XA(T,V)S 650-750-850 JD7 Compressors

Scott Ellinger

Committed to
sustainable productivity
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 Systems Overview XAS 750 JD

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Product Designation Oil Injected Compressors
Engine supplier
Working principle C : Caterpillar
Product range A : Single stage D : Deutz
X : Oil injected compressor Silencing J : John Deere Prime mover
portable R : Two stage : Un-silenced Y : Yanmar D : diesel engine
compressor compressor S : Silenced K : Kubota E : electric motor

X A T S 750 J D
Working pressure Capacity (FAD)
Liter/sec
: std pressure 102psi CFM (US-version)
M: 125psi
T : 150psi
H: 175psi
V: 200psi
Compressor systems

 Four major components :

– Air system
– Oil system
– Control system
– Electrical system
Air system
Air filter

 Filtration of the inlet air in 3 stages :

– centrifugal dust separation
– paper filter element
– safety cartridge
 Vacuum indicator gives an indication when the pressure drop over
the filter element is too high  filter element needs to be replaced
Air filter

Air inlet Centrifugal separation

Vacuum indicator Filter element

Dust

to compressor element
 REGULATING SYSTEM REG VALVE
Adjusting receiver pressure
by changing spring tension
Spring loaded
Regulating pressure:
• to speed regulator
• to unloading valve
Receiver pressure
• to pressure gauge and loading valve
Regulating Valve Service Kit – 2911 0111 00
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In order to regulate the pressure inside the reciever
tank of our compressor, the air intake and the
engine speed have to be controlled. This is done
pneumatically. For that reason, we need regulating
pressure. The regulating valve reduces the pressure
inside the tank, thus providing the regulating
pressure. This regulating pressure is then supplied
to the unloader valve and the speed regulator or
RPS.
The air receiver pressure can be set to another value
by adjusting the spring tension of the regulating valve.
This is done by turning the handle on top the valve.
Increasing the spring tension, by turning in, will
increase the regulating pressure and consequently the
pressure inside the vessel. Turning out will decrease
the pressure.
Unloading valve

 Opens and closes the air inlet to the compressor element.

– Open position at load condition
=> Air consumption
– Closed position at no load condition
=> No air consumption.
 Control of the valve by regulating pressure.
 Unloading Valve or Air System Inlet Valve

Control Air closes the inlet

Opens by compressor element

inlet vacuum

Assembly includes blow down

valve

Unloading valve service kit – 2911 0110 00

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No-Load Condition Load Condition

Unloading valve Regulating valve Unloading valve Regulating valve

Min Press valve Load solenoid Min Press valve Load solenoid
Unload Condition Blow- Down Condition

Unloading valve Regulating valve Unloading valve Regulating valve

Min Press valve Load solenoid Min Press valve Load solenoid
AIR SYSTEM MIN PRESS VALVE

Maintains a minimum pressure

of 58 PSI for oil flow

Also contains the final check

valve

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Oil System
Oil System

 Air receiver
 Oil cooler
 Oil filter/TBV
 Compressor
element
 Oil separator
 Scavenge line
Oil injected screw compressors
Compressor element

Lubrication to the bearings

Air inlet

Oil Air/Oil

Oil
Oil injected screw compressors

 Oil is used for :

– Cooling : compression heat is absorbed by
the oil
– Lubrication of rotors, bearings, gears
– Sealing between rotors and rotor and
housing
– Corrosion protection of the internal metal
parts
Oil injected screw compressors

Oil is injected in the bottom of the rotor housing,

on the bearings and gears
Compression Suction
Compression principle

Delivery Compression start

Oil separator
Scavenge line
Oil Separator filter element should be replaced Separator element
Every 1,000 hours or yearly.

Centrifugal separation

Air/Oil
Oil
Scavenging Line

Evacuates separated oil from separator element

Flows by pressure difference between air
receiver and compressor element
Restrictor to minimize air loss back to the
compressor element

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Oil Separator

 Classic Reasons For Oil Carryover

– Over filled receiver
– Plugged scavenge line
– Wrong type of oil (no anti foam agent)
– Shut down with air outlet valves open
– Scavenge tube installed improperly

Separator Element Service Kit – 2911 0112 00

Oil Filters
 Remove contamination

Size 1.5
–2 filters in parallel
–Bypass opens at 36psi

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Thermostatic Valve

Start of opening Completely open Part number Used in

104 °F 140 °F 1619 7560 00 Size 1,5
140 °F 167 °F 1202 5869 02
149 °F 176 °F 1202 5869 03
158 °F 185 °F 1202 5869 01 Size 2, except XRVS
167 °F 194 °F 1202 5869 04
176°F 203 °F 1615 9720 00 XRVS

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 Thermostatic Valve

Position of valve
! & spring = critical !
 When valve is fitted
improperly, oil will be
continuously cooled, creating
a lot of condensate

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Oil Stop Valve
Oil & air mixture

To compressor
element
Spring loaded valve Oil from filters

Prevents elements from

flooding with oil after shut
down
Closed by spring force
and oil pressure
Opens by discharge air
from element
Drain : lowest point of
element

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 Control System

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Control Panel
 XC2002 Status

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 XC2002 Menus

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 Basic Operations

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 Shutdown

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 XC2002 Service Timer Reset

 Scroll through the controller menu to “Parameters” (on some units

“Parameters” may be a submenu under “Extra Views”)
 Press Enter to select Parameters
 Scroll to ST1 Reset or ST2 Reset as needed (ST1 = 500 hours, ST2
= 1000 hours)
 Press Enter to select to reset the appropriate timer
 Center option will highlight; scroll to highlight “Yes” and press Enter
 Change Password to 2003 and press Enter
 Service timer is reset

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 XC2002 Alarms

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 XC2002 Alarms
If an Alarm occurs, a pop-up window will display for as long as the
alarm is active, in any view. The flashing red Alarm LED will light up.
The Alarm icon(s) will be shown with an acknowledgement check box.
Push the Enter button to acknowledge the alarm. An acknowledged
Alarm will mark the check box and light the red Alarm LED.
An Alarm should always be acknowledged before solving the cause of
the Alarm.
The Alarm display can be left by pushing the Back button.
If more than one Alarm occurs, the Up and Down arrows may be used
to scroll through the list. Newest Alarms will be at the bottom of the list.
If a Shutdown occurs, the Shutdown Display will be shown.

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 XC2002 Event Log
XC2002 keeps an event log of the last 15 events.
 Shutdowns
 Warnings
 Service timer resets
 Unit type changes

Running hours at time of event logged

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 Engine Faults

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 Compressor Faults

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 Electrical System

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 Wiring Diagram (1)

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 Wiring Diagram (2)

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 Maintenance

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Maintenance – XAS 750 JD IT4

Daily:
 Check engine oil level
 Check compressor oil level
 Check coolant level
 Drain water from fuel filter
 Empty air filter vaccuator valve
 Check tire pressure
 Maintenance – XAS 750 JD IT4

Initial Service at 50 Hours

 Check electrolyte level and terminals of battery
 Check for leaks in Air, Oil, and Fuel systems
 Check wheel nut torque
 Check and adjust brakes
 Check and adjust fan belts
 Replace compressor oil filters (spin-on)

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 Maintenance – XAS 750 JD IT4
500 Hour service pack part number 1310 0723 29 (typical 6 months)
 Perform 50 hour service tasks
 Clean oil cooler, radiator, intercooler
 Grease door hinges
 Grease towing eye shaft or ball coupling and shaft
 Analyze coolant
 Replace engine oil and filter
 Replace fuel primary filter and prefilter

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 Maintenance – XAS 750 JD IT4
1000 Hour service pack part number 1310 0723 30 (typical 12 months)
 Perform 500 hour service tasks
 Test safety valve and shut down switches
 Check rubber flexibles
 Replace air filters and separator element
 Replace compressor oil and filter
 Replace bleed off valve unloader
 Clean oil stop valve and fuel tank
 Replace filter element from regulating valve
 Clean flow restrictor in oil scavenge line
 Inspection by Atlas Copco service technician
Check/adjust engine valves every 2000 hours or per John Deere
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 IT4 EXHAUST
AFTERTREATMENT

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Tier 4: Terms and Key Words
Regeneration: The process of eliminating built up soot from the
exhaust system
Two types of Regeneration
 Active Regeneration:
– Using a hydrocarbon (fuel) to elevate exhaust gas temperatures above
1100 F (600 C) in order to remove built up soot from the exhaust filter

 Passive (Natural) Regeneration:

– Using temperature alone to burn soot by elevated exhaust temperature
 Can be controlled by temperature management of the exhaust stream
– Can be achieved by maintaining exhaust gas temperature
– Can also be achieved by control valves including VGT that effect exhaust backpressure
Tier 4: Terms and Key Words
 Soot
– Incomplete combustion of hydro carbons in the exhaust stream
– Can be purged from the DPF by re-generation

 Ash
– Incomplete combustion of some hydrocarbon by-products
– CANNOT be purged from the DPF by re-generation
– EPA Mandated that DPF must withstand 4500 hrs before ash cleaning is needed

 HPCR
– High Pressure Common Rail fuel system
– System pressures up to 30,000 psi
– Allows multiple injection events to take place reducing emissions

 VGT
– Variable Geometry Turbocharger
– Inlet guide vanes can adjust to provide exact boost pressure to work in conjunction
with the EGR
Tier 4: Terms and Key Words
 NOx
– Nitrogen Oxides
– Highly reactive gasses that form from emissions

 EGR
– Exhaust Gas Recirculation
– Recycles a portion of exhaust gas back to the engine

 ULSD
– Ultra low sulfur fuel (less than 15 ppm)
– Must be used on all IT4 machines
– Normal diesel fuel will kill an EGR and DOC within a few tanks

 Low ash Engine oil

– Must be used on all IT4 machines to reduce the formation of ash accumulating in
the DPF

 CANbus – Method of communication between controllers or networks. All Atlas Copco

controllers use SAE J1939 CANbus communication
Tier 4: DOC and DPF

Diesel Particulate
Filter (DPF)

Diesel Oxidation
Catalyst (DOC)

CEM- Cleaning Emission Module

Tier 4: Diesel Oxidation Catalyst (DOC)

 Open cell substrate flow though device

 Reduces HC and CO significantly
 Reduces Pm 10 to 30%
 Converts NO to NO2 for passive regeneration of the DPF
 Oxidizes HC (diesel fuel) as part of active regeneration strategy
 No servicing required
 Requires use of low sulfur diesel or ULSD
 Typically element is =100% of engine displacement in size
Tier 4: Diesel Particulate Filter (DPF)

 Wall flow, high filtration efficiency

(95%+)
 Traps ash, soot and any particles
 Needs periodic regeneration / cleaning
 Periodic ash cleaning required
 No muffler required in the vast majority
of applications
 XC2002 DPF Status Indicators

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Xc2002 – DPF Information

Manual Regeneration
• Parameter
• DPF – Diesel Particulate filter – can
change from AUTO to ON or turn OFF
completely (not recommended!)
• STATION REGEN. – Stationary (manual)
Regeneratoin – OFF or ON
• Both need to be set to “ON” for manual
regeneration
• Both are password protected
• Unit will not regenerate until soot level is
~70%
Procedure: Stationary/Forced DPF Regeneration
 Atlas Copco recommends that the DPF configuration be
left in the AUTO mode at all times however in the event
that a stationary or forced regeneration in desired the
following process should be followed..
 Unit WILL NOT regenerate until soot level is above 72%
– Go to the "STATION REGEN" screen. For normal 1
operation this should be in OFF mode.
 Press the enter button (1), a password window will 2
appear. Enter 1968 and press the enter button.
 Use the up or down (2) arrow to change the
selection to ON and press the enter button.
– Go to the "DPF" screen. For normal operation this
should be in the AUTO mode.
 Press the enter button (1)
 Use the up or down (2) arrow to change the
selection to ON and press the enter button.

 This will set the unit up for regeneration, after a few

moments the regeneration icon should appear confirming
the unit is regenerating.
– The stationary/forced regeneration can take in excess
of 3 hours to complete.
Procedure: Stationary/Forced DPF Regeneration
 Upon completion of the stationary/forced regeneration it is highly recommended to reset the
unit to automatically regenerate to prevent engine derate & shutdown due to high soot load.
– Go to the "STATION REGEN" screen. (For normal operation this should be in OFF mode).
 Press the enter button, a password window will appear. Enter 1968 and press the enter
button.
 Use the up or down arrow to change the selection to OFF and press the enter button.
– Go to the "DPF" screen. For normal operation this should be in the AUTO mode.
 Press the enter button,
 Use the up or down arrow to change the selection to AUTO and press the enter button.

 The unit is now ready for normal operation.

 Contact Numbers
•Main Number Atlas Copco Technical Support
1-800-732-6762 Option 3

•Clayton Jones - Hurricane Boosters/Compressors - Supervisor

1-216-643-6802 direct & 1-317-681-4602 mobile

•Andrew Stevenson – Compressors: Low Pressure

1-720-479-2486 direct & 1-404-751-6717 mobile

•Will Hudson – Generators/Compressors

1-800-732-6762 Ext. 12920 & 1-832-454-8123 mobile

•Andrew Calendar – Compressors: High Pressure

1-720-479-2487 direct & 1-404-242-6203 mobile

•Jon Monaco - Hydraulic Att./Handheld Tools

1-800-732-6762 Ext. 12929 & 1-216-816-5008 mobile

•Brandon Dyer – Compressors: Low Pressure/Hydraulic Att.

1-216-643-6807 direct & 1-216-219-2290 mobile

•Scott Ellinger – Compressors

1-720-479-2476 direct & 1-720-375-1795 mobile

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 Committed to
sustainable productivity.