Atlas Copco XA186 Dd - User Manual

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Instruction Manual and Parts List

for Portable Compressors

XA186 Dd XAHS146 Dd

XAS186 Dd XAVS136 Dd

XATS156 Dd

PAGE

Instruction manual for portable compressors................................................................................3

Instructieboek voor transportabele compressoren.................................................................29

Manuel d'instructions pour compresseurs mobiles...............................................................55

Bedienungsanleitung fŸr fahrbare Kompressoren.................................................................81

Libro de instrucciones para compresores transportables.............................................107

Instruktionsbok fšr transportabla kompressorer...................................................................133

Istruzioni per l'uso di compressori mobili...................................................................................159

Bruksanvisning for mobil kompressorer......................................................................................185

Instruktionsbog til mobile kompressorer.....................................................................................211

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ÊÔÚËÙÔ‡˜ Û˘ÌÈÂÛÙ¤˜............................................................................237

Manual de instru•›es para compressores port‡teis............................................................263

SiirrettŠvien kompressorin ohjekirja................................................................................................289

Parts list Ð Onderdelenlijst Ð Liste de pi•ces Ð Ersatzteilliste Ð

Lista de las partes Ð Reservdelsfšrteckning Ð Listino parti di

ricambio Ð Deleliste Ð Reservedelsliste Ð K·Ù¿ÏÔÁÔ˜

EÍ·ÚÙËÌ¿ÙˆÓ Ð Lista de pe•as Ð Osaluettelo .......................................................................317

GlossaryÐ Woordenlijst Ð Glossaire Ð Glossar Ð Glosario Ð

Ordlista Ð Glossario Ð Ordliste Ð Ordliste Ð °ÏˆÛÛ·ÚÈÔ Ð

Gloss‡rio Ð Sanasto............................................................................................................................................415

ATLAS COPCO – PORTABLE AIR DIVISION

B-2630 AARTSELAAR BELGIUM

Registration code

Collection: X1

Tab: 38

Printed matter N¡

2950 1122 00

1998 Ð 12

2950 1122 00 EN

1998 -12

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Summary

Safety Precautions

General Safety Guidelines

Essential rules for safe operation, maintenance, and repair of compressors.

Safe Use and Operation

Procedures for safe operation, towing, lifting, and general use.

Safety in Maintenance and Repair

Guidelines for safe maintenance, repair, and handling of components.

Specific Safety Warnings

Detailed precautions for batteries, fuel systems, and pressure vessels.

Operating Instructions

Parking, Towing, and Lifting Instructions

Procedures for safely parking, towing, and lifting the compressor unit.

Before Starting Checks

Essential checks and preparations before starting the compressor.

Starting and Stopping Procedures

Step-by-step guide for safely starting and stopping the compressor.

During Operation Monitoring

Guidelines for monitoring the compressor during operation and performing checks.

Maintenance Procedures

Preventive Maintenance Schedule

Oil and Oil Filter Change

Steps for changing engine and compressor oil and filters.

Adjustments and Servicing

Regulating System Adjustment

How to adjust the continuous regulating system for correct pressure.

Air Filter Maintenance and Replacement

Brake System Adjustment Procedures

Technical Specifications

Shutdown Switch and Safety Valve Settings

Settings for engine shutdown switches and safety valves.

Compressor and Engine Performance Data

Performance data, specifications, and operating limits for compressors and engines.

Summary

Safety Precautions

General Safety Guidelines

Essential rules for safe operation, maintenance, and repair of compressors.

Safe Use and Operation

Procedures for safe operation, towing, lifting, and general use.

Safety in Maintenance and Repair

Guidelines for safe maintenance, repair, and handling of components.

Specific Safety Warnings

Detailed precautions for batteries, fuel systems, and pressure vessels.

Operating Instructions

Parking, Towing, and Lifting Instructions

Procedures for safely parking, towing, and lifting the compressor unit.

Before Starting Checks

Essential checks and preparations before starting the compressor.

Starting and Stopping Procedures

Step-by-step guide for safely starting and stopping the compressor.

During Operation Monitoring

Guidelines for monitoring the compressor during operation and performing checks.

Maintenance Procedures

Preventive Maintenance Schedule

Oil and Oil Filter Change

Steps for changing engine and compressor oil and filters.

Adjustments and Servicing

Regulating System Adjustment

How to adjust the continuous regulating system for correct pressure.

Air Filter Maintenance and Replacement

Brake System Adjustment Procedures

Technical Specifications

Shutdown Switch and Safety Valve Settings

Settings for engine shutdown switches and safety valves.

Compressor and Engine Performance Data

Performance data, specifications, and operating limits for compressors and engines.

The provided document is an instruction manual for a series of portable compressors manufactured by Atlas Copco. The specific models covered are XA186 Dd, XAHS146 Dd, XAS186 Dd, XAVS136 Dd, and XATS156 Dd. The manual emphasizes safety precautions, operational instructions, maintenance procedures, and technical specifications for these units.

Function Description

The Atlas Copco portable compressors are solid, safe, and reliable machines designed to deliver pulsation-free compressed air. They are primarily used for various applications requiring a continuous supply of compressed air. The core function involves drawing in ambient air, compressing it using a screw-type rotor element, separating the oil from the compressed air, and then delivering the purified air at a specified working pressure.

The compressor is driven by a water-cooled diesel engine, with power transmitted through a heavy-duty coupling. An oil injection system is integral to the compressor element, providing sealing, cooling, and lubrication for the rotors and bearings. The oil system operates without a dedicated oil pump, relying on air pressure to circulate oil from the air receiver/oil separator through the oil cooler and filter to the compressor element.

A continuous regulating system is employed to match the air output to the air consumption. This system includes a regulating valve, an unloader assembly with an integrated blow-down valve, and a speed regulator. When air consumption increases, the receiver pressure decreases, prompting the regulating valve to supply control air to the unloader and engine speed regulator, thereby increasing air output. Conversely, when consumption decreases, the system reduces output. The blow-down valve automatically depressurizes the air receiver when the compressor is stopped.

Safety devices are incorporated throughout the system, including a thermal shut-down switch for compressor overheating, a safety valve for the air receiver, and low oil pressure and high coolant temperature shut-down switches for the engine.

Important Technical Specifications

The manual provides detailed technical specifications for the different compressor models, including working pressures, free air delivery, engine details, and noise levels.

Compressor Type and Working Pressure:

XA(S)186 Dd: Nominal effective working pressure of 7 bar(e) (non-silenced version XA186 Dd).
XATS156 Dd: Nominal effective working pressure of 10.3 bar(e).
XAHS146 Dd: Nominal effective working pressure of 12 bar(e).
XAVS136 Dd: Nominal effective working pressure of 14 bar(e).

Reference Conditions (for performance data):

Absolute inlet pressure: 1 bar(e)
Relative air humidity: 0%
Air inlet temperature: 20 °C

Limitations:

Minimum effective receiver pressure: 4 bar(e) for all models.
Maximum effective receiver pressure (compressor unloaded): Ranges from 8.5 bar(e) (XA(S)186 Dd) to 15.5 bar(e) (XAVS136 Dd).
Maximum ambient temperature at sea level: 50 °C for all models.
Minimum starting temperature: -10 °C (without cold start equipment), -20 °C (with cold start equipment).

Engine Specifications:

Make: Deutz
Type: BF4M1012EC
Number of cylinders: 4
Bore: 94 mm
Stroke: 115 mm
Swept volume: 3.192 l
Output (according to SAE J1995 at normal shaft speed, 70% load factor): 80 kW
Engine shaft speed (normal and maximum): 2500 r/min for all models.
Engine shaft speed (compressor unloaded): 1700 r/min for all models.
Fuel consumption (at full load): Ranges from 16.3 kg/h to 16.9 kg/h.
Engine oil consumption (maximum): 14 g/h.

Capacities:

Compressor oil system: 24 l
Nett capacity of air receiver: 42 l
Fuel tanks: 175 l
Engine oil sump: 9 l (initial fill), 8.5 l (refill max.)
Cooling system: 14 l

Noise Level:

Sound pressure level (LP) at 7 m distance: Ranges from 72 dB(A) to 74 dB(A).
Sound power level (LW): Ranges from 100 dB(A) to 102 dB(A).

Dimensions and Weight (with brakes, fixed towbar):

Length: 3941 mm
Width: 1716 mm
Height: 1661 mm
Weight (ready to operate): 1670 kg

Usage Features

The compressors are designed for ease of use and safety, with several features enhancing their operational characteristics:

Portability and Towing:

Units can be equipped with adjustable or non-adjustable towbars, various towing eyes (AC, DIN, ball, ITA, NATO), and overrun/parking brakes.
Instructions are provided for safe parking, towing, and lifting, including securing the jockey wheel/prop, applying the parking brake, and connecting safety cables.
The manual warns against exceeding maximum towing speed and operating on slopes greater than 15 degrees.

Control Panel:

A centralized control panel groups essential indicators and switches, including an hourmeter, working pressure gauge, loading valve, start/stop button, and LED indicators for fuel ON, preheat, charge, compressor outlet temperature, engine coolant temperature, and engine oil pressure.
Fault situations trigger immediate engine shutdown and illuminate corresponding LED lamps, which remain on until reset.

Air Quality Options:

Available options include aftercoolers, water separators, fine filters, and reheaters to provide higher quality compressed air for specific applications.
A lubricator option is available for 7 bar units.

Cold Start Capability:

Units can be equipped with cold start equipment for operation down to -20 °C, often utilizing ether fuel systems.

Safety Features:

The manual extensively details general and specific safety precautions for handling, operating, maintenance, and repair, covering aspects like pressurized components, hot parts, electrical hazards, noise exposure, and handling of lubricants and fuels.
Safety pictograms are used throughout the manual to highlight dangerous situations.
The bodywork is internally lined with sound-absorbing material for noise reduction and features hinged doors for maintenance access.

Maintenance Features

The manual provides a comprehensive maintenance schedule and instructions to ensure the longevity and reliable operation of the compressor.

Service Paks:

Atlas Copco offers "Service Paks" containing genuine parts for routine maintenance, aiming to minimize downtime and simplify budgeting.

Preventive Maintenance Schedule:

A detailed schedule outlines daily, initially (around 50 hours), normal (every 500 hours), and yearly (every 1000 hours) checks and replacements.
Key maintenance tasks include:
- Daily Checks: Engine oil level, compressor oil level, water level, air filter vacuator valves, fuel filter water drain, air intake vacuum indicators.
- Initial Checks: Electrolyte level and battery terminals, tire pressure, leaks in air/oil/fuel systems.
- Normal Checks (every 500 hours): Engine minimum/maximum speeds, torque of wheel nuts, fan V-belts (adjust), engine oil (change), engine oil filter (change), fuel prefilter (change).
- Yearly Checks (every 1000 hours): Brake system (check/adjust), safety valve (test), door hinges (grease), towing eye shaft/ball coupling (grease), shut-down switches, pressure drop over separator element (measure/replace), fuel tank (clean), compressor oil (change), compressor oil filter (replace), air filter elements (replace), fuel filter (replace), engine inlet/outlet valves (adjust).

Oil System Maintenance:

Instructions for checking engine and compressor oil levels, adding oil, and changing oil and oil filters.
Specific oil types (PAROIL M, PAROIL SAE 15W40, PAROIL S) are recommended based on ambient temperature.
Warnings against mixing different oil brands or types, and against overfilling the oil system.

Air Filter Maintenance:

Procedures for cleaning the dust trap and replacing air filter elements.
Emphasis on using genuine Atlas Copco air filters to prevent damage to the engine and compressor element.
Instructions for resetting vacuum indicators.

Cooling System Maintenance:

Regular cleaning of the compressor oil cooler, engine water cooler, and intercooler to maintain cooling efficiency.
Steam cleaning with a cleansing agent is recommended, with precautions for jet angle to avoid damage.

Battery Care:

Instructions for activating dry-charged batteries, recharging, and general maintenance (keeping clean and dry, checking electrolyte level, tightening terminals).

Brake Adjustment (if optioned):