Atlas Copco XAHS 186 Cud PNE Instruction Manual Download

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Maintenance Log

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Summary of Contents for XAHS 186 Cud PNE

Page 1: ...Instruction Manual for Portable Compressors English XAHS 186 Cud PNE Engine 6BT5 9 ...

Page 2: ......

Page 3: ...RGY DIVISION www atlascopco com Printed matter N 9096 3227 00 11 2018 Instruction Manual for Portable Compressors XAHS 186 Cud PNE The information provided in this book is applicable for compressors with Sr No PNA 814619 and onward ...

Page 4: ...r modifications additions or conversions made without the manufacturer s approval in writing 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 2018 Atlas Copco India Ltd Any unauthorized use or copying of the contents or any part thereof is prohibited This applies in particular to trade...

Page 5: ...inuous regulating system 23 3 2 Markings and information labels 24 3 3 Electric system 25 4 Operating instructions 28 4 1 Parking towing and lifting instructions 28 4 1 1 Parking instructions 28 4 1 2 Towing instructions 29 4 1 3 Lifting instructions 29 4 2 Height adjustment With adjustable towbar 30 4 3 Before starting 31 4 4 Starting Stopping 32 4 4 1 Control panel 32 4 5 Operations overview 34 ...

Page 6: ...ng system 49 7 2 Air filters engine compressor 51 7 2 1 Main parts 51 7 2 2 Cleaning the dust trap 51 7 2 3 Replacing the filter element and the safety cartridge 51 7 3 Air receiver 52 7 4 Safety valve 52 7 5 Fuel system 53 7 5 1 Priming instructions 53 7 5 2 Replacing fuel filter elements 53 8 Problem solving 54 9 Technical specifications 58 9 1 Torque values 58 9 1 1 General torque values 58 9 2...

Page 7: ...ing and skill for each category of job Skill level 1 Operator An operator is trained in all aspects of operating the unit with the push buttons and is trained to know the safety aspects Skill level 2 Mechanical technician A mechanical technician is trained to operate the unit the same as the operator In addition the mechanical technician is also trained to perform maintenance and repair as describ...

Page 8: ...s and for modifications additions or conversions made without the manufacturer s approval in writing If any statement in this manual does not comply with local legislation the stricter of the two shall be applied Statements in these safety precautions should not be interpreted as suggestions recommendations or inducements that it should be used in violation of any applicable laws or regulations GE...

Page 9: ... wear safety clothing Depending on the kind of activities these are safety glasses ear protection safety helmet including visor safety gloves protective clothing safety shoes Do not wear the hair long and loose protect long hair with a hairnet or wear loose clothing or jewelry 16 Take precautions against fire Handle fuel oil and anti freeze with care because they are inflammable substances Do not ...

Page 10: ...s shackles etc shall never be bent and shall only have stress in line with their design load axis The capacity of a lifting device diminishes when the lifting force is applied at an angle to its load axis 8 For maximum safety and efficiency of the lifting apparatus all lifting members shall be applied as near to perpendicular as possible If required a lifting beam shall be applied between hoist an...

Page 11: ...suitable for the working pressure Never use frayed damaged or deteriorated hoses Replace hoses and flexibles before the lifetime expires Use only the correct type and size of hose end fittings and connections 10 If the compressor is to be used for sand blasting or will be connected to a common compressed air system fit an appropriate non return valve check valve between compressor outlet and the c...

Page 12: ...e parts have cooled down to room temperature 19 Never operate the unit in surroundings where there is a possibility of taking in flammable or toxic fumes 20 If the working process produces fumes dust or vibration hazards etc take the necessary steps to eliminate the risk of personnel injury 21 When using compressed air or inert gas to clean down equipment do so with caution and use the appropriate...

Page 13: ...stripping an engine or other machine or undertaking major overhaul on it prevent all movable parts from rolling over or moving 6 Make sure that no tools loose parts or rags are left in or on the machine Never leave rags or loose clothing near the engine air intake 7 Never use flammable solvents for cleaning fire risk 8 Take safety precautions against toxic vapours of cleaning liquids 9 Never use m...

Page 14: ...unction properly 20 Maintenance and repair work should be recorded in an operator s logbook for all machinery Frequency and nature of repairs can reveal unsafe conditions 21 When hot parts have to be handled e g shrink fitting special heat resistant gloves shall be used and if required other body protection shall be applied 22 When using cartridge type breathing filter equipment ascertain that the...

Page 15: ... Disconnect in the reverse order Pressure vessels Maintenance installation requirements 1 The vessel can be used as pressure vessel or as separator and is designed to hold compressed air for the following application pressure vessel for compressor medium AIR OIL and operates as detailed on the data plate of the vessel the maximum working pressure ps in bar psi the maximum working temperature Tmax ...

Page 16: ...d then use only correct parts supplied by Seetru and in accordance with the instructions available for the valve type Safety valves must be frequently tested and regularly maintained The set pressure should be periodically checked for accuracy When fitted the lifting device should be operated at pressures not less than 75 of the set pressure to ensure free and easy movement of internal parts The f...

Page 17: ...g purposes Compressor oil system The oil is boosted by air pressure The system has no oil pump The oil is removed from the air in the air oil vessel at first by centrifugal force secondly through the oil separator element The vessel is provided with an oil level indicator Regulation The compressor is provided with a single or dual pressure continuous regulating system and a blow off valve which is...

Page 18: ...high coolant temperature shut down sensors The electric system is equipped with a 12V main switch Frame and axles The compressor engine unit is supported by rubber buffers in the frame The standard compressor unit has a adjustable towbar with brakes Bodywork The bodywork has openings for the intake and outlet of cooling air and hinged doors for maintenance and service operations The bodywork is in...

Page 19: ... 19 Main parts ...

Page 20: ...Cc Filler Cap coolant FCe Filler Cap engine oil FCt Filler Cap fuel tank FF Fuel Filter FPco Filler Plug compressor oil FT Fuel Tank MPV Minimum Pressure Valve OC Oil Cooler OFce Oil Filter compressor element OFe Oil Filter engine OLG Oil Level Gauge R Radiator RB Recovery Bottle RV Regulating Valve S Starting Motor SL Support Leg SR Speed Regulator ST Strainer SV Safety Valve TB Towbar UV Unloadi...

Page 21: ... 21 REGULATING SYSTEM OVERVIEW ...

Page 22: ...oil filters OF and the oil stop valve OSV to the compressor element CE When the compressor is stopped check valve incorporated in the unloader valve prevents the oil from flowing back into the compressor element to air flow The compressor element has an oil gallery in the bottom of its casing The oil for rotor lubrication cooling and sealing is injected through holes in the gallery Lubrication of ...

Page 23: ...between maximum load speed and unloading speed the output of a screw compressor is proportional to the rotating speed 2 Air inlet throttling If the air consumption is equal to or exceeds the maximum air output the engine speed is held at maximum load speed and the throttle valve TV is fully open If the air consumption is less than the maximum air output air receiver pressure increases and the regu...

Page 24: ...ves without connected hoses Rotation direction Inlet Outlet Compressor oil drain Battery charge indication 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 compressor with open doors Lifting permitted Use diesel fuel only Fuel ON Preheater 4 75 bar 69 psi Tyre pressure Low Coo...

Page 25: ... 25 ELECTRIC SYSTEM Circuit Diagram ...

Page 26: ... 26 Wiring Diagram ...

Page 27: ... 27 ...

Page 28: ...obilize the compressor by placing wheel chocks in front of or behind the wheels Locate the rear end of the compressor upwind away from contaminated wind streams and walls Avoid recirculation of exhaust air from the engine This can cause overheating and engine power decrease The operator is expected to apply all relevant Safety precautions Before putting the compressor in to use check the brake sys...

Page 29: ...mpressor with air hoses connected to the air outlet valves LIFTING INSTRUCTIONS To lift the compressor use a lift truck or crane with sufficient capacity weight see indication on Dataplate See to it that the compressor will be lifted vertically and remains level Before towing the compressor ensure that the towing equipment of the vehicle matches the towing eye Switch of the compressor before movin...

Page 30: ...should be undertaken on levelled ground and in coupled condition When readjusting make sure that the front point of the towbar is horizontal to the coupling point Before starting a trip ensure that the adjustment shaft is secure so that the stability and safety is guaranteed while driving If necessary tighten the locking nut 2 corresponding to table Before towing the compressor make sure that the ...

Page 31: ...ecessary See section Synthetic compressor oil SCREWLUB for the oil to be used 5 Check that the fuel tank contains sufficient fuel Top up if necessary Consult the Engine Operation Manual for the type of fuel 6 Drain any water and sediment from the fuel filters until clean fuel flows from the drain cock 7 Empty the dust trap of each air filter AF See section Replacing the filter element and the safe...

Page 32: ...option F1 Circuit breaker button H3 LED red Charge indication PG Working pressure guage H4 LED red Compressor outlet temperature LV Loading valve H5 LED red Engine oil temperature N4 Control module H6 LED red Engine oil pressure S Start Stop button H7 LED red Low coolant H8 LED red Not in use ...

Page 33: ...start button in the 0 position The control panel in addition 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 CUD A fault which occurs with the engine either alternator voltage too low coolant tempera...

Page 34: ...he vent screw 1 on the fuel filter Operate the hand pump 2 until fuel comes out of the bore for the vent screw and air is completely removed from the fuel system Fasten the vent screw 1 Switch the ON OFF switch to position ON The instrument panel will now perform a brief selftest Push the start button and the starter motor will automatically try to start the engine When the engine is running the a...

Page 35: ...sor and engine Service Paks minimize downtime and keep your maintenance budget low Order Service Paks at your local Atlas Copco dealer SERVICE KITS A service kit is a collection of parts to fit a specific repair or rebuilding task It guarantees that all necessary parts are replaced at the same time which improves the uptime of the unit The order numbers of the Service Kits are listed in the Atlas ...

Page 36: ... to compressor applications Maintenance schedule can be adapted depending on application environment and quality of maintenance Maintenance schedule Daily 750 hours 1500 hours 2250 hours Service pak XAHS 186 Cud 9095 0499 35 9095 0499 40 9095 0499 45 Engine oil level Check Condensate 10 Drain Compressor oil level Check Coolant level Check Air filter vacuator valves Empty Fuel filter water drain Dr...

Page 37: ...ce Fan V belts 3 Adjust Adjust Adjust Fuel tank Clean Clean Clean Compressor oil 1 7 Replace Replace Change Compressor oil filter 5 Replace Replace Replace Coolant 8 4 Analyse Analyse Analyse Air filter element 1 Replace Replace Replace Engine oil 3 12 Change Change Change Engine oil filter 3 Replace Replace Replace Fuel filter Water seperator 3 6 13 Replace Replace Replace Joint of height adjustm...

Page 38: ...quency of renewal 7 See section Oil specifications 8 The following part numbers can be ordered from Atlas Copco to check on inhibitors and freezing point 2913 0028 00 refractometer 2913 0029 00 pH meter 9 See section Safety valve 10 See section Before starting 11 Replace all rubber flexibles each 6 years according to DIN 20066 12 Engine oil oil filter should be replaced after every 250hrs of opera...

Page 39: ...which keeps the compressor in excellent condition Only use synthetic compressor oil Never mix synthetic with mineral oil Remark When changing from mineral to synthetic oil or the other way around you will need to do an extra rinse After doing the complete change procedure to synthetic oil run the unit for a few minutes to allow good and complete circulation of the synthetic oil Then drain the synt...

Page 40: ...izontal check the level of the compressor oil The pointer of the oil level gauge 1 must register in the upper extremity of the green range Add oil if necessary OIL AND OIL FILTER CHANGE ENGINE OIL AND OIL FILTER CHANGE For replacing the engine oil filter 1 See section Preventive maintenance schedule for the compressor Never mix oils of different brands or types Use only non toxic oils where there ...

Page 41: ...en operating in high ambient temperatures in very dusty or high humidity conditions it is recommended to change the oil more frequently 1 Run the compressor until warm Close the outlet valve s 3 and stop the compressor Wait until the pressure is released through the automatic blow down valve Unscrew the oil filler plug 2 one turn This uncovers a vent hole which permits any pressure in the system t...

Page 42: ... in the upper part of the green area COOLANT SPECIFICATIONS Never add more oil Overfilling results in oil consumption Never remove the cooling system filler cap while coolant is hot The system may be under pressure Remove the cap slowly and only when coolant is at ambient temperature A sudden release of pressure from a heated cooling system can result in personal injury from the splash of hot cool...

Page 43: ...nges the concentration of additives and is therefore not allowed REPLACING THE COOLANT Drain Completely drain the entire cooling system Used coolant must be disposed or recycled in accordance with laws and local regulations Fill To assure proper operation and the release of trapped air run the engine until normal engine operation temperature is reached Turn off the engine and allow to cool Recheck...

Page 44: ... jet at max power Close the service door s Remove any dirt from the coolers with a fibre brush Never use a wire brush or metal objects To avoid damaging the coolers angle between jet and coolers should be approx 90 Protect the electrical and controlling equipment air filters etc against penetration of moisture Never leave spilled liquids such as fuel oil coolant and cleansing agents in or around t...

Page 45: ...ock the battery a few times so that possible air bubbles can escape wait 10 minutes and check the level in each cell once more if required add electrolyte Refit plugs and or cover Place the battery in the compressor RECHARGING A BATTERY Before and after charging a battery always check the electrolyte level in each cell if required top up with distilled water only When charging batteries each cell ...

Page 46: ...at least 10 mm 0 4 in to 15 mm 0 6 in Top up with distilled water only Keep the terminals and clamps tight clean and lightely covered with petroleum jelly COMPRESSOR ELEMENT OVERHAUL When a compressor element is due for overhaul it needs to be done by Atlas Copco This guarantees the use of genuine parts and correct tools with care and precision ...

Page 47: ...tected caps plastic tapes STORAGE OF ENGINE MORE THAN 6 MONTHS FROM THE DATE OF ENGINE SHIPMENT FROM CUMMINS PLANT Cooling system passage 1 Prepare the engine for long term storage process 2 Prepare the engine to fit on the equipment Install the engine on the equipment and ensure the connections are fitted completely Fill the cooling system with the engine coolant Compleat EG recommended Leave the...

Page 48: ...E 1 Clean off the accumulated dirt from exterior of the engine 2 Remove all protected caps wrappings and tape from connections such as breathers fuel in and out connections water in and out connections etc 3 Use the suitable solvent cleaner or degreaser to remove rust preventive compound from unpainted external surfaces of the engine 4 Fill the oil pan with the new lube oil Replace the fuel lube o...

Page 49: ... 49 Adjustments and servicing procedures ADJUSTMENT OF THE CONTINUOUS REGULATING SYSTEM ...

Page 50: ...y turning the adjusting wheel clockwise and anti clockwise respectively To adjust the normal working pressure proceed as follows 1 Loosen the lock nut of the regulating valve 2 Release Regulating Valve turn out 3 With the outlet valves AOV closed adjust the regulating valve RV until a pressure is reached of nominal pressure 2 bar 29 psi 4 Lock the regulating valve RV by fixing the lock nut ...

Page 51: ...ed A dirty safety cartridge 3 is an indication of a malfunctioning filter element 3 Reassemble in reverse order of dismantling 4 Inspect and tighten all air intake connections 1 Snap clips 4x 4 Filter element 2 Dust trap cover 5 Filter housing 3 Safety cartridge 6 Vacuator valve AIR FILTERS ENGINE COMPRESSOR 6 1 2 3 4 5 The Atlas Copco air filters are specially designed for the application The use...

Page 52: ...f the lifting gear twice a year This can be done by screwing the cap of the valve anti clockwise A check of the set pressure once a year according to the local regulations This check cannot be done on the compressor and must be carried out on a proper test bench Daily drain condensate All adjustments or repairs are to be done by an authorized representative of the safety valve 2 supplier see secti...

Page 53: ...eplacement of the fuel filter REPLACING FUEL FILTER ELEMENTS Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire To help prevent possible injury turn the ON OFF switch in position OFF when changing fuel filters or water separator elements Clean up fuel spills immediately Do not loosen the fuel lines at the fuel manifold The fittings may be damaged and or a loss of pr...

Page 54: ...egulating valve RV defective Have regulating valve removed and inspected by an Atlas Copco Service representative Blow down valve stuck in open position Check and correct as necessary Loading valve LV leaking past O ring With compressor running at max load speed disconnect hose leading to unloader If air leaks from the hose remove and inspect loading valve Replace damaged or worn O rings Oil separ...

Page 55: ...e leaking hoses Air intake throttle valve does not close for some reason Remove air filters air intake manifold and throttle valve spring seat Withdraw the valve and inspect Replace parts where necessary Caution the spring seat is fixed with 4 short and 2 long setscrews first remove the short screws then release the spring tension unscrewing the long ones Minimum pressure valve malfunctioning Remo...

Page 56: ...top and recheck oil level Possible faults Corrective actions Insufficient compressor cooling Locate compressor away from walls when banked with other compressors leave space between them Oil cooler clogged externally Clean oil cooler Refer to section Cleaning coolers Oil cooler clogged internally Consult Atlas Copco Oil filters clogged Replace oil filters Oil level too low Check oil level Top up w...

Page 57: ... or battery connections while the engine is running 3 When recharging the battery disconnect it from the alternator Before using booster cables to start the engine be sure of the polarity and connect the batteries correctly 4 Never operate the engine without the main or voltage sensing cables connected in the circuit ...

Page 58: ...agon screws and nuts with strength grade 8 8 For hexagon screws and nuts with strength grade 12 9 Thread size Torque value Nm lbf ft M6 9 6 64 M8 23 16 97 M10 46 34 69 M12 80 59 04 M14 125 92 25 M16 205 151 29 Thread size Torque value Nm lbf ft M6 15 11 07 M8 39 28 78 M10 78 57 56 M12 135 99 63 M14 210 154 98 M16 345 254 61 Secure the drain cock and tank cap of the fuel tank handtight ...

Page 59: ... The inlet conditions are specified at the air inlet grating outside the canopy Designation Unit XAHS 186 Cud Absolute inlet pressure bar e 1 psi 14 5 Relative air humidity 0 Air inlet temperature C 20 F 68 Nominal effective working pressure bar e 12 psi 175 ...

Page 60: ...effective receiver pressure bar e 4 psi 58 Maximum effective receiver pressure compressor unloaded bar e 13 5 psi 196 Maximum ambient temperature at sea level without aftercooler C 45 F 113 with aftercooler C 40 F 104 Minimum starting temperature C 10 F 14 ...

Page 61: ... cfm 373 Typical oil content of compressed air mg m3 free air 3 oz 1000 cu ft 0 003 Engine oil consumption maximum g h 217 1 oz h 7 66 Compressed air temperature at outlet valve without aftercooler C Ambient 65 F Ambient 149 with aftercooler C Ambient 12 F Ambient 54 Noise level Sound pressure level LP complies with ISO 2151 under free field conditions at 7 m distance dB A Sound pressure level LP ...

Page 62: ...217 ed 3 1996 annex D Tolerance 5 25 l s 53 cfm FAD 250 l s 530 cfm 4 250 l s 530 cfm 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 ...

Page 63: ...l 46 23 Shipping dimension Length meter 4 2 Width meter 1 8 Height meter 1 8 Shipping weight Kg 1850 Designation Unit All units Make Cummins Type 6BT 5 9C Coolant Water Ethylene GLYCOL Number of cylinders 6 Bore mm 102 in 4 01 Stroke mm 120 in 4 72 Swept volume l 5 9 cu in 360 04 Designation All units Capacity of oil sump Initial fill l 17 4 US gal 4 59 Capacity of cooling system l 29 US gal 7 7 ...

Page 64: ...cturer 3 Vehicle identification number 4 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 5 Model 6 Working pressure 7 Speed 8 Engine power 9 Manufacturing year ...

Page 65: ...aterials for recycling in the future is forseen DISPOSAL OF MATERIALS Dispose contaminated substances and material separately according to local applicable environmental legislations Before dismantling a machine at the end of its operating lifetime drain all fluids and dispose of according the applicable local disposal regulations Remove the batteries Do not throw batteries into the fire explosion...

Page 66: ... 66 Maintenance Log Compressor Customer Serial number Service hours Maintenance action Date By initials ...

Page 67: ... 67 Maintenance Log Compressor Customer Serial number Service hours Maintenance action Date By initials ...

Page 68: ... 68 Maintenance Log Compressor Customer Serial number Service hours Maintenance action Date By initials ...

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