Atlas Copco XAS 185 KDU T4F HOP Instruction Manual
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Atlas Copco XAS 185 KDU T4F HOP Instruction Manual

Atlas Copco XAS 185 KDU T4F HOP Instruction Manual

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Instruction Manual for AC Compressors
English
XAS 185 KDU T4F HOP
CALIFORNIA Proposition 65
WARNING
Breathing diesel engine exhaust exposes you to chemicals known to
the State of California to cause cancer and birth defects or other
reproductive harm.
• Always start and operate the engine in a well-ventilated area.
• If in an enclosed area, vent the exhaust to the outside.
• Do not modify or tamper with the exhaust system.
• Do not idle the engine except as necessary.
For more information go to
www.P65warnings.ca.gov/diesel.
Engine Kubota V2403

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Summary of Contents for Atlas Copco XAS 185 KDU T4F HOP

  • Page 1 Instruction Manual for AC Compressors English Engine Kubota V2403 XAS 185 KDU T4F HOP CALIFORNIA Proposition 65 WARNING Breathing diesel engine exhaust exposes you to chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.
  • Page 3 Instruction Manual for AC Compressor XAS 185 KDU T4F HOP Original instructions Printed matter No. 1310 3014 61 ATLAS COPCO - PORTABLE ENERGY DIVISION 10/2019 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

    Table of Contents Preface 6.4.14 Force dpf regeneration ........37 6.4.15 Service regeneration........37 Please read the following instructions carefully before Safety precautions ..........7 6.4.16 Settings............37 starting to use your compressor. 1.1 Introduction ............7 6.4.17 Fault codes ............40 It is a solid, safe and reliable machine, built according to 6.4.18 Emergency stop..........
  • Page 6 10.2 Compressor / engine specification...... 55 10.2.1 Reference conditions........55 10.2.2 Limitations ............55 10.2.3 Performance data..........55 10.3 Design data ............55 Disposal.............. 58 11.1 General ............... 58 11.2 Disposal of materials .......... 58 Maintenance log..........59 - 6 -...

  • Page 7: Safety Precautions

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

  • Page 8: Safety During Use And Operation

    or sparks on a machine, the surrounding components 4 Place the unit on level ground and chock the wheels Close the compressor air outlet valve before shall first be screened with non-flammable material. before disconnecting the unit from the towing vehicle. connecting or disconnecting a hose.

  • Page 9: Safety During Maintenance And Repair

    - the engine exhaust system is in good condition, damping material. Keep the material free of dirt and 15 Strike the object with the full face of the hammer. liquids such as fuel, oil and cleansing agents. - air outlet valves and manifold, hoses, couplings, etc. are in good 16 Never use a hammer with a loose head.

  • Page 10: Ether Fuel Systems

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

  • Page 12: Leading Particulars

    Leading particulars Description of Safety Pictogram Used in this GENERAL DESCRIPTION Compressor oil system Manual The oil is boosted by air pressure. The system has no oil pump. The oil is removed from the air, in the air/oil vessel first by centrifugal force, second through the oil separator This symbol draws your attention to dangerous situations.
  • Page 13 Frame and axles Data plate A separate service panel (4) is located at the rear to aid in service of the separator element filter. The compressor/engine unit is supported by rubber buffers The compressor is furnished with a data plate located at in the frame.

  • Page 14: Main Parts

    Main parts - 14 -...
  • Page 15 Reference Name Reference Name Air Filter (Compressor element) FPco Compressor Oil Filling Plug Air Filter (Engine) Lifting Bale Air Receiver Minimum Pressure Nozzle Battery Oil Cooler Compressor Element Oil Filter Engine Oil Level Gauge Exhaust Pipe Radiator Cooling Fan Safety Valve Water Separator Thermostatic By-pass valve FCeo...

  • Page 16: Overview

    Overview 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 Separator Blow Down valve Pressure Sender By-Pass Valve Oil Filter Regulating Valve Compressor Element Safety Cartridge Cooling Fan...

  • Page 18: Air Flow

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

  • Page 20: Electrical System

    Electrical system Circuit Diagram - 1310 3200 51 - 20 -...
  • Page 21 - 21 -...

  • Page 22: Operating Instructions

    Operating instructions LIFTING INSTRUCTIONS BEFORE STARTING 1. Before initial start-up, prepare battery for operation if not already done. When lifting the compressor, the hoist has to be placed in 2. With the compressor standing level, check the level of such a way that the compressor, which must be placed If the compressor is to be connected to a the engine oil.

  • Page 23: Rear-End Of Compressor Upwind

    REAR-END OF COMPRESSOR UPWIND Locate rear-end of the compressor upwind (see figure), away from contaminated wind- Remove transportation supports before mounting compressor on streams and walls. Avoid recirculation of exhaust gasses from the engine. This can cause truck. overheating and engine power decrease. The compressor oil lifetime will be shortened when the compressor air inlet air is contaminated.

  • Page 24: Starting / Stopping

    STARTING / STOPPING Safety precautions Do not disconnect power supply to control box in any way when the control box is switched on. This will result in loss of controller data. Do not switch off the circuit breaker when the control box is switched on. This will result in loss of controller data.

  • Page 25: Control Panel

    CONTROL PANEL 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.

  • Page 26: 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. MAIN VIEW   Means that the Diesel Particle Filter is being regenerated.
  • Page 27 Reference Name Reference Name Reference Name DPF REGENERATION INHIBITED OPERATION MODE FUELTANK Diesel Particle Filter Regeneration Local Running at internal fueltank.   Inhibited means that the DPF regeneration OPERATION MODE FUELTANK is inhibited, even if all criteria to activate a Remote Running at internal fueltank &...

  • Page 28: Automatic Functions

    - These functions can be configured according to the needs of the application. - These functions may require an Atlas Copco Service Key to be accessible. - Contact Atlas Copco Technical Support for assistance in setting up a machine with Automatic Functions.

  • Page 29: Possible Views

    POSSIBLE VIEWS Main View Setup View Alarm View Measuring 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 settings. the full list of alarms. MEASUREMENTS Use the Enter button to enter the selected sub menu.

  • Page 30: Starting

    STARTING Switch on the battery switch if so equipped. blow down valve. After power up, the vessel pressure Active Buttons normally is low enough to proceed with the starting Switch the controller on by pressing the power button. Start Button procedure.
  • Page 31 The display now shows The engine starts cranking, the display shows The display now shows MAIN VIEW MAIN VIEW ENGINE CRANKING ENGINE RESTING 0RPM 800RPM 120s 324RPM 1286h 324RPM 0.0bar 1286h --RPM 0.0bar The engine cranks until 800 rpm is reached. Active Buttons Active Buttons If 800 rpm is not reached within 30 seconds, the starting...
  • Page 32 The engine starts running at idle speed. The display shows The display now shows After warming up the machine is ready to be loaded and is waiting for a load command; the display shows MAIN VIEW MAIN VIEW ENGINE WARMING UP ENGINE WARMING UP 13°C 40°C...
  • Page 33 During operation The engine will now run at maximum rpm, the display will During loading the following display is shown (default show 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.

  • Page 34: Stopping

    STOPPING After pressing the STOP button the display will show: After cooling down the engine will stop and the display will show MAIN VIEW ENGINE STOPPING After a Stop command, or in case of a controlled stop Active Buttons 1286h --RPM 5.3bar alarm, the machine will cool down and run at minimum...

  • Page 35: Shutdown

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

  • Page 36: 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 37: Turning Regeneration Back To Auto

    TURNING REGENERATION BACK TO AUTO SERVICE REGENERATION then this alarm can be acknowledged by pressing the Machine is not running: Machine is running: ENTER button. If the fuel level is still low, the view Power the controller down. At next power up, the DPF •...
  • Page 38 Set Clock Go To Diagnostics • scroll to the preferred setting • press ENTER. Press the SETTINGS VIEW button Press the SETTINGS VIEW button Now press BACK until you are back in the Main View (or • scroll to ‘1000 GENERAL SETTINGS’ •...
  • Page 39 Set the Auto Load Function Auto Start/Auto Stop Suggested Atlas Copco transducers Parameter 1170 – Auto Start, 1180 – Auto Stop Parameters 1160 – 1180 can be configured in any order and will remain inactive until Atlas Copco Model No.

  • Page 40: Fault Codes

    FAULT CODES There are several parameters that are continuously When one of these parameters exceeds its specified limit watched. the compressor will react depending the present status of the control box. Alarm code Alarm text Fail class Trigger 1231 FUEL FILL CHECK Warning 1503 INITIAL OVERHAUL REQUIRED...
  • Page 41 Alarm code Alarm text Fail class Trigger 3720 INTERSTAGE PRESSURE SENSOR CIRCUIT Warning 4000 L.P. ELEMENT TEMPERATURE HIGH Warning 4010 L.P. ELEMENT TEMP. ALARM 2 Controlled Stop 4020 L.P. ELEMENT TEMP. ALARM 3 Shutdown 4040 L.P. ELEMENT TEMP. SENSOR CIRCUIT Shutdown 4070 AMBIENT TEMPERATURE SENSOR CIRCUIT...
  • Page 42 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 7224...

  • Page 43: 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 44: Maintenance

    Maintenance USE OF SERVICE PAKS PREVENTIVE MAINTENANCE SCHEDULE FOR For engine maintenance refer to Engine Operation THE COMPRESSOR Manual. Service Paks include all genuine parts needed for normal maintenance of both compressor and engine. Service Paks The schedule contains a summary of the maintenance The maintenance schedule has to be seen as a guideline for minimize downtime and keep your maintenance budget instructions.
  • Page 45 API service classification: CJ-4 grade or above vice Procedures lems that will significantly degrade Machine and • *1: Included within Atlas Copco Service Kit Engine performance. Ambient temperature: below 35 °C (95 °F) • *2: When biodiesel fuel is used, change the fuel filter...

  • Page 46: Lubrication Oils

    LUBRICATION OILS Engine coolant It is strongly recommended to use Atlas Copco branded lubrication oils for compressor. PARCOOL - EG Order number 1.3 gallon container: 1604 8159 00 * Keep the bolts of the housing, the lifting eye, the towbar and the axle securely tightened.

  • Page 47: Oil Level Check

    (AOV). 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 (OLG) again registers in the upper extremity of the Before removing oil filler plug, ensure that green range.

  • Page 48: Cleaning Coolers

    RECHARGING A BATTERY Remove any dirt from the coolers with a To purchase service paks contact your local Atlas Copco Before and after charging a battery, always check the fiber brush. Never use a wire brush or metal objects.

  • Page 49: Adjustments And Servicing Procedures

    Adjustments and servicing procedures ADJUSTMENT OF THE CONTINUOUS REGULATING SYSTEM - 49 -...

  • Page 50: Air Filter Engine/Compressor

    2. With the outlet valves (AOV) closed, loosen the regu- Inspect and tighten all air intake connections. The Atlas Copco air filters are specially lating valve’s locknut and adjust the regulating valve Reset the vacuum indicator by pushing the reset but- designed for the application.

  • Page 51: Air Receiver

    AIR RECEIVER FUEL SYSTEM WATER SEPARATOR WITH PRIMARY PUMP The air receiver is tested according to official standards. Fuel filter Regularly have inspections carried out in conformity with local regulations. Primary pump Replacing the filter element: Water separator 1. Unscrew the final filter element from the adapter head(1).

  • Page 52: 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 53 Remove valve and check for proper opening and closing. Replace if out of order. Fan blade(s) broken. Check and correct if necessary. Oil separator element (OS) clogged. Have element removed and inspected by an Atlas copco Service representative. - 53 -...

  • Page 54: Technical Specifications

    Technical specifications TORQUE VALUES CRITICAL TORQUE VALUES GENERAL TORQUE VALUES Assemblies Torque value Variance The following tables list the recommended torques applied for general applications at Axles to frame: ft.lbf assembly of the compressor. Wheel nuts For hexagon screws and nuts with strength grade 8.8 Bolts, axle(s)/frame Compressor to frame: Thread size...

  • Page 55: Compressor / Engine Specification

    COMPRESSOR / ENGINE SPECIFICATION REFERENCE CONDITIONS PERFORMANCE DATA Designation Unit XAS 185 KDU Designation Unit XAS 185 KDU Absolute inlet pressure bar(e) Engine shaft speed, normal and maximum 2700 14.7 Engine shaft speed, compressor unloaded 1600 Relative air humidity Free airdelivery 83.06 Air inlet temperature °C...
  • Page 56 Engine Rejection limits Designation Unit XAS 185 KDU Designation Unit All units Make Kubota Safety valve - maximum opening (psi) 175.1 pressure Type V2403 Safety valve - minimum opening (psi) 164.9 Ethylene glycol mix w/SCA Coolant pressure package Vessel pressure at no load, minimum (psi) Number of cylinders Vessel pressure at no load, maximum...
  • Page 57 Altitude unit performance curve - 57 -...

  • Page 58: Disposal

    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 59: Maintenance Log

    Maintenance log Compressor Customer..................................................Serial number..................................................... Service hours Maintenance action Date By initials - 59 -...
  • Page 60 - 60 -...
  • Page 62 www.atlascopco.com...

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