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

• +92 42 574 9406 /9408
  
• +92 42 574 9409
  
• atlascopco.pakistan@pk.atlascopco.com
  

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

• +92 (0)322 8401183
  
• +92 42 574 9409
  
• atlascopco.pakistan@pk.atlascopco.com