Atlas Copco Portable Compressor

XAS 185 JDU7

Instruction Book
1310 3011 92 Ed. 0 2008-12

“Copyright 2008, Atlas Copco Compressors LLC, Rock Hill SC USA

Any unauthorized use or copying of the contents or any part of this book is
prohibited. This applies in particular to trademarks, model denominations, part
numbers and drawings.”

No. 1310 3011 92 Ed. 0

2008-12
OWNERSHIP DATA
Unit model: Owner's machine no.:

Engine type: Unit service no.:

Delivery date: Engine serial no.:

Service plan: First start-up date:

Selected Lubricants

Compressor: Capacity:

Bearing grease type, electric motor:

Printed Matter Nos.

Atlas Copco instruction book / rev: Atlas Copco logbook:

Atlas Copco parts list / rev: Engine parts list:

Local Atlas Copco Representative

Name:

Address:

Telephone: Contact persons: Service:

Telefax: Parts:

2 1310 3011 92
Contents
1 Safety Precautions for Portable Compressors 4
1.1 Introduction 4
1.2 General Safety Precautions 4
1.3 Safety during use and operation 5
1.4 Safety During Maintenance and Repair 6
1.5 Tool Applications Safety 7
1.6 Batteries 7
1.7 Ether fuel Systems 7
1.8 Pressure vessels 8
1.9 Safety valve 8
1.10 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 Main Parts 11
2.4 Air Flow (see Fig. 2.4) 12
2.5 Oil system (see Fig. 2.4) 13
2.6 Continuous regulating system 13
2.7 Electrical System 14
3 Operating Instructions 15
3.1 Parking, Towing And Lifting Instructions 15
3.2 Before Starting 15
3.3 Starting/Stopping (See Fig. 3.3) 16
3.4 During Operation 16
4 Maintenance 16
4.1 Use of Service Paks 16
4.2 Preventive Maintenance Schedule For The Compressor 16
4.3 Lubrication oils 17
4.4 Oil Level Check 17
4.5 Oil And Oil Filter Change (see Fig. 4.5) 18
4.6 Cleaning Coolers 18
4.7 Battery Care 19
4.8 Storage 19
4.9 Service Kits 19
5 Adjustments and Servicing Procedures 20
5.1 Adjustment of the Continuous Regulating System (See Fig. 5.1) 20
5.2 Air Filter Engine/Compressor 21
5.3 Air Receiver 21
5.4 Safety Valve 21
5.5 Fuel System (see Fig. 5.4) 21
6 Problem Solving 22
6.1 Problem Solving Chart 22
6.2 Alternator Precautions 22
7 Technical Specifications 25
7.1 Settings of Shutdown Switches and Safety Valve 25
7.2 Compressor/Engine Specifications 25

1310 3011 92 3
 IMPORTANT

1 Safety Precautions for Portable Compressors

To be read attentively and acted on accordingly before towing, lifting, operating,
performing maintenance or repairing the compressor

1.1 Introduction 3 The supervisor, or the responsible person, shall at all

times make sure that all instructions regarding
The policy of Atlas Copco is to provide the users of their machinery and equipment operation and maintenance
equipment with safe, reliable and efficient products. are strictly followed and that the machines with all
Factors taken into account are among others: accessories and safety devices, including the entire
- the intended and predictable future use of the compression or vacuum system with pipes, valves,
products, and the environments in which they are connectors, hoses, etc., as well as the consuming
expected to operate, devices, are in good repair, free of abnormal wear or
abuse, and are not tampered with.
- applicable rules, codes and regulations,
4 Maintenance, overhaul and repair work shall only be
- the expected useful product life, assuming proper carried out by adequately trained personnel; if required,
service and maintenance. under supervision of someone qualified for the job.
Before handling any product, take time to read the relevant 5 Whenever there is an indication or any suspicion that
instruction book. Besides giving detailed operating an internal part of a machine is overheated, the
instructions, it also gives specific information about safety, machine shall be stopped. No inspection covers shall
preventive maintenance, etc. be opened before sufficient cooling time has elapsed;
These precautions are general and some statements will this is to avoid the risk of spontaneous ignition of the oil
therefore not always apply to a particular unit. vapor when air is admitted.

When handling, operating, overhauling and/or performing 6 Maintenance work, other than routine attention, shall
maintenance or repair on Atlas Copco equipment, the only be undertaken when the machine is turned off.
mechanics are expected to use safe engineering practices 7 Before dismantling any pressurized component, the
and to observe all relevant local safety requirements and compressor or the equipment shall be effectively
ordinances. The following list is a reminder of special isolated from all sources of pressure and be completely
safety directives and precautions mainly applicable to Atlas vented to atmosphere. In addition, a warning sign
Copco equipment. bearing a legend such as "work in progress; do not
This brochure applies to machinery processing or open" shall be attached to each of the isolating valves.
consuming air or inert gas. Processing of any other gas 8 Before a machine is being repaired, steps shall be
requires additional safety precaution typical to the taken to prevent inadvertent starting. In addition, a
application and are not included herein. warning sign bearing a legend such as "work in
All responsibility for any damages or injury resulting from progress; do not start" shall be attached to the starting
neglecting these precaution: or by non-observance of equipment. The battery shall be disconnected and
ordinary caution and due care required in handling, removed or the terminals covered by insulating caps.
operating, maintenance or repair, also if not expressly 9 Normal ratings (pressures, temperatures, speeds, etc.)
mentioned in this brochure or the instruction book(s), is shall be durably marked.
disclaimed by Atlas Copco.
10 Never operate a machine or equipment beyond its
If any statement does not comply with local legislation, the rated limits (pressure, temperature, speed, etc.).
stricter of the two shall be applied. Statements in this
manual should not be interpreted as suggestions:, 11 Maintenance and repair work should be recorded in an
recommendations or inducements that it should be used in operator's logbook for all machinery. Frequency and
violation of any applicable laws or regulations. nature of repairs can reveal unsafe conditions.
12 The machinery and pneumatic equipment shall be kept
1.2 General Safety Precautions clean, i.e. as free as possible from oil, dust or other
1 The owner is responsible for maintaining the unit in a deposits.
safe operating condition. Unit parts and accessories
13 To prevent an increase in working temperature, inspect
must be replaced if missing or unsuitable for safe
and clean heat transfer surfaces (cooler fins,
operation.
intercoolers, water jackets, etc.) regularly. For every
2 Use only lubricating oils and greases recommended or machine establish a suitable time interval for cleaning
approved by Atlas Copco or the machine operations.
manufacturer. Ascertain that the selected lubricants
14 All regulating and safety devices shall be maintained with
comply with all applicable safety regulations, especially
due care to ensure that they function properly. They may
with regard to explosion or fire risk and the possibility
not be by-passed.
of decomposition or generation of hazardous gases.

4 1310 3011 92
15 Care shall be taken to avoid damage to safety valves - ascertain that the pressure vessel(s) is (are)
and other pressure relief devices, especially to avoid depressurized,
plugging by paint, oil coke or dirt accumulation, which
could interfere with the functioning of the device. - check the drawbar, the brake system and the towing eye.
Also check the coupling of the towing vehicle,
16 Pressure and temperature gauges shall be checked
regularly with regard to their accuracy. They shall be - check that the pivot wheel or stand leg is safely locked in
replaced whenever outside acceptable tolerances. the raised position,

17 Parts shall only be replaced by genuine Atlas Copco - ascertain that the towing eye can swivel freely on the
replacement parts. hook,

18 Safety devices shall be tested as described in the - check that the wheels are secure and that the tires are in
maintenance schedule of the instruction book(s) to good condition and inflated correctly,
determine that they are in good operating condition. - connect the signal cable, check all lights and connect the
19 Never use flammable solvents or carbon tetrachloride pneumatic brake couplers,
for cleaning parts. Take safety precautions against - attach the safety break-away cable to the towing
toxic vapors when cleaning parts in or with cleaning vehicle,
products.
- remove wheel chocks, if applied, and disengage the
20 Observe scrupulous cleanliness during maintenance parking brake.
and repair. Keep away dirt by covering the parts and
exposed openings with clean cloth, paper or tape. - Apply safety chains to tow vehicle.
21 Protect the engine, alternator, air intake filter, electrical 2 If the unit is to be backed up by the towing vehicle,
and regulating components, etc. to prevent moisture disengage the overrun brake mechanism (if equipped).
ingress, e.g. when steam-cleaning.
3 Never exceed the maximum towing speed of the unit.
22 When performing any operation involving heat, flames
4 Place the unit on level ground and chock the wheels before
or sparks on a machine, the surrounding components
disconnecting the unit from the towing vehicle. Unclip the
shall first be screened with non-flammable material.
safety break-away cable
23 Never use a light source with open flame for inspecting
5 When the unit has to operate in a fire-hazardous
the interior of a machine, pressure vessel, etc.
environment, each engine exhaust has to be provided with
24 On portable units, support the drawbar and axle(s) a spark arrestor to trap incendiary sparks.
securely if working underneath the units or when
6 The exhaust contains carbon monoxide which is a lethal
removing a wheel. Do not rely on jacks.
gas. When the unit is used in a confined space, conduct
25 Prior to stripping a compressor, engine or other the engine exhaust to the outside atmosphere by a pipe of
machine or undertaking major overhaul on it, prevent sufficient diameter (min. 4 inches); do this in such a way
all movable parts with a mass exceeding 15 kg (30 lbs) that no extra back pressure is created for the engine. If
from rolling over or moving. necessary, install an extractor.
26 When repair has been completed, make sure that no 7 When operating in a dust-laden atmosphere, place the unit
tools, loose parts or rags are left in, or on, the so that dust is not carried towards it by the wind. Operation
machine, the prime mover or the driving gear. The in clean surroundings considerably extends the intervals for
machine shall be barred several revolutions to ensure cleaning the air intake filters and the cores of the coolers.
that there is no mechanical interference within the
8 Locate the unit away from walls. Take all precautions to
machine or driver.
ensure that hot air exhausted from the engine and driven
machine cooling systems cannot be recirculated. If such
1.3 Safety during use and operation hot air is taken in by the engine or driven machine cooling
fan, this may cause overheating of the unit; if taken in for
To lift a unit, all loose or pivoting parts, e.g. doors shall first combustion, the engine power will be reduced.
be securely fastened. Do not attach cables, chains or
ropes directly to the lifting eye; apply a crane hook or lifting 9 No external force may be exerted on the air outlet valves,
shackle meeting local safety rules. e.g. by pulling on hoses or by installing auxiliary equipment
directly to a valve, e.g. a water separator, a lubricator, etc.
Helicopter lifting using the lifting eye is forbidden.
10 Distribution pipework and air hoses must be of correct size
It is strictly forbidden to dwell or stay in the risk zone under and suitable for the working pressure.
a lifted load. Never lift the unit over people or residential
areas. Never use frayed, damaged or deteriorated hoses.
Replace hoses and flexibles of which the lifetime expired.
Lifting acceleration and retardation shall be kept within safe Use only the correct type and size of hose end fittings and
limits. connections. Install safety pins on quick type hose
1 Before towing the unit: connections.
A hose connected to a 2 inch (50 mm) valve must be
provided with a safety wire (8 mm) fixed to the hose for
effective pressures as from 10 bar (145 psi) up, although it
is recommended to apply such safeguard already from 4
bar (60 psi) up. The safety wire ends have to be attached,

1310 3011 92 5
 one to the eye provided next to the compressor air - there are no fuel, oil or coolant leaks,
outlet valve, the other one to a point near to the air
inlet of the applied equipment. - all fasteners are tight
Finally a wire mesh hose can be fixed over the hose - all electrical leads are secure and in good order,
ends to dampen the blast in case a connection starts
leaking or should become undone. - the engine exhaust system is in good condition,

Close the compressor air outlet valve before - air outlet valves and manifold, hoses, couplings,
connecting or disconnecting a hose. Ascertain that a etc. are in good repair, free of wear or abuse,
hose is fully depressurized before disconnecting it.
- the wheel nuts are tightened to the proper torque.
When blowing through a hose or air line, ensure that
When more than one compressor is connected to a common
the open end is held securely. A free end will whip
header, be sure each compressor has a non-return valve (check
and may cause injury.
valve) to prevent reverse rotation when stopping.
Never play with compressed air. Never apply it to your
skin or direct an air stream at people. Never use it to 1.4 Safety During Maintenance and Repair
clean dirt from your clothes. When using it to clean
down equipment, do so with extreme caution and use Maintenance and repair work shall only be carried out by
eye protection. adequately trained personnel: if required, under supervision of
11 Never move a unit when external lines or hoses are someone qualified for the job.
connected to the outlet valves, to avoid damage to 1 Use only the correct tools for maintenance and repair work.
valves and/or manifold and hoses.
2 Use only genuine spare parts.
12 Never refill fuel while the unit is running. Keep fuel
away from hot parts such as air outlet pipes or the 3 All maintenance work, other than routine attention, shall
engine exhaust. Do not smoke when fueling. When only be undertaken when the unit is stopped. Ensure that
fueling from an automatic pump, a ground cable the unit cannot be started inadvertently.
should be connected to the unit to discharge static
4 Before removing any pressurized component, effectively
electricity. Never spill nor leave oil, fuel, coolant or
isolate the compressor from all sources of pressure and
cleansing agent in or around the unit.
relieve the entire system of pressure. Do not rely on non-
13 Never operate the unit in surroundings where there is return valves (check valves) to isolate pressure systems.
a possibility of taking in flammable or toxic fumes.
5 Never use flammable solvents or carbon tetrachloride for
14 Never operate the unit at pressures or speeds below cleaning parts. Take safety precautions against toxic
or in excess of the limit ratings stated on the Principal vapors from cleaning liquids.
Data sheet.
6 Scrupulously observe cleanliness during maintenance and
15 On water-cooled engines with closed cooling circuit: when performing repairs. Keep dirt away by covering the
allow the unit to cool before removing a pressure cap. parts and exposed openings with a clean cloth, paper or
tape.
16 All doors shall be shut during operation so as not to
disturb the cooling air flow inside the body-work and/or 7 Never weld on or perform any operation involving heat near
render the silencing less effective. A door should be the fuel or oil systems. Fuel and oil tanks must be
kept open for a short period only, e.g. for inspection or completely purged, e.g. by steam-cleaning, before carrying
adjustment out such operations.
17 Wear ear protectors when environmental noise can Never weld on, or in any way modify, pressure vessels.
reach or exceed 85 dB(A). Beware of long-time Disconnect the alternator cables during arc welding on the
exposure to noise. unit.
8 Support the drawbar and the axle securely if working
underneath the unit or when removing a wheel. Do not rely
18 Periodically check that: on jacks.
- all safety equipment is in good working order, 9 Make sure that no tools, loose parts or rags are left in or on
- all guards and air conducting baffles are in place the unit.
and securely fastened, 10 Before clearing the unit for use after maintenance or
- all hoses and/or pipes inside the unit are in good overhaul, check that operating pressures, temperatures and
condition, secure and not rubbing, speeds are correct and that the control and shutdown
devices function correctly.
11 Do not remove any of, or tamper with, the sound damping
material. Keep the material free of dirt and liquids such as
fuel, oil and cleansing agents.
12 Protect the electrical and regulating components, the air
filter, etc. to prevent moisture from entering them, e.g. when
steam-cleaning.

6 1310 3011 92
1.5 Tool Applications Safety 1.6 Batteries
Apply the proper tool for each job. With the knowledge of 1 The electrolyte in batteries is a sulphuric acid solution which
correct tool use and knowing the limitations of tools, along can be fatal if swallowed and can cause blindness if the
with some common sense, many accidents can be solution contacts your eyes. It will also cause burns if it
prevented. contacts your skin. Therefore, be careful when handling
Special service tools are available for specific jobs and batteries, e.g. when checking the charge condition.
should be used when recommended. The use of these
tools will save time and prevent damage to parts. 2 Install a sign prohibiting fire, open flame and smoking at the
post where batteries are being charged.
1 Use only wrenches or sockets whose size fits the
fastener. 3 When batteries are being charged, an explosive gas
mixture forms in the cells and might escape through the
2 Apply an open-end wrench only in the place of the vent holes in the plugs.
fastener head, square to the thread axis.
Thus an explosive atmosphere may form around the battery
3 Do not use a pipe or other improvised leverage if ventilation is poor, and can remain in and around the
extensions on handles. battery for several hours after it has been charged.
4 Do not hammer on wrenches or other tools which are Therefore:
not specially designed for it.
- never smoke near batteries being, or having recently
5 Always support the ratchet head when using socket been, charged,
extensions.
- never break live circuits at battery terminals, because a
6 Discard any wrench with broken or battered points or spark usually occurs.
edges.
4 When connecting an auxiliary battery (AB) in parallel to the
7 Never use hand type sockets on power or impact tools. unit battery (CB) with booster cables: connect the + pole of
AB to the + pole of CB, then connect the - pole of AB to the
8 Select only heavy-duty impact sockets for use with mass of the unit. Disconnect in the reverse order. Incorrect
pneumatic or electric impact tools. connection will damage alternator.
9 Replace sockets showing cracks or wear; keep
sockets clean. 1.7 Ether fuel Systems
10 Never use screwdrivers for prying, punching, chiseling,
scoring or scraping. Ether fuel systems are used for diesel cold starting.

11 Use the correct type and size of screwdriver for the 1 Do not use ether as a starting aid in conjuntion with other
job. The bit must match the fastener. stating aids (i.e. glow plug, air intake heater etc..) as an
explosive condition may result in severe engine damage or
12 A screwdriver with rounded edges will slip; it needs to personal injury.
be redressed or discarded.
2 This type of fuel is extremely flammable, toxic and
13 Never use a screwdriver or any other tool near a live poisonous. Avoid contact with eyes or skin and breathing
wire or electrical component. Plastic covering of the fumes. If accidentally swallowed, do not induce
handles is for comfort and grip only. They are not vomiting but call a physician immediately.
intended to act as insulation if such is not clearly
marked by the manufacturer. 3 If fuel enters or fumes irritate the eyes, flush the latter with
large quantities of clean water and call for medical aid.
14 Never strike a hammer against a hardened object; use
a soft drift against the object and strike against the 4 Before operating ether cold starting aids, read the
drift. instructions and the container label.

15 Strike the object with the full face of the hammer. 5 Never operate ether cold starting aids while the engine is
running as this can cause severe damage.
16 Never use a hammer with a loose head.
6 When maintenance, tests or repair has to be performed, do
17 Discard a hammer with chipped or mushroomed face. so in a well-ventilated area only, away from heat, open
flame or sparks. Ascertain that the area is clearly marked
18 Never use a chisel or punch with a chipped or
out with signs prohibiting fire, open flame and smoking.
mushroomed striking face.
7 Wear eye protection when testing a system. Make sure
19 Always pull on a wrench or socket handle, if possible,
that openings of a spray container, valve, tube or atomizer
and adjust your stance to prevent a fall if something
are pointed away from yourself and others while testing.
lets go.
8 Do not store ether containers in temperatures above 70ºC
20 Wear approved eye protection when using percussion
(160 ºF),
tools or when scraping, chipping, shaving or grinding.
9 Do not incinerate, puncture or attempt to remove the center
21 Wear protective gloves when holding a chisel or
core valve, side safety valve or any other part of an ether
punch.
container.

1310 3011 92 7
1.8 Pressure vessels 3 Noise, even at reasonable levels, can cause irritation
and disturbance which, over a long period of time, may
Maintenance / installation requirements: cause severe injuries to the nervous system of human
beings.
1 The vessel can be used as a pressure vessel or as a
separator and is designed to hold compressed air for When the sound pressure level, at any point where
the following applications: personnel normally has to attend, is:

- pressure vessel for compressor. below 70 dB(A): no action needs to be taken,

above 70 dB(A): noise-protective devices should be
- medium AIR/OIL, provided for people continuously being
and operates as detailed on the data plate of the present in the room,
vessel: below 85 dB(A): no action needs to be taken for
occasional visitors staying a limited time
- the maximum working pressure in psi, only,
above 85 dB(A): room to be classified as a noise-
2 The pressure vessel is only to be used for the
hazardous area and an obvious warning
applications as specified above and in accordance with
shall be placed permanently at each
the technical specifications. Safety reasons prohibit
entrance to alert people entering the
any other applications.
room, for even relatively short times,
3 National legislation requirements with respect to re- about the need to wear ear protectors,
inspection must be complied with. above 95 dB(A): the warning(s) at the entrance(s) shall
be completed with the recommendation
4 No welding or heat treatment of any kind is permitted that also occasional visitors shall wear
to those vessel walls which are exposed to pressure. ear protectors,
5 The vessel is provided and may only be used with the above 105 dB(A): special ear protectors that are adequate
required safety equipment such as pressure guage, for this noise level and the spectral
overpressure control devices, safety valve, etc. composition of the noise shall be
provided and a special warning to that
6 Draining of condensate shall be performed regularly effect shall be placed at each entrance.
when vessel is in use.
4 Insulation or safety guards of parts the temperature of
7 Installation, design and connections should not be which can be in excess of 80 ºC (175 ºF) and which may be
changed. accidentally touched by personnel shall not be removed
8 Bolts of cover and flanges may not be used for extra before the parts have cooled to room temperature.
fixation. 5 When hot parts have to be handled, e.g. shrink fitting,
special heat-resistant gloves shall be used and, if required,
1.9 Safety valve other body protection shall be applied.
6 If the working process produces fumes, dust or vibration
All adjustments or repairs are to be done by an authorized hazards, etc., take the necessary steps to eliminate the risk
representative of the valve supplier. of personnel injury.
Following checks must be carried out: 7 Before lifting machines, all loose parts which could be liable
1 A check of the opening of the lifting gear,1 or 2 times a to fall down shall be removed or secured; pivoting parts
year. This can be done by lifting the ring or lever. such as doors, etc. shall be safely immobilized.

2 A check of the set pressure once a year according to 8 To lift heavy parts, a hoist of ample capacity, tested and
the local regulations, if required. This check may not approved according to local safety regulations, shall be
be done with the compressor supplying the air used.
pressure and must be carried out on a proper test 9 When lifting machinery, only hooks or shackles meeting
bench. local safety regulations shall be applied. Never shall
cables, chains or ropes be applied directly on or through
1.10 Injury Prevention lifting eyes. Never allow sharp bends in lifting cables,
chains or ropes.
1 Stationary housing guards are provided on all rotating
or reciprocating parts not otherwise protected and 10 Lifting hooks, eyes, shackles, etc. shall never be bent and
which may be hazardous to personnel. Machinery shall only have stress in line with their design load axis.
shall never be put into operation, when such guards The capacity of a lifting device diminishes when the lifting
have been removed, operate only when guards are force is applied at an angle to its load axis.
securely reinstalled. 11 For maximum safety and efficiency of the lifting apparatus
2 Do not open electrical cabinets, cubicles or other all lifting members shall be applied as near to perpendicular
equipment while voltage is supplied. If such cannot be as possible. If required, a lifting beam shall be applied
avoided, e.g. for measurements, tests or adjustments, between hoist, and load.
have the action carried out by a
qualified electrician only, with appropriate tools, and
ascertain that the required bodily protection against
electrical hazards is applied.

8 1310 3011 92
12 When heavy parts are being lifted with a hoist, it is
strictly forbidden to 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
hanging on a hoist. Lifting acceleration and retardation
shall be kept within safe limits.
13 A hoist has to be installed in such a way that the object
will be lifted perpendicular. If that is not possible, the
necessary precautions must be taken to prevent load-
swinging, e.g. by using two hoists, each at
approximately the same angle not exceeding 30deg
from the vertical.
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 the operator as
well as for any bystander. Do not apply compressed
air or inert gas to your skin or direct an air or gas
stream at people. Never use it to clean dirt from your
clothes.
15 Before blowing compressed air or inert gas through a
hose, ensure that the open end is held securely, so Fig. 2.1 General view of XAS 185 JDU7
that it cannot whip and cause injury.
16 When washing parts in or with a cleaning solvent, 2.2 General Description
provide the required ventilation and use appropriate
protection such as a breathing filter, safety glasses, The XAS 185 Utility is a silenced, single-stage, oil-injected
rubber apron and gloves, etc. screw compressor, built for a normal effective working pressure
of 7 bar (102 psi).
17 Safety shoes should be compulsory in any workshop
and if there is a risk, however small, of failing objects, — Engine
wearing of a safety helmet should be included. The compressor is driven by a water-cooled diesel engine. The
18 If there is a risk of inhaling hazardous gases, fumes or engine’s power is transmitted to the compressor through a
dust, the respiratory organs must be protected and, flexible coupling.
depending on the nature of the hazard, so must the — Compressor
eyes and skin.
The compressor casing houses two screw-type rotors, mounted
19. Remember that where there is visible dust, the finer, on ball and roller bearings. The male rotor, driven by the
invisible particles will almost certainly be present too; engine, drives the female rotor. The male rotor has four lobes
but the fact that no dust can be seen is not a reliable and the female rotor has six flutes. Thus, the male rotor
indication that dangerous, invisible dust is not present revolves at 1 1/2 times the speed of the female rotor. The
in the air. element delivers pulsation-free air.
20. When using cartridge type breathing filter equipment, Injected oil is used for sealing, cooling and lubricating purposes.
ascertain that the correct type of cartridge is used and
that its useful service life is not surpassed.
— Compressor Oil System
2 Leading Particulars The oil is boosted by air pressure. The system has no oil pump.
The oil is removed from the air, in the air/oil vessel first by
2.1 Description of Safety Pictograms centrifugal force, second through the oil separator element. The
Used in this Manual vessel is provided with an oil level indicator.
f This symbol draws your attention to dangerous — Regulation
situations. The operation concerned may
endanger persons and cause injuries. The compressor is provided with a continuous regulating system
and a blow-down valve which is integrated in the unloader
+ This symbol is followed by supplementary
assembly. The valve is closed during operation by outlet
pressure of the compressor element and opens by air receiver
information.
pressure when the compressor is stopped.
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.
1310 3011 92 9
— Cooling System
Engine and compressor are provided with a radiator and 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 and an
alternator/V-belt protection system.
— Frame
The compressor/engine unit is supported by rubber buffers
in the frame. There are mounting bolt holes on the bottom
of the frame to fully mount and support the compressor to
the intended mounting arrangement.

— Bodywork
The bodywork has openings at the shaped front and rear
end for the intake and outlet of cooling air. The bodywork is
partially lined with sound-absorbing material.
— Lifting Eye
A lifting eye is accessible through the roof panel at the top
of the unit.
— Control Panel
The control panel grouping the air pressure gauge, control
switch etc., is placed at rear of the air compressor.
— Data Plate
The compressor is furnished with a data plate located on
the air discharge side of the unit showing the compressor
type, serial number, maximum final pressure and normal
working pressure.

10 1310 3011 92
2.3 Main Parts

TT Oc
M

G1
Lh
VLe
DB

AFe

AFc

FT
FC1
EP
E
M1
OFc
CE
SV

AR
CP
FR
AV

Fig 2.3Main parts of XAS 185 JD

AFe Air Filter Engine F Cooling Fan OFe Oil Filter Engine
AFc Air Filter Compressor FC1 Fuel Filler Cap OFc Oil Filter Compressor
AR Air Receiver FT Fuel Tank SV Safety Valve
AV Air Outlet Valve G1 Alternator TT Top Tank
CE Compressor Element LH Lift Hook VLe Vacuum Indicator Engine
CP Control Panel M Muffler
DB Drive Belt M1 Starter Motor Engine
E Engine OC Oil Cooler
EP Exhaust Pipe

1310 3011 92 11
Compressor Regulating System (Load Condition)

Fig. 2.4 Compressor Regulating System

AFe Air Filter Engine E Engine MPV Minimum Pressure SR Speed Regulator
AFc Air Filter Compressor EP Exhaust Pipe Nozzle SV Safety Valve
AR Air Receiver F Cooling Fan OC Oil Cooler TS Temperature Switch
AV Air Outlet Valve FC1 Fuel Filler Cap OFe Oil Filter Engine UA Unloader Assembly
BDV Blow Down Valve FP Compressor Oil Filling OFc Oil Filter Compressor UV Unloader Valve
CE Compressor Element Plug OLG Oil Level Gauge VH Vent Hole
CP Control Panel FR Flow Restrictor OS Oil Separator VIe Vacuum Indicator
CV Check Valve G1 Alternator PG Pressure Gauge Engine
DB Drive Belt LV Optional Loading RV Regulating Valve VIc Vacuum Indicator
DP Drain Plug Valve SL Scavenge Line Compressor

2.4 Air Flow (see Fig. 2.4) The check valve prevents blow-back of compressed air when
the compressor is stopped. In the air receiver/oil separator
The system comprises: (AR/OS), most of the oil is removed from the air/oil mixture: the
AF Air filter remaining oil is removed by the separator element.
AR/OS Air receiver/oil separator The oil collects in the receiver and on the bottom of the
CE Compressor element separator element.
UA/UV Unloader assembly with unloader valve The air leaves the receiver via the minimum pressure valve
BDV Blow-down valve (MPV) which prevents the receiver pressure from dropping
below the minimum working pressure, even when the air outlet
MPV Minimum pressure valve
valves are open. This ensures adequate oil injection and
LV Loading Valve prevents oil consumption.
Air drawn through the airfilter (AF) into the compressor
element (CE) is compressed. At the element outlet, A temperature switch (TS) and a working pressure gauge (PG)
compressed air and oil pass into the air receiver/oil are comprised in the system.
separator (AR/OS).

12 1310 3011 92
A blow-down valve (BDV) is fitted in the unloader assembly by means of control air to the unloader, matches the air output
to automatically depressurize the air receiver (AR) when to the air consumption. The air receiver pressure is maintained
the compressor is stopped. between the pre-selected working pressure and the
corresponding unloading pressure.
2.5 Oil system (see Fig. 2.4) When starting the compressor, the unloader valve (UV) is kept
open by spring force, the engine runs at maximum speed. The
The system comprises: compressor element (CE) takes in air and pressure builds up in
AR/OS Air receiver/oil separator the receiver. The unloader valve is closed.

RV/UA Regulation Valve/Unloader Valve The air output is controlled from maximum output (100%) to no
output (0%) by:
OC Oil cooler
1. Speed control of the engine between maximum load speed
OF Oil filter and unloading speed (the output of a screw compressor is
proportional to the rotating speed).
The lower part of the air receiver (AR) serves as the oil
tank. 2. Air inlet throttling.
Air pressure forces the oil from the air receiver/oil separator 3. Blow off valve (BOV).
(AR/OS) through the oil cooler (OC) and oil filter (OF) to the
compressor element (CE). If the air consumption is equal to or exceeds the maximum air
output, the engine speed is held at maximum load speed and
The compressor element has an oil gallery in the bottom of the unloading valve is fully open.
its casing. The oil for rotor lubrication, cooling and sealing
is injected through holes in the gallery. If the air consumption is less than the maximum air output, the
regulating valve supplies control air to unloader valve (UV) to
Lubrication of the bearings is ensured by oil injected into reduce the air output and holds air receiver pressure between
the bearing housings. the normal working pressure and the corresponding unloading
pressure of approx. 1.5 bar (21.75 psi) above the normal
The injected oil, mixed with the compressed air, leaves the
working pressure.
compressor element and re-enters the air receiver, where it
is separated from the air as described in section 2.4. The When the air consumption is resumed, the unloader valve
oil that collects in the bottom of the oil separator element is gradually opens the air intake and the speed regulator increases
returned to the system through scavenging line (SL), which the engine speed.
is provided with a flow restrictor (FR).
The construction of the regulating valve is such that any
The oil filter by-pass valve opens when the pressure drop increase (decrease) of the air receiver pressure above the pre-
over the filter is above normal because of a clogged filter. set valve opening pressure results in a proportional increase
The oil then by-passes the filter without being filtered. For (decrease) of the control pressure to the unloading valve.
this reason, the oil filter must be replaced at regular
intervals (see section 4.2). Part of the control air is vented to atmosphere, and any
condensate discharged, through the vent holes (VH).
For starting applications under 18°F, see Maintenance
Section.

2.6 Continuous regulating system

(see Fig. 2.4)
The system comprises:
RV Regulating valve
UA Unloader assembly
SR Speed regulator
The compressor is provided with a continuous regulating
system. This system is provided with a blow-down valve
(BDV) which is integrated in the unloader assembly (UA).
The valve is closed during operation by outlet pressure of
the compressor element and opens by air receiver
pressure when the compressor is stopped.
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,

1310 3011 92 13
Electrical System

2.7.1 Circuit Diagram

0 1 2 3

S1

0
1
12V DC S1 2
3
1
10A F1 5 2 2
30
3 3 K3
4 4 87 87a

K4 87a
87 87a S5

8 3 3 3 9 9 9 2 30
K4 86 S6 87
S8 11
85 K0
G2 30
G1 R1 S2 P2 +
+ B+ 87a
D+ 6
- B- K0 30
S3 S
87
P
P1 27 30
K5 87 M1
h
V2 Y1 K3 86 86 K2 M
30 26
85 85 H1 H2 K5 85 K1 86
15 Temp GENERAL S7 86 85
HTR 87 ALARM
87a S4
30 K1 K2 30
87
12 12 12 12 12 12 12 12 12

Figure 2.7 Circuit diagram

F1 Circuit breaker P1 Hour meter
G1 Alternator P2 Fuel Level Gauge
G2 Battery S1 Contact switch (Off-On-Override-Start)
H1 Temperature alarm lamp S2 Temperature switch engine
H2 General alarm lamp S3 Oil pressure switch engine
HTR Air inlet preheat S4 Lamp test switch
K0 Starter solenoid (part of M1) S5 Temperature switch (Compressor)
K1 Relay S6 Low Fuel Level switch
K2 Relay S7 Fuel Level sender
K3 Relay S8 Preheat Pushbutton
K4 Relay Y1 Fuel solenoid valve
K5 Relay R1 Resistor
M1 Starter motor V2 Diode

14 1310 3011 92
2.7.2 Description (see Fig. 2.7) The operator is expected to apply all relevant safety
precautions, including those mentioned on the Inside of the
Operation of the electric circuit In detail cover of this book.
Start button S1 position 1: Attention:
Line 2 on 12V contact K3 closed (30-87), lamp H2 is — Check and retighten the wheel nuts and drawbar bolts to
on. K4 excites contact K4 (87-87a). Thermocontact the specified torque. See section 7.
element S5 normally closed, K1 excites contact K1
(30-87).
Use of preheat:
Start button S1 position 1 press pushbutton S8, 3.1.1 Lifting Instructions
energizes relay K5 and provides power to the
When lifting the compressor, the hoist has to be placed in such
glowplug.
a way that the compressor, which must be placed level, will be
Start button S1 position 2: lifted vertically.
Line 3 on 12V (override function) hourmeter P1, and Ue the lifting bale provided to lift the unit.
fuel solenoid Y1 is excited. Thermocontact engine S2
f Lifting acceleration and retardation must be kept
normally closed, oil pressure contact S3 open.
within safe limits (max. 2xg).
Start button S1 position 3:
Helicopter lifting is not allowed.
Start relay K0 is excited and starter motor is running,
engine builds up oil pressure and oil pressure contact 3.2 Before Starting
S3 closes. K3 excited and contact K3 changes over to
(30-87). Relay K2 no longer excited, contact K2 f If the compressor is to be connected to a common
opens, lamp H1 goes out. Alternator also commences compressed air system, fit an appropriate check
supplying voltage and K4 is no longer excited and valve between compressor outlet and air system.
contact K4 changes over to (87-87a). Lamp H2 goes Observe the right mounting position/direction!
out, one can release start button S1 and it returns to
position 1. Exciting the safety devices occurs no
longer across line 3 but across line 2 to line 4 and this 1. Before initial start-up, prepare battery for operation if not
way to line 3. already done. See section 4.7.

Explanation of shutdowns: 2. With the compressor standing level, check the level of the
engine oil. Add oil, if necessary, to the upper mark on
Oil pressure contact S3 opens, K3 no longer excited. dipstick. Consult the Engine Operation Manual for the type
K3 changes over (87a-87), engine cuts out because and viscosity grade of the engine oil.
fuel solenoid Y1 no longer excited and lamp H2 goes
on simultaneously. 3. Check the level of the compressor oil. The pointer of oil
level gauge (OLG- Fig. 2.3) should register in the green
Thermocontact S2 opens, K3 no longer excited. K3 range. Add oil if necessary. See section 4.3 for the oil to
changes over (87a-87), engine cuts out because fuel be used.
solenoid Y1 no longer excited and lamp H2 goes on
simultaneously. f Before removing oil filler plug (FP- Fig. 2.3), ensure
that the pressure is released by opening an air outlet
Thermocontact S5 opens, K1 no longer excited. valve.
Contact K1 changes over (87-87a). K3 no longer
excited. K3 changes over (97a-87), engine cuts out 4. Check that the fuel tank contains sufficient fuel. Top up, if
because fuel solenoid Y1 no longer excited and lamp necessary. Consult the Engine Operation Manual for the
H2 and H1 go on simultaneously. Take-over relay K2 type of fuel.
is excited simultaneously with H1 and contact K2
closes (30-87). 5. Drain any water and sediment from the fuel filter until clean
fuel flows from the drain cock.
Thermocontact S5 cools off and closes, K1 excited
again and contact K1 changes over (87-87a). 6. Press vacuator valve (VV- Fig. 2.3) of the air filter to
However, lamp H1 remains on across line 9 and remove dust.
contact K2 (30-87). 7. Check the air filter service indicator (VI- Fig. 2.3). If the red
A fault in the alternator part causes terminal D+ to go to 0V part shows completely, service or replace the filter element.
and K4 to be excited. Contact K4 changes over to (87a- Reset the indicator.
87), engine cuts out because fuel solenoid Y1 no longer 8. Open an air outlet valve (AV-fig. 2.2) to allow air flow to the
excited and lamp H2 goes on simultaneously. atmosphere.
9. Check coolant level in overflow bottle. Top off coolant if
3 Operating Instructions necessary. Consult engine’s operation manual for
water/coolant specifications.

3.1 Lifting Instructions

Safety Precautions

1310 3011 92 15
3.3 Starting/Stopping (See Fig. 3.3) The control panel in addition indicates receiver pressure (PG)
and accumulated operating hours (P1).
Before starting, first operate the circuit breaker button (Fl)
located on the back of the control panel cover.
To start, the start button is turned clockwise to position 1,
lamp H2 (general alarm) will go on and the preahest relay Fault situations and protective devices:
K5 will be energized. The glow plug (HTR) will be activated.
— The starter motor is protected against prolonged starting
The button should be held in this position for 10 to 15
or against attempts to start when the unit is already running.
seconds to allow for proper pre-heating of the cylinders.
When the button is turned further to position 3, the starter — A fault which occurs with the engine, either: engine oil
motor will set the engine in motion. Lamp H2 will go out as pressure (too low), compressor oil temperature (too high),
soon as the engine has been started. The start button engine coolant (too high) or alternator voltage (too low) will
automatically springs back to position 1. Make sure one always and immediately cause the engine to cut out and the
discharge valve is opened at time of start-up to control lamp H2 will go on. By doing some simple checks, it can
regulate engine speed at higher rpm for proper warm- be determined what it was that caused the engine to fail: low oil
up – stay out of path of discharge valve during level, clogged-up cooler, slack alternator belt tension or broken
process. Lamp H1 only produces a signal when the belt.
compressor outlet temperature is too high. Correct
operation of the lamp itself can be checked by operating — When the outlet temperature of the element becomes too
the lamp test button S4 located on the control panel. When high, a thermocontact will also switch off the unit immediately.
the start button is in position 1 and the engine is not Both control lamp H1 and H2 will go on. Both control lamps will
running, the lamp test can be used. Lamp H1 will go on remain on until the unit has been restarted (start button to
and will automatically go out when the unit is started. position 3) or the contact is turned off (start button to position 0):
Shutting-down is simply done by turning the start button also when, due to cooling off, the thermocontact has closed
counter clockwise to position 0 (with valves closed). again (= memory function).

F1 Fuse reset (Circuit breaker) located

inside the unit on the control panel’s
3.4 During Operation
cover
f The doors must be closed during operation and
H1 Temperature alarm (red) may be opened for short periods only.
H2 General alarm (red)
LV Loading valve (optional) 4 Maintenance
PG Working pressure gauge
P1 Hour meter 4.1 Use of Service Paks
P2 Fuel gauge Service Paks include all genuine parts needed for normal
S1 Contact switch (engine ignition) maintenance of both compressor and engine. Service Paks
minimize downtime and keep your maintenance budget low.
S4 Preheat button
You may order Service Paks from your local Atlas Copco dealer.

F1
P1 4.2 Preventive Maintenance Schedule For
The Compressor
P2 The schedule contains a summary of the maintenance
running hours
1/2 instructions.
0 1
PG Read the respective section before taking maintenance
measures.
When servicing, replace all disengaged packings, e.g. gaskets,
H1,H2 0-rings, washers.
For engine maintenance refer to Engine Operation Manual.
The maintenance schedule has to be seen as a guideline for
S1 units operating in a duty environment typical to compressor
applications. Maintenance schedule can be adapted depending
on application environment and quality of maintenance
S4

Fig. 3.3 Control panel

16 1310 3011 92
.
MAINTENANCE SCHEDULE Daily Initially Normal Bi-Yearly Yearly Note
Around Or every 250 Or every 500 Or every
50 hours hours hours 1000 hours
Kit Part # Kit Part # Kit Part #
1310300374 1310312532 1310312584
Engine oil level Check
Compressor oil level Check
Air filter dust valve Empty
Fuel filter water drain Drain
Air intake vacuum indicator Check
Electrolyte level and terminals of battery Check Check Check Check
Leaks in air-, oil- or fuel system Check Check Check Check
Oil cooler package Clean Clean Clean
Engine minimum and maximum speeds Check Check Check Check
Safety valve Test
Door Hinges Grease Grease Grease
Shut-down switches Check
Pressure drop over separator element (2) Measure Measure Replace
Fan v-belt (3) Adjust Adjust Adjust Adjust
Fuel tank Clean Clean Clean
Compressor oil Change
Compressor oil filter Replace Replace
Air filter element (1) Replace
Engine oil (3) Change Change Change Change
Engine oil filter (3) Replace Replace Replace Replace
Fuel filter (Primary and Final) (3) Replace Replace Replace
Engine intake and exhaust valves (3) Adjust Adjust
Inspection by Atlas Copco Service technician f

(1) More frequently when operating in a dusty environment.

(2) Replace the element when the pressure drop exceeds 11.5 psi.
(3) Refer to the John Deere instruction manual.

f Keep the bolts of the housing, the lifting eye, the towbar and the axle securely tightened. Refer to
Compressor/Engine Specifications (section 7.2) for the torque values.

4.3 Lubrication oils Between -13°F and 122°F Paroil S See Engine Manual
It is strongly recommended to use Atlas Copco branded Between 18° and 104°F Paroil M 15W-40
lubrication oils for compressor.
Note: Additional equipment is needed to run the
Compressor oil PAROIL: compressor below 18°F. A thermostatic bypass valve
arrangement that wil bypass the compressor oil cooler,
5 gallon pail: order number 1310 0334 30 along with synthetic oil, offers the best protection of the
Skid (24) 5 gallon pails: order number 1310 0334 32 compressor against cold weather related problems.

Skid (4) 55 gallon drums: order number 1310 0334 33 f Operation of compressor in ambient temperatures
lower that 18°F (-8°C) without the correct type of oil
Compressor oil Paroil – S: will void your warranty and may result in element
1 gallon pail: order number 1615 5950 00 failure and/or fire.

5 gallon pail:
55 gallon drum:
order number
order number
1615 5951 00
1615 5952 00
+ If you want to use another brand of oil, consult Atlas
Copco for more information concerning the
recommended oil and service intervals.

4.4 Oil Level Check

f Never mix oils of different brands or types
Temperature Range Type of Oil
Compressor Engine

1310 3011 92 17
4.4.1 Check Engine Oil Level 4.4.2 Check Compressor Oil Level
Consult also the Engine Operation Manual for the oil With the unit standing level, engine stopped, check the level of
specifications, viscosity recommendations and oil change the compressor oil. The pointer of the oil level gauge (OLG)
intervals. must register in the upper extremity of the green range. Add oil
via the oil fill plug (FP) if necessary.
See schedule.
f Before removing oil filler plug, ensure that the
Check engine oil level according to the instructions in the pressure is released by opening an air outlet valve.
Engine Operation Manual and top up with oil if necessary.

4.5 Oil And Oil Filter Change (see Fig. 2 Drain the oil by removing all drain plugs. Drain plugs are
located at the oil tank, discharge manifold, and oil injection
4.5) manifold. Catch the oil in a drain pan. Screw out the filler
plug to speed up draining. Tighten the plugs after draining.
3 Remove the oil filter (OFc), e.g. by means of a special tool.
Catch the oil in a drain pan.
4 Clean the filter seat on the manifold, taking care that no dirt
drops 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
(OLG) registers in the upper extremity of the green range.
Take care that no dirt drops into the system. Reinstall and
tighten the filler plug.
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 (AV). Screw out filler plug (FP) and add oil until the
Fig. 4.5 Oil filters pointer of the oil level gauge (OLG) again registers in the
upper extremity of the green range. Reinstall and tighten
4.5.1 Engine Oil And Oil Filter Change the filler plug.

Consult also the Engine Operators Manual for oil and oil f Never add more oil. Overfilling results in oil
filter consumption.

(1) change intervals.

(2) oil types. 4.6 Cleaning Coolers
Keep the coolers clean to maintain the cooling efficiency. Front
4.5.2 Compressor Oil And Oil Filter cooler baffle is removable for access by unscrewing 4 bolts.
Change f Remove any dirt from the coolers with a fiber brush.
Never use a wire brush or metal objects.
The quality and the temperature of the oil determine the oil
change interval.
When cleaning by air jet, blow air through the cooler in reverse
The prescribed interval (See section 4.2) is based on an oil direction of normal flow.
temperature of up to 100ºC (212ºF) and normal operating
conditions. If the dirt is oily, wash the coolers with degreaser or a cleansing
agent.
When operating in high ambient temperatures, in very
dusty or high humidity conditions, it is recommended to f Protect the electrical and controlling equipment, air
change the oil more frequently. filters etc. against penetration of moisture.

+ In this case, contact Atlas Copco.

A spray gun should preferably be used to apply the solvent to
the fins. Rinse the blocks by means of a water jet max. 100 psi
at 2 inch distance after a soaking-in period. Steam cleaning
1 Run the compressor until warm. Close the outlet may also be applied.
valve(s) and stop the compressor. Wait until the
f To avoid damaging the coolers, angle between
pressure is released through the automatic blow-down
waterjet and coolers should be approx. 90º.
valve. Unscrew the oil filler plug (FP) one turn. This
uncovers a vent hole, which permits any pressure in
the system to escape. f Never leave spilled liquids such as fuel, oil, water and
cleansing agents in or around the compressor.

18 1310 3011 92
4.7 Battery Care Load and unload the compressor a few times to operate the
unloading and regulating components. Close the air outlet
valves after stopping.
+ Before handling batteries, read the relevant
safety precautions and act accordingly. + If the compressor is going to be stored without
running from time to time, protective measures must
An ASB (Service Bulletin) dealing elaborately with batteries be taken as described In a separate Service Bulletin
and due care is available on request. (ASB), which may be obtained on request. Consult
If the battery is still dry, it must be activated as described in Atlas Copco.
point 4.7.1.
The battery must be in operation within 2 months from 4.9 Service Kits
being activated; if not, it needs to be recharged first.
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
4.7.1 Electrolyte time which improves the uptime of the unit.
f Read the safety instructions carefully To purchase service paks contact your local Atlas Copco
representative.
Electrolyte in batteries is a sulphuric acid solution in
distilled water. 250/750 hr. Pak: order number 1310300374

The solution must be made up before being introduced into 500 hr. Pak: order number 1310312532
the battery. 1000 hr. Pak: order number 1310312584

4.7.2 Recharging A Battery

Before and after charging a battery, always check the
electrolyte level 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 manufacturers instructions.

Apply with preference the slow charging method and adjust

the charge current according to the following rule of thumb:
battery capacity in Ah (amp hours) divided by 20 gives safe
charging current in Amps.

4.7.3 Battery Maintenance

Keep the battery clean and dry
- Keep the electrolyte level at 10 to 15 mm above the
plates or at the indicated level; top up with distilled water
only.
- Keep the terminals and clamps tight, clean, and
lightly covered petroleum jelly.

4.8 Storage
Run the compressor regularly, e.g. twice a week, until
warm.

1310 3011 92 19
5 Adjustments and Servicing Procedures

5.1 Adjustment of the Continuous Regulating System (See Fig. 5.1)

Fig. 5.1 Compressor Regulating System

The working pressure is determined by the tension of the 4. Open an outlet valve just enough to let the engine run at
spring in the regulating valve (RV). This tension can be maximum speed. The working pressure must be 102 psig/
increased to raise the pressure and decreased to lower it 7 bar(e).
by turning the adjusting wheel clockwise and counter-
clockwise respectively. Adjust if necessary with regulating valve (RV).

To adjust the normal working pressure, proceed as follows: 5. Check the engine maximum speed (see section 7.2).
Adjust the maximum speed by means of adjusting eccentric
1. Start and warm up the engine (see section 3.3). nut on top of speed regulator (SR).
2. With the outlet valves (AV) closed, loosen the 6. Close the outlet valves, check that the pressure is between
regulating valve’s locknut and adjust the regulating 120-126 psig/ 8.3-8.7 bar(e).
valve (RV) until your reach the desired pressure of 123
psig/8.5 bar(e). Lock the regulating valve by fixing the locknut.

3. Check the minimum speed of the engine (see section

7.2). Adjust minimum speed stop screw if necessary.

20 1310 3011 92
5.2 Air Filter Engine/Compressor 4. Inspect and tighten all air intake connections.
5. Reset the vacuum indicator by pushing the reset button (8-
Fig. 5.3).
5.2.1Main Parts

Fig. 5.2 Air filter

1 Snap clips
Fig. 5.3 Vacuum indicator
2 Dust trap
7 Air filter contamination indicator
3 Filter element 8 Reset button
4 Safety cartridge 9 Red indicator

5 Filter housing Always replace both air filter elements at the

6 Vacuator valve same time !!

5.2.2Recommendations 5.3 Air Receiver

f The Atlas Copco air filters are specially designed The air receiver is tested according to official standards.
for the application. The use of non-genuine air Regularly have inspections carried out in conformity with local
filters may lead to severe damage of engine regulations.
and/or compressor element.
Never run the compressor without air filter
element.
5.4 Safety Valve
f All adjustments or repairs are to be done by an
New elements must also be inspected for tears or authorized representative of the valve supplier.
punctures before installation.
Discard the element (3) when damaged. Following checks must be carried out:
In heavy duty applications it is recommended to install a - a check of the opening of the lifting gear, twice a year. This
safety cartridge. can be done by lifting the ring or lever.
A dirty safety cartridge (4) is an indication of a mal- - a check of the set pressure once a year according to the local
functioning air filter element. Replace the element and the regulations. This check cannot be done on the machine and
safety cartridge in this case. must be carried out on a proper test bench.
Replace the safety cartridge together with the filter
element. The safety cartridge cannot be cleaned. 5.5 Fuel System (see Fig. 5.4)

5.2.3 Cleaning The Dust Trap

To remove dust from the dust trap pinch the vacuator valve
(6) 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 (3) from the housing (5).
1
If the element is to be serviced for immediate re-use,
reinstall the dust trap to protect the air intake system
while cleaning the element.
Fig. 5.4 Fuel Filter
3. Reassemble in reverse order of dismantling.
1310 3011 92 21
 It is assumed that the engine is in good condition, that there is
adequate fuel flow to the filter and injection equipment, and
Replacing the filter element: compressor/engine maintained with the recommended oil.
f An electrical fault must be traced by an electrician.
1 Unscrew the final filter element (1) from the adapter
head.
Make sure that the wires are not damaged and that they are
2 Clean the adapter head sealing surface. Lightly oil the clamped tight to their terminals.
gasket of the new element and screw the latter onto
the header until the gasket is properly seated, then 6.2 Alternator Precautions
tighten with both hands.
3 After replacing the final filter’s element, prime fuel 1 Never reverse the polarity of the battery or the alternator.
system with manual prime button (FU) located below 2 Never break any alternator or battery connections while
the fuel filter’s housing. the engine is running.
4 Check for fuel leaks once the engine has been 3 When recharging the battery, disconnect it from the
restarted. alternator. Before using booster cables to start the
engine, be sure of the polarity and connect the batteries
6 Problem Solving positive to positive, negative to negative.
4 Never operate the engine without the main or voltage
6.1 Problem Solving Chart sensing cables connected in the circuit.
The chart helps to solve mechanical problems.

Problem Possible faults Corrective actions

1. Lamps (H1, H2) do not a. Discharged or defective a. Check electrolyte level and charge battery. If no cells are
light up when switching battery. shorted and battery is discharged, trace cause and
(S1) to ”l“ and applying correct.
b. Loose battery cable(s) or
lamp test. oxidized terminals. b. Check and correct as necessary.
c. Loose connection or c. Check wiring and connections, correct as necessary.
damaged wiring.
d. With (S1) switched in ” I “, check voltage between ground
d. Contact switch (S1) and respectively each of the terminals of (S1). Voltage
defective. must register at each of the terminals; if not, replace (S1).
e. Circuit breaker defective. e. Replace circuit breaker.

2. General alarm lamp (H2) a. Lamp (H2) blown, a. Replace lamp.

does not light up when
b. Alternator/regulator b. Disconnect the wire from alternator terminal D+ and
switching (S1) to “1”; defective. connect it to terminal D-. If (H1) lights up, replace the
lamp (H1) lights up when alternator; if not, test (S1); see remedy 1d.
applying lamptest.

3. Temperature alarm lamp a. Lamp (H1) blown, a. Replace lamp.

(H1) does not light up
when switching (S1) to b. See fault 1d. b. See 1d.
the “I“ position and
applying lamp test.

4. Starter motor does not a. Low battery output. a. See remedy 1a.
crank engine after
switching (S1) to “I” b. Start button (S1) defective. b. With (S1) in position “I”, check voltage between earth and
each of the terminals of (S1). Voltage must register at
c. Alternator output inlay (K4) each of the terminals; if not replace (S1).
defective.
c. Replace (K4).
d. Start solenoid (KO) or
starter motor defective d. Check start solenoid (K0). Have starter motor repaired.

22 1310 3011 92
 Problem Possible faults Corrective actions
5. Starter motor cranks a. Switch (S1) defective, a. See remedy 4b.
engine when Switching
S1 to “I” but engine does b. Fuel solenoid (Y1) defective. b. Check solenoid and its valve; correct or
not fire. replace as necessary.
c. Low battery output.
c. See 1a.

6. Engine fires but a. Alternator drive belt broken or slipping, a. Check and correct as necessary.
general alarm lamp
(H2) remains alight; b. Alternator/regulator defective. b. Have assembly repaired.
compressor stops
when releasing (S1).

7. Engine is running but a. Override switch released too soon. a. Release switch after engine oil
shuts down pressure has built up to above the
immediately after S1 b. Insufficient engine oil pressure. minimum allowed value.
has been released. c. Fuel tank contains insufficient fuel. b. Stop at once, consult the engine
d. Engine oil pressure shut-down switch, Instruction manual.
engine temperature switch or c. Fill fuel tank.
compressor temperature switch
defective. d. Remove and test switches. Replace if
out of order.

8. General alarm lamp a. Insufficient engine oil pressure or too a. Stop at once, consult Engine Operation
(H2) remains alight for high engine coolant temperature. Manual.
over 5 seconds after
starting. b. Engine oil pressure switch (S3), or b. Stop at once, test switches, replace as
compressor temperature switch (S5) necessary.
defective.
c. Replace (K1).
c. Relay (K1) defective.

9. Hourmeter does not a. Hourmeter defective, a. Replace.

count running time.

10. Compressor does not a. Air leaks in regulating system. a. Check and repair.
unload and engine
keeps running at b. Regulating valve (RV) incorrectly set or b. Adjust or repair regulating valve; see
maximum speed when defective. section 5.1.
closing the air outlet c. Unloading valve (UV) or its actuating c. Repair unloading valve assembly.
valves; safety valve piston stuck.
blows.

11. Compressor capacity a. Air consumption exceeds capacity of a. Check equipment connected.
or pressure below compressor.
normal, b. Service air filter element (AF).
b. Choked air filter element (AF).
c. Speed regulation cable maladjusted;
c. Unloading valve (UV) not completely see section 5.1.
open.
d. Check the maximum speed, service the
d. Engine does not run at maximum fuel filter.
speed.
e. Have element removed and inspected
e. Oil separator element (OS) clogged. by an Atlas Copco Service
representative.

12. No air output. a. Drive coupling broken. a. Consult Atlas Copco.

13. Working pressure rises a. See faults 10. a. See remedies 10.
during operation and
causes safety valve to b. Safety valve (SV) opens too soon. b. Replace safety valve;
blow. Consult Atlas Copco

1310 3011 92 23
 Problem Possible faults Corrective actions
14. Excessive compressor a. Restrictor in oil scavenging line a. Dismount, clean and refit restrictor;
oil consumption. Oil clogged,
mist being discharged b. Replace element.
from air outlet valve (5- b. Oil separator element (OS)
defective. c. Check for overfilling. Release
fig. 4.2). pressure and drain oil to correct
c. Oil level too high. level.
15. Compressor shuts down a. Alternator V-belt broken or slipping, a. Re-tense or replace V-belt.
through a shut-down
switch. b. Compressor overheating. b. See condition 17.
c. Engine oil pressure too low. c. Check engine lubricating system.
d. Engine temperature too high d. Check engine cooling; see engine
operation manual
16. Air and oil expelled from a. Unloader valve defective, a. Repair valve.
air filter after stopping.
b. Wrong oil type with no foam- b. Consult Atlas Copco.
retarding additives.

17. Compressor a. Insufficient compressor cooling, a. Relocate compressor for adequate

overheating, ventilation.
b. Oil cooler (OC) clogged externally.
b. Clean cooler; see section 4.6.
c. Oil system clogged internally.
c. Consult Atlas Copco.
d. Oil level too low.
d. See section 4.4.
e. Cooling fan (F) defective.
e. Replace fan.
f. Oil separator element clogged.
f. Replace oil separator.
g. Oil filter clogged.
g. Replace oil filter.
h. Broken fan belt.
h. Replace.

24 1310 3011 92
 7 Technical Specifications
7.1 Settings of Shutdown Switches and Safety Valve
Compressor XAS185 JDU7
Temperature safety switch trip point............................................................ °F/(°C) 248/(120)
Safety valve effective opening pressure .................................................. psig/(bar) 150/(10.3)
(check stamping on valve)
Engine
Low oil pressure safety switch trip point .................................................. psig/(bar) 12/(.8)
Temperature safety switch trip point............................................................ °F/(°C) 239/(115)

7.2 Compressor/Engine Specifications

Compressor
Maximum effective pressure.................................................................... psig/(bar) 123/(8.5)
Normal effective working pressure .......................................................... psig/(bar) 100/(7.0)
Minimum effective working pressure ....................................................... psig/(bar) 58/(4.0)
3
Typical oil content of the compressed air ..................................................... mg/m <5
Free air delivery at working pressure, ........................................................cfm/(l/s) 185/(87)
maximum loading speed and referance conditions 1,2).
1) Referance conditions as specified are measured at the air inlet grating outside the canopy:
-Air intake pressure (absolute) 1 bar (14.5 psi)
-Air intake temperature 20°C (68°F)
-Relative air humidity 0%
2) Free air delivery is measured according to ISO 1217 ed. 3 1996 annex D which corresponds to American ANSI
PTC9.
With a tolerance of :+/- 5% 25 l/s<FAD<250 l/s
Engine XAS 185 JDU7
Make .................................................................................................................................. John Deere
Model .................................................................................................................................. 4024T
Type .................................................................................................................................. 4CYL./Turbo
Maximum operating speed (compressor loaded) rpm ................................................. 2750±20
Minimum operating speed (compressor unloaded) rpm ................................................. 1600±20
Fuel consumption (at full load) .......................................................................................... 3 gal/hr
Fuel consumption (at unload) .......................................................................................... 1 gal/hr
Capacities
Compressor oil system ............................................................................................gal/(l) 2/(7.4)
Engine lube oil system with filter ..................................................................................gal/(l) 2/(7.4)
Fuel tank ...................................................................................................................gal/(l) 25/(94)
Engine cooling system …....……………………….gal/(l) .......................................... 2.5/(9.2)

1310 3011 92 25
Engine XAS 185 JDU 7
Overall length in/(mm) ...... 84(2134)
Overall width in/(mm) ............... 33(851)
Overall height in/(mm) ............... 45(1143)
Gross weight (wet), approximately lb/(kg) ............... 1800(839)
Gross weight (dry), approximately lb/(kg ............... 2200(1000)
Sound pressure level dB(A).................................................................................................... 74
at 7m (23 ft). approximately
Battery (One, BCI Group size 31)...................................................................................... 12V-700CCA
Limitations

Maximum allowed ambient operating temperature °F /°C .................................................... 125/(52)

Minimum starting temperature 1) °F /°C…………………………………..……. 18(-8)
1) without the use of starting aids.

26 1310 3011 65