Service training

Compactors – India
Date – 27.08.2013
Agenda

 Atlas Copco Overview

 Nasik India Overview

 Products from India

 RCE India

 Product specification CA 250D

Atlas Copco
Board of Directors

President and CEO

Executive Group Management and Corporate Functions

Mining and Rock

Compressor Industrial Construction
Technique Excavation Technique
Technique
Technique

Oil-free Air Atlas Copco Tools Underground Rock Construction Tools

and Assembly Systems Excavation Road Construction
Industrial Air Motor Vehicle Industry Surface Drilling Equipment
Specialty Rental Atlas Copco Tools Equipment Portable Air
Gas and Process and Assembly Systems Drilling Solutions
General Industry Service division
Secoroc (CRS)
Compressor Technique
Service Chicago Pneumatic Tools Geotechnical Drilling
and Exploration
Airtec Industrial Technique
Service Rocktec
Service Division

Customer Centers and Service Providers

Atlas Copco - Strong brands to fit customer needs
Location of factory

200 kms
from
Nasik
Mumbai
Nasik factory

Built Up Area 22000 sqm

Business area / divisions in Nasik

CR BA
• Construction Tools (CTD)
• Road Construction Equipment (RCE)
• Construction Technique Service (CRS)
MR BA
• Drilling Solutions (ADS)
• Surface Drilling Equipment (SDE)
• Rocktec (RTE)
• Underground Rock Excavation (URE)
• Mining and Rock excavation service (MRS)

IT BA
CPV
 RCE products
Dynapac Products

Compactors

Soil Compactor Asphalt

Compactor

• CA300D Platform
• CA250i (KOEL Engine) • CC224 HF CAB
• CA300D ROPS
• CA250iD • CC384 HF CAB
• CC224HF Platform
• CA300D Cabin
• CC384HF Platform

• CA250D Platform • CA270D Platform • CC384 Hfi (KOEL

Engine)
• CA250D ROPS • CA270D ROPS
• CA250D Cabin • CA270D Cabin

8
 CTD products
 We produce Pneumatic breaker & Rock drills both in AC & CP Brand
for both in Indian Market & World Market.
 We produce MB 1500 Hydraulic Breaker for Local market.
 We produce products for Light Compaction & Concrete products
both for world market & Indian market.

9
ADS India – Current Product Range

Blasthole Drills Feeder Crusher Waterwell Drills

IBH 10 SCH 200

TH5

IDM 30
TH10

IDM 45
TH10 LM
IDM 70
TH10 LM
OBC
DMH
 SDE Products : AirROC Crawler RIGs

AirROC T25W AirROC D35 AirROC T25 AirROC T35

AirROC D40W AirROC D40 AirROC D45
AirROC D50

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 SDE Products : PowerROC Crawler Rigs

ICM 260 PowerROC D40

12
Nasik RCE Organization

General
Manager /
Operations
C Pandit

Design & Flow team

and order Sourcing Quality Technical Product
Developmen Marketing
t handling service

Rajesh Amol M.S.Naray Dyanesh

Shisheer Amardeep khetrapal Joshi anan vidya
bhargava shisodia
 Roller Range - Nasik, India

CC Rollers

CA Rollers

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 CA Rollers

Basic model Plus model

CA250D CA250D Plus

CA270D CA270D Plus

CA300D CA300D Plus

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 CA Rollers
3 different models

CA250D CA270D CA300D

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 CA250D
3 different models

Includes:

 Tier 1 engine
 Platform
CA250D Platform

Options:
Includes:
 Compaction Meter
 PD Shell
 Tier 1 engine
 ROPS  Vandal cover
CA250D ROPS  Canopy (for
platform version)

Includes:

 Tier 1 engine
 ROPS Cab

CA250D Cab

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 CA270D
4 different models

Includes: Includes:

 Tier 1 engine  Tier 1 engine

 Canopy  Canopy
 Single Speed  Dual Speed Axle
CA270D Canopy Axle
CA270D Canopy
Single Speed Dual Speed

Option
Includes: Includes:

 Tier 1 engine  Tier 1 engine

 ROPS  ROPS Cabin
 Dual Speed Axle  Dual Speed Axle
CA270D ROPS CA270D Cabin
Dual Speed Dual Speed

Options
Compaction Meter
Vandal Cover

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 CA300D
3 different models

Includes:

 Tier 1 engine
 Canopy
CA300D Canopy

Options:
Includes:
 Compaction Meter
 Tier 1 engine
 PD Shell
 ROPS
CA300D ROPS  Vandal cover

Includes:

 Tier 1 engine
 ROPS Cab

CA300D Cab

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 Large CC Rollers

Basic model Plus model

CC224HF CC224HF Plus

CC384HF CC384HF Plus

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 CC Rollers
2 different models

CC224HF CC384HF

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 CC224HF Rollers
2 different models

Includes:

 Tier 3 engine
 Canopy

CC224HF - Canopy Options:

 Edge Cutter
 Cutter disc
Includes:  Offset drum

 Tier 3 engine
 ROPS Cab

CC224HF - Cabin

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 CC384HF Rollers
2 different models

Includes:

 Tier 3 engine
 Canopy

CC384HF - Canopy Options:

 Edge Cutter
 Cutter disc
Includes:

 Tier 3 engine
 ROPS Cab

CC384HF - Cabin

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Compaction principles
Product specifications – CA 250D
Major Component location – CA 250D
 Hydraulic tank

Instrument
panel Radiator &
Oil cooler
Vibration Engine
motor

Fuel tank

Hydraulic
pumps
Drum drive Steering Rear Axle
motor cylinders & Hitch
Propulsion pump

Forward Control
Valve

Reverse
Propulsion pump

Measuring Point
Propulsion Pressure
Forward
(right side of the
machine)
Propulsion pump

Measuring Point
Propulsion Pressure
Reverse
(left side of the
machine)
Charge
Pressure
Adjusting
Propulsion pump

Control Valve
Propulsion Pump
Propulsion motor
Dual Speed
(Option)
Vibration pump

Low Amplitude High Amplitude

Pressure Pressure

Charge
Pressure
Vibration pump

High

Low
Vibration motor
Steering pump
Steering cylinder

Steering Cylinders
Cooler
Hydraulic Oil Cooler
Hydraulic oil filter

Hydraulic Oil
Filter
Brake system

Brake
Valve

Brakes
Battery switch, relay and fuses
Main Fuses

Hydraulic Oil
Filter

Start
Relay -K1
Fuel Solenoid
–K2
Battery Switch
Electronic control unit - ECU

ECU
Protection
Cover.
Remove To
Access ECU
Control Unit
Instrument panel

3 4 5 1. Working Light
1 2 2. Traffic Light
3. Hazard
4. Horn
5. High / Low Speed,
Traction Control
6. Rotating Beacon
7. Parking Brake
8. Direction Indication
9. Electronic Throttle
Control In Three
Fixed Positions:
6 11 Low / Mid / High
10. Low / High
Amplitude
7 8 10 11. Front / Rear / Both
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Instrument panel

5. 6. 7. 8. 1. Low Fuel Level

1. 2. 3. 4. 9. 10.
2. Water Temperature - Engine
3. Oil Pressure - Engine
Hydraulic Oil 4. Battery / Charing
Filter 5. Fuel Level
6. Hour Meter
7. Hydraulic Temperature
8. Parking Brake Indication
9. Air Filter
10. Glow plug

Only for Tier 3

Lubricant capacity

Sl No Description Quantity
1 Hydraulic oil in system 23 lts
2 Hydraulic oil tank 52 lts
3 Drum Oil 15 lts
4 Rear axle oil differential (Carraro) 14.5 lts
5 Rear axle planetory gear (Carraro) 1.3 lts/side
6 Transmission oil 0.5 lts
7 Engine oil 11 lts
8 Coolant 24 lts
Hydraulic system pressure

Sl No System Pressure
1 Drive system 38.0 MPa
2 Supply system (Charge) 2.0 MPa
3 Vibration system 42.5 MPa
4 Control system (Steering) 17.5 MPa
5 Brake release 1.4 MPa
Maintenance shedule
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
 Refuel

 Test Brakes

After the first 50 hours of operation

 Change engine oil
 Change engine oil filter
 Change fuel filter
 Change hydraulic oil filter
 Change rear axle oil (Both planetory and transmission) Carraro axle
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 that the guiding cylinders are tight
 Check the wheel-nuts are tightened
 Check the wheel-nuts are tightened

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 and bolted joints
 Change the engine oil
 Change the engine oil filter
Every 500 hours of operation (Every 3 months)
 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
 Check engine valve clearances
 Check belt tension for drive system
Every 2000 hours of operation (Every 1 year)
 Change the hydraulic fluid
 Change the oil in the drum
 Lubricate the Forward/Reverse lever
Operation – CA 250D
Before starting & starting
 Do the daily checks
 Switch on Master switch / Battery switch
 Pull out emergency stop switch
 Make sure throttle 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
Stoping & Parking
 Park the machine in safe place
 Switch off all the lights
 Engage parking brake
 Put the trottle in low idle
 Let the engine run for 2-3 minutes
 Switch off the ignition switch
 Switch off the master switch / batterry switch
Hydraulic operation – CA 250D
Interlocks – CA 250D
Engine start
Vibration
Interlocks
Hydraulic circuit – CA 250D
Electrical circuit – CA 250D
ECU programing – CA 250D
 Committed to
sustainable productivity.