation by air receiver pressure and opens
by air receiver pressure via the compressor element maximum air output, the engine speed is held at
maximum load speed and the unloading valve is fully XA(S) 137 KdG - XA(S) 300 KD7G:
when the compressor is stopped.
open. When the generator is switched on, the solenoid valve
When the air consumption increases, the air receiver (SOV) via the speed regulator (SR) controls the motor
If the air consumption is less than the maximum air
pressure will decrease and vice versa. This receiver and allows it to reach maximum speed (the normal
output, the regulating valve supplies control air to
pressure variation is sensed by the regulating valve control system is switched off).
which, by means of control air to the unloader, unloader valve (UV) to reduce the air output and
holds air receiver pressure between the normal
matches the air output to the air consumption. The air
working pressure and the corresponding unloading
receiver pressure is maintained between the pre-
selected working pressure and the corresponding pressure at approx. 1.5 bar (22 psi) above the normal
working pressure.
unloading pressure.
When starting the compressor, the throttle valve (TV) When the air consumption is resumed, the blow off
valve (BOV) closes and the unloader valve (UV)
is kept open by spring force, the engine runs at
gradually opens the air intake and the speed regulator
maximum speed. The compressor element (CE) takes
in air and pressure builds up inside the receiver (AR). (SR) increases the engine speed.
- 23 -
ELECTRICAL SYSTEM
All compressors are equipped with a negative earthed system.
9822 0841 56 Engine Kubota V3800 12

10A S1 43
F1
2
d2 d2 1 ab3
X1:1
V3
3
C3 30
V2 K6
15
87
4
b3 b3 87a
4
b3
15
13
1
1
dc2 f2 d2 d3 b3 30
K5
87
87a
3
30 b3
30
K2 K3 3
6
87 C3 b3 b3
87
K6 86
3
87
G2 X1:3 b3
K2 86
B+ K7 85
21
20
+ IG
7
d3 f2 L 30 b3 b3 b3 b3 b3
3
G1 - GND a3
85
14
X1:4 b3
22
X1:2 b3 X1:6 X1:7 X1:8 X1:9
X3:A K5 86 K7 86
M1 85
X3:B 85 H1 S5 H2
K0
16
17
a3
13
3
X1:5 X1:12 b3 b3
S4 S3
P
M
E P1 + V1
K3 86 Y1
h P2
- 85
12
a6
12
12
12
12
12
12
12
a6 b6 b6 b6 b6 b6
b6 X1:10
12
b6 X1:11
- 24 -
Reference Name Reference Name Wire size Colour code
E Glowplugs engine S3 Pressure switch engine oil aa = 0.5 mm2 1 = brown
F1 Circuit breaker S4 Temperature switch engine coolant a = 1 mm2 2 = red
G1 Battery S5 Temperature switch compressor b = 1.5 mm2 3 = orange
G2 Charging alternator V1 Free wheeling diode c = 2.5 mm2 4 = yellow
H1 Lamp engine alarm V2 Diode d = 4 mm2 5 = green
H2 Lamp compressor temperature V3 Diode e = 6 mm2 6 = blue
alarm X1 Connector f = 10 mm2 7 = purple
K0 Starter solenoid X3 Auxiliary connector g = 16 mm2 8 =grey
K2 Relay starter protection h = 25 mm2 9 = white
K3 Relay glowplugs i = 35 mm2 10 = black
K5 Relay engine alarm j = 50 mm2
K6 Relay temperature oil compressor
K7 Relay engine oil pressure
M1 Starter motor
P1 Hourmeter
P2 Electric fuel feed pump
S1 Start switch
1 Off
2 On
3 Override - Preheat
4 Start
- 25 -
All compressors are equipped with a negative earthed system.
9822 0841 62 Engine Kubota V3307
- 26 -
Reference Name Reference Name Wire size Colour code
E Glowplugs engine S3 Pressure switch engine oil aa = 0.5 mm2 1 = brown
F1 Circuit breaker S4 Temperature switch engine coolant a = 1 mm2 2 = red
F2 Fuse S5 Temperature switch compressor b = 1.5 mm2 3 = orange
F3 Fuse V1 Free wheeling diode c = 2.5 mm2 4 = yellow
G1 Battery V2 Diode d = 4 mm2 5 = green
G2 Charging alternator V3 Diode e = 6 mm2 6 = blue
H1 Lamp engine alarm X1 Connector f = 10 mm2 7 = purple
H2 Lamp compressor temperature X3 Auxiliary connector g = 16 mm2 8 =grey
alarm h = 25 mm2 9 = white
K0 Starter solenoid i = 35 mm2 10 = black
K2 Relay starter protection j = 50 mm2
K3 Relay glowplugs
K5 Relay engine alarm
K6 Relay temperature oil compressor
K7 Relay engine oil pressure
K22 Relay start
M1 Starter motor
P1 Hourmeter
P2 Electric fuel feed pump
S1 Start switch
1 Off
2 On
3 Override - Preheat
4 Start
- 27 -
X1.1 X1.2
X1.3
L2 L1 L2 L1
16A 16A L3 N
L3 N L3 N
16A
L2
L1
L2
L3
L1
L2
L3
N
N
N
c0 c0 c0 c6 c54 c0 c0 c0 c6 c54 c0 c6 c54 XA(S) 137 KdG - XA(S) 300 KD7G
This generator is built to supply a sheer
alternating current IT network.
PE
1 3 5 7
K5 2 4 6 8
W1
S7
U1
V1
b0 3
c0 c0 c0 c6 16 52 51 b3
Q1 MX b3
34
b6 b0 b0 b3 b3 b3
16 W1 16 13
To Circuit diagram
16A 16A 16A 16A 13 13 13 9822 0797 01
K6 14 12
11 A1
D1
H3 A1 K5 PR Y2 35
N R<
b6 b0 R T PE L A2 b6 A2 b6 B b6 b6
W1 b54 b54 b6 12 12 12 12
b0
12
W1
b54
c0 c0 c0 c6 b0
N
W
U
N
V
U1 V1 W1 N
G3
S6
u
- 28 -
Reference Name DESCRIPTION
D1 Diode Generator function:
G3 Generator Turn switch S6 to position 1. The solenoid valve
H3 Lamp (Power control) Y2 via the speed regulator SR controls the motor
and allows it to reach maximum speed (the normal
K5 Contactor 4-pole control system is switched off). Lamp H1 is
K6 Insulation Monitoring Relay activated (sockets X1.1, X1.2, X1.3 are under
tension).
Q1 Main circuit breaker 4-pole
S6 Thermal contact (N/O) The generator can be switched off by turning
switch S6 to position 0.
S7 Switch (Generator-compressor)
In the case of an insulation fault, lamp H2 of the
X1.1 Socket outlet system is activated. When the red lamp H2 is active,
X1.2 Socket outlet a reset can only be made by stopping and restarting
the unit.
X1.3 Socket outlet
Y2 Solenoid valve (Generator
operation)
- 29 -
MARKINGS AND INFORMATION LABELS
Compressor outlet temperature too Read the instruction manual before

Reset fuse.
high. starting.
Compressor outlet temperature. On / off button. Service every 24 hours.
Compressor outlet pressure. Hours, time. Warning! Part under pressure.
Prohibition to open air valves without

Dangerous outlet gases. Do not stand on outlet valves.
connected hoses.
Danger, hot surface. Compressor loaded. Start-Stop indication of switch.
Do not run the compressor with open

Electrocution hazard. Runlamp.
doors.
Atlas Copco mineral compressor oil. Airfilter. Lifting permitted.
Atlas Copco synthetic compressor oil. Compressor temperature too high. Use diesel fuel only.
4.75 bar
Atlas Copco mineral engine oil. Rotation direction. (69 psi)
Tyre pressure.
Sound power level in accordance

Atlas Copco synthetic engine oil. Inlet. with Directive 2000/14/EC
(expressed in dB (A)).
Horizontal towbar position required in

Manual. Outlet.
case of coupling.
Read the instruction manual before

Compressor oil drain.
working on the battery.
- 30 -
Operating instructions PARKING INSTRUCTIONS
PARKING, TOWING AND LIFTING

INSTRUCTIONS
Safety precautions
(4) (4)
The operator is expected to apply all
relevant safety precautions, including
those mentioned on the pages 7 - 13 of
this book.
(2)
(2)
Attention:
Before putting the compressor into use, (1)
check the brake system as described in
section Brake (= option) adjustment.
Non-adjustable towbar with standard support leg without Parking position of jockey wheel
After the first 100 km travel: brakes
Check and retighten the wheel nuts and
towbar bolts to the specified torque. See When parking a compressor, secure support leg (1) or
section Height adjustment and section (3) jockey wheel (2) to support the compressor in a level
Torque values. position. Be sure that the jockey wheel (2) is blocked
by the blocking pin (4).
Check the brake adjustment. See section
Brake (= option) adjustment. Apply parking brake by pulling parking brake handle
(3) upwards. Place the compressor as level as
possible; however, it can be operated temporarily in
When using a towing vehicle to an out-of-level position not exceeding 15°. If the
manoeuver the unit, take care that the compressor is parked on sloping ground, immobilize
jockey wheel is lifted maximally. the compressor by placing wheel chocks (available as
option) in front of or behind the wheels.
When the jockey wheel is on the ground, (2)
the unit may only be manoeuvered by
hand.
(4)
Adjustable towbar with jockey wheel and brakes
- 31 -
TOWING INSTRUCTIONS
(1)
(3)
(2)
Locate the rear-end of the compressor upwind, away Label on towbar

from contaminated wind-streams and walls. Do not
obstruct air evacuation from the cooling system. Before towing the compressor, ensure
Avoid recirculation of exhaust air from the engine. that the towing equipment of the vehicle
This causes overheating and engine power decrease. matches the towing eye or ball connector
and ensure that the service doors are
closed and locked properly.
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 (1) completely downwards
and connect breakaway cable (2) to the vehicle.
Secure jockey wheel (3) or support leg in the highest
possible position (see figure). The jockey wheel is
prevented from turning.
- 32 -
HEIGHT ADJUSTMENT LIFTING INSTRUCTIONS
(with adjustable towbar)
• Remove spring pin (1).
• Release locking nut (2) with support tools
(B) (1)
(Extension tube 3).
• Adjust required height of the towbar.
(A)
(3) • Tighten locking nut (2) by hand first. (2)
(2) • Secondly tighten locking nut (2) with a tightening
torque corresponding to table. With an extension
(1) tube (3) (”A” corresponding to table) and
handforce (”B” corresponding to table) easy
tightening is possible.
X*
• Fix locking nut (2) with spring pin (1).

XX
Attention:
When lifting the compressor, the hoist has to be
Before towing the compressor, make placed in such a way that the compressor, which must
sure that the joints of the towbar are • Height adjustment should be undertaken on be placed level, is lifted vertically. Keep lifting
secured with maximum strength without levelled ground and in coupled condition. acceleration and retardation within safe limits.
damaging the towbar. Be sure that there • When readjusting, make sure that the front point Preferably use the lifting eye (1) herefore open the
is no clearance between the teeth of the of the towbar is horizontal with the coupling small door (2).
joints. point.
Lifting acceleration and retardation
• Before starting a trip, ensure that the adjustment must be kept within safe limits (max. 2g).
shaft is secure, so that stability and safety is
guaranteed while driving. If necessary, tighten the Helicopter lifting is not allowed.
locking nut (2) corresponding with table. Lifting is not allowed when the unit is
For specific instruction see below! running.
Type M [Nm/lbf.ft.] ”A” [mm/in] ”B” [N/lbf]

*ZV 2000 250 - 300 / 185 - 221 600 / 23.4 420 - 500 / 95 - 112
*ZV 2500 350 - 400 / 260 - 295 600 / 23.4 580 - 660 / 131 - 148
- 33 -
CONTROL PANEL STARTING/STOPPING
BEFORE STARTING
(P1) (PG) (H2) (S1) 1. Before initial start-up, prepare battery for
operation if not already done. See section Battery
care.
2. With the compressor standing level, check the
level of the engine oil. Add oil, if necessary, up to
the upper mark on the dipstick. Consult the
Engine Operation Manual for the type and
viscosity grade of the engine oil.
3. Check the level of the compressor oil. See section
Compressor regulating system. The pointer of
oil level gauge (OLG) should register in the green
range. Add oil if necessary. See section Oil
(H1) (0)(1) (2)(3) specifications for the oil to be used.
Before removing oil filler plug (FP),
Reference Name ensure that the pressure is released by
opening an air outlet valve.
P1 Hour meter
PG Working pressure gauge 4. Check that the fuel tank contains sufficient fuel.
Top up, if necessary. Consult the Engine
H1 General alarm lamp (red) Operation Manual for the type of fuel.
H2 Temperature alarm lamp (red) 5. Drain any water and sediment from the fuel filter
S1 Start switch with preheating position until clean fuel flows from the drain cock.
6. Press vacuator valves (VV) of the air filters to
remove dust.
The control panel indicates receiver pressure (PG) and accumulated operating hours (P1).
7. 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.
8. Open the air outlet valve to allow air flow to the
atmosphere.
- 34 -
STARTING PROCEDURE
0 - 20 sec
(F1) 1 2 3 4 5 6 7
1. Open air outlet valve. 6. The start switch automatically springs back to
2. Press circuit breaker F1. position 1.
Lamp H1 will only come on when the compressor
3. Turn start switch S1 clockwise to position 1, lamp
H2 (temperature alarm lamp) will go on. outlet temperature is too high.
7. Close the air outlet valve(s) (AOV).
4. To preheat turn the start switch S1 clockwise to
position 2 for max 20 sec.
Before starting, open the air outlet valve(s) (AOV)
and push circuit breaker button (F1) once (open hood Recommended preheating time:
first). 20°C (68°F): 3 sec
Circuit breaker button should now be in position B. 0°C (32°F): 5 sec
-15°C (5°F): 10 sec
The circuit breaker button is a
protection against unintended starting 5. Turn start switch S1 further clockwise into
of the compressor. position 3.
The general alarm lamp H1 will go on.
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 waiting 30 seconds.
General alarm lamp H1 will go out as soon as the
engine has been started.
- 35 -
DURING OPERATION Fault situations and protective devices: STOPPING PROCEDURE
A fault involving the engine, either oil pressure (too

When the engine is running, the air low), coolant temperature (too high), will always and
outlet valves (ball valves) must always be
immediately cause the engine to cut out and the alarm
put in a fully opened or fully closed
lamp H1 will light up.
position. 3 min
By doing some simple checks, it can be determined
The hood must be closed during what it was that caused the engine to fail: low oil
operation and may be opened for short level, clogged-up cooler. 1 2 3 4
periods only. Alarm lamp H2 will light up. The alarm lamp will
stay on, until the compressor has been restarted (start 1. Close the air outlet valves (AOV).
switch to position 3), or the contact is turned off (start
Be aware not to touch hot parts when the switch to position 0; also when, due to cooling off, the 2. Run unloaded for 3 minutes.
door is open. thermocontact has closed again (= memory function). 3. Turn the start switch S1 counterclockwise (CCW)
to position 0.
Regularly carry out following checks:
Be aware not to touch hot parts when the
1. Ensure that the regulating valve (RV) is correctly door is open.
adjusted, i.e. starts decreasing the engine speed
when reaching the preset working pressure in the
receiver. 4. Push the circuit breaker button (F1) once (open
hood first).
2. Check the air filter vacuum indicator (VI). If the
yellow piston reaches the red marked service Do not open the air outlet valve when
range, replace the filter element. Reset the machine is shut down. Remaining air
indicator by pushing the reset button. inside the vessel will automatically be
evacuated via a blow down valve!
If pressure is released from the vessel too
quickly, oil will start creating foam. This
foam could reach the oil separator
element resulting in oil carry over.
Failures caused by incorrectly shutting
down the compressor will not be covered
by warranty!
- 36 -
GENERATOR FUNCTION (XA(S) 137 KdG - XA(S) 300 KD7G) and DdG
Fault situations and protective devices:

(K6)
• Open the left machine door and check that the
circuit breakers are up. If the circuit breakers are
down, put them up (switch them on). Circuit
(X1.1) (X1.3) (X1.2) (S1)(PE) breakers in the up position can be indicative of a
serious electrical fault.
• When the yellow LED on the insulation
monitoring relay (K6) is activated, it means that a
(Q1) serious insulation fault has occurred. Reset by first
1 2 3 4 5 6 7 8 9 10
switching off the motor, then restart it.
• The insulation monitoring relay K8 must be
adjusted to 10 kΩ. This adjustment may not be
changed.
Control panel (generator) Generator control box
X1.1 Socket 400 V/16 A Q1 Main circuit breaker 4-pole

X1.2 Socket 400 V/16 A K8 Insulation monitoring relay
X1.3 Socket 230 V/16 A
S1 ON/OFF switch Before connecting an electrical device,
PE Earthing clamp always check the data listed on the rating
plate.
Start the unit in accordance with the normal
procedure. Let the motor warm up until it reaches
operational temperature.
Only use the generator after the
compressor has been switched over from
NO-LOAD to LOAD.
- 37 -
Maintenance
LIABILITY SERVICE KITS SAFETY PRECAUTIONS
The manufacturer does not accept any liability for any A service kit is a collection of parts to fit a specific Before performing any maintenance
damage arising from the use of non-original parts and repair or rebuilding task. jobs always put the battery switch in the
for modifications, additions or conversions made It guarantees that all necessary parts are replaced at “OFF” position. See section Battery
without the manufacturer’s approval in writing. care.
the same time which improves the uptime of the unit.
The order numbers of the Service Kits are listed in the Always observe the applicable safety
Atlas Copco Parts List (ASL). precautions. See section Safety during
SERVICE PAKS maintenance and repair.
Contact Atlas Copco. Please note that when the battery switch
A Service Pak is a collection of parts to be used for a is off there can still be some parts live!
specific maintenance task, e.g. after 50, after 500 and
after 1000 running hours.
It guarantees that all necessary parts are replaced at
the same time keeping down time to a minimum. STORAGE
The order number of the Service Paks are listed in the Run the compressor regularly, e.g. twice a week, until
Atlas Copco Parts List (ASL). warm.
Load and unload the compressor a few times to
operate the unloading and regulating components.
Use of service paks
Close the air outlet valves after stopping.
Service Paks include all genuine parts needed for
normal maintenance of both compressor and engine. If the compressor is going to be stored
without running from time to time,
Service Paks minimize downtime and keep your protective measures must be taken.
maintenance budget low.
Order Service Paks at your local Atlas Copco dealer.
- 38 -
PREVENTIVE MAINTENANCE SCHEDULE
The schedule contains a summary of the maintenance The maintenance schedule has to be seen as a
Unauthorised modifications can lead to instructions. Read the respective section before taking guideline for compressors operating in a dusty
risk for injury or machine damage. maintenance measures. environment typical to compressor applications.
Maintenance schedule can be adapted depending on
When servicing, replace all disengaged packings, e.g.
Always keep the machine tidy in order to application, environment and quality of maintenance.
gaskets, O-rings, washers.
prevent fire hazard.
For engine maintenance refer to Engine Operation
Manual.
Poor maintenance can void any
warranty claims.
MAINTENANCE SCHEDULE COMPRESSOR

To determine the maintenance intervals, use of service hours, or calendar time, whichever occurs first.
Service hours Daily 50 hrs Every Every Yearly
after initial 500 hrs 1000 hrs
start-up
Service pak Engine oil filter 2913 3087 00
Engine Kubota V3800 (Com2) Standard fuel system 2912 4517 05 2912 4518 06
Heavy duty fuel system 2912 4520 05 2912 4521 06
Service pak Engine oil filter 2913 3087 00
Engine Kubota V3307 (Com3) Standard fuel system 2912 4533 05 2912 4519 06
Heavy duty fuel system 2912 4534 06 2912 4522 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 a reduced price, compared to individual components. Refer to the parts list for more information on the contents of the
service kits.
Drain water from fuel filter x
Check on abnormal noise x
Check/Fill fuel level (3) x
Check engine oil level (if necessary top up) x
Check compressor oil level x
(to be continued on page 40)
- 39 -
Daily 50 hrs Every Every Yearly
Maintenance schedule (hrs) after initial 500 hrs 1000 hrs
(continuation of page 39)
start-up
Drain water from spillage-free frame x
Empty air filter vacuator valves x
Check coolant level x
Check control panel x
Check air intake vacuum indicators x
Check for leaks in engine-, compressor-, air-, oil-, or fuel system x x x x
Check electrolyte level and terminals of battery x x x x
Hoses and clamps - Inspect/Replace x x x x
Change engine oil (2) x x x x
Replace engine oil filter (2) x x x x
Check electrical system cables for wear x x x x
Inspect/Adjust fan belt x
Replace fan belt x x x
Drain/Clean fuel tank water and sediments (1) x x x
Replace fuel (pre)filters (6) x x x
Clean oil cooler(s) (1) x x x
Inspection by Atlas Copco service technician x x x
Check torque on critical bolt connections x x x
Check engine (minimum and maximum) speed x x x
Clean after cooler (option) (1) x x x
Clean radiator (1) x x x
Replace compressor oil filter(s) (5) x x
- 40 -
Daily 50 hrs Every Every Yearly
Maintenance schedule (hrs) after initial 500 hrs 1000 hrs
start-up
Grease hinges x x
Adjust engine inlet and outlet valves (2) x x
Replace DD/PD/QD filter (option) x x
Change compressor oil (1) (7) x x
Replace oil separator element x x
Replace air filter element (1) x x
Check/Replace safety cartridge (1) (11) x x
Check functioning of regulating valve x
Check/Test glow plugs x
Test safety valve (9) x
Analyse Coolant (4) (8) x
Measure alternator insulation resistance (on optional generatorset) x
Check rubber flexibles (10) x
Check emergency stop x
- 41 -
Notes
1. More frequently when operating in a dusty environment. Keep the bolts of the housing, the lifting
2. Refer to engine operation manual. eye, the towbar and the axle securely
tightened.
3. After a day’s work.
Refer to section Technical specifications
4. Yearly is only valid when using PARCOOL. Change coolant every 5 years. and section Height adjustment for the
5. Use Atlas Copco oil filters, with by-pass valve as specified in the parts list. torque values.
6. Gummed or clogged filters means fuel starvation and reduced engine performance.
7. See section Oil specifications.
8. Check inhibitors and freezing point using tools:
• 2913 0028 00 : refractometer
• 2913 0029 00 : pH meter.
9. See section Safety valve.
10. Replace all rubber flexibles every 6 years, according to DIN 20066.
For other specific engine and alternator requirements refer to specific manuals.
11. Safety cartridge PN 2914 5024 00
- 42 -
Daily 50 km Every Every Yearly
Maintenance schedule (km) after initial 500 km 2000 km
start-up
Check coupling head x x x
Check height of adjusting facility x x
Check drawbar handbrake lever spring actuator, reversing lever, linkage x x x x x
and all movable parts for ease of movement
Check tyre pressure x x x x
Check torque of wheel nuts x x x
Grease coupling head, drawbar bearings at the housing of the overrun x x x
brake
Check brake system (if installed) and adjust if necessary x x x
Oil or grease brake lever and moving parts such as bolts and joints x x x
Check/Adjust lateral play of wheel bearing (conventional bearing) x x x
Check tyres for uneven wear x x
Grease sliding points on height adjusting parts x x
Check safety cable for damage x x
Check Bowden cable on height adjustable connection device for damage x x
Lubricate torsion bar axle trailing arm x x
Check brake lining wear x
Change wheel hub bearing grease x
- 43 -
OIL SPECIFICATIONS
It is strongly recommended to use Atlas PAROIL from Atlas Copco is the ONLY oil tested PAROIL releases excess heat efficiently, whilst
Copco branded lubrication oils for both and approved for use in all engines built into Atlas maintaining excellent bore-polish protection to limit
compressor and engine. Copco compressors and generators. oil consumption.
Extensive laboratory and field endurance tests on PAROIL has an excellent Total Base Number (TBN)
Atlas Copco equipment have proven PAROIL to retention and more alkalinity to control acid
Only use mineral based compressor oil match all lubrication demands in varied conditions. It formation.
PAROIL M in XAS 137 Kd - XAS 300 meets stringent quality control specifications to
KD7, XAS 137 KdG - XAS 300 KD7G PAROIL prevents soot build-up.
ensure your equipment will run smoothly and
and XAHS 107 Kd - XAHS 225 KD7. reliably. PAROIL is optimized for the latest low emission
The quality lubricant additives in PAROIL allow for EURO -3 & -2, EPA TIER II & III engines running on
High-quality, mineral, hydraulic or synthesized extended oil change intervals without any loss in low sulphur diesel for lower oil and fuel consumption.
hydrocarbon oil with rust and oxidation inhibitors, performance or longevity.
anti-foam and anti-wear properties is recommended. PAROIL E xtra is a synthetic ultra high performance
The viscosity grade should correspond to the ambient PAROIL provides wear protection under extreme diesel engine oil with a high viscosity- index. Atlas
temperature and ISO 3448, as follows: conditions. Powerful oxidation resistance, high Copco PAROIL E xtra is designed to provide
chemical stability and rust- inhibiting additives help excellent lubrication from start-up at temperatures as
reduce corrosion, even within engines left idle for low as -25° C (-13° F).
Never mix synthetic with mineral oil. extended periods. PAROIL E is a mineral based high performance
Remark: PAROIL contains high quality anti-oxidants to diesel engine oil with a high viscosity- index. Atlas
control deposits, sludge and contaminants that tend to Copco PAROIL E is designed to provide a high level
When changing from mineral to
build up under very high temperatures. PAROIL's of performance and protection under ‘standard’
synthetic oil (or the other way around), ambient conditions from -5°C (23°F) onward.
you will need to do an extra rinse: detergent additives keep sludge forming particles in a
fine suspension, instead of allowing them to clog your PAROIL E Mission Green is a low SAPS oil. It has
After doing the complete change filter and accumulate in the valve/rocker cover area. better (lower) emission values. The temperature range
procedure to synthetic oil, run the unit
equals the temperature range of PAROIL E.
for a few minutes to allow proper and
complete circulation of the synthetic oil.
Then drain the synthetic oil again and
fill again with new synthetic oil. To set
correct oil levels, follow the normal
instructions.
- 44 -
COMPRESSOR OIL
Synthetic compressor oil PAROIL S

Liter US gal Order number
50˚ C 122˚ F can 5 1.3 1630 0160 00
40˚ C 104˚ F can 20 5.3 1630 0161 00
30˚ C 86˚ F barrel 210 55.2 1630 0162 00
PAROIL M
PAROIL M
PAROIL S
PAROIL S
20˚ C 68˚ F container 1000 265 1630 0163 00
10˚ C 50˚ F
Mineral compressor oil PAROIL M
-0˚ C 32˚ F
-10˚ C 14˚ F
can 5 1.3 1615 5947 00
-20˚ C -4˚ F
can 20 5.3 1615 5948 00
-30˚ C -22˚ F
barrel 210 55.2 1615 5949 00
-40˚ C -40˚ F
Choose your compressor oil based on the ambient

temperatures in the actual operating area.
- 45 -
ENGINE OIL
Synthetic engine oil PAROIL E xtra

50˚ C 122˚ F can 5 1.3 1630 0135 00
PAROIL E Mission Green
PAROIL E Mission Green

40˚ C 104˚ F can 20 5.3 1630 0136 00
30˚ C 86˚ F
PAROIL EXTRA
PAROIL EXTRA
PAROIL E
PAROIL E
Mineral engine oil PAROIL E
20˚ C 68˚ F
10˚ C 50˚ F
can 5 1.3 1615 5953 00
-0˚ C 32˚ F
can 20 5.3 1615 5954 00
-10˚ C 14˚ F
barrel 210 55.2 1615 5955 00
-20˚ C -4˚ F
-30˚ C -22˚ F PAROIL E Mission Green

-40˚ C -40˚ F Liter US gal Order number
can 5 1.3 1630 0471 00
can 20 5.3 1630 0472 00
Choose your engine oil based on the ambient barrel 210 55.2 1630 0473 00
temperatures in the actual operating area.
- 46 -
OIL LEVEL CHECK CHECK COMPRESSOR OIL LEVEL OIL AND OIL FILTER CHANGE
Never mix oils of different brands or ENGINE OIL AND OIL FILTER CHANGE
types.
(2) For replacing the engine oil filter, see section
Use only non-toxic oils where there is a
risk of inhaling delivered air. Preventive maintenance schedule.
(1)
CHECK ENGINE OIL LEVEL
Consult also the Engine Operation Manual for the oil

specifications, viscosity recommendations and oil
change intervals.
For intervals, see Preventive maintenance schedule.
Check engine oil level in accordance with the
instructions in the Engine Operation Manual and if With the unit standing horizontal, check the level of
necessary, top up with oil. 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 oil filler plug (2),
ensure that the pressure is released by
opening an air outlet valve.
- 47 -
COMPRESSOR OIL AND OIL FILTER CHANGE
2. Drain the oil by removing all relevant drain plugs.

(1) (2) Drain plugs are located at the air receiver,
compressor element and compressor oil cooler.
Catch the oil in a drain pan. Unscrew the filler
plug to speed up draining. Tighten the plugs after
draining.
As the filter has left hand thread turn the
filter clockwise to remove the filter.
3. Remove the oil filter (1), 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. Turn the filter
(3) anticlockwise and screw it into place until the
gasket contacts its seat, then tighten one half turn
The quality and the temperature of the oil determine only.
the oil change interval.
5. Fill the air receiver until the pointer of the oil level
The prescribed interval (see section Preventive gauge (3) registers in the upper extremity of the
maintenance schedule) is based on an oil green range. Take care that no dirt drops into the
temperature of up to 100 °C (212 °F) and normal system. Reinstall and tighten the filler plug.
operating conditions.
6. Run the unit unloaded for a few minutes to
When operating in high ambient temperatures, in very circulate the oil and evacuate the air trapped in the
dusty or high humidity conditions, it is recommended oil system.
to change the oil more frequently.
7. Stop the compressor. Let the oil settle for a few
In this case, contact Atlas Copco. minutes. Check that the pressure is released by
opening an air outlet valve. Screw out filler plug
(2) and add oil until the pointer of the oil level
1. Run the compressor until warm. Close the outlet gauge (3) again registers in the upper extremity of
valve(s) and stop the compressor. Wait until the the green range. Reinstall and tighten the filler
pressure is released through the automatic blow- plug.
down valve. Unscrew the oil filler plug (2) one
turn. This uncovers a vent hole, which permits any
pressure in the system to escape. Never add more oil. Overfilling results in
oil consumption.
- 48 -
COMPRESSOR OIL FLUSHING PROCEDURE
Not respecting compressor oil changing 4. Check the interior of the oil vessel (see pictures).
intervals in accordance with the If varnish deposits are discovered, contact Atlas
maintenance schedule, can lead to Copco Service dept. and do not continue.
serious problems, including fire hazard! 5. Put in a new oil separator, screw on new
The manufacturer does not accept any compressor oil filter(s) and close the oil vessel
liability for damage arising from not according to the instructions.
following the 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 procedure is only warm, leaving as little oil in the system as
valid in case the replaced oil has not exceeded its possible, especially in dead areas, if possible blow
lifetime. For more information consult Atlas Copco Vessel cover
out remaining oil by pressurising the oil. contaminated clean
Service 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 such as 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
possible, 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 S xtreme
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 S xtreme 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
- 49 -
COOLANT SPECIFICATIONS PARCOOL EG
PARCOOL EG is the only coolant that has been Because PARCOOL EG inhibits corrosion, deposit
It is strongly recommended to use Atlas tested and approved by all manufacturers of formation is minimized. This effectively eliminates
Copco branded coolant. engines currently used in Atlas Copco flow restriction problems through the engine coolant
The use of the correct coolant is important for proper compressors and generators. ducts and the radiator, minimizing the risk of engine
heat transfer and protection of liquid-cooled engines. overheating and possible failure.
Atlas Copco's PARCOOL EG extended life coolant is
Coolants used in these engines must be mixtures of the new range of organic coolants purpose-designed It reduces water pump seal wear and has excellent
good quality water (distilled or de-ionised), special to meet the needs of modern engines. PARCOOL EG stability when subjected to sustained high operating
coolant additives and anti-freeze, if required. Coolant can help prevent leaks caused by corrosion. temperatures.
that is not to manufacturer's specification will result PARCOOL EG is also fully compatible with all
in mechanical damage of the engine. PARCOOL EG is free of nitride and amines to protect
sealants and gasket types developed to join different
your health and the environment. Longer service life
The freezing point of the coolant must be lower than materials used within an engine. reduces the amount of coolant produced and needing
the freezing point that can occur in the area. The PARCOOL EG is a ready to use Ethylene Glycol disposal to minimise environmental impact.
difference must be at least 5°C (9°F). If the coolant based coolant, premixed in an optimum 50/50
freezes, it may crack the cylinder block, radiator or dilution ratio, for antifreeze protection guaranteed to
coolant pump. -40°C (-40°F).
Consult the engine's operation manual and follow the
manufacturer's directions.
PARCOOL EG
Never mix different coolants and mix the
coolant components outside the cooling Liter US gal Order number
system. can 5 1.3 1604 5308 00
can 20 5.3 1604 5307 01
barrel 210 55.2 1604 5306 00
To ensure protection against corrosion, cavitation and formation of deposits, the concentration of the additives
in the coolant must be kept to certain limits, as stated by the manufacturer's guidelines. Topping up the coolant
with water only, changes the concentration and is therefore not allowed.
Liquid-cooled engines are factory-filled with this type of coolant mixture.
PARCOOL EG Concentrate
can 5 1.3 1604 8159 00
- 50 -
HANDLING PARCOOL EG COOLANT CHECK Glycol concentration measurement
PARCOOL EG should be stored at ambient Never remove the cooling system filler • To optimise the unique engine protection features
temperatures, while periods of exposure to cap while coolant is hot. of the PARCOOL EG, the concentration of the
temperatures above 35°C (95°F) should be Glycol in the water should always be above 33
The system may be under pressure. vol.%.
minimized. PARCOOL EG can be stored for a Remove the cap slowly and only when
minimum of 5 years in unopened containers without coolant is at ambient temperature. A • Mixtures exceeding a 68 vol.% mix ratio in water
any effect on the product quality of performance. sudden release of pressure from a heated are not recommended, as this will lead to high
PARCOOL EG is compatible with most other cooling system can result in personal engine operating temperatures.
coolants based on ethylene glycol, but you only get injury from the splash of hot coolant. • A refractometer can be ordered from Atlas Copco
the benefits of 5 years protection when its used on its with part number 2913 0028 00.
own. Exclusive use of PARCOOL EG is In order to guarantee the lifetime and quality of the
recommended for optimum corrosion protection and In case of a mix of different coolant
product, thus optimising engine protection, regular products this type of measuring might
sludge control. coolant-condition-analysis is recommended. provide incorrect values.
For simple density-measuring of Ethylene Glycol and The quality of the product can be determined by three
Propylene Glycol in general the standard available parameters:
‘density’ measuring devices are used to measure the
concentration of EG. In case a device is used to Visual check TOPPING UP/REPLACING COOLANT
measure EG, no PG can be measured afterwards as a
result of the difference in the density. More specific • Verify the appearance of the coolant with regard to • Verify whether the engine cooling system is in a
measurements can be done by the use of a its colour and make sure that no loose particles are good condition (no leaks, clean,...).
refractometer. This device can measure both EG and floating around.
PG. A mix of both products will be show unreliable • Check the condition of the coolant.
results! pH measurement • If the condition of the coolant is no longer up to
Mixed EG coolants with identical glycol type can be • Check the pH value of the coolant using a pH- standard, the complete coolant should be replaced
measured by use of a refractometer as well as the measuring device. (see section Replacing the coolant).
‘density’ system. The mixed coolants will be • The pH-meter can be ordered from Atlas Copco • Always top-up with PARCOOL EG Concentrate /
considered as one product. with part number 2913 0029 00. PARCOOL EG.
The use of distilled water is recommended. If you • Typical value for EG = 8.6. • Topping up the coolant with water only, changes
have exceptionally soft water it would be acceptable, the concentration of additives and is therefore not
as well. Basically, the engine metals are going to • If the pH-level is below 7 or above 9.5, the coolant
allowed.
corrode to some extent no matter what water you use, should be replaced.
and hard water will encourage the resulting metal
salts to precipitate.
PARCOOL EG comes as a pre-mixed coolant to
safeguard the quality of the complete product.
It is recommended that topping up of the cooling
system is always done with PARCOOL EG.
- 51 -
REPLACING THE COOLANT CLEANING COOLERS
Drain Steam cleaning in combination with a cleansing agent

• Completely drain the entire cooling system. (1) may be applied.
• Used coolant must be disposed of or recycled in To avoid damaging the coolers, angle
accordance with legislation and local regulations. between jet and coolers should be
approx. 90° (do not use jet at max.
Flush power) .
• Flush twice with clean water. Used coolant must
be disposed or recycled in accordance with laws Protect the electrical and controlling
and local regulations. equipment, air filters, etc. against
penetration of moisture.
• Using the Atlas Copco Instruction book,
determine the amount of PARCOOL EG required Install the baffle (1).
and pour into the radiator top tank.
• It should be clearly understood that proper Never leave spilled liquids such as fuel,
cleaning reduces contamination risks. oil, water and cleansing agents in or
around the compressor.
• In case of "other" coolant residues inside the Keep the coolers clean to maintain cooling efficiency.
system, the coolant with the lowest properties
influences the quality of the ‘mixed’ coolant. Remove any dirt from the coolers with a
fibre brush. Never use a wire brush or
Fill metal objects.
• To assure proper operation and the release of Remove the baffle (1). Then clean by air jet in reverse
trapped air, run the engine until normal engine direction of normal flow.
operation temperature is reached. Turn off the
engine and allow to cool.
• From the Atlas Copco Instruction book, determine
the amount of PARCOOL EG required.
• Mix concentrate and water before filling.
• Fill with a maximum rate of 10 l/min (0.35 cu.ft/
min).
• Recheck coolant level and add coolant mixture if
necessary.
Caution: do not top up when the engine

is hot.
- 52 -
BATTERY CARE ACTIVATING A DRY-CHARGED BATTERY MAKE-UP DISTILLED WATER
• Take out the battery. The amount of water evaporating from batteries is
Before handling batteries, read the largely dependant on the operating conditions, i.e.
• Battery and electrolyte must be at an equal
relevant safety precautions and act temperature above 10 °C (50 °F). temperatures, number of starts, running time between
accordingly. start and stop, etc...
• Remove cover and/or plug from each cell.
If the battery is still dry, it must be activated as If a battery starts to need excessive make-up water,
described in section Activating a dry-charged • Fill each cell with electrolyte until the level this points to overcharging. Most common causes are
battery. reaches the mark on the battery. If there is no mark high temperatures or a too high voltage regulator
on the battery, the level must be above the plates setting.
The battery must be in operation within 2 months for at least 10 mm (0.4 in) to 15 mm (0.6 in).
from being activated; if not, it needs to be recharged If a battery does not need any make-up water at all
first. • Rock the battery a few times so that possible air over a considerable time of operation, an
bubbles can escape; wait 10 minutes and check the undercharged battery condition may be caused by
level in each cell once more; if required, add poor cable connections or a too low voltage regulator
electrolyte. setting.
ELECTROLYTE • Refit plugs and/or cover.
• Place the battery in the compressor.
Read the safety instructions carefully.
RECHARGING A BATTERY
Electrolyte in batteries is a sulphuric acid solution in
distilled water. Before and after charging a battery, always check the
electrolyte level in each cell; if required, top up with
The solution must be made up before being
distilled water only. When charging batteries, each
introduced into the battery.
cell must be open, i.e. plugs and/or cover removed.
Always pour the sulphuric acid carefully
Use a commercial automatic battery
into the distilled water; never pour the
charger in accordance with the
water into the acid.
manufacturer’s instructions.
Preferably use 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.
- 53 -
PERIODIC BATTERY SERVICE COMPRESSOR ELEMENT OVERHAUL
• Keep the battery clean and dry. When a compressor element is due for overhaul, it
needs to be done by Atlas Copco. This guarantees the
• Keep the electrolyte level at 10 to 15 mm above
the plates or at the indicated level; top up with use of genuine parts and correct tools with care and
precision.
distilled water only. Never overfill, as this will
cause poor performance and excessive corrosion.
• Record the quantity of distilled water added.
• Keep the terminals and clamps tight, clean, and
lightely covered with petroleum jelly.
• Carry out periodic condition tests. Test intervals
of 1 to 3 months, depending on climate and
operating conditions, are recommended.
If doubtful conditions are noticed or malfunctions
arise, keep in mind that the cause may be in the
electical system, e.g.loose terminals, voltage
regulator maladjusted, poor performance of
compressor, etc...
- 54 -
Adjustments and servicing procedures
ADJUSTMENT OF THE CONTINUOUS PNEUMATIC REGULATING SYSTEM
The working pressure is determined by the tension of

the spring in the regulating valve (RV). This tension
can be increased to raise the pressure and decreased to
lower it by turning the adjusting wheel clockwise and
anti-clockwise respectively.
The solenoid valve (SOV) is only present
at units equipped with a generator
(XA(S) 137 KdG - XA(S) 300 KD7G).
(RV)
Be aware not to touch hot parts when the

door is open.
(SOV)
(E)
(SR)
(AR)
(AOV)
- 55 -
Engine Kubota V3800
X Y Z1 – Z2 To adjust the normal working pressure, proceed as
follows:
XAS 127 Kd - XAS 275 KD7 bar(e) 8.3 7 8.1 – 8.5
1. Start and warm up the engine (see section
psi 120 101 117 – 123 Starting/Stopping).
XA(S) 137 Kd - XA(S) 300 KD7 bar(e) 8.3 7 8.1 – 8.5 2. With the outlet valves (AOV) closed, loosen the
psi 120 101 117 – 123 regulating valve’s lock nut and adjust the
regulating valve (RV) until a pressure of X bar(e)
XA(S) 137 KdG - XA(S) 300 KD7G bar(e) 8.3 7 8.1 – 8.5
is reached (see table).
psi 120 101 117 – 123
3. Check the minimum speed of the engine. Adjust
XAHS 107 Kd - XAHS 225 KD7 bar(e) 13.4 12 13.2 – 13.6 minimum speed stop screw if necessary.
psi 194 174 191 – 197 4. Open an outlet valve (AOV) sufficiently to let the
engine (E) run at maximum speed. The working
pressure must be Y bar(e); adjust if necessary with
Engine Kubota V3307 regulating valve (RV) (see table).
X Y Z1 – Z2 5. Check the engine maximum speed. Adjust the
maximum speed by means of adjustable eccentric
XAS 137 Kd - XAS 300 KD7 bar(e) 8.3 7 8.1 – 8.5 nut on top of speed regulator (SR).
psi 120 101 117 – 123
6. Close the outlet valves (AOV), check that the
XAS 137 KdG - XAS 300 KD7G bar(e) 8.3 7 8.1 – 8.5 pressure is between Z1 and Z2 bar(e) (see table).
psi 120 101 117 – 123 Lock the regulating valve (RV) by fixing the lock
nut.
XAHS 107 Kd - XAHS 225 KD7 bar(e) 13.4 12 13.2 – 13.6
psi 194 174 191 – 197
- 56 -
AIR FILTER ENGINE/COMPRESSOR MAIN PARTS CLEANING THE DUST TRAP
The Atlas Copco air filters are specially Remove dust daily.
(1)
designed for the application. The use of To remove dust from the dust trap squeeze the
non-original air filters may lead to vacuator valve (6) several times.
severe damage of the engine and/or
compressor element.
Never run the compressor without air
filter element. CLEANING INSTRUCTIONS FILTER
ELEMENT
If element cleaning can not be avoided, care should be
SERVICING taken that the filter element (4) is not washed out.
Please note that engine damage can cause
Always select the service point according to the (6)(2) (3)(4) (5) (8) considerable costs, which makes the cost of a new
vacuum indicator or display message. A regular (7) filter element seam insignificant.
inspection or cleaning as it is sometimes practiced in (9)
the field is more likely to be damaging than useful as Safety cartridges (3) can not be cleaned but must be
there is a risk that the element will be damaged and exchanged.
dust will gain access to the engine. 1. Snap clips 6. Vacuator valve Please note that a cleaned element will never match
Atlas Copco always recommends exchanging 2. Dust trap cover 7. Vacuum indicator the service life and performance of a new element.
rather than cleaning the filter element in order to 3. Safety cartridge 8. Reset button Take the element from the air filter housing (5) (see
avoid damage and ensure maximum engine (option) section Replacing the air filter element).
protection. 4. Filter element 9. Yellow indicator
5. Filter housing
- 57 -
REPLACING THE AIR FILTER ELEMENT
New elements must also be inspected for tears or

(1) punctures before installation.
Discard the element (4) when damaged.
In heavy duty applications it is recommended to
install a safety cartridge, which can be ordered with
part no.: 2914 9311 00.
A dirty safety cartridge (3) is an indication of a mal-
functioning air filter element. In that case replace the
element and safety cartridge.
The safety cartridge cannot be cleaned.
(6) (2) (3)(4) (5)
1. Release the snap clips (1) and remove the dust trap
(2). Clean the trap.
2. Remove the element (4) and the safety cartridge.
In order to clean, position a pipe with an end bent by
approx. 90° on the end of a compressed-air pistol. The 3. Reassemble in reverse order of dismantling. Make
pipe must be long enough to reach the bottom of the sure the vacuator valve (6) points down.
filter element. Carefully blow out the filter element 4. Inspect and tighten all air intake connections.
with dry compressed air (max. 5 bar (72.5 psi)) from
the inside to the outside until there is no more 5. Reset the vacuum indicator by pressing the reset
development of dust. The end of the pipe must not button (5).
touch the element.
Next carefully examine the element for possible
damage. Never beat or knock the element as this will
damage it and there will be a danger of damage to the
engine.
Carefully clean the inside of the housing and put the
element in the housing (see section Replacing the air
filter element).
- 58 -
AIR RECEIVER SAFETY VALVE FUEL SYSTEM
All adjustments or repairs are to be done

(2) by an authorized representative of the
valve supplier.
Following checks must be carried out on the safety

valve (2):
(1) • 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 (1)
proper test bench.
The air receiver (1) is tested according to official Replacing the filter element
standards. Carry out regular inspections in conformity
1. Unscrew the filter element (1) from the adapter
with local regulations. 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.
- 59 -
BRAKE (= OPTION) ADJUSTMENT BRAKE SHOE ADJUSTMENT
Lift and support the compressor. Make sure that all

Before jacking up the compressor, brakes are off (overrunbrake and hand brake lever).
connect it to a towing vehicle or attach a (4) The brake cables must be free from tension. Lock the
minimum weight of 50 kg (110 lb) to the swivel cams of the wheel brake from the outside by
towbar. means of a pin ∅ 4 mm (4) through the hole as shown
in the Figure.
Turn the adjusting bolt (1) clockwise with a wrench
till the wheel locks up. Center the brake shoes by
actuating the parking brake several times.
Turn the adjusting bolt anti-clockwise until the wheel
is running free in direction of travel (approx. 1 full
turn of the adjusting bolt).
(5) (1) (3) (2) Check the position of the equalizer (see section
Brake cable adjustment, 6) with the parking brake
actuated.
1. Adjusting bolt 4. Pin ∅ 4 mm Perpendicular position of equalizer = identical
2. Axle 5. Plug clearance of wheel brakes.
3. Brake cable Re-adjust the brake shoes, if necessary.
To test, slightly apply the parking brake and check
Check the thickness of the brake lining. Remove identical brake torque on left and right side.
both black plastic plugs (5), one on each wheel. Remove locking pin (4). Remove clearance from
When the brake lining has been worn down to a brake cables.
thickness of 1 mm (0.039 in) or less, the brake shoes
have to be replaced. After inspection and/or Check all lock nuts (Brake cable adjustment, 2).
replacement re-insert both plugs.
Brake shoe adjustment re-establishes the brake
lining-to-drum clearance and compensates for lining
wear.
- 60 -
BRAKE CABLE ADJUSTMENT BRAKE ADJUSTMENT CHECK
(1) (6) (4) (2)

11
0˚ +
4
+0 ˚
˚
(1) (2) (3) (4) (2) (5)
This check has to be performed when brake parts

1. Brake cable 4. Brake cable nut were replaced.
2. Lock nut 5. Main brake cable
1. Check if the towing eye rod of the overrun brake
3. Adjusting nut 6. Equalizer
mechanism is in the outmost position.
2. Check if the adjustable towbar (= option) is in the
1. With the towing eye pulled out in the outmost actual towing position.
position and the hand brake lever in the downward
3. Apply the hand brake lever.
position, loosen the lock nuts (2). Turn adjusting
nuts and brake cable nuts (4) clockwise until there 4. Push the compressor a few centimeters backwards
is no slack in the brake mechanism. so that the brake lever is automatically pulled up
further.
The equalizer (6) must remain perpendicular to
main brake cable (5). Check the reference angle. The angle from the control
device top cover to the inside of the pulled handbrake
2. Apply the hand brake lever several times and
lever must be 110° +4°.
repeat the adjustment. Tighten the nuts with their
lock nuts (2). Remove the jack and the blocks. Adjust if necessary.
3. Road test the compressor and brake several times.
Check brake shoe and brake cable adjustment and
adjust if necessary.
- 61 -
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.
Grease: part number 1626 5402 80
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.
- 62 -
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 and tightening torque in compliance with the table.
permanent lubrication and are designed for high
mileages.
Therefore, there is no grease change or regreasing
necessary.
- 63 -
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.
- 64 -
TOWBAR AND OVERRUN BRAKE CHECK
(1)
(2) (x)
Coupling head Height adjustment facility Brake play

First initially, then every 5,000 Initially, before every journey, up to 500 After the first run, then every 2,000 -
kilometres or annually. kilometres, then every 5,000 kilometres 3,000 kilometres.
or annually.
Check coupling head for wear and correct operation. The check is carried out visually on the stroke (x) of
After every adjustment the clamping nuts (1) must be the overrun coupling.
Check the wear indicator (use within the "+" range
screwed up tight and secured with the spring pin (2).
only). As soon as this is more than 50 mm when the brakes
Tightening torque: are applied, adjust the wheel brakes.
Check the coupling head fastenings (see arrows,
Figure) at regular intervals for firm seating. M 24 = 250 - 350 Nm Check towbar, handbrake lever, spring actuator,
M 32 = 350 - 400 Nm reversing lever, linkage and all movable parts for ease
of movement.
Check tight fit of the clamping nuts and correct
positioning of the adjustment facility.
- 65 -
TOWBAR AND OVERRUN BRAKE
LUBRICATION
(1)
(2)
Safety cable and Bowden cable Coupling head Towbar bushes of overrun coupling
Initially, then every 5,000 kilometres or Initially, after 2,000 - 3,000 kilometres,
annually. At regular intervals.
then every 5,000 kilometres.
Check safety cable (1) for damage; every 5,000 Oil ball coupling at regular intervals in the specified Apply general purpose grease via the grease nipples
kilometres or annually. locations and moving parts. until fresh grease can be seen emerging from the
Check Bowden cable (2) on height-adjustable bushes.
Grease the contact surface of the ball of the towing
connection devices for damage; every 5,000 vehicle.
kilometres or annually.
- 66 -
Reversing lever, moving parts and pivot pins Sliding locations on the height-adjusting
device
Initially, after 2,000 - 3,000 kilometres,
then every 5,000 kilometres. For the first time, after 2,000 - 3,000
kilometres, then every 5,000 kilometres.
Check reversing lever for ease of motion.
If fitted, apply general purpose grease via the grease Oil threaded parts and grease toothed parts.
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.
All moving parts of drawbar, handbrake lever, spring
actuator, reversing lever, linkages etc. are to be oiled
or greased as required.
- 67 -
Problem solving
It is assumed that the engine is in good condition and Make sure that the wires are not damaged and that
that there is adequate fuel flow to the filter and they are clamped tight to their terminals.
injection equipment.
An electrical fault must be traced by an

electrician.
Problem Possible faults Corrective actions

1. Starter motor does not crank engine a. Low battery output. a. Check electrolyte level and charge battery. If no cells are
after switching startbutton (S) to shorted and battery is discharged, trace cause and
” ”. correct.
2. Starter motor cranks engine when a. Low battery output. a. See corrective action 1.
switching start button (S) to ” ”, but
engine does not fire.
3. Engine fires, but engine stops when a. Alternator drive belt broken or slipping. a. Check and correct if necessary.
releasing start button (S).
b. Alternator/regulator defective. b. Have assembly repaired.
4. Hourmeter (P1) does not count a. Hourmeter (P1) defective. a. Replace.
running time.
5. Engine is running, but shuts down a. Start button (S) released too soon. a. Release button after engine oil pressure has built up
immediately after start button (S) has above the minimum allowed level.
been released. b. Insufficient engine oil pressure. b. Stop at once, consult the engine instruction manual.
c. Fuel tank contains insufficient fuel. c. Fill fuel tank.
6. Compressor is loaded automatically to a. Air intake throttle valve stuck in opened position. a. Check and, if necessary consult Atlas Copco.
full capacity after starting. b. Air leaks in regulating system. b. Check hoses and their fittings. Stop leaks; replace
leaking hoses.
- 68 -
7. Engine does not speed up immediately a. Regulating valve defective. a. Check and, if necessary consult Atlas Copco.
after compressor loading valve button
b. Air intake throttle valve stuck in closed position. b. Check and, if necessary consult Atlas Copco.
has been pressed and compressor does
not deliver air.
8. Excessive compressor oil a. Compressor oil level too high. a. Check oil level. Release pressure and drain oil to correct
consumption. Oil mist being level.
discharged from air outlet valves.
9. Compressor capacity or pressure a. Air consumption exceeds capacity of compressor. a. Check equipment connected.
below normal.
b. Choked air filter elements. b. Remove and inspect elements.
c. Unloading valve not completely open. c. Check and, if necessary consult Atlas Copco.
10. Compressor does not unload and a. Regulating valve incorrectly set or defective. a. Check and, if necessary consult Atlas Copco.
engine keeps running at max. speed
b. Air leaks in regulating system. b. Check hoses and their fittings. Stop leaks and, if
when closing the air outlet valves,
necessary consult Atlas Copco.
safety valve blows.
c. Unloading valve stuck. c. Check and, if necessary consult Atlas Copco.
11. Working pressure rises during a. Regulating valve incorrectly set or defective. a. Check and, if necessary consult Atlas Copco.
operation and causes safety valve to
b. Air leaks in regulating system. b. Check hoses and their fittings. Stop leaks and, if
blow. necessary consult Atlas Copco.
c. Unloading valve stuck. c. Check and, if necessary consult Atlas Copco.
d. Safety valve defective. d. Check safety valve; consult Atlas Copco.
12. After working some time, the unit a. Fuel tank contains insufficient fuel. a. Fill fuel tank.
stops through a shutdown switch.
b. Air in fuel system, or insufficient fuel supply. b. Check filters and hoses for leaks, dirt and bends.
c. Engine oil pressure too low. c. Refer to the engine instruction manual.
d. Engine temperature too high. d. See corrective actions 14.
e. Compressor temperature too high. e. See corrective actions 15.
f. Low coolant level. f. Top up cooling system.
13. Air and oil mist expelles from air a. Unloader valve jammed. a. Check and, if necessary consult Atlas Copco.
filters immediately after stopping.
b. Wrong oil type (without foam-retarding additives). b. Consult Atlas Copco.
- 69 -
14. Engine overheating. a. Insufficient engine cooling. a. Relocate compressor.
b. Engine oil cooler clogged externally. b. Clean engine oil cooler. Refer to section Cleaning
coolers.
15. Compressor overheating. a. Insufficient compressor cooling. a. Locate compressor away from walls; when banked with
other compressors, leave space between them.
b. Oil cooler clogged externally. b. Clean oil cooler. Refer to section Cleaning coolers.
c. Oil level too low. c. Check oil level. Top up with recommended oil.
16. After working for some time, the unit a. Air in fuel system, or insufficient fuel supply. a. Check filters and hoses for leaks, dirt and bends.
stops for no apparent reason.
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.
- 70 -
Available options
Vessel type: EURO Air quality equipment: Aftercooler + water separator

ASME Aftercooler + water separator + fine filter
Towbar: Adjustable with brakes (A) PD
Fixed with brakes (A) Aftercooler + water separator + fine filter
DD + PD
Fixed without brakes
Aftercooler + water separator + fine filter
Without towbar: Support (without undercarriage) PD + reheater (C)
Towing eyes: Atlas Copco Aftercooler + water separator + fine filter
DIN DD + PD + reheater (C)
Ball Aftercooler + water separator + reheater
Italian Lubricator on 7 bar units
NATO Cold start: -20 °C (-4 °F)
AC (France) Customer colour: Single
Towbar support: Support leg Double
Jockey wheel Triple
Road signalisation: Full (B)
A. These units meet your local safety regulations and are available with overrun
Safety: Wheel chocks and parking brakes.
Safety cartridge B. Reflectors and lights for safety on the road.
Refinery equipment: Spark arrestor C. Quality air through the aftercooler, reheater and fine filters.
Inlet shut down valve
- 71 -
Technical specifications
TORQUE VALUES
FOR GENERAL APPLICATIONS FOR IMPORTANT ASSEMBLIES
The following tables list the recommended torques applied for general applications
during assembly of the compressor. Assemblies Torque value (Nm / lbf.ft)
Wheel nuts 120 (89) +/- 10%
Bolts, axle/beams 205 (151) +/- 10%
For hexagon screws and nuts with strength grade 8.8 Bolts, towbar/axle 80 (59) +/- 10%
Bolts, towbar/bottom 205 (151) +/- 10%
Thread size Torque value (Nm / lbf.ft)
Bolts, towing eye/towbar 80 (59) +/- 10%
M6 8 (6) +/-25 %
Bolts, lifting eye/flywheel housing 80 (59) +/- 10%
M8 20 (15) +/-25 %
Bolts, engine/drive housing (M12) 80 (59) +/- 10%
M10 41 (30) +/-25 %
Bolts, engine/drive housing (M14) 125 (92) +/- 10%
M12 73 (54) +/-25 %
Bolts, compressor element/drive 80 (59) +/- 5%
M14 115 (85) +/-25 % housing
M16 185 (137) +/-25 % Safety switches 35 (26) +/- 10%
Joints adjustable towbar (M24) 275 (203) +/- 10%
For hexagon screws and nuts with strength grade 12.9
Joints adjustable towbar (M32) 375 (277) +/- 5%
Thread size Torque value (Nm / lbf.ft)
M6 14 (10) +/-21 % Secure the drain cock and tank cap of the fuel tank handtight.
M8 34 (25) +/-23 %
M10 70 (52) +/-24 %
M12 120 (89) +/-25 %
M14 195 (144) +/-23 %
M16 315 (233) +/-23 %
- 72 -
COMPRESSOR/ENGINE/GENERATOR SPECIFICATIONS
REFERENCE CONDITIONS
Designation XAS 127 Kd - XA(S) 137 Kd - XA(S) 137 KdG - XAHS 107 Kd - XA(S) 137 Kd - XA(S) 137 KdG - XAHS 107 Kd -
XAS 275 KD7 XA(S) 300 KD7 XA(S) 300 KD7G XAHS 225 KD7 XA(S) 300 KD7 XA(S) 300 KD7G XAHS 225 KD7
230/400 V 230/400 V
Engine Kubota V3800 Com 2 Engine Kubota V3307 Com 3

Absolute inlet pressure bar(e) 1 1 1 1 1 1 1
psi 14.5 14.5 14.5 14.5 14.5 14.5 14.5
Relative air humidity % 0 0 0 0 0 0 0
Air inlet temperature °C 20 20 20 20 20 20 20
°F 68 68 68 68 68 68 68
Nominal effective working pressure bar(e) 7 7 7 12 7 7 12
psi 102 102 102 174 102 102 174
The inlet conditions are specified at the air inlet grating outside the canopy.
- 73 -
LIMITATIONS
Designation XAS 127 Kd - XA(S) 137 Kd - XA(S) 137 KdG - XAHS 107 Kd - XAS 137 Kd - XAS 137 KdG - XAHS 107 Kd -
XAS 275 KD7 XA(S) 300 KD7 XA(S) 300 KD7G XAHS 225 KD7 XAS 300 KD7 XAS 300 KD7G XAHS 225 KD7
230/400 V 230/400 V

Minimum effective receiver pressure bar(e) 5 4 4 4 4 4 4
psi 74 58 58 58 60 58 58
Maximum effective receiver bar(e) 9 8.5 8.5 13.5 8.5 8.5 13.5
pressure, compressor unloaded psi 131 123 123 195 123 123 195
Maximum ambient standard °C 50 45 50 50 45 45 45
temperature at °F 122 113 122 122 113 113 113
sealevel
aftercooler °C 40 40 40 40 40 40 40
option °F 113 104 104 104 104 104 104
Minimum starting temperature °C - 10 - 10 - 10 - 10 - 10 - 10 - 10
°F 14 14 14 14 14 14 14
Minimum starting temperature, with °C - 20 - 20 - 20 - 20 - 20 - 20 - 20
coldstart equipment 1) °F -4 -4 -4 -4 -4 -4 -4
Altitude capability see curves
1) Coldstart: Compressor: PAROIL S i.s.o. PAROIL M

Engine: PAROIL E xtra i.s.o. PAROIL E
- 74 -
Performance data
Max. allowable working pressure as a function altitude and ambient temperature.
Temperature °F Temperature °F
14 32 50 68 86 104 122 14 32 50 68 86 104 122
6000 4000 13.124
5000 16.405
3000 9.843
4000 13.124
7 bar
7 bar
Altitude m
Altitude m
Altitude ft
Altitude ft
102 psi 102 psi
3000 9.843 2000 6.562
2000 6.562
1000 3.281
1000 3.281
0 0 ft 0 0 ft
-10,0 0,0 10,0 20,0 30,0 40,0 50,0 -10,0 0,0 10,0 20,0 30,0 40,0 50,0
Temperature °C Temperature °C
XAS 127 Kd XA(S) 137 Kd
XAS 275 KD7 Kubota V3800 XA(S) 300 KD7 Kubota V3800
- 75 -
Temperature °F Temperature °F
14 32 50 68 86 104 122
14 32 50 68 86 104 122
4000 13.124
4000 13.124
3000 9.843
3000 9.843
12 bar
7 bar
175 psi
Altitude m
Altitude m
Altitude ft
Altitude ft
102 psi
2000 6.562
2000 6.562
1000 3.281
1000 3.281
0 0 ft
0 0 ft
-10,0 0,0 10,0 20,0 30,0 40,0 50,0
-10,0 0,0 10,0 20,0 30,0 40,0 50,0
Temperature °C Temperature °C
XAHS 107 Kd
XA(S) 137 KdG
XAHS 225 KD7 Kubota V3800
XA(S) 300 KD7G Kubota V3800
- 76 -
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

4000 13.124 4000 13.124 4000 13.124
7 bar 7 bar
3000 9.843 3000 9.843 3000 9.843
102 psi 102 psi
12 bar
175 psi
2000 6.562 2000 6.562 2000 6.562

Altitude m
Altitude m
Altitude m
Altitude ft
Altitude ft
Altitude ft
1000 3.281 1000 3.281 1000 3.281
0 0 ft 0 0 ft 0 0 ft
-10,0 0,0 10,0 20,0 30,0 40,0 50,0 -10,0 0,0 10,0 20,0 30,0 40,0 50,0 -10,0 0,0 10,0 20,0 30,0 40,0 50,0
XAS 137 Kd XAS 137 KdG XAHS 107 Kd

XAS 300 KD7 Kubota V3307 XAS 300 KD7G Kubota V3307 XAHS 225 KD7 Kubota V3307
Temperature °C Temperature °C Temperature °C
- 77 -
PERFORMANCE DATA
At reference conditions, if applicable, and at normal shaft speed, unless otherwise stated.
230/400 V 230/400 V

Engine shaft speed, normal and r/min 2400 2400 2400 2400 2400 2400 2400
maximum
Engine shaft speed, compressor r/min 1700 1700 1700 1700 1700 1700 1700
unloaded
Free air delivery 1) standard l/s 128 138 109 106 128 96.5 94
cfm 271 292 231 225 271 204 200
with l/s 123 132 105 102 123 92.5 91
aftercooler cfm 261 280 222 216 260 196 193
1)
Free Air Delivery (volume flow rate) is measured according to ISO 1217 ed.4 2009 annex D
Tolerance:
• +/- 5% 25 l/s (53 cfm) < FAD < 250 l/s (530 cfm)
• +/- 4% 250 l/s (530 cfm) < FAD
- 78 -
Fuel consumption
230/400 V 230/400 V

at 100% FAD kg/h 11.8 12.6 12.6 12.6 11.8 11.9 11.8
lb/h 26.0 27.7 27.7 27.7 26.0 26.3 26.0
at 75% FAD kg/h 9.8 10.1 10.1 10.1 9.7 9.8 9.7
lb/h 21.6 22.2 22.2 22.2 21.4 21.6 21.4
at 50% FAD kg/h 8.4 8.0 8.4 8.4 8.3 8.4 8.3
lb/h 18.5 17.6 18.5 18.5 18.3 18.5 18.3
at 25% FAD kg/h 6.9 6.7 6.9 6.9 6.5 6.5 6.5
lb/h 15.2 14.7 15.2 15.2 14.4 14.4 14.4
at 0% FAD kg/h 6.9 6.7 6.9 6.9 5.8 5.8 5.8
lb/h 15.2 14.7 15.2 15.2 12.7 12.7 12.7
Specific fuel standard g/m3 25.6 25.4 32.1 33.0 25.6 34.2 34.9
consumption at lb/103 cu.ft 1.57 1.58 2.00 2.06 1.59 2.12 2.16
100% FAD
with g/m3 26.6 26.5 33.3 - 26.6 35.7 36.2
aftercooler lb/103 cu.ft 1.66 1.65 2.1 - 1.65 2.22 2.25
- 79 -
230/400 V 230/400 V

Typical oil content of compressed air mg/m3 <5 <5 <5 <5 <5 <5 <5
oz/103 cft < 0.005 < 0.005 < 0.005 < 0.005 < 0.005 < 0.005 < 0.005
Engine oil consumption (maximum) g/h 8.6 8.6 8.6 8.6 3.6 3.6 3.6
oz/h 0.303 0.303 0.303 0.303 0.126 0.126 0.126
Compressed air standard °C 90 90 90 90 90 90 90
temperature at °F 194 194 194 194 194 194 194
outlet valves
with °C 30 30 30 30 30 30 30
aftercooler °F 86 86 86 86 86 86 86
Noise level Engine Kubota V3800 Com 2 Engine Kubota V3307 Com 3
Sound pressure level (Lp) measured
dB(A) 74 71
according to ISO 2151
Sound power level (Lw) measured
dB(A) 102 98
according to 2000/14/EC
- 80 -
DESIGN DATA
Compressor
Designation
Number of compression stages 1
Engine
Designation XAS 127 Kd - XAS 275 KD7

XA(S) 137 Kd - XA(S) 300 KD7
XAS 137 KdG - XAS 300 KD7G
Make Kubota Kubota
Type V3800 V3307
Coolant Liquid Liquid
Number of cylinders 4 4
Bore mm 100 94
in 3.94 3.70
Stroke mm 120 120
in 4.72 4.72
Swept volume l 3.769 3.331
cu.in 300.0 203.3
Output according to DIN 6271 kW 71 55.4
at normal shaft speed BHP 95.0 74.3
- Load factor % 50 50
- 81 -
XA(S) 137 Kd - XA(S) 300 KD7
Capacity of oil sump:
- Initial fill l 11 11
US gal 2.91 2.91
- Refill (max.) 1) l 9.5 9.5
US gal 2.5 2.5
Capacity of cooling system l 13.5 13.5
US gal 3.6 3.6
1)
With filter change.
- 82 -
Unit

XA(S) 137 Kd - XA(S) 300 KD7
Capacity of compressor oil l 13 13
system US gal 3.43 3.43
Net capacity of air receiver l 35 35
US gal 9.25 9.25
Capacity of fuel tank l 130 130
US gal 34.3 34.3
Air volume at inlet grating m3/s 2.5 2.5
(approx.) 1) cfm 88 88
1)
Air required for engine and compressor cooling, for combustion and for compression.
Unit dimensions
with brakes towbar

fixed adjustable
Length mm 3768 4278
in 148.3 168.4
Width mm 1676 1676
in 66 66
Height mm 1479 1479
in 58.2 58.2
Weight (ready-to-operate) see dataplate
Air outlet valves: 3x ¾”
- 83 -
DESIGN DATA FOR GENERATOR
Alternator Electrical power circuit
Designation Designation 230/400V (3 phase)

Standard IEC 34-1 Rated continuous active power COP kW 9.6
Make MECC ALTE Rated power factor (lagging) 0.8
Model TR-2 ---/2 Rated continuous apparent power kVA 12
Rated output kVA 12 3ph COP
Degree of protection IP 23 Rated voltage 3ph line to line V 400
Insulation Rated current 3ph A 17.4
- stator class H Rated continuous apparent power kVA
1ph COP
- rotor class H
Rated voltage 1ph line to line V 230
Number of phases 3
Rated current 1ph A 16
Number of leads 6
Frequency droop % <5
Circuit-breaker
Fault current protection
Designation 230/400V (3 phase)

Designation 230/400V (3 phase)
Number of poles 4
Insulation resistance kOhm 13
Rated current In 1ph/3ph A 16/16
Thermal release It 1ph/3ph A 16/32
Magnetic release Im A 3..5 In
- 84 -
Data plate
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 7 A Maximum permitted total weight of the
2- C kg (7)
D kg vehicle
(8)
B Maximum permitted axle load
(9)
C Maximum permitted load on the towing eye
8 Model
(10)
9 Working pressure
(11)
10 Speed
11 Engine power
S/N Manuf. year (12) 12 Manufacturing year
Atlas Copco Airpower n.v. 13 CE mark in accordance with Machine Directive
0038 Boomsesteenweg 957
B-2610, WILRIJK 89/392 EC
14 Register number or number of notified body
(13) (14)
- 85 -
Disposal
GENERAL DISPOSAL OF MATERIALS
When developing products and services, Atlas Copco Dispose of contaminated substances and material
tries to understand, address, and minimize the separately, in accordance with locally applicable
negative environmental effects that the products and environmental legislation.
services may have, when being manufactured,
Before dismantling a machine at the end of its
distributed, used and disposed.
operating lifetime drain and dispose of all fluids of
Recycling and disposal policy are part of the according the applicable local disposal regulations.
development of all Atlas Copco products. Atlas
Remove the batteries. Do not throw batteries into the
Copco company standards determine strict fire (explosion risk) or residual waste. Separate the
requirements.
machine into metal, electronics, wiring, hoses,
Material selection, substantial recyclability, insulation and plastic parts.
disassembly possibilities and separability of materials
Dispose of all components in accordance with
and assemblies are considered, as well as
applicable disposal regulations.
environmental perils and dangers to health during the
recycling and disposal of the unavoidable rates of Remove spilled fluid mechanically; pick up the rest
non-recyclable materials. using an absorbing agent (for example sand, sawdust)
and dispose of it in accordance with 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 are therefore
almost infinitely 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 correct
disposal of the product you help prevent
possible negative consequences for
environment and health as a result of
inappropriate waste handling.
Recycling and re-usage of material help
preserve natural resources.
- 86 -
Maintenance Log
Compressor .......................................................................................... Customer ...............................................................................................
Serial number........................................................................................ ................................................................................................................
Service hours Maintenance action Date By initials
- 87 -
Following documents are provided with this unit:
- Test Certificate
- EC Declaration of Conformity:
1
EC DECLARATION OF CONFORMITY
2 We, Atlas Copco Airpower n.v., declare under our sole responsibility, that the product
3 Machine name :
4 Commercial name :
5 Serial number :
6 Which falls under the provisions of article 12.2 of the EC Directive 2006/42/EC on the approximation of the
laws of the Member States relating to machinery, is in conformity with the relevant Essential Health and
Safety Requirements of this directive.
The machinery complies also with the requirements of the following directives and their amendments as
indicated.
7 Directive on the approximation of laws of the Harmonized and/or Technical Att’

Member States relating to Standards used mnt
a. Pressure equipment 97/23/EC X
EN ISO 12100-1
b. Machinery safety 2006/42/EC EN ISO 12100-2
EN 1012-1
c. Simple pressure vessel 87/404/EEC X
EN 61000-6-2
d. Electromagnetic compatibility 2004/108/EC
EN 61000-6-4
EN 60034
e. Low voltage equipment 2006/95/EC EN 60204-1
EN 60439
f. Outdoor noise emission 2000/14/EC ISO 3744 X
8.a The harmonized and the technical standards used are identified in the attachments hereafter
8.b Atlas Copco Airpower n.v. is authorized to compile the technical file
9 Conformity of the product to the

Conformity of the specification to the
10
specification and by implication to the
Directives
directives
11
12 Issued by Product engineering Manufacturing
13
14 Name
15 Signature
16 Place , Date
Form 5009 0600 00
ed. 09, 2010-03-15
Atlas Copco Airpower n.v. A company within the Atlas Copco Group
Postal address Visitors address Phone: +32 (0)3 870 21 11 Com. Reg. Antwerp 44651
P.O. Box 100 Boomsesteenweg 957 Fax: +32 (0)3 870 24 43 V.A.T. 403.992.231
B-2610 Wilrijk-Antwerp B-2610 Wilrijk-Antwerp
Belgium Belgium For info, please contact your local Atlas Copco representative
www.atlascopco.com
p.1(1)
- 88 -
Notes
- 89 -
Notes
- 90 -

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Instruction Manual

for Portable Compressors

XAS 127 Kd - XAS 275 KD7

XAS 127 Kd - XAS 275 KD7

Copyright 2012, Atlas Copco Airpower n.v., Antwerp, Belgium.

This symbol is followed by Compressor oil system

The compressors type XAS 127 Kd - XAS 275 KD7, Regulation

(AR) (RV) (TB)

OVERVIEW (LOAD CONDITION)

Reference Name The system comprises: The system comprises:

9822 0841 56 Engine Kubota V3800 12

9822 0841 62 Engine Kubota V3307

Compressor outlet temperature too Read the instruction manual before

Compressor outlet temperature. On / off button. Service every 24 hours.

Compressor outlet pressure. Hours, time. Warning! Part under pressure.

Prohibition to open air valves without

Danger, hot surface. Compressor loaded. Start-Stop indication of switch.

Do not run the compressor with open

Atlas Copco mineral compressor oil. Airfilter. Lifting permitted.

Sound power level in accordance

Horizontal towbar position required in

Read the instruction manual before

PARKING, TOWING AND LIFTING

Adjustable towbar with jockey wheel and brakes

Locate the rear-end of the compressor upwind, away Label on towbar

For both non-adjustable - and adjustable towbar, the

• Fix locking nut (2) with spring pin (1).

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

A fault involving the engine, either oil pressure (too

Fault situations and protective devices:

Control panel (generator) Generator control box

X1.1 Socket 400 V/16 A Q1 Main circuit breaker 4-pole

MAINTENANCE SCHEDULE COMPRESSOR

(to be continued on page 43)

Synthetic compressor oil PAROIL S

Choose your compressor oil based on the ambient

Synthetic engine oil PAROIL E xtra

PAROIL E Mission Green

PAROIL E Mission Green

-30˚ C -22˚ F PAROIL E Mission Green

Consult also the Engine Operation Manual for the oil

2. Drain the oil by removing all relevant drain plugs.

Drain Steam cleaning in combination with a cleansing agent

Caution: do not top up when the engine

Preferably use the slow charging method and adjust

The working pressure is determined by the tension of

Be aware not to touch hot parts when the

New elements must also be inspected for tears or

All adjustments or repairs are to be done

Following checks must be carried out on the safety

Lift and support the compressor. Make sure that all

(1) (6) (4) (2)

(1) (2) (3) (4) (2) (5)

This check has to be performed when brake parts

• Check wheel bolts for firm seating (initially)

Tightening torques of wheel bolts

Spanner Thread Tightening

Cylindrical hub cap shape Wheel bolts tightening

Compact bearings After the first run, likewise after each