XAS 185 KD7 T4

Instruction Manual for AC Compressors English

Engine Kubota V2403

ATLAS COPCO - PORTABLE ENERGY DIVISIONwww.atlascopco.com

Instruction Manual for AC Compressor

XAS 185 KD7 T4

Printed matter Nr1310 3013 85

09/2014

Original instructions

Warranty and Liability Limitation

Use only authorized parts. Any damage or malfunction caused by the use of unauthorized partThe manufacturer does not accept any liability for any damage aris s made without the manufacturer's approval inwriting.Neglecting maintenance or making changes to the setup of the mac k.While every effort has been made to ensure that the information in me responsibility for possible errors.

Copyright 2014, Atlas Copco.

Any unauthorized use or copying of the contents or any part thereofThis applies in particular to trademarks, model denominations, part

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s is not covered by Warranty or Product Liability.ing from modifications, additions or conversion

hine can result in major hazards, including fire risthis manual is correct, Atlas Copco does not assu

is prohibited. numbers and drawings.

3.2.10 Turning Regeneration Back To Auto ...................................................................34

.11 Force Dpf Regeneration ....................................34

.12 Service Regeneration .........................................34

.13 Settings ..............................................................34

.14 Fault Codes ........................................................36

.15 Emergency Stop ................................................39

.16 Parking Instructions ...........................................40

.17 Towing Instructions ...........................................40

.18 Lifting Instructions ............................................40Before Starting ..................................................40

Maintenance ..............................................41Use Of Service Paks .........................................41Preventive Maintenance Schedule For The Compressor .......................................................41

Technical Specifications ...........................42Reference Conditions .......................................42Limitations ........................................................42Altitude Unit Performance Curve ................................................................43Performance Data .............................................44Design Data ......................................................44

.1 Compressor ........................................................44

.2 Engine ................................................................44

.3 Unit ....................................................................44Lubrication Oils ................................................46

.1 Check Engine Oil Level ....................................47

.2 Check Compressor Oil Level ............................47

.3 Engine Oil And Oil Filter Change .....................47

.4 Compressor Oil And Oil Filter Change .............47Cleaning Coolers ..............................................48Battery Care ......................................................48

.1 Electrolyte .........................................................48

.2 Recharging A Battery ........................................48

.3 Battery Maintenance .........................................48Storage ..............................................................48

0 Service Kits ......................................................48

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PrefacePlease read the following instructions carefully beforestarting to use your compressor.It is a solid, safe and reliable machine, built according tothe latest technology. Follow the instructions in thisbooklet and we guarantee you years of troublefreeoperation.Always keep the manual available near the machine.In all correspondence always mention the compressortype and serial number, shown on the data plate.The company reserves the right to make changes withoutprior notice.

Table of contents

1 Safety precautions for portable compressor ...................................................7

1.1 Introduction ........................................................71.2 General safety precautions .................................71.3 Safety during use and operation .........................81.4 Safety during maintenance and repair ................91.5 Tool applications safety ......................................91.6 Batteries ..............................................................91.7 Ether fuel Systems ............................................101.8 Pressure vessels ................................................101.9 Safety valves .....................................................101.10 Injury Prevention ..............................................10

2 Leading particulars ....................................122.1 Description of Safety Pictograms Used in this

Manual ..............................................................122.2 General description ...........................................122.3 Main Parts .........................................................142.4 Air flow ............................................................182.5 Oil system .........................................................182.6 Continuous regulating system ..........................182.7 Electric system ..................................................202.7.1 Circuit Diagram ................................................. 20

3 Operating instructions ...............................223.1 Parking, towing and lifting instructions ...........223.1.1 Drawbar Preparations for Towing .................... 223.2 StartiNg / Stopping ...........................................233.2.1 Overview Icons ................................................. 243.2.2 Starting ............................................................. 273.2.3 Stopping ............................................................ 313.2.4 Shutdown .......................................................... 323.2.5 Power Off ......................................................... 323.2.6 Diesel Particulate Filter regeneration ............... 323.2.7 Automatic Dpf Regeneration (Default) ............ 333.2.8 Inhibit Dpf Regeneration .................................. 333.2.9 Increasing Soot Load ........................................ 33

3.23.23.23.23.23.23.23.23.3

44.14.2

55.15.25.3

5.45.55.55.55.55.65.65.65.65.65.75.85.85.85.85.95.1

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6 Adjustments And Servicing Procedures ... 496.1 Adjustment Of The Continuous Regulating

System ..............................................................496.2 Air Filter Engine/compressor ...........................506.2.1 Main Parts ......................................................... 506.2.2 Cleaning The Dust Trap .................................... 506.2.3 Replacing The Air Filter Element ..................... 506.3 Air Receiver ......................................................516.4 Safety Valve .....................................................516.5 Fuel System ......................................................51

7 Problem Solving ....................................... 527.1 Problem Solving Chart .....................................527.2 Alternator Precautions ......................................52

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

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

Normal ratings (pressures, temperatures, speeds, etc.)shall be durably marked.Never operate a machine or equipment beyond its ratedlimits (pressure, temperature, speed, etc.).Maintenance and repair work should be recorded in anoperator's logbook for all machinery. Frequency andnature of repairs can reveal unsafe conditions.The machinery and pneumatic equipment shall be keptclean, i.e. as free as possible from oil, dust or otherdeposits.To prevent an increase in working temperature, inspectand clean heat transfer surfaces (cooler fins,intercoolers, water jackets, etc.) regularly. For everymachine establish a suitable time interval for cleaningoperations.All regulating and safety devices shall be maintainedwith due care to ensure that they function properly.They may not be bypassed.Care shall be taken to avoid damage to safety valvesand other pressure relief devices, especially to avoidplugging by paint, oil coke or dirt accumulation, whichcould interfere with the functioning of the device.Pressure and temperature gauges shall be checkedregularly with regard to their accuracy. They shall bereplaced whenever outside acceptable tolerances.Parts shall only be replaced by genuine Atlas Copcoreplacement parts.Safety devices shall be tested as described in themaintenance schedule of the instruction book(s) todetermine that they are in good operating condition.Never use flammable solvents or carbon tetrachloridefor cleaning parts. Take safety precautions againsttoxic vapors when cleaning parts in or with cleaningproducts.Observe scrupulous cleanliness during maintenanceand repair. Keep away dirt by covering the parts andexposed openings with clean cloth, paper or tape.Protect the engine, alternator, air intake filter, electricaland regulating components, etc. to prevent moistureingress, e.g. when steam-cleaning.

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Safety precautions for portable compressor

Introduction

The policy of Atlas Copco is to provide the users of theirequipment 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 therelevant instruction manual. Besides giving detailedoperating instructions, it also gives specific informationabout safety, preventive maintenance, etc.These precautions are general and some statements willtherefore not always apply to a particular unit.When handling, operating, overhauling and/orperforming maintenance or repair on Atlas Copcoequipment, the mechanics are expected to use safeengineering practices and to observe all relevant localsafety requirements and ordinances. The following list isa reminder of special safety directives and precautionsmainly applicable to Atlas Copco equipment.This brochure applies to machinery processing orconsuming air. Processing of any other gas requiresadditional safety precautions typical to the applicationand are not included herein.All responsibility for any damage or injury resulting fromneglecting these precautions or by non-observance ofordinary caution and due care required in handling,operating, maintenance or repair, also if not expresslymentioned in this instruction manual, is disclaimed byAtlas Copco.If any statement does not comply with local legislation,the stricter of the two shall be applied. Statements in thismanual should not be interpreted as suggestions,recommendations or inducements that it should be used inviolation of any applicable laws or regulations.

General safety precautions1 The owner is responsible for maintaining the unit in a

safe operating condition. Unit parts and accessoriesmust be replaced if missing or unsuitable for safeoperation.

2 Use only lubricating oils and greases recommended orapproved by Atlas Copco or the machine manufacturer.Ascertain that the selected lubricants comply with allapplicable safety regulations, especially with regard toexplosion or fire risk and the possibility ofdecomposition or generation of hazardous gases.

3 The supervisor, or the responsible person, shall at alltimes make sure that all instructions regardingmachinery and equipment operation and maintenanceare strictly followed and that the machines with allaccessories and safety devices, as well as theconsuming devices, are in good repair, free ofabnormal wear or abuse, and are not tampered with.

4 Maintenance, overhaul and repair work shall only becarried out by adequately trained personnel; ifrequired, under supervision of someone qualified forthe job.

5 Whenever there is an indication or any suspicion thatan internal part of a machine is overheated, themachine shall be stopped but no inspection covers shallbe opened before sufficient cooling time has elapsed;this to avoid the risk of spontaneous ignition of oilvapour when air is admitted.

6 Maintenance work, other than routine attention, shallonly be undertaken when the machine is turned off.

7 Before dismantling any pressurized component, thecompressor or the equipment shall be effectivelyisolated from all sources of pressure and be completelyvented to atmosphere. In addition, a warning signbearing a legend such as "work in progress; do notopen" shall be attached to each of the isolating valves.

8 Before a machine is being repaired, steps shall be takento prevent inadvertent starting. In addition, a warningsign bearing a legend such as "work in progress; do notstart" shall be attached to the starting equipment. Thebattery shall be disconnected and removed or theterminals covered by insulating caps.

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To be read attentively and acted accordingly before towing, lifting, operating, performing maintenanceor repairing the compressor.

- Apply safety chains to tow vehicle. equipment. Finally a wire mesh hose can be fixed overthe hose ends to dampen the blast in case a connectionstarts leaking or should become undone. Close the compressor air outlet valve beforeconnecting or disconnecting a hose. Ascertain that ahose is fully depressurized before disconnecting it. When blowing through a hose or air line, ensure thatthe open end is held securely. A free end will whip andmay cause injury. Never play with compressed air. Never apply it to yourskin or direct an air stream at people. Never use it toclean dirt from your clothes. When using it to cleandown equipment, do so with extreme caution and useeye protection.Never move a unit when external lines or hoses areconnected to the outlet valves, to avoid damage tovalves and/or manifold and hoses.Never refill fuel while the unit is running. Keep fuelaway from hot parts such as air outlet pipes or theengine exhaust. Do not smoke when fueling. Whenfueling from an automatic pump, a ground cable shouldbe connected to the unit to discharge static electricity.Never spill nor leave oil, fuel, coolant or cleansingagent in or around the unit.Never operate the unit in surroundings where there is apossibility of taking in flammable or toxic fumes.1Never operate the unit at pressures or speeds below orin excess of the limit ratings stated on the PrincipalData sheet.On water-cooled engines with closed cooling circuit:allow the unit to cool before removing a pressure cap.All doors shall be shut during operation so as not todisturb the cooling air flow inside the body-work and/or render the silencing less effective. A door should bekept open for a short period only, e.g. for inspection oradjustmentWear ear protectors when environmental noise canreach or exceed 85 dB(A). Beware of long-timeexposure to noise.Periodically check that:

ll safety equipment is in good working order,ll guards and air conducting baffles are in place and securelyastened,

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22 When performing any operation involving heat, flamesor sparks on a machine, the surrounding componentsshall first be screened with non-flammable material.

23 Never use a light source with open flame for inspectingthe interior of a machine, pressure vessel, etc.

24 On portable units, support the drawbar and axle(s)securely if working underneath the units or whenremoving a wheel. Do not rely on jacks.

25 Prior to stripping a compressor, engine or othermachine or undertaking major overhaul on it, preventall movable parts with a mass exceeding 15 kg (30 lbs)from rolling over or moving.

26 When repair has been completed, make sure that notools, loose parts or rags are left in, or on, the machine,the prime mover or the driving gear. The machine shallbe barred several revolutions to ensure that there is nomechanical interference within the machine or driver.

Safety during use and operation

To lift a unit, all loose or pivoting parts, e.g. doors shallfirst be securely fastened. Do not attach cables, chains orropes directly to the lifting eye; apply a crane hook orlifting shackle meeting local safety rules.Helicopter lifting using the lifting eye is forbidden.It is strictly forbidden to dwell or stay in the risk zoneunder a lifted load. Never lift the unit over people orresidential areas.Lifting acceleration and retardation shall be kept withinsafe 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.

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-hazardousenvironment, each engine exhaust has to be providedwith a spark arrestor to trap incendiary sparks.

6 The exhaust contains carbon monoxide which is alethal gas. When the unit is used in a confined space,conduct the engine exhaust to the outside atmosphereby a pipe of sufficient diameter (min. 4 inches); do thisin such a way that no extra back pressure is created forthe engine. If necessary, install an extractor.

7 When operating in a dust-laden atmosphere, place theunit so that dust is not carried towards it by the wind.Operation in clean surroundings considerably extendsthe intervals for cleaning the air intake filters and thecores of the coolers.

8 Locate the unit away from walls. Take all precautionsto ensure that hot air exhausted from the engine anddriven machine cooling systems cannot berecirculated. If such hot air is taken in by the engine ordriven machine cooling fan, this may causeoverheating of the unit; if taken in for combustion, theengine power will be reduced.

9 No external force may be exerted on the air outletvalves, e.g. by pulling on hoses or by installingauxiliary equipment directly to a valve, e.g. a waterseparator, a lubricator, etc.

10 Distribution pipework and air hoses must be of correctsize and suitable for the working pressure. Never usefrayed, damaged or deteriorated hoses. Replace hosesand flexibles of which the lifetime expired. Use onlythe correct type and size of hose end fittings andconnections. Install safety pins on quick type hoseconnections. A hose connected to a 2 inch (50 mm)valve must be provided with a safety wire (8 mm) fixedto the hose for effective pressures as from 145 psi (10bar) up, although it is recommended to apply suchsafeguard already from (60 psi) 4 bar up. The safety wire ends have to be attached, one to the eyeprovided next to the compressor air outlet valve, theother one to a point near to the air inlet of the applied

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- all hoses and/or pipes inside the unit are in good condition, wire or electrical component. Plastic covering ofhandles is for comfort and grip only. They are notintended to act as insulation if such is not clearlymarked by the manufacturer.Never strike a hammer against a hardened object; use asoft drift against the object and strike against the drift.Strike the object with the full face of the hammer.Never use a hammer with a loose head.Discard a hammer with chipped or mushroomed face.Never use a chisel or punch with a chipped ormushroomed striking face.Always pull on a wrench or socket handle, if possible,and adjust your stance to prevent a fall if something letsgo.Wear approved eye protection when using percussiontools or when scraping, chipping, shaving or grinding.Wear protective gloves when holding a chisel or punch.

tteries

hen servicing batteries, always wear protectingthing and glasses.The electrolyte in batteries is a sulphuric acid solutionwhich is fatal if it hits your eyes, and which can causeburns if it contacts your skin. Therefore, be carefulwhen handling batteries, e.g. when checking the chargecondition.Install a sign prohibiting fire, open flame and smokingat the post where batteries are being charged.When batteries are being charged, an explosive gasmixture forms in the cells and might escape through thevent holes in the plugs. Thus an explosive atmospheremay form around the battery if ventilation is poor, andcan remain in and around the battery for several hoursafter 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.When connecting an auxiliary battery (AB) in parallelto the unit battery (CB) with booster cables: connectthe + pole of AB to the + pole of CB, then connect the- pole of CB to the mass of the unit. Disconnect in thereverse order.Incorrect connection will damagealternator.

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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 commonheader, 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 becarried 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, thecompressor or equipment shall be effectively isolatedfrom all sources of pressure and the entire system shallbe relieved of pressure. Do not rely on non-returnvalves (check valves) to isolate pressure systems.

5 Never use flammable solvents for cleaning (fire-risk).Take safety precautions against toxic vapours ofcleaning liquids.

6 Scrupulously observe cleanliness during maintenanceand when performing repairs. Keep dirt away bycovering the parts and exposed openings with a cleancloth, paper or tape.

7 Never weld on or perform any operation involving heatnear the fuel or oil systems. Fuel and oil tanks must becompletely purged, e.g. by steam-cleaning, beforecarrying out such operations. Never weld on, or in anyway modify, pressure vessels. Disconnect thealternator cables during arc welding on the unit.

8 Support the drawbar and the axle securely if workingunderneath the unit or when removing a wheel. Do notrely on jacks.

9 Make sure that no tools, loose parts or rags are left inor on the unit.

10 Before clearing the unit for use after maintenance oroverhaul, check that operating pressures, temperaturesand speeds are correct and that the control andshutdown devices function correctly.

11 Do not remove any of, or tamper with, the sounddamping material. Keep the material free of dirt andliquids such as fuel, oil and cleansing agents.

12 Protect the electrical and regulating components, theair 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 ofcorrect tool use and knowing the limitations of tools,along with some common sense, many accidents can beprevented.Special service tools are available for specific jobs andshould be used when recommended. The use of thesetools 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

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below 70 dB(A): no action needs to be taken,above 70 dB(A): noise-protective devices should beprovided for people continuously being present in theroom,below 85 dB(A): no action needs to be taken foroccasional visitors staying a limited time only,above 85 dB(A): room to be classified as a noise-hazardous area and an obvious warning shall beplaced permanently at each entrance to alert peopleentering 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 alsooccasional visitors shall wear ear protectors,above 105 dB(A): special ear protectors that areadequate for this noise level and the spectralcomposition of the noise shall be provided and aspecial warning to that effect shall be placed at eachentrance.Insulation or safety guards of parts the temperature ofwhich can be in excess of 80 ºC (175 ºF) and whichmay be accidentally touched by personnel shall not beremoved before the parts have cooled to roomtemperature.When hot parts have to be handled, e.g. shrink fitting,special heat-resistant gloves shall be used and, ifrequired, other body protection shall be applied.If the working process produces fumes, dust orvibration hazards, etc., take the necessary steps toeliminate the risk of personnel injury.Before lifting machines, all loose parts which could beliable to fall down shall be removed or secured;pivoting parts such as doors, etc. shall be safelyimmobilized.To lift heavy parts, a hoist of ample capacity, tested andapproved according to local safety regulations, shall beused.When lifting machinery, only hooks or shacklesmeeting local safety regulations shall be applied. Nevershall cables, chains or ropes be applied directly on orthrough lifting eyes. Never allow sharp bends in liftingcables, chains or ropes.Lifting hooks, eyes, shackles, etc. shall never be bentand shall only have stress in line with their design loadaxis. The capacity of a lifting device diminishes when

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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 enginedamage or personal injury.

2 This type of fuel is extremely flammable, toxic andpoisonous. Avoid contact with eyes or skin andbreathing the fumes. If accidentally swallowed, do notinduce vomiting but call a physician immediately.

3 If fuel enters or fumes irritate the eyes, flush the latterwith large quantities of clean water and call for medicalaid.

4 Before operating ether cold starting aids, read theinstructions and the container label.

5 Never operate ether cold starting aids while the engineis 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 clearlymarked out with signs prohibiting fire, open flame andsmoking.

7 Wear eye protection when testing a system. Make surethat openings of a spray container, valve, tube oratomizer are pointed away from yourself and otherswhile testing.

8 Do not store ether containers in temperatures above160 ºF (70ºC),

9 Do not incinerate, puncture or attempt to remove thecenter core valve, side safety valve or any other part ofan 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 thefollowing 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 theapplications as specified above and in accordance withthe technical specifications. Safety reasons prohibitany 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 permittedto those vessel walls which are exposed to pressure.

5 The vessel is provided and may only be used with therequired safety equipment such as manometer,overpressure control devices, safety valve, etc.

6 Draining of condensate shall be performed daily whenvessel 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 authorizedrepresentative 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 bedone with the compressor supplying the air pressureand must be carried out on a proper test bench.

Injury Prevention1 Stationary housing guards are provided on all rotating

or reciprocating parts not otherwise protected andwhich may be hazardous to personnel. Machinery shallnever be put into operation, when such guards havebeen removed, operate only when guards are securelyreinstalled.

2 Do not open electrical cabinets, cubicles or otherequipment while voltage is supplied. If such cannot beavoided, e.g. for measurements, tests or adjustments,have the action carried out by a qualified electricianonly, with appropriate tools, and ascertain that therequired bodily protection against electrical hazards isapplied.

3 Noise, even at reasonable levels, can cause irritationand disturbance which, over a long period of time, maycause severe injuries to the nervous system of humanbeings.When the sound pressure level, at any point wherepersonnel normally has to attend, is:

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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 toperpendicular as possible. If required, a lifting beamshall be applied between hoist, and load.

12 When heavy parts are being lifted with a hoist, it isstrictly forbidden to dwell or pass under the load or inthe space which is liable to be hit if the load or part ofit should topple over or come loose. Never leave a loadhanging on a hoist. Lifting acceleration and retardationshall be kept within safe limits.

13 A hoist has to be installed in such a way that the objectwill be lifted perpendicular. If that is not possible, thenecessary precautions must be taken to prevent load-swinging, e.g. by using two hoists, each atapproximately the same angle not exceeding 30degfrom the vertical.

14 When using compressed air or inert gas to clean downequipment, do so with caution and use the appropriateprotection, at least safety glasses, for the operator aswell as for any bystander. Do not apply compressed airor inert gas to your skin or direct an air or gas stream atpeople. Never use it to clean dirt from your clothes.

15 Before blowing compressed air or inert gas through ahose, ensure that the open end is held securely, so thatit cannot whip and cause injury.

16 When washing parts in or with a cleaning solvent,provide the required ventilation and use appropriateprotection such as a breathing filter, safety glasses,rubber apron and gloves, etc.

17 Safety shoes should be compulsory in any workshopand 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 ordust, the respiratory organs must be protected and,depending on the nature of the hazard, so must the eyesand 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 reliableindication that dangerous, invisible dust is not presentin the air.

20 When using cartridge type breathing filter equipment,ascertain that the correct type of cartridge is used andthat its useful service life is not surpassed.

mpressor oil systeme oil is boosted by air pressure. The system has no oilmp. The oil is removed from the air, in the air/oil vesselst by centrifugal force, second through the oil separatorment. The vessel is provided with an oil level indicator.

gulatione compressor is provided with a continuous regulatingstem and a blow-down valve which is integrated in theloader assembly. The valve is closed during operation outlet pressure of the compressor element and opens by receiver pressure when the compressor is stopped.hen the air consumption increases, the air receiverssure will decrease and vice versa.is receiver pressure variation is sensed by the regulatinglve which, by means of control air to the unloader andgine speed regulator, matches the air output to the airnsumption. The air receiver pressure is maintainedtween the pre-selected working pressure and therresponding unloading pressure

oling systemgine and compressor are provided with a radiator and cooler. The cooling air is generated by a fan, driven by engine.

fety devicesthermal shut-down sensor protects the compressor

ainst overheating. The air receiver is provided with aety valve. The engine is equipped with low oil pressured high coolant temperature shut-down sensors and anernator/V-belt protection system.

ame and axlese compressor/engine unit is supported by rubber buffersthe frame. e standard XAS 185 KD7 is equipped with a adjustablewbar with a towing eye and road lighting.

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Leading particulars

Description of Safety Pictograms Used in

this Manual

General description

The XAS 185 KD7 is a silenced, single-stage, oil-injectedscrew compressor, built for an effective working pressureof 100 psi (7 bar).

EngineThe compressor is driven by a water-cooled diesel engine.The engine’s power is transmitted to the compressorthrough a flexible coupling.

CompressorThe 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 malerotor has four lobes and the female rotor has six flutes.Thus, the male rotor revolves at 1 1/2 times the speed ofthe female rotor. The element delivers pulsation-free air.Injected oil is used for sealing, cooling and lubricatingpurposes.

CoThpufirele

ReThsyunbyairWpreThvaencobeco

CoEnoilthe

SaA agsafanalt

FrThin Thdra

This symbol draws your attention todangerous situations. The operationconcerned may endanger persons and causeinjuries.

This symbol is followed by supplementaryinformation.

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As an option, the unit can be equipped with electric orhydraulic braking systems.When driving backwards the hydraulic brake is notengaged automatically.

BodyworkThe bodywork has openings at the shaped front and rearend for the intake and outlet of cooling air and hingeddoors for maintenance and service operations. Thebodywork is internally lined with sound-absorbingmaterial.

Lifting eyeA lifting eye is accessible through the roof panel at the topof the unit.

Control panelThe control panel grouping the air pressure gauge, controlswitch etc., is placed at the right hand/ rear of aircompressor.

Data plateThe compressor is furnished with a data plate located onthe front, drivers side of the unit showing the compressortype, serial number, maximum final pressure and normalworking pressure.

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Main Parts

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Reference NameAFc Air Filter (Compressor element)AFe Air Filter (Engine)AOV Air Outlet ValvesAR Air ReceiverB BatteryCE Compressor ElementDPF Diesel Particulate FilterDSe Dip Stick Engine OilE EngineEP Exhaust PipeF Cooling FanFWs Fuel Water SeparatorFCc Filler Cap (Coolant)FCeo Filler Cap (Engine Oil)FCf Filler Cap (Fuel)FFf Final Fuel Filter

Reference NameFT Fuel TankFFp Primary Fuel FilterFPco Compressor Oil Filling PlugLB Lifting BaleMPN Minimum Pressure NozzleOC Oil CoolerOFc Oil Filter (Compressor)OFe Oil Filter (Engine)OLG Oil Level GaugeR RadiatorRV Regulating ValveS Starter Motor EngineSR Speed RegulatorSV Safety ValveTT Top TankTBV Thermostatic By-pass valveUV Unloading ValveVV Vacuuator Valve

- 16 -

Compressor regulating system (Load Condition)

- 17 -

Reference NameAFc Air Filter CompressorAFe Air Filter EngineAFE Air Filter ElementAR Air ReceiverAV Air Outlet ValveBDV Blow Down valveBPV By-Pass Valve Oil FilterCE Compressor ElementCH Coupling HousingCP Control PanelCV Check ValveDP Drain PlugE EngineEW Electrical WiringF Cooling FanFP Compressor Oil Filling Plug

Reference NameM ManifoldMPN Minimum Pressure NozzleOC Oil CoolerOFc Oil Filter (Compressor)OFe Oil Filter (Engine)OS Oil SeparatorPS Pressure SenderRV Regulating ValveS SolenoidSC Safety CartridgeSL Scavenge LineSV Safety ValveTS Temperature SwitchUV Unloader ValveVi Vacuum Indicator

ntinuous regulating system

e system comprises:

e compressor is provided with a continuous regulatingstem. This system is provided with a blow-down valveDV) which is integrated in the unloader assembly (UA).e valve is closed during operation by outlet pressure of compressor element and opens by air receiver pressureen the compressor is stopped.

hen the air consumption increases, the air receiverssure will decrease and vice versa. This receiverssure variation is sensed by the regulating valve which,

means of control air to the unloader, matches the airtput to the air consumption. The air receiver pressure isintained between the pre-selected working pressure and corresponding unloading pressure. When starting the

mpressor, the unloader valve (UV) is kept open byring force, the engine runs at maximum speed. Thempressor element (CE) takes in air and pressure builds in the receiver. The unloader valve is closed.e air output is controlled from maximum output (100%)no output (0%) by:Speed control of the engine between maximum load speed and unloading speed (the output of a screw compressor is proportional to the rotating speed).

Air inlet throttling.Blow off valve (BOV).

the air consumption is equal to or exceeds the maximum output, the engine speed is held at maximum load speedd the unloading valve is fully open.the air consumption is less than the maximum air output, regulating valve supplies control air to unloader valveV) to reduce the air output and holds air receiverssure between the normal working pressure and the

V Regulating valveA Unloader ValveR Speed regulator

- 18 -

Air flow

The system comprises:

Air drawn through the airfilter (AF) into the compressorelement (CE) is compressed. At the element outlet,compressed air and oil pass into the air receiver/oilseparator (AR/OS).In the air receiver/oil separator (AR/OS), most of the oil isremoved from the air/oil mixture: the remaining oil isremoved by the separator element.The oil collects in thereceiver and on the bottom of the separator element.The oil collects in the receiver and on the bottom of theseparator element.The air leaves the receiver via the minimum pressurenozzle (MPN) which prevents the receiver pressure fromdropping below the minimum working pressure, evenwhen the air outlet valves are open. This ensures adequateoil 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 unloaderassembly 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/oilseparator (AR/OS) through the oil cooler (OC) and oilfilter (OF) to the compressor element (CE).The compressor element has an oil gallery in the bottom ofits casing. The oil for rotor lubrication, cooling and sealingis injected through holes in the gallery.Lubrication of the bearings is ensured by oil injected intothe bearing housings.The injected oil, mixed with the compressed air, leaves thecompressor element and re-enters the air receiver, where itis separated from the air as described in section 2.4. Theoil that collects in the bottom of the oil separator elementis 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 dropover the filter is above normal because of a clogged filter.The oil then by-passes the filter without being filtered. Forthis reason, the oil filter must be replaced at regularintervals.

Co

Th

Thsy(BThthewhWpreprebyoumathecospcoupThto 1.

2.3.If airanIf the(Upre

AF Air filterAR/OS Air receiver/oil separatorCE Compressor elementUA/UV Unloader assembly with unloader valveBDV Blow-down valveMPV Minimum pressure valveLV Loading Valve

AR/OS Air receiver/oil separatorRV/UA Regulation Valve/Unloader ValveOC Oil coolerOF Oil filter

RUS

- 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 valvegradually opens the air intake and the speed regulatorincreases the engine speed.The construction of the regulating valve is such that anyincrease (decrease) of the air receiver pressure above thepre-set valve opening pressure results in a proportionalincrease (decrease) of the control pressure to theunloading valve.Part of the control air is vented to atmosphere, and anycondensate discharged, through the vent holes (VH).

- 20 -

Electric system

CIRCUIT DIAGRAM - 1310 3200 51

- 21 -

3

2

45

5 6

- 22 -

Operating instructions

Parking, towing and lifting instructions

Safety precautions

Attention

DRAWBAR PREPARATIONS FOR TOWING Atlas Copco XAS 185 KD7 compressors may be suppliedto a customer with a folded drawbar. The drawbar ispositioned in it’s upright position for shipping purposesonly. When the compressor is received by the endcustomer, the drawbar will need to be put into it’soperating 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 pinchthe wire harness that runs through the drawbar duringthe unfolding process. Pull the excess harness outthrough 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 forshipping purposes only. The drawbar is to remain inthe down position after it’s initial setup. REUSE OFLOCKNUTS IS STRICTLY PROHIBITTED BYATLAS COPCO

The operator is expected to apply allrelevant Safety precautions for portablecompressor.

Check and retighten the wheel nuts anddrawbar bolts to the specified torque. Seesection Technical Specifications.

1

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.

- 23 -

Starting / Stopping

Safety precautions

Battery switchIf the compressor is equipped with a battery switch:When the compressor is not in use this switch must alwaysbe in the “OFF” position.It is not allowed to use this switch as an emergency switchor for stopping the compressor. It will cause damage in thecontrol unit when using this switch for stopping.Always first shut off the control unit and wait until thedisplay is dark before switching the battery switch toposition “OFF”.

Control panel

Do not disconnect power supply to controlbox in any way when the control box isswitched on. This will cause memory loss.Do not switch off the circuit breaker whenthe control box is switched on. This willcause memory loss.

Please be aware that the (optional)preheater unit is still “live” with the batteryswitch in “OFF” position.

Reference NameSTART 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 SequenceMEASUREMENTS 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.

eference NameCompressor statusVessel pressure indication or info textCompressor info

Main View Indication

Measuring View Indication

Settings View Indication

Alarm View Indication

DPF REGENERATIONHigh Exhaust System Temperature.Means that the Diesel Particle Filteris being regenerated.DPF REGENERATION NEEDEDMeans that the Diesel Particle Filterneeds to be regenerated.Please force DPF Regeneration.

- 24 -

OVERVIEW ICONS

R123

- 25 -

Reference NameDPF REGENERATION INHIBITEDDiesel Particle Filter RegenerationInhibited.Means that the DPF regeneration isinhibited, even if all criteria toactivate a regeneration are met.OVERHAULInitial Overhaul required.

OVERHAULMinor Overhaul required.

OVERHAULMajor Overhaul required.

AUTO LOADThis 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 NameOPERATION MODELocal

OPERATION MODERemote

ALARMActive & not-acknowledged Shutdown Alarm.

ALARMActive & not-acknowledged Non-Shutdown Alarm.ALARMActive & acknowledged Alarm.

FUELTANKRunning at internal fueltank.

arm View

e the Up and Down navigation buttons to scroll through full list of alarms. e DM Lists and the Log Lists can be selected andtered to access the sublist.

- 26 -

Possible views

Main View

Measuring View

Use the Up and Down navigation buttons to scroll throughthe full list of measurements.

Setup View

Use the Up and Down navigation buttons to scroll throughthe full list of settings. Use the Enter button to enter the selected submenu. Use the Back button to leave the entered (sub)menu.

Al

UstheThen

e display now shows

ter pressing the START button, the engine electronicsCU) will be powered up. soon as communication between compressor controllerd engine controller is established, the machine willheat according to the parameters of the engine

ntroller.

- 27 -

STARTINGSwitch on the battery switch if so equipped.Switch the controller on by pressing the power button.The instrument panel will now perform a selftest; thefollowing display will be shown and the controller isinitialized:

During initializing all buttons/inputs/outputs/alarms areinactive.This view will be shown for about 2 seconds, after whichthe display will show the Main View.

The actual vessel pressure is shown. If the measuredvessel pressure is higher than 1.5 bar, the unit will notstart. The vessel pressure has to be lowered by opening theblow down valve. After power up, the vessel pressurenormally is low enough to proceed with the startingprocedure.

The display now shows

The machine is now ready to be started and is waiting fora start command.

Th

Af(EAsanpreco

Xc2003v1.00.0 (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

The display now shows e display now shows

Active Buttons

Stop Button(to cancel Start command)

Measurement View Button

Settings View Button

Alarms View Button

- 28 -

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 startingprocedure is cancelled and the engine will rest for sometime. (Resting time depends on cranking time).

Th

Active Buttons

Stop Button(to cancel Start command)

Measurement View Button

Settings View Button

Alarms View Button

ter warming up the machine is ready to be loaded and isiting for a load command; the display shows

Active Buttons

Stop Button(to cancel Start command)

Load Button(to initiate Automatic Load)

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’scoolant temperature reaches 40 deg C (104 deg F), with aminimum time of 15 seconds and a maximum time of 300seconds.

The display now shows Afwa

Active Buttons

Stop Button(to cancel Start command)

Measurement View Button

Settings View Button

Alarms View Button

ring operation

gularly carry out following checks: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.Check the air outlet temperature of the compressor element.Check the engine oil pressure, the coolant tempera-ture and display of control box.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.

The doors must be closed during operationand may be opened for short periods forinspection and adjustments only.

Be aware not to touch hot or moving partswhen the door is open.

When the engine is running, the air outletvalves (ball valves) must always be put in afully opened or fully closed position.

- 30 -

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

The loading valve will be energized and pressure startsbuilding up.

During loading the following display is shown (defaultdisplay)

The controller controls the speed of the engine in order tomeet the requested working pressure, at the mosteconomical fuel usage.

Du

Re1.

2.

3.

4.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

ter cooling down the engine will stop and the displayll show

e engine is stopped, and the controller will do a doubleeck 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

- 31 -

STOPPINGAfter pressing the STOP button the display will show:

After a Stop command, or in case of a controlled stopalarm, the machine will cool down and run at minimumrpm for 1 minute before it will stop.

Afwi

Thch

Active Buttons

Start Button(to initiate Start command)

Measurement View Button

Settings View Button

Alarms View Button

ESEL PARTICULATE FILTER GENERATION

hen the Diesel Particle Filter regeneration process ispt at its default ‘AUTOMATIC’ setting, then the DPFeneration will be performed automatically when theot Load exceeds 60%.e controller display will indicate an ongoing DPFgeneration by showing the HEST icon (High Exhauststem Temperature):

e DPF regeneration process will continue, until the Sootad has become as low as possible, or until the engine ispped.hen the DPF regeneration process is stopped, the HESTn will disappear from the display.

HEST Icon

- 32 -

SHUTDOWNWhen the machine is shutdown due to a critical alarm oran emergency stop the display will show

POWER OFFSwitch 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 mustalways be in the “OFF” position.It is not allowed to use this switch as an emergency switchor for stopping the compressor. It can damage the controller or the engine’s ElectronicControl Unit when using the battery switch for stopping.Always first shut off the controller and wait until thedisplay is dark before switching the battery switch toposition “OFF”.

DIREWkeregSoThReSy

ThLostoWico

Active Buttons

Measurement View Button

Settings View Button

Alarms View Button

Enter Button(to acknowledge the shown alarm)

CREASING SOOT LOADhen the DPF Regeneration is Inhibited, or when thegine does not get sufficient possibility to automaticallyrform a full DPF Regeneration, the Soot Load willceed the normal levels.e controller will show the DPF Regeneration Neededn. In case of Inhibited DPF Regeneration, the DPFgeneration Needed Icon will overwrite the DPFibited Icon.

quired Action:Force DPF Regeneration, see paragraph FORCE DPF REGENERATION

hen DPF Regeneration is started, the DPF Regenerationeded icon will disappear and the HEST icon will pop-.

DPF Regeneration needed

- 33 -

AUTOMATIC DPF REGENERATION (DEFAULT)In specific cases, when the engine speed is constant atMinimum RPM, it can happen that the DPF regenerationalready starts from 30% Soot Load (LSR - Low SpeedRegeneration).This can happen in following situations:• Warming Up• Not Loaded• Loaded (when running in Unload condition - mini-

mum RPM)• CooldownWhen an LSR is ongoing while the soot load is less than60%, and the engine speed changes (engine is stopped,machine gets loaded, …), then the DPF Regenerationprocess will be stopped.If the Soot Load is higher than 30% when cooling downshould start (then an LSR is expected to be started) thecontroller will ask:

If Enter is pressed within 10 seconds then the controllerwill allow the DPF regeneration to be completed beforethe engine is stopped.

If Enter is not pressed (within 10 seconds), then the enginewill be stopped after cooling down.

INHIBIT DPF REGENERATIONWhen running in an environment where an elevatedexhaust temperature is not allowed, it might be necessaryto inhibit DPF regeneration. This has to be done atCustomer Service Level. Go to General settings 1000.Parameter 1142 ECU DPF Regeneration Enable - Set to"OFF". The controller has now put the DPF Regenerationin a FORCED OFF mode, which is Inhibit DPFRegeneration.The compressor controller will communicate with theengine controller and the (RED) Inhibit DPF regenerationicon will appear:

When the controller gets powered down, it will (at nextpower up) fall back to its default settings, meaningAUTOMATIC DPF regeneration.

INWenpeexThIcoReInh

Re•

WNeup

A full DPF Regeneration can take up to anhour.

DPF Regeneration Inhibited.

TTINGSr buttons to be used see “Control Panel”

knowledge an Alarman alarm becomes active, for example a Low Fuel Levelarning:

n this alarm can be acknowledged by pressing theTER button. If the fuel level is still low, the view

ll change to:

soon as the fuel level is higher than the warning level, alarm icon will automatically disappear. long as there is an alarm icon in the middle of thettom part of the view, all active acknowledged /

- 34 -

TURNING REGENERATION BACK TO AUTOMachine is not running:Power the controller down. At next power up, the DPFRegeneration settings will be back to default, and anAutomatic DPF Regeneration will take place at thesoonest 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 AUTOMATICDPF REGENERATION.Customer Level can now select between AUTORegeneration & INHIBIT Regeneration, as long as thecontroller is not powered down (after power down, it willfall back to its default DPF Regeneration settings, and aService Level is needed to go back to Inhibit DPFRegeneration).

FORCE DPF REGENERATIONMachine 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 REGENERATIONMachine 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"

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AcIf W

theENwi

AstheAsbo

Unit will not regenerate if soot level is nothigh enough.

Unit will not regenerate if soot level is nothigh enough.

ECU warning 7009 will be active while in diagnos-tics.

- 35 -

unacknowledged alarms can be seen by pressing theALARM VIEW buttonPressing the ALARM VIEW button again, will bring youback to the Main View.

Set ClockPress 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 andpress ENTER.To change any other setting, the highlighted figure iseditable.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 (orin the menu you require).

Set LanguagePress 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 (orin the menu you require).

Set UnitsPress 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 (orin the menu you require).

Change Display SettingsPress 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 (orin the menu you require).

Go To DiagnosticsPress 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 ECUdiagnostics (read DM1 List, DM2 List, ECU values,perform engine diagnostics, …).Now press BACK until you’re back in the Main View (orin the menu you require).To leave Diagnostics, press the STOP button.

•

TriggerXcXcXcXcXcXcXcXcXcXcXcXcXcXcXcXcXcXcXcXcXcXcXcXcXcXcXcXcXcXcXcXcXcXcXcXcXc

- 36 -

FAULT CODESThere are several parameters that are continuouslywatched.

When one of these parameters exceeds its specified limitthe compressor will react depending the present status ofthe control box.

Alarmcode Alarmtext Failclass1231 FUEL FILL CHECK Warning1503 INITIAL OVERHAUL REQUIRED Warning1522 MINOR OVERHAUL WITHIN ** H Warning1523 MINOR OVERHAUL WITHIN ** D Warning1524 MINOR OVERHAUL REQUIRED Warning1552 MAJOR OVERHAUL WITHIN ** H Warning1553 MAJOR OVERHAUL WITHIN ** D Warning1554 LOAD PREVENTION - FIRE RISK Inhibit Load1558 COMP. OIL CHANGE WITHIN ** H Warning1559 COMP. OIL CHANGE WITHIN ** D Warning2000 EMERGENCY STOP INPUT Shutdown2040 REMOTE EMERGENCY STOP Shutdown2070 COOLANT LEVEL LOW WARNING Warning2080 COOLANT LEVEL LOW SHUTDOWN Shutdown2090 ΔP AIRFILTERS HIGH Warning2100 NO PROJECTFILE DOWNLOADED Warning2752 NAM OILTRONIX BYPASS CIRCUIT Shutdown After Stop2762 NAM OILTRONIX CLOSED CIRCUIT Shutdown After Stop2772 NAM AIRXPERT OPENED CIRCUIT Shutdown2782 NAM AIRXPERT CLOSED CIRCUIT Shutdown3000 FUEL LEVEL LOW WARNING Warning3010 FUEL LEVEL LOW SHUTDOWN Controlled Stop3020 FUEL LEVEL SENSOR CIRCUIT Warning3050 VESSEL PRESSURE HIGH WARNING Controlled Stop3060 VESSEL PRESSURE HIGH SHUTDOWN Shutdown3070 VESSEL PRESSURE SENSOR CIRCUIT Shutdown3120 REGULATING PRESSURE SENSOR CIRCUIT Shutdown3170 AIR DISCHARGE PRESSURE SENSOR CIRCUIT Warning3320 INLET PRESSURE SENSOR CIRCUIT Shutdown3450 BATTERY LOW ALARM Indication3460 BATTERY HIGH ALARM Warning3660 FIRE RISK - CHECK OILSTOPVALVE Shutdown3680 OSV PRESSURE SENSOR CIRCUIT Controlled Stop3720 INTERSTAGE PRESSURE SENSOR CIRCUIT Warning4000 L.P. ELEMENT TEMPERATURE HIGH Warning4010 L.P. ELEMENT TEMP. ALARM 2 Controlled Stop4020 L.P. ELEMENT TEMP. ALARM 3 Shutdown

XcXcXcXcXcXcXcXcXcXcXcXcXcXcXcXcXcXcXcXcXcXcXcXcXcXc

ECUECUECUXcXcXcXcXcXcXcXcXcXcXcXc

Trigger

- 37 -

4040 L.P. ELEMENT TEMP. SENSOR CIRCUIT Shutdown4070 AMBIENT TEMPERATURE SENSOR CIRCUIT Warning4100 AIR DISCHARGE TEMPERATURE ALARM 1 Warning4110 AIR DISCHARGE TEMPERATURE ALARM 2 Controlled Stop4120 A.D. TEMPERATURE SENSOR CIRCUIT Warning4150 H.P. ELEMENT TEMPERATURE ALARM 1 Warning4160 H.P. ELEMENT TEMPERATURE ALARM 2 Controlled Stop4170 H.P. ELEMENT TEMPERATURE ALARM 3 Shutdown4190 H.P. ELEMENT TEMP. SENSOR CIRCUIT Shutdown4220 AFTERCOOLER AIR TEMP SENSOR CIRCUIT Warning4230 AFTERCOOLER FREEZING DANGER Indication5200 AIR SHUT OFF Shutdown6190 CHARGE MONITORING FAIL Indication6327 START FAILURE Shutdown6329 STARTER SPEED TOO LOW Shutdown6388 VESSEL PRESSURE TOO LOW TO LOAD Indication6426 UNINTENTIONAL RUN Shutdown6427 RUN FAILURE Shutdown6428 STOP FAILURE Shutdown6708 DRAINING 1 Warning6709 DRAINING 2 Warning6749 OILTRONIX FUNCTIONALITY DISABLED Warning6760 OILTRONIX COUPLING FAILURE Shutdown After Stop6769 OILTRONIX COMPONENT FAILURE Shutdown6981 INLET VALVE POS. FAILURE Shutdown7002 ECU COMMUNICATION Shutdown7007 ECU RED LAMP Shutdown7008 ECU AMBER LAMP Warning7009 ECU PROTECT LAMP Warning7010 ECU ENGINE SPEED TOO LOW Shutdown7020 ECU ENGINE SPEED ALARM 2 Shutdown7030 ECU ENGINE COOLANT TEMP. ALARM Controlled Stop7050 ECU ENGINE AIR INLET TEMP. ALARM 1 Controlled Stop7100 ECU DPF SOOT LOAD HIGH Warning7110 PLEASE FORCE DPF REGENERATION ! Inhibit Load7120 LOAD PREVENTION - HIGH DPF SOOT LOAD Controlled Stop7130 SOOT LOAD TOO HIGH - CALL ATLAS COPCO Warning7222 COMBO COMMUNICATION FAILURE Warning7223 COMBO PA SENSOR WARNING Warning7224 COMBO RHA SENSOR WARNING Warning7225 COMBO TA SENSOR WARNING Warning

Alarmcode Alarmtext Failclass

U - AMBIENT AIR TEMPERATUREU - AIR INLET TEMPERATUREU - FUEL TEMPERATUREU - OIL TEMPERATUREU - ENGINE SPEEDU - INJECTOR 1U - INJECTOR 2U - INJECTOR 3U - INJECTOR 4U - INJECTOR 5U - INJECTOR 6U - INJECTOR 7U - INJECTOR 8U - SOOT LOAD

- 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 LISTA 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 PRESSUREECU - INTERCOOLER TEMPERATUREECU - FUEL PRESSUREECU - FUEL FILTER PRESSUREECU - WATER IN FUELECU - OIL LEVELECU - OIL FILTER PRESSUREECU - OIL PRESSUREECU - TURBO BOOST PRESSUREECU - TURBO OIL PRESSUREECU - INTAKE MANIFOLD TEMPERATUREECU - AIR INLET PRESSUREECU - COOLANT TEMPERATUREECU - COOLANT LEVELECU - SUPPLY VOLTAGE

ECECECECECECECECECECECECECEC

- 39 -

EMERGENCY STOP

When an emergency stop button (1) is pressed, power toall outputs is terminated, by the emergency stop itself(hardware) as well as by the software.When the emergency stop button (1) is pressed theoperator can unlock the emergency stop by turning itcounterclockwise.

The emergency stop button is only to beused in emergency situations; not forstopping procedures.

(1)

on dipstick. Consult the Engine Operation Manual for the type and viscosity grade of the engine oil.Check the level of the compressor oil. The pointer of oil level gauge (OLG) should register in the green range. Add oil if necessary.

Check that the fuel tank contains sufficient fuel. Top up, if necessary. Consult the Engine Operation Man-ual for the type of fuel.

Check coolant level in overflow bottle. Top off coolant if necessary. Consult engine’s operation manual for water/coolant specifications.Drain any water and sediment from the fuel filter until clean fuel flows from the drain cock.Press vacuator valve (VV) of the air filter to remove dust.Check the air filter service indicator (VI). If the red part shows completely, service or replace the filter element. Reset the indicator.Open an air outlet valve (AV) to allow air flow to the atmosphere.

- 40 -

PARKING INSTRUCTIONS When parking a compressor, secure prop (1) or nose wheelto support the compressor in a level position. Place thecompressor as level as possible; however, it can beoperated temporarily in an out-of-level position notexceeding 15°. If the compressor is parked on slopingground, immobilize the compressor by placing wheelchocks in front of or behind the wheels. Locate thecompressor upwind, away from contaminated wind-streams and walls. Avoid recirculation of exhaust air fromthe engine. This causes overheating and engine powerdecrease.

TOWING INSTRUCTIONSBefore towing the compressor, make sure that the towingequipment of the vehicle matches the towing eye or ballconnectorThe drawbar should be as level as possible and thecompressor and towing eye end in a level position. Securenose prop (1) in the highest position. Attach safety chains/cables in a crisscross manner to the tow vehical. This willhelp prevent the towbar from contacting ground in eventof a breakaway. Connect road lights when applicable.

LIFTING INSTRUCTIONSWhen lifting the compressor, the hoist has to be placed insuch a way that the compressor, which must be placedlevel, will be lifted vertically. Use the lifting bale providedto 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

3.

4.

5.

6.

7.

8.

9.

Lifting acceleration and retardation mustbe 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!

e taking maintenance measures.gaged packings, e.g. gaskets, 0-rings, washers.ngine Operation Manual.

o be seen as a guideline for units operating in a dutyor applications. Maintenance schedule can be adaptedment and quality of maintenance

enance will cause problems that will significantly nce.

CJ-4 gradeC (95 °F)

urs Every 1000 hours1310 9230 05

Note

ChangeChange See change interval

il change Replace w/ oil changeReplace

Check

inspecting, be sure toine.

engine oil:

al

400 hours

- 41 -

Maintenance

Use of Service Paks

Service Paks include all genuine parts needed for normal maintenance of both compressorand 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 beforWhen servicing, replace all disenFor engine maintenance refer to EThe maintenance schedule has tenvironment typical to compressdepending on application environ

• 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 maintdegrade the engine performa

API service classification: aboveAmbient temperature: below 35 °

MAINTENANCE SCHEDULE Daily Initial 50hours + Every 250/750 hours1310 9230 03

Every 500 ho1310 9230 04

Check engine oil level CheckCheck of fuel level CheckCheck of coolant level CheckCheck of fan belt Check ChangeChange of engine oil Change ChangeReplacement of oil filter cartridge Replace Replace w/ o*1- Replacement of fuel filter cartridge ReplaceCleaning 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

When changing or level and stop the eng

Changing interval of

Models Interv

V2403 Every

- 42 -

Technical Specifications

Reference conditions

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

Limitations

Designation XAS 185 KD7Absolute inlet pressure bar(e) 1

psi 14.7Relative air humidity % 0Air inlet temperature °C 20

°F 68Normal effective working pressure bar(e) 7

psi 100

Designation XAS 185 KD7Minimum effective receiver pressure bar(e) 4

psi 58Maximum effective receiver pressure, compressor unloaded

bar(e) 8.4-8.7psi 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

1)

% 80qts 10gal 2.5qts 11 gal 2.75 qts 10gal 2.5

All unitsqts 12.2gal 3.05US gal 4.5l 17.03US gal 20.1l 76.08

3) cfm 6340m3/s 2.99

XAS 185 KD7

- 44 -

Performance data

Design Data

COMPRESSOR

ENGINE

UNIT

Designation XAS 185 KD7Engine shaft speed, normal and maximum rpm 2700Engine shaft speed, compressor unloaded rpm 1600Free air delivery2) l/s 83.53

cfm 177Fuel consumption -at full load gal/hr 2.33

-at unload gal/hr 0.94Specific fuel consumption gal/ft3 0.00022Typical oil content of compressed air mg/m3 <5

oz/1000 cu.ft < 0.005Engine oil consumption (maximum) g/hr NA

oz/h NACompressed air temperature at outlet valves °C 93.3

°F 200Noise level6) dB(A) <76

Designation All unitsNumber of compression stages 1

Designation XAS 185 KD7Make KubotaType V2403

Coolant Ethylene glycol mix w/SCA package

Number of cylinders 4

Borein 3.43mm 87.12

Strokein 4.03mm 102.36

Swept volumecu.in 148.53l 2.43

Output at normal shaft speed5) hp 49kW 36.53

- Load factor

Capacity of oil sump

-Refill (max.)4)

Capacity of cooling system

Designation

Capacity of compressor oil system

Net capacity of air receiver

Capacity of fuel tanks

Air volume at inlet grating (approx.)

Designation

- 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 DTolerance:• +/- 5% 25 l/s (53 cfm) < FAD < 250 l/s (530 cfm)• +/- 4% 250 l/s (530 cfm) < FADThe 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 12173) Air required for engine and compressor cooling, combustion and for compression.4) with filter change5) 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°F6) Measured in accordance with ISO 2151 under free field conditions at 7m distance

gine oil

gine coolant

PAROIL - EXTRA 5W40Order number

1.3 gallon (5 Liter) Container: 1630 0135 015.2 gallon (20 Liter) Pail: 1630 0136 0155 gallon ( 209 Liter) Drum: 1626 0102 00

PAROIL - E MISSION GREEN 15W40Order number

1.3 gallon (5 Liter) Container: 1630 0471 005.2 gallon (20 Liter) Pail: 1630 0472 0055 gallon ( 209 Liter) Drum: 1630 0473 00

PARCOOL - EGOrder number

1.3 gallon container: 1604 5308 005.3 gallon pail: 1604 5307 0155 gallon drum: 1604 5306 001 gallon pail: 1604 8159 00

elow 18°F. Please contact Atlas Copco for more

Type of OilEngineSee Engine Operation Manual15W-40

res lower than 18°F (-8°C) without the correctult in element failure and/or fire.

- 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 brandedlubrication oils for compressor.

Compressor oil

En

En

* Keep the bolts of the housing, the liftingeye, the towbar and the axle securelytightened. Refer to Compressor/EngineSpecifications for the torque values.

PAROIL - MOrder number

1 gallon pail: 1615 5947 005.2 gallon pail: 1615 5948 0055 gallon drum: 1615 5949 00

PAROIL - SOrder number

1 gallon pail: 1630 0160 005.2 gallon pail: 1630 0161 0055 gallon drum: 1630 0162 00264 gallon container: 1630 0163 00

(1) Additional equipment is needed to run the compressor binformation about Cold Weather Packages

Temperature RangeCompressor

Between -13°F and 122°F(1) PAROIL SBetween 18°F and 104°F PAROIL M

Operation of compressor in ambient temperatutype of oil will void your warranty and may res

drain pan. Screw out the filler plug to speed up drain-ing. Tighten the plugs after draining.Remove the oil filter (OFc), e.g. by means of a spe-cial tool. Catch the oil in a drain pan.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.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.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.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 add more oil. Overfilling results in oilconsumption.

- 47 -

OIL LEVEL CHECK

CHECK ENGINE OIL LEVELConsult also the Engine Operation Manual for the oilspecifications, viscosity recommendations and oil changeintervals. See schedule.Check engine oil level according to the instructions in theEngine Operation Manual and top up with oil if necessary.

CHECK COMPRESSOR OIL LEVELWith the unit standing level, engine stopped, check thelevel of the compressor oil. The pointer of the oil levelgauge (OLG) must register in the upper extremity of thegreen range. Add oil via the oil fill plug (FP) if necessary.

ENGINE OIL AND OIL FILTER CHANGEConsult also the Engine Operators Manual for oil and oilfilter(1) change intervals.(2) oil types.

COMPRESSOR OIL AND OIL FILTER CHANGEThe quality and the temperature of the oil determine the oilchange interval.The prescribed interval is based on an oil temperature ofup to 100ºC (212ºF) and normal operating conditions.When operating in high ambient temperatures, in verydusty or high humidity conditions, it is recommended tochange 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

3.

4.

5.

6.

7.

Never mix oils of different brands or types

Before removing oil filler plug, ensure thatthe pressure is released by opening an airoutlet valve.

In this case, contact Atlas Copco.

orage

n the compressor regularly, e.g. twice a week, untilrm.ad and unload the compressor a few times to operate theloading and regulating components. Close the air outletlves after stopping.

rvice Kits

service kit is a collection of parts to fit a specific repairrebuilding task.guarantees that all necessary parts are replaced at the

e time which improves the uptime of the unit. purchase service paks contact your local Atlas Copcoresentative.

If the compressor is going to be storedwithout running from time to time,protective measures must be taken asdescribed 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 03500 hrs 1310 9230 041000 hrs 1310 9230 05

- 48 -

Cleaning Coolers

Keep the coolers clean to maintain the cooling efficiency.Front cooler baffle is removable for access by unscrewing4 bolts.

When cleaning by air jet, blow air through the cooler inreverse direction of normal flow.If the dirt is oily, wash the coolers with degreaser or acleansing agent.

A spray gun should preferably be used to apply the solventto the fins. Rinse the blocks by means of a water jet max.100 psi at 2 inch distance after a soaking-in period. Steamcleaning may also be applied.

Battery Care

An ASB (Service Bulletin) dealing elaborately withbatteries and due care is available on request.If the battery is still dry, it must be activated as describedin point 4.7.1.The battery must be in operation within 2 months frombeing activated; if not, it needs to be recharged first.

ELECTROLYTE

Electrolyte in batteries is a sulphuric acid solution indistilled water.The solution must be made up before being introducedinto the battery.

RECHARGING A BATTERYBefore and after charging a battery, always check theelectrolyte level in each cell; if required, top up withdistilled water only. When charging batteries, each cellmust be open, i.e. plugs and/or cover removed.

Apply with preference the slow charging method andadjust the charge current according to the following rule ofthumb: battery capacity in Ah (amp hours) divided by 20gives safe charging current in Amps.

BATTERY MAINTENANCEKeep 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.

St

RuwaLounva

Se

A or It samTorep

Remove any dirt from the coolers with afiber brush. Never use a wire brush or metalobjects.

Protect the electrical and controllingequipment, air filters etc. againstpenetration of moisture

To avoid damaging the coolers, anglebetween waterjet and coolers should beapprox. 90º.

Never leave spilled liquids such as fuel, oil,water and cleansing agents in or around thecompressor.

Before handling batteries, read the relevantsafety precautions and act accordingly.

Read the safety instructions carefully

Use a commercial automatic batterycharger according to manufacturersinstructions.

- 49 -

Adjustments and Servicing Procedures

Adjustment of the Continuous Regulating System

dirty safety cartridge (4) is an indication of a mal-ctioning air filter element. Replace the element and theety cartridge in this case.place the safety cartridge together with the filterment. The safety cartridge cannot be cleaned.

EANING THE DUST TRAP remove dust from the dust trap pinch the vacuatorlve (6) several times.

PLACING THE AIR FILTER ELEMENT

Release the snap clips (1) and remove the dust trap (2). Clean the trap.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.Reassemble in reverse order of dismantling.Inspect and tighten all air intake connections.Reset the vacuum indicator by pushing the reset but-ton.

Air filter contamination indicatorReset buttonRed indicator

- 50 -

The working pressure is determined by the tension of thespring in the regulating valve (RV). This tension can beincreased to raise the pressure and decreased to lower it byturning the adjusting wheel clockwise and counter-clockwise respectively.To adjust the normal working pressure, proceed asfollows: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 orpunctures before installation.Discard the element (3) when damaged.In heavy duty applications it is recommended to install asafety cartridge.

A funsafReele

CLTova

RE

1.

2.

3.4.5.

1 Snap clips2 Dust trap3 Filter element4 Safety cartridge (Optional)5 Filter housing6 Vacuator valve

The Atlas Copco air filters are speciallydesigned for the application. The use of non-genuine air filters may lead to severedamage of engine and/or compressorelement.Never run the compressor without air filterelement.

789

- 51 -

Air Receiver

The air receiver is tested according to official standards.Regularly have inspections carried out in conformity withlocal 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 themachine 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 byan authorized representative of the valvesupplier.

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.Never operate the engine without the main or voltage sensing cables connected in the circuit.

ecessary.

Atlas copco Service representative.

nnect hose leading to unloader. If air leaks from the hose, d or worn O-rings.

opco Service representative.

if possible: solve; else: contact Atlas copco.

installation.

Atlas copco Service representative.

eaking hoses.

if possible: solve; else: contact Atlas copco.

- 52 -

Problem Solving

Problem Solving Chart

Use the chart on the following pages to help solvemechanical problems.It is assumed that the engine is in good condition, thatthere is adequate fuel flow to the filter and injectionequipment, and compressor/engine maintained with therecommended oil.

Make sure that the wires are not damaged and that they areclamped tight to their terminals.

Alternator Precautions1. Never reverse the polarity of the battery or the

alternator.2. Never break any alternator or battery connections

while the engine is running.

3.

4.

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 anelectrician.

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 n

Regulating valve (RV) defective. Have regulating valve removed and inspected by an

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, discoremove and inspect loading valve. Replace damage

Oil separator element clogged. Have element removed and inspected by an Atlas c

Air intake throttle valve remains partially closed. Check unloader and identify reason for open valve;

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

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

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

Air intake throttle valve does not close for some reason. Check unloader and identify reason for open valve;

Minimum pressure valve malfunctioning. Remove and inspect valve.

Blow-off valve malfunctioning. Remove and inspect valve.

the polarity and connect the batteries correctly.

filter elements and safety cartridges. Check the oil level minutes, stop and recheck oil level.

ith other compressors, leave space between them.

cessary.

sing. Replace if out of order.

pco Service representative.

- 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 precautions1. 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 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 airand add oil if necessary. Run the compressor for a few

Possible faults Corrective actions

Insufficient compressor cooling. Locate compressor away from walls; when banked w

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 ne

Thermostatic by-pass valve remains stuck in open position. Remove valve and check for proper opening and clo

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

Oil separator element (OS) clogged. Have element removed and inspected by an Atlas co

......................................................................................

......................................................................................

Date By initials

- 54 -

Maintenance Log

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

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

Service hours Maintenance action

......................................................................................

......................................................................................

Date By initials

- 55 -

Maintenance Log

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

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

Service hours Maintenance action

- 56 -

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