Instruction Manual

for Portable Compressors

English

XAHS 146 Dd - XAHS 300 DD6

XATS 156 Dd - XATS 350 DD6
Engine Deutz
XA(S) 186 Dd - XA(S) 375 DD6
TCD
XAVS 166 Dd - XAVS 340 DD6
XAHS 186 Dd - XAHS 375 DD6
XATS 156 Dd - XATS 350 DD6 Engine Deutz
XA(S) 186 Dd - XA(S) 375 DD6 BF4M
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Instruction Manual
for Portable Compressors

XAHS 146 Dd
XATS 156 Dd
XA(S) 186 Dd
XAVS 166 Dd
XAHS 186 Dd

Original instructions

Printed matter N°
2954 2230 07 ATLAS COPCO - PORTABLE ENERGY DIVISION
11/2014 www.atlascopco.com
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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 from modifications, additions or
conversions made without the manufacturer's approval in writing.
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.

Copyright 2014, 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.

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Preface Table of contents 4.1.2 Towing instructions ............................... 28

Follow the instructions in this booklet and we 4.1.3 Height adjustment .................................. 29
guarantee you years of troublefree operation. It is a 1 Safety precautions ...................................... 7 4.1.4 Instructions ball coupling (option)......... 30
solid, safe and reliable machine, built according to 1.1 Introduction .................................................. 7 4.1.5 Lifting instructions................................. 30
the latest technology. 4.2 Starting/Stopping ....................................... 31
1.2 General safety precautions ........................... 8
Always keep the manual available near the machine. 4.2.1 Before starting ....................................... 31
1.3 Safety during transport and installation ....... 9
In all correspondence always mention the 4.2.2 Control panel ......................................... 31
1.4 Safety during use and operation................. 10
compressor type and serial number, shown on the 4.2.3 During operation .................................... 32
data plate. 1.5 Safety during maintenance and repair........ 11
1.6 Tool applications safety ............................. 12 5 Maintenance ............................................. 33
The company reserves the right to make changes
without prior notice. 1.7 Specific safety precautions......................... 13 5.1 Use of service paks .................................... 33
5.2 Preventive maintenance schedule for the
2 Leading particulars.................................. 14
compressor 33
2.1 Description of safety pictograms used in this 5.3 Oil specifications........................................ 37
manual 14
5.3.1 Compressor oil....................................... 38
2.2 General description .................................... 14 5.3.2 Engine oil............................................... 38
5.3.3 Compressor oil level check.................... 39
3 Main Parts................................................. 16
5.3.4 Daily check ............................................ 39
3.1 Compressor regulating system ................... 20 5.3.5 Check after a longer period without running
3.1.1 Overview (Load condition)................... 20 the compressor 39
3.1.2 Air flow.................................................. 21
5.4 Engine oil ................................................... 40
3.1.3 Oil system .............................................. 21
5.4.1 Engine oil level check............................ 40
3.1.4 Continuous regulating system................ 22
5.4.2 Engine oil and oil filter change.............. 40
3.2 Electrical system ........................................ 24 5.4.3 Compressor oil and oil filter change...... 40
3.2.1 Dip switches for
5.5 Compressor Oil Flushing Procedure .......... 41
XAHS 146 Dd, XATS 156 Dd and XA(S)
5.6 Coolant specifications ................................ 42
186 Dd 25
5.6.1 PARCOOL EG ...................................... 42
3.2.2 Dip switches for
5.6.2 Handling PARCOOL EG ...................... 43
XAVS 166 Dd and XAHS 186 Dd 25
5.7 Coolant check............................................. 43
3.3 Markings and information labels ............... 26
5.8 Topping up/replacing coolant .................... 43
4 Operating instructions ............................. 27 5.8.1 Topping up without draining from the
4.1 Parking, towing and lifting instructions ..... 27 cooling system 44
4.1.1 Parking instructions ............................... 27 5.8.2 Topping up after limited quantity draining
from the cooling system 45

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5.8.3 Replacing the coolant ............................. 46 6.8.3 Wheel bolts check .................................. 55
5.9 Cleaning coolers ......................................... 46 6.8.4 Wheel bearing adjustment...................... 56
5.10 Battery care................................................. 47 6.9 Towbar and overrun brake ......................... 57
5.10.1 Electrolyte .............................................. 47 6.9.1 Towbar and overrun brake check........... 57
5.10.2 Activating a dry-charged battery............ 47 6.9.2 Lubrication............................................. 58
5.10.3 Recharging a battery .............................. 47
5.10.4 Make-up distilled water.......................... 47 7 Problem solving ........................................ 60
5.10.5 Periodic battery service .......................... 47
8 Available options ...................................... 63
5.11 Storage........................................................ 48
5.12 Service paks................................................ 48 9 Technical specifications ........................... 64
5.13 Service kits ................................................. 48 9.1 Torque values ............................................. 64
5.14 Compressor element overhaul .................... 48 9.1.1 For general applications......................... 64
5.15 Liability ...................................................... 48 9.1.2 Critical torque values ............................. 64
9.2 Settings of shutdown switches and safety
6 Adjustments and servicing procedures .. 49 valves 65
6.1 Adjustment of the continuous regulating 9.3 Compressor/Engine/Generator specifications.
system 49 66
6.2 Air filter engine/compressor....................... 50 9.3.1 Reference conditions.............................. 66
6.2.1 Cleaning the dust trap ............................ 50 9.3.2 Limitations ............................................. 66
6.2.2 Recommendations .................................. 50 9.3.3 Performance data ................................... 67
6.2.3 Replacing the air filter element .............. 50 9.3.4 Design data............................................. 69
6.3 Air receiver................................................. 50
6.4 Safety valve ................................................ 50 10 Data plate .................................................. 71
6.5 Fuel system................................................. 51
11 Disposal ..................................................... 72
6.5.1 Fuel......................................................... 51
11.1 General ....................................................... 72
6.6 Brake (= option) adjustment....................... 51
11.2 Disposal of materials.................................. 72
6.7 Brake shoe adjustment................................ 51
6.7.1 Test procedure of brake cable adjustment... 12 Maintenance Log...................................... 73
52
6.7.2 Brake cable adjustment .......................... 53
6.8 Wheels ........................................................ 54
6.8.1 Wheel check ........................................... 54
6.8.2 Lubrication ............................................. 54

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Safety precautions
To be read attentively and acted accordingly before towing, lifting, operating, performing
maintenance or repairing the unit.

INTRODUCTION

The policy of Atlas Copco is to provide the users of It is the responsibility of management to appoint Take necessary steps to keep unauthorized persons
their equipment with safe, reliable and efficient operators with the appropriate training and skill for away from the unit and eliminate all possible sources
products. Factors taken into account are among each category of job. of danger at the unit.
others: When handling, operating, overhauling and/or
Skill level 1: Operator
- the intended and predictable future use of the performing maintenance or repair on Atlas Copco
products, and the environments in which they are An operator is trained in all aspects of operating the
unit with the push-buttons, and is trained to know the equipment, the mechanics are expected to use safe
expected to operate, engineering practices and to observe all relevant local
safety aspects.
- applicable rules, codes and regulations, safety requirements and ordinances. The following
- the expected useful product life, assuming proper Skill level 2: Mechanical technician list is a reminder of special safety directives and
service and maintenance, A mechanical technician is trained to operate the unit precautions mainly applicable to Atlas Copco
- providing the manual with up-to-date the same as the operator. In addition, the mechanical equipment.
information. technician is also trained to perform maintenance and These safety precautions apply to machinery
repair, as described in the instruction manual, and is processing or consuming air. Processing of any other
Before handling any product, take time to read the
allowed to change settings of the control and safety gas requires additional safety precautions typical to
relevant instruction manual. Besides giving detailed
system. A mechanical technician does not work on the application and are not included herein.
operating instructions, it also gives specific
live electrical components.
information about safety, preventive maintenance, Neglecting the safety precautions may endanger
etc. Skill level 3: Electrical technician people as well as environment and machinery:
Keep the manual always at the unit location, easy An electrical technician is trained and has the same - endanger people due to electrical, mechanical or
accessible to the operating personnel. qualifications as both the operator and the mechanical chemical influences,
technician. In addition, the electrical technician may - endanger the environment due to leakage of oil,
See also the safety precautions of the engine and
carry out electrical repairs within the various solvents or other substances,
possible other equipment, which are separately sent
enclosures of the unit. This includes work on live - endanger the machinery due to function failures.
along or are mentioned on the equipment or parts of
electrical components.
the unit. All responsibility for any damage or injury resulting
These safety precautions are general and some Skill level 4: Specialist from the manufacturer from neglecting these precautions or by non-
statements will therefore not always apply to a This is a skilled specialist sent by the manufacturer or observance of ordinary caution and due care required
particular unit. its agent to perform complex repairs or modifications in handling, operating, maintenance or repair, also if
to the equipment. not expressly mentioned in this instruction manual, is
Only people that have the right skills should be
In general it is recommended that not more than two disclaimed by Atlas Copco.
allowed to operate, adjust, perform maintenance or
repair on Atlas Copco equipment. people operate the unit, more operators could lead to
unsafe operating conditions.

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The manufacturer does not accept any liability for any GENERAL SAFETY PRECAUTIONS 9 Care shall be taken to avoid damage to safety
damage arising from the use of non-original parts and valves and other pressure-relief devices,
for modifications, additions or conversions made 1 The owner is responsible for maintaining the unit especially to avoid plugging by paint, oil coke or
without the manufacturer’s approval in writing. in a safe operating condition. Unit parts and dirt accumulation, which could interfere with the
accessories must be replaced if missing or functioning of the device.
If any statement in this manual does not comply with
unsuitable for safe operation.
local legislation, the stricter of the two shall be 10 Pressure and temperature gauges shall be checked
applied. 2 The supervisor, or the responsible person, shall at regularly with regard to their accuracy. They shall
Statements in these safety precautions should not be all times make sure that all instructions regarding be replaced whenever outside acceptable
interpreted as suggestions, recommendations or machinery and equipment operation and tolerances.
inducements that it should be used in violation of any maintenance are strictly followed and that the
11 Safety devices shall be tested as described in the
machines with all accessories and safety devices,
applicable laws or regulations. maintenance schedule of the instruction manual
as well as the consuming devices, are in good
to determine that they are in good operating
repair, free of abnormal wear or abuse, and are
condition. See the Preventive maintenance
not tampered with.
schedule for the compressor.
3 Whenever there is an indication or any suspicion
12 Mind the markings and information labels on the
that an internal part of a machine is overheated,
unit.
the machine shall be stopped but no inspection
covers shall be opened before sufficient cooling 13 In the event the safety labels are damaged or
time has elapsed; this to avoid the risk of destroyed, they must be replaced to ensure
spontaneous ignition of oil vapour when air is operator safety.
admitted. 14 Keep the work area neat. Lack of order will
4 Normal ratings (pressures, temperatures, speeds, increase the risk of accidents.
etc.) shall be durably marked. 15 When working on the unit, wear safety clothing.
5 Operate the unit only for the intended purpose and Depending on the kind of activities these are:
within its rated limits (pressure, temperature, safety glasses, ear protection, safety helmet
speeds, etc.). (including visor), safety gloves, protective
clothing, safety shoes. Do not wear the hair long
6 The machinery and equipment shall be kept clean,
and loose (protect long hair with a hairnet), or
i.e. as free as possible from oil, dust or other
wear loose clothing or jewellery.
deposits.
16 Take precautions against fire. Handle fuel, oil and
7 To prevent an increase in working temperature,
anti-freeze with care because they are
inspect and clean heat transfer surfaces (cooler
inflammable substances. Do not smoke or
fins, intercoolers, water jackets, etc.) regularly.
approach with naked flame when handling such
See the Preventive maintenance schedule for
substances. Keep a fire-extinguisher in the
the compressor.
vicinity.
8 All regulating and safety devices shall be
maintained with due care to ensure that they
function properly. They may not be put out of
action.

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SAFETY DURING TRANSPORT AND - check that the wheels are secure and that the 7 Lifting hooks, eyes, shackles, etc., shall never be
INSTALLATION tyres are in good condition and inflated bent and shall only have stress in line with their
correctly, design load axis. The capacity of a lifting device
Transport of the unit has to be done by authorized/ - connect the signalisation cable, check all lights diminishes when the lifting force is applied at an
experienced people. and connect the pneumatic brake couplers, angle to its load axis.
When towing, lifting or transporting the compressor ascertain that the signalisation cable can not 8 For maximum safety and efficiency of the lifting
in any way, the battery switch must always be drag on the ground when towing the unit, apparatus all lifting members shall be applied as
switched off. - attach the safety break-away cable or safety near to perpendicular as possible. If required, a
To lift a unit, all loose or pivoting parts, e.g. doors and chain to the towing vehicle, lifting beam shall be applied between hoist and
towbar, shall first be securely fastened. load.
- remove wheel chocks, if applied, and
Do not attach cables, chains or ropes directly to the disengage the parking brake, 9 Never leave a load hanging on a hoist.
lifting eye; apply a crane hook or lifting shackle - check whether springs on wheelchocks are 10 A hoist has to be installed in such a way that the
meeting local safety regulations. Never allow sharp missing or broken. object will be lifted perpendicular. If that is not
bends in lifting cables, chains or ropes. possible, the necessary precautions must be taken
2 To tow a unit use a towing vehicle of ample to prevent load-swinging, e.g. by using two
Helicopter lifting is not allowed. capacity. Refer to the documentation of the hoists, each at approximately the same angle not
It is strictly forbidden to dwell or stay in the risk zone towing vehicle. exceeding 30° from the vertical.
under a lifted load. Never lift the unit over people or 3 If the unit is to be backed up by the towing
residential areas. Lifting acceleration and retardation 11 Locate the unit away from walls. Take all
vehicle, disengage the overrun brake mechanism precautions to ensure that hot air exhausted from
shall be kept within safe limits. (if it is not an automatic mechanism). the engine and driven machine cooling systems
1 Before towing the unit: 4 Never exceed the maximum towing speed of the cannot be recirculated. If such hot air is taken in
- ascertain that the pressure vessel(s) is (are) unit (mind the local regulations). by the engine or driven machine cooling fan, this
depressurized, 5 Place the unit on level ground and apply the may cause overheating of the unit; if taken in for
- check the towbar, the brake system and the parking brake before disconnecting the unit from combustion, the engine power will be reduced.
towing eye. Also check the coupling of the the towing vehicle. Unclip the safety break-away 12 Before moving the compressor, switch it off.
towing vehicle, cable or safety chain. If the unit has no parking
- check the towing and brake capability of the brake or jockey wheel, immobilize the unit by
towing vehicle, placing chocks in front of and/or behind the
wheels. When the towbar can be positioned
- check that the towbar, jockey wheel or stand vertically, the locking device must be applied and
leg is safely locked in the raised position, kept in good order. The unit must always be used/
- keep hands/fingers away from the coupling parked/stored in a non publicly accessible area,
device and all other potential pinch points. locked away from access by unauthorized
Keep feet away from the towbar to avoid persons.
injury if it should slip, 6 To lift heavy parts, a hoist of ample capacity,
- ascertain that the towing eye can swivel freely tested and approved according to local safety
on the hook, regulations, shall be used.

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SAFETY DURING USE AND OPERATION 8 Do not use compressed air from any type of effective. A door should be kept open for a short
compressor, without taking extra measures, for period only e.g. for inspection or adjustment.
1 When the unit has to operate in a fire-hazardous breathing purposes as this may result in injury or 15 Periodically carry out maintenance works
environment, each engine exhaust has to be death. For breathing air quality, the compressed according to the maintenance schedule.
provided with a spark arrestor to trap incendiary air must be adequately purified according to local
sparks. legislation and standards. Breathing air must 16 Stationary housing guards are provided on all
always be supplied at stable, suitable pressure. rotating or reciprocating parts not otherwise
2 The exhaust contains carbon monoxide which is a
protected and which may be hazardous to
lethal gas. When the unit is used in a confined 9 Distribution pipework and air hoses must be of personnel. Machinery shall never be put into
space, conduct the engine exhaust to the outside correct diameter and suitable for the working operation, when such guards have been removed,
atmosphere by a pipe of sufficient diameter; do pressure. Never use frayed, damaged or before the guards are securely reinstalled.
this in such a way that no extra back pressure is deteriorated hoses. Replace hoses and flexibles
created for the engine. If necessary, install an before the lifetime expires. Use only the correct 17 Noise, even at reasonable levels, can cause
extractor. Observe any existing local regulations. type and size of hose end fittings and connections. irritation and disturbance which, over a long
Make sure that the unit has sufficient air intake period of time, may cause severe injuries to the
10 If the compressor is to be used for sand-blasting nervous system of human beings. When the sound
for operation. If necessary, install extra air intake
or will be connected to a common compressed-air pressure level, at any point where personnel
ducts.
system, fit an appropriate non-return valve (check normally has to attend, is:
3 When operating in a dust-laden atmosphere, place valve) between compressor outlet and the
the unit so that dust is not carried towards it by the connected sand-blasting or compressed-air - below 70 dB(A): no action needs to be taken,
wind. Operation in clean surroundings system. Observe the right mounting position/ - above 70 dB(A): noise-protective devices
considerably extends the intervals for cleaning direction. should be provided for people continuously
the air intake filters and the cores of the coolers. being present in the room,
11 Before removing the oil filler plug, ensure that the
4 Close the compressor air outlet valve before pressure is released by opening an air outlet - below 85 dB(A): no action needs to be taken
connecting or disconnecting a hose. Ascertain valve. for occasional visitors staying a limited time
that a hose is fully depressurized before only,
12 Never remove a filler cap of the cooling water
disconnecting it. Before blowing compressed air - above 85 dB(A): room to be classified as a
system of a hot engine. Wait until the engine has
through a hose or air line, ensure that the open end noise-hazardous area and an obvious warning
sufficiently cooled down.
is held securely, so that it cannot whip and cause shall be placed permanently at each entrance
injury. 13 Never refill fuel while the unit is running, unless to alert people entering the room, for even
5 The air line end connected to the outlet valve otherwise stated in the Atlas Copco Instruction relatively short times, about the need to wear
must be safeguarded with a safety cable, attached Book (AIB). Keep fuel away from hot parts such ear protectors,
next to the valve. as air outlet pipes or the engine exhaust. Do not
- above 95 dB(A): the warning(s) at the
smoke when fuelling. When fuelling from an
6 No external force may be exerted on the air outlet entrance(s) shall be completed with the
automatic pump, an earthing cable should be
valves, e.g. by pulling on hoses or by installing recommendation that also occasional visitors
connected to the unit to discharge static
auxiliary equipment directly to a valve, e.g. a shall wear ear protectors,
electricity. Never spill nor leave oil, fuel, coolant
water separator, a lubricator, etc. Do not step on or cleansing agent in or around the unit. - above 105 dB(A): special ear protectors that
the air outlet valves. are adequate for this noise level and the
14 All doors shall be shut during operation so as not spectral composition of the noise shall be
7 Never move a unit when external lines or hoses
to disturb the cooling air flow inside the provided and a special warning to that effect
are connected to the outlet valves, to avoid
bodywork and/or render the silencing less shall be placed at each entrance.
damage to valves, manifold and hoses.

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18 The unit has parts, which may be accidentally 25 Remember that where there is visible dust, the SAFETY DURING MAINTENANCE AND
touched by personal, of which the temperature finer, invisible particles will almost certainly be REPAIR
can be in excess of 80°C (176°F). The insulation present too; but the fact that no dust can be seen
or safety guard, protecting these parts shall not be is not a reliable indication that dangerous, Maintenance, overhaul and repair work shall only be
removed before the parts have cooled down to invisible dust is not present in the air. carried out by adequately trained personnel; if
room temperature. As it is technically not 26 Never operate the unit at pressures or speeds required, under supervision of someone qualified for
possible to insulate all hot parts or to install safety below or in excess of its limits as indicated in the the job.
guards around hot parts (e.g. exhaust manifold, technical specifications. 1 Use only the correct tools for maintenance and
exhaust turbine), the operator / service engineer repair work, and only tools which are in good
must always be aware not to touch hot parts when 27 Do not use aerosol types of starting aids such as
ether. Such use could result in an explosion and condition.
opening a machine door.
personal injury. 2 Parts shall only be replaced by genuine Atlas
19 Never operate the unit in surroundings where Copco replacement parts.
there is a possibility of taking in flammable or
toxic fumes. 3 All maintenance work, other than routine
attention, shall only be undertaken when the unit
20 If the working process produces fumes, dust or is stopped. Steps shall be taken to prevent
vibration hazards, etc., take the necessary steps to inadvertent starting. In addition, a warning sign
eliminate the risk of personal injury. bearing a legend such as ”work in progress; do
21 When using compressed air or inert gas to clean not start” shall be attached to the starting
down equipment, do so with caution and use the equipment. On engine-driven units the battery
appropriate protection, at least safety glasses, for shall be disconnected and removed or the
the operator as well as for any bystander. Do not terminals covered by insulating caps. On
apply compressed air or inert gas to your skin or electrically driven units the main switch shall be
direct an air or gas stream at people. Never use it locked in open position and the fuses shall be
to clean dirt from your clothes. taken out. A warning sign bearing a legend such
22 When washing parts in or with a cleaning solvent, as ”work in progress; do not supply voltage” shall
provide the required ventilation and use be attached to the fuse box or main switch.
appropriate protection such as a breathing filter, 4 Before dismantling any pressurized component,
safety glasses, rubber apron and gloves, etc. the compressor or equipment shall be effectively
23 Safety shoes should be compulsory in any isolated from all sources of pressure and the entire
workshop and if there is a risk, however small, of system shall be relieved of pressure. Do not rely
falling objects, wearing of a safety helmet should on non-return valves (check valves) to isolate
be included. pressure systems. In addition, a warning sign
bearing a legend such as ”work in progress; do
24 If there is a risk of inhaling hazardous gases,
not open” shall be attached to each of the outlet
fumes or dust, the respiratory organs must be
valves.
protected and depending on the nature of the
hazard, so must the eyes and skin. 5 Prior to stripping an engine or other machine or
undertaking major overhaul on it, prevent all
movable parts from rolling over or moving.

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6 Make sure that no tools, loose parts or rags are left 15 Protect the engine, alternator, air intake filter, 23 Make sure that oil, solvents and other substances
in or on the machine. Never leave rags or loose electrical and regulating components, etc., to likely to pollute the environment are properly
clothing near the engine air intake. prevent moisture ingress, e.g. when steam- disposed of.
7 Never use flammable solvents for cleaning (fire- cleaning. 24 Before clearing the unit for use after maintenance
risk). 16 When performing any operation involving heat, or overhaul, check that operating pressures,
8 Take safety precautions against toxic vapours of flames or sparks on a machine, the surrounding temperatures and speeds are correct and that the
cleaning liquids. components shall first be screened with non- control and shutdown devices function correctly.
flammable material.
9 Never use machine parts as a climbing aid.
17 Never use a light source with open flame for
10 Observe scrupulous cleanliness during inspecting the interior of a machine.
maintenance and repair. Keep away dirt, cover
the parts and exposed openings with a clean cloth, 18 Disconnect –battery-clamp before starting TOOL APPLICATIONS SAFETY
paper or tape. electrical servicing or welding (or turn battery-
switch in “off” position). Apply the proper tool for each job. With the
11 Never weld on or perform any operation
involving heat near the fuel or oil systems. Fuel 19 When repair has been completed, the machine knowledge of correct tool use and knowing the
and oil tanks must be completely purged, e.g. by shall be barred over at least one revolution for limitations of tools, along with some common sense,
steam-cleaning, before carrying out such reciprocating machines, several revolutions for many accidents can be prevented.
operations. Never weld on, or in any way modify, rotary ones to ensure that there is no mechanical Special service tools are available for specific jobs
pressure vessels. Disconnect the alternator cables interference within the machine or driver. Check and should be used when recommended. The use of
during arc welding on the unit. the direction of rotation of electric motors when these tools will save time and prevent damage to
starting up the machine initially and after any parts.
12 Support the towbar and the axle(s) securely if alteration to the electrical connection(s) or switch
working underneath the unit or when removing a gear, to check that the oil pump and the fan
wheel. Do not rely on jacks. function properly.
13 Do not remove any of, or tamper with, the sound- 20 Maintenance and repair work should be recorded
damping material. Keep the material free of dirt in an operator’s logbook for all machinery.
and liquids such as fuel, oil and cleansing agents. Frequency and nature of repairs can reveal unsafe
If any sound-damping material is damaged, conditions.
replace it to prevent the sound pressure level from
increasing. 21 When hot parts have to be handled, e.g. shrink
fitting, special heat-resistant gloves shall be used
14 Use only lubricating oils and greases and, if required, other body protection shall be
recommended or approved by Atlas Copco or the applied.
machine manufacturer. Ascertain that the
selected lubricants comply with all applicable 22 When using cartridge type breathing filter
safety regulations, especially with regard to equipment, ascertain that the correct type of
explosion or fire-risk and the possibility of cartridge is used and that its useful service life is
decomposition or generation of hazardous gases. not surpassed.
Never mix synthetic with mineral oil.

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SPECIFIC SAFETY PRECAUTIONS Pressure vessels Safety valves

Maintenance/installation requirements: 1 All adjustments or repairs are to be done by an
Batteries authorized representative of the valve supplier
1 The vessel can be used as pressure vessel or as
When servicing batteries, always wear protecting separator and is designed to hold compressed air (see also Preventive maintenance schedule for
clothing and glasses. for the following application: the compressor).
1 The electrolyte in batteries is a sulphuric acid - pressure vessel for compressor, 2 Only trained and technically competent personnel
solution which is fatal if it hits your eyes, and should consider overhaul, re-set or performance
- medium AIR/OIL,
which can cause burns if it contacts your skin. testing of safety valves.
Therefore, be careful when handling batteries, and operates as detailed on the data plate of the
vessel: 3 The safety valve is supplied with either a lead
e.g. when checking the charge condition.
security seal or crimped cover to deter
2 Install a sign prohibiting fire, open flame and - the maximum working pressure ps in bar (psi),
unauthorised access to the pressure regulation
smoking at the post where batteries are being - the maximum working temperature Tmax in device.
charged. °C (°F),
4 Under no circumstances should the set pressure of
3 When batteries are being charged, an explosive - the minimum working temperature Tmin in °C the safety valve be altered to a different pressure
gas mixture forms in the cells and might escape (°F), than that stamped on the valve without the
through the vent holes in the plugs. Thus an - the capacity of the vessel V in l (US gal). permission of the installation designer.
explosive atmosphere may form around the 2 The pressure vessel is only to be used for the 5 If the set pressure must be altered then use only
battery if ventilation is poor, and can remain in applications as specified above and in accordance correct parts supplied by Atlas Copco and in
and around the battery for several hours after it with the technical specifications. Safety reasons accordance with the instructions available for the
has been charged. Therefore: prohibit any other applications. valve type.
- never smoke near batteries being, or having 3 National legislation requirements with respect to 6 Safety valves must be frequently tested and
recently been, charged, re-inspection must be complied with. regularly maintained.
- never break live circuits at battery terminals, 4 No welding or heat treatment of any kind is 7 The set pressure should be periodically checked
because a spark usually occurs. permitted to those vessel walls which are exposed for accuracy.
4 When connecting an auxiliary battery (AB) in to pressure.
8 When fitted, the compressors should be operated
parallel to the unit battery (CB) with booster 5 The vessel is provided and may only be used with at pressures not less than 75% of the set pressure
cables: connect the + pole of AB to the + pole of the required safety equipment such as to ensure free and easy movement of internal
CB, then connect the – pole of CB to the mass of manometer, overpressure control devices, safety parts.
the unit. Disconnect in the reverse order. valve, etc.
9 The frequency of tests is influenced by factors
6 Draining of condensate shall be performed daily such as the severity of the operating environment
when vessel is in use. and aggressiveness of the pressurised medium.
7 Installation, design and connections should not be 10 Soft seals and springs should be replaced as part
changed. of the maintenance procedure.
8 Bolts of cover and flanges may not be used for 11 Do not paint or coat the installed safety valve.
extra fixation.
9 (Pressure) vessel maintenance is to be performed
by Atlas Copco.

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Leading particulars
DESCRIPTION OF SAFETY PICTOGRAMS GENERAL DESCRIPTION Compressor
USED IN THIS MANUAL The compressor casing houses two screw-type rotors,
mounted on ball and roller bearings. The male rotor,
This symbol draws your attention to driven by the engine, drives the female rotor. The
dangerous situations. The operation element delivers pulsation-free air.
concerned may endanger persons and Injected oil is used for sealing, cooling and
cause injuries. lubricating purposes.

This symbol is followed by Compressor oil system

supplementary information. 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.

The compressors type XAHS 146 Dd, XATS 156 Dd, Regulation
XA(S) 186 Dd, XAVS 166 Dd and XAHS 186 Dd are The compressor is provided with a continuous
silenced, single-stage, oil-injected screw regulating system and a blow-down valve which is
compressors, built for a nominal effective working integrated in the unloader assembly. The valve is
pressure, ranging from 7 bar (102 psi) up to 12 bar closed during operation by air receiver pressure and
(175 psi) (see chapter Technical specifications). opens by air receiver pressure via the compressor
element when the compressor is stopped.
Engine
When the air consumption increases, the air receiver
The compressors are driven by a liquid-cooled diesel pressure will decrease and vice versa.
engine.
This receiver pressure variation is sensed by the
The engine’s power is transmitted to the compressor regulating valve which, by means of control air to the
through a heavy-duty coupling. unloader and engine speed regulator, matches the air
output to the air consumption. The air receiver
pressure is maintained between the pre-selected
working pressure and the corresponding unloading
pressure.

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Cooling system Bodywork

The engine is equipped with a liquid cooler and The bodywork has openings at the shaped front and
intercooler. All compressors are equipped with an oil rear end for the intake and outlet of cooling air and
cooler. hinged door for maintenance and service operations.
The cooling air is generated by a fan, driven by the The bodywork is internally lined with sound-
engine. absorbing material.

Safety devices Lifting eye

A lifting eye is accessible when the small door at the
A thermal shut-down switch protects the compressor
against overheating. The air receiver is provided with top of the unit is unlocked.
a safety valve.
Control panel
The engine is equipped with low oil pressure and high
The control panel grouping the air pressure gauge,
oil temperature shut-down switches.
control switch etc., is placed in the center at the rear
end.
Frame and axle
The compressor/engine unit is supported by rubber Data plate
buffers in the frame.
The compressor is furnished with a data plate
The standard unit has a non-adjustable towbar with a showing the product code, the unit number and the
towing eye. working pressure (see chapter Data plate).
As an option the unit can be equipped with an
Serial number
adjustable towbar, an overrun and parking brake and
towing eyes type DIN, ball, ITA, GB, NATO, AC The serial number is located on the right-hand side
(France), (see chapter Available options). towards the front on the upper edge of the frame and
also on the data plate.
The braking system consists of an integrated parking
brake and overrunbrake. When driving backwards the
overrunbrake is not engaged automatically.

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Main Parts

(FCc)
(CLS) (IC)
(A) (CT)
(S)
(E) (VIe)
(AFce) (CC)
(EP) (F)
(VIce) (SL)
(SV)
(RV) (TB)
(AR)
(FPco) (BH)
(MPV)

(OC)

(FF)

(FFfp)

00
00 (SN)

(DPoc)

(OFe)
(FT)
(DSe)
(AFe)

(AOV)
(VV)
(OLG) (FCeo)
(OFce) (VV)
(FCft)
(CE) (CP) (FLG)

XAHS 146 Dd, XATS 156 Dd and XA(S) 186 Dd with some options

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Reference Name Reference Name

A Alternator IC Intercooler
AFce Air Filter (compressor element) MPV Minimum Pressure Valve
AFe Air Filter (engine) OC Oil Cooler
AOV Air Outlet Valves OFce Oil Filter (compressor element)
AR Air Receiver OFe Oil Filter (engine)
BH Brake Handle OLG Oil Level Gauge (compressor
CC Coolant Cooler element)
CE Compressor Element RV Regulating Valve
CLS Coolant Level Switch S Starting Motor
CP Control Panel SL Support Leg
CT Coolant Tank SN Serial Number
DPoc Drain Plug Oil Cooler SV Safety Valve
DSe Engine Oil Level Dipstick TB Towbar
E Engine VIce Vacuum Indicator (compressor
element)
EP Exhaust Pipe
VIe Vacuum Indicator (engine)
F Fan
VV Vacuator Valve
FCeo Filler Cap (engine oil)
FCft Filler Cap (fuel tank)
FCc Filler Cap (coolant)
FF Fuel Filter
FFfp Fuel Prefilter
FLG Fuel Level Gauge
FPco Filler Plug (compressor oil)
FT Fuel Tank

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(FCc)
(IC)
(A) (CLS) (CT)
(S) (FCeo)
(E) (VIe)
(AFce) (CC)
(VIce) (F)
(SV) (EP) (SL)
(RV)
(AR) (TB)
(FPco)
(BH)
(MPV)

(OC)

(FF)

(FFfp)
00
00

(SN)

(DPoc)

(OFe)
(FT)
(DSe)
(AOV) (AFe)
(OLG)
(OFce) (VV)
(FCft)
(FLG)
(CE) (CP)

XAVS 166 Dd and XAHS 186 Dd with some options

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Reference Name Reference Name

A Alternator IC Intercooler
AFce Air Filter (compressor element) MPV Minimum Pressure Valve
AFe Air Filter (engine) OC Oil Cooler
AOV Air Outlet Valves OFce Oil Filter (compressor element)
AR Air Receiver OFe Oil Filter (engine)
BH Brake Handle OLG Oil Level Gauge (compressor
CC Coolant Cooler element)
CE Compressor Element RV Regulating Valve
CLS Coolant Level Switch S Starting Motor
CP Control Panel SL Support Leg
CT Coolant Tank SN Serial Number
DPoc Drain Plug Oil Cooler SV Safety Valve
DSe Engine Oil Level Dipstick TB Towbar
E Engine VIce Vacuum Indicator (compressor
element)
EP Exhaust Pipe
VIe Vacuum Indicator (engine)
F Fan
VV Vacuator Valve
FCeo Filler Cap (engine oil)
FCft Filler Cap (fuel tank)
FCc Filler Cap (coolant)
FF Fuel Filter
FFfp Fuel Prefilter
FLG Fuel Level Gauge
FPco Filler Plug (compressor oil)
FT Fuel Tank

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COMPRESSOR REGULATING SYSTEM

OVERVIEW (LOAD CONDITION)

Reference Name
(AFce) (VI) AFce Air Filter (compressor element)
(SC) AFe Air Filter (engine)
AOV Air Outlet Valves
(VV)
AR Air Receiver
(AFE) (VI)
BDV Blow Down Valve
(SC)
BOV Blow Off Valve
(LV) (VV) CE Compressor Element
(RV)
(PG) CH Coupling Housing
CV Check Valve
(SV) DP Drain Plug
(FR)

(BOV) (SR) E Engine

(E) (OCce)
F Fan
(UV)
(UA)
FP Filler Plug
(VH) (CH) FR Flow Restrictor
(OS) (BDV)
LV Loading Valve
(CV)
(OF) MPV Minimum Pressure Valve
(AR) (SL) NRV Non Return Valve
(FP) OCce Oil Cooler (compressor element)
(AOV)
OF Oil Filter
(CE) (F)
(TS) OLG Oil Level Gauge
(DP)
OS Oil Separator
(SL)
(MPV) (NRV) (DP)
(OLG)
(DP)

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AIR FLOW OIL SYSTEM

Reference Name The system comprises: The system comprises:

PG Pressure Gauge AF Air filter AR/OS Air receiver/oil separator
RV Regulating Valve AR/OS Air receiver/oil separator OC Oil cooler
SC Safety Cartridge (option) CE Compressor element OF Oil filter
SL Scavenge Line UA/UV Unloader assembly with unloader valve
The lower part of the air receiver (AR) serves as an oil
SR Speed Regulator BDV Blow-down valve tank.
SV Safety Valve LV Loading valve Air pressure forces the oil from the air receiver/oil
TS Temperature Switch separator (AR/OS) through the oil cooler (OCce) and
Air drawn through the airfilter (AFce) into the oil filter (OF) to the compressor element (CE).
UA Unloader Assembly compressor element (CE) is compressed. At the
element outlet, compressed air and oil pass into the air The compressor element has an oil gallery in the
UV Unloader Valve bottom of its casing. The oil for rotor lubrication,
receiver/oil separator (AR/OS).
VH Vent Hole cooling and sealing is injected through holes in the
The check valve (CV) prevents blow-back of gallery.
VI Vacuum Indicator compressed air when the compressor is stopped. In
VV Vacuator Valve the air receiver/oil separator (AR/OS), most of the oil Lubrication of the bearings is ensured by oil injected
is removed from the air/oil mixture; the remaining oil into the bearing housings.
is removed by the separator element. The injected oil, mixed with the compressed air,
The oil collects in the receiver and on the bottom of leaves the compressor element and re-enters the air
the separator element. receiver, where it is separated from the air as
described in section Air flow. The oil that collects on
The air leaves the receiver via a minimum pressure the bottom of the oil separator element is returned to
valve (MPV) which prevents the receiver pressure the system through a scavenging line (SL), which is
from dropping below the minimum working pressure provided with a flow restrictor (FR).
(specified in section Limitations), even when the air
outlet valves are open. This ensures adequate oil The oil filter by-pass valve opens when the pressure
injection and prevents oil consumption. drop over the filter is above normal because of a
clogged filter. The oil then by-passes the filter
A temperature switch (TS) and a working pressure without being filtered. For this reason, the oil filter
gauge (WPG) are comprised in the system. must be replaced at regular intervals (see section
A blow-down valve (BDV) is fitted in the unloader Preventive maintenance schedule for the
assembly to automatically depressurise the air compressor).
receiver (AR) when the compressor is stopped.

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CONTINUOUS REGULATING SYSTEM

(RV)

(BOV) (SR)

(UV)
(UA)
(VH)

(AR)

(CE)

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The system comprises: The air output is controlled from maximum output The construction of the regulating valve (RV) is such
RV Regulating valve (100%) to no output (0%) by: that any increase (decrease) of the air receiver
1. Speed control of the engine between maximum pressure above the pre-set valve opening pressure
UA Unloader assembly results in a proportional increase (decrease) of the
load speed and unloading speed (the output of a
SR Speed regulator control pressure to the unloading valve and the speed
screw compressor is proportional to the rotating
regulator.
speed).
The compressor is provided with a continuous Part of the control air is vented into the atmosphere,
regulating system. This system is provided with a 2. Air inlet throttling.
and any condensate discharged, through the vent
blow-down valve, which is integrated in the unloader 3. Blow off valve (BOV). holes (VH).
assembly (UA). The valve is closed during operation
by air receiver pressure and opens by air receiver If the air consumption is equal to or exceeds the
pressure via the compressor element when the maximum air output, the engine speed is held at
compressor is stopped. maximum load speed and the unloading valve is fully
open.
When the air consumption increases, the air receiver
pressure will decrease and vice versa. This receiver If the air consumption is less than the maximum air
pressure variation is sensed by the regulating valve output, the regulating valve supplies control air to
unloader valve (UV) to reduce the air output and
which, by means of control air to the unloader,
holds air receiver pressure between the normal
matches the air output to the air consumption. The air
receiver pressure is maintained between the pre- working pressure and the corresponding unloading
selected working pressure and the corresponding pressure at approx. 1.5 bar (22 psi) above the normal
unloading pressure. working pressure.

When starting the compressor, the unloader valve When the air consumption is resumed, the blow off
(UV) is kept open by spring force, the engine runs at valve (BOV) closes and the unloader valve (UV)
maximum speed. The compressor element (CE) takes gradually opens the air intake and the speed regulator
(SR) increases the engine speed.
in air and pressure builds up inside the receiver (AR).

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ELECTRICAL SYSTEM

All compressors are equipped with a negative earthed system.

(9822 0893 12)

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DD6.book Page 25 Monday, November 10, 2014 11:25 AM

Reference Name Reference Name For correct functioning of the module,

the dip switches at the back of the
1 To be used with Cold Start Option. S5 Engine Low Oil Pressure Switch module should be positioned as follows.
2 To be used with Refinery S7 Overspeed Control Test Switch
Equipment. S8 Push Button
3 Position of DIP-switches. S9 Coolant Level Switch DIP SWITCHES FOR
X1 Module Connector XAHS 146 Dd, XATS 156 Dd AND XA(S) 186 Dd
B6 Fuel Level Sensor Y1 Fuel Stop Solenoid
F1 Circuit Breaker Standard (no coldstart) With coldstart option
Y2 Excess Fuel Provider
G1 Battery 12V Y3 Overspeed Solenoid Not used
G2 Charging Alternator Preheat-Coldstart
K0 Starter Solenoid Low fuel level
K5 Auxiliary Starter Relay Low coolant level
K6 Cold Start Relay
K9 Overspeed Relay
M1 Starter Motor DIP SWITCHES FOR
N4 Control Module XAVS 166 Dd AND XAHS 186 Dd
N5 Overspeed Control Module
P1 Hourmeter Standard (no coldstart) With coldstart option

P2 Glowplug Not used

P3 Fuel Level Gauge Preheat-Coldstart
S3 Compressor Temperature Switch Low fuel level
S4 Engine Temperature Switch Low coolant level

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DD6.book Page 26 Monday, November 10, 2014 11:25 AM

MARKINGS AND INFORMATION LABELS

Compressor outlet temperature too

On / off button. Service every 24 hours.
high.

Compressor outlet temperature. Hours, time. Warning! Part under pressure.

Prohibition to open air valves without

Compressor outlet pressure. Do not stand on outlet valves.
connected hoses.

Dangerous outlet gases. Compressor loaded. Start-Stop indication of switch.

Do not run the compressor with open

Danger, hot surface. Runlamp.
doors.

Electrocution hazard. Airfilter. Lifting permitted.

Atlas Copco mineral compressor oil. Compressor temperature too high. Use diesel fuel only.

Atlas Copco synthetic compressor oil.

4.75 bar
Rotation direction. (69 psi)
Tyre pressure.
Atlas Copco mineral engine oil.
Sound power level in accordance
Atlas Copco synthetic engine oil. Inlet. with Directive 2000/14/EC
(expressed in dB (A)).
Sound power level in accordance
Manual. Outlet. with Directive 2000/14/EC
(expressed in dB (A)).
Sound power level in accordance
Read the instruction manual before
Compressor oil drain. with Directive 2000/14/EC
working on the battery.
(expressed in dB (A)).

Read the instruction manual before Horizontal towbar position required in

Reset fuse.
starting. case of coupling.

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Operating instructions PARKING INSTRUCTIONS

PARKING, TOWING AND LIFTING

INSTRUCTIONS

Safety precautions
(4) (4)
Never load the vehicles in excess of the
permissible total weight.
Never overstress the coupling or
suspension system due to reckless or
aggressive driving or mishandling. (2)
(2)
Avoid subjecting the axles to any
impacts or jolting. Adapt your driving
speed at all times to the road conditions.
Ensure that wheels and tyres are not (1)
misaligned or out-of-balance.
Only use the jacking points indicated by Non-adjustable towbar with standard support leg without Parking position of jockey wheel
Atlas Copco. brakes
The operator is expected to apply all
It must be noted that, with the parking
relevant safety precautions, including (3) brake activated, the vehicle can roll back
those mentioned on the pages 7 - 13 of
about 30 cm until the braking force takes
this book.
full effect.
Attention:
When parking a compressor, secure support leg (1) or
Before putting the compressor into use, jockey wheel (2) to support the compressor in a level
check the brake system as described in position. Be sure that the jockey wheel (2) is blocked
section Brake (= option) adjustment. by the blocking pin (4).
After the first 100 km travel - Yearly or Apply parking brake by pulling parking brake handle
every 5000 km: (3) upwards. Place the compressor as level as
(2)
Check and retighten the wheel nuts and possible; however, it can be operated temporarily in
towbar bolts to the specified torque. See an out-of-level position not exceeding 15°. If the
section Height adjustment and section (4) compressor is parked on sloping ground, immobilize
Torque values. the compressor by placing wheel chocks (available as
option) in front of or behind the wheels.
Check the brake adjustment. See section Adjustable towbar with jockey wheel and brakes
Brake (= option) adjustment.

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TOWING INSTRUCTIONS

(1)

(3)
(2)

Locate the rear-end of the compressor upwind, away Label on towbar

from contaminated wind-streams and walls. Avoid
recirculation of exhaust air from the engine. This Inspections, prior to each run
causes overheating and engine power decrease. • Check tyre pressure and tyre condition
• Check wheel fixation
• Check screwed joints on firm seating.
• Check functioning of lighting and braking
systems (option)
• The jockey wheel must be parallel to the direction
of travel at all times.
• Inspect the coupling. The ball joint must fully
enclose the ball and be locked.
• At height adjustable towing facility (option),
check the joint connection for a tight fit.

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DD6.book Page 29 Monday, November 10, 2014 11:25 AM

HEIGHT ADJUSTMENT
(with adjustable towbar)
Before towing the compressor, ensure • Remove spring pin (1).
that the towing equipment of the vehicle • Release locking nut (2) with support tools
matches the towing eye or ball connector (B) (Extension tube 3).
and ensure that the service doors are
closed and locked properly. • Adjust required height of the towbar.
(A)
(3) • Tighten locking nut (2) by hand first.
For both non-adjustable - and adjustable towbar, the
(2) • Secondly tighten locking nut (2) with a tightening
towbar should be as level as possible and the
compressor and towing eye end in a level position. torque corresponding to table. With an extension
(1) tube (3) (”A” corresponding to table) and
Push the hand brake lever (1) completely downwards handforce (”B” corresponding to table) easy
and connect breakaway cable (2) to the vehicle. tightening is possible.

X*
Secure jockey wheel (3) or support leg in the highest

XX
possible position (see figure). The jockey wheel is • Fix locking nut (2) with spring pin (1).
prevented from turning.
Attention:

Before towing the compressor, make • Height adjustment should be undertaken on

sure that the joints of the towbar are levelled ground and in coupled condition.
secured with maximum strength without
damaging the towbar. Be sure that there • When readjusting, make sure that the front point
is no clearance between the teeth of the of the towbar is horizontal with the coupling
joints. point.
• Before starting a trip, ensure that the adjustment
shaft is secure, so that stability and safety is
guaranteed while driving. If necessary, tighten the
locking nut (2) corresponding with table.

For specific instruction see below!

Type M [Nm/lbf.ft.] ”A” [mm/in] ”B” [N/lbf]

ZV 2000 250 - 300 / 184.5 - 221.4 600 / 23.4 420 - 500 / 94.5 - 112.5
ZV 2500 350 - 400 / 258.3 - 295.2 600 / 23.4 580 - 660 / 130.5 - 148.5

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INSTRUCTIONS BALL COUPLING (OPTION) LIFTING INSTRUCTIONS

Coupling:
Open coupling jaw by pulling the lever vigorously
upwards in the direction of the arrow. Lower the (1)
opened coupling onto the ball of the vehicle coupling
and the lever will automatically be lowered. Closing
and locking are carried out automatically. Check the (2)
"+" (see figure) position!
Connect the breakaway cable and electrical plug
(option) to the towing vehicle. Raise the jockey wheel
up fully and secure by firmly clamping it. Release
parking brake before setting off.
Visual check: the ball should no longer be visible
in coupled condition.

Uncoupling: When lifting the compressor, the hoist has to be

The handle of the ball coupling and the Lower the jockey wheel. Disconnect breakaway cable placed in such a way that the compressor, which must
handbrake lever may never be used as a and electrical plug. Pull the lever vigorously upwards be placed level, is lifted vertically. Keep lifting
manoeuvring aid; internal components in the direction of the arrow and hold. Wind down acceleration and retardation within safe limits.
may get damaged! jockey wheel (option) and lift the compressor off the Preferably use the lifting eye (1) herefore open the
ball of the towing vehicle. small door (2).
The coupling (ball coupling) on the tow bar is type
approved. The maximum load at the coupling may not Secure the compressor by means of a wheel chock
be exceeded. and/or by applying the parking brake. Lifting acceleration and retardation
must be kept within safe limits (max. 2g).
When coupling lower the jockey wheel to the ground.
Reverse the car up to the compressor or, in the case of Helicopter lifting is not allowed.
a small compressor, manoeuvre the compressor up to Lifting is not allowed when the unit is
the car's trailer coupling. running.

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STARTING/STOPPING CONTROL PANEL

BEFORE STARTING
(P1) (H1) (H2) (H3) (H4) (N4)
1. Before initial start-up, prepare battery for
operation if not already done. See section Battery
care.
2. With the compressor standing level, check the
level of the engine oil. Add oil, if necessary, up to
the upper mark on the dipstick. Consult the 000 0 (F1)
Engine Operation Manual for the type and
viscosity grade of the engine oil.
3. Check the level of the compressor oil. See section
Compressor regulating system. The pointer of
the oil level gauge (OLG) should register in the
green range. Add oil if necessary. See section Oil
specifications for the oil to be used.
Before removing the oil filler plug (FP),
ensure that the pressure is released by
opening an air outlet valve. (LV) (PG) (H5) (H6) (H7) (H8) (S)

4. Check that the fuel tank contains sufficient fuel.

Top up, if necessary. Consult the Engine P1 Hourmeter
Operation Manual for the type of fuel. F1 Circuit Breaker Button
5. Drain any water and sediment from the fuel filter PG Working pressure gauge
until clean fuel flows from the drain cock. LV Loading Valve
N4 Control Module
6. Press vacuator valves (VV) of the air filters to
remove dust. S Start/Stop Button
H1 LED (green) Fuel ON
7. Check the air filter vacuum indicators (VI). If the
H2 LED (green) Preheat (option)
yellow piston reaches the red marked service
range, replace the filter element. Reset the H3 LED (red) Charge Indication
indicator by pushing the reset button. H4 LED (red) Compressor Outlet Temperature
H5 LED (red) Engine Oil Temperature
8. Open air outlet valve to allow air flow to the
atmosphere. H6 LED (red) Engine Oil Pressure
H7 LED (red) Low Coolant
H8 LED (red) Low Fuel

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DURING OPERATION

Fault situations and protective devices (Also refer When the engine is running, the air
Never push the start button when the
to chapter Problem solving): outlet valves (ball valves) must always be
engine is running.
• The starter motor is protected against prolonged in a fully opened or fully closed position.
Make sure the fuel tank is filled up. starting.
(max. cranking time: 20 sec. (60 sec. for XAHS Regularly carry out following checks:
Before starting, first operate the circuit breaker button 186 Dd)).
(F1) at the right side of the control panel (open right- 1. That regulating valve (see section Main Parts,
hand service door first). • A fault which occurs with the engine, either RV) is correctly adjusted, i.e. starts decreasing the
alternator voltage (too low), coolant temperature engine speed when reaching the preset working
To start, the start/stop button (S) is switched to too high, oil pressure too low or fuel level too low pressure in the receiver.
position ”I”, the green fuel ON lamp (H1), the red will always and immediately cause the engine to
charge indication lamp (H3) and preheat lamp (H2) cut out and one of the control lamps H3, H5, H6, 2. Check the air filter vacuum indicators (see section
go on (preheat lamp only, if ”cold start” option is H7 or H8 to light up. Main Parts, VI). If the yellow piston reaches the
installed). After preheating, the preheat lamp goes red marked service range, replace the filter
out. Push the start/stop button in position ” ”. 20 • When the outlet temperature of the element element. Reset the indicators by pushing the reset
sec. (60 sec. for XAHS 186 Dd) cranking, 1 min. rest becomes too high, a thermocontact will also button.
(= a cycle). Max. 3 cycles are allowed. The starter switch off the unit immediately.
Control lamp H4 will light up. The doors must be closed during
motor will set the engine in motion. Lamps H1 and
operation and may be opened for short
H3 will go out as soon as the engine has been started. • The control lamps will remain on untill the unit periods only.
After the start/stop button is released, it automatically has been reset (start button switched to position
springs back to position ”I”. ”0”).
Run the engine a few minutes at no-load to warm up.
When the engine is running smoothly, press loading
valve (LV) and release as soon as pressure starts to
build up.
Shutting down is simply done by pushing the start
button in the ”0” position.
The control panel in addition indicates receiver
pressure (PG) and accumulated operating hours (P1).

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Maintenance
USE OF SERVICE PAKS PREVENTIVE MAINTENANCE SCHEDULE FOR THE COMPRESSOR
Service Paks include all genuine parts needed for The schedule contains a summary of the maintenance The maintenance schedule has to be seen as a
normal maintenance of both compressor and engine. instructions. Read the respective section before taking guideline for units operating in a dusty environment
maintenance measures. typical for compressor applications. Maintenance
Service Paks minimize downtime and keep your
schedule can be adapted depending on application
maintenance budget low. When servicing, replace all disengaged packings, e.g.
gaskets, O-rings, washers. environment and quality of maintenance.
Order Service Paks at your local Atlas Copco dealer.
For engine maintenance refer to Engine Operation
Manual.

To determine the maintenance intervals, use service hours, or calendar time, whichever occurs first.
Maintenance schedule (running hrs) Daily 50 hrs after Every Every Every Yearly
initial start-up 500 hrs 1000 hrs 2000 hrs
Service Paks
XAHS 146 Dd - XAHS 300 DD6 Deutz TCD 2912 4499 05 2912 4501 06
XATS 156 Dd - XATS 350 DD6 Deutz TCD 2912 4499 05 2912 4502 06
XA(S) 186 Dd - XA(S) 375 DD6 Deutz TCD
XATS 156 Dd - XATS 350 DD6 Deutz BF4M 2912 4306 05 2912 4337 06
XA(S) 186 Dd - XA(S) 375 DD6 Deutz BF4M
XAVS 166 Dd - XAVS 340 DD6 Deutz TCD 2912 4500 05 2912 4503 06
XAHS 186 Dd - XAHS 375 DD6 Deutz TCD
Oil Separator Kit 2911 0075 00
For the most important subassemblies, Atlas Copco has developed service kits that combine all wear parts. These service kits offer you the benefits of genuine parts,
save administration costs and are offered at a reduced price, compared to individual components. Refer to the parts list for more information on the contents of the
service kits.
Drain water from fuel filter x
Empty air filter vacuator valves x
Check engine oil level (if necessary top up) x
Check compressor oil level (if necessary top up) x
(to be continued on page 34)

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Maintenance schedule (running hrs) Daily 50 hrs after Every Every Every Yearly
(continuation of page 33) initial start-up 500 hrs 1000 hrs 2000 hrs
Check coolant level x
Check/Fill fuel level (3) x
Check control panel x
Check on abnormal noise x
Check electrical system cables for wear x x x x
Check for leaks in engine-, compressor-, air-, oil-, or fuel x x x x x
system
Check torque on critical bolt connections x x x x x
Check electrolyte level and terminals of battery x x x x x
Check engine (minimum and maximum) speed x x x x x
Hoses and clamps - Inspect/Replace x x x x
Drain/Clean fuel tank water and sediments (1) x x x x
Check air intake vacuum indicators (1) x x x x
Change engine oil (2) x x x x
Replace engine oil filter (2) x x x x
Replace fuel (pre)filters (6) x x x x
Clean flow restrictor in oil scavenge line x x x x
Adjust engine inlet and outlet valves (2) x x x
Check/Test glow plugs - grid heater x x x x
Clean after cooler (option) (1) x x x x
Clean oil cooler(s) (1) x x x x
Clean radiator (1) x x x x
Clean intercooler (1) x x x x
Check functioning of regulating valve x x x
Replace compressor oil filter(s) (5) x x x
Test safety valve (9) x x x
(to be continued on page 35)

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Maintenance schedule (running hrs) Daily 50 hrs after Every Every Every Yearly
(continuation of page 34) initial start-up 500 hrs 1000 hrs 2000 hrs
Replace bleed-off valve unloader x x x
Check rubber flexibles (10) x x x
Replace DD/PD/QD filter (option) x x x
Change compressor oil (1) (7) x x x
Replace oil separator element x x x
Replace air filter element (1) x x x
Inspection by Atlas Copco service technician x x x
Grease hinges x
Check emergency stop x
Analyse coolant (4) (8) x
Check/Replace safety cartridge x
Inspect starter motor x
Inspect turbocharger x
Inspect waterpump x
Inspect alternator x
(to be continued on page 36)

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Notes Maintenance schedule (km) Daily 50 km Every Every Yearly

(continuation of page 35)
after initial 500 2000
start-up km km
1. More frequently when operating in a
dusty environment. To determine the maintenance intervals, use mileage indication in km or calender time, whichever occurs
2. Refer to engine operation manual. first.
3. After a days work. Check towbar, handbrake lever, spring actuator, x x x x x
4. Yearly is only valid when using reversing lever, linkage and all movable parts for
PARCOOL. Change coolant every 5 ease of movement
years. Check height of adjusting facility x x
5. Use Atlas Copco oil filters, with by- Check coupling head x x x
pass valve as specified in the parts list.
6. Gummed or clogged filters means fuel Check tyre pressure x x x x
starvation and reduced engine Oil or grease brake lever and moving parts such as x x x
performance. bolts and joints
7. See section Oil specifications. Grease coupling head, towbar bearings at the x x x
8. The following part numbers can be housing of the overrun brake
ordered from Atlas Copco to check on
inhibitors and freezing points: Check torque of wheel nuts x x x
• 2913 0028 00 refractometer Check brake system (if installed) and adjust if x x x
• 2913 0029 00 pH meter necessary
9. See section Safety valve. Lubricate torsion bar axle trailing arm x x
10. Replace all rubber flexibles every 6 Grease sliding points on height adjusting parts x x
years.
Check tyres for uneven wear x x
For other specific engine and alternator
requirements refer to specific manuals. Check safety cable for damage x x
Check hub cap for firm seating x x
Check Bowden cable on height adjustable x x
Keep the bolts of the housing, the lifting connection device for damage
beam, tow bar and axles securely Check/adjust lateral play of wheel bearing x
tightened. For torque values see section (compact bearing)
Technical specifications.
Check brake lining wear x

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OIL SPECIFICATIONS

It is strongly recommended to use Atlas PAROIL from Atlas Copco is the ONLY oil tested PAROIL releases excess heat efficiently, whilst
Copco branded lubrication oils for both and approved for use in all engines built into Atlas maintaining excellent bore-polish protection to limit
compressor and engine. If you want to Copco compressors and generators. oil consumption.
use another brand of oil, consult Atlas Extensive laboratory and field endurance tests on PAROIL has an excellent Total Base Number (TBN)
Copco. Atlas Copco equipment have proven PAROIL to retention and more alkalinity to control acid
match all lubrication demands in varied conditions. It formation.
High-quality, mineral, hydraulic or synthesized meets stringent quality control specifications to
hydrocarbon oil with rust and oxidation inhibitors and ensure your equipment will run smoothly and PAROIL prevents Soot build-up.
anti-foam and anti-wear properties is recommended. reliably. PAROIL is optimized for the latest low emission
The viscosity grade should correspond to the ambient The quality lubricant additives in PAROIL allow for EURO -3 & -2, EPA TIER II & III engines running on
temperature and ISO 3448, as follows: extended oil change intervals without any loss in low sulphur diesel for lower oil and fuel consumption.
performance or longevity. PAROIL E is a mineral based high performance
Never mix synthetic with mineral oil. PAROIL provides wear protection under extreme diesel engine oil with a high viscosity- index. Atlas
conditions. Powerful oxidation resistance, high Copco PAROIL E is designed to provide a high level
Remark: of performance and protection under ‘standard’
chemical stability and rust- inhibiting additives help
When changing from mineral to reduce corrosion, even within engines left idle for ambient conditions from -10°C (14°F) onward.
synthetic oil (or the other way around), extended periods. PAROIL E xtra is a Synthetic ultra high performance
you will need to do an extra rinse: PAROIL contains high quality anti-oxidants to diesel engine oil with a high viscosity- index. Atlas
After a complete change over to control deposits, sludge and contaminants that tend to Copco PAROIL E xtra is designed to provide
synthetic oil, run the unit for a few build up under very high temperatures. excellent lubrication from start-up at temperatures as
minutes to allow proper and complete low as -25°C (-13°F).
PAROIL’s detergent additives keep sludge forming
circulation of the synthetic oil. particles in a fine suspension, instead of allowing
Then drain the synthetic oil again and them to clog your filter and accumulate in the valve/
fill again with new synthetic oil. To set rocker cover area.
correct oil levels, follow the normal
instructions.

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COMPRESSOR OIL ENGINE OIL

Mineral compressor oil PAROIL M

Liter US gal Order number
can 5 1.3 1615 5947 00
can 20 5.3 1615 5948 00
barrel 209 55.2 1615 5949 00

Synthetic compressor oil PAROIL S

Liter US gal Order number
can 5 1.3 1630 0160 00
can 20 5.3 1630 0161 00
barrel 209 55.2 1630 0162 00
container 1000 265 1630 0163 00

Mineral engine oil PAROIL E

Liter US gal Order number
Choose your compressor oil based on the ambient can 5 1.3 1615 5953 00 Choose your engine oil based on the ambient
temperatures in the actual operating area. temperatures in the actual operating area.
can 20 5.3 1615 5954 00
barrel 209 55.2 1615 5955 00

Synthetic engine oil PAROIL E xtra

Liter US gal Order number
can 5 1.3 1630 0135 01
can 20 5.3 1630 0136 01
barrel 209 55.2 1626 0102 00

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COMPRESSOR OIL LEVEL CHECK DAILY CHECK CHECK AFTER A LONGER PERIOD
WITHOUT RUNNING THE COMPRESSOR
Check the compressor oil level daily, after running
the compressor. 1. Depending on the level indicator, check the oil
level via:
The compressor oil level needs to be • the pointer of the oil level gauge (1). The
checked with the compressor in an pointer must register in the green area.
horizontal position after running the
compressor to warm up so that the • the oil filler plug. The level must be between
thermostatic valve is open. the two markings as indicated in the label on
the oil vessel.
1. Stop the compressor with closed air outlet valve
2. If the oil level is too low, remove the oil filler plug
(1) (3) and let it rest for a short period, to allow the
system to relief pressure inside the vessel and (2) and check if there is still oil in the vessel
(2)
settle down the oil. • No oil in the vessel: Top up the compressor
2. Depending on the level indicator, check the oil with oil until the pointer of the oil level gauge
level via: is in the upper part of the green area or the oil
(3) level is at the upper level as indicated on the
• the pointer of the oil level gauge (1). The label and follow the steps as described above
pointer must register in the green area. in Daily check.
• the oil filler plug. The level must be between • Oil in the vessel: Start up the unit to warm up
the two markings as indicated in the label on and give time for the thermostatic valve to
the oil vessel. open. Stop the compressor with closed outlet
3. If the oil level is too low, add oil via the oil filler valve (3) and follow the steps described above
plug (2) in Daily check.

Before removing the oil filler plug, At temperatures below 0°C, you have to
ensure that the pressure is released by load the compressor to be sure that the
opening the air outlet valve (3) and compressor thermostat will be open.
checking the vessel pressure on the
controller or the pressure gauge.
4. Top up with oil until:
• the pointer of the oil level gauge is in the upper
part of the green area
• the oil level is at the upper level as indicated on
the label
5. Reinstall and tighten the filler plug.

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DD6.book Page 40 Monday, November 10, 2014 11:25 AM

ENGINE OIL COMPRESSOR OIL AND OIL FILTER CHANGE

ENGINE OIL LEVEL CHECK 2. Drain the compressor oil by removing all relevant
drain plugs. Drain plugs are fitted at the air
receiver (DPar), compressor element (DPcv,
Never mix oils of different brands or DPosv) and compressor oil cooler (DPoc). Catch
types. the oil in a drain pan. Unscrew the filler plug (2) to
Use only non-toxic oils where there is a speed up draining. After draining, reposition and
risk of inhaling delivered air. tighten the drain plugs.
(2)
(4)
00
00

3. Remove the oil filters (3), e.g. by means of a

Consult the Engine Operation Manual for oil special tool. Catch the oil in a drain pan.
specifications and viscosity recommendations. 4. Clean the filter seat on the manifold, taking care
For intervals, see Preventive maintenance schedule that no dirt drops into the system. Oil the gasket of
for the compressor. the new filter element. Screw it into place until the
gasket contacts its seat, then tighten one half turn
Check engine oil level in accordance to the (5) only.
instructions in the Engine Operation Manual and if (3) (1)
necessary, top up with oil. 5. Fill the air receiver until the pointer of the oil level
The quality and the temperature of the oil determine gauge is in the upper part of the green area. Be
the oil change interval. sure that no dirt gets into the system. Reinstall and
tighten the filler plug (2).
The prescribed interval is based on normal operating
ENGINE OIL AND OIL FILTER CHANGE conditions and an oil temperature of up to 100 °C 6. Start the compressor and let it run unloaded for a
(212 °F) (see section Preventive maintenance few minutes.
See section Preventive maintenance schedule for
the compressor. schedule for the compressor). 7. Stop the compressor, wait a few minutes and top
When operating in high ambient temperatures, in very up with oil until the pointer of the oil level gauge
dusty or high humidity conditions, it is recommended is in the upper part of the green area.
to change the oil more frequently.
Never add more oil. Overfilling results in
In this case, contact Atlas Copco. oil consumption.

1. Run the compressor until warm. Close the outlet

valve(s) (1) and stop the compressor. Wait until
the pressure is released through the automatic
blow-down valve. Unscrew the oil filler plug (2)
by a single turn. This uncovers a vent hole, which
permits any pressure in the system to escape.

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COMPRESSOR OIL FLUSHING PROCEDURE

Not respecting compressor oil changing 4. Check the interior of the oil vessel (see pictures).
intervals in accordance with the If varnish deposits are discovered, contact Atlas
maintenance schedule, can lead to Copco Service dept. and do not continue.
serious problems, including fire hazard! 5. Put in a new oil separator, screw on new
The manufacturer does not accept any compressor oil filter(s) and close the oil vessel
liability for damage arising from not according to the instructions.
following the maintenance schedule or
not using genuine parts. 6. Fill the oil vessel with the minimum amount of
replacement oil, run the compressor under light
To avoid problems when changing over to a new type load conditions for 30 minutes.
of oil (see table) a special Compressor Oil Flushing 7. Thoroughly drain the system when the oil is
Procedure has to be followed. The procedure is only warm, leaving as little oil in the system as
valid in case the replaced oil has not exceeded its possible, especially in dead areas, if possible blow
lifetime. For more information consult Atlas Copco Vessel cover
out remaining oil by pressurising the oil. contaminated clean
Service dept.
8. Fill the system with the final oil charge.
Aged oil can be recognized best by using an oil
sampling analysis program. Indicators for aged oil are 9. Run the compressor under light load conditions
strong smell, or contamination such as sludge and for 15 minutes and check for leakage.
varnish inside the oil vessel and oil stop valve or a 10. Check the oil level and top up if necessary.
brownish colour of the oil.
11. Collect all waste lubricant used during the
Whenever aged oil is discovered, eg. when changing flushing process and dispose of it in accordance
the oil separator, contact Atlas Copco Service dept. to with the applicable procedures for managing
have your compressor cleaned and flushed. waste lubricant.
1. First thoroughly drain the system when the oil is
warm, leaving as little oil in the system as
possible, especially in dead areas, if possible blow
out remaining oil by pressurising the oil system. Vessel
Check the instruction manual for detailed contaminated clean
description.
2. Remove the compressor oil filter(s).
PAROIL M PAROIL S
3. Open the oil vessel and remove the oil separator
element. PAROIL M draining * flushing
Instructions on replacing the oil PAROIL S draining ** draining *
separator element are available from * When changing over to the same oil within the oil changing interval, draining is sufficient
Atlas Copco Service dept. ** Change over not recommended

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COOLANT SPECIFICATIONS PARCOOL EG

Never remove the cooling system filler PARCOOL EG is the only coolant that has been Because PARCOOL EG inhibits corrosion, deposit
cap while coolant is hot. tested and approved by all manufacturers of formation is minimized. This effectively eliminates
engines currently used in Atlas Copco flow restriction problems through the engine coolant
The system may be under pressure. compressors and generators. ducts and the radiator, minimizing the risk of engine
Remove the cap slowly and only when overheating and possible failure.
coolant is at ambient temperature. A Atlas Copco's PARCOOL EG extended life coolant is
sudden release of pressure from a heated the new range of organic coolants purpose-designed It reduces water pump seal wear and has excellent
cooling system can result in personal to meet the needs of modern engines. PARCOOL EG stability when subjected to sustained high operating
injury from the splash of hot coolant. can help prevent leaks caused by corrosion. temperatures.
PARCOOL EG is also fully compatible with all
PARCOOL EG is free of nitride and amines to protect
sealants and gasket types developed to join different
your health and the environment. Longer service life
It is strongly recommended to use Atlas materials used within an engine.
reduces the amount of coolant produced and disposal
Copco branded coolant. PARCOOL EG is a ready to use Ethylene Glycol requirements, which limits environmental impact.
based coolant, premixed in an optimum 50/50
The use of the correct coolant is important for proper dilution ratio, for antifreeze protection guaranteed to
heat transfer and protection of liquid-cooled engines. -40°C (-40°F).
Coolants used in these engines must be mixtures of
good quality water (distilled or de-ionised), special
coolant additives and anti-freeze, if required. Coolant PARCOOL EG
that is not to manufacturer's specification will result
in mechanical damage of the engine. Liter US gal Order number
The freezing point of the coolant must be lower than can 5 1.3 1604 5308 01
the freezing point that can occur in the area. The
difference must be at least 5°C (9°F). If the coolant can 20 5.3 1604 5307 02
freezes, it may crack the cylinder block, radiator or barrel 210 55.2 1604 5306 01
coolant pump.
To ensure protection against corrosion, cavitation and formation of deposits, the concentration of the additives
Consult the engine's operation manual and follow the in the coolant must be kept to certain limits, as stated by the manufacturer's guidelines. Topping up the coolant
manufacturer's directions. with water only, changes the concentration and is therefore not allowed.
Never mix different coolants and mix the Liquid-cooled engines are factory-filled with this type of coolant mixture.
coolant components outside the cooling
system.
PARCOOL EG Concentrate
Liter US gal Order number
can 5 1.3 1604 8159 01

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HANDLING PARCOOL EG COOLANT CHECK Glycol concentration measurement

PARCOOL EG should be stored at ambient Never remove the cooling system filler • To optimise the unique engine protection features
temperatures, while periods of exposure to cap while coolant is hot. of the PARCOOL EG, the concentration of the
temperatures above 35°C (95°F) should be Glycol in the water should always be above
The system may be under pressure. 33 vol.%.
minimized. PARCOOL EG can be stored for a Remove the cap slowly and only when
minimum of 5 years in unopened containers without coolant is at ambient temperature. A • Mixtures exceeding a 68 vol.% mix ratio in water
any effect on the product quality of performance. sudden release of pressure from a heated are not recommended, as this will lead to high
PARCOOL EG is compatible with most other cooling system can result in personal engine operating temperatures.
coolants based on ethylene glycol, but you only get injury from the splash of hot coolant. • A refractometer can be ordered from Atlas Copco
the benefits of 5 years protection when its used on its with part number 2913 0028 00.
own. Exclusive use of PARCOOL EG is In order to guarantee the lifetime and quality of the
recommended for optimum corrosion protection and In case of a mix of different coolant
product, thus optimising engine protection, regular products this type of measuring might
sludge control. coolant-condition-analysis is recommended. provide incorrect values.
For simple density-measuring of Ethylene Glycol and The quality of the product can be determined by three
Propylene Glycol in general the standard available parameters:
‘density’ measuring devices are used to measure the
concentration of EG. In case a device is used to Visual check TOPPING UP/REPLACING COOLANT
measure EG, no PG can be measured afterwards as a
result of the difference in the density. More specific • Verify the appearance of the coolant with regard to • Verify whether the engine cooling system is in a
measurements can be done by the use of a its colour and make sure that no loose particles are good condition (no leaks, clean,...).
refractometer. This device can measure both EG and floating around.
PG. A mix of both products will be show unreliable • Check the condition of the coolant.
results! pH measurement • If the condition of the coolant is no longer up to
Mixed EG coolants with identical glycol type can be • Check the pH value of the coolant using a pH- standard, the complete coolant should be replaced
measured by use of a refractometer as well as the measuring device. (see section Replacing the coolant).
‘density’ system. The mixed coolants will be • The pH-meter can be ordered from Atlas Copco • Always top-up with PARCOOL EG Concentrate /
considered as one product. with part number 2913 0029 00. PARCOOL EG.
The use of distilled water is recommended. If you • Typical value for EG = 8.6. • Topping up the coolant with water only, changes
have exceptionally soft water it would be acceptable, the concentration of additives and is therefore not
as well. Basically, the engine metals are going to • If the pH-level is below 7 or above 9.5, the coolant
allowed.
corrode to some extent no matter what water you use, should be replaced.
and hard water will encourage the resulting metal
salts to precipitate.
PARCOOL EG comes as a pre-mixed coolant to
safeguard the quality of the complete product.
It is recommended that topping up of the cooling
system is always done with PARCOOL EG.

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TOPPING UP WITHOUT DRAINING FROM THE COOLING SYSTEM

The quantity of PARCOOL EG Concentrate to be topped up can be estimated with the following formula and/or graph:

Corrections concentrate in measured system towards 50% volume by using PARCOOL EG Concentrate

PN: 1604 8159 01 Example:

Total volume coolant = 14 Liter
Measured concentration = 33 Vol %
50- 33 = 17 * 14 / 50 = 4,8 Liter PARCOOL EG Concentrate

Top-up volume PARCOOL EG Concentrate without drainage

6,0
In case of expansion tank at low level, this quantity is to
5,5 1 be filled without draining from the cooling system.

5,0 2
4,5
Top-up volume (liter)

4,0

3,5
3
3,0

2,5

2,0
4 1 Refractometer indication -20° C (-4° F) (33%)
1,5
2 Refractometer indication -22° C (-7.6° F)
1,0
3 Refractometer indication -25° C (-13° F)
0,5 4 Refractometer indication -30° C (-22° F)
5
0,0 5 Refractometer indication -36° C (-32.8° F)
4 5 6 7 8 9 10 11 12 13 14 15 16
Engine coolant capacity (liter)

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TOPPING UP AFTER LIMITED QUANTITY DRAINING FROM THE COOLING SYSTEM

The quantity of PARCOOL EG Concentrate to be topped up after draining a calculated volume from the cooling system, can be estimated with the following formula and/
or graph:
Corrections concentrate in measured system towards 50% volume by using PARCOOL EG Concentrate
PN: 1604 8159 01 Example:
Total volume coolant = 80 Liter
Measured concentration = 33 Vol %
50- 33 = 17 * 80 / 67 = 20 Liter PARCOOL EG Concentrate

100- 33 = 67
Top-up volume PARCOOL EG Concentrate with drainage
25,0
In case of expansion tank at normal level, this quantity is to
be drained from the cooling system.
22,5 1

20,0 2

17,5
Top-up volume (liter)

15,0 3

12,5

10,0
4
7,5
1 Refractometer indication -20° C (-4° F) (33%)
5,0 2 Refractometer indication -22° C (-7.6° F)
3 Refractometer indication -25° C (-13° F)
2,5
5 4 Refractometer indication -30° C (-22° F)
0,0 5 Refractometer indication -36° C (-32.8° F)
4 8 12 16 20 24 28 32 36 40 44 48 52 56 60 64 68 72 76 80 84
Engine coolant capacity (liter)

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REPLACING THE COOLANT CLEANING COOLERS

Drain
Protect the electrical and controlling
• Completely drain the entire cooling system. (3) equipment, air filters, etc. against
(2) penetration of moisture.
• Used coolant must be disposed of or recycled in (1)
accordance with legislation and local regulations.
Close the service door(s).
Flush Never leave spilled liquids such as fuel,
• Flush twice with clean water. Used coolant must oil, water and cleansing agents in or
be disposed of or recycled in accordance with around the compressor.
legislation and local regulations.
• Using the Atlas Copco Instruction book, Caution: do not top up when the engine
determine the amount of PARCOOL EG required is hot.
and pour into the radiator top tank. 00
00

• It should be clearly understood that proper

cleaning reduces contamination risks.
• In case of "other" coolant residues inside the Keep the coolers clean to maintain the cooling
system, the coolant with the lowest properties efficiency.
influences the quality of the ‘mixed’ coolant.
Remove any dirt from the coolers with a
Fill fibre brush. Never use a wire brush or
metal objects.
• To assure proper operation and the release of
trapped air, run the engine until normal engine Then clean by air jet in reverse direction of normal
operation temperature is reached. Turn off the flow.
engine and allow to cool. Steam cleaning in combination with a cleansing agent
• Recheck coolant level and add coolant mixture if may be applied.
necessary.
To avoid damaging the coolers, angle
In case of a mix of different coolant between jet and coolers should be
products this type of measuring might approx. 90° (do not use jet at max.
provide incorrect values. power).

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BATTERY CARE ACTIVATING A DRY-CHARGED BATTERY MAKE-UP DISTILLED WATER

• Take out the battery. The amount of water evaporating from batteries is
Before handling batteries, read the largely dependant on the operating conditions, i.e.
relevant safety precautions and act • Battery and electrolyte must be at equal
temperature above 10°C (50°F). temperatures, number of starts, running time between
accordingly. start and stop, etc...
• Remove cover and/or plug from each cell.
If the battery is still dry, it must be activated as If a battery starts to need excessive make-up water,
described in section Activating a dry-charged • Fill each cell with electrolyte until the level this points to overcharging. Most common causes are
battery. reaches 10 mm (0.4 in) to 15 mm (0.6 in) above high temperatures or a too high voltage regulator
the plates, or to the level marked on the battery. setting.
The battery must be in operation within 2 months
from being activated; if not, it needs to be recharged • Rock the battery a few times so that possible air If a battery does not need any make-up water at all
first. bubbles can escape; wait 10 minutes and check the over a considerable time of operation, an
level in each cell once more; if required, add undercharged battery condition may be caused by
electrolyte. poor cable connections or a too low voltage regulator
ELECTROLYTE • Refit plugs and/or cover. setting.
• Place the battery in the compressor.

Read the safety instructions carefully. PERIODIC BATTERY SERVICE

RECHARGING A BATTERY
• Keep the battery clean and dry.
Electrolyte in batteries is a sulphuric acid solution in
distilled water. Before and after charging a battery, always check the • Keep the electrolyte level at 10 to 15 mm above
The solution must be made up before being electrolyte level in each cell; if required, top up with the plates or at the indicated level; top up with
introduced into the battery. distilled water only. When charging batteries, each distilled water only. Never overfill, as this will
cell must be open, i.e. plugs and/or cover removed. cause poor performance and excessive corrosion.
Always pour the sulphuric acid carefully • Record the quantity of distilled water added.
into the distilled water; never pour the Use a commercial automatic battery
water into the acid. charger according to its manufacturer’s • Keep the terminals and clamps tight, clean, and
instructions. lightely covered in petroleum jelly.
Apply with preference the slow charging method and • Carry out periodic condition tests. Test intervals
adjust the charge current according to the following of 1 to 3 months, depending on climate and
rule of thumb: operating conditions, are recommended.
battery capacity in Ah divided by 20 gives safe If doubtful conditions are noticed or malfunctions
charging current in Amp. arise, keep in mind that the cause may be in the
electical system, e.g.loose terminals, voltage
regulator maladjusted, poor performance of
compressor, etc...

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STORAGE SERVICE PAKS COMPRESSOR ELEMENT OVERHAUL

Run the compressor regularly, e.g. twice a week, until A Service Pak is a collection of parts to be used for a When a compressor element is due for overhaul, it is
warm. specific maintenance measure. recommended to have it done by Atlas Copco. This
guarantees the use of genuine parts and correct tools
Load and unload the compressor a few times to It guarantees that all necessary parts are replaced at
with care and precision.
operate the unloading and regulating components. the same time keeping down time to a minimum.
Close the air outlet valves after stopping.
The order number of the Service Paks are listed in the
If the compressor is going to be stored Atlas Copco Parts List.
without running from time to time, LIABILITY
protective measures must be taken.
The manufacturer does not accept any liability for any
SERVICE KITS damage arising from the use of non-original parts and
for modifications, additions or conversions made
A service kit is a collection of parts to fit a specific without the manufacturer’s approval in writing.
repair or rebuilding task.
It guarantees that all necessary parts are replaced at
the same time which improves the uptime of the unit.
The order numbers of the Service Kits are listed in the
Atlas Copco Parts List.

Contact Atlas Copco.

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DD6.book Page 49 Monday, November 10, 2014 11:25 AM

Adjustments and servicing procedures

ADJUSTMENT OF THE CONTINUOUS REGULATING SYSTEM

X Y Z1 – Z2
(1) XAHS 146 Dd bar 13.5 12 13.2 – 13.6
psi 196 174 191.5 – 197.5
XATS 156 Dd bar 11.8 10.3 11.7 – 12.2
psi 171 149 167 – 173
00
00

XA(S) 186 Dd bar 8.3 7 8.1 – 8.5

psi 120.5 101.5 117.5 – 123.5
XAVS 166 Dd bar 15.5 14 15.3 – 15.7
psi 225 203 219 – 227
(2) XAHS 186 Dd bar 13.5 12 13.3 – 13.7
psi 196 174 191.5 – 197.5
The working pressure is determined by the tension of
the spring in the regulating valve (1). This tension can To adjust the normal working pressure, proceed as 4. Open an outlet valve (2) sufficiently to let the
be increased to raise the pressure and decreased by follows: engine run at maximum speed. The working
turning the adjusting wheel clockwise and anti- pressure must be Y bar; adjust if necessary with
clockwise respectively. 1. Start and warm up the engine (see section
Starting/Stopping). regulating valve (1) (see table).

2. With the outlet valves (2) closed, loosen the 5. Check the engine maximum speed. Adjust the
regulating valve’s lock nut and adjust the maximum speed by means of adjustable eccentric
regulating valve (1) until a pressure of X bar is nut on top of speed regulator.
reached (see table). 6. Close the outlet valves (2), check that the pressure
3. Check the minimum speed of the engine. Adjust is between Z1 and Z2 bar (see table). Lock the
regulating valve (1) by fixing the lock nut.
minimum speed stop screw if necessary.

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AIR FILTER ENGINE/COMPRESSOR RECOMMENDATIONS AIR RECEIVER

The air receiver (1) is tested according to official

The Atlas Copco air filters are specially standards. Carry out regular inspections in conformity
(1)
designed for the application. The use of with local regulations.
non-original air filters may lead to
severe damage of engine and/or
compressor element.
Never run the compressor without air SAFETY VALVE
filter element.
All adjustments or repairs are to be done
New elements must also be inspected for tears or by an authorized representative of the
punctures before installation. valve supplier.
Discard the element (4) when damaged.
(6)(2) (3)(4) (5) (8) Following checks must be carried out on the safety
(7) In heavy duty applications it is recommended to valve (2):
(9) install a safety cartridge, which can be ordered with
part no.: 2914 9311 00 • a check of the opening of the lifting gear, twice a
year. This can be done by screwing the cap of the
A dirty safety cartridge (3) is an indication of a mal- valve anti-clockwise.
1. Snap clips 6. Vacuator valve functioning air filter element. In that case replace the
2. Dust trap cover 7. Vacuum indicator element and safety cartridge. • an annual check of the set pressure according to
local regulations. This check cannot be done on
3. Safety cartridge 8. Reset button The safety cartridge cannot be cleaned. the machine and must be carried out on a proper
(option) test bench.
4. Filter element 9. Yellow indicator
5. Filter housing
REPLACING THE AIR FILTER ELEMENT

1. Release the snap clips (1) and remove the dust trap
CLEANING THE DUST TRAP (2). Clean the trap.
2. Remove the element (4) and the safety cartridge.
Remove dust daily.
3. Reassemble in reverse order of dismantling. Make
To remove dust from the dust trap squeeze the
sure the vacuator valve (6) points down.
vacuator valve (6) several times.
4. Inspect and tighten all air intake connections.
5. Reset the vacuum indicator by pressing the reset
button (5).

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FUEL SYSTEM BRAKE (= OPTION) ADJUSTMENT

Before jacking up the compressor,

connect it to a towing vehicle or attach a (4)
minimum weight of 50 kg (110 lb) to the
towbar.

BRAKE SHOE ADJUSTMENT

Check the thickness of the brake lining. Remove

(1) both black plastic plugs (5), one on each wheel.
When the brake lining has been worn down to a
thickness of 1 mm (0.039 in) or less, the brake shoes
have to be replaced. After inspection and/or
(5) (1) (3) (2)
replacement re-insert both plugs.
Brake shoe adjustment re-establishes the brake
lining-to-drum clearance and compensates for lining 1. Adjusting bolt 4. Pin ˘ 4 mm
Replacing the filter element wear.
1. Unscrew the filter element (1) from the adapter 2. Axle 5. Plug
Lift and support the compressor. Make sure that all 3. Brake cable
head. brakes are off (overrunbrake and hand brake lever).
2. Clean the adapter head sealing surface. Lightly oil The brake cables must be free from tension. Lock the
the gasket of the new element and screw the latter swivel cams of the wheel brake from the outside by Check the position of the equalizer (see section
onto the header until the gasket is properly seated, means of a pin ˘ 4 mm (4) through the hole as shown Brake cable adjustment, 6) with the parking brake
then tighten with both hands. in the Figure. actuated.
3. Check for fuel leaks once the engine has been Turn the adjusting bolt (1) clockwise with a wrench Perpendicular position of equalizer = identical
restarted. till the wheel locks up. Center the brake shoes by clearance of wheel brakes.
actuating the parking brake several times. Re-adjust the brake shoes, if necessary.
Turn the adjusting bolt anti-clockwise until the wheel To test, slightly apply the parking brake and check
FUEL is running free in direction of travel (approx. 1 full identical brake torque on left and right side.
turn of the adjusting bolt).
Remove locking pin (4). Remove clearance from
For fuel specifications, please contact your Atlas
Copco Customer Center. brake cables.
Check all lock nuts (Brake cable adjustment, 2).

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TEST PROCEDURE OF BRAKE CABLE ADJUSTMENT

Correct and wrong position of markings

1. Check if the towing eye rod of the overrun brake
mechanism is in the outmost position.

1
2. Check if the adjustable towbar (= option) is in the
actual towing position.
2
3. Apply the hand brake lever.
4. Push the compressor a few centimeters backwards
B. Acceptable so that the brake lever is automatically pulled up
further.
5. Check the position of the arrow marking ”1” at the
catch lock in combination with the arrow marking
”2” at the toothed sector, according to A,B,C,D.

C. Too loose;
adjust brake cables
(Section Brake
A. Adjusted correctly cable adjustment)

D. Too tight;
adjust brake cables
(Section Brake
cable adjustment)

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BRAKE CABLE ADJUSTMENT

1. With the towing eye pulled out in the outmost

(1) (6) (4) (2) position and the hand brake lever in the downward
position (see Figure), loosen the lock nuts (2).
Turn adjusting nuts and brake cable nuts (4)
clockwise until there is no slack in the brake
mechanism.
The equalizer (6) must remain perpendicular to
main brake cable (5).
2. Apply the hand brake lever several times and
repeat the adjustment. Tighten the nuts with their
lock nuts (2). Remove the jack and the blocks.
3. Road test the compressor and brake several times.
Check brake shoe and brake cable adjustment and
(1) (2) (3) (4) (2) (5)
adjust if necessary.

Hand brake lever downward - brake not operated

1. Brake cable 4. Brake cable nut
2. Lock nut 5. Main brake cable
3. Adjusting nut 6. Equalizer

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WHEELS LUBRICATION

WHEEL CHECK

• Check wheel bolts for firm seating (initially)

• Check hub caps for firm seating (every 2,500 km
or anually)
• Check tyres for uneven wear (every 2,500 km or
anually)
• Check lateral play of wheel bearing. If necessary,
readjust.
Compact bearings (every 2 years)
Conventional bearings (after 500 km, every 2,500
km or anually) Tapered type hub cap Greasing bearing race

Taper roller bearings and deep groove ball Fill the hub caps to 3/4 full with grease.
bearing
Fit wheel hubs, adjust the bearing play and fit the hub
Axles fitted with taper roller bearings are caps.
recognizable by a tapered type hub cap, see Figure.
Remove wheels and wheel hubs.
Mark dismounted wheel hubs and bearing races so
that their identity is not mistaken during reassembly.
Clean wheel hubs thoroughly inside and outside.
Remove old grease totally.
Clean taper roller bearings and seals (using diesel oil)
and check for reuseability.
Work BPW special longlife grease ECO_Li 91 into
the cavities between the taper roller and cage. Smear
grease into the hub's outer bearing race.

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WHEEL BOLTS CHECK

Tightening torques of wheel bolts

Spanner Thread Tightening torque

width (mm) Nm (lbf.ft)
19 M 12x1.5 110 (81)
24 M 18x1.5 280 (207)

Cylindrical hub cap shape Wheel bolts tightening

Compact bearings After the first run, likewise after each

Compact bearings are recognizable by cylindrical hub wheel change.
cap shape, see Figure.
Tighten wheel bolts crosswise using a torque wrench
Compact bearings are maintenance-free due to and tightening torque in compliance with the table.
permanent lubrication and are designed for high
mileages.
Therefore, there is no grease change or regreasing
necessary.

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WHEEL BEARING ADJUSTMENT

Conventional taper roller bearings Compact bearings

Taper roller bearings are recognisable by the conical Compact bearings are recognizable by their
profile of the hub cap. cylindrical hub cap shape.
• Lever off hub cap. Remove split pin from axle nut
and tighten so that rotation of the wheel is slightly If noticeable bearing play is felt, the
braked. compact bearings should be replaced.
• Turn back the axle nut to the next possible split pin
hole, by a maximum of 30 degrees.
• Insert split pin and bend ends slightly outwards.
• Check wheel rotation, fit hub cap.

Bearing play Important:

Jack up the compressor, release brakes. The grease in the hub cap and bearing must not be
contaminated with dirt during this job!
Turn wheels manually and rock.
If any bearing play is perceivable, adjust the bearings.

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TOWBAR AND OVERRUN BRAKE

TOWBAR AND OVERRUN BRAKE CHECK

Check coupling head

First initially, then every 5,000
kilometres or annually.
(x)
Check coupling head for wear and correct operation.
Check the wear indicator (use within the "+" range
only).
Check the coupling head fastenings (see arrows,
Figure) at regular intervals for firm seating.
Check the coupling head fastenings Brake play check

Check height adjustment facility Brake play check

Initially, before every journey, up to 500 After the first run, then every 2,000 -
kilometres, then every 5,000 kilometres 3,000 kilometres.
or annually.
The check is carried out visually on the stroke (x) of
After every adjustment the clamping nuts must be the overrun coupling.
tightened and secured with the spring elements.
As soon as this is more than 50 mm when the brakes
Tightening torque: are applied, adjust the wheel brakes.
M 24 = 250 - 350 Nm Check towbar, handbrake lever, spring actuator,
M 32 = 350 - 400 Nm reversing lever, linkage and all movable parts for ease
of movement.
Check tight fit of the clamping nuts and correct
positioning of the adjustment facility.

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LUBRICATION

(2)
(1)

Towbar Lubrication coupling head Greasing towbar

First initially, then every 5,000 Lubricate the coupling head Towbar bushes on the housing of the
kilometres or annually. overrun coupling
At regular intervals.
Initially, after 2,000 - 3,000 kilometres,
Check safety cable (1) for damage; every 5,000 every 5,000 kilometres.
kilometres or annually.
Oil ball coupling at regular intervals in the specified
Check Bowden cable (2) on height-adjustable locations and moving parts. Apply general purpose grease via the grease nipples
connection devices for damage; every 5,000 until fresh grease can be seen emerging from the
Grease the contact surface of the ball of the towing
kilometres or annually. vehicle. bushes.

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(1)

Reversing lever Lubrication points Heigth adjusting device

Reversing lever Lubricate all moving parts and pivot pins at Grease sliding locations on the height-
the overrun coupling adjusting device
Initially, after 2,000 - 3,000 kilometres,
every 5,000 kilometres. Initially, after 2,000 - 3,000 kilometres, For the first time after 2,000 - 3,000
every 5,000 kilometres. kilometres travelled, then every 5,000
Check reversing lever (1) for ease of motion. kilometres.
All moving parts of drawbar, handbrake lever, spring
If fitted, apply general purpose grease via the grease
actuator, reversing lever, linkages etc. are to be oiled Oil threaded parts and grease toothed parts.
nipple until fresh grease can be seen emerging from
the bush. or greased as required.

If grease nipples are not fitted, then apply oil to the

reversing lever bush.

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Problem solving
It is assumed that the engine is in good condition and Make sure that the wires are not damaged and that
that there is adequate fuel flow to the filter and they are clamped tight to their terminals.
injection equipment.
For position of dip switches refer to
An electrical fault must be traced by an section Electrical system.
electrician.

Problem Possible faults Corrective actions

1. Starter motor does not crank engine a. Low battery output. a. Check electrolyte level and charge battery. If no cells are
after switching startbutton (S) to shorted and battery is discharged, trace cause and
” ”. correct.
2. Starter motor cranks engine when a. Low battery output. a. See corrective action 1.
switching start button (S) to ” ”, but
engine does not fire.
3. Engine fires, but engine stops when a. Alternator drive belt broken or slipping. a. Check and correct if necessary.
releasing start button (S).
b. Alternator/regulator defective. b. Have assembly repaired.
4. Hourmeter (P1) does not count a. Hourmeter (P1) defective. a. Replace.
running time.
5. Engine is running, but shuts down a. Start button (S) released too soon. a. Release button after engine oil pressure has built up
immediately after start button (S) has above the minimum allowed level.
been released.
b. Insufficient engine oil pressure. b. Stop at once, consult the engine instruction manual.
c. Fuel tank contains insufficient fuel. c. Fill fuel tank.
6. Compressor is loaded automatically to a. Loading valve stuck in loading position. a. Remove and dismantle loading valve. Correct if
full capacity after starting. necessary.
b. Air intake throttle valve stuck in opened position. b. Check and, if necessary consult Atlas Copco.
c. Air leaks in regulating system. c. Check hoses and their fittings. Stop leaks; replace
leaking hoses.

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Problem Possible faults Corrective actions

7. Unit does not load after pressing the a. Regulating valve defective. a. Check and if necessary consult Atlas Copco.
loading button.
8. Engine does not speed up immediately a. Regulating valve defective. a. Check and, if necessary consult Atlas Copco.
after compressor loading valve button
b. Air intake throttle valve stuck in closed position. b. Check and, if necessary consult Atlas Copco.
has been pressed and compressor does
not deliver air.
9. Excessive compressor oil a. Compressor oil level too high. a. Check oil level. Release pressure and drain oil to correct
consumption. Oil mist being level.
discharged from air outlet valves.
10. Compressor capacity or pressure a. Air consumption exceeds capacity of compressor. a. Check equipment connected.
below normal.
b. Choked air filter elements. b. Remove and inspect elements.
c. Unloading valve not completely open. c. Check and, if necessary consult Atlas Copco.
11. Compressor does not unload and a. Regulating valve incorrectly set or defective. a. Check and, if necessary consult Atlas Copco.
engine keeps running at max. speed
b. Air leaks in regulating system. b. Check hoses and their fittings. Stop leaks and, if
when closing the air outlet valves,
necessary consult Atlas Copco.
safety valve blows.
c. Unloading valve stuck. c. Check and, if necessary consult Atlas Copco.
12. Working pressure rises during a. Regulating valve incorrectly set or defective. a. Check and, if necessary consult Atlas Copco.
operation and causes safety valve to
b. Air leaks in regulating system. b. Check hoses and their fittings. Stop leaks and, if
blow.
necessary consult Atlas Copco.
c. Unloading valve stuck. c. Check and, if necessary consult Atlas Copco.
d. Safety valve defective. d. Check safety valve; consult Atlas Copco.
13. After working some time, the unit a. Fuel tank contains insufficient fuel. a. Fill fuel tank.
stops through a shutdown switch. b. Air in fuel system, or insufficient fuel supply. b. Check filters and hoses for leaks, dirt and bends.
c. Engine oil pressure too low. c. Refer to the engine instruction manual.
d. Engine temperature too high. d. See corrective actions 15.
e. Compressor temperature too high. e. See corrective actions 16.
f. Low coolant level. f. Top up cooling system.

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Problem Possible faults Corrective actions

14. Air and oil mist expelles from air a. Unloader valve jammed. a. Check and, if necessary consult Atlas Copco.
filters immediately after stopping.
b. Wrong oil type (without foam-retarding additives). b. Consult Atlas Copco.
15. Engine overheating. a. Insufficient engine cooling. a. Relocate compressor.
b. Engine oil cooler clogged externally. b. Clean engine oil cooler. Refer to section Cleaning
coolers.
16. Compressor overheating. a. Insufficient compressor cooling. a. Locate compressor away from walls; when banked with
other compressors, leave space between them.
b. Oil cooler clogged externally. b. Clean oil cooler. Refer to section Cleaning coolers.
c. Oil level too low. c. Check oil level. Top up with recommended oil.
17. After working for some time, the unit a. Air in fuel system, or insufficient fuel supply. a. Check filters and hoses for leaks, dirt and bends.
stops for no apparent reason.

Alternator precautions
1. Never reverse the polarity of the battery or the
alternator.
2. Never break any alternator or battery connections
while the engine is running.
3. When recharging the battery, disconnect it from
the alternator. Before using booster cables to start
the engine, be sure of the polarity and connect the
batteries correctly.
4. Never operate the engine without the main or
voltage sensing cables connected in the circuit.

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Available options
Vessel type: EURO Air quality equipment: Aftercooler + water separator
ASME Aftercooler + water separator + fine filter
Towbar: Adjustable with brakes (A) PD
Fixed with brakes (A) Aftercooler + water separator + fine filter
PD + QD
Fixed without brakes
Aftercooler + water separator + fine filter
Without towbar: Support (without undercarriage) PD + reheater (C)
Towing eyes: Atlas Copco Aftercooler + water separator + fine filter
DIN PD + QD + reheater (C)
Ball Aftercooler + water separator + reheater
Italian Lubricator on 7 bar units
GB Safety: Wheel chocks
NATO Safety cartridge
AC (France) Refinery equipment: Spark arrestor
Towbar support: Support leg Inlet shut down valve
Jockey wheel Cold start: -20 °C (-4 °F)
Road signalisation: Full (B) Customer colour: Single
Safety: Wheel chocks Double
Safety cartridge Triple
Refinery equipment: Spark arrestor
A. These units meet your local safety regulations and are available with overrun
Inlet shut down valve and parking brakes.
B. Reflectors and lights for safety on the road.
C. Quality air through the aftercooler, reheater and fine filters.

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Technical specifications
TORQUE VALUES

FOR GENERAL APPLICATIONS CRITICAL TORQUE VALUES

The following tables list the recommended torques applied for general applications
during assembly of the compressor. Assemblies Torque value (Nm / lbf.ft)
Wheel bolts see section Wheel bolts check
Bolts, axle/beams 80 (59) +/- 10 %
For hexagon screws and nuts with strength grade 8.8 Bolts, towbar/axle 80 (59) +/- 10 %
Thread size Torque value (Nm / lbf.ft) Bolts, towbar/bottom 80 (59) +/- 10 %
M6 8 (6) +/-25 % Bolts, towing eye/towbar 80 (59) +/- 10 %
M8 20 (15) +/-25 % Bolts, lifting eye/flywheel housing 80 (59) +/- 10 %
M10 41 (30) +/-25 % Bolts, engine/drive housing (M12) 80 (59) +/- 10 %
M12 73 (54) +/-25 % Bolts, engine/drive housing (M14) 125 (92) +/- 10 %
M14 115 (85) +/-25 % Bolts, compressor element/drive 80 (59) +/- 5 %
housing
M16 185 (137) +/-25 %
Safety switches 35 (26) +/- 5 %
For hexagon screws and nuts with strength grade 12.9

Thread size Torque value (Nm / lbf.ft) Secure the drain cock and tank cap of the fuel tank handtight.
M6 14 (10) +/-21 %
M8 34 (25) +/-23 %
M10 70 (52) +/-24 %
M12 120 (89) +/-25 %
M14 195 (144) +/-23 %
M16 315 (233) +/-23 %

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SETTINGS OF SHUTDOWN SWITCHES AND SAFETY VALVES

Designation XAHS 146 Dd XATS 156 Dd XA(S) 186 Dd XAVS 166 Dd XAHS 186 Dd XATS 156 Dd XA(S) 186 Dd
XAHS 300 DD6 XATS 350 DD6 XA(S) 375 DD6 XAVS 340 DD6 XAHS 375 DD6 XATS 350 DD6 XA(S) 375 DD6
COM3 COM3 COM3 COM3 COM3 COM2 COM2
Engine oil pressure bar 2 2 2 2 2 - -
psi 29 29 29 29 29 - -
Engine oil temperature °C 113 113 113 113 113 - -
°F 235 235 235 235 235 - -
Compressor temperature °C 120 120 120 120 120 - -
°F 248 248 248 248 248 - -
Safety valve opening pressure
- EC type bar 15 13.5 10 17 17 13.5 10
- ASME type psi 218 200 150 250 250 200 150

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COMPRESSOR/ENGINE/GENERATOR SPECIFICATIONS

REFERENCE CONDITIONS

Designation XAHS 146 Dd XATS 156 Dd XA(S) 186 Dd XAVS 166 Dd XAHS 186 Dd XATS 156 Dd XA(S) 186 Dd
XAHS 300 DD6 XATS 350 DD6 XA(S) 375 DD6 XAVS 340 DD6 XAHS 375 DD6 XATS 350 DD6 XA(S) 375 DD6
COM3 COM3 COM3 COM3 COM3 COM2 COM2
Absolute inlet pressure bar 1 1 1 1 1 1 1
psi 14.5 14.5 14.5 14.5 14.5 14.5 14.5
Relative air humidity % 0 0 0 0 0 0 0
Air inlet temperature °C 20 20 20 20 20 20 20
°F 68 68 68 68 68 68 68
Nominal effective working pressure bar 12 10.5 7 14 12 10.3 7
psi 174 152 102 203 174 149 102
The inlet conditions are specified at the air inlet grating outside the canopy.

LIMITATIONS

Designation XAHS 146 Dd XATS 156 Dd XA(S) 186 Dd XAVS 166 Dd XAHS 186 Dd XATS 156 Dd XA(S) 186 Dd
XAHS 300 DD6 XATS 350 DD6 XA(S) 375 DD6 XAVS 340 DD6 XAHS 375 DD6 XATS 350 DD6 XA(S) 375 DD6
COM3 COM3 COM3 COM3 COM3 COM2 COM2
Minimum effective receiver pressure bar 4 4 4 4 4 4 4
psi 58 58 58 58 58 58 58
Maximum effective receiver pressure, bar 13.5 11.8 8.5 15.5 13.5 11.8 8.5
compressor unloaded psi 196 171 123 225 196 171 123
Maximum ambient no °C 50 50 50 45 45 50 50
temperature at sealevel aftercooler °F 122 122 122 113 113 122 122
with °C 49 47 47 40 40 - -
aftercooler °F 114 114 114 104 104 - -
Minimum starting no °C -10 -10 -10 -10 -10 -10 -10
temperature aftercooler °F 14 14 14 14 14 14 14
with °C -20 -20 -20 -20 -20 -20 -20
aftercooler °F -4 -4 -4 -4 -4 -4 -4

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PERFORMANCE DATA

At reference conditions, if applicable, and at normal shaft speed, unless otherwise stated.

Designation XAHS 146 Dd XATS 156 Dd XA(S) 186 Dd XAVS 166 Dd XAHS 186 Dd XATS 156 Dd XA(S) 186 Dd
XAHS 300 DD6 XATS 350 DD6 XA(S) 375 DD6 XAVS 340 DD6 XAHS 375 DD6 XATS 350 DD6 XA(S) 375 DD6
COM3 COM3 COM3 COM3 COM3 COM2 COM2
Engine shaft speed, normal and maximum r/min 2300 2300 2300 2200 2200 2300 2300
Engine shaft speed, compressor unloaded r/min 1700 1700 1700 1700 1700 1700 1700
Free air delivery 1) standard l/s 151 161 185 158 173 166 185
cfm 320 341 392 335 367 352 392
with l/s 147 157 181 154 169 - -
aftercooler cfm 311 333 384 326 358 - -

1)
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)
• +/- 4% 250 l/s (530 cfm) < FAD
The international standard ISO 1217 corresponds to following national standards:
• British BSI 1571 part 1
• German DIN 1945 Part 1
• Swedish SS-ISO 1217
• American ANSI PTC9

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Fuel consumption

Designation XAHS 146 Dd XATS 156 Dd XA(S) 186 Dd XAVS 166 Dd XAHS 186 Dd XATS 156 Dd XA(S) 186 Dd
XAHS 300 DD6 XATS 350 DD6 XA(S) 375 DD6 XAVS 340 DD6 XAHS 375 DD6 XATS 350 DD6 XA(S) 375 DD6
COM3 COM3 COM3 COM3 COM3 COM2 COM2
at 100% FAD kg/h 18.1 18 17.4 21.2 21 18.3 17.4
lb/h 39.9 39.7 38.4 46.7 46.3 40.34 38.36
at unload kg/h - - - - - 9.6 8.5
lb/h - - - - - 21.17 18.74
Specific fuel consumption
at 100% FAD standard g/m3 33.1 30.6 26.1 35.8 33.5 30.3 26
lb/103 cu.ft 2.07 1.91 1.63 2.24 2.09 1.88 1.62
Typical oil content of compressed air mg/m3 <5 <5 <5 <5 <5 <5 <5
oz/103 cft < 0.005 < 0.005 < 0.005 < 0.005 < 0.005 < 0.005 < 0.005
Engine oil consumption (maximum) g/h 18.2 17.8 17.4 20.8 20.9 14 14
oz/h 0.64 0.63 0.61 0.73 0.74 0.49 0.49
Compressed air temperature standard °C 90 90 90 95 95 90 90
at outlet valves °F 194 194 194 203 203 194 194
with °C ambient + 9 ambient + 9 ambient + 9 ambient + 9 ambient + 9 - -
aftercooler °F ambient + 16 ambient + 16 ambient + 16 ambient + 16 ambient + 16 - -
Sound pressure level (LP), measured dB(A) 71 71 71 71 71 72 71
according to ISO 2151 under free field
conditions at 7 m distance
Sound power level (Lw) complies with dB(A) 99 99 99 99 99 100 99
2000/14/EC

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DESIGN DATA

Compressor
Designation
Number of compression stages 1

Engine
Designation XAHS 146 Dd XATS 156 Dd XA(S) 186 Dd XAVS 166 Dd XAHS 186 Dd XATS 156 Dd XA(S) 186 Dd
XAHS 300 DD6 XATS 350 DD6 XA(S) 375 DD6 XAVS 340 DD6 XAHS 375 DD6 XATS 350 DD6 XA(S) 375 DD6
COM3 COM3 COM3 COM3 COM3 COM2 COM2
Make Deutz Deutz Deutz Deutz Deutz Deutz Deutz
Type TCD2012LO4 TCD2012LO4 TCD2012LO4 TCD2013LO4 TCD2013LO4 BF4M2012C BF4M2012C
Coolant Liquid Liquid Liquid Liquid Liquid Liquid Liquid
Number of cylinders 4 4 4 4 4 4 4
Bore mm 101 101 101 108 108 101 101
in 3.98 3.98 3.98 4.25 4.25 3.98 3.98
Stroke mm 126 126 126 130 130 126 126
in 4.96 4.96 4.96 5.12 5.12 4.96 4.96
Swept volume l 4.038 4.038 4.038 4.764 4.764 4.038 4.038
cu.in 246.4 246.4 246.4 251.2 251.2 246.4 246.4
Output according to SAE J1995 at normal kW 83 83 83 104 104 90 90
shaft speed BHP 113 113 113 141 141 122 122
- Load factor % 65 65 65 65 65 70 70
Capacity of oil sump:
- Initial fill l 9 9 9 12 12 8.5 8.5
US gal 2.2 2.2 2.2 2.9 2.9 2.0 2.0
- Refill (max.) 1) l 8.5 8.5 8.5 11.5 11.5 8 8
US gal 2.0 2.0 2.0 2.8 2.8 1.9 1.9
Capacity of cooling system l 14 14 14 16 16 14 14
US gal 3.4 3.4 3.4 3.9 3.9 3.4 3.4
1) With filter change.

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Unit Unit dimensions

Designation XAHS 146 Dd - XAHS 300 DD6 with brakes towbar

XATS 156 Dd - XATS 350 DD6
XA(S) 186 Dd - XA(S) 375 DD6 fixed adjustable
XAVS 166 Dd - XAVS 340 DD6
XAHS 186 Dd - XAHS 375 DD6 Length mm 3941 4356
XATS 156 Dd - XATS 350 DD6 in 155.2 171.5
XA(S) 186 Dd - XA(S) 375 DD6
Width mm 1716 1716
Capacity of compressor oil l 24
system in 67.6 67.6
US gal 5.9
Height mm 1661 1661
Net capacity of air receiver l 42
in 65.4 65.4
US gal 10.3
Weight (ready-to-operate) kg 1800 1825
Capacity of fuel tank l 175
lb 3970 4025
US gal 43
Air volume at inlet grating m3/s 3.9
(approx.) 1) cfm 8300
1)
Air required for engine and compressor cooling, for combustion and for
compression.

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Data plate
1 Company code
(1) (2) (3) 2 Product code
3 Unit serial number
Atlas Copco Airpower n.v. (4) 4 Name of the manufacturer
(5) 5 EEC or national type approval number
A kg (6) 6 Vehicle identification number
1- B kg 7 Undercarriage
2- C kg (7)
D kg A Maximum permitted total weight of the
(8) vehicle
(9) B Maximum permitted load on the towing eye
(10) C Maximum permitted load on axle (or front
axle on dual axle units)
(11)
D Maximum permitted load on rear axle (on dual
axle units)
S/N Manuf. year (12) 8 Model
Atlas Copco Airpower n.v. 9 Working pressure
0038 Boomsesteenweg 957
B-2610, WILRIJK 10 Speed
11 Engine power
(13) (14) 12 Manufacturing year
13 CE mark in accordance with Machine Directive
89/392 EC
14 Register number or number of notified body

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Disposal
GENERAL DISPOSAL OF MATERIALS

When developing products and services, Atlas Copco Dispose of contaminated substances and material
tries to understand, address, and minimize the separately, in accordance with locally applicable
negative environmental effects that the products and environmental legislation.
services may have, when being manufactured,
Before dismantling a machine at the end of its
distributed, used and disposed.
operating lifetime drain and dispose of all fluids of
Recycling and disposal policy are part of the according the applicable local disposal regulations.
development of all Atlas Copco products. Atlas
Remove the batteries. Do not throw batteries into the
Copco company standards determine strict
fire (explosion risk) or residual waste. Separate the
requirements.
machine into metal, electronics, wiring, hoses,
Material selection, substantial recyclability, insulation and plastic parts.
disassembly possibilities and separability of materials
Dispose of all components in accordance with
and assemblies are considered, as well as
applicable disposal regulations.
environmental perils and dangers to health during the
recycling and disposal of the unavoidable rates of Remove spilled fluid mechanically; pick up the rest
non-recyclable materials. using an absorbing agent (for example sand, sawdust)
and dispose of it in accordance with local disposal
Your Atlas Copco compressor consists for the most
regulations. Do not drain into the sewage system or
part of metallic materials, that can be remelted in
surface water.
steelworks and smelting works and are therefore
almost infinitely recyclable. The plastic used is
labelled; sorting and fractioning of the materials for
recycling in the future is forseen.

This concept can only succeed with your

help. Support us by disposing
professionally. By assuring correct
disposal of the product you help prevent
possible negative consequences for
environment and health as a result of
inappropriate waste handling.
Recycling and re-usage of material help
preserve natural resources.

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Maintenance Log

Compressor .......................................................................................... Customer ...............................................................................................

Serial number........................................................................................ ................................................................................................................

Service hours Maintenance action Date By: initials

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Following documents are provided with this unit:

- Test Certificate
- EC Declaration of Conformity:

1
EC DECLARATION OF CONFORMITY
2 We, Atlas Copco Airpower n.v., declare under our sole responsibility, that the product
3 Machine name :
4 Commercial name :
5 Serial number :

6 Which falls under the provisions of article 12.2 of the EC Directive 2006/42/EC on the approximation of the
laws of the Member States relating to machinery, is in conformity with the relevant Essential Health and
Safety Requirements of this directive.

The machinery complies also with the requirements of the following directives and their amendments as
indicated.

7 Directive on the approximation of laws of the Harmonized and/or Technical Att’

Member States relating to Standards used mnt
a. Pressure equipment 97/23/EC X

EN ISO 12100-1
b. Machinery safety 2006/42/EC EN ISO 12100-2
EN 1012-1
c. Simple pressure vessel 87/404/EEC X
EN 61000-6-2
d. Electromagnetic compatibility 2004/108/EC
EN 61000-6-4
EN 60034
e. Low voltage equipment 2006/95/EC EN 60204-1
EN 60439
f. Outdoor noise emission 2000/14/EC ISO 3744 X

8.a The harmonized and the technical standards used are identified in the attachments hereafter
8.b Atlas Copco Airpower n.v. is authorized to compile the technical file

9 Conformity of the product to the

Conformity of the specification to the
10
specification and by implication to the
Directives
directives
11
12 Issued by Product engineering Manufacturing
13
14 Name
15 Signature

16 Place , Date
Form 5009 0600 00
ed. 09, 2010-03-15

Atlas Copco Airpower n.v. A company within the Atlas Copco Group

Postal address Visitors address Phone: +32 (0)3 870 21 11 Com. Reg. Antwerp 44651
P.O. Box 100 Boomsesteenweg 957 Fax: +32 (0)3 870 24 43 V.A.T. 403.992.231
B-2610 Wilrijk-Antwerp B-2610 Wilrijk-Antwerp
Belgium Belgium For info, please contact your local Atlas Copco representative
www.atlascopco.com
p.1(1)

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