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Atlas Copco XAS 185 KDU T4F HOP, Instruction Manual

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Summary of Contents for XAS 185 KDU T4F HOP

Page 1: ...rea vent the exhaust to the outside Do not modify or tamper with the exhaust system Do not idle the engine except as necessary For more information go to www P65warnings ca gov diesel CALIFORNIA Proposition 65 WARNING Breathing diesel engine exhaust exposes you to chemicals known to the State of California to cause cancer and birth defects or other reproductive harm ...

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Page 3: ...ATLAS COPCO PORTABLE ENERGY DIVISION www atlascopco com Printed matter No 1310 3014 61 10 2019 Instruction Manual for AC Compressor XAS 185 KDU T4F HOP Original instructions ...

Page 4: ...roval 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 2019 Construction Equipment North America LLC RockHill SC USA Any unauthorized use or copying of the co...

Page 5: ...s 28 6 4 4 Possible views 29 6 4 5 Starting 30 6 4 6 Stopping 34 6 4 7 Shutdown 35 6 4 8 Power off 35 6 4 9 Diesel particulate filter regeneration 35 6 4 10 Automatic dpf regeneration default 36 6 4 11 Inhibit dpf regeneration 36 6 4 12 Increasing soot load 36 6 4 13 Turning regeneration back to auto 37 6 4 14 Force dpf regeneration 37 6 4 15 Service regeneration 37 6 4 16 Settings 37 6 4 17 Fault...

Page 6: ...ressor engine specification 55 10 2 1 Reference conditions 55 10 2 2 Limitations 55 10 2 3 Performance data 55 10 3 Design data 55 11 Disposal 58 11 1 General 58 11 2 Disposal of materials 58 12 Maintenance log 59 ...

Page 7: ...e 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 the machine is turned off 7 Before dismant...

Page 8: ...ted 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 valves e g by pulling on hoses or by installing auxiliary equipment directly to a valve e g a water separator a lubricator etc 10 Distribution pipework and air hoses must b...

Page 9: ...ave 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 which are not specially designed for it 5 Always support the ratchet head when using socket exten...

Page 10: ...g 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 electrical cabinets cubicles ...

Page 11: ... 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 and use appropriate protection ...

Page 12: ...essor is provided with a continuous regulating system and a blow down valve which is integrated 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 sense...

Page 13: ...n the roof allow for access to 1 Lifting eye 2 Engine oil and dipstick 3 Coolant fill A separate service panel 4 is located at the rear to aid in service of the separator element filter Lifting eye A lifting eye is accessible through the roof panel at the top of the unit Control panel The controls are located at the rear of the compressor The machine is controlled via the XC2003 controller 1 that ...

Page 14: ... 14 Main parts ...

Page 15: ...Exhaust Pipe F Cooling Fan WS Water Separator FCeo Filler Cap Engine Oil FF Fuel Filter FT Fuel Tank Reference Name FPco Compressor Oil Filling Plug LB Lifting Bale MPN Minimum Pressure Nozzle OC Oil Cooler OF Oil Filter OLG Oil Level Gauge R Radiator SV Safety Valve TBV Thermostatic By pass valve UV Unloading Valve VV Vacuuator Valve ...

Page 16: ... 16 Overview COMPRESSOR REGULATING SYSTEM LOAD CONDITION ...

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

Page 18: ...sses 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 operation by outlet pressure of the compressor elemen...

Page 19: ... 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 Electrical system Circuit Diagram 1310 3200 51 ...

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Page 22: ...contains sufficient fuel Top up if necessary Consult the Engine Operation Manual for the type of fuel 5 Check coolant level in overflow bottle Top up coolant if necessary Consult engine s operation manual for water coolant specifications 6 Drain any water and sediment from the fuel filter until clean fuel flows from the drain cock 7 Press vacuator valve VV of the air filter to remove dust 8 Check ...

Page 23: ... and walls Avoid recirculation of exhaust gasses from the engine This can cause overheating and engine power decrease The compressor oil lifetime will be shortened when the compressor air inlet air is contaminated Remove transportation supports before mounting compressor on truck Before moving the compressor switch it off ...

Page 24: ...ontrol unit Always first shut off the control unit and wait until the display is dark before switching the battery switch to position OFF Do not disconnect power supply to control box in any way when the control box is switched on This will result in loss of controller data Do not switch off the circuit breaker when the control box is switched on This will result in loss of controller data Please ...

Page 25: ...not loaded sequence when the controller is running in Loaded Sequence MEASUREMENTS VIEW BUTTON This button will enter the Measurements View when not already in the Measurements View or when already in the Measurements View it will enter the Main View SETTINGS VIEW BUTTON This button will enter the Settings View when not already in the Settings View or when already in the Settings View it will ente...

Page 26: ...o text 3 Compressor info Main 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 27: ...con PRESET Depending of which pressure and or flow setting is active the controller will show its dedicated icon Reference Name OPERATION MODE Local OPERATION MODE Remote OPERATION MODE PC control OPERATION MODE Automatic OPERATION MODE Automatic Mode is active but the Auto Start and Auto Stop function are both inactive OPERATION MODE Block Mode ALARM Active not acknowledged Shutdown Alarm ALARM A...

Page 28: ...or starts to deliver air as soon as it can with the Auto Load function Auto Re Load The compressor will start loading itself as soon as there is air demand by the application with the Auto Re Load function Auto Stop This function stops the engine when no air demand is present for a pre configured period of time Fuel savings can be achieved by using this function These functions can be configured a...

Page 29: ...ered 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 sub list MEASUREMENTS LOADED 1300RP M 22 4bar 41 1286h h 6 8 2 1 s r u o H g n i n n u R m p r 0 0 3 1 m p r e n i g n E U C E m p r 0 0 3 1 d e e p S d e t s e u q e R U C E 4 2 d a o L t o o S F P D U C E r a b 4 2 2 e ...

Page 30: ...ssure has to be lowered by opening the blow down valve After power up the 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 The display now shows Press the START button to power up the engine electronics ECU As soon as communication between compressor controller and engine co...

Page 31: ...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 800RPM 324RPM 0RPM MAIN VIEW ENGINE CRANKING 324RPM 0 0bar 1286h 40 Active Buttons Stop Button to cancel Start command Measurement View Button Settings View Button Alarms View Button 120s 54s 0s MAIN VIEW ENGINE RES...

Page 32: ...s ready to be loaded and is waiting for a load command the display shows MAIN VIEW ENGINE WARMING UP 1200RPM 3 3 bar 1286h 40 C 25 C 13 C 300s 76s 0s 40 Active Buttons Stop Button to cancel Start command Measurement View Button Settings View Button Alarms View Button MAIN VIEW ENGINE WARMING UP 1200RPM 2 9 bar 1286h 30s 7s 0s 40 Active Buttons Stop Button to cancel Start command Load Button to ini...

Page 33: ...e 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 to cancel Load command Measurement View Button Settings View Button Alarms View Button Active Buttons Stop Button to cancel Star...

Page 34: ...he 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 Button MAIN VIEW ENGIN...

Page 35: ...he 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 Syste...

Page 36: ...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 37: ...Enable and change to ON SERVICE REGENERATION Machine is running Press the Settings View Button Enter the 7000 ENGINE menu Go to parameter 7140 SERVICE REGENERAION Scroll to Enable and change to ON SETTINGS For buttons to be used see Control Panel Acknowledge an Alarm If an alarm becomes active for example a Low Fuel Level Warning then this alarm can be acknowledged by pressing the ENTER button If ...

Page 38: ...RE 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 are 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 BACKLIGHT ENTER the DISPLAY BACKLIGHT menu scroll to the setting you wou...

Page 39: ...the configured Pressure for an elapsed time configured by Delay When Enable is set to On Function parameter 1160 is automatically set to Auto Load If you are using an external sensor to control automatic functionality the sensor s pressure values at 0 5V and 4 5V must be specified in 13180 parameter If Function is set to On the machine engine will stop after being in Loaded Sequence for the elapse...

Page 40: ... LOW WARNING Warning Xc 2080 COOLANT LEVEL LOW SHUTDOWN Shutdown Xc 2090 P AIRFILTERS HIGH Warning 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 LEV...

Page 41: ...ING DANGER Indication Xc 5200 AIR SHUT OFF Shutdown Xc 6190 CHARGE MONITORING FAIL Indication Xc 6327 START FAILURE Shutdown Xc 6329 STARTER SPEED TOO LOW Shutdown Xc 6388 VESSEL PRESSURE TOO LOW TO LOAD Indication Xc 6426 UNINTENTIONAL RUN Shutdown Xc 6427 RUN FAILURE Shutdown Xc 6428 STOP FAILURE Shutdown Xc 6708 DRAINING 1 Warning Xc 6709 DRAINING 2 Warning Xc 6749 OILTRONIX FUNCTIONALITY DISAB...

Page 42: ...LTER 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 COOLANT TEMPERATURE ECU COOLANT LEVEL ECU SUPPLY VOLTAGE ECU AMBIENT AIR TEMPERATURE ECU AIR INLET TEMPERATURE ECU FUEL TEMPERATURE ECU OIL TEMPERATURE ECU ENGINE SPEED ECU INJECTOR 1 ECU INJECTOR 2 ECU INJ...

Page 43: ...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 44: ...ts operating in a duty environment typical to compressor applications Maintenance schedule can be adapted depending on 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 ...

Page 45: ...e Machine and Engine performance API service classification CJ 4 grade or above 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 O...

Page 46: ...1630 0160 00 5 gallon pail 1630 0161 00 55 gallon drum 1630 0162 00 264 gallon container 1630 0163 00 PAROIL EXTRA Order number 1 3 gallon 5 Liter Container 1630 0135 01 5 gallon 20 Liter Pail 1630 0136 01 PAROIL E MISSION GREEN Order number 1 3 gallon 5 Liter Container 1630 0471 00 5 gallon 20 Liter Pail 1630 0472 00 55 gallon 209 Liter Drum 1630 0473 00 PARCOOL EG Order number 1 3 gallon contain...

Page 47: ...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 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 ...

Page 48: ...INTENANCE 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 Clos...

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

Page 50: ...e 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 AIR FILTER ELEMENT 1 Release the snap clips 1 and remove the dust trap 2 Clean the trap 2 Remove the element 3 from the housing 5 If the el...

Page 51: ...w the final filter element from the adapter head 1 2 Clean the adapter head 1 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 2 introduces dirty unfiltered fuel to the injectors 4 After replacing the final filte...

Page 52: ...spect 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 maximum load speed disconnect hose leading to unloader If air leaks from the hose remove and inspect loadi...

Page 53: ...es 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 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 co...

Page 54: ...85 136 25 M16 288 212 25 Assemblies Torque value Variance Axles to frame Nm ft lbf Wheel nuts N A N A Bolts axle s frame N A N A Compressor to frame Bolts elements gear casing 80 59 10 Bolts elements support 46 34 10 Bolts support buffer N A N A Bolts buffer frame N A N A Engine to frame Bolts engine support 92 68 10 Bolts support buffer 49 36 10 Bolts buffer frame 62 46 10 Lifting beams to0frame ...

Page 55: ... 12 C F 10 F Minimum starting temperature with Coldstart C 25 C F 13 F Altitude capability See curves Designation Unit XAS 185 KDU Engine shaft speed normal and maximum rpm 2700 Engine shaft speed compressor unloaded rpm 1600 Free airdelivery2 manimum l s 83 06 cfm 176 Fuel consumption at 100 gal hr 2 37 gal hr 10 5hr 75 gal hr 1 73 gal hr 14 5hr 50 gal hr 1 33 gal hr 18 8hr 25 gal hr 1 23 gal hr ...

Page 56: ...stance Designation Unit XAS 185 KDU 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 Power output at normal shaft speed5 hp 49 kW 36 53 Load factor 80 Capacity of oil sump qts 10 gal 2 5 Refill maximum 4 qts 11 gal 2 75 Capacity of cooling system qts 11 5 gal 2 9 Designation Unit A...

Page 57: ... 57 Altitude unit performance curve ...

Page 58: ...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 59: ... 59 Maintenance log Compressor Customer Serial number Service hours Maintenance action Date By initials ...

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Page 62: ...www atlascopco com ...

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