Atlas Copco Railway compressors

GAR5 H 6.2CC CMT

Instruction book preliminary

Atlas Copco offer:

Customer contract n°: /
Contract edition: /
Compressor integrator: RCC

End customer: /

Type of vehicle: CMT

Product numbers: 8152 0086 55

Designation: GAR5 H 6.2CC CMT

• Copyright 2005, 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.

• Use only authorized parts. Any damage or malfunction caused

by the use of unauthorized parts is not covered by Warranty or
Product Liability.

• This instruction book meets the requirements for instructions

specified by the machinery directive 89/392/EEC and is valid
for CE as well as non-CE labelled machines.

N°. 9819 0067 09 ed 00

2013-01

Web site: http://www.atlascopco-compressors.com

 This instruction book describes how to handle the machines to ensure safe operation,
optimum efficiency and long service life.

Read this book before putting the machine into operation to ensure correct handling,
operation and proper maintenance from the beginning. The maintenance schedule comprises
measures for keeping the machine in good condition.

Keep the book available for the operator and make sure that the machine is operated
and that maintenance is carried out according to the instructions. Record all operating data,
maintenance performed, etc. in an operator's logbook available from Atlas Copco. Follow all
relevant safety precautions.

Repairs must be carried out by trained personnel from Atlas Copco who can be contacted for
any further information.

In all correspondence always mention the type and the serial number, shown on the data plate.

For all data not mentioned in the text, see sections "Preventive maintenance schedule" and
"Principal data".

The company reserves the right to make changes without prior notice.

9819 0067 09 2
 5.8 Thermostatic valve (BV1) ____________18
CONTENTS
5.9 Unloader valve (UV) ________________19
5.10 Air filter (AF) ____________________20
1 SAFETY PRECAUTIONS ___________ 4
5.11 Coolers (OC) _____________________20
1.1 Safety icons ________________________ 4 5.11.1 Clean coolers (OC), Cooler door grills and
Air inlet grating with a brush _________________ 21
1.2 Safety precautions during installation __ 4 5.11.2 Clean coolers (OC) and door grills with a
1.3 Safety precautions during operation ___ 5 solvent 21

1.4 Safety precautions during maintenance or 5.12 Part numbers of oil service kits _____22
repair __________________________________ 6 5.13 Storage directives _________________22
2 GENERAL DESCRIPTION__________ 8 6 Overhauling instructions____________23
2.1 Introduction _______________________ 8 6.1 Replacement and overhauling instructions
2.1.1 Compressor overview _________________ 8 for compressor element, gearbox, coupling
2.1.2 Principal diagram ___________________ 10
housing and shaft seal ____________________23
2.1.3 Air flow___________________________ 11
2.1.4 Oil system _________________________ 11 6.2 Replacement of temperature gauge/switch
23
2.2 Operation of the Load/Unload system
(UV) 11 6.3 Replacement of blow-off valve ________23
2.2.1 Load / unload valve: _________________ 11
6.4 Replacement of drain valves__________23
2.3 Hydraulic motor ___________________ 12
7 PROBLEM SOLVING______________24
2.4 First mounted equipments : _________ 12
2.4.1 Element oil outlet temperature switch (T1) 12 7.1 Before starting repairs ______________24
2.4.2 Air Inlet (AF) & Air filter clogged indicator 7.2 Mechanical faults and suggested remedies
(V) 13 24
3 COMPRESSOR INSTALLATION ___ 13 8 PRINCIPAL DATA GAR 5-14 _______25
3.1 Moving / lifting: ___________________ 13 8.1 Standard conditions_________________25
3.2 Installation directives. ______________ 14 8.2 Supply voltages ____________________25
3.3 Documentation list _________________ 14 8.3 Drive motor _______________________25
4 OPERATING INSTRUCTIONS _____ 14 8.4 Technical data _____________________25
4.1 Initial start-up_____________________ 14
4.1.1 Safety ____________________________ 14
4.1.2 Remark ___________________________ 14
4.1.3 Moving/lifting ______________________ 14
4.1.4 Start-up ___________________________ 14
4.1.5 Temperature switch (T1)______________ 14
4.2 Stopping for maintenance ___________ 14
4.3 Taking out of operation at end of
compressor service life___________________ 14
5 MAINTENANCE _________________ 15
5.1 Preventive maintenance schedule _____ 15
5.2 Oil specifications___________________ 16
5.3 Oil level __________________________ 16
5.4 Oil and oil filter change _____________ 16
5.5 Oil separator element change ________ 17
5.6 Safety valve (SV COMP) ____________ 17
5.7 Temperature gauge/switch (T1) ______ 18

9819 0067 09 3
1 SAFETY PRECAUTIONS

1.1 Safety icons

Explanation

Danger for life

Warning

Important note

1.2 Safety precautions during installation

Any responsibility for damage or injury resulting from neglecting these precautions, or non-observance of the normal caution
and care required for installation, operation, maintenance and repair, even if not expressly stated, will be disclaimed by Atlas
Copco.

General precautions
1. The operator must employ safe working practices and observe all related local work safety requirements and
regulations.

2. If any of the following statements does not comply with local legislation, the stricter of the two shall apply.
3. Installation, operation, maintenance and repair work must only be performed by authorised, trained, specialised
personnel.

4. The compressor is not considered capable of producing air of breathing quality. For air of breathing quality, the
compressed air must be adequately purified according to local legislation and standards.
5. Before any maintenance, repair work, adjustment or any other non-routine checks, stop the compressor, press the
emergency stop button, switch off the voltage and depressurise the compressor. In addition, the power isolating
switch must be opened and locked.

6. Never play with compressed air. Do not apply the air to your skin or direct an air stream at people. Never use the
air to clean dirt from your clothes. When using the air to clean equipment, do so with extreme caution and wear eye
protection.

Precautions during installation

1. The machine must only be lifted using suitable equipment in accordance with local safety regulations. Loose or
pivoting parts must be securely fastened before lifting. It is strictly forbidden to dwell or stay in the risk zone under
a lifted load. Lifting acceleration and deceleration must be kept within safe limits. Wear a safety helmet when
working in the area of overhead or lifting equipment.
2. Place the machine where the ambient air is as cool and clean as possible. If necessary, install a suction duct.
Never obstruct the air inlet. Care must be taken to minimise the entry of moisture at the inlet air.

3. Any blanking flanges, plugs, caps and desiccant bags must be removed before connecting the pipes.
4. Air hoses must be of correct size and suitable for the working pressure. Never use frayed, damaged or worn hoses.
Distribution pipes and connections must be of the correct size and suitable for the working pressure.

5. The aspirated air must be free of flammable fumes, vapours and particles, e.g. paint solvents, that can lead to
internal fire or explosion.
6. Arrange the air intake so that loose clothing worn by people cannot be sucked in.

7. Ensure that the discharge pipe from the compressor to the aftercooler or air net is free to expand under heat and
that it is not in contact with or close to flammable materials.

9819 0067 09 4
8. No external force may be exerted on the air outlet valve; the connected pipe must be free of strain.

9. If remote control is installed, the machine must bear a clear sign stating: DANGER: This machine is remotely
controlled and may start without warning.
10. The machines must be installed in such a way that an adequate flow of cooling air is available and that the
exhausted air does not recirculate to the compressor air inlet or cooling air inlet.
11. The electrical connections must correspond to the local codes. The machines must be earthed and protected
against short circuits by fuses in all phases. A lockable power isolating switch must be installed near the
compressor.
12. On machines with automatic start-stop system or if the automatic restart function after voltage failure is activated, a
sign stating "This machine may start without warning" must be affixed near the instrument panel.
13. In multiple compressor systems, manual valves must be installed to isolate each compressor. Non return valves
(check valves) must not be relied upon for isolating pressure systems.
14. Never remove or tamper with the safety devices, guards or insulation fitted on the machine. Every pressure vessel
or auxiliary installed outside the machine to contain air above atmospheric pressure must be protected by a
pressure-relieving device or devices as required.
15. Pipework or other parts with a temperature in excess of 80°C (176°F) and which may be accidentally touched by
personnel in normal operation must be guarded or insulated. Other high temperature pipework must be clearly
marked.
16. If the ground is not level or can be subject to variable inclination, consult the Atlas Copco Customer Centre.

Also consult the following safety precautions: Safety precautions during operation and Safety precautions during maintenance.
Some precautions are general and may not apply to your machine

1.3 Safety precautions during operation

All responsibility for any damage or injury resulting from neglecting these precautions, or by non-observance of ordinary caution
and due care required in installation, operating, maintenance or repair, even if not expressly mentioned, will be disclaimed by
Atlas Copco.

General precautions
1. The operator must employ safe working practices and observe all related local work safety requirements and
ordinances.
2. If any of the following statements does not comply with local legislation, the stricter of the two shall apply.
3. Installation, operation, maintenance and repair shall only be performed by authorized, trained, competent
personnel.
4. The compressor is not considered as capable of producing air of breathing quality. For breathing air quality, the
compressed air must be adequately purified according to local legislation and standards.

5. Before any maintenance or repair, adjustment, or any check other than routine attention, stop the compressor,
press the emergency stop button, switch off the voltage and depressurize the compressor. In addition, the power
isolating switch shall be opened and locked.

6. Never play with compressed air. Do not apply it to your skin or direct an air stream at people. Never use it to clean
dirt from your clothes. When using it to clean equipment, do so with extreme caution and use eye protection.

Precautions during operation

1. Use only the correct type and size of hose end fittings and connections. When blowing through a hose or air line,
ensure that the open end is held securely. A free end will whip and may cause injury. Make sure that a hose is fully
depressurized before disconnecting it.

2. Persons switching on remotely controlled machines shall take adequate precautions to ensure that there is no one
checking or working on the machine. To this end, a suitable notice shall be affixed to the remote start equipment.

9819 0067 09 5
3. Never operate the machine when there is a possibility of taking in flammable or toxic fumes, vapours or particles.

4. Never operate the machine below or in excess of its limit ratings.

5. Keep all bodywork doors shut during operation. The doors may be opened for short periods only, e.g. to carry out
routine checks. Wear ear protectors when opening a door.

6. People staying in environments or rooms where the sound pressure level reaches or exceeds 90 dB(A) shall wear
ear protectors.
7. Periodically check that:

• All guards are in place and securely fastened

• All hoses and/or pipes inside the machine are in good condition, secure and not rubbing
• There are no leaks
• All fasteners are tight

• All electrical leads are secure and in good order

• Safety valves and other pressure-relief devices are not obstructed by dirt or paint
• Air outlet valve and air net, i.e. pipes, couplings, manifolds, valves, hoses, etc. are in good repair, free of
wear or abuse
8. If warm cooling air from compressors is used in air heating systems, e.g. to warm up a workroom, take precautions
against air pollution and possible contamination of the breathing air.

9. Do not remove any of, or tamper with, the sound-damping material.

10. Never remove or tamper with the safety devices, guards or insulations fitted on the machine. Every pressure vessel
or auxiliary installed outside the machine to contain air above atmospheric pressure shall be protected by a
pressure-relieving device or devices as required.

Also consult following safety precautions: Safety precautions during installation and Safety precautions during maintenance.
Some precautions are general and may not apply to your machine

1.4 Safety precautions during maintenance or repair

All responsibility for any damage or injury resulting from neglecting these precautions, or by non-observance of ordinary caution
and due care required in installation, operating, maintenance or repair, even if not expressly mentioned, will be disclaimed by
Atlas Copco.

General precautions
1. The operator must employ safe working practices and observe all related local work safety requirements and
ordinances.
2. If any of the following statements does not comply with local legislation, the stricter of the two shall apply.

3. Installation, operation, maintenance and repair shall only be performed by authorized, trained, competent
personnel.
4. The compressor is not considered as capable of producing air of breathing quality. For breathing air quality, the
compressed air must be adequately purified according to local legislation and standards.
5. Before any maintenance or repair, adjustment, or any check other than routine attention, stop the compressor,
press the emergency stop button, switch off the voltage and de-pressurize the compressor. In addition, the power
isolating switch shall be opened and locked.
6. Never play with compressed air. Do not apply it to your skin or direct an air stream at people. Never use it to clean
dirt from your clothes. When using it to clean equipment, do so with extreme caution and use eye protection.

9819 0067 09 6
Precautions during maintenance or repair
1. Always wear safety glasses.
2. Use only the correct tools for maintenance and repair work.
3. Use only genuine spare parts.

4. All maintenance work shall only be undertaken when the machine has cooled down.
5. A warning sign bearing a legend such as "work in progress; do not start" shall be attached to the starting
equipment.

6. Persons switching on remotely controlled machines shall take adequate precautions to ensure that there is no one
checking or working on the machine. To this end, a suitable notice shall be affixed to the remote start equipment.
7. Before removing any pressurized component, effectively isolate the machine from all sources of pressure and
relieve the entire system of pressure.
8. Never use flammable solvents or carbon tetrachloride for cleaning parts. Take safety precautions against toxic
vapours of cleaning liquids.
9. Scrupulously observe cleanliness during maintenance and repair. Keep dirt away by covering the parts and
exposed openings with a clean cloth, paper or tape.

10. Never weld or perform any operation involving heat near the oil system. Oil tanks must be completely purged, e.g.
by steam-cleaning, before carrying out such operations. Never weld on, or in any way modify, pressure vessels.
11. Whenever there is an indication or any suspicion that an internal part of a machine is overheated, the machine
shall be stopped but no inspection covers shall be opened before sufficient cooling time has elapsed; this to avoid
the risk of spontaneous ignition of the oil vapour when air is admitted.
12. Never use a light source with open flame for inspecting the interior of a machine, pressure vessel, etc.

13. Make sure that no tools, loose parts or rags are left in or on the machine.
14. Before clearing the machine for use after maintenance or overhaul, check that operating pressures, temperatures
and time settings are correct. Check that all control and shut-down devices are fitted and that they function
correctly. If removed, check that the coupling guard of the compressor drive shaft has been reinstalled.

15. Every time the separator element is renewed, examine the discharge pipe and the inside of the oil separator vessel
for carbon deposits; if excessive, the deposits should be removed.
16. Protect the motor, air filter, electrical and regulating components, etc. to prevent moisture from entering them, e.g.
when steam-cleaning.

17. Make sure that all sound-damping material, e.g. on the bodywork and in the air inlet and outlet systems of the
compressor, is in good condition. If damaged, replace it by genuine Atlas Copco material to prevent the sound
pressure level from increasing.
18. Never use caustic solvents which can damage materials of the air net, e.g. polycarbonate bowls.

19. The following safety precautions are stressed when handling refrigerant:

• Never inhale refrigerant vapours. Check that the working area is adequately ventilated; if required, use
breathing protection.

• Always wear special gloves. In case of refrigerant contact with the skin, rinse the skin with water. If liquid
refrigerant contacts the skin through clothing, never tear off or remove the latter; flush abundantly with fresh
water over the clothing until all refrigerant is flushed away; then seek medical first aid.

20. Protect hands to avoid injury from hot machine parts, e.g. during draining of oil.

Also consult following safety precautions: Safety precautions during installation and Safety precautions during operation.
Some precautions are general and may not apply to your machine.

9819 0067 09 7
2 GENERAL DESCRIPTION

2.1 Introduction
GAR5 H 6.2CC CMT is air-cooled, single-stage, oil-injected screw compressors. It is designed to feed brake systems and other
pneumatic appliances of trains or trams with compressed air.
GAR5 H 6.2CC CMT is a completed unit for mounting inside locomotives, rail cars or truck on the floor.

The GAR 8152 0086 55 air supply unit included the compressor element, an oil separator, an oil cooler (oil/oil) and an hydraulic
drive motor.

How runs the heart of the compressor?

The compressor element encloses two counter - rotating rotors, supported in long life angular contact bearing, witch compress
the air. There are only two moving parts, making the element sturdy and simple. Air inlet and outlet are automatically opened
and closed by the ends of the rotors as they rotate, thereby eliminating the need for extra valves and timing mechanisms. The
absence of valves and the use of minimal moving parts increase reliability and reduce wear to a minimum.

Due to overlapping and continuous compression cycles, the rotary screw design generates virtually no vibration and provides
pulsation free air. Since there is no metal-to-metal contact within the compression chamber the unit gives no reduction in
operational performance.

The GAR incorporates an elastic coupling, transmitting the power of the drive motor to the compressor element, specially
designed to reduce the torque peaks at start-up of the machine.

The coupling housing is connecting the element to the motor for permanent alignment to optimize the reliability of the drive
system.

2.1.1 Compressor overview OC

AF
Y1

MPV

T1

UV

9819 0067 09 8
 SV COMP

OT / OS

FC

M1
OF

BV1

V
OUT

GI

Dp1

9819 0067 09 9
Designation of the components

AF Air filter
BV1 Oil cooler By pass valve
Dp1 Drain plug
E Compressor screw element
FC Oil filling plug
GI Oil sight glass
OC Oil cooler
OF Oil filter
OS Oil separator element
OT Oil Tank
OUT Compressor air outlet
M1 Hydraulic Motor
MPV Minimum pressure valve
SV COMP Safety Valve
T1 Temperature switch
UV Unloader valve
V Vacuum indicator
Y1 Vent valve 3/2 NC
2.1.2 Principal diagram

9819 0067 09 10
 2.1.3 Air flow
The Air is sucked into the compressor thought an air filter (AF). This air passes through the compression element (E) via the
load/unload valve (UA) where it is mixed with oil injected during compression. A check valve is set up at the outlet of the
element. Inside the Oil tank / oil separator (OS), the compressed air is pre-de oiled by shocks, then flows through the oil
separator. It then passes through the mini pressure valve (VP1) forming a check valve.

The Minimum pressure valve (VP1) prevents the receiver pressure from dropping below a minimum pressure, needed for
lubrication of compressor element (E) and also backflow of compressed air when the compressor is stopped.

2.1.4 Oil system

In air receiver/oil separator (OS), most of the oil is removed from the air/oil mixture centrifugally. The balance is removed by oil
separator element (OS). The lower part of the receiver serves as oil tank.

Air pressure forces the oil from the oil tank through oil cooler (OC) and filter (OF) to compressor element (E).

The oil system is provided with a by-pass valve (BV1). When the oil temperature is below 75°C, by-pass valve (BV1) shuts off
the oil supply from oil cooler (OC). Air pressure forces the oil from oil tank (OS) through oil filter (OF) to compressor element
(E). Oil cooler (OC) is by-passed.
By-pass valve (BV1) starts opening the oil supply to cooler (OC) when the oil temperature has increased to the above-
mentioned value.

Oil stop valve, included to the element, prevents the compressor element from flooding with oil when the compressor is
stopped. The valve is opened by element outlet pressure when the compressor is started.

2.2 Operation of the Load/Unload system (UV)

2.2.1 Load / unload valve:

The GAR units is equipped with a load/unload system. It has been design for 2 kind of applications

1. Duty cycle lower than 10%

A duty cycle of 10% means that the number of start –ups is mostly of the time more than the number of starting authorized by
the motor supplier. To tackle this issue the load / unload valve allow to run the compressor without provide compressed air by
de-energized the solenoid valve (Y1) : it’s a idling time (adjustable following the customer air needs)

2.Duty cycle upper than 40%

In that case the period of time when the compressor is stopped is not so long enough to cool naturally the different
components. So we introduce a load/ unload valve allowing to run the compressor unloaded and as consequence keep a
mechanical cooling ensure by the fan linked in line with the motor shaft.

Loading
When the system pressure decreases to loading pressure, the solenoid valve (Y1) will be energized, the intake valve opens,
and air output is resumed. Then the pressure drops inside the pneumatic network

Unloading
When the maximum pressure (i.e. unloading pressure) is reached, the solenoid valve controlling the air intake valve is de-
energized. The air intake valve closes, and the internal unit pressure will be vented to atmosphere. Air output is stopped, and
the unit runs unloaded.

Restarting
At every stop, the compressor blows of the air inside the oil separator vessel to the inlet valve. This is done by activating the
blow-off solenoid valve (either by the train control system or by the compressor control system). Because of this
depressurisation, it is natural that oil starts foaming during this blow-off period. When excessive foaming happens, at next start-
up of the compressor, this oil is carried along into the air system, causing rapid contamination of the pre-filter and the dryer. To
limit this foaming, a blow-off nozzle is installed (as part of the blow-off solenoid valve). This nozzle reduces the intensity of
blowing off – and therefore the amount of foaming, but because of this, the time to depressurise the oil separator vessel will
increase.
The depressurisation is also useful to make the start current as low as possible (higher the pressure in the vessel, higher the
motor current).
The combination of both effects requires respecting a minimum stop time of 30s.
This minimum stop time should be controlled by the train control system.

9819 0067 09 11
2.3 Hydraulic motor

The GAR5 H 6.2CC CMT is an oil screw compressor driven by a PARKER hydraulic motor model F11-6. This hydraulic motor is
an axial piston motor, which is bent axis, fixed displacement heavy duty motor series.

Hydraulic fluids
Ratings and performance data for series F11 are based on operating with good quality, contamination free,
petroleum-based fluids.
Hydraulic fluids type HLP (DIN 51524), automatic transmission fluids type A, or API CD engine oils can be used.
Fire resistant fluids (when used under modified operating conditions) and synthetic fluids may also be suitable.

Viscosity
The ideal operating range is 15 to 30 mm2/s [cSt].
At operating temperature, the viscosity (of the drain fluid) should be kept above 8 mm2/s [cSt].
At start-up, the viscosity should not exceed 1000 mm2/s [cSt]

Filtration
To obtain the highest service life of the F11/F12, the fluid cleanliness should meet or exceed ISO code 18/13 (ISO
4406).
During normal operating conditions, a 10 µm (absolute) filter is recommended.

Technical data :
3
Motor Displacements Cm /rev 5 10
Continuous Pressure Bar 350 350
Intermittent Pressure Bar 420 420
Minimum continuous speed Rpm 50 50
Maximum continuous speed Rpm 12 800 10 200
Maximum intermittent speed Rpm 14 000 11 200
Maximum continuous motor input flow L/min 63 100
Maximum intermittent motor input flow L/min 69 110
Approximate Weight 1) Kg 5 7.5
Remark : Intermittent = max 6 seconds in any one minute

For more information, please visit the following website:

www.parker.com/eu

2.4 First mounted equipments :

2.4.1 Element oil outlet temperature switch (T1)

The temperature switch (T1: Figure 1) must be connected to the electrical installation to shut down the compressor if a
temperature of 120°C (248°F) is reached.
After temperature had decreased, compressor mustn’t be able to automatically restart itself!
The unit must be checked and an intervention by hand has to be done
to restart the machine after the shut down.

The temperature switch has an indicator scale with three pointers:

- a white one, indicating the temperature of the air outlet of the compressor
element,
- a red one indicating the shut-down setting of the switch (Red Failure)
120°C (248°F) .

Figure 1: Oil temperature switch

If for any reason pointer settings change, a special key mounted at the back of the temperature is available to get the initial
settings.

9819 0067 09 12
 2.4.2 Air Inlet (AF) & Air filter clogged indicator (V)
This device measures the pressure difference over the air filter. When 50 mbar is reached (meaning that the filter is clogged),
the flag becomes red, change of the filter is then required.

Red flag indicator

3 COMPRESSOR INSTALLATION

3.1 Moving / lifting:

The compressor can be moved using the fixation point of the coupling housing. Make sure that the chains cannot damage the
compressor. The lifting equipment must be placed in such a way that the compressor will be lifted horizontally. Lift smoothly
and avoid twisting
The mechanism (engine, slings, structure…) must be fitted to support a weight more than 120kg as the unit has a weight
around 100kg.

9819 0067 09 13
3.2 Installation directives.
1. The compressor must be installed in such way, that rain, snow, dust, etc cannot enter or block the system. The intake
and cooling air must be as clean as possible
2. Re circulation of cooling air to the compressor must be avoided.
3. If operating in dusty surroundings, install a pre-filter upstream of the air intake filter
4. If supplied, install service indicator lamps for the air intake filter and oil separator and a pressure gauge on the control
board. Integrate the air outlet temperature switch in an alarm/shut-down circuit
5. Check that the electrical connections correspond to the local codes. Check the connections for correct tightness. The
installation must be earthed and protected against short circuits by fuses of the inert type in all phases. An isolating
switch must be installed near the compressor.
6. Provide an air outlet valve in order to isolate the compressor. Close the valve. Connect the air net to the valve.
7. Stick labels on obvious places on the compressor, warning the operator that the compressor is automatically
controlled and may be started without warning.

3.3 Documentation list

SPARE PART LIST : 9819006710
DIMENSION. DRAWING : 9819006711
SERVICE DIAGRAM : 9819006712
DIAGRAM FLOW : 9819006713

4 OPERATING INSTRUCTIONS

4.1 Initial start-up

4.1.1 Safety
The operator must apply all relevant safety precautions, including those mentioned in this book.

4.1.2 Remark
Consult section 3 for the electric connections, installation directives and dimension drawings.

4.1.3 Moving/lifting
The compressor can be moved by a lift truck using the lifting eye on the coupling housing. (see section 3.1)

4.1.4 Start-up
1. Check the oil level. The oil level must be between the middle and the top of sight-glass (Figure 2). If the level does not
exceed the middle, add oil. See sections 5.3 and 5.4.
2. connect the compressor to the control electrical network
3. Check the drive motor label for correct rotation direction.
Start the compressor and stop it immediately. Check the rotation while the compressor is coasting to a stop.
4. Start and run the compressor.
5. Run the compressor until warm (the temperature of the element outlet should reach 60°C above ambient), stop the
compressor and check the oil level.

4.1.5 Temperature switch (T1)

1. If T<120°C, there is no signal, the unit can runs
2. Else (T>120°C) “Red warning” signal, the compressor have to be stopped automatically!
After temperature had decreased, compressor mustn’t be able to automatically restart itself;
The unit must be checked and an intervention by hand has to be done to restart the machine Maintenance must be
scheduled: see the section 7.

4.2 Stopping for maintenance

At the end of the service life of the compressor, proceed as follows:

1. Stop the compressor and close the air outlet valve (if provided).
2. Switch off the voltages and disconnect the compressor from the mains.
3. Depressurise the oil separator vessel. This is done automatically within one minute.
4. Depressurise the part of the air net, which is connected to the outlet valve.
5. Disconnect the compressor and the dryer air outlet pipe from the air net.

4.3 Taking out of operation at end of compressor service life

See section 4.2 Stopping for maintenance and
1. Drain the oil circuits for the compressor.
2. Disconnect the condensate piping (if provided).

9819 0067 09 14
5 MAINTENANCE
Warning

Before carrying out any maintenance, repair work or adjustments, proceed as follows:
• Stop the compressor.
• Switch off the voltage.
• Depressurise the compressor.
For detailed instructions, see section Problem solving. The operator must apply all relevant Safety precautions.
Warranty - Product Liability
Use only authorised parts. Any damage or malfunction caused by the use of unauthorised parts is not covered
by Warranty or Product Liability.
Service kits
For overhauling or carrying out preventive maintenance, service kits are available (see section Service kits).
Service contracts
Atlas Copco offers several types of service contracts, relieving you of all preventive maintenance work. Consult
your Atlas Copco Customer Centre.
General
When servicing, replace all removed gaskets, O-rings and washers.

5.1 Preventive maintenance schedule

The schedule comprises a summary of the maintenance instructions. Read the respective section before taking maintenance
measures. The "longer interval" checks must also include the "shorter interval" checks.
Use only authorised parts. Warranty or Product Liability does not cover any damage or malfunction caused by the use
of unauthorised parts.

Maintenance schedule still to be defined

Period (*) Running Operation Kit available
hours (*)

(*) Whichever interval comes first

(**) The life time is depending of the use of the compressor; with many start/stop cycles, after the first 4 years, AC recommends to
check the proper functioning of the (alarm) pressure switch yearly and replace if necessary.

The following table gives the recommended tightening torque for general applications:
Thread size M5 M6 M8 M10 M12 M16 M20
Hexagon screws, bolts, nuts (strength class 8.8) Nm 5 8 20 41 73 185 355
Socket screws (strength class 12.9) Nm 8 14 34 70 120 315 600
Important
In case of aluminium parts, the tightening torques must be reduced to 2/3 of the above values
The following table gives the recommended tightening torque for VBO couplings:
Ext Ø of tube (mm) 4 8 12 16 18 28
tightening torque (Nm) 22 40 50 50 95 105
Tool size 14 19 24 30 30 46
Assembly instruction for VBO coupling:
1. For mounting only use acid free Vaseline
2. Insert tube until the tube touches the back of the coupling. Then retreat the coupling for 2 to 3 mm.
3. Use the above mentioned torques for tightening and re-torque after mounting.

9819 0067 09 15
5.2 Oil specifications
It is strongly recommended to use Atlas Copco Roto-Xtend Duty ( RXD ) Fluid. This is special oil for screw compressors,
which keeps the compressor in excellent condition.
For ambient temperatures below -25 °C, the compressor must be equipped with heaters and /or trace heating.

Attention
Never mix oils of different brands or types. Use only non-toxic oils. For use of other oils, contact ATLAS COPCO

5.3 Oil level

Run the compressor until warm (the temperature of the element outlet should reach 60°C above ambient), stop the compressor
and check the oil level.

OIL LEVEL TO BE CHECKED

WHEN THE COMPRESSOR IS
STOPPED

- maximum level

- Minimum level

Figure 2: Oil level sight glass

5.4 Oil and oil filter change

Only use Atlas Copco Roto Xtend Duty (RxD) oil.

1. Run the compressor until warm. Stop it and close the compressor outlet valve. Switch off the power. Wait one minute.
Depressurise the oil system by opening oil filler plug (FC) one turn to permit any pressure to escape.
2. Remove plug (DP1). Drain the oil by opening drain valve. Collect the oil in a collector and deliver it to the local oil collection
service. Close the valve and reinstall the plug. Drain the cooler in case of a complete overhaul.
3. Remove the oil filter (OF).
4. Clean the filter seat on the manifold. Oil the gasket of the new element. Screw the element into place until the gasket
contacts its seat, then tighten by hand (approximately half a turn).
5. Remove plug (FC) and fill receiver/oil separator (OT) with oil until the level reaches the filler neck. Take care that no dirt
drops into the system. Fit and tighten plug (FC).
6. Run the compressor for two minutes. Stop the compressor and check the oil level (see section 5.3).
7. If the oil level is not correct, wait one minute to allow the oil to settle. Depressurise the system by opening oil filler plug (FC)
one turn to permit any pressure to escape. Repeat step 5 and further.

9819 0067 09 16
5.5 Oil separator element change

1. If the oil and oil filter are also to be changed, first carry out steps 1 up to 4 of section 5.4.
2. Stop the compressor. Switch off the power and depressurize the oil system by opening oil filler plug (FC) one turn to permit
any pressure to escape.
3. Remove the different pipes connecting to the oil separator cover. Check scavenging line for blockage.
4. Remove the oil separator cover (6 bolts).
5. Remove oil separator element (OS).
6. Clean the oil separator compartment (if necessary).
If the oil separator compartment is wet on the inside (moisture), the compressor element may be operating at too low
temperatures. Consult Atlas Copco.
If the bottom cup of the oil separator element is completely filled with oil, the oil scavenging line is clogged. Inspect
the parts and replace, if necessary.
7. Fit a new oil separator element.
8. Refit the cover. Use two new O-rings.
9. If the oil and the oil filter are changed: carry out steps 5 and 6 of section 5.4. Check for leaks.

5.6 Safety valve (SV COMP)

Testing
Safety valves can be tested in the workshop for correct opening pressure.

Important
No adjustments are allowed. Never runs the compressor without safety valve.

1. Stop the compressor. Close the outlet valve and switch off the power. Open plug (FC) one turn to permit any pressure to
escape.
2. Remove the safety valve and replace it by a tested one, so that the compressor may be restarted.
3. Fit the valve to a pipe to which an accurate pressure gauge is fitted.
4. Connect the pipe to a depressurized part of the compressed air net via a pressure regulator.
5. Pressurize the valve gradually while observing the pressure gauge.
6. The valve should not leak until the opening pressure is reached (maximum allowed tolerance is 0.5 bar).
7. If the valve does not open at the pressure specified in section 7.2, consult Atlas Copco or replace the valve.

9819 0067 09 17
5.7 Temperature gauge/switch (T1)
Have the temperature shut-down function tested
The temperature switch has 2 pointers: the white pointer indicates the actual temperature at the outlet of the compressor
element, the green pointer is pre-set at the alarm temperature and the red pointer is set at the shut-down temperature. Check
the switch while the compressor is running.

1. To check the warning level, move the green pointer by means of the special key (this key is located on the back of the
temperature switch) until it passes the white pointer. Exactly at this moment, the alarm indication on the Mona-dashboard
should light up.
2. To check the shut-down level, move the red pointer by means of the special key until it passes the white pointer. Exactly at
this moment, the compressor must stop automatically and a red LED should burn on the front side of the CVS
3. After this test, adjust the red pointer to 120 degrees.
4. Replace the gauge/switch, if necessary.

Testing
Temperature switches can be tested in the workshop for correct switching temperature.

Important
No adjustments are allowed. Never run the compressor without temperature switch.

1. Stop the compressor. Close the outlet valve and switch off the power. Open plug (FC) one turn to permit any pressure to
escape.
2. Remove the temperature switch but keep the electrical connections.
3. Place the capillary in an oil bath together with a temperature indicator.
4. Heat up the oil until the temperature reaches 120°C +/- 3°C. The switch should give a shut-down signal.
7. If the temperature switch does not switch within the given tolerances, replace the switch (see section 6.2).

The part number to order from Atlas Copco is:

See ASL

5.8 Thermostatic valve (BV1)

1. When the oil temperature is below 50 degrees Celsius, start the compressor. Measure the temperature of pipe (bubble
25) while observing the oil temperature on temperature gauge (T1).
2. This pipe should remain more or less cold until the oil temperature reaches approx. 75 degrees Celsius.
3. Replace the thermostatic valve if it opens too quickly. Observe the correct direction of mounting or too late when
reaching 75°c ± 5 °C of the gauge temperature

9819 0067 09 18
5.9 Unloader valve (UV)

Re-greasing:
1. Disconnect the connector from the air release solenoid valve
2. Remove the blow off solenoid valve by unscrewing the coil
3. Remove the various pipes plugged to the SCU (Spring Controlled Unloader ) valve
4. Remove the inlet elbow from the load/unload valve
5. Take out the 4 fixing screws and remove the valve
6. The seals and the pistons shown on the exploded view drawing below must be lubricated with Klübersynth® AR 34-
401 ( referred to the ASL )
7. Reassemble by the opposite way

1 year (4000hrs)
(kit available)

2 years (8000hrs)
(kit available)
See 6.3 / contact AC

Replacement: See maintenance schedule (section 5.1) for complete replacement (kit available)

9819 0067 09 19
5.10 Air filter (AF)

Inspecting
If the cartridge is excessively dirty, the change interval should be adapted. Consult Atlas Copco. Always replace dirty or
damaged elements.

Replacing
1. Stop the compressor. Switch off the power. Release the clips and remove the cover.
2. Unscrew the nut and take out the filter element.
3. Remove the dust from the cover.
4. Fit the new filter element.
5. Refit the cover. Observe the indication "TOP"

Note: A kit is available (referred to ASL)

5.11 Coolers (OC)

Keep the coolers clean to maintain the cooling efficiency.
Remove any dirt from the coolers with a fibre brush.
Never use a wire brush or metal objects. Then clean by air jet.
If necessary wash the coolers with a cleaning agent.
In case of problem consult Atlas Copco.

9819 0067 09 20
5.11.1 Clean coolers (OC), Cooler door grills and Air inlet grating with a brush

1. Make sure the surface of the cooler is at room temperature, it is a MUST

2. Remove the cooler door.
3. Use industrial vacuum cleaner without any hose attachments to the nozzle for maximum suction power to thoroughly clean
the cooler. Hold the vacuum nozzle directly flat on the cooler grills. Start from one corner and move it slowly up and down
through the whole cooler surface
4. Use nylon hand brush to clean the surface of the cooler [Recommended brush is MrClean Brush as below]

MrClean Brush:

Note: THIS BRUSH IS NOT TO BE USED FOR CLEANING OF THE COOLER DOOR OR ANY
OTHER ITEMS. IT IS STRICTLY FOR THE COOLER FINS

This brush is available from all warehouses [e.g. Bunnings Warehouse]

Brand: MRCLEAN TUFFMATES
Part Number: BR 013
Note: Based on availability of the above equipment, a suitable alternative is to be considered

5. Use hand scrubber brush to clean the surface of the cooler door [inside and out] to make sure the cooler door grills are
clean, then wipe thoroughly with a piece of cloth. Recommended brush is Oates Deck Scrub as below.
5a: Use the scrubber edge to clean the heavier dirt and grease off the door first,
5b. Then use the brush side to thoroughly clean the door [make sure the door grills as fully clean].

Oates Deck Scrub:

Note: THIS BRUSH IS NOT TO BE USED FOR THE COOLER FINS, ONLY FOR THE
COOLER DOOR
This brush is available from all warehouses [e.g. Bunnings Warehouse]
Brand: Oates deck Scrub
Part Number: BM-103
Note: Based on availability of the above equipment, a suitable alternative is to be considered

6. Use the industrial vacuum again without any attachment to thoroughly clean the cooler again as above.
7. Clean the air inlet grill with the vacuum and the scrubber brush in the same manners as the cooler door

5.11.2 Clean coolers (OC) and door grills with a solvent

(Mandatory action) In continuation of the section 5.11.1 above:

1. Apply the procedures shown in section 5.11.1

2. Evenly spray either Loctite 7840 industrial solvent (preferred option) or CleanPlus Heavy Duty Degreaser (acceptable
alternative) on the cooler surface, and leave it for 5 minutes for the solvent to breakdown any grease or hard particles.
3. Use the Brush intended for the cooler fins to thoroughly clean any hard particles deposited on the cooler fins. Wipe the
cooler surface with a clean cloth.
4. Use the industrial vacuum cleaner without any attachments again to thoroughly clean the cooler fins and wipe with a clean
piece of cloth.
5. Perform a visual inspection and repeat steps 2 to 4 if there are any hard particles still deposited on the cooler fins.
6. Using the above solvent, clean the combi-cooler panel grills (inside and outside). Wipe it clean with a piece of cloth.

9819 0067 09 21
 Preferred Option: Loctite 7840

Loctite 7840 is available from Blackwoods

http://www2.blackwoods.com.au/Default.aspx

T 13 73 23

Second Alternative: CleanPlus heavy Duty Degreaser

Note: Spray bottle will be needed for this product

CleanPlus Heavy Duty Degreaser is available from

CleanPlus Detergents pty ltd
http://www.cleanplus.com.au/index.html
T +612 9738 7444

5.12 Part numbers of oil service kits

The part numbers to order from Atlas Copco are:

Roto-Xtend Duty Fluid

5 2901 1700 00
20 l 2901 1701 00
209 l 2901 1702 00
1000 l 2901 1703 00

See the Atlas Copco Spare part List too for a better understanding.

5.13 Storage directives

Consult Atlas Copco. Specials actions are requested.
(DR 067 A Storage directives GAR compressor units)

9819 0067 09 22
6 Overhauling instructions
Attention
1. Apply all relevant safety precautions, including those mentioned in this book.
2. Before carrying out any maintenance or repair, stop the compressor and switch off the power. Close the air outlet valve and
depressurize the air system.
3. When handling hot parts, special heat-resistant gloves must be used.

6.1 Replacement and overhauling instructions for compressor element, gearbox, coupling housing and
shaft seal
1. If the compressor element or the gearbox parts are to be replaced, run the compressor until warm (if possible), stop the
compressor and close the air outlet valve. Depressurize and drain the oil (see section 5.4).
2. Make sure that the parts to be dismantled are cooled down sufficiently. Remove the compressor module from the
locomotive.
3. Loosen the motor cables in the motor connecting box and put the cables aside (if applicable).
4. Loosen the pipe couplings of the Dp switch and the vacuum switch (if supplied).
5. Loosen the support bracket of both switches (if provided) and remove the switches together with the bracket.
6. After removing the bolts connecting the fan housing and the gearbox, the motor with fan housing can be removed.
Support the compressor element if necessary.
7. If the compressor element (~20kg) is to be removed from the gearbox, dismount the unloader from the compressor
element inlet. Remove the pipe from between the air receiver and check valve. Remove the pipe from between the check
valve and oil stop valve. Unscrew the 13 bolts fixing the compressor element to the gear casing. Remove the compressor
element from the gearbox. Replace the compressor element if necessary. Remove for this first the gear followed by the
flange (4 bolts).
8. If the shaft seal is to be replaced, remove the retainer with shaft seal from the gearbox housing and remove the bushing
from the gear shaft. Fit the new shaft seal into an new retainer with an o-ring and a suitable pressing tool. Place the
retainer in the gearbox. Heat the new bushing to 100 degrees Celsius and fit it to the shaft. Take care not to damage the
seal lips.
9. Inspect all parts for wear. Replace all damaged parts. Always use new gaskets, O-rings, etc. Refit all parts in the opposite
order.
10. When the compressor element or the gearbox parts have been replaced: also inspect the oil cooler (clean or replace
if necessary) and change the oil, oil filter and separator element.

6.2 Replacement of temperature gauge/switch

1. Remove the gauge/switch (T1). Disconnect the electrical connections from the switch. Remove the temperature sensor
from the check valve housing.
2. Fit the gauge/switch in the opposite order.

6.3 Replacement of blow-off valve

1. Remove the wiring connector from the solenoid valve
2. Remove the piping connections.
3. Remove the manifold with the solenoid valve from the support.
3. Remove the blow-off valve.
4. Fit the new valve in the opposite order (hand tight).

6.4 Replacement of drain valves

1. Remove the wiring connector from the solenoid valve
2. Remove the piping connections.
3. Remove the drain valve.
4. Fit the new valve in the opposite order (hand tight).

9819 0067 09 23
7 PROBLEM SOLVING

7.1 Before starting repairs

Stop the compressor and switch off the voltage. Close the air outlet valve and depressurise the air system. Furthermore, apply
all relevant safety precautions, including those mentioned in this book.

7.2 Mechanical faults and suggested remedies

1. Compressor starts running, but does not deliver air
a. Check valve in air inlet stuck in closed position
a. Have valve checked
b. Minimum pressure valve (MPV) leaking (when net is depressurised)
b. Have valve checked

2. Condensate is not discharged from moisture trap during loading

a. Discharge pipe clogged
a. Check and correct as necessary
b. Float valve malfunctioning
b. Remove float valve assembly, clean and check

3. Compressor air output or pressure below normal

a. Air consumption exceeds air output of compressor
a. Check equipment connected
b. Choked air inlet filter element (AF)
b. Replace filter element
c. Check valve in the air inlet does not fully open
c. Have valve checked
d. Oil separator element (OS) clogged
d. Have element replaced
e. Air leakage
e. Check and correct as necessary
f. Safety valve (SV COMP) leaking
f. Have valve replaced

4. Safety valve (SV COMP) blows

a. Minimum pressure valve (MPV) malfunctioning
a. Have valve checked
b. Oil separator element (OS) clogged
b. Have element replaced
c. Safety valve (SV COMP) out of order
c. Replace safety valve

5. Element outlet temperature above normal

a. Insufficient cooling air or cooling air temperature too high
a. Check for cooling air restriction or improve ventilation of compressor room. Avoid recirculation of cooling air. If
installed, check capacity of compressor room fan
b. Oil level too low
b. Check and correct as necessary
c. Oil cooler (OC) clogged
c. Clean cooler
d. By-pass valve (BV) malfunctioning
d. Have valve tested

9819 0067 09 24
8 PRINCIPAL DATA GAR 5-14

8.1 Standard conditions

Ambient
Min. operating temperature :0 °C
Max. Operating temperature : 40 °C
Max. Storage temperature : 70 °C
Humidity : 0-100 %
Application
Duty cycle : 10-100 % (minimum running time of 45 s)
Max. number of starts : 30 /hour
Minimum stop time : 60 s
Inclination : 20 ° (in all directions)
Movement : in all directions
Max. altitude : 1200 m (above sea level)
Vibration based on standards EN 61373 A1 Class B
Amplitude : 0,5 g
Frequency : 5-150 Hz
Shape : sinusoidal
Shock & acceleration
Vertical : +/- 1 g (in addition to gravity)
Lateral acceleration : +/- 3 g
Horizontal : +/- 5 g (in all directions)
Shape : ½ sinusoidal

8.2 Supply voltages

Control voltage Tolerances

VDC Control voltage DC : -30% + 25%
24 VDC

8.3 Drive motor

The drive motor is a Parker F11-06 SAE application

GAR 5 GAR 7 GAR 10 GAR 14

Theorical motor speed rpm 2905 4035 4935 7660
*HYD* Flow l/min 18 25 31 47
*HYD* Pressure bar 189 190 192 212
FAD l/min 645 910 1100 1555

8.4 Technical data

FAD measured at ambient 30 °C and hydraulic oil temperature 50°C

Model GAR 5-14

Make Atlas Copco
Limitations for operation
Min. inlet temperature °C 0
Max. Air inlet temperature °C 40
Min. working pressure bar(e) 4
Max. working pressure bar(e) 10
FAD outlet l/s See section 8.3
Oil carry-over at compressor outlet ppm 3

9819 0067 09 25