Atlas Copco XAS 185 Service Manual

XAS 185 KD7 T4

Instruction Manual

for AC Compressors

English

Engine Kubota V2403

ATLAS COPCO - PORTABLE ENERGY DIVISION

www.atlascopco.com

Printed matter Nr

1310 3013 85

09/2014

Instruction Manual for AC Compressor

XAS 185 KD7 T4

Original instructions

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Warranty and Liability Limitation

Use only authorized parts.

Any damage or malfunction caused by the use of unauthorized parts is not covered by Warranty or Product Liability.

The manufacturer does not accept any liability for any damage arising from modifications, additions or conversions made without 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.

Any unauthorized use or copying of the contents or any part thereof is prohibited.

This applies in particular to trademarks, model denominations, part numbers and drawings.

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Preface

Please read the following instructions carefully before

starting to use your compressor.

It is a solid, safe and reliable machine, built according to

the latest technology. Follow the instructions in this

booklet and we guarantee you years of troublefree

operation.

Always keep the manual available near the machine.

In all correspondence always mention the compressor

type and serial number, shown on the data plate.

The company reserves the right to make changes without

prior notice.

Table of contents

1 Safety precautions for portable

compressor ...................................................7

1.1 Introduction ........................................................7

1.2 General safety precautions .................................7

1.3 Safety during use and operation .........................8

1.4 Safety during maintenance and repair ................9

1.5 Tool applications safety ......................................9

1.6 Batteries ..............................................................9

1.7 Ether fuel Systems ............................................10

1.8 Pressure vessels ................................................10

1.9 Safety valves .....................................................10

1.10 Injury Prevention ..............................................10

2 Leading particulars ....................................12

2.1 Description of Safety Pictograms Used in this

Manual ..............................................................12

2.2 General description ...........................................12

2.3 Main Parts .........................................................14

2.4 Air flow ............................................................18

2.5 Oil system .........................................................18

2.6 Continuous regulating system ..........................18

2.7 Electric system ..................................................20

2.7.1 Circuit Diagram................................................. 20

3 Operating instructions ...............................22

3.1 Parking, towing and lifting instructions ...........22

3.1.1 Drawbar Preparations 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 Regeneration .........................................34

3.2.13 Settings ..............................................................34

3.2.14 Fault Codes ........................................................36

3.2.15 Emergency Stop ................................................39

3.2.16 Parking Instructions ...........................................40

3.2.17 Towing Instructions ...........................................40

3.2.18 Lifting Instructions ............................................40

3.3 Before Starting ..................................................40

4 Maintenance ..............................................41

4.1 Use Of Service Paks .........................................41

4.2 Preventive Maintenance Schedule For The

Compressor .......................................................41

5 Technical Specifications ...........................42

5.1 Reference Conditions .......................................42

5.2 Limitations ........................................................42

5.3 Altitude Unit Performance

Curve ................................................................43

5.4 Performance Data .............................................44

5.5 Design Data ......................................................44

5.5.1 Compressor ........................................................44

5.5.2 Engine ................................................................44

5.5.3 Unit ....................................................................44

5.6 Lubrication Oils ................................................46

5.6.1 Check Engine Oil Level ....................................47

5.6.2 Check Compressor Oil Level ............................47

5.6.3 Engine Oil And Oil Filter Change .....................47

5.6.4 Compressor Oil And Oil Filter Change .............47

5.7 Cleaning Coolers ..............................................48

5.8 Battery Care ......................................................48

5.8.1 Electrolyte .........................................................48

5.8.2 Recharging A Battery ........................................48

5.8.3 Battery Maintenance .........................................48

5.9 Storage ..............................................................48

5.10 Service Kits ......................................................48

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6 Adjustments And Servicing Procedures ... 49

6.1 Adjustment Of The Continuous Regulating

System ..............................................................49

6.2 Air Filter Engine/compressor ...........................50

6.2.1 Main Parts .........................................................50

6.2.2 Cleaning The Dust Trap ....................................50

6.2.3 Replacing The Air Filter Element .....................50

6.3 Air Receiver ......................................................51

6.4 Safety Valve .....................................................51

6.5 Fuel System ......................................................51

7 Problem Solving ....................................... 52

7.1 Problem Solving Chart .....................................52

7.2 Alternator Precautions ......................................52

8 Maintenance Log ...................................... 54

9 Maintenance Log ...................................... 55

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Safety precautions for portable compressor

Introduction

The policy of Atlas Copco is to provide the users of their

equipment with safe, reliable and efficient products.

Factors taken into account are among others:

- the intended and predictable future use of the products, and

the environments in which they are expected to operate,

- applicable rules, codes and regulations,

- the expected useful product life, assuming proper service and

maintenance,

Before handling any product, take time to read the

relevant instruction manual. Besides giving detailed

operating instructions, it also gives specific information

about safety, preventive maintenance, etc.

These precautions are general and some statements will

therefore not always apply to a particular unit.

When handling, operating, overhauling and/or

performing maintenance or repair on Atlas Copco

equipment, the mechanics are expected to use safe

engineering practices and to observe all relevant local

safety requirements and ordinances. The following list is

a reminder of special safety directives and precautions

mainly applicable to Atlas Copco equipment.

This brochure applies to machinery processing or

consuming air. Processing of any other gas requires

additional safety precautions typical to the application

and are not included herein.

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 Copco.

If any statement does not comply with local legislation,

the stricter of the two shall be applied. Statements in this

manual should not be interpreted as suggestions,

recommendations or inducements that it should be used in

violation of any applicable laws or regulations.

General safety precautions

1 The owner is responsible for maintaining the unit in a

safe operating condition. Unit parts and accessories

must be replaced if missing or unsuitable for safe

operation.

2 Use only lubricating oils and greases recommended or

approved by Atlas Copco or the machine manufacturer.

Ascertain that the selected lubricants comply with all

applicable safety regulations, especially with regard to

explosion or fire risk and the possibility of

decomposition or generation of hazardous gases.

3 The supervisor, or the responsible person, shall at all

times make sure that all instructions regarding

machinery and equipment operation and maintenance

are strictly followed and that the machines with all

accessories and safety devices, as well as the

consuming devices, are in good repair, free of

abnormal wear or abuse, and are not tampered with.

4 Maintenance, overhaul and repair work shall only be

carried out by adequately trained personnel; if

required, under supervision of someone 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 the machine is turned off.

7 Before dismantling any pressurized component, the

compressor or the equipment shall be effectively

isolated from all sources of pressure and be completely

vented to atmosphere. In addition, a warning sign

bearing a legend such as "work in progress; do not

open" shall be attached to each of the isolating valves.

8 Before a machine is being repaired, steps shall be taken

to prevent inadvertent starting. In addition, a warning

sign bearing a legend such as "work in progress; do not

start" shall be attached to the starting equipment. The

battery shall be disconnected and removed or the

terminals covered by insulating caps.

9 Normal ratings (pressures, temperatures, speeds, etc.)

shall be durably marked.

10 Never operate a machine or equipment beyond its rated

limits (pressure, temperature, speed, etc.).

11 Maintenance and repair work should be recorded in an

operator's logbook for all machinery. Frequency and

nature of repairs can reveal unsafe conditions.

12 The machinery and pneumatic equipment shall be kept

clean, i.e. as free as possible from oil, dust or other

deposits.

13 To prevent an increase in working temperature, inspect

and clean heat transfer surfaces (cooler fins,

intercoolers, water jackets, etc.) regularly. For every

machine establish a suitable time interval for cleaning

operations.

14 All regulating and safety devices shall be maintained

with due care to ensure that they function properly.

They may not be bypassed.

15 Care shall be taken to avoid damage to safety valves

and other pressure relief devices, especially to avoid

plugging by paint, oil coke or dirt accumulation, which

could interfere with the functioning of the device.

16 Pressure and temperature gauges shall be checked

regularly with regard to their accuracy. They shall be

replaced whenever outside acceptable tolerances.

17 Parts shall only be replaced by genuine Atlas Copco

replacement parts.

18 Safety devices shall be tested as described in the

maintenance schedule of the instruction book(s) to

determine that they are in good operating condition.

19 Never use flammable solvents or carbon tetrachloride

for cleaning parts. Take safety precautions against

toxic vapors when cleaning parts in or with cleaning

products.

20 Observe scrupulous cleanliness during maintenance

and repair. Keep away dirt by covering the parts and

exposed openings with clean cloth, paper or tape.

21 Protect the engine, alternator, air intake filter, electrical

and regulating components, etc. to prevent moisture

ingress, e.g. when steam-cleaning.

To be read attentively and acted accordingly before towing, lifting, operating, performing maintenance

or repairing the compressor.

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22 When performing any operation involving heat, flames

or sparks on a machine, the surrounding components

shall first be screened with non-flammable material.

23 Never use a light source with open flame for inspecting

the interior of a machine, pressure vessel, etc.

24 On portable units, support the drawbar and axle(s)

securely if working underneath the units or when

removing a wheel. Do not rely on jacks.

25 Prior to stripping a compressor, engine or other

machine or undertaking major overhaul on it, prevent

all movable parts with a mass exceeding 15 kg (30 lbs)

from rolling over or moving.

26 When repair has been completed, make sure that no

tools, loose parts or rags are left in, or on, the machine,

the prime mover or the driving gear. The machine shall

be barred several revolutions to ensure that there is no

mechanical interference within the machine or driver.

Safety during use and operation

To lift a unit, all loose or pivoting parts, e.g. doors shall

first be securely fastened. Do not attach cables, chains or

ropes directly to the lifting eye; apply a crane hook or

lifting shackle meeting local safety rules.

Helicopter lifting using the lifting eye is forbidden.

It is strictly forbidden to dwell or stay in the risk zone

under a lifted load. Never lift the unit over people or

residential areas.

Lifting acceleration and retardation shall be kept within

safe limits.

1 Before towing the unit:

- ascertain that the pressure vessel is depressurized,

- check the drawbar, the brake system and the towing eye. Also

check the coupling of the towing vehicle,

- check that the pivot wheel or stand leg is safely locked in the

raised position,

- ascertain that the towing eye can swivel freely on the hook,

- check that the wheels are secure and that the tires are in good

condition and inflated correctly,

- connect the signal cable, check all lights and connect the

pneumatic brake couplers,

- attach the safety break-away cable to the towing vehicle,

- remove wheel chocks, if applied, and disengage the parking

brake.

- Apply safety chains to tow vehicle.

2 If the unit is to be backed up by the towing vehicle,

disengage the overrun brake mechanism (if equipped).

3 Never exceed the maximum towing speed of the unit.

4 Place the unit on level ground and chock the wheels

before disconnecting the unit from the towing vehicle.

Unclip the safety break-away cable

5 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.

6 The exhaust contains carbon monoxide which is a

lethal gas. When the unit is used in a confined space,

conduct the engine exhaust to the outside atmosphere

by a pipe of sufficient diameter (min. 4 inches); do this

in such a way that no extra back pressure is created for

the engine. If necessary, install an extractor.

7 When operating in a dust-laden atmosphere, place the

unit so that dust is not carried towards it by the wind.

Operation in clean surroundings considerably extends

the intervals for cleaning the air intake filters and the

cores of the 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

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 be of correct

size and suitable for the working pressure. Never use

frayed, damaged or deteriorated hoses. Replace hoses

and flexibles of which the lifetime expired. Use only

the correct type and size of hose end fittings and

connections. Install safety pins on quick type hose

connections. A hose connected to a 2 inch (50 mm)

valve must be provided with a safety wire (8 mm) fixed

to the hose for effective pressures as from 145 psi (10

bar) up, although it is recommended to apply such

safeguard already from (60 psi) 4 bar up.

The safety wire ends have to be attached, one to the eye

provided next to the compressor air outlet valve, the

other one to a point near to the air inlet of the applied

equipment. Finally a wire mesh hose can be fixed over

the hose ends to dampen the blast in case a connection

starts leaking or should become undone.

Close the compressor air outlet valve before

connecting or disconnecting a hose. Ascertain that a

hose is fully depressurized before disconnecting it.

When blowing through a hose or air line, ensure that

the open end is held securely. A free end will whip and

may cause injury.

Never play with compressed air. Never apply it to your

skin or direct an air stream at people. Never use it to

clean dirt from your clothes. When using it to clean

down equipment, do so with extreme caution and use

eye protection.

11 Never move a unit when external lines or hoses are

connected to the outlet valves, to avoid damage to

valves and/or manifold and hoses.

12 Never refill fuel while the unit is running. Keep fuel

away from hot parts such as air outlet pipes or the

engine exhaust. Do not smoke when fueling. When

fueling from an automatic pump, a ground cable should

be connected to the unit to discharge static electricity.

Never spill nor leave oil, fuel, coolant or cleansing

agent in or around the unit.

13 Never operate the unit in surroundings where there is a

possibility of taking in flammable or toxic fumes.

14 1Never operate the unit at pressures or speeds below or

in excess of the limit ratings stated on the Principal

Data sheet.

15 On water-cooled engines with closed cooling circuit:

allow the unit to cool before removing a pressure cap.

16 All doors shall be shut during operation so as not to

disturb the cooling air flow inside the body-work and/

or render the silencing less effective. A door should be

kept open for a short period only, e.g. for inspection or

adjustment

17 Wear ear protectors when environmental noise can

reach or exceed 85 dB(A). Beware of long-time

exposure to noise.

18 Periodically check that:

- all safety equipment is in good working order,

- all guards and air conducting baffles are in place and securely

fastened,

- 9 -

- all hoses and/or pipes inside the unit are in good condition,

secure and not rubbing,

- there are no fuel, oil or coolant leaks,- all fasteners are tight

- all electrical leads are secure and in good order,

- the engine exhaust system is in good condition,

- air outlet valves and manifold, hoses, couplings, etc. are in good

repair, free of wear or abuse,

- the wheel nuts are tightened to the proper torque.

When more than one compressor is connected to a common

header, be sure each compressor has a non-return valve

(check valve) to prevent reverse rotation when stopping.

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 be replaced by genuine spare parts.

3 All maintenance work, other than routine attention,

shall only be undertaken when the unit is stopped.

Ensure that the unit cannot be started inadvertently

4 Before removing any pressurized component, the

compressor or equipment shall be effectively isolated

from all sources of pressure and the entire system shall

be relieved of pressure. Do not rely on non-return

valves (check valves) to isolate pressure systems.

5 Never use flammable solvents for cleaning (fire-risk).

Take safety precautions against toxic vapours of

cleaning liquids.

6 Scrupulously observe cleanliness during maintenance

and when performing repairs. Keep dirt away by

covering the parts and exposed openings with a clean

cloth, paper or tape.

7 Never weld on or perform any operation involving heat

near the fuel or oil systems. Fuel and oil tanks must be

completely purged, e.g. by steam-cleaning, before

carrying out such operations. Never weld on, or in any

way modify, pressure vessels. Disconnect the

alternator cables during arc welding on the unit.

8 Support the drawbar and the axle securely if working

underneath the unit or when removing a wheel. Do not

rely on jacks.

9 Make sure that no tools, loose parts or rags are left in

or on the unit.

10 Before clearing the unit for use after maintenance or

overhaul, check that operating pressures, temperatures

and speeds are correct and that the control and

shutdown devices function correctly.

11 Do not remove any of, or tamper with, the sound

damping material. Keep the material free of dirt and

liquids such as fuel, oil and cleansing agents.

12 Protect the electrical and regulating components, the

air filter, etc. to prevent moisture from entering them,

e.g. when steamcleaning.

Tool applications safety

Apply the proper tool for each job. With the knowledge of

correct tool use and knowing the limitations of tools,

along with some common sense, many accidents can be

prevented.

Special service tools 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 which are

not specially designed for it.

5 Always support the ratchet head when using socket

extensions.

6 Discard any wrench with broken or battered points or

edges.

7 Never use hand type sockets on power or impact tools.

8 Select only heavy-duty impact sockets for use with

pneumatic or electric impact tools.

9 Replace sockets showing cracks or wear; keep sockets

clean.

10 Never use screwdrivers for prying, punching,

chiseling, scoring or scraping.

11 Use the correct type and size of screwdriver for the job.

The bit must match the fastener.

12 A screwdriver with rounded edges will slip; it needs to

be redressed or discarded.

13 Never use a screwdriver or any other tool near a live

wire or electrical component. Plastic covering of

handles is for comfort and grip only. They are not

intended to act as insulation if such is not clearly

marked by the manufacturer.

14 Never strike a hammer against a hardened object; use a

soft drift against the object and strike against the drift.

15 Strike the object with the full face of the hammer.

16 Never use a hammer with a loose head.

17 Discard a hammer with chipped or mushroomed face.

18 Never use a chisel or punch with a chipped or

mushroomed striking face.

19 Always pull on a wrench or socket handle, if possible,

and adjust your stance to prevent a fall if something lets

go.

20 Wear approved eye protection when using percussion

tools or when scraping, chipping, shaving or grinding.

21 Wear protective gloves when holding a chisel or punch.

Batteries

When servicing batteries, always wear protecting

clothing and glasses.

1 The electrolyte in batteries is a sulphuric acid solution

which is fatal if it hits your eyes, and which can cause

burns if it contacts your skin. Therefore, be careful

when handling batteries, e.g. when checking the 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 has been charged. Therefore:

- never smoke near batteries being, or having recently been,

charged,

- never break live circuits at battery terminals, because a

spark usually occurs.

4 When connecting an auxiliary battery (AB) in parallel

to the unit battery (CB) with booster cables: connect

the + pole of AB to the + pole of CB, then connect the

- pole of CB to the mass of the unit. Disconnect in the

reverse order.Incorrect connection will damage

alternator.

- 10 -

Ether fuel Systems

Ether fuel systems are used for diesel cold starting.

1 1 Do not use ether as a starting aid in conjunction with

other stating aids (i.e. glow plug, air intake heater etc.)

as an explosive condition may result in severe engine

damage or personal injury.

2 This type of fuel is extremely flammable, toxic and

poisonous. Avoid contact with eyes or skin and

breathing the fumes. If accidentally swallowed, do not

induce vomiting but call a physician immediately.

3 If fuel enters or fumes irritate the eyes, flush the latter

with large quantities of clean water and call for medical

aid.

4 Before operating ether cold starting aids, read the

instructions and the container label.

5 Never operate ether cold starting aids while the engine

is running as this can cause severe damage.

6 When maintenance, tests or repair has to be performed,

do so in a well-ventilated area only, away from heat,

open flame or sparks. Ascertain that the area is clearly

marked out with signs prohibiting fire, open flame and

smoking.

7 Wear eye protection when testing a system. Make sure

that openings of a spray container, valve, tube or

atomizer are pointed away from yourself and others

while testing.

8 Do not store ether containers in temperatures above

160 ºF (70ºC),

9 Do not incinerate, puncture or attempt to remove the

center core valve, side safety valve or any other part of

an ether container.

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 psi (bar),

2 The pressure vessel is only to be used for the

applications as specified above and in accordance with

the technical specifications. Safety reasons prohibit

any other applications.

3 National legislation requirements with respect to re-

inspection must be complied with.

4 No welding or heat treatment of any kind is permitted

to those vessel walls which are exposed to pressure.

5 The vessel is provided and may only be used with the

required safety equipment such as manometer,

overpressure control devices, safety valve, etc.

6 Draining of condensate shall be performed daily when

vessel is in use.

7. Installation, design and connections should not be

changed.

8. Bolts of cover and flanges may not be used for extra

fixation.

Safety valves

All adjustments or repairs are to be done by an authorized

representative of the valve supplier.

Following checks must be carried out:

1 A check of the opening of the lifting gear,1 or 2 times

a year. This can be done by lifting the ring or lever.

2 A check of the set pressure once a year according to the

local regulations, if required. This check may not be

done 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 electrical cabinets, cubicles or other

equipment while voltage is supplied. If such cannot be

avoided, e.g. for measurements, tests or adjustments,

have the action carried out by a qualified electrician

only, with appropriate tools, and ascertain that the

required bodily protection against electrical hazards is

applied.

3 Noise, even at reasonable levels, can cause irritation

and disturbance which, over a long period of time, may

cause severe injuries to the nervous system of human

beings.

When the sound pressure level, at any point where

personnel normally has to attend, is:

below 70 dB(A): no action needs to be taken,

above 70 dB(A): noise-protective devices should be

provided for people continuously being present in the

room,

below 85 dB(A): no action needs to be taken for

occasional visitors staying a limited time only,

above 85 dB(A): room to be classified as a noise-

hazardous area and an obvious warning shall be

placed permanently at each entrance to alert people

entering the room, for even relatively short times,

about the need to wear ear protectors,

above 95 dB(A): the warning(s) at the entrance(s)

shall be completed with the recommendation that also

occasional visitors shall wear ear protectors,

above 105 dB(A): special ear protectors that are

adequate for this noise level and the spectral

composition of the noise shall be provided and a

special warning to that effect shall be placed at each

entrance.

4 Insulation or safety guards of parts the temperature of

which can be in excess of 80 ºC (175 ºF) and which

may be accidentally touched by personnel shall not be

removed before the parts have cooled to room

temperature.

5 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.

6 If the working process produces fumes, dust or

vibration hazards, etc., take the necessary steps to

eliminate the risk of personnel injury.

7 Before lifting machines, all loose parts which could be

liable to fall down shall be removed or secured;

pivoting parts such as doors, etc. shall be safely

immobilized.

8 To lift heavy parts, a hoist of ample capacity, tested and

approved according to local safety regulations, shall be

used.

9 When lifting machinery, only hooks or shackles

meeting local safety regulations shall be applied. Never

shall cables, chains or ropes be applied directly on or

through lifting eyes. Never allow sharp bends in lifting

cables, chains or ropes.

10 Lifting hooks, eyes, 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

- 11 -

the lifting force is applied at an angle to its load axis.

11 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, and load.

12 When heavy parts are being lifted with a hoist, it is

strictly forbidden to dwell or pass under the load or in

the space which is liable to be hit if the load or part of

it should topple over or come loose. Never leave a load

hanging on a hoist. Lifting acceleration and retardation

shall be kept within safe limits.

13 A hoist has to be installed in such a way that the object

will be lifted perpendicular. If that is not possible, the

necessary precautions must be taken to prevent load-

swinging, e.g. by using two hoists, each at

approximately the same angle not exceeding 30deg

from the vertical.

14 When using compressed air or inert gas to clean down

equipment, do so with caution and use the appropriate

protection, at least safety glasses, for the operator 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 and use appropriate

protection such as a breathing filter, safety glasses,

rubber apron and gloves, etc.

17 Safety shoes should be compulsory in any workshop

and if there is a risk, however small, of failing objects,

wearing of a safety helmet should be included.

18 If there is a risk of inhaling hazardous gases, fumes or

dust, the respiratory organs must be protected and,

depending on the nature of the hazard, so must the eyes

and skin.

19 Remember that where there is visible dust, the finer,

invisible particles will almost certainly be present too;

but the fact that no dust can be seen is not a reliable

indication that dangerous, invisible dust is not present

in the air.

20 When using cartridge type breathing filter equipment,

ascertain that the correct type of cartridge is used and

that its useful service life is not surpassed.

- 12 -

Leading particulars

Description of Safety Pictograms Used in

this Manual

General description

The XAS 185 KD7 is a silenced, single-stage, oil-injected

screw compressor, built for an effective working pressure

of 100 psi (7 bar).

Engine

The compressor is driven by a water-cooled diesel engine.

The engine’s power is transmitted to the compressor

through a flexible coupling.

Compressor

The compressor casing houses two screw-type rotors,

mounted on ball and roller bearings. The male rotor,

driven by the engine, drives the female rotor. The male

rotor has four lobes and the female rotor has six flutes.

Thus, the male rotor revolves at 1 1/2 times the speed of

the female rotor. The element delivers pulsation-free air.

Injected oil is used for sealing, cooling and lubricating

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

first by centrifugal force, second through the oil separator

element. The vessel is provided with an oil level indicator.

Regulation

The compressor 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 sensed by the regulating

valve which, by means of control air to the unloader and

engine speed regulator, matches the air output to the air

consumption. The air receiver pressure is maintained

between the pre-selected working pressure and the

corresponding unloading pressure

Cooling system

Engine and compressor are provided with a radiator and

oil cooler. The cooling air is generated by a fan, driven by

the engine.

Safety devices

A thermal shut-down sensor protects the compressor

against overheating. The air receiver is provided with a

safety valve. The engine is equipped with low oil pressure

and high coolant temperature shut-down sensors and an

alternator/V-belt protection system.

Frame and axles

The compressor/engine unit is supported by rubber buffers

in the frame.

The standard XAS 185 KD7 is equipped with a adjustable

drawbar with a towing eye and road lighting.

This symbol draws your attention to

dangerous situations. The operation

concerned may endanger persons and cause

injuries.

This symbol is followed by supplementary

information.

- 13 -

As an option, the unit can be equipped with electric or

hydraulic braking systems.

When driving backwards the hydraulic brake is not

engaged automatically.

Bodywork

The bodywork has openings at the shaped front and rear

end for the intake and outlet of cooling air and hinged

doors for maintenance 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 the unit showing the compressor

type, serial number, maximum final pressure and normal

working pressure.

- 14 -

Main Parts

- 15 -

Reference Name

AFc Air Filter (Compressor element)

AFe Air Filter (Engine)

AOV Air Outlet Valves

AR Air Receiver

BBattery

CE Compressor Element

DPF Diesel Particulate Filter

DSe Dip Stick Engine Oil

E Engine

EP Exhaust Pipe

F Cooling Fan

FWs Fuel Water Separator

FCc 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

RRadiator

RV Regulating Valve

S Starter Motor Engine

SR Speed Regulator

SV Safety Valve

TT Top Tank

TBV Thermostatic By-pass valve

UV Unloading Valve

VV Vacuuator Valve

- 16 -

Compressor regulating system (Load Condition)

- 17 -

Reference Name

AFc Air Filter Compressor

AFe Air Filter Engine

AFE Air Filter Element

AR Air Receiver

AV Air Outlet Valve

BDV Blow Down valve

BPV By-Pass Valve Oil Filter

CE Compressor Element

CH Coupling Housing

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 Vacuum Indicator

- 18 -

Air flow

The system comprises:

Air drawn through the airfilter (AF) into the compressor

element (CE) is compressed. At the element outlet,

compressed air and oil pass into the air receiver/oil

separator (AR/OS).

In the air receiver/oil separator (AR/OS), most of the oil is

removed from the air/oil mixture: the remaining oil is

removed by the separator element.The oil collects in the

receiver and on the bottom of the separator element.

The oil collects in the receiver and on the bottom of the

separator element.

The air leaves the receiver via the minimum pressure

nozzle (MPN) which prevents the receiver pressure from

dropping below the minimum working pressure, even

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 automatically depressurize the air receiver

(AR) when the compressor is stopped.

Oil system

The system comprises:

The lower part of the air receiver (AR) serves as oil tank.

Air pressure forces the oil from the air receiver/oil

separator (AR/OS) through the oil cooler (OC) and oil

filter (OF) to the compressor element (CE).

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 the bearings is ensured by oil injected into

the bearing housings.

The injected oil, mixed with the compressed air, leaves the

compressor element and re-enters the air receiver, where it

is separated from the air as described in section 2.4. The

oil that collects in the bottom of the oil separator element

is returned to the system through scavenging line (SL),

which is provided with a flow restrictor (FR).

The oil filter by-pass valve opens when the pressure drop

over the filter is above normal 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 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, matches the air

output to the air consumption. The air receiver pressure is

maintained between the pre-selected working pressure and

the corresponding unloading pressure. When starting the

compressor, the unloader valve (UV) is kept open by

spring force, the engine runs at maximum speed. The

compressor element (CE) takes in air and pressure builds

up in the receiver. The unloader valve is closed.

The air output is controlled from maximum output (100%)

to no output (0%) by:

1. Speed control of the engine between maximum load

speed and unloading speed (the output of a screw

compressor is proportional to the rotating speed).

2. Air inlet throttling.

3. Blow off valve (BOV).

If the air consumption is equal to or exceeds the maximum

air output, the engine speed is held at maximum load speed

and the unloading valve is fully open.

If the air consumption is less than the maximum air output,

the regulating valve supplies control air to unloader valve

(UV) to reduce the air output and holds air receiver

pressure between the normal working pressure and the

AF Air filter

AR/OS Air receiver/oil separator

CE Compressor element

UA/UV Unloader assembly with unloader valve

BDV Blow-down valve

MPV Minimum pressure valve

LV Loading Valve

AR/OS Air receiver/oil separator

RV/UA Regulation Valve/Unloader Valve

OC Oil cooler

OF Oil filter

RV Regulating valve

UA Unloader Valve

SR Speed regulator

- 19 -

corresponding unloading pressure of approx. 21.75 psi

(1.5 bar) above the normal working pressure.

When the air consumption is resumed, the unloader valve

gradually opens the air intake and 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).

- 20 -

Electric system

CIRCUIT DIAGRAM - 1310 3200 51

- 21 -

- 22 -

Operating instructions

Parking, towing and lifting instructions

Safety precautions

Attention

DRAWBAR PREPARATIONS FOR TOWING

Atlas Copco XAS 185 KD7 compressors may be supplied

to a customer with a folded drawbar. The drawbar is

positioned in it’s upright position for shipping purposes

only. When the compressor is received by the end

customer, the drawbar will need to be put into it’s

operating position. To do this:

1. With the weight of the compressor still on the drawbar,

pull the pin on the jacking device (prop or nose wheel)

and move it into the down position. Be sure to re-

insert the pin to keep the jack locked in place.

2. Use the jack to support the compressor in a level

position by turning the handle at the top of the jack.

3. Using the appropriate tools, remove the shipping

bracket and fold the drawbar into it’s down position.

Disgard locknut.

Note: take the necessary precautions as to not pinch

the wire harness that runs through the drawbar during

the unfolding process. Pull the excess harness out

through the front of the drawbar.

4. Reuse the shipping bracket bolt 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-attach the prop to the drawbar in the down posi-

tion and install keeper pin. Jack the unit up with the

prop to remove the blocking.

7. Using bolt, washers, and locknut (items 4,5,6) from

shipping bag, insert bolt through hole on top of draw-

bar using washers and secure with locknut. Torque

nut and bolt to 130 ft-lbs.

8. Discard any remaining hardware and the shipping

bracket.

9. Retorque the all drawbar attachment bolts to their

specified value after 5-10 hours of use.

Note: the pivoting feature of the drawbar is for

shipping purposes only. The drawbar is to remain in

the down position after it’s initial setup. REUSE OF

LOCKNUTS IS STRICTLY PROHIBITTED BY

ATLAS COPCO

The operator is expected to apply all

relevant Safety precautions for portable

compressor.

Check and retighten the wheel nuts and

drawbar bolts to the specified torque. See

section Technical Specifications.

- 23 -

Starting / Stopping

Safety precautions

Battery switch

If the compressor is equipped with a battery switch:

When the compressor is not in use this switch must always

be in the “OFF” position.

It is not allowed to use this switch as an emergency switch

or for stopping the compressor. It will cause damage in the

control unit when using this switch for stopping.

Always first shut off the control unit and wait until the

display is dark before switching the battery switch to

position “OFF”.

Control panel

Do not disconnect power supply to control

box in any way when the control box is

switched on. This will cause memory loss.

Do not switch off the circuit breaker when

the control box is switched on. This will

cause memory loss.

Please be aware that the (optional)

preheater unit is still “live” with the battery

switch in “OFF” position.

Reference Name

START BUTTON: 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 will:- initiate

the Auto Load function when the controller is

in normal running sequence, but not ready to

be loaded.

- initiate the loading sequences when the

controller is ready to be loaded.

- initiate the 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 enter the Main View.

ALARMS VIEW BUTTON: This button will

enter the Alarms View when not already in the

Alarms View, or when already in the Alarms

View it will enter the Main View.

NAVIGATION BUTTONS: These buttons

are used to navigate through the display

menu’s.

ENTER BUTTON: Confirms/stores the

selection/change.

BACK BUTTON: Moves back one level or

ignores the change.

- 24 -

OVERVIEW ICONS

Reference Name

1 Compressor status

2 Vessel pressure indication or info 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.

- 25 -

Reference Name

DPF REGENERATION INHIBITED

Diesel Particle Filter Regeneration

Inhibited.

Means that the DPF regeneration is

inhibited, even if all criteria to

activate a regeneration are met.

OVERHAUL

Initial Overhaul required.

OVERHAUL

Minor Overhaul required.

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 & acknowledged Alarm.

FUELTANK

Running at internal fueltank.

- 26 -

Possible views

Main View

Measuring View

Use the Up and Down navigation buttons to scroll through

the full list of measurements.

Setup View

Use the 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.

- 27 -

STARTING

Switch on the battery switch if so equipped.

Switch the controller on by pressing the power button.

The instrument panel will now perform a selftest; the

following display will be shown and the controller is

initialized:

During initializing all buttons/inputs/outputs/alarms are

inactive.

This view will be shown for about 2 seconds, after which

the display will show the Main View.

The actual vessel pressure is shown. If the measured

vessel pressure is higher than 1.5 bar, the unit will not

start. The vessel pressure 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

After pressing the START button, the engine electronics

(ECU) will be powered up.

As soon as communication between compressor controller

and engine controller is established, the machine will

preheat according to the parameters of the engine

controller.

Xc2003

v1.00.0 (r7307)

Active Buttons

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

- 28 -

The display now shows

The engine starts cranking, the display shows

The engine cranks until 800 rpm is reached.

If 800 rpm is not reached within 30 seconds, the 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

- 29 -

The engine starts running at idle speed. The display shows

The engine will run at minimum rpm, until the engine’s

coolant temperature reaches 40 deg C (104 deg F), with a

minimum time of 15 seconds and a maximum time of 300

seconds.

The display now shows After warming up the machine is ready to be loaded and is

waiting for a load command; the display 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)

Load Button

(to initiate Automatic Load)

Measurement View Button

Settings View Button

Alarms View Button

- 30 -

The engine will now run at maximum rpm, the display will

show

The loading valve will be energized and pressure starts

building up.

During loading the following display is shown (default

display)

The controller controls the speed of the engine in order to

meet the requested working pressure, at the most

economical fuel usage.

During operation

Regularly carry out following checks:

1. Ensure that the regulating valve (RV) is correctly

adjusted, i.e. starts decreasing the engine speed when

reaching the preset working pressure in the receiver.

2. Check the air outlet temperature of the compressor

element.

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

(to cancel Load command)

Measurement View Button

Settings View Button

Alarms View Button

Active Buttons

Stop Button

(to cancel Start command)

Load Button

(to cancel Load command)

Measurement View Button

Settings View Button

Alarms View Button

The doors must be closed during operation

and may be opened for short periods for

inspection and adjustments only.

Be aware not to touch hot or moving parts

when the door is open.

When the engine is running, the air outlet

valves (ball valves) must always be put in a

fully opened or fully closed position.

- 31 -

STOPPING

After pressing the STOP button the display will show:

After a Stop command, or in case of a controlled stop

alarm, the machine will cool down and run at minimum

rpm for 1 minute before it will stop.

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 Button

- 32 -

SHUTDOWN

When the machine is shutdown due to a critical alarm or

an emergency stop the display will show

POWER OFF

Switch the controller off by pressing the Power button.

If the compressor is equipped with a battery switch:

When the compressor is not in use, this switch must

always be in the “OFF” position.

It is not allowed to use this switch as an emergency switch

or for stopping the compressor.

It can damage the controller or the engine’s Electronic

Control Unit when using the battery switch for stopping.

Always first shut off the controller and wait until 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

System Temperature):

The DPF regeneration process will continue, until the Soot

Load has become as low as possible, or until the engine is

stopped.

When the DPF regeneration process is stopped, the HEST

icon will disappear from the display.

Active Buttons

Measurement View Button

Settings View Button

Alarms View Button

Enter Button

(to acknowledge the shown alarm)

HEST Icon

- 33 -

AUTOMATIC DPF REGENERATION

(DEFAULT)

In specific cases, when the engine speed is constant at

Minimum RPM, it can happen that the DPF regeneration

already starts from 30% Soot Load (LSR - Low Speed

Regeneration).

This can happen in following situations:

• Warming Up

• Not Loaded

• Loaded (when running in Unload condition - mini-

mum RPM)

• Cooldown

When an LSR is ongoing while the soot load is less than

60%, and the engine speed changes (engine is stopped,

machine gets loaded, …), then the DPF Regeneration

process will be stopped.

If the Soot Load is higher than 30% when cooling down

should start (then an LSR is expected to be started) the

controller will ask:

If Enter is pressed within 10 seconds then the controller

will allow the DPF regeneration to be completed before

the engine is stopped.

If Enter is not pressed (within 10 seconds), then the engine

will be stopped after cooling down.

INHIBIT DPF REGENERATION

When running in an environment where an elevated

exhaust temperature is not allowed, it might be 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 the controller gets powered down, it will (at next

power up) fall back to its default settings, meaning

AUTOMATIC DPF regeneration.

INCREASING SOOT LOAD

When the DPF Regeneration is Inhibited, or when the

engine does not get sufficient possibility to automatically

perform a full DPF Regeneration, the Soot Load will

exceed the normal levels.

The controller will show the DPF Regeneration Needed

Icon. In case of Inhibited DPF Regeneration, the DPF

Regeneration Needed Icon will overwrite the DPF

Inhibited Icon.

Required Action:

• Force DPF Regeneration, see paragraph FORCE

DPF REGENERATION

When DPF Regeneration is started, the DPF Regeneration

Needed icon will disappear and the HEST icon will pop-

up.

A full DPF Regeneration can take up to an

hour.

DPF Regeneration Inhibited.

DPF Regeneration needed

- 34 -

TURNING REGENERATION BACK TO AUTO

Machine is not running:

Power the controller down. At next power up, the DPF

Regeneration settings will be back to default, and an

Automatic DPF Regeneration will take place at the

soonest appropriate moment.

Machine is running:

• Press the Settings View Button

• Enter the '1000 GENERAL SETTINGS' menu

• Scroll one line down and Enter the ‘1140 ECU DPF

REGENERATION’ menu

• Scroll down and Enter the 'MODE' parameter

• Scroll down and Enter the 'AUTOMATIC' setting

• Press the Back button 3 times to get back to the Main

view

• Also make sure parameter '1142 ECU DPF REGEN-

ERATION ENABLE' is set to "ON"

DPF Regeneration setting will now be AUTOMATIC

DPF REGENERATION.

Customer Level can now select between AUTO

Regeneration & INHIBIT Regeneration, as long as the

controller is not powered down (after power down, it will

fall back to its 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 parameter '7140 SERVICE REGENERA-

TION'

• 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 the fuel level is still low, the view

will change to:

As soon as the fuel level is higher than the warning level,

the alarm icon will automatically disappear.

As long as there is an alarm icon in the middle of the

bottom part of the view, all active acknowledged /

Unit will not regenerate if soot level is not

high enough.

Unit will not regenerate if soot level is not

high enough.

- 35 -

unacknowledged alarms can be seen by pressing the

ALARM VIEW button

Pressing the ALARM VIEW button again, will bring you

back to the Main View.

Set Clock

Press the SETTINGS VIEW button

• scroll to ‘1000 GENERAL SETTINGS’

• press ENTER

• scroll to ‘1290 DATE/TIME’

• ENTER the Date/Time menu

• scroll to the parameter you want to change

• ENTER this parameter.

To change the ‘Month’, scroll to the preferred month and

press ENTER.

To change any other setting, the highlighted figure is

editable.

Scroll up/down and press ENTER to change. Use left/

right to shift between editable figures.

Now press BACK until you’re back in the Main View (or

in the menu you require).

Set Language

Press the SETTINGS VIEW button.

• scroll to ‘1000 GENERAL SETTINGS’

• press ENTER

• scroll to ‘1300 LANGUAGES’

• ENTER the LANGUAGES menu,

• ENTER the ‘SETTINGS’ parameter

• scroll to the preferred language

• press ENTER.

Now press BACK until you’re back in the Main View (or

in the menu you require).

Set Units

Press the SETTINGS VIEW button,

• scroll to ‘1000 GENERAL SETTINGS’

• press ENTER

• scroll 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 BACKLIGHT’

• ENTER the DISPLAY BACKLIGHT menu

• scroll to the setting you would like to change

• press ENTER.

To change a setting, the highlighted figure is editable.

Scroll up/down and press ENTER to change. Use left/

right to shift between editable figure.

Now press BACK until you’re back in the Main View (or

in the menu you require).

Go To Diagnostics

Press the SETTINGS VIEW button

• scroll to ‘1000 GENERAL SETTINGS’

• press ENTER

• scroll to ‘1150 DIAGNOSTICS’

• ENTER the Diagnostics menu,

• ENTER the ‘ENABLE’ parameter

• scroll to ‘ON’ and press ENTER.

Now the ECU will get power and one can perform ECU

diagnostics (read DM1 List, DM2 List, ECU values,

perform engine diagnostics, …).

Now press BACK until you’re back in the Main View (or

in the menu you require).

To leave Diagnostics, press the STOP button.

• ECU warning 7009 will be active while in diagnos-

tics.

- 36 -

FAULT CODES

There are several parameters that are continuously

watched.

When one of these parameters exceeds its specified limit

the compressor will react depending the present status of

the control box.

Alarmcode Alarmtext Failclass Trigger

1231 FUEL FILL CHECK Warning Xc

1503 INITIAL OVERHAUL REQUIRED Warning Xc

1522 MINOR OVERHAUL WITHIN ** H Warning Xc

1523 MINOR OVERHAUL WITHIN ** D Warning Xc

1524 MINOR OVERHAUL REQUIRED Warning Xc

1552 MAJOR OVERHAUL WITHIN ** H Warning Xc

1553 MAJOR OVERHAUL WITHIN ** D Warning Xc

1554 LOAD PREVENTION - FIRE RISK Inhibit Load Xc

1558 COMP. OIL CHANGE WITHIN ** H Warning Xc

1559 COMP. OIL CHANGE WITHIN ** D Warning Xc

2000 EMERGENCY STOP INPUT Shutdown Xc

2040 REMOTE EMERGENCY STOP Shutdown Xc

2070 COOLANT LEVEL LOW WARNING Warning Xc

2080 COOLANT LEVEL LOW SHUTDOWN Shutdown Xc

2090 ΔP 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 LEVEL LOW SHUTDOWN Controlled Stop Xc

3020 FUEL LEVEL SENSOR CIRCUIT Warning Xc

3050 VESSEL PRESSURE HIGH WARNING Controlled Stop Xc

3060 VESSEL PRESSURE HIGH SHUTDOWN Shutdown Xc

3070 VESSEL PRESSURE SENSOR CIRCUIT Shutdown Xc

3120 REGULATING PRESSURE SENSOR CIRCUIT Shutdown Xc

3170 AIR DISCHARGE PRESSURE SENSOR CIRCUIT Warning Xc

3320 INLET PRESSURE SENSOR CIRCUIT Shutdown Xc

3450 BATTERY LOW ALARM Indication Xc

3460 BATTERY HIGH ALARM Warning Xc

3660 FIRE RISK - CHECK OILSTOPVALVE Shutdown Xc

3680 OSV PRESSURE SENSOR CIRCUIT Controlled Stop Xc

3720 INTERSTAGE PRESSURE SENSOR CIRCUIT Warning Xc

4000 L.P. ELEMENT TEMPERATURE HIGH Warning Xc

4010 L.P. ELEMENT TEMP. ALARM 2 Controlled Stop Xc

4020 L.P. ELEMENT TEMP. ALARM 3 Shutdown Xc

- 37 -

4040 L.P. ELEMENT TEMP. SENSOR CIRCUIT Shutdown Xc

4070 AMBIENT TEMPERATURE SENSOR CIRCUIT Warning Xc

4100 AIR DISCHARGE TEMPERATURE ALARM 1 Warning Xc

4110 AIR DISCHARGE TEMPERATURE ALARM 2 Controlled Stop Xc

4120 A.D. TEMPERATURE SENSOR CIRCUIT Warning Xc

4150 H.P. ELEMENT TEMPERATURE ALARM 1 Warning Xc

4160 H.P. ELEMENT TEMPERATURE ALARM 2 Controlled Stop Xc

4170 H.P. ELEMENT TEMPERATURE ALARM 3 Shutdown Xc

4190 H.P. ELEMENT TEMP. SENSOR CIRCUIT Shutdown Xc

4220 AFTERCOOLER AIR TEMP SENSOR CIRCUIT Warning Xc

4230 AFTERCOOLER FREEZING 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 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 Warning ECU

7010 ECU ENGINE SPEED TOO LOW Shutdown Xc

7020 ECU ENGINE SPEED ALARM 2 Shutdown Xc

7030 ECU ENGINE COOLANT TEMP. ALARM Controlled Stop Xc

7050 ECU ENGINE AIR INLET TEMP. ALARM 1 Controlled Stop Xc

7100 ECU DPF SOOT LOAD HIGH Warning Xc

7110 PLEASE FORCE DPF REGENERATION ! Inhibit Load Xc

7120 LOAD PREVENTION - HIGH DPF SOOT LOAD Controlled Stop Xc

7130 SOOT LOAD TOO HIGH - CALL ATLAS COPCO Warning Xc

7222 COMBO COMMUNICATION FAILURE Warning Xc

7223 COMBO PA SENSOR WARNING Warning Xc

7224 COMBO RHA SENSOR WARNING Warning Xc

7225 COMBO TA SENSOR WARNING Warning Xc

Alarmcode Alarmtext Failclass Trigger

- 38 -

Details of ECU triggered alarms can be monitored via the ECU DM1 LIST menu

In case of ECU AMBER LAMP or ECU PROTECT LAMP:

Only possible when engine is running or if Diagnostics

Mode is active.

Access the ECU DM1 LIST menu via Alarm View.

In case of ECU RED LAMP:

Do NOT acknowledge the ECU RED LAMP alarm.

DM1 alarms are automatically copied into the Alarm

View, and can be read there.

For all ECU triggered alarms, the respective SPN code is

shown in the ECU DM1 LIST

A full list of supported SPN codes 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 - 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 - INJECTOR 3

ECU - INJECTOR 4

ECU - INJECTOR 5

ECU - INJECTOR 6

ECU - INJECTOR 7

ECU - INJECTOR 8

ECU - SOOT LOAD

- 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)

- 40 -

PARKING INSTRUCTIONS

When parking a compressor, secure prop (1) or nose wheel

to support the compressor in a level position. Place the

compressor as level as possible; however, it can be

operated temporarily in an out-of-level position not

exceeding 15°. If the compressor is parked on sloping

ground, immobilize the compressor by placing wheel

chocks in front of or behind the wheels. Locate the

compressor upwind, away from contaminated wind-

streams and walls. Avoid recirculation of exhaust air from

the engine. This causes overheating and engine power

decrease.

TOWING INSTRUCTIONS

Before towing the compressor, make sure that the towing

equipment of the vehicle matches the towing eye or ball

connector

The drawbar should be as level as possible and the

compressor and towing eye end in a level position. Secure

nose prop (1) in the highest position. Attach safety chains/

cables in a crisscross manner to the tow vehical. This will

help prevent the towbar from contacting ground in event

of a breakaway. Connect road lights when applicable.

LIFTING INSTRUCTIONS

When lifting the compressor, the hoist has to 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

the type and viscosity grade of the engine oil.

3. Check the level of the compressor oil. The pointer of oil

level gauge (OLG) should register in the green range.

Add oil if necessary.

4. Check that the fuel tank contains sufficient fuel. Top

up, if necessary. Consult the Engine Operation Man-

ual for the type of fuel.

5. Check coolant level in overflow bottle. Top off 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 the air filter service indicator (VI). If the red part

shows completely, service or replace the filter element.

Reset the indicator.

9. Open an air outlet valve (AV) to allow air flow to the

atmosphere.

Lifting acceleration and retardation must

be kept within safe limits (max. 2g).

Helicopter lifting is not allowed.

If the compressor is to be connected to a

common compressed air system, fit an

appropriate check valve between

compressor outlet and air system. Observe

the right mounting position/direction!

- 41 -

Maintenance

Use of Service Paks

Service Paks include all genuine parts needed for normal maintenance of both compressor

and engine. Service Paks minimize downtime and keep your maintenance budget low.

You may order Service Paks from your local Atlas Copco dealer.

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, 0-rings, washers.

For engine maintenance refer to Engine Operation Manual.

The maintenance schedule has to be seen as a guideline for units operating in a duty

environment typical to compressor applications. Maintenance schedule can be adapted

depending on application environment and quality of maintenance

• When the battery is used for less than 100 hours in a year, check its electrolyte

yearly. (for refillable battery's only)

• *1: When biodiesel fuel is used, change the fuel filter cartridge, fuel hose and clamp

bands with new ones at intervals half of the usual ones.

• *2: Consult your local KUBOTA dealer for this service.

• The items in the engine manual marked *3 are registered as emission related critical

parts by KUBOTA in the U.S. EPA nonroad emission regulation. As the engine

owner, you are responsible for the performance of the required maintenance on the

engine according to the above instruction. Please see the warranty statement in

detail.

• The items listed above are not necessary to keep the emission-related warranty

valid.

• Failure to perform the maintenance will cause problems that will significantly

degrade the engine performance.

API service classification: above CJ-4 grade

Ambient temperature: below 35 °C (95 °F)

MAINTENANCE SCHEDULE Daily Initial 50hours + Every

250/750 hours

1310 9230 03

Every 500 hours

1310 9230 04

Every 1000 hours

1310 9230 05

Note

Check engine oil level Check

Check of fuel level Check

Check of coolant level Check

Check of fan belt Check Change Change

Change of engine oil Change Change Change See change interval

Replacement of oil filter cartridge Replace Replace w/ oil change Replace w/ oil change

*1- Replacement of fuel filter cartridge Replace Replace

Cleaning of water separator Check

*2- Cleaning of fuel tank interior Check

*2- Cleaning of water jacket and radiator interior Check

*2- Replacement of fan belt Check

*2- Check of valve clearance Check

When changing or inspecting, be sure to

level and stop the engine.

Changing interval of engine oil:

Models Interval

V2403 Every 400 hours

- 42 -

Technical Specifications

Reference conditions

The inlet conditions are specified at the air inlet grating outside the canopy.

Limitations

Designation XAS 185 KD7

Absolute inlet pressure bar(e) 1

psi 14.7

Relative air humidity % 0

Air 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

°F NA

Altitude capability see curves

- 43 -

ALTITUDE UNIT PERFORMANCE CURVE

- 44 -

Performance data

Design Data

COMPRESSOR

ENGINE

UNIT

Designation XAS 185 KD7

Engine shaft speed, normal and maximum rpm 2700

Engine shaft speed, compressor unloaded rpm 1600

Free air delivery

l/s 83.53

cfm 177

Fuel consumption -at full load gal/hr 2.33

-at unload gal/hr 0.94

Specific fuel consumption gal/ft

0.00022

Typical oil content of compressed air mg/m

oz/1000 cu.ft < 0.005

Engine oil consumption (maximum) g/hr NA

oz/h NA

Compressed air temperature at outlet valves °C 93.3

°F 200

Noise level

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

l2.43

Output at normal shaft speed

hp 49

kW 36.53

- Load factor % 80

Capacity of oil sump

qts 10

gal 2.5

-Refill (max.)

qts 11

gal 2.75

Capacity of cooling system

qts 10

gal 2.5

Designation All units

Capacity of compressor oil system

qts 12.2

gal 3.05

Net capacity of air receiver

US gal 4.5

l 17.03

Capacity of fuel tanks

US gal 20.1

l 76.08

Air volume at inlet grating (approx.)

cfm 6340

/s 2.99

Designation XAS 185 KD7

- 45 -

1) At reference conditions, if applicable, and at normal shaft speed unless otherwise stated.

2) Free Air Delivery (volume flow rate) is measured according to ISO 1217 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:

• 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 gravity @ 60°F

6) Measured in accordance with ISO 2151 under free field conditions at 7m distance

- 46 -

1. More frequently when operating in a dusty

environment.

2. Replace the element when the pressure drop exceeds

11.5 psi.

3. Refer to the Kubota instruction manual

Lubrication oils

It is strongly recommended to use Atlas Copco branded

lubrication oils for compressor.

Compressor oil

Engine oil

Engine coolant

* 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

5.2 gallon pail: 1615 5948 00

55 gallon drum: 1615 5949 00

PAROIL - S

Order number

1 gallon pail: 1630 0160 00

5.2 gallon pail: 1630 0161 00

55 gallon drum: 1630 0162 00

264 gallon container: 1630 0163 00

PAROIL - 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 gallon drum: 1604 5306 00

1 gallon pail: 1604 8159 00

(1) Additional equipment is needed to run the compressor below 18°F. Please contact Atlas Copco for more

information about Cold Weather Packages

Temperature Range Type of Oil

Compressor Engine

Between -13°F and 122°F

(1)

PAROIL S See Engine Operation Manual

Between 18°F and 104°F

PAROIL M 15W-40

Operation of compressor in ambient temperatures lower than 18°F (-8°C) without the correct

type of oil will void your warranty and may result in element failure and/or fire.

- 47 -

OIL LEVEL CHECK

CHECK ENGINE OIL LEVEL

Consult also the Engine Operation Manual for the oil

specifications, viscosity recommendations and oil change

intervals. See schedule.

Check engine oil level according to the instructions in the

Engine Operation Manual and top up with oil if necessary.

CHECK COMPRESSOR OIL LEVEL

With the unit standing level, engine stopped, check the

level of the compressor oil. The pointer of the oil level

gauge (OLG) must register in the upper extremity of the

green range. Add oil via the oil fill plug (FP) if necessary.

ENGINE OIL AND OIL FILTER CHANGE

Consult also the Engine Operators Manual for oil and oil

filter

(1) change intervals.

(2) oil types.

COMPRESSOR OIL AND OIL FILTER

CHANGE

The quality and the temperature of the oil determine the oil

change interval.

The prescribed interval is based on an oil temperature of

up to 100ºC (212ºF) and normal operating conditions.

When 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) and stop the compressor. Wait until the

pressure is released through the automatic blow-

down valve. Unscrew the oil filler plug (FP) one turn.

This uncovers a vent hole, which 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 seat on the manifold, taking care that

no dirt drops into the system. Oil the gasket of the

new filter element. Screw it into place until the gas-

ket contacts its seat, then tighten one half turn only.

5. Fill the air receiver until the pointer of the oil level

gauge (OLG) registers in the upper extremity of the

green range. Take care that no dirt drops into the sys-

tem. Reinstall and tighten the filler plug.

6. Run the unit at no load for a few minutes to circulate

the oil and to evacuate the air trapped in the oil sys-

tem.

7. Stop the compressor. Let the oil settle for a few min-

utes. Check that the pressure is released by opening

an air outlet valve (AV). Screw out filler plug (FP)

and add oil until the pointer of the oil level gauge

(OLG) again registers in the upper extremity of the

green range. Reinstall and tighten the filler plug.

Never mix oils of different brands or types

Before removing oil filler plug, ensure that

the pressure is released by opening an air

outlet valve.

In this case, contact Atlas Copco.

Never add more oil. Overfilling results in oil

consumption.

- 48 -

Cleaning Coolers

Keep the coolers clean to maintain the cooling efficiency.

Front cooler baffle is removable for access by unscrewing

4 bolts.

When cleaning by air jet, blow air through the cooler in

reverse direction of normal flow.

If the dirt is oily, wash the coolers with degreaser or a

cleansing agent.

A spray gun should preferably be used to apply the solvent

to the fins. Rinse the blocks by means of a water jet max.

100 psi at 2 inch distance after a soaking-in period. Steam

cleaning may also be applied.

Battery Care

An ASB (Service Bulletin) dealing elaborately with

batteries and due care is available on request.

If the battery is still dry, it must be activated as described

in point 4.7.1.

The battery must be in operation within 2 months from

being activated; if not, it needs to be recharged first.

ELECTROLYTE

Electrolyte in batteries is a sulphuric acid solution in

distilled water.

The solution must be made up before being introduced

into the battery.

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

must be open, i.e. plugs and/or cover removed.

Apply with preference the slow charging method and

adjust the charge current according to the following rule of

thumb: battery capacity in Ah (amp hours) divided by 20

gives safe charging current in Amps.

BATTERY 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. Close the air outlet

valves after stopping.

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.

To purchase service paks contact your local Atlas Copco

representative.

Remove any dirt from the coolers with a

fiber brush. Never use a wire brush or metal

objects.

Protect the electrical and controlling

equipment, air filters etc. against

penetration of moisture

To avoid damaging the coolers, angle

between waterjet and coolers should be

approx. 90º.

Never leave spilled liquids such as fuel, oil,

water and cleansing agents in or around the

compressor.

Before handling batteries, read the relevant

safety precautions and act accordingly.

Read the safety instructions carefully

Use a commercial automatic battery

charger according to manufacturers

instructions.

If the compressor is going to be stored

without running from time to time,

protective measures must be taken as

described In a separate Service Bulletin

(ASB), which may be obtained on request.

Consult Atlas Copco.

Hours Pak Order number

50/250/750 hrs 1310 9230 03

500 hrs 1310 9230 04

1000 hrs 1310 9230 05

- 49 -

Adjustments and Servicing Procedures

Adjustment of the Continuous Regulating System

- 50 -

The working pressure is determined by the tension of the

spring in the regulating valve (RV). This tension can be

increased to raise the pressure and decreased to lower it by

turning the adjusting wheel clockwise and counter-

clockwise respectively.

To adjust the normal working pressure, proceed as

follows:

1. Start and warm up the engine.

2. With the outlet valves (AV) closed, loosen the regu-

lating valve’s locknut and adjust the regulating valve

(RV) until your reach the desired pressure of 123

psig/8.5 bar(e).

3. Open an outlet valve just enough to let the engine run

at maximum speed. The working pressure must be

102 psig/ 7 bar(e). Adjust if necessary with regulat-

ing valve (RV).

4. Close the outlet valves, check that the pressure is

between 120-126 psig/ 8.3-8.7 bar(e). Lock the regu-

lating valve by fixing the locknut.

Air Filter Engine/Compressor

MAIN PARTS

Recommendations

New elements must also be inspected for 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 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

element is to be serviced for immediate re-use, rein-

stall the dust trap to protect the air intake system

while cleaning the element.

3. Reassemble in reverse order of dismantling.

4. Inspect and tighten all air intake connections.

5. Reset the vacuum indicator by pushing the reset but-

ton.

1 Snap clips

2Dust trap

3 Filter element

4 Safety cartridge (Optional)

5 Filter housing

6 Vacuator valve

The Atlas Copco air filters are specially

designed for the application. The use of non-

genuine air filters may lead to severe

damage of engine and/or compressor

element.

Never run the compressor without air filter

element.

7 Air filter contamination indicator

8 Reset button

9 Red indicator

- 51 -

Air Receiver

The air receiver is tested according to official standards.

Regularly have inspections carried out in conformity with

local regulations.

Safety Valve

Following checks must be carried out:

– a check of the opening of the lifting gear, twice a year.

This can be done by lifting the ring or lever.

– a check of the set pressure once a year according to the

local regulations. This check cannot be done on the

machine 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. Do not fill with fuel before assembling new filter.

Filling the fuel filter introduces dirty (unfiltered) fuel

to the injectors.

4. After replacing the final filter’s element, prime fuel

system with manual prime bulb located below the

fuel filter’s housing.

5. Check for fuel leaks once the engine has been

restarted.

All adjustments or repairs are to be done by

an authorized representative of the valve

supplier.

- 52 -

Problem Solving

Problem Solving Chart

Use the chart on the following pages to help solve

mechanical problems.

It is assumed that the engine is in good condition, that

there is adequate fuel flow to the filter and injection

equipment, and compressor/engine maintained with the

recommended oil.

Make sure that the wires are not damaged and that they are

clamped tight to their terminals.

Alternator Precautions

1. Never reverse the polarity of the battery or the

alternator.

2. Never break any alternator 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 batter-

ies positive to positive, negative to negative.

4. Never operate the engine without the main or voltage

sensing cables connected in the circuit.

Problem: Compressor capacity or pressure below normal.

Problem: Pressure in air receiver rises above maximum and causes safety valve to blow.

An electrical fault must be traced by an

electrician.

Possible faults Corrective actions

Air consumption exceeds capacity of compressor. Check equipment connected.

Choked air filter elements (AF). Remove and 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 valve. Replace damaged or worn O-rings.

Oil separator element clogged. Have element removed and inspected by an Atlas copco Service representative.

Air intake throttle valve remains partially closed. Check unloader and identify reason for open valve; if possible: solve; else: contact Atlas copco.

Safety valve (SV) leaking. Remove and inspect. Replace if not airtight after reinstallation.

Blow-off valve leaking. Remove and inspect. Replace if necessary.

Possible faults Corrective actions

Regulating valve (RV) opens too late or its ball valve spring is broken. Have regulating valve removed and inspected by an Atlas copco Service representative.

Air leaks in regulating system. Check hoses and their fittings. Stop leaks; replace leaking hoses.

Air intake throttle valve does not close for some reason. Check unloader and identify reason for open valve; if possible: solve; else: contact Atlas copco.

Minimum pressure valve malfunctioning. Remove and inspect valve.

Blow-off valve malfunctioning. Remove and inspect valve.

- 53 -

Problem: After working some time, the unit stops through a shutdown switch.

Problem: Air and oil mist expelles from air filters immediately after stopping.

Problem: Compressor overheating.

Alternator precautions

1. Never reverse the polarity of the battery or the alternator.

2. Never break any alternator 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.

Possible faults Corrective actions

Engine oil pressure too low. Refer to the engine instruction manual.

Compressor or engine overheating. See corrective actions “Compressor overheating”.

Fuel tank contains insufficient 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. 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 with recommended oil if necessary.

Thermostatic by-pass valve remains stuck in open position. Remove valve and check for proper opening and closing. Replace if out of order.

Fan blade(s) broken. Check and correct if necessary.

Oil separator element (OS) clogged. Have element removed and inspected by an Atlas copco Service representative.

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Maintenance Log

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

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

Service hours Maintenance action Date By initials

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Maintenance Log

Service hours Maintenance action Date By initials

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