Atlas Copco XAS 185 KD7 T4 Instruction Manual
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Atlas Copco XAS 185 KD7 T4 Instruction Manual

Atlas Copco XAS 185 KD7 T4 Instruction Manual

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Instruction Manual for AC Compressors
English
XAS 185 KD7 T4
Engine Kubota V2403-CR-E4

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Don Dragus
May 18, 2025

How to raise Idle speed, unit quits running with low engine speed warning, all filters have been replaced.

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Summary of Contents for Atlas Copco XAS 185 KD7 T4

  • Page 1 Instruction Manual for AC Compressors English XAS 185 KD7 T4 Engine Kubota V2403-CR-E4...
  • Page 3 Instruction Manual for AC Compressor XAS 185 KD7 T4 Original instructions Printed matter Nr 1310 3013 85 rev.01 ATLAS COPCO - PORTABLE ENERGY DIVISION 02/2015 www.atlascopco.com...
  • Page 4 Neglecting maintenance or making changes to the setup of the machine can result in major hazards, including fire risk. While every effort has been made to ensure that the information in this manual is correct, Atlas Copco does not assume responsibility for possible errors.

  • Page 5: Table Of Contents

    Preface Table of contents 3.2.11 Force Dpf Regeneration ........34 3.2.12 Service Regeneration .........34 Please read the following instructions carefully before 3.2.13 Settings ..............34 starting to use your compressor. Safety Precautions For Portable 3.2.14 Fault Codes ............36 Compressor ..........7 It is a solid, safe and reliable machine, built according to 3.2.15 Emergency Stop ..........39 the latest technology.
  • Page 6 6.2.1 Main Parts ............51 6.2.2 Cleaning The Dust Trap ........51 6.2.3 Replacing The Air Filter Element ..... 51 6.3 Air Receiver ............52 6.4 Safety Valve .............52 6.5 Fuel System ............52 Problem Solving ........53 7.1 Problem Solving Chart ........53 7.2 Alternator Precautions ........53 7.3 General ..............55 7.4 Disposal of materials .........55...

  • Page 7: Safety Precautions For Portable Compressor

    1 The owner is responsible for maintaining the unit in a The policy of Atlas Copco is to provide the users of their 10 Never operate a machine or equipment beyond its rated safe operating condition. Unit parts and accessories equipment with safe, reliable and efficient products.

  • Page 8: Safety During Use And Operation

    equipment. Finally a wire mesh hose can be fixed over 22 When performing any operation involving heat, flames - Apply safety chains to tow vehicle. or sparks on a machine, the surrounding components 2 If the unit is to be backed up by the towing vehicle, the hose ends to dampen the blast in case a connection shall first be screened with non-flammable material.

  • Page 9: Safety During Maintenance And Repair

    10 Before clearing the unit for use after maintenance or wire or electrical component. Plastic covering of - all hoses and/or pipes inside the unit are in good condition, secure and not rubbing, overhaul, check that operating pressures, temperatures handles is for comfort and grip only. They are not and speeds are correct and that the control and intended to act as insulation if such is not clearly - there are no fuel, oil or coolant leaks,- all fasteners are tight...

  • Page 10: Ether Fuel Systems

    below 70 dB(A): no action needs to be taken, 3 National legislation requirements with respect to re- Ether fuel Systems inspection must be complied with. above 70 dB(A): noise-protective devices should be Ether fuel systems are used for diesel cold starting. 4 No welding or heat treatment of any kind is permitted provided for people continuously being present in the 1 1 Do not use ether as a starting aid in conjunction with...
  • Page 11 the lifting force is applied at an angle to its load axis. 11 For maximum safety and efficiency of the lifting apparatus all lifting members shall be applied as near to perpendicular as possible. If required, a lifting beam shall be applied between hoist, and load. 12 When heavy parts are being lifted with a hoist, it is strictly forbidden to dwell or pass under the load or in the space which is liable to be hit if the load or part of...

  • Page 12: Leading Particulars

    Leading particulars Compressor oil system Description of Safety Pictograms Used in General description The oil is boosted by air pressure. The system has no oil this Manual pump. The oil is removed from the air, in the air/oil vessel first by centrifugal force, second through the oil separator This symbol draws your attention to element.
  • Page 13 As an option, the unit can be equipped with electric or hydraulic braking systems. When driving backwards the hydraulic brake is not engaged automatically. Bodywork The bodywork has openings at the shaped front and rear end for the intake and outlet of cooling air and hinged doors for maintenance and service operations.

  • Page 14: Main Parts

    Main Parts - 14 -...
  • Page 15 Reference Name Reference Name Air Filter (Compressor element) Fuel Tank Air Filter (Engine) Primary Fuel Filter Air Outlet Valves FPco Compressor Oil Filling Plug Air Receiver Lifting Bale Battery Minimum Pressure Nozzle Compressor Element Oil Cooler Diesel Particulate Filter Oil Filter (Compressor) Dip Stick Engine Oil Oil Filter (Engine) Engine...
  • Page 16 Compressor regulating system (Load Condition) - 16 -...
  • Page 17 Reference Name Reference Name Air Filter Compressor Manifold Air Filter Engine Minimum Pressure Nozzle Air Filter Element Oil Cooler Air Receiver Oil Filter (Compressor) Air Outlet Valve Oil Filter (Engine) Blow Down valve Oil Separator By-Pass Valve Oil Filter Pressure Sender Compressor Element Regulating Valve Coupling Housing...

  • Page 18: Air Flow

    Air flow Oil system Continuous regulating system The system comprises: The system comprises: The system comprises: AR/OS Air receiver/oil separator Regulating valve Air filter RV/UA Regulation Valve/Unloader Valve Unloader Valve AR/OS Air receiver/oil separator Oil cooler Speed regulator Compressor element Oil filter UA/UV Unloader assembly with unloader valve...
  • Page 19 corresponding unloading pressure of approx. 21.75 psi (1.5 bar) above the normal working pressure. When the air consumption is resumed, the unloader valve gradually opens the air intake and the speed regulator increases the engine speed. The construction of the regulating valve is such that any increase (decrease) of the air receiver pressure above the pre-set valve opening pressure results in a proportional increase (decrease) of the control pressure to the...

  • Page 20: Electric System

    Electric system CIRCUIT DIAGRAM - 1310 3200 51 - 20 -...
  • Page 21 - 21 -...

  • Page 22: Operating Instructions

    Retorque the all drawbar attachment bolts to their DRAWBAR PREPARATIONS FOR TOWING specified value after 5-10 hours of use. Atlas Copco XAS 185 KD7 compressors may be supplied Note: the pivoting feature of the drawbar is for to a customer with a folded drawbar. The drawbar is shipping purposes only.

  • Page 23: Starting / Stopping

    Control panel Starting / Stopping BACK BUTTON: Moves back one level or ignores the change. Safety precautions Do not disconnect power supply to control box in any way when the control box is switched on. This will cause memory loss. Do not switch off the circuit breaker when the control box is switched on.

  • Page 24: Overview Icons

    OVERVIEW ICONS Reference Name Compressor status Vessel pressure indication or info text Compressor info Main View Indication Measuring View Indication Settings View Indication Alarm View Indication DPF REGENERATION High Exhaust System Temperature. Means that the Diesel Particle Filter is being regenerated. DPF REGENERATION NEEDED Means that the Diesel Particle Filter needs to be regenerated.
  • Page 25 Reference Name Reference Name DPF REGENERATION INHIBITED OPERATION MODE Diesel Particle Filter Regeneration Local Inhibited. OPERATION MODE Means that the DPF regeneration is inhibited, even if all criteria to Remote activate a regeneration are met. ALARM OVERHAUL Active & not-acknowledged Shutdown Alarm. Initial Overhaul required.
  • Page 26 Possible views Setup View Alarm View Main View Use the Up and Down navigation buttons to scroll through Use the Up and Down navigation buttons to scroll through the full list of alarms. Measuring View the full list of settings. The DM Lists and the Log Lists can be selected and Use the Enter button to enter the selected submenu.

  • Page 27: Starting

    STARTING The display now shows Switch on the battery switch if so equipped. Active Buttons Switch the controller on by pressing the power button. Measurement View Button The instrument panel will now perform a selftest; the following display will be shown and the controller is Settings View Button initialized: Alarms View Button...
  • Page 28 The display now shows The engine starts cranking, the display shows The display now shows The engine cranks until 800 rpm is reached. Active Buttons If 800 rpm is not reached within 30 seconds, the starting Active Buttons Stop Button procedure is cancelled and the engine will rest for some Stop Button (to cancel Start command)
  • Page 29 The engine starts running at idle speed. The display shows The display now shows After warming up, the unit will be loaded and ready for use. Active Buttons Active Buttons The engine will run at minimum rpm, until the engine’s Stop Button coolant temperature reaches 40 deg C (104 deg F), with a Stop Button...
  • Page 30 During operation During usage the following display is shown (default display) The doors must be closed during operation and may be opened for short periods for inspection and adjustments only. Be aware not to touch hot or moving parts when the door is open. When the engine is running, the air outlet valves (ball valves) must always be put in a fully opened or fully closed position.

  • Page 31: Stopping

    STOPPING After cooling down the engine will stop and the display will show After pressing the STOP button the display will show: Active Buttons After a Stop command, or in case of a controlled stop The engine is stopped, and the controller will do a double Start Button alarm, the machine will cool down and run at minimum check to see if the engine is really stopped.

  • Page 32: Shutdown

    SHUTDOWN POWER OFF DIESEL PARTICULATE FILTER REGENERATION When the machine is shutdown due to a critical alarm or Switch the controller off by pressing the Power button. When the Diesel Particle Filter regeneration process is an emergency stop the display will show kept at its default ‘AUTOMATIC’...

  • Page 33: Automatic Dpf Regeneration (Default)

    AUTOMATIC DPF REGENERATION (DEFAULT) INHIBIT DPF REGENERATION INCREASING SOOT LOAD In specific cases, when the engine speed is constant at When running in an environment where an elevated When the DPF Regeneration is Inhibited, or when the Minimum RPM, it can happen that the DPF regeneration exhaust temperature is not allowed, it might be necessary engine does not get sufficient possibility to automatically already starts from 30% Soot Load (LSR - Low Speed...

  • Page 34: Turning Regeneration Back To Auto

    TURNING REGENERATION BACK TO AUTO SERVICE REGENERATION SETTINGS Machine is not running: Machine is running: For buttons to be used see “Control Panel” Power the controller down. At next power up, the DPF • Press the Settings Menu Acknowledge an Alarm Regeneration settings will be back to default, and an •...
  • Page 35 • scroll to the unit you would like to change: • ECU warning 7009 will be active while in diagnos- unacknowledged alarms can be seen by pressing the ALARM VIEW button ‘1340 TEMPERATURE UNITS’ tics. ‘1350 PRESSURE UNITS’ Pressing the ALARM VIEW button again, will bring you ‘1360 FUEL FLOW UNITS’...

  • Page 36: Fault Codes

    FAULT CODES When one of these parameters exceeds its specified limit the compressor will react depending the present status of There are several parameters that are continuously the control box. watched. Alarmcode Alarmtext Failclass Trigger 1231 FUEL FILL CHECK Warning 1503 INITIAL OVERHAUL REQUIRED Warning...
  • Page 37 Warning 7110 PLEASE FORCE DPF REGENERATION ! Inhibit Load 7120 LOAD PREVENTION - HIGH DPF SOOT LOAD Controlled Stop 7130 SOOT LOAD TOO HIGH - CALL ATLAS COPCO Warning 7222 COMBO COMMUNICATION FAILURE Warning 7223 COMBO PA SENSOR WARNING Warning...
  • Page 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: For following alarms, the Xc controller also shows full text ECU - AMBIENT AIR TEMPERATURE next to the SPN code: Only possible when engine is running or if Diagnostics ECU - AIR INLET TEMPERATURE Mode is active.

  • Page 39: Emergency Stop

    EMERGENCY STOP The emergency stop button is only to be used in emergency situations; not for stopping procedures. When an emergency stop button (1) is pressed, power to all outputs is terminated, by the emergency stop itself (hardware) as well as by the software. When the emergency stop button (1) is pressed the operator can unlock the emergency stop by turning it counterclockwise.

  • Page 40: Parking Instructions

    PARKING INSTRUCTIONS on dipstick. Consult the Engine Operation Manual for the type and viscosity grade of the engine oil. When parking a compressor, secure prop (1) or nose wheel 3. Check the level of the compressor oil. The pointer of oil to support the compressor in a level position.

  • Page 41: Maintenance

    Maintenance For engine maintenance refer to Engine Operation Use of Service Paks Preventive Maintenance Schedule For Manual. The Compressor Service Paks include all genuine parts needed for normal The maintenance schedule has to be seen as a guideline for maintenance of both compressor and engine. Service Paks The schedule contains a summary of the maintenance units operating in a duty environment typical to minimize downtime and keep your maintenance budget...
  • Page 42 When changing or inspecting, be sure to vice Procedures level and stop the engine. • *1: Included within Atlas Copco Service Kit • *2: When biodiesel fuel is used, change the fuel filter Changing interval of engine oil: cartridge, fuel hose and clamp bands with new ones at intervals half of the usual ones.

  • Page 43: Technical Specifications

    Technical Specifications Reference conditions Designation XAS 185 KD7 Absolute inlet pressure bar(e) 14.7 Relative air humidity Air inlet temperature °C °F Normal effective working pressure bar(e) The inlet conditions are specified at the air inlet grating outside the canopy. Limitations Designation XAS 185 KD7 Minimum effective receiver pressure...

  • Page 44: Altitude Unit Performance Curve

    ALTITUDE UNIT PERFORMANCE CURVE - 44 -...

  • Page 45: Performance Data

    Performance data Designation XAS 185 KD7 - Load factor Designation XAS 185 KD7 Capacity of oil sump Engine shaft speed, normal and maximum 2700 Engine shaft speed, compressor unloaded 1600 -Refill (max.) Free air delivery 83.53 2.75 Capacity of cooling system Fuel consumption -at full load gal/hr...
  • Page 46 1) At reference conditions, if applicable, and at normal shaft speed unless otherwise stated. 2) Free Air Delivery (volume flow rate) is measured according to ISO 1217 ed.3 1996 annex D Tolerance: • +/- 5% 25 l/s (53 cfm) < FAD < 250 l/s (530 cfm) •...

  • Page 47: Lubrication Oils

    Between 18°F and 104°F 15W-40 (1) Additional equipment is needed to run the compressor below 18°F. Please contact Atlas Copco for more information about Cold Weather Packages Operation of compressor in ambient temperatures lower than 18°F (-8°C) without the correct type of oil will void your warranty and may result in element failure and/or fire.

  • Page 48: Check Engine Oil Level

    (AV). Screw out filler plug (FP) green range. Add oil via the oil fill plug (FP) if necessary. In this case, contact Atlas Copco. and add oil until the pointer of the oil level gauge Before removing oil filler plug, ensure that...

  • Page 49: Cleaning Coolers

    Remove any dirt from the coolers with a fiber brush. Never use a wire brush or metal RECHARGING A BATTERY To purchase service paks contact your local Atlas Copco objects. representative. Before and after charging a battery, always check the When cleaning by air jet, blow air through the cooler in electrolyte level in each cell;...

  • Page 50: Adjustments And Servicing Procedures

    Adjustments and Servicing Procedures Adjustment of the Continuous Regulating System - 50 -...

  • Page 51: Air Filter Engine/Compressor

    Filter element Safety cartridge (Optional) Filter housing Vacuator valve Recommendations The Atlas Copco air filters are specially designed for the application. The use of non- genuine air filters may lead to severe damage of engine and/or compressor element. Never run the compressor without air filter element.

  • Page 52: Air Receiver

    Air Receiver Fuel System The air receiver is tested according to official standards. Regularly have inspections carried out in conformity with local regulations. 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.

  • Page 53: Problem Solving

    Have element removed and inspected by an Atlas copco Service representative. Air intake throttle valve remains partially closed. Check unloader and identify reason for open valve; if possible: solve; else: contact Atlas copco. Safety valve (SV) leaking. Remove and inspect. Replace if not airtight after reinstallation.
  • Page 54 Fan blade(s) broken. Check and correct if necessary. Oil separator element (OS) clogged. Have element removed and inspected by an Atlas copco Service representative. Alternator precautions 1. Never reverse the polarity of the battery or the alternator. Never break any alternator or battery connections while the engine is running.

  • Page 55: General

    Your Atlas copco compressor consists for the most part of metallic materials, that can be remelted in steelworks and smelting works and that is therefore almost infinite recyclable.

  • Page 56: Maintenance Log

    Maintenance Log Compressor Customer..................................................Serial number..................................................... Service hours Maintenance action Date By initials - 56 -...
  • Page 57 Maintenance Log Compressor Customer..................................................Serial number..................................................... Service hours Maintenance action Date By initials - 57 -...
  • Page 58 - 58 -...
  • Page 60 www.atlascopco.com...

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