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Instruction manual for PAS Dry-Prime
Centrifugal Diesel Driven Pumps
English
PAS 4 WDM - W 250
PAS 4 DDM - W 260
PAS 4 WDM - A 250
PAS 4 DDM - A 260
PAS 6 WDM - W 250
PAS 4 DDM - W 250
PAS 6 WDM - A 250
PAS 4 DDM - A 250
PAS 8 WDM - W 305
PAS 6 DDM - W 250
PAS 8 WDM - A 305
PAS 6 DDM - A 250
PAS 4 DDM - W 220
PAS 8 DDM - W 305
PAS 4 DDM - A 220
PAS 8 DDM - A 305
Instruction Manual
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Table of Contents
Troubleshooting
Related Manuals for Atlas Copco PAS 4 WDM-W 250
Summary of Contents for Atlas Copco PAS 4 WDM-W 250
- Page 1 Instruction Manual Instruction manual for PAS Dry-Prime Centrifugal Diesel Driven Pumps English PAS 4 WDM - W 250 PAS 4 DDM - W 260 PAS 4 WDM - A 250 PAS 4 DDM - A 260 PAS 6 WDM - W 250 PAS 4 DDM - W 250 PAS 6 WDM - A 250 PAS 4 DDM - A 250...
- Page 3 PAS 8 DDM - W 305 PAS 4 DDM - A 220 PAS 8 DDM - A 305 Instruction manual .................. 5 Circuit diagrams ..................57 Original instructions Printed matter N° 2954 9780 00 ATLAS COPCO - PORTABLE ENERGY DIVISION www.atlascopco.com 06/2017...
- Page 4 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. Copyright 2017, Varisco SpA, PADOVA, ITALY. Any unauthorized use or copying of the contents or any part thereof is prohibited.
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Page 5: Table Of Contents
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 Adjustments and service Checks and trouble shooting . .43 Technical specifications ..55 procedures........33 Engine troubleshooting....43 5.4.1 Replacing the impeller....33 13.1 Technical specifications of Pump troubleshooting.....46 unit/engine/pump......55 5.4.2 Replacing the front wear plate..35 6.2.1 Overview of possible 13.2 Critical bolt connections....58...
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Page 7: Safety Precautions For Pumps
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: General Safety Precautions
The manufacturer does not accept any liability for any Whenever there is an indication or any suspicion 14 Keep the work area neat. Lack of order will increase damage arising from the use of non-original parts and for that an internal part of a machine is overheated, the the risk of accidents. -
Page 9: Safety During Transport And Installation
- connect the signalisation cable, check all lights 10 For maximum safety and efficiency of the lifting Safety during transport and and connect the pneumatic brake couplers, apparatus all lifting members shall be applied as installation - attach the safety break-away cable or safety near to perpendicular as possible. -
Page 10: Safety During Use And Operation
- above 85 dB(A): room to be classified as a noise- vibration hazards, etc., take the necessary steps to otherwise stated in the Atlas Copco Instruction hazardous area and an obvious warning shall be eliminate the risk of personnel injury. -
Page 11: Safety During Maintenance And Repair
Replace the damaged wires or correct the dangerous or dust, the respiratory organs must be protected and Parts shall only be replaced by genuine Atlas Copco condition before restarting. Make sure that all depending on the nature of the hazard, so must the replacement parts. -
Page 12: Tool Applications Safety
13 Use only lubricating oils and greases recommended and, if required, other body protection shall be or approved by Atlas Copco or the machine applied. manufacturer. Ascertain that the selected lubricants 20 When... -
Page 13: Battery Safety Precautions
Battery safety precautions When servicing batteries, always wear protecting clothing and glasses. 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. -
Page 14: Main Parts
Main parts General description The PAS 4-6-8 are suitable for handling clean water, dirty water or liquids up to 50°C, containing solids in suspension. The PAS 4-6-8 WDM/DDM-W... pumps are driven by a fluid-cooled diesel engine, manufactured by KOHLER. The PAS 4-6-8 DDM-A... pumps are driven by air-cooled diesel engine, manufactured by HATZ. SELF-PRIMING CENTRIFUGAL DIESEL DRIVEN PUMP: PAS 4WDM-W250, VACUUM PRIME CENTRIFUGAL DIESEL DRIVEN PUMP: PAS 4DDM-A220, PAS 4WDM-A250, PAS 6WDM-W250, PAS 6WDM-A250, PAS 8WDM-W305, PAS... - Page 15 Description Load-bearing frame (incorporates the fuel tank) Free-turning wheels Battery box Support leg (must be raised during transport) Pump drawbar Plug for draining fuel Suction pipe Delivery pipe Pump Kit lifting Engine Engine control and protection control panel Fuel level sight gauge Fuell tank filler cap Anti vibration mounting Separator...
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Page 16: Markings
Markings Markings provide instructions and information. They Presence of rotating parts. 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. A brief description of all markings provided on the Danger of crushing or cutting. -
Page 17: Field Of Application
Despite the pump is able to work with air within the In self-priming pump, the air is drawn into the pump suction line, Atlas Copco recommends to avoid this – Owner's manual for the unit; situation as far as possible in order to guarantee a due to the negative pressure created by the moving –... -
Page 18: Engine
The non-return valve has a dual function: it prevents the suction pipe from 2.4.7 Drain plugs and filler caps emptying when the pump is off; in the event of accidental emptying of the suction The drain holes for the engine oil, the coolant and the plug for the fuel, are located pipe, this holds a sufficient amount of liquid in the pump casing to prime the pump. -
Page 19: Electrical Features
CONTROL PANEL FOR MECHANICAL ENGINES Electrical features 2.5.1 Control and indicator panels CONTROL PANEL FOR TURBO COMMON RAIL ENGINES (KDI 1903 TCR) Description Ignition key switch. Position: "0 - 1 - 2". 0: Unit is turned off. 1: Ignition is turned on. 2: Engine start with mechanical starter protection. -
Page 20: Installation And Connection
Installation and connection Lifting Installation Before lifting the unit, check its dimensions and 3.2.1 Indoor installation weight, which can be found on the Data plate. If the pump is operated indoors, install an exhaust When lifting the unit, the hoist has to be placed in pipe of sufficient diameter to duct the engine exhaust such a way that the pump, which must be placed level, towards the outside. -
Page 21: Pipework
(for larger diameter, seek Atlas Copco’s advice). Where possible, avoid curves, elbows or construction liable to limit the flow of liquid to the pump. Install the pump as near to the liquid to be pumped as possible. -
Page 22: Operating Instructions
Fill the pump casing completely. When the pump is Operating instructions 4.2.1 Priming stopped, the casing does not empty and therefore it is not necessary to refill it. If the pump does not prime, do not In your own interest, always strictly operate it for more than 2 minutes to observe relevant... -
Page 23: Maintenance
Maintenance Maintenance schedules - ENGINE HATZ 5.1.1 Maintenance schedule for - PAS4DDM-A220 = PAS4DDM-A250 = PAS4WDM-A250 = 2M41; PAS8WDM-A305 = PAS 8 DDM-A305 = 4M41; PAS6WDM-A250 = PAS4 DDM-A260 = PAS6 DDM-A250 = 3M41 Before carrying out any maintenance activity, check that the start switch is in position O and that no electrical power is present on the terminals. 25 hrs Every 250 Every 500... - Page 24 25 hrs Every 250 Every 500 Every 1000 Every 2000 Every 5000 Maintenance schedule (running hours) Daily after Yearly hours hours hours hours hours start-up Maintain the dry air filter Replace the filter cartridge Check the air filter maintenance indicator Check and set the tappet clearance Replace the oil filter Replace the fuel filter...
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Page 25: Maintenance Schedules - Engine Kohler
Maintenance schedules - 5.1.2 ENGINE KOHLER 5.1.3 Maintenance schedule PAS4WDM-W250 = PAS6WDM-W250 = PAS4DDM-W220 = PAS4DDM-W250 (SAME ENGINE KDI 1903M); PAS4DDM-W260 = PAS6DDM-W250 = KDI2504M; PAS8WDM-W305 = PAS8DDM-W305 = KDI1903TCR Before carrying out any maintenance activity, check that the start switch is in position O and that no electrical power is present on the terminals. Every 250 Every 500 Every 1000... - Page 26 Every 250 Every 500 Every 1000 Every 2000 Every 5000 Maintenance schedule (running hours) Daily Yearly hours hours hours hours hours Replace fuel filter cartridge Replace alternator belt Change coolant Replace manifold hose (ait filter - intake manifold) Replace coolant hoses Replace fuel line hose Replace dry air cleaner cartridge After 6 checks with cleaning...
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Page 27: Pas
5.1.4 PAS...DDM... Every 500 Every 1000 Every 2000 Maintenance schedule (running hours) Daily Yearly hours hours hours Pump Check vacuum pump oil level Inspect mechanical seal; oil level; leaks Change vacuum pump oil Change mechanical seal oil Inspect wear plates, replace if necessary Inspect impeller, replace if necessary Clean the screen insert in the exhaust pipe Inspect vacuum pump diaphragm, replace if necessary... -
Page 28: Pas
5.1.5 PAS...WDM... Maintenance schedule (running hours) Daily Every 500 hours Every 2000 hours Yearly Pump Inspect mechanical seal; grease level; leaks Add mechanical seal grease Inspect wear plates, replace if necessary Inspect impeller, replace if necessary Inspect the mechanical seal, replace if necessary Inspect the check valve, replace if necessary Daily 1 month... -
Page 29: Use Of Maintenance Schedule
– When the pump has to be lifted out of the unit for The order number of the Service Paks are listed in the maintenance activities: PAS..DDM Atlas Copco Parts list (ASL). Order Service Paks at • Drain the water To avoid the risk of running dry, an oil tank with your local Atlas Copco dealer. -
Page 30: Vacuum Pump Check
PAS...WDM. 5.2.3 Vacuum pump check Engine maintenance The mechanical seal does not require maintenance procedures The vacuum pump is of diaphragm type; its during the first 500 hours of operation of the pump. lubrication is oil bath type. Refer to the Engine Operation Manual for a full After this period, grease the seal periodically through Running the vacuum pump with an insufficient maintenance schedule. -
Page 31: Engine Oil And Oil Filter Change
– The pH-meter can be ordered from Atlas Copco – Top up the engine oil level. with part number 2913 0029 00. – Run the engine for 1 minute and check the oil –... -
Page 32: Topping Up Of Coolant
– If the condition of the coolant is outside the limits, and local regulations. the complete coolant should be replaced (see – From the Atlas Copco Instruction book, determine section “Replacing the coolant”). the amount of 2954 9810 00 required and pour –... -
Page 33: Adjustments And Service Procedures
Adjustments and service procedures 5.4.1 Replacing the impeller - 33 -... - Page 34 - 34 -...
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Page 35: Replacing The Front Wear Plate
Empty the pump casing. 5.4.3 Replacing the check valve residual liquid may be found in the PAS 4 WDM - W250 pump casing, head and suction line. PAS 4 WDM - A250 Take the necessary precautions if the PAS 6 WDM - W250 liquid is hazardous. -
Page 36: Replacing The Mechanical Seal
– Wash the head with solvent to remove any residue – Reassemble the casing gasket (43) after smearing 5.4.4 Replacing the mechanical seal of grease and clean the seats of the stationary seal both sides with grease. Empty the pump casing. and lip seal thoroughly. -
Page 37: Replacing The Bearings
– Remove the flexible coupling hub and the shaft The vacuum pump and shaft are coupled with belts key. and pulleys. Remove the guard belt. Check that the belts are not damaged or broken every 500 hours or 6 – Remove the outer bearing cover months;... - Page 38 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.
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Page 39: Cleaning Cooler
5.4.8 Cleaning cooler 5.4.9 Cleaning the fuel tank 5.4.10 Battery care Before handling batteries, read the – Keep the water cooler clean to maintain the relevant safety precautions and act Observe all relevant environmental cooling efficiency. accordingly. and safety precautions. –... -
Page 40: 3Recharging A Battery
level in each cell once more; if required, add 5.4.10.5 Periodic battery service 5.4.11 Servicing air filter engine electrolyte. – Keep the battery clean and dry. 5.4.11.1 Main parts – Refit plugs and/or cover. – Keep the electrolyte level at 10 to 15 mm above –... -
Page 41: 2Recommendation
5.4.11.2 Recommendation 5.4.11.4 Replacing the air filter element 5.4.12 Replacing fuel filter element – Release the snap clips (1) and remove the dust trap The Atlas Copco air filters are (2). Clean the trap. specially designed – Remove the element (4) from the housing (5). -
Page 42: 5.4.13 Replacing Breather Filter
5.4.13 Replacing breather filter Cover O-ring Element Body While replacing the breather filter, also check the PCV (positive crankcase ventilation) valve: – Remove the cover (1) and element (3). – Press on the PCV valve and check that it moves smoothly. –... -
Page 43: Checks And Trouble Shooting
Checks and trouble Engine troubleshooting Not enough power – Restriction in a fuel pipe. shooting The table below gives an overview of the possible engine problems and their possible causes. – Fault in fuel lift pump. When a failure occurs, always –... - Page 44 – 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 45 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. –...
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Page 46: Pump Troubleshooting
Pump troubleshooting Before examining the possible causes of operating problems, ensure that all control instruments are working correctly. 6.2.1 Overview of possible operating problems Symptom Possible cause Corrective action Pump does not prime 1. Air leak in the joints or cracks in the Check that coupling and dampers are tight and inspect the suction line. - Page 47 Pump does not deliver liquid 1. The pump is not primed. See “Pump does not prime”. 2. The head required by the system is greater Revise the system design or re-select the pump. than the rated head of the pump. 3.
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Page 48: Residual Risks
Disassemble the casing and remove the foreign objects. Bearings do not last 1. Bearing are rusted. Change the bearings. Contact Atlas Copco Serviceability. Seal leaks 1. Seal is not working correctly. If the seal leaks during operation, it must be replaced. Contact Atlas Copco Service department. -
Page 49: Storage Of The Pump
Storage of the pump Storage Preparing for operation after storage – Store the pump in a dry, frost-free room which is well ventilated. Before operating the pump again, remove the wrapping, VCI paper and silica gel bags and check the pump thoroughly (go through the checklist “Before starting” on –... -
Page 50: Disposal
(for example sand, sawdust) and recyclable materials. dispose it according the applicable local disposal Your Atlas Copco pump consists for the most part of regulations. Do not drain into the sewage system or metallic materials, that can be remelted in steelworks surface water. -
Page 51: Options Available For Pas 4-6-8 Wdm- W/A 250
Options available for PAS 4-6-8 WDM- W/A 250 Circuit diagrams - PAS 4-6-8 WDM-A/DDM-A Fuse Fuse Battery Alternator Starter motor Starting switch Temperature switch Oil pressure Pressure switch for air filter (maintenance) Diode Terminal strip at instruments box Connector Solenoid - 51 -... -
Page 52: Wiring - Harness - Engine Kohler Kdi1903M-Kdi2504M
Wiring - Harness Engine Kohler KDI1903M-KDI2504M Legend (it is used to link the control panel) erature sensor - 52 -... -
Page 53: Engine Connector - Kohler Kdi1903M-Kdi2504M
Engine Connector Kohler KDI1903M-KDI2504M 1: Engine connector Position pins Side connector Control panel Connection description - 53 -... -
Page 54: Wiring - Harness - Engine Kohler 1903Tcr
Wiring - Harness - Engine Kohler 1903TCR Cables side Legend Panel - Relays and fuses Diagnostic port Supply mains Throttle Supply Panel A.C. pump Clogged air filter Relays/Fuses side Fuel filter Engine connector Optionals connector Vehicle side Engine connector Control Panel - 54 -... -
Page 55: Technical Specifications
Technical specifications 13.1 Technical specifications of unit/engine/pump FEATURES Pump model Engine model PAS 4D...220 / 4D...250 / 4W...250 KOHLER KDI 1903M HATZ 2M41 PAS 4D...260 / 6D...250 KOHLER KDI 2504M HATZ 3M41 PAS 6W...250 KOHLER KDI 1903M HATZ 3M41 PAS 8D...305 / 8W...305 KOHLER KDI 1903TCR HATZ 4M41 Ports (Pump model) - Page 56 FEATURES SELF-PRIMING CENTRIFUGAL PUMP Pump data Model PAS 4W...250 PAS 6W...250 PAS 8W..305 Spherical solids handling Diameter (mm) Impeller diameter (mm) Number of vanes Dimensions A B C (mm) 1730 2200 2035 1730 2200 2035 2238 2708 2543 D E (mm) 1335 1880 1335...
- Page 57 PAS 4 WDM - W 250: 780 kg PAS 4 DDM - W 220: 800 kg PAS 6 DDM - W 250: 865 kg PAS 4 WDM - A 250: 830 kg PAS 4 DDM - A 220: 850 kg PAS 6 DDM - A 220: 935 kg PAS 6 WDM - W 250: 800 kg PAS 4 DDM - W 260: 830 kg...
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Page 58: 13.2 Critical Bolt Connections
13.2 Critical bolt connections 13.2.1 Fastener torque of impeller nut THREAD FASTENER TORQUE MODEL (metric) Nm (max) PAS 4 M30x2 PAS 6 M30X2 PAS 8 M30X2 - 58 -... -
Page 59: 13.2.2 Torque Setting For Metric Thread Screws
13.2.2 Torque setting for metric thread screws Table of tightening torques for standard screws with coarse thread 12.9 IN CONFORMITY WITH STANDARD DIN 267 Pitch Torque values Torque values Ø screw Hex mm Coarse (mm) 1,25 1,75 1204 - 59 -... -
Page 60: Conversion List Of Si Units Into British Units
Varisco spa 35129 Padova – Italy: name and 13.3 Conversion list of SI units 13.4 Data plate address of manufacturer. into British units 1 bar 14.504 psi 0.035 oz 1 kg 2.205 lbs 1 km/h 0.621 mile/h 1 kW 1.341 hp (UK and US) 0.264 US gal 0.220 lmp gal (UK) 0.035 cu.ft... - Page 61 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 For info, please contact your local Atlas Copco representative Italy www.atlas copco.com p.1(10) - 61 -...
- Page 62 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) - 62 -...
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