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