Instruction Manual

for Portable Compressors

XAHS
XATS
XA(S)
XAVS
XAHS

Printed maner N
2954 2230 02

1112006

146 Dd
156 Dd
186 Dd
166 Dd
186 Dd

ATLAS COPCO PORTABLE AIR DIVISION

www.allascopco.com

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

Instruction Manual

Please read the fol/owing instructions ('are/Jllly before starting 10

lise YOllr machine. Follow 'h" illstmctimJs ill this hooklet and we
guumlltee you years a/trouble/ree operation.

Always keep rile milnJlal available lIear the muchi"e.

III "II correjpcmdelJce always mem;oll the compressor t)1Jt! and
serial uumbtr. sho",,, on the dura plate.
The company reserves the right to muke changes without prior
"otice.

PAGE

CONTENTS

CALIFORNIA

SafelY prKllulions for porlable oompres_s

Proposition 65 Warning
Diesel engine exhaust and some of its
constituents are known to the State of
California to cause cancer, birth
defects, and other reproductive harm.

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 for
modifications, additions or conversions made without the manufacturer's approval
in writing.

Copyright 2006, 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.

1.1

10Iroouclloo

1.2

Geoer.) safety pn."'DUlioos

1.3

Safely <luriog transport and iostallallon

1.4

S"fely lIuriog usc and opcmlioo

1.5

Safely during mulolelUlnee and repair

1.6

Tool upplic':ttions s;lfCl~

1.7

Specific safely preeaulion

9
_.10

IO

I..ellding parliculats

II

2.1

Dcscriplioo of ..felY piclogrtlOlS

used in lhis Olaoual

2.2

Geoc'ral dc'Scripoon

11

2.3

Markings aod information labcls

12

2.4

Main Pans

13

2.5

AirOow

2.6

Oil .y.tem

2.1

Conliouuu. regulatiog systelll

16

17

11

15

2.8

Eleeln,.,1 .yot"O'

2.8.1

Circuil di.'grarn for XAHS 146 Dd.

XATS 156DduodXA( ) 186 Dd

2.8.2

Cireuil dia~raOl for XAV

XAHS 186 Dd

16

17

166 Dd and
.... .18

Operating iuSlrudioos

19

3.1

Parking. lowing and lifting 'o.lnJctioo

19

3.1.1

!':,rking In.lfuclion

19

3.1.2

Towing ill>l"'clioo

19

3.1.3

Heigh! adjustment (with adju'lJlble lowbar)

20

3.1.4

Lifliog in.lruelions

20

3.2

Kcloru staroog

20

3.3

SluniogiSloppiog

21

3.4

Duriog operalion

22

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

CONTENTS

PAGE

CONTENTS

PAGE

Instruction Manual

SAFETY PRECAUTIONS FOR PORTABLE COMPRESSORS

1.

Tu be nad ntltnlinty and ac:ted Dt"CUrdingly befun towing, lifting. operating. perfonning maintenance or repairing the compressor

MDint~ancr

22

4.1

Usc of St.. ke paks

4.2

Pre\'enlive maintenance sch(dulc

for Ihe comp,es.'or

4.3

Lubric.tion oils

22
22
24

Adjustm.nts and servicing produres "

32

5.1

Adjustntent of the c<lnlinuous regulating system

32

5.2

Air Oller engindc<lmpre.<sor

33

5.2.1

Main paris

3J

5.2.2

Cleaning Ihe dllsllrnp

33

4.4

Oille\'el check

24

5.2.3

Recommend31ions

33

4.4.1

Check engine oil leveL

24

5.2.4

Replacing l,h. ,ir filler elem.nt

33

4.4.2

Check comlJl'C"so' oil level..

25

5.3

Ai, receil'cr

4.5

Oil,nd 011 filler change

25

504

'fety'..I'e

4.5.1

Enginc oil nod oil fillcr change

25

5.5

Fuel sysl.m

34

4.5.2

Compressor oil nnd oil filler chang

25

5.6

Brok. (. oplion) adjustm.nt

34

4.6

Coolanl.

26

5.6.1

Brake shoe adjustment

34

4.6.1

Coolnol pccificalions

26

5.6.2

Test procedure of !>rake cable adjustment

35

4.6.2

PARCOOL EO

26

5.6.3

Brak. cable adjuslmenl.

35

4.6.3

Handling PARCOOL EG

26

4.6.4

Coolnnl check

27

4.6.5
4.6.6

Topping up/replacing cool.nt

ToppIng up without drnining f,om
Ih. cooling s)'Stem

4.6.7

Topping up .ft.. limiled quanlily

drnining from the cooling syslcm

19

4.6.8

Rcplacing lhe coolanl..

30

4.7

Oeaning cool.rs

30

4.8

Ban.ry C<l'

31

4.8.1

Elcclrolyte

31

4.8.2

Activating a dry-chnrged bnllery

31

"."

27

R.charging a bnllery

31

4.8.4

Ban.ry mainl.nance

JI

4.9

Slomg

31

4.10

S.n'ice p.1k.'

31

4.11

4.12

Compr.",er .I.m.nt o\'elhaul

3I

4.13

Liabilily

31

JI

AllemGlOr precautions

AvaUable options
8

Technical specllications
S.I

36
39

Torque values

40
40

8.1.1

Fer general arrlicalion

8.1.2

For imporlant "s""mblles

40

8.2

settings of shutdown switches and sMcty "al,'es

40

8.3

CompressorlEogine spcciroca ions

41

8.4

Coo"."ion list of 51 unils into BritIsh unilS

42

Data plate

the inh:ndcd and prcwclablc fl,.IIure usc of the pnxJucts. and the
cn\'iNnll~nlS in which the)' arc c:\pc:clcd to operate.

applicable rulcs. codes :md

.40

42

~g.ulalions.

Ihe expe,-,cd usdul prodUC1 life. assum.ing. proper s(l"\icc and

mainlenancc.

33

36

INTRODUCTION

others:

33

"

Problem solving
6.1

28

4.8.3

lc. Idts

(;

1 .1

"the policy of Atlas Copeo is 10 prO\'ide the users of their equipment with
saC.:. reliable and ellident products. Factors laken inlo aCl:ount are among

pro\"icJing the lIIanual with up-to-date information.

Betore han1ling iUl)' prodlk:t. take time to read the:' relc\'am instruction
mJ.nual. Iksides gh'ing detailJ ~r.uing inslructions. it also givcs spedfic
infonnation about safety. pre\'~ntilo'e maintenance. etc.
Kcep t~ manual always 011 the unil localion. easy acc~'Ssible 10 the oper:uing
p.:rsoMcl.

If an)' statemeTll in this manual does not comply with local legislalion. the
stricter of thc two shall bt: applit!:d.

Slatemenis in these safely pn.-cautions should nol be interpretcd as

suggo:tions. recommenda!ions or induetl11Cllls Ihat il should be used in
violation of any applicable laws or regulations.

1 .2

GENERAL SAFETY PRECAUTIONS

S~ also the safel)' pre~'aulions of lhe engine aoo possible other equipment.
whkh are stp'J.r.11\:ly sent along or are IntnlioJ1(d on Ihe: equipmenl or pans
orlhe unil.

'Ibc owner is responsible for maintaining the: unit in :I; safe opemling
c.:onWtion. Unil par1S and accessories must be repla<.:ed if missing or
unsuitable for safe opcr.1tion.

1hesc safel)' precautions art: g.cner.11 and some statements \\ill thererore not
alwa)'s apply to a panicular unil.

The super\'isor. or th~ responsible person. shall al all titnes make sure
Ihat all instructions reganling machinery am equipment operation and
maintenance are strictly followed and that the machines with all
accessories and safcly devices. as wcll as the consuming de\'ices. are in
good repair. free of abnonnal wear or abuse. and are not tampered with,

Onl)' people that have the righl skills should be allowc:d 10 oper.1te. adjust.
pcrfonn maintenance or repair on Atlas Copeo equ.ipment. It is the
responsibilit)' of management to appoint opcr.ltors with the appropriate
Ir.:lining .md skiU for e~b calcgory of job.
Skill te\'ell: Oprratur
An operator is lr:Uocd in all aspe.ecs of Op'--"r.l1ing
bunons. aud is Irained to know the salet)' asPCCI5.

t~

unil with the push-

Skillle,'el 2: Mechanical technidan

A l",-'Chanical tedmit.;an is traiDl..'d to oJX'lOlte the: unil the same as the
operator. In addilion. the ITlC'l:hanieal lechnidan is also tr.:lined to pc:rfunn
lIlaintenan,c: and repair. as described in the instrue:tion manual. and is
allowed to change scllings uf the t.'Onirol and Slll~ty s)'stem. A mechanil-al
ltehnician dfA'S nOf work on Ii\'c elcctrical componcms.

Wllt!:never there is an indkation or any suspicion that an internal pan of

a machine is ovcme3led. Ihe machine sh311 be Slopped bUI no inspeclion
CO\'CI'S shall ~ opened before sufficient cooling time h3s elapsed: Ihis to
avoid the risk of spont~us ignition of oil vapour when :tir is admined.
Nonnal ratings (pressures. temperatures. speeds. etc.) shall be dur.lbly
"",<ked.

Op:rJle (he unit only for the intentk.-d purpost and within ils raled limits
(pressure. temperature. s~eds. ctc.).
The machinery and eqwpmcnl shall Ix kept clean. i,e. as fl\..'C as possible

from oil. dust or OIher deposils.

Skil1lnel 3: EIlricallechniciun
An d:cllical technician is trained and has Ihe same qualifications as both the
opcralur and thc mcchankallcl..'hnician. In addition. Ihe clc::clrical technician
mol)' carry out electrical repairs within the various enclosures of the unil.
This includes work (m li\'~ eleclrical components.

10 prcw:nl an increase in working lemperalure, insp..'Ct and clean he:al

transfer surfaces (cooler fins. intercoolers. waler jackels. el<':.) regularly.
Sec the maintenance schedule.
All regulating and safety dcvices shall be maintained with due care to
ensure thai they function properly. They may not be put out of action.

Skill level 4: S~iulist rn)m the msnuructurer

This is a skilled specialist scnt b)' the manufaclurer or its agt!:nt to perfonn
complclt repairs or 1Il0difications to the: equipment.

Care shall be taken 10 avoid damage to safely val\'es and other pressurerelief de\'ices. especially 10 avoid plogging by paint. oil coke or din
accumulation. which could interfere with the functioning of the device.

il is reoouunemk.-d thaI not more than ttvO ~ple opc~fe the unit.
op:raturs l."Ould lead 10 Imsafe operating conditions. Take necessary
sleps to keep unauthorized pc:rsons away from Ihe: unit and eliminale all
possible sources or danger at th~ unil.
In

~cncr.ll

lOOn:

10 Pressure and lemper.tture 8auges shall be checked n:gularly with regan!

lO lheir accuracy. They shoJlI bt: repbced whenever oUlside acceptable
lolerances.
II Safct)' devices shall be: tested as de:scribtxl in the: mainlenance schedule
of the instrul1ion manual to detenninc that Ihc:y are in good operating
condition.

When handling. operating.. o\'erhauling and/or pc:rfonning maintenance or

repair on Atlas Copco ~'Quipmenl. the rnechanics are eltpeeted to use safc
eng.il'k.."Cring pra~1ices and 10 ohscrve all rele\'ant local safety rt.'qUirements
and onIinance.s. The foIlOl\'ing list is a reminder of special safcly directives
and pn:l,.'autions maioly applicable to Atlas Copco (quipl~nl.

12 Mind the markings and infonnation labels on the unil.

safet)' pl\."Cautions appl)' to machinef)' pmc..'essing or consuming air.

Pl'\X.'~"Ssin~ of any olher gas requires additional safely precaulions typical to
th~ applicalion and arc nut indudcd herein,

1..$ Keep the work area

accidenls.

'nll,'SC

Neglecling the safety precautions may cndanger people as well as

en\'irunmenl and machillen':
endanger peoplc due 10 eleclri,a1. mechanical or chemical influences.
endanger the en\'inllunenl due to leakage of oil. soh'ents or other
substances.
endanger the machinery due to function failures.
All responsibility for an)' damage or injuf)' resulting from neglecting these
pn..'<.'aulinns or by oon-ob.scr\'anec of onlinary c3ution and due c;w reqwred
in handling. operaling. ulJimenam;c or repair. also if 0U1 expressly
mention~'d in this instnk.tion manual. is diSl..'lailllt..'d by Alias Copt."\).

The manufacturer does not accepi any Iiabilil)' for any damage arising from
the liSC (d non-original pans and for tnodificalions. additions or conversions
made wilhom the manufacturer's approval in wriling.

13 In the evc:nl the safel)' labels are dam:Jged or destroyed. the)' must be:
rcpl3ced to ensure optr.1lor safely.
1'k,."Cf. Lack

of order will increase the risk of

I S When working on the unit. wear sal~ty c1olhing. De~nding on Ihe kind
of acti\'ities these are: safety glasses. ear protection. safety helmet
(inclUding visor), safely glo\'es. protective clothing. safcly shoes. Do not
wear the hair long and loose (proteci long hair with a hairncl). or wear
loose clothing or jewc:lry.
16 Take prec3utions againsl fire. Handle fud oil and aIlli-freeze with care
because they 0lfC inllammable substances. Do nOI smoke or 3pproach
wilh naked flame when handling such substaoces. K~p a fireextinguisher in lhe \'icinity.

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

1.3

1.4

SAFETY DURING TRANSPORT AND

INSTALLATION

Whcn Ihe unit has 10 operale in a fire-liazanious en\'immncnl. each

engine exhaust has to be pro\'il1ed \\ilh a spark arreslor 10 tmp
incendiary sparks.

To lifl 3 unit. :dlloose or pivOIing pans. e.g. doors and lowhae. shalllirst he
securely fastened.

TIle exhauSi contains c:lloon ltlonoxil1e which is J. lethal gas. When lhe

Do nol aU3ch cables. chains or l'OfICs direclly (01he lifting eye; apply 3 crome
hook or lifting shackle meeting 1IKai safety regulations. Never allow sh:lrp
~nds in lifting cables. chains or ropes.

unil is uS\:d in J. confined s~cc, condul,.'1 lhe engine exhall51 10 lhe

outside atmosphere hy :1 pipe of sullicient diameler. do Ihis in such a
",a)' thai no extra h3Ck prcs.t;ure is created (or the engine. If necessal').
inSlaJl an extmC1or. Observe an)' existin~ local regulations. M3ke sure
thai Ihe unil has sufficienl air in lake for oper:uion. If nccCSS3ry. inSiall
extm air intake ducls.

Helicopter lifting is not allowed

It is siridty forbidden to dwell or Slay in the risk 7.one under a lifted load.
Never lift Ihe Unil over people or rc:sidenlial .m:3S. Lifting aeteIer-nion and
rcl:mbuon shall be kepi within safe limils.
t

When operating in a dusi-laden auoosphc:re. place lhe unit so thai dust is

not camed towards il b)' lhe wind. Operation in clean surroundings
considerably extends the inlervals for cleaning Ihe air intake filters and
the cores of the coolers,

Before towing the unit:

ascenain that the pressure vessel(s) is (arc) depressurized.
check the lowbar. lhe brake system and the towing eye. Also check
Ihe coupling or the lowing vchicle.

Close the compressor air oUilcl \alve before connecling or

disconnecting a hose. Asccnain Ihal ::I ho~ is fully dcpressuri7.cd hefore
discoMeding it Before hlo\\>;ng compressed air through :1 hose or air
line. ensure tOOt the u~n end is held securely. so that it cJ.nOOt wlupand
cause injury.

check the lOWing and brake capability ofthc lowing vcruclc.

check lh.u the towbar. jockey wheel or stand leg is SO!fcly loclrred in

Ihe raised position.

ascenain that lhe towing eye can swivel freely on the hook.
check th3t ttJ( wheels arc secure and th3t the 1)'rc5 are in good
condition and inOaled coTCctly.
eonnecl the signaliS3tion cable, check all lights and COnTleCI lhe
pneum:nic bDke coupl~rs.
al1ach Ihe safely hreak-away cable or safely chain to lhe towing
v~hicle.

remove wheel chocks. if applied. and disengage the parking hrake.

To tow a unit usc a towing vehid~ of ample capacily. Refer
documentation of Ihe towing vehicle.

10

Ihe

If Ihe unit is 10 be backed up by the lowing vehicle. disengage lhe

o\'enun bf3ke mech.3nism (if il is 001 an aUlom:uic mechanism).
Never exceed the l1l3ximum towing speed of the unit (mind lhe local
regulations).
Place Lhe unil on level ground and apply thc ~r1Ong brakc hcfore
cJisconoccting lhe unit from the lowing ,,ehidc. Unclip Ihe safcly breakaway c"hJe or safely chain. If lhe unil has no parking broke or jockey
wheet. immooili7.e the unit by placing chocks in front of and/or hchind
the wheels. When Ihe towhar Can be position~d \ertically. the locking
device must be applied and kepi in good onler.
To lift heavy pans. a hoist of ample capacity. tesled and appro\'ed
according to 10Cl1 safely regulations. shall he used.
Lifling hooks. C}'CS, shackles, CIC.. shall nevcr be Nni ;md soon onl)'
have stress in line with their design load axis. 1bc capacily of a lifling
de\ice diminishes when the lifting fOICe is applied at an angle to its load
a.xis.

For maximum safety and efficiency of the lifting ap~liuus alllifung

members shall be applied as near 10 perpendicuLu as possible. If
required. a lining beam shall he: :1pplied between hoisl :1nd load.
Never leave :1 load hanging on a hoist

10 A hoisl has to be installed in sucll a way that the ohject will be lilled
perpendicular. If lItal is nOi possible. the necessal')' precaulions must be
taken to pre\'ent load-swinging. e.g. by using two hoiSlS, each at
approximately Ihe sallle 3J1gle nol exceeding 30 from lhe \eniC:11.
}I 1.ocale the unil :1way from WJ.lls. Take all precOlwions 10 ensure Ihal hOi
air exhausted from the ~ng.ine :1nd dri\'en machine cooling syslems
cannot be recirculated. If such hot air is taken in b)' Ihe engine or dri\'en
machine cooling fan. this limy cause overheating of the unit; if lJ.ken in
for comroSiion. the engine power will he raJuced.

SAFETY DURING USE AND OPERATION

1be air line end connecl~d to the outlel v:1lve musl be

a s:afct), cable. J.llachcd next to the \'al\'c.
6

s.3f~l!uarded with

Nt.! elernal fol"C't 1001)' heellel1...,1 on lhe .uroUlIcI \'alvcs. e.g. h)' pulling
on hoses or hy inslalling auxiliary equipment directly 10:1 \'al\'c. e.g. a
waler separalor. a luhricalor. eiC. 00 nOi slep on Ihe air OUticl val\'es.
Nev~r mo\'e a unil when exlernal lincs or hoses are connected 10 Ihe
outlet val\'es. 10 a\'oid damage to \'al\'cs. manifold and hoses.

Do not use ct>lnpressed air from any I}'PC of compressor. withoullaking

eXIra measures. fur hfe::llhing purposes 01S lhis may resulr in injW)' or
dcalh. Fur hreathing air quality. the compressed :air mu~ be adequ:lldy
purified acconling 10 local legislation and seandards. Bre:uhing air must
alwJ.ys be supplied al stahle. suitahle pressure.
Distribution pipework and air hoses must ~ of correct diameler and
suilJ.hlc for the working pressure. Ne\'er usc fmycd. d:lJooged or
dCferiur.lIed hoses. RC('lJ3CC hoses Ol"d tlcxiblcs hcfore the lifctime
expires. Usc ani)' the correci IYpe and size of hose end linings and
connections.
10 If the compressor is 10 he used for sand-bl::lsling or will he connccted 10
a common compressed-air system. fit an appropriale non-relurn valve
(check valve) hclwcen compressor oullet and Ihe connected sandblasting orcomprcssed-air sysecm. Observe the right mounling posilion!
direction.
II Befote remo\ing thc oil filler plug. ensure lh.3t the pressure is released
h)' opelling an air oullet valve.

12 Ne\'cr remO\'e :1 filler cap of the cooling waler sySiem of ::I hot

enp.i~.

Wail unlillhe engine has sufficiently cooled down.

13 Nc\'er refill fuel while the unit is running, unless olherwise stated in lhe
Alias Copeo Instruction Book. Keep fuel away fmm hot pJ.rts such as air
outlet pipes or Ihe ~ng.ine exhausl. Do not smoke when fuelling. When
fuelling from an autom:lIic pump. an eanhing cahlc should hc cunnecled
10 Ihe unil to dischargc stalic eleclricity. Never spill nor leave oil. fuel.
molanl or cleansing. a~enl in or around the unit.

Instruction Manual

I'" All doors shall be shul during DpCmtion so as noc to dislUrb Ih~ cooling
air How inside lhc bodywork and/or render the silencing le~ ~rrecti\'C.
A dour should be kept open for a short period only e.g. for inspection or
adjuslment.
15 Periodically carl')' OUI maintcnancc works acconling 10 Ihe maint~nance
schOOu"'.
16 StalioJlary housing s.uanfs art pro\'itkd on aU roc.l1ing or n:ciprocaling
p.arts nut ()(herwiSc: protecl\."tf and which may Ix h:J.ZJ.rdoIIS 10 personnel.
MachineI')' shall tk.':\~r tJ( put into operation. w~n such guards ha\'c
~n remo\'oo. btfore the guards are securtl)' tcim.lalled.

1.5

Maintenance. overhaul and repair work shall unly he cnllf~ll UUI h)'
adequately tr-.uncd personnel; if required, unller ~lIl'crvilliuu ul' MIIIICIIIIQ
qualified for thc job.
I

Pans shall only be

lak~n.

Iimit~d

aoo\"( 85 dB(A):

room to be clJ.ssifi\."lI as a 1I0isehazanJous area and an obvious

warning shall be placcd pennancntl)' al caeh enlrance: 10 alcn peopl~
Ihe room. for cven rc1ali\'cl)' shon timcs. abuut th~ need to
wt:ar car protC:":IUrs.

cm~ring

puns

Make sure thai no tools. loos(' piUlS or rags ace Idl in or on the l1\achine.
Ne\"~r le:1\'c rags or loose clothing near the: engine air intake.

,ho\"e 95 dB(A):

warning(s) al Ihe CnlrJ~(s) shall bt complelCtt with Ihe:

te<.'Qrrunendatiun thai also occasional visi10rs shJ.1I w~ar ~ar
protectors,

replal,.~lncnl

Before dismantling any pressurizoo compo~nt. the compressor or

equipment sh31l he: ellectively isolated from all sources of pressure and
the:: entire sysl~m shall ~ relic\\.'tI of pressure. 00 nOl rely on non-relurn
\'al\"es (ehcck valves) to isol3lc pressure syslems. In addition. :1 warning
sign btaring a lcg~nd such as "work in progress; do not o~n" shaH be
allOichtd 10 ~::teh of th~ outl~t \':1}\'\.'5.
Prior 10 stripping an ~nginc or oth~r machin~ or undeluking major
overllaul on it. prevent all movablc pans from rolling ov~r or moving.

""Iuw 85 dBCA):

Ih~

Alias COJ)\."O

only

~quiprnc:nt.

noise-protC\.'li\'c d.:\il,,-cs should be pro\rjdoo for pt."Oph: l.:Ofllinuously

being prcsent in lhe room.
;)C,.1ion nceds to he tak.:n for lX"1.03Sional \;sitors sla)'ing a
lime only.

repl~ by g~nuill(

Dllli

On engine..<Jriv~n units th~ b:1ltel)' shan be disconnected and removed or

the tenninals covered by insulating caps.
On electrically driven units lite main switch shall be locked in o~n
position and th~ fuses shall be taken OUI. A warning sign btaring a
legend such as "work in progress; do not supply voltage" Shall be::
allachtd 10 Ihe fuse box or troin SWiICh.

,ho,e 70 dB(A):

110

Use only the: com.'C1 lools for m:lin1~nance and repair wJlrk.
(ools which are in good condition.

All mainte:nance work. other man routine J.ttcntion. sh311 only be

uooenak~n when the unit is stopp.-d. Steps shall be taken 10 prc.\'cnt
inad\"~n~nl suning. In addilion. a warning sign bc3ring a Jc:gcnd such as
"work in progress: do nol Sian" sh:1t1 be allachf..'d (0 Ihe staRing

17 Noisc. e\'~n J.I r~:UOnolblc l~\els. can cause irritalion and distum:tnl:e
which. oyer a tong period of limc. rna)' l:ause .5c:\tre injuries to Ihe
nervous sysl.:m ofhwnan bdngs.
When Ihe sound pressure level. at any poim where personn~1 nonnall)'
has 10 al1cnd. is:
""Iuw 70 dBcAJ:
no action nc~ds lU ~

SAFETY DURING MAINTENANCE AND RePAIR

NC\'~r US~

Tak~ saf~IY

aho\"e 105 dB{A):

Nc\'~r ~

spt:\.:ial car protL'CIOrs Ihal J.re adeqwte for lhis noise level and thc
spt..'\:lrJI "..omposilion of Ihc noise shall be: provided and a special
warning 10 lhal dIet.' shilll hl: placed ar each cntl"':lOCc.

10 Observe scrupulous deanliness during maintenance and repair. Keep

III Insulalion or safely g.uards uf pans the lcmpc:mlure of which can be in

~lIcess of 80C (175
and whkh ma)' bt: accid~nl:1l1y louchcd by
~rsonnel shall not ~ remo\'cd before the pans have cooled 10 room
telnpcmture.
19 Ne\'cr opcrJlc lhe: unil in surroundings where there is J. possibilit)' of
filing in l1:unmablc ()( toxic fumes.

on

20 IT Ihe working prt>C\.'SS produl,.,\:s fumes. dust or \ibr.uion hilZards. elC.,

take the n\."CeSS:lf)' secps to eliminatc th~ risk of ~rsonnc::l injul)'.
21 When using compresscd :lir or incn gas to clean down ~quipl1'lt:nl. do so
wilh caution and use Ihe approprialc protectiun. at leasl S3f~ty glOlSscs.
fur the opemtor as wcll as for an)' hyslander. Do not apply compress.."tJ
air or ine:n gas to )'our skin or dircc1 an air or g3S slream J.l poople.
Never us~ it 10 clean din from your clothes.
22 When washing pans in or with a clcaning sol\'ent. provide th~ required
\'cntilation and usc appropriate protcdion such as a breathing filter.
safety glasses. rubt-:r apron and gloves. CIC.
23 Safcl)' shO\."S should ht: compulsol')' in any workshup aud if there is a
risk. hlJwcv~r slnOill. of faHing. objects. w~aring of a safel}' hchntl should
Ix inducted.
24 If Ihcre is a risk of inhaling hal:1rdous gases. funlt:s or dust. lite
l\.'SpirJlory urgans lOOS! bt protel.,ro and dt~nding on the: nature of lhe
hazan!. so loosllhc eycs and skin.
25 Remember that wht:re there is \;sible duSl. the finer. imisihJ.c panicles
will almust L'cnainly be pR:S4:nt 100; bolthc f....1 lhal no dusl can ~ ~en
is nOl a reliable indicatiollihal dangcrous. invisible dUSI is not prc~nt in
thc air.
26 N~ver operJt~ the nnit Oil pressurcs or specds below or in excess of its
iii nits as imlicalL'd in Ihc I\.'l,;lmical spcdlicalions.

awOlY din,

IlammabJc: sol\'enls for cle.1ning (fire-risk).

precautions againsl10xic \.'apours of cleaning liquids.

machine pans as J. climbing aid.

cov~r

the pans and

~lIposed

openings \1r;lh :1 dean cloth.

pOl~rorlJ.~.

II

Nev~r

wcld on or pcrfonn any operation im'olving hcal near the fuel or

oil s)'stems. Fuel and oil lanks mUSI be complctel)' purged. c.g. by
sleam-d':J.ning. before carrying out such operations. Never weld un. or
in any way modify. pressure vessels. Disl,.'Onneet the alternator cabl~s
during an.: weldi ng on the unit.

12 Suppon the towbar and the allle{s) securely if working underneath Ihe
unil or when removing a wheel. Do not rely on j:1cks.
13 Do 1101 remo\'~ an)' of. or l;unlXr with. the sound-damping m:1t~riJ.1.
Keep the material free of din and liquids soclt as fuel oil aDd cleansing
ag~nts. U any sound-damping matcrial is dam::lged. repl:lC~ it to pre\'~nl
Ihe sound pressun: level from increasing.
J4 Use only lubricaling oils and gre:lS\.'S ret.'011lI'11l:nded or approved by
Atlas Copeo or th~ machine: manufaclur~r. Asc~nain that Ihe selected
lubricanls cOlllply wilh all applicablc safely regulations. ~speciJ.n)' with
regard to ~lIplosion or fire-risk and the possibilit), of decomposition or
gen~mlion of hazanlous gases. Never lnix synlhclic wilh min~r:11 oil.
15 Protect thc cngine. ahernalor. air inlOlkc filter. electrical and regulating
I,.'tunponc:nls. eIC.. lO pre\'~nl moislure ingress. t.g. when sle:un-eleaning.
16

17

When ~rfonning an)' oper.nion involving heal. names or sparks on a

machine. lhe SUlTOunding components shall first be screened wilh nonn:unmable loot~rial.
N~\'cr US~ iJ

liglu source with open

OJ.m~

for ins~C1ing 1tJ( int~rior of a

m.xhinc.

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

18 When rep:tir has been complcled. the machine shall he barred o\'er 011
IcaS( one revolUlion for reciprocating lIlachines. se\'eral re\'olutions for
roc3J)' ones 10 ensure thai there is no mcdunic3l interference within the
m:tehinc or driver. Check the dinxlion of rol31ion of elcclric mOlors
when staning up Ihe machine initially 300 after any aUcr.uion to the
elcctrical conneaion(s) or 5";lcl1 gear. 10 check thai the oil pump 3nd

the fan function properly.

19 Maintenance and repair work shoukl be recanted in an O(lCl'ilIOr"S
loghook for all machiner)'. Frequency and nature of rep3.irs can reve3J

unsafe conditions.
20 When hot pans have 10 be handletl e.g. shrink fining.. special heal
resistant g.lo\'es shall be used and. jf required. olher bOll)' prOicetion

shall be ,pplied.
21 When using canridg.e type breathing filter equipment. 3SCcn:tin th'lI the
correct type of can ridge is used and thal its useful service life is not
sUrJUssed.
22 Make sure thou oil. soh'ems and other subsl3nccs likcl)' 10 pollolc lhe
enviromnenl are properly disposed of.
23 Bdore ctearing. the urnl for usc after maintenance or overltaul. check
rnat operating pressures. 1empera1ures and speeds are CtnTCCt and Ihat
1he comrol and shUtdown devices function correcdy.

1.6

TOOL APPLICATIONS SAFETY

Appl)' the proper 1001 for each job, With the knowledge of correci 1001 usc
and knowing. the limit3tions of 10015. along wilh some common s~nse. man)'
accidems can be prcvenled,
Special service tools are available for specific jobs and should be used when
recommended. The use of these lools will sa\'e time and prevent damage 10
pans,

1.7

SPECIFIC SAFETY PRECAUTIONS

BaUerirs
When sc....icing balleris. atway!i wear protecting clothing. and glasse!i.

Instruction Manual

2.

LEADING PARTICULARS

2.1

DESCRIPTION OF SAFETY PICTOGRAMS USED IN

THIS MANUAL

This symbol draws )'oor alienIion to dangerous

situations. The operation roncerned ma) endanger
persons and cause injuries.

10c electrolyte in ballerics is a SUlphuric acid solwiun which is fatal if it

hilS )'uur eyes. and which can cause bums if 11 conlac.:ls your skin.
llierefore. be careful when h:mdLing batlcries. e.g. when dlcckin~ the
charge condition.
I05lal1 a sign prohibiting fire. open name and smoking allhe post where
balleries afC being charged,

This S)'mbol is followed by supplementary infonnalion.

When baltc:ries are being charged. an explosi\'e gas O'rixture fonns in the
cells and might escape through the ventilates in the plugs,
ll1US an explosh"e almosphere ITU)' fonn around Ihc ballC1)' if
\'enlit3tion is poor. and can remain in and around the ballery for several
hours afler il has ~n charged. Therefore:

Regulation
The compressor is provided with a continuous regulating system and
a blowdown valve which is integrated in the un loader assembly. The
,'al,e is closed during operntion by air recei ver pressure and opens by
air reeci verprcssure via the compressor element when the compressor
is stopped.
When the air consumption ifk:rcases. the air receiver pressure will
decrease and vice versa.
This receiver pressure variation is sensed by the rcgttlating valve
which. by means of COOlfO) air to the unlO'Jdcr ilnd engine spct::d
rcguhuor. nlah.:hcs the air output to the air consumption. The air
receiver pressure is maintained between the pre-selected working
pressure and the corr<sponding unloading pressure.

ne\'er smoke near hauerics heinp;. or h:I\'in~ rccemly hcen, charged.

Cooling system
The engine is equipped with a liquid cooler and intercooler. All
conlpressors are equipped with an oil cooler.
The cooling air is generated by a fan. driven by the engine.

- ne\'er break lh..c cirt"uils al ballery leonina Is. hccausc a spark usually
occurs.
When connecting an auxilial')' bailer)" (A B) in parallel 10 the unit baileI')'
(CB) wilh hoosier cables: connect1he + pole uf AH to Ihl: + pole or CA.
1hen connect the - pole of CB to the ma!iS of 1he unit Disconnect in the
reverse order.

Safety devices
A thermal shut-down switch protects the compressor against
overheating. The air recei\'er is provided with a safety val\'e,
The engine is equipped with low oil prcssure "od high coolant
lcmpcmturc shutcJown switches and a coulant level switch.

Pressure vessels
(nceurding tu directi\'e 87/4041EF.C annex II 2)
Maintenance/installation requirements:
The vesset can he used as pressure vcssel or as separalor and is designed
10 hold compre!ised air for Ihe following application:

Frame and axle

The compressor/enginc unit is supported by rubber buffers in the

- pressure \'essel for comprcssor.

- mediuIR AIR/OIL.
and opcrales as detailed on lhe dala plate of lhe vessel:
Ihe maximum working pressure ps in har (psi).

fmme.

Fig. 2.1

General \'ie'" of XAVS )66 Dd with some options

lhe maximum working Icmpcr:lIUre Tl11ax in C (of).

lhe minimum working lemper:Hurc Tmin in C (oF),
the cap3cil)' ofltlc vcssel V in I (US ~at. Imp ~al. cu.l'I).
The pressure vessel is onl)' tu be used for lhe aJl(llications as spccilie<l
ahovc and in accordance with the technical specilicaliuns. Safct)'
fCasonS prohibit any 01her applications.
Nationallegislalion requirclrtems wilh rcSPCCllO re-inspection IUUSI he
complied with.
No welding. or heat Irc:ntrten1 of an)' kind is pennillcd to lhose \'c!isel
walls which are exposed 10 pressure.
The vessel is provided and may only he U!iCd wilh the required safet)

2.2

GENERAL DESCRIPTION

The c"",prcssors type XAHS 146 Dd. XATS 156 Dd. XA(Sj 186
Dd. XAVS 166 Dd and XAHS 186 Dd are silcncc-d. single-stage.
oil-injcctl.:u st:r~w contpressors. buill for a nominal cITet:ti\'e
working pressure. ranging from 7 bar op to 14 bar (see chapter ~ ..
lcchnkal SPCCiti1'3lions).

The standard unit h"s" non-adjustable towbar with a towing eye.

As an option the unit can he equipped with an adjustable towbar, an
overrun aDd parking brokc and towing eyes type DIN. ball. ITA. GB.
NATO. AC (France). (for available optioos sec chapler 7.).
The braking system ....on:;ists of an integrated parking hrJk.e and
o\'crrunbrakc, When driving bac.:kwards the ovcnunbrakc is nOl
cngagcd automatically.
Bodywork
The bodywork has openings at the shaped from and rear end for tbe
intake and outlet uf cooling air and hinged doors for maintenance and
service operations. The bodywork is interoally lined with soundabsorbing material.

Engine

cquipmenl such as lRanometcr. o\'elflrcssure conlrol device!i. safcty

vah'e. elc.
Draining. of condensate shall he pcrfonncd regularly when \'cssel is in

The cl1ntprCssors arc drin:n by a liquiut:ooJcd diesel cngine.

The engine's power is tnmsmiucu (0 Ihe compressor through a heavy-

usc.

duty coupliog.

Lifting eye
A lifting: eye is nCf:essiblc when the small door at the top of the unit
is unlocked. '

Inslall.alion. design and conneclions shouhl nm he changed.

Holls of cover and Oang,es rna)' nol he u~ for eXira Ihalion.

Compressor
The compressor c.:~lsing hou~s (wo scrcwtypc rotors. mounted on

Safety val,'es
All adjustIRents ur repairs are to be donc h)' an authorized representative of
the val\'e supplier (sw InalnlL'nant'C SdlCJulc ,1.2,.

ball and rollcr bearings. Thc OIale rotor. driven by the engine. dri,cs
the female rotor. The clement ddi\'crs pulsation-frl'e air.
Injected oil is used for scaling. cooling ancJ lubricating purposc:s.
Compressor oil system
The oil is buusted by air pressure. The system has no oil pump.
The oil is removed from the air. in the air/oil \'essel ill first by
centrifugal force. secondly by the uil ~piJr;,tlOr element.
The vessel is provided with an oil Ic\'d indicatur.

10

Control panel
Thccontrol panel grouping the air pressure gauge. control switch etc.,
is placed at the right hamll rear end corner.
Data plate
The compressor is furnished wilh a data plate showing the product
codc. the unit number and the working pressure (see chapter 9.).

Serial number
Thc serial number is located on the right-haod side towards Ihe front
on thc upper cdge of the frame and also on the data pl"tc.

II

XAHS 146 Od - XATS 156 Od - XA(S) 186 Od - XAVS 166 Od - XAHS 186 Od

2.3

2.4

MARKINGS AND INFORMATION LABELS

c~t

Compressor owlelle~r.uW"e too high.

C~I

Compressor outlet temperolure.

CQ &

&

&
&

o
o
o

~OOID

Rt..--alJ the instruction manual

Danger. heal nat

Electrocution hazard.

Alias Copro synthetic compressor oil.

PAROlL

Alias Capro mineral engine oil.

E3-

//

Manual.
Read the instruction manU'll
before working 00 the bauef)'.

On I ofr buuOll.

(3

Hours. time.

-t)''1'

:@

.....

~e,..

(AFcE)
(EP)

(AA)
(FP1)
(MPV)

Warning!

Pari under pressure.

(OC)

O~I

Stan-Stop indk:uion of switch.

ii!dlesel

(TB)

(RV)

Do nOI stand on outlet \'al\'es.

(SV)

Service C\'ef}' 24 hours.

@
@

(VICE)

~fore ~laJ1ing.

Do not run the molor with npm doors

(OPec)

lifting pennincd.

(OFE)
Ust diesel fuel only.

(FT)
(DSE)

Reset fuse.

0 I

(E)(S)

Dangemu.~

PAROILS

~OmmJ

(CLS) (FC3) (IC)

(A)

Outlet.

Compressoc oil df"3in.

Atlas Copro minerai compressor oil.

D~

MAIN PARTS

Inlet

([j)~

PAROILM

SAE1SW40

Compressor owlet pressure.

outld.

Instruction Manual

Prohibition 10 open air val"es withow C'OMCet.ed hoses.

Compn:"", Ioodcd.

Rwllamp.

Airfillcr.

Compressor temperature too high.

ROlation direction.

4.75 bar /69 psi

IDJ
~

(AFE)

Tyre pressure.

Sourd power level in 3C'(,'(lI'd:l.Occ with

Directive 2OOO/t,M:C (~x('lf~~ in dB (1\)1.

(CE) (CP)

Sound power 1I~\'d in 3C'roCdallC'C with

Direeth'e 2000/141EC (expressed in dB (Al).

Fig. 2.2

MJin ~ns ofXAHS 146 DtJ. XATS 156 DtJ and XA{S) 186l>d wilh $011lC options

Sound power le\'el in xrocd:mcc wilh

Directive 2000/14IEC (expressed in dO (Al).

~~
i::~~ 6

Hori7.0fllallowbar position required

in ,,:3.lie of couplin{:.,

Altcnlator
Air Filter (c.:ompressor demc:nt)
Air Filtc:r (enginc)
AFE
AnV Air Outlct Valvcs
Air Receivcr
AR
Brake Handle
UH
enolant Coolcr
CC
Compressor Ek~mcnl
CE
Coolant Levcl Switch
CI.S
Control Pand
CP
o Kllant Tank
CT
DPnc Dr-din Plug Oil Coolcr
Engine Oill.cwl Dipstick
DSE
A
AI' CE

E
EI'
I'
Fe l
FC,

Fe;

FF I
FF2
FLG

I'P I

FT
IC
MPV

Engint:
Exhaust Pipe
Fan
Filler Cap (engine oil)
Filler Cap (fuel lank)
Filler Cap (coolanl)
Fuel Prefiltcr
Fucl Filtcr
Fuel Lcyd Gaugc
Filler Plug (compressor oil)
Fuel Tank
Intercoolcr
Minimwn Pressure Val\'c

oc

OilCoolcr

OFCE
OFE
OLG

Oil Filter (compressor clement)

RV
S
SL

SN
SV
TO
VICE
VIE

VV

Oil Filter (engine)

Oil Lcvel Gauge (compressor element)
Regulating Valve
Staning Motor
Support Leg
Serial Number
Safcty Valve
Towbar
Vacuum Indicator (compr. elcment)
Vacuum Indicalor (enginc)
Vacualor Valvc

13
12

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

Instruction Manual

COMPRESSOR REGULA TlNG SYSTEM (LOAD CONDITION)

(AFCE)

(VI)

(SC)~~~~~"-----(VVl--l::J--lI--_v

(DC)

(OS)

(FF1)
(SN)
(DPec)

(>

(OFE)
(FT)

AFCE Air Filter (compr. elemen!)

AFE Air Filter (engine)
AOV Air Outlet Valves
Air Receiver
AR
BDV Blow Down Valve
BOV Blow Off Valve
Cnmprcssnr Element
CE
CH
Coupling Housing
CV
Check Valve

(VV)
(FLG) (FC2)
(CE)
Fig. 2.3

Regulating S)'SlCIlI

Fig.2A

(CP)

2.5

Main pans ofXAVS 166 Dd and XAHS 186 Dd with some options

DP
E
F

Drain Plug
Engine
Fan
Fillcr Plug
FP
Flow RestriclOr
FR
LV
Loading Valve
MPV Minimum Pressure Valve
NRV Non Return Valve
OCCE Oil Cooler (eompr. clem.)

OF
OLG
OS
PG

RV
SC
SL
SR
SV

Oil Filler

Oil Lcvd Gauge

Oil Separator
Pressure Gauge
Rcgulaling Valve
Safcly Cartridge (option)
Scavenge Line
Speed Regulator
Safety Valve

TS
UA
UV
VH
VI
VV

Temperature Switch
Un loader Assembly
Unloadcr Valve
Vent Hnle
Vacuum Indicator
Vacualor Valve

AIR FLOW
(SEE FIG. 2.4)

A
AFCE
AFE
AOV
AR
BH
CC
CE
CLS
CP
CT
DPec
DS E

Alternator
Air Filter (compressor clement)
Air Filter (engine)
Air Outlet Valves
Air Receiver
Brake Handle

Compressor Element
Coolant Level Switch

Engine
Exhaust Pipe
Fao
Filler Cap (ellgine nil)
Filler Cap (fuel tank)
Filler Cap (ellnlalll)
Fuel Prefilter
Fuel Filter
Fuel Level Gauge

Control Panel

Filler Plug (compressor oil)

Cnolanl Tank
Drain Plug Oil Cooler
Engine Oil Level Dipstick

Fuel Tank
Intercooler
Minimum Pressure Valve

Coolant Cooler

OC
OFCE
OFE
OLG
RV
S
SL
SN
SV
TB
VICE
VIE
VV

Oil Cooler
Oil Filter (compressor element)

Oil Filter (engine)

Oil Level Gauge (compressor clcmcl11)
Reg.ulating Valve
Starting Molor
Support Leg
Serial Number
SafelY Val\'e
Towbar
Vacuum Indic:.nor lcompr. clement)
Vacuum Indicator (engine)
VacualOr Valve

The s)'slem comprises:

AF

ARIOS
CE

UNUV
BDV
LV

Air filler
Air reccivcr/oiI separator
Compressor clement
Unloader assembly with unloader \'al\'e
Blow-down valve
Loading \'alve

Air drawn through the airlilter lAFCE ) into the cnmpressor elemcnt
(CE) iscompressed. Allhe clemcnl outlet. compressed air and oil pass
into thc air receiver/oil separator (ARlOS).
Thc check \'alve (CV) prevents blow-back ofcompressed air whcn the
comprcssor is stopped. In the air recei\cr/oil separator (ARlOS), most
of the oil is removed from the air/oil mixture: the remaining oil is
removed by the separator element.

14

The oil collects in the receiver and on the bottom of the separator
element.
The air leaves the receiver via a minimum pressure val vc (MPV) which
prevents the receiver pressure from dropping below the minimum
working pressure (specificd in section S.3), even when the air outlet
valves arc open. This ensures adeqmlle oil injection and prevents oil
consumption.
A temperalure switch (TS) and a working pressure gauge (PG) arc
comprised in the system.
A blow-down valve (BDV) is fined in the unloader assembly to
automatically depressurise the air receiver (ARl when the compressor
is stopped.

15

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

2.6

OIL SYSTEM
(SEE FIG.

2.4)

The s)'slem comprises:

ARIaS

OCCE
OF

2.7

CONTINUOUS REGULATING SYSTEM

(SEE FIG.

2.4)

The syslem comprises:

Air receiver/oil separator

Oil cooler

RV
UA

Uoloader assembly

Oil filter

SR

Speed regulator

The compressor is provided with acontinuous regulating system. This

Air pressure forces the oil from the air receiver/oil separator (ARlOS)
through the oil cooler (OCCE) aod oil filter (OF) to the compressor
clemem (CE).

system is provided with a blow-down val\ e which is integrated in the

unloadcr assembly (UA). The \'ah'c is closed during operation by air
recei \'er pressure and opens by airrecci verpressure \'ia the compressor
element when the compressor is stopped.

Lubrieatioo of the beariogs is eosured by oil iojected ioto the beariog

housiogs.
The injectcdoil. mixed with the compressedair.leu\'cs the compressor
element and re-enters the air receiver, where it is separated from the
air as described in section ~.:i. Theoil that collects in the bouomofthe
oil separatorelement is returned tothe system through scavenging line
(SI.). which is provided with a flow reslrictor (FR),

The oil filter by-pass valve opeos wheo the pressure drop over the filter
is above oormal because ofa clogged filter. The oiltheo by-passes the
filter without beiog filtered. For this reasou. the oil filter must he
replaced at regular iotervals (see sectioo 4,2).

2.8

All compressors are cquipp~d with a ncgati\'~ carthcd system.

ri-- ---------~I~h-!

;0;

e2

When the air consumption increases. the air receiver pressure will
decrease and vice \'ersa. This recei ver pressure variation is sensed by
lhe regulatiog ,'alve which. by meaos of comrol air to the uoloader.
matches the air output to the air consumption. The airrecei\'er pressure
is maintained between the pre-selected working pressure and the
corresponding unloading pressure.

I,
j
1.

When starting the compressor. the unlo:.uler v:.t1\'e (UV) is kept open
by spring force. the engine runs at maximum spced. Thc compressor
elemeOi (CE) takes io air and pressure builds up io thc receh'er (AR).
The air output is controlled from maximum output (I f)()t,7c ) tono output
(0%) by:

ELECTRICAL SYSTEM

2.8.1 CIRCUIT DIAGRAM FOR XAHS 146 Do. XATS 156 Do AND XA(S1186 Do

Regulatiog valve

The lower pan of the air receiver (AR) serves as oiltaok.

The compressor elemem has ao oil gallery io the bOllom of its casiog.
The oil for rotor IUbricatioo, cooliog aod sealiog is iojected through
holes io lhe gallery.

Instruction Manual

11

2. Air inietthrolliiog.

If the air consumption is less than the maximum air OUlput. the
regulatiog valve supplies comrol air to uoloader vah'e (UV) toreduee
the air output and holds air recei\'er pressure bctween the nomml
workiog pressure and the correspoodiog uoloading pressure ofapprox.
1.5 bar above the nomlal working pressure.
When the air consumption isresumed.the hlowoIT\'al\'c (I30V)closcs
aod the uoloadcr valve (UV) gradually opeos the air intakc and the
speed regulator (SR) iocreases the eogioe speed.
Thecoostructioo of the regulatiog valve(RV) is such thataoy iocrease
(decrease) of the air recei\'er pressure aboyc the pre-sct \'ah'e opening
pressure results in a proportional increase (decreasc) of the control
pressurc to the unloading valve and the speed regulator.

c,

~i
2

iOl

tm p~j

e3 '",

c2

KS'

::: l!-L"
::

Gt~:

I,

,,1 I

d2

\--

~Mt

:< M')
I~

~ __ -=__

:I
~: I
e6n

iI

jO

T7/

1,'-

I
II

I
L._._.__ ~_._._._.j

3. Blow off \,ah'e (BOV).

If the air consumption is equal to or exceeds thc maximum air output.

the engine speed is held at maximum load speed and the unloading
valve is fully opeo.

!~

i !I
K6.,: I
'[30; I

1. Speed coolrol of the eogioe between maximuOlload speed aod

unloading speed (the output ofa screw eompressoris proportional
to the rotatiog speed).

Tn be uscd with Cold Start Option.

Tn be uscd with Rctincr)' Equipmclu.
Position of DIP-switchcs.
Fig. 2.5

86
Fl

Gl
G2

KO
K5
KG
K9

Circuit diagrJ.1l) (Nr. 9822 0893 12)

Fuell..c\'el Scnsor
Circuit Breaker
Baltcr)' 12V
Charging Alternator
Startcr Solenoid
Auxiliary Starter Relay
Cold Stan Relay
Overspced Relay

N5

Starter Motor
Comrol Module
Overs peed Comrol Module

S5
S7
S8

PI
P2
P3
S3
S4

Hourm~tcr

Glowplug
Fuel L~\'el Gaug~
Compressor T~mpcralUre Switch
Engine Temperature Switch

S9
Xl
Yl
Y2
Y3

MI
N4

Engine Low Oil Pressure Switch

Overspced Control T~st Switch
Push Bullon
Coolant L~vel SwilCh
Module Connector
Fuel Slop Solenoid
Excess Fuel Provider
OYcrspced Solenoid

Not~:

For correct fuoctiooiog of th. modulc. the dip switches at the back of the module should be positiooed as follows
With coldstart optioo

Staodard (00 coldstart)

Part of the control air is vented to atmosphere. and :.my condcnsate

discharged. through the vent holes (VH1.

Not used
I'rehcatColdstart
Low fuel level
Low coolant le\'c1
Fig. 2.6

L>ip swih:hcs

17

16

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

Instruction Manual

2.8.2 CIRCUIT DIAGRAM FOR XAVS 166 Do AND XAHS 186 Do

3.

OPERATING INSTRUCTIONS

The compressor is equipped with a negative earthed system.

3.1

PARKING. TOWING AND LIFTING INSTRUCTIONS

,,- .. -.. __ ._-_..__ ...

[ I

e2

i I!
'~~iP2~! I
I

e3

\S39'

' '"
l

!,T--'

i:

1!
i,~

',---<

,:

"i~/-'
MJ:I
i,i:.,l, M, /!

,
"

,:

.".__-1'-_- --'

"I"

Attention:
Before pUlling the compressor in to use. check the brake system
:'IS dt:scribed in section 5.0.

----~~i:;~~~;tJi:~I:-~:l
1301 __
,

~~SMS

All

.....-

COMT EMiT ENGP!

4E:J

PHi

SPl

8-

FCS

Fe

SP2 j

03 03

K5~ i1
I
O3

._._.

J>-L-.....!
S :6~
i r:

II!

I I

: l"'bf03ri03::!'!i~lb2I"

/- II:

i- I;;
1

._L.L.._.

I I
03

~Il)

::.

X':9li':';'--Xij"-Xill'lit'~T5 -i,:,------,~-i,:,i--I-----!

I ,

KS

31 'I ,,"

61-

d2

K6

Fb

C2

~l ~!~"
I
'1

Safety precautions.
The operator is expected to appl}' all rele"ant safety
precautions, including those mentioned on the pages
7 W of this book.

--')

Fig. 3.3

Parking position of jockey wheel

Fig.. 3.-1

Rcar-cod of compressor upwind

After the lirst 100 km travel- Yearly or every 5000 km:

Check and retighten the wheel nuts and towbar bolts tn the
spcciIit:d torque. See $Celion 3.1.3 and section ~.I.
Cht:L'k the brake adjustment. St:e section 5.6.

3.1.1

PARKING INSTRUCTIONS

~ i! 03 -I "O3~
:: ~!:-1 i
i :K9': 1
O3! 1 ; : c6
03 03 1:- "l" i-,- -i'-;Ja:i h PI I,
I
II Ii
r-l~)IG "2
I;N5 ~
j] ,:!:: i I, J.vtkJ
I'
'
i
I
5
I,
I! 1 i
+ ~
~
i ! I.
I! I i
b31~
i
b31~ b31~ b3f! 1c3,;;:;l;~
ill' i
;--' --- -I
: K9L. : i 1803

'I'

;1_1

If

,- __ ,G!:-i,_,
,-_.............,._-!--\,:.:
b. )

I 'C.t

Ii!
55, i K6' I

;,:86 ~G.--_

__\' ,I
.1 ';

L._]

-j --

1'

3.1.2 TOWING INSTRUCTIONS

iii],," ,,6 I: U L L1----1-----"

'i ""'F'"''-ill '""'
.
~~
I"
~ i ~ '~ L' ~ I ~. I~ L
~~HI_----:~_-="4'''''----_''''':''=i-''''--~L~-.L1-i~"L'-';'!...l--"'''~~- ,,- ,,- -,
I

(2)

53

54
I!I

59

,0

11:0-\

57,

,I

Y3;

Yll

58'

,,-

,,;-

7/:;

~._._._._.~_._. __ J

b6-

L_.~__ ._._._._._.j - -

L.,J

To he used with Cold Stan Oplion.

To be used with Refinery Equipment.
Position of DIP-switches.

(5)
Fig.3.t

Fig. 2.7
B6
Fl
01
02
KO
K5

K6
K9

(1)-

Non-adjustablc lowbar wilh standard suppol1leg wilhout brakes

t==~IP4II

Circuil diagram (Nr. 9822 089312)

Fuel Level Sensor
Circuit Breaker
Battery 12V

MI

Stancr M(uor

55

Engine Low Oil Pressure Switch

N4
N5

Control Module

57

Ovcrspccd Control Test Switch

PI
P2
P3
S3
54

S8
59
XI

Push DUllon

Charging Alternator

Overspecd Control Module

Hounneter
Olowplug
Fuel Level Gauge
Compressor Temperature Swilch

Y2

Engine Temperature Switch

Y3

Staner .solenoid

Auxiliary Staner Relay

Cold Stan Relay
Overspeed Relay

Yl

Conlaln Level Switch

Module Connector

Fuel SlUP Solenoid

Excess Fucl Provider
Overspecd Solenoid
Fig. 3.5

Note:
For correct functioning of the module, the dip switches at the back of the module should be pnsitioned as follows
Standard (no coldstar!)

Fig. 3.2

Not used
Low fuel level
Low coolant level
Fig. 2.8

Dip switches

Label on lowbar. towing inslruclions

For hoth non-adjustable - and adjustable towbar. the towbarshould be

as level as possible and the compressor and towing eye end in a le"el
position.

With coldstart option

Preheat-Coldstart

Before towing the compressor, ensure that the towing

equipment of the vehicle matches the lowing e}'e or ball
connector and ensure that the service doors are closed
and locked properly.

Adjustablc lowhar wilh jock~)' wheel and hrakcs

When parking a compressor, secure support leg (I) or jockey wheel

(2) tosuppurt thccompressorin a level position. Be sure that thejockey
wheel (2) is blocked by the blocking pin (6).
Apply parking brake hy pulling parking brake handle (3) upwards.
Place the compressor as I~\'el as possible: however. it l:an be operated
temporarily in an out-of-Ievel position not exceeding ISO. If the
clmlprcssor is parked un sloping ground. immobilize the compressor
by placing wheel chocks (availahle as option) in front ofor behind the
wheels. Locate the r""r-end of the compressor upwind. (see fig. 3.4).
away from contaminated wind-streams and walls. Avoid recirculation
of exhaust air from the engine. This e;tuSCS overheating and engine
power decre:'lse.

Push the hand brake lever (3) completely downwards and connect
breakaway cable (5) tothe vehicle. Secure jockey wheel (2) or support
leg (I) in the highest possible position. The jockey wheel is prevented
from turning.

Fig. 3.6

Towing posilion ofjockcy wheel

19
18

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

3.1.3 HEIGHT ADJUSTMENT (WITH ADJUSTABLE

Instruction Manual

3.3

3.1.4 LIFTING INSTRUCTIONS

STARTING/STOPPING

TOWBAR)

Before towing the compressor. make sure that the

joints of the lowbar are secured 'lith maximum
strength without damaging the towbar. Be sure thaI
there is no clearance between the teeth of the joints.

"\

~~r(~
Fig. 3.8

"A" (mm)

"B"IN)

ZV2000

250300

600

420500

ZV 2500

350400

600

580660

Lifting acceleration and retardalion must be kept

within safe limits (ma 2g).
Helicopter lifting is not allowed.
Lifting is not allowed when lhe unit is running.

Remove spring pin (I).

Release locking nul (2) wilh suppon tools (Exlension tube 3).

Adjusl required height of lhe lowbar.

Tighlen locking nUl (2) by band first.

Secondly lighten locking nut (2) wilb a tighlening lorque

corresponding to lable I (Fig. 3.8). Wilh an extension lube (3)
("Aoo corresponding 10 lable I) and handforee ("Boo
corresponding to lable I) easy tighlening is possible.

Fix locking nul (2) wilb spring pin (I).

Atlention:

3.2

BEFORE STARTING

I. Before inilial slarr-up. prep.,re bancry far operalion if nOI already

done. See seelion 4.~.
2. With the compressorstandinc. lc\'cl. check the level of the cne.inc
oil. Add oil. if necessary. 10 ihe upper mark on dipslick. ('OI;:.UIt
Ihe Engine Operalion Manual for Ihe Iype and "iscosily grade of
the engine oil.
3. Check the level of the compressor oil. The poinler of oil le\'el
gauge (Fig. ~.I. OLG) should regisler in Ihe green range. Add oil
if necessary. Sec seelion ~.3 fort he oil 10 be used.

Heighl adjustment should be undenaken on levelled ground and

in coupled condition.

Wben readjusting. make sure Ibat tbe front poinl oflbe lowbar is
borizontal to tbe coupling point.

Before starting a trip. ensure that the adjustment shaft is secure.

so Ibatthe stability and safety is guaranleed while driving. If
nC\:essary tigblen the locking nUl (2) corresponding 10 lable I
(Fig. 3.8).

4. Check Ihallhe fuel lank cOOlains sufficienl fuel. Top lip. if

ncces..ary. Consullihe Engine Operalion Manu," for Ihe Iype of
fuel.

Before removing oil filler plug (Fi~. 2.4. FPI. ensure

that the pressure is released b)' opening an air ouUet
\'ah'e.

I
PI
FI
PG
l.V
N4

Hnunnclcr
Circuit Breaker BUllon
Working Pressun: Gauge:
Loading Valve
Comro! MmJulc

S
HI

SI;ul/S",p Bultnn
LED I.green)
Fuel ON

(0

H2
H3
H4
H5
H6
H7
H8

LED (green)
LED (red)
U>D(n:d)

LED (red)
I.ED(rcd)
LED (wd)
LED (red)

P,,:heal (nplion)
Charge Indication
Compressor OUilel Tempermure
Engine Oil TelO~r.J1ure
Engine Oil Pressure
Low Coolant
LowFucl

N.. e~ push the start buUon when the engine is

runnmg.

Make sure Ihe fucl tank is filkd up.

Before staning. firsl operale Ihe cireuil breaker bUllon (FI) at the righl
silk of the l:t1nlco) panel (op:n ri~h(-hand sen'ice door firse).
To ~I<lrt. the st;,nlslOP bUllon (S) is switched 10 position 'T', the gn.~n
fuel ON lamp (H I). lbe wd charge indication lamp (H3) and pwbeat
lamp(H2) goon (preheallaOlponly. if "cold s",,," oplion is inslalb!).
After preheming.lhe prehcat lamp goes out. I'ush Ihe slart/slop bUllon
inposilion" (D ".211sec.(60sec.forXAHS 186 Ddlcranking. I Olin.
rest (= a cycle). Max. 3 cycles are allowed. The sianer mOlor will SCi
the engine in 11101ion. Lamps H I and H3 will go oUI as soon as Ihe
engine has bt:en started. Arter the start/stop button is released. it
alllummil,.ully springs back to position 'T',

Run the engine a I~w minules 31 noload to Warnl up,

Shulling down is simply done hy pushing the sl.m bUllon in Ihe "0"
posilion,

remove

III

Coruml panel

6. Press vaeuator valves (fig. 2.4. VV) of Ihe air fillers

dust.

10

(H5) (H6) (H7) (H8) (5)

When Ihc engine is running smOOlhly. press la"ding valve (LV) "nd
rclcuse <IS soon as pressure st.IrtS to build up.

7. Check lhe air fillenacuum indicalors (Fig. ~.~. VI).lflhe yellow

piston reaches lhe red marked ser\'iee range. repl..... lhe filler
element. Resel Ihe indicator hy pushing the reset bulton.

20

Fig. 3.9

(PG)

5. Drain any waler and sedimenl froOllhe fuel filler until clean fuel
flows from the drain cock.

8. Open air outlet valve to allow ;:lir flow

(Fl)

./

\...
(LV)

I'Y/

<3> 0
'---D OV
00>10' o~
(!)/O ~
:::.~~O I

<lDC~

Preferably usc Ihe lifting eye (I) hercfare open Ihe small door (2).

xxx

"\

~~ ~e- ~~ ~g~=

UfJing eye

When Iifling Ihe compressor. Ihe hoisl has 10 be placed in such a

way Ihat the compressor. which IIIUSI be placed IO"el. will be lifted
venicillly. Keep lifting acceleration and retardation within safe
limits.

H . In adjustment

(N4)

I I II

For specific instruction see below!

Fig. 3.7

(Hl) (H2) (H3) (H4)

(Pl)

Fault situations and protecth'e de"iees (Also refer to chapter 6.

Problem Solving):
-

Thc starter OIOlOr is protecled againsl prolonged slaning.

(max. cranking time: 20 sec. (60 sec. for XAHS 186 Dd.
A fault which occurs wilh Ihe engine, dlher 311ernulor voltage
low). coolanllemperdlure 100 high. oil pressure 100 low or
fuelle\'el too low will.tlways and immediately cause the engine
10 CUI out "nd une of Ihe conlrollamps H3. H5. H6. H7 or H8 10
Iighl up.

(100

When Ihe outletlemperalure of Ihe clemen I becomes too high. a

rnermocontact will also swjt,h off the unit immcUiatcly,
Conlrollamp H4 will light up.

The ,of1lrollamps will remain on untilllhe unit has been reset

(slarl bUllOn swilched to posilion "0").

The l.:ontml panel in addition indicates recci\'cr pressure (PG) and

aCl.:uJ1lulatc.=d opt:wling hours (1)1),

the atmosphere.

21

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

3.4

Instruction Manual

DURING OPERATION

Initial1y

MAINTENANCE SCHEDULE

When the engine is running, the air outlet valves (ball

valves) must alwa)'s be put in a rully opened or rul1)'
elosed position.
Regularly carry out following checks:

'0

I. Tha, regulating valve (1'i~, 2.2 Ii~. 2.). RV) is eorrec,ly

adjus,ed. i.e. stOf'S decreasing (he engine speed when reaching 'he

50 !Jour!i aflr/' initial

stan-up
Service Pats
XAHS 146 Dd
XATS 156 Dd - XA(S) 186 Dd
XAVS 166 Dd - XAIIS 186 Dd

preset working pressure in tbe receiver.

2. Check the air liller vacuum indicators (Fig. :2.:2 to Fig. 2.." VI),
1f the yellow piston rcaches the red marked service range. rephlcc
'he filter element. Resetlhe indicators by pushing Iheresel bUllon,

Comprcs~ur oil

Ic\'el

Cool.n,lcvcl (3)
Cool.n' (7)
Air liller \,;]euaIOr \'alves

The doors must be closed durinll operation and ma)' be

opened ror short periods only.

Fuel filter water drain

Air ill1ake vacuum indicalors

4.

MAINTENANCE

4.1

USE OF SERVICE PAKS

I.eaks in air-, oil- or fucl system

Enginc minimum and ma:dmum speeds

Service P:1ks minimize downtime and keep your maintenance budget

SafclY valve

iow.

Doorhingc!'O

Order Service Paks at your local AUas Copeo dealer.

Check
Check
Chcck

Coolm (Oil. Coolanl. Inler-)

Tvrquc of whcel nms

2912447.\ 05

2912447506

29124413 05

2912 <\476 06

2912447405

2912 4477 06

AnaJ)'si$

Analysis

Check
Check
Check
Clean
Check
Check
CheekiAdju"

Check

Brake syslem lif inslalled)

Check
Check
ChcdJAdjwa

Check/Adjusl

(irca:-c

Grea."C

Coupling hcad and all it50 moving parts I !'Ohafl

Joillls of heighl ;]djuslmcOi adjuslable lowbar

llh:ck

(jrca.~c

Grca.liC

Grea..liic

Mc;\.,""~

Check
Replace (6)
Adju<l

l>ressurc drop o\'cr scparator clement (2)

COMPRESSOR

Fan V-helt, I))

Adjust

Fllcl1.1nk

Clean

Compressor oil

When servicing, replac.. all discngaed paekings. e.g. g.skels.

O-rings. washers.

Air filtcr clemcOl50 (I)

For engine maimenance refer to Engine Operation Manual.

The maintenance schedule has 10 be seen as guideline for unils
operating in a dusty en \'ironment lypical to ~-ompressor applications.
Maintenance schedule can be adapled depending On applicalion
environment and qualily of mainlenanee.

Safcl)' carlridgcs (I) ((Jplion)

Engille oil (3) (4)

E.ngine oil filler (J)
Fuel m,er ()( (5)
Fuel prefilter (3)
Engine inici and outlet valves (3)
PD/QD fiher (op,ion)

22

Clean
Change

Compressor oil Oller

(I) More frequcnll)' whcn operaling in a dusly environment_

(2) Repl~(:e the cJcmclU when (he flrc~("rc drop cxcecd~ 0.8 bar,
(3) Every 1500 hours. Rcfcrto the OeUt7 operalion manual.
(4) 500 hours only \':llid whcn m~ing PAROIL SAE 15 W 40.
(5) In ca.~c of poor fucl qualily, replace fuel fillcr more frequently,

Clean

Check
Check

Grease

PREVENTIVE MAINTENANCE SCHEDULE FOR THE

The schedule contains a summary of the maintenance instructions.

Read the respective section before taking maintenance measures,

Oleck
OleCk

Te!H

Shuldo"'n switches

4.2

Yearly
or ("1'C").' 1000 IWIIl's

Empty
Dmil1
Check

prc~"urc

Service Paks include all genuine paris needed for nomlal maintenance
ofbo,h compressor and engine.

500 lIo"rs

Check
Check
Check

Elcctrolylc Ic"cl ;]nd Icnninals of ball~r)'

Tyrc

Normal
01' (,I'r'y

Change
Replace
Replace

Replace
Replace
Replace
Change
Replace
Repl.ce
Repl.ee
Adjus' (3)
Repl.ee

(6) Clean TC'1<lilll'r when TCpladng c1cmclII.

lI1unlx'no can he ordered froln Alias Copen to
check 011 inhihilon; and trcC7jll~ JKlillt:
291 J Otl28 00: Rcrraclomclcr
2913 0029 ()(); pH-me,er

(7) TIlc follO\\ing pan

Keep the bnlt~ or lhe housing.thelirtiog eJe.lhe lowbar and lhe axle securelJ tighteoed.
Rerer to section H. 'TechniclJl sllecificatiol1s' and section .ll .' ror the torque ,,'alues.

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

4.3

LUBRICATION OILS

High-quality, mineral. hydr:lUIk or synthesized hydn>l'arhlln oil \\'ilh

rust and llxidation inhibitors and aJlti-tll:.UU and alui-\\'C;lf pnl)lCrtics
is ~commcndcd. The viscosity gr<:ldc shuuld correspond 10 the
ambiem lemperalure and ISO 3448. a, follnws:
TIpe of lubricant
between 25C ami +40C

between -I Oec and +40C

I Compressor" I
I PAROII.S I

PAROILM

Engine

II'ARUII. 15W40

PAROlL from Alia, Cupeo is lhe ONLY oil lesled and "pprmed Illf
usc in all engines built inln Atlns Copeo cnmprcssors and generators.
Extensive Inbl1r.tlOry and neld cndur.lIll:c tests 011 Atlas Cop.:o
equipment han: proven PAROIL 10 I1Imdl alliubril.:mioll dcl11muh in
varied conditions. It meets stringent lJuu1ily cuntro) spcdtkminns 10
ensure your equipment will run smnOlhly and rcli<lhly.
The 'Iuality lubrkam additives in PAROII. alln\\' for extended oil
change intervals without any loss in performance or longe\'ity.

PAROII. provides wear prot~ction undcr extrcmc conditions.

Powerful oxidatiun resistance. high chemical stahility >lnd rustinhibiting additivcs help rcdul.'c corrosion. evcn within cllgines len
idle for extended pcriods.

Mine",1 compressor oil PAROIL 1\1:

- 5 liler can:
order number L615 5947 00
- 20 liter con:
order number 1615594800
- 210 liter barrel:
order number 1615594900

PAROII. prevenls Soot build-up

PAROIL is optimized for the liltcst low cmission EURO -3 & -2. cPA
TIER II & III engines running on ItIW sulphur diesel for lower oil <Jnd
fllel consumption,
PAROIL 5W30is a Synthetic ultra high performancc diesel enginc oil
with a high \'iscosity- index. Atlns CUPCll PAROIL 5W3() is designed
to provide excellentlubrkation from start-up in tcmpcratures as IllW
as-25""C.
PAROIL 15W41l isa mineml based high pcrfllflllanl'c diesel engille oil
witlla high \'iSl:l1sity- index. AtII.ISC(IPCoPAROII. 15V\'-JO isdesi~ncd
to provide a high le\'el of perfonni:lllcc I.lnd protcl'tion in 'sl;llld;lrd'
ambient conditions as from - 15"C.

4.4.2

CHECK COMPRESSOR OIL LEVEL

When npcrnting in high mnhienttemperatures. in ,"ery dusty or high

humidity l.onditions. it is recommended to change the oil more
frequently.

2. Drain the oil hy remo\"ing all rcle\'nnt drain plugs. Drain pi ugs nrc
locatcd at tile air recei vcr. cOinpressorelement and compressor oil
cooler, C:uch the oil in 1.1 drain pan. Screw out the filler plug to
speed up draining. Tighten the plugs nfter draining.

Remark:
When changing from mineral to synlhetic oil (or the
other way around). )'ou will need to do an extra rinse:

OIL LEVEL CHECK

Never mix oils of different brands or t)'pes.

Use onl)' non-toxic oils where there is a risk of inhaling

delh'ered air.

In lhis case. contact Atlas Copeo.

I. Ruuthe compressor until warm, Close the outlet \'ah'e(s) (5) and
SUlp tile ctlmpressor. Vi'nit until thc pressure is relenscd through
the automatic hlllw-down \"al \e. Unscrew the oil filler plug (2) one
turn, This unCl}\"ers a vent Iiole. which permits any pressure in the
system to escape.

Ne\'er mix s)'nthetie with mineral oil.

4.4

4.4.1

1615595001
16155951 01
1615 5952 01
1604 742200

Afler doing lhe complete change procedure 10 synthelie

oil, run the unit for a few minutes to aUow good and
eomplele circulation of lhe S) nthetic oil. Then drain lhe
s) nthelie oil again and lill again with new s)'nthetie oil.
To set eorreet oille\ els, proceed as in normal
instruction.

COMPRESSOR OIL AND OIL FILTER CHANGE

Th~ prcsl'rihed illler\'al (sec scltion -4.2) is b~lsed on nnoil temperature

of up to I(K} DC and normal opemting conditions.

Symhelic engine oil PAROIL 5W30:

- 5 liter can:
order number 1604606000
- 20 liter can:
order number L60460S900
Symhetie compressor oil PAROIL S:
- 5 liter can:
order number
- 20 liter can:
order number
- 210 liter barrel:
order number
- 11lU0 liter comainer: order number

4.5.2

The quality nlld the lempentture of the oil determine the oil changc
intervill.

Minel1ll engine oil PAROIL 15W40:

- 5 liter can:
order number 1615 595300
- 20 Iiler can:
order number 1615595400
- 210 liter barrel:
order number 1615595500

PAROII. contains high quality anti-oxidants to l'olllrol depusits.

sludge and contl.1minnnts thl.lltend to build up under wry high
lempenuures.
PAROIL's dctergent additives kecp sludge ronnin~ partidcs in <J tine
suspcnsiOiI instcad ofallowing themtoelog your IiIh:r aud ;lccunlUll.1tc
in the val \'c1rocker eu\'er area.
PAROIL rclcl.1sescxcess hcmeffidently. whilst maiutainingexl'c1lent
bore-polish protection to limit oil consumption,
PAROIL has an cxcellcnt Totnl Basc Numhcr (TUN) retcntioll and
more nlkalinity to control add fl1ffiUuilln.

Instruction Manual

3. Remove the "il filter (3). e.g. hy means "f 0 spccioltool. Catch
the oil in a drain pall.
Fig. ..J,t

Check compressor oillc\'ct

With the unil standing level. check the level of the compressor oil. 1!le
pointer of the oille\'cI gauge (I) must register in the upper extremuy
of the green nmge. Add oil if necessary.

aIt..

Before remm'ing oilliller plug (2). ensure lhat lhe

pressure is released b)' opening an air ouUet val\"< (3).

4.5

OIL AND OIL FILTER CHANGE

4.5.1

ENGINE OIL AND OIL FILTER CHANGE

CHECK ENGINE OIL LEVEL

Consult also thc Enginc Operation i"lanual for thc oil spcdtkations.
\'iscnsity recommendations and oil chl.1nge inten'nls.

4.

t~lcan

the filtcr scatlll1 the manifold. taking care that no dirt drops
into the system. Oil the gasket of the n~w filter clement. Screw it
into place until the gasket eontal.ts its seat. then tighten one half
tum only.

5. Filltlu: air rcceiver until the pointer of the oil level gauge (4)
registers in the upper extremity of the green range. Take cnrc that
no dirt drops into the system. Reinstall and tighten the filler plug,
0, Run the unit at no load for a few minutes to circulate the oil and
to e\ncu:.Ue the nir trapped in the oil system.
7. Stop the compressor. Let the nil settle for a f~w minutes. Check
that the pressure is relcl.1scd by opening an air outlet valve (5).
Screw nutlillcrplug (2) and >ldd oil ul1lilthe pointerofthe oille\"el
lWUge 14) auain ret?isters in the upper extremity of the green mnge.
i{ei~stoll a~d tighien tbe filler plug.

aIt..

SL'C schedule.

Ne"er ad~ more oil. O"erlilling results in oil

consumption.

Chcl'k engine oillcvcI according to thc instructions in the Engine

Operation Manonl <Jlld tnp up with oil if necessary.

If you want to use anolher brand of oil. eonsull the

Engine Operation l\Ian1lal

It is strongl)' recommended to use Atlas Copeo branded

lubrication oils for bolh compressor and engine. If )'011
wanl to use anolher brand of oil. eons1lll Alias Copeo.

Fig. 4.2

Oittibcrs

For replacing the engine oil filter (I). see section 4.2.
24

25

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

4.6

COOLANT

4.6.1 COOLANT SPECIFICATIONS

Never remO\le the cooling s)'stem liller C"dp while

coolant is hot.
The s)'stem rna)' be under pressure. Remove the cap
slowl)' and only when coolant is at ambienl
temperature. A sudden release of pressure from a
heated cooling system can result in personal injur)'
from the splash of hot coolant.

It is strongl)' recommended to use Alias Copco branded

coolant.

The usc of the correct coolant is impon;ml for glXld hCallmnsfcr .md
protection of liquid-cooled engines. Cool~nts used in these engines
must be mixtures of good quality walcr (distilled or dc-ionised),
special coolant lJdditivcs and if ncccsSJry freeze protection. Coolant
thaI is nol to manufacturer's spcdfil'lIlion will result in mcch.mkal
damage of the engine.

The freezing point of the coolant must be lower than the freezing point
lhm can occur in the area. The difference nlust be allc.lsi 5 "l' (9 r).
If the coolant freezes. it may crack the cylinder block. mdii.llor or
coolanl pump.
Consult the engine's openllion mllnual and follow the nmnufacturer's
directions.

It..

Never mix different coolants and mix the coolant

. . componcnts outside lhe cooling s)'stem.

4.6.2 PARCOOL EG
PARCOOL EG is the onl)' coolant that has been tested and
approved b)' all engine manufacturers currenll)' in use in Atlas
Copco compressors and generators.
Alias Copeo's PARCOOL EO eXlended lifc coolanl is lhc new range
of organic coolants purpose designed to meet the needs of modern
cngincs. PARCOOL EO can help prc\'ent leaks c:\Used by corrosion.
PARCOOL EO is also fully compalible with all scalants and gaskel
types de\'e1oped to join different materials used within lln engine.
PARCOOI. EO is a ready 10 usc Elhylene Glycol bascd coolant.
premixed in;lI\ optimum 50/50 dilution ri.llio, for alllifreeze protection
guamntc-cd 10 -40'C (-40F).

PARCOOLEG
- 5 liter can:
- 20 liter can:
- 210 liler harrel:

Instruction Manual

4.6.4 COOLANT CHECK

order number 1604 5308 00
ordcr numbcr 1604 5307 01
order nu mbcr 1604 5306 00

To ensure protection i.lgainst corrosion, cavitation and fomlation of

deposits. the loncentri.llion of the additi\'es in the coolant must be kept
betwl.'Cn certain limits. as stated by the manufacturer's guidelines.
Topping up the coolant with water only. changes theconcentmtion und
is therefore not allowed.
Liquid-coolcd engines arc faclory-fillcd Wilh lhis lype of coolant
mixture.
PARCOOL EG Concentrate
- 5 lilcr can:
order numbcr 1604 8159 00

4.6.5 TOPPING UP/REPLACING COOLANT

Never remove the cooling s)'stem filler cap while

coolant is hot.

Veri!'y if thc engine cooling systcm is in a good condition (no

leaks. clean....).

The s)'stem rna)' be under pressure. Remon lhe cap

slow I)' and onl)' when coolant is al ambienl
temperature. A sudden release of pressure from a
heated cooling system can result in personal injur)'
from the splash of hot coolant.

Check the condition of the coolant.

In ordcr 10 guarantee lhe lifelime and qualily of lhe produCl.lhus 1o

optimise engine protection, regular coolant-conditiolt-analysis is
ad,"isablc.

If the condition of the coolant is outside the limits. the complcte

coolant should bc rcplaccd (SCC sec lion 4.6.8 Replacing the
coolant),
-

Always lOp-Up wilb PARCOOL EO Conccntralc I PARCOOl.

EO,

Topping up the coolant with w;llcr only. chrlOges the

concentr:llilln of udditi\'cs :lnd is thercforc not allowed.

The qualily of lhc producl can be delefOlincd by lhree pommclcrs:

4.6.3 HANDLING PARCOOL EG

Visual check
-

PARCOOl. EO should be slored al ambicntlempemlures. while

periods of exposure to tempcmtures above 35 C (95-F) should be
minimized. PARCOOL EG can be stored for a minimum of 5 years in
unopened containers without any effcct on the product quality of
perfomlance.
PARCOOl. EO is compalible with mosl olher coolanlS based on
ethylene glycol. but you only get the benefits of 5 years protection
when its used on its own. Exclusive use of PARCOOL EO is
recommended for optimum corrosion protection and sludge control.
I'or simple density-measuring of Elhylene Olycol and l'ropylene
Glycol in general the standard available 'density' measuring devices
llre used to measure the concentration uf EG In case a de"ke is used
to mellsure Eel no PG can be measured afterwards as a result of the
difference in the density. More specific measurements can be done by
the use ofn refractometer. This device can measure both EO and PG
A mix of both products will be show unreliable results!
Mixcd EO coolants wilh idcntical glycollype can be measurcd hy use
llf i.I refractometer as well as the 'density' system. The mixed coolants
will be considered as one product.
The use of distilled watcr is recommended. If you hi.l\'c exceptiunally
soft waterit would be acceptable, as well. Basically, the engine metals
arc going to corrode tosume extent no mauerwhat water you use, and
hard wnter will encourage the resulting metal salts to pn...c ipitate.

Verify thc outlook of the coolant regarding colour and make sure
that nn loose particles are (loating around.

pH measurement
-

Chcck the pH valuc of the coolant using a pH-measunng dc\'ice.

Thc pH-melcr can be ordcred from Alias Copeo wilh pan numhcr
2913 0029 00.

Typical \'alue for EO = 8.6.

If lhe pH-level is hclow 7 or abo\'e 9.5. lhc coolant should bc

replaced.

GI)'col concentration measurement

-

To optimise the unique engine protcction features of thc

PARCOOI. EG lhe conccnlralion of lhe Olycol in lhe walcr
should be always ahove 33 vol.%.

Mixtures with more than 68 \'01.% mix ratio in water arc not
recommcnded. as this will lead to high enginc operating
temperaturcs.

A rcfrnctometcr can be ordered rrom Atlas Copco with pan

numbcr 2913 0028 00.

It..

In case of a mix of different coolant products this t)'pe

. . of measurement might prm'ide incorrect ,,alues.

('ARCOOL EO comes as a pre-mixed coolanllO safeguard lhe qualily

of the complete product.
It is recommended that topping upofthe cooling system is always done
Wilh PARCOOL EO.

Because PARCOOL EG inhibits corrosion. deposit formi.uion is

minimized. Thiscffectivcly eliminates the problem llfrestricted nnw
through theenginecoolllnt dUlts and the mdhuor. minimizing the risk
for engine overhearing and possible f:'lilure.
It reduces water pump seal wear and has excellent st;tbility when
subjected to sustained high opcrJting temperi.ltures.
PAReOOL EG is free of nitride and amines wpnllect your health lind
the environment. Longer ser\'ice life reduces the mnmnU of cooli.llll
produced and needing disposllito minimise ell\'inmmellllli impllct.

26

27

XAHS 146 Dd - XATS 156 Dd - XA{S) 186 Dd - XAVS 166 Dd - XAHS 186 Dd

4.6.6

TOPPING UP WITHOUT DRAINING FROM THE

COOLING SYSTEM

Instruction Manual

4,6.7

TOPPING UP AFTER LIMITED QUANTITY

DRAINING FROM THE COOLING SYSTEM

11le 411~nlity of PARCOOL E(i Com:cnmllc III be lopped up 1.:;,111 be

cSlinullcu with the fulluwing furmukl :'lndlur graph:

The qu.nlily of PARCOOL EO Concentrnle 10 be lopped up .her

draining a calculatcd vlllumc from the cooling systcm. can hc
eSlimated with lhe [ollowing [omlUlnd/or graph:

Corrections concentrate in measured s)'stem towards 50%

..alume by using PARCOOL EG ConeentrJte

Corrections concentrate in measured s)'stem towards 50%

volume b)' using PARCOOL EG Concentrate

PN: 1604 8159 llO

PN: 16048159llO

Example:

Example:

Total vulume coolant =

[H]I-iler

I\leasured concentration =

c;ID~"~

Total \'Glume coolant

80

I\'leasured concentration =

50-00 = (]zj* ~/ffiQ1= ~~] l.iler PARCOOL EO Cuncenlr.le

In case or ~xp:.msioll lank at low level. this quantit)' is 10 be tilled
withollt draining frum the cooling system.

Liler

roe:'[jjJ I"YJ"I100- 33

=~

[j[

Liler PARCOO!. EO Concenlrme

In C.lSoC of cxp>ll1$ioll tank at normallc\'cl. this qualllity is to he
drained from the cooling systcm.

Top-up volume PARCOOL EG Concentrate without drainage

6.0
5,5

Top-up volume PARCOOL EG Concentrate with drainage

1-----------------8-

25,0

5,0

22,5

4,5
20,0
4,0

.
E
::I

>
"::I

...
{:.

17,5

3,5
~

2,5
2,0
1,5

II

----- --- --- ---

--------0,5
--- --iii
0,0 ~,-=======::::;==;=:=;:::==::======:::==;::=::==:---J
4
5
7
6
8
9
10
11
12
13
14
15
16
1,0

15,0 f - - - - - - - - - - - - -

E
::I
Q
>

12,5

"-

10,0

3,0

Engine coolant capacity (liter)

...
...
::I

---- --- --II

7,5

---

5,0
2,5

1216 20 24 2832 36 40 44 48 52'56 60 6468 72 76 80

84

Engine coolant capacity lfiterl

Rcfn.U:hUllctcr indic~llion
Rcl"nIC(lIl11ctcr indication
Refractometer indic"llion
J{cfnu:IOI11CICr indil'ution
Refractometer indication

28

-200 C (33 t7u)

_22 9 C
_25 0 C

-301;1 C
_36" C

3
4
5

Rcfnu:lOmctcr indk>ltion <wo C (337,)

Rcfmctomctcr indication -22~ C
Rcfmctomctcr indkation -25' C
Rcrmctomctcr indic..'ation -30'" C
Rcfmctomctcr indication _36 0 C

29

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

4.6.8

REPLACING THE COOLANT

4.7

CLEANING COOLERS

Instruction Manual

4.8

Uruin
-

Completely dr.lin the entire l:ooling system.

Used coolant must he disposed or rccyl.:lcd in i.U:cordllnl'c with

laws nod local regulations.

Before handling baltenes, read the rele"anl safet~

precautions and act aceordingl).
Iflhe hallcry is still dry. it must be acti\'atcd as describcd in section
4.lC.

Flush

recycled in :.u:cordanl.:c with laws nod local rc,gul;lIions.

From the Atlas Copen Instruction book. dctcmtinc the mnouni of
PARCOOL EG required and pOUf into the r;:luiiJIor top lank.

It should be dearly understood thai the risk for conti.1l11inalion is

reduced in ellSC of proper l:leaning.

In ei.ISC a certain content of 'other' coohmt rcm'lins in Ihe system.

tile eoolllOl with the Illwcst propcnics illt1UCIlccS the lJu;t1ily {If

4.8.1

the 'mixed' cool:.l111.

4.8.2

Recheck cool'IOI le\'el and :Idd if nccessary.

In case of a mix of dillerent coolanl produels Ihis I~'pe

of measurement might pro\'ide incorrect \alues.

Run the compressor regularly. e.g. twicc a weck. until waml.

Load and unload the cumpressor a few timcs to operatc thc
unluading and regulating l:omponents. Closc the air olltlet \'ah'cs
:lftcr stOppillg.

If the compressor is going 10 be stored without running

Fig. 4.3

Compressor oil cooter (I). engine coolanl cooler (2) and engine
oill,:ooler(3)

Kccp Ihc cnulcrs (I). (2) and (3) clean 10 maimain the cooling
dficiency.

Read the safety instructions carefull).

Take 001 the banery.

Banery and electrolyte mUSI be al equallempemlure above 10 'c.

Remove any dirt from the coolers with a fibre brush.

Ne\"er use a wire brush or metal objects.

ll1ell dean by air jet in re\'erse direction of nomlal now.

Rcmo\'c cover andlor plug from cach ccll.

Fill cach cell wilh electrolyte umillhe level reachcs 1010 15 mm
ahove the plates. or to the level marked on the battcry.

SERVICE PAKS

A Scn"ice Pak is a clllicction of parts to hc uscd for a sped fie

m~lintcmmcc mcaS1lre.

It guarantees th:1I all nel.cssary parts arc replaccd at thc samc timc
keeping down time 10 a minimum,
The ordcr numhcr of the Scr\'icc Paks arc listed in the Atlas Copeo
Pnrts List.

ACTIVATING A DRY-CHARGED BATTERY

from time to time. protecth"e measures must be taken.

4.10

The solulion must be made op he fore heing introdoced imo thc

hanery.

To assure proper opcr:.ttion llOd the release of Inlpped air. run the
engine until nlurn.11 engine opcr'ltion tempcnlture is rellclled.
Turn off the engine .lOd lIlIow to coo!'

STORAGE

ELECTROLYTE

Elcctrolyte in batterics is a sulphuric acid solution in distillcd water.

Fill
-

4.9

The hattcry must he in operation within 2 months from hcing

acti\'atcd: if not. it needs to hc reehargcd first.

Flush twice with clean w.ller. Used ClXl);tnll11ust be disposed or

BATTERY CARE

Rock the hanery a few times so Ihat possihle air bohbles can
escape: wait 10 minutcs and chcck thc Ic\"cl in e.lch cell oncc
more; if required. add electrolyte.

Relit plugs and/or cover.

Placc thc battcry in the eomprcssor.

4.11

SERVICE KITS

A scn icc kit i" a l."ollectilln of pans 10 lit n spccinc repair or

rehuilding task,

It guarantees th;1I all neccssary pnns are replaccd at the samc time
which imprm"cs thc uptime of thc unit.
ll1C order numhcrs of the Scrvicc Kits are listcd in the Atlas Copeo
Pnrts List.
~

Conlacl Atlas Copco.

4.12

COMPRESSOR ELEMENT OVERHAUL

Steam c1c:ming in combination with'l dcansingugcnt maybe 'Ipplied.

A
A

To amid damaging Ihe coolers, angle bel ween jet and

coolers should be approx. 90 ".
(do nol use jet at max. power)
Prolect Ihe eleclrical and coni rolling equipmenl, air
filters, etc. against penetration of moisture.

4.8.3

Before and after charging a hanery. always check Ihe e1eetrolyle

Icvel in each cell: if requircd. lOp up with di<lilled waler only. Whcn
charging battcries. cach cell must be open. Le. plugs and/or cO\'cr
removed.
Use a commercial aulomatic batteI')' charger according
to its manufacturer's instructions.

Close the ser\'ice door(s).

A
A

Ne\'er lea\"e spilled liquids such as fuel, oil, water and

cleansing agents in or around the compressor.

Caution: do nollop all "hen the engine is hal.

Apply with preference the slow charging method and adjostthe

charge eUlTent according to the following role of thomb:
banery capacity in Ah divided hy 20 gives safe charging cOlTent in
Amp.

4.8.4

30

RECHARGING A BATTERY

BATTERY MAINTENANCE

Kcep Ihe banery clean and dry.

Keep Ihe electrolyte level al 10 10 15 mOl ablwe Ihe plates or al

thc indicated Ic\'el: top up with distillcd water only.

Kcep thc terminals and clamps tight. c1can. and Iightcly covcred
wilh petroleum jelly.

Whcn a compressor elcment is duc for ovcrhaul. it is recommcndcd"

to have it donc hy Atlas Copeo. This guarantecs thc usc of genuinc
parts nnd corrcct tools with care and precision.

4.13

LIABILITY

ll1C llmnufal.turcr docs not accept any liability fornny damage arising
frolllthe usc llf nlm-original parts and for moditkations. additions or
cOI1\"ersions made without the manufacturer's appro\'al in writing.

XAHS 146 Oct - XATS 156 Oct - XA(S) 186 Oct - XAVS 166 Oct - XAHS 186 Oct

5.

ADJUSTMENTS AND SERVICING PROCEDURES

5.1

ADJUSTMENT OF THE CONTINUOUS REGULATING SYSTEM

Instruction Manual

5.2

AIR FILTER ENGINE/COMPRESSOR

5.2.4

5.2.1

MAIN PARTS

I.

Relea<e Ihe snap dips (I) and remove Ihe dusllrap (2).
Clean Ihe lrap.

2.

Remove the clement (4) from thc housing (5).

(1)

REPLACING THE AIR FILTER ELEMENT

3. Rcassenthlc in rcvcrse ordcr of dismantling.

4. Inspcl.'l and lighlen all .tir inlake conncctions.

(AFCE)

'

(SC)

t-+--,

(VV)

"- j --

5. Rcset the \Ul'uum indicator (FI,t;.

Fig.. 5.3

(6) (2)

(3) (4)

(5)

(OS)

Fig. 5.2

3
4
5
6

CLEANING THE DUST TRAP

Remove dust daily.

Fig. 5.1

Regulating syslcm

The Wllrking pressure is dctcnnincd by the tcnshm lll" the sprillg in the
rcguluting ,',II\'e (RV). This tension can he increased III mise the
pressure and decreased to lower it hy turning the adjusting wheel

To adjust the nnrm.1I working pressure. proceed as follows:

clockwise uno antidockwisc respectively.

2. With the outlet \,a) ves (AOV)doscd.looscn the regulating \,u)\'c's

lock nut and adjust the regulating valve (RV) until a pressure of
X bar(e) is reached (sec table).

ZI-Z2

b"r(e)

b"r(e)

bar(e) b"r(e)

XAHS 146Dd

13.5

12

13.2 - 13.6

XATS 156Dd

II.~

1Il.3

11.7 - 12.2

XA(S) 186Dd

~.3

~.I-~.5

XAVS 166 Dd

15.5

14

15.3 - 15.7

XAHS 186 Dd

13.5

12

13..1- 13.7

To remove dust from the dust trap pineb Ihe vaeuator valve (6) <eveml
times.

4. Opcn an outlet valve (AOV)just enuugh to letlhe engine (E) run

at maximum speed. The working pressure must be Y bar(e): adjust
if necessary with regulating valve (RV) (see table).

5.3

AIR RECEIVER

The air recei\'cr is tested according to official standards. Rcgularly

Im\'c inspections carried nut in conformity with locul rcgulations.

5.4

SAFETY VALVE

All adjustments or repairs are to be done by an

authorized representative of the valve supplier.

Following chcl.'ks must he carried out:

I. Slart and waml up Ihe engine (sec section 3.3).

3. (')leek the Ininimum speed of tile engine. Adjust minimum speed

stop screw if necessary.

Val"umn indicalor

Air filtcr contamination indicator

Resct hullon
Yellow indicator

Air filler

Snap clips
Dllsttrap
Sarety c:lnridgc (option)
Filter c!emcll1
Filtcr hllllsing
VacualOr vah'c

5.2.2

to:
9

:L~).

5.2.3

RECOMMENDATIONS

The Atlas Copeo air filters are specially designed for

the application. The use of non-genuine air lillers rna)'
lead to severe damage of engine andlor compressor

check llf the opening ufthc lifting gear. twice a year.

Thisc.m hc done hy screwing the capofthe valvc antic1ockwise.

;;t

a check of the set pressurc once a ycar according to the I(x.'al

regulations. This chcck cannot he done on the machinc and must
he"carried 01lt on a proper lest hench.

element.
Ne"'er run the compressor without air filter element.

5. Chcl.'k the engine maximum speed. Adjust the maximum speed

by means of adjusting eccentric nut on lOp of speed rcguhnor (SR).

New clements must also be inspcl"ted for tears or puncturcs before

installation.

6. Closc the outlet vah'cs (AOV). check that the pressure is between
ZI and Z2 baric) (sec t"ble). Lock the regulating valve (RV) by
Iixing the luck nul.

Discard Ihe element (4) wben damaged.

In heavy dUly appliealions it is recommended to inslall a safety
eanridge which can be ordered with pari no.: 2914 9311 (Xl
A dirty safety cartridge (3) is an indication of a mal-functioning air
fillerelemem. Replace theelemem and the s.1felyeartridge in Ibis case.
The safely cartridge eannOI be cleaned.

32

33

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

5.5

5.6

FUEL SYSTEM

BRAKE (= OPTION) ADJUSTMENT

Berore jacking up the compressor, connect it to a

towing "ehicle or allach a weight or minimum 50 kg to
the towbar.

Instruction Manual

5.6.2

TEST PROCEDURE OF BRAKE CABLE

5.6.3

BRAKE CABLE ADJUSTMENT

ADJUSTMENT

I. Check if the towing eye rod of the o\'errun brake mechanism is

in the outmost position.
2. Check if the adjustahle towbar (= option) is in the actUi:tltowing.
position.

5.6.1

BRAKE SHOE ADJUSTMENT

ChCl'k the thickness of the bmkc lining. Rcmo\'c bUlh bhlck phlSlic
plugs (5). one on each wheel. When the brake lining has been worn 10

thkknl:ss of I mOl or less. the brake shoes have to be rcphlccd. After

illspcctilln ;,mdlor rcp!;,u:cmcnt re-inscrt both plugs.

<I

3. Apply lhe hand hrake lever.

4. Push thecomprcssora few centimeters hackwardssothatthe hrake

levcr is automatically pullcd furlhcr up.
5. Chcek thc position of lhe arrow marking "I" at thc calch lock in
combination with the arrow marking "2" at the toothed sector.
according to Fig. 5 6 A.B.C.D.
Fi~.

.1

4
5

(}
Fig. 5.4

Fuel filh:r

A.

~ld;lph:r

Fig. 5.5

BrJkc shoe adjustment

hcud.

2. Clean the nd;,tpter head sC~lling surfm:c. Lightly uilthc g;'lskCl or

the new clement nnll Sl:fCW the latter Olllo Ihe he'lller umillhc
gi.lskcl is properly seined. then lighten with hOlh hmu.ls.
3. Check fur fud ki.lks unce the engine hi.ls been n:sli.lflcd.

Adjusting bult
Axle

.,
oJ

Brake eahle arrany.cmelll

Brake l'ahh:
Luck lIul
Adjusting lUll
Iklkc cahlc Ilul
Main hr.lke cahle
Equ:lli:r.cr

l. With the lOwing eyc pulled out in the outmost position and the
hand hrake Ic\'cr in the downward posilion (Fig. 5J:\).looscn the
lock mIls (fig. 5.7.2), Turn i.ldjusting nuts nnd bmke cahle nuts
<I'-ig. 5.7. 4) clockwise until there is no slack in the bmke
ntcchnnism.

Replacing the lilter clement

I. Unscrew the Iillcr clement (I) from the

5.7

The equalizer Wig. 5.7. 6) must remuin perpendicular to main

hmke cahlc Wig. 5.7. 5).

Brak~ cahle
Piu0-tmm

Plug

2. Apply lhe hand hrakc Ic\'cr sc"craltimcs and rcpcallhc

alUustment. Tighten the nuts with their lock nuts (Fig. 5.7.2).
RClllll\'e the j;:tck ~md the hlocks.

Bmke shllc ;tdjustmcnt re-establishes thc bmke litting-to-drum

demance ;,md compens;,ttcs for lining wear.
l.ift mid support the compressor. Muke surc that all bmkes arc off
(O\'errunhrakc and hand brake Ic\'er). The brake cables musl be frce
from tension. Lock the swi\'elcamsofthewheel brake from the outside
by means of a pin" 4 mnt (4) through the holc as shown in Fig. 5.5.

3. Roud test the compressor and hrakc sc\'cmltimes. Check brake

shlle and hr;,tke cuhle ;'Idjustment and if necessary adjust.

B. Acccpt.hle

Turn the adjusting. holt ( I)dockwise with a wrench lilllhe wheel locks
up. Center the bmke shws by actuating the parking bmke sc\'eral
times.
Turn thc adjusting bolt anti-clockwise until the wheel is running frce
in direction uf lmvcl (approx. I full tum of lhe adjusting bolt).
Check lheposition oflhee4ualizcr(Fi~.5.7. 6)with thc parking brake
:.IltU<ned.

C. Tou loose:
adjust hrakc cahles
(S~ctiol1 :'.6. ,)

Perpcndicular position of cqualizer = idcntical clearance of wheel

bmkcs.

Fig. S.X

H;uld hrake lever dm\II\\anl- brake nut opcrated

Re-;,tdjustthe brake shocs. if necessary.

To test. slightly npply the parking brakc and chcck identical bntke
torque on left and right side.
Remo\'c IOl'king pin
c;,tblcs.
Check all lock nuts

(I;i~.

(Fi~.

5.5. 4). Remove clc;,tntnce fmnt hmke

5.7.2).

D. Tuulighl:
adjlLc;l hrake eahles
(Seclion 5A:~)
Fig. 5.6

Currect and wrung. position of markings

35

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

6.

Instruction Manual

PROBLEM SOLVING

It is assumed that the cng.in~ is in good ,,:anditillll and that tlk:rc is

adequate fucl now (0 the filter and in.i~lilm equiplllent.

6 .1

I. Ne\'er re\'erse the polarity of the bancry or the allcmator.

An electrical fault must be traced b)' an electrician.

Mo.Ike sure: that the wires o.Ire not damaged and that they an: damped
light to lhelr temlino.lls.
For position or dip switches ",fer to section 1.8.1 to
2.~.2 Circuit Diagrams.

1. Nc\'cr break any allCmalororharlcrYC(lOn~tions while the engine

is running.

Possihl. fnlllts

5. Engine is running:. hut shuts

down immediately after
Slarl bUllon (S) bas been
released.

a. Stan huUun (5) released

J. \Vhen rc'Cbarging Ihe ballery. disconnccl il from the alternator.

Befure using booster ~ablcs 10 stan the eng.ine. be sure of the
polarity and connccllhe batteries correctly.
4. Ncvcr opcnllc the: enginc without the m0.l1n or \ollo.lgc sensing
co.Iblcs conncctc:d in the dn:uit.

Problem

Possible faults

I. Stancr nluh.lr docs not nan k

:1.

Luw h..1ttery output.

a. Check declrulyle level and charge hall.ry.

If no c.:ells arc shoncd and battery is
discharged. trace "ause.: and corrcc.:t.

2. Staner mOlor cmnks engine

when switchinll st:.lrl hutton
(S) 10" (j) ". but engine
dnes not lire.

;;1.

Low ballery output.

a. See lorrcc.:li\,e action 1.

3. Engine

lift$. but engine

stops whc:n rc:leasing start
bUllon (S).

u.

Alternahlf dri\c: bdt broken or slipping.

b. Altern:.lIor/reguhllor ddi:cti\c.

a. Check and correct if necessary.

Hl'lJrnleter (I) I) docs nOI

l'ounl running time.

a. Hourmetcr (1)1) tlcfectl\'C.

a. Replace.

en2.inc ~Iftcr Swih:hinll

.";;'IOOllon (S) 10" <D

Problem
ALTERNATOR PRECAUTIONS

".

Correcti"e actions

b. Have assembly repaired.

6. Compressor i< 1",,<1ed

aUlom.lIieally 10 full
capacity after start1ng.

7. Unil doc< nOiload after

pres<ing Ihe IO.1ding valve
hulton.
8. Engine docs nOI speed up
ilnmcdi31clyaftcr
comprcssor loading. \'al\'c
hutton has hccn prcssed and
c.:onlpressordocs not dcli\'cr
air.

Corrective actions
100 SOOIl.

c. Fuel tank contains insufficient fuel.

a. Release button ance engine nil pressure has

built up ahu\'e the minimum allowed level.
h. Stop at ClOCC. c<')fIsult the engine inst.ruclilln
manual.
c. FiJI fucllank.

a. Loading valve stuck in loading position.

a.

h. Insuffidem enginc oB pressure.

h. Air inlake Ihrollie "ah'e <luck in opened

position.
c. Air leaks in rcgulating system.

Rcmo\'c and disomntle loadine \,al\c.

Correcl if nec,",sary.
..
b. Chc'Ck and. if necc<sary con<ull Alla<
Copen.
c. Chl.~k hoses and their fillings. Stup Icaks:
rcpl3lc leaking ho~s.

3.

Regulating valvc defectivc.

a. Check mid if ncccssaf)' l'onsuJ( Atlas

Copco.

3.

Rcgulating valvc dcfccthc.

a. Check and. if IIcl'cssary consult Atlas

Copeo.
h. Chcek and. irncccssary consull AII:Js
Copen.

h. Air intakc thrallic mh'c stuck in c1o:-;cd

posilion.

9. Exccssivc comprcssor oil

consumption. Oil mist
being discharged from air
nUllcl \'alvcs.

a. Compressor oil levcl too high.

a. Check oillev.l. Release pres<urc and drain

oil to correct Ic\el.

10. Compressor l-apadty or

prcssure helow noml3l.

Air consumption cXl"'Ccds ca~ll.:ity of

compressor.
h. Cooked air filler c1emenl<.
c. Unloading valve nol complelely open.

a. Chc\.k equipmcnt (,.onI1Clh.,.t1.

a.

/:1. Remove and inspeci c1cments.

c'. Cbcck and. if necessary cOII<ull Alla<
CClp:O.

36
J7

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

Problem
II. Compressor docs nut
unloau anu engine kc'Cps
runnin~

at max. speed when

dosing the air outkt valves.

~lrc(y \"..II\'e blows.

12. Working pressure rises

during np:ratiun and C'1USCS
s;lfcly Yi..ll\'c 10 bluw.

Possible raults

Corrective actions

a. Regulating "..tin: inCllffi:l'tly ~t ur dctcc.:tivc.

a.

b. Air IC:lks in

c. Unluading.

a.

r~gubling

\':J)n:

system.

stul:k.

Regulating \":lIn: incllffi:clly scI or detective.

C1",ck anu. ir necessary consult Alias

Copeo.

b. Check hoses anu lheir finings. SlOP leaks

and. ir necessary consuh Alias Copeo.

Instruction Manual

AVAILABLE OPTIONS

7.

Ves"'-'Ilype:

ASME
Towbar:

AujuSlable wilh brakes (AI

Fixeu wilh hrakes (Al
Fixed without hrakes

WilhoUllowhar:

Support (wilhoOI onderearriagel

Towing eyes:

AllasCopeo

c. Check and. if no.:cssary cOllsull Alias

Copeo.

a. Chtck and. i r nC1:cssary consulL AlIas

Copeo.

b. Air leaks in n:.g.uhJlin,g system.

b. Check hoses and theiT fillings. SlOp leaks

and. if necessary consolt Alias Copeo.

c. Un!tl;I\Jin,g v:lln: stuck.

c.

d. SOIle(}' \,.II\"C dcl':t.:ti "c.

d. Check safely val"e: consult Alias Copeo.

SUIllC ti mc.
the unit stups through .1
shutdown swit~h.

tl.

~.

J4. Air anu Ilil misl expelles

from ~ir Iiltcrs immcdiately
afler slopping.

15. Engine overheating.

16. Compressor lwerhe;'lling.

....uelwnk

~onlUins

insutlh:iellt fuel.

b. Air in fuel systelll. or insurticicnl fucl supply.

Engine Ilil pressure IOU luw.

Gil

38

Supponleg
Jockey wheel

Road signalismion:

Full (Ill

Air qoalily eqoipment:

Aftcrc()()ler + water separator

Aflcrcoolcr + wOller SCP.1n1tnT + line tilter P))
Aften:oolcr + w;ucr separalllr + fine I1Itcr PI) + (JI)
Aftcn:ooler + water sepOlratm + line tiltcr PI) + rcheater Ie)
Aflercooler + waler "'-'p:Jralor + line liher PD + QD + rehe:Jler (Cl
Alicr~l')olcr + waler separator + rchCaler
Lubricator on 7 bar units

Safely:

Wheelc'hocks
Safely carlridge

Kefineryequipmenl:

Spark arrcSlor
Inlel shul down ,aive

ColdSiart:

-20C (-4 Fl

Customer colour:

Single
r>uuble
Triple

d. Sec l'orrccti\,c al,;tions 15.

Compressor tcmpenllurc too high.

e. Sec

t".

Low cool'lIlt Ic\'l.:1.

f.

Top op cooling syslem.

u.

Unloadcr

a.

Check anu. if nc'Cessary consoil Alias

Copeo.

b. Wrung niltypc (withuul fonOl-rcwrding

;Idditin:s).

<.J. Insuftkicnl engine cooling.

h, Engine cool:'lIlt cll\llcr l'Il)g~c..-d eXlcrn;dly.

<.J.

Insurticicnt CUllIpres..;ur ~(,x.)ling.

h. Oil cuoh.:r dugged cxternally.

c. Oil lc\'cltou low,

17. After working for some

time. the unit SlOps fur no
:'lp~lreOi re<.Json.

Towhar supporl:

d. Engine tempewturc too high.

jallllllcd.

a.

Air in fuel system. or Insufficient fucl supply.

NATO
AC (Francel

a. Fill fuel lank.

h. Chc<k Iiilers and hoses for leaks, uin anu
benus.
c. Refcr to the enginc inslruction manual.

e.

\';11\'1.:

[)IN
Ball
halian

Check and. if nl.'Ccssary consult Athls

Copeo.

t 3. After wurking

EURO

~orrccti\'c

actions 16.

b. Consoil Alias Copeo.

a. Rdocalc compressor.
b.

Clt~an

engine: cool..o, loolcr. Refer to

section 4.7.

Locate comprcssor away frum walls: \\ hen

han ked with oth....or compressurs.lca\c spaL:e
hetween tl'k:m.
b. Clcan nil cookr. Refer to section ,1.7,

:'1.

1.',

Check oil k\'cl. Top up wilh rccommcnded

oil.

a. Check fiilers anu hoses for leaks. uin anu

benus.

A.

These units mcel yuur local ~1rcty regulalions and arc a\'ailable \",ith ovcrrun and parking hrakes.

Il.

ReneeloTS and lights for snfely on Ihe TO:Jd.

C.

Qualily air lhroogh Ihe aflereoolcr. rehealer anu fine filleTS.

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

8.

TECHNICAL SPECIFICATIONS

8.1

TORQUE VALUES

8.1.1

FOR GENERAL APPLICATIONS

8.3
8.1.2

Unit

Torque \'aJue

WhcdmllS

Nm

Uohs. axldhcams

Nm

For hexagon screws and nulS with strength grade 8.8

Bulls.IO\\'har/axlc
BoiLs. lllwbarlbollom
Bolls. lowing cycllowhar

Nm
Nln
Nm

120
205
HO
205
HO
205
HO
125
HO
J5
275
375

MH
2J

MIO
46

MI2
HO

MI4
125

For hengon screws and nuts "'ith strength grade 12.9

Threads;Lc
M6 MH
MIO MI2 MI4
Nm
15
3V
n
DS
210

MI6
205

MI6
345

Bulls. lifling. cydnywhLocl housing

r-tm

Blilis. cnginddriw housing (M 12)

Nm

Uults. engine/drive housing (M 14)

Utllts. c.:ompn:ssor clclncntldri\'c housing

Nm
Nm

Saf..:'l)' .switches
Juinls ;Jdjllstabh: tnwbar

(M2n

Nm
Nm

(M32)

Nm

+/- 15
+/- 20
+/- 10
+/- 20
+/- 10

+ 20
+/- 10
+/- 10

+/- 5
+/- 5
+/- 25

+/- 25

Note:
Secure Ihe tank cap and drain plug oC Ihe Cuel tank handtighl.

Designation

Reference conditions
I. Ahsolule illler pres!'ure
2. Rcl:ui\'c air humidit)'
3. Air inlcllemperature
4. Nominal effecti"e working prc$~lrc
TIle inlet condilinns arc specified allhe
air inlet ~rntil1g llulsidc Ihe canopy

SETTINGS OF SHUTDOWN SWITCHES AND SAFETY VALVES

Compressor llpe
Designation
En~int:

nil pn.'ssurc

E.ngine nillcm[Jl:rJlun:
CnmpreSltllf Icmp:r.lIun.:
Sar('IY valve up:ning pressure
ECI)'(lC
ASME IYJIC

XAHS
1460d
I'nit

Value

XATS
I560d
\'alue

XA(S)
11I6Od
Value

XAVS
166Dd
Value

XAHS
11I6Od
Value

~;"lC)

C
C

ILl
120

111
120

In
120

113
120

ILl
120

hi.lr(1.')

15
21H

Ll.5
200

10

17
250

17
250

psi

XATS

XA(Sl

XAVS

XAHS

156 Dd

11I6Od

166 Od

11l6Dd

Unit

Value

Value

Value

Vnlue

Value

~or(cl

I
0
20
12

I
0
20
7

I
0
20
14

150

\I-

C
l>ar(cl

II

20
IO.J

I
I)

20
12

Limitations

I. Minimum errective receiver pressure

2. MaXimum effective recciver pressure.
compressor unloaded
3. Maximu!" :unhicnt temperature at
sC31e\'eI U

4. Minimum slarting. temperature

5. Millimum sl:'ll1ing temperature. with
coldslan cqlliplnCI11
6. Altitudc capahilit)'

8.2

XAHS
I460d

FOR IMPORTANT ASSEMBLIES

Assemblies

M6
9

COMPRESSOR/ENGINE SPECIFICATIONS

Compressor In"

The following (abies lisllhe n.:t:ommcndct..llurqucs applied fof gcncr;:l1

~pplkalions aI ilsscmbly oflhl: cumprC~l)r.

Threads;""
Nm

Instruction Manual

Performance data 2)
I. Enginc sh:tft speed. normal and
maximllm
2. Enginc sh:tft spced. c()mprc~!\or
unloaded
J. Engine sh:tfl speed, gcnernlor at
m:tltimllm load
4. Free air delivcry 3.
5. I:ucl con~umplion:

- .. [uliinad
- :It full IO:ld + gcnerator
- al unload
6. Specific fuel consumption
7. Typical nil culllelll or compressed :lir

~ar(el

~ar(c)

D.5

II.~

8.5

15.5

D.5

'C
'C

50
.10

50

50

- III

-10

50
- 10

.J()

'C
m

51101l

- 2U
511110

- 2n
5000

- 20
5000

- 20
5000

r/min

2JOO

BOO

2JOO

BOO

2JOO

r/min

171lO

1700

1700

1550

1550

r/min
Vs

141

166

1~5

158

175

kph

16.7

10

17.4

20.7

20.7

8.1
J2.9
<5

9.1,
JIU
<5

85
26
<5

11.4
33.8
<5

3.1.8
<5

- 20

45

k~

kglh

m
m;'"'m

l
1

12.4

free air

8. Engine oil consumptiun (mJxilllum)

9. Compressed air tcmper::J.lure al ouilci
valvcs
10. Noise le\'cl
- Sunod J"OCS$Urc k\'cI fI.P), measured
accordilll! IU ISO 2151 under free
field cOnditiolt$ at 7 m dis(am.'C
- S01ll1d power Icvel (LW) complies
wilh 2000114/EC
I)

Fur aflcrcoolcr applicalion: sec: APe

2)

Al refcrence:
~Ialed,

condilion~,

glh

14

14

14

14

Ct2.1

90

90

90

90

tJ5

dllL"l

71

71

71

71

71

dllIA)

99

99

99

99

99

Xlt- Tal'111

if applicat'llc. ;md:ll nanll:ll

!l
~h:lfl ~I"ccd, llllk"5~ tllherwi~c

11:113

Mca"llrl."d ;uxonhng 10

Tolera1lce

ISO 1::!17 t.d,~

+I-:'~
2:' II~ <I:A()<~:'O I/~
1111)6 '1IIl1C'" (l
+1- -1';(0 2~ I/~ <FAD
TIle inll'tl\;lIi\l11,d ~Ialldard ISO 1217 c;orrc~pond~ 10 f\lllowins n:lliOIl:l1 "I:llldard~:
- nrili~h USI I ~71 p:ln I
- (icrm;lIIllIN Pl.l~ Pan I
- SWl'\li~h SSISI> I ::!17
- AIllc;ril";1II ANSI PTC9
Free 'Iirddi\'ery

Free :lir dcli\'l'ry \'I,lnnie 00\\ roue

~o

41

XAHS 146 Dd - XATS 156 Dd - XA(S} 186 Dd - XAVS 166 Dd - XAHS 186 Dd

XAHS 146 Dd XAVS 166 Dd

Compressor t)'pe

8.4

81

CONVERSION LIST OF

UNITS INTO BRITISH

UNITS

XATS 156 Dd XAHS I86D<1

XA(S) 186 Dd
Design data

Comluessor
I. Numher of cUlllpn:ssiul1
stages

Engine
I. Make
2. Type
3. Coolant
4. Nmnhcr of cylinders
5. Bure
6. Stroke
7. Swept vulume
8. Output accon.liug to SAE

DCll)Z
Dcull
TCIJ20121.04 TCIn013L04
Liquid
Liquid
4
4
111111
lOl
lO8
126
130
mm
4.038
4.764

J1995 at normal shaH sp:l:d

kW

- l.uad factor
9. Capacity of oil sump:
-lnitiallill
- Relill (max.) I)
IO.CaJXIdIY of cooling system

(if,

14504 psi
0.0.15 o.
kg
2.205 Ib
kmlh
0.621 milc/h
kW
1.341 hp (UK and US)
0.264 US gal
I
0.220 Imp gal (UK)
I
I
0.0.15 ClI.I\
m
3.281 ft
mm
0.039 in
m3/min = .15.315 cfm
mbar
0.401 in we
0.2251bf
N
Nm
0.7.18Ibf.f1
F
32+(1.8" 'Cl
(1'1: 32)/1.8
t"'C
- r\ h:mpCrJIUn: difference of I ':c = a

I har
l,g

llnit

Designation

83
65

104
65

85
14

12
115
16

9.

(3)

(1)

24

42
175

42
175

dHllIl~
n ..
un

1-

II

3.lJ

11II

k91
kg

kg

.21

Air rcquirro for cll~illc alld

~'ollltnC!>'illr CllOlill~. ~'llIlIhll~lh'lI

;llId (Ill

~I-

~t\1I11Irc~siloll:l

(,E .... - L . . . .-

l.cn,b!th
Width
Height
Wcight (ready to operate)

10\\ bar

mm
mm
mm
kg

(9)

'"w

I
Unit dimensions
with brakes

(8)

lb!e!nttellflb2le
culll. wcrki:l:;(ct(nlblwrit1

_n
l""IIcf=f."...."",,,,,Ill,,,~ji!:t,,,I,,,k:.&=.,-,I::::,,,,,,,Ol,,,i::::
.. _
Wilh

(7)

(10)
(11)

3.lJ

lillcrchall~c.

tl

5)
(6)

;.Cl1:e(lttG:/::etr.:

mJ/s

-!4)

ATLAD COPCO AIRPOWER n.v. -

-YA3-0~C -MOlllllI

24

of 1.8 F

DATA PLATE

Unit
I. Capacity of compressur
oilsyslcm
2. Net cap,u:ity of air
n.:cci\'l::r
3. Capacity (If lilcitilllk
4. Air n)lumf at inlct grating
(approx.) .l

Icmpcr.lIur~ dilTcrcnc~

fixed

adjustable

1'141
1716
1661
1800

4156
1716
1661
1825

---,,,,,,::..,-'1- (12)

-==
-

l14)
-

13)

I. Cumpany code
1. Product codc
.~. Unit ~erialnllmbcr
..J. Name of manufacturer
5. EEC or national type approval number
6. Vehicle idcntilication numher
7. A ~laximum pennilled ladt:n weight of the vehicle
n M\lximum pcnnitted road weight of the ,ehicle
C Maximum pcnnillcd laden weight of the lOwing eyc
l:t Mudel
lJ. Working pn:ssufC
10. Speed
II. Engine power
11. M\lllufacturing ycar
1.1. CE-Inark in accordance with Machine Directivc 89/391 EEC
14. Rcgistcr IlUmber or number of notilicd body

42