Atlas Copco PAS Series Instruction Manual

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Instruction manual

for PAS Series Pump

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PAS 100 HF T4F CNP ITH

PAS 150 HF T4F CNP ITH

Instruction Manual

DEUTZ D2.9L4

DEUTZ TD2.9L4

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Summary of Contents for Atlas Copco PAS Series

Page 1 Instruction Manual Instruction manual for PAS Series Pump English PAS 100 HF T4F CNP ITH DEUTZ D2.9L4 PAS 150 HF T4F CNP ITH DEUTZ TD2.9L4...
Page 3 PAS 100 HF T4F CNP ITH PAS 150 HF T4F CNP ITH Instruction Manual for PAS Series Pump Instruction manual .................. 5 Circuit diagrams ..................63 Original instructions Printed matter N° ATLAS COPCO - PORTABLE ENERGY DIVISION 2960 1490 00 www.atlascopco.com...
Page 4 While every effort has been made to ensure that the information in in this manual is correct, Atlas Copco does not assume responsibility for possible errors. Copyright 2018, Varisco SpA, PADOVA, ITALY. 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.
Page 5 Please read the following instructions carefully before starting to use your machine. 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. Atlas Copco reserves the right to make changes without prior notice.
Page 6 Checks and trouble shooting. .57 10.3 Torque values ........82 10.4 Data plate..........84 Engine troubleshooting....57 Pump troubleshooting ....60 Spare parts ....85 6.2.1 Overview of possible 11.1 Ordering spare parts......85 operating problems ......61 Storage of the pump .
Page 7 The policy of Atlas Copco is to provide the users of their Atlas Copco equipment. It is the responsibility of unsafe operating conditions. Take necessary steps to equipment with safe, reliable and efficient products.
Page 8 The manufacturer does not accept any liability for any covers shall be opened before sufficient cooling 15 When working on the unit, wear safety clothing. damage arising from the use of non-original parts and for time has elapsed; this to avoid the risk of Depending on the kind of activities these are: spontaneous ignition of oil vapour when air is safety glasses, ear protection, safety helmet...
Page 9 - check the towbar, the brake system and the via the holes in the frame at the front and back or consult Atlas Copco. towing eye. Also check the coupling of the via the lifting beam. To prevent damage, never 15.
Page 10 5. Never refill fuel while the unit is running, unless down equipment, do so with caution and use the noise hazardous area and an obvious warning otherwise stated in the Atlas Copco Instruction appropriate protection, at least safety glasses, for shall be placed permanently at each entrance Book (AIB).
Page 11 15. Safety shoes should be compulsory in any sure that all electric connections are securely inadvertent starting. In addition, a warning sign workshop and if there is a risk, however small, tightened. bearing a legend such as "work in progress; do of falling objects, wearing of a safety helmet not start"...
Page 12 20. Make sure that oil, solvents and other substances -never smoke near batteries being, or having recently recommended or approved by Atlas Copco or likely to pollute the environment are properly been, charged, the machine manufacturer. Ascertain that the disposed of.
Page 13 Main parts General description The PAS 100-150 dry-prime centrifugal pumps, are suitable for handling clean water, dirty water or liquids up to 50°C, containing solids in suspension. The PAS 100-150 pumps are driven by a fluid-cooled diesel engine, manufactured by DEUTZ. An overview of the main parts is given in the diagram below. Lifting beam Side doors Engine exhaust...
Page 14 Air filter Air separator Coupling Centrifugal pump Control Panel Check valve assembly Discharge pipe Engine Filler cap engine oil Filler cap fuel Filler cap coolant Battery Hinge assembly Oil filter Engine oil level dipstick Suction pipe Vacuum pump - 14 -...
Page 15 Flow Diagram - 15 -...
Page 16 Markings Read the instruction manual Markings provide instructions and information. They before using the lifting eye. also warn of hazards. For convenience and safety, keep all markings in legible condition, replacing them when damaged or missing. Replacement markings are available from the factory. Read the instruction manual A brief description of all markings provided on the before using the lifting eye.
Page 17 Despite the pump is able to deal with air in the suction Vacuum created in the suction pipe by the vacuum line, Atlas Copco recommends to avoid this situation pump, forces water to penetrate the pump. When The engine is equipped with the following safety...
Page 18 2.4.5 Bodywork 2.4.8 Drain plugs and filler caps Electrical features The pump, the engine, the cooling system, etc. are The drain holes for the engine oil, the coolant and the The electrical features described in this chapter are enclosed in a sound-insulated bodywork that can be plug for the fuel, are located and labelled on the standard provided on this pump.
Page 19 Control panel The control panel controls and automatically starts/stops governed diesel engine. Description Emergency stop button Pull the Emergency Stop button "OUT" to allow engine operation. Push the Emergency Stop button to shutdown the engine LCD displays SAE J1939 parameters and diagnostics. Configuration via display: transducer start-stop, transducer alarms, engine run speed, automatic start/stop mode.
Page 20 LED INDICATION MODEL PW750 AUTO STANDY LED (Green) An illuminated AUTO STANDBY LED indicates the keyswitch is in the "auto start" position and the system is ready to start. PREHEAT LED (Amber) An illuminated PREHEAT LED indicates the keyswitch is in the "auto start" position and the system is ready to start.
Page 21 MODEL PW1000 Legacy PW750 Legacy PW750 Legacy PW750 Legacy PW750 Indicator (Diesel Exhaust Fluid) - 21 -...
Page 22 Description Float switch connector with cap. The control Panel uses a four position circular plastic connector for the two floats inputs switch. The control panel is equipped with a harness interface auxiliary interface I/O. Pin 1: High Float (colour cable GREY). Pin 2: Low Float (colour cable TANGERINE).
Page 23 2.6.1 Display interface Five buttons access a context dependent button bar when any button from 1 to 4 is pressed. The graphical menu structure uses easily understood icons to indicate the button's current function. After 5 seconds of inactivity the button bar disappears. Button 1: Analog Gauge (pages) Button 2: Digital Gauge (pages) Button 3: Single Analog gauge...
Page 24 ACTIVE ALARM Example Alarms message. Afert identification, the exit button becomes active. Standard J1939 abbreviations are used for alarms. SNP: Suspect Parameter Number. FMI: Failure Mode Indicator - 24 -...
Page 25 ALARM LIST ANALOG GAUGE PAGES The Alarm List is accessed by pressing any button while an alarm popup is displayed or by pressing any of the first 4 buttons to show the button bar and then button 4 Alarms not yet acknowledged are shown in grey on black while acknowledged alarms are shown in black on grey.
Page 26 DIGITAL GAUGE PAGES SIGLE ANALOG GAUGE CONFIGURATION To adapt the control panel to the requirements of a particular application, a large number of parameters are configurable. The "Configuration" Menu allows the user to set various operating parameters such as US or metric units, scale limits for tachometer and service timers.
Page 27 DISPLAY The Display Menu allows the user to configure items affecting how information is displayed. This menu allows the user to set the units used for speed, distance, pressure, volume and temperature independently. Button 4 cycles through the available values for the selected item. The Configuration menu and its six choices.
Page 28 LANGUAGE MENU BUTTON BEEP The soft buttons emit an audible beep when this item is On. Button beep is disabled by setting this item to Off. The audible beep still sounds when an alarm occurs. Button 4 cycles between On and Off. GAUGE Speed MPH (miles per hour) km/h (kilometers per hour)
Page 29 SERVICE SYSTEM Pressing Button 4 allows adjusting the selected Sets the sixteen (16) service intervals in hours and The System Menu allows the user to configure items service timer. resets the service timer. Setting the service interval to affecting how the system functions. Button 4 cycles Button 1 decreases the service interval time, while 0 disables the timer and the word Off is displayed.
Page 30 • The tank drains: 2.6.2 Float switches Operating procedure: The pump is fitted with two float switches for 1. Connect the float switches as follows: operation in Auto mode. These float switches must be • Connect the Start float to Connector indicated coupled to the connectors, located at the side of the by label “A Start float”.
Page 31 Installation and connection To be able to lift the unit by means of a forklift, Lifting Installation rectangular slots are provided at the bottom of the The lifting eye, to lift the unit by means of a hoist, is frame. 3.2.1 Indoor installation integrated in the bodywork and easily accessible from...
Page 32 – Use coolant for the engine cooling system. Refer to the Engine instruction book for the proper coolant mixture. – Check the tightness of the bolts and nuts. - 32 -...
Page 33 In the same way, bends in the suction should be avoided as much as possible. Atlas Copco recommends fluid velocities up to 2 m/s (6 ft/sec) on the suction and 3 m/s (9ft/sec) on the discharge.
Page 34 Users can attempt to rectify the fault by restoring factory defaults (pass on seal. Configuration Menu for details). Contact your local Atlas Copco dealer for assistance if the fault persists. After the start-up screen is cleared, the display shows readings on its virtual If the pump does not prime.
Page 35 AUTOMATIC START/STOP CONTROL PANELOPERATION Turning the control system key to the "AUTO START" position causes all LEDs to illuminate at once, the "Auto Standby" indicator is illuminated and the start-up screen is displayed while a self test is performed. After the start-up screen is cleared, the display shows the transducer reading and switch status on the Transducer/Switch gauge.
Page 36 Maintenance The maintenance schedule contains a summary of the maintenance instructions. Read the respective section before taking maintenance measures. For engine maintenance refer to Engine Operation Manual. The maintenance schedule has to be seen as a guideline for units operating in a dusty environment typical to the pump's applications.
Page 37 Every Every Every Every Regular service period Daily Annually 500 hrs 1000 hrs 3000 hrs 2 years Fuel filter Replace Check level (if necessary top up) Coolant Check additive concetration Replace Engine tightness (visual inspection for Check leaks) Exhaust system including exhaust after Check treatment components for leaks Check...
Page 38 Every Every Every Every Regular service period Daily Annually 500 hrs 1000 hrs 3000 hrs 2 years General Control panel Check for alarms and warnings Condensate and water from spillage-free Drain frame or catch basin (if applicable) Locks and hinges Grease Emergency stop Check function...
Page 39 Every Every Every Every Regular service period Daily Annually 500 hrs 1000 hrs 3000 hrs 2 years Pump Check oil level (if necessary top up) Vacuum pump oil Replace Inspect (if necessary replace) Vacuum pump diaphragm and valves Replace Inspect (if necessary tension or replace) Vacuum pump belt Replace...
Page 40 Every Every Every Every Regular service period Daily Annually 500 hrs 1000 hrs 3000 hrs 2 years Check valve Inspect (if necessary replace) Inspect function of floater and valve Separator Clean components Rubber couplings Inspect (if necessary replace) Pump shaft bearings Replace - 40 -...
Page 41 Pump maintenance residual liquid may be found in the procedures pump casing, head and suction line. Take the necessary precautions if liquid hazardous GENERAL RECOMMENDATIONS (inflammable, corrosive, poisonous, – Handling must be carried out by specialized infected). personnel to avoid damage to the pump and to persons.
Page 42 LUBRIFICATING THE PUMP LUBRIFICATING THE DIAPHRAGM VACUUM PUMP Every month check the oil level using indicators The vacuum pump is of diaphragm type; its (min. oil level, max. oil level) and if necessary to up lubrication is oil bath type. through the cap (Ref.
Page 43 Adjustments and service procedures 5.2.1 Positioning the impeller with reference to the wear plate(s) In all models, the distance between the top of the impeller blades and the surface of the wear plate must be between 0.3 - 0.6 mm To achieve this, dimensions A and B must be as nearly as possible equal.
Page 44 Servicing of impeller Pump Hinge and tighten the (2) bolts (4x). The Atlas Copco Pump is integrated with a Hinge Servicing of impeller mechanism to access the impeller in order to perform basic cleaning and examining the impeller and wear Wear Plate Adjustment plate conditions.
Page 45 5.2.3 Replacement belt The vacuum pump and shaft are coupled with belts and pulleys. Remove the guard belt. Check that the belts are not damaged or broken every 500 hours or 6 months; at the same time check the alignment of the pulleys (for example, using a square ruler).
Page 46 The belts used are the detachable link type; to remove the belt release the link, turning the head of the pin by 90 degrees Fig.A. Insert the tool turning it (to reassemble the belt, overlap the last link by inserting it on the head of the pin and turn it by 90°), Fig.B.
Page 47 5.2.4 Inspection ball valve (only 100 - 150 HF) It's strongly recommended to check the ball valve function and cleanness before usage of the pump. Small debris can accumulate in the ball valve housing. Open the valve cover to check the status of the ball and if necessary clean and remove any solid bodies from the valve housing.
Page 48 – Unscrew the oil filter element (OF) from the Engine maintenance 5.3.2 Engine oil and oil filter change adapter head. procedures Refer to the Engine Operation Manual for more – Clean the adapter head sealing surface. Lightly oil detailed instructions. For the intervals, see also Refer to the Engine Operation Manual for a full the gasket of the new element and screw the latter section “Maintenance schedules”.
Page 49 Flush parameters. high engine operating temperatures. – Flush twice with clean water. Used coolant must – A refractometer can be ordered from Atlas Copco be disposed or recycled in accordance with laws Visual check with part number 2913 0028 00.
Page 50 5.3.5 Servicing air filter engine 5.3.5.5 Recommendation 5.3.5.4 Main parts The Atlas Copco air filters are specially designed application. The use of non-genuine air filters may lead to severe damage of engine and/or alternator. Never run the unit without air filter element.
Page 51 5.3.6 Replacing the filter element New elements must also be inspected for tears or punctures before installation. 1. Release the snap clips (1) and remove the dust trap cover (2). Clean the inside of the cover. 2. Remove the element (3). 3.
Page 52 – Steam cleaning in combination with a cleansing 5.3.7 Cleaning cooler 5.3.8 Cleaning the fuel tank agent may be applied. To avoid damaging the coolers, angle between jet and coolers should be approx. 90°. Protect the electrical and controlling equipment, air filters, etc. against penetration of moisture.
Page 53 – Rock the battery a few times so that possible air If a battery does not need any make-up water at all 5.3.9 Battery care bubbles can escape; wait 10 minutes and check the over considerable time operation, Before handling batteries, read the level in each cell once more;...
Page 54 ISO 3448, as follows: Specifications PAROIL retention and more alkalinity to control acid formation. PAROIL from Atlas Copco is the ONLY oil tested and approved for use in all engines built into Atlas Engine Type of lubricant PAROIL prevents Soot build-up.
Page 55 Remove the cap slowly and only low as -25°C (-13°F). when coolant ambient Atlas Copco's PARCOOL EG extended life coolant is temperature. A sudden release of the new range of organic coolants purpose designed Order pressure from a heated cooling to meet the needs of modern engines.
Page 56 Order Litre cu.ft number 0.175 1604 5308 00 1604 5307 01 barrel 55.2 7.35 1604 5306 00 To ensure protection against corrosion, cavitation and formation of deposits, the concentration of the additives in the coolant must be kept between certain limits, as stated by the manufacturer's guidelines.
Page 57 Checks and trouble shooting Engine troubleshooting Not enough power – Restriction in a fuel pipe. When a failure occurs, always The table below gives an overview of the possible report what you experienced before, engine problems and their possible causes. –...
Page 58 – Incorrect valve tip clearances. – Fault in cold start system. The pressure of the lubricating oil is too low – Wrong grade of lubricating oil. – Engine overload. – Restriction in fuel tank vent. – Not enough lubricating oil in sump. –...
Page 59 Crankcase pressure – Restriction in breather pipe. – Vacuum pipe leaks or fault in exhaust. Bad compression – Restriction in air filter/cleaner or induction system. – Incorrect valve tip clearances. The engine starts and stops – Dirty fuel filter element. –...
Page 60 Pump troubleshooting The paragraph reports the most common problems that may occur during use of the pump and the possible remedies. In case operation defects founded in the starting phase or after a period of operating time, before intervene on the pump is necessary: –...
Page 61 6.2.1 Overview of possible operating problems Symptom Possible cause Corrective action Pump does not prime 1. Suction tubes or inlet filter clogged. The Remove the obstruction. vacuum gauge indicates a high value. 2. Suction tube collapse. Use reinforced suction tube. 3.
Page 62 Low or no flow 1. The pump does not prime, See causes given in Pump does not prime. 2. Head required by the system is greater Revise system design or select a different pump. than the rated head of the pump. 3.
Page 63 Pump does not provide enough pressure 1. Viscosity of the liquid is higher than Contact the pump manufacturer once you have measured the viscosity expected. of the liquid. Viscosity for centrifugal pumps should not exceed 50 cSt. Check for other possible causes: see Low or no flow. 2.
Page 64 Storage of the pump – Stacking to be done with similar size pump. Storage – While stacking care must be taken to place the – Store the pump in a dry, frost-free room which is pump in the correct position and not dropped. well ventilated.
Page 65 This concept can only succeed with your non-recyclable materials. help. Support disposing Your Atlas Copco pump consists mostly of metallic professionally. assuring correct materials, that can be remelted in steel and melting disposal of the product you help prevent works and are therefore amost infinitely recyclable.
Page 66 – Never move the pump while piping is connected Options to the unit. Undercarriage – Always apply the hand brake when parking. To tow a unit use a towing vehicle of ample capacity. – Leave enough space for operation, inspection and Refer to the documentation of the towing vehicle.
Page 67 External fuel tank View inside connection (with/without quick couplings) The option external fuel tank connection allows to bypass the internal fuel tank and to connect an external fuel tank to the unit. View outside When using this option, make sure to connect the fuel supply line as well as the fuel return line.
Page 68 Overview Filler cap (fuel tank) Engine External fuel supply coupling Fuel filter engine Primary coarse fuel filter / water separator Fuel tank 3-way valve - 68 -...
Page 69 Suction and discharge pipes Bauer Perrot/Cardan DIN / ASME Discharge DIN / ASME Discharge Bauer Discharge Perrot/Cardan Suction DIN / ASME Suction Bauer Suction Perrot/Cardan - 69 -...
Page 70 Circuit diagrams The applicable circuit diagram for the PAS 100-150 units. Circuit diagrams - PAS 100-150 HF PREHEAT PREHEAT - 70 -...
Page 71 Description Item INTERFACE CONNECTOR ENGINE X17 (1) INTERFACE CONNECTOR CONTROL PANEL Y4 (2) WARNING AIR FILTER Y10 (3) D+ (ALTERNATOR) Y7 (4) FUEL LEVEL GAUGE (1.SIGNAL - 2.RESERVE WARNING) Y3 (5) GROUND Y6 (6) COOLANT LEVEL SENSOR Y8 (7) + SUPPLY Y5 (9) FUEL PRE-FILTER / WATER IN FUEL Y9 (10)
Page 72 Wiring - Harness - PAS 100-150 HF 14: D2.2 14: D2.1 - 72 -...
Page 73 Description Item INTERFACE CONNECTOR ENGINE INTERFACE CONNECTOR CONTROL PANEL WARNING AIR FILTER D+ (ALTERNATOR) FUEL LEVEL GAUGE (1.SIGNAL - 2.RESERVE WARNING) GROUND COOLANT LEVEL SENSOR FEEDBACK PREHEAT + SUPPLY FUEL PRE-FILTER / WATER IN FUEL PANEL FUSES / RELAYS FUEL PUMP PRE -HEAT ECU CONNECTOR - 73 -...
Page 74 Connectors Sheet - 1 - 74 -...
Page 75 Sheet - 2 - 75 -...
Page 76 Sheet - 3 - 76 -...
Page 77 Sheet - 4 - 77 -...
Page 78 Technical specifications 10.1 Technical specifications of unit/engine/pump FEATURES Pump model Engine model PAS 100 HF PAS 150 HF Connection (mm/in) 100/4" 150/6" Weight (kg) Fuel tank capacity (l) Solids handling (mm) Dimensions A B C (mm) Engine Brand DEUTZ D2.9L4 DEUTZ TD2.9L4 2900 2900...
Page 79 FEATURES PAS 100 HF PAS 150 HF Vacuum pump oil tank (l) Mechanical seal oil tank (l) Non return check valve Ball type Ball type - 79 -...
Page 80 10.2 Dimension Drawing - PAS 100-150 HF - 80 -...
Page 81 10.3 Torque values 10.3.1 General torque values 10.3.2 Critical torque values The following tables list the recommended torques applied for general applications Assemblies at assembly of the compressor. Axles to frame: For hexagon screws and nuts with strength grade 8.8 Wheel nuts Bolts, axle/frame Thread size...
Page 82 10.4 Data plate QR CODE Every electrically driven pump is equipped with an identification plate which gives the following information: Type of unit Product Number Serial Number Weight (kg) Max capacity of the pump (m3/h) Max head (m) Max speed (rpm) Power (kW) Voltage (V) 10 Current (A)
Page 83 Spare parts 11.1 Ordering spare parts For spare parts see parts list. To avoid errors in delivery, please give the following information when ordering spare parts: – Pump type. – Pump serial number – Quantity required. – Part number. – Part description.
Page 84 A company within the Atlas Copco Group VARISCO S.p.A. Postal address Phone: +39 049 8294111 I.V.A. 00209080282 Terza Strada, 9 - Z.I. Nord Fax: +39 049 8076762 35129 PADOVA Italy For info, please contact your local Atlas Copco representative www.atlas copco.com p.1(10) - 84 -...
Page 85 A company within the Atlas Copco Group Postal address Phone: +39 049 8294111 I.V.A. 00209080282 Terza Strada, 9 - Z.I. Nord Fax: +39 049 8076762 35129 PADOVA Italy For info, please contact your local Atlas Copco representative www.atlas copco.com p.2(10) - 85 -...
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This manual is also suitable for:

Pas 100 hf t4f cnp ithPas 150 hf t4f cnp ithDeutz d2.9l4 Deutz td2.9l4