1. XAS 400 JD7 iT4 Compressor Scott Malm
Committed to sustainable productivity

2. Air/Oil System Overview - XAS 400 JD iT4

3. Product Designation Oil Injected Compressors
Engine supplier
C : Caterpillar
D : Deutz
J : John Deere
Y : Yanmar
K : Kubota
Working principle
A : Single stage compressor
R : Two stage compressor
Product range
X : Oil injected
portable compressor
Silencing
: Un-silenced
S : Silenced
Prime mover
D : diesel engine
E : electric motor X A T S
400 J D
Capacity (FAD)
Liter/sec CFM (US-version)
Working pressure
: standard pressure psi
T : “ten” pressure psi
H : high pressure psi

4. Compressor systems Air system Oil system Control system
Four major components :
Air system
Oil system
Control system
Electrical system

5. Air system
The following slides explain how the regulating system of the XA(H)S works. They will give you an overview of the different parts and their function.

6. Air system
Air filter Compressor Element (AFCE) (with vacuator valve VV, Safety Cartridge SC and vacuum indicator VI)
Unloading Valve (UV)
Compressor Element (CE)
Temperature Switch (TS)
Check Valve (CV)
Air Receiver (AR)
Non Return Valve
Minimum Pressure Valve (MPV)
Air Outlet Valve (AOV)

7. Air filter centrifugal dust separation paper filter element
Filtration of the inlet air in 3 stages :
centrifugal dust separation
paper filter element
safety cartridge (optional)
Vacuum indicator gives an indication when the pressure drop over the filter element is too high  filter element needs to be replaced

8. Air filter Centrifugal separation Air inlet Vacuum indicator
Filter element
Dust
to compressor element

9. REGULATING SYSTEM REG VALVE
Spring loaded
Adjusting receiver pressure
by changing spring tension
to pressure gauge and loading valve
to speed regulator
to unloading valve
Regulating pressure:
Receiver pressure
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.

10. Regulating valve Adjusting receiver pressure
by changing spring tension
Spring loaded
Pressure gauge
to speed regulator
to unloading valve
Regulating pressure
Receiver pressure
to blow-down valve
Regulating Valve Service Kit –

11. Unloading valve Open position at load condition => Air consumption
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.

12. Unloading Valve or Air System Inlet Valve
Legend
Receiver Pressure
From Pressure Regulator right now very low to zero pressure
Spring loaded in the open
position
Control Air closes the inlet
Also serves as check valve
Unloading valve service kit –

13. No-Load Condition Load Condition

14. Unload Condition Blow- Down Condition

15. AIR SYSTEM MIN PRESS VALVE
Maintains a minimum pressure
of PSI for oil flow
Also contains the final check
valve

16. Oil System
The following slides explain how the regulating system of the XA(H)S works. They will give you an overview of the different parts and their function.

17. Oil System Air receiver Oil cooler Oil filter Compressor element
Oil separator
Scavenge line
The following slides explain how the regulating system of the XA(H)S works. They will give you an overview of the different parts and their function.

18. Oil injected screw compressors

19. Compressor element
Lubrication to the bearings
Air inlet
Oil
Air/Oil

20. 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

21. Oil injected screw compressors
Oil is injected in the bottom of the rotor housing,
on the bearings and gears

22. Compression principle
Suction
Compression start
Delivery
Compression

23. Oil separator Scavenge line Separator element Centrifugal separation
* Oil Separator filter element should be replaced
Every 1,000 hours or yearly.
Centrifugal separation
Oil
Air/Oil

24. Oil Separator Classic Reasons For Oil Carryover
Over filled receiver
Plugged scavenge line
Wrong type of oil (no anti foam agent)
Scavenge tube installed improperly
Being used improperly for application (Sandblasting)
Separator Element Service Kit –

25. Control System

26. Control Panel – XC2002 Controller
Stop Button

27. XC2002 Status

28. XC2002 Menus Software Level 1.70.0 for XAS 400 JD iT4
Unit Type 15 For XAS 400 JD iT4

29. Basic Operations

30. Shutdown

31. XC2002 Alarms

32. 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 keep flashing. The Alarm will be shown with the phrase “Unack”. Push the Enter button to acknowledge the alarm. Once the alarm is acknowledged if it is still active then the red LED in the triangle will stay on solid. 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 alarm code will be shown.

33. XC2002 Event Log XC2002 keeps an event log of the last 30 events.
Shutdowns
Warnings
Service timer resets
Unit type changes
Running hours at time of event logged

34. Engine Faults

35. Compressor/Engine Faults

36. Electrical System

37. Wiring Diagram

38. Legend – Wiring Diagram

39. Wiring Diagram - Engine

40. Wiring Diagram – Legend - Engine

41. Maintenance

42. Maintenance – XA(T,V)S 400 JD IT4
Daily:
Check engine oil level
Check compressor oil level
Check coolant level
Drain water from fuel filter
Empty air filter vacuator valve
Check tire pressure

43. Maintenance – XA(T,V)S 400 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 (if equipped)
Check and adjust brakes
Check and adjust fan belts
Replace compressor oil filter

44. Maintenance – XA(T,V)S 400 JD IT4
500 Hour service pack part number
Perform 50 hour service tasks
Clean oil cooler, radiator, intercooler
Lubricate door hinges
Grease towing eye shaft or ball coupling and shaft
Analyze coolant
Replace/Check air filter elements
Replace engine oil and filter
Replace fuel filters

45. Maintenance – XA(T,V)S 400 JD IT4
1000 Hour service pack part number
Perform 500 hour service tasks
Test safety valve and shut down switches
Check all compressor Oil/Air hoses
Replace separator element
Replace compressor oil and spin on filter
Replace blow down valve on unloader Assy.
Clean flow restrictor in oil scavenge line

46. IT4 EXHAUST AFTERTREATMENT

47. IT4 Exhaust Aftertreatment
Diesel Particulate Filter (DPF)
Diesel Oxidation Catalyst (DOC)

48. XC2002 DPF Status Indicators

49. Stationary DPF Regeneration
Go to the “STATION REGEN” screen. For normal operation this should be “OFF”.
Press the “Enter” button. This function is not password protected.
Use the up/down arrow to change the selection to “ON” and press the “Enter” button.
Go to the “DPF” screen. For normal operation this should be in “AUTO” mode.
Press the “ENTER” button.
This is password protected. Enter “1968”
This will set the unit up for manual regeneration; after a few moments, the regeneration icon should appear, confirming the unit is regenerating.
After completion, Set both STATION REGEN to “OFF” and DPF to unit to “AUTO” mode.
Atlas Copco recommends that the DPF configuration be left in the AUTO mode at all times; however, in the event that a stationary or manual regeneration is desired, the following process should be followed.

50. Committed to sustainable productivity.