Pts 1600 Cud S3at3 App

Instruction Manual
for Portable Compressors

English
PTS 1600 Cud S3A/T3 APP QSX15

PTS 1600 Cud S3A/T3 APP
Instruction Manual for
Portable Compressors
Instruction manual .................................................................................. 5
Circuit diagrams .................................................................................... 89
Original instructions
Printed matter N°
2954 7430 01 ATLAS COPCO - PORTABLE ENERGY DIVISION
12/2013 www.atlascopco.com
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 from modifications,
additions or conversions made without the manufacturer's approval in writing.
Neglecting maintenance or making changes to the setup of the machine can result in major
hazards, including fire risk.
While every effort has been made to ensure that the information in this manual is correct,
Atlas Copco does not assume responsibility for possible errors.
Copyright 2013, 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.
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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 3.3.9 Fuel tanks ..........................................20 5 Operating instructions ................32
portable compressors ................ 8 3.3.10 Control panel ....................................20 5.1 Before starting..................................32
3.3.11 Data plate ..........................................20
2 About this manual .................... 15 5.2 Operating ..........................................33
3.3.12 Automatic fire suppression
5.2.1 Starting..............................................33
2.1 Description of safety pictograms ...15 system ...............................................20
5.2.2 During operation ..............................33
2.2 Abbreviations ...................................15 3.4 Electrical features.............................21 5.2.3 Stopping............................................33
2.3 Definitions ........................................15 3.4.1 User Interface and
5.3 Setting the compressor
Compressor Control Module...........21
2.4 Directions..........................................15 control module .................................34
3.4.2 Indicator lamps.................................21
5.3.1 Control...............................................34
3 Main parts ................................. 16 3.4.3 Fuses .................................................22
5.3.2 Functionality .....................................35
3.1 General description .........................16 3.5 Operation flows................................23 5.3.3 A closer look at some
3.5.1 Air flow system.................................23 operating procedure blocks.............37
3.2 Markings ...........................................18
3.5.2 Cooling and lubricating oil system .25
3.3 Mechanical features.........................19 5.4 Operation via User Interface ...........40
3.5.3 Fuel system.......................................27
3.3.1 Engine ...............................................19 5.4.1 General..............................................40
3.5.4 Water system....................................29
3.3.2 Compressor ......................................19 5.4.2 Ready for Start status ......................40
3.3.3 Compressor elements......................19 4 Installation .................................30 5.4.3 Standby status..................................41
3.3.4 Cooling and lubrication ...................19 5.4.4 Permissive start status.....................41
4.1 Transporting and lifting...................30
3.3.5 Speed regulation and 5.4.5 Cranking status.................................42
4.1.1 Transporting .....................................30
unloading system.............................19 5.4.6 Warmup status .................................42
4.1.2 Lifting ................................................30
3.3.6 Safety devices ..................................19 5.4.7 Not Loaded status ............................44
4.2 Parking ..............................................31 5.4.8 Load/Unload status ..........................44
3.3.7 Frame and axles ...............................20
3.3.8 Bodywork..........................................20
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5.4.9 Cooldown status ..............................45 6.3.3 Compressor element 6.4.9 Servicing air inlet shut-down
5.4.10 Stopping status ................................46 overhaul ............................................60 valve ..................................................69
5.4.11 Start failure status............................46 6.4 Adjustment and servicing 6.4.10 Servicing water separator ...............69
5.4.12 Shutdown status ..............................47 procedures ........................................61 6.4.11 Servicing electric blow-off valve.....69
5.4.13 Emergency stop status ....................47 6.4.1 Coolant ..............................................61 6.4.12 Servicing automatic fire
5.4.14 System info status ...........................48 6.4.1.1 Coolant level check ..........................61 suppression system .........................69
5.4.15 Options status ..................................48 6.4.1.2 Adding coolant for units with 6.5 Engine consumable specifications .70
5.4.16 Process Info status ...........................49 optional preheater............................61 6.5.1 Engine fuel specifications................70
5.5 Operating the automatic fire 6.4.1.3 Testing coolant inhibitor level.........61 6.5.2 Engine oil specifications ..................70
suppression system.........................51 6.4.1.4 Replacing the coolant ......................62 6.5.3 Engine coolant specifications..........71
5.5.1 Main components ............................51 6.4.2 Air filter .............................................62
5.5.2 Operation ..........................................52 6.4.2.1 Main parts .........................................62 7 Checks and trouble
5.5.3 Control module ................................52 6.4.2.2 Cleaning the dust trap......................62 shooting .................................... 72
5.5.3.1 Indicators ..........................................52 6.4.2.3 Replacing the air filter 7.1 Problem solving chart......................72
5.5.3.2 Buttons..............................................53 element and the safety 7.2 Battery and alternator precautions 72
cartridge ............................................62
5.5.4 Daily check........................................53 7.3 Trouble shooting..............................73
6.4.2.4 Cleaning the filter element ..............63
6 Maintenance.............................. 54 6.4.3 Fuel system.......................................64 7.4 Compressor control module
6.4.3.1 Draining primary fuel filters ............64 trouble shooting...............................79
6.1 Maintenance schedule.....................54
7.4.1 Process information .........................79
6.1.1 Use of preventive 6.4.3.2 Priming the system ..........................64
7.4.2 Warnings...........................................79
maintenance schedule.....................57 6.4.3.3 Cleaning fuel tanks...........................65
6.4.4 Cleaning coolers...............................65 7.4.3 Shutdowns........................................80
6.1.2 Service paks and kits .......................57
6.2 Engine maintenance procedures....58 6.4.5 Poly V-belt tension adjustment .......66 8 Available options...................... 81
6.4.6 MP safety valve adjustment ............66
6.2.1 Engine oil level check ......................58 8.1 Preheater...........................................81
6.4.7 Checking intercooler relief valves...67
6.2.2 Engine oil and oil filter change ........59
6.4.8 Battery care.......................................67 8.2 Heating kit ........................................81
6.3 Compressor maintenance 8.3 Anti-frost device...............................81
6.4.8.1 Electrolyte .........................................67
procedures........................................59
6.4.8.2 Activating a dry-charged 8.4 Hot weather pack.............................82
6.3.1 Compressor oil level check .............59
battery ...............................................67
6.3.2 Compressor oil and oil filter 8.5 Cold climate fuel ..............................82
6.4.8.3 Recharging a battery........................68
change...............................................60
6.4.8.4 Maintaining the battery
voltage...............................................68
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9 Storage of the compressor ...... 82
9.1 Storage instructions ........................82
10 Disposal ..................................... 83
10.1 General..............................................83
10.2 Disposal of materials .......................83
11 Technical specifications ........... 84

11.1 Torque values...................................84
11.2 Settings of shutdowns and
safety valves.....................................84
11.3 Compressor/engine
specifications....................................85
11.4 Conversion list of SI units into
British units ......................................88
11.5 Dataplate ..........................................88
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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 Skill level 1: Operator In general it is recommended that not more than two
An operator is trained in all aspects of operating the unit people operate the unit, more operators could lead to
The policy of Atlas Copco is to provide the users of their unsafe operating conditions. Take necessary steps to
with the push-buttons, and is trained to know the safety
equipment with safe, reliable and efficient products. keep unauthorized persons away from the unit and
aspects.
Factors taken into account are among others: eliminate all possible sources of danger at the unit.
Skill level 2: Mechanical technician
- the intended and predictable future use of the When handling, operating, overhauling and/or
A mechanical technician is trained to operate the unit the
products, and the environments in which they are performing maintenance or repair on Atlas Copco
same as the operator. In addition, the mechanical
expected to operate, equipment, the mechanics are expected to use safe
technician is also trained to perform maintenance and
- applicable rules, codes and regulations, repair, as described in the instruction manual, and is engineering practices and to observe all relevant local
- the expected useful product life, assuming proper allowed to change settings of the control and safety safety requirements and ordinances. The following list is
service and maintenance, system. A mechanical technician does not work on live a reminder of special safety directives and precautions
electrical components. mainly applicable to Atlas Copco equipment.
- providing the manual with up-to-date information.
Skill level 3: Electrical technician These safety precautions apply to machinery processing
Before handling any product, take time to read the or consuming air. Processing of any other gas requires
An electrical technician is trained and has the same
relevant instruction manual. Besides giving detailed additional safety precautions typical to the application
qualifications as both the operator and the mechanical
operating instructions, it also gives specific information and are not included herein.
technician. In addition, the electrical technician may
about safety, preventive maintenance, etc.
carry out electrical repairs within the various enclosures Neglecting the safety precautions may endanger people
Keep the manual always at the unit location, easily
of the unit. This includes work on live electrical as well as environment and machinery:
accessible to the operating personnel.
components. - endanger people due to electrical, mechanical or
See also the safety precautions of the engine and
Skill level 4: Specialist from the manufacturer chemical influences,
possible other equipment, which are separately sent
along or are mentioned on the equipment or parts of the This is a skilled specialist sent by the manufacturer or its - endanger the environment due to leakage of oil,
unit. agent to perform complex repairs or modifications to the solvents or other substances,
equipment.
These safety precautions are general and some - endanger the machinery due to function failures.
statements will therefore not always apply to a particular All responsibility for any damage or injury resulting
unit. from neglecting these precautions or by non-observance
Only people that have the right skills should be allowed of ordinary caution and due care required in handling,
to operate, adjust, perform maintenance or repair on operating, maintenance or repair, also if not expressly
Atlas Copco equipment. It is the responsibility of mentioned in this instruction manual, is disclaimed by
management to appoint operators with the appropriate Atlas Copco.
training and skill for each category of job.
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The manufacturer does not accept any liability for any 4 Normal ratings (pressures, temperatures, speeds, 13 In the event the safety labels are damaged or
damage arising from the use of non-original parts and for etc.) shall be durably marked. destroyed, they must be replaced to ensure operator
modifications, additions or conversions made without 5 Operate the unit only for the intended purpose and safety.
the manufacturer’s approval in writing. within its rated limits (pressure, temperature, 14 Keep the work area neat. Lack of order will increase
If any statement in this manual does not comply with speeds, etc.). the risk of accidents.
local legislation, the stricter of the two shall be applied. 6 The machinery and equipment shall be kept clean, 14 When working on the unit, wear safety clothing.
Statements in these safety precautions should not be i.e. as free as possible from oil, dust or other Depending on the kind of activities these are: safety
interpreted as suggestions, recommendations or deposits. glasses, ear protection, safety helmet (including
inducements that it should be used in violation of any 7 To prevent an increase in working temperature, visor), safety gloves, protective clothing, safety
applicable laws or regulations. inspect and clean heat transfer surfaces (cooler fins, shoes. Do not wear the hair long and loose (protect
intercoolers, water jackets, etc.) regularly. See the long hair with a hairnet), or wear loose clothing or
1.2 General safety precautions maintenance schedule. jewellery.
1 The owner is responsible for maintaining the unit in 8 All regulating and safety devices shall be 15 Take precautions against fire. Handle fuel, oil and
a safe operating condition. Unit parts and maintained with due care to ensure that they anti-freeze with care because they are inflammable
accessories must be replaced if missing or function properly. They may not be put out of substances. Do not smoke or approach with naked
unsuitable for safe operation. action. flame when handling such substances. Keep a fire-
2 The supervisor, or the responsible person, shall at extinguisher in the vicinity.
9 Care shall be taken to avoid damage to safety valves
all times make sure that all instructions regarding and other pressure-relief devices, especially to
machinery and equipment operation and avoid plugging by paint, oil coke or dirt
maintenance are strictly followed and that the accumulation, which could interfere with the
machines with all accessories and safety devices, as functioning of the device.
well as the consuming devices, are in good repair,
free of abnormal wear or abuse, and are not 10 Pressure and temperature gauges shall be checked
tampered with. regularly with regard to their accuracy. They shall
be replaced whenever outside acceptable tolerances.
3 Whenever there is an indication or any suspicion
that an internal part of a machine is overheated, the 11 Safety devices shall be tested as described in the
machine shall be stopped but no inspection covers maintenance schedule of the instruction manual to
shall be opened before sufficient cooling time has determine that they are in good operating condition.
elapsed; this to avoid the risk of spontaneous 12 Mind the markings and information labels on the
ignition of oil vapour when air is admitted. unit.
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1.3 Safety during transport and 2 To tow a unit use a towing vehicle of ample 10 Never leave a load hanging on a hoist.
capacity. Refer to the documentation of the towing 11 A hoist has to be installed in such a way that the
installation vehicle. object will be lifted perpendicular. If that is not
To lift a unit, all loose or pivoting parts, e.g. doors and 3 If the unit is to be backed up by the towing vehicle, possible, the necessary precautions must be taken to
towbar, shall first be securely fastened. disengage the overrun brake mechanism (if it is not prevent load-swinging, e.g. by using two hoists,
Do not attach cables, chains or ropes directly to the an automatic mechanism). each at approximately the same angle not exceeding
lifting eye; apply a crane hook or lifting shackle meeting 4 In case of transporting a non-trailer unit on a truck, 30° from the vertical.
local safety regulations. Never allow sharp bends in fasten it to the truck by attaching straps via fork lift 12 Locate the unit away from walls. Take all
lifting cables, chains or ropes. holes, via the holes in the frame at the front and precautions to ensure that hot air exhausted from the
Helicopter lifting is not allowed. back or via the lifting beam. To prevent damage, engine and driven machine cooling systems cannot
It is strictly forbidden to dwell or stay in the risk zone never put straps on the roof surface of the unit. be recirculated. If such hot air is taken in by the
under a lifted load. Never lift the unit over people or 5 Never exceed the maximum towing speed of the engine or driven machine cooling fan, this may
residential areas. Lifting acceleration and retardation unit (mind the local regulations). cause overheating of the unit; if taken in for
shall be kept within safe limits. combustion, the engine power will be reduced.
6 Place the unit on level ground and apply the parking
1 Before towing the unit: brake before disconnecting the unit from the towing
- ascertain that the pressure vessel(s) is (are) vehicle. Unclip the safety break-away cable or
depressurized, safety chain. If the unit has no parking brake or
- check the towbar, the brake system and the jockey wheel, immobilize the unit by placing
towing eye. Also check the coupling of the chocks in front of and/or behind the wheels. When
towing vehicle, the towbar can be positioned vertically, the locking
- check the towing and brake capability of the device must be applied and kept in good order.
towing vehicle,
7 To lift heavy parts, a hoist of ample capacity, tested
- check that the towbar, jockey wheel or stand leg
and approved according to local safety regulations,
is safely locked in the raised position,
shall be used.
- ascertain that the towing eye can swivel freely on
the hook, 8 Lifting hooks, eyes, shackles, etc., shall never be
- check that the wheels are secure and that the bent and shall only have stress in line with their
tyres are in good condition and inflated correctly, design load axis. The capacity of a lifting device
- connect the signalisation cable, check all lights diminishes when the lifting force is applied at an
and connect the pneumatic brake couplers, angle to its load axis.
- attach the safety break-away cable or safety 9 For maximum safety and efficiency of the lifting
chain to the towing vehicle, apparatus all lifting members shall be applied as
- remove wheel chocks, if applied, and disengage near to perpendicular as possible. If required, a
the parking brake. lifting beam shall be applied between hoist and
load.
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1.4 Safety during use and 7 Never move a unit when external lines or hoses are 14 All doors shall be shut during operation so as not to
connected to the outlet valves, to avoid damage to disturb the cooling air flow inside the bodywork
operation valves, manifold and hoses. and/or render the silencing less effective. A door
1 When the unit has to operate in a fire-hazardous 8 Do not use compressed air from any type of should be kept open for a short period only e.g. for
environment, each engine exhaust has to be compressor, without taking extra measures, for inspection or adjustment.
provided with a spark arrestor to trap incendiary breathing purposes as this may result in injury or 15 Periodically carry out maintenance works according
sparks. death. For breathing air quality, the compressed air to the maintenance schedule.
2 The exhaust contains carbon monoxide which is a must be adequately purified according to local 16 Stationary housing guards are provided on all
lethal gas. When the unit is used in a confined legislation and standards. Breathing air must always rotating or reciprocating parts not otherwise
space, conduct the engine exhaust to the outside be supplied at stable, suitable pressure. protected and which may be hazardous to
atmosphere by a pipe of sufficient diameter; do this 9 Distribution pipework and air hoses must be of personnel. Machinery shall never be put into
in such a way that no extra back pressure is created correct diameter and suitable for the working operation, when such guards have been removed,
for the engine. If necessary, install an extractor. pressure. Never use frayed, damaged or deteriorated before the guards are securely reinstalled.
Observe any existing local regulations. Make sure hoses. Replace hoses and flexibles before the 17 Noise, even at reasonable levels, can cause irritation
that the unit has sufficient air intake for operation. If lifetime expires. Use only the correct type and size and disturbance which, over a long period of time,
necessary, install extra air intake ducts. of hose end fittings and connections. may cause severe injuries to the nervous system of
3 When operating in a dust-laden atmosphere, place 10 If the compressor is to be used for sand-blasting or human beings.
the unit so that dust is not carried towards it by the will be connected to a common compressed-air When the sound pressure level, at any point where
wind. Operation in clean surroundings considerably system, fit an appropriate non-return valve (check personnel normally has to attend, is:
extends the intervals for cleaning the air intake valve) between compressor outlet and the connected - below 70 dB(A): no action needs to be taken,
filters and the cores of the coolers. sand-blasting or compressed-air system. Observe - above 70 dB(A): noise-protective devices should
4 Close the compressor air outlet valve before the right mounting position/direction. be provided for people continuously being
connecting or disconnecting a hose. Ascertain that a 11 Before removing the oil filler plug, ensure that the present in the room,
hose is fully depressurized before disconnecting it. pressure is released by opening an air outlet valve. - below 85 dB(A): no action needs to be taken for
Before blowing compressed air through a hose or occasional visitors staying a limited time only,
12 Never remove a filler cap of the coolant system of a - above 85 dB(A): room to be classified as a noise-
air line, ensure that the open end is held securely, so
hot engine. Wait until the engine has sufficiently hazardous area and an obvious warning shall be
that it cannot whip and cause injury.
cooled down. placed permanently at each entrance to alert
5 The air line end connected to the outlet valve must
13 Never refill fuel while the unit is running, unless people entering the room, for even relatively
be safeguarded with a safety cable, attached next to
otherwise stated in the Atlas Copco Instruction short times, about the need to wear ear
the valve.
Book (AIB). Keep fuel away from hot parts such as protectors,
6 No external force may be exerted on the air outlet air outlet pipes or the engine exhaust. Do not smoke - above 95 dB(A): the warning(s) at the
valves, e.g. by pulling on hoses or by installing when fuelling. When fuelling from an automatic entrance(s) shall be completed with the
auxiliary equipment directly to a valve, e.g. a water pump, an earthing cable should be connected to the recommendation that also occasional visitors
separator, a lubricator, etc. Do not step on the air unit to discharge static electricity. Never spill nor shall wear ear protectors,
outlet valves. leave oil, fuel, coolant or cleansing agent in or
around the unit.
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- above 105 dB(A): special ear protectors that are 22 When washing parts in or with a cleaning solvent, 1.5 Safety during maintenance
adequate for this noise level and the spectral provide the required ventilation and use appropriate
composition of the noise shall be provided and a protection such as a breathing filter, safety glasses, and repair
special warning to that effect shall be placed at rubber apron and gloves, etc. Maintenance, overhaul and repair work shall only be
each entrance. 23 Safety shoes should be compulsory in any carried out by adequately trained personnel; if required,
18 The unit has parts of which the temperature can be workshop and if there is a risk, however small, of under supervision of someone qualified for the job.
in exess of 80 °C (176 °F), and which may be falling objects, wearing of a safety helmet should be 1 Use only the correct tools for maintenance and
accidentally touched by personnel when opening included. repair work, and only tools which are in good
the machine during or just after operation. 24 If there is a risk of inhaling hazardous gases, fumes condition.
Insulation or safety guards protecting these parts or dust, the respiratory organs must be protected and 2 Parts shall only be replaced by genuine Atlas Copco
shall not be removed before the parts have cooled depending on the nature of the hazard, so must the replacement parts.
down sufficiently, and must be re-installed before eyes and skin.
operating the machine. As it is not possible to 3 All maintenance work, other than routine attention,
insulate or protect all hot parts by guards (e.g. 25 Remember that where there is visible dust, the finer, shall only be undertaken when the unit is stopped.
exhaust manifold, exhaust turbine), the operator / invisible particles will almost certainly be present Steps shall be taken to prevent inadvertent starting.
service engineer must always be aware not to touch too; but the fact that no dust can be seen is not a In addition, a warning sign bearing a legend such as
hot parts when opening a machine door. reliable indication that dangerous, invisible dust is “work in progress; do not start” shall be attached to
not present in the air. the starting equipment.
19 Never operate the unit in surroundings where there
26 Never operate the unit at pressures or speeds below On engine-driven units the battery shall be
is a possibility of taking in flammable or toxic
or in excess of its limits as indicated in the technical disconnected and removed or the terminals covered
fumes.
specifications. by insulating caps.
20 If the working process produces fumes, dust or On electrically driven units the main switch shall be
vibration hazards, etc., take the necessary steps to 27 When operating the compressor in Remote or Auto
locked in open position and the fuses shall be taken
eliminate the risk of personnel injury. mode, observe all relevant local legislation.
out. A warning sign bearing a legend such as “work
21 When using compressed air or inert gas to clean in progress; do not supply voltage” shall be attached
down equipment, do so with caution and use the to the fuse box or main switch.
appropriate protection, at least safety glasses, for 4 Before dismantling any pressurized component, the
the operator as well as for any bystander. Do not compressor or equipment shall be effectively
apply compressed air or inert gas to your skin or isolated from all sources of pressure and the entire
direct an air or gas stream at people. Never use it to system shall be relieved of pressure. Do not rely on
clean dirt from your clothes. non-return 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 attached to each of the outlet valves.
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5 Prior to stripping an engine or other machine or 14 Use only lubricating oils and greases recommended 20 When hot parts have to be handled, e.g. shrink
undertaking major overhaul on it, prevent all or approved by Atlas Copco or the machine fitting, special heat-resistant gloves shall be used
movable parts from rolling over or moving. manufacturer. Ascertain that the selected lubricants and, if required, other body protection shall be
6 Make sure that no tools, loose parts or rags are left comply with all applicable safety regulations, applied.
in or on the machine. Never leave rags or loose especially with regard to explosion or fire-risk and 21 When using cartridge type breathing filter
clothing near the engine air intake. the possibility of decomposition or generation of equipment, ascertain that the correct type of
hazardous gases. Never mix synthetic with mineral cartridge is used and that its useful service life is not
7 Never use flammable solvents for cleaning (fire- oil.
risk). surpassed.
15 Protect the engine, alternator, air intake filter, 22 Make sure that oil, solvents and other substances
8 Take safety precautions against toxic vapours of electrical and regulating components, etc., to
cleaning liquids. likely to pollute the environment are properly
prevent moisture ingress, e.g. when steam-cleaning. disposed of.
9 Never use machine parts as a climbing aid. 16 When performing any operation involving heat, 23 Before clearing the unit for use after maintenance or
10 Observe scrupulous cleanliness during maintenance flames or sparks on a machine, the surrounding overhaul, check that operating pressures,
and repair. Keep away dirt, cover the parts and components shall first be screened with non- temperatures and speeds are correct and that the
exposed openings with a clean cloth, paper or tape. flammable material. control and shutdown devices function correctly.
11 Never weld on or perform any operation involving 17 Never use a light source with open flame for
heat near the fuel or oil systems. Fuel and oil tanks inspecting the interior of a machine.
must be completely purged, e.g. by steam-cleaning, 18 When repair has been completed, the machine shall
before carrying out such operations. Never weld on, be barred over at least one revolution for
or in any way modify, pressure vessels. Disconnect reciprocating machines, several revolutions for
the alternator cables during arc welding on the unit. rotary ones to ensure that there is no mechanical
12 Support the towbar and the axle(s) securely if interference within the machine or driver. Check the
working underneath the unit or when removing a direction of rotation of electric motors when starting
wheel. Do not rely on jacks. up the machine initially and after any alteration to
13 Do not remove any of, or tamper with, the sound- the electrical connection(s) or switch gear, to check
damping material. Keep the material free of dirt and that the oil pump and the fan function properly.
liquids such as fuel, oil and cleansing agents. If any 19 Maintenance and repair work should be recorded in
sound-damping material is damaged, replace it to an operator’s logbook for all machinery. Frequency
prevent the sound pressure level from increasing. and nature of repairs can reveal unsafe conditions.
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1.6 Tool applications safety 4 When connecting an auxiliary battery (AB) in
parallel to the unit battery (CB) with booster cables:
Apply the proper tool for each job. With the knowledge connect the + pole of AB to the + pole of CB, then
of correct tool use and knowing the limitations of tools, connect the - pole of CB to the mass of the unit.
along with some common sense, many accidents can be Disconnect in the reverse order.
prevented.
Special service tools are available for specific jobs and
should be used when recommended. The use of these Piping and coolers
tools will save time and prevent damage to parts. (according to directive 97/23)
1.7 Specific safety precautions Safety valves

Batteries All adjustments or repairs are to be done by an
When servicing batteries, always wear protecting authorized representative of the valve supplier (see
clothing and glasses. “Maintenance schedule”).
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.
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2 About this manual
2.1 Description of safety 2.3 Definitions ECM Engine Control Module. This is the
pictograms basic engine control module used by
Control panel This is the panel on the unit where
DDC for the engine controls
the User Interface, power switch,
This symbol draws your attention to (emissions, safeties, fuel injection,
DDR connector, PC connector,
! dangerous situations. The operation
concerned may endanger persons
remote control connector, heater
switch, light switch and pressure CCM
...).
Compressor Control Module. This
and cause injuries. setpoint buttons are situated. module is linked with the ECM and
is used for speed regulation and for
Technician AC personnel allowed to change
This symbol is followed by the compressor controls (unloading
settings of the control and safety
supplementary information. system, safeties, ...). It can be
system.
operated via PC or User Interface.
2.2 Abbreviations Operator AC personnel or user allowed to
User Interface Max. working pressure setpoint
operate the compressor unit with the
AC Atlas Copco setpoint calibrated in the CCM.
push-buttons.
At this max. setpoint the engine
AIB Atlas Copco Instruction Book
Load Operating condition with inlet speed will be regulated between
ASB Service Bulletin
compressor open and engine speed max. and min. speed when running in
ASL Atlas Copco List manual or automatic operation.
regulated between minimum and
CAC Charge Air Cooler maximum.
CAN Controller Area Network Interface
CCM Compressor Control Module Not loaded Operating condition with inlet 2.4 Directions
compressor forced to closed position
DDR Diagnostic Data Reader The driving direction has always been originated
by operator command. The engine
ECM Engine Control Module with, when the sides of the unit are denoted. E.g. the
speed is held at minimum.
EOM Engine Operation Manual towbar is at the front and the User Interface is at the
LP Low-pressure Unload Operating condition with inlet rear right-hand side of the unit.
MAX Maximum compressor forced to closed position
by working pressure command. The
MIN Minimum
engine speed is held at minimum.
MP Medium-pressure
PAR Portable Energy Division DDR Diagnostic Data Reader. This is a
PC Personal Computer tool that can be connected to the
RPM Revolves Per Minute ECM to read and calibrate engine
parameters.
UI User Interface
- 15 -
3 Main parts
3.1 General description
The PTS 1600 Cud is a portable, two-stage screw compressor unit, which delivers oil-free air. The PTS 1600 Cud is built for a nominal effective working pressure of 0.5-
10.3 bar (7-150 psi) at 1650 rpm, 0.5-9.3 bar (7-135 psi) at 1750 rpm and 0.5-6.9 bar (7-100 psi) at 1850 rpm. An overview of the main parts is given in the diagram below.
AL Alarm lamp
AOV Air outlet valve
BH Brake handle
CP Control panel
EP Exhaust pipe
ES Emergency stop
FCF Filler cap fuel
IL Indicator lamps
TB Towbar
- 16 -
AC1 Aftercooler 1
AC2 Aftercooler 2
AFC Air intake filter (compressor)
AFE Air intake filter (engine)
B Battery
BS Battery Switch
CAC Charge air cooler
CELP LP compressor element
CEMP MP compressor element
E Engine
EP Exhaust pipe
F1 Cooling fan 1
F2 Cooling fan 2
FCW Filler cap cooling water
FC Fuel cooler
FFPC Primary coarse fuel filter / Water separator
FT Fuel tank
GC Gear casing
IC Intercooler
IH Air inlet housing (compressor)
M Muffler
MSA Muffler (Integrated Spark Arrestor)
OC Oil cooler
OFC Oil filters (compressor)
OFE Oil filter (engine)
PH Pre-heater (optional)
RAD Radiator
VI Vacuum indicator
WS Water separator
- 17 -
3.2 Markings
A brief description of all markings provided on the
compressor is given hereafter. Rotation direction Use diesel fuel only
Dangerous outlet
Inlet Sound power level in accordance
with Directive 84/533/EC
(expressed in dB (A))
Danger, heat flat
Outlet
Electrocution hazard
Compressor oil drain
Atlas Copco engine oil Read the instruction manual

before starting
Manual
Service every 24 hours
Read the instruction manual

before working on the battery Warning!
Part under pressure
On/Off button
Do not stand on outlet valves
Prohibition to open air valves

without connected hoses Start/Stop indication of switch
Airfilter Do not run the motor with open

doors
- 18 -
3.3 Mechanical features
3.3.1 Engine The male rotors have four lobes and the female rotors Water condensate from the water separator is drained
six flutes. Thus, the male rotors revolve at 1 1/2 times through a nipple in the bottom of the frame in the back
The compressor is driven by a liquid-cooled diesel
the speed of the female rotors. The absence of contact of the unit.
engine, manufactured by Cummins. This engine has
the following characteristics: direct fuel injection, between the rotors and between the rotor crests and Oil is used for jacket-cooling of the compressor
the compressor casings eliminates wear and power elements, as well as for lubricating the rotor bearings,
electronic unit injection that is mechanically actuated,
loss. The elements deliver pulsation-free air. timing and drive gears. The system includes an oil
turbocharged, and air-to-air aftercooled.
For general description, see Engine Operation Air and oil sealing rings are fitted on the rotor shafts. pump and an oil filter.
The air seals are located next to the compression
Manual (EOM).
space, the oil seals next to the rotor bearings. The leak 3.3.5 Speed regulation and unloading
3.3.2 Compressor air from the air seals is evacuated to the atmosphere system
through vent-holes. Any oil that might gather
The compressor has one low-pressure and one The regulation of the unit is governed by the Engine
between the oil and air seals is prevented from
medium-pressure compressor element, individually Controle Module (ECM) and the Compressor Control
entering the compression space, as it is drained Module (CCM), which will vary engine speed and
bolted to the housing of a common step up gear. The through the same vent holes.
step up gear is bolted directly to the engine flywheel operate the compressor throttle valve and unloading
housing. The power from the engine is transmitted to valve through a 3-way loading valve.
3.3.4 Cooling and lubrication
the step up gear shaft through a flexible coupling.
The radiator, intercoolers, aftercooler and oil cooler 3.3.6 Safety devices
are installed side by side in the front of the unit. These
3.3.3 Compressor elements Two relief valves and a MP safety valve protect the
coolers are air-cooled by an axial fan, which is belt- LP and MP sides of the compressor respectively.
Each compressor element houses two screw-type driven from the compressor main-shaft.
rotors, mounted on ball and roller bearings. The male A check valve prevents blow-back of compressed air
The unit is provided with a second aftercooler, with
rotor, driven by the step up gear, and the female rotor when the compressor is unloaded or stopped.
are synchronized through timing gears, which water separator, CAC (= charge air cooler) / fuel
cooler placed in the back of the unit. The cooling air Pressure and thermal shutdown switches protect the
maintain the slight clearance between the rotors. compressor against abnormal operating conditions.
is generated by an axial fan, which is belt-driven from
the engine fan shaft.
- 19 -
3.3.7 Frame and axles 3.3.12 Automatic fire suppression
system To avoid battery drainage during
The compressor/engine unit is supported on a frame
long-term storage, please disconnect
which also carries the compressor cooling block. The PTS 1600 is fitted with an automatic fire
the batteries and remove the
The front axle is provided with a steering gear and a suppression system. This installation will respond internal battery from the Ansul
hinged towbar with towing eye. The towbar can be automatically to a fire in the engine compartment by
controller. After restoring the power
locked in the raised position. switching of the engine and spreading extinguishing
supply, push the reset button to
powder throughout the engine compartment. reactivate the system.
The unit is equipped with a parking brake, operated
by a handle close to the towbar. In case of an extinguishing powder release by the fire
suppression system, please be carefull when opening
3.3.8 Bodywork the doors of the compressor. Although this fire
suppression system is designed and tested to
The bodywork has openings for the intake, cooling
extinguish most common compressor fires, there is
and exhaust air and specially hinged doors for
always a chance that not all flames are extinguished.
maintenance and service operations. The bodywork is
internally lined with sound-absorbing material. The After activation of the system always contact Atlas
air outlet valves are in the frame, at the back. Copco immediately to investigate and repair the
machine.
3.3.9 Fuel tanks For more detailed information on the Automatic fire
The unit has two interconnected fuel tanks, but can suppression system, refer to “Operating the automatic
also be connected to an external fuel tank. fire suppression system” on page 51.
3.3.10 Control panel Repairs and maintenance must be

The control panel is located behind a small door at the
rear right-hand side of the unit.
! done by authorized personnel only.
Please contact Atlas Copco if the
fire suppression system shows any
3.3.11 Data plate irregularities.
Disconnecting the system from the
The compressor is furnished with a data plate compressor batteries will result in a
showing among others type, serial number and
battery and detection fault.
nominal working pressure.
- 20 -
3.4 Electrical features 3.4.2 Indicator lamps
1
The electrical features described in this chapter are 7
standard provided on this compressor.
3.4.1 User Interface and Compressor 8

2
6
Control Module 3
General description of the User Interface

The User Interface consists of a color LCD display
which gives the user the essential process information
feedback. 5 4
Any mix-up of buttons and button functions is

reduced to an absolute minimum thanks to an 1 Running hours and warning bar. When warnings
occur, they swap with the running hours on this
ergonomic design, which has as few buttons as
bar, showing the next message every 3 seconds.
possible.
2 Setpressure bar
3 Additional information bar
4 Compressor status bar
5 Button function bar
1079 9932 09
STOP
6 Air discharge pressure and shutdown information !
bar
7 Fuel bar 1 2 3 4
8 This is what the fuel level bar would look like if
you hook up external fuel supply.
1 Stop lamp
The User Interface is built in into the side of the rear 2 Warning lamp
right corner panel, with an emergency stop button 3 Maintenance lamp
directly underneath, for maximum safety during the 4 Wait-to-Start lamp
cranking procedure.
- 21 -
3.4.2.1 Stop lamp 3.4.2.4 Wait-to-Start Lamp 3.4.3 Fuses
The Stop lamp (1) provides critical operator messages. The Wait-to-Start lamp (4) indicates that the pre-start
These messages require immediate and decisive operator intake manifold heater warm-up sequence is active. An
response. The Stop lamp is also used to flash out OEM-supplied grid heater will automatically heat the
Diagnostics fault codes. intake manifold when needed prior to engine starting.
This lamp is used by the following features: Intake manifold heating improves engine starting in cold
temperatures and reduces white smoke. The operator
– Diagnostic Fault Code Flashout
should delay engine starting until after the lamp has
– Engine Protection extinguished.
This lamp is used by the following feature:
3.4.2.2 Warning lamp
– Air Intake (Grid) Heaters
The Warning lamp (2) provides important operator
messages. These messages require timely operator
attention. The Warning lamp is also used to delineate
Diagnostics fault codes.
3.4.2.3 Maintenance Lamp

The Maintenance lamp (3) indicates that routine engine 1
maintenance should be performed. 2
3
The lamp is used by the following features.
4
– Maintenance Monitor
– Real Time Clock (RTC) The Compressor Control Module (CCM) is equipped
with the following four fuses:
1 Fuse ECM: 20 A
2 Fuse CCM: 20 A
3 Fuse UI: 10 A
4 Overspeed shutdown: 3 A
- 22 -
3.5 Operation flows
3.5.1 Air flow system An air-operated balancing piston is fitted behind the
male rotor rear thrust bearing of MP compressor
Description element. The piston decreases the load on the male
Air drawn through the air intake filters (AFC), and rotor front thrust bearing during loaded operation.
unloader (UA) into LP compressor element (CELP) is During loading the MP compressor element
compressed and discharged to the intercooler (IC) balancing piston is actuated by working pressure,
where the heat of first-stage compression is removed while during unloading the pressure on the piston
by the cooling air flow. equals the atmospheric pressure.
The cooled air then enters MP compressor element Two intercooler relief valves (RV), an electric blow-
(CEMP) where it is further compressed and off valve (BOV) and a MP safety valve (SV) are
discharged through check valve (CV), aftercooler 1 comprised in the system.
(AC1), aftercooler 2 (AC2) and water separator (WS)
to air outlet valves (AOV).
During loaded operation air inlet throttle valve (TV)
is open and unloading valve (UV) closed. These
valves are simultaneously closed and opened
respectively by loading solenoid valve (LSV) through
unloader piston (UP) when the working pressure
reaches its preset maximum. The pressure of the MP
compressor element is then released to the
atmosphere through the unloading valve and the
blow-off silencers (BOS), resulting in closing of the
check valve. The throttle valve leaves an air passage
in the closed position. Thus air remains drawn into the
compressor to maintain a reasonable pressure ratio
over the elements.
- 23 -
Overview
AC1 Aftercooler 1
AC2 Aftercooler 2
VI
TV AFC Air intake filter (compressor)
Engine LSV C1
sensor C2 UP
BOS Blow-off silencer
Compressor
inputs Unloaded UV
UA BOV Blow-off valve
AFC
SC
VV BV By-pass valve
C1 Chamber (unloader assembly)
BOS C2 Chamber (unloader assembly)
ECM
M D
CEMP MP compressor element
CELP
S CV Check valve
Data ON Setpoint S
link OFF RPM D Diaphragm (unloader assembly)
CEMP CV
Throttle AOV IC Intercooler
valve
Compressor signal
LSV Loading solenoid valve
Compressor WS RV
sensor CCM outputs M Membrane (unloader assembly)
inputs
RV Intercooler relief valve
AC2 SV
S Air outlet silencer (compressor element)
BOV
AC1
IC
SC Safety cartridge
SV MP safety valve
CAN bus TV Throttle valve (unloader assembly)
VI UA Unloader assembly
TV
UP Unloader piston (unloader assembly)
LSV C1 UV Unloading valve (unloader assembly)
CAN card
C2 UP
UV
VI Vacuum indicator
UA AFC VV Vacuator valve (dust ejector)
User Compressor SC VV
PC
Interface Loaded
WS Water separator
Push-buttons BOS
PC on UI Remote
control control M D
inputs CELP
S
User S
CEMP
CV
- 24 -
3.5.2 Cooling and lubricating oil system
Description
Oil from the oil sump (OS) of gear casing (GC) is Bypass valve (BVOC) opens when the pressure rise
circulated by an oil pump (OP), mounted on the front over the oil cooler is above normal. This will happen
of the gear casing. The pump is driven from the main mainly when starting the compressor from cold in low
drive shaft. The oil is pumped to the cooling jacket of ambient temperatures. The bypassing of the oil cooler
the MP compressor element (CEMP) and to the will ensure rapid warming of the oil to the normal
cooling jacket of the LP compressor element (CELP) working temperature.
and from there through the air-cooled oil cooler (OC). A pressure shutdown sensor and a temperature
From the LP element cooling jacket the oil passes reading sensor (TS) are comprised in the system.
through oil filter (OFC) on gear casing before entering
the LP and MP element oil pipes and ducts to
lubricate the rotor bearings, driving and timing gears.
The oil then flows back to the oil sump.
The gear casing is vented to the atmosphere through a
breather pot assembly.
The bypass valve (BVOF) of the oil filter opens when
the pressure drop over the filter is above normal due
to clogging of the element. The oil is then circulated
without being filtered. For this reason, it is imperative
to replace the oil filter at regular intervals.
Bypass valve (BVOS) opens when the pressure drop
over the filter and lubricating circuit is above normal.
The oil is then returned to the oil sump.
- 25 -
Overview
BVOC Bypass valve (oil cooler)
LUBRICATING BVOF Bypass valve (oil filter)
CIRCUIT BVOS Bypass valve (oil sump)
OGLP CEMP MP compressor element
CELP CEMP
DPOC Drain plug (oil cooler)
DPOS Drain plug (oil sump)
OGMP F1 Cooling fan 1 (RAD, IC, AC1, OC)
GC Gear casing
OC Oil cooler
OFC Compressor oil filter (with bypass valve)
OGLP Oil gallery (LP compressor element)
GC OGMP Oil gallery (MP compressor element)
DPOS OS OP Oil pump
OS Oil sump
TS Temperature sensor
CELP CEMP
OC
BVOF
OFC
GC
OS F1
DPOS t TS
DPOC
OP BVOS
COOLING CIRCUIT BVOC
- 26 -
3.5.3 Fuel system
Description
The unit must be stopped before
In case of internal fuel supply, fuel from the fuel tanks
(FT) is circulated by the engine fuel pump (FPE). The
! switching from the internal to an
external fuel source.
fuel is pumped through a 3-way valve (TWV) to two
primary coarse fuel filters (FFPC). When using external fuel, both the supply and the
The fuel then passes through the secondary fuel filters return hose must be connected to the external fuel
(FFSE) and enters the engine (E). supply couplings (EFC).
No restrictions are allowed in those hoses.
The fuel, which is not used by the engine to combust,
Take the necessary precautions to keep the fuel return
returns via the air-cooled fuel cooler (FC) and the 3-
hose opened and connected, while the unit is running.
way valve to the fuel tanks.
Check that the primary fuel filters are not both shut
Normally the primary fuel filters are in parallel. By off.
means of the fuel shut-off cock (FSC), seated on the
Restart the unit.
housing of the filters, one of the filters can be shut off
when it has to be serviced. This can even be done
while the engine is running.
Do not put the fuel shut-off cock in

! the lowered position (the handle
pointer points up) when the engine
is running, because both filters will
be shut off and no fuel will flow to
the engine.
An electrical priming pump (EPP) is comprised in the

system to fill up filters and fuellines after
maintenance and servicing. A description of this
procedure can be found on page 64.
Instead of internal fuel supply via the fuel tanks,
external fuel supply is possible.
- 27 -
Overview
BPV Bypass valve
CFT Filler cap (fuel tank)
CV Check valve
E Engine
EFC External fuel supply coupling
F2 Cooling fan 2 (AC2, CAC/FC)
FC Fuel cooler
FFPC Primary coarse fuel filter / water separator
FFSE Secondary engine fuel filter
FPE Engine fuel pump
FSC Fuel shut-off cock
FT Fuel tank
TWV 3-way valve
VL Venting line
fuel selector in
horizontal position
(internal)
fuel selector in
vertical position
(external)
- 28 -
3.5.4 Water system
Overview
E Engine
RADIATOR F1 Cooling fan 1 (RAD, IC, AC1, OC)
RAD Radiator
TT TTRAD Top tank (radiator)
WPE Engine water pump (radiator)
Description
The water system contains a coolant flow to cool the
engine’s cylinders.
The coolant is circulated by the engine water pump
WP (WPE), seated on the back of the engine (E). When the
coolant returns from the engine, it passes through the
radiator (RAD), which is air-cooled by the cooler fan
(F1).
The radiator top tank (TTRAD) supplies the coolant to
the system and gives the coolant in the system room to
expand.
- 29 -
4 Installation
The operator is expected to apply all 4.1.2 Lifting
! relevant safety precautions,
including those mentioned on
To lift the unit, use a lift truck or crane with sufficient
capacity (wet weight of unit is 8560 kg (18875 lbs)).
pages 7-10 of this book. 1 Use the lifting positions of the unit as shown in the
figure below.
4.1 Transporting and lifting See to it that the unit will be lifted vertically and
remains level.
4.1.1 Transporting Lifting acceleration and retardation
Road transport is only allowed on a trailer, with
sufficient capacity (wet weight of unit is 8560 kg
! must be kept within safe limits (max.
4g).
(18875 lbs)). Helicopter lifting is not allowed.
Before towing the unit on the trailer, block the towbar
by locking the blocking device (1) in downward
position. The blocking device has to be pulled up first,
before it can be turned over. – Leave the towbar in blocked position on the trailer
and secure the unit (see section 4.2).
! Release brake before towing. – Lock blockage device in upward position when
unit is manoeuvred to its working location.
– Lock all service doors.
- 30 -
4.2 Parking
– Locate the wind direction and place the rear end of – Place wheel chocks in front of and behind the – Lock the towbar (2) in the raised position with
the unit upwind, away from contaminated wind wheels before the unit is disconnected from the catcher (3).
streams and walls. Avoid recirculation of exhaust towing or lifting vehicle.
air from the engine. This causes overheating and
engine power decrease.
1
– Park the unit on solid level ground.
– Engage the parking brake by pulling parking
brake handle (1).
3
- 31 -
5 Operating instructions
5.1 Before starting – Move the power switch on the control panel (CP)
to the ON position and read the fuel level on the Make sure that nobody is in the unit
– With the unit standing level, check the engine and
compressor oil levels (see section 6.2.1 and 6.3.1).
display. Top up the fuel tanks (FT), if necessary.
Consult the Engine Operation Manual for the type
! and all doors are closed prior to
starting the unit.
Add oil if necessary. See section 6.5 for the types of fuel. Move the control panel power switch to
of oil to be used. In cold ambient conditions
OFF again after filling.
Normally, there is no need to add oil between two (temperature below -5°C (23°F)),
oil changes; if there is, check the source of oil – Check the level of the coolant in the engine the engine must be preheated before
comsumption. radiator (RAD). See section 6.4.1.1. Add coolant starting.
if necessary. Consult the Engine Operation In auto mode, connect the engine
– Attach the air line(s) to the closed air outlet Manual for the coolant solutions to be used. and compressor block heater and
valve(s) (AOV).
– Press the vacuator valves of the air filters (AFC the battery charger to the 220 Volt/
The air line end connected to the and AFE) to remove dust. See section 6.4.2.2. 110 Volt receptacle.
! outlet valve must be safeguarded

with a safety cable, attached next to
– Check the air filter vacuum indicators (VI). If the
yellow piston reaches the red marked service
the valve. range (see section 6.4.2.3), clean or replace the
No external force may be applied to filter elements (see sections 6.4.2.3 and 6.4.2.4).
the air outlet valves, e.g. by pulling Reset the indicator by pushing the reset button.
hoses or by connecting equipment
directly to the valves (e.g. a water – Check the electrolyte level in the batteries (B).
separator, a lubricator, pipe Top up if necessary, with distilled water (see
extensions, etc.). section 6.4.8.1).
– Put the fuel shut-off cock, which is seated on the
– Select fuel source (internal/external) and lock the primary fuel filter housing in the back of the unit,
selector valve. in the raised position (the handle pointer points
down/filter selection ”ALL ON”).
– Turn ON the battery switch (BS).
– Drain any water and sediment from the primary
coarse fuel filters (FFPC).
- 32 -
5.2 Operating
5.2.1 Starting When the unit is in the standby status for a long time,
the following action should be performed: The pressure is not immediately
– Move the control panel power switch to ON. The
display of the User Interface will light up. See also – Without application: turn OFF the battery switch. ! relieved from the unit, when the
Stop button is pushed.
chapter 5.3. – Running: supply power to the battery conditioner.
– Once the engine has stopped, switch the control
– Use the arrow keys to set the working pressure.
panel power switch to the OFF position.
5.2.2 During operation
Make sure that nobody is in the unit – Turn OFF the battery switch
Regularly carry out following checks:
! and all doors are closed prior to
starting the unit. – Check alarm lamp at the front and alarm lamp and
horn at the back of the unit.
– Push the start button on the panel. The horn will
When starting up the unit and also when a
sound.
shutdown occurs, the alarm lamps and the horn
The compressor can be loaded after the warmup will be activated. But when a warning occurs, only
period. the lamps will be activated.
• Manual: push the button below the indication – Check the air filter service indicator.
LOAD, in the display. If the yellow signal shows in the window of the
• Automatic: the compressor will load indicator (see section 6.4.2.3), clean or replace the
automatically when the button below the filter elements.
indication AUTO LOAD, in the display, is
– Check the air outlet temperature of the MP
pushed during the warmup period.
compressor element.
The unit will LOAD/UNLOAD according to the
air demand. 5.2.3 Stopping
– Open the air outlet valve(s). – Close the air outlet valve(s).
– On the User Interface, push the function button
The start/stop instructions are
available in different languages on below the indication Noload.
request. – Push the Stop button.
- 33 -
5.3 Setting the compressor When the PC mode is active, monitoring the
operation on the UI stays possible. Further, the UI can
control module PC
only be used for looking at the System information
DDR and the Process information.
5.3.1 Control
1 5.3.1.3 Control commands
5.3.1.1 Arrow buttons
The arrow buttons are generally used to increase or 1 1
2 Start command
decrease the setpressure.
0 0
Local: Pressing the Start button on the UI.
3
In the Process Info status however, they are used to Remote: Activating the Remote Start input.
4
scroll the text up and down the screen, and in the PC: Clicking the Start button on the PC.
Options status they are used to change the user
1 Remote Stop command
parameters. Local: Pressing the Stop button on the UI.
2 Internal lights
3 Heaters
Remote: Activating the Remote Stop input.
5.3.1.2 Control modes
PC: Clickig the Stop button on the PC.
The CCM can be controlled via three different control 4 Harness connector
modes: When this control mode is active, monitoring the Load command
operation on the UI stays possible. Further, the UI can Local: Pressing the Load button on the UI.
Local control mode Remote: Activating the Remote Load input (when
only be used for looking at the System information
The CCM is controlled by means of the UI. The and the Process information, and for changing not loaded).
Control Mode parameter is Local when the Remote parameters in the Options status. PC: Cliking the Load button with the mouse.
parameter is disable or disable lock.
The Local control mode is the default mode. PC control mode Noload command
Local: Pressing the Noload button on the UI.
The CCM is controlled by means of a PC. This
Remote control mode Remote: Activating the Remote Load input (when
control mode can only be selected with the Connect
The CCM is controlled by means of the remote loaded).
button on the PC. When the button is clicked, the
inputs; the remote control connector is located at the PC: Clicking the Noload button with the
Control Mode parameter becomes remote PC,
back of the UI. mouse.
regardless of the state of the Remote parameter.
The Control Mode parameter is Remote when the Changing the Remote parameter will not effect the
Remote parameter is enable or enable lock. Control Mode parameter until the Disconnect button
is clicked.
- 34 -
5.3.1.4 Enable parameters 5.3.2 Functionality When the cooldown time has elapsed, the stopping
There are six enable parameters with four possible The start and stop function can be set to manual or procedure begins. The engine stops and the
conditions. automatic operation. compressor will automatically return to the Ready for
Start status.
The lock extension gives the Rental companies the It is possible to combine these two into a semi-
possibility to prohibit the operator from changing the automatic operation. 5.3.2.2 Automatic start/automatic stop
parameters via the UI, thus restricting the operator to
When switching on the power, the compressor goes to
one condition 5.3.2.1 Manual start/manual stop
the Ready for Start status.
Parameter E/D Lock CCM operation When switching on the power, the compressor goes to From this status more information about all system
Autostart enable x Automatic start the Ready for Start status. configuration settings can be got, or the automatic
disable x Manual start From this status more information about all system start can be immediately activated, by pressing the
Autostop enable x Automatic stop configuration settings can be got, or the engine can be OK button.
disable x Manual stop started immediately by pressing the Start button.
When the automatic start is activated, the air
Remote enable x Remote Control Mode When the Start button is pressed, the CCM checks all discharge pressure is constantly displayed.
disable x Local Control Mode sensor inputs and parameters. The engine cranking When more air is needed, the pressure drops, and the
Air enable x Air Disch. Temp. procedure begins. compressor starts the cranking procedure.
Discharge Control activated The engine starts, and the warmup procedure begins. When the engine starts, the compressor still runs
Temperature disable x Air Disch. Temp.
Regulation When the compressor is ready to be loaded, it goes through the Warmup status, but the Not Loaded status
Control not active
into the Not Loaded status. is skipped, and the regulating system immediately
Re/Unload enable - Re/Unload press.
The operator can now load the compressor at any time becomes active.
Control adjustable with UI
by pressing the Load button. When the compressor runs in the Unload status for a
disable - Re/Unload press. not
adjustable with UI When loaded, the compressor’s regulating system preset time, the stopping procedure begins. The
Unload RPM enable - Unload RPM adjustable becomes active. engine stops and the compressor returns to the
Control with UI Actual pressure and setpressure are displayed, as well Standby status, with the automatic start already
disable - Unload RPM not as the condition of the regulating system (load or activated.
adjustable with UI unload).
The operator can put the compressor back to the Not The automatic operation can
Loaded status, by pressing the Noload button. ! always be interrupted by pressing
the Stop button.
When the operator presses the Stop button in any
status from Warmup to Load, the compressor
immediately goes to the Cooldown status.
- 35 -
Emergency
Stop
Emergency Stop Shutdown
Reset Reset
System Info Options
System Return Return

Info
Power ON
Ready for Start OK Standby
Stop Start
if
Automatic
Start
Reset Permissive Start
Start Failure Cranking
Stop
Not Loaded Warmup
Stop
Stop
if No/Unload
timer running
Noload Load Cooldown Stopping
Stop
: operator action
Load / Unload : automatic action
- 36 -
5.3.3 A closer look at some operating procedure blocks
5.3.3.1 Process information At any time the operator can leave the Options status 5.3.3.5 Warming up
While the compressor is running, the operator can and go to the Ready for Start status by pressing the When the engine starts, the compressor enters the
take a brief look at all the incoming compressor and Return button. Warmup status. This means the engine is going to run
engine data, by pressing the Process Info button. idle until the engine coolant temperature has reached
5.3.3.4 Cranking procedure
This can be very useful for troubleshooting over the a specific value.
When a start request is made, either by the operator or
phone. If this coolant temperature setting is already reached,
automaticaly, all the compressor parameters are
there is no warmup, and loading can immediately
5.3.3.2 System information checked.
commence.
When in the Ready for Start status the System Info When one of these parameters is out of its limits, the
When after a specified maximum time the coolant
button is pressed, all the system configuration settings operator is prompted to the Start failure status, and
temperature setting is not reached, the compressor
are displayed, such as: unit type, max. and min. set must return to the Ready for Start status or to the
will proceed anyway.
pressure, active control mode, max. set RPM, battery System Info status.
When starting manually, the operator can press the
voltage. When all the parameters are within limits, the engine
Auto Load button. This will result in a skipping of the
From here the operator can enter the Options status, starts cranking.
Not Loaded status, and loading directly after the
where he can configure all the parameters he has The starter motor runs for a preset time, and then the Warmup status.
access to. engine rests for some time, before trying to start
again. 5.3.3.6 Pressure regulating system
5.3.3.3 Options
This cycle is repeated for a number of times. A PID regulating system is implemented in the CCM
Here the screen shows all the parameters the operator When the engine does not start, the starting procedure and becomes active in the Load/Unload status. This
can edit. With the arrow buttons, one scrolls to an is ended, and the operator is prompted to the Start PID regulates the air discharge pressure by adjusting
object, and toggles or selects it with the right function Failure status after several failed attempts. the engine RPM between RPM Min. and RPM Max.
button.
When during the cranking procedure the operator When the air discharge pressure, which is monitored,
Selected values can be changed with the arrow presses the Stop button, a stopping procedure will be drops below the Reload pressure, the loading valve is
buttons, and the new value is confirmed with the OK executed, and the compressor will return to the Ready opened and the PID becomes active (load condition).
button. for Start status.
- 37 -
When less air is needed, the pressure rises and the PID 5.3.3.8 Shutdowns 5.3.3.11Loading Valve Control
will decrease the engine RPM. There are several parameters which are continuously When the compressor is going to the load condition,
When the engine RPM is at its minimum, and the air watched. When one of these parameters exceeds the and the engine RPM setpoint is above 1420 RPM the
flow needed is still smaller than the compressor’s specified limits, the compressor will shutdown loading valve is opened when the engine reaches
output, the pressure will rise until it reaches the immediately. 1400 RPM.
Unload pressure. Then the PID will become inactive The parameters appear on the screen. If the engine RPM setpoint is below 1400 RPM, the
and the loading valve will close. The engine runs at The operator can leave the Shutdown status at any loading valve is opened at the engine RPM setpoint -
RPM Min. (unload condition). time, and go to the Ready for Start status or to the 20 RPM.
When the air discharge pressure drops again, below Process Info status by pressing the reset button.
the Reload pressure, the loading valve is opened and 5.3.3.12Pressure Calibration
Restarting before the parameter is back within its
the PID becomes active.
limits is impossible, because of the parameter check To compensate the offset error of the Air Discharge
in the cranking procedure. Pressure sensor, a Pressure Calibration parameter is
5.3.3.7 Cooling down
implemented.
When the Stop button is pressed, the engine runs idle 5.3.3.9 Emergency stop The offset error is measured by comparing the sensor
for a specified time. If the engine already ran value with that of a verified and stamped pressure
When an emergency stop button is hit, this message
unloaded for some time, before pressing the Stop gauge.
appears on the screen.
button, this time is substracted from the cooldown This parameter is programmed with the value that
time because the engine conditions in these cases are Until the emergency stop button is reset, the operator
cannot do anything. compensates the error.
the same. This is also why the engine stops without Ex. Pressure gauge value: 7.8 bar
cooldown in automatic stop operation. When the emergency stop button is reset, the operator
Sensor value: 8.1 bar
When a unit goes to cooldown due to "Engine coolant can proceed to the Ready for Start status or to the Parameter value: - 0.3 bar
Process Info status.
temperature too high" (see “Engine warnings”). The
unit will shut down and on the screen appears "ready 5.3.3.10Unload RPM Control
for start". When pressing the start button "start
request denied" will be displayed. After resetting, this It allows compensation of engine power at high
message is cleared and a start attempt can be made. altitude applications.
Cooldown Time: default 3 minutes. In the Unload condition the engine will run at the
Unload RPM.
In the Load condition the engine will not run slower
than the Unload RPM. If the Unload RPM parameter
is enable, it is possible for the user to change the
Unload RPM with the UI.
- 38 -
5.3.3.13Poweroff 5.3.3.14Powerdown PC control mode
When the power is switched on, a Wrong Poweroff To save the batteries, the CCM and UI are equipped When an action is performed via the PC, demanding
flag is set. with a Powerdown function. a response from the CCM or UI (Start signal,
When the power is switched off when the engine is When the compressor is not running and the changing settings, ...), the CCM will come out of
not running, the Wrong Poweroff flag is reset. Automatic start is not activated, the CCM and UI will Powerdown.
When pressing the emergency stop, the programs of go to Powerdown mode if there has not been any When a button on the UI is pressed, the CCM will
the CCM and the UI keep on running, but the power action during the Powerdown time. come out of Powerdown as well.
to the outputs is cut off, so the engine will stop In Powerdown mode the CCM and UI will perform as When there has not been any action during three
immediately. little as possible to reduce the power consumption. minutes, the CCM will return to Powerdown.
When the power is switched off then, the Wrong The screen of the UI will therefore be shut down.
Poweroff flag is reset. 5.3.3.15Air Discharge Temperature Control
Local control mode (optional)
When the power is switched off while the engine is
When a button is pressed on the UI, the CCM will By changing the temperature of the cooling air going
running, the programs of the CCM and the UI will
return to its previous status. through the aftercooler it is possible to heat the
keep on running and the CCM will stop in a controlled
manner (cooldown - stopping procedure), before it discharge air to a certain setting.
Remote control mode
will Powerdown and reset the Wrong Poweroff flag. This is done with a proportional valve controlled with
When the compressor is in the Ready for Start status a PWM signal, and mounted on a cooler.
When the power is switched off as well as the and the Remote start button is pressed, the CCM will
emergency stop is pressed, no power supply to the The Air Discharge Temperature Control becomes
come out of Powerdown and go directly to the
CCM is left and the engine cannot be shut down active after the Warmup status, and stays active for as
Permissive Start or Standby status. Pressing any other
properly. The Wrong Poweroff flag is not reset. long as the engine is running. The operation of the Air
Remote control button (except Remote ON), will only
When the power is then switched on again, the Wrong Discharge Temperature Control depends on the Air
result in deactivating the Powerdown, also when the
Poweroff counter will add 1. Discharge Temperature Control Parameter.
CCM is in any other status.
Executing a wrong poweroff can result in memory When the Remote ON input is not active, none of the Air Discharge Temperature Control parameter
damage. Remote inputs can deactivate the Powerdown. “Disable”
When a button on the UI is pressed, the CCM will When the parameter is disable or disable lock, the PID
come out of Powerdown. will regulate the Air Discharge Temperature to a
When there has not been any action during three fixed value of 4°C to prevent freezing.
minutes, the CCM will return to Powerdown. The CCM will run through the standard Warmup
procedure, with the valve closed.
- 39 -
Air Discharge Temperature Control parameter 5.4 Operation via User Interface 5.4.2 Ready for Start status
“Enable”
When the parameter is enable or enable lock, the PID 5.4.1 General 5.4.2.1 Manual start
will regulate the Air Discharge Temperature to the In this section an overview is given of all statuses of
Air Discharge Temperature Setting. the CCM.
After starting the compressor, the CCM will first run
through the Temperature Control Warmup procedure The reactions of the compressor to actions of the
in the Warmup status. This procedure will override operator and to signals from the compressor itself, are
the standard Warmup procedure and settings. also shown.
When the engine started, the CCM executes

A: action (carried out by operator)
following Warmup procedure if the Air Discharge
S: signal (generated by compressor)
Control Parameter is Enable (lock);
R: reaction
If the Coolant Water Temperature is at 50°C or above,
the Warmup procedure is ended. S Warnings R Are shown on the screen
When the Warmup procedure has ended, the CCM A Emergency stop button R To emergency stop status
can go to the Not Loaded status, or to the Load/ (see section 5.4.13)
Unload status. A ↓-button, press once R Set pressure - 0.1 bar
A ↑-button, press once R Set pressure + 0.1 bar
5.3.3.16Barometric Calibration A ↓-button, press R Set pressure - 0.1 bar/
continuously second
For applications running in low barometric pressure
A ↑-button, press R Set pressure + 0.1 bar/
environments (high altitude), Cummins compensates continuously second
the diesel injection. A Power OFF switch R End of operation
A System info button R To system info status
(see section 5.4.14)
A Start command R To permissive start status
(see section 5.4.4)
Other actions and signals have no effect in this status.
- 40 -
5.4.2.2 Automatic start 5.4.3 Standby status 5.4.4 Permissive start status
In this status the CCM checks if the parameters are
out of range and checks all sensor inputs for sensor
faults.
This status does not require any action from the
operator, and is therefore not visible on the screen.
Yet, some buttons and signals do have a function.
S Warnings R Are shown on the screen

A Shutdowns R To start failure status (see
section 5.4.11)
A Emergency stop button R To emergency stop status
S Warnings R Are shown on the screen S Warnings R Are shown on the screen (see section 5.4.13)
A Emergency stop button R To emergency stop status A Emergency stop button R To emergency stop status A ↓-button, press once R Set pressure - 0.1 bar
(see section 5.4.13) (see section 5.4.13)
A ↓-button, press once R Set pressure - 0.1 bar A ↓-button, press once R Set pressure - 0.1 bar
A ↓-button, press R Set pressure - 0.1 bar/
A ↑-button, press once R Set pressure + 0.1 bar A ↑-button, press once R Set pressure + 0.1 bar continuously second
A ↓-button, press R Set pressure - 0.1 bar/ A ↓-button, press R Set pressure - 0.1 bar/ A ↑-button, press R Set pressure + 0.1 bar/
continuously second continuously second continuously second
A ↑-button, press R Set pressure + 0.1 bar/ A ↑-button, press R Set pressure + 0.1 bar/ A Stop command R To ready for start status
continuously second continuously second (see section 5.4.2)
A Power OFF switch R End of operation A Stop command R Automatic start A Power OFF switch R Automatic start
A System info button R To system info status deactivated. To Ready deactivated. End of
(see section 5.4.14) for Start status, automatic operation
A OK button or Remote R To standby status (see start (see section 5.4.2)
A Autostart pressure R To permissive start status
start input (if Remote section 5.4.3)
control mode) reached (see section 5.4.4) If all parameters are within the defined limits,
A Power OFF switch R Automatic start cranking will begin, the CCM will go to the Cranking
deactivated. End of status.
operation
- 41 -
5.4.5 Cranking status If cranking:
5.4.6 Warmup status
S Crank time elapsed S The starter motor output
is desactivated for the 5.4.6.1 Manual start
duration of the crank
time (resting).
Crank counter +1
The starter motor output is activated when the CCM

enters this status.
The Crank counter is reset to 0.
If resting:
S Crank time elapsed S The starter motor is
A Shutdowns R To start failure status (see reactivated, the screen
section 5.4.11) shows “Crank attempt S Warnings R Are shown on the screen
A Crank counter = Max. R To start failure status (see X”, with X being the A Shutdowns R To start failure status (see
crank attempts section 5.4.11) Crank counter. section 5.4.11)
A Starter lockout activation R The starter motor output A Max. warmup time R Not Loaded status or
RPM reached is activated; to Warmup elapsed Load/Unload status (see
status (see section 5.4.6) section 5.4.7)
A Emergency stop button R To emergency stop status A Emergency stop button R To emergency stop status
A ↓-button, press once R Set pressure - 0.1 bar (see section 5.4.13)
A ↑-button, press once R Set pressure + 0.1 bar A ↓-button, press once R Set pressure - 0.1 bar
A ↓-button, press R Set pressure - 0.1 bar/ A ↑-button, press once R Set pressure + 0.1 bar
continuously second A ↓-button, press R Set pressure - 0.1 bar/
A ↑-button, press R Set pressure + 0.1 bar/ continuously second
continuously second A ↑-button, press R Set pressure + 0.1 bar/
A Power OFF switch R To stopping status (see continuously second
section 5.4.10) A Stop command R To stopping status (see
A Stop command To stopping status (see section 5.4.10)
section 5.4.10) A Power OFF switch R To stopping status (see
section 5.4.10)
- 42 -
A Auto load button R After the Warmup status, 5.4.6.2 Automatic start A Manual load button R After the Warmup status,
or Remote Load input the CCM will skip the or Remote Load input the CCM will go to the
if Remote control mode Not Loaded status and go if Remote control mode Not Loaded status (see
directly to the Load/ section 5.4.7) before
Unload status (see going to the Load/
section 5.4.8) Unload status (see
“Automatic load” will section 5.4.8)
appear on the screen “Automatic load” will
If min. Warmup time is elapsed: disappear from the
display
S Coolant = Warmup R To Not Loaded status
temperature (see section 5.4.7) If min. Warmup time is elapsed:
or Load/Unload status S Coolant = Warmup temp. R To Load/Unload status
(see section 5.4.8) (see section 5.4.8)
If Auto Load button was pressed: or Not Loaded status (see
S Warnings R Are shown on the screen section 5.4.7)
A Manual load button R Auto Load condition is
or Remote Load input canceled A Shutdowns R To shutdown status (see If Manual Load button was pressed:
if Remote control mode section 5.4.12) A Auto load button R Manual Load condition
Other actions and signals have no effect in this status. A Max. warmup time R To Not Loaded status or Remote Load input is canceled
elapsed (see section 5.4.7) or if Remote control mode
Load/Unload status (see Other actions and signals have no effect in this status.
section 5.4.8)
A ↓-button, press once R Set pressure - 0.1 bar
continuously second
continuously second
A Stop command R To stopping status (see
section 5.4.10)
A Power OFF switch R To stopping status (see
section 5.4.10)
- 43 -
5.4.7 Not Loaded status 5.4.8 Load/Unload status A Noload command R To Not Loaded status
(see section 5.4.7)
5.4.8.1 Manual stop If Loaded:
S Unload pressure reached R “Unload” appears on the
screen
If Unloaded:
A Reload pressure reached R “Load” appears on the
screen

S Shutdowns R To Shutdown status (see
section 5.4.12)
continuously second
A ↑-button, press R Set pressure + 0.1 bar/ S Warnings R Are shown on the screen
continuously second A Shutdowns R To Shutdown status (see
A Stop command R To Stopping status (see section 5.4.12)
section 5.4.10) A Emergency stop button R To emergency stop status
A Power OFF switch R To Stopping status (see (see section 5.4.13)
section 5.4.10) A ↓-button, press once R Set pressure - 0.1 bar
A Load command R To Load/Unload status A ↑-button, press once R Set pressure + 0.1 bar
(see section 5.4.8)
Other actions and signals have no effect in this status. continuously second
continuously second
A Stop command R To Cooldown status (see
section 5.4.9)
A Power OFF switch R To Cooldown status (see
section 5.4.9)
- 44 -
5.4.8.2 Automatic stop If Loaded: 5.4.9 Cooldown status
S Unload pressure reached R “Unload” appears on the
screen
Autostop timer activated
If Unloaded:
A Reload pressure reached R “Load” appears on the
screen
Autostop timer reset
S Autostop time elapsed R To stopping status (see
section 5.4.10)

A Shutdowns R To shutdown status (see
section 5.4.12)
A Cooldown time elapsed R Stopping status (see
section 5.4.10)
S Warnings R Are shown on the screen A ↑-button, press once R Set pressure + 0.1 bar
A Shutdowns R To Shutdown status (see A ↓-button, press R Set pressure - 0.1 bar/
section 5.4.12) continuously second
A Emergency stop button R To emergency stop status A ↑-button, press R Set pressure + 0.1 bar/
(see section 5.4.13) continuously second
A ↓-button, press once R Set pressure - 0.1 bar A Emergency Stop button R To emergency Stop
A ↑-button, press once R Set pressure + 0.1 bar status (see section 5.4.13)
A ↓-button, press R Set pressure - 0.1 bar/ Other actions and signals have no effect in this status.
continuously second
continuously second
A Stop command R To Cooldown status (see
section 5.4.9)
A Power OFF switch R To Cooldown status (see
section 5.4.9)
A Noload command R To Not Loaded status
(see section 5.4.7)
- 45 -
5.4.10 Stopping status 5.4.11 Start failure status Sreen B: Start failure, origin in Cranking status.
First a stopping procedure is executed, and the
operator has to wait.
S Warnings R Are shown on the screen S Warnings R Are shown on the screen
A Shutdowns R To shutdown status (see A Emergency Stop button R To emergency Stop
section 5.4.12) Sreen A: Start failure, origin in Permissive start status (see section 5.4.13)
A Stopping procedure has R If manual start: status. A ↓-button, press once R Set pressure - 0.1 bar
ended To Ready for Start status
(see section 5.4.2)
If automatic start: A ↓-button, press R Set pressure - 0.1 bar/
To Standby status (see continuously second
section 5.4.3) A ↑-button, press R Set pressure + 0.1 bar/
If Power OFF: continuously second
End of operation A Power OFF switch R End of operation
A Emergency Stop button R To emergency Stop A Reset button R To Ready for Start status
status (see section 5.4.13) (see section 5.4.2)
continuously second
continuously second
- 46 -
5.4.12 Shutdown status Screen B: Emergency Stop is unlocked.
First a stopping procedure is executed. S Warnings R Are shown on the screen
A Emergency Stop button R To emergency Stop
status (see section 5.4.13)
continuously second
continuously second
A Power OFF switch R End of operation
A Reset button R To Ready for Start status
(see section 5.4.2)
5.4.13 Emergency stop status
Screen A: Emergency Stop is pressed. continuously second
continuously second
A Power OFF switch R End of operation
If Emergency Stop is locked:
A Unlock Emergency Stop R To screen B
If Emergency Stop is unlocked:
A Lock Emergency Stop R To screen A
A Reset button R To Ready for Start status
(see section 5.4.2)
- 47 -
5.4.14 System info status – Battery Voltage 5.4.15 Options status
– Software version UI
– Software version CCM

A Return button R To Ready for Start status
(see section 5.4.2)
A Options button R To options status (see
section 5.4.15)
This status gives a summary of the following (see section 5.4.13)
parameters: A Power OFF switch R End of operation
– Unit Type Other actions and signals have no effect in this status. In this status, the operator can change the parameters
– Unit Serial Number for which he has clearance.
The Rental companies can deny access to the gray
– Engine Serial Number parameters for the operator.
– Fleet Number In that case, the parameters are not shown on the
screen.
– Maximum Setpressure
With the arrow buttons, a parameter is selected.
– Minimum Setpressure Parameters which toggle between different settings
– Maximum Set RPM (e.g.: Pressure Units), can be changed by pressing the
Toggle button.
– Unload pressure Other parameters (e.g.: Display Luminosity) can be
– Reload pressure changed by pressing the Edit button.
After changing the value with the arrow buttons, the
– Output Code: This code is directly proportional to
new value needs to be confirmed with the OK button.
the Maximum set RPM, and gives a rough
indication of the maximum Free Air Delivery A Return button R To Ready for Start status
(FAD) with the current setting. (see section 5.4.2)
– Active Control Mode: Local control; Remote
control; PC control.
– Air Inlet Temperature
- 48 -
The parameters the operator can change are: 5.4.16 Process Info status 5.4.16.2Process Info status function
– Display Luminosity This status is not an active status, but can be entered
5.4.16.1Two key access
from the following statuses:
– Pressure Units (Metric/Imperial)
Depending on the setting of the Infobutton parameter,
– Standby status
– Temperature Units (Metric/Imperial) the operator has access to the Process Info status by
pressing a single named function key, the Process – Permissive Start status
– Flow Units (Metric/Imperial)
Info button. In that case the Infobutton parameter is – Cranking status
– Start method (if Autostart = enable or disable) enable.
– Warmup status
– Autostart pressure (if Autostart = enable or enable When the Infobutton parameter is disable, the access
lock) to the Process Info status is made by a two button – Noload status
– Stop method (if Autostop = enable or disable) function. – Load/Unload status
While pressing the unnamed function button, which – Cooldown status
– Autostop time (if Autostop = enable or enable
lock) otherwise would be the Process Info button, the other
function button has to be pressed. – Shutdown status
– Control mode (if Remote = enable or disable) – Start Failure status
The Infobutton parameter can be changed with the
(Local/Remote)
PC, Rental companies clearance. – Emergency Stop status
– Air discharge temperature control (if Air
Discharge Temperature Control Parameter = The Process Info status gives a summary of all
parameters measured by the CCM, and those taken
enable or disable)
from the ECM’s dataline.
– Air discharge temperature setpoint (if Air
Discharge Temperature Control Parameter =
enable or enable lock)
– Reload/Unload pressure (if enabled)
- 49 -
These parameters are: – Compressor oil temperature
S Shutdowns R To Shutdown status (see
– Air discharge temperature section 5.4.12)
A Time-out R Back to active
– Air discharge temp. setting compressor status
– Air disch. temp. valve pos. A Emergency Stop button R To Emergency Stop
status (see section 5.4.13)
– Coolant temperature A ↓-button R Scroll text down
– Fuel temperature A ↑-button R Scroll text up
A Return button R Back to active
– Fuel level compressor status
– Engine fuel consumption A Stop command R Same function as in the
active compressor status
– Battery voltage
– Compressor status Other actions and signals have no effect in this status.
– Loading valve status
– Engine RPM
– Engine power contact
– Set RPM
– Starter engine status
– Air discharge pressure
– Oiler valve status
– Set pressure
– Blow-off valve status
– LP intercooler pressure
– Flap lock solenoid
– MP intercooler pressure
– Engine load
– Compressor oil pressure
– Engine boost pressure
– Engine oil pressure
– Air inlet temperature
– Engine fuel pressure
– Ambient temperature
– LP element temperature
– MP element temperature
- 50 -
5.5 Operating the automatic fire suppression system
5.5.1 Main components
1 Control module
2 Cylinder with extinguishing powder
3 Large nitrogen cylinder
4 Manual actuator
1 5 Small nitrogen cylinder
6 Small nitrogen cylinder
7 Nozzles
8 Automatic actuator
4
7 6
7
5
- 51 -
5.5.2 Operation 5.5.3 Control module Staff that are not familiar with this
The fire suppression system is equipped with a
manual and automatic activation.
The automatic fire suppression installation is
constantly monitored by a control module. It is
! system are not allowed to run checks
on the system. Wrong handling may
The automatic activation detects a fire via a heat powered by the machine’s batteries but also fitted lead to an inactive system or release
sensitive wire. As soon as a fire is detected, the with an internal battery guaranteeing power supply of extinguishing powder.
control module (1) shuts down the compressor. After should the batteries fail. All repairs have to be done by
a delay of 30 seconds the automatic actuator (8) A number of LED’s indicate the system status. authorized personnel.
releases a small nitrogen cartridge (6), by which the
larger nitrogen bottle (3) is released. The compressed
5.5.3.1 Indicators
gas will blow the extinguishing powder from cylinder
(2) through the nozzles (7) into the engine 1. POWER
compartment.
LED pulses every three seconds when indicating
The manual activation is a push button (4) on the normal power. If the power drops below an
outside of the compressor. Removing the lock pin and 2 1 acceptable level of either the internal or external
pushing the button releases a separate nitrogen 3
power source, the green POWER LED will be
cartridge (5) which activates the powder release and 4
5 extinguished.
shuts down the machine
The automatic fire suppression system is directly 6 7 2. BATTERY
powered by the compressor batteries. This means that LED pulses every 10 seconds when low power
the system remains powered when the battery switch condition is detected from either the internal or
is switched off. external power source. Please check the system and
restore power supply.
3. ALARM
The alarm LED will flash in case of an alarm
1 Power 5 Release
condition. An alarm condition is caused by detection
2 Battery 6 Delay
circuit activation.
3 Alarm 7 Reset
4 Detection
- 52 -
4. DETECTION 5.5.4 Daily check
The detection LED and the audio pulse once every 10 The LED’s status on the ANSUL control module
seconds when the control module detects a problem in should be checked daily prior to starting up the
the detection circuit. Please check the integrity of the compressor. The green Power LED (1) should flash
detection wire. every three seconds, no other LED may flash and no
audio alarm should be sounding! It is not allowed to
5. RELEASE
start up the compressor when there are any deviations.
The release LED and the audio pulse once every 10
seconds when the control module detects a problem in
the release circuit. Please check the connection with
the automatic actuator.
5.5.3.2 Buttons
6. DELAY
This button is used during programming and can be
used for maintenance checks.
7. RESET
Pressing this button for more than 1 second will reset
the controller after a fault detection or activates the
system after restoring power e.g. after replacing the
internal battery.
- 53 -
6 Maintenance
6.1 Maintenance schedule
every every every every every
Maintenance schedule Daily 50 hrs
250 hrs 1000 hrs 1500hrs 6000 hrs 10000 hrs
Service pak - 2912 4580 04 2912 4581 05 2912 4582 06 - - -
Check engine oil level x x x x x x

Check compressor oil level x x x x x x
Check coolant levels (radiator) x x x x x x
Check coolant additive and antifreeze x x x x x
concentration
Check routing and condition of flexible hoses x x x x x x
Drain prefilters (water separators) 30µ x x x x x x
Change fuel prefilter 30µ x x x x x x
Check fan cooling x x x x x x
Check on abnormal noise and smoke x x x x x x
Change engine fuel filter x x x x x x
Add engine oil x x
Change engine oil x(2) x x x x
Replace engine oil filters x x x x x
Change coolant filter x x
Coolant fan belt tensioner x
Check engine compressor drive belt x x x x x
Check engine fan drive belt x x x x x
- 54 -
Service pak - 2912 4580 04 2912 4581 05 2912 4582 06 - - -
Clean service filter water separator x x x x x

Grease turntable x x x x x
Check tension and condition of poly V-belts x x x x
Check electrolyte and terminals on batteries x x x x
Drain water and sediment in fuel tanks x x x
Clean air filters elements (1) x x x x x
Replace air filter elements (1) x x x
Replace air filter safety cartridge x x x
Change engine air filter and cartridge x x x
Check air intake piping x
Check charge air piping x
Test safety / relief valves x x
Check coolant condition x x x
Drain air tanks and reservoirs x x x x x
Check crankcase breather tube x
Replace the crancase breather internal Only Cummins
Clean gear casing breather pot x x
Replace compressor oil filter x x
Inspect / Adjust engine valve clearance x
Grease engine fan drive x
- 55 -
Service pak - 2912 4580 04 2912 4581 05 2912 4582 06 - - -
Grease fan drive x

Replace cooler system water temperature x
regulator
Change compressor oil x x
Replace silencers glasswool and insert (every 2 x
years)
Replace roller diaphragm of unloader cylinder x
Replace parts of unloader cylinder x
Replace diaphragm of the balancing pistons x
Replace check valve in compressed-air sytem x
Replace coolant x
- 56 -
Notes: 6.1.1 Use of preventive maintenance 6.1.2 Service paks and kits
– The initial service pak, which has been supplied schedule
6.1.2.1 Service paks
with the unit, should be performed after the first The maintenance schedule contains a summary of the
50 hours. maintenance instructions. Read the respective section Service paks include all genuine parts needed for
before taking maintenance measures. normal maintenance of both compressor and engine.
– For grey-marked service activity intervals, new
parts are included in the service pak mentioned on When servicing, replace all disengaged packings, e.g. Service paks minimise downtime and keep your
top of the column. gaskets, O-rings, washers. maintenance budget low.
(1) More frequently when operating in a dusty The maintenance schedule has to be seen as a Order service paks at your local Atlas Copco dealer.
environment. guideline for units operating in a dusty environment
6.1.2.2 Service kits
typical to compressor applications. The maintenance
(2) Engine oil change interval can be increased until A service kit is a collection of parts to fit a specific
schedule can be adapted depending on application,
500 hrs depending on fuel consumption over that repair or rebuilding task.
environment and quality of maintenance.
period of time.
It guarantees that all necessary parts are replaced at
Contact your local Cummins the same time which improves the uptime of the unit.
! support for more information and
make sure to have their agreement
Atlas Copco service kits offer you all the benefits of
genuine Atlas Copco parts, save on administration
to increase oil change interval. costs and are offered at a reduced price compared to
the loose components.
The order numbers of the service paks and kits are
Keep the bolts of the housing, the listed in the Atlas Copco Parts List (ASL).
! lifting eye, the towbar and the axle
securely tightened.
Refer to “Technical specifications” Contact Atlas Copco.
on page 84 and to “Torque values”
on page 84.
- 57 -
6.2 Engine maintenance procedures
Refer to the engine’s operator manual for full When the warning is generated, the oil level
maintenance schedule. maintainer valve is opened. Oil flows from the oil
tank into the oil sump of the engine and into the small
6.2.1 Engine oil level check A oil tank. The warning condition will disappear.
Check the engine oil level via the dipstick on the The oil level rises until the oil reaches the full level.
engine and via the transparent tube on the engine oil Then the oil level maintainer valve is closed.
tank. B When the warning does not disappear, because the oil
Add correct oil (see section 6.5), if necessary. tank is empty, the warning will be displayed on the
screen of the User Interface.
The unit has been equipped with an automatic oil
level control. When the oil reaches the shutdown level, the CCM
C generates an Engine Oil Level shutdown and the unit
The oil level maintainer valve controls the oil level in
will deactivate.
the oil sump of the engine. This valve is seated
underneath the oil tank in the back of the unit. When the oil level maintainer valve would not close
after the oil level has reached the full level, the oil will
A small oil tank with three level switches is mounted D start to overfill the engine.
on the engine and is functioning as a communicating
vessel with the oil sump of the engine. These level When the oil reaches the overfill shutdown level, the
switches (overfill - full - warning - shutdown) are CCM generates an Engine Oil Level shutdown and
connected to the CCM and control the oil level the unit will deactivate.
A Oil level switch ‘overfill’
maintainer valve. B Oil level switch ‘full’
C Oil level switch ‘warning’
D Oil level switch ‘shutdown’
When the engine is running, the oil level diminishes.
When the oil reaches the warning level, the CCM
generates an Engine Oil Level warning. This warning
is not immediately displayed on the screen of the User
Interface, but is held back for the duration of the
Engine Oil Level Warning Time.
- 58 -
6.2.2 Engine oil and oil filter change 6.3 Compressor maintenance
procedures
6.3.1 Compressor oil level check
1
The engine oil filters (1) are located at the unit’s left-
hand side.
– Consult, besides the maintenance schedule, the
– Put a proper drain pan under the engine oil filters
Engine Operation Manual as well for oil and oil
and replace the oil filters.
filter change intervals.
– Close the drain cock and tighten all drain plugs
– To drain oil from system, open the oil filler cap,
before filling the system with fresh oil.
remove the drain plug, located at the right-hand – Close the outlet valve(s) and stop the unit. Before
side under the unit and open the drain cock (1). – Reinstall the oil filler cap. checking the compressor oil level, wait approx. 10
– Use a proper drain pan. – Check on leakages. minutes to allow oil to return to the oil sump.
– Check the oil level with the dipstick (1).
– Add correct oil (see section 6.5), if necessary.
- 59 -
6.3.2 Compressor oil and oil filter – Run the unit at Not Loaded for a few minutes to
change circulate the oil. Stop and depressurize the unit.
Screw out the filler plug, add oil, if necessary,
until the oil level registers between markings A
and B (see section 6.5). Reinstall and tighten the
filler plug.
Never add more oil. Overfilling results in oil
consumption.
2 6.3.3 Compressor element overhaul

1 When a compressor element is due for overhaul, it is
recommended to have it done by Atlas Copco. This
guarantees the use of genuine parts and correct tools
1 with care and precision.
– Run the compressor until warm. Close the outlet – Loosen the bypass plug (2) (bypass to the oil
valve(s) and stop the compressor. sump) to allow the oil in the oil filter (1) to be
– Drain the oil by removing the drain plug and drained.
opening the drain cock (1). The drain plug is – Remove the oil filter, e.g. by means of the handle
located at the left-hand side under the unit. Catch of a spanner in the slot at the top.
the oil in a drain pan. Screw out the filler plug to
speed up draining. Close the drain cock and – Clean the filter seat on the manifold, see to it that
tighten the plugs after draining. no dirt drops into the system. Oil the gasket of the
new filter element. Screw the element into place
until the gasket contacts its seat, then tighten one
half turn only.
- 60 -
6.4 Adjustment and servicing procedures
6.4.1 Coolant 6.4.1.2 Adding coolant for units with 6.4.1.3 Testing coolant inhibitor level
optional preheater Use coolant test strips to measure, chloride nitrite and
6.4.1.1 Coolant level check
glycol concentrations. Cavitation/corrosion
This instruction is only applicable protection is indicated on the strip by the level of
! for units equipped with an optional
“Preheater".
nitrite concentration. Freeze/boilover protection is
determined by glycol concentration. Use the test
1
1
strips as follows:
– Dip the strip into coolant for one second. Remove
and shake briskly to eliminate excess fluid.
– Immediately compare end pad (% glycol) to the
color chart.
– Sixty seconds (one minute) after dipping,
compare the nitrite pad.
For the best results make the tests while the coolant is
between 10°C - 60°C (50°F - 140°F). Wait at least 60
seconds, but not longer than 75 seconds, before
reading the nitrite level.
– Check the levels of the coolant in the radiator
cooler. The levels show in transparent tubes fitted
at the radiator top tank. The levels should
normally be at the bottom of the filler pipes as Open the preheater drain point (1) during filling of the
they go into the tanks. coolant. This way air can be vented out of the cooler.
– Add coolant, if necessary. The location of the
radiator filler cap (1) is shown in figure above.
– Use PARCOOL EG as coolant.
- 61 -
6.4.1.4 Replacing the coolant 6.4.2 Air filter 6.4.2.2 Cleaning the dust trap
To remove dust from the dust trap pinch the vacuator
6.4.2.1 Main parts
valve (6) several times.
6.4.2.3 Replacing the air filter element and

the safety cartridge
The instructions that apply to one air filter should be
repeated for both air filters engine and air filters
compressor.
– Release the snap clips (1) and remove the dust trap
cover (2). Clean the inside of the cover.
1 – Withdraw the filter element (4) and safety

cartridge (3) from the housing (5).
Discard the filter element when damaged.
Consult the Engine Operation Manual and section A dirty safety cartridge is an indication of a
6.4.1.3 for coolant specifications. malfunctioning filter element.
– To drain coolant from system, remove drain Replace the filter element and the safety cartridge at
plugs. Drain plugs are located at the right- and 1 Snap clips (4x)
the same time.
left-hand side under the unit and open the drain 2 Dust trap cover
cocks (1). 3 Safety cartridge New elements should be inspected
– Use a proper drain pan. 4 Filter element for tears and punctures before
5 Filter housing installation.
– Before filling the system, close the drain cocks
and tighten all plugs. 6 Vacuator valve (dust ejector)
The safety cartridge cannot be
The Atlas Copco air filters are
! cleaned.
! specially designed for the

application. The use of non-genuine
air filters may lead to severe damage
of engine and/or compressor
elements.
- 62 -
– Reassemble in reverse order of dismantling. – Carefully knock the end faces of the filter element
– Inspect and tighten all air intake connections. on a flat surface to remove the dry contaminant.
Never strike on a hard surface. Then blow dry air
– Reset the air filter vacuum indicator by pushing up and down the pleats in the reverse direction of
the reset button (8). normal flow; subsequently blow up and down the
pleats on both sides of the element. The air
8 pressure may not exceed 5 bar (73 psi) and a
reasonable distance must be maintained between
7 the hose nozzle and the pleats.
– If the contaminant is oily, soak the element for 10
9
minutes in luke-warm water in which a non-
foaming detergent is dissolved. Then, move the
element to and fro in the solution for 5 minutes.
7 Air filter contamination indicator – Rinse with soft water until the drain water is clear.
8 Reset button Let the element dry. Never use compressed air to
9 Yellow indicator hasten drying.
– Inspect the element by placing a light inside it.
6.4.2.4 Cleaning the filter element
Spots or ruptures of the paper render the element
– Withdraw the filter element (see section 6.4.2.3). unfit for further use.
Reinstall the dust trap cover to protect the air
– Reassemble in reverse order of dismantling.
intake system while cleaning the element.
– Reset the air filter service indicator by pushing the
Never run the compressor without reset button (8).
! air filter element.
- 63 -
6.4.3 Fuel system 6.4.3.2 Priming the system
– Check to make sure the drain valve at the base of
6.4.3.1 Draining primary fuel filters
the fuel filter is closed.
– Remove the vent cap from the top of the clear
cover. Fill the fuel filter full of clean fuel.
Reinstall the vent cap and tighten by hand only.
– Start the engine. When the lubrication system
reaches its normal operating pressure, increase
engine speed to high idle for one or two minutes.
After the air is purged, loosen the vent cap until
the fuel level lowers to just above the bottom of
the collar. Tighten the vent cap by hand only.
Drain condensate from the primary coarse fuel filters
(water separators) regularly by loosening the drain The clear filter cover will not fill
plugs (3). Catch the condensate in a drain pan. completely during engine operation.
Tighten the plugs after draining. It will gradually fill over time and
The fuel system comprises: the fuel level will rise as the filter
becomes clogged.
1 Two primary coarse fuel filters / water
separators – Hand tighten the collar again while the engine is
2 One secondary engine fuel filter running. To avoid damage, do not use tools to
tighten the collar.
To avoid damaging the aluminium

! fuel processor body, do not
overtighten fuel lines or fuel line
fittings.
- 64 -
6.4.3.3 Cleaning fuel tanks 6.4.4 Cleaning coolers
Keep all coolers clean to maintain the cooling
1 efficiency.
The fan side surface of the radiator, intercooler,
aftercooler 1 and oil cooler is accessible by opening
the service doors.
The CAC/Charge air cooler and aftercooler 2 are
located at the rear end of the unit, under the air filters.
– Remove any dirt from the coolers with a fibre
brush. Never use a wire brush or metal objects.
Then clean by air jet in reverse direction of normal
flow.
2
– If the dirt is oily, wash the coolers with fuel or a
cleansing agent.
To drain sediment and water from the fuel tanks (1), Protect the electrical and controlling
remove the drain plug (2) of both fuel tanks and
frame.
! equipment, air filters, etc. against
penetration of moisture.
For a better drainage slightly slope the unit. – A spray gun should preferably be used to apply the
Use water to clean the inside of the fuel tanks, use a solvent to the cooler block. Rinse the block by
high-pressure purifier if necessary. Spurt the means of a water jet after a soaking-in period.
sediment and water to the drain side of the tank. Steam-cleaning may also be applied.
– Close the service doors.
After cleaning or heavy rains, drain – Do not leave liquids behind.
! the spillage-free frame.
- 65 -
6.4.5 Poly V-belt tension adjustment Correct the V-belt tension by loosening the fixing 6.4.6 MP safety valve adjustment
To check the cooler fan poly V-belt tension, measure screw (1) of V-belt tensioner (2). Loosen the lock nut
the belt frequency. Use tensioning tool 2913 0022 00. on the adjusting screw (3). Turn the adjusting screw
clockwise to increase V-belt tension or counter-
The arrows show where the frequency should be
clockwise to decrease V-belt tension.
measured.
The correct belt frequency is 50 Hz ±2.5 Hz. After adjusting the V-belt tension, retighten the
adjusting screw lock nut and the fixing screw.
All adjustments and repairs and

3
! following checks must be done by
an authorized representative of the
valve supplier.
1 – A check of the opening of the lifting gear, once a
2
year.
– A check of the set pressure once a year according
to the local regulations. This check cannot be done
on the unit and must be carried out on a proper test
bench.
- 66 -
6.4.7 Checking intercooler relief valves 6.4.8 Battery care
Before handling batteries, read the

1 relevant safety precautions and act
1 accordingly.
If the battery is still dry, it must be activated as
described in section 6.4.8.2.
2 The battery must be in operation within 2 months
from being activated; if not, it needs to be recharged
3 first.
6.4.8.1 Electrolyte
4
Read the safety instructions

5
! carefully.
Electrolyte in batteries is a sulphuric acid solution in
1 Valve housing distilled water.
Test the two intercooler relief valves 2 Spring The solution must be made up before being
! (1), which are fitted on the MP air
inlet pipe, statically on a compressed
3 Valve introduced into the battery.
4 Valve seat
air line at least once a year. 6.4.8.2 Activating a dry-charged battery
5 Washer, copper
– Take out the battery.
The valves should open at a pressure as specified in
– Battery and electrolyte must be at equal
the chapter Technical specifications.
temperature above 10°C.
If the valves open too soon: remove a washer, if
– Remove cover and/or plug from each cell.
installed, between valve seat (4) and housing (1) or
add a washer between spring (2) and housing. – Fill each cell with electrolyte until the level
If the valves open too late: remove a washer, if reaches 10 to 15 mm above the plates, or reaches
installed, between spring and housing or add a washer the level marked on the battery.
between valve seat and housing.
- 67 -
– Rock the battery a few times so that possible air 6.4.8.4 Maintaining the battery voltage 6.4.8.5 Battery maintenance
bubbles can escape; wait 10 minutes and check the To maintain the battery voltage, use the unit’s – Keep the battery clean and dry.
level in each cell once more; if required, add automatic battery charger.
electrolyte. – Keep the electrolyte level at 10 to 15 mm above
– Battery charger EEC/AUS: 240 VAC / 24 VDC - the plates or at the indicated level; top up with
– Refit plugs and/or cover. 100 VA distilled water only.
– Place the battery in the compressor. – Battery charger USA: 120 VAC / 24 VDC - – Keep the terminals and clamps tight, clean, and
100 VA lightely covered with petroleum jelly.
6.4.8.3 Recharging a battery
When power is supplied to the charger, the battery
Before and after charging a battery, always check the
voltage will be kept within preset limits.
electrolyte level in each cell; if required, top up with
distilled water only. When charging batteries, each Three LEDs on top of the battery charger show the
cell must be open, i.e. plugs and/or cover removed. charging condition:
– Green: AC supply voltage present
Use a commercial automatic battery
– Yellow: Battery voltage high
charger according to its
manufacturer’s instructions. – Red: DC voltage present / unit charging
Apply with preference the slow charging method and Do not use the unit’s automatic
adjust the charge current according to the following
rule of thumb: battery capacity in Ah divided by 20 ! battery charger to charge an empty
battery. In this case use a
gives safe charging current in Amp. commercial automatic battery
To keep a battery charged, use the unit’s battery charger (see section 6.4.8.3).
charger.
Do not use this battery charger to charge an empty
battery.
- 68 -
6.4.9 Servicing air inlet shut-down 6.4.11 Servicing electric blow-off valve 6.4.12 Servicing automatic fire
valve The blow-off valve, fitted on the MP air inlet pipe, is suppression system
The air shut-off valve is part of the refinery opened to release air when the air inlet throttle valve Do not use a high pressure cleaner
equipment and is mounted on the piping between the
engine inlet and the motor charge air cooler outlet.
is closed; it closes when the throttle valve is opened.
! to clean the fire suppressing system
or parts of it.
The valve prevents combustion air to enter the engine.
When an overspeed is detected, the engine will Preventive maintenance
shutdown (emergency stop) and the air shut-off valve To prevent the nozzles from getting dirty, ensure that
will close. the nozzles are covered by caps.
To reset the air shut-off valve, pull the handle of the Check the heat sensitive detection wire for actual
valve up until a click is heared. damage. A damaged detection wire can lead to a false
release of the fire suppression system.
1
6.4.10 Servicing water separator
Periodic maintenance
The water separator in the back of the unit filters
water condensate out of the compressed air, before To give maximum assurance that the system will
the air is discharged through the outlet valves. operate as intended, maintenance must be performed
Water condensate from the water separator is drained every six months or sooner, depending on the
through a nipple in the bottom of the frame. Connect operating and/or environment conditions.
a drain hose to the nipple and make sure that the
2 Maintenance must be performed by authorized
condensate is properly disposed of. personnel only. Please contact Atlas Copco.
Service the filter of the water separator every 500 3 All maintenance activities are to be recorded in a
hours. logbook.
Replace the membrane, the diaphragm valve

assembly (1) and the spring every 2000 hours (kit
2906 0568 00).
- 69 -
6.5 Engine consumable PAROIL contains high quality anti-oxidants to
Never mix synthetic with mineral control deposits, sludge and contaminants that tend to
specifications
! oil. build up under very high temperatures.
PAROIL's detergent additives keep sludge forming
6.5.1 Engine fuel specifications
particles in a fine suspension instead of allowing them
For fuel specifications, please contact your Atlas If you want to use another brand of to clog your filter and accumulate in the valve/rocker
Copco Customer Center. oil, consult Atlas Copco for more cover area.
information concerning the
PAROIL releases excess heat efficiently, whilst
6.5.2 Engine oil specifications recommended oil and service
maintaining excellent bore-polish protection to limit
intervals.
It is strongly recommended to use oil consumption.
! Atlas Copco branded lubrication
oils for both compressor and engine.
Specifications PAROIL PAROIL has an excellent Total Base Number (TBN)
retention and more alkalinity to control acid
PAROIL from Atlas Copco is the ONLY oil tested
High-quality, mineral, hydraulic or synthesized and approved for use in all engines built into Atlas formation.
hydrocarbon oil with rust and oxidation inhibitors, Copco compressors and generators. PAROIL prevents Soot build-up.
anti-foam and anti-wear properties is recommended. Extensive laboratory and field endurance tests on PAROIL is optimized for the latest low emission
The viscosity grade should correspond to the ambient Atlas Copco equipment have proven PAROIL to EURO -3 & -2, EPA TIER II, III & IV engines
temperature and ISO 3448, as follows. match all lubrication demands in varied conditions. It running on low sulphur diesel for lower oil and fuel
meets stringent quality control specifications to consumption.
Ambient temperature ensure your equipment will run smoothly and
Type of lubricant
range reliably.
The quality lubricant additives in PAROIL allow for
PAROIL E extended oil change intervals without any loss in
between -10°C and 50°C
Mission Green performance or longevity.
PAROIL provides wear protection under extreme
conditions. Powerful oxidation resistance, high
chemical stability and rust- inhibiting additives help
reduce corrosion, even within engines left idle for
extended periods.
- 70 -
PAROIL E Mission Green 6.5.3 Engine coolant specifications Specifications PARCOOL EG
PAROIL E Mission Green is a mineral based high Never remove the cooling system PARCOOL EG is the only coolant that has been
performance diesel engine oil with a high viscosity-
index. Atlas Copco PAROIL E Mission Green is
! filler cap while coolant is hot.
The system may be under pressure.
tested and approved by all engine manufacturers
currently in use in Atlas Copco compressors and
designed to provide a high level of performance and Remove the cap slowly and only generators.
protection in standard ambient conditions as from when coolant is at ambient Atlas Copco's PARCOOL EG extended life coolant is
-10°C. temperature. A sudden release of the new range of organic coolants purpose designed
pressure from a heated cooling to meet the needs of modern engines. PARCOOL EG
US Imp Order system can result in personal injury can help prevent leaks caused by corrosion.
Liter cu.ft
gal gal number
from the splash of hot coolant. PARCOOL EG is also fully compatible with all
can 5 1.3 1.1 0.175 1630 0471 00 It is strongly recommended to use sealants and gasket types developed to join different
Atlas Copco branded coolant. materials used within an engine.
can 20 5.3 4.4 0.7 1630 0472 00
The use of the correct coolant is important for good PARCOOL EG is a ready to use Ethylene Glycol
barrel 209 55.2 46 7.32 1630 0473 00 heat transfer and protection of liquid-cooled engines. based coolant, premixed in an optimum 50/50
Coolants used in these engines must be mixtures of dilution ratio, for antifreeze protection guaranteed to
good quality water (distilled or de-ionised), special -40°C.
coolant additives and if necessary freeze protection. Because PARCOOL EG inhibits corrosion, deposit
Coolant that is not to manufacturer's specification will formation is minimized. This effectively eliminates
result in mechanical damage of the engine. the problem of restricted flow through the engine
The freezing point of the coolant must be lower than coolant ducts and the radiator, minimizing the risk for
the freezing point that can occur in the area. The engine overheating and possible failure.
difference must be at least 5°C. If the coolant freezes, It reduces water pump seal wear and has excellent
it may crack the cylinder block, radiator or coolant stability when subjected to sustained high operating
pump. temperatures.
Consult the engine's operation manual and follow the
manufacturer's directions.
Never mix different coolants and

! mix the coolant components outside
the cooling system.
- 71 -
PARCOOL EG is free of nitride and amines to protect 7 Checks and trouble 7.2 Battery and alternator
your health and the environment. Longer service life
shooting precautions
reduces the amount of coolant produced and needing
disposal to minimise environmental impact. – Never reverse the polarity of the battery or the
7.1 Problem solving chart alternator.
US Imp Order The chart helps to solve mechanical and electrical – Never break any alternator or battery connections
Liter cu.ft
gal gal number problems. while the engine is running.
It is assumed that the engine is in good condition and
can 5 1.3 1.1 0.175 1604 5308 00 – When recharging the battery, disconnect it from
that there is adequate fuel flow to the filter and
the alternator. Before using booster cables to start
can 20 5.3 4.4 0.7 1604 5307 01 injection equipment.
the engine, be sure of the polarity and connect the
batteries correctly.
barrel 210 55.2 46 7.35 1604 5306 00 An electrical fault must be traced by
To ensure protection against corrosion, cavitation and

! an electrician. – Never operate the engine without the main or
voltage sensing cables connected in the circuit.
formation of deposits, the concentration of the Make sure that the wires are not damaged and that
additives in the coolant must be kept between certain they are clamped tight to their terminals.
limits, as stated by the manufacturer's guidelines.
Topping up the coolant with water only, changes the
concentration and is therefore not allowed.
Liquid-cooled engines are factory-filled with this
type of coolant mixture.
- 72 -
7.3 Trouble shooting
Symptom Possible cause Corrective action

Compressor loaded automatically Loading solenoid valve stuck in loaded position. Remove and check loading solenoid valve.
to full capacity after starting Replace valve if necessary.
Air intake throttle valve in open position. Check position throttle valve.
Disconnect loading solenoid valve from throttle valve housing
and connect independent compressed-air line to throttle valve
housing. Repeatedly admit air and listen for opening and
closing sound of throttle valve. If sound is not evident, remove
unloader valve assembly, dismantle and inspect.
Replace parts where necessary.
Compressor does not deliver air or Diaphragm of unloader piston cracked. If air blows from venting device, open unloader piston cover
not immediatly after loading and replace diaphragm.
solenoid valve has been energized.
Air intake throttle valve stuck in closed position. Disconnect loading solenoid valve from throttle valve housing
unloader valve assembly, dismantle and inspect. Replace parts
where necessary.
Air leaks in regulating system. Same action as above.
Loading solenoid valve out of order. Check loading solenoid valve and electric wiring. Replace
valve, if necessary.
- 73 -
Compressor capacity or pressure Air consumption exceeds capacity of compressor. Check equipment connected.
below normal
Choked air filter element. Remove and inspect air filter element. Clean or replace
element, if necessary.
Working pressure setpoint incorrect. Adjust setting.
Engine not up to max. load speed. Check engine and correct if necessary.
Electric blow-off valve malfunctioning. Check interstage pressure. Check functioning of loading
solenoid valve. Replace diaphragm of blow-off valve if
necessary.
Loading solenoid valve leakage. With unit running at max. load speed, disconnect pipe from
loading solenoid valve. If air leaks, remove and inspect loading
solenoid valve. Replace valve, if necessary.
Compressor element(s) not in order. Check interstage pressure and have compressor element(s)
inspected by Atlas Copco.
Air intake throttle valve remains partially closed. Disconnect loading solenoid valve from throttle valve housing
where necessary.
Compressor capacity or pressure Safety valve or relief valve(s) leaking. Remove and inspect safety valve or relief valve(s). Replace
below normal valve(s) if not airtight after reinstallation.
Unloading valve leaking. Remove and inspect unloading valve. Replace valve, if
necessary.
Pipe connections leaking. Check connections and repair if necessary.
- 74 -
Air pressure rises above maximum Working pressure setpoint incorrect. Adjust setting.
and causes safety valve to blow off
Air intake throttle valve does not close for some reason. Check position throttle valve.
Disconnect loading solenoid valve from throttle valve housing
where necessary.
Unloading valve malfunctioning. Remove and inspect unloading valve and blow-off silencers.
Compressor overheating Insufficient compressor cooling. Move unit away from walls; when banked with other units,
leave space between them.
Oil cooler clogged externally. Clean oil cooler.
Oil cooler clogged internally. Consult Atlas Copco.
Compressor oil filter clogged. Replace oil filter.
Compressor oil level too low. Before checking compressor oil level, wait approx. 10 minutes
after unit has stopped.
Add correct oil, if necessary. Never overfill.
Fan blade broken or fan drive defective. Check and correct, if necessary.
Working pressure too high. Adjust setting.
Pressure ratio over compressor element(s) too high. Consult Atlas Copco.
necessary.
Bypass valve of oil cooler remains stuck in open position. Remove bypass valve, clean and inspect.
- 75 -
Engine running but compressor Loading solenoid valve inoperative. Check loading solenoid valve and electric wiring. Replace
does not load when ‘Load’ button is valve, if necessary.
pressed
Diaphragm of unloader piston perforated or throttle valve Remove unloader piston cover and inspect rolling diaphragm.
remains closed for some reason. If in order, check piston for free axial movement by hand. If
jammed, remove throttle valve housing, dismantle and replace
defective parts.
Control panel ‘Load’ button inoperative. Consult Atlas Copco.
Compressor oil pressure too low Compressor oil level too low. Before checking compressor oil level, wait approx. 10 minutes
after unit has stopped.
Add correct oil, if necessary. Never overfill.
Compressor oil filter clogged. Replace compressor oil filter.
Bypass valve in oil pump stuck in open position. Remove bypass valve, clean and inspect.
Oil pump failure. Remove oil pump and inspect parts for wear.
Bypass valve of oil sump stuck in open position. Remove bypass valve, clean and inspect.
Ambient temperature too low. Use heaters, check oil viscosity.
Compressor oil pressure sensor disconnected. Connect wiring.
- 76 -
Engine does not start Engine oil pressure does not build up. See Engine Operation Manual.
Compressor oil pressure does not build up. See problem “Compressor oil pressure too low”.
Faulty compressor oil pressure shutdown switch. Remove and test switch. Replace, if out of order.
ECM fault. Consult Atlas Copco.
Coolant level(s) too low. Check and adjust coolant level(s), if necessary.
Crank time too short. Adjust crank time on User Interface.
Ambient temperature too low. Connect engine heaters.
Speed sensor inoperative. Check speed sensor and electric wiring.
Insufficient fuel supply. Check fuel lines or bleed.
Temperature or pressure sensor missing or malfunctioning. Check via the User Interface display and replace sensor.
After working for some time, the Restriction in fuel supply to engine. Check fuel lines and fuel filters.
unit keeps shutting down
Air leak in fuel suction line or fuel filters. Check suction side of electric fuel pump and fuel filters for air
leaks.
Compressor oil pressure too low. See problem “Compressor oil pressure too low”.
Engine oil pressure too low. See Engine Operation Manual.
Compressor overheating. See “Compressor overheating”
Engine overheating. See Engine Operation Manual.
Excessive oil fumes or air flow Compressor element(s) seals defective. Have compressor element(s) inspected by Atlas Copco.
coming from breather pot assembly
on gear casing.
- 77 -
Intercooler pressure below normal Choked air filter elements. Remove and inspect air filter elements.
Clean or replace elements, if necessary.
Intercooler relief valve(s) leaking. Remove valve(s), clean and inspect.
necessary.
Air leak between LP and MP compressor element. Inspect pipe connections and intercooler.
Replace leaking O-rings, gaskets or intercooler, if necessary.
LP compressor element not in order. Have LP compressor element inspected by Atlas Copco.
Intercooler clogged internally. Consult Atlas Copco.
Intercooler pressure above normal Aftercooler clogged internally. Consult Atlas Copco.
MP compressor element not in order. Have MP compressor element inspected by Atlas Copco.
MP silencer and/or check valve give restriction. Check and take corrective action.
- 78 -
7.4 Compressor control module trouble shooting
7.4.1 Process information Apparatus warnings Effect Process warnings Effect
While the compressor is running, the operator can Fuel Level Sensor Shutdown Fuel Level Warning
take a brief look at all the incoming compressor and Air Discharge Pressure Sensor Shutdown Engine Oil Level Low Warning
engine data, by pressing the Process Info button. Compressor Oil Pressure Sensor Shutdown Air Discharge Temperature Warning
This can be very useful for trouble shooting over the LP Element Temperature Sensor Shutdown Autostart Pressure higher than Setpressure Warning
phone. MP Element Temperature Sensor Shutdown Battery Voltage Low Warning
Loading Valve Output Shutdown Battery Not Charging Warning
7.4.2 Warnings ECM Communication Link Shutdown
When a warning is generated, the warning will appear CAN Communication Link Shutdown Engine warnings Effect
on the screen of the UI, and the user is prompted to a Starter Relay Shutdown Engine Coolant Level Sensor Failure Shutdown
malfunction or a potential shutdown. Compressor Intercooler Pressure 1 Warning Engine Coolant Temp. Sensor Failure Shutdown
Sensor Engine Oil Temperature Sensor Failure Warning
There are two kinds of warnings: Process warnings
and Apparatus warnings. Compressor Intercooler Pressure 2 Warning Engine Fuel Temperature Sensor Shutdown
Sensor Failure
– Process warnings do not have any effect on the Compressor Oil Temperature Sensor Warning Engine Air Inlet Temp. Sensor Failure Warning
CCM’s operation. They are generated when a Air Discharge Temperature Sensor Warning Engine Turbo Boost Press. Sensor Warning
measured value has exceeded its limits. These Air Inlet Temperature Sensor Warning Failure
Process warnings are: fuel level warning, engine
Oil Level Maintainer Valve Output Warning Engine Oil Pressure Sensor Failure Shutdown
oil level warning, compressor oil level warning
Flasher Lights Output Warning Engine Fuel Pressure Sensor Failure Shutdown
and discharge temperature warning.
Horn Output Warning Engine Coolant Level Low Shutdown
– During operation, all sensors, some outputs and Blow-off Valve Output Warning Engine Coolant Temperature Too High Cooldown*
the communication lines are continuously EEPROM Warning Engine Air Inlet Temperature High Warning
checked for failures. When such a failure occurs, Default Mode Warning Engine Oil Pressure Too Low Shutdown
the CCM will generate an Apparatus warning.
Turbo Boost Pressure High Warning
Some errors can cause the CCM to go to the
Process warnings Effect Engine Fuel Pressure Too Low Shutdown
Shutdown status (if running) or to the Start Failure
Fuel Level Shutdown Engine Injector X Failure Shutdown
status (if in Permissive Start status).
Engine Oil Level Too Low Shutdown Fuel Temperature Too High Shutdown
Engine Oil Overfill Shutdown Engine RPM Sensor Failure Shutdown
LP Element Temperature Shutdown *NOTE: See “Cooling down” on page 38.
MP Element Temperature Shutdown
- 79 -
7.4.3 Shutdowns – Fuel level shutdown
The unit comprises several shutdown sensors: – Engine oil level shutdown (switch)
– Engine shutdowns (by ECM): – Engine oil level overfill shutdown (switch)
• Engine Coolant Level Sensor Failure – LP element temperature shutdown
• Engine Coolant Temp. Sensor Failure
– MP element temperature shutdown
• Engine Oil Temperature Sensor Failure
– Compressor oil pressure shutdown
• Engine Fuel Temperature Sensor Failure
– Apparatus shutdown:
• Engine Air Inlet Temp. Sensor Failure
• Air discharge pressure sensor
• Engine Turbo Boost Press. Sensor Failure
• LP element temperature sensor
• Engine Oil Pressure Sensor Failure
• MP element temperature sensor
• Engine Fuel Pressure Sensor Failure
• Loaded solenoid valve output
• Engine Coolant Level Low
• ECM communication link
• Engine Coolant Temperature Too High
• CAN communication link
• Engine Air Inlet Temperature High
• Engine Oil Pressure Too Low
• Turbo Boost Pressure High
• Engine Fuel Pressure Too Low
• Engine Injector X Failure
• Fuel Temperature Too High
• Engine RPM Sensor Failure
- 80 -
8 Available options
8.1 Preheater 8.2 Heating kit 8.3 Anti-frost device
The preheater option allows setting a higher outlet The heating kit is a cold start option. The anti-frost device is a kind of cover plate that
temperature of the compressed air via the compressor It consists of heater plugs that are to be installed in makes the first aftercooler to cool down the
controller. engine and gearbox, making sure that the engine starts compressed air less and prevents the formed
at temperatures as low as -25°C (-13°F). condensate from freezing.
- 81 -
8.4 Hot weather pack 8.5 Cold climate fuel 9 Storage of the
Cold climate diesel fuel can be used in ambient compressor
conditions as low as -25°C (-13°F).
9.1 Storage instructions
Run the compressor regularly, e.g. twice a week, until
warm.
Load and unload the compressor a few times to
operate the unloading and regulating components.
Close the air outlet valves after stopping.
If the unit is going to be stored

without running from time to time,
protective measures must be taken.
The hot weather pack option allows the compressor to

run in ambient conditions up to 50°C (122°F) (45°C
(113°F) is standard).
- 82 -
10 Disposal
10.1 General 10.2 Disposal of materials
This concept can only succeed with your
When developing products and services, Atlas Copco
tries to understand, address, and minimize the
! help. Support us by disposing
professionally. By assuring a correct
Dispose contaminated substances and material
separately, according to local applicable
negative environmental effects that the products and disposal of the product you help to environmental legislations.
services may have, when being manufactured, prevent possible negative consequences Before dismantling a machine at the end of its
distributed, and used, as well as at their disposal. for environment and health, that can operating lifetime drain all fluids and dispose of
Recycling and disposal policy are part of the occur with an inappropriate waste according the applicable local disposal regulations.
development of all Atlas Copco products. Atlas handling.
Remove the batteries. Do not throw batteries into the
Copco company standards determine strict Recycling and re-usage of material helps
fire (explosion risk) or into the residual waste.
requirements. to preserve natural resources.
Separate the machine into metal, electronics, wiring,
Selecting materials the substantial recyclability, the hoses, insulation and plastic parts.
disassembly possibilities and the separability of Dispose all components according to the applicable
materials and assemblies are considered as well as the disposal regulations.
environmental perils and dangers to health during the
Remove spilled fluid mechanically; pick up the rest
recycling and disposal of the unavoidable rates of not
recyclable materials. with absorbing agent (for example sand, sawdust) and
dispose it according the applicable local disposal
Your Atlas Copco compressor consists for the most regulations. Do not drain into the sewage system or
part of metallic materials, that can be remelted in surface water.
steelworks and smelting works and that is therefore
almost infinite recyclable. The plastic used is
labelled; sorting and fractioning of the materials for
recycling in the future is forseen.
- 83 -
11 Technical specifications
11.1 Torque values 11.1.2 For important assemblies 11.2 Settings of shutdowns and
Assemblies Unit Torque safety valves
11.1.1 For general applications values
Designation Value
The following tables list the recommended torques Axles to frame:
Engine shutdowns (see EOM)
applied for general applications at assembly of the Wheel nuts Nm 80 + 10/- 0
Fuel level 5%
compressor. Bolts, towing eye/towbar Nm 80 ± 10
LP element temperature 250°C
For hexagon screws and nuts with strength grade 8.8: Bolts, towbar/turntable Nm 80 ± 10 MP element temperature 250°C
Bolts, front axle/frame Nm 80 ± 10 Compressor oil pressure 1.2 bar(e)
Thread size M6 M8 M10 M12 M14 M16
Bolts, rear axle/frame Nm 205 ± 20
Nm 9 23 46 80 125 205
Compressor to frame: MP safety valve opening pressure
Bolts, elements/gear casing Nm 80 ± 10 EEC type 15 bar(e)
For hexagon screws and nuts with strength grade Bolts, gear casing/support Nm 205 ± 20 USA/AUS type 220 psi
12.9:
Bolts, support/buffer Nm 205 ± 20 Relief valves opening pressure 3.7 bar(e)
Thread size M6 M8 M10 M12 M14 M16 Bolts, buffer/frame Nm 80 ± 10
Nm 15 39 78 135 210 345 Engine to frame:
Bolts, engine/support Nm 205 ± 20
Bolts, support/buffer Nm 205 ± 20
Bolts, buffer/frame Nm 80 ± 10
Lifting beam to frame:
Bolts, lifting beams/yoke Nm 80 ± 10
(M12)
Bolts, lifting beams/yoke Nm 205 ± 20
(M16)
Bolts, yoke/lifting supports Nm 205 ± 20
Bolts, lifting supports/frame Nm 205 ± 20
- 84 -
11.3 Compressor/engine specifications
Designation Unit Value
Reference conditions
Absolute inlet pressure bar(e) 1
Relative air humidity % 1
Air inlet temperature °C 20
Normal effective working pressure bar(e) 6.9 9.3 10.3
The inlet conditions are specified at the air inlet grating outside the canopy
Limitations
Minimum effective receiver pressure bar(e) 3 3 3
Maximum effective receiver pressure, compressor unloaded bar(e) 8.0 10.3 11.3
Maximum ambient temperature (standard environment) °C 45 45 45
Maximum ambient temperature (hot environment) °C 50 50 50
Minimum starting temperature °C -25 -25 -25
Performance data 1)
Engine shaft speed, normal and maximum r/min 1850 1750 1650
Engine shaft speed, compressor unloaded r/min 1200 1200 1200
Free air delivery 2) l/s 762 718 663
Fuel consumption at full load kg/h 75 74.4 73.2
Fuel consumption at unload kg/h 12.6 12.6 12.6
Specific fuel consumption g/m³ 27.34 28.78 30.67
Typical oil content of compressed air mg/m³ 0
free air
Engine oil consumption (maximum) g/h NA NA NA
Compressed air temperature at outlet valves °C 30 30 30
Noise level
Sound pressure level (LP), measured according to EPA with a tolerance of ± 3dB(A)
dB(A) TBD
under free field conditions at 7 m distance
Sound power level (LW) complies with 84/532/533/EEC and 85/406/EEC limits dB(A) TBD
- 85 -
Design data
Compressor
Number of compressor stages 2 in serial
Engine
Make Cummins
Type QSX15
Coolant Liquid
Number of cylinders 6
Bore mm 137
Stroke mm 169
Swept volume l 15.0
Output according to SAEJ1995 at normal shaft speed kW 395
Load factor % 100
Capacity of oil sump:
Initial fill l 84
Refill (max.) 4) l TBD
Capacity of cooling system (intercooler)
Capacity of cooling system (engine jackets) l 120
Unit
Capacity of compressor oil system l 84
Capacity of fuel tanks l 900
Air volume at inlet grating (approx.) 3) m³/s 15
Unit dimensions
Length mm 5240
(with towbar in towing position) mm 6770
Width mm 2210
Height mm 2350
Weight (ready to operate) kg 8560
Weight (without fuel) kg 7760
- 86 -
Notes
1) At reference conditions, if applicable, and in normal shaft speed, unless otherwise stated.
2) Data Measured according to Tolerance

Free air delivery ISO 1217 ed. 3 1996 annex D ± 5% 25 l/s <FAD<250 l/s
± 4% 250 l/s <FAD
The international standard ISO 1217 corresponds to following national standards:

British BSI 1571 part 1
German DIN 1945 part 1
Swedish SS-ISO 1217
American ANSI PTC9
3) Air required for engine and compressor cooling, combustion and for compression
4) With filter change
- 87 -
11.4 Conversion list of SI units 11.5 Dataplate
into British units 1 Company code
1 2 3 2 Product code
1 bar = 14.504 psi 3 Unit serial number
1g = 0.035 oz ATLAS COPCO AIRPOWER n.v. 4 4 Name of manufacturer
1 kg = 2.205 lbs ★★★★★ 5 5 EEC or national type approved number
-YA3- ★★★★★ -00- ★★★★★ - 6
1 km/h = 0.621 mile/h ★★★★ kg
6 Vehicle identification number
A
1 kW = 1.341 hp (UK and US) 1- ★★★★ kg B 7 7 A. Maximum permitted laden weight of the
1l = 0.264 US gal 2- ★★★★ kg C vehicle
1l = 0.220 lmp gal (UK) B. Maximum permitted road weight of the front
p max(e) . working/betrieb/service bar ★★ 8 axle
1l = 0.035 cu.ft Speed/Drehzahl/Regime rpm ★★★★ 9
10 C. Maximum permitted road weight of the rear
1m = 3.281 ft p engine/motor/moteur kw ★★★★
Manuf. year/Baujahr/Ann ³e de fabrication ★★★★ 11 axle

1 mm = 0.039 in
8 Working pressure
1 m³/min = 35.315 cfm 9 Speed
1 mbar = 0.401 in wc 10 Engine power
MADE BY ATLAS COPCO AIRPOWER n.v. WILRIJK, BELGIUM
1N = 0.225 lbf 11 Manufacturing year

1 Nm = 0.738 lbf.ft 1615 6945 00
12 EC mark in accordance with Machine Directive
12
t°F = 32 + (1.8 x t°C) 89/392 EEC
t°C = (t°F - 32)/1.8
A temperature difference of 1°C = a temperature

difference of 1.8°F.
- 88 -
Circuit diagrams
- 89 -
9822 0900 20/00
Applicable for PTS 1600 T3, Circuit diagram Engine and Controller
04.1, 05.1
24 (a2)
24 (k0)
24 (c2)
24M (a2)
24 (f2)
24 (f2)
87
K1 F5
08.2
30 3A
25M (a2)
3 (c3)
KO
MATIC 03.5 25M (a2)
VARIANTS SCHE 04.1
G1
G2 +
_ M1
DC DC KO G4
G3 + M 441
SEE ECC OR USA
_
(k0)
03.4
19U
19U
(b6 19U) 05.1
S1
19 (k0)
19 (f6)
19 (f6)
04.1, 05.1, 05.1, 05.1, 05.5, 05.6, 06.1, 06.1, 08.1
- 90 -
03.9 24 (c2)
F1
20 A
05.10
05.10
05.10
05.9
06.1
99
(b2)
(b2)
(b2)
(b2)
(b2)
(a3)
X1-18 X1-20 X1-07 X1-08 X1-17 X1-38
LS5 15 (a3) H2
X1-06
C
1004 (a2)
X2-17 X1-16 8 (a3) H3
1005 (a6) X1-05
6 (a3) H5
B X2-19
X1-04
306 (a3) H7
1006 (a3)
A X2-06 X2-27 1002 (b3)
1007 (a7)
N4
Y3 A1
D X2-05 ENGINECONTROL MODULE
A2
X2-11 1003 (b3)
24M (b2)
28 (a3)
20 (a8)
21 (a7)
19 (c6)
A B C D E
X10
X1-50 X1-40 X1-39 X1-30 X1-29
19 (b6)
19 (b6)
19 (b6)
19 (b6)
19 (b6)
03.9 25M (a2)
03.9 19 (c6)
- 91 -
24
03.9
24(d2)
24(b2)
24 (a2)
F4 2 F3 2
Y7 A1 38 (a3) SEE ECC OR USA
VARIANTS SCHEMATIC
a2
F7 S7 20A 1 10A 1 27M (d2)
24MF4 (d2)
A2 06.1
24M (b2)
24M (b2)
10A p
38 (a3)
a0
241M
7 8
241M (a2) 44 (a3)
16 15 4 2
(b2)
K4 S2
5
USER INTER
FACE
R1 6 8
N1 S3 16 26 (d2)
6
19 (c6) 8
24MK4 (d2) 12
241M (a2) 39 (a3)
11 12 17
S6
13
241M (a2) 1 9 19UM (a6)
11
3 4
A 15 28 (a3) 04.1, 06.1, 07.2

P.A.C
B 4 20 (a8)
Can H 04.1, 06.1
C 5 21 (a3)
Can L 04.1, 06.1
3 4 E 6 18 (a8)
Sig. gnd 06.1
IL (a3)
connector for
241M (a2) (a6) 19UM DDRreader 7
1 N2 2
H1-3
1000 (a3)
1001 (a3)
24M (a2)
19 (c6)
19 (c6)
04.8
04.8
04.1
N3
19U (a6)
F8
03.3
10A
08.1 39 (a3)
19 (b6)
03.9
- 92 -
63 (a5)
SIG 07.2
FUEL LEVEL SENSOR
83 (a7)
OV 07.2
58 (a5) 07.4
SIG
COMPRESSOR OIL
TEMPE
RATURE SENSOR 78 (a7)
OV 07.4
SIG
59 (a5)
27M (d2) 27M (a2) 07.5
05.10 LOW PRESSURE ELEMENT
301
TEMPE
OV 07.5
60 (a5)
+12V 07.2
MEDIUM PRESSURE ELEMENT
27M (a2) TEMPE
EMERGENCY STOP OV 07.2
307
61 (a5)
+12V 07.6
HIGH PRESSURE ELEMENT
TEMPERATURE SENSOR 81 (a7)
OV 07.6
27M (a2) 57 (a5)
318 +12V 07.7
AMBIENTTEMPE
RATURE
SENSOR 77 (a7)
OV 07.7
+12V
62 (a5)
AIR DISCHA
RGE
07.7
TEMPE
OV 07.7
+12V
40 (a3)
07.10
AIR DISCHA
RGE 50 (a9)
PRESSURE SENSORSIG 07.10
70 (a5)
OV 07.9
28 (a3) +12V
41 (a9) 07.8
04.7, 05.10
319
COMPRESSOR INTE
RCOOLER 2 51 (a5) 07.7
PRESSURE SENSOR SIG
OV
71 (a7)
07.8
20 (a8) 42 (a9)
05.10 USER INTER
FACE +12V
311
07.6
COMPRESSOR INTE
RCOOLER 1 52 (a5)
SIG 07.6
218 214 205 221 215 211 216 217 210 219 131 122 204 220 201 212 207 203 224 208 209 223
PRESSURE SENSOR
21 (a8) 72 (a7)
05.10 OV 07.6
213
314
43 (a9)
+12V 07.4
121
18 (a8) COMPRESSOR OIL 53 (a5)
- 93 -
04.7, 05.10 PRESSURE SENSORSIG 07.4
111
128
X1(CONTROLLER)
73 (a7)
OV 07.4
113
ENGINE OIL
(OVERFILL SHUTDOWN) 34 (a5)
LEVEL SWI
TCH 08.8
118
ENGINE OIL (SHUTDOWN)

37 (a5)
08.6
120
LEVEL SWI
TCH
ENGINE OIL
(WARNING)
36 (a5)
08.5
130
LEVEL SWI
TCH
439 (a3) ECM

35 (a5)
04.6 ENGINE OIL (FULL) 08.4
324
126
LEVEL SWITCH
30 (a5)
08.3
136
EXTERNAL FUEL SUPP

LY
SWITCH
18 (a6)
SPARE 08.1
129
320
AUTOMATICACTUATOR 10 (a3)
SOLENOID
08.10
310
SPARE SPARE
305
321
OIL LEVELMAINTAINER 9 (a3)

SOLENOIDVALVE
08.9
315
SPARE 5X3 (a3)

DIODE 08.7
323
302
ENGINE TOP
S LAMPP
4 (a3)
08.6
303
BLOW OFF SOLENOID

VALVE
7 (a3)
08.5
304
LOADING SOLENOID
VALVE
7 (a3)
08.4
309
1 (a3)
AUXILIARY STARTER REL
AY 08.3
312
ECM
308
313
19 (b6) 03.9
19 (b6) 03.9
83 (a7)
U
06.1
V-
63 (a5)
+
06.1
LT2
28 (a3)
05.10
V+
TT1
U
(a7) 78 58 (a5) 73 (a7) 06.1

L-
06.1 06.1
53 (a5)
+
06.1
PT4
43 (a9) 06.1
L+
P
06.1
(a7) 79 TT2
TT3 59 (a5)
06.1
(a7) 80 60 (a5)
06.1 06.1
72 (a7)
U
06.1
L-
52 (a5)
+
06.1
TT4
PT3
(a7) 81 61 (a5) 42 (a9) 06.1

06.1 06.1
L+
P
- 94 -
TT5
(a7) 77 57 (a5)
06.1 06.1
TT6
(a7) 82 62 (a5) 71 (a7)

U
06.1 06.1 06.1

L-
51 (a5)
+
06.1
PT2
41 (a9) 06.1
L+
P
70 (a7)
U
06.1
L-
50 (a5)
+
06.1
40 (a3)
PT1
06.1
L+
P
05.1
03.9
06.1
39 (a3)
19 (b6)
18
K1
87
19 (a6) 1 (a3)
06.1
S5
86
85
18 (a6) 30 (a5) 06.1
30 03.5
Y1
19 (a6) 2 (a3)
LS1
06.1
A2
A1
18 (a6) 35 (a5)
06.1
Y4
19 (a6) 7 (a3)
LS2
06.1
A2
A1
18 (a6) 36 (a5)
06.1
- 95 -
H4-5
19 (a6) 4 (a3)
LS3
06.1
18 (a6) 37 (a5)
06.1
D1
H6
19 (a6) SH6 (a3) 5X3

LS4
06.1
2
1
18 (a6) 34 (a5)
06.1
D2
Y2
19 (a6) 9 (a3)
06.1
A2
A1
Y6
19 (a6) 19 (a6)
06.1
A2
A1
D1 Diode LS4 Level Switch - Engine Oil Level Overfill TT1 Temperature Sensor - Compressor Oil
D2 Diode Shutdown Temperature
F1 Fuse ECM LS5 Level Switch - Coolant TT2 Temperature Sensor - Low Pressure
F3 Fuse User Interface LT2 Level Sensor - Fuel Level Element Temperature
F4 Fuse Controller M1 Starter Motor TT3 Temperature Sensor - Medium Pressure
F5 Fuse Flap Lock Solenoid N1 Detection module Element Temperature
F7 Fuse Fire Extinguisher N2 IR interface module TT4 Temperature Sensor - High Pressure
F8 Fuse Fire Extinguisher N3 Flame detector Element Temperature
G2 Battery N4 Engine control module TT5 Temperature Sensor - Ambient
G3 Battery PT1 Pressure Sensor - Air Discharge Pressure Temperature
H1-3 Lamp Internal Lights PT2 Pressure Sensor - Compressor Intercooler TT6 Temperature Sensor - Air Discharge
H2 Lamp Engine Stop Pressure 2 Temperature
H3 Lamp Engine Warning PT3 Pressure Sensor - Compressor Intercooler Y1 Solenoid Loading Valve
H4-5 Lamp Engine Warning Pressure 1 Y2 Solenoid Oil Level Maintainer Valve
H5 Lamp Maintenance PT4 Pressure Sensor - Compressor Oil Pressure Y3 Refinery Equipment - Air Shut-off Valve
H6 Horn R1 Resistor 4K7 Y4 Solenoid Blow-off Valve
H7 Lamp Wait-to-start S1 Battery Switch Y6 Solenoid Automatic Actuator
K0 Starter Motor Relay S2 Emergency Stop Y7 Solenoid Automatic Actuator
K1 Auxiliary Starter Relay S3 Emergency Stop
K4 Solid State Relay S5 External Fuel Supply Switch
LS1 Level Switch - Engine Oil Level Full S6 Internal Lights On/Off Switch
LS2 Level Switch - Engine Oil Level Warning S7 Pressure Switch
LS3 Level Switch - Engine Oil Level Shutdown (for manual actuator)
- 96 -
- 97 -
9822 0899 97/01
Applicable for PTS 1600 T3 - Circuit diagram (EC)
Cubicle
K1
L1 X3:E L1 X1:B L1 X7:4 L1 1 2 LM
C1 C1 C1 C1 C1
L2 X3:D L2 X1:A L2 X7:5 L2 3 4 LM
C1 C1 C1 C1 C1
Q1 G1
X5 X4:1
X7:6 LM 24 X7:3 24
L L +
L C1 C1 b2 b2
PE N TO MAIN
PE N X7:7 N 19 X7:2 X4:2 19
C54 C6
C6
N
PE
-
b6 b6 CIRCUIT
L1 L2 L2 DIAGRAM
C1 C1 C1 X7:8 PE 24M
C54 a2
X2:1
R3 R2 R1
A11
a2
PE
S1
PE PE
C54 C54 C54 USER
A3 A2 A1 A1 INTERFACE
C1 C1 C1 a3
TS3 TS2 TS1 19 X2:2
b6
A1
a3
K1 X4:3
N2 A1
C6 N1 a3 A1
N1
C6 C6 a3
X7:1
PE X3:C PE X1:C PE
C54 C54 C54
N1 X3:B N1 X1:D N
C6 C6
N2 X3:A N2 X1:E N C6
C6 C6 C6 Legend
K1
Wire size : Colour code :
2
aaa = 0.35mm 0 = black
aa = 0.5mm 2 1 = brown A7
ab = 0.75 mm 2 2 = red A7
a = 1 mm 2 3 = orange -
b = 1.5mm 2 4 = yellow
-
c = 2.5mm 2 5 = green
d = 4 mm 2 6 = blue
e = 6 mm 2 7 = purple
f = 10 mm 2 8 = grey
h = 16 mm 2 9 = white
j = 50 mm 2 54= green/yellow
k = 95 mm 2
- 98 -
G1 Battery charger
K1 Relay
Q1 Circuit breaker
R1 Water separator drain nozzle heater
R2 Engine oil heater
R3 Compressor oil heater
S1 Heater switch
TS1 Temperature switch
X1 Connector rear mains wiring
X2 Connector user interface
X3 Connector main mains wiring
X4 Connector rear wiring
X5 Power socket
X7 Terminal strip
- 99 -
9822 0899 98/01
Applicable for PTS 1600 T3 - Circuit diagram (USA)
Cubicle
X3:E X1:B L1 1
K1 2
L1 L1 X7:4 L1 LMA
C1 X3:D C1 X1:A L2 C1 C1 C1
L2 L2 X7:5 L2 3 4 LMB
C1 C1 C1 C1 C1
Q1 G1
X5 LA X7:3 X4:1 24
X7:6 LMA L 24
L LA
C1 C1
+
b2 b2 TO MAIN
C1
PE
PE NA X7:7 NA X7:2 X4:2 19 CIRCUIT
N C6 NA N - 19 DIAGRAM
C54 C6 C6 PE b6 b6
L1 L2 L2
C1 C1 C1 PE 24M
C54 a2
X2:1
R3 R2 R1 Q2
X6 A11
LB X7:8 LB LMB
L C1 a2
C1 C1
PE NB S1
PE PE PE PE N
C54 C6
C54 C54 C54
A3 A2 A1 A1 USER
C1 C1 C1 X7:9 PE a3
TS3 TS2 TS1 C54 19 X2:2 INTERFACE
b6
A1
a3
K1 X4:3
N2 A1
C6 a3 A1
N1 N1 a3
C6 C6
X7:1
PE X3:C PE X1:C PE
C54 C54 C54
N1 X3:B N1 X1:D NB
C6 X3:A C6 C6
N2 N2 X1:E NA
Legend
C6 C6 C6 K1
Wire size : Colour code :
aaa = 0.35mm 2 0 = black A7
aa = 0.5mm 2 1 = brown A7
ab = 0.75 mm 2 2 = red -
a = 1 mm 2 3 = orange -
b = 1.5mm 2 4 = yellow
c = 2.5mm 2 5 = green
d = 4 mm 2 6 = blue
e = 6 mm 2 7 = purple
f = 10 mm 2 8 = grey
h = 16 mm 2 9 = white
j = 50 mm 2 54= green/yellow
k = 95 mm 2
- 100 -
G1 Battery charger
K1 Relay
Q1 Circuit breaker
Q2 Circuit breaker
R1 Water separator drain nozzle heater
R2 Engine oil heater
R3 Compressor oil heater
S1 Heater switch
X1 Connector rear mains wiring
X2 Connector user interface
X3 Connector main mains wiring
X4 Connector rear wiring
X5 Power socket
X6 Power socket
X7 Terminal strip
- 101 -
9822 0899 30/02
Applicable for PTS 1600 T3 - Circuit wiring
EM
ST
CAT LEVEL SW
TOPTANK
BATTERY SWITCH RAD
FUEL SENDER
FUEL FILTER
CONTINUOUS ENGINE
pICLP
HEATER
GROUND FOR HEATER
INTERNAL LIGHTS
FRONT SIDE
BLOW OFF
MOTOR
tOUTMP t COMP
OIL
OILER ENGINE HEATER TEMP. SWITCH
ECM REFINERY
VALVE EQUIPMENT
HORN
FLASHER
SOL
LOCK
FLAP
INTERNAL LIGHT FLASHER
COMP OIL HEATER

LIGHT START
ALT ENGINE
pICHP LIGHT
COMP HEATER t SW
STARTER
B+ RELAY
tAMB D+
tOUTHP pOILCOMP
p
DISCH PRIMING
D- PUMP
WS DRAIN HEATER (ELECTRICAL)
WS DRAIN SWITCH 1
LOAD
SOL
RELAY AND
CIRCUIT
BREAKER
FUEL SWITCH
tDISCH SD
EXT/INT
W FULL OVER
tOUTLP
M
C
C
USER INTERFACE
ENGINE OIL LEVEL SWITCHES
V BAT C
THIS WIRE IS PLACED BENEATH THE ELEMENT
1604 7429 02
1604 7781 01
9822 0899 97 EC
9822 0899 98 USA
1604 2050 00
- 102 -
- 103 -
1626 8282 00/00 (page1/2/3)
Applicable for PTS 1600 T3 - Wire harness front See note 53
2
See note 51 6 4
CIRCUIT
ALTERNATOR 8
BREAKER ADDITIONAL CIRCUIT CIRCUIT
See note 54 58 60 SOLID STATE RELAY USER CIRCUIT BREAKER BREAKER
6 4 8 2 INTERFACE BREAKER CONTROLLER ECM
818 819 820 821 95 96 117 118 822 823 81 82
24
19
150
250 See note 19
Cavity: AIR INLET See note 19
24MF4
27MK4
240M
24MF4
4 31-PIN BREAKOUT
24M
25M
1 SHUTDOWN VALVE See note 19
24
24
24
1
19
38
24
CONNECTOR AUXILIARY
250
9
150
2 2 1 2 1 2
100
20 50 See note 34 STARTER RELAY 1 2
3 3
1400
1002 27 72 71 241M
21 945 810 1+
4 4 1003
30 946 11 825 824 130 19UM
5 5 811 2-
63 56 57 69 70 241M 11 AL NO
6 6 812
100 1007 05
8 19 83 948 100
9
7 7
44
38
10
2 7 18 1004 07 39
24M 949
70
813 12 AL C
50
11 3 1 6
8 14
1002
1003
17
12 4 5 16 1005 19 970 130 44
950
150
25M
19
24
15 SH C
150
814
20
1
3
13
14 15
9 8 1006
24 951 06 100 Splice 241M 16 SH NC
10 15 815
See note 1 801
5H6
11 9 100
600
62
13 10 241M
0
10
1+
300 130 816
0
82
10
15 11 19UM 2-
24 817
16 16
57
17 12
lice
77
Sp
19 13 200 200 300 600 400 800 300
Wires braided until TO PAGE 2
inside connector 18 5X3
1 18 807 805 806 97 100 103 Splices: in this area 39 832 831 830
750
0
IL 5H6
40
800
2 19 STARTER ENGINE 150 See note 65
28 19 Splice Diodes integrated
3 20 note 18b 74
15 350 802 200 into wiring
6 23 24 3
note 18a 76 100 75 STARTER RELAY
50
13
7 24 Splices:
40
50
70
9 8 19
note 56 note 26.1
50
10
2 7 18
26
19B
11 17 8 30 73 note 57
IL
3 1 6
400
100
12 4 5 305 in this area 241M 241
FIRE EXTINGUISHER
16
13 14 15 9 25 826
19 53 52 51
10 31 CAN 19 70 70
See note 2 10 J-1939 C 930 106 107
11 55 label: 21 100
27MK4 B 932
12 840 CAN J1939 A 933 20
306 See note 7 See note 30 30 Splice
13 26 1 3 1 2
AIR DISCHARGE See note 31
100
19UM 4 2 102 803 804
14 841 PRESSURE
16 842
19B in this area See note 9
INTERNAL LIGHT
20 45 20
70 (x4)
50
240M
240M
240M
240M
240M
37
18
18
36
18
35
18
34
305
306
19
19
19
19
19
99
15
13
61 62 63 64 65 66 67 68 903 904 905 906 907 908 909 910 911 912 913 914 915 916 917
1 2 1 2 1 2 1 2
Cavity: 29 30 39 40 37 18 28 07 08 17 38 06 16 05 04
See note 9 See note 9 See note 9 See note 9 ENGINE

ENGINE OIL ENGINE OIL ENGINE OIL ENGINE OIL OVERFILL ELECTRONICS
See note 3
SHUTDOWN LEVEL WARNING LEVEL FULL LEVEL SHUTDOWN LEVEL
PAGE 1
- 104 -
X1 1 2 3 4 5 6 7 8 9 10 X2 1 2 3 4 5 6 X3 1 2 3 4 5 6
15 16
11 20
CONTROLLER 21 30
See note 11 7
13
12
18
See note 12 7
13
12
18
See note 13 LP-IC PRESSURE
25 26
See note 7
31 32 33 34 35 36 37 38 39 40 19 20 21 22 23 24 19 20 21 22 23 24
2 4
Cavity: 122 131 111 113 118 120 121 126 128 129 130 136 201 203 204 205 218 207 208 209 210 211 212 213 215 216 217 219 220 221 214 223 224 301 302 303 304 307 308 309 311 310 312 313 314 315 318 319 320 321 323 324 3 1
first digit is
connector number 150 151 152 153 154 155 156 157 158 159 160 161 162 163 164 165 166 167 168 169 170 171 172 173 174 175 176 177 178 179 180 181 182 183 184 185 186 188 189 190 191 244 192 193 194 195 196 197 201
See note 9 234 235 236

1 2
INTERNAL LIGHT
27M
27M
27M
5X3
77
57
53
73
34
37
43
35
18
18
36
30
40
41
62
58
63
70
71
42
61
79
50
72
59
60
80
81
82
78
83
52
51
19
20
10
19
21
28
99
4
7
9
232 233
50 (x3)
71
51
41
50
19B
IL
50
300
300
600
30
0
1200
100 600 150 250 250 300 200
TO PAGE 1 TO PAGE 3
300
300
250
50
50
81
61
52
72
42
60 221 See note 8
80
350
216 215 214 213 212 222 MP ELEMENT TEMPERATURE
100
See note 8
750
See note 16 HP-IC PRESSURE
See note 7 100
See note 15 1 3 COMPRESSOR OIL TEMPERATURE
4 2
58
HP ELEMENT TEMPERATURE 223
See note 8
78 224
79 217
800
59 See note 8
218
150
50
100
See note 7 LP ELEMENT TEMPERATURE
202
43
53
2 4
3 1
203
204
73
550
COMPRESSOR OIL PRESSURE

50
19
2
205 206
2 1
3
See note 14
LOADING VALVE
PAGE 2
- 105 -
See note 21
FLASHER LIGHT
See note 19
1 2
COOLANT LEVEL
See note 40
D B A C
918 900 901 902 304 305
50
1007
1005
1006
1004
19
BLOW OFF VALVE
4
50
50
1
7
300
300
See note 14 3 19
301
2
1000
1700
2200
150
26
306
1800 1400
TO PAGE 2
27M EMERGENCY STOP
307
Splice:
308 105
in this area
PAGE 3
- 106 -
TERMINAL END A TERMINAL END B WIRE
NR. TERMINAL NR. TERMINAL NR. MM² COLOR
69 see note 19 192 see note 13 1 1 orange
71 AMP 342145-1 75 AMP 130090-0 3 2.5 orange
185 see note 13 97 splice 4 1 orange
304 see note 19 4 1 orange
1 see note 1 4 1 orange
62 see note 9 73 splice 18 1 blue
63 see note 9 18 1 blue
158 see note 11 18 1 grey
18 see note 2 18 1 grey
31 see note 2 74 see note 18 19 4 blue
60 AMP 165034-0 74 see note 18 19 10 blue
189 see note 13 74 see note 18 19 1.5 blue
193 see note 13 74 see note 18 19 1.5 blue
803 Splice 903 see note 3 19 1.5 blue
904 see note 3 19 1.5 blue
930 See note 30 19 1 blue
- 107 -
807 Splice 818 faston AMP 5-160446-2 19 1 blue
842 see note 2 103 splice 19B 1 blue
107 see note 9 19B 1 blue
233 see note 9 19B 1 blue
841 pin Deutsch 1060-12-0166 800 splice 19UM 1 blue
811 uninsulated wire ferrule AMP 0-925856-1 19UM 1 blue
817 uninsulated wire ferrule AMP 0-925856-1 19UM 1 blue
818 faston AMP 5-160446-2 19UM 1 blue
3 see note 1, 31 805 splice 20 1 grey
191 see note 13, 31 20 1 grey
933 see note 30, 31 20 1 grey
4 see note 1, 31 806 splice 21 1 purple
194 see note 13, 31 21 1 purple
932 see note 30, 31 21 1 purple
19 see note 2 100 splice IL 1 orange
106 see note 9 IL 1 orange
232 see note 9 IL 1 orange
15 see note 1 76 see note 18 24 4 red
58 AMP 33466, see note 54 76 see note 18 24 10 red
117 AMP 3-520117-2 76 see note 18 24 2.5 red
95 AMP 3-520117-2 76 see note 18 24 1.5 red
72 AMP 342145-1 76 see note 18 24 2.5 red
822 insulated faston 6,3x0,8 76 see note 18 24 4 red
81 AMP 3-520117-2 76 see note 18 24 2.5 red
- 108 -
908 see note 3 102 Splice 240M 1.5 red
909 see note 3 240M 1.5 red
82 AMP 3-520117-2 240M 2.5 red
910 see note 3 240M 1.5 purple
826 eye M12 802 splice 241 inline fuse; see notes 56. 57 red
801 splice 241M 1 red
810 uninsulated wire ferrule AMP 0-925856-1 241M 1 red
14 see note 1 96 AMP 3-520117-2 24M 1.5 red
118 AMP 3-520117-2 8 see note 1 25M 1.5 red
30 see note 2 306 terminal end 26 4 red
307 terminal end 105 splice 27M 4 red
183 see note 13 27M 1 red
823 insulated faston 6,3x0,8 821 faston AMP 160913-4 24MF4 4 red
820 faston AMP 160913-4 840 see note 2 27MK4 4 red
5 see note 1 161 see note 11 30 1 green
819 faston AMP 5-160446-2 824 socket Deutsch 0462-201-16141 38 1 orange
- 109 -
813 uninsulated wire ferrule AMP 0-925856-1 832 splice 39 1 orange
831 splice diode 1N5402 (3A, 100V)
9 see note 1 5H6 1 orange
830 splice diode 1N5402 (3A, 100V)
184 see note 13 5X3 1 orange
163 see note 12 236 see note 7 41 1 white
814 uninsulated wire ferrule AMP 0-925856-1 825 socket Deutsch 0462-201-16141 44 1 orange
168 see note 12 234 see note 7 71 1 purple
- 110 -
917 see note 3 26 See note 2 306 1 orange
56 see note 19 945 see note 34 1002 1.5 orange
57 see note 19 946 see note 34 1003 1.5 orange
- 111 -
NOTES
Note 1: Connector: Deutsch HD N 36 - 24-19 SN Note 11:Connector: Deutsch DRC 16-40S

- 059 Terminals: Deutsch 0462-201-16141
Terminals: Size 12 (large): Deutsch Unused cavities to be sealed with:
0462-203-12141 Deutsch 11407
Size 16 (small): Deutsch
0462-201-16141 Note 12:Connector: Deutsch DRC 16-24S
Unused cavities to be sealed with: Terminals: Deutsch 0462-201-16141
Deutsch 114017 Unused cavities to be sealed with:
Deutsch 11407
Note 2: Connector: Deutsch HD N 34 - 24-19 PN
- 059 Note 13:Connector: Deutsch DRC 16-24SB
Terminals: Size 12 (large): Deutsch Terminals: Deutsch 0462-201-16141
0460-202-12141 Note 7: Connector: G&H 17984.000.001 Unused cavities to be sealed with:
Size 16 (small): Deutsch (DIN 72585 - 4 pins) Deutsch 11407
0460-202-16141 Terminals: G&H 26570.201.184
Nut: Deutsch 112263-90 Wire seal: G&H 14414.627.626 Note 14:Connector: Hirschmann GDM-2009J
Lockwasher:Deutsch 112264 Unused cavities to be sealed with: Seal: Hirschmann GDM3-16
Unused cavities shall be sealed with: G&H 14416.627.646
Deutsch 114017 Wiring braided until connector, and Note 15:Connector: G&H 14730.598.696
attached to strain relief with nylon strap. Use this connector for sealing the
Note 3: Connector: Deutsch HD36-24-47SE G&H 17984.000.002
Terminals 1.5 mm²: Note 8: Connector: AMP 0-963040-3
Deutsch 1062-16-0122 Terminals: AMP 0-929939-1 Note 16:Connector: AMP 106462-1
Terminals 1 mm²: Wire seal: AMP 828904-1 Use this connector for sealing the
Deutsch 1062-20-0122 Seal grommet:Bosch 1280 703 26026 AMP 0-963040-3
Unused cavities shall be sealed with:
Deutsch 114017 (1 mm²) Note 9: Connector: Deutsch DTM 06-2S
Deutsch 0413-204-2005 Terminals: Deutsch 1062-20-01221
(1.5 mm²) Wedge: Deutsch WM 2S
- 112 -
Note 18:AMP 133544-4 Note 22:Wire insulation should be resistant to oil,
Shrinkable sleeve to be attached as in fuel and coolant.
drawing.
Wall thickness: min. 1 mm. Note 27: All wire type H05V-K/H07V-K according
Wires may be devided over two terminals if to AC standard 0995 2000 00 unless
necessary. specified otherwise
1 2 3
Note 30:connector: Deutsch DT 06-3S
terminals: Deutsch 0462-201-16141
secondary lock :Deutsch W3S-1939
Note 53:Relay socket
Note 31:Twisted cables 3 turns each 100mm Housing: Bosch 3 334 485 008
Faston: AMP 5-160446-2
5 4 Faston: AMP 160913-4
Note 34:Connector: Deutsch HD36-24-31SE-059
1: Braiding Terminals: Deutsch 1062-16-0122
2: Insulated wires Unused cavities to be sealed with: Note 54:Terminal provided with a red shrinkable
3: Terminal Deutsch HD10-114017 sleeve
4: Non-insulated wires
5: Sleeve Note 40:Connector body: Note 55: Deutsch DT Series
Packard Electric 12110293 housing Deutsch DT 06-2S
Note 18a: The colour of the shrinkable Terminals: Packard Electric 12048074 socket Deutsch 0462-201-16141
sleeve should be red Wire Seals: Packard Electric 12048087 wedge Deutsch W2S
Note 18b: The colour of the shrinkable Secondary lock :
sleeve should be blue Packard Electric 12052845 Note 56: Fuse holder Multicomp MCCQ-211CN
Note 41:Relay socket (or equal)
Note 19:Connector: Deutsch DT 06-2S Housing : E-T-A R20-4B5-0 + BS-01
Terminals: Deutsch 0460-201-16141 Faston : 6,3 x 0,8 Note 57: Fuse (10A) Littelfuse 0257010(or equal)
Wedge: Deutsch W 2S or
Note 51:Protection cap: 1612 0846 00 (or equal) Multicomp MCATQ 10A
Note 20:Connector: Deutsch DT 04-2P ORIENTATION AS STATED BELOW Fuse holder's wires to be cut to appropriate
Terminals: Deutsch 0460-202-16141 Harness to be fixed on the protection cap. length
Wedge: Deutsch W 2P
Note 52:Rubber cap mounted over eye terminal. Note 60: Wire harness shall be provided with a
Note 21:This part of the harness should be resistant Use nylon strap to prevent rubber cap from marking label with AC part number and
to temperatures up to 105 °C. falling off edition
- 113 -
Note 61: Scan test to be performed on every
conductor
Note 62:Marking to be printed on each end of all

wires
Note 63:All plugs seen from wire connecting side
Note 64:Wire harness finishing: black braiding,

unless stated otherwise
Note 65:Diodes positioned as on drawing
Note 66:Terminal and shrinkable sleeve to be

mounted as in drawing
Wire number printed on shrinkable sleeve
1 2 3
5 4
1: Braiding
2: Insulated wires
3: Terminal
4: Non-insulated wires
5: Sleeve
Note 66.1 shrinkable sleeve color = red

Note 66.2 shrinkable sleeve color = blue
Note 67:Label indicating AC part. Nr.and edition,

testing and/or production date, supplier
reference
Black text on white background
- 114 -
- 115 -
1626 9916 00/02
Applicable for PTS 1600 T3 - Wire harness rear
See note 2 USER INTERFACE

19 8 9
18 7 2 10
12 17 6 1 3 11
16 5 4 12
14
15 13
OILER VALVE 9 10
See note 1
1 2 3 8 4 5 6 7 11 12 13 15 16 17 250
CONTINUOUS GROUND
19
FOR INTERNAL LIGHTS OUTLET TEMP. REG. VALVE
9
71 72 82 17 18 19 20 21 22 23 24 25 26 27 4 1
30
50
10 9
76 94 350 31 2
1
19 50
95 20 3
32
27MK4
See note 3 50 24M COSMOS
1001
1000
21
103 107 106 104 105

24M
24M
33 4
A
A1
20
21
18
19
22
28
26
50
4
19
19B
A E 30
50
34 5
B
28 B D 63
35 6
C
450
C
Splice : 20 83 (Male)
FUEL FILTER HEATER AMBIENT TEMPERATURE See note 12 36 7
D
400
77 See note 7 See note 6 21 25M

19 8 9
37 9 18 10
E
7 2
in this area 24 84 20 17 6 1 3 11
50 5H6 11
50
38 16 5 4 12
24M 85 22 See note 2 15

14
13
7 54 12
88
2 1
19B 19B
86 8 62
39 13 See note 4
300 50
INTERNAL LIGHT 55
89 14
200
24 1 82
61
4 3
67 68 200 40 15
FUEL LEVEL 19 2 1 2 57
62
See note 11 41 17
A1 3 77
63
50 19
+24VDC See note 5 42
850
200
57
supply 28 77
24M 8
99 43
130 24
2300 100 350 2170 280 200 250 80 44 10
3 1
2 4
signal 63 24
1 87 16
Splices :
150
ground 83
5H6
2
19
19
49 51 52 53 66 83 100 101 102

4
18 1
46
in this area
500
150
500
22 2
47
450
28 3
3 4 5 6 48
1001 4
49 (Female)
50
30
18
1000 5
50
50 8
62
82
19 9
2
See note 2 1 2 1
See note 3 15
18 7 2 10
HORN FLASHER LIGHT 56 6 1

Splice 17
16
6 3
12
11
13 7
5 4
210 96 15
14
13
54 28 29 305
500 90 57 9
1
FUEL FILTER 78 79
55 CONNECTOR 10 See note 1
91 58 11
19UM
50
50
25M
305
306
313
314
315
306
36J
See note 9 13
15
13
64
70
1 2
note 13 See note 6 313
65 15
note 14 314
EXT/INT FUEL 66 17
SELECTION SWITCH 110 111 112 113 114 115 116 117 118 315
69 19
See note 2
130
note 26.2 AIR DISCHARGE 26

TEMPERATURE 70 8
A B C D E F G H J
19U
19 10
73
SELECTION SWITCHES
27MK4
INDICATOR LIGHTS 200 12
See note 15 19UM 201 14
202
19B 16
74
36J 18
75
- 116 -
nr. terminal nr. terminal nr. mm² color
1 See note 11 35 See note 11 63 1 Green
2 See note 11 36 See note 11 63 1 Purple
3 See note 2 38 See note 4 5H6 1 Orange
30 See note 4 83 Splice 4 1 Orange
82 See note 1 4 1 Orange
96 See note 1 111 See note 15 13 1 Orange
4 See note 2 49 Splice 19 1 Blue
6 See note 3 19 1 Blue
21 See note 1 19 1.5 Blue
202 eye M10 210 splice 19U inline fuse; see note 2
201 socket Deutsch 1062-12-0166 19UM 1 blue
22 See note 1 22 1.5 Orange
84 See note 7 87 See note 4 24 4 Red
17 See note 1 51 Splice 24M 1.5 Red
43 See note 4 24M 1.5 Red
85 See note 7 24M 1 Red
103 See note 12 24M 1.5 Red
71 See note 1 24M 1 Red
37 See note 1 118 See note 35 25M 1 Red
- 117 -
18 See note 1 101 Splice 20 1 Grey
32 See note 4 20 1 Grey
19 See note 1 102 Splice 21 1 Grey
20 See note 1 53 Splice 18 1 Blue
23 See note 1 200 See note 4 27MK4 4 Red
76 AMP 160136-0 77 Splice See note
8 See note 2 19B 1.5 Blue
86 See note 7 19B 4 Blue
72 See note 1 63 See note 5 A1 1 Orange
- 118 -
75 See note 1 116 See note 15 36J 1.5 Orange
- 119 -
NOTES
Note 1: Connector: Deutsch HD 36 - 24-19 SN - Note 5: Connector: Deutsch DTP 06 - 4S Note 10:Wire insulation should be resistant to oil, diesel
059 Terminals: Deutsch 0460-204-12141 fuel and coolant.
Terminals: Size 12 (large): Deutsch Unused Cavities to be sealed with:
0462-203-12141 Deutsch 114017 Note 11:Connector according to DIN 72585 4 pins.
Size 16 (small): Deutsch Secondary Lock: Deutsch WP 4S Connector: G&H 17984.000.002
0462-201-16141 Terminals: G&H 26570.201.184
Unused Cavities to be sealed with: Note 6: Connector: AMP 0-963040-3 Wire seal: G&H 14414.627.626
Deutsch 114017 Terminals: AMP 0-929939-1 Unused cavities to be sealed with:
Wiring braided until connector, and Wire seal: AMP 828904-1 G&H 14416.627.646
attached to strain relief with nylon strap. Seal Grommet: Bosch 1280 703 26026 Strain relief of fuel level:
G&H 14830.625.699
Note 2: Connector: Deutsch DTM 06-2S Note 7: - Terminals 84, 85 shall be equipped with a Wiring braided until connector, and
Terminals: Deutsch 1062-20-0122 label with printing: attached to strain relief with nylon strap.
Secondary Lock: Deutsch W 2S “ALWAYS INSULATE WIRE”.
- Label and printing must be water, oil and Note 12:Connector: Deutsch HD14-5-16P
Note 3: Connector: Deutsch DT 06-2S coolant resistant. Terminals: Deutsch 0460-202-16141
Terminals: Deutsch 0460-201-16141 - Terminals 84, 85, 86 shall be equipped Unused Cavities to be sealed with:
Secondary Lock: Deutsch W 2S with a shrinkable sleeve with a layer of Deutsch 114017
glue, as in drawing below, and strapped to Protective cover Deutsch HDC 16-5 fixed
Note 4: Connector: Deutsch HD 34 - 24-19 - PN - the harness with nylon straps. to harness with wire.
059 Both ends of wirde run at least 200mm into
Terminals: Size 12 (large): Deutsch harness.
0460-204-12141
Size 16 (small): Deutsch Note 13:Fuse holder: Multicomp MCCQ-211CN (or
0460-202-16141 equal)
Nut: Deutsch 112263-90 1 2 3
Lockwasher:Deutsch 112264 Note 14:Fuse (10A): Littelfuse 0257010 (or equal)
Unused Cavities to be sealed with: 1: Wire or
Deutsch 114017 2: Sleeve Multicomp MCCQ-211CN (or
Wiring braided until connector, and 3: Squeezed tight when hot equal)
attached to strain relief with nylon strap. Fuse holder's wires to be cut to appropriate
Note 9: Connector: Deutsch DT06-2S length
Terminals: 1062-16-0144
Wedge: W2SA
- 120 -
Note 15:Connector: Deutsch HD16-9-16S
or
1 2 3
Deutsch HD16-9-96S
Terminals: Deutsch 0462-209-16141
or
Deutsch 0462-209-16141
Note 20: Wire harness shall be provided with a 5 4

marking label with AC part number and
edition. 1: Braiding
2: Insulated wires
Note 21: Scan test to be performed on every 3: Terminal
conductor 4: Non-insulated wires
5: Sleeve
Note 22: Marking to be printed on each end of all
wires Note 26.1: shrinkable sleeve color = red
Note 26.2: shrinkable sleeve color = blue
Note 23: All plugs seen from wire connecting side
Note 27: All wire type H05V-K/H07V-K according
Note 24: Wire harness finishing: black braiding, to AC standard 0995 2000 00 unless
unless stated otherwise specified otherwise
Note 25: Diodes positioned as on drawing Note 28: Label indicating AC part. Nr.and edition,
testing and/or production date, supplier
Note 26: Terminal and shrinkable sleeve to be reference
mounted as in drawing Black text on white background
Wire number printed on shrinkable sleeve
- 121 -
1626 9917 00/01
Applicable for PTS 1600 - Wire harness (add-on)
15 15
11 1 A
13 13
12 2 B
305 305 3 C
13
SELECTION SWITCHES CUBICLE
306 306 4 D
14
INDICATOR LIGHTS CONNECTOR
313 900 313
15 5 E
See Note 2 314 314
6 F See Note 1
16
36J 36J 7 G
17
315 315
18 8 H
25M 25M
19 9 J
50
150
TERMINAL END A WIRE TERMINAL END B

nr. terminal nr. mm² color nr. terminal
1 See note 1 15 1 orange 11 See note 2
7 See note 1 36J 1.5 orange 17 See note 2
9 See note 1 25M 1 red 19 See note 2
Note 1: Connector: Deutsch HD 14-9-16P Note 2: Provide wires with AMP DIN wire ferrules
Terminal: Deutsch 0460-202-16141 Tubing form with plastic sleeve, according
DIN46228, part 4
- 122 -
- 123 -
Following documents are provided with this unit:
– Test Certificate
– EC Declaration of Conformity:
1
EC DECLARATION OF CONFORMITY
2 We, Atlas Copco Airpower n.v., declare under our sole responsibility, that the product
3 Machine name : Compressor (≥ 350 kW)
4 Commercial name :
5 Serial number :
6 Which falls under the provisions of article 12.2 of the EC Directive 2006/42/EC on the approximation of the
laws of the Member States relating to machinery, is in conformity with the relevant Essential Health and
Safety Requirements of this directive.
The machinery complies also with the requirements of the following directives and their amendments as
indicated.
7 Directive on the approximation of laws of the Harmonized and/or Technical Att’

Member States relating to Standards used mnt
a. Pressure equipment 97/23/EC x
EN ISO 12100-1
b. Machinery safety 2006/42/EC EN ISO 12100-2
EN 1012-1
EN 61000-6-2
d. Electromagnetic compatibility 2004/108/EC
EN 61000-6-4
EN 60034
e. Low voltage equipment 2006/95/EC EN 60204-1
EN 60439
8.a The harmonized and the technical standards used are identified in the attachments hereafter
8.b Atlas Copco Airpower n.v. is authorized to compile the technical file
9 Conformity of the product to the

10
Conformity of the specification to the
specification and by implication to the
Directives
directives
11
12 Issued by Product engineering Manufacturing
13
14 Name
15 Signature
16 Place , Date
Form 5009 0600 05
ed. 10, 2011-05-15
Atlas Copco Airpower n.v. A company within the Atlas Copco Group
Postal address Visitors address Phone: +32 (0)3 870 21 11 Com. Reg. Antwerp 44651
P.O. Box 100 Boomsesteenweg 957 Fax: +32 (0)3 870 24 43 V.A.T. 403.992.231
B-2610 Wilrijk-Antwerp B-2610 Wilrijk-Antwerp
Belgium Belgium For info, please contact your local Atlas Copco representative
www.atlascopco.com
p.1(2)
- 124 -
Pressure Equipment Directive 97/23/EC
1. Conformity assessments followed : See table T.1
a. b. c. d. Notified e. Reference certificate

Category Applicable Module body
I H (1)
II x H (1) 0038/PED/20030004/A/M
III H (1)
B (1)
IV
D (1)
Table T.1
(1) Notified body number 0038

Lloyd’s Register Verification ltd
71 Fenchurch street
EC3M – 4 BF London
United Kingdom
2 Description of the pressure equipment constituting the assembly : see table T.2
a. Equipment, subject to the Simple Pressure Vessel directive 2009/105/EC, is

excluded from 97/23/EC according article I, section 3.3.
b. Equipment of category I, according 97/23/EC, is integrated into the machine and
falls under the exclusion of article I, section 3.6.
c. Equipment of article 3.3 of 97/23/EC is subject to good engineering practice
d. Equipment g.Declarationof
and higher
conformity attached
(including conformity
e. Description and/or f.Part number assessment procedure
followed, identification of
standards)
Safety valve x
h.Cat.II
i.Safety Safety valve x
accessories
Table T.2
3. Harmonised standards used : see table T.2
4. National technical standards and specifications used: see table T.2
Form 5009 0600 05
ed. 10, 2011-05-15
Atlas Copco Airpower n.v. A company within the Atlas Copco Group
Postal address Visitors address Phone: +32 (0)3 870 21 11 Com. Reg. Antwerp 44651
P.O. Box 100 Boomsesteenweg 957 Fax: +32 (0)3 870 24 43 V.A.T. 403.992.231
B-2610 Wilrijk-Antwerp B-2610 Wilrijk-Antwerp
Belgium Belgium For info, please contact your local Atlas Copco representative
www.atlascopco.com
p.2(2)
- 125 -
- 126 -
Printed in Belgium 12/2013 - 2954 7430 01

Pts 1600 Cud S3at3 App

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What are the main components of the compressor?

What are the main components of the compressor?

How should the compressor be transported and installed?

How should the compressor be transported and installed?

Instruction Manual

for Portable Compressors

PTS 1600 Cud S3A/T3 APP QSX15

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

Circuit diagrams .................................................................................... 89

Copyright 2013, Atlas Copco Airpower n.v., Antwerp, Belgium.

11 Technical specifications ........... 84

1.7 Specific safety precautions Safety valves

1 The electrolyte in batteries is a sulphuric acid

Atlas Copco engine oil Read the instruction manual

Read the instruction manual

Prohibition to open air valves

Airfilter Do not run the motor with open

3.3.10 Control panel Repairs and maintenance must be

3.4.1 User Interface and Compressor 8

General description of the User Interface

Any mix-up of buttons and button functions is

3.4.2.3 Maintenance Lamp

Do not put the fuel shut-off cock in

An electrical priming pump (EPP) is comprised in the

! outlet valve must be safeguarded

Emergency Stop Shutdown

System Info Options

System Return Return

Start Failure Cranking

Noload Load Cooldown Stopping

When the engine started, the CCM executes

S Warnings R Are shown on the screen

The starter motor output is activated when the CCM

S Warnings R Are shown on the screen

S Warnings R Are shown on the screen

A ↓-button, press once R Set pressure - 0.1 bar

Check engine oil level x x x x x x

Clean service filter water separator x x x x x

Grease fan drive x

2 6.3.3 Compressor element overhaul

6.4.2.3 Replacing the air filter element and

1 – Withdraw the filter element (4) and safety

! specially designed for the

To avoid damaging the aluminium

All adjustments and repairs and

Before handling batteries, read the

Read the safety instructions

Replace the membrane, the diaphragm valve

Never mix different coolants and

To ensure protection against corrosion, cavitation and

Symptom Possible cause Corrective action

If the unit is going to be stored

The hot weather pack option allows the compressor to

2) Data Measured according to Tolerance

The international standard ISO 1217 corresponds to following national standards:

4) With filter change

Manuf. year/Baujahr/Ann ³e de fabrication ★★★★ 11 axle

1N = 0.225 lbf 11 Manufacturing year

A temperature difference of 1°C = a temperature