Atlas Copco XAS 97 JD User manual

“Copyright 1999, Atlas Copco Compressors, Inc. Holyoke, Massachusetts
Any unauthorized use or copying of the contents or any part of this book is
prohibited. This applies in particular to trademarks, model denominations, part
numbers and drawings.”
No. 1310 3011 65 Ed. 1
2004-05
Atlas Copco Portable Compressors
XAS 97 JD
Instruction Book
1310 3011 65 Ed. 12004-09

2 1310 3011 65
OWNERSHIP DATA
Unit model: Owner's machine no.:
Engine type: Unit service no.:
Delivery date: Engine serial no.:
Service plan: First start-up date:
Selected Lubricants
Compressor: Capacity:
Bearing grease type, electric motor:
Printed Matter Nos.
Atlas Copco instruction book / rev: Atlas Copco logbook:
Atlas Copco parts list / rev: Engine parts list:
Local Atlas Copco Representative
Name:
Address:
Telephone: Contact persons: Service:
Telefax: Parts:

1310 3011 65 3
Contents
1Safety Precautions for Portable Compressors 3
1.1 Introduction 4
1.2 General Safety Precautions 4
1.3 Safety during use and operation 5
1.4 Safety During Maintenance and Repair 6
1.5 Tool Applications Safety 6
1.6 Batteries 7
1.7 Ether fuel Systems 7
1.8 Pressure vessels 7
1.9 Safety valve 7
1.10 Injury Prevention 8
2Leading Particulars 9
2.1 Description of Safety Pictograms Used in this Manual 9
2.2 General Description 9
2.3 Main Parts 10
2.4 Air Flow (see Fig. 2.4) 11
2.5 Oil system (see Fig. 2.4) 12
2.6 Continuous regulating system 12
2.7 Electrical System 13
3Operating Instructions 14
3.1 Parking, Towing And Lifting Instructions 14
3.2 Before Starting 15
3.3 Starting/Stopping (See Fig. 3.3) 16
3.4 During Operation 16
4Maintenance 16
4.1 Use of Service Paks 16
4.2 Preventive Maintenance Schedule For The Compressor 16
4.3 Lubrication oils 17
4.4 Oil Level Check 17
4.5 Oil And Oil Filter Change (see Fig. 4.5) 18
4.6 Cleaning Coolers 18
4.7 Battery Care 18
4.8 Storage 19
4.9 Service Kits 19
5Adjustments and Servicing Procedures 20
5.1 Adjustment of the Continuous Regulating System (See Fig. 5.1) 20
5.2Air Filter Engine/Compressor 21
5.3 Air Receiver 21
5.4 Safety Valve 21
5.5 Fuel System (see Fig. 5.4) 21
6Problem Solving 22
6.1 Problem Solving Chart 22
6.2 Alternator Precautions 22
7Technical Specifications 24
7.1 Settings of Shutdown Switches and Safety Valve 24
7.2 Compressor/Engine Specifications 24
1Safety Precautions for Portable Compressors
To be read attentively and acted on accordingly before towing, lifting, operating,
performing maintenance or repairing the compressor

4 1310 3011 65
1.1 Introduction
The policy of Atlas Copco is to provide the users of their
equipment with safe, reliable and efficient products.
Factors taken into account are among others:
-the intended and predictable future use of the
products, and the environments in which they are
expected to operate,
-applicable rules, codes and regulations,
-the expected useful product life, assuming proper
service and maintenance.
Before handling any product, take time to read the relevant
instruction book. Besides giving detailed operating
instructions, it also gives specific information about safety,
preventive maintenance, etc.
These precautions are general and some statements will
therefore not always apply to a particular unit.
When handling, operating, overhauling and/or performing
maintenance or repair on Atlas Copco equipment, the
mechanics are expected to use safe engineering practices
and to observe all relevant local safety requirements and
ordinances. The following list is a reminder of special
safety directives and precautions mainly applicable to Atlas
Copco equipment.
This brochure applies to machinery processing or
consuming air or inert gas. Processing of any other gas
requires additional safety precaution typical to the
application and are not included herein.
All responsibility for any damage or injury resulting from
neglecting these precaution: or by non-observance of
ordinary caution and due care required in handling,
operating, maintenance or repair, also if not expressly
mentioned in this brochure or the instruction book(s), is
disclaimed by Atlas Copco.
If any statement does not comply with local legislation, the
stricter of the two shall be applied. Statements in this
manual should not be interpreted as suggestions:,
recommendations or inducements that it should be used in
violation of any applicable laws or regulations.
1.2 General Safety Precautions
1 The owner is responsible for maintaining the unit in a
safe operating condition. Unit parts and accessories
must be replaced if missing or unsuitable for safe
operation.
2 Use only lubricating oils and greases recommended or
approved by Atlas Copco or the machine
manufacturer. Ascertain that the selected lubricants
comply with all applicable safety regulations, especially
with regard to explosion or fire risk and the possibility
of decomposition or generation of hazardous gases.
3 The supervisor, or the responsible person, shall at
all times make sure that all instructions regarding
machinery and equipment operation and
maintenance are strictly followed and that the
machines with all accessories and safety devices,
including the entire compression or vacuum
system with pipes, valves, connectors, hoses, etc.,
as well as the consuming devices, are in good
repair, free of abnormal wear or abuse, and are
not tampered with.
4 Maintenance, overhaul and repair work shall only be
carried out by adequately trained personnel; if required,
under supervision of someone qualified for the job.
5 Whenever there is an indication or any suspicion that
an internal part of a machine is overheated, the
machine shall be stopped. No inspection covers shall
be opened before sufficient cooling time has elapsed;
this is to avoid the risk of spontaneous ignition of the oil
vapor when air is admitted.
6 Maintenance work, other than routine attention, shall
only be undertaken when the machine is standing still.
7 Before dismantling any pressurized component, the
compressor or the equipment shall be effectively
isolated from all sources of pressure and be completely
vented to atmosphere. In addition, a warning sign
bearing a legend such as "work in progress; do not
open" shall be attached to each of the isolating valves.
8 Before a machine is being repaired, steps shall be
taken to prevent inadvertent starting. In addition, a
warning sign bearing a legend such as "work in
progress; do not start" shall be attached to the starting
equipment. The battery shall be disconnected and
removed or the terminals covered by insulating caps.
9 Normal ratings (pressures, temperatures, speeds, etc.)
shall be durably marked.
10 Never operate a machine or equipment beyond its
rated limits (pressure, temperature, speed, etc.).
11 Maintenance and repair work should be recorded in an
operator's logbook for all machinery. Frequency and
nature of repairs can reveal unsafe conditions.
12 The machinery and pneumatic equipment shall be kept
clean, i.e. as free as possible from oil, dust or other
deposits.
13 To prevent an increase in working temperature, inspect
and clean heat transfer surfaces (cooler fins,
intercoolers, water jackets, etc.) regularly. For every
machine establish a suitable time interval for cleaning
operations.
14 All regulating and safety devices shall be maintained with
due care to ensure that they function properly. They may
not be put out of action.
15 Care shall be taken to avoid damage to safety valves and
other pressure relief devices, especially to avoid plugging
by paint, oil coke or dirt accumulation, which could interfere
with the functioning of the device.
16 Pressure and temperature gauges shall be checked
regularly with regard to their accuracy. They shall be
replaced whenever outside acceptable tolerances.
17 Parts shall only be replaced by genuine Atlas Copco
replacement parts.
18 Safety devices shall be tested as described in the
maintenance schedule of the instruction book(s) to
determine that they are in good operating condition.
19 Never use flammable solvents or carbon tetrachloride for
cleaning pans. Take safety precautions against toxic
vapors when cleaning parts in or with cleaning products.
20 Observe scrupulous cleanliness during maintenance and
repair. Keep away dirt by covering the parts and exposed
openings with clean cloth, paper or tape.

1310 3011 65 5
21 Protect the engine, alternator, air intake filter, electrical
and regulating components, etc. to prevent moisture
ingress, e.g. when steam-cleaning.
22 When performing any operation involving heat, flames
or sparks on a machine, the surrounding components
shall first be screened with non-flammable material.
23 Never use a light source with open flame for inspecting
the interior of a machine, pressure vessel, etc.
24 On portable units, support the drawbar and axle(s)
securely if working underneath the units or when
removing a wheel. Do not rely on jacks.
25 Prior to stripping a compressor, engine or other
machine or undertaking major overhaul on it, prevent
all movable parts with a mass exceeding 15 kg (30 lbs)
from rolling over or moving.
26 When repair has been completed, make sure that no
tools, loose parts or rags are left in, or on, the
machine, the prime mover or the driving gear. The
machine shall be barred several revolutions to ensure
that there is no mechanical interference within the
machine or driver.
1.3 Safety during use and operation
To lift a unit, all loose or pivoting parts, e.g. doors shall first
be securely fastened. Do not attach cables, chains or
ropes directly to the lifting eye; apply a crane hook or lifting
shackle meeting local safety rules.
Helicopter lifting using the lifting eye is forbidden.
It is strictly forbidden to dwell or stay in the risk zone under
a lifted load. Never lift the unit over people or residential
areas.
Lifting acceleration and retardation shall be kept within safe
limits.
1 Before towing the unit:
-ascertain that the pressure vessel(s) is (are)
depressurized,
-check the drawbar, the brake system and the towing
eye. Also check the coupling of the towing vehicle,
-check that the pivot wheel or stand leg is safely
locked in the raised position,
-ascertain that the towing eye can swivel freely on
the hook,
-check that the wheels are secure and that the tires
are in good condition and inflated correctly,
-connect the signal cable, check all lights and
connect the pneumatic brake couplers,
-attach the safety break-away cable to the
towing vehicle,
-remove wheel chocks, if applied, and disengage the
parking brake.
-Apply safety chains to tow vehicle.
2 If the unit is to be backed up by the towing vehicle,
disengage the overrun brake mechanism (if equipped).
3 Never exceed the maximum towing speed of the unit.
4 Place the unit on level ground and chock the wheels before
disconnecting the unit from the towing vehicle. Unclip the
safety break-away cable
5 When the unit has to operate in a fire-hazardous
environment, each engine exhaust has to be provided with
a spark arrestor to trap incendiary sparks.
6 The exhaust contains carbon monoxide which is a lethal
gas. When the unit is used in a confined space, conduct
the engine exhaust to the outside atmosphere by a pipe of
sufficient diameter (min. 4 inches); do this in such a way
that no extra back pressure is created for the engine. If
necessary, install an extractor.
7 When operating in a dust-laden atmosphere, place the unit
so that dust is not carried towards it by the wind. Operation
in clean surroundings considerably extends the intervals for
cleaning the air intake filters and the cores of the coolers.
8 Locate the unit away from walls. Take all precautions to
ensure that hot air exhausted from the engine and driven
machine cooling systems cannot be recirculated. If such
hot air is taken in by the engine or driven machine cooling
fan, this may cause overheating of the unit; if taken in for
combustion, the engine power will be reduced.
9 No external force may be exerted on the air outlet valves,
e.g. by pulling on hoses or by installing auxiliary equipment
directly to a valve, e.g. a water separator, a lubricator, etc.
10 Distribution pipework and air hoses must be of correct size
and suitable for the working pressure.
Never use frayed, damaged or deteriorated hoses.
Replace hoses and flexibles of which the lifetime expired.
Use only the correct type and size of hose end fittings and
connections.
A hose connected to a 2 inch (50 mm) valve must be
provided with a safety wire (8 mm) fixed to the hose for
effective pressures as from 10 bar (145 psi) up, although it
is recommended to apply such safeguard already from 4
bar (60 psi) up. The safety wire ends have to be attached,
one to the eye provided next to the compressor air outlet
valve, the other one to a point near to the air inlet of the
applied equipment.
Finally a wire mesh hose can be fixed over the hose ends
to dampen the blast in case a connection starts leaking or
should become undone.
Close the compressor air outlet valve before connecting or
disconnecting a hose. Ascertain that a hose is fully
depressurized before disconnecting it.
When blowing through a hose or air line, ensure that the
open end is held securely. A free end will whip and may
cause injury.
Never play with compressed air. Never apply it to your skin
or direct an air stream at people. Never use it to clean dirt
from your clothes. When using it to clean down equipment,
do so with extreme caution and use eye protection.
11 Never move a unit when external lines or hoses are
connected to the outlet valves, to avoid damage to valves
and/or manifold and hoses.
12 Never refill fuel while the unit is running. Keep fuel away
from hot parts such as air outlet pipes or the engine
exhaust. Do not smoke when fueling. When fueling from
an automatic pump, a ground cable should be connected to
the unit to discharge static electricity. Never spill nor leave
oil, fuel, coolant or cleansing agent in or around the unit.

6 1310 3011 65
13 Never operate the unit in surroundings where there is
a possibility of taking in flammable or toxic fumes.
14 Never operate the unit at pressures or speeds below
or in excess of the limit ratings stated on the Principal
Data sheet.
15 On water-cooled engines with closed cooling circuit:
allow the unit to cool before removing a pressure cap.
16 All doors shall be shut during operation so as not to
disturb the cooling air flow inside the body-work and/or
render the silencing less effective. A door should be
kept open for a short period only, e.g. for inspection or
adjustment
17 Wear ear protectors when environmental noise can
reach or exceed 90 dB(A). Beware of long-time
exposure to noise.
18 Periodically check that:
-all safety equipment is in good working order,
-all guards and air conducting baffles are in place
and securely fastened,
-all hoses and/or pipes inside the unit are in good
condition, secure and not rubbing,
-there are no fuel, oil or coolant leaks,
-all fasteners are tight
-all electrical leads are secure and in good
order,
-the engine exhaust system is in good condition,
-air outlet valves and manifold, hoses,
couplings, etc. are in good repair, free of wear
or abuse,
-the wheel nuts are tightened to the proper
torque.
When more than one compressor is connected to a
common header, be sure each compressor has a non-
return valve (check valve) to prevent reverse rotation when
stopping.
1.4 Safety During Maintenance and Repair
Maintenance and repair work shall only be carried out by
adequately trained personnel: if required, under supervision
of someone qualified for the job.
1 Use only the correct tools for maintenance and repair
work.
2 Use only genuine spare parts.
3 All maintenance work, other than routine attention,
shall only be undertaken when the unit is stopped.
Ensure that the unit cannot be started inadvertently.
4 Before removing any pressurized component,
effectively isolate the compressor from all sources of
pressure and relieve the entire system of pressure. Do
not rely on non-return valves (check valves) to isolate
pressure systems.
5 Never use flammable solvents or carbon tetrachloride for
cleaning parts. Take safety precautions against toxic
vapors of cleaning liquids.
6 Scrupulously observe cleanliness during maintenance and
when performing repairs. Keep dirt away by covering the
parts and exposed openings with a clean cloth, paper or
tape.
7 Never weld on or perform any operation involving heat near
the fuel or oil systems. Fuel and oil tanks must be
completely purged, e.g. by steam-cleaning, before carrying
out such operations.
Never weld on, or in any way modify, pressure vessels.
Disconnect the alternator cables during arc welding on the
unit.
8 Support the drawbar and the axle securely if working
underneath the unit or when removing a wheel. Do not rely
on jacks.
9 Make sure that no tools, loose parts or rags are left in or on
the unit.
10 Before clearing the unit for use after maintenance or
overhaul, check that operating pressures, temperatures and
speeds are correct and that the control and shutdown
devices function correctly.
11 Do not remove any of, or tamper with, the sound damping
material. Keep the material free of dirt and liquids such as
fuel, oil and cleansing agents.
12 Protect the electrical and regulating components, the air
filter, etc. to prevent moisture from entering them, e.g. when
steam-cleaning.
1.5 Tool Applications Safety
Apply the proper tool for each job. With the knowledge of
correct tool use and knowing the limitations of tools, along with
some common sense, many accidents can be prevented.
Special service tools are available for specific jobs and should
be used when recommended. The use of these tools will save
time and prevent damage to parts.
1 Use only wrenches or sockets whose size fits the fastener.
2 Apply an open-end wrench only in the place of the fastener
head, square to the thread axis.
3 Do not use a pipe or other improvised leverage extensions
on handles.
4 Do not hammer on wrenches or other tools which are not
specially designed for it.
5 Always support the ratchet head when using socket
extensions.
6 Discard any wrench with broken or battered points or
edges.
7 Never use hand type sockets on power or impact tools.
8 Select only heavy-duty impact sockets for use with
pneumatic or electric impact tools.
9 Replace sockets showing cracks or wear; keep sockets
clean.
10 Never use screwdrivers for prying, punching, chiseling,
scoring or scraping.

1310 3011 65 7
11 Use the correct type and size of screwdriver for the
job. The bit must match the fastener.
12 A screwdriver with rounded edges will slip; it needs to
be redressed or discarded.
13 Never use a screwdriver or any other tool near a live
wire or electrical component. Plastic covering of
handles is for comfort and grip only. They are not
intended to act as insulation if such is not clearly
marked by the manufacturer.
14 Never strike a hammer against a hardened object; use
a soft drift against the object and strike against the
drift.
15 Strike the object with the full face of the hammer.
16 Never use a hammer with a loose head.
17 Discard a hammer with chipped or mushroomed face.
18 Never use a chisel or punch with a chipped or
mushroomed striking face.
19 Always pull on a wrench or socket handle, if possible,
and adjust your stance to prevent a fall if something
lets go.
20 Wear approved eye protection when using percussion
tools or when scraping, chipping, shaving or grinding.
21 Wear protective gloves when holding a chisel or
punch.
1.6 Batteries
1 The electrolyte in batteries is a sulphuric acid solution
which is fatal if it hits your eyes, and which can cause
burns if it contacts your skin. Therefore, be careful
when handling batteries, e.g. when checking the
charge condition.
2 Install a sign prohibiting fire, open flame and smoking
at the post where batteries are being charged.
3When batteries are being charged, an explosive gas
mixture forms in the cells and might escape through
the vent holes in the plugs.
Thus an explosive atmosphere may form around the
battery if ventilation is poor, and can remain in and
around the battery for several hours after it has been
charged.
Therefore:
-never smoke near batteries being, or having recently
been, charged,
-never break live circuits at battery terminals,
because a spark usually occurs.
4 When connecting an auxiliary battery (AB) in parallel to
the unit battery (CB) with booster cables: connect the +
pole of AB to the + pole of CB, then connect the -pole
of AB to the mass of the unit. Disconnect in the
reverse order.
1.7 Ether fuel Systems
Ether fuel systems are used for diesel cold starting.
1 Do not use ether as a starting aid in conjuntion with
other stating aids (i.e. glow plug, air intake heater etc..)
as an explosive condition may result in severe engine
damage or personal injury.
2 This type of fuel is extremely flammable, toxic and
poisonous. Avoid contact with eyes or skin and breathing
the fumes. If accidentally swallowed, do not induce
vomiting but call a physician immediately.
3 If fuel enters or fumes irritate the eyes, flush the latter with
large quantities of clean water and call for medical aid.
4 Before operating ether cold starting aids, read the
instructions and the container label.
5 Never operate ether cold starting aids while the engine is
running as this can cause severe damage.
6 When maintenance, tests or repair has to be performed, do
so in a well-ventilated area only, away from heat, open
flame or sparks. Ascertain that the area is clearly marked
out with signs prohibiting fire, open flame and smoking.
7 Wear eye protection when testing a system. Make sure
that openings of a spray container, valve, tube or atomizer
are pointed away from yourself and others while testing.
8 Do not store ether containers in temperatures above 70ºC
(160 ºF),
9 Do not incinerate, puncture or attempt to remove the center
core valve, side safety valve or any other part of an ether
container.
1.8 Pressure vessels
Maintenance / installation requirements:
1 The vessel can be used as a pressure vessel or as a
separator and is designed to hold compressed air for the
following applications:
-pressure vessel for compressor.
-medium AIR/OIL,
and operates as detailed on the data plate of the vessel:
-the maximum working pressure in psi,
2 The pressure vessel is only to be used for the applications
as specified above and in accordance with the technical
specifications. Safety reasons prohibit any other
applications.
3 National legislation requirements with respect to re-
inspection must be complied with.
4 No welding or heat treatment of any kind is permitted to
those vessel walls which are exposed to pressure.
5 The vessel is provided and may only be used with the
required safety equipment such as manometer,
overpressure control devices, safety valve, etc.
6 Draining of condensate shall be performed 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.
1.9 Safety valve
All adjustments or repairs are to be done by an authorized
representative of the valve supplier.

8 1310 3011 65
Following checks must be carried out:
1 A check of the opening of the lifting gear,1 or 2 times a
year. This can be done by lifting the ring or lever.
2 A check of the set pressure once a year according to
the local regulations, if required. This check may not
be done with the compressor supplying the air
pressure and must be carried out on a proper test
bench.
1.10 Injury Prevention
1 Stationary housing guards are provided on all rotating
or reciprocating parts not otherwise protected and
which may be hazardous to personnel. Machinery
shall never be put into operation, when such guards
have been removed, before the guards are securely
reinstalled.
2 Do not open electrical cabinets, cubicles or other
equipment while voltage is supplied. If such cannot be
avoided, e.g. for measurements, tests or adjustments,
have the action carried out by a
qualified electrician only, with appropriate tools, and
ascertain that the required bodily protection against
electrical hazards is applied.
3 Noise, even at reasonable levels, can cause
irritation and disturbance which, over a long period
of time, may cause severe injuries to the nervous
system of human beings.
When the sound pressure level, at any point where
personnel normally has to attend, is:
below 70 dB(A): no action needs to be taken,
above 70 dB(A): noise-protective devices should be
provided for people continuously
being present in the room,
below 85 dB(A): no action needs to be taken for
occasional visitors staying a limited
time only,
above 85 dB(A): room to be classified as a noise-
hazardous area and an obvious
warning shall be placed
permanently at each entrance to
alert people entering the room, for
even relatively short times, about
the need to wear ear protectors,
above 95 dB(A): the warning(s) at the entrance(s)
shall be completed with the
recommendation that also
occasional visitors shall wear ear
protectors,
above 105 dB(A): special ear protectors that are
adequate for this noise level and
the spectral composition of the
noise shall be provided and a
special warning to that effect shall
be placed at each entrance.
4 Insulation or safety guards of parts the temperature of
which can be in excess of 80 ºC (175 ºF) and which
may be accidentally touched by personnel shall not be
removed before the parts have cooled to room
temperature.
5 When hot parts have to be handled, e.g. shrink fitting,
special heat-resistant gloves shall be used and, if
required, other body protection shall be applied.
6 If the working process produces fumes, dust or vibration
hazards, etc., take the necessary steps to eliminate the risk
of personnel injury.
7 Before lifting machines, all loose parts which could be liable
to fall down shall be removed or secured; pivoting parts
such as doors, etc. shall be safely immobilized.
8 To lift heavy parts, a hoist of ample capacity, tested and
approved according to local safety regulations, shall be
used.
9 When lifting machinery, only hooks or shackles meeting
local safety regulations shall be applied. Never shall
cables, chains or ropes be applied directly on or through
lifting eyes. Never allow sharp bends in lifting cables,
chains or ropes.
10 Lifting hooks, eyes, shackles, etc. shall never be bent and
shall only have stress in line with their design load axis.
The capacity of a lifting device diminishes when the lifting
force is applied at an angle to its load axis.
11 For maximum safety and efficiency of the lifting apparatus
all lifting members shall be applied as near to perpendicular
as possible. If required, a lifting beam shall be applied
between hoist, and load.
12 When heavy pans are being lifted with a hoist, it is strictly
forbidden to dwell or pass under the load or in the space
which is liable to be hit if the load or part of it should topple
over or come loose. Never leave a load hanging on a hoist.
Lifting acceleration and retardation shall be kept within safe
limits.
13 A hoist has to be installed in such a way that the object will
be lifted perpendicular. If that is not possible, the
necessary precautions must be taken to prevent load-
swinging, e.g. by using two hoists, each at approximately
the same angle not exceeding 30deg from the vertical.
14 When using compressed air or inert gas to clean down
equipment, do so with caution and use the appropriate
protection, at least safety glasses, for the operator as well
as for any bystander. Do not apply compressed air or inert
gas to your skin or direct an air or gas stream at people.
Never use it to clean dirt from your clothes.
15 Before blowing compressed air or inert gas through a hose,
ensure that the open end is held securely, so that it cannot
whip and cause injury.
16 When washing parts in or with a cleaning solvent, provide
the required ventilation and use appropriate protection such
as a breathing filter, safety glasses, rubber apron and
gloves, etc.
17 Safety shoes should be compulsory in any workshop and if
there is a risk, however small, of failing objects, wearing of
a safety helmet should be included.
18 If there is a risk of inhaling hazardous gases, fumes or dust,
the respiratory organs must be protected and, depending
on the nature of the hazard, so must the eyes and skin.
19. Remember that where there is visible dust, the finer,
invisible particles will almost certainly be present too; but
the fact that no dust can be seen is not a reliable indication
that dangerous, invisible dust is not present in the air.
20. When using cartridge type breathing filter equipment,
ascertain that the correct type of cartridge is used and that
its useful service life is not surpassed.

1310 3011 65 9
2Leading Particulars
2.1 Description of Safety Pictograms
Used in this Manual
?This symbol draws your attention to dangerous
situations. The operation concerned may
endanger persons and cause injuries.
?This symbol is followed by supplementary
information.
Fig. 2.1 General view of XAS 97 JD
2.2 General Description
The XAS 97 is a silenced, single-stage, oil-injected screw
compressor, built for a normal effective working pressure of
7 bar (102 psi).
—Engine
The compressor is driven by a water-cooled diesel engine.
The engine’s power is transmitted to the compressor
through a flexible coupling.
—Compressor
The compressor casing houses two screw-type rotors,
mounted on ball and roller bearings. The male rotor, driven
by the engine, drives the female rotor. The male rotor has
four lobes and the female rotor has six flutes. Thus, the
male rotor revolves at 1 1/2 times the speed of the female
rotor. The element delivers pulsation-free air.
Injected oil is used for sealing, cooling and lubricating
purposes.
—Compressor Oil System
The oil is boosted by air pressure. The system has no oil
pump.
The oil is removed from the air, in the air/oil vessel first by
centrifugal force, second through the oil separator element.
The vessel is provided with an oil level indicator.
—Regulation
The compressor is provided with a continuous regulating system
and a blow-down valve which is integrated in the unloader
assembly. The valve is closed during operation by outlet
pressure of the compressor element and opens by air receiver
pressure when the compressor is stopped.
When the air consumption increases, the air receiver pressure
will decrease and vice versa.
This receiver pressure variation is sensed by the regulating
valve which, by means of control air to the unloader and engine
speed regulator, matches the air output to the air consumption.
The air receiver pressure is maintained between the pre-
selected working pressure and the corresponding unloading
pressure.
—Cooling System
Engine and compressor are provided with a radiator and oil
cooler. The cooling air is generated by a fan, driven by the
engine.
—Safety Devices
A thermal shut-down switch protects the compressor against
overheating. The air receiver is provided with a safety valve.
The engine is equipped with low oil pressure and high coolant
temperature shut-down switches and an alternator/V-belt
protection system.
—Frame and Axle
The compressor/engine unit is supported by rubber buffers in
the frame.
The standard XAS 97 is equipped with a non-adjustable
drawbar with a towing eye and road lighting.
As an option, the unit can be equipped with electric, hyduralic
and/or parking brake.
When driving backwards the hyduralic brake is not engaged
automatically.
—Bodywork
The bodywork has openings at the shaped front and rear end for
the intake and outlet of cooling air and a specially hinged
canopy for maintenance and service operations. The bodywork
is partially lined with sound-absorbing material.
—Lifting Eye
A lifting eye is accessible through the roof panel at the top of the
unit.
—Control Panel
The control panel grouping the air pressure gauge, control
switch etc., is placed behind a door at the front of the unit.
—Data Plate
The compressor is furnished with a data plate located on the
front of the unit showing the compressor type, serial number,
maximum final pressure and normal working pressure.

10 1310 3011 65
2.3 Main Parts
AV
FP
AR/OS
SV RV
AFe
AFc
OFc
OFe
VLc
FC1
FF
F
E
EP
G1
CP PG
Fig 2.3 Main parts of XAS 97 JD
AFe Air Filter Engine
AFc Air Filter Compressor
AR Air Receiver
AV Air Outlet Valve
BDV Blow Down Valve
CE Compressor Element
CP Control Panel
CV Check Valve
DB Drive Belt
DP Drain Plug
Dse Dipstick Engine Oil Level
EEngine
EP Exhaust Pipe
FCooling Fan
FC1 Fuel Filler Cap
FC2 Engine Oil Filler Cap
FFa Fuel Filter (Final)
FFb Fuel Filter (Primary)
FP Compressor Oil Filling Plug
FR Flow Restrictor
FT Fuel Tank
FU Fuel Pump Manual
G1 Alternator
LV Loading Valve
MPV Minimum Pressure Nozzle
M1 Starter Motor Engine
OC Oil Cooler
OFe Oil Filter Engine
OFc Oil Filter Compressor
OLG Oil Level Gauge
OS Oil Separator
PG Pressure Gauge
RV Regulating Valve
SL Scavenge Line
SR Speed Regulator
SV Safety Valve
TS Temperature Switch
UA Unloader Assembly
UV Unloader Valve
VH Vent Hole
VIe Vacuum Indicator Engine
VIc Vacuum Indicator Compressor
VV Vacuator Valve

1310 3011 65 11
Compressor Regulating System (Load Condition)
Fig. 2.4 Compressor Regulating System
AFe Air Filter Engine
AFc Air Filter Compressor
AR Air Receiver
AV Air Outlet Valve
BDV Blow Down Valve
CE Compressor Element
CP Control Panel
CV Check Valve
DB Drive Belt
DP Drain Plug
Dse Dipstick Engine Oil
Level
EEngine
EP Exhaust Pipe
FCooling Fan
FC1 Fuel Filler Cap
FC2 Engine Oil Filler Cap
FFa Fuel Filter (Final)
FFb Fuel Filter (Primary)
FP Compressor Oil Filling
Plug
FR Flow Restrictor
FT Fuel Tank
FU Fuel Pump Manual
G1 Alternator
LV Loading Valve
MPV Minimum Pressure
Nozzle
M1 Starter Motor Engine
OC Oil Cooler
OFe Oil Filter Engine
OFc Oil Filter Compressor
OLG Oil Level Gauge
OS Oil Separator
PG Pressure Gauge
RV Regulating Valve
SL Scavenge Line
SR Speed Regulator
SV Safety Valve
TS Temperature Switch
UA Unloader Assembly
UV Unloader Valve
VH Vent Hole
VIe Vacuum Indicator
Engine
VIc Vacuum Indicator
Compressor
VV Vacuator Valve
2.4 Air Flow (see Fig. 2.4)
The system comprises:
AF Air filter
AR/OS Air receiver/oil separator
CE Compressor element
UA/UV Unloader assembly with unloader valve
BDV Blow-down valve
MPV Minimum pressure valve
LV Loading Valve
Air drawn through the airfilter (AF) into the compressor
element (CE) is compressed. At the element outlet,
compressed air and oil pass into the air receiver/oil separator
(AR/OS).
The check valve prevents blow-back of compressed air when
the compressor is stopped. In the air receiver/oil separator
(AR/OS), most of the oil is removed from the air/oil mixture: the
remaining oil is removed by the separator element.
The oil collects in the receiver and on the bottom of the
separator element.
The air leaves the receiver via the minimum pressure valve
(MPV) which prevents the receiver pressure from dropping
below the minimum working pressure, even when the air outlet
valves are open. This ensures adequate oil injection and
prevents oil consumption.

12 1310 3011 65
A temperature switch (TS) and a working pressure gauge
(PG) are comprised in the system.
A blow-down valve (BDV) is fitted in the unloader assembly
to automatically depressurize the air receiver (AR) when
the compressor is stopped.
2.5 Oil system (see Fig. 2.4)
The system comprises:
AR/OS Air receiver/oil separator
RV/UA Regulation Valve/Unloader Valve
OC Oil cooler
OF Oil filter
The lower part of the air receiver (AR) serves as oil tank.
Air pressure forces the oil from the air receiver/oil separator
(AR/OS) through the oil cooler (OC) and oil filter (OF) to the
compressor element (CE).
The compressor element has an oil gallery in the bottom of
its casing. The oil for rotor lubrication, cooling and sealing
is injected through holes in the gallery.
Lubrication of the bearings is ensured by oil injected into
the bearing housings.
The injected oil, mixed with the compressed air, leaves the
compressor element and re-enters the air receiver, where it
is separated from the air as described in section 2.4. The
oil that collects in the bottom of the oil separator element is
returned to the system through scavenging line (SL), which
is provided with a flow restrictor (FR).
The oil filter by-pass valve opens when the pressure drop
over the filter is above normal because of a clogged filter.
The oil then by-passes the filter without being filtered. For
this reason, the oil filter must be replaced at regular
intervals (see section 4.2).
2.6 Continuous regulating system
(see Fig. 2.4)
The system comprises:
RV Regulating valve
UA Unloader assembly
SR Speed regulator
The compressor is provided with a continuous regulating
system. This system is provided with a blow-down valve
(BDV) which is integrated in the unloader assembly (UA).
The valve is closed during operation by outlet pressure of
the compressor element and opens by air receiver
pressure when the compressor is stopped.
When the air consumption increases, the air receiver
pressure will decrease and vice versa. This receiver
pressure variation is sensed by the regulating valve which, by
means of control air to the unloader, matches the air output to
the air consumption. The air receiver pressure is maintained
between the pre-selected working pressure and the
corresponding unloading pressure.
When starting the compressor, the unloader valve (UV) is kept
open by spring force, the engine runs at maximum speed. The
compressor element (CE) takes in air and pressure builds up in
the receiver. The unloader valve is closed.
The air output is controlled from maximum output (100%) to no
output (0%) by:
1. Speed control of the engine between maximum load speed
and unloading speed (the output of a screw compressor is
proportional to the rotating speed).
2. Air inlet throttling.
3. Blow off valve (BOV).
If the air consumption is equal to or exceeds the maximum air
output, the engine speed is held at maximum load speed and
the unloading valve is fully open.
If the air consumption is less than the maximum air output, the
regulating valve supplies control air to unloader valve (UV) to
reduce the air output and holds air receiver pressure between
the normal working pressure and the corresponding unloading
pressure of approx. 1.5 bar (21.75 psi) above the normal
working pressure.
When the air consumption is resumed, the unloader valve
gradually opens the air intake and the speed regulator increases
the engine speed.
The construction of the regulating valve is such that any
increase (decrease) of the air receiver pressure above the pre-
set valve opening pressure results in a proportional increase
(decrease) of the control pressure to the unloading valve.
Part of the control air is vented to atmosphere, and any
condensate discharged, through the vent holes (VH).

1310 3011 65 13
Electrical System
2.7.1 Circuit Diagram
Figure 2.7 Circuit diagram
F1 Circuit breaker (10A)
G1 Alternator
G2 Battery
H1 Temperature alarm lamp
H2 General alarm lamp
HTR Engine pre-heater (Glow plug)
K0 Starter solenoid (part of M1)
K1 Relay
K2 Relay
K3 Relay
K4 Relay
K5 Relay
M1 Starter motor
P1 Hour meter
P2 Fuel Level Gauge
S1 Contact switch (Off-On-Override-start)
S2 Temperature switch engine
S3 Oil pressure switch engine
S4 Lamp test switch
S5 Temperature switch (Compressor)
S6 Low Fuel Level switch
S7 Fuel Level sender
Y1 Fuel solenoid valve
R1 Resistor
V2 Diode

14 1310 3011 65
2.7.2 Description (see Fig. 2.7)
Operation of the electric circuit In detail
Start button S1 position 1:
Line 2 on 12V contact K3 closed (13-11), lamp H2 is
on. K4 excites contact K4 (18-15). Thermocontact
element S5 normally closed, K1 excites contact K1 (1-
4).
Use of preheat:
Start button S1 position 1 press pushbutton S4,
energizes relay K5 and provides power to the
glowplug.
Start button S1 position 2:
Line 3 on 12V (override function) hourmeter P1, glow
plug relay K5, and fuel solenoid Y1 is excited.
Thermocontact engine S2 normally closed, oil
pressure contact S3 open.
Start button S1 position 3:
Start relay K0 is excited and starter motor is running,
engine builds up oil pressure and oil pressure contact
S3 closes. K3 excited and contact K3 changes over to
(13-10). Relay K2 no longer excited, contact K2
opens, lamp H1 goes out. Alternator also commences
supplying voltage and K4 is no longer excited and
contact K4 changes over to (18-16). Lamp H2 goes
out, one can release start button S1 and it returns to
position 1. Exciting the safety devices occurs no
longer across line 3 but across line 2 to line 4 and this
way to line 3.
Explanation of shutdowns:
Oil pressure contact S3 opens, K3 no longer excited.
K3 changes over (13-11), engine cuts out because fuel
solenoid Y1 no longer excited and lamp H2 goes on
simultaneously.
Thermocontact S2 opens, K3 no longer excited. K3
changes over (13-11), engine cuts out because fuel
solenoid Y1 no longer excited and lamp H2 goes on
simultaneously.
Thermocontact S5 opens, K1 no longer excited.
Contact K1 changes over (4-2). K3 no longer excited.
K3 changes over (13-11), engine cuts out because fuel
solenoid Y1 no longer excited and lamp H2 and H1 go
on simultaneously. Take-over relay K2 is excited
simultaneously with H1 and contact K2 closes (8-6).
Thermocontact S5 cools off and closes, K1 excited
again and contact K1 changes over (4-1). However,
lamp H1 remains on across line 9 and contact K2 (6-
8).
A fault in the alternator part causes terminal D+ to go to 0V
and K4 to be excited. Contact K4 changes over to (18-15),
engine cuts out because fuel solenoid Y1 no longer excited
and lamp H2 goes on simultaneously.
3Operating Instructions
3.1 Parking, Towing And Lifting
Instructions
Safety Precautions
The operator is expected to apply all relevant safety
precautions, including those mentioned on the Inside of the
cover of this book.
Attention:
—Check and retighten the wheel nuts and drawbar bolts to
the specified torque. See section 7.
3.1.1Drawbar Preparations for Towing (see
Figs. 3.1A-C)
Atlas Copco XAS97 compressors may be supplied to a
customer with a folded drawbar (see Fig. 3.1A). The drawbar is
positioned in it’s upright position for shipping purposes only.
When the compressor is received by the end customer, the
drawbar will need to be put into it’s operating position. To do
this:
1) With the weight of the compressor still on the drawbar, pull
the pin on the jacking device (prop or nose wheel) and
move it into the down postion. Be sure to re-insert the pin to
keep the jack locked in place.
2) Use the jack to support the compressor in a level position
by turning the handle at the top of the jack.
3) Using the appropriate tools, remove the shipping bracket
(see Fig. 3.1A, item 1) and fold the drawbar into it’s down
position(see Fig. 3.1B).Do not discard the shipping
bracket’s hardware.
Note: take the necessary precautions as to not pinch the
wire harnessthat runs through the drawbar during the
unfolding process. Pull the excess harness out through the
front of the drawbar.
4) Reuse the shipping bracket hardware to secure the drawbar
by reinserting the bolt through both drawbar halves(item 2,
3).Secure and tighten with the locknut. Torque the nut
and bolt to 130 ft-lbs (refer to section 7.2
Compressor/Engine specifications).
5) Using a jack stand or by blocking, support the end of the
drawbar (see Fig. 3.1C). With the compressor properly
supported remove the prop or nose wheel and tighten the
pivot nut/bolt (item 4, 5). Torque the nut and bolt to 130 ft-
lbs (refer to section 7.2 Compressor/Engine specifications).
6) Re-attach the prop to the drawbar in the down position and
install keeper pin. Jack the unit up with the prop to remove
the blocking.
7) Discard any remaining hardware and the shipping bracket.
8) Retorque the all drawbar attachment bolts to their specified
value after 5-10 hours of use.
Note: the pivoting feature of the drawbar is for shipping
purposes only. The drawbar is to remain in the down
position after it’s initial setup.

1310 3011 65 15
1
Fig. 3.1ADrawbar
3
2
Fig. 3.1BDrawbar
5
4
Fig. 3.1C Drawbar
3.1.2Parking Instructions (see Fig. 3.2)
When parking a compressor, secure prop (1) or nose wheel
to support the compressor in a level position. Place the
compressor as level as possible; however, it can be
operated temporarily in an out-of-level position not
exceeding 15?. If the compressor is parked on sloping
ground, immobilize the compressor by placing wheel
chocks in front of or behind the wheels. Locate the
compressor upwind, away from contaminated wind-streams
and walls. Avoid recirculation of exhaust air from the
engine. This causes overheating and engine power decrease.
3.1.3Towing Instructions
Before towing the compressor, make sure that the towing
equipment of the vehicle matches the towing eye or ball
connector
The drawbar should be as level as possible and the compressor
and towing eye end in a level position. Secure nose prop (1) in
the highest position. Attach safety chains/cables in a criscross
manner to the tow vechical. This will help prevent the towbar
from contacting ground in event of a breakaway. Connect road
lights when applicable.
3.1.4 Lifting Instructions
When lifting the compressor, the hoist has to be placed in such
a way that the compressor, which must be placed level, will be
lifted vertically.
Preferably use the lifting bale.
?Lifting acceleration and retardation must be kept
within safe limits (max. 2xg).
Helicopter lifting is not allowed.
3.2 Before Starting
?If the compressor is to be connected to a common
compressed air system, fit an appropriate check
valve between compressor outlet and air system.
Observe the right mounting position/direction!
1. Before initial start-up, prepare battery for operation if not
already done. See section 4.7.
2. With the compressor standing level, check the level of the
engine oil. Add oil, if necessary, to the upper mark on
dipstick. Consult the Engine Operation Manual for the type
and viscosity grade of the engine oil.
3. Check the level of the compressor oil. The pointer of oil
level gauge (OLG-Fig. 2.3) should register in the green
range. Add oil if necessary. See section 4.3 for the oil to
be used.
?Before removing oil filler plug (FP-Fig. 2.3), ensure
that the pressure is released by opening an air outlet
valve.
4. Check that the fuel tank contains sufficient fuel. Top up, if
necessary. Consult the Engine Operation Manual for the
type of fuel.
5. Drain any water and sediment from the fuel filter until clean
fuel flows from the drain cock.
6. Press vacuator valve (VV-Fig. 2.3) of the air filter to
remove dust.
7. Check the air filter service indicator (VI-Fig. 2.3). If the red
part shows completely, service or replace the filter element.
Reset the indicator.
8. Open an air outlet valve (AV-fig. 2.2) to allow air flow to the
atmosphere.
9. Check coolant level in overflow bottle. Top off coolant if
necessary. Consult engine’s operation manual for
water/coolant specifications.

16 1310 3011 65
3.3 Starting/Stopping (See Fig. 3.3)
Before starting, first operate the circuit breaker button (Fl)
located on the back of the control panel cover.
To start, the start button is turned clockwise to position 1,
lamp H2 (general alarm) will go on and the preahest relay
K5 will be energized. The glow plug (HTR)will be activated.
The button should be held in this position for 10 to 15
seconds to allow for proper pre-heating of the cylinders.
When the button is turned further to position 3, the starter
motor will set the engine in motion. Lamp H2 will go out as
soon as the engine has been started. The start button
automatically springs back to position 1. Lamp H1 only
produces a signal when the compressor outlet temperature
is too high. Correct operation of the lamp itself can be
checked by operating the lamp test button S4 located on
the control panel. When the start button is in position 1 and
the engine is not running, the lamp test can be used. Lamp
H1 will go on and will automatically go out when the unit is
started. Shutting-down is simply done by turning the start
button counter clockwise to position 0 (with valves closed).
F1 Fuse reset (Circuit breaker) located
inside the unit on the control panel’s
cover
H1 Temperature alarm (red)
H2 General alarm (red)
LV Loading valve (optional)
PG Working pressure gauge
P1 Hour meter
P2 Fuel gauge
S1 Contact switch(engine ignition)
S4 Preheat button
P1
running hours
PG H1,H2 S1 S4
P2
LV
Fig. 3.3 Control panel
The control panel in addition indicates receiver pressure
(PG) and accumulated operating hours (P1).
Fault situations and protective devices:
—The starter motor is protected against prolonged
starting or against attempts to start when the unit is already
running.
—A fault which occurs with the engine, either:
engine oil pressure (too low), compressor oil temperature
(too high), engine coolant (too high) or alternator voltage
(too low) will always and immediately cause the engine to
cut out and the control lamp H2 will go on. By doing some
simple checks, it can be determined what it was that
caused the engine to fail: low oil level, clogged-up cooler, slack
alternator belt tension or broken belt.
—When the outlet temperature of the element becomes
too high, a thermocontact will also switch off the unit
immediately. Both control lamp H1 and H2 will go on. Both
control lamps will remain on until the unit has been restarted
(start button to position 3) or the contact is turned off (start
button to position 0): also when, due to cooling off, the
thermocontact has closed again (= memory function).
3.4 During Operation
?The doors must be closed during operation and
may be opened for short periods only.
4Maintenance
4.1 Use of Service Paks
Service Paks include all genuine parts needed for normal
maintenance of both compressor and engine. Service Paks
minimize downtime and keep your maintenance budget low.
You may order Service Paks from your local Atlas Copco dealer.
4.2 Preventive Maintenance Schedule For
The Compressor
The schedule contains a summary of the maintenance
instructions.
Read the respective section before taking maintenance
measures.
When servicing, replace all disengaged packings, e.g. gaskets,
0-rings, washers.
For engine maintenance refer to Engine Operation Manual.
The maintenance schedule has to be seen as a guideline for
units operating in a duty environment typical to compressor
applications. Maintenance schedule can be adapted depending
on application environment and quality of maintenance

1310 3011 65 17
.
MAINTENANCE SCHEDULE Daily Initially
Around
50 hours
Normal
Or every
250 hours
Bi-Yearly
Or every
500 hours
Yearly
Or every
1000 hours
Note
Engine oil level Check
Compressor oil level Check
Air filter dust valve Empty
Fuel filter water drain Drain
Air intake vacuum indicator Check
Electrolyte level and terminals of battery Check Check Check Check
Tire pressure Check Check Check Check
Leaks in air-, oil-or fuel system Check Check Check Check
Oil cooler package Clean Clean Clean
Engine minimum and maximum speeds Check Check Check Check
Torque of wheel nuts Check Check Check Check
Brake system (if installed) Check/
Adjust Check/ Adjust Check/ Adjust Check/ Adjust
Safety valve Test
Door Hinges Grease Grease Grease
Towing eye shaft or ball coupling and its shaft Grease Grease Grease
Shut-down switches Check
Pressure drop over separator element (2) Measure Measure Replace
Fan v-belt (3)Adjust Adjust Adjust Adjust
Fuel tank Clean Clean Clean
Compressor oil Change
Compressor oil filter Replace Replace
Air filter element (1) Replace
Engine oil (3) Change Change Change Change
Engine oil filter (3) Replace Replace Replace Replace
Fuel filter (Primary and Final) (3) Replace Replace Replace
Engine intake and exhaust valves (3) Adjust Adjust
Inspection by Atlas Copco Service technician ?
(1) More frequently when operating in a dusty environment.
(2) Replace the element when the pressure drop exceeds 11.5 psi.
(3) Refer to the John Deere instruction manual.
?Keep the bolts of the housing, the lifting eye, the towbar and the axle securely tightened. Refer to
Compressor/Engine Specifications (section 7.2) for the torque values.
4.3 Lubrication oils
It is strongly recommended to use Atlas Copco branded
lubrication oils for compressor.
Compressor oil PAROIL:
5 gallon pail: order number 1310 0334 30
Skid (24) 5 gallon pails: order number 1310 0334 32
Skid (4) 55 gallon drums: order number 1310 0334 33
?If you want to use another brand of oil, consult
Atlas Copco for more information concerning
the recommended oil and service intervals.
4.4 Oil Level Check
?Never mix oils of different brands or types
4.4.1 Check Engine Oil Level
Consult also the Engine Operation Manual for the oil
specifications, viscosity recommendations and oil change
intervals.
See schedule.
Check engine oil level according to the instructions in the
Engine Operation Manual and top up with oil if necessary.
4.4.2 Check Compressor Oil Level
With the unit standing level, engine stopped, check the level of
the compressor oil. The pointer of the oil level gauge (OLG)
must register in the upper extremity of the green range. Add oil
via the oil fill plug (FP) if necessary.
?Before removing oil filler plug, ensure that the
pressure is released by opening an air outlet valve.

18 1310 3011 65
4.5 Oil And Oil Filter Change (see Fig.
4.5)
AR/OS
OFc
FP
OLG
AV
Fig. 4.5 Oil filters
4.5.1 Engine Oil And Oil Filter Change
Consult also the Engine Operators Manual for oil and oil
filter
(1) change intervals.
(2) oil types.
4.5.2 Compressor Oil And Oil Filter
Change
The quality and the temperature of the oil determine the oil
change interval.
The prescribed interval (See section 4.2) is based on an oil
temperature of up to 100ºC (212ºF) and normal operating
conditions.
When operating in high ambient temperatures, in very
dusty or high humidity conditions, it is recommended to
change the oil more frequently.
?In this case, contact Atlas Copco.
1 Run the compressor until warm. Close the outlet
valve(s) and stop the compressor. Wait until the
pressure is released through the automatic blow-down
valve. Unscrew the oil filler plug (FP) one turn. This
uncovers a vent hole, which permits any pressure in
the system to escape.
2 Drain the oil by removing all drain plugs. Drain plugs
are located at the oil tank, discharge manifold, and oil
injection manifold. Catch the oil in a drain pan. Screw
out the filler plug to speed up draining. Tighten the
plugs after draining.
3 Remove the oil filter (OFc), e.g. by means of a special
tool. Catch the oil in a drain pan.
4 Clean the filter seat on the manifold, taking care that
no dirt drops into the system. Oil the gasket of the
new filter element. Screw it into place until the gasket
contacts its seat, then tighten one half turn only.
5 Fill the air receiver until the pointer of the oil level gauge
(OLG) registers in the upper extremity of the green range.
Take care that no dirt drops into the system. Reinstall and
tighten the filler plug.
6 Run the unit at no load for a few minutes to circulate the oil
and to evacuate the air trapped in the oil system.
7 Stop the compressor. Let the oil settle for a few minutes.
Check that the pressure is released by opening an air outlet
valve (AV). Screw out filler plug (FP) and add oil until the
pointer of the oil level gauge (OLG) again registers in the
upper extremity of the green range. Reinstall and tighten
the filler plug.
?Never add more oil. Overfilling results in oil
consumption.
4.6 Cleaning Coolers
Keep the coolers clean to maintain the cooling efficiency.
?Remove any dirt from the coolers with a fiber brush.
Never use a wire brush or metal objects.
When cleaning by air jet, blow air through the cooler in reverse
direction of normal flow.
If the dirt is oily, wash the coolers with degreaser or a cleansing
agent.
?Protect the electrical and controlling equipment, air
filters etc. against penetration of moisture.
A spray gun should preferably be used to apply the solvent to
the fins. Rinse the blocks by means of a water jet max. 100 psi
at 2 inch distance after a soaking-in period. Steam cleaning
may also be applied.
?To avoid damaging the coolers, angle between
waterjet and coolers should be approx. 90º.
?Never leave spilled liquids such as fuel, oil, water and
cleansing agents in or around the compressor.
4.7 Battery Care
?Before handling batteries, read the relevant safety
precautions and act accordingly.
An ASB (Service Bulletin) dealing elaborately with batteries and
due care is available on request.
If the battery is still dry, it must be activated as described in
point 4.7.1.
The battery must be in operation within 2 months from being
activated; if not, it needs to be recharged first.
4.7.1 Electrolyte
?Read the safety instructions carefully
Electrolyte in batteries is a sulphuric acid solution in distilled
water.

1310 3011 65 19
The solution must be made up before being introduced into
the battery.
4.7.2 Recharging A Battery
Before and after charging a battery, always check the
electrolyte level in each cell; if required, top up with distilled
water only. When charging batteries, each cell must be
open, i.e. plugs and/or cover removed.
?Use a commercial automatic battery charger
according to manufacturers instructions.
Apply with preference the slow charging method and adjust
the charge current according to the following rule of thumb:
battery capacity in Ah (amp hours) divided by 20 gives safe
charging current in Amps.
4.7.3 Battery Maintenance
Keep the battery clean and dry
-Keep the electrolyte level at 10 to 15 mm above the
plates or at the indicated level; top up with distilled water
only.
-Keep the terminals and clamps tight, clean, and
lightly covered petroleum jelly.
4.8 Storage
Run the compressor regularly, e.g. twice a week, until
warm.
Load and unload the compressor a few times to operate
the unloading and regulating components. Close the air
outlet valves after stopping.
?If the compressor is going to be stored without
running from time to time, protective measures
must be taken as described In a separate Service
Bulletin (ASB), which may be obtained on
request. Consult Atlas Copco.
4.9 Service Kits
A service kit is a collection of parts to fit a specific repair or
rebuilding task.
It guarantees that all necessary parts are replaced at the same
time which improves the uptime of the unit.
To purchase service paks contact your local Atlas Copco
representative.
250/750 hr. Pak: order number 1310300374
500 hr. Pak: order number 1310300375
1000 hr. Pak: order number 1310300373

20 1310 3011 65
5Adjustments and Servicing Procedures
5.1 Adjustment of the Continuous Regulating System (See Fig. 5.1)
Fig. 5.1 Compressor Regulating System
The working pressure is determined by the tension of the
spring in the regulating valve. This tension can be
increased to raise the pressure and decreased to lower it
by turning the adjusting wheel clockwise and counter-
clockwise respectively.
To adjust the normal working pressure, proceed as follows:
1. Start and warm up the engine (see section 3.3).
2. With the outlet valves (AV) closed, loosen the
regulating valve’s locknut and adjust the regulating
valve (RV) until your reach the desired pressure of 123
psig/8.5 bar(e).
3. Check the minimum speed of the engine (see section
7.2). Adjust minimum speed stop screw if necessary.
4. Open an outlet valve just enough to let the engine run at
maximum speed. The working pressure must be 102 psig/
7 bar(e).
Adjust if necessary with regulating valve (RV).
5. Check the engine maximum speed (see section 7.2).
Adjust the maximum speed by means of adjusting eccentric
nut on top of speed regulator (SR).
6. Close the outlet valves, check that the pressure is between
120-126 psig/ 8.3-8.7 bar(e).
Lock the regulating valve by fixing the locknut.