XA186 Dd XAHS146 Dd

XAS186 Dd XAVS136 Dd
XATS156 Dd

Registration code
Collection: X1
Tab: 38

Printed matter N¡
2950 1122 00 ATLAS COPCO – PORTABLE AIR DIVISION
B-2630 AARTSELAAR BELGIUM
1998 Ð 12
 INSTRUCTION MANUAL

Congratulations on the purchase of your Atlas Copco compressor. It

is a solid, safe and reliable machine, built according to the latest
technology. Follow the instructions in this booklet and we guarantee
you years of troublefree operation. Please read the following
instructions carefully before starting to use your machine.
Always keep the manual available near the machine.
In all correspondence always mention the compressor type and serial
number, shown on the data plate.
The company reserves the right to make changes without prior
notice.

CONTENTS PAGE

1. Safety precautions for portable compressors ......................................5

Ð Introduction ......................................................................................................................5
Ð General safety precautions ..................................................................................5
Ð Safety during use and operation ....................................................................6
Ð Safety during maintenance and repair ....................................................6
Ð Tool applications safety ..........................................................................................7
Ð Specific safety precautions ..................................................................................7
Ð Batteries................................................................................................................................7
Ð Ether fuel systems........................................................................................................7
Ð Pressure vessels ..............................................................................................................7
Ð Safety valve ........................................................................................................................8
Ð Injury prevention ........................................................................................................8

2. Leading particulars ......................................................................................................9

2.1 Description of safety pictograms used
in this manual..................................................................................................9
2.2 General description ....................................................................................9
2.3 Markings and information labels ..................................................10
2.4 Main parts ......................................................................................................11
2.5 Air flow ............................................................................................................12
2.6 Oil system ......................................................................................................13
2.7 Continuous regulating system ........................................................13

3. Operating instructions ..........................................................................................14

3.1 Parking, towing and lifting instructions ..................................14
3.1.1 Parking instructions ................................................................................14
3.1.2 Towing instructions ................................................................................14
3.1.3 Lifting instructions ..................................................................................15
3.2 Before starting ............................................................................................15
3.3 Starting/Stopping ......................................................................................16
3.4 During operation ......................................................................................16

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XAS136/186 Dd

CONTENTS PAGE CONTENTS PAGE

4. Maintenance ....................................................................................................................17 6. Problem solving ............................................................................................................25

4.1 Use of service paks ..................................................................................17 6.1 Alternator precautions ..........................................................................25
4.2 Preventive maintenance schedule
for the compressor....................................................................................17
4.3 Lubrication oils ..........................................................................................18 7. Available options ........................................................................................................25

4.4 Oil level check ............................................................................................18

4.4.1 Check engine oil level ..........................................................................18
8. Technical specifications ..........................................................................................26
4.4.2 Check compressor oil level ..............................................................18
8.1 Torque values ..............................................................................................26
4.5 Oil and oil filter change ......................................................................19
8.1.1 For general applications ......................................................................26
4.5.1 Engine oil and oil filter change ......................................................19
8.1.2 For important assemblies ....................................................................26
4.5.2 Compressor oil and oil filter change ..........................................19
8.2 Settings of shutdown switches and
4.6 Cleaning coolers ........................................................................................19
safety valves ................................................................................................26
4.7 Battery care ..................................................................................................20
8.3 Compressor/engine specifications ..............................................26
4.7.1 Activating a dry-charged battery ..................................................20
8.4 Conversion list of SI units into British units........................27
4.7.2 Electrolyte ......................................................................................................20
4.7.3 Recharging a battery ..............................................................................20
4.7.4 Battery maintenance ..............................................................................20 9. Data plate ............................................................................................................................27
4.8 Storage ..............................................................................................................20
4.9 Service kits ....................................................................................................20
4.10 Compressor element overhaul ........................................................20 10. Circuit diagram...............................................................................................................28
4.11 Liability ............................................................................................................20

5. Adjustments and servicing procedures ..................................................21

5.1 Adjustment of the continuous
regulating system ......................................................................................21
5.2 Air filter engine/compressor ............................................................22
5.2.1 Main parts ......................................................................................................22
5.2.2 Recommendations ....................................................................................22
5.2.3 Cleaning the dust trap ............................................................................22
5.2.4 Replacing the air filter element ......................................................22
5.3 Air receiver ....................................................................................................22
5.4 Safety valve ..................................................................................................22
5.5 Fuel system ....................................................................................................23
5.6 Brake (= option) adjustment ............................................................23
5.6.1 Brake shoe adjustment ..........................................................................23
5.6.2 Test procedure of brake cable adjustment ............................24
5.6.3 Brake cable adjustment ........................................................................24

4
 --SAFETY PRECAUTIONS FOR PORTABLE COMPRESSORS--
To be read attentively and acted accordingly before towing, lifting, operating,
performing maintenance or repairing the compressor

8 Before a machine is being repaired, steps shall be taken to prevent

INTRODUCTION inadvertent starting. In addition, a warning sign bearing a legend such as
The policy of Atlas Copco is to provide the users of their equipment with safe, ãwork in progress; do not startÒ shall be attached to the starting
reliable and efficient products. Factors taken into account are among others: equipment. On engine-driven units the battery shall be disconnected and
removed or the terminals covered by insulating caps. On electrically
Ð the intended and predictable future use of the products, and the
driven units the main switch shall be locked in open position and the fuses
environments in which they are expected to operate,
shall be taken out. A warning sign bearing a legend such as ãwork in
Ð applicable rules, codes and regulations, progress; do not supply voltageÒ shall be attached to the fuse box or main
Ð the expected useful product life, assuming proper service and switch.
maintenance. 9 Normal ratings (pressures, temperatures, speeds, etc.) shall be durably
Before handling any product, take time to read the relevant instruction book. marked.
Besides giving detailed operating instructions, it also gives specific
10 Never operate a machine or equipment beyond its rated limits (pressure,
information about safety, preventive maintenance, etc.
temperature, speed, etc.).
These precautions are general and some statements will therefore not always
apply to a particular unit. 11 Maintenance and repair work should be recorded in an operatorÕs logbook
for all machinery. Frequency and nature of repairs can reveal unsafe
When handling, operating, overhauling and/or performing maintenance or conditions.
repair on Atlas Copco equipment, the mechanics are expected to use safe
engineering practices and to observe all relevant local safety requirements and 12 The machinery and pneumatic equipment shall be kept clean, i.e. as free
ordinances. The following list is a reminder of special safety directives and as possible from oil, dust or other deposits.
precautions mainly applicable to Atlas Copco equipment. 13 To prevent an increase in working temperature, inspect and clean heat
This brochure applies to machinery processing or consuming air or inert transfer surfaces (cooler fins, intercoolers, water jackets, etc.) regularly.
gas. Processing of any other gas requires additional safety precautions For every machine establish a suitable time interval for cleaning
typical to the application and are not included herein. operations.
All responsibility for any damage or injury resulting from neglecting 14 All regulating and safety devices shall be maintained with due care to
these precautions or by non-observance of ordinary caution and due care ensure that they function properly. They may not be put out of action.
required in handling, operating, maintenance or repair, also if not
expressly mentioned in this brochure or the instruction book(s), is 15 Care shall be taken to avoid damage to safety valves and other pressure-
disclaimed by Atlas Copco. relief devices, especially to avoid plugging by paint, oil coke or dirt
accumulation, which could interfere with the functioning of the device.
If any statement does not comply with local legislation, the stricter of the
two shall be applied. Statements in this brochure should not be 16 Pressure and temperature gauges shall be checked regularly with regard to
interpreted as suggestions, recommendations or inducements that it their accuracy. They shall be replaced whenever outside acceptable
should be used in violation of any applicable laws or regulations. tolerances.
17 Parts shall only be replaced by genuine Atlas Copco replacement parts.
GENERAL SAFETY PRECAUTIONS 18 Safety devices shall be tested as described in the maintenance schedule of
the instruction book(s) to determine that they are in good operating
1 The owner is responsible for maintaining the unit in a safe operating
condition.
condition. Unit parts and accessories must be replaced if missing or
unsuitable for safe operation. 19 Never use flammable solvents or carbon tetrachloride for cleaning parts.
2 Use only lubricating oils and greases recommended or approved by Atlas Take safety precautions against toxic vapours when cleaning parts in or
Copco or the machine manufacturer. Ascertain that the selected lubricants with cleaning products.
comply with all applicable safety regulations, especially with regard to 20 Observe scrupulous cleanliness during maintenance and repair. Keep
explosion or fire risk and the possibility of decomposition or generation away dirt by covering the parts and exposed openings with clean cloth,
of hazardous gases. paper or tape.
3 The supervisor, or the responsible person, shall at all times make sure that 21 Protect the motor, alternator, air intake filter, electrical and regulating
all instructions regarding machinery and equipment operation and components, etc. to prevent moisture ingress, e.g. when steam-cleaning.
maintenance are strictly followed and that the machines with all
accessories and safety devices, including the entire compression or 22 When performing any operation involving heat, flames or sparks on a
vacuum system with pipes, valves, connectors, hoses, etc., as well as the machine, the surrounding components shall first be screened with non-
consuming devices, are in good repair, free of abnormal wear or abuse, flammable material.
and are not tampered with.
23 Never use a light source with open flame for inspecting the interior of a
4 Maintenance, overhaul and repair work shall only be carried out by machine, pressure vessel, etc.
adequately trained personnel; if required, under supervision of someone
qualified for the job. 24 On portable units, support the drawbar and axle(s) securely if working
underneath the units or when removing a wheel. Do not rely on jacks.
5 Whenever there is an indication or any suspicion that an internal part of a
machine is overheated, the machine shall be stopped but no inspection 25 Prior to stripping a compressor, engine or other machine or undertaking
covers shall be opened before sufficient cooling time has elapsed; this to major overhaul on it, prevent all movable parts with a mass exceeding 15
avoid the risk of spontaneous ignition of the oil vapour when air is kg (30 lbs) from rolling over or moving.
admitted. 26 When repair has been completed, make sure that no tools, loose parts or
6 Maintenance work, other than routine attention, shall only be undertaken rags are left in, or on, the machine, the prime mover or the driving gear.
when the machine is standing still. The machine shall be barred over at least one revolution for reciprocating
7 Before dismantling any pressurized component, the compressor or the machines, several revolutions for rotary ones to ensure that there is no
equipment shall be effectively isolated from all sources of pressure and be mechanical interference within the machine or driver. Check the direction
completely vented to atmosphere. In addition, a warning sign bearing a of rotation of electric motors when starting up the machine initially and
legend such as ãwork in progress; do not openÒ shall be attached to each after any alteration to the electrical connection(s) or switch gear, to check
of the isolating valves. that the oil pump and the fan function properly.

5
 Never play with compressed air. Never apply it to your skin or direct an
SAFETY DURING USE AND OPERATION air stream at people. Never use it to clean dirt from your clothes. When
using it to clean down equipment, do so with extreme caution and use eye
To lift a unit, all loose or pivoting parts, e.g. doors and drawbar, shall first be
protection.
securely fastened. Do not attach cables, chains or ropes directly to the lifting
eye; apply a crane hook or lifting shackle meeting local safety rules. Do not use compressed air from any type of compressor, without taking
extra measures, for breathing purposes as this may result in injury or
Helicopterlifting using the lifting eye is forbidden.
death. For breathing air quality, the compressed air must be adequately
It is strictly forbidden to dwell or stay in the risk zone under a lifted load. purified according to local legislation and standards.
Never lift the unit over people or residential areas. Breathing air must always be supplied at stable, suitable pressure.
Lifting acceleration and retardation shall be kept within safe limits. 11 Never move a unit when external lines or hoses are connected to the
1 Before towing the unit: outlet valves, to avoid damage to valves and/or manifold and hoses.
Ð ascertain that the pressure vessel(s) is (are) depressurized, 12 Never refill fuel while the unit is running. Keep fuel away from hot parts
Ð check the drawbar, the brake system and the towing eye. Also check such as air outlet pipes or the engine exhaust. Do not smoke when
the coupling of the towing vehicle, fuelling. When fuelling from an automatic pump, an earthing cable should
be connected to the unit to discharge static electricity. Never spill nor
Ð check that the pivot wheel or stand leg is safely locked in the raised
leave oil, fuel, coolant or cleansing agent in or around the unit.
position,
Ð ascertain that the towing eye can swivel freely on the hook, 13 Never operate the unit in surroundings where there is a possibility of
taking in flammable or toxic fumes.
Ð check that the wheels are secure and that the tyres are in good
condition and inflated correctly, 14 Never operate the unit at pressures or speeds below or in excess of the
limit ratings stated on the Principal Data sheet.
Ð connect the signalisation cable, check all lights and connect the
pneumatic brake couplers, 15 On water-cooled engines with closed cooling circuit: allow the unit to
Ð attach the safety break-away cable to the towing vehicle, cool before removing a pressure cap.
Ð remove wheel chocks, if applied, and disengage the parking brake. 16 All doors shall be shut during operation so as not to disturb the cooling air
flow inside the body-work and/or render the silencing less effective. A
2 If the unit is to be backed up by the towing vehicle, disengage the overrun door should be kept open for a short period only, e.g. for inspection or
brake mechanism. adjustment.
3 Never exceed the maximum towing speed of the unit. 17 Wear ear protectors when environmental noise can reach or exceed 90
4 Place the unit on level ground and apply the parking brake before dB(A). Beware of long-time exposure to noise.
disconnecting the unit from the towing vehicle. Unclip the safety break- 18 Periodically check that:
away cable. If the unit has no parking brake the support of the towbar
partly acts as a brake; it is recommended to immobilize the unit by Ð all safety equipment is in good working order,
placing chocks before or behind the wheels. Ð all guards and air conducting baffles are in place and securely
When the towbar can be positioned vertically, the locking device must be fastened,
applied and kept in good order. Ð all hoses and/or pipes inside the unit are in good condition, secure and
not rubbing,
5 When the unit has to operate in a fire-hazardous environment, each
engine exhaust has to be provided with a spark arrestor to trap incendiary Ð there are no fuel, oil or coolant leaks,
sparks. Ð the tension of drive belts is correct,
6 The exhaust contains carbon monoxide which is a lethal gas. When the Ð all fasteners are tight,
unit is used in a confined space, conduct the engine exhaust to the outside Ð all electrical leads are secure and in good order,
atmosphere by a pipe of sufficient diameter (min. 100 mm); do this in
Ð the engine exhaust system is in good condition,
such a way that no extra back pressure is created for the engine. If
necessary, install an extractor. Ð air outlet valves and manifold, hoses, couplings, etc. are in good
repair, free of wear or abuse,
7 When operating in a dust-laden atmosphere, place the unit so that dust is
not carried towards it by the wind. Operation in clean surroundings Ð the wheel nuts are tightened to the proper torque.
considerably extends the intervals for cleaning the air intake filters and When more than one compressor is connected to a common header, be sure
the cores of the coolers. each compressor has a non-return valve (check valve) to prevent reverse
rotation when stopping.
8 Locate the unit away from walls. Take all precautions to ensure that hot
air exhausted from the engine and driven machine cooling systems cannot
be re-circulated. If such hot air is taken in by the engine or driven SAFETY DURING MAINTENANCE AND REPAIR
machine cooling fan, this may cause overheating of the unit; if taken in
for combustion, the engine power will be reduced. Maintenance and repair work shall only be carried out by adequately trained
9 No external force may be exerted on the air outlet valves, e.g. by pulling personnel; if required, under supervision of someone qualified for the job.
on hoses or by installing auxiliary equipment directly to a valve, e.g. a 1 Use only the correct tools for maintenance and repair work.
water separator, a lubricator, etc.
2 Use only genuine spare parts.
10 Distribution pipework and air hoses must be of correct size and suitable
for the working pressure. Never use frayed, damaged or deteriorated 3 All maintenance work, other than routine attention, shall only be
hoses. Replace hoses and flexibles of which the lifetime expired. Use only undertaken when the unit is stopped. Ensure that the unit cannot be started
the correct type and size of hose end fittings and connections. inadvertently.

A hose connected to a 2 inch (50 mm) valve must be provided with a 4 Before removing any pressurized component, effectively isolate the
safety wire (¯ 8 mm) fixed to the hose (each 500 mm) for effective compressor from all sources of pressure and relieve the entire system of
pressures as from 10 bar (145 psi) up, although it is recommended to pressure. Do not rely on non-return valves (check valves) to isolate
apply such safeguard already from 4 bar (60 psi) up. The safety wire ends pressure systems.
have to be attached, one to the eye provided next to the compressor air 5 Never use flammable solvents or carbon tetrachloride for cleaning parts.
outlet valve, the other one to a point near to the air inlet of the applied Take safety precautions against toxic vapours of cleaning liquids.
equipment. 6 Scrupulously observe cleanliness during maintenance and when
Finally a wire mesh hose can be fixed over the hose ends to dampen the performing repairs. Keep dirt away by covering the parts and exposed
blast in case a connection starts leaking or should become undone. openings with a clean cloth, paper or tape.
Close the compressor air outlet valve before connecting or disconnecting 7 Never weld on or perform any operation involving heat near the fuel or
a hose. Ascertain that a hose is fully depressurized before disconnecting oil systems. Fuel and oil tanks must be completely purged, e.g. by steam-
it. cleaning, before carrying out such operations.
When blowing through a hose or air line, ensure that the open end is held Never weld on, or in any way modify, pressure vessels. Disconnect the
securely. A free end will whip and may cause injury. alternator cables during arc welding on the unit.

6
8 Support the drawbar and the axle(s) securely if working underneath the
SPECIFIC SAFETY PRECAUTIONS
unit or when removing a wheel. Do not rely on jacks.
9 Make sure that no tools, loose parts or rags are left in or on the unit. Batteries
10 Before clearing the unit for use after maintenance or overhaul, check that 1 The electrolyte in batteries is a sulphuric acid solution which is fatal if it
operating pressures, temperatures and speeds are correct and that the hits your eyes, and which can cause burns if it contacts your skin.
control and shut-down devices function correctly. Therefore, be careful when handling batteries, e.g. when checking the
charge condition.
11 Do not remove any of, or tamper with, the sound-damping material. Keep 2 Install a sign prohibiting fire, open flame and smoking at the post where
the material free of dirt and liquids such as fuel, oil and cleansing agents. batteries are being charged.
12 Protect the electrical and regulating components, the air filter, etc. to 3 When batteries are being charged, an explosive gas mixture forms in the
cells and might escape through the vent holes in the plugs.
prevent moisture from entering them, e.g. when steam-cleaning.
Thus an explosive atmosphere may form around the battery if ventilation
is poor, and can remain in and around the battery for several hours after it
TOOL APPLICATIONS SAFETY has been charged. Therefore:
- never smoke near batteries being, or having recently been, charged,
Apply the proper tool for each job. With the knowledge of correct tool use and - never break live circuits at battery terminals, because a spark usually
knowing the limitations of tools, along with some common sense, many occurs.
accidents can be prevented. 4 When connecting an auxiliary battery (AB) in parallel to the unit battery
(CB) with booster cables: connect the + pole of AB to the + pole of CB,
Special service tools are available for specific jobs and should be used when
then connect the - pole of CB to the mass of the unit. Disconnect in the
recommended. The use of these tools will save time and prevent damage to reverse order.
parts.
Ether fuel systems
1 Use only spanners or sockets whose opening fits the fastener.
Ether fuel systems are used for diesel cold starting.
2 Apply an open-end spanner only in the plane of the fastener head, square
1 This type of fuel is extremely flammable, toxic and poisonous. Avoid
to the thread axis. Never cock an open-end spanner.
contact with eyes or skin and breathing the fumes. If accidently
3 Do not use a pipe or other improvised leverage extensions on handles. swallowed, do not induce vomiting but call a physician immediately.
2 If fuel enters or fumes irritate the eyes, flush the latter with large
4 Do not hammer on spanners or other tools which are not specially
quantities of clean water and call for medical aid.
designed therefore.
3 Before operating ether cold starting aids, read the instructions and the
5 Do not use adjustable spanners to tighten or slacken fasteners; they are container label.
intended to hold the other end of the fastener. 4 Never operate ether cold starting aids while the engine is running as this
can cause severe damage.
6 Always support the ratchet head when using socket extensions.
5 When maintenance, tests or repair has to be performed, do so in a well-
7 Discard any spanner with broken or battered points or edges. ventilated area only, away from heat, open flame or sparks. Ascertain that
the area is clearly marked out with signs prohibiting fire, open flame and
8 Never use hand type sockets on power or impact tools. smoking.
9 Select only heavy-duty impact sockets for use with pneumatic or electric 6 Wear eye protection when testing a system. Make sure that openings of a
impact tools. spray container, valve, tube or atomizer are pointed away from yourself
and others while testing.
10 Replace sockets showing cracks or wear; keep sockets clean. 7 Do not store ether containers in temperatures above 70 ¡C (160 ¡F).
11 Never use screwdrivers for prying, punching, chiselling, scoring or 8 Do not incinerate, puncture or attempt to remove the centre core valve,
scraping. side safety valve or any other part of an ether container.

12 Use the correct type and size of screwdriver for the job. The bit must Pressure vessels
match the fastener.
(according to directive 87/404/EEC annex II § 2)
13 A screwdriver with rounded edges will slip; it needs to be redressed or
Maintenance/installation requirements:
discarded.
1 The vessel can be used as pressure vessel or as separator and is designed
14 Never use a screwdriver or any other tool near a live wire or electrical to hold compressed air for the following application:
component. Plastic covering of handles is for comfort and grip only. Ð pressure vessel for compressor,
They are not intended to act as insulation if such is not clearly marked by Ð medium AIR/OIL,
the manufacturer. and operates as detailed on the data plate of the vessel:
15 Never strike a hammer against a hardened object; use a soft drift against Ð the maximum working pressure ps in bar,
the object and strike against the drift. Ð the maximum working temperature Tmax in ¡C,
16 Strike the object with the full face of the hammer. Ð the minimum working temperature Tmin in ¡C,
Ð the capacity of the vessel V in l.
17 Never use a hammer with a loose head.
2 The pressure vessel is only to be used for the applications as specified
18 Discard a hammer with chipped or mushroomed face. above and in accordance with the technical specifications. Safety reasons
prohibit any other applications.
19 Never use a chisel or punch with a chipped or mushroomed striking face.
3 National legislation requirements with respect to re-inspection must be
20 Always pull on a spanner or socket handle, if possible, and adjust your complied with.
stance to prevent a fall if something lets go. 4 No welding or heat treatment of any kind is permitted to those vessel
21 Wear approved eye protection when using percussion tools or when walls which are exposed to pressure.
scraping, chipping, shaving or grinding. 5 The vessel is provided and may only be used with the required safety
equipment such as manometer, overpressure control devices, safety valve,
22 Wear protective gloves when holding a chisel or punch. etc.

7
6 Draining of condensate shall be performed regularly when vessel is in 11 For maximum safety and efficiency of the lifting apparatus all lifting
use. members shall be applied as near to perpendicular as possible. If required,
a lifting beam shall be applied between hoist and load.
7 Installation, design and connections should not be changed.
12 When heavy parts are being lifted with a hoist, it is strictly forbidden to
8 Bolts of cover and flanges may not be used for extra fixation. dwell or pass under the load or in the space which is liable to be hit if the
load or part of it should topple over or come loose. Never leave a load
Safety valve hanging on a hoist. Lifting acceleration and retardation shall be kept
within safe limits.
All adjustments or repairs are to be done by an authorized representative of
13 A hoist has to be installed in such a way that the object will be lifted
the valve supplier.
perpendicular. If that is not possible, the necessary precautions must be
Following checks must be carried out: taken to prevent load-swinging, e.g. by using two hoists, each at
approximately the same angle not exceeding 30¡ from the vertical.
1 A check of the opening of the lifting gear, 1 or 2 times a year. This can be
done by screwing the cap of the valve anti-clockwise. 14 When using compressed air or inert gas to clean down equipment, do so
with caution and use the appropriate protection, at least safety glasses, for
2 A check of the set pressure once a year according to the local regulations, the operator as well as for any bystander. Do not apply compressed air or
if required. This check may not be done with the compressor supplying inert gas to your skin or direct an air or gas stream at people. Never use it
the air pressure and must be carried out on a proper test bench. to clean dirt from your clothes.
15 Before blowing compressed air or inert gas through a hose, ensure that the
INJURY PREVENTION open end is held securely, so that it cannot whip and cause injury.
16 When washing parts in or with a cleaning solvent, provide the required
1 Stationary housing guards are provided on all rotating or reciprocating ventilation and use appropriate protection such as a breathing filter, safety
parts not otherwise protected and which may be hazardous to personnel. glasses, rubber apron and gloves, etc.
Machinery shall never be put into operation, when such guards have been 17 Safety shoes should be compulsory in any workshop and if there is a risk,
removed, before the guards are securely reinstalled. however small, of failing objects, wearing of a safety helmet should be
2 Do not open electrical cabinets, cubicles or other equipment while voltage included.
is supplied. If such cannot be avoided, e.g. for measurements, tests or 18 If there is a risk of inhaling hazardous gases, fumes or dust, the
adjustments, have the action carried out by a qualified electrician only, respiratory organs must be protected and, depending on the nature of the
with appropriate tools, and ascertain that the required bodily protection hazard, so must the eyes and skin.
against electrical hazards is applied. 19 Remember that where there is visible dust, the finer, invisible particles
will almost certainly be present too; but the fact that no dust can be seen
3 Noise, even at reasonable levels, can cause irritation and disturbance
is not a reliable indication that dangerous, invisible dust is not present in
which, over a long period of time, may cause severe injuries to the the air.
nervous system of human beings.
20 When using cartridge type breathing filter equipment, ascertain that the
When the sound pressure level, at any point where personnel normally correct type of cartridge is used and that its useful service life is not
has to attend, is: surpassed.
below 70 dB(A): no action needs to be taken,
above 70 dB(A): noise-protective devices should be provided for people
continuously being present in the room,
below 85 dB(A): no action needs to be taken for occasional visitors
staying a limited time only,
above 85 dB(A): room to be classified as a noise-hazardous area and an
obvious warning shall be placed permanently at each
entrance to alert people entering the room, for even
relatively short times, about the need to wear ear
protectors,
above 95 dB(A): the warning(s) at the entrance(s) shall be completed
with the recommendation that also occasional visitors
shall wear ear protectors,
above 105 dB(A):special ear protectors that are adequate for this noise
level and the spectral composition of the noise shall be
provided and a special warning to that effect shall be
placed at each entrance.
4 Insulation or safety guards of parts the temperature of which can be in
excess of 80 ¡C (175 ¡F) and which may be accidentally touched by
personnel shall not be removed before the parts have cooled to room
temperature.
5 When hot parts have to be handled, e.g. shrink fitting, special heat-
resistant gloves shall be used and, if required, other body protection shall
be applied.
6 If the working process produces fumes, dust or vibration hazards, etc.,
take the necessary steps to eliminate the risk of personnel injury.
7 Before lifting machines, all loose parts which could be liable to fall down
shall be removed or secured; pivoting parts such as doors, drawbars, etc.
shall be safely immobilized.
8 To lift heavy parts, a hoist of ample capacity, tested and approved
according to local safety regulations, shall be used.
9 When lifting machinery or parts with one or more lifting eyes, only hooks
or shackles meeting local safety regulations shall be applied. Never shall
cables, chains or ropes be applied directly on or through lifting eyes.
Never allow sharp bends in lifting cables, chains or ropes.
10 Lifting hooks, eyes, shackles, etc. shall never be bent and shall only have
stress in line with their design load axis. The capacity of a lifting device
diminishes when the lifting force is applied at an angle to its load axis.

8
 INSTRUCTION MANUAL

2. LEADING PARTICULARS

2.1 DESCRIPTION OF SAFETY PICTOGRAMS USED IN – Regulation

THIS MANUAL The compressor is provided with a continuous regulating system and
a blow-down valve which is integrated in the unloader assembly. The
This symbol draws your attention to dangerous valve is closed during operation by outlet pressure of the compressor
situations. The operation concerned may endanger element and opens by air receiver pressure when the compressor is
persons and cause injuries. stopped.

☞ This symbol is followed by supplementary information.

When the air consumption increases, the air receiver pressure will
decrease and vice versa.
This receiver pressure variation is sensed by the regulating valve
which, by means of control air to the unloader and engine speed
regulator, matches the air output to the air consumption. The air
receiver pressure is maintained between the pre-selected working
pressure and the corresponding unloading pressure.

– Cooling system
The engine is provided with a water cooler and intercooler and the
compressor is provided with an oil cooler.
The cooling air is generated by a fan, driven by the engine.

– Safety devices
A thermal shut-down switch protects the compressor against
overheating. The air receiver is provided with a safety valve.
The engine is equipped with low oil pressure and high coolant
temperature shut-down switches.

– Frame and axle

Fig. 2.1 General view of XA(S)186 The compressor/engine unit is supported by rubber buffers in the
(adjustable towbar with brakes and jockey wheel are options) frame.
The standard unit has a non-adjustable towbar with a towing eye.
2.2 GENERAL DESCRIPTION As an option the unit can be equipped with an adjustable towbar, an
overrun and parking brake and towing eyes type AC, DIN, ball, ITA,
The XAS186 Dd is a silenced, single-stage, oil-injected screw
NATO.
compressor, built for a nominal effective working pressure of 7 bar
(non-silenced version XA186 Dd). The new braking system consists of an integrated parking brake and
The XATS156 Dd is built for a nominal effective working pressure of overrunbrake. When driving backwards the overrunbrake is not
10.3 bar. The XAHS146 Dd is built for a nominal effective working engaged automatically.
pressure of 12 bar. The XAVS136 Dd is built for a nominal effective
working pressure of 14 bar.
– Bodywork
The bodywork has openings at the shaped front and rear end for the
– Engine intake and outlet of cooling air and hinged doors for maintenance and
The compressor is driven by a water-cooled diesel engine. service operations. The bodywork is internally lined with sound-
The engineÕs power is transmitted to the compressor through a heavy- absorbing material.
duty coupling.
– Lifting eye
– Compressor A lifting eye is accessible when a small door at the top of the unit is
The compressor casing houses two screw-type rotors, mounted on unlocked.
ball and roller bearings. The male rotor, driven by the engine, drives
the female rotor. The element delivers pulsation-free air.
– Control panel
Injected oil is used for sealing, cooling and lubricating purposes. The control panel grouping the air pressure gauge, control switch etc.,
is placed at the right hand/ rear end corner.
– Compressor oil system
The oil is boosted by air pressure. The system has no oil pump. – Data plate
The compressor is furnished with a data plate showing the type, serial
The oil is removed from the air, in the air/oil vessel first by
number and normal working pressure (see chapter 9).
centrifugal force, second through the oil separator element.
The vessel is provided with an oil level indicator.

9
XAS136/186 Dd

2.3 MARKINGS AND INFORMATION LABELS

Compressor outlet temperature too high. Inlet.

Compressor outlet temperature. Outlet.

Compressor outlet pressure. Compressor oil drain.

Dangerous outlet. Read the instruction manual before starting.

Danger, heat flat. Service every 24 hours.

24h

Electrocution hazard. Warning !

Part under pressure.

PAROIL M Atlas Copco compressor oil. Do not stand on outlet valves.

PAROIL Atlas Copco engine oil.

SAE 15W40 Start-Stop indication of switch.

Manual. Do not run the motor with open doors.

Read the instruction manual

before working on the battery. Lifting permitted.

Reset fuse. Use diesel fuel only.

diesel

On / off button. 4.25 bar / 61 psi Tyre pressure

Hours, time.
Sound power level in accordance with
Directive 84/533/EC (expressed in dB (A)).

Prohibition to open air valves without connected hoses.

Horizontal towbar position required in case of

Compressor loaded. coupling.

Runlamp.

Airfilter.

Compressor temperature too high.

Rotation direction.

10
 INSTRUCTION MANUAL

2.4 MAIN PARTS

FC 3
IC
A WLG WT
S FC1
E
AFCE VI E
EP WC
VI CE
SV F
RV P
AR
FP1

MPV
TB

BH

OC

FF1
00
00

DPOC

FF2
OFE
FT
DS E
AFE
AOV
OLG
OFCE VV
FC 2
CP
CE

Fig. 2.2 Main parts of XAS136/186 Dd (adjustable towbar, brakes and roadsignalisation are options)

A Alternator F Fan OFE Oil Filter (engine)

AFCE Air Filter (compressor element) FC1 Filler Cap (engine oil) OLG Oil Level Gauge
AFE Air Filter (engine) FC2 Filler Cap (fuel tank) P Prop
AOV Air Outlet Valves FC3 Filler Cap (water) RV Regulating Valve
AR Air Receiver FF1 Fuel Prefilter S Starting Motor
BH Brake Handle SV Safety Valve
FF2 Fuel Filter
CE Compressor Element TB Towbar
CP Control Panel FP1 Filler Plug (compressor oil) VICE Vacuum Indicator (compressor element)
DPOC Drain Plug Oil Cooler FT Fuel Tank VIE Vacuum Indicator (engine)
DSE Engine Oil Level Dipstick IC Intercooler VV Vacuator Valve
MPV Minimum Pressure Valve WC Water Cooler
E Engine
OC Oil Cooler WLG Water Level Gauge
EP Exhaust Pipe
OFCE Oil Filter (compressor element) WT Water Tank
11
XAS136/186 Dd

COMPRESSOR REGULATING SYSTEM (LOAD CONDITION)

AFCE VI

VV
AFE VI
PG

VV
LV RV

FR SV
SR
E OC
UV BOV
UA
OS VH CH
BDV
SL
CV

AR OF
FP
AOV
CE F
DP TS

SL
MPV NRV OLG DP

DP

Fig. 2.3

AFCE Air filter (compr. element) CV Check Valve NRV Non Return Valve SR Speed Regulator
AFE Air filter (engine) DP Drain Plug OC Oil Cooler SV Safety Valve
AOV Air Outlet Valves E Engine OF Oil Filter TS Temperature Switch
AR Air Receiver F Fan OLG Oil Level Gauge UA Unloader Assembly
BDV Blow Down Valve FP Filler Plug OS Oil Separator UV Unloader Valve
BOV Blow Off Valve FR Flow Restrictor PG Pressure Gauge VH Vent Hole
CE Compressor Element LV Loading Valve RV Regulating Valve VI Vacuum Indicator
CH Coupling Housing MPV Minimum Pressure Valve SL Scavenge Line VV Vacuator Valve

2.5 AIR FLOW (SEE FIG. 2.3)

The system comprises:
AF Air filter The oil collects in the receiver and on the bottom of the separator
AR/OS Air receiver/oil separator element.
CE Compressor element The air leaves the receiver via a minimum pressure valve (MPV)
UA/UV Unloader assembly with unloader valve which prevents the receiver pressure from dropping below the
BDV Blow-down valve minimum working pressure (specified in section 8.3), even when the
air outlet valves are open. This ensures adequate oil injection and
LV Loading valve
prevents oil consumption.
Air drawn through the airfilter (AFCE) into the compressor element
(CE) is compressed. At the element outlet, compressed air and oil A temperature switch (TS) and a working pressure gauge (PG) are
pass into the air receiver/oil separator (AR/OS). comprised in the system.

The check valve (CV) prevents blow-back of compressed air when A blow-down valve (BDV) is fitted in the unloader assembly to
the compressor is stopped. In the air receiver/oil separator (AR/OS), automatically depressurise the air receiver (AR) when the compressor
most of the oil is removed from the air/oil mixture; the remaining oil is stopped.
is removed by the separator element.

12
 INSTRUCTION MANUAL

2.6 OIL SYSTEM (SEE FIG. 2.3) 2.7 CONTINUOUS REGULATING SYSTEM (SEE FIG. 2.3)
The system comprises: The system comprises:
AR/OS Air receiver/oil separator RV Regulating valve
OC Oil cooler UA Unloader assembly
OF Oil filter SR Speed regulator
The lower part of the air receiver (AR) serves as oil tank. The compressor is provided with a continuous regulating system.
This system is provided with a blow-down valve which is integrated
Air pressure forces the oil from the air receiver/oil separator (AR/OS)
in the unloader assembly (UA). The valve is closed during operation
through the oil cooler (OC) and oil filter (OF) to the compressor
by outlet pressure of the compressor element and opens by air
element (CE).
receiver pressure when the compressor is stopped.
The compressor element has an oil gallery in the bottom of its casing.
When the air consumption increases, the air receiver pressure will
The oil for rotor lubrication, cooling and sealing is injected through
decrease and vice versa. This receiver pressure variation is sensed by
holes in the gallery.
the regulating valve which, by means of control air to the unloader,
Lubrication of the bearings is ensured by oil injected into the bearing matches the air output to the air consumption. The air receiver
housings. pressure is maintained between the pre-selected working pressure and
the corresponding unloading pressure.
The injected oil, mixed with the compressed air, leaves the
compressor element and re-enters the air receiver, where it is When starting the compressor, the unloader valve (UV) is kept open
separated from the air as described in section 2.5. The oil that collects by spring force, the engine runs at maximum speed. The compressor
in the bottom of the oil separator element is returned to the system element (CE) takes in air and pressure builds up in the receiver.
through scavenging line (SL), which is provided with a flow restrictor The unloader valve is closed.
(FR).
The air output is controlled from maximum output (100%) to no
The oil filter by-pass valve opens when the pressure drop over the output (0%) by:
filter is above normal because of a clogged filter. The oil then by-
1. Speed control of the engine between maximum load speed and
passes the filter without being filtered. For this reason, the oil filter
unloading speed (the output of a screw compressor is
must be replaced at regular intervals (see section 4.2).
proportional to the rotating speed).
2. Air inlet throttling.
3. Blow off valve (BOV).

If the air consumption is equal to or exceeds the maximum air output,

the engine speed is held at maximum load speed and the unloading
valve is fully open.
If the air consumption is less than the maximum air output, the
regulating valve supplies control air to unloader valve (UV) to reduce
the air output and holds air receiver pressure between the normal
working pressure and the corresponding unloading pressure of
approx. 1.5 bar above the normal working pressure.
When the air consumption is resumed, the unloader valve gradually
opens the air intake and the speed regulator increases the engine
speed.
The construction of the regulating valve is such that any increase
(decrease) of the air receiver pressure above the pre-set valve opening
pressure results in a proportional increase (decrease) of the control
pressure to the unloading valve.
Part of the control air is vented to atmosphere, and any condensate
discharged, through the vent holes (VH).

13
XAS136/186 Dd

3. OPERATING INSTRUCTIONS
3.1 PARKING, TOWING AND LIFTING INSTRUCTIONS
6 6
Safety precautions
The operator is expected to apply all relevant safety
precautions, including those mentioned on the pages 5 -
8 of this book.
2
2
Attention:
Ð Before putting the compressor in to use, check the brake system
as described in section 5.6. Fig. 3.3 Parking position of jockey wheel

Ð After the first 100 km travel:

Ð Check and retighten the wheel nuts and towbar bolts to the
specified torque. See section 8.1.
Ð Check the brake adjustment. See section 5.6.

3.1.1 PARKING INSTRUCTIONS

Fig. 3.4 Rear-end of compressor upwind

4 3.1.2 TOWING INSTRUCTIONS

5 1

Fig. 3.1 Non-adjustable towbar with standard prop without brakes

4 Fig. 3.5 Label on towbar, towing instructions

7 Before towing the compressor, make sure that the
4
towing equipment of the vehicle matches the towing eye
or ball connector.

For both non-adjustable - and adjustable towbar, the towbar should be

2 as level as possible and the compressor and towing eye end in a level
5
6 position. Turn the locking handles (7) in such a way that there is no
clearance between the teeth of the joints; this can be checked by
moving the towbar up and down at the towing eye. Mount safety pins
Fig. 3.2 Adjustable towbar with jockey wheel and brakes (4). Push hand brake lever (3) completely downwards and connect
breakaway cable (5) to the vehicle. Secure jockey wheel (2) or prop
When parking a compressor, secure prop (1) or jockey wheel (2) to (1) in the highest possible position. The jockey wheel is prevented
support the compressor in a level position. Be sure that the jockey from turning.
wheel (2) is blocked by the blocking pin (6).
Apply parking brake by pulling parking brake handle (3) upwards.
Place the compressor as level as possible; however, it can be operated 6 6
temporarily in an out-of-level position not exceeding 15¡. If the
compressor is parked on sloping ground, immobilise the compressor
by placing wheel chocks (available as option) in front of or behind
the wheels. Locate the rear-end of the compressor upwind, (See Fig.
3.4), away from contaminated wind-streams and walls. Avoid 2 2
recirculation of exhaust air from the engine. This causes overheating
and engine power decrease.
Fig. 3.6 Towing position of jockey wheel

14
 INSTRUCTION MANUAL

3.1.3 LIFTING INSTRUCTIONS 3.2 BEFORE STARTING

1. Before initial start-up, prepare battery for operation if not already

done. See section 4.7.

1 2. With the compressor standing level, check the level of the engine
oil. Add oil, if necessary, to the upper mark on dipstick. Consult
the Engine Operation Manual for the type and viscosity grade of
the engine oil.
2 3. Check the level of the compressor oil. The pointer of oil level
gauge (OLG- Fig. 2.3) should register in the green range. Add oil
if necessary. See section 4.3 for the oil to be used.

Before removing oil filler plug (FP - Fig. 2.3), ensure

that the pressure is released by opening an air outlet
valve.

4. Check that the fuel tank contains sufficient fuel. Top up, if
necessary. Consult the Engine Operation Manual for the type of
fuel.
5. Drain any water and sediment from the fuel filter until clean fuel
flows from the drain cock.
6. Press vacuator valves (VV- Fig. 2.3) of the air filters to remove
dust.
Fig. 3.7 Lifting eye
7. Check the air filter service indicators (VI- Fig. 2.3). If the yellow
When lifting the compressor, the hoist has to be placed in such a way piston reaches the red marked service range, replace the filter
that the compressor, which must be placed level, will be lifted element. Reset the indicator by pushing the reset button.
vertically. 8. Check water level in engine water top tank. Top up, if necessary.
Consult the Engine Operation Manual for water/coolant
Preferably use the lifting eye (1) after opening the small door (2).
specifications.

Lifting acceleration and retardation must be kept within

safe limits (max. 4xg).
Helicopter lifting is not allowed.

15
XAS136/186 Dd

3.3 STARTING/STOPPING H1 H2
H3 H4 N4
P1

000 0 F1

LV PG H7 H8 S
H5 H6
Fig. 3.8 Control panel

P1 Hourmeter H2 LED (green) Preheat (option)

F1 Circuit breaker button H3 LED (red) Charge indication
PG Working pressure gauge H4 LED (red) Compressor outlet temperature
LV Loading valve H5 LED (red) Engine coolant temperature
N4 Control module H6 LED (red) Engine oil pressure
S Start/Stop button H7 LED (red) Spare 1
H1 LED (green) Fuel ON H8 LED (red) Spare 2

Before starting, first operate the circuit breaker button (F1) at the Ð When the outlet temperature of the element becomes too high, a
right side of the control panel (open right-hand service door first). thermocontact will also switch off the group immediately.
To start, the start/stop button (S) is switched to position ÓIÓ, the green Control lamp H4 will light up.
fuel ON lamp (H1), the red charge indication lamp (H3) and preheat Ð The control lamps will remain on untill the group has been reset
lamp (H2) go on (preheat lamp only, if Ócold startÓ option is (start button switched to position Ó0Ó).
installed). After preheating, the preheat lamp goes out. When the
start/stop button is pushed in position Ó Ó, the starter motor will set
the engine in motion. Lamps H1 and H3 will go out as soon as the
engine has been started. After the start/stop button is released, it 3.4 DURING OPERATION
automatically springs back to position ÓIÓ.
Run the engine a few minutes at no-load to warm up. The doors must be closed during operation and may be
When the engine is running smoothly, press loading valve (LV) and opened for short periods only.
release as soon as pressure starts to build up.
Shutting down is simply done by pushing the start button in the Ó0Ó Regularly carry out following checks:
position.
1. That regulating valve (RV) is correctly adjusted, i.e. starts
The control panel in addition indicates receiver pressure (PG) and decreasing the engine speed when reaching the preset working
accumulated operating hours (P1). pressure in the receiver.
Fault situations and protective devices (Also refer to Sect. 6 2. Check the air filter vacuum indicators (VI - Fig. 2.3). If the
Problem Solving): yellow piston reaches the red marked service range, replace the
Ð The starter motor is protected against prolonged starting or filter element. Reset the indicators by pushing the reset button.
against attempts to start when the group is already running. 3. On compressors with aftercooler, check that the automatic drain
(max. cranking time: 20 sec.) of the water separator is operative without air leakage.
Ð A fault which occurs with the engine, either oil pressure too low,
coolant temperature (too high) or alternator voltage (too low) will
always and immediately cause the engine to cut out and one of
the control lamps H3, H5 or H6 to light up.

16
 INSTRUCTION MANUAL

4. MAINTENANCE

4.1 USE OF SERVICE PAKS 4.2 PREVENTIVE MAINTENANCE SCHEDULE FOR THE

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

MAINTENANCE SCHEDULE Daily Initially Normal Yearly Remarks

around 50 hours or every 500 hours or every 1000 hours

Service pak XA(S) and XATS supplied with unit 2912 4306 05 2912 4307 06
Service pak XAHS and XAVS supplied with unit 2912 4306 05 2912 4309 06
Engine oil level Check
Compressor oil level Check
Water level (3) (5) Check
Air filter vacuator valves Empty
Fuel filter water drain Drain
Air intake vacuum indicators Check
Electrolyte level and terminals of battery Check Check Check
Tyre pressure Check Check Check
Leaks in air-, oil- or fuel system Check Check Check
Oil cooler Clean Clean
Water cooler Clean Clean
Intercooler Clean Clean
Engine minimum and maximum speeds Check Check Check
Torque of wheel nuts Check Check Check
Brake system (if installed) Check/Adjust Check/Adjust Check/Adjust
Safety valve Test
Door Hinges Grease Grease
Towing eye shaft or ball coupling
and its shaft Grease Grease
Shut-down switches Check
Pressure drop over separator element (2) Measure Replace
Fan V-belts (3) Adjust Adjust Adjust
Fueltank Clean Clean
Compressor oil Change
Compressor oil filter Replace Replace
Air filter elements (1) Replace
Engine oil (3) (4) Change Change Change
Engine oil filter (3) Replace Replace Replace
Fuel prefilter (3) Replace Replace Replace
Fuel filter (3) Replace Replace
Engine inlet and outlet valves (3) Adjust Adjust first adjustment
Inspection by Atlas Copco
Service technician
(1) More frequently when operating in a dusty environment. (5) Check additive concentration every 500 h.
(2) Replace the element when the pressure drop exceeds 0.8 bar. Change coolant every 1000 h.
(3) Refer to the Deutz operation manual.
(4) 500 hours only valid when using PAROIL SAE 15 W 40.

Keep the bolts of the housing, the lifting eye, the towbar and the axle securely tightened.
Refer to ÔTechnical specificationsÕ for the torque values.
17
XAS136/186 Dd

4.3 LUBRICATION OILS 4.4 OIL LEVEL CHECK

It is strongly recommended to use Atlas Copco branded lubrication

oils for both compressor and engine. Never mix oils of different brands or types.

Mineral compressor oil PAROIL M: Use only non-toxic oils where there is a risk of inhaling
for use in normal conditions. delivered air.

- 5 liter can : order number 1615 5947 00

- 20 liter can : order number 1615 5948 00
- 208 liter barrel : order number 1615 5949 00 4.4.1 CHECK ENGINE OIL LEVEL

Consult also the Engine Operation Manual for the oil specifications,
viscosity recommendations and oil change intervals.
Mineral engine oil PAROIL SAE 15 W 40: See schedule.
for use in normal conditions.
Check engine oil level according to the instructions in the Engine
- 5 liter can : order number 1615 5953 00 Operation Manual and top up with oil if necessary.
- 20 liter can : order number 1615 5954 00
- 208 liter barrel : order number 1615 5955 00

4.4.2 CHECK COMPRESSOR OIL LEVEL

Synthetic compressor oil PAROIL S:
for use in ambient temp. below -10¡ C.
- 5 liter can : order number 1615 5950 00
- 19 liter can : order number 1615 5951 00
- 208 liter barrel : order number 1615 5952 00

Never mix synthetic with mineral oil.

2

☞ If you want to use another brand of oil, consult Atlas

00
00

Copco for more information concerning the

1
recommended oil and service intervals.

Fig. 4.1 Check compressor oil level

With the unit standing level, check the level of the compressor oil.
The pointer of the oil level gauge (1) must register in the upper
extremity of the green range. Add oil if necessary.

Before removing oil filler plug (2), ensure that the

pressure is released by opening an air outlet valve (3).

18
 INSTRUCTION MANUAL

4.5 OIL AND OIL FILTER CHANGE

6 Run the unit at no load for a few minutes to circulate the oil and
to evacuate the air trapped in the oil system.
7 Stop the compressor. Let the oil settle for a few minutes. Check
that the pressure is released by opening an air outlet valve (5).
Screw out filler plug (2) and add oil until the pointer of the oil
level gauge (4) again registers in the upper extremity of the green
range. Reinstall and tighten the filler plug.

Never add more oil. Overfilling results in oil

consumption.
2
00
00

4
4.6 CLEANING COOLERS

3
2
1
5
3 1
Fig. 4.2 Oil filters

4.5.1 ENGINE OIL AND OIL FILTER CHANGE

See section 4.2.

4.5.2 COMPRESSOR OIL AND OIL FILTER CHANGE

The quality and the temperature of the oil determine the oil change
interval.
The prescribed interval (See section 4.2) is based on an oil
temperature of up to 100 ¡C and normal operating conditions.
When operating in high ambient temperatures, in very dusty or high Fig. 4.3 Compressor oil cooler (1) and engine water cooler (2)
humidity conditions, it is recommended to change the oil more and intercooler (3)
frequently.

☞ In this case, contact Atlas Copco.

Keep the coolers (1), (2) and (3) clean to maintain the cooling
efficiency.

1 Run the compressor until warm. Close the outlet valve(s) (5) and Steam cleaning in combination with a cleansing agent may be
stop the compressor. Wait until the pressure is released through applied.
the automatic blow-down valve. Unscrew the oil filler plug (2) The fan side surface of the coolers is accessible by removing the fan
one turn. This uncovers a vent hole, which permits any pressure cowl upper part.
in the system to escape.
2 Drain the oil by removing all relevant drain plugs. Drain plugs To avoid damaging the coolers, angle between jet and
are located at the air receiver, compressor element and coolers should be approx. 90 ¡.
compressor oil cooler. Catch the oil in a drain pan. Screw out the (do not use jet at max. power)
filler plug to speed up draining. Tighten the plugs after draining.
Close the service door(s).
3 Remove the oil filter (3), e.g. by means of a special tool. Catch
the oil in a drain pan.
Never leave spilled liquids such as fuel, oil, water and
4 Clean the filter seat on the manifold, taking care that no dirt drops cleansing agents in or around the compressor.
into the system. Oil the gasket of the new filter element. Screw it
into place until the gasket contacts its seat, then tighten one half
turn only.
5 Fill the air receiver until the pointer of the oil level gauge (4)
registers in the upper extremity of the green range. Take care that
no dirt drops into the system. Reinstall and tighten the filler plug.

19
XAS136/186 Dd

4.7 BATTERY CARE 4.7.4 BATTERY MAINTENANCE

☞
Ð Keep the battery clean and dry
Before handling batteries, read the relevant safety
precautions and act accordingly. Ð Keep the electrolyte level at 10 to 15 mm above the plates or at
the indicated level; top up with distilled water only.
An ASB (Service Bulletin) dealing elaborately with batteries and due
Ð Keep the terminals and clamps tight, clean, and lightely covered
care is available on request.
petroleum jelly.
If the battery is still dry,it must be activated as described in point
4.7.1.
The battery must be in operation within 2 months from being
activated; if not, it needs to be recharged first.
4.8 STORAGE
Run the compressor regularly, e.g. twice a week, until warm.
4.7.1 ACTIVATING A DRY-CHARGED BATTERY Load and unload the compressor a few times to operate the unloading
and regulating components. Close the air outlet valves after stopping.
Ð Take out the battery.
Ð
Ð
Battery and electrolyte must be at equal temperature above 10 ¡C.
Remove cover and/or plug from each cell.
☞ If the compressor is going to be stored without running
from time to time, protective measures must be taken as
described in a separate Service Bulletin (ASB), which
Ð Fill each cell with electrolyte until the level reaches 10 to 15 mm
may be obtained on request.
above the plates, or to the level marked on the battery.
Ð Rock the battery a few times so that possible air bubbles can
escape; wait 10 minutes and check the level in each cell once
more; if required, add electrolyte.
Ð Refit plugs and/or cover. 4.9 SERVICE KITS
Ð Place the battery in the compressor. A service kit is a collection of parts to fit a specific repair or
rebuilding task.
It guarantees that all necessary parts are replaced at the same time
which improves the uptime of the unit.
4.7.2 ELECTROLYTE The order numbers of the Service Kits are listed in the Atlas Copco
Parts List (ASL).
Read the safety instructions carefully

Electrolyte in batteries is a sulphuric acid solution in distilled water.

☞ Contact Atlas Copco.

The solution must be made up before being introduced into the

battery.

4.10 COMPRESSOR ELEMENT OVERHAUL

When a compressor element is due for overhaul, it is recommended

4.7.3 RECHARGING A BATTERY
to have it done by Atlas Copco. This guarantees the use of genuine
Before and after charging a battery, always check the electrolyte level parts and correct tools with care and precision.
in each cell; if required, top up with distilled water only. When
charging batteries, each cell must be open, i.e. plugs and/or cover
removed.

☞ Use a commercial automatic battery charger according

to its manufacturer's instructions.
4.11 LIABILITY
The manufacturer does not accept any liability for any damage
Apply with preference the slow charging method and adjust the arising from the use of non-original parts and for modifications,
charge current according to the following rule of thumb: additions or conversions made without the manufacturerÕs approval
battery capacity in Ah divided by 20 gives safe charging current in in writing.
Amp.

20
 INSTRUCTION MANUAL

5. ADJUSTMENTS AND SERVICING PROCEDURES

5.1 ADJUSTMENT OF THE CONTINUOUS REGULATING SYSTEM

AFCE VI

VV
AFE VI
PG

VV
LV RV

FR SV
SR
E OC
UV BOV
UA
OS VH CH
BDV
SL
CV

AR OF
FP
AOV
CE F
DP TS

SL
MPV NRV OLG DP

DP

Fig. 5.1

The working pressure is determined by the tension of the spring in Tabel

the regulating valve (RV). This tension can be increased to raise the
X Y Z1 Ð Z2
pressure and decreased to lower it by turning the adjusting wheel
bar bar bar bar
clockwise and anti-clockwise respectively.
XA(S) 8.3 7 8.1 Ð 8.5
XATS 12 10.3 11.7Ð 12.2
To adjust the normal working pressure, proceed as follows: XAHS 13.4 12 13.2Ð 13.6
XAVS 15.5 14 15.3Ð 15.7
1. Start and warm up the engine (see section 3.3).
2. With the outlet valves (AOV) closed, loosen the regulating
valveÕs lock nut and adjust the regulating valve (RV) until a
pressure of X bar(e) is reached (see tabel). 5. Check the engine maximum speed. Adjust the maximum speed
by means of adjusting eccentric nut on top of speed regulator
3. Check the minimum speed of the engine. Adjust minimum speed
(SR).
stop screw if necessary.
6. Close the outlet valves (AOV), check that the pressure is between
4. Open an outlet valve (AOV) just enough to let the engine (E) run
Z1 and Z2 bar(e) (see tabel). Lock the regulating valve (RV) by
at maximum speed. The working pressure must be Y bar(e);
fixing the lock nut.
adjust if necessary with regulating valve (RV) (see tabel).

21
XAS136/186 Dd

5.2 AIR FILTER ENGINE/COMPRESSOR

5.2.1 MAIN PARTS 5.2.3 CLEANING THE DUST TRAP

To remove dust from the dust trap pinch the vacuator valve (6)
1 several times.

5.2.4 REPLACING THE AIR FILTER ELEMENT

1. Release the snap clips (1) and remove the dust trap (2).
Clean the trap.
2. Remove the element (4) from the housing (5).
3. Reassemble in reverse order of dismantling.
4. Inspect and tighten all air intake connections.
5. Reset the vacuum indicator (Fig. 5.3).

7
6 2 3 4 5
9
Fig. 5.2 Air filter
1 Snap clips
2 Dust trap
3 Safety cartridge (option) Fig. 5.3 Vacuum indicator

4 Filter element 7 Air filter contamination indicator

5 Filter housing 8 Reset button

6 Vacuator valve 9 Yellow indicator

5.2.2 RECOMMENDATIONS 5.3 AIR RECEIVER

The air receiver is tested according to official standards. Regularly

The Atlas Copco air filters are specially designed for the have inspections carried out in conformity with local regulations.
application. The use of non-genuine air filters may lead
to severe damage of engine and/or compressor element.

Never run the compressor without air filter element. 5.4 SAFETY VALVE

New elements must also be inspected for tears or punctures before

All adjustments or repairs are to be done by an
installation.
authorized representative of the valve supplier.
Discard the element (4) when damaged.
In heavy duty applications it is recommended to install a safety
Following checks must be carried out:
cartridge which can be ordered with
part no.: 2914 9311 00 Ð a check of the opening of the lifting gear, twice a year.
This can be done by screwing the cap of the valve anti-clockwise.
A dirty safety cartridge (3) is an indication of a mal-functioning air
filter element. Replace the element and the safety cartridge in this Ð a check of the set pressure once a year according to the local
case. regulations. This check cannot be done on the machine and must
be carried out on a proper test bench.
The safety cartridge cannot be cleaned.

22
 INSTRUCTION MANUAL

5.5 FUEL SYSTEM 5.6 BRAKE (= OPTION) ADJUSTMENT

Before jacking up the compressor, connect it to a towing

vehicle or attach a weight of minimum 50 kg to the
towbar.

5.6.1 BRAKE SHOE ADJUSTMENT

Check the thickness of the brake lining. Remove both black plastic
plugs (5). When the brake lining has been worn to a thickness of
1 mm or less, the brake shoes have to be replaced. After inspection
and/or replacement re-insert both plugs.
1
4

Fig. 5.4 Fuel filter

5 1 3 2
Replacing the filter element Fig. 5.5 Brake shoe adjustment
1. Unscrew the filter element (1) from the adapter head. 1 Adjusting bolt
2. Clean the adapter head sealing surface. Lightly oil the gasket of 2 Axle
the new element and screw the latter onto the header until the 3 Brake cable
gasket is properly seated, then tighten with both hands. 4 Pin ¿ 4 mm
5 Plug
3. Check for fuel leaks once the engine has been restarted.

Brake shoe adjustment re-establishes the brake lining-to-drum

clearance and compensates for lining wear.
Lift and support the compressor. Make sure that all brakes are off
(overrunbrake and hand brake lever). The brake cables must be free
from tension. Lock the swivel cams of the wheel brake from the
outside by means of a pin ¿ 4 mm (4) through the hole as shown in
Fig. 5.5.
Turn the adjusting bolt (1) clockwise with a wrench till the wheel
locks up. Center the brake shoes by actuating the parking brake
several times.
Turn the adjusting bolt anti-clockwise until the wheel is running free
in direction of travel (approx. 1 full turn of the adjusting bolt).
Check the position of the equalizer (Fig. 5.7, 6) with the parking
brake actuated.
Perpendicular position of equalizer = identical clearance of wheel
brakes.
Re-adjust the brake shoes, if necessary.
To test, slightly apply the parking brake and check identical brake
torque on left and right side.
Remove locking pin (4). Remove clearance from brake cables.
Check all lock nuts (Fig. 5.7, 2).

23
XAS136/186 Dd

5.6.2 TEST PROCEDURE OF BRAKE CABLE ADJUSTMENT 5.6.3 BRAKE CABLE ADJUSTMENT

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

the outmost position.
1 6 4 2
2. Check if the adjustable towbar (= option) is in the actual towing
position.
3. Apply the hand brake lever.
4. Push the compressor a few centimeters backwards so that the
brake lever is automatically pulled further up.
5. Check the position of the arrow marking Ó1Ó at the catch lock in
combination with the arrow marking Ó2Ó at the toothed sector,
according to Fig. 5.6 A,B,C,D.

1 2 3 4 2 5
1 Fig. 5.7 Brake cable arrangement
2 1 Brake cable
2 Lock nut
3 Adjusting nut
4 Brake cable nut
5 Main brake cable
6 Equalizer

A. Adjusted correctly
1. With the towing eye pulled out in the outmost position and the
hand brake lever in the downward position (Fig. 5.8), loosen the
lock nuts (Fig. 5.7, 2). Turn adjusting nuts and brake cable nuts
(Fig. 5.7, 4) clockwise until there is no slack in the brake
mechanism.
The equalizer (Fig. 5.7, 6) must remain perpendicular to main
brake cable (Fig. 5.7, 5).
2. Apply the hand brake lever several times and repeat the
adjustment. Tighten the nuts with their lock nuts (Fig. 5.7, 2).
Remove the jack and the blocks.
3. Road test the compressor and brake several times. Check brake
shoe and brake cable adjustment and if necessary adjust.

B. Acceptable

C. Too loose; Fig. 5.8 Hand brake lever downward - brake not operated
adjust brake cables
(Section 5.6.3)

D. Too tight;
adjust brake cables
(Section 5.6.3)

Fig. 5.6 Correct and wrong position of markings

24
 INSTRUCTION MANUAL

6. PROBLEM SOLVING
It is assumed that the engine is in good condition and that there is
adequate fuel flow to the filter and injection equipment. 6.1 ALTERNATOR PRECAUTIONS

1. Never reverse the polarity of the battery or the alternator.

An electrical fault must be traced by an electrician.
2. Never break any alternator or battery connections while the
engine is running.
Make sure that the wires are not damaged and that they are clamped 3. When recharging the battery, disconnect it from the alternator.
tight to their terminals. Before using booster cables to start the engine, be sure of the
polarity and connect the batteries correctly.
4. Never operate the engine without the main or voltage sensing
cables connected in the circuit.

7. AVAILABLE OPTIONS
The XA186 Dd, XAS186 Dd, XATS156 Dd, XAHS146 Dd and XAVS136 Dd can be delivered with following options:
Vessel type: EURO
ASME
Towing bar: Adjustable with brakes (A1)
Fixed with brakes (A2)
Fixed without brakes
Without towing bar: Support (without undercarriage)
Towing eyes: Atlas Copco
DIN
Ball
Italian
NATO
Towbar support: Leg
Jockey wheel
Road signalisation: Full (B)
Air quality equipment: Aftercooler + water separator
Aftercooler + water separator + fine filter
Aftercooler + water separator + fine filter + reheater (C)
Aftercooler + water separator + reheater
Lubricator on 7 bar units
Generator (D): 230/400 V-50 Hz
Safety: Wheel chocks
Safety cartridge
Refinery equipment: Spark arrestor
Inlet shut down valve
Cold start: -20 ¡C (-4 ¡F)
Customer colour: Single
Double
Triple

A. Series 6 units meet your local safety regulations and are available with overrun and parking brakes.
B. Reflectors and lights for safety on the road.
C. Quality air through the aftercooler, reheater and fine filters.
D. Simultaneous electric and pneumatic power.

25
XAS136/186 Dd

8. TECHNICAL SPECIFICATIONS
8.1 TORQUE VALUES 8.3 COMPRESSOR/ENGINE SPECIFICATIONS

8.1.1 FOR GENERAL APPLICATIONS

Compressor type XAVS136 Dd
The following tables list the recommended torques applied for general XAHS146 Dd
applications at assembly of the compressor. XATS156 Dd
XA(S)186 Dd
For hexagon screws and nuts with strength grade 8.8
Designation Unit
Thread size M6 M8 M10 M12 M14 M16 Reference conditions
Nm 9 23 46 80 125 205 1. Absolute inlet pressure bar(e) 1 1 1 1
2. Relative air humidity % 0 0 0 0
3. Air inlet temperature ¡C 20 20 20 20
For hexagon screws and nuts with strength grade 12.9 4. Nominal effective working pressure bar(e) 7 10.3 12 14
Thread size M6 M8 M10 M12 M14 M16 The inlet conditions are specified at
the air inlet grating outside the canopy
Nm 15 39 78 135 210 345

Limitations
1. Minimum effective receiver pressure bar(e) 4 4 4 4
2. Maximum effective receiver pressure,
compressor unloaded bar(e) 8.5 11.8 13.5 15.5
8.1.2 FOR IMPORTANT ASSEMBLIES
3. Maximum ambient temperature at sea level ¡C 50 50 50 50
Assemblies Unit Torque value 4. Minimum starting temperature ¡C -10 -10 -10 -10
Wheel nuts Nm 120 +/- 15 5. Minimum starting temperature,
Bolts, axle/beams Nm 205 +/- 20 with coldstart equipment ¡C -20 -20 -20 -20
6. Altitude capability m (see page 315) (see page 316)
Bolts, towbar/axle Nm 80 +/- 10
Altitude unit performance curve
Bolts, towbar/bottom Nm 205 +/- 20 Max. allowable working pressure as a function
Bolts, towing eye/towbar Nm 80 +/- 10 of altitude and ambient temperature
Bolts, lifting eye/flywheel housing Nm 205 + 20
Bolts, engine/drive housing (M12) Nm 80 +/- 10
Bolts, engine/drive housing (M14) Nm 125 +/- 10 Performance data 1)
Bolts, compressor element/drive housing Nm 80 +/- 5 1. Engine shaft speed, normal and maximum r/min 2500 2500 2500 2500
Safety switches Nm 35 +/- 5 2. Engine shaft speed, compressor unloaded r/min 1700 1700 1700 1700
3. Free air delivery 2) l/s 185 156 141 133
Note: 4. Fuel consumption:
Ð at full load kg/h 16.9 16.7 16.3 16.8
Secure the tankcap and drain cock of the fuel tank handtight. Ð at unload kg/h 7.5 7.5 7.3 7.6
5. Specific fuel consumption g/m3 25.4 29.7 32.1 35
8.2 SETTINGS OF SHUTDOWN SWITCHES AND 6. Typical oil content of compressed air mg/m3 <5 <5 <5 <5
SAFETY VALVES free air

Designation Unit Value

7. Engine oil consumption (maximum) g/h 14 14 14 14
Engine oil pressure bar(e) 2 8. Compressed air temperature at outlet valves ¡C 90 90 90 90
Engine oil temperature ¡C 113 9. Noise level
Compressor temperature ¡C 120 Ð Sound pressure level (LP), measured
Safety valve opening pressure Ð according to EPA with a tolerance of
Ð +/- 3 dB(A) under free field conditions
EC type XA(S) bar(e) 10 Ð at 7 m distance dB(A) 74 72 72 72
XATS bar(e) 17
Ð Sound power level (LW) complies
XAHS bar(e) 17 Ð with 84/532/EEC and
XAVS bar(e) 17 Ð 85/406/EEC limits dB(A) 102 100 100 100
ASME type XA(S) psi 150
XATS psi 250
XAHS psi 250
XAVS psi 250

26
 INSTRUCTION MANUAL

8.4 CONVERSION LIST OF SI UNITS INTO BRITISH

UNITS
Design data
1 bar = 14.504 psi
Compressor 1g = 0.035 oz
1. Number of compression stages 1 1 kg = 2.205 lb
1 km/h = 0.621 mile/h
Engine 1 kW = 1.341 hp (UK and US)
1. Make Deutz 1l = 0.264 US gal
2. Type BF4M1012EC 1l = 0.220 Imp gal (UK)
1l = 0.035 cu.ft
3. Coolant Water
1m = 3.281 ft
4. Number of cylinders 4
1 mm = 0.039 in
5. Bore mm 94 1 m3/min = 35.315 cfm
6. Stroke mm 115 1 mbar = 0.401 in wc
7. Swept volume l 3.192 1N = 0.225 lbf
8. Output according to SAE J1995 1 Nm = 0.738 lbf.ft
at normal shaft speed kW 80 t ¡F = 32 + (1.8 x t ¡C)
Ð Load factor % 70 t ¡C = (t ¡F - 32)/1.8
9. Capacity of oil sump: Ð A temperature difference of 1 ¡C = a temperature difference of 1.8 ¡F
Ð Initial fill l 9
Ð Refill (max.) 4) l 8.5
10. Capacity of cooling system l 14

Unit 9. DATA PLATE

1. Capacity of compressor oil system l 24
2. Nett capacity of air receiver l 42 1 2 3
3. Capacity of fuel tanks l 175
4. Air volume at inlet grating (approx.) 3) m3/s 3.9 ATLAS COPCO AIRPOWER n.v. 4
★★★★★ 5
-YA3-★★★★★-00-★★★★★-
Unit dimensions ★★★★ kg A

with brakes towbar 1- ★★★★ kg B 6

★★★★ kg C
7
fixed adjustable
p max(e) . working/betrieb/service bar ★★ 8
Length mm 3941 4356
Speed/Drehzahl/Regime rpm ★★★★ 9
Width mm 1716 1716 p engine/motor/moteur kw ★★★★ 10
Manuf. year/Baujahr/Année de fabrication ★★★★ 11
Height mm 1661 1661
Weight (ready to operate) kg 1670 1725

MADE BY ATLAS COPCO AIRPOWER n.v. WILRIJK, BELGIUM

1615 6945 00
1) At reference conditions, if applicable, and at normal shaft speed, unless otherwise
12
stated
2) Data Measured according to Tolerance
Free air delivery ISO 1217 ed.3 1996 annex D +/Ð 5% 25 l/s <FAD<250 l/s 11. Company code
+/Ð 4% 250 l/s <FAD 12. Product code
The international standard ISO 1217 corresponds to following national standards: 13. Unit serial number
- British BSI 1571 part 1 14. Name of manufacturer
- German DIN 1945 Part 1 15. EEC or national type approval number
- Swedish SS-ISO 1217 16. Vehicle identification number
- American ANSI PTC9 17. A Maximum permitted laden weight of the vehicle
Free air delivery = volume flow rate B Maximum permitted road weight of the vehicle
3) Air required for engine and compressor cooling, combustion and for compression C Maximum permitted laden weight of the towing eye
4) with filter change. 18. Working pressure
19. Speed
10. Engine power
11. Manufacturing year
12. EC mark in accordance with Machine Directive 89/392 EEC

27
XAS136/186 Dd

10. CIRCUIT DIAGRAM

The compressor is equipped with a negative earthed system.

Fig. 10.1 Circuit diagram (Nr. 9822 0893 12)

F1 Circuit breaker (10A) N4 Control module

G1 Battery P1 Hourmeter
G2 Alternator P2 Glowplug
K0 Starter solenoid S3 Compressor temperature switch
K5 Auxiliary start relay S4 Engine temperature switch
K6 Cold start relay S5 Engine oil low pressure switch
M1 Starter motor Y1 Fuel solenoid valve

28
XA(S)186 Dd

5000 540 A: Altitude

Hoogte
Altitude
4000 616
Hšhenlage
Altitud
7bar(e)
3000 701
Hšjd
Altitudine
A P
(m) (mbar) H¿yde
2000 795 H¿jde over havet
À„fiÌÂÙÚÔ
Altitude
1000 899 Korkeus merenpinnasta

0 1013
-10 0 10 20 30 40 50 T: Temperature
T
Temperatuur
(¡C) Temperature
Temperature
Temperatura
Temperatur
Temperatura
Temperatur
XATS156 Dd Temperatur
£ÂÚÌÔÎÚ·Û›·˜
Temperatura
LŠmpštila

5000 540

P: Atmospheric pressure
Atmosferische druk
4000 616
Pression de lÕatmosphere
AtmosphŠrischer Druck
3000
10,3bar(e)
701
Presi—n atmosfŽrica
AtmosfŠrtryck
A P Pressione atmosferica
(m) (mbar)
2000 795
Atmosf¾re trykk
Atmosf¾risk tryk
AÙÌoÛÊ·ÈÚÈÎË ›ÂÛË
1000 899 Press‹o atmosfŽrica
Ilmanpaine

0 1013
-10 0 10 20 30 40 50

T
(¡C)

315
XAHS146 Dd

5000 540
A: Altitude
Hoogte
4000 616
Altitude
Hšhenlage
Altitud
12bar(e)
3000 701 Hšjd
Altitudine
A P H¿yde
(m) (mbar)
2000 795 H¿jde over havet
À„fiÌÂÙÚÔ
Altitude
1000 899 Korkeus merenpinnasta

0 1013 T: Temperature
-10 0 10 20 30 40 50
Temperatuur
T
(¡C)
Temperature
Temperature
Temperatura
Temperatur
Temperatura
Temperatur
XAVS136 Dd Temperatur
£ÂÚÌÔÎÚ·Û›·˜
Temperatura
LŠmpštila

5000 540

P: Atmospheric pressure
Atmosferische druk
4000 616 Pression de lÕatmosphere
AtmosphŠrischer Druck
Presi—n atmosfŽrica
3000 701 AtmosfŠrtryck
14bar(e)
Pressione atmosferica
A P
(m) (mbar) Atmosf¾re trykk
2000 795
Atmosf¾risk tryk
AÙÌoÛÊ·ÈÚÈÎË ›ÂÛË
Press‹o atmosfŽrica
1000 899
Ilmanpaine

0 1013
-10 0 10 20 30 40 50

T
(¡C)

316