September 14, 2008

Atlas Copco XRHS 485 Md, Mercedez OM442LA Engine Overhauling

Air Compressors play an integral role in all the construction fields especially the one in which I have remained involved for quite a sometime, i.e., Construction of High Pressure Natural Gas Pipelines. Air Compressors with a capacity of more or equal to 1000 cfm are used primarily for Air Pigging to clean out built pipelines to insure smooth efficient and clean flow of natural gas to the end user before final commissioning. In the recent years I had an option to get my hands on Atlas Copco's XRHS 385 and XRVS 466 machines both powered by Mercedes-Benz Engines. Recently I got posted in the Central Maintenance Hub of Sui Northern Gas Pipelines located on 38 km Multan Road near Manga Mandi where I have been given the task of overhauling two of the XRHS 485 Md air compressors which could not bear the brunt of harsh field conditions and are out of order right now.

Following is the information I came across in the process of indenting spares for these maintenance starved machines.

The Atlas Copco Group was founded in 1873. It is a global industrial group of companies headquartered in Stockholm, Sweden. This Group employs more than 33,000 people.

Atlas Copco companies develop and manufacture industrial tools, compressed air equipment, construction and mining equipment, assembly systems on 68 production sites in 20 countries and offer related service and equipment rental. The products are sold and rented under different brands through a worldwide sales and service network reaching 150 countries, half of which are served by wholly or partly owned sales companies. The Group operates through a number of divisions within four business areas; Compressor Technique, Construction and Mining Technique, and Industrial Technique.

ATLAS COPCO XRHS485 Md, Air Compressor

Compressor / Engine Specification

COMPRESSOR / ENGINE

Number of compression stages

2

COMPRESSOR

Air receiver capacity

180 l


Maximum (unloading) pressure

22 bar


Temperature above ambient of air leaving air outlet valves

75˚ C


Normal working pressure

20 bar


Max. ambient temperature at sea level, normal working pressure and max. load speed

50˚ C


Up to the altitude of

5000m


Sound power level (LW) complies with 84/532/533/EEC and 85/406/EEC limits

102 dB(A)


Minimum working pressure

12 bar


Sound pressure level according to ISO 2151

74 dB(A)


Free air delivery

480 l/s

DIMENSION

Overall length, drawbar raised

± 4520 mm


Compressor cooling system

Oil


Overall width

± 2210 mm


Mercedes diesel engine, water-cooled

OM 442 LA


Overall height

± 2462 mm


Maximum load speed

1700 r/min


Minimum turning circle

Ø 9728 mm


Unloading speed

1050 r/min

TOWING

Compressors with parking brake only



Electrical system, negative earthed

24 V


Max. towing speed

25 km/h


Number

2


Michelin tires:



Voltage / Capacity

12V / 143 Ah


Type

XZA TL


Weight



Size

205/75R17.5in


Standard unit DRY

4960 kg


Pressure, front / rear

6 / 6 bar


Standard unit WET

5600 kg

TOWING

Compressors with pneumatic brakes (optional equipment)


FILLING CAPACITIES

Compressor oil system

±83 l


Max. towing speed

80 km/h


Engine oil system

±30 l


Michelin tyres:



Fuel tank

665 l


Type

XZA


Engine cooling system

64 l


Size

215/75R17.5in





Pressure, front / rear

6 / 6 bar


Following are the Parts required for General Overhauling of an OM 442 LA Mercedes-Benz Engine installed in an Atlas Copco XRHS 485 Md Air Compressor.

Sr. #

Description

Figure #

Part #

Qty.

01

Crankshaft Seal (Front)

22-01015-116

0139971447

01

02

Crankshaft Seal (Rear)

23-01030-47

0139971647

01

03

Valve Intake

25-01075-29

4420500526

01

04

Valve Exhaust

25-01075-29

4420500227

08

05

Valve Seat Intake

25-01075-23

4220530531

08

06

Valve Seat Exhaust

25-01075-23

4420530032

08

07

Valve Guide

25-01075-20

4220530430

16

08

Valve Seal

25-01075-53

4220530196

16

09

Head Gasket

25-01075-80

4420160420

01

10

Fuel Injection Nozzle

25-01075-104

0020170912

08

11

Valve Cover Gasket

25-01075-119

4420160621

01

12

Cylinder Head Assembly

25-01075-5

429010022080

08

13

Big End Bearing

26-03015-56

4420301160

08

14

Main Bearing

26-03015-50

4420302540

05

15

Main Bearing Thrust

26-03015-53

4220300345

01

16

Cylinder Kit (Pistons, Piston Rings, Gudgeon Pins, Retainers, Liners)

27-03045-26

4420303517

08

17

Liner Rings

27-03045-53

0259978448

08

18

Liner Rings

27-03045-56

0259978548

08

19

Liner Rings

27-03045-59

4230110284

08

20

Connecting Rod Bush

27-03045-8

4420380150

08

21

Plunger Barrel (Fuel Injection)

29-07030-89

0000741432

08

22

Plunger Barrel Bush (Fuel Injection)

29-07030-122

0000743029

08

23

Spring (Fuel Injection)

29-07030-80

0010743293

08

24

Check Valve (Fuel Injection)

29-07030-83


08

25

Delievery Valve (Fuel Injection)

29-07030-86

0000748784

08

26

Fuel Delivery Pump

31-07030-653

0000903150

01

27

Turbocharger Complete Assembly

40-09075-11

0040966099

01

28

Oil Pump

49-18015-5

4231802501

01

29

Coolant Pump Repair Kit

53-20015-32

4222000404

01

30

FAN (Radiator)

1615543801


01

31

FAN Belt

53-20015-86


01


These part numbers are applicable to only 441.901 Mercedes-Benz Engine models.

And are taken from the Parts Catalogue Supplied by Mercedes-Benz with the following information;

Book Edition: 1615684000

Key; 22-101015-116

22 is the Page Number

01015 is the Figure Code inscribed on the top left of the Parts Catalogue

And 116 is the Figure No.

CONTACTS in PAKISTAN

Compressors and Generators

Dereck Devlin - Country Manager

Atlas Copco Pakistan (Pvt) Ltd

Plot No. 18, 1st Floor, 18-XX - Khayaban-e-Iqbal Road
DHA - Lahore - PAKISTAN

Construction and Mining Equipment

Amir Saleem - Country Manager

Atlas Copco Pakistan (Pvt) Ltd

Plot No. 60 J, Street: 07 - Industrial Area, I-10/3
Islamabad - PAKISTAN

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