Atlas Copco XAHS 146 Dd, XAHS 186 Dd, XATS 156 Dd, XA(S) 186 Dd, XAVS 166 Dd Instruction Manual
XAHS 146 Dd
XATS 156 Dd
XA(S) 186 Dd
XAVS 166 Dd
XAHS 186 Dd
Instruction Manual for Portable Compressors
English
Instruction Manual
for Portable Compressors
XAHS 146 Dd
XATS 156 Dd
XA(S) 186 Dd
XAVS 166 Dd
XAHS 186 Dd
ATLAS COPCO - PORTABLE AIR DIVISION
www.atlascopco.com
Printed matter N°
2954 2230 02
11/2006
4
XAHS 146 Dd - XATS 156 Dd - XA(S) 186 Dd - XAVS 166 Dd - XAHS 186 Dd
Warranty and Liability Limitation
Use only authorized parts.
Any damage or malfunction caused by the use of unauthorized parts is not covered
by Warranty or Product Liability.
The manufacturer does not accept any liability for any damage arising for
modifications, additions or conversions made without the manufacturer's approval
in writing.
Copyright 2006, Atlas Copco Airpower n.v., Antwerp, Belgium.
Any unauthorized use or copying of the contents or any part thereof is prohibited.
This applies in particular to trademarks, model denominations, part numbers and
drawings.
5
Instruction Manual
Please read the following instructions carefully before starting to
use your machine. Follow the instructions in this booklet and we
guarantee you years of troublefree operation.
Always keep the manual available near the machine.
In all correspondence always mention the compressor type and
serial number, shown on the data plate.
The company reserves the right to make changes without prior
notice.
English
Instruction Manual
CONTENTS PAGE
1 Safety precautions for portable compressors ......................7
1.1 Introduction.................................................................7
1.2 General safety precautions ....................................... .. .7
1.3 Safety during transport and installation ......................8
1.4 Safety during use and operation..................................8
1.5 Safety during maintenance and repair.........................9
1.6 Tool applications safety ............................................10
1.7 Specific safety precautions.............................. .. ........1 0
2 Leading particulars ...............................................................11
2.1 Description of safety pictograms
used in this manual....................................................11
2.2 General description ................... .. ..............................11
2.3 Markings and information labels................... ............12
2.4 Main Parts .................................................................13
2.5 Air flow .....................................................................15
2.6 Oil system..................................................................16
2.7 Continuous regulating system...................................16
2.8 Electrical system .................................................... ...17
2.8.1 Circuit diagram for XAHS 146 Dd,
XATS 156 Dd and XA(S) 186 Dd ............................17
2.8.2 Circuit diagram for XAVS 166 Dd and
XAHS 186 Dd...........................................................18
3 Operating instructions..........................................................19
3.1 Parking, towing and lifting instructions ....................19
3.1.1 Parking instructions.............................. .. ...................19
3.1.2 Towing instructions................................ ...................19
3.1.3 Height adjustment (with adjustable towbar) .............20
3.1.4 Lifting instructions ....................................................20
3.2 Before starting...........................................................20
3.3 Starting/Stopping.......................................................21
3.4 During operation .......................................................22
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XAHS 146 Dd - XATS 156 Dd - XA(S) 186 Dd - XAVS 166 Dd - XAHS 186 Dd
CONTENTS PAGE
4 Maintenance........................................................................... 22
4.1 Use of service paks ............................................. ......22
4.2 Preventive maintenance schedule
for the compressor .................................................... 22
4.3 Lubrication oils............................................... .......... 24
4.4 Oil level check .......................................................... 24
4.4.1 Check engine oil level............................................... 24
4.4.2 Check compressor oil level............................... .. ...... 25
4.5 Oil and oil filter change ............................................ 25
4.5.1 Engine oil and oil filter change................................. 25
4.5.2 Compressor oil and oil filter change.........................25
4.6 Coolant...................................................................... 26
4.6.1 Coolant specifications............................................... 26
4.6.2 PARCOOL EG ......................................................... 26
4.6.3 Handling PARCOOL EG.......................................... 26
4.6.4 Coolant check .......................................................... 27
4.6.5 Topping up/replacing coolant................................... 27
4.6.6 Topping up without draining from
the cooling system .................................................... 28
4.6.7 Topping up after limited quantity
draining from the cooling system ............................. 29
4.6.8 Replacing the coolant................................................ 30
4.7 Cleaning coolers ....................... ................................ 30
4.8 Battery care.............................................. ................. 31
4.8.1 Electrolyte................................................................. 31
4.8.2 Activating a dry-charged battery .............................. 31
4.8.3 Recharging a battery .................................................31
4.8.4 Battery maintenance ......................................... ........ 31
4.9 Storage ...................................................................... 31
4.10 Service paks.............................................................. 31
4.11 Service kits................................................................ 31
4.12 Compressor element overhaul ................. ................. 31
4.13 Liability..................................................................... 31
CONTENTS PAGE
5 Adjustments and servicing procedures..............................32
5.1 Adjustment of the continuous regulating system...... 32
5.2 Air filter engine/compressor ..................................... 33
5.2.1 Main parts ................................. ................................ 33
5.2.2 Cleaning the dust trap ............................................... 33
5.2.3 Recommendations..................................................... 33
5.2.4 Replacing the air filter element........................... ......33
5.3 Air receiver ............................................................... 33
5.4 Safety valve............................................................... 33
5.5 Fuel system ............................................................... 34
5.6 Brake (= option) adjustment .....................................34
5.6.1 Brake shoe adjustment.............................................. 34
5.6.2 Test procedure of brake cable adjustment ................ 35
5.6.3 Brake cable adjustment.............................................35
6 Problem solving..................................................................... 36
6.1 Alternator precautions...............................................36
7 Available options................................................................... 39
8 Technical specifications........................................................ 40
8.1 Torque values............................................................ 40
8.1.1 For general applications............................................ 40
8.1.2 For important assemblies .......................................... 40
8.2 Settings of shutdown switches and safety valves .....40
8.3 Compressor/Engine specifications............................ 41
8.4 Conversion list of SI units into British units.............42
9 Data plate ............................................................................... 42
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Instruction Manual
1. SAFETY PRECAUTIONS FOR PORTABLE COMPRESSORS
To be read attentively and acted accordingly before towing, lifting, operating, performing maintenance or repairing the compressor
1.1 INTRODUCTION
The policy of Atlas Copco is to provide the users of their equipment with
safe, reliable and efficient products. Factors taken into account are among
others:
- the intended and predictable future use of the products, and the
environments in which they are expected to operate,
- applicable rules, codes and regulations,
- the expected useful product life, assuming proper service and
maintenance,
- providing the manual with up-to-date information.
Before handling any product, take time to read the relevant instruction
manual. Besides giving detailed operating instructions, it also gives specific
information about safety, preventive maintenance, etc.
Keep the manual always at the unit location, easy accessible to the operating
personnel.
See also the safety precautions of the engine and possible other equipment,
which are separately sent along or are mentioned on the equipment or parts
of the unit.
These safety precautions are general and some statements will therefore not
always apply to a particular unit.
Only people that have the right skills should be allowed to operate, adjust,
perform maintenance or repair on Atlas Copco equipment. It is the
responsibility of management to appoint operators with the appropriate
training and skill for each category of job.
Skill level 1: Operator
An operator is trained in all aspects of operating the unit with the pushbuttons, and is trained to know the safety aspects.
Skill level 2: Mechanical technician
A mechanical technician is trained to operate the unit the same as the
operator. In addition, the mechanical technician is also trained to perform
maintenance and repair, as described in the instruction manual, and is
allowed to change settings of the control and safety system. A mechanical
technician does not work on live electrical components.
Skill level 3: Electrical technician
An electrical technician is trained and has the same qualifications as both the
operator and the mechanical technician. In addition, the electrical technician
may carry out electrical repairs within the various enclosures of the unit.
This includes work on live electrical components.
Skill level 4: Specialist from the manufacturer
This is a skilled specialist sent by the manufacturer or its agent to perform
complex repairs or modifications to the equipment.
In general it is recommended that not more than two people operate the unit,
more operators could lead to unsafe operating conditions. Take necessary
steps to keep unauthorized persons away from the unit and eliminate all
possible sources of danger at the unit.
When handling, operating, overhauling and/or performing maintenance or
repair on Atlas Copco equipment, the mechanics are expected to use safe
engineering practices and to observe all relevant local safety requirements
and ordinances. The following list is a reminder of special safety directives
and precautions mainly applicable to Atlas Copco equipment.
These safety precautions apply to machinery processing or consuming air.
Processing of any other gas requires additional safety precautions typical to
the application and are not included herein.
Neglecting the safety precautions may endanger people as well as
environment and machinery:
- endanger people due to electrical, mechanical or chemical influences,
- endanger the environment due to leakage of oil, solvents or other
substances,
- endanger the machinery due to function failures.
All responsibility for any damage or injury resulting from neglecting these
precautions or by non-observance of ordinary caution and due care required
in handling, operating, maintenance or repair, also if not expressly
mentioned in this instruction manual, is disclaimed by Atlas Copco.
The manufacturer does not accept any liability for any damage arising from
the use of non-original parts and for modifications, additions or conversions
made without the manufacturer’s approval in writing.
If any statement in this manual does not comply with local legislation, the
stricter of the two shall be applied.
Statements in these safety precautions should not be interpreted as
suggestions, recommendations or inducements that it should be used in
violation of any applicable laws or regulations.
1.2 GENERAL SAFETY PRECAUTIONS
1 The owner is responsible for maintaining the unit in a safe operating
condition. Unit parts and accessories must be replaced if missing or
unsuitable for safe operation.
2 The supervisor, or the responsible person, shall at all times make sure
that all instructions regarding machinery and equipment operation and
maintenance are strictly followed and that the machines with all
accessories and safety devices, as well as the consuming devices, are in
good repair, free of abnormal wear or abuse, and are not tampered with.
3 Wheneve r there is an indication or any suspicion that an internal part of
a machine is overheated, the machine shall be stopped but no inspec tion
covers shall be opened before sufficient cooling time has elapsed; this to
avoid the risk of spontaneous ignition of oil vapour when air is admitted.
4 Nor mal ratings (pressures, temperatures, speeds, etc.) shall be durably
marked.
5 Operate the unit only for the intended purpose and within its rated limits
(pressure, temperature, speeds, etc.).
6 The machinery and equipment shall be kept clean, i.e. as free as possible
from oil, dust or other deposits.
7 To prevent an increase in working temperature, inspect and clean heat
transfer surfaces (cooler fins, intercoolers, water jackets, etc.) regularly.
See the maintenance schedule.
8 All regula ting and safety devices shall be maintained with due care to
ensure that they function properly. They may not be put out of action.
9 Care shall be taken to avoid damage to safety valves and other pressure-
relief devices, especially to avoid plugging by paint, oil coke or dirt
accumulation, which could interfere with the functioning of the device.
10 Pressure and temperature gauges shall be checked regularly with regard
to their accuracy. They shall be replaced whenever outside acceptable
tolerances.
11 Safety devices shall be tested as described in the maintenance schedule
of the instruction manual to determine that they are in good operating
condition.
12 Mind the markings and information labels on the unit.
13 In the event the safety labels are damaged or destroyed, they must be
replaced to ensure operator safety.
14 Keep the work area neet. Lack of order will increase the risk of
accidents.
15 When working on the unit, wear safety clothing. Depending on the kind
of activities these are: safety glasses, ear protection, safety helmet
(including visor), safety gloves, protective clothing, safety shoes. Do not
wear the hair long and loose (protect long hair with a hairnet), or wear
loose clothing or jewelry.
16 Take precautions against fire. Handle fuel, oil and anti-freeze with care
because they are inflammable substances. Do not smoke or approach
with naked flame when handling such substances. Keep a fire-
extinguisher in the vicinity.
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XAHS 146 Dd - XATS 156 Dd - XA(S) 186 Dd - XAVS 166 Dd - XAHS 186 Dd
1.3 SAFETY DURING TRANSPORT AND
INSTALLATION
To lift a unit, all loose or pivoting parts, e.g. doors and towbar, shall first be
securely fastened.
Do not attach cables, chains or ropes directly to the lifting eye; apply a crane
hook or lifting shackle meeting local safety regulations. Never allow sharp
bends in lifting cables, chains or ropes.
Helicopter lifting is not allowed.
It is strictly forbidden to dwell or stay in the risk zone under a lifted load.
Never lift the unit over people or residential areas. Lifting acceleration and
retardation shall be kept within safe limits.
1 Before towing the unit:
- ascertain that the pressure vessel(s) is (are) depressurized,
- check the towbar, the brake system and the towing eye. Also check
the coupling of the towing vehicle,
- check the towing and brake capability of the towing vehicle,
- check that the towbar, jockey 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 tyres are in good
condition and inflated correctly,
- connect the signalisation cable, check all lights and connect the
pneumatic brake couplers,
- attach the safety break-away cable or safety chain to the towing
vehicle,
- remove wheel chocks, if applied, and disengage the parking brake.
2 To tow a unit use a towing vehicle of ample capacity. Refer to the
documentation of the towing vehicle.
3 If the unit is to be backed up by the towing vehicle, disengage the
overrun brake mechanism (if it is not an automatic mechanism).
4 Neve r exceed the maximum towing speed of the unit (mind the local
regulations).
5 Place the unit on level ground and apply the parking brake before
disconnecting the unit from the towing vehicle. Unclip the safety breakaway cable or safety chain. If the unit has no parking brake or joc key
wheel, immobilize the unit by placing chocks in front of and/or behind
the wheels. When the towbar can be positioned vertically, the locking
device must be applied and kept in good order.
6 To lift heavy parts, a hoist of ample capacity, tested and approved
according to local safety regulations, shall be used.
7 Lifting hooks, eyes, shackles, etc., shall never be bent and shall only
have stress in line with their design load axis. The capacity of a lifting
device diminishes when the lifting force is applied at an angle to its load
axis.
8 For maximum safety and efficiency of the lifting apparatus all lifting
members shall be applied as near to perpendicular as possible. If
required, a lifting beam shall be applied between hoist and load.
9 Never leave a load hanging on a hoist.
10 A hoist has to be installed in such a way that the object will be lifted
perpendicular. If that is not possible, the necessary precautions must be
taken to prevent load-swinging, e.g. by using two hoists, each at
approximately the same angle not exceeding 30° from the vertical.
11 Locate the unit away from walls. Take all precautions to ensure that hot
air exhausted from the engine and driven machine cooling systems
cannot be recirculated. If such hot air is taken in by the engine or driven
machine cooling fan, this may cause overheating of the unit; if taken in
for combustion, the engine power will be reduced.
1.4 SAFETY DURING USE AND OPERATION
1 When the unit has to operate in a fire-hazardous environment, each
engine exhaust has to be provided with a spark arrestor to trap
incendiary sparks.
2 The exhaust contains carbon monoxide which is a lethal gas. When the
unit is used in a confined space, conduct the engine exhaust to the
outside atmosphere by a pipe of sufficient diameter; do this in such a
way that no extra back pressure is created for the engine. If necessary,
install an extractor. Observe any existing local regulations. Make sure
that the unit has sufficient air intake for operation. If necessary, install
extra air intake ducts.
3 When operating in a dust-laden atmosphere, place the unit so that dust is
not carried towards it by the wind. Operation in clean surroundings
considerably extends the intervals for cleaning the air intake filters and
the cores of the coolers.
4 Close the compressor air outlet valve before connecting or
disconnecting a hose. Ascertain that a hose is fully depressurized before
disconnecting it. Before blowing compressed air through a hose or air
line, ensure that the open end is held securely, so that it cannot whip and
cause injury.
5 The air line end connected to the ou tlet valve must be safeguarded with
a safety cable, attached next to the valve.
6 No external force may be exerted on the air outlet valves, e.g. by pulling
on hoses or by installing auxiliary equipment directly to a valve, e.g. a
water separator, a lubricator, etc. Do not step on the air outlet valves.
7 Never move a unit when external lines or hoses are connecte d to the
outlet valves, to avoid damage to valves, manifold and hoses.
8 Do not use compressed air from any type of compressor, without taking
extra measures, for breathing purposes as this may result in injury or
death. For breathing air quality, the compressed air must be adequately
purified according to local legislation and standards. Breathing air must
always be supplied at stable, suitable pressure.
9 Distribution pipework and air hoses must be of correct diameter and
suitable for the working pressure. Never use frayed, damaged or
deteriorated hoses. Replace hoses and flexibles before the lifetime
expires. Use only the correct type and size of hose end fittings and
connections.
10 If the compressor is to be used for sand-blasting or will be connected to
a common compressed-air system, fit an appropriate non-return valve
(check valve) between compressor outlet and the connected sandblasting or compressed-air system. Observe the right mounting position/
direction.
11 Before removing the oil filler plug, ensure that the pressure is released
by opening an air outlet valve.
12 Never remove a filler cap of the cooling water system of a hot engine.
Wait until the engine has sufficiently cooled down.
13 Never refill fuel while the unit is running, unless otherwise stated in the
Atlas Copco Instruction Book. Keep fuel away from hot parts such as air
outlet pipes or the engine exhaust. Do not smoke when fuelling. When
fuelling from an automatic pump, an earthing cable should be connected
to the unit to discharge static electricity. Never spill nor leave oil, fuel,
coolant or cleansing agent in or around the unit.
9
Instruction Manual
14 All doors shall be shut during operation so as not to disturb the cooling
air flow inside the bodywork and/or render the silencing less effective.
A door should be kept open for a short period only e.g. for inspection or
adjustment.
15 Periodically carry out maintenance works according to the maintenance
schedule.
16 Stationary housing guards are provided on all rotating or reciprocating
parts not otherwise protected and which may be hazardous to personnel.
Machinery shall never be put into operation, when such guards have
been removed, before the guards are securely reinstalled.
17 Noise, even at reasonable levels, can cause irritation and disturbance
which, over a long period of time, may cause severe injuries to the
nervous system of human beings.
When the sound pressure level, at any point where personnel normally
has to attend, is:
- below 70 dB(A):
no action needs to be taken,
- above 70 dB(A):
noise-protective devices should be provided for people continuously
being present in the room,
- below 85 dB(A):
no action needs to be taken for occasional visitors staying a limited
time only,
- above 85 dB(A):
room to be classified as a noise-hazardous area and an obvious
warning shall be placed permanently at each entrance to alert people
entering the room, for even relatively short times, about the need to
wear ear protectors,
- above 95 dB(A):
the warning(s) at the entrance(s) shall be completed with the
recommendation that also occasional visitors shall wear ear
protectors,
- above 105 dB(A):
special ear protectors that are adequate for this noise level and the
spectral composition of the noise shall be provided and a special
warning to that effect shall be placed at each entrance.
18 Insulation or safety guards of parts the temperature of which can be in
excess of 80 °C (175 °F) and which may be accidentally touched by
personnel shall not be removed before the parts have cooled to room
temperature.
19 Never operate the unit in surroundings where there is a possibility of
taking in flammable or toxic fumes.
20 If the working process produces fumes, dust or vibration hazards, etc.,
take the necessary steps to eliminate the risk of personnel injury.
21 When using compressed air or inert gas to clean down equipment, do so
with caution and use the appropriate protection, at least safety glasses,
for the operator as well as for any bystander. Do not apply compressed
air or inert gas to your skin or direct an air or gas stream at people.
Never use it to clean dirt from your clothes.
22 When washing parts in or with a cleaning solvent, provide the required
ventilation and use appropriate protection such as a breathing filter,
safety glasses, rubber apron and gloves, etc.
23 Safety shoes should be compulsory in any workshop and if there is a
risk, however small, of falling objects, wearing of a safety helmet should
be included.
24 If there is a risk of inhaling hazardous gases, fumes or dust, the
respiratory organs must be protected and depending on the nature of the
hazard, so must the eyes and skin.
25 Remember that where there is visible dust, the finer, invisible particles
will almost certainly be present too; but the fact that no dust can be seen
is not a reliable indication that dangerous, invisible dust is not present in
the air.
26 Never operate the unit at pressures or speeds below or in excess of its
limits as indicated in the technical specifications.
1.5 SAFETY DURING MAINTENANCE AND REPAIR
Maintenance, overhaul and repair work shall only be carried out by
adequately trained personnel; if required, under supervision of someone
qualified for the job.
1 U se 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 Atlas Copco replacement parts.
3 All maintenance work, other than routine attention, shall only be
undertaken when the unit is stopped. Steps shall be taken to prevent
inadvertent starting. In addition, a warning sign bearing a legend such as
”work in progress; do not start” shall be attached to the starting
equipment.
On engine-driven units the battery shall be disconnected and removed or
the terminals covered by insulating caps.
On electrically driven units the main switch shall be locked in open
position and the fuses shall be taken out. A warning sign bearing a
legend such as ”work in progress; do not supply voltage” shall be
attached to the fuse box or main switch.
4 Before dismantling any pressurized component, the compressor or
equipment shall be effectively isolated from all sources of pressure and
the entire system shall be relieved of pressure. Do not rely on non-retur n
valves (check valves) to isolate pressure systems. In addition, a warning
sign bearing a legend such as ”work in progress; do not open” shall be
attached to each of the outlet valves.
5 Prior to stripping an engine or other machine or undertaking major
overhaul on it, prevent all movable parts from rolling over or moving.
6 Make sure that no tools, loose parts or rags are left in or on the machine.
Never leave rags or loose clothing near the engine air intake.
7 Never use flammable solvents for cleaning (fire-risk).
8 Take safety precautions against toxic vapours of cleaning liquids.
9 Never use machine parts as a climbing aid.
10 Observe scrupulous cleanliness during maintenance and repair. Keep
away dirt, cover the parts and exposed openings with a clean cloth,
paper or tape.
11 Never weld on or perform any operation involving heat near the fuel or
oil systems. Fuel and oil tanks must be completely purged, e.g. by
steam-cleaning, before carrying out such operations. Never weld on, or
in any way modify, pressure vessels. Disconnect the alternator cables
during arc welding on the unit.
12 Support the towbar and the axle(s) securely if working underneath the
unit or when removing a wheel. Do not rely on jacks.
13 Do not remove any of, or tamper with, the sound-damping material.
Keep the material free of dirt and liquids such as fuel, oil and cleansing
agents. If any sound-damping material is damaged, replace it to prevent
the sound pressure level from increasing.
14 Use only lubricating oils and greases recommended or approved by
Atlas Copco or the machine manufacturer. Ascertain that the selected
lubricants comply with all applicable safety regulations, especially with
regard to explosion or fire-risk and the possibility of decomposition or
generation of hazardous gases. Never mix synthetic with mineral oil.
15 Protect the engine, alternator, air intake filter, electrical and regulating
components, etc., to prevent moisture ingress, e.g. when steam-cleaning.
16 When performing any operation involving heat, flames or sparks on a
machine, the surrounding components shall first be screened with non-
flammable material.
17 Never use a light source with open flame for inspecting the interior of a
machine.
10
XAHS 146 Dd - XATS 156 Dd - XA(S) 186 Dd - XAVS 166 Dd - XAHS 186 Dd
18 When repair has been completed, the machine shall be barred over at
least one revolution for reciprocating machines, several revolutions for
rotary ones to ensure that there is no mechanical interference within the
machine or driver. Check the direction of rotation of electric motors
when starting up the machine initially and after any alteration to the
electrical connection(s) or switch gear, to check that the oil pump and
the fan function properly.
19 Maintenance and repair work should be recorded in an operator’s
logbook for all machinery. Frequency and nature of repairs can reveal
unsafe conditions.
20 When hot parts have to be handled, e.g. shrink fitting, special heat-
resistant gloves shall be used and, if required, other body protection
shall be applied.
21 When using cartridge type breathing filter equipment, ascertain that the
correct type of cartridge is used and that its useful service life is not
surpassed.
22 Make sure that oil, solvents and other substances likely to pollute the
environment are properly disposed of.
23 Before clearing the unit for use after maintenance or overhaul, check
that operating pressures, temperatures and speeds are correct and that
the control and shutdown devices function correctly.
1.6 TOOL APPLICATIONS SAFETY
Apply the proper tool for each job. With the knowledge of correct tool use
and knowing the limitations of tools, along with some common sense, many
accidents can be prevented.
Special service tools are available for specific jobs and should be used when
recommended. The use of these tools will save time and prevent damage to
parts.
1.7 SPECIFIC SAFETY PRECAUTIONS
Batteries
When servicing batteries, always wear protecting clothing and glasses.
1 The electrolyte in batteries is a sulphuric acid solution which is fatal if it
hits your eyes, and which can cause burns if it contacts your skin.
Therefore, be careful when handling batteries, e.g. when checking the
charge condition.
2 Install a sign prohibiting fire, open flame and smoking at the post where
batteries are being charged.
3 When batteries are being charged, an explosive gas mixture forms in the
cells and might escape through the vent holes in the plugs.
Thus an explosive atmosphere may form around the battery if
ventilation is poor, and can remain in and around the battery for several
hours after it has been charged. Therefore:
- never smoke near batteries being, or having recently been, charged,
- never break live circuits at battery terminals, because a spark usually
occurs.
4 When connecting an auxiliary battery (AB) in parallel to the unit battery
(CB) with booster cables: connect the + pole of AB to the + pole of CB,
then connect the - pole of CB to the mass of the unit. Disconnect in the
reverse order.
Pressure vessels
(according to directive 87/404/EEC annex II § 2)
Maintenance/installation requirements:
1 The vessel can be used as pressure vessel or as separator and is designed
to hold compressed air for the following application:
- pressure vessel for compressor,
-medium AIR/OIL,
and operates as detailed on the data plate of the vessel:
- the maximum working pressure ps in bar (psi),
- the maximum working temperature Tmax in °C (°F),
- the minimum working temperature Tmin in °C (°F),
- the capacity of the vessel V in l (US gal, Imp gal, cu.ft).
2 The pressure vessel is only to be used for the applications as specified
above and in accordance with the technical specifications. Safety
reasons prohibit any other applications.
3 National legislation requi rements with respect to re-inspection must be
complied with.
4 No welding or heat treatment of any kind is permitted to those vessel
walls which are exposed to pressure.
5 The vessel is provided and may only be used with the required safety
equipment such as manometer, overpressure control devices, safety
valve, etc.
6 Draining of condensate shall be performed regularly when vessel is in
use.
7 Installation, design and connections should not be changed.
8 Bolts of cover and flanges may not be used for extra fixation.
Safety valves
All adjustments or repairs are to be done by an authorized representative of
the valve supplier (see maintenance schedule 4.2).
11
Instruction Manual
2. LEADING PARTICULARS
2.1 DESCRIPTION OF SAFETY PICTOGRAMS USED IN
THIS MANUAL
Fig. 2.1 General view of XAVS 166 Dd with some options
2.2 GENERAL DESCRIPTION
The compressors type XAHS 146 Dd, XATS 156 Dd, XA(S) 186
Dd, XAVS 166 Dd and XAHS 186 Dd are silenced, single-stage,
oil-injected screw compressors, built for a nominal effective
working pressure, ranging from 7 bar up to 14 bar (see chapter 8.,
technical specifications).
– Engine
The compressors are driven by a liquid-cooled diesel engine.
The engine’s power is transmitted to the compressor through a heavyduty coupling.
– Compressor
The compressor casing houses two screw-type rotors, mounted on
ball and roller bearings. The male rotor, driven by the engine, driv es
the female rotor. The element delivers pulsation-free air.
Injected oil is used for sealing, cooling and lubricating purposes.
– Compressor oil system
The oil is boosted by air pressure. The system has no oil pump.
The oil is removed from the air, in the air/oil vessel at first by
centrifugal force, secondly by the oil separator element.
The vessel is provided with an oil level indicator.
– Regulation
The compressor is provided with a continuous regulating system and
a blow-down valve which is integrated in the unloader assembly. The
valve is closed during operation by air receiver pressure and opens by
air receiver pressure via the compressor element when the compressor
is stopped.
When the air consumption increases, the air receiver pressure will
decrease and vice versa.
This receiver pressure variation is sensed by the regulating valve
which, by means of control air to the unloader and engine speed
regulator, matches the air outp ut to the air consumption. The air
receiver pressure is maintained between the pre-selected working
pressure and the corresponding unloading pressure.
– Cooling system
The engine is equipped with a liquid cooler and intercooler. All
compressors are equipped with an oil cooler.
The cooling air is generated by a fan, driven by the engine.
– Safety devices
A thermal shut-down switch protects the compressor against
overheating. The air receiver is provided with a safety valve.
The engine is equipped with low oil pressure and high coolant
temperature shut-down switches and a coolant level switch.
– Frame and axle
The compressor/engine unit is supported by rubber buffers in the
frame.
The standard unit has a non-adjustable towbar with a towing eye.
As an option the unit can be equipped with an adjustable towbar, an
overrun and parking brake and towing eyes type DIN, ball, IT A, GB,
NATO, AC (France), (for available options see chapter 7.).
The braking system consists of an integrated parking brake and
overrunbrake. When driving backwards the overrunbrake is not
engaged automatically.
–Bodywork
The bodywork has openings at the shaped front and rear end for the
intake and outlet of cooling air and hinged doors for maintenance and
service operations. The bodywork is internally lined with soundabsorbing material.
– Lifting eye
A lifting eye is accessible when the small door at the top of the unit
is unlocked.
– Control panel
The control panel grouping the air pressure gauge, control switch etc.,
is placed at the right hand/ rear end corner.
– Data plate
The compressor is furnished with a data plate showing the product
code, the unit number and the working pressure (see chapter 9.).
– Serial number
The serial number is located on the right-hand side towards the front
on the upper edge of the frame and also on the data plate.
This symbol draws your attention to dangerous
situations. The operation concerned may endanger
persons and cause injuries.
This symbol is followed by supplementary information.
12
XAHS 146 Dd - XATS 156 Dd - XA(S) 186 Dd - XAVS 166 Dd - XAHS 186 Dd
2.3 MARKINGS AND INFORMATION LABELS
Compressor outlet temperat ure too high.
Compressor outlet temperature.
Compressor outlet pressure.
Dangerous outlet.
Danger, heat flat.
Electrocution hazard.
Atlas Copco mineral compressor oil.
Atlas Copco synthetic compressor oil.
Atlas Copco mineral engine oil.
Manual.
Read the instruction manual
before working on the battery.
Reset fuse.
On / off button.
Hours, time.
Prohibition to open air valves without conn e cted h os es.
Compressor loaded.
Runlamp.
Airfilter.
Compressor temperature too high.
Rotation direction.
Inlet.
Outlet.
Compressor oil drain.
Read the instruction manual before starting.
Service every 24 hours.
Warning!
Part under pressure.
Do not stand on outlet valves.
Start-Stop indication of switch.
Do not run the motor with open doors.
Lifting permitted.
Use diesel fuel only.
Tyre pressure.
Sound power level in accordance with
Directive 2000/14/EC (expressed in dB (A)).
Sound power level in accordance with
Directive 2000/14/EC (expressed in dB (A)).
Sound power level in accordance with
Directive 2000/14/EC (expressed in dB (A)).
Horizontal towbar position require d
in case of coupling.
4
.75 bar / 69 ps
i
13
Instruction Manual
2.4 MAIN PARTS
0
00
0
(FLG)
(FC1)
(CE)
(CP)
(BH)
(TB)
(AR)
(A)
(FT)
(F)
(EP)
(RV)
(E)
(SV)
(VV)
(VV)
(OLG)
(OF
E)
(CT)
(CC)
(SL)
(OC)
(AOV)
(VI
E)
(FF
2)
(FF
1)
(AF
E)
(DS
E)
(FC
2)
(MPV)
(FP
1)
(OF
CE)
(AF
CE)
(FC
3)
(VI
CE)
(S)
(CLS)
(DP
OC)
(IC)
(SN)
AAlternator
AF
CE
Air Filter (compressor element)
AF
E
Air Filter (engine)
AOV Air Outlet Valves
AR Air Receiver
BH Brake Handle
CC Coolant Cooler
CE Compressor Element
CLS Coolant Level Switch
CP Control Panel
CT Coolant Tank
DP
OC
Drain Plug Oil Cooler
DS
E
Engine Oil Level Dipstick
E Engine
EP Exhaust Pipe
FFan
FC
1
Filler Cap (engine oil)
FC
2
Filler Cap (fuel tank)
FC
3
Filler Cap (coolant)
FF
1
Fuel Prefilter
FF
2
Fuel Filter
FLG Fuel Level Gauge
FP
1
Filler Plug (compressor oil)
FT Fuel Tank
IC Intercooler
MPV Minimum Pressure Valve
OC Oil Cooler
OF
CE
Oil Filter (compressor element)
OF
E
Oil Filter (engine)
OLG Oil Level Gauge (compressor elemen t)
RV Regulating Valve
S Starting Motor
SL Support Leg
SN Serial Number
SV Safety Valve
TB Towbar
VI
CE
Vacuum Indicator (compr. element)
VI
E
Vacuum Indicator (engine)
VV Vacuator Valve
Fig. 2.2 Main parts of XAHS 146 Dd, XATS 156 Dd and XA(S) 186 Dd with some options
14
XAHS 146 Dd - XATS 156 Dd - XA(S) 186 Dd - XAVS 166 Dd - XAHS 186 Dd
0
0
0
0
(FLG)
(IC)
(DP
OC)
(CLS)
(S)
(VI
CE)
(FC
3)
(FC1)
(AF
CE)
(OF
CE)
(FP
1)
(MPV)
(FC
2)
(DS
E)
(AF
E)
(FF
1)
(FF
2)
(VI
E)
(AOV)
(OC)
(SN)
(SL)
(CC)
(CT)
(OF
E)
(OLG)
(VV)
(TB)
(SV)
(E)
(RV)
(EP)
(F)
(FT)
(A)
(CP)
(CE)
(BH)
(AR)
Fig. 2.3 Main parts of XAVS 166 Dd and XAHS 186 Dd with some options
AAlternator
AF
CE
Air Filter (compressor element)
AF
E
Air Filter (engine)
AOV Air Outlet Valves
AR Air Receiver
BH Brake Handle
CC Coolant Cooler
CE Compressor Element
CLS Coolant Level Switch
CP Control Panel
CT Coolant Tank
DP
OC
Drain Plug Oil Cooler
DS
E
Engine Oil Level Dipstick
E Engine
EP Exhaust Pipe
FFan
FC
1
Filler Cap (engine oil)
FC
2
Filler Cap (fuel tank)
FC
3
Filler Cap (coolant)
FF
1
Fuel Prefilter
FF
2
Fuel Filter
FLG Fuel Level Gauge
FP
1
Filler Plug (compressor oil)
FT Fuel Tank
IC Intercooler
MPV Minimum Pressure Valve
OC Oil Cooler
OF
CE
Oil Filter (compressor element)
OF
E
Oil Filter (engine)
OLG Oil Lev el Gauge (compressor elemen t)
RV Regulating Valve
S Starting Motor
SL Support Leg
SN Serial Number
SV Safety Valve
TB Towbar
VI
CE
Vacuum Indicator (compr. element)
VI
E
Vacuum Indicator (engine)
VV Vacuator Valve
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