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Atlas Copco XAS 185 KD7 T4, Instruction Manual

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Atlas Copco XAS 185 KD7 T4 Instruction Manual Download Page 39

- 39 -

EMERGENCY STOP

When an emergency stop button (1) is pressed, power to
all outputs is terminated, by the emergency stop itself
(hardware) as well as by the software.
When the emergency stop button (1) is pressed the
operator can unlock the emergency stop by turning it
counterclockwise.

The emergency stop button is only to be

used in emergency situations; not for

stopping procedures.

(1)

Summary of Contents for XAS 185 KD7 T4

Page 1: ...Engine Kubota V2403 CR E4 XAS 185 KD7 T4 Instruction Manual for AC Compressors English ...

Page 2: ......

Page 3: ...ATLAS COPCO PORTABLE ENERGY DIVISION www atlascopco com Printed matter Nr 1310 3013 85 rev 01 02 2015 Instruction Manual for AC Compressor XAS 185 KD7 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 2015 Atlas Copco Any unauthorized use or copying of the contents or any part the...

Page 5: ...parations For Towing 22 3 2 Starting Stopping 23 3 2 1 Overview Icons 24 3 2 2 Starting 27 3 2 3 Stopping 31 3 2 4 Shutdown 32 3 2 5 Power Off 32 3 2 6 Diesel Particulate Filter regeneration 32 3 2 7 Automatic Dpf Regeneration Default 33 3 2 8 Inhibit Dpf Regeneration 33 3 2 9 Increasing Soot Load 33 3 2 10 Turning Regeneration Back To Auto 34 3 2 11 Force Dpf Regeneration 34 3 2 12 Service Regene...

Page 6: ...ap 51 6 2 3 Replacing The Air Filter Element 51 6 3 Air Receiver 52 6 4 Safety Valve 52 6 5 Fuel System 52 7 Problem Solving 53 7 1 Problem Solving Chart 53 7 2 Alternator Precautions 53 7 3 General 55 7 4 Disposal of materials 55 8 Maintenance Log 56 ...

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: ...ted 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 reg...

Page 13: ...and service operations The bodywork is internally lined with sound absorbing material Lifting eye A lifting eye is accessible through the roof panel at the top of the unit Control panel The control panel grouping the air pressure gauge control switch etc is placed at the right hand rear of air compressor Data plate The compressor is furnished with a data plate located on the front drivers side of ...

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

Page 15: ... Filler Cap Coolant FCeo Filler Cap Engine Oil FCf Filler Cap Fuel FFf Final Fuel Filter Reference Name FT Fuel Tank FFp Primary Fuel Filter FPco Compressor Oil Filling Plug LB Lifting Bale 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 Top Tank...

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

Page 17: ... CP Control Panel CV Check Valve DP Drain Plug E Engine EW Electrical Wiring F Cooling Fan FP Compressor Oil Filling Plug Reference Name M Manifold MPN Minimum Pressure Nozzle OC Oil Cooler OFc Oil Filter Compressor OFe Oil Filter Engine OS Oil Separator PS Pressure Sender RV Regulating Valve S Solenoid SC Safety Cartridge SL Scavenge Line SV Safety Valve TS Temperature Switch UV Unloader Valve Vi...

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 1310 3200 51 ...

Page 21: ... 21 ...

Page 22: ... to 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 at...

Page 23: ...This button will initiate the starting sequences if the controller is in Ready To Start Sequence or will re enter the normal running sequence when in Cooldown Sequence STOP BUTTON This button will initiate the cooldown stopping sequences if the controller is in normal running sequence LOAD BUTTON This button has been disabled The compressor is constantly loaded MEASUREMENTS VIEW BUTTON This button...

Page 24: ...ain View Indication Measuring View Indication Settings View Indication Alarm View Indication DPF REGENERATION High Exhaust System Temperature Means that the Diesel Particle Filter is being regenerated DPF REGENERATION NEEDED Means that the Diesel Particle Filter needs to be regenerated Please force DPF Regeneration ...

Page 25: ...equired OVERHAUL Major Overhaul required AUTO LOAD This icon will be shown if the Auto Load functionality is enabled or by means of a parameter setting or by means of pressing the load button before the machine is ready to be loaded Reference Name OPERATION MODE Local OPERATION MODE Remote ALARM Active not acknowledged Shutdown Alarm ALARM Active not acknowledged Non Shutdown Alarm ALARM Active ac...

Page 26: ...e Up and Down navigation buttons to scroll through the full list of settings Use the Enter button to enter the selected submenu Use the Back button to leave the entered sub menu Alarm View Use the Up and Down navigation buttons to scroll through the full list of alarms The DM Lists and the Log Lists can be selected and entered to access the sublist ...

Page 27: ...e vessel pressure normally is low enough to proceed with the starting procedure The display now shows The machine is now ready to be started and is waiting for a start command NOTE Before starting open the service valves to decrease engine start load It may be necessary to manually prime the fuel system The display now shows After pressing the START button the engine electronics ECU will be powere...

Page 28: ...e starting procedure is cancelled and the engine will rest for some time Resting time depends on cranking time The display now shows Active Buttons Stop Button to cancel Start command Measurement View Button Settings View Button Alarms View Button Active Buttons Stop Button to cancel Start command Measurement View Button Settings View Button Alarms View Button ...

Page 29: ...me of 15 seconds and a maximum time of 300 seconds The display now shows After warming up the unit will be loaded and ready for use Active Buttons Stop Button to cancel Start command Measurement View Button Settings View Button Alarms View Button Active Buttons Stop Button to cancel Start command Load Button disabled Measurement View Button Settings View Button Alarms View Button ...

Page 30: ...ement 3 Check the engine oil pressure the coolant tempera ture and display of control box 4 Avoid the engine running out of fuel Nevertheless if this happens fill the fuel tank and prime the fuel sys tem to speed up starting Active Buttons Stop Button to cancel Start command Load Button disabled Measurement View Button Settings View Button Alarms View Button The doors must be closed during operati...

Page 31: ...op After cooling down the engine will stop and the display will show The engine is stopped and the controller will do a double check to see if the engine is really stopped Active Buttons Start Button to initiate Start command Measurement View Button Settings View Button Alarms View Button Active Buttons Start Button to initiate Start command Measurement View Button Settings View Button Alarms View...

Page 32: ... the display is dark before switching the battery switch to position OFF DIESEL PARTICULATE FILTER REGENERATION When the Diesel Particle Filter regeneration process is kept at its default AUTOMATIC setting then the DPF regeneration will be performed automatically when the Soot Load exceeds 60 The controller display will indicate an ongoing DPF Regeneration by showing the HEST icon High Exhaust Sys...

Page 33: ...necessary to inhibit DPF regeneration This has to be done at Customer Service Level Go to General settings 1000 Parameter 1142 ECU DPF Regeneration Enable Set to OFF The controller has now put the DPF Regeneration in a FORCED OFF mode which is Inhibit DPF Regeneration The compressor controller will communicate with the engine controller and the RED Inhibit DPF regeneration icon will appear When th...

Page 34: ...s default DPF Regeneration settings and a Service Level is needed to go back to Inhibit DPF Regeneration FORCE DPF REGENERATION Machine is running Press the Settings View Button Enter the 1000 GENERAL SETTINGS menu Go to parameter 1130 STATIONARY REGENERA TION Scroll to Enable and change to ON SERVICE REGENERATION Machine is running Press the Settings Menu Enter the 7000 ENGINE menu Go to paramete...

Page 35: ... to the unit you would like to change 1340 TEMPERATURE UNITS 1350 PRESSURE UNITS 1360 FUEL FLOW UNITS ENTER the preferred menu ENTER the SETTINGS parameter scroll to the preferred setting press ENTER Now press BACK until you re back in the Main View or in the menu you require Change Display Settings Press the SETTINGS VIEW button scroll to 1000 GENERAL SETTINGS press ENTER scroll to 1310 DISPLAY B...

Page 36: ...ing Xc 2100 NO PROJECTFILE DOWNLOADED Warning Xc 2752 NAM OILTRONIX BYPASS CIRCUIT Shutdown After Stop Xc 2762 NAM OILTRONIX CLOSED CIRCUIT Shutdown After Stop Xc 2772 NAM AIRXPERT OPENED CIRCUIT Shutdown Xc 2782 NAM AIRXPERT CLOSED CIRCUIT Shutdown Xc 3000 FUEL LEVEL LOW WARNING Warning Xc 3010 FUEL LEVEL LOW SHUTDOWN Controlled Stop Xc 3020 FUEL LEVEL SENSOR CIRCUIT Warning Xc 3050 VESSEL PRESSU...

Page 37: ...own Xc 6428 STOP FAILURE Shutdown Xc 6708 DRAINING 1 Warning Xc 6709 DRAINING 2 Warning Xc 6749 OILTRONIX FUNCTIONALITY DISABLED Warning Xc 6760 OILTRONIX COUPLING FAILURE Shutdown After Stop Xc 6769 OILTRONIX COMPONENT FAILURE Shutdown Xc 6981 INLET VALVE POS FAILURE Shutdown Xc 7002 ECU COMMUNICATION Shutdown Xc 7007 ECU RED LAMP Shutdown ECU 7008 ECU AMBER LAMP Warning ECU 7009 ECU PROTECT LAMP...

Page 38: ...s is provided by the engine manufacturer For following alarms the Xc controller also shows full text next to the SPN code ECU FUEL FILTER PRESSURE ECU INTERCOOLER TEMPERATURE ECU FUEL PRESSURE ECU FUEL FILTER PRESSURE ECU WATER IN FUEL ECU OIL LEVEL ECU OIL FILTER PRESSURE ECU OIL PRESSURE ECU TURBO BOOST PRESSURE ECU TURBO OIL PRESSURE ECU INTAKE MANIFOLD TEMPERATURE ECU AIR INLET PRESSURE ECU CO...

Page 39: ...rminated by the emergency stop itself hardware as well as by the software When the emergency stop button 1 is pressed the operator can unlock the emergency stop by turning it counterclockwise The emergency stop button is only to be used in emergency situations not for stopping procedures 1 ...

Page 40: ... 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 the type and viscosity grade of the engine oil 3 Check the level of the compressor oil The pointer of ...

Page 41: ... application environment and quality of maintenance Maintenance Table Sections And Sequences Maintenance Schedule Daily Initial 50hours Every 250 750 hours Every 500 hours Every 1000 hours Note Service Kits 1310 9230 03 1310 9230 04 1310 9230 05 Daily Operational Checks Check Fuel Level Check Check Compressor Oil Level Check Check Coolant Level Check Check Fan Belt Check Fuel Filter Water Drain Em...

Page 42: ...achine and Engine performance API service classification above CJ 4 grade Ambient temperature below 35 C 95 F Maintenance Table Sections And Sequences Maintenance Schedule Daily Initial 50hours Every 250 750 hours Every 500 hours Every 1000 hours Note Service Kits 1310 9230 03 1310 9230 04 1310 9230 05 Engine Preventative Maintenance Change Engine Oil Replace Replace Replace Replace Engine Oil Fil...

Page 43: ...inlet temperature C 20 F 68 Normal effective working pressure bar e 7 psi 100 Designation XAS 185 KD7 Minimum effective receiver pressure bar e 4 psi 58 Maximum effective receiver pressure compressor unloaded bar e 8 4 8 7 psi 120 125 Maximum ambient temperature at sea level C 52 F 125 Minimum starting temperature C 10 C tested 12 C F 14 F Minimum starting temperature with coldstart equipment C NA...

Page 44: ... 44 ALTITUDE UNIT PERFORMANCE CURVE ...

Page 45: ... F 200 Noise level6 dB A 76 Designation All units Number of compression stages 1 Designation XAS 185 KD7 Make Kubota Type V2403 Coolant Ethylene glycol mix w SCA package Number of cylinders 4 Bore in 3 43 mm 87 12 Stroke in 4 03 mm 102 36 Swept volume cu in 148 53 l 2 43 Output at normal shaft speed5 hp 49 kW 36 53 Load factor 80 Capacity of oil sump qts 10 gal 2 5 Refill max 4 qts 11 gal 2 75 Cap...

Page 46: ...responds to following national standards American ANSI PTC9 British BSI 1571 part 1 German DIN 1645 Part 1 Swedish SS ISO 1217 3 Air required for engine and compressor cooling combustion and for compression 4 with filter change 5 Gross power guaranteed within 5 at SAE J1668 and ISO 3046 conditions 77 F air inlet temperature 29 31 in Hg barometer 104 F fuel inlet temperature 0 853 fuel specific gra...

Page 47: ...ROIL EXTRA 5W40 Order number 1 3 gallon 5 Liter Container 1630 0135 01 5 2 gallon 20 Liter Pail 1630 0136 01 55 gallon 209 Liter Drum 1626 0102 00 PAROIL E MISSION GREEN 15W40 Order number 1 3 gallon 5 Liter Container 1630 0471 00 5 2 gallon 20 Liter Pail 1630 0472 00 55 gallon 209 Liter Drum 1630 0473 00 PARCOOL EG Order number 1 3 gallon container 1604 5308 00 5 3 gallon pail 1604 5307 01 55 gal...

Page 48: ...ermits 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 vessel Catch the oil in a drain pan Screw out the filler plug to speed up drain ing 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 s...

Page 49: ... 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 C...

Page 50: ... 50 Adjustments and Servicing Procedures Adjustment of the Continuous Regulating System ...

Page 51: ...s 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 THE DUST TRAP To remove dust from the dust trap pinch the vacuator valve 6 several times REPLACING THE A...

Page 52: ...m 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 Do not fill with fuel before assembling new filter Filling the fuel filter introduces dirty unfiltered fuel to the injectors ...

Page 53: ...inspect elements Clean or replace if necessary Regulating 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...

Page 54: ...ent fuel Fill fuel tank Low coolant level Top up cooling system Possible faults Corrective actions Check valve at element outlet Remove and inspect Replace if necessary Replace air filter elements and safety cartridges Check the oil level and add oil if necessary Run the compressor for a few minutes stop and recheck oil level Possible faults Corrective actions Insufficient compressor cooling Locat...

Page 55: ...ials 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 ris...

Page 56: ... 56 Maintenance Log Compressor Customer Serial number Service hours Maintenance action Date By initials ...

Page 57: ... 57 Maintenance Log Compressor Customer Serial number Service hours Maintenance action Date By initials ...

Page 58: ... 58 ...

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Page 60: ...www atlascopco com ...

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