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Atlas Copco XA(S) 186 Dd, Instruction Manual, Page: 1 / 44

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XAHS 146 Dd
XATS 156 Dd
XA(S) 186 Dd
XAVS 166 Dd
XAHS 186 Dd

Instruction Manual for Portable Compressors
English

Summary of Contents for XA(S) 186 Dd

Page 1: ...XAHS 146 Dd XATS 156 Dd XA S 186 Dd XAVS 166 Dd XAHS 186 Dd Instruction Manual for Portable Compressors English ...

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Page 3: ...Instruction Manual for Portable Compressors XAHS 146 Dd XATS 156 Dd XA S 186 Dd XAVS 166 Dd XAHS 186 Dd ATLAS COPCO PORTABLE AIR DIVISION www atlascopco com Printed matter N 2954 2230 02 11 2006 ...

Page 4: ...ty or Product Liability The manufacturer does not accept any liability for any damage arising for modifications additions or conversions made without the manufacturer s approval in writing Copyright 2006 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...

Page 5: ...y during use and operation 8 1 5 Safety during maintenance and repair 9 1 6 Tool applications safety 10 1 7 Specific safety precautions 10 2 Leading particulars 11 2 1 Description of safety pictograms used in this manual 11 2 2 General description 11 2 3 Markings and information labels 12 2 4 Main Parts 13 2 5 Air flow 15 2 6 Oil system 16 2 7 Continuous regulating system 16 2 8 Electrical system ...

Page 6: ... a dry charged battery 31 4 8 3 Recharging a battery 31 4 8 4 Battery maintenance 31 4 9 Storage 31 4 10 Service paks 31 4 11 Service kits 31 4 12 Compressor element overhaul 31 4 13 Liability 31 CONTENTS PAGE 5 Adjustments and servicing procedures 32 5 1 Adjustment of the continuous regulating system 32 5 2 Air filter engine compressor 33 5 2 1 Main parts 33 5 2 2 Cleaning the dust trap 33 5 2 3 ...

Page 7: ...ger the environment due to leakage of oil solvents or other substances endanger the machinery due to function failures All responsibility for any damage or injury resulting from neglecting these precautions or by non observance of ordinary caution and due care required in handling operating maintenance or repair also if not expressly mentioned in this instruction manual is disclaimed by Atlas Copc...

Page 8: ... by the engine or driven machine cooling fan this may cause overheating of the unit if taken in for combustion the engine power will be reduced 1 4 SAFETY DURING USE AND OPERATION 1 When the unit has to operate in a fire hazardous environment each engine exhaust has to be provided with a spark arrestor to trap incendiary sparks 2 The exhaust contains carbon monoxide which is a lethal gas When the ...

Page 9: ... below or in excess of its limits as indicated in the technical specifications 1 5 SAFETY DURING MAINTENANCE AND REPAIR Maintenance overhaul and repair work shall only be carried out by adequately trained personnel if required under supervision of someone qualified for the job 1 Use only the correct tools for maintenance and repair work and only tools which are in good condition 2 Parts shall only...

Page 10: ... 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...

Page 11: ...ntained between the pre selected working pressure and the corresponding unloading pressure Cooling system The engine is equipped with a liquid cooler and intercooler All compressors are equipped with an oil cooler The cooling air is generated by a fan driven by the engine Safety devices A thermal shut down switch protects the compressor against overheating The air receiver is provided with a safet...

Page 12: ...thout connected hoses Compressor loaded Runlamp Airfilter Compressor temperature too high Rotation direction Inlet Outlet Compressor oil drain Read the instruction manual before starting Service every 24 hours Warning Part under pressure Do not stand on outlet valves Start Stop indication of switch Do not run the motor with open doors Lifting permitted Use diesel fuel only Tyre pressure Sound powe...

Page 13: ...Engine Oil Level Dipstick E Engine EP Exhaust Pipe F Fan FC1 Filler Cap engine oil FC2 Filler Cap fuel tank FC3 Filler Cap coolant FF1 Fuel Prefilter FF2 Fuel Filter FLG Fuel Level Gauge FP1 Filler Plug compressor oil FT Fuel Tank IC Intercooler MPV Minimum Pressure Valve OC Oil Cooler OFCE Oil Filter compressor element OFE Oil Filter engine OLG Oil Level Gauge compressor element RV Regulating Val...

Page 14: ...Coolant Level Switch CP Control Panel CT Coolant Tank DPOC Drain Plug Oil Cooler DSE Engine Oil Level Dipstick E Engine EP Exhaust Pipe F Fan FC1 Filler Cap engine oil FC2 Filler Cap fuel tank FC3 Filler Cap coolant FF1 Fuel Prefilter FF2 Fuel Filter FLG Fuel Level Gauge FP1 Filler Plug compressor oil FT Fuel Tank IC Intercooler MPV Minimum Pressure Valve OC Oil Cooler OFCE Oil Filter compressor e...

Page 15: ...ven when the air outlet valves are open This ensures adequate oil injection and prevents oil consumption A temperature switch TS and a working pressure gauge PG are comprised in the system A blow down valve BDV is fitted in the unloader assembly to automaticallydepressurisetheair receiver AR when thecompressor is stopped BOV AFCE LV DP MPV NRV UV UA VH BDV CV CH AOV AFE RV SR VV VI VV SV FR PG AR ...

Page 16: ...topped When the air consumption increases the air receiver pressure will decrease and vice versa This receiver pressure variation is sensed by the regulating valve which by means of control air to the unloader matchestheairoutputtotheairconsumption Theairreceiverpressure is maintained between the pre selected working pressure and the corresponding unloading pressure When starting the compressor th...

Page 17: ...ry Starter Relay K6 Cold Start Relay K9 Overspeed Relay M1 Starter Motor N4 Control Module N5 Overspeed Control Module P1 Hourmeter P2 Glowplug P3 Fuel Level Gauge S3 Compressor Temperature Switch S4 Engine Temperature Switch S5 Engine Low Oil Pressure Switch S7 Overspeed Control Test Switch S8 Push Button S9 Coolant Level Switch X1 Module Connector Y1 Fuel Stop Solenoid Y2 Excess Fuel Provider Y3...

Page 18: ...iary Starter Relay K6 Cold Start Relay K9 Overspeed Relay M1 Starter Motor N4 Control Module N5 Overspeed Control Module P1 Hourmeter P2 Glowplug P3 Fuel Level Gauge S3 Compressor Temperature Switch S4 Engine Temperature Switch S5 Engine Low Oil Pressure Switch S7 Overspeed Control Test Switch S8 Push Button S9 Coolant Level Switch X1 Module Connector Y1 Fuel Stop Solenoid Y2 Excess Fuel Provider ...

Page 19: ...bilize the compressor by placing wheel chocks available as option in front of or behind the wheels Locate the rear end of the compressor upwind see Fig 3 4 awayfromcontaminatedwind streamsandwalls Avoidrecirculation of exhaust air from the engine This causes overheating and engine power decrease Fig 3 3 Parking position of jockey wheel Fig 3 4 Rear end of compressor upwind 3 1 2 TOWING INSTRUCTION...

Page 20: ...ation if not already done See section 4 8 2 With the compressor standing level check the level of the engine oil Add oil if necessary to the upper mark on dipstick Consult the Engine Operation Manual for the type and viscosity grade of the engine oil 3 Check the level of the compressor oil The pointer of oil level gauge Fig 2 4 OLG should register in the green range Add oil if necessary See sectio...

Page 21: ...indicates receiver pressure PG and accumulated operating hours P1 Fault situations and protective devices Also refer to chapter 6 Problem Solving The starter motor is protected against prolonged starting max cranking time 20 sec 60 sec for XAHS 186 Dd A fault which occurs with the engine either alternator voltage too low coolant temperature too high oil pressure too low or fuel level too low will ...

Page 22: ... and keep your maintenance budget low Order Service Paks at your local Atlas Copco dealer 4 2 PREVENTIVE MAINTENANCE SCHEDULE FOR THE COMPRESSOR The schedule contains a summary of the maintenance instructions Read the respective section before taking maintenance measures When servicing replace all disengaged packings e g gaskets O rings washers For engine maintenance refer to Engine Operation Manu...

Page 23: ...ntake vacuum indicators Check Electrolyte level and terminals of battery Check Check Check Tyre pressure Check Check Check Leaks in air oil or fuel system Check Check Check Coolers Oil Coolant Inter Clean Clean Engine minimum and maximum speeds Check Check Check Torque of wheel nuts Check Check Check Brake system if installed Check Adjust Check Adjust Check Adjust Safety valve Test Door hinges Gre...

Page 24: ... excellent lubrication from start up in temperatures as low as 25 C PAROIL15W40isamineralbasedhighperformancedieselengineoil withahighviscosity index AtlasCopcoPAROIL15W40isdesigned to provide a high level of performance and protection in standard ambient conditions as from 15 C Mineral compressor oil PAROIL M 5 liter can order number 1615 5947 00 20 liter can order number 1615 5948 00 210 liter b...

Page 25: ...ugs are locatedattheairreceiver compressorelementandcompressoroil cooler Catch the oil in a drain pan Screw out the filler plug to speed up draining Tighten the plugs after draining 3 Remove the oil filter 3 e g by means of a special tool Catch the oil in a drain pan 4 Clean the filter seat on the manifold taking care that no dirt drops into the system Oil the gasket of the new filter element Scre...

Page 26: ...ncentration of the additives in the coolant must be kept between certain limits as stated by the manufacturer s guidelines Toppingupthecoolantwithwateronly changestheconcentrationand is therefore not allowed Liquid cooled engines are factory filled with this type of coolant mixture PARCOOL EG Concentrate 5 liter can order number 1604 8159 00 4 6 3 HANDLING PARCOOL EG PARCOOL EG should be stored at...

Page 27: ...ore than 68 vol mix ratio in water are not recommended as this will lead to high engine operating temperatures A refractometer can be ordered from Atlas Copco with part number 2913 0028 00 4 6 5 TOPPING UP REPLACING COOLANT Verify if the engine cooling system is in a good condition no leaks clean Check the condition of the coolant If the condition of the coolant is outside the limits the complete ...

Page 28: ...r indication 20 C 33 2 Refractometer indication 22 C 3 Refractometer indication 25 C 4 Refractometer indication 30 C 5 Refractometer indication 36 C 14 33 33 17 14 50 4 8 50 Total volume coolant Measured concentration In case of expansion tank at low level this quantity is to be filled without draining from the cooling system Liter Vol Liter PARCOOL EG Concentrate 4 0 0 0 5 1 0 1 5 2 0 2 5 3 0 3 5...

Page 29: ...ctometer indication 20 C 33 2 Refractometer indication 22 C 3 Refractometer indication 25 C 4 Refractometer indication 30 C 5 Refractometer indication 36 C 80 33 33 33 17 67 80 67 20 50 100 Total volume coolant Measured concentration In case of expansion tank at normal level this quantity is to be drained from the cooling system Liter Vol Liter PARCOOL EG Concentrate 4 8 12 16 20 24 28 32 36 40 44...

Page 30: ...e until normal engine operation temperature is reached Turn off the engine and allow to cool Recheck coolant level and add if necessary 4 7 CLEANING COOLERS Fig 4 3 Compressor oil cooler 1 engine coolant cooler 2 and engine oil cooler 3 Keep the coolers 1 2 and 3 clean to maintain the cooling efficiency Then clean by air jet in reverse direction of normal flow Steamcleaningincombinationwithacleans...

Page 31: ...top up with distilled water only Keep the terminals and clamps tight clean and lightely covered with petroleum jelly 4 9 STORAGE 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 4 10 SERVICE PAKS A Service Pak is a collection of parts to be used for a spe...

Page 32: ...e table 3 Check the minimum speed of the engine Adjust minimum speed stop screw if necessary 4 Open an outlet valve AOV just enough to let the engine E run atmaximumspeed TheworkingpressuremustbeYbar e adjust if necessary with regulating valve RV see table 5 Check the engine maximum speed Adjust the maximum speed bymeansofadjustingeccentricnutontopofspeedregulator SR 6 Close the outlet valves AOV ...

Page 33: ...t 4 from the housing 5 3 Reassemble in reverse order of dismantling 4 Inspect and tighten all air intake connections 5 Reset the vacuum indicator Fig 5 3 Fig 5 3 Vacuum indicator 7 Air filter contamination indicator 8 Reset button 9 Yellow indicator 5 3 AIR RECEIVER The air receiver is tested according to official standards Regularly have inspections carried out in conformity with local regulation...

Page 34: ...tes for lining wear Lift and support the compressor Make sure that all brakes are off overrunbrake and hand brake lever The brake cables must be free fromtension Locktheswivelcamsofthewheelbrakefromtheoutside by means of a pin 4 mm 4 through the hole as shown in Fig 5 5 Turntheadjustingbolt 1 clockwisewithawrenchtillthewheellocks up Center the brake shoes by actuating the parking brake several tim...

Page 35: ...ulled out in the outmost position and the hand brake lever in the downward position Fig 5 8 loosen the lock nuts Fig 5 7 2 Turn adjusting nuts and brake cable nuts Fig 5 7 4 clockwise until there is no slack in the brake mechanism The equalizer Fig 5 7 6 must remain perpendicular to main brake cable Fig 5 7 5 2 Apply the hand brake lever several times and repeat the adjustment Tighten the nuts wit...

Page 36: ...ithout the main or voltage sensing cables connected in the circuit An electrical fault must be traced by an electrician For position of dip switches refer to section 2 8 1 to 2 8 2 Circuit Diagrams Problem Possible faults Corrective actions 1 Starter motor does not crank engine after switching startbutton S to a Low battery output a Check electrolyte level and charge battery If no cells are shorte...

Page 37: ...their fittings Stop leaks replace leaking hoses 7 Unit does not load after pressing the loading valve button a Regulating valve defective a Check and if necessary consult Atlas Copco 8 Engine does not speed up immediately after compressor loading valve button has been pressed and compressor does not deliver air a Regulating valve defective b Air intake throttle valve stuck in closed position a Che...

Page 38: ...nsufficient fuel b Air in fuel system or insufficient fuel supply c Engine oil pressure too low d Engine temperature too high e Compressor temperature too high f Low coolant level a Fill fuel tank b Check filters and hoses for leaks dirt and bends c Refer to the engine instruction manual d See corrective actions 15 e See corrective actions 16 f Top up cooling system 14 Air and oil mist expelles fr...

Page 39: ... filter PD Aftercooler water separator fine filter PD QD Aftercooler water separator fine filter PD reheater C Aftercooler water separator fine filter PD QD reheater C Aftercooler water separator reheater Lubricator on 7 bar units Safety Wheel chocks Safety cartridge Refinery equipment Spark arrestor Inlet shut down valve Cold start 20 C 4 F Customer colour Single Double Triple A These units meet ...

Page 40: ...le Nm 80 10 Bolts towbar bottom Nm 205 20 Bolts towing eye towbar Nm 80 10 Bolts lifting eye flywheel housing Nm 205 20 Bolts engine drive housing M12 Nm 80 10 Bolts engine drive housing M14 Nm 125 10 Bolts compressor element drive housing Nm 80 5 Safety switches Nm 35 5 Joints adjustable towbar M24 Nm 275 25 M32 Nm 375 25 Note Secure the tank cap and drain plug of the fuel tank handtight 8 2 SETT...

Page 41: ...ure bar e 4 4 4 4 4 2 Maximum effective receiver pressure compressor unloaded bar e 13 5 11 8 8 5 15 5 13 5 3 Maximum ambient temperature at sealevel 1 C 50 50 50 50 45 4 Minimum starting temperature C 10 10 10 10 10 5 Minimum starting temperature with coldstart equipment C 20 20 20 20 20 6 Altitude capability m 5000 5000 5000 5000 5000 Performance data 2 1 Engine shaft speed normal and maximum r ...

Page 42: ...n number 7 A Maximum permitted laden weight of the vehicle B Maximum permitted road weight of the vehicle C Maximum permitted laden weight of the towing eye 8 Model 9 Working pressure 10 Speed 11 Engine power 12 Manufacturing year 13 CE mark in accordance with Machine Directive 89 392 EEC 14 Register number or number of notified body Compressor type XAHS 146 Dd XAVS 166 Dd XATS 156 Dd XAHS 186 Dd ...

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Page 44: ...Printed in Belgium 11 2006 2954 2230 02 www atlascopco com ...

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