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Atlas Copco XAS 185 CD7 T4, Instruction Manual, Page: 38 / 40

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Atlas Copco XAS 185 CD7 T4 Instruction Manual Download Page 38

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Maintenance Log

Compressor Customer.......................................................................................................................................................................................................................................................

Serial number.....................................................................................................................................................................................................................................................................

Service hours

Maintenance action

Date

By initials

Summary of Contents for XAS 185 CD7 T4

Page 1: ...XAS 185 CD7 T4 Instruction Manual for AC Compressors English Engine Caterpillar C2 2 ...

Page 2: ......

Page 3: ...ATLAS COPCO PORTABLE ENERGY DIVISION www atlascopco com Printed matter Nr 1310 3013 76 06 2014 Instruction Manual for AC Compressor XAS 185 CD7 T4 Original instructions ...

Page 4: ... the manufacturer s approval in writing Neglecting maintenance or making changes to the setup of the machine can result in major hazards including fire risk While every effort has been made to ensure that the information in this manual is correct Atlas Copco does not assume responsibility for possible errors Copyright 2014 Atlas Copco Any unauthorized use or copying of the contents or any part the...

Page 5: ... Diagram 20 2 7 2 Description 22 3 Operating instructions 23 3 1 Parking Towing and Lifting instructions 23 3 1 1 Drawbar Preparations for Towing 23 3 1 2 Parking Instructions 24 3 1 3 Towing Instructions 24 3 1 4 Lifting Instructions 24 3 2 Before Starting 24 3 3 Starting Stopping 25 4 Maintenance 26 4 1 Use of Service Paks 26 4 2 Preventive Maintenance Schedule For The Compressor 26 4 2 1 Check ...

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Page 7: ...ne qualified for the job 5 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 oil vapour when air is admitted 6 Maintenance work other than routine attention shall only be undertaken when th...

Page 8: ... coolers 8 Locate the unit away from walls Take all precautions to ensure that hot air exhausted from the engine and driven machine cooling systems cannot be recirculated If such hot air is taken in 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 9 No external force may be exerted on the air outlet valve...

Page 9: ... are available for specific jobs and should be used when recommended The use of these tools will save time and prevent damage to parts 1 Use only wrenches or sockets whose size fits the fastener 2 Apply an open end wrench only in the place of the fastener head square to the thread axis 3 Do not use a pipe or other improvised leverage extensions on handles 4 Do not hammer on wrenches or other tools...

Page 10: ... with the compressor supplying the air pressure and must be carried out on a proper test bench Injury Prevention 1 Stationary housing guards are provided on all rotating or reciprocating parts not otherwise protected and which may be hazardous to personnel Machinery shall never be put into operation when such guards have been removed operate only when guards are securely reinstalled 2 Do not open ...

Page 11: ... as well as for any bystander Do not apply compressed air or inert gas to your skin or direct an air or gas stream at people Never use it to clean dirt from your clothes 15 Before blowing compressed air or inert gas through a hose ensure that the open end is held securely so that it cannot whip and cause injury 16 When washing parts in or with a cleaning solvent provide the required ventilation an...

Page 12: ...d in the unloader assembly The valve is closed during operation by outlet pressure of the compressor element and opens by air receiver pressure when the compressor is stopped 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 and engine speed regul...

Page 13: ...nished with a data plate located on the front drivers side of the unit showing the compressor type serial number maximum final pressure and normal working pressure TYPE OF VEHICLE TYPE DE VEHICULE TRA REM V I N N I V SECURITE DES VEHICULES AUTOMOBILES DU CANADA ET U S A EN VIGUEUR A LA DATE DE SA FABRICATION CONFORME A TOUTES LES NORMES QUI LUI SONT APPLICABLES EN VERTU DU REGLEMENT SUR LA MOTOR V...

Page 14: ... 14 Main Parts ...

Page 15: ...Filler Cap Coolant FCeo Filler Cap Engine Oil FCf Filler Cap Fuel FFf Final Fuel Filter FT Fuel Tank Reference Name FFp Primary Fuel Filter FPco Compressor Oil Filling Plug LB Lifting Bale M Muffler MPN Minimum Pressure Nozzle OC Oil Cooler OFc Oil Filter Compressor OFe Oil Filter Engine OLG Oil Level Gauge R Radiator RV Regulating Valve S Starter Motor Engine SR Speed Regulator SV Safety Valve TT...

Page 16: ... 16 Compressor regulating system Load Condition ...

Page 17: ...pling Housing CP Control Panel CV Check Valve DP Drain Plug E Engine EW Electrical Wiring F Cooling Fan Reference Name FP Compressor Oil Feeling Plug MPN Minimum Pressure Nozzle OC Oil Cooler OFc Oil Filter Compressor OS Oil Separator RV Regulating Valve SC Safety Cartridge SL Scavenge Line SR Speed Regulator SV Safety Valve TS Temperature Switch UV Unloader Valve Vi Vacuum Indicator VV Vacuuator ...

Page 18: ... because of a clogged filter The oil then by passes the filter without being filtered For this reason the oil filter must be replaced at regular intervals Continuous regulating system The system comprises The compressor is provided with a continuous regulating system This system is provided with a blow down valve BDV which is integrated in the unloader assembly UA The valve is closed during operat...

Page 19: ...d the speed regulator increases the engine speed The construction of the regulating valve is such that any increase decrease of the air receiver pressure above the pre set valve opening pressure results in a proportional increase decrease of the control pressure to the unloading valve Part of the control air is vented to atmosphere and any condensate discharged through the vent holes VH ...

Page 20: ... 20 Electric system CIRCUIT DIAGRAM ...

Page 21: ...rter Motor Solenoid K1 K5 Relay M1 Starter Motor P1 Hour Meter P2 Fuel Level Gauge S1 Contact Switch Off On Override Start S2 Temperature Switch Engine S3 Oil Pressure Switch Engine S4 test Lamp S5 Temperature Switch Compressor S6 Low Fuel Level Switch S7 Fuel Level Sender S8 Preheat Pushbutton Y1 Fuel Stop Solenoid Valve R1 Resistor V2 Diode ...

Page 22: ... devices occurs no longer across line 3 but across line 2 at K3 to line 4 and this way to line 3 through K4 Explanation of shutdowns Oil pressure contact S3 opens K3 no longer excited K3 changes over 87 87a engine cuts out because fuel solenoid Y1 no longer excited and lamp H2 goes on simultaneously Low Fuel Switch S6 opens K3 no longer excited K3 changes over 87 87a engine cuts out because fuel s...

Page 23: ...o secure the drawbar by reinserting the bolt through both drawbar halves item 2 3 Secure and tighten with the locknut sup plied in the shipping bag Torque the nut and bolt to 130 ft lbs 5 Using a jack stand or by blocking support the end of the drawbar With the compressor properly supported remove the prop or nose wheel and tighten the pivot nut bolt Torque the nut and bolt to 130 ft lbs 6 Re atta...

Page 24: ...be placed in such a way that the compressor which must be placed level will be lifted vertically Use the lifting bale provided to lift the unit Before Starting 1 Before initial start up prepare battery for operation if not already done 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 th...

Page 25: ...button counter clockwise to position 0 with valves closed During operation the canopy must remain closed and can only be opened for short periods The control panel in addition indicates receiver pressure PG and accumulated operating hours P1 Fault situations and protective devices The starter motor is protected against attempts to start when the unit is already running A fault which occurs with th...

Page 26: ...urs Normal Or every 250 hours 1310 3004 30 Bi yearly Or every 500 hours 1310 3004 31 Yearly or every 1000 hours 1310 3004 32 Note Engine oil level Check Compressor oil level Check Air filter dust valve Empty Fuel filter water drain Drain Air intake vacuum indicator Check Electrolyte level and terminals of battery Check Check Check Check Tire pressure Check Check Check Check Leaks in air oil or fue...

Page 27: ...itially Around 50 Hours Normal Or every 250 hours 1310 3004 30 Bi yearly Or every 500 hours 1310 3004 31 Yearly or every 1000 hours 1310 3004 32 Note Keep the bolts of the housing the lifting eye the towbar and the axle securely tightened Refer to Compressor Engine Specifications for the torque values PAROIL M Order number 1 gallon pail 1615 5947 00 5 gallon pail 1615 5947 00 55 gallon drum 1615 5...

Page 28: ...ch permits any pressure in the system to escape 2 Drain the oil by removing all drain plugs Drain plugs are located at the oil tank discharge manifold and oil injection manifold 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 OFc e g by means of a spe cial tool Catch the oil in a drain pan 4 Clean the filter seat ...

Page 29: ...Y MAINTENANCE Keep the battery clean and dry Keep the electrolyte level at 10 to 15 mm above the plates or at the indicated level top up with distilled water only Keep the terminals and clamps tight clean and lightly covered petroleum jelly 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 ...

Page 30: ... 30 Adjustments and Servicing Procedures Adjustment of the Continuous Regulating System ...

Page 31: ...tears or punctures before installation Discard the element 3 when damaged In heavy duty applications it is recommended to install a safety cartridge A dirty safety cartridge 4 is an indication of a mal functioning air filter element Replace the element and the safety cartridge in this case Replace the safety cartridge together with the filter element The safety cartridge cannot be cleaned CLEANING...

Page 32: ...chine and must be carried out on a proper test bench Fuel System Replacing the filter element 1 Unscrew the final filter element from the adapter head 2 Clean the adapter head sealing surface Lightly oil the gasket of the new element and screw the latter onto the header until the gasket is properly seated then tighten with both hands 3 After replacing the final filter s element prime fuel system w...

Page 33: ...tact switch S1 defective e Circuit breaker defective a Check electrolyte level and charge battery If no cells are shorted and battery is discharged trace cause and correct b Check and correct as necessary c Check wiring and connections especially grounds correct as necessary d With S1 switched in position 1 check voltage between ground and respectively each of the terminals of S1 Volt age must reg...

Page 34: ...e switch S5 defective c Relay K1 defective a Stop at once consult Engine Operation Manual b Stop at once test switches replace as necessary c Replace K1 9 Hour meter does not count running time a Hour meter defective a Replace 10 Compressor does not unload and engine keeps running at maximum speed when closing the air outlet valves safety valve blows a Air leaks in regulating system b Regulating v...

Page 35: ...ature too high a Re tense or replace V belt b See condition 17 c Check engine lubricating system d Check engine cooling see engine operation manual 16 Air and oil expelled from air filter after stopping a Unloader valve defective b Wrong oil type with no foam retarding additives a Repair valve b Consult Atlas Copco 17 Compressor overheating a Insufficient compressor cooling b Oil cooler OC clogged...

Page 36: ...185 CD7 Make Caterpillar Model C2 2 Type 4CYL NA Maximum operating speed compressor loaded rpm 2750 20 Minimum operating speed compressor unloaded rpm 1550 50 Fuel consumption at full load 2 7 gal hr Fuel consumption at unload 1 0 gal hr Capacities Compressor oil system gal 2 ltr 7 4 Engine lube oil system with filter gal 2 5 ltr 9 5 Fuel tank gal 25 ltr 94 Engine cooling system gal 2 5 ltr 9 2 Co...

Page 37: ...A 12V 925CCA Limitations Maximum towing speed mph 55 km h 88 Maximum allowed ambient operating temperature F 125 C 52 Minimum starting temperature 1 F 18 C 8 1 without the use of additional equipment Engine Dimensions PE Canopy Steel Canopy Overall length including towbar in 127 125 mm 3226 3200 Overall width in 64 60 mm 1626 1524 Overall height in 61 57 mm 1549 1448 Gross weight wet approximately...

Page 38: ... 38 Maintenance Log Compressor Customer Serial number Service hours Maintenance action Date By initials ...

Page 39: ... 39 Maintenance Log Compressor Customer Serial number Service hours Maintenance action Date By initials ...

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