Atlas Copco XAS 185 KD T4F HOP User manual

Engine Kubota D1803-CR-TIE4B
XAS 185 KD T4F HOP
Instruction Manual for AC Compressors
English
•Always start and operate the engine in a well-ventilated area.
• If in an enclosed area, vent the exhaust to the outside.
• Do not modify or tamper with the exhaust system.
• Do not idle the engine except as necessary.
For more information go to www.P65warnings.ca.gov/diesel.
CALIFORNIA Proposition 65
WARNING
Breathing diesel engine exhaust exposes you to chemicals known to
the State of California to cause cancer and birth defects or other
reproductive harm.

ATLAS COPCO - PORTABLE ENERGY DIVISION
www.atlascopco.com
Printed matter No
1310 3018 02
10/2019
Instruction Manual for AC Compressor
XAS 185 KD T4F HOP
Original instructions

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Warranty and Liability Limitation
Use only authorized parts.
Any damage or malfunction caused by the use of unauthorized parts is not covered by Warranty or Product Liability.
The manufacturer does not accept any liability for any damage arising from modifications, additions or conversions made
without the manufacturer's approval in writing.
Neglecting maintenance or making changes to the setup of the machine can result in major hazards, including fire risk.
While every effort has been made to ensure that the information in this manual is correct, Atlas Copco does not assume
responsibility for possible errors.
Copyright 2019, Construction Equipment North America LLC, RockHill SC USA.
Any unauthorized use or copying of the contents or any part thereof is prohibited.
This applies in particular to trademarks, model denominations, part numbers and drawings.

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Preface
Please read the following instructions carefully before
starting to use your 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 trouble free
operation.
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.
Table of contents
1 Safety precautions .............................................. 7
1.1 Introduction .......................................................... 7
1.2 General safety precautions ................................... 7
1.3 Safety during use and operation ........................... 8
1.4 Safety during maintenance and repair .................. 9
1.5 Tool applications safety........................................ 9
1.6 Specific safety precautions ................................... 9
2 Leading particulars .......................................... 12
2.1 General description............................................. 12
3 Main parts ......................................................... 14
4 Overview............................................................ 16
4.1 Compressor regulating system (load Condition) 16
4.2 Air flow .............................................................. 18
4.3 Oil system........................................................... 18
4.4 Continuous regulating system ............................ 18
5 Electrical system ............................................... 20
6 Operating instructions ..................................... 25
6.1 Parking, towing and lifting instructions ............. 25
6.1.1 Draw bar preparations for towing ................... 25
6.1.2 Parking instructions......................................... 26
6.1.3 Towing Instructions ........................................ 26
6.1.4 Lifting Instructions.......................................... 26
6.2 Before starting .................................................... 27
6.3 Starting / stopping............................................... 28
6.3.1 Control panel................................................... 29
6.3.2 Overview icons ............................................... 30
6.3.3 Automatic functions........................................ 32
6.3.4 Possible views ................................................. 33
6.3.5 Starting ............................................................ 34
6.3.6 Stopping .......................................................... 38
6.3.7 Shutdown ........................................................ 39
6.3.8 Power off......................................................... 39
6.3.9 Diesel particulate filter regeneration............... 39
6.3.10 Automatic dpf regeneration (default).............. 40
6.3.11 Inhibit dpf regeneration................................... 40
6.3.12 Increasing soot load ........................................ 40
6.3.13 Turning regeneration back to auto .................. 41
6.3.14 Force dpf regeneration .................................... 41
6.3.15 Service regeneration........................................ 41
6.3.16 Settings............................................................ 41
6.3.17 Fault codes ...................................................... 44
6.3.18 Emergency stop............................................... 47
7 Maintenance...................................................... 48
7.1 Use of service paks............................................. 48
7.2 Service kits ......................................................... 48
7.3 Preventive maintenance schedule....................... 49
7.4 Oil specifications ................................................ 51
7.4.1 Lubrication oils ............................................... 51
7.5 Oil level check.................................................... 52
7.5.1 Check engine oil level..................................... 52
7.5.2 Check compressor oil level ............................. 52
7.5.3 Engine oil and oil filter change ....................... 52
7.5.4 Compressor oil and oil filter change ............... 52
7.6 Cleaning coolers ................................................. 53
7.7 Battery care......................................................... 53
7.7.1 Electrolyte ....................................................... 53
7.7.2 Recharging a battery ....................................... 53
7.7.3 Battery maintenance........................................ 53
7.7.4 Storage ............................................................ 53
8 Adjustments and servicing procedures .......... 54
8.1 Adjustment of the continuous regulating system 54
8.2 Air Filter engine/compressor.............................. 55
8.2.1 Main parts ....................................................... 55
8.2.2 Cleaning the dust trap ..................................... 55
8.2.3 Replacing the air filter element ....................... 55
8.2.4 Air filter maintenance ..................................... 55
8.3 Air receiver......................................................... 56
8.4 Safety valve ........................................................ 56
8.5 Fuel system......................................................... 56
9 Problem solving ................................................ 57
9.1 Problem solving chart......................................... 57
9.2 Alternator precautions ........................................ 57
10 Technical specifications.................................... 59

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10.1 Torque values ..................................................... 59
10.1.1 General torque values...................................... 59
10.1.2 Critical torque values ...................................... 59
10.2 compressor /engine specifications...................... 60
10.2.1 Reference conditions....................................... 60
10.2.2 Limitations ...................................................... 60
10.2.3 Altitude unit performance curve ..................... 61
10.2.4 Performance data............................................. 62
10.3 Design data ......................................................... 62
10.3.1 Compressor ..................................................... 62
10.3.2 Engine ............................................................. 62
10.3.3 Unit.................................................................. 62
10.3.4 Rejection limits ............................................... 63
11 Disposal.............................................................. 64
11.1 General ............................................................... 64
11.2 Disposal of materials .......................................... 64
12 Maintenance log................................................ 65
13 Maintenance log................................................ 66

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Safety precautions
INTRODUCTION
The policy of Atlas Copco is to provide the users of their
equipment with safe, reliable and efficient products.
Factors taken into account are among others:
- the intended and predictable future use of the products, and
the environments in which they are expected to operate,
- applicable rules, codes and regulations,
- the expected useful product life, assuming proper service and
maintenance,
Before handling any product, take time to read the
relevant instruction manual. Besides giving detailed
operating instructions, it also gives specific information
about safety, preventive maintenance, etc.
These precautions are general and some statements will
therefore not always apply to a particular unit.
When handling, operating, overhauling and/or
performing maintenance or repair on Atlas Copco
equipment, the mechanics are expected to use safe
engineering practices and to observe all relevant local
safety requirements and ordinances. The following list is
a reminder of special safety directives and precautions
mainly applicable to Atlas Copco equipment.
This brochure applies to machinery processing or
consuming air. Processing of any other gas requires
additional safety precautions typical to the application
and are not included herein.
All responsibility for any damage or injury resulting from
neglecting these precautions or by non-observance of
ordinary caution and due care required in handling,
operating, maintenance or repair, also if not expressly
mentioned in this instruction manual, is disclaimed by
Atlas Copco.
If any statement does not comply with local legislation,
the stricter of the two shall be applied. Statements in this
manual should not be interpreted as suggestions,
recommendations or inducements that it should be used in
violation of any applicable laws or regulations.
GENERAL SAFETY PRECAUTIONS
1 The owner is responsible for maintaining the unit in a
safe operating condition. Unit parts and accessories
must be replaced if missing or unsuitable for safe
operation.
2 Use only lubricating oils and greases recommended or
approved by Atlas Copco or the machine manufacturer.
Ascertain that the selected lubricants comply with all
applicable safety regulations, especially with regard to
explosion or fire risk and the possibility of
decomposition or generation of hazardous gases.
3 The supervisor, or the responsible person, shall at all
times make sure that all instructions regarding
machinery and equipment operation and maintenance
are strictly followed and that the machines with all
accessories and safety devices, as well as the
consuming devices, are in good repair, free of
abnormal wear or abuse, and are not tampered with.
4 Maintenance, overhaul and repair work shall only be
carried out by adequately trained personnel; if
required, under supervision of someone qualified for
the job.
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 covers shall
be opened before sufficient cooling time has elapsed;
this to avoid the risk of spontaneous ignition of oil
vapour when air is admitted.
6 Maintenance work, other than routine attention, shall
only be undertaken when the machine is turned off.
7 Before dismantling any pressurized component, the
compressor or the equipment shall be effectively
isolated from all sources of pressure and be completely
vented to atmosphere. In addition, a warning sign
bearing a legend such as "work in progress; do not
open" shall be attached to each of the isolating valves.
8 Before a machine is being repaired, steps shall be taken
to prevent inadvertent starting. In addition, a warning
sign bearing a legend such as "work in progress; do not
start" shall be attached to the starting equipment. The
battery shall be disconnected and removed or the
terminals covered by insulating caps.
9 Normal ratings (pressures, temperatures, speeds, etc.)
shall be durably marked.
10 Never operate a machine or equipment beyond its rated
limits (pressure, temperature, speed, etc.).
11 Maintenance and repair work should be recorded in an
operator's logbook for all machinery. Frequency and
nature of repairs can reveal unsafe conditions.
12 The machinery and pneumatic equipment shall be kept
clean, i.e. as free as possible from oil, dust or other
deposits.
13 To prevent an increase in working temperature, inspect
and clean heat transfer surfaces (cooler fins,
intercoolers, water jackets, etc.) regularly. For every
machine establish a suitable time interval for cleaning
operations.
14 All regulating and safety devices shall be maintained
with due care to ensure that they function properly.
They may not be bypassed.
15 Care shall be taken to avoid damage to safety valves
and other pressure relief devices, especially to avoid
plugging by paint, oil coke or dirt accumulation, which
could interfere with the functioning of the device.
16 Pressure and temperature gauges shall be checked
regularly with regard to their accuracy. They shall be
replaced whenever outside acceptable tolerances.
17 Parts shall only be replaced by genuine Atlas Copco
replacement parts.
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 condition.
19 Never use flammable solvents or carbon tetrachloride
for cleaning parts. Take safety precautions against
toxic vapors when cleaning parts in or with cleaning
products.
20 Observe scrupulous cleanliness during maintenance
and repair. Keep away dirt by covering the parts and
exposed openings with clean cloth, paper or tape.
21 Protect the engine, alternator, air intake filter, electrical
and regulating components, etc. to prevent moisture
ingress, e.g. when steam-cleaning.
22 When performing any operation involving heat, flames
To be read attentively and acted accordingly before towing, lifting, operating, performing maintenance
or repairing the compressor.

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or sparks on a machine, the surrounding components
shall first be screened with non-flammable material.
23 Never use a light source with open flame for inspecting
the interior of a machine, pressure vessel, etc.
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.
25 Prior to stripping a compressor, engine or other
machine or undertaking major overhaul on it, prevent
all movable parts with a mass exceeding 15 kg (30 lbs)
from rolling over or moving.
26 When repair has been completed, make sure that no
tools, loose parts or rags are left in, or on, the machine,
the prime mover or the driving gear. The machine shall
be barred several revolutions to ensure that there is no
mechanical interference within the machine or driver.
SAFETY DURING USE AND OPERATION
To lift a unit, all loose or pivoting parts, e.g. doors shall
first be 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.
Helicopter lifting using the lifting eye is forbidden.
It is strictly forbidden to dwell or stay in the risk zone
under a lifted load. Never lift the unit over people or
residential areas.
Lifting acceleration and retardation shall be kept within
safe limits.
1 Before towing the unit:
- ascertain that the pressure vessel is depressurized,
- check the drawbar, the brake system and the towing eye. Also
check the coupling of the towing vehicle,
- check that the pivot wheel or stand leg is safely locked in
the raised position,
- ascertain that the towing eye can swivel freely on the hook,
- check that the wheels are secure and that the tires are in good
condition and inflated correctly,
- attach the safety break-away cable to the towing vehicle,
- remove wheel chocks, if applied, and disengage the parking
brake.
- Apply safety chains to tow vehicle.
2 If the unit is to be backed up by the towing vehicle,
disengage the overrun brake mechanism (if equipped).
3 Never exceed the maximum towing speed of the unit.
4 Place the unit on level ground and chock the wheels
before disconnecting the unit from the towing vehicle.
Unclip the safety break-away cable
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 sparks.
6 The exhaust contains carbon monoxide which is a
lethal gas. When the unit is used in a confined space,
conduct the engine exhaust to the outside atmosphere
by a pipe of sufficient diameter (min. 4 inches); do this
in such a way that no extra back pressure is created for
the engine. If necessary, install an extractor.
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 considerably extends
the intervals for cleaning the air intake filters and the
cores of the coolers.
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
recirculated. If such hot air is taken in by the engine or
driven machine cooling fan, this may cause
overheating of the unit; if taken in for combustion, the
engine power will be reduced.
9 No external force may be exerted on the air outlet
valves, e.g. by pulling on hoses or by installing
auxiliary equipment directly to a valve, e.g. a water
separator, a lubricator, etc.
10 Distribution pipework and air hoses must be of correct
size and suitable for the working pressure. Never use
frayed, damaged or deteriorated hoses. Replace hoses
and flexibles of which the lifetime expired. Use only
the correct type and size of hose end fittings and
connections. Install safety pins on quick type hose
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 145 psi (10
bar) up, although it is recommended to apply such
safeguard already from (60 psi) 4 bar up.
The safety wire ends have to be attached, one to the eye
provided next to the compressor air outlet valve, the
other one to a point near to the air inlet of the applied
equipment. Finally a wire mesh hose can be fixed over
the hose ends to dampen the blast in case a connection
starts leaking or should become undone.
Close the compressor air outlet valve before
connecting or disconnecting a hose. Ascertain that a
hose is fully depressurized before disconnecting it.
When blowing through a hose or air line, ensure that
the open end is held securely. A free end will whip and
may cause injury.
Never play with compressed air. Never apply it to your
skin or direct an 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 protection.
11 Never move a unit when external lines or hoses are
connected to the outlet valves, to avoid damage to
valves and/or manifold and hoses.
12 Never refill fuel while the unit is running. Keep fuel
away from hot parts such as air outlet pipes or the
engine exhaust. Do not smoke when fueling. When
fueling from an automatic pump, a ground cable should
be connected to the unit to discharge static electricity.
Never spill nor leave oil, fuel, coolant or cleansing
agent in or around the unit.
13 Never operate the unit in surroundings where there is a
possibility of taking in flammable or toxic fumes.
14 Never operate the unit at pressures or speeds below or
in excess of the limit ratings stated on the Principal
Data sheet.
15 On liquid-cooled engines with closed cooling circuit:
allow the unit to cool before removing a pressure cap.
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 door should be
kept open for a short period only, e.g. for inspection or
adjustment
17 Wear ear protectors when environmental noise can
reach or exceed 85 dB(A). Beware of long-time
exposure to noise.
18 Periodically check that:
- all safety equipment is in good working order,
- all guards and air conducting baffles are in place and securely
fastened,
- all hoses and/or pipes inside the unit are in good condition,
secure and not rubbing,

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- there are no fuel, oil or coolant leaks,- all fasteners are tight
- all electrical leads are secure and in good order,
- the engine exhaust system is in good condition,
- air outlet valves and manifold, hoses, couplings, etc. are in good
repair, free of wear or abuse,
- the wheel nuts are tightened to the proper torque.
When more than one compressor is connected to a common
header, be sure each compressor has a non-return valve
(check valve) to prevent reverse rotation when stopping.
SAFETY DURING MAINTENANCE AND REPAIR
Maintenance, overhaul and repair work shall only be
carried out by adequately trained personnel; if required,
under supervision of someone qualified for the job.
1 Use only the correct tools for maintenance and repair
work, and only tools which are in good condition.
2 Parts shall only be replaced by genuine spare parts.
3 All maintenance work, other than routine attention,
shall only be undertaken when the unit is stopped.
Ensure that the unit cannot be started inadvertently
4 Before removing any pressurized component, the
compressor or equipment shall be effectively isolated
from all sources of pressure and the entire system shall
be relieved of pressure. Do not rely on non-return
valves (check valves) to isolate pressure systems.
5 Never use flammable solvents for cleaning (fire-risk).
Take safety precautions against toxic vapours of
cleaning liquids.
6 Scrupulously observe cleanliness during maintenance
and when performing repairs. Keep dirt away by
covering the parts and exposed openings with a clean
cloth, paper or tape.
7 Never weld on or perform any operation involving heat
near the fuel or oil systems. Fuel and oil tanks must be
completely purged, e.g. by steam-cleaning, before
carrying out such operations. Never weld on, or in any
way modify, pressure vessels. Disconnect the
alternator cables during arc welding on the unit.
8 Support the drawbar and the axle securely if working
underneath the 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.
10 Before clearing the unit for use after maintenance or
overhaul, check that operating pressures, temperatures
and 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 steamcleaning.
TOOL APPLICATIONS SAFETY
Apply the proper tool for each job. With the knowledge of
correct tool use and knowing the limitations of tools,
along with some common sense, many accidents can be
prevented.
Special service tools are available for specific jobs and
should be used when recommended. The use of these
tools will save time and prevent damage to parts.
1 Use only wrenches or sockets whose size fits the
fastener.
2 Apply an open-end wrench only in the place of the
fastener head, square to the thread axis.
3 Do not use a pipe or other improvised leverage
extensions on handles.
4 Do not hammer on wrenches or other tools which are
not specially designed for it.
5 Always support the ratchet head when using socket
extensions.
6 Discard any wrench with broken or battered points or
edges.
7 Never use hand type sockets on power or impact tools.
8 Select only heavy-duty impact sockets for use with
pneumatic or electric impact tools.
9 Replace sockets showing cracks or wear; keep sockets
clean.
10 Never use screwdrivers for prying, punching,
chiseling, scoring or scraping.
11 Use the correct type and size of screwdriver for the job.
The bit must match the fastener.
12 A screwdriver with rounded edges will slip; it needs to
be redressed or discarded.
13 Never use a screwdriver or any other tool near a live
wire or electrical component. Plastic covering of
handles is for comfort and grip only. They are not
intended to act as insulation if such is not clearly
marked by the manufacturer.
14 Never strike a hammer against a hardened object; use a
soft drift against the object and strike against the drift.
15 Strike the object with the full face of the hammer.
16 Never use a hammer with a loose head.
17 Discard a hammer with chipped or mushroomed face.
18 Never use a chisel or punch with a chipped or
mushroomed striking face.
19 Always pull on a wrench or socket handle, if possible,
and adjust your stance to prevent a fall if something lets
go.
20 Wear approved eye protection when using percussion
tools or when scraping, chipping, shaving or grinding.
21 Wear protective gloves when holding a chisel or punch.
SPECIFIC SAFETY PRECAUTIONS
Batteries
When servicing batteries, always wear protecting
clothing and glasses.
1 The electrolyte in batteries is a sulphuric acid solution
which is fatal if it hits your eyes, and which can cause
burns if it contacts your skin. Therefore, be careful
when handling batteries, e.g. when checking the charge
condition.
2 Install a sign prohibiting fire, open flame and smoking
at the post where batteries are being charged.
3 When batteries are being charged, an explosive gas
mixture forms in the cells and might escape through the
vent holes in the plugs. 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 has been charged. Therefore:
- never smoke near batteries being, or having recently been,
charged,
- never break live circuits at battery terminals, because a
spark usually occurs.
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, then connect the
- pole of CB to the mass of the unit. Disconnect in the
reverse order.Incorrect connection will damage
alternator.

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Ether fuel Systems
Ether fuel systems are used for diesel cold starting.
1 1 Do not use ether as a starting aid in conjunction with
other stating aids (i.e. glow plug, air intake heater etc.)
as an explosive condition may result in severe engine
damage or personal injury.
2 This type of fuel is extremely flammable, toxic and
poisonous. Avoid contact with eyes or skin and
breathing the fumes. If accidentally swallowed, do not
induce vomiting but call a physician immediately.
3 If fuel enters or fumes irritate the eyes, flush the latter
with large quantities of clean water and call for medical
aid.
4 Before operating ether cold starting aids, read the
instructions and the container label.
5 Never operate ether cold starting aids while the engine
is running as this can cause severe damage.
6 When maintenance, tests or repair has to be performed,
do so in a well-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
smoking.
7 Wear eye protection when testing a system. Make sure
that openings of a spray container, valve, tube or
atomizer are pointed away from yourself and others
while testing.
8 Do not store ether containers in temperatures above
160 ºF (70ºC),
9 Do not incinerate, puncture or attempt to remove the
center core valve, side safety valve or any other part of
an ether container.
Pressure vessels
Maintenance/installation requirements:
1 The vessel can be used as pressure vessel or as
separator and is designed to hold compressed air for the
following application:
- pressure vessel for compressor,
- medium AIR/OIL,
and operates as detailed on the data plate of the vessel:
- the maximum working pressure ps in psi (bar),
2 The pressure vessel is only to be used for the
applications as specified above and in accordance with
the technical specifications. Safety reasons prohibit
any other applications.
3 National legislation requirements with respect to re-
inspection must be complied with.
4 No welding or heat treatment of any kind is permitted
to those vessel walls which are exposed to pressure.
5 The vessel is provided and may only be used with the
required safety equipment such as manometer,
overpressure control devices, safety valve, etc.
6 Draining of condensate shall be performed daily when
vessel is in use.
7. Installation, design and connections should not be
changed.
8. Bolts of cover and flanges may not be used for extra
fixation.
Safety valves
All adjustments or repairs are to be done by an authorized
representative of the valve supplier.
Following checks must be carried out:
1 A check of the opening of the lifting gear,1 or 2 times
a year. This can be done by lifting the ring or lever.
2 A check of the set pressure once a year according to the
local regulations, if required. This check may not be
done with the compressor supplying the air pressure
and must be carried out on a proper test bench.
Injury Prevention
1 Stationary housing guards are provided on all rotating
or reciprocating parts not otherwise protected and
which may be hazardous to personnel. Machinery shall
never be put into operation, when such guards have
been removed, operate only when guards are securely
reinstalled.
2 Do not open electrical cabinets, cubicles or other
equipment while voltage is supplied. If such cannot be
avoided, e.g. for measurements, tests or adjustments,
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.
3 Noise, even at reasonable levels, can cause irritation
and disturbance which, over a long period of time, may
cause severe injuries to the nervous system of human
beings.
When the sound pressure level, at any point where
personnel normally has to attend, is:
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 ºC (175 ºF) 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, 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, 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