TRAINING – KILTON MOTORS

Amol Joshi

June 2016
COMMITTED TO SUSTAINABLE PRODUCTIVITY

We stand by our responsibilities towards our customers,

towards the environment and the people around us.
We make performance stand a test of time. This is what
we call – Sustainable Productivity.
AGENDA
 Atlas Copco Overview

 Nasik India Overview / RCE Organization

 Products from Nasik – RCE

 Compaction principle

 Product training CA 250D

 Study of electrical Circuit for CA

 Operational & Maintenance (PMS) requirement for CA & CC

 Pre commissioning checks review for CA

 Trouble Shooting tips

 Feedback session with service team

 Stock machine verification

CUSTOMER-FOCUSED STRUCTURE
Board of Directors

President and CEO

Group Management and corporate functions

Compressor Industrial Mining and Rock Excavation Construction

Technique Technique Technique Technique

Compressor Technique Service Industrial Technique Service Mining and Rock Excavation Construction
Industrial Air MVI Tools and Assembly Service Technique Service

Oil-free Air Systems Underground Rock Specialty Rental

General Industry Tools Excavation Portable Energy
Vacuum Solutions
and Assembly Systems Surface and Exploration Drilling Road Construction Equipment
Gas and Process
Chicago Pneumatic Tools Drilling Solutions Construction Tools
Quality Air
Rock Drilling Tools
Airtec
Rocktec

Common service providers

ATLAS COPCO - STRONG BRANDS TO FIT CUSTOMER NEEDS
LOCATION OF FACTORIES IN INDIA

Nashik – MR, CR, ITBA

Pune Dapodi - CT
Pune Chakan - CT
Nasik Hyderabad - RDT
Pune
Hyderabad
 NASHIK FACTORY

Built Up Area 22000 m² Plant area : 3 000 m²

BUSINESS AREA / DIVISIONS IN NASHIK
CR BA
• Construction Tools (CTD)
• Road Construction Equipment (RCE)
• Construction Technique Service (CRS)
MR BA
• Drilling Solutions (ADS)
• Surface Exploration Division (SED)
• Rocktec (RTE)
• Underground Rock Excavation (URE)
• Mining and Rock excavation service (MRS)

IT BA
CPV
 9

Paul Hense
President RCE

Ihab Eldessouky
C . Pandit
V.P.Marketing
Operations Manager

Pravin Joshi Amol Joshi Hirdesh Kumar

Assembly Manager Quality Manager Tech.Ser.Manager

Rajesh Khetrapal Shisheer Bhargava Vishwesh Rai

Sourcing Manager Engineering Manager Pro.Mar. Manager

9
HISTORY
CC425

CC125

Product Portfolio built up

14

CC224 HF CA NVI CAB CC1250

12

10 CC385 HF
CA300D
CA NVI machine

8 F181C
CA270D

CA255
6
CA250D

CC384
2
CA250

0
2008 2009 2010 2011 2012 2013 2014 2015

No. of Products added Cumulative no.s

RCE PRODUCTS MADE IN INDIA

Compactors
Only to India
CC 425

Soil Compactor Asphalt

Compactor

• CC 125 ( India )
• CC 1250

Only to India • CA300D Platform

• CA255 • CA300D ROPS

• CA255D • CA300D Cabin • CC2200 CAB • CC3800 CAB

• CC2200 Platform • CC3800 Platform

• CA250D Platform • CA270D Platform (SS, DS)

• CA250D ROPS • CA270D ROPS
Only to India
• CA250D Cabin • CA270D Cabin
• CC385
COMPACTION PRINCIPLES

Types of Compaction -
PRODUCT SPECIFICATIONS – CA 250D
Component Identification

Pre Air Cleaner

Operator Console
With Vandalism Cover
Engine Hood

Drum Drive
Driving Lights

Tractor Frame with

in-built diesel tank

Steering Hitch
Drum
Rear Axle
 Steering Pump Engine
ROC Unit

Vibration Pump
Propulsion Pump

Hydraulic Cylinders
 17

DRUM ASSLY (WITH TWO BEARING ARRANGMENT)

Support bearing
Drum shell

Inner tube

Bearing housing Drum gear

(D or PD)
DRUM ASSLY (WITH TWO BEARING ARRANGMENT)

Vibration side
Drive side

18
 19

DRUM ASSLY (WITH CARTRIDAGE ARRANGAMENT)

Drum shell
Vibration motor
intermediate shaft Drive disc

Support bearing Drum cartridge Drum gear

(D or PD)
HYDRAULIC SCHEMATIC
Rear Axle/Drum Axial Piston
Drum Motor Drive Motor Pump-Travel

Steering
Cylinder Steering Valve Gear Pump Engine

Axial Piston
Vibration Motor Pump-Vibration

Hydraulic system Controls driving and Steering

20
TRANSMISSION SYSTEM

Axial Piston
Tyres Rear Axle Motor Pump Engine

21
Hydraulic Circuit -------
 Charge system and Brake release
Charge pressure = 15 to 30 bar

Steering
pump

No
steering

Brake Solenoid:
Position for Brake
release

Charge Pressure
High Pressure
Suction Pressure
Case Drain Charge Pressure
Measuring Port
Machine in Forward / Reverse Direction Axle Motor – Axle Drum Gear
110 CC

Steering
pump -26 CC

No
steering

Vibration Low /
High selector
Sol.Valve

Charge Pressure
Measuring Port Propulsion Pump – 75 CC

Vibration Motor - 32CC Vibration Pump – 40 CC

Machine in Forward / Reverse Direction
Axle Motor – Axle Drum Gear
Vibration Low / High 130 CC

Steering
pump -26 CC

No
steering

Vibration Low /
High selector
Sol.Valve

Charge Pressure
Measuring Port Propulsion Pump – 75 CC

Vibration Motor - 32CC Vibration Pump – 40 CC

Machine in Forward / Reverse Direction
Axle Motor – Axle Drum Gear
Vibration Low / High 130 CC

Steering Left / Right, Breaks Disengaged

Steering
pump -26 CC

Steering Left
/ Right

Vibration Low /
High selector
Sol.Valve

Charge Pressure
Measuring Port Propulsion Pump – 75 CC

Vibration Motor - 32CC Vibration Pump – 40 CC

ELECTRICAL CIRCUIT
LUBRICANT CAPACITY

Sl Description Quantity Recommended oil Part no

No
1 Hydraulic oil in system 23 lts
Atlas Copco Hydraulic300 9106230330 (20 liters)
2 Hydraulic oil tank 52 lts

3 Drum Oil 15 lts Atlas Copco Drum Oil 1000 4812156456 (5 liters)

4 Rear axle oil differential (Carraro) 14.5 lts Shell Spirax S4 TXM SAE P/N 5501527800 (20 liters)
10W30,
5 Rear axle planetory gear (Carraro) 1.5 lts/side Shell Spirax S4 TXM SAE P/N 5501527800 (20 liters)
10W30,
6 Transmission Box 0.3 lts Shell Spirax S4 TXM SAE P/N 5501527800 (20 liters)
10W30,
7 Engine oil 11 lts Atlas Copco Engine Oil 100 P/N 5580020624 (5 liters),
P/N 5501522700 (20 liters)
8 Coolant 24 lts K-COOL SUPERPLUS
HYDRAULIC SYSTEM PRESSURE

Sl No System Pressure

1 Drive system 38.0 MPa

2 Supply system (Charge) 2.0 MPa

3 Vibration system 32.5 MPa

4 Control system (Steering) 17.5 MPa

5 Brake release 1.8 – 3.0 MPa

OPERATION & MAINTENANCE
OPERATION & MAINTENANCE
MAINTENANCE SCHEDULE

EVERY 10 HOURS OF OPERATION (DAILY)

 Check engine oil level
 Check coolant level
 Check hydraulic oil level
 Check scrapper settings
 Grease the steering cylinder bearings
 Refuel
 Test Brakes

AFTER THE FIRST 50 HOURS OF OPERATION

 Change engine oil
 Change engine oil filter
 Change fuel filters
 Change hydraulic oil filter
 Change rear axle oil (Both planetary, differential and transmission)
EVERY 50 HOURS OF OPERATION (WEEKLY)

 Check that hoses and couplings are not leaking

 Inspect/clean the filter element in the air cleaner
 Lubricate the articulation
 Check the wheel-nuts are tightened
 Check tyre pressure

EVERY 250 HOURS OF OPERATION (MONTHLY)

 Check oil level in rear axle/planetary gearing

 Check oil level in the drum
 Check battery
 Clean the coolers
 Check rubber elements (AVM) and bolted joints
 Change engine oil
EVERY 500 HOURS OF OPERATION (EVERY 3 MONTHS)
 Change the engine oil
 Change the engine oil filter
 Replace the fuel filter
 Clean the fuel pre-filter
 Check bleeder filter on hydraulic reservoir

EVERY 1000 HOURS OF OPERATION (EVERY 6 MONTHS)

 Change the hydraulic fluid filter

 Drain the condensate from hydraulic reservoir
 Drain condensate from fuel tank
 Change oil in rear axle differential
 Change oil in the rear axle planetary gearing
 Change transmission oil
 Check engine valve clearances (Engine People)
 Change coolant
EVERY 2000 HOURS OF OPERATION (EVERY 1 YEAR)
 Change the hydraulic fluid
 Change the oil in the drum
 Lubricate the Forward/Reverse lever
OPERATION
Before starting & starting

 Do the daily checks

 Switch on Master switch / Battery switch
 Pull out emergency stop switch
 Make sure throttle lever in low idle
 FNR lever in neutral
 Parking brake switch engaged (On)
 Switch on the ignition switch
 Check the warning lamps in instrument panel
 Check horn
 Check lights, indicators
 Check backup alarm

 Start the engine and keep machine idle for 2-3 minutes
OPERATION
Stopping and parking

 Park the machine in safe place

 Switch off all the lights

 Engage parking brake

 Put the trottle in low idle

 Put FNR in neutral

 Let the engine run for 2-3 minutes

 Switch off the ignition switch

 Switch off the master switch / batterry switch

TIGHTENING TORQUE
COMMISSIONING CHECK LIST
PRODUCT SPECIFICATIONS – CC 3800
LUBRICANT CAPACITY

SL. Description Quantity

No
1 Drum Oil 14 lts 14.8 qts

2 Drum Gear 1.1 lts 1.2 qts

3 Hydraulic oil 40 ltrs 42 qts

4 Engine Oil 11 lts 11.7 qts

5 Coolant 18.6 lts 19.7 qts

HYDRAULIC SYSTEM PRESSURE
MAINTENANCE SCHEDULE
EVERY 10 HOURS OF OPERATION (DAILY)
Before starting up for the first time on that day
 Check engine oil level
 Check coolant level
 Check hydraulic oil level
 Check scrapper settings
 Fill water tank
 Check water sprinkler system
 Refuel
 Test Brakes

AFTER THE FIRST 50 HOURS OF OPERATION

 Change engine oil
 Change engine oil filter
 Change fuel filters
 Change hydraulic oil filter
 Change drum gear oil
EVERY 50 HOURS OF OPERATION (WEEKLY)
 Check that hoses and couplings are not leaking
 Inspect/clean the filter element in the air cleaner

EVERY 250 HOURS OF OPERATION (MONTHLY)

 Check oil level in the drum
 Check battery
 Clean the coolers
 Check rubber elements (AVM) and bolted joints
EVERY 500 HOURS OF OPERATION
 Change the engine oil
 Change the engine oil filter
 Replace the fuel filter
 Clean the fuel pre-filter
 Check bleeder filter on hydraulic reservoir

EVERY 1000 HOURS OF OPERATION

 Change the hydraulic fluid filter
 Change drum gear oil
 Change drum oil
 Check engine valve clearances (Engine People)
 Change coolant
EVERY 2000 HOURS OF OPERATION

 Change the hydraulic fluid

 Drain and clean the water tank
 Drain and clean the fuel tank
 Check the condition of the articulation
 COMMITTED TO
SUSTAINABLE PRODUCTIVITY.