Instruction Manual

for Portable Compressors

XRV 1000 SD5

 Instruction Manual
for Portable Compressors

XRV 1000 SD5

Instruction manual .................................................................................. 5

Printed Matter N°
2950 5330 01
ATLAS COPCO - PORTABLE AIR DIVISION
03/2009 www.atlascopco.com
XRV 1000 SD5

Warranty and Liability Limitation

Use only authorized parts.
Any damage or malfunction caused by the use of unauthorized parts is not covered by Warranty
or Product Liability.
The manufacturer does not accept any liability for any damage arising for modifications, addi-
tions or conversions made without the manufacturer's approval in writing.

Copyright 2009, Atlas Copco Airpower n.v., Antwerp, Belgium.

Any unauthorized use or copying of the contents or any part thereof is prohibited.
This applies in particular to trademarks, model denominations, part numbers and drawings.

4 2950 5330 01
 Instruction Manual

Congratulations on the purchase of your AC compressor. It is a

solid, safe and reliable machine, built according to the latest
technology. Follow the instructions in this booklet and we
guarantee you years of troublefree operation. Please read the
following instructions carefully before starting to use your
machine.
Always keep the manual available near the machine. In all
correspondence always mention the compressor type and serial
number, shown on the data plate.
The company reserves the right to make changes without prior
notice.

Contents

1 Safety precautions for portable 4 Maintenance.............................................................18

compressors ...............................................................6 4.1. General ................................................................18
1.1. Introduction...........................................................6 4.2. Daily operation....................................................18
1.2. General safety precautions ..................................6 4.3. Maintenance after first 100 hours of
1.3. Safety during transport and installation.............7 operation .............................................................18
1.4. Safety during use and operation.........................7 4.4. Maintenance after 1000 hours of
1.5. Safety during maintenance and repair ...............8 operation .............................................................18
1.6. Tool applications safety .......................................9 4.5. Servicing compressor elements ........................18
1.7. Battery safety precautions ...................................9 4.6. Replacement of parts and adjustment
procedure ............................................................18
2 Description ...............................................................10
2.1. Introduction.........................................................10
5 Problem solving .....................................................21
2.2. Description of components................................10
6 Technical specifications ....................................23
2.3. Compressor unit - Operating description..........10
6.1. Compressor lubrication......................................23
2.4. Compressor lubrication and cooling
6.2. Specifications of the engine/alternator/unit .....23
system .................................................................10
2.5. Discharge system - Operating
description...........................................................11
2.6. Air intake system - Operating
description...........................................................13
2.7. Instrument panel assembly - Operating
description...........................................................13
2.8. Electric and safety system .................................13

3 Operation ...................................................................15
3.1. General ................................................................15
3.2. Initial start up procedure....................................17
3.3. Procedure for subsequent start ups..................17
3.4. Stopping procedure............................................17

2950 5330 01 5
XRV 1000 SD5

1 Safety precautions for portable compressors

To be read attentively and acted accordingly before towing, lifting, operating, performing maintenance or repairing the compressor.

1.1 Introduction The manufacturer does not accept any liability for any damage arising from the
use of non-original parts and for modifications, additions or conversions made
The policy of Atlas Copco is to provide the users of their equipment with safe, without the manufacturer’s approval in writing.
reliable and efficient products. Factors taken into account are among others:
If any statement in this manual does not comply with local legislation, the
- the intended and predictable future use of the products, and the stricter of the two shall be applied.
environments in which they are expected to operate,
Statements in these safety precautions should not be interpreted as suggestions,
- applicable rules, codes and regulations, recommendations or inducements that it should be used in violation of any
- the expected useful product life, assuming proper service and applicable laws or regulations.
maintenance,
- providing the manual with up-to-date information.
Before handling any product, take time to read the relevant instruction manual.
1.2 General safety precautions
Besides giving detailed operating instructions, it also gives specific 1 The owner is responsible for maintaining the unit in a safe operating
information about safety, preventive maintenance, etc. condition. Unit parts and accessories must be replaced if missing or
Keep the manual always at the unit location, easily accessible to the operating unsuitable for safe operation.
personnel. 2 The supervisor, or the responsible person, shall at all times make sure that
See also the safety precautions of the engine and possible other equipment, all instructions regarding machinery and equipment operation and
which are separately sent along or are mentioned on the equipment or parts of maintenance are strictly followed and that the machines with all
the unit. accessories and safety devices, as well as the consuming devices, are in
good repair, free of abnormal wear or abuse, and are not tampered with.
These safety precautions are general and some statements will therefore not
always apply to a particular unit. 3 Whenever there is an indication or any suspicion that an internal part of a
machine is overheated, the machine shall be stopped but no inspection
Only people that have the right skills should be allowed to operate, adjust, covers shall be opened before sufficient cooling time has elapsed; this to
perform maintenance or repair on Atlas Copco equipment. It is the avoid the risk of spontaneous ignition of oil vapour when air is admitted.
responsibility of management to appoint operators with the appropriate
training and skill for each category of job. 4 Normal ratings (pressures, temperatures, speeds, etc.) shall be durably
marked.
Skill level 1: Operator
5 Operate the unit only for the intended purpose and within its rated limits
An operator is trained in all aspects of operating the unit with the push-buttons, (pressure, temperature, speeds, etc.).
and is trained to know the safety aspects.
6 The machinery and equipment shall be kept clean, i.e. as free as possible
Skill level 2: Mechanical technician from oil, dust or other deposits.
A mechanical technician is trained to operate the unit the same as the operator. 7 To prevent an increase in working temperature, inspect and clean heat
In addition, the mechanical technician is also trained to perform maintenance transfer surfaces (cooler fins, intercoolers, coolant jackets, etc.) regularly.
and repair, as described in the instruction manual, and is allowed to change See “General”.
settings of the control and safety system. A mechanical technician does not
8 All regulating and safety devices shall be maintained with due care to
work on live electrical components. ensure that they function properly. They may not be put out of action.
Skill level 3: Electrical technician
9 Care shall be taken to avoid damage to safety valves and other pressure-
An electrical technician is trained and has the same qualifications as both the relief devices, especially to avoid plugging by paint, oil coke or dirt
operator and the mechanical technician. In addition, the electrical technician accumulation, which could interfere with the functioning of the device.
may carry out electrical repairs within the various enclosures of the unit. This 10 Pressure and temperature gauges shall be checked regularly with regard to
includes work on live electrical components. their accuracy. They shall be replaced whenever outside acceptable
Skill level 4: Specialist from the manufacturer tolerances.
This is a skilled specialist sent by the manufacturer or its agent to perform 11 Safety devices shall be tested as described in the maintenance schedule of
complex repairs or modifications to the equipment. the instruction manual to determine that they are in good operating
condition.
In general it is recommended that not more than two people operate the unit,
more operators could lead to unsafe operating conditions. Take necessary steps 12 Mind the markings and information labels on the unit.
to keep unauthorized persons away from the unit and eliminate all possible 13 In the event the safety labels are damaged or destroyed, they must be
sources of danger at the unit. replaced to ensure operator safety.
When handling, operating, overhauling and/or performing maintenance or 14 Keep the work area neat. Lack of order will increase the risk of accidents.
repair on Atlas Copco equipment, the mechanics are expected to use safe 15 When working on the unit, wear safety clothing. Depending on the kind of
engineering practices and to observe all relevant local safety requirements and activities these are: safety glasses, ear protection, safety helmet (including
ordinances. The following list is a reminder of special safety directives and visor), safety gloves, protective clothing, safety shoes. Do not wear the
precautions mainly applicable to Atlas Copco equipment. hair long and loose (protect long hair with a hairnet), or wear loose
These safety precautions apply to machinery processing or consuming air. clothing or jewellery.
Processing of any other gas requires additional safety precautions typical to the 16 Take precautions against fire. Handle fuel, oil and anti-freeze with care
application and are not included herein. because they are inflammable substances. Do not smoke or approach with
Neglecting the safety precautions may endanger people as well as environment naked flame when handling such substances. Keep a fire-extinguisher in
and machinery: the vicinity.
- endanger people due to electrical, mechanical or chemical influences,
- endanger the environment due to leakage of oil, solvents or other
substances,
- endanger the machinery due to function failures.
All responsibility for any damage or injury resulting from neglecting these
precautions or by non-observance of ordinary caution and due care required in
handling, operating, maintenance or repair, also if not expressly mentioned in
this instruction manual, is disclaimed by Atlas Copco.

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 Instruction Manual

1.3 Safety during transport and 1.4 Safety during use and operation
installation 1 When the unit has to operate in a fire-hazardous environment, each engine
exhaust has to be provided with a spark arrestor to trap incendiary sparks.
To lift a unit, all loose or pivoting parts, e.g. doors and towbar, shall first be
securely fastened. 2 The exhaust contains carbon monoxide which is a lethal gas. When the
unit is used in a confined space, conduct the engine exhaust to the outside
Do not attach cables, chains or ropes directly to the lifting eye; apply a crane atmosphere by a pipe of sufficient diameter; do this in such a way that no
hook or lifting shackle meeting local safety regulations. Never allow sharp extra back pressure is created for the engine. If necessary, install an
bends in lifting cables, chains or ropes. extractor. Observe any existing local regulations. Make sure that the unit
Helicopter lifting is not allowed. has sufficient air intake for operation. If necessary, install extra air intake
It is strictly forbidden to dwell or stay in the risk zone under a lifted load. ducts.
Never lift the unit over people or residential areas. Lifting acceleration and 3 When operating in a dust-laden atmosphere, place the unit so that dust is
retardation shall be kept within safe limits. not carried towards it by the wind. Operation in clean surroundings
1 Before towing the unit: considerably extends the intervals for cleaning the air intake filters and the
- ascertain that the pressure vessel(s) is (are) depressurized, cores of the coolers.
- check the towbar, the brake system and the towing eye. Also check the 4 Close the compressor air outlet valve before connecting or disconnecting a
coupling of the towing vehicle, hose. Ascertain that a hose is fully depressurized before disconnecting it.
- check the towing and brake capability of the towing vehicle, Before blowing compressed air through a hose or air line, ensure that the
- check that the towbar, jockey wheel or stand leg is safely locked in the open end is held securely, so that it cannot whip and cause injury.
raised position, 5 The air line end connected to the outlet valve must be safeguarded with a
- ascertain that the towing eye can swivel freely on the hook, safety cable, attached next to the valve.
- check that the wheels are secure and that the tyres are in good condition
and inflated correctly, 6 No external force may be exerted on the air outlet valves, e.g. by pulling
- connect the signalisation cable, check all lights and connect the on hoses or by installing auxiliary equipment directly to a valve, e.g. a
pneumatic brake couplers, water separator, a lubricator, etc. Do not step on the air outlet valves.
- attach the safety break-away cable or safety chain to the towing vehicle, 7 Never move a unit when external lines or hoses are connected to the outlet
- remove wheel chocks, if applied, and disengage the parking brake. valves, to avoid damage to valves, manifold and hoses.
2 To tow a unit use a towing vehicle of ample capacity. Refer to the 8 Do not use compressed air from any type of compressor, without taking
documentation of the towing vehicle. extra measures, for breathing purposes as this may result in injury or
3 If the unit is to be backed up by the towing vehicle, disengage the overrun death. For breathing air quality, the compressed air must be adequately
brake mechanism (if it is not an automatic mechanism). purified according to local legislation and standards. Breathing air must
always be supplied at stable, suitable pressure.
4 Never exceed the maximum towing speed of the unit (mind the local
regulations). 9 Distribution pipework and air hoses must be of correct diameter and
suitable for the working pressure. Never use frayed, damaged or
5 Place the unit on level ground and apply the parking brake before deteriorated hoses. Replace hoses and flexibles before the lifetime expires.
disconnecting the unit from the towing vehicle. Unclip the safety break- Use only the correct type and size of hose end fittings and connections.
away cable or safety chain. If the unit has no parking brake or jockey
wheel, immobilize the unit by placing chocks in front of and/or behind the 10 If the compressor is to be used for sand-blasting or will be connected to a
wheels. When the towbar can be positioned vertically, the locking device common compressed-air system, fit an appropriate non-return valve
must be applied and kept in good order. (check valve) between compressor outlet and the connected sand-blasting
or compressed-air system. Observe the right mounting position/direction.
6 To lift heavy parts, a hoist of ample capacity, tested and approved
according to local safety regulations, shall be used. 11 Before removing the oil filler plug, ensure that the pressure is released by
opening an air outlet valve.
7 Lifting hooks, eyes, shackles, etc., shall never be bent and shall only have
stress in line with their design load axis. The capacity of a lifting device 12 Never remove a filler cap of the coolant system of a hot engine. Wait until
diminishes when the lifting force is applied at an angle to its load axis. the engine has sufficiently cooled down.
8 For maximum safety and efficiency of the lifting apparatus all lifting 13 Never refill fuel while the unit is running, unless otherwise stated in the
members shall be applied as near to perpendicular as possible. If required, Atlas Copco Instruction Book (AIB). Keep fuel away from hot parts such
a lifting beam shall be applied between hoist and load. as air outlet pipes or the engine exhaust. Do not smoke when fuelling.
When fuelling from an automatic pump, an earthing cable should be
9 Never leave a load hanging on a hoist. connected to the unit to discharge static electricity. Never spill nor leave
10 A hoist has to be installed in such a way that the object will be lifted oil, fuel, coolant or cleansing agent in or around the unit.
perpendicular. If that is not possible, the necessary precautions must be 14 All doors shall be shut during operation so as not to disturb the cooling air
taken to prevent load-swinging, e.g. by using two hoists, each at flow inside the bodywork and/or render the silencing less effective. A door
approximately the same angle not exceeding 30° from the vertical. should be kept open for a short period only e.g. for inspection or
11 Locate the unit away from walls. Take all precautions to ensure that hot air adjustment.
exhausted from the engine and driven machine cooling systems cannot be 15 Periodically carry out maintenance works according to the maintenance
recirculated. If such hot air is taken in by the engine or driven machine schedule.
cooling fan, this may cause overheating of the unit; if taken in for
combustion, the engine power will be reduced. 16 Stationary housing guards are provided on all rotating or reciprocating
parts not otherwise protected and which may be hazardous to personnel.
Machinery shall never be put into operation, when such guards have been
removed, before the guards are securely reinstalled.
17 Noise, even at reasonable levels, can cause irritation and disturbance
which, over a long period of time, may cause severe injuries to the nervous
system of human beings.
When the sound pressure level, at any point where personnel normally has
to attend, is:
- 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,

2950 5330 01 7
XRV 1000 SD5

- above 95 dB(A): the warning(s) at the entrance(s) shall be completed 1.5 Safety during maintenance and repair
with the recommendation that also occasional visitors shall wear ear
protectors, Maintenance, overhaul and repair work shall only be carried out by adequately
- above 105 dB(A): special ear protectors that are adequate for this noise trained personnel; if required, under supervision of someone qualified for the
level and the spectral composition of the noise shall be provided and a job.
special warning to that effect shall be placed at each entrance. 1 Use only the correct tools for maintenance and repair work, and only tools
18 Insulation or safety guards of parts the temperature of which can be in which are in good condition.
excess of 80°C (175°F) and which may be accidentally touched by 2 Parts shall only be replaced by genuine Atlas Copco replacement parts.
personnel shall not be removed before the parts have cooled to room
temperature. 3 All maintenance work, other than routine attention, shall only be
undertaken when the unit is stopped. Steps shall be taken to prevent
19 Never operate the unit in surroundings where there is a possibility of inadvertent starting. In addition, a warning sign bearing a legend such as
taking in flammable or toxic fumes. “work in progress; do not start” shall be attached to the starting equipment.
20 If the working process produces fumes, dust or vibration hazards, etc., take On engine-driven units the battery shall be disconnected and removed or
the necessary steps to eliminate the risk of personnel injury. the terminals covered by insulating caps.
21 When using compressed air or inert gas to clean down equipment, do so On electrically driven units the main switch shall be locked in open
with caution and use the appropriate protection, at least safety glasses, for position and the fuses shall be taken out. A warning sign bearing a legend
the operator as well as for any bystander. Do not apply compressed air or such as “work in progress; do not supply voltage” shall be attached to the
inert gas to your skin or direct an air or gas stream at people. Never use it fuse box or main switch.
to clean dirt from your clothes. 4 Before dismantling any pressurized component, the compressor or
22 When washing parts in or with a cleaning solvent, provide the required equipment shall be effectively isolated from all sources of pressure and the
ventilation and use appropriate protection such as a breathing filter, safety entire system shall be relieved of pressure. Do not rely on non-return
glasses, rubber apron and gloves, etc. valves (check valves) to isolate pressure systems. In addition, a warning
sign bearing a legend such as ”work in progress; do not open” shall be
23 Safety shoes should be compulsory in any workshop and if there is a risk, attached to each of the outlet valves.
however small, of falling objects, wearing of a safety helmet should be
included. 5 Prior to stripping an engine or other machine or undertaking major
overhaul on it, prevent all movable parts from rolling over or moving.
24 If there is a risk of inhaling hazardous gases, fumes or dust, the respiratory
organs must be protected and depending on the nature of the hazard, so 6 Make sure that no tools, loose parts or rags are left in or on the machine.
must the eyes and skin. Never leave rags or loose clothing near the engine air intake.
25 Remember that where there is visible dust, the finer, invisible particles will 7 Never use flammable solvents for cleaning (fire-risk).
almost certainly be present too; but the fact that no dust can be seen is not 8 Take safety precautions against toxic vapours of cleaning liquids.
a reliable indication that dangerous, invisible dust is not present in the air. 9 Never use machine parts as a climbing aid.
26 Never operate the unit at pressures or speeds below or in excess of its 10 Observe scrupulous cleanliness during maintenance and repair. Keep away
limits as indicated in the technical specifications. dirt, cover the parts and exposed openings with a clean cloth, paper or
tape.
11 Never weld on or perform any operation involving heat near the fuel or oil
systems. Fuel and oil tanks must be completely purged, e.g. by steam-
cleaning, before carrying out such operations. Never weld on, or in any
way modify, pressure vessels. Disconnect the alternator cables during arc
welding on the unit.
12 Support the towbar and the axle(s) securely if working underneath the unit
or when removing a wheel. Do not rely on jacks.
13 Do not remove any of, or tamper with, the sound-damping material. Keep
the material free of dirt and liquids such as fuel, oil and cleansing agents.
If any sound-damping material is damaged, replace it to prevent the sound
pressure level from increasing.
14 Use only lubricating oils and greases recommended or approved by Atlas
Copco or the machine manufacturer. Ascertain that the selected lubricants
comply with all applicable safety regulations, especially with regard to
explosion or fire-risk and the possibility of decomposition or generation of
hazardous gases. Never mix synthetic with mineral oil.
15 Protect the engine, alternator, air intake filter, electrical and regulating
components, etc., to prevent moisture ingress, e.g. when steam-cleaning.
16 When performing any operation involving heat, flames or sparks on a
machine, the surrounding components shall first be screened with non-
flammable material.
17 Never use a light source with open flame for inspecting the interior of a
machine.
18 When repair has been completed, the machine shall be barred over at least
one revolution for reciprocating machines, several revolutions for rotary
ones to ensure that there is no mechanical interference within the machine
or driver. Check the direction of rotation of electric motors when starting
up the machine initially and after any alteration to the electrical
connection(s) or switch gear, to check that the oil pump and the fan
function properly.
19 Maintenance and repair work should be recorded in an operator’s logbook
for all machinery. Frequency and nature of repairs can reveal unsafe
conditions.
20 When hot parts have to be handled, e.g. shrink fitting, special heat-
resistant gloves shall be used and, if required, other body protection shall
be applied.

8 2950 5330 01
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21 When using cartridge type breathing filter equipment, ascertain that the Piping and coolers
correct type of cartridge is used and that its useful service life is not (according to directive 97/23)
surpassed.
22 Make sure that oil, solvents and other substances likely to pollute the Safety valves
environment are properly disposed of.
All adjustments or repairs are to be done by an authorized representative of the
23 Before clearing the unit for use after maintenance or overhaul, check that valve supplier (see “General”).
operating pressures, temperatures and speeds are correct and that the
control and shutdown devices function correctly.

1.6 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.

1.7 Battery safety precautions

Batteries
When servicing batteries, always wear protecting clothing and glasses.
1 The electrolyte in batteries is a sulphuric acid solution which is fatal if it
hits your eyes, and which can cause burns if it contacts your skin.
Therefore, be careful when handling batteries, e.g. when checking the
charge condition.
2 Install a sign prohibiting fire, open flame and smoking at the post where
batteries are being charged.
3 When batteries are being charged, an explosive gas mixture forms in the
cells and might escape through the vent holes in the plugs.
Thus an explosive atmosphere may form around the battery if ventilation
is poor, and can remain in and around the battery for several hours after it
has been charged. Therefore:
- never smoke near batteries being, or having recently been, charged,
- never break live circuits at battery terminals, because a spark usually
occurs.
4 When connecting an auxiliary battery (AB) in parallel to the unit battery
(CB) with booster cables: connect the + pole of AB to the + pole of CB,
then connect the - pole of CB to the mass of the unit. Disconnect in the
reverse order.

2950 5330 01 9
XRV 1000 SD5

2 Description The oil has three basic functions:

– As a coolant, it controls the increase in air temperature that is
2.1 Introduction normally associated with the heat from compressions.
– It seals leaks between rotors and housing.
The Atlas Copco two stage air compressor XRV 1000 SD5 offers
– It acts as a lubricant film between the rotors, allowing one rotor to
excellent reliability and reduced maintenance.
act on the other without metal-to-metal contact between them.
When compared to other compressors, the Atlas Copco compressor
After the air/oil mixture is discharged into the compressor, the oil
unit has unique mechanical reliability, without wear and with no
is separated from the air. At this instant, the air flows through the
inspection needed for its internal moving parts. Read item 5
airline and the oil is cooled so it can be re-injected into the
(maintenance) to keep your compressor in perfect working order. If
compressor unit.
you have any doubts that are not clarified by reading the text, ask
your nearest Atlas Copco distributor or the Atlas Copco service
department. 2.4 Compressor lubrication and cooling
system
2.2 Description of components
The lubrication and cooling system is designed to provide suitable
The complete assembly includes a screw rotation compressor, lubrication, as well as to keep the machine at the correct operating
diesel engine, air intake system, cooling and lubrication system, air temperature.
discharge system, capacity control system, instrument panel and
As well as the oil cooler and the oil tube interconnection, the
electrical system.
system has:
A compact case offers good mobility and easy handling. Large – Thermostatic valve,
service doors offer easy access to all the components. The Atlas – Fan,
Copco XRV 1000 SD5 air compressor is made to work at a nominal
pressure of 25 bar (365 psi). The compressor is operated by a diesel – Oil cut-out valve.
engine designed to work in diverse conditions.
The thermostatic valve has a regulator that sends the oil to the
For more details about the engine see the Operating Manual. cooler.

The engine cooling system consists of a radiator, a fan, a The oil stop valve acts as a flow control valve, interrupting the flow
thermostatic valve and an intercooler. of oil when the compressor stops.

This fan cools both the oil used in the cooling system and in the The oil is used in the lubrication and cooling system as lubricant
compressor lubrication. and coolant.

The air produced by the fan blows through the radiator and the oil On start up, the oil flows form the vessel/separator to the
cooler, thereby removing the heat in the oil produced by compressor. The circulating oil is forced from the high pressure
compression of the air. area of the vessel/separator into the low pressure area in the
compressor unit. A minimum pressure valve (see compressor
discharge system) is designed to maintain sufficient flow of oil in
2.3 Compressor unit - Operating any situation.
description
When the oil control system starts, the oil is directed first into the
The Atlas Copco XRV 1000 SD5 air compressors use a dual stage, filters, where after being filtered it is injected into the compressor
lubricated compressor unit with positive dislocation. This unit chamber and compressor unit bearings.
supplies smooth air to meet requirements. With an Atlas Copco
compressor, there is no need for maintenance or internal inspection The filters are constructed with a “by-pass” valve, which allows the
of the compressor unit. oil to pass through directly when the filter is blocked and needs
replacement, or when the viscosity of the oil is to high for suitable
The oil is injected inside the compressor unit in large amounts and circulation.
mixed directly with the air as the rotors turn and compress the air.

10 2950 5330 01
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The oil goes to the filters and starts to control the temperature. In A safety valve (located on the wet side of the separator) is regulated
this system, the oil is sent to the cooler. to open when the vessel pressure exceeds 27.58 bar (400 psi). A
thermostat will disconnect the unit if the discharge temperature of
The cooler works in conjunction with the fan and the engine. The the compressor unit reaches 130 °C (266 °F), and another will
fan forces air through the cooler, removing the compression heat discharge the unit if the temperature of the low pressure stages
from the oil. From the cooler, the oil returns to the control system. reaches 130 °C (266 °F).
All the oil flows to the compressor unit. The oil goes into the
control system and flows into the compressor unit where it The oil is added to the vessel via a cap on its upper part. An
lubricates and cools the compression chamber, as well as indicator allows the operator to see the oil level in the vessel.
lubricating the bearings and gears.
Do not open covers, plugs or other components when
When the compressor is operating, a pressure signal keeps the the compressor is working or pressurised. Stop the
circuit open and the oil flowing freely to the compressor unit. When compressor and relieve all internal pressure before
the compressor stops, so does the pressure signal, and the circuit is acting as indicated.
blocked via a non-return valve, isolating the compressor unit from
the oil circuit.

2.5 Discharge system - Operating

description

The compressor unit discharges the air/oil mixture through a

retention valve into the vessel/separator. The discharge retention
valve prevents the air within the vessel from returning to the
compression chamber when the machine is disconnected.

The vessel has three main functions:

– To act as the primary oil separator;
– To serve as an oil vessel;
– To be the final oil separator element.

The air/oil mixture enters the vessel/separator and is directed onto

the wall of the tank. The direction of the movement is altered and
its speed reduces significantly, which results in oil drops falling to
the bottom of the vessel. The small amount of oil remaining in the
compressed air is removed in the separator element when the air
goes through. A return line (return tube) connects the base of the
separator element to the compressor unit. The oil collected into the
separator element base is returned to the compressor unit due to the
pressure differential between the vessel and the compressor unit
intake.

The vessel is constructed in accordance with ASME standards. A

minimum pressure valve, located after the separator, ensures
minimum pressure in the vessel of 9.65 bar (140 psi) in any
situation. This pressure is necessary for good separation of the air/
oil and for good oil circulation.

There is also a final retention valve inside the minimum pressure

valve. This prevents the compressed air in the line returning into
the compressor unit when it stops or when the unit is relieved.

2950 5330 01 11
XRV 1000 SD5

RV

S10 TV UA

AF

OC
BV
F BN

WPG

E C CELP

MPV
P
FR SV

CEHP AOV

DP1
TG
TBV
OSE

OF OR
CV TG
DP3

DP4 OSV SG OFP

BN

TBV

DP2

AF Air filter MPV Minimum pressure valve

AOV Air outlet valve OC Oil cooler
AR Separator tank OF Oil filter
BV Thermostatic valve OFP Oil top-up point
C Coupling OSE Oil separator element
CEHP High pressure element of the compressor OSV Oil stop valve
CELP Low pressure element of the compressor P Pressure switch
CV Stop valve RV Regulating valve
DP1 Oil cooler drain plug SG Visor
DP2 Water collector drain plug SV Safety valve
DP3 Retention valve drain plug S10 Restriction indicator
DP4 Oil stop valve drain plug TV Master valve
E Motor UA Discharge assembly
F Fan WPG Work pressure gauge
FR Oil return line flow restriction

12 2950 5330 01
 Instruction Manual

2.6 Air intake system - Operating Coordination instruments

description 19 This switch can be used to visualise engine and coordinator
errors, as well as to adjust the programming of the engine
The air intake system has two air filters, a restriction indicator, an parameters, which the ACB can see on the “Display”.
unloading valve for the compressor air and the piping to connect 20 Engine diagnostics button, see list of possible errors.
engine and compressor.
21 Coordinator diagnostics button, see list of possible errors.
The air filters (one for the engine and the other for the compressor) 22 Failure light. See table of engine or coordinator faults.
are "dry" type filters.
Note that long flashes are tens and short flashes are units.
All the filters clean even the dirtiest air, however in some cases you
will need to check the air restriction indicator more frequently. The E.g.: Long-long and short-short-short-short-short = fault code 25.
air filter restriction indicators are located on the filters themselves.
After resolving the fault, turn the master switch to the SYSTEM
When these indicators show red this indicates that the filter is OFF position and 10 seconds later move it to the ON position. If the
blocked. defect persists contact Atlas Copco.

The filters must then be cleaned or changed, depending on how

seriously they are blocked. See item 5 for air filter (Maintenance 23
Procedure).
24
The indicators must be checked constantly.

2.7 Instrument panel assembly - Operating

description
1 2 11 12
Motor instruments
1 Engine oil pressure gauge
3 4 13 14
2 Tachometer indicating engine rotation speed, with time clock
built in.
5/6/7 15/16
3 Fuel level indicator.
8/9/10 17/18
4 Engine water temperature indicator.
5 Warning light for engine air filter restriction.
6 Warning light for battery charge. 19 20 21 22
7 Warning light for low engine water level.
8 Protection fuse port. 2.8 Electric and safety system
9 Warning light for high engine water temperature.
The electric system consists not only of the equipment needed to
10 Warning light for low engine oil pressure.
operate the compressor, but also a system for disconnecting the
Compressor instruments machine in the event of a malfunction.
11 Intermediate air pressure indicator, 1 stage. The components of the electrical system are a starter motor with an
12 Indicator of outflow pressure. internal solenoid, two batteries an alternator with a voltage
13 Intermediate air temperature indicator pressure gauge, 1 stage. regulator, and a fuel stop solenoid.
14 Compressor air outlet indicator pressure gauge. With a special 10 A fuse, a compressor discharge temperature
15 Warning light for air filter compressor restriction. sensor that will disconnect the machine when the temperature
16 Start up switch. exceeds 130 °C (266 °F), an engine water temperature sensor that
will disconnect the machine when it reaches 98 °C (208.4 °F), and
17 Charge and relief switch. an engine pressure sensor that will disconnect the machine when
18 Compressor stop button. the engine oil pressure is too low.

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14
Engine coordinator
– COO XRV 1000 SD5

Electronic engine
module – EMS S6

ENGINE COMPRESSOR

A – Alternator AP – Panel earth

ACM – Electronic engine accelerator AC – Chassis earth
B – Battery F1 – Fuse
B25 – Accelerator sensor H1 – Battery charge light
CAN-D – Engine diagnostics dial H2 – Panel illumination light
COO – Engine coordinator H3 – Restriction light
EMS S6 – Engine control electronic module IP+ – Positive isolator
E7 – Actuator K2 – Start up block/impediment relay
Gc – Engine pressure gauge K4 – Seal relay
GP – Engine water temperature S1 – General start up switch
H4 – Engine restriction light S3 – Panel illumination switch
H5 – Engine/coordinator fault light S4 – Compressor charge switch
H6 – Low water level light S5 – Emergency stop button
Connector for
H7 – High water temperature light S6 – High exit air temperature cut-out
Oiltronix option
H8 – Low oil pressure light S7 – Start up impediment cut-out
feed
IC – Fuel indicator S13 – Minimum entry pressure cut-out
MS – Starter motor S18 – Start up impediment cut-out
R1 – Diagnostic dial resistor S19 – Compressor air filter pressure gauge
R2 – Speed adjustment resistor Y4 – Charge/Relief solenoid
S8 – Coordinator diagnostics button
S9 – Engine diagnostics button
S20 – Air filter pressure gauge
SU3 – Fuel level sensor
TG – Tachometer / time clock

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 Instruction Manual

3 Operation Compressor final discharge thermometer

Breaks the electrical circuit when the discharge temperature
reaches 130 °C (266 °F) (disconnecting the machine).
3.1 General
Intermediate discharge thermometer
Atlas Copco fits its compressors with an extensive range of
controllers and indicators to ensure suitable operation. It is Breaks the electrical circuit when the intermediate discharge
advisable to get to know and learn how to interpret all the readings temperature reaches 130 °C (266 °F) (disconnecting the machine).
that indicate a need for technical services or the start of equipment
malfunction. before starting up your Atlas Copco compressor, read Discharge valve
this section carefully, familiarising yourself with the indicators and Relieves the vessel pressure during relief operations or after
controllers, their purposes, locations and uses. disconnection.

Control/indicators/purpose Oil stop valve

Connect/disconnect switch
This stops the flow of oil that goes to the compressor when it stops
working. It allows a flow of oil when the compressor starts up.
Turn this switch to the connect position to energise the electrical
system, and to the start up position to activate the engine. The Minimum pressure valve
switch is located on the panel.
Keeps a minimum pressure of 9.65 bar (140 psi) in the compressor
Start up button
vessel. The valve piston restricts the discharge of air from the
vessel when the pressure falls to 6.89 bar (100 psi). It also has a
Press the button to start the engine. Wait for the engine to fire and retention valve that prevents the line pressure returning to the
release the button. vessel during relief and after the unit is stopped.
Battery indicator light Safety valve
Indicates the performance of the engine alternator, and is the first Opens to the atmosphere if the tank pressure is very high.
indication of electrical malfunction. Regulated at 15% above the operating pressure.
Engine water temperature indicator Intake control
Indicates the temperature of the engine water. The normal Regulates the amount of air allowed into the unit through the piston
temperature is 80 °C (176 °F). valve. This amount of air is determined by the amount of air that is
being consumed in the line.
Tachometer
Its function is to show engine rotation speed. Pressure regulator
Opens the pressure in the line between the vessel and the admission
Engine oil pressure gauge
control, allowing it to regulate the air supply in line with demand.
Indicates engine oil pressure. The normal reading is 6.9 kg/cm²
(15.2 lb/cm²). Relief valve
Releases tank pressure to the atmosphere to discharge the
Final discharge pressure gauge
compressor.
Permanently indicates the compressor charge and discharge
conditions.

Intermediary discharge pressure gauge

Permanently indicates the intermediary pressure in charge
conditions and must never show 0 bar when operating. The normal
reading is 1.8 to 2.0 bar (26.1 to 29.0 psi) in relief and
approximately 5.0 to 5.2 bar (72.5 to 75.4 psi) under load.

Compressor discharge temperature indicator

Indicates the compressor discharge air temperature.

Intermediate temperature indicator

Indicates the compressor intermediary discharge temperature.

Oil level visor

Indicates the oil level in the vessel.

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XRV 1000 SD5

3.1.1 List of possible errors when using the 3.1.2 List of possible errors when pressing the
EMS Coordinator Diagnostics test Engine Diagnostics Test Button
Button Code Description

Flash code Description of fault 0 No fault was found.

111 Error signal coming from the fine adjustment for the 11 Running too fast. One or both the engine rotation sensors are
nominal speed signal. indicating an engine speed higher than 3000 rpm.

112 Error signals coming from the accelerator pedal sensor. 12 Engine 1 rotation sensor faulty or incorrect signal.

121 Error signal coming from the regulator adjustment resistor 13 Engine 2 rotation sensor faulty or incorrect signal.
module. 14 Cooling liquid temperature sensor faulty or incorrect signal.
122 Error signal coming from the slow and engine speed 15 Air intake temperature sensor faulty or incorrect signal.
adjustment resistor module. 16 Air pressure sensor faulty or incorrect signal.
13 No communication (EMS) with the engine. 17 Oil temperature sensor faulty or incorrect signal.
14 Short circuit in the tachometer signal circuit. 18 Oil pressure sensor 1 faulty or incorrect signal.
15 Atmospheric pressure sensor defective. 20 Coolant liquid level sensor faulty.
17 Short circuit in the cooling liquid temperature indicator 23 Internal fault code in the coordinator.
signal cable. 24 Accelerator/brake. If the accelerator and the brake are
18 Short circuit in the signal circuit of the oil pressure indicator. operated simultaneously.
19 Short circuit in the signal circuit of the oil pressure light. 25 Accelerator sensor/safety cut-out. Accelerator sensor/
21 Different versions of the communication protocol between kickdown cut-out.
the coordinator and the EMS. 27 Disconnection of turning engine.
22 Start up switch defective or has a short circuit. 28 Disconnection due to oil pressure.
23 Supply voltage is very high. 31 Torque limited due to oil pressure.
24 Supply voltage is very low. 32 Incorrect parameters for limited operating mode function.
25 The check value at the end of the operating line (EOL) is 33 Battery voltage incorrect or no signal.
incorrect. 37 Emergency cut-out activated in accordance with the CAN
26 Road speed sensor signal missing or incorrect. message for the coordinator.
27 The RCB (Remote Control Box) switch signals are unlikely. 43 CAN circuit has control unit fault.
28 Incorrect signals coming from the rotation cut-out adjustors. 47 Immobiliser function. Incorrect ignition key code.
29 Remote start up cut-out defective. 48 CAN message from coordinator incorrect or lacking.
31 No communication between slave and master coordinators 49 Wrong CAN version in the control unit or coordinator.
32 Short circuit in the coolant temperature warning light signal 51 PDE in cylinder 1: the solenoid valve is not working
cable. correctly.
33 Short circuit in the charge warning light signal cable light. 52 PDE in cylinder 2: the solenoid valve is not working
44 Error signal coming from the fixed speed cut-outs. correctly.
35 Lack of CAN communication. 53 PDE in cylinder 3: the solenoid valve is not working
correctly.
Notes: 54 PDE in cylinder 4: the solenoid valve is not working
1) Simple engine rotation correctly.
55 PDE in cylinder 5: the solenoid valve is not working
2) Variable engine rotation
correctly.
56 PDE in cylinder 6: the solenoid valve is not working
correctly.
57 PDE in cylinder 7: the solenoid valve is not working
correctly.
58 PDE in cylinder 8: the solenoid valve is not working
correctly.
59 Incorrect signal for additional analogue input.
61 Incorrect disconnection of the control unit.
66 Disconnection due to level of cooling liquid.
69 Starter motor function interrupted or not activated.
82 Engine speed above that needed at start up.
83 Fault in the memory circuit (EEPROM) in the control unit.
84 Date transfer to the control unit memory (EEPROM) was
interrupted.
85 Internal temperature incorrect in the control unit.
86 Internal fault in the control unit: fault in the hardware
control.
87 RAM failure in the control unit.
88 Internal fault in the control unit: lack of memory.

16 2950 5330 01
 Instruction Manual

89 Incorrect certification: unlicensed edition of the software. 3.4 Stopping procedure

93 Engine rotation sensors faulty or not connected. 1. Turn the load/no load switch to the “NO LOAD” position.
94 Disconnection due to high cooling liquid temperature
2. Wait 40 seconds.
96 Torque limited due to high cooling liquid temperature
98 Voltage to one of the sensors defective. 3. Push the “STOP COMPRESSOR” button until the engine
99 Internal fault in the processor hardware (TPU).
stops completely.
4. After the engine stops, turn the ON-OFF/start-up switch to the
“OFF” position.
3.2 Initial start up procedure
After running the stop routine, check the gauges on
The procedure below must be followed for initial start up of the the instrument panel and ensure that they are all
compressor. giving the right reading for each phase of the
1. The machine's position on the surface must allow it to be operations. After the machine has been operating, you
refilled. are recommended to make a general check of the
machine and the instrument panel to ensure that the
2. Fill the vessel with the oil recommended in the table that compressor unit is working correctly.
comes with the compressor
3. Check the level of engine oil constantly, and add more if
necessary.
4. Fill the fuel tank.
5. Check the batteries.
6. Close the service valves.
7. Turn the load/no load switch to the “NO LOAD” position.
8. Turn the ON-OFF/start up switch to the “ON” position.
9. Check the fuel level.
10. Turn the ON-OFF/start up switch to the “START UP”
position, wait until the charge light goes out and release the
switch.
11. Wait 3 minutes and put the compressor on “LOAD”.

3.3 Procedure for subsequent start ups

For subsequent start ups, follow the procedure below:

1. Check whether the low water light is on.
2. Turn the load/no load switch to the “NO LOAD” position.
3. Turn the ON-OFF/start up switch to the “ON” position.
4. Check the fuel level.
5. Turn the ON-OFF/start up switch to the “START UP”
position, wait until the charge light goes out and release the
switch.
6. Wait 3 minutes and put the compressor on “LOAD”.

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XRV 1000 SD5

4 Maintenance 4.3 Maintenance after first 100 hours of

operation
4.1 General After100 hours of operation, minor maintenance is recommended.
You need to remove any foreign material from the system that may
A good maintenance programme is the key to long life for your
have accumulated in the machine during installation. The
compressor.
maintenance procedures described below are to avoid unwanted
Below is a programme that, if followed correctly, will allow your problems.
compressor to operate perfectly. 1. Clean the return line orifice and filter.
2. Check the battery level and top up with water if necessary.
This programme also includes the maintenance routines for the
engine. However, for maintenance that is not covered in this 3. Check the engine oil and the oil filter. It is best to do this when
programme, follow the instructions in the Engine Operating the engine is hot.
Manual. 4. Change the oil filter.

See section 4.6 for a detailed description of the components of the

4.4 Maintenance after 1000 hours of
compressor.
operation
Do not open covers, plugs or other components when 1. Change the fuel filter. If the filter keeps getting blocked,
the compressor is working or pressurised. Stop the change it frequently.
compressor and relieve all internal pressures before
opening any of the items mentioned. 2. Check the fanbelt tensions.
3. Clean the external radiator regardless of atmospheric
contamination. Clean the radiator more frequently if
4.2 Daily operation necessary.
Before starting the compressor, you must check the oil level in the 4. Change the compressor oil
vessel. If it is low, top up with as much oil as necessary. If oil has 5. Change the oil filter.
to be added frequently, there is a problem that is causing this 6. Lubricate the joints and couplings.
excessive consumption. See section 5, under the heading
“Excessive oil consumption”, which mentions probable causes and
their solutions. 4.5 Servicing compressor elements
– 4000 hours: Service the High Pressure compressor element.
Also check the engine oil level and the water level in the radiator.
– 8000 hours: Service the Low Pressure compressor element.
After running the stop routine, check the gauges and indicators to
ensure that they are all working correctly and giving the right 4.6 Replacement of parts and adjustment
reading for each phase of the operations.
procedure
Once the compressor is warmed up, you are recommended to make
a general inspection of it, and of the indicators and gauges to ensure 4.6.1 Changing the oil filter elements
that the compressor unit is working normally. 1. Using a filter tool, remove the old element.
2. Clean a supporting surface.
You also need to check the air filter maintenance indicator. If the
indicators show red, clean or change them immediately. See the 3. Smear a thin film of oil on the rubber joint.
section on air filter maintenance, section 4.6.2. After maintenance 4. Fit the new filter element by hand until it is well seated in the
of the filters, manually return the indicator to the normal position. rebate.
5. Then give a further ½ to ¾ turn.
6. Restart the machine and check for leaks.

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 Instruction Manual

4.6.2 Maintenance of air intake filter Inspection of the element

1. Shine a powerful light into the filter element to check for
The air filter must be serviced in any of the following cases: damage or holes. Concentrated light will appear through
1. When the filter obstruction indicator is on. damaged areas of the element.
2. Every 6 months. 2. Inspect all the joints and surfaces of the filter housing that
come into contact with joints. Correct any problems
The procedures to change and clean the air filter element are as immediately
follows: 3. Where new filters are stored for later use, they must be stored
in clean containers.
1. Clean the external part of the filter housing.
4. After installing the element, inspect (by opening, if necessary)
2. Remove the air filter, loosening the clips that hold the cover. all the air input connections before restarting the operation.
3. Remove the elements and clean the base and the interior of the
cover using a damp cloth. Do not blast it with compressed air. 4.6.3 Oil separator element replacement
4. Clean or replace the elements with new ones.
The separator must be changed when too much oil is going through
5. Replace the cover. the line. To change the oil separator element, proceed as follows:
6. Rearm the filter maintenance indicator.
1. Relieve the pressure in the vessel and in all pressurised lines.
2. Disconnect all the piping connected to the vessel cover, in
3 order to remove it (return line, network connection, etc.)
2
3. Loosen and remove the screws from the vessel cover.
4. Remove the vessel cover.
5. Remove the oil separator element.
4
6. Remove the rest of the cover joint and the vessel, taking care
not to drop any parts into the vessel.
7. Fit the new joints: one on the tank and the other above the oil
separator element.

Fit the earth for the separator element joints

8. Refit the separator element in the vessel, taking care not to

knock it against the walls of the vessel.
9. Clean the cover, the washers and the screws. Open them with
a 7.6 kg.m. (55 ft/pounds) torque .
5 1 10. Reconnect all the piping, ensuring that the end of the return
line reaches to 1.2 cm (0.47 in) from the base of the separator
element. This allows a suitable return of oil to the compressor
1 Housing unit.
2 Clamps
11. Clean the return line filter before restarting.
3 Filter element
4 Safety element 4.6.4 Control system adjustments
5 Valve
The air filter element is cleaned using compressed air. When using The control system is designed to balance the input of air in the
compressed air for this purpose, never exceed a pressure of 207 kPa compressor and the engine rotation speed to satisfy the demand for
(2.6 bar / 37.7 psi). air from zero to maximum capacity.

The filter element must be cleaned from the inside to the outside, Slow speed and working rotation are regulated by the Coordinator
cleaning each paper fold and moving the air jet up and down so the electronic module.
impurities are removed. If there are traces of grease or oil, the
element must be changed. When the element is satisfactorily clean,
inspect it carefully before installing it. (See inspection of the
element).

2950 5330 01 19
XRV 1000 SD5

4.6.5 Oil stop valve maintenance

SCREW
1. Maintenance of this valve is limited to changing the six items
that accompany the service kit. O-RING

2. Remove the four screws that fix the valve to the unit, and O-RING

remove the pipe that has to be connected.

3. Open the cover to get access to the piston and the O-ring, and
change them. VALVE SEAT

4. There is an elastic ring on the opposite side from the cover.

Remove this ring, which gives access to the spring and to the
spool, which is also part of the kit. O-RING
O-RING
5. Reinstall the valve, not forgetting to change the two rings on
VALVE
the upper part of the valve.
VALVE
BUFFER
SPRING
O-RING SPRING
O-RING HOUSING

PRESSURE
VALVE BODY WASHER

SCREW

PLUG
VALVE
WASHER
SCREW

SPRING BUFFER
4.6.7 Engine oil drain

SPRING GUIDE Drain the engine oil by opening the ball valve (1). To get easy
ELASTIC RING
access to the ball valve, remove the plate at the bottom of the frame
(see Parts list “FRAME AND SUPPORTS”, item 3).

Close the ball valve (1) after draining.

4.6.6 Stop/discharge valve maintenanceì

The stop/discharge valve is removed from the unit as follows:

1. Remove the discharge pipe that is connected to the valve.
2. Remove the unit high pressure valve, which is fixed with four
screws.
3. When removing the valve it will automatically be opened.
4. Maintenance is limited to changing the rings, springs and
valves.

Close the engine oil drain valve during filling and

operation.

20 2950 5330 01
 Instruction Manual

5 Problem solving
Possible problems and their solutions

Problem Possible causes Correction

The unit does not start a. Lack of fuel. Add diesel oil, if necessary.
b. Diesel filter blocked. Change the element.
c. Battery voltage low. Check the electrolyte level and add water.
Recharge, if necessary.
d. Air filter blocked. Clean or change the element.
e. Problems in the diesel engine. Consult the engine manual.
f. Defect in the oil pressure cut-outs, high water Check continuity, and replace if necessary.
temperature or high discharge temperature.
g. Fuse burned out. Check continuity, replace if necessary.
Machine stops when a. Lack of fuel. Check the level and add diesel if necessary.
working normally b. High discharge temperature cut-out open.
– Lack of cooling. Clean the cooler and check the ventilation.
– Tank oil level low. Add oil.
– Oil very dirty. Change the oil.
– Oil filter blocked. Clean the element.
– Thermostatic valve working incorrectly. Change the element.
c. Fault in the switch. Check if there is no circuit, or a short circuit, in the
solenoid. If the circuit is normal, the switch may be
defective.
– Fault in the engine oil pressure cut-out. Check the oil pressure. Check continuity and
replace if necessary.
d. High water temperature cut out is open.
– Air flow restricted. Clean the radiator.
– Lack of ventilation. Check the belt and slacken if necessary.
– Water level low. Add water
– Cut-out defective. Change it
– Fuse burned out. Change it
Machine not developing a. Excess demand for air. Check if there are leaks or open valves in the
normal operating pressure. service line.
b. Air filter dirty. Check the indicators and clean or replace the
elements if necessary.
c. Pressure regulator deregulated. Adjust the regulator in accordance with the
instructions in the maintenance section.
d. Pressure regulator defective. Check and clean the regulator and replace the
regulator kit if necessary.
e. Minimum pressure valve defective. Check for leaks in the valve. Check whether the
piston is moving freely.
Low air consumption and a. Regulating valve badly adjusted. Readjust or clean it
excess pressure, causing the b. Leak in the control system, causing loss of Check the control line (hose). Check the
relief valve to open (safety). pressurised signal. diaphragm, and change it if damaged. Check the
regulator valve.
c. Admission valve defective. Remove the valve and change it if necessary.
d. Safety valve defective. Change the safety valve.
e. Air/oil separator element blocked. Change the separator element.

2950 5330 01 21
XRV 1000 SD5

Insufficient air supply. a. Filters blocked Clean or replace the elements.

b. Air/oil separator blocked. Replace the separator element, replace the
compressor oil and the oil filter.
c. Pressure regulator defective Adjust or repair.
d. Engine rotation speed very low. Arrange SCANIA service.
Excessive consumption of a. Return line blocked. Clean the orifice and “Y” filter.
compressor oil. b. eak in the lubrication system. Inspect all tubes, hoses and connections.
c. Air/oil separator element damaged or not Change the separator element.
working correctly.
d. Compressor oil boiling. Check that the correct oil is being used. Change
the compressor oil.
Compressor overheating. a. Fan belt loose or broken. Fix or replace the belt
b. Radiators honeycomb blocked. Clean the honeycomb completely.
c. Thermostat valve defective. Change the valve element.
d. Oil radiator tubes blocked internally Clean the tubes completely.
Do not use caustic solutions.
e. Compressor oil level low. Top up the level.
f. Oil filter blocked. Replace the oil filters.
g. Oil return line blocked. Clean the “Y” filter and unblock the orifice.
Engine overheating. a. Fan belt loose or broken. Fix or replace the belt
b. Radiator honeycomb blocked. Clean completely.
c. Radiator water level low. Fill completely.
d. Engine oil level low. Top up the level.
e. Engine water pump defective. Change the pump.
f. Engine thermostat valve defective. Change the element.
g. Radiator blocked internally. Clean it completely.
h. Low oil level. Top up.

22 2950 5330 01
 Instruction Manual

6 Technical specifications

6.1 Compressor lubrication

The life of the compressor depends on the choice of lubricant and maintenance. Ambient temperature, relative humidity, discharge pressure
and the levels of contamination must be taken into account when choosing the lubricant. Humidity must always be below the hottest
conditions. Depending on humidity or the level of contaminations, the interval for exchange recommended below must be reduced to deal
with the conditions.

PAROIL S68 1000 hours

For the engine oil specification see the reference in the Engine Operating manual.

6.2 Specifications of the engine/alternator/unit

Metric US

Reference conditions Absolute inlet pressure 1.0 bar 14.5 psi

Relative air humidity 0% 0%
Air inlet temperature 20°C 68°F
Normal effective working pressure 25 bar 365 psi
* The inlet conditions are specified outside the canopy.

Limitations 1) Minimum effective receiver pressure 15 bar 220 psi

Maximum effective receiver pressure at no load 26.5 bar 385 psi
Maximum ambient temperature 8) 45°C 113°F
Minimum ambient temperature 0°C 32°F
Altitude capability 1000 m 3281 ft
Maximum effective working pres. (at ref. conditions) 25 bar 365 psi
Angularity of operation 15° 15°

Performance data 2) Engine shaft speed, normal and maximum 1800 rpm 1800 rpm
Engine shaft speed at no load 1300 rpm 1300 rpm
Free air delivery 3) 465 l/s 985 cfm
Fuel consumption (tolerance ± 5%)
- at full load 72.9 kg/h 160.7 lb/h
- at unload 13.5 kg/h 29.8 lb/h
Specific fuel consumption (per FAD unit) 40.4 g/m3 0.68 lb/yard3
3
Maximum oil content of compressed air 3 mg/m 0.005 lb/yard3
Engine oil consumption (maximum) <0.3 g/kWh <0.01 oz/kWh
Compressed air temperature at outlet valve 9) 100°C 212°F
Noise level 5):
Sound pressure level (LP), measured using ISO 9614-2 under
free field conditions at 7 m (21 ft) distance 78 dB(A) 78 dB(A)

Design data compressor Number of compression stages 2 2

Design data engine Make SCANIA SCANIA

Type DC1250A DC1250A
Coolant water/additive water/additive
Number of cylinders 6 6
Bore 127 mm 4.95 in
Stroke 154 mm 6.00 in
Swept volume 11.7 l 3.1 US gal
Output according to IFN at normal shaft speed7) 330 kW 440 hp
Minimum capacity of oil sump (including oil filter) 28 l 7.4 US gal
Maximum capacity of oil sump (including oil filter) 33 l 8.7 US gal
Battery capacity 150 Ah 150 Ah
Cold cracking amperes – SAE J537 950 A 950 A
Capacity of cooling system 65 l 17.2 US gal
Normal oil pressure 3-6 bar 44-87 psi
Minimum permitted oil pressure 0.7 bar 10 psi
Minimum permitted oil temperature 120°C 248°F
Oil cleaner filtration 5-7 Micron 5-7 Micron
Oil change intervals 400 h 400 h

2950 5330 01 23
XRV 1000 SD5

Maximum exhaust gas temperature 495°C 923°F

Maximum back pressure at muffler outlet 700 mmH2O 27.3 inH2O

Design data fan Power consumption 10 kW 13.4 hp

Ratio 0.68 0.68
Fan speed 1224 rpm 1224 rpm
Number of shovels 16 16

Design data unit Capacity of compressor oil system 85 l 22.4 US gal

Net capacity of air receiver 180 l 47.5 US gal
Capacity of fuel tank 565 l 149.2 US gal
Air volume flow at inlet (approx.) 4) 15.5 m3/s 32,860 cfm
Overall dimensions (approx.) (LxWxH) 3850 x 2200 x 2240 mm 150.2 x 85.8 x 87.4 in
Net mass weight (approx.) 6) 4550 kg 10,032.8 lb
Total mass of unit ready to operate (approx.) 5200 kg 11,466.0 lb
Dimension drawing 1031 2007 39 1031 2007 39

Notes

1) At reference conditions, if applicable, and normal shaft speed.

2) Unless otherwise stated, at reference conditions and at normal shaft speed.
3) The free air delivery is guaranteed according to ISO 1217 ed. 3 1996 annex D ±5% 25 l/s < FAD > 250 l/s and ±4% 250 l/s < FAD.
4) Air required for engine and compressor cooling, combustion and compression.
5) To be confirmed at first production units.
6) Without oil, fuel and water
7) At to IFN.
8) Considering maximum compressor oil temperature 130 °C.
9) a = ambient.

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