19, 9852 1825 01 service manual st14 dd

Atlas Copco ScooptramST14Service manual

PM nr 9852 1825 012007-11

Atlas Copco Rock Drills ABSE-70191 Örebro, Sweden

SAFETY INSTRUCTIONS

Before starting, read all instructions carefully.

Special attention must be paidto information alongsidethis symbol.

Only use genuine Atlas Copco parts.

1250 0071 04

©Copyright 2007, Atlas Copco Rock Drills AB, SwedenAny unauthorised use or copying of the contents or any part thereof is prohibited.

This applies in particular to trademarks, model denominations, part numbers and drawings.

Atlas Copco I

Table of Contents
Chapter 1: SafetyReference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Chapter 2: Preventive MaintenanceService Management . . . . . . . . . . . . . . . . . . . . . . . . 3

Requirements for Use in Demanding Environments. . . . . . . . . . . . . . . . . . . . . . . . . . 3

Special Tools are Required for High Torque Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Before Performing Maintenance . . . . . . . . . . . . 4Electric Welding. . . . . . . . . . . . . . . . . . . . . . . . . 4Hydraulic System Cleanliness . . . . . . . . . . . . . . 4Independent Oil Analysis . . . . . . . . . . . . . . . . . . 5General Safety When You Service the Vehicle . 5

Every 250 Hours Operation . . . . . . . . . . . . . 6Every 500 Hours Operation . . . . . . . . . . . . . . . . 8Atlas Copco Service Kits . . . . . . . . . . . . . . . . . . 9

Every 1000 Hours Operation . . . . . . . . . . . 10Every 2000 Hours Operation . . . . . . . . . . . 10Every 5000 Hours Operation . . . . . . . . . . . 10

New or Reconditioned Components . . . . . . . . 11Under first shift (½ hour) . . . . . . . . . . . . . . . . . 11

Cooling Fan Drive Belt . . . . . . . . . . . . . . . 11After first shift (8 hours) . . . . . . . . . . . . 11

Wheel Bolts and Nuts . . . . . . . . . . . . . . . . . 11Cooling Fan Drive Belt . . . . . . . . . . . . . . . 11

After 250 hours operation . . . . . . . . . . . 11Trunnions and Pins, Boom Z-bar . . . . . . . . 11Trunnions and Pins, Bucket . . . . . . . . . . . . 11Trunnions and Pins, Steering . . . . . . . . . . . 11Trunnions and Pins, Swivel . . . . . . . . . . . . 11Expander Shafts, Loadframe and Boom. . . 11Expander Shafts, Z-bar . . . . . . . . . . . . . . . . 11Bolt Connection, Engine Mount. . . . . . . . . 11Axle Breather . . . . . . . . . . . . . . . . . . . . . . . 12Axle, Bolt Connection . . . . . . . . . . . . . . . . 12Axle, Differential . . . . . . . . . . . . . . . . . . . . 12Axle, Planetary Gears . . . . . . . . . . . . . . . . . 12Driveline, Upbox - Transmission . . . . . . . . 12Driveline, Loadframe - Transmission -

Powerframe . . . . . . . . . . . . . . . . . . . . . . . 12Low Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . 12High Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Stall Speed . . . . . . . . . . . . . . . . . . . . . . . . . 13Transmission, breather . . . . . . . . . . . . . . . . 13Transmission, Bolt Connection . . . . . . . . . 13Upbox, Breather . . . . . . . . . . . . . . . . . . . . . 13

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13AC, Cab Unit . . . . . . . . . . . . . . . . . . . . . . . 14Cab and Cab Door . . . . . . . . . . . . . . . . . . . 14Hyd Oil Tank, Breather . . . . . . . . . . . . . . . 14Hyd Oil Filter Switch . . . . . . . . . . . . . . . . . 14Brake Acc, Precharge Press . . . . . . . . . . . . 14Ride Control Acc, Precharge Press . . . . . . 15Tow Hook Acc, Precharge Press . . . . . . . . 15Brake Release. . . . . . . . . . . . . . . . . . . . . . . 15Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . 15Engine Oil Filter. . . . . . . . . . . . . . . . . . . . . 16Air Filter, Filter Element . . . . . . . . . . . . . . 16Exhaust System . . . . . . . . . . . . . . . . . . . . . 16Save log and parameter files . . . . . . . . . . . 16CAN Modules . . . . . . . . . . . . . . . . . . . . . . 16Clean the machine . . . . . . . . . . . . . . . . . . . 17Wheel Bolts and Nuts. . . . . . . . . . . . . . . . . 17Doors and Hoods . . . . . . . . . . . . . . . . . . . . 17Steering and Bucket Stop . . . . . . . . . . . . . . 17Driveline, Between Upbox and Transmission

Lubrication . . . . . . . . . . . . . . . . . . . . . . . 17Midship Driveline Lubrication. . . . . . . . . . 17Front axle lubrication . . . . . . . . . . . . . . . . . 17Rear axle lubrication . . . . . . . . . . . . . . . . . 18Engine fan hub bearing . . . . . . . . . . . . . . . 18Axle, Bolt Connection . . . . . . . . . . . . . . . . 19Driveline, Upbox - Transmission . . . . . . . . 19Driveline, Loadframe - Transmission -

Powerframe . . . . . . . . . . . . . . . . . . . . . . . 19Bolt connections, Engine Cradle -

Powerframe . . . . . . . . . . . . . . . . . . . . . . . 19Transmission, bolt connection . . . . . . . . . . 19AC, cab unit . . . . . . . . . . . . . . . . . . . . . . . . 19Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . 19Engine Cooling, Hoses and Pipes . . . . . . . 19Engine Coolant, Filter . . . . . . . . . . . . . . . . 20Expander Shafts, Loadframe and Boom . . 20Expander Shafts, Z-bar. . . . . . . . . . . . . . . . 20Load and powerframe . . . . . . . . . . . . . . . . 20Trunnions and Pins, Boom Z-bar . . . . . . . . 20Trunnions and Pins, Bucket . . . . . . . . . . . . 20Trunnions and Pins, Steering . . . . . . . . . . . 21Trunnions and Pins, Swivel . . . . . . . . . . . . 21Transmission, Oil and Filter Change . . . . . 22Upbox, Oil Filter . . . . . . . . . . . . . . . . . . . . 23Hydraulic Oil Change . . . . . . . . . . . . . . . . 23Stop the engine and check the hydraulic oil

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IIST14

level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Hydraulic Oil Filter . . . . . . . . . . . . . . . . . . . 23Hyd Oil Pressure . . . . . . . . . . . . . . . . . . . . . 24Air Filter, Safety Cartridge . . . . . . . . . . . . . 24Air Filter, Indicator . . . . . . . . . . . . . . . . . . . 24Axles, Differentials and Planetaries . . . . . . 25

Differential. . . . . . . . . . . . . . . . . . . . . . . 25Planetary . . . . . . . . . . . . . . . . . . . . . . . . 25

Alternator. . . . . . . . . . . . . . . . . . . . . . . . . . . 25Engine Coolant . . . . . . . . . . . . . . . . . . . . . . 26Hoses and Couplings . . . . . . . . . . . . . . . . . . 27Fuel Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . 27Fuel Injectors. . . . . . . . . . . . . . . . . . . . . . . . 27Fuel Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . 27Air Intake. . . . . . . . . . . . . . . . . . . . . . . . . . . 27Cooling Fan Drive Belt . . . . . . . . . . . . . . . . 27

Chapter 3: Power UnitIntroduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30ECM Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . 30Fuel sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Injectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Calibration codes. . . . . . . . . . . . . . . . . . . . . 31Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 32Fuel Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Engine Oil System . . . . . . . . . . . . . . . . . . . . . . . . . 32Lubricating Oil Pump . . . . . . . . . . . . . . . . . . . . 32Oil Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32Oil Pressure & Temperature sensors. . . . . . . . . 32

Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . 33Coolant Recommendations . . . . . . . . . . . . . . . . 33Coolers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Air Intake System . . . . . . . . . . . . . . . . . . . . . . . . . . 34Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Engine Air Filter Restriction Indicator . . . . . . . 34Turbo Charger . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Exhaust System. . . . . . . . . . . . . . . . . . . . . . . . . . . . 35Silencers / Catalyst . . . . . . . . . . . . . . . . . . . . . . 35Particle filter (Optional) . . . . . . . . . . . . . . . . . . 35Exhaust Heat Shields . . . . . . . . . . . . . . . . . . . . 36

Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . 36ECU. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Temperature & pressure sensors . . . . . . . . . . . . 37

Temperature. . . . . . . . . . . . . . . . . . . . . . . . . 37Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Other . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Upbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Replacing Engine Support Systems . . . . . . . . . . . . 38

R&R Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Removing the Engine Package . . . . . . . . . . 38Replacing the Engine Package . . . . . . . . . . 40

Remove the Engine Cooling Package. . . . . . . . 41Replace the Cooling Package . . . . . . . . . . . . . . 42Remove Hydraulic & Fuel Coolers . . . . . . . . . 42Replace Hydraulic & Fuel Coolers. . . . . . . . . . 42Remove Exhaust System Components . . . . . . . 42Replace the Exhaust System. . . . . . . . . . . . . . . 43Replace Fuel System Components . . . . . . . . . . 43

Remove Fuel Filter . . . . . . . . . . . . . . . . . . . 44Replace Fuel Filters . . . . . . . . . . . . . . . . . . 44Remove Fuel Cooler . . . . . . . . . . . . . . . . . . 44Replace Fuel Cooler . . . . . . . . . . . . . . . . . . 44Remove Fuel Valves, Solenoid and Lines . 44Replace Fuel Valves, Solenoid and Lines. . 44Removing the Fuel Tank. . . . . . . . . . . . . . . 44Replace the Fuel Tank . . . . . . . . . . . . . . . . 45

R&R Electronic Engine Control System . . . . . 45Removing the ECM . . . . . . . . . . . . . . . . . . 45Replacing the ECM. . . . . . . . . . . . . . . . . . . 45

Chapter 4: Power TrainIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . 48Converter. . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48Transmission Controller APC 200 . . . . . . . 49Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Charge Pump. . . . . . . . . . . . . . . . . . . . . 50Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . 50Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 50Solenoids . . . . . . . . . . . . . . . . . . . . . . . . 50

Transmission Oil Temperature . . . . . . . . . . 51Checking Transmission Control Pressure . . 51Flow and Fluids. . . . . . . . . . . . . . . . . . . . . . 51

Driveline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52Universal Joint Bearings . . . . . . . . . . . . . . . 52Driveline Support Bearings. . . . . . . . . . . . . 52

Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . 53

Wheel and Tire Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . 54

Proper Inflation . . . . . . . . . . . . . . . . . . . . . . 54Over-inflation results in: . . . . . . . . . . . . 54Under-inflation results in: . . . . . . . . . . . 54

Atlas Copco III

Rolling Radius and Tire Sizing . . . . . . . . . 54Example: . . . . . . . . . . . . . . . . . . . . . . . . 54Driving Practices: . . . . . . . . . . . . . . . . . 55

Replace Powertrain Components . . . . . . . . . . . . . . 56Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Remove . . . . . . . . . . . . . . . . . . . . . . . . . 56Reinstall . . . . . . . . . . . . . . . . . . . . . . . . 57

Transmission Tube-in-shell Cooler . . . . . . 57Remove . . . . . . . . . . . . . . . . . . . . . . . . . 57Reinstall . . . . . . . . . . . . . . . . . . . . . . . . 58

Transmission Oil Filter. . . . . . . . . . . . . . . . 58Remove . . . . . . . . . . . . . . . . . . . . . . . . . 58Reinstall . . . . . . . . . . . . . . . . . . . . . . . . 58

Transmission Solenoids . . . . . . . . . . . . . . . 58Remove . . . . . . . . . . . . . . . . . . . . . . . . . 58Reinstall . . . . . . . . . . . . . . . . . . . . . . . . 58

Driveline. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58Phasing the Driveline . . . . . . . . . . . . . . . . . 59Installing the Drive Shaft . . . . . . . . . . . . . . 59Yokes and Bearing Mounts . . . . . . . . . . . . 59Installing Driveline Guards . . . . . . . . . . . . 59Upbox to Transmission Driveline . . . . . . . 60


Transmission to Rear Axle Driveline . . . . . 60Remove . . . . . . . . . . . . . . . . . . . . . . . . . 60Reinstall . . . . . . . . . . . . . . . . . . . . . . . . 60

Midship Driveline. . . . . . . . . . . . . . . . . . . . 61Remove . . . . . . . . . . . . . . . . . . . . . . . . . 61Reinstall . . . . . . . . . . . . . . . . . . . . . . . . 61

Midship-to-Transmission Driveline . . . . . . 61Remove . . . . . . . . . . . . . . . . . . . . . . . . . 61Reinstall . . . . . . . . . . . . . . . . . . . . . . . . 61

Midship to Front Axle . . . . . . . . . . . . . . . . 61Remove . . . . . . . . . . . . . . . . . . . . . . . . . 61Reinstall . . . . . . . . . . . . . . . . . . . . . . . . 62

Axles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62Front Axle. . . . . . . . . . . . . . . . . . . . . . . . . . 62


Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . 63Remove . . . . . . . . . . . . . . . . . . . . . . . . . 63Reinstall . . . . . . . . . . . . . . . . . . . . . . . . 63

Liquid Cooled Multi-Disc Brake . . . . . . . . . . . 64Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 64Cleaning and Inspection . . . . . . . . . . . . . . . 66

Inspection . . . . . . . . . . . . . . . . . . . . . . . 66Housing, Covers, etc. . . . . . . . . . . . . . . 66Piston and Housing Seals . . . . . . . . . . . 66

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 67Tire Mounting Procedures . . . . . . . . . . . . . . . . 68

Tire and Wheel Safety . . . . . . . . . . . . . . . . 68Earthmover Rim Locking Wheel Flange With

Heavy Duty Driver . . . . . . . . . . . . . . . . . 68Demounting . . . . . . . . . . . . . . . . . . . . . . . . 68Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . 69Wheel Inspection . . . . . . . . . . . . . . . . . . . . 69Mismatched Rims. . . . . . . . . . . . . . . . . . . . 70Mounting and Inflating Safety . . . . . . . . . . 70Mounting and Inflating Procedures . . . . . . 70Wheel Nut Torque . . . . . . . . . . . . . . . . . . . 72Operating Precautions . . . . . . . . . . . . . . . . 72Recapping. . . . . . . . . . . . . . . . . . . . . . . . . . 72

Chapter 5: Main FrameIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73Load Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Removing the Bucket. . . . . . . . . . . . . . . . . . . . 73Replacing the Bucket . . . . . . . . . . . . . . . . . 74Removing the Z-Bar. . . . . . . . . . . . . . . . . . 74Reinstalling the Z-Bar . . . . . . . . . . . . . . . . 75Removing the Boom . . . . . . . . . . . . . . . . . 75Replacing the boom . . . . . . . . . . . . . . . . . . 76

Power Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77Removing and Replacing Hoods . . . . . . . . . . . 77

Hood Removal . . . . . . . . . . . . . . . . . . . 77Hood Replacement . . . . . . . . . . . . . . . . . . . 77

Separating the Load & Power Frames . . . . . . . . . . 78Separation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78Reconnection . . . . . . . . . . . . . . . . . . . . . . . . . . 79Articulation Pins . . . . . . . . . . . . . . . . . . . . . . . 79

Pin Removal . . . . . . . . . . . . . . . . . . . . . . . . 80Pin Installation . . . . . . . . . . . . . . . . . . . . . . 80

Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82Steering Stops . . . . . . . . . . . . . . . . . . . . . . . . . 82Oscillating Axle Stops . . . . . . . . . . . . . . . . . . . 83Bucket Rollback Stop . . . . . . . . . . . . . . . . . . . 83Bucket Rollover (Dump) Stops . . . . . . . . . . . . 83Bucket Stops (Pads) . . . . . . . . . . . . . . . . . . . . . 83

Chapter 6: Hydraulic SystemsIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85Expression . . . . . . . . . . . . . . . . . . . . . . 85

Steering, Hoist, Dump & EOD . . . . . . . . . . . . 86Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . 86Cooling & Filtration System . . . . . . . . . . . . . . 86

System components . . . . . . . . . . . . . . . . . . . . . . . . 87


IVST14

Variable Piston Pumps . . . . . . . . . . . . . . . . . . . 87Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Steering Cylinders . . . . . . . . . . . . . . . . . . . . 87Dump Cylinder . . . . . . . . . . . . . . . . . . . . . . 87Hoist Cylinders . . . . . . . . . . . . . . . . . . . . . . 87

Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . 88Tank and Filters . . . . . . . . . . . . . . . . . . . . . . . . 88

Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . 88Breather and Filter. . . . . . . . . . . . . . . . . . . . 88

Tank Air Breather . . . . . . . . . . . . . . . . . 88Hydraulic Oil Filter . . . . . . . . . . . . . . . . 88

Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . 89Main Control Valve (VMC) . . . . . . . . . . . . 89Auxiliary Valve (AUV). . . . . . . . . . . . . . . . 89

Steering, Hoist, Dump & EOD system . . . . . . . . . . 90Dump & Hoist Functions . . . . . . . . . . . . . . . . . 91

Boom Up . . . . . . . . . . . . . . . . . . . . . . . . . . . 91Boom Down . . . . . . . . . . . . . . . . . . . . . . . . 91Bucket float . . . . . . . . . . . . . . . . . . . . . . . . . 91Ride Control (option) . . . . . . . . . . . . . . . . . 91

Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91SAHR Brake System . . . . . . . . . . . . . . . . . . . . 91Brake System Components . . . . . . . . . . . . . . . . 92Brake System Operation . . . . . . . . . . . . . . . . . . 92

Pump (VPLS2) . . . . . . . . . . . . . . . . . . . . . . 92Accumulator (ACC1) . . . . . . . . . . . . . . . . . 92Auxiliary Valve Block (AUV) . . . . . . . . . . 92

Brake Application . . . . . . . . . . . . . . . . . . . . . . . 92Brake Operation . . . . . . . . . . . . . . . . . . . . . 92Service Brake Operation . . . . . . . . . . . . . . . 92Park Brake Operation . . . . . . . . . . . . . . . . . 93Brake Cooling . . . . . . . . . . . . . . . . . . . . . . . 93

Brake Release for Towing. . . . . . . . . . . . . . . . . 93Hand Operated Hydraulic Pump . . . . . . . . . 93

Tow Hook with Brake Release (Option). . . . . . 94Tow Hook System Components . . . . . . . . . 94

Brake Release Manifold . . . . . . . . . . . . 94Tow Hook Accumulator . . . . . . . . . . . . 94Tow Hook Cylinder . . . . . . . . . . . . . . . . 95Air bleed, optional tow hook system. . . 95

Deaeration of brakes . . . . . . . . . . . . . . . . . . . . . 95Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

System principle . . . . . . . . . . . . . . . . . . . . . . . . 96Filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96Hydraulic Oil Cooler (CO2) . . . . . . . . . . . . . . . 96Cooling pumps (FCP) . . . . . . . . . . . . . . . . . . . . 96Brake Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . 96

General Maintenance Procedures . . . . . . . . . . . . . . 97Before Starting . . . . . . . . . . . . . . . . . . . . . . . . . 97

Check Cleanliness . . . . . . . . . . . . . . . . . . . . 97Relieving Hydraulic Pressure . . . . . . . . . . . . . . 97Before Removing Any Hose. . . . . . . . . . . . . . . 97Pressure Setting Checks and Adjustments . . . . 98

Setting Dump and Hoist and Steering Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Setting Brake Pressure . . . . . . . . . . . . . . . . 98Hydraulic System Startup . . . . . . . . . . . . . . . . . 99Preparation for Trial Run . . . . . . . . . . . . . . . . . 99Trial Run. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99Removal and Replacement Procedures . . . . . 101

Steering Cylinder Removal and Replacement. . . . . . . . . . . . . . . . . . . . . . 101

Steering Cylinder Removal . . . . . . . . . 101Steering Cylinder Installation . . . . . . . 101

Dump Cylinder Removal and Replacement. . . . . . . . . . . . . . . . . . . . . . 101

Dump Cylinder Installation. . . . . . . . . 102Hoist Cylinder Removal and Replacement102

Hoist Cylinder Removal . . . . . . . . . . . 102Hoist Cylinder Installation . . . . . . . . . 103

Hydraulic Pump Removal and Replacement. . . . . . . . . . . . . . . . . . . . . . 103

Pump Installation . . . . . . . . . . . . . . . . 103Hydraulic Valve Removal and Replacement .

103Valve Removal . . . . . . . . . . . . . . . . . . 103Valve Replacement . . . . . . . . . . . . . . . 104Valve Cartridge Removal & Service. . 104

Hydraulic Manifolds . . . . . . . . . . . . . . . . . 104Manifold Replacement . . . . . . . . . . . . 104

Chapter 7: Electrical SystemsSystem Design . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . 105Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . 105Power Circuits . . . . . . . . . . . . . . . . . . . . . . . . 105

Non-keyed Power . . . . . . . . . . . . . . . . . . . 105Keyed Power . . . . . . . . . . . . . . . . . . . . . . . 105Protected Power . . . . . . . . . . . . . . . . . . . . 105Power Grid . . . . . . . . . . . . . . . . . . . . . . . . 105Grounding . . . . . . . . . . . . . . . . . . . . . . . . . 106

System Components . . . . . . . . . . . . . . . . . . . . . . . 107Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107RCS Components . . . . . . . . . . . . . . . . . . . . . . 107Switches and Circuit Breakers . . . . . . . . . . . . 107

ISO Switch (S300) . . . . . . . . . . . . . . . . . . 107

Atlas Copco V

RCS On Switch (S101) & Off Switch (S102) . . . . . . . . . . . . . . . . . 107

Circuit Breakers . . . . . . . . . . . . . . . . . . . . 107Park Brake Switch (S138) . . . . . . . . . . . . 107Main Brake Switch (B422). . . . . . . . . . . . 108Air Filter Switch (B360). . . . . . . . . . . . . . 108Transmission Filter Switch (B435) . . . . . 108Hydraulic Filter Switch (B139) . . . . . . . . 108Bucket Position Sensor (B405) . . . . . . . . 108Boom Position Sensor (B406) . . . . . . . . . 108

System functions . . . . . . . . . . . . . . . . . . . . . . . . . 109Power Up Vehicle . . . . . . . . . . . . . . . . . . . . . 109Engine On. . . . . . . . . . . . . . . . . . . . . . . . . . . . 109Engine Off . . . . . . . . . . . . . . . . . . . . . . . . . . . 109Shut Down Vehicle . . . . . . . . . . . . . . . . . . . . 109Vehicle Lights . . . . . . . . . . . . . . . . . . . . . . . . 109

Cabin Work Lights . . . . . . . . . . . . . . . . . . 109Rear Lights . . . . . . . . . . . . . . . . . . . . . . . . 109Boom Lights . . . . . . . . . . . . . . . . . . . . . . . 110Load Lights. . . . . . . . . . . . . . . . . . . . . . . . 110Drift Light (H234) . . . . . . . . . . . . . . . . . . 110Dome Light. . . . . . . . . . . . . . . . . . . . . . . . 110Status Beacon (H390). . . . . . . . . . . . . . . . 110

Backup Alarm . . . . . . . . . . . . . . . . . . . . . . . . 111Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111Diagnostic Outlets . . . . . . . . . . . . . . . . . . . . . 111CD Player . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111Socket Outlet 12V . . . . . . . . . . . . . . . . . . . . . 111Wipers & Washers . . . . . . . . . . . . . . . . . . . . . 111Air Condition . . . . . . . . . . . . . . . . . . . . . . . . . 112Door Interlock . . . . . . . . . . . . . . . . . . . . . . . . 112Lincoln Lube (X5) . . . . . . . . . . . . . . . . . . . . . 112Hydraulic Oil Fill Motor . . . . . . . . . . . . . . . . 112Fuel Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

General Maintenance Diagnosis & Calibration . . 113Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Battery Booster Cables . . . . . . . . . . . . . . . 113Storage of Lead Acid Batteries. . . . . . . . . 113

Removing and Replacing Electrical Components 114Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

Battery Removal . . . . . . . . . . . . . . . . . . . . 114Battery Replacement . . . . . . . . . . . . . . . . 114

Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115Alternator Removal . . . . . . . . . . . . . . . . . 115Alternator Replacement . . . . . . . . . . . . . . 115

Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115Starter Removal . . . . . . . . . . . . . . . . . . . . 115Starter Replacement . . . . . . . . . . . . . . . . . 115

Engine Sensors . . . . . . . . . . . . . . . . . . . . . . . . 115

Sensor Removal . . . . . . . . . . . . . . . . . . . . 115Sensor Replacement . . . . . . . . . . . . . . . . . 115

Engine Diagnostic Interfaces . . . . . . . . . . . . . 116

Chapter 8: Control SystemIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

D501 Display Module . . . . . . . . . . . . . . . . . . 117D540 Decoder Module. . . . . . . . . . . . . . . . . . 117D510, D511 & D512

I/O modules. . . . . . . . . . . . . . . . . . . . . . . . . 117D602 TCU . . . . . . . . . . . . . . . . . . . . . . . . . . . 117D601 ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . 117D520 Remote control machine unit (option) . 117Module placement . . . . . . . . . . . . . . . . . . . . . 118

Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119Access levels . . . . . . . . . . . . . . . . . . . . . . . . . 119Logging in . . . . . . . . . . . . . . . . . . . . . . . . . . . 119Menu structure . . . . . . . . . . . . . . . . . . . . . . . . 119Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

Numerical values . . . . . . . . . . . . . . . . . . . 119M1.7 RCS shutdown . . . . . . . . . . . . . . . . . . . 120M2.2 Load weigh (opt.) . . . . . . . . . . . . . . . . . 120

M2.2.1 Settings . . . . . . . . . . . . . . . . . . . . 120M2.3 Ride Control (opt.) . . . . . . . . . . . . . . . . 121Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Actuations & Sensors . . . . . . . . . . . . . . . . 121M5.4 Administration . . . . . . . . . . . . . . . . . . . 122

Saving parameters . . . . . . . . . . . . . . . . . . 122Loading parameters . . . . . . . . . . . . . . . . . 122

M5.5 Passwords . . . . . . . . . . . . . . . . . . . . . . . 123M6 Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

M6.1 Save . . . . . . . . . . . . . . . . . . . . . . . . 123Logs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

Statistics log . . . . . . . . . . . . . . . . . . . . 123Production log . . . . . . . . . . . . . . . . . . 123Maintenance log . . . . . . . . . . . . . . . . . 123Assert log . . . . . . . . . . . . . . . . . . . . . . 124Event log. . . . . . . . . . . . . . . . . . . . . . . 124DTC log . . . . . . . . . . . . . . . . . . . . . . . 124

Software update . . . . . . . . . . . . . . . . . . . . . . . . . . 125Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . 125Update . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125After update . . . . . . . . . . . . . . . . . . . . . . . . . . 125

Chapter 9: Vehicle SpecificationsPerformance Related Data . . . . . . . . . . . . . . . 127

Vehicle Weight. . . . . . . . . . . . . . . . . . 127Scoop Capacity. . . . . . . . . . . . . . . . . . 127


VIST14

Operating Times . . . . . . . . . . . . . . . . . 127Speed (level ground) . . . . . . . . . . . . . . 127

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127Upbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127Transmission . . . . . . . . . . . . . . . . . . . . . . . 127Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

Dana 53R . . . . . . . . . . . . . . . . . . . . . . . 127Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . 128

Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128Test conditions. . . . . . . . . . . . . . . . . . . 128

Noise Level . . . . . . . . . . . . . . . . . . . . . . . . . . 128Electrical System. . . . . . . . . . . . . . . . . . . . . . . 128

Description. . . . . . . . . . . . . . . . . . . . . . 128Vehicle running lights . . . . . . . . . . . . . 128Batteries . . . . . . . . . . . . . . . . . . . . . . . . 128

Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128Description. . . . . . . . . . . . . . . . . . . . . . 128

Turning radius data . . . . . . . . . . . . . . . . . . . . . 128Description. . . . . . . . . . . . . . . . . . . . . . 128

Bucket data . . . . . . . . . . . . . . . . . . . . . . . . . . . 128Description. . . . . . . . . . . . . . . . . . . . . . 128

Accumulator precharge pressure (N2) . . . . . . 128Fluids and Lubrication . . . . . . . . . . . . . . . . . . 129

Fluid Capacities. . . . . . . . . . . . . . . . . . . . . 129Engine . . . . . . . . . . . . . . . . . . . . . . . . . 129Fuel Tank. . . . . . . . . . . . . . . . . . . . . . . 129Cooling System . . . . . . . . . . . . . . . . . . 129Transverter. . . . . . . . . . . . . . . . . . . . . . 129Up Box. . . . . . . . . . . . . . . . . . . . . . . . . 129Axles . . . . . . . . . . . . . . . . . . . . . . . . . . 129Hydraulic Tank . . . . . . . . . . . . . . . . . . 129

Diesel Fuel Quality and Selection . . . . . . . 129Fuel Oil Selection Chart . . . . . . . . . . . . . . 130

General Fuel Classification . . . . . . . . . 130Engine Coolant Specifications . . . . . . . . . 130Engine Coolant . . . . . . . . . . . . . . . . . . . . . 130Lubricating Oil Specifications. . . . . . . . . . 130Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130Air Condition Refrigerant . . . . . . . . . . . . . 131

Torque Specifications . . . . . . . . . . . . . . . . . . . 132Use the Correct Tool for the Job . . . . . . . . 132Torque Values by Bolt Size & Thread . . . 132

Scope . . . . . . . . . . . . . . . . . . . . . . . . . . 132Definitions . . . . . . . . . . . . . . . . . . . . . . 132High Strength. . . . . . . . . . . . . . . . . . . . 132Tolerances . . . . . . . . . . . . . . . . . . . . . . 132Unified Coarse Thread (UNC) . . . . . . 132

Unified Coarse Thread (UNC) . . . . . . 132Unified Fine Thread (UNF) . . . . . . . . 133Unified Fine Thread (UNF) . . . . . . . . 133Metric Coarse Thread . . . . . . . . . . . . . 133Metric Coarse Thread . . . . . . . . . . . . . 133

Atlas Copco 1

Chapter 1: Safety
ReferenceN o t e Always read the information under Safety
before starting to use the Scooptram or starting maintenance work.

1250 0099 89

Chapter 1: SafetyService Manual

2ST14

Atlas Copco 3

Chapter 2: Preventive Maintenance 1 2 3 4

The main filter bay contains: 1. Engine Oil Fill2. Fire Suppression Manual Actuator3. Fuel filter4. Oil filter upbox5. Fuel Fill

6. Battery switch7. Engine Oil Level Dipstick

5 6 7

Service ManagementSafe and efficient operation of the vehicle depends on the proper maintenance of the engine, drivetrain, chassis, and related systems. Inspect the vehicle at the recommended intervals to ensure that all components are performing as expected. Special care must be taken when making repairs and replacing components. Contact Atlas Copco for replacement parts and service kits designed specifically for your vehicle.

Requirements for Use in Demanding EnvironmentsThe ST14 has been designed for rugged use in a demanding environment. Reliability can be increased by maintaining factory specified service intervals, and by always tightening bolts, during repair and replacement of components, to the proper torque values. Use only new fluids and filters, and make sure that all mating surfaces are clean and in sound condition.

Clean the machine before each shift, remove rocks from the loadframe and prevent dirt from get into the hydraulic system by checking valves and other hydraulic components. Dirt in the hydraulic system will cause damage.

Chapter 2: Preventive MaintenanceService Manual

4ST14

All bolts, nuts, screws, and other fasteners must be in place and properly secured. The torque of major components should be checked periodically as specified in the service schedules.

Special Tools are Required for High Torque SettingsAlways use the correct tool for the job. Mechanical torque wrenches are based upon leverage and have limitations. Hydraulic torque tools are more efficient in tight quarters, and can apply the high torque values that are required, quickly and safely. Contact your local Atlas Copco representative for further information.

Before Performing Maintenance Before performing any maintenance on the machine you must first read and understand the safety manual.

Electric WeldingImportant Use caution in electric welding.

Serious damage to the engine control computer and the battery isolator can occur.

Perform the following before any electric welding:

STEP 1 Open the battery compartment.

STEP 2 Turn the battery switch to the OFF position.

STEP 3 Connect the welding machine ground clamp on the vehicle as closely as possible to the point at which the welding is to be done.

Hydraulic System Cleanliness Important Foreign matter of any kind will

cause problems in hydraulic systems, making absolute cleanliness essential.

The six primary rules for hydraulic systems cleanliness.

• Clean the area where the work shall be carried out if there is dirt or other waste there. Wipe clean all hose and pipe connections before you open any connections.

• Remove all loose paint before opening any con-nections.

• Plug or cap any hose, pipe, valve, or cylinder immediately after opening a connection.

• Flush any unsealed hose or pipe with hydraulic oil before installing it in the system.

• Install all hoses, pipes, valves, or cylinders imme-diately after unplugging or uncapping connec-tions.

• Always fill the hydraulic tank through the return filter with the electric refill pump.

Atlas Copco 5

Maintenance Intervals
Independent Oil AnalysisAtlas Copco recommends the establishment of an oil analysis programme. Regular oil analysis can indicate problems and the approach of maximum wear limits, before they are discovered by system performance checks.
The objective of a preventative maintenance program is diagnosis and repair before failure. Good sampling techniques and independent laboratory analysis are considered primary elements of a good program.

N o t e Oil analysis is not to be used to determine if oil can be re-used past recommended service life. Change the oil during recommended service intervals even when oil analysis shows oil to be up to standards. A comprehensive analysis program can aid in establishing optimum service intervals.

General Safety When You Service the VehicleRead the safety and information decals on the vehicle. Also read and understand this operator’s manual. You must understand the operation of this vehicle before performing maintenance.

Do not attempt repairs that you do not understand. See the service manual for this vehicle or see your Atlas Copco sales company or dealer for more information.

Before performing any maintenance on the Scooptram, review the following safety precautions. They're included for your protection.

STEP 1 Empty the bucket completely and lower it to the ground.

STEP 2 Shut down the engine.

STEP 3 Apply the park brake.

STEP 4 Block the wheels

STEP 5 Turn the Ignition Switch and Master Switch to OFF position.

STEP 6 If you must service the vehicle in the articulation area with the engine running, always place the Articulation Lock in the LOCKED position.

Never Work Under An Unsupported Boom, See safety chapter for further instructions.

STEP 7 Before you service the vehicle, always put a DO NOT OPERATE tag in the cab on the steering wheel or lever.


6ST14

Every 250 Hours Operation

Item Task Special Instructions CheckAxle, breather Inspect and check for

damageAxle, bolt connection Check for damage Check all the bolts on front and rear axlesAxle, differential Check oil level Check oil level when machine is standing on flat

surface and at normal operating temperature.Oil capacity on front or rear axle differential is 50.2 liters.

Axle, planetary gears Check oil level Check oil level when machine is standing on flat surface and at normal operating temperature. Oil capacity is 9.5 liters each.

Driveline, upbox - gearbox Check for loose and missing bolts

Driveline, loadframe - gearbox - powerframe

Check for loose and missing bolts

Low idle Check idle Idle shall be 800±25 rpmHigh idle Check idle Idle shall be 2160±50 rpmStall idle Check idle Idle shall be 1830±50 rpmTransmission, breather Inspect and check for

damageTransmission, bolt connection

Check bolts connection and rubber damper

Upbox, breather Inspect and check for damage

Battery Check battery connections and that they are mounted correctly

AC, cab unit Control and change filterCab and cab door Check bolt torques and

lubricate hingesTorque should be M22, Grade 10.9 and 622Nm.

Hyd oil tank, breather Inspect and check for damage

Hyd oil filter switch Check alarm function Perform a alarm test. See “Hyd Oil Filter Switch” on page 14.

Brake acc, precharge press

Check precharge press Pressure should be 83±2 bar

Ride control acc, precharge press


Tow hook acc, precharge press


Brake release Perform a brake release test

Pressure should be over 83 bar

Engine oil Change the engine oil Oil capacity is 36 litersEngine oil filter Change the engine oil filter Always replace the filter when changing oilAir filter, filter element Change the filter Change the filter in the element. See “Air Filter,

Filter Element” on page 16.Exhaust system Inspect mounting and

check for leakage Save log and parameter files

Save and archive log and data files

CAN modules Check for error codesClean the machine Clean entire unit Remove rocks from the loadframeWheel bolts and nuts Check bolt and nuts

torquesTorque should be UNC ¾, Grade 8 and 383 Nm on bolts and nuts

Doors and hoods Lubricate, check function and ware

Steering and bucket stop Check functionDriveline, between upbox and transmission lubrication

lubricate

Midship driveline lubrication

lubricate

Atlas Copco 7

Front axle lubrication lubricateRear axle lubrication lubricateEngine fan hub bearing lubricate


8ST14


Item Task Special Instructions CheckAxel, bolt connection Check bolt torques Front: UNC 1½, Grade 8, moment 3220 Nm

Rear: M24, Grade 10.9, moment 790 NmDriveline, upbox - gearbox Check bolt torques Torque should be M12 Grade 10.9 and 88 - 102 NmDriveline, loadframe - gearbox - powerframe

Check bolt torques Torque should be UNC ½, Grade 8 and 149-163 Nm.

Bolt connections, engine cradle - powerframe

Check bolt torques Torque should be M24, Grade 10.9 and 790 Nm.

Transmission, bolt connection

Check bolt torques Torque should be UNC 7/8, Grade 8 and 620 Nm

AC, cab unit Change filterFuel filter Check filter and change it if

necessarryCheck fuel level in the filter and change filter if necessary.

Engine cooling, hoses and pipes

Check hoses and couplings for wear and damages

Engine coolant, filter Change filterBolt connection, engine mount

Check bolt torques Front: UNC 5/8, Grade 8 and 215 Nm Rear: M20, Grade 10.9 and 455 Nm

Expander shafts, loadframe and boom

Check bolt torques Torque should be M30, Grade 10.9 and 1570 Nm

Expander shafts, z-bar Check bolt torques Torque should be M30, Grade 10.9 and 1570 NmLoad and power frame Check machine frame for

damage Trunnions and pins, boom z-bar


Trunnions and pins, bucket Check bolt torques Torque should be M30, Grade 10.9 and 1569 NmTrunnions and pins, steering


Trunnions, swivel Check bolt torques Torque should be M24, Grade 10.9 and 790 Nm

Atlas Copco 9

Atlas Copco Service KitsProtect your vehicle and maintain your warranty with Atlas Copco Service Kits. Reduce time spent with inventory and shipping.

The 1000 hour Consumable Kit includes all of the service items to support one ST14 through the first 1000 hours.

The 1000 hour Maintenance Kit includes only items for routine maintenance at the 1000 hour interval. Kits are also available for repairing specific systems.

• Service Kits

• Bearing Kits

• Gasket and Seal Kits

• Repair Kits

• Accessory kits

Contact your local Atlas Copco representative for further information.


10ST14




Item Task Special Instructions CheckTransmission, oil and filter change

Change oil and filter. Clean the strainer

Check oil level when machine is standing on flat surface and at normal operating temperature.Always replace the filter when changing oil. Oil capacity is 65 liters.

Upbox, oil filter Change filter Always replace the filter when changing oil.Hyd oil change Change oil Always use the electric refill pump when filling up.

Oil capacity is 218 liters.Hyd oil, filter Change filter Always replace the filter when changing oil.Hyd oil pressure Check system pressure Perform a hyd oil pressure test. See “Hyd Oil

Pressure” on page 24.Air filter, safety cartridge Change the filter Change the filter in the element. See “Air Filter,

Safety Cartridge” on page 24Air filter, indicator Test indicator function

Item Task Special Instructions CheckAxel, differential Drain and change oil Check oil level when machine is standing on flat

surface. Axel, planetary gear Drain and change oil Check oil level when machine is standing on flat

surface.Alternator Test function Voltage should be between 24-27VEngine coolant Clean and refill coolant

Item Task Special Instructions CheckHoses and couplings Replace all hosesFuel tank Drain and cleanFuel injectors Check function and change

if necessaryFuel hoses Replace all hosesAir intake Replace hoseCooling fan drive belt Change drive belt

Atlas Copco 11

N e w C o m p o n e n t s

New or Reconditioned ComponentsUnder f irst shift (½ hour)

Cooling Fan Drive BeltAfter replacing a worn belt, check the belt tension after 1/2 hour of operation and again after 8 hours of operation.

Belt tension should be such that a firm push with thumb, at a point midway between the two pulleys, will depress the belt 13-19mm (1/2”- 3/4”)

After f irst shif t (8 hours)

Wheel Bolts and NutsCheck torque. It should be UNC ¾, Grade 8 and 383 Nm on bolts and nuts

Cooling Fan Drive BeltAfter replacing a worn belt, check the belt tension after 1/2 hour of operation and again after 8 hours of operation.


After 250 hours operation

Trunnions and Pins, Boom Z-barCheck torque. It should be Grade 10.9 and 1569 Nm

Trunnions and Pins, BucketCheck torque. It should be M30, Grade 10.9 and 1569 Nm

Trunnions and Pins, SteeringCheck torque. It should be, Grade 10.9 and 1569 Nm

Trunnions and Pins, SwivelCheck torque. It should be M24, Grade 10.9 and 790 Nm

Expander Shafts, Loadframe and BoomCheck torque. It should be M30, Grade 10.9 and 1570 Nm

Expander Shafts, Z-barCheck torque. It should be M30, Grade 10.9 and 1570 Nm

Bolt Connection, Engine MountCheck torque. It should be; Front: UNC 5/8, Grade 8 and 215 Nm Rear: M20, Grade 10.9 and 455 Nm


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Maintenance Procedures by IntervalE v e r y 2 5 0 H o u r s• Repeat Daily

Axle BreatherCheck that the axle breather is not damaged or blocked.

Breather on the rear axle is located on left hand side on top of the axle mounted on the powerframe, and front axle is located on right hand side in the middle of the powerframe under dump cylinder.

Axle, Bolt Connection

Check bolts

Check all bolts on front and rear axle that hold the axle to the frame for damage. Change if necessary.

Axle, Differential

Differential plug

STEP 1 Park the vehicle on a level surface, apply the parking brake, and stop the engine.

STEP 2 Let vehicle to stand 5 minutes to allow oil to settle to normal level.

STEP 3 Remove the oil level plug. The oil level must be up to the bottom of the plug hole. Add oil as required.

STEP 4 Install the oil level plug and check the other differential.

Axle, Planetary Gears

1. Drain plug2. Arrow

STEP 1 With the vehicle on a level surface, move the vehicle forward or back until the oil level/drain plug is horizontal with the wheel centerline and the direction arrow is pointing up or down.

STEP 2 Apply the parking brake.

STEP 3 Remove the oil level/drain plug. The oil level must be up to the bottom of the plug hole. Add oil as required.

STEP 4 Install the oil level/drain plug and check the other planetaries.

Driveline, Upbox - TransmissionMake sure no bolt is missing or loose. Make sure there is not any loose play in the drivelines and bearings

Driveline, Loadframe - Transmission - Powerframe Make sure no bolt is missing or loose. Make sure there is not any loose play in the drivelines and bearings.

Low IdleSTEP 1 Start the engine and make sure it is warm,

approximately 80° C.

STEP 2 Engine speed, temperature and oil pressure is shown in "F2" menu on display.

STEP 3 Let the engine be on low idle (no load) and write down the rpm.

STEP 4 Idle should be around 800±25 rpm.

Important If the rpm is to low it could damage the engine and even the upbox, transmission and driveline.

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2

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High IdleSTEP 1 Start the engine and make sure it is warm,

approximately 80° C.

STEP 2 Engine speed, temperature and oil pressure is shown in "F2" menu on display.

STEP 3 Push down the throttle all the way and wait until the engine has full rpm and write down the rpm.

STEP 4 High idle should be around 2160±50 rpm with no load

Stall Speed

Menu Operator, Converter Stall

STEP 1 Go to menu "Operator/Converter Stall" and make sure that stall speed rpm is set to 2200 rpm at engine rpm.

STEP 2 Adjust if necessary. Mark Converter stall check box and press Enter.

STEP 3 Second gear will automatically be chosen and the park brake will activate. Press and hold down the throttle pedal during the test.

STEP 4 When engine and transmission is at normal operating temperature approximately 80° C, read and write down rpm.

STEP 5 Stall speed should be around 1830±50 rpm.

STEP 6 Release the throttle pedal and let the engine run at low idle for a while.

STEP 7 Un-mark "converter stall" check box or release and apply the park brake to get out of Converter stall.

N o t e You may need do this test more then one time, because the engine and transmission need to be at correct temperature. It takes longer time for the engine than the transmission to reach correct temperature.

Transmission, breather

Transmission breather

Check that the breather is working correctly and are not damaged.

Transmission, Bolt ConnectionCheck bolt connections and rubber damper that holds the transmission into the powerframe.

Upbox, BreatherCheck that the breather is working correctly and are not damaged.

BatteryCheck that the batteries are mounted correctly and the battery connections are tightened and have not started to corrode.

Also check that all cables to the alternator, starter and all the other electrical components is not damaged or started to wear out.

N o t e Dry batteries is used as standard on the machine and under normal conditions their is no maintenance. But you should compensating-charge when the machine has been standing with the electrical on for a longer time without engine running


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AC, Cab Unit

AC filter in the cab unit

Replace the AC filter.

Cab and Cab Door• Check bolts and vibration damper in the cab for

damage.

• Check torques on the bolts in the cab, they should be M22, Grade 10.9 and 622Nm.

• Lubricate all hinges.

Hyd Oil Tank, Breather

Hydraulic oil tank breather

Check that the breather is working correctly and are not damaged.

When hydraulic oil reaches normal operating temperature shall the hydraulic tank be pressurized, control that by pressing down the pin on the breather.

Hyd Oil Filter Switch

Check that the cable is undamaged by short-circuit the contacts on the cables.

Then check for alarm on the display, then you know if the cable and warning function works or not.

Brake Acc, Precharge Press

Brake accumulator

STEP 1 The pressure on the accumulator hydraulic side must be drained before checking the precharge pressure.

STEP 2 Remove the protection over the valve and then remove the hood.

STEP 3 Connect a manometer to the valve.

STEP 4 Open the valve on the accumulator through loose the valve nut.

STEP 5 Check the pressure on the manometer, it should be 83±2 bar.

STEP 6 Close the valve again with the valve nut and remove the manometer.

STEP 7 Put back the hood and the valve protection.

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Ride Control Acc, Precharge Press

Ride control accumulator

Perform a precharge pressure test. See “Brake Acc, Precharge Press” on page 14

The pressure should be 100±5 bar.

Tow Hook Acc, Precharge Press

Tow hook accumulator

Perform a precharge pressure test. See “Brake Acc, Precharge Press” on page 14

The pressure should be 76±2 bar.

Brake Release

Brake release hole

To tow a machine that has not the ability to release the brakes by the control system, the brakes have to be manually released.

N o t e First, there has to be pressure in the brake accumulator (ACC1). If there is not enough pressure, it has to be pumped up by using the hand pump (HPB).

STEP 1 Lower the boom to the ground.

STEP 2 Stop the engine.

STEP 3 Block all wheels.

Manometer connection point on the junction block, BRJ3.

STEP 4 Connect a manometer to the BRJ3 valve.

STEP 5 Remove the screw that protect the hole in the panel.

STEP 6 Push in a screwdriver in the release hole and check that the pressure is over 83 bar on the manometer. The brakes are released as long as the button is pressed.

STEP 7 Then remove the screwdriver and check the that the pressure goes down to zero.

STEP 8 Then repeat this test a couple of times to control that the brakes working properly.

Engine Oil

1. Engine oil fill2. Engine oil level dipstick

Check oil level when machine is standing on flat surface.Switch off the engine and allow the oil to drain down from the engine’s internal parts for some minutes. This eliminates the risk of overfilling.

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Push the dipstick completely down and pull out. The oil level must be between the ADD and FULL marks on the dipstick.

Fill up the oil engine to FULL-mark.

WARNING Engine oil can reach temperatures exceeding 104°C (220°F). Do not change oil immediately following engine shutdown.

Engine Oil Filter

Engine filter, always replace the filter when changing oil.

STEP 1 Remove the oil filters by turning counterclockwise using a strap wrench or filter removal tool.

STEP 2 Discard the filters.

STEP 3 Clean the filter sealing surface with a clean cloth.

STEP 4 Apply clean oil to the gasket of each new filter.

STEP 5 Fill each new filter with new 15W-40 engine oil and install each filter.

STEP 6 Turn each filter clockwise until the gasket makes contact with the filter base. Continue to turn the filter 2/3 turn by hand.

STEP 7 Fill the crankcase through the filler tube to the top dipstick mark.

STEP 8 Start the engine and run at idle speed and check the engine oil pressure. Then, check for oil leaks around the filter.

STEP 9 Stop the engine and check the engine oil level after a few minutes.

Air Filter, Filter Element

Filter element

STEP 1 Remove the air filter cover.

STEP 2 Remove the outer filter.

STEP 3 Inspect filter gasket surface and replace if needed.

STEP 4 Install a new primary element.

Exhaust System

Exhaust system

Check exhaust system for damage and leakage. Check bolt connection and check that clamps are not loose.

Save log and parameter filesSave log and parameter files according to local rules. Send these files to your local Customer Center or archive them on a safe place.

For instructions on how to save log and parameter files. See “M5.4 Administration” on page 122.

CAN ModulesSTEP 1 Go to menu "Diagnostics/Modules".

STEP 2 Check that all modules have green color, which indicates that it is no faults.

STEP 3 If some module are colored in red, mark it and press enter for more information.

Module TCU D602 shows diagnostics and comments about the transmission.

Module ECU D601 shows diagnostics and comments about errors on the engine.

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2 5 0 H o u r s

Module JoyR D561 shows information about right lever function.

Module JoyL D560 shows information about left lever function.

Module ENC D576 shows steering angle.

About other modules are only status showed.

For more information. See “Diagnostics” on page 121.

Clean the machineClean the hole machine with high pressure washer or if it is possible with steam washer.

Wheel Bolts and Nuts

Wheel nuts

Check torque on the wheel bolts and nuts. It should be UNC ¾, Grade 8 and 383 Nm on bolts and nuts.

Doors and Hoods

Hinges on the hydraulic door

Lubricate all hinges on doors and hoods. Check function and locking device.

Steering and Bucket StopCheck function and that the speed is slowing down just before it reach the end position. Check that steering goes soft against the stop.

Driveline, Between Upbox and Transmission Lubrication

Lubrication point

Lubricate this point.

Midship Driveline Lubrication

Lubrication point

Lubricate this point.

Front axle lubrication

Lubricate the nipples on the front axle yoke.


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2 5 0 H o u r s

Rear axle lubrication

Lubricate the nipples on the rear axle yoke.

Engine fan hub bearing

Lubrication hose

Lubricate the fan hub bearing through this nipple.

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5 0 0 H o u r s

E v e r y 5 0 0 H o u r s• Repeat Daily

• Repeat 250 Hours

Axle, Bolt ConnectionCheck torque on all bolts on front and rear axle that hold the axle to the frame.

Bolt dimension for front axle is UNC 1½, Grade 8, moment 3220 Nm.

Bolt dimension for rear axle is M24, Grade 10.9, moment 790 Nm.

Driveline, Upbox - TransmissionCheck the torque on the driveline bolts between upbox and transmission.

Bolt dimension is M12 Grade 10.9, and moment 88 - 102 Nm.

Driveline, Loadframe - Transmission - Powerframe Check the torque on the driveline bolts between loadframe, transmission and powerframe. Bolt dimension is UNC ½, Grade 8, and moment 149 - 163 Nm.

Bolt connections, Engine Cradle - PowerframeCheck the torque on the bolts that holds the engine cradle in to the powerframe. Bolt dimension is M24, Grade 10.9 and 790 Nm.

Transmission, bolt connectionCheck the torque on the bolts that holds the transmission in to the powerframe. Bolt dimension is UNC 7/8, Grade 8 and 620 Nm.

AC, cab unit

AC filter

Change the AC filter in the cab.

Fuel Filter

Fuel filter

Check the fuel level in the filter and change if neccesary. Other wait until the fuel level rise, the filter must be changed after 1000 hours if not earlier.

STEP 1 Clean both fuel filters and the area around each filter.

STEP 2 Drain the fuel until the reservoir is empty.

STEP 3 Turn each filter anti-clockwise and remove the filter head. Discard the old filters.

STEP 4 Use a clean cloth and wipe the mounting surface of each filter. Make sure this area is clean.

STEP 5 Install the new filter and O-rings.

STEP 6 Reinstall the protective casing.

STEP 7 Fill with fuel through the ventilation cover.

STEP 8 Start the engine.

Engine Cooling, Hoses and PipesCheck hoses, pipes and couplings for wear and damages.


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Engine Coolant, FilterReplace the coolant system filter every 500 hours of operation or when the cooling system is refilled.

STEP 1 Rotate the two filter shutoff valves clockwise to the OFF position.

STEP 2 Use a strap wrench and turn the filter counterclockwise to remove. Discard the old filter.

STEP 3 Use a clean cloth and clean the filter mounting area on the filter head.

STEP 4 Apply a thin layer of clean grease or oil to the gasket of the new filter.

STEP 5 Turn the new filter clockwise onto the filter base until the filter gasket makes contact. Continue to turn the new filter 2/3 turn.

STEP 6 Rotate the two filter shutoff valves counterclockwise to the OPEN position.

Expander Shafts, Loadframe and BoomCheck torque. It should be M30, Grade 10.9 and 1570 Nm

Expander Shafts, Z-barCheck torque. It should be M30, Grade 10.9 and 1570 Nm

Load and powerframe

Look for frame cracks at major stress points.

Check frames for damage that could cause down time.

Trunnions and Pins, Boom Z-bar

Bolts on Z-bar

Bolts on Z-bar

Check torque it should be Grade 10.9 and 1569 Nm

Trunnions and Pins, Bucket

Bolts on bucket

Check torque it should be M30, Grade 10.9 and 1569 Nm

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Trunnions and Pins, Steering

Steering bolts

Check torque it should be Grade 10.9 and 1569 Nm

Trunnions and Pins, Swivel

Bolts on the swivel

Check torque it should be M24, Grade 10.9 and 790 Nm


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1 0 0 0 H o u r s

E v e r y 1 0 0 0 H o u r s• Repeat Daily



Transmission, Oil and Filter Change

1. Transmission Strainer2. Transmission Oil Drain Hoses3. Upbox Strainer

STEP 1 Clean the area around the transmission oil filler tube and drain hoses.

STEP 2 Remove the drain hose and oil strainer assembly. Drain all the transmission oil.

STEP 3 Replace the transmission oil filters and clean the strainer assembly and breather.

Transmission oil filter are located behind the hydraulic hatch

STEP 4 Install the drain hoses and strainer and add new oil to FULL mark.

STEP 5 Start the engine and run at idle for a few minutes with the transmission in NEUTRAL. Check for oil leaks.

STEP 6 Check the transmission oil level once oil temperature has reached normal operating range. The machine must be standing on a flat surface, another it will show wrong level. Level should be between the HIGH and LOW mark.

Check transmission oil level

N o t e If the machine not are standing on a flat surface can you check the oil level with the oil level stick instead of the sight glass. The oil stick is located on top of the transmission.

Transmission oil dip stick, on top of the transmission.

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Upbox, Oil Filter

Upbox oil filter

Always replace the filter when changing transmission oil.

Hydraulic Oil ChangeChange the hydraulic oil and clean/replace the reservoir breather every 1000 hours of operation.

STEP 1 Raise the boom to its full height so that the pistons will be extended in the hoist cylinders.

STEP 2 Move the bucket to its full rolled back position so that the piston will be extended in the dump cylinder.

N o t e In these positions the hydraulic oil in the cylinders will be below the pistons and will drain more completely.

STEP 3 Secure the boom with a chain hoist or by securely blocking the boom and bucket assembly with support stands.

DANGER Perform this step carefully. With the oil drained there will be no pressure to support the boom or bucket.

STEP 4 Vent the reservoir by depressing the relief valve on top of the tank.

DANGER Check the temperature of hydraulic oil before draining. Hydraulic oil temperature can reach 121° C (250°F).

STEP 5 Select a container sufficient to hold the entire amount of oil in the system and place underneath the reservoir drain.

STEP 6 Remove the drain plug from the reservoir and drain the oil.

STEP 7 Disconnect the hoist and dump cylinders’ hoses at the lowest points so as to completely

drain the cylinders.

STEP 8 Clean the inside of the reservoir. If it is difficult to clean, use a mixture of five parts fuel oil to one part of clean lubricating oil. Be sure to flush out the bottom of the tank. Make sure that all of the flushing solution is removed from the reservoir.

STEP 9 Disconnect any other hoses that might trap hydraulic oil in the system and shift the hydraulic control levers to permit any oil in the control valves to drain.

STEP10 Replace the hydraulic filter.

STEP11 Re-connect all hoses and fittings previously disconnected.

STEP12 Install the reservoir drain plug.

STEP13 Pump new oil into the hydraulic reservoir.

Important Always use the electric refill pump when filling up.

STEP14 Start the engine, cycle dump/hoist and steering and check for oil leaks.

Stop the engine and check the hydraulic oil level.

Hydraulic Oil Filter

Hyd oil filter

Always replace the filter when changing oil or when indicated.

The hydraulic filter system uses an in-tank filter which is located on the top of the tank. The filter head is made out of cast steel and has a hex bolt type head that allows it to be removed easily. Follow these steps to change the filter:

STEP 1 Depress the bleed valve relief button on the tank breather to relieve tank pressure. Remove the filter head by unscrewing it.

STEP 2 Remove the filter element from the body assembly and discard it.


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STEP 3 Remove O-ring from the head assembly and inspect for cuts or excessive wear and replace if necessary. Inspect the head assembly for wear or cracks.

STEP 4 Wipe head assembly O-ring with clean cloth, Apply a thin layer of clean grease or oil to the O-ring and replace on the head assembly.

Important When changing filter ensure that it has completely filled with hydraulic oil prior to closing the filter housing and starting the vehicle. Air pockets can cause cavitation and damage the prim pumps.

STEP 5 Start the engine and run at idle speed.

STEP 6 Stop the engine and check the hydraulic oil level.

Hyd Oil PressureSTEP 1 Go to menu "Diagnostics/Modules/D512/

Actuations/Sensors".

STEP 2 Start engine and activate boom down.

STEP 3 Pressure for sensor B411:1 shall be 278 - 280 bar which is normal system pressure on the machine.

STEP 4 The pressure can also be checked with a calibrated manometer to the measure socket for sensor B411:1 and then activate boom down.

Air Filter, Safety Cartridge

Change the safety cartridge.

STEP 1 Remove the air filter cover.

STEP 2 Remove the outer filter.

STEP 3 Inspect filter gasket surface and replace if needed.

STEP 4 Install a new primary element.

Air Filter, IndicatorSTEP 1 Remove the air intake on the filter.

STEP 2 Let the engine go on idle.

STEP 3 Cover one part on the intake and check that the indicator alarms. Check that the alarm appears on the display.

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Axles, Differentials and PlanetariesThe differential thrust screw to ring gear clearance must be adjusted to maintain proper contact during heavy loading on ring gear.

Change the oil of the differentials and planetaries every 1000 hours of operation.

N o t e Drain oil after vehicle has warmed up. Always drain into a catch basin or container.

Differential

STEP 1 Park the vehicle on a level surface, apply the parking brake, and stop the engine.

STEP 2 Place adequate receptacle under the axle to receive drained oil.

STEP 3 Remove the oil drain plugs and completely drain each differential.

STEP 4 Replace the oil drain plugs.

STEP 5 Remove the oil level plug and put new oil in each differential. The oil level must be up to the bottom of the oil level plug hole.

STEP 6 Replace the oil level plug.

Differential drain plug

Planetary

STEP 1 With the vehicle on a level surface, move the

vehicle forward or back until the oil level/drain plug is at the bottom of the hub.

STEP 2 Apply the parking brake, and stop the engine.

STEP 3 Remove the oil level/drain plug.

STEP 4 After all the oil has been drained, reposition the vehicle so that the oil level/drain plug is in the level check position.

STEP 5 Put new oil into the planetary. The oil level must be up to the bottom of the oil level/drain plug hole.

STEP 6 Install the oil level/drain plug, then repeat procedure with the other planetaries.

Planetary drain plug at bottom

AlternatorSTEP 1 Start the engine.

STEP 2 Go to menu "Vehicle/Information" and note charger voltage that should be between 24 - 27V dependent on the condition on the batteries.

STEP 3 Stop engine.

STEP 4 Replace the alternator if necessary.


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Engine CoolantDrain, flush, and refill the engine coolant every 2000 hours of operation. After cleaning the system, replace the coolant filter.

DANGER If the engine coolant temperature is high, be careful when opening the refill cap. Hot coolant can rush out and may cause burn injury.

N o t e If the cooling system is drained, flushed, and refilled with new coolant, use a precharge filter instead of the service filter to ensure the correct concentration of Supplemental Coolant Additive (SCA).

STEP 1 Open the radiator drain valve/cap and the two drain valves on the engine.

STEP 2 Remove the coolant reservoir cap (if applicable).

STEP 3 After all coolant is removed, close the drain valves.

STEP 4 Add a cleaning solution to the cooling system and fill the system with clean water. Follow the directions included with the cleaning solution.

STEP 5 After you drain the cleaning solution from the cooling system, flush with clean water.

STEP 6 Remove and replace the cooling system filter with a new precharge filter.

STEP 7 Fill the cooling system with premixed coolant (No supplemental coolant additive).

STEP 8 Start the engine and run at idle speed for two minutes. Check for leaks during this period.

STEP 9 Stop the engine and check the coolant level. Add coolant as required to raise the level up to the top of the sight window.

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Hoses and CouplingsReplace all rubber intake piping and clamps. This will insure clean air reaching the engine.

Replace all hydraulic system and engine fuel and coolant system hoses.

Fuel Tank Drain and flush the fuel tank.

STEP 1 Loosen the drain plug on the bottom of the fuel tank and drain fuel into a proper container.

DANGER If the fuel tank is full, there will be pressure on the drain plug. Recommend draining tank with low fuel level.

STEP 2 Flush tank with clean diesel fuel. Make sure that all contaminants are dislodged and removed from the tank.

STEP 3 Remove any feed line screens or strainers, clean and re-install.

STEP 4 Re-install fuel tank drain plug and re-fill tank with diesel fuel.

STEP 5 Bleed all air from the fuel system.

Fuel InjectorsCheck function on the fuel injectors and replace if neccesary.

Start the function test with the software Detroit Diesel Diagnostic Link 6.2 or ask you local Detroit Diesel service to help you locate the problems with the fuel injectors.

DDEC Reader

You can also use the DDEC Reader to check if there are any problems with the injectors. Read how to use it in the Detroit Diesel service guide.

For more information on the fuel injectors see the Detroit Diesel service guide.

Fuel HosesReplace all fuel hoses.

Air IntakeChange all hoses between the filter housing and the turbo charger.

Cooling Fan Drive BeltReplace the cooling fan drive belt. After replacing a worn belt, check the belt tension after 1/2 hour of operation and again after 8 hours of operation.



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Atlas Copco 29

Chapter 3: Power Unit

IntroductionThis section will cover all of the major components of the power unit. This section will not cover any major rebuild or disassembly of the engine itself. For information concerning the engine, see your authorized Atlas Copco dealer.

The power unit is supported by the following systems:

• Fuel System

• Engine Oil System

• Cooling System

• Air Intake System

• Exhaust System

• Electrical System

• Upbox

Fuel System Efficient engine operation depends upon correct operating practices and proper preventive maintenance. Operating temperatures, air supply, and the general mechanical condition of the engine have an important bearing on its efficiency. As important as all of these factors are, however, none is more important than using a fuel which is of a grade and quality that meets requirements and specifications.

The fuel system is supported by the following system:

• Fuel Tank

• Fuel Filter/Water Separator

• Fuel Pump

• ECM Cooling

• Sensors

• Electronic Unit Injectors

• Check valve

• Fuel Cooler

Chapter 3: Power UnitService Manual

30ST14

Fuel flow1. Fuel tank2. Fuel filter3. Fuel pump4. ECM5. Temperature and pressure sensors6. Engine injectors7. Check valve8. Cooler

Fuel TankThe fuel tanks on any diesel installation are as important as the other components of the fuel system.

Carelessness when filling fuel tanks can allow dirt to get into the fuel system. It takes very little dirt to damage fuel injection pumps and injectors, and the repair of these engine components can be expensive.

Important Always use the strainer when filling the tank.

Fuel tank strainer

Fuel Filter

1. Fuel Filter2. Shut off valve3. Water Drain Knob

Important Only use fuel which is free from dirt particles and water to extend life of the fuel system.

Diesel fuels also contain more gums and abrasive particles which are difficult to extract during refining. Therefore, an efficient fuel filter or filters are provided by engine manufacturers.

The fuel filter is located on top of the fuel tank. The filter is equipped with a drain valve at the bottom for draining water and sediment which collects at the bottom of the filter shell. This should be done whenever water can be seen in the clear filter bowl.

Fuel Pump

1. Fuel Outlet2. Fuel Pump Housing3. Fuel Inlet

The fuel pump is located on the intake side of the engine and is driven by the bull gear. It supplies fuel flow to the injectors through temperature and pressure sensors and the engine ECM during engine operation.

ECM Cooling

1. Diesel in2. Diesel out

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2 3 4 5 6 7 8

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Atlas Copco 31

The ECM is cooled with diesel fuel.

Fuel sensors

1. Pressure sensor2. Temperature sensor

The temperature and pressure sensors are located on the right hand side of the engine, close to the starter.

Injectors

1. Injector Solenoid2. Fuel Inlet3. Injector Spray Nozzle4. Injector Follower Spring5. Injector Body

The Electronic Unit Injector (EUI) is a lightweight, compact unit that injects diesel fuel directly into the combustion chamber. The amount of fuel injected and the beginning of injection timing is determined by the engine Electronic Control Module (ECM). The ECM sends a command pulse which activates the injector solenoid. The EUI performs four functions:

• Creates the high-fuel pressure required for effi-cient injection.

• Meters and injects the exact amount of fuel required to handle the load.

• Atomizes the fuel for mixing with the air in the combustion chamber.

• Permits continuous fuel flow for component cool-ing.

The EUI operates on the same basic principle as the mechanical injector. However, the EUI uses a solenoid operated poppet valve to control injection timing and metering. The source of the high pressure fuel delivery is a cam and rocker arm system.Fuel injection begins when the poppet valve closes.

• Opening the poppet valve ends injection.

• The duration of valve closure determines quantity of fuel injected.

The solenoid only controls how much fuel will be delivered.

Calibration codes

1. Part number2. Calibration code

All DDEC III injectors contain injector calibration codes.

• Top side of load plate has two sets of numbers. The first set is the last four digits of the injector part number.

• The injector calibration code is etched next to the part number on the load plate. This number can be from 00 to 99.

• The injector calibration codes are used by the ECM to equalize the outputs of the injectors.

• The DDR (diagnostic data reader) is used to view and update injector calibration codes.

• If the calibration code is missing use 01 for default setting.

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Check Valve

1. Output2. Input

The check valve is placed in front of the engine and it’s function is to prohibit fuel from reversing direction.

Fuel Cooler

The fuel cooler is mounted on the grille door.

The fuel cooler, cools the diesel fuel as it flows back to the tank. The fuel cooler is located inside the engine cooler.

Engine Oil System Oil from the sump is drawn up by the oil pump through the oil filters to the main oil gallery, and is distributed to various parts of the engine. It then flows by gravity back to the engine sump.

The major components in the Scooptram engine oil system are:

• Oil Pump

• Oil Filters

• Oil Pressure & Temperature sensors

Lubricating Oil Pump The oil lubrication pump is a gear pump mounted to the cylinder block and driven off the engine. It is the heart of the engine oil system and is usually equipped with an inlet screen located in the oil pan to strain out any contaminants that could damage the pump.

Oil Filters

Change the oil filters every 125 hours.

On the Scooptram engine the oil filters are located on the left hand side of the engine, below the turbocharger. The filters are of the disposable spin-on type that require changing every time the engine oil itself is changed, usually every 250 hours, depending on the OEM specifications.

Oil Pressure & Temperature sensorsThe sensor for oil pressure is located on the right hand side, in front of the engine together with the temperature switch.

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Atlas Copco 33

Cooling System

Engine and cooling package

On the Atlas Copco Scooptram, the engine and engine cooling package is mounted on a cradle that can be removed from the vehicle as one unit.

It is not necessary to drain the engine coolant to remove the entire engine and radiator package. This is because of the tube-in-shell cooler that is mounted beside the engine.

See “Chapter 4: Power Train” on page 47.

The cooling systems on board the Atlas Copco Scooptrams are composed of the following systems:

• Engine, combustion air cooler

• Fuel and hydraulic cooler

• Hydraulic cooler and AC condensor

DANGER If the engine has been running within the previous hour, the temperature of the engine components, the coolant, the oil, and radiators can be high enough to cause serious burns. Allow the engine and the entire cooling system to cool before initiating removal procedures.

Coolant RecommendationsUse genuine Detroit Diesel Power Cool or an equivalent fully formulated, inhibited ethylene glycol (IEG)-base coolant (low silicate formulation) that meets or exceeds the standard of either the GM 6038-M formulation (GM 1899-M performance), or ASTM D 4985 requirements.

A 50/50 mix of quality fully formulated, inhibited propylene glycol antifreeze and water may also be used if it provides required freeze, boil over, and inhibitor protection. Do not mix ethylene glycol and propylene glycol antifreeze. Flush the cooling system thoroughly before replacing ethylene glycol with propylene glycol antifreeze.

A 50% Power Cool antifreeze/water solution is normally used as a factory fill. Concentrations over 67% are not recommended because of poor heat transfer capability, adverse freeze protection and possible silicate dropout. Concentrations below 33% offer little freeze, boil over or corrosion protection.

If (IEG) or pre-charged inhibited propylene glycol (IPC) is not used, Detroit Diesel Maintenance Product supplement I inhibitors must be added to the coolant at initial fill. Inhibitor levels in all coolants used must be maintained at proper concentration thereafter.

Antifreeze solution should be used year-round to provide freeze and boil over protection as well as a stable environment for seals and hoses.

In extremely hot environments, clean, soft, properly inhibited water may be used if Detroit Diesel Maintenance Product supplemental corrosion inhibitors are also added in the right concentration. If water is used, supplemental coolant additive levels should be increased from 3% to 6% by volume.

CoolersThe engine cooling package houses the following coolers.

1. Fuel cooler2. AC condensor (option)3. Intercooler4. Water cooler

5. Transmission cooler (option)6. Hydraulic cooler

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2

3

4

5 6


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Air Intake System

Air cleaner

The air intake system fulfills two primary functions:

• Provides clean, contaminant free combustion air to the engine.

• Provides forced-air cooling to the engine and/or various sub-systems.

Important The air cleaner is of vital importance to engine life and performance.

Air Cleaner

Air cleaner

On Detroit Diesel engines, the combustion air flows through a turbo-charger, driven off engine exhaust air, and an after-cooler before entering the cylinders.

The Scooptram engines use an engine driven fan to circulate air through the engine cooling radiator. This radiator also serves as the combustion air aftercooler.

Engine Air Filter Restriction Indicator

Engine air filter restriction indicator

The air filter restriction indicator is located on top of the air filter and is connected to the RCS system.

As the air cleaner element becomes dirty the flow of air to the engine will become restricted. This can limit engine performance. Visual inspection of the filters is not always sufficient for determining replacement. In some cases, there may be little visual indication of dirt, yet the filter may be internally plugged with very fine particles.

When intake air restriction has reached the allowed trip point, a warning sign on the RCS display will show yellow. This notifies the operator that the filter requires changing.

Turbo Charger

The turbocharger is mounted on the engine.

The turbocharger is designed to increase the overall efficiency of the engine.

Oil for lubricating the turbocharger is supplied under pressure through an external oil line extending from the oil filter adapter to the top of the center housing.

The pictures below explain the engine intake air and exhaust flow.

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Engine air flow1. Air inlet2. Compressor3. Charge air cooler4. Cylinder5. Exhaust mainfold and cylinder head porting6. Turbine7. Turbine exhaust outlet

Turbo air flow1. Ambient air inlet2. Compressor wheel3. Compressed air discharge4. Exhaust gas inlet5. Turbine wheel6. Turbine exhaust gas discharge

•Engine exhaust air flow

•Compressed air flow

•Fresh air

Exhaust System

Exhaust is expelled from the back of the turbo, runs through the flex tube to the purifier, through the silencer and exits out the tail pipe.

The purpose of the exhaust system is to discharge engine exhaust gases in a safe direction, purify exhaust, and to reduce engine noise.

The exhaust system is composed of:

• Silencer

• Particle filter

• Heat shields

Silencers / CatalystThe exhaust silencers act in the same manner as the mufflers on a car.

Back pressure caused by an exhaust restriction could lead to engine damage, therefore the silencers should be inspected often and serviced/replaced when a restriction is detected.

Particle filter (Optional)The exhaust particle filter reduce the amount of carbon monoxide, hydrocarbons, and diesel odor that is emitted from the combustion process of the engine.


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Exhaust Heat Shields

Heat Shielding

The exhaust heat shields are installed on all Atlas Copco Scooptrams to protect personnel when they are conducting service on or around the engine. They also provide some protection for the exhaust system from debris while the scooptram is operating.

Electrical systemThe engine’s electrical system is controlled by an ECU Electronic Control Unit, sometimes called ECM. The ECU reads data from all the sensor on the engine and tells the EUI how to operate. See “Injectors” on page 31.

Engine electrical system function1. Input2. Analysis3. Output

The engine’s electrical system consists of:

• ECU

• EUI

• Temp sensors

• Pressure sensors

ECUThe ECU is located between the engine and the upbox, beneath the surge tank.

The ECU have the following connections:

1. Injector harness connector2. Engine harness connector

3. Vehicle interface harness connector4. Communication harness connector

1 2

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5. Power harness connector

Temperature & pressure sensorsThe following sensors are connected to the engine’s electrical system:

Temperature• Oil (OTS)

• Fuel (FTS)

• Coolant (CTS)

• Air (ATS)

Pressure• Oil (OPS)

• Fuel (FPS)

• Turbo (TBS)

Other• Timing reference (TRS)

• Syncronous reference (SRS)

• Throttle position (TPS)

• Coolant level (CLS) (located on surge tank)

The normal operating range of each sensor is 0.25 to 4.75 volts. During operation, the ECM sends a 5 volt signal to each sensor and expects to receive a return signal between 0.25 and 4.75 volts. If the signal is below 0.25 volts or above 4.25 volts, the ECM knows there is a problem with the wire or the sensor, not the engine or the machine. This is how DDEC is able to tell the difference between low oil pressure and a faulty wire leading to the oil pressure sensor.

Upbox

Upbox

The upbox transfers engine output over the rear axle, allowing the scooptram to maintain its low height clearance. The up box transmits engine output on 1:1 ratio to the transmission. The upbox is composed of a Drive Plate and the Driveline Coupling. The drive plate is the engine mounting area and shaft, a flex plate between the engine and upbox disperses engine vibration.

This is how the lubrication of the upbox works:

Upbox lubrication circuit


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Replacing Engine Support Systems N o t e This section contains removal and

replacement instructions covering the engine and its support systems. Maintenance procedures on the engine are included in the engine’s OEM manual. Preventive maintenance is covered in this manual. See “Chapter 2: Preventive Maintenance” on page 3.

The procedures in the following paragraphs describe removal and replacement of the various engine accessory components and of the engine as a package.

DANGER Block all wheels, set the parking brake, place a "Do Not Operate" tag on the steering joystick and isolation switch before performing maintenance on the power train systems.

DANGER If the engine has been running within the previous hour, the temperature of the engine and exhaust system components can be high enough to cause serious burns. Allow the engine and exhaust system to cool before initiating removal procedures.

Before you do any job on the machine, always:

• make sure the vehicle is parked correctly and safe.

• turn the battery isolation switch (S300) to the "OFF" position.

• put a "Do not operate" tag on the isolation switch and steering joystick or steering wheel.

• if work with hydraulic and accumulators is to be done, make sure there is no pressure stored.

R&R Engine DANGER The engine package could weigh more than 1134 kilograms (2500 pounds). Do not reach or lean underneath the engine as it is being removed or re-installed.

Removing the Engine Package

STEP 1 Remove the engine hood.

1. Slip Yoke2. Brake Accumulator

STEP 2 Disconnect the transmission driveline on the slip yoke at the upbox.

STEP 3 Remove the brake accumulator and mounting bracket.

1. Shut off valve

STEP 4 Turn the fuel shut off valve to the off position.

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2

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STEP 5 Disconnect and immediately cap the line that connects the oil pan to drain hose.

STEP 6 Disconnect the inlet fuel line from the fuel tank.

STEP 7 Disconnect the wiring harness from the engine ECM.

STEP 8 Disconnect the coolant level sensor, located on the serge tank, and place the entire ECM wiring harness out of the way where it will not get caught as the engine is removed.

STEP 9 Disconnect the air intake tubes from the air cleaner to the engine.

STEP10 Remove the heat shield from the turbo.

STEP11 Disconnect the exhaust and turbo tubes.

STEP12 Loosen the four engine cradle bolts.

STEP13 Prepare an adequate hoist with spreader bars and chains.

STEP14 Use the three lifting eyes to hoist the engine package out of its compartment.

STEP15 Attach a hoist chain to the lifting eye of the radiator brace at the front of the engine.

STEP16 Attach hoist chains to the two lifting eyes located on each side at the back of the engine.


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STEP17 While watching carefully to make certain that it does not catch on any engine compartment items, lift the engine unit clear of the engine compartment and place it securely on blocks or a support structure on the floor.

Replacing the Engine Package

STEP 1 Using the same hoist, spreader bar, and chain set-up as used for removal, lift the engine package from the blocks or support structure to a point above its position in the engine compartment.

N o t e Engine cradle grommets (vibration dampers placed between frame and engine cradle) need to be replaced when worn or damaged.

STEP 2 While watching carefully to make certain that it does not catch on any engine compartment items, carefully lower the engine until it rests on the four engine mounts and is in proper alignment between the turbocharger and the exhaust head pipe.

STEP 3 Reinstall the two bolts that secure the front engine mount (center) to the power frame, but do not tighten.

STEP 4 Reinstall the two bolts that secure each rear engine mount (left and right) to the power frame, but do not tighten.

STEP 5 Inspect the engine position. If it is in the correct position, tighten the four engine mount bolts to their proper torque. See “Torque Specifications” on page 132.

STEP 6 Remove the chains, spreader bar, and hoist from above the engine.

STEP 7 Reinstall the engine to transmission driveline.

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STEP 8 Reconnect the electrical wiring harness to the engine ECM.

STEP 9 Reconnect the inlet fuel line from the fuel tank.

STEP10 Reconnect the oil drain hose.

STEP11 Turn the fuel shut off valve to the on position.

STEP12 Reinstall the clamp that secures the front end of the exhaust system head pipe to the turbocharger.

STEP13 Reinstall the engine hoods.

Remove the Engine Cooling Package The engine radiator can be removed from the engine cradle package without disturbing the other engine components.

Remove the cooling system package as follows:

STEP 1 Remove the engine hood and the mount plate

Engine Hoods

STEP 2 Remove the complete Air filter.

Remote Radiator Drain

STEP 3 Place a suitable receptacle below the engine coolant radiator and drain all engine coolant.

STEP 4 Disconnect the air hoses that connect to the charge air cooler.

STEP 5 Disconnect and cap all coolant hoses from the radiator.

STEP 6 Remove the fan shroud and fan.


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STEP 7 Remove the upper end support bracket.

STEP 8 Install lift eyes on top of radiator and place hoist hook.

STEP 9 Loosen and remove the bolts from the radiator located on the bottom of the engine package cradle.

STEP10 Lift the cooling system package clear of the scooptram and store it in a safe location.

Replace the Cooling PackageReinstall the cooling system package as follows:

STEP 1 Using the hoist and lifting chains arrangement used in the removal, lift the cooling system package into position on the engine cradle.

STEP 2 Reinstall the lock nuts that fasten the bottom of the cooling system shell to the engine cradle. Remove the lifting chains and hardware and the hoist.

STEP 3 Reinstall the radiator support arm.

STEP 4 Reinstall the fan and fan shroud.

STEP 5 Reinstall the hoses that connect to the engine block and oil cooler.

STEP 6 Reinstall the hoses that connect to the charge air cooler.

STEP 7 Close the engine coolant radiator drain cock. If the engine block was drained, close the two drains on the engine.

STEP 8 Fill the radiator with the proper coolant mixture. See “Engine Coolant” on page 130.

STEP 9 Reinstall the engine hood.

Remove Hydraulic & Fuel Coolers Remove the radiator as follows:

STEP 1 Open the engine radiator protective doors.

STEP 2 Disconnect and immediately cap the lines that connect the radiator to the hydraulic system.

STEP 3 Remove the bolts that secure the radiator to the cooling system shell.

STEP 4 Remove the radiator.

Replace Hydraulic & Fuel Coolers Reinstall the radiator in the reverse order of removal.

Remove Exhaust System ComponentsSome vehicles are equipped with catalytic exhaust purifiers. The purifier and the silencer do not require periodic maintenance.

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Heat shields

STEP 1 Remove the exhaust system heat shields and upper clamps to gain access.

STEP 2 Remove the bolts on the component that requires inspection or replacement.

Replace the Exhaust SystemReinstall the component in the reverse order of removal.

Replace Fuel System ComponentsRemove and replace the fuel system components as outlined in the following paragraphs.

Important Cleanliness is absolutely essential in all work done on the scooptram fuel

system. Always follow these rules regarding cleanliness in maintenance operations on the fuel system.

• Steam clean the area of the scooptram on which the work will be performed if there is a substantial accumulation of dirt or other debris.

• Wipe clean hose and pipe connections before opening any connection.

• Remove all loose paint before opening any sec-tion of the head pipe to the rear section connec-tions.

• Plug or cap any hose or connection immediately after opening it.

• Flush any unsealed hose or pipe with fuel before installing it in the system.


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Remove Fuel Filter

1. Fuel Filter2. Collar3. Shut off valve4. Water Drain Knob

Remove the fuel filters as follows:

STEP 1 Clean the fuel filter and the surrounding area.

STEP 2 Turn the fuel shut off valve 90 degrees to the OFF position.

STEP 3 Drain the fuel out of the filter by opening the drain knob.

STEP 4 Remove the clear cover by turn the collar counter clockwise and remove it.

Replace Fuel Filters Reinstall the fuel filters as follows:

STEP 1 Wipe the mounting surface for the filter with a clean cloth.

STEP 2 Apply a thin layer of grease to each filter gasket.

STEP 3 Fill each filter with clean diesel fuel.

STEP 4 Install the filter on the filter mount and close the cover by turning the collar clockwise.

STEP 5 Turn the shut-off valves the ON position.

STEP 6 Start the engine, run it at idle speed, and check for fuel leaks.

Remove Fuel CoolerRemove the fuel cooler as follows:

STEP 1 Disconnect and immediately cap the hoses.

STEP 2 Remove the cover on the side of the Intercooler.

STEP 3 Remove the bolts and then remove the cooler.

Replace Fuel CoolerReinstall the fuel cooler in reverse order of removal.

Remove Fuel Valves, Solenoid and Lines

Fuel Lines

Remove a fuel valve or line as follows:

STEP 1 Clean the fuel valve or ends of the fuel line and the surrounding area.

STEP 2 Always close the shut off valve (turn to OFF position) before removing any parts.

STEP 3 Disconnect the component and remove it.

Replace Fuel Valves, Solenoid and Lines Reinstall a fuel valve or line as follows:

STEP 1 Make certain that the connections are clean, both on the component to be installed and the components to which it connects.

STEP 2 Install the component.

STEP 3 Turn the fuel valve to the ON position.

STEP 4 Start the engine, run it at idle speed, and check for fuel leaks.

Removing the Fuel Tank

Remove the fuel tank as follows:

STEP 1 Close the fuel shut-off valve to the fuel tank.

STEP 2 Place a suitable receptacle under the fuel drain of the tank, remove drain plug and drain

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2

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the tank.

STEP 3 Disconnect and remove the batteries and all electrical cables.

STEP 4 Remove the Upbox hoses and remove the Ansul system and hoses.

STEP 5 Remove the engine oil fill hose.

STEP 6 Position a hoist over the fuel tank and rig chains from the hoist hook to the lifting rings at the front and rear of the tank.

STEP 7 Take up the slack in the chains, but do not lift the tank yet.

STEP 8 Remove the bolts that attach the fuel tank to the power frame.

STEP 9 Lift the tank from the frame and set it on blocks in a safe location.

STEP10 Remove the receptacle from under the power frame.

STEP11 Close the fuel valve of the tank and temporarily seal all fittings and outlets.

Replace the Fuel Tank Reinstall the fuel tank as follows:

STEP 1 Lift the tank from the storage position and place it on the frame.

STEP 2 Re-install the bolts that secure the tank to the power frame. See “Torque Specifications” on page 132.

STEP 3 Remove the hoist and the chains.

STEP 4 Remove all temporary seals from fittings and outlets.

STEP 5 Open the fuel valve to the tank.

STEP 6 Start the engine, run it at idle speed and check for fuel leaks.

R&R Electronic Engine Control SystemRemoving the ECM

STEP 1 Remove the fuel hoses and plug them immediately.

STEP 2 Disconnect the cables from the ECM.

STEP 3 Unscrew the four (4) screw that holds the ECM.

N o t e The engine electronic control system is an integral part of the engine package. Refer to the engine manual for removal and replacement information.

Replacing the ECMReinstall the component in the reverse order of removal.


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Chapter 4: Power Train

IntroductionPower from the engine is transmitted directly from the engine flywheel through the upbox (ratio of 1:1) to the transverter whose output shafts transmit power via drivelines to the front and rear differentials. The upbox transfers engine output over the rear axle, allowing the scooptram to maintain its low height clearance.

Important Protect the transmission when towing the vehicle. The transmission will be damaged if the lower drivelines are not disconnected.

Instructions on how to tow the vehicle you will find in the operators manual.

N o t e The parking brake must be disengaged before you move the vehicle or damage to the tires or vehicle may occur.

Chapter 4: Power TrainService Manual

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1. Front Axle2. Front Driveline3. Driveline Support Bearing4. Midship Driveline5. Transmission to Midship Driveline6. Transmission

7. Rear Driveline8. Rear Axle9. Upbox to Transverter Driveline10.Up Box11.Engine

Components

1 2 3 4 3 5 6 7 8 9 10 11

Transmission

Transmission

The Transmission consists of:

• Converter

• APC200

• Transmission hydraulics

The transmission is an electronically controlled automatic transmission/torque converter that is employed by a series of push buttons or selector switch located in the operator’s compartment. The transmission electrically defaults to neutral whenever the vehicle is shut off, or if a problem with the transmission develops during operation.

Transmission manual

The transmission manual including in the documentation will tell you more about the transmission details and repairing.

ConverterAn torque converter is a hydrodynamic system that transmits energy from an engine to a transmission through the use of hydraulic oil.

An torque converter consists of three elements:

• An rotating impeller which causes oil within it to flow outward by centrifugal force.

• An turbine which is driven by the flowing oil.

• An stator to increase torque.

When a load is applied to the Scooptram, it reduces the turbine speed.

The impeller continues to rotate at the same RPM as the engine. This causes oil to flow from the impeller through the turbine.

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Transmission Controller APC 200

The APC 200 controller, located at service bay.

The purpose of the APC200 is to control the functions of the transmission. Up shifting, down shifting and control of the disconnect are main functions of the APC200.

Other functions include the ability to drive a speedometer and to communicate with a diagnostic device.

It receives input from the operator via Can bus system regarding throttle positions and gear selection control and monitors transmission output.

If an error has been detected, the APC200 will command the transmission to remain in neutral. Also if a problem develops during operation of the vehicle, the APC200 will automatically ramp down to neutral.

If no errors exist, the APC200 will calculate a speed ratio between the engine rpm and the transmission output and shift to the appropriate gear.

If the operator selects third gear, the transmission will shift from neutral to first then second and finally third as the vehicle is accelerated.

Also if the direction is changed by the operator, the transmission APC200 will shift down to neutral as the vehicle slows, then change directions when the vehicle has stopped.

The connections back of the APC are as follow:

Connections back on the APC 200.

Hydraulics

1. Cooler2. Filter3. Transmission4. Chargepump5. Sight gauge

The transmission system is lubricated with transmission oil that is also used to actuate the gear changes when the transmission solenoids activate.

Wire Pin Func Type Description

B01 L1 VFS4+ HbrgA

B02 M1 ANI4 Sns 5V Reference voltage out

B03 N1 VFS5+ HbrgB

B04 P1 ANI5 Sns

B05 R1 VFS6+ Pwm

B06 S1 ANI6 Sns

B07 L2 CANL Comm CAN Lo

B08 M2 CANH Comm CAN Hi

B09 N2 RXD Comm RS232 RXD

B10 P2 TXD Comm RS232TXD

B11 R2 SS3 Sns

B12 S2 SPWR Pwr Switched Battery Plus

B13 L3 DIGIN6 Ptp

B14 M3 DIGIN7 Ptp

B15 N3 DIGIN8 Ptp

B16 P3 DIGIN9 Ptp

B17 R3 ANI3 Ptp

B18 S3 SGND Gnd VFS Ground

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5


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The transmission system is composed of the following systems:

• Charge pump

• Oil cooler

• Oil filter

• Solenoids

Charge Pump

Charge pump, located on top of the transmission.

The transmission charge pump is directly mounted on top of the transmission.The pump supports the filter and cooling circuit and also the clutch pressure.

Cooler

Transmission cooler

1. Oil drain2. Water drain

The transmission tube-in-shell cooler serves a dual purpose. When starting the vehicle, the engine coolant passing through the heat exchanger warms the hydraulic fluid. Later, after the hydraulic oil heats up, the engine coolant cools the hydraulic fluid.

Filter

Transmission oil filter

After oil leaves the charging pump and before it moves to the pressure regulating valve, it is sent through a filter to remove impurities from the fluid.

This is a 10 micron filter and should be changed each time the system oil is changed or as indicated by the service indicator.

Solenoids

Solenoids

The gear selection switches is a rotary type that allow the operator to interface with the transmission.

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Flow and Fluids

Transmission Oil TemperatureThe oil temperature of transmission is monitored by a temperature sensor and gauge. A maximum temperature of 120° C (248° F) at the converter outlet may not be exceeded. Under normal service conditions, higher temperatures will not be reached, unless a problem exists.

If the temperature exceeds 120° C (248° F), the Scooptram must be stopped and inspected for external oil leakage. The oil temperature you will see in F3 menu in the RCS system.

Instruction how to check the oil level you will find in operators manual.

Checking Transmission Control PressureClutch pressure should be checked regularly. A drop in pressure will allow the clutch plates to slip, which increases friction and causes wear of the clutch disc.

Check at low engine idle (800 rpm) with oil temperature 80°-95° C (175°-200° F). Pressure should be between 16,5-20,7 bar (240-300 psi).

Attach a calibrated pressure gauge to the transmission charging pump pressure port on top of the

transmission, near the charge pump or look at D3 menu.

Start the vehicle and shift into forward (or reverse), then shift through all the gears. Record the pressure reading for each gear. All speed clutch pressures must be within 0.34 bar (5psi) of each other. If clutch pressure varies more than 0.34 bar (5psi) in any one gear, repair the clutch.

N o t e Atlas Copco Scooptram’s are equipped with modulated shift transmissions. Due to the combination of clutch leakage, piston bleed orifice flow rate and flow limiting orifices, directional clutch pressures can be as much as 2.1 bar (30 psi) lower than system pressure.

Engine speed must remain constant during the entire leakage test. Another test that may help warn of failing clutches before the 0.34 bar (5psi) pressure variance shows up is the pressure drop test.

In this test, the drop in pressure and the speed of return to original pressure is monitored. When the transmission is shifted into gear, the needle on the transmission/converter oil pressure gauge will drop off quickly as oil enters the clutch, and as the clutch fills, the needle will slowly return to original reading.


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With oil temperature at 80°-95° C (175°-200°F) and the engine at idle, go through each gear and note the drop in pressure and the speed of recovery back to original pressure.

The clutch that may drop to a lower pressure and/or return to original pressure slower than the others should be suspect and may signal the need to make a pressure test with the master gauge.

N o t e Larger size clutch packs (usually 1st and 2nd gears), will fall off to a lower pressure than smaller size clutches (forward and reverse and higher gears), and will also return more slowly to the original reading. Be sure to compare readings of the same size clutches.

DrivelineThe purpose of the driveline is to transmit power from the engine to the drive axles. Atlas Copco equipment uses both non-telescoping and telescoping drive shafts and drive shaft support bearings.

All of the drive shafts have a universal joint located at each end to permit pivoting, and accommodate angularity between two (2) intersecting shafts.

Telescoping shafts have a splined slip joint to compensate for movement between the connected components.

During normal operation, the chassis, engine, transmission and axles all experience some movement relating to surface irregularities and varying stress loads. Each time these conditions are encountered, a change in the overall length of the drive shaft occurs.

Important The upbox to transmission and midship driveline has grease fittings that needs to be greased every 250 hours. See “Driveline, Between Upbox and Transmission Lubrication” on page 17.

Universal Joint Bearings

Bearing

Universal joints employ various types of bearing tap assemblies. They are specified on any particular scooptram based on their torque loading capabilities.

Driveline Support BearingsDrive shaft support bearings are used at locations where a driveline passes through a frame bulkhead, usually at the midships area; or in the middle of a long span.

Driveline support bearings are mounted to a frame cross member. These bearings require regular lubrication and are provided with lube fittings for that purpose.

On ST14 a remote access lube line and fitting is installed for convenience of servicing.

Remote lubrication on the powerframe, to lube the bearings.

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Remote lubrication on the load frame, to lube the bearings.

Axles

Axle and posi-stop brake manuals.

The front and rear axles have spiral bevel type ring gear and pinion with further reduction provided by planetary gear set within the wheel hub. For more information how to repair the axles see the axle manuals included in the documentation.

Front axle

Rear axle

Important The front and rear axle has grease fitting located on the input shaft that’s need to be greased every 250 hours. See “Front axle lubrication” on page 17 and See “Rear axle lubrication” on page 18

In the spare parts catalogue you will find all the including parts for the axles.

Wheels and Tires

Tire

An effective wheel and tire maintenance program can pay big dividends in improved productivity and longer tire life.

This chapter will identify several major areas to consider in establishing a tire and wheel maintenance program:

• Road Maintenance

• Wheel and Tire Inspection and Maintenance

• Air Pressure Inspection

• Rolling Radius & Tire Sizing

• Driving Practices


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The following are very important, but are not covered within this chapter:

• Records Maintenance

• Mechanical and Driver Training

• Access to Wheel and Tire Handling Equipment

• Road Maintenance and Tire Life

Wheel and Tire Inspection and MaintenanceWheels should be visually inspected for signs of rust, cracking or other damage that would reduce their reliability. Small rocks and dirt will get into shallow cuts in the tread and if neglected will be gradually pounded through the cord body. Separation of either tread and/or plies can result from neglected cuts.

One simple method of preventing this from occurring is to use an awl or similar tool to clean out the cut and remove any stones or other matter lodged in the cut.

Next, use a sharp, narrow-bladed knife and cut away the rubber around the cut to form a cone-shaped cavity extending to the bottom of the cut. The sides of the cavity should be slanted enough to prevent stones from wedging into it.

Tires with tread cuts treated in this manner may be continued in service without danger of further growth of these injuries.

Large cord body breaks over 1/3 of the width of the tire cannot be economically repaired for use in normal service.

N o t e Keep tires free from oil, grease, and fuel. Never clean tires with petroleum products. If a petroleum product does get on a tire, promptly flush off or wipe off with water.

Proper InflationThe importance of correct inflation in off-road tires cannot be over-emphasized. Poor tire maintenance almost always results in under-inflated tires and therefore unnecessary tire expense.

N o t e Inflation pressures are based on the standard Scooptram configuration; a 8 kph (5 mph) maximum speed; and the offroad rating by the tire and rim association Inc.

Over-inflat ion results in:• Excessive cutting

• Lower impact resistance

• Rapid center wear

• Cut growth

• Poor re-tread ability

Under-inflat ion results in:• Ply and tread separation as a result of excessive

heat build up.

• Cracking and excessive flexing.

• Bead failures from excessive strain.

• Tubeless liner separation from heat.

• Rapid wear from tread disfiguration.

• Rapid wear from heat, reducing the cut resistance and wearing ability of the tread rubber compound.

Rolling Radius and Tire SizingImportant Never put different sized tires on a

Scooptram.

When the rolling radius of tires on the same axle is different, they are not rotating at the same speed. This sets up a continuous stress on the axle components which is relieved by tire skid.

When the rolling radius difference occurs between the front and rear axles on a four-wheel drive vehicle this additional stress is amplified throughout the entire drive train.

Improper inflation is the most common cause of a difference in rolling radius. Two identical tires which are not equally inflated will have a different rolling radius.

Other reasons for a difference in the rolling radius would be the use of different sized tires or unequally worn tires on the vehicle.

Atlas Copco Inc. recommends that the tire rolling radius tolerances be matched as shown in the following equation:

N o t e If the miss-match is larger than 2%, one side of the no-spin will disengage (the smaller tire). The other side will carry all of the torque.

Example: 30" RR tire +/- 4% = 31.2" RR to 28.8" RR.

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Driving Practices:A proper tire maintenance program and maintaining haulage ways in good condition cannot guarantee optimum service life of tires. Poor driving practices are a major cause of excessive wear and permanent damage.

Drivers can help to reduce tire costs by:

• Avoiding obstacles and keeping away from chuckholes or other hazards, which can damage tires.

• Not climbing or driving up on the ore pile. Such practice subjects tires to cutting and concentrated impact.

• Operators should lower the bucket when approaching the ore pile, to clear the work area.

• Preventing excessive braking. Heat developed by braking may be transferred to the beads (and/or inner liner of tubeless tires) causing these areas to become charred or cracked.

• Not letting tires rub against side walls or against barriers erected to facilitate unloading.

• Avoiding taking turns at high speeds and driving in the lowest gear applicable.

The driver who drives carefully and who makes a reasonable attempt to prevent tire damage saves a substantial amount of money on tire costs.


56ST14

Replace Powertrain ComponentsBefore start working with the machine, always read “Safety Awareness manual” and “Operator manual” to work with and park the vehicle correctly.

DANGER If the Scooptram has been in operation within the previous hour, the temperature of the engine, the engine cooling and exhaust systems, and the transmission components can be hot enough to cause serious burns. Allow all components to cool before initiating removal procedures.

DANGER -Release the brake accumulator pressure by depressing the park brake override button. -Depress the hydraulic tank relief valve to relieve tank pressure. -Hydraulic pressure will still be high. Use extreme caution while removing hydraulic components. -The accumulators is charged with compressed nitrogen

Before you start working with the machine, always make sure following things:

• Install articulation lock prior to lifting the vehicle.

• Attach a do not operate tag to the off/on/start switch.

TransmissionRemove and replace the transmission assembly as outlined in the following paragraphs.

N o t e It is important to identify and label all hoses and wiring prior to removing them from the transmission. This will allow the speedy re-installation of the transmission

RemoveBefore start working with the machine, always read “Safety Awareness manual”.

STEP 1 Put a suitable container below the transmission and drain the oil. After the oil is out of the transmission, clean and replace the drain plug.

STEP 2 Remove and plug all hoses that are connected to the transmission.

STEP 3 Remove all electrical wiring on the transmission and bulkhead on cab.

STEP 4 Disconnect the engine to transmission driveline from the transmission.

STEP 5 Disconnect the transmission to midship and rear drivelines.

STEP 6 Mount on two (2) lifting devices.

Lifting devices

STEP 7 Release the six (6) bolts that hold the transmission mounts.

Four of the six bolts.

STEP 8 Lift up the transmission really slow and make sure it’s not get caught anywhere.

Atlas Copco 57

Lifting the transmisson

N o t e It is important to make sure that the transmission hoisting chains are adjusted so that the transmission is lifted evenly out of the compartment.

STEP 9 Put it safe on a stand on the floor and make sure it cant fall over.

Reinstal lInstall the transmission as follows:

STEP 1 Using the same hoist, spreader bar, chains, and lift fittings as used in removal, lift the transmission from its stand and, taking care that it does not catch on anything, lower it into the power frame until the mounting brackets set solidly on the frame.

STEP 2 Remove the hoist, transmission lift spreader bar, chains, and lift fittings.

STEP 3 Reinstall the bolts that secure each transmission mounting bracket to the power frame.

STEP 4 Reinstall the driveline sections.

STEP 5 Reconnect the electrical harness to the transmission.

STEP 6 Reinstall the dump/hoist, steering, and brake pumps. Reconnect the hydraulic lines and their retainer clamps to the pumps.

STEP 7 Uncap or unplug and reinstall the hydraulic lines and their retainer clamps that run above the transmission.

STEP 8 Fill the transmission with proper oil.

STEP 9 Replace the transmission/hydraulic/fuel cooling radiator and the lines that feed the

radiator, ensuring that the retaining clamps are also reinstalled to the appropriate hose.

STEP10 Reinstall the hood above the transmission compartment.

STEP11 After starting the engine, check the transmission oil level and leaks in the system.

Transmission Tube-in-shell Cooler

1. Hydraulic oil in connector 2. Heat exchanger shell housing3. Hydraulic oil out connector4. Coolant out connector5. Coolant in connector6. Oil drain7. Water drain

Remove

STEP 1 Place separate containers under the vehicle to collect engine coolant and hydraulic oil.

STEP 2 Remove the air cleaner assembly as a unit.

STEP 3 Remove the heat exchanger protective shield.

STEP 4 Drain the engine coolant & transmission oil from the tube-in-shell cooler.

STEP 5 After the transmission oil has been drained, remove the connectors.

STEP 6 After the coolant has been drained, remove the coolant connectors.

STEP 7 Unfasten the bolts to the retaining brackets and remove the unit.

STEP 8 Clean up residual fluids before installing the replacement.

321 54

6 7


58ST14

Reinstal lReinstall by reversing the removal steps.

Transmission Oil Filter

Transmission oil filter, hydraulic hatch

Remove

STEP 1 Open hatch in service bay hydraulic.

STEP 2 Use a tool to turn the filters counter clockwise.

Installation instructions for the transmission filter

Reinstal l

STEP 1 Fill the new filter with transmission oil and lubricate the sealing.

STEP 2 Turn it clockwise and tighten it only by hand first.

STEP 3 Use a tool to tighten it 1/2 turn more.

Transmission Solenoids

Solenoids on the transmission

RemoveBefore start working with the machine, always read “Safety Awareness manual”.

STEP 1 Remove the right rear wheel.

STEP 2 Remove the inspection hatch.

STEP 3 Remove the nine (9) bolts holding the valve section and remove the valve.

N o t e Be careful with the sealing’s behind the valve.

Reinstal lReinstall the component in the reverse order of removal.

N o t e Make sure all the sealing’s are correct in place.

DrivelineN o t e Most driveline sections are removed and

replaced in somewhat similar manners. However, for ease in locating procedures and precise coverage of minor differences, the following paragraphs contain procedures for each driveline section.

Atlas Copco 59

DANGER Make certain that all wheels are blocked securely before removing a driveline section.

N o t e In each of the following replacement procedures, the procedure assumes that the Scooptram is in the same condition and position as at the conclusion of the associated removal procedure.

Phasing the Driveline

Check the drive shaft.

When a splined shaft is assembled to a slip yoke, splines must be aligned so that the yokes at either end of the shaft are in the same plane, that is “in phase”. Drive shafts are phased and balanced at the factory and are “marked” for correct assembly with match marks at the yoke flange ends and on the propeller shaft.

Lubricate the splines thoroughly, and properly assemble and “phase” the shaft.

Misphasing the drive shaft can cause vibrations throughout the driveline, contributing to bearing failure.

Installing the Drive ShaftInstall drive shafts with the slip yoke toward the source of power (torque). Reverse installation if doing it provides better access to the lube fitting on the slip yoke.

N o t e The lube fitting on each of the universal joints and the fitting on the slip yoke should all be on the same side of the shaft for ease of servicing.

Yokes and Bearing MountsN o t e Yoke faces, bearing mounting faces, and

keyways must be free of burrs, nicks, dirt and paint to allow proper assembly and retention of the bearings.

STEP 1 To assemble the cross and bearing assembly to a yoke, insert the key of one bearing cap into the keyway of the yoke flange.

STEP 2 Insert the key of the opposite bearing cap into the yoke. The bearing cap has machined surfaces keyway, so some compression of the seals may be required to seat the second bearing. This can be done using a C clamp, tapping with a soft hammer, or by using hand pressure.

N o t e Do not use bearing mounting cap screws as jacking screws in order to seat the bearing in the yoke.

STEP 3 Once the bearings are properly seated, insert the cap screw fasteners and torque them to the proper values using a suitable torque wrench.

N o t e Do not use lock washers, lock plates or lock wire to secure the fasteners. These devices will not prevent the fasteners from loosening. Proper torque is the most reliable method of securing fasteners.

Installing Driveline Guards

Driveline guards.

Driveline guards help restrain a drive shaft when a universal joint fails. The guard prevents the drive shaft from rotating out of control within the frame of the Scooptram and damaging other components, and causing possible injury to personnel.

If the scooptram does not have driveline guards, it is recommended that these devices be fabricated and installed on the scooptram, or ordered from Atlas Copco.

DANGER Always make sure there is a driveline guard installed around or over the midship drive shaft. This guard provides protection for the operator.


60ST14

Upbox to Transmission Driveline

Driveline between upbox and transmission

Remove and reinstall the upbox to transmission driveline as outlined in the following paragraphs.

Remove

STEP 1 Wrap several layers of masking tape around the bearings on the rear universal joint cross.

STEP 2 Remove the bolts that secure the rear universal joint cross to the upbox yoke. Make certain that the tape holds the bearings in place on the cross.

STEP 3 Wrap several layers of masking tape around the bearings on the front universal joint cross.

STEP 4 Remove the bolts that secure the front universal joint cross to the transmission input shaft yoke. Make certain that the tape holds the bearings in place on the cross.

STEP 5 Remove the driveline section.

Reinstal l

STEP 1 Place the upbox to transmission driveline section in approximate position.

STEP 2 Reinstall the bolts that secure the front universal joint cross to the transmission input shaft yoke, but do not tighten yet. Remove the tape from the bearings on the cross.

STEP 3 Remove the bolts that secure the rear universal joint cross to the upbox output shaft yoke. Make certain that the tape holds the bearings in place on the cross.

STEP 4 Reinstall the bolts that secure the front universal joint cross to the transmission yoke, but do not tighten yet. Remove the tape from the bearings on the cross.

STEP 5 Inspect the positions of the bearings. If all are in the correct position, torque the bolts to their proper value, See “Driveline, Upbox - Transmission” on page 19.

Transmission to Rear Axle Driveline

Driveline between transmission and rear axle

Remove and replace the transmission to rear axle driveline as outlined in the following paragraphs.

Remove


STEP 2 Remove the bolts that secure the rear universal joint cross to the rear axle input shaft yoke. Make certain that the tape holds the bearings in place on the cross.


STEP 4 Remove the bolts that secure the front universal joint cross to the transmission rear output shaft yoke. Make certain that the tape holds the bearings in place on the cross.


Reinstal l

STEP 1 Place the transmission to rear axle driveline in approximate position.

STEP 2 Reinstall the bolts that secure the rear universal joint cross to the transmission front output shaft yoke, but do not tighten yet. Remove the tape from the bearings on the cross.

STEP 3 Reinstall the bolts that secure the rear universal joint cross to the rear axle input shaft yoke, but do not tighten yet. Remove the tape from the bearings on the cross.

STEP 4 Inspect the positions of the bearings. If all are in the correct position, torque the bolts to their proper setting. See “Driveline, Loadframe - Transmission - Powerframe” on page 19.

Atlas Copco 61

Midship DrivelineRemove and replace the midship driveline as outlined in the following paragraphs.

Remove

Midship driveline


STEP 2 Remove the bolts that secure the rear universal joint cross to the transmission to midship output shaft yoke. Make certain that the tape holds the bearings in place on the cross.


STEP 4 Remove the bolts that secure the rear universal joint cross to the front driveline. Make certain that the tape holds the bearings in place on the cross.


Reinstal l

STEP 1 Place the midship driveline in approximate position.

STEP 2 Reinstall the bolts that secure the rear universal joint cross to the front driveline, but do not tighten yet. Remove the tape from the bearings on the cross.

STEP 3 Reinstall the bolts that secure the rear universal joint cross to the transmission to midship output shaft yoke, but do not tighten yet. Remove the tape from the bearings on the cross.

STEP 4 Inspect the positions of the bearings. If all are in the correct position, torque the bolts their proper setting. See “Driveline, Loadframe - Transmission - Powerframe” on page 19.

Midship-to-Transmission DrivelineRemove and replace the midship-to-transmission driveline as outlined below.

Remove


STEP 2 Remove the bolts that secure the front universal joint cross to the midship driveline yoke. Make certain that the tape holds the bearings in place on the cross.


STEP 4 Remove the bolts that secure the rear universal joint cross to the midship shaft yoke. Make certain that the tape holds the bearings in place on the cross.


Reinstal l

STEP 1 Place the driveline in approximate position.

STEP 2 Reinstall the bolts that secure the rear universal joint cross to the transmission yoke, but do not tighten yet. Remove the tape from the bearings on the cross.

STEP 3 Reinstall the bolts that secure the front universal joint cross to the midship driveline, but do not tighten yet. Remove the tape from the bearings on the cross.


Midship to Front Axle

Remove


STEP 2 Remove the bolts that secure the front universal joint cross to the axle output shaft yoke. Make certain that the tape holds the bearings in place on the cross.


STEP 4 Remove the bolts that secure the rear universal joint cross to the midship driveline. Make certain that the tape holds the bearings in place on the cross.



62ST14

Reinstal l

STEP 1 Place the driveline in the approximate position.

STEP 2 Reinstall the bolts that secure the rear universal joint cross to the midship driveline, but do not tighten yet. Remove the tape from the bearings on the cross.

STEP 3 Reinstall the bolts that secure the front universal joint cross to the axle output shaft yoke, but do not tighten yet. Remove the tape from the bearings on the cross.


AxlesFront AxleRemove and replace the front axle as outlined in the following paragraphs.

Remove

STEP 1 Remove tires.

STEP 2 Relieve all pressure from the hydraulic system by venting at the breather and/or loosening the tank cap.

STEP 3 Disconnect the midship to front axle driveline from the front axle.

STEP 4 Disconnect the brake and brake cooling lines from the wheel ends. Immediately cap or plug each line or connection.

Brake cooling lines

STEP 5 Place a dolly under the axle.

STEP 6 Secure a hoist with spreader bar to the axle.

Important Be sure the hoist is capable of lifting the axle.

STEP 7 Remove the nuts from the bolts that secure the axle to each side of the axle hanger.

Bolts

STEP 8 Lower the axle to the dolly.

STEP 9 Detach the hoist and roll out the dolly.

STEP10 Reattach the hoist to lift the axle up on to stands for service.

Reinstal l

STEP 1 Using the same hoist, sling and dolly used for removal, lift the axle from the axle stand and set it back in position under the vehicle.

STEP 2 Lift the axle into position.

STEP 3 Reinstall the bolts that secure the axle to each side of the hanger and tighten moderately, but do not torque the nuts at this time.

STEP 4 After all bolts are in position and snug, torque in alternating sequence to proper value. See “Axle, Bolt Connection” on page 19

STEP 5 Uncap or unplug and reconnect the brake and brake cooling lines.

STEP 6 Reinstall the midship to front axle driveline to the front axle.

STEP 7 Reinstall tires.

Atlas Copco 63

Rear AxleRemove and replace the rear axle as outlined in the following paragraphs.

Remove

STEP 1 Remove tires

STEP 2 Bleed all pressure from the hydraulic system by venting at the breather and/or loosening the tank cap.

STEP 3 Disconnect the transmission to rear axle driveline.

STEP 4 Disconnect the brake and brake cooling lines from the wheel ends. Immediately cap or plug each line or connection.

Brake cooling lines, and the bolts on step 7 to the right.

STEP 5 Place a dolly under the axle.

STEP 6 Secure a hoist with spreader bar to the axle.

Important Be sure the hoist is capable of lifting the axle.

STEP 7 Remove the nuts from the bolts that secure the entire axle assembly, which includes the oscillating cradle, to each side of the axle hanger.

Bolts, see picture on step 4.

STEP 8 Lower the axle to the dolly.

STEP 9 Detach the hoist and roll out the dolly.

STEP10 Reattach the hoist to lift the axle up on to stands for service.

Reinstal l

STEP 1 Using the same hoist, sling and dolly used for removal, lift the axle from the axle stand and set it back in position under the vehicle.

STEP 2 Lift the axle into position.

STEP 3 Reinstall the bolts that secure the axle to each side of the hanger and tighten moderately, but do not torque the nuts at this time.

STEP 4 After all bolts are in position and snug, torque in alternating sequence to proper value. See “Axle, Bolt Connection” on page 19.

STEP 5 Uncap or unplug and reconnect the brake and brake cooling lines.

STEP 6 Reinstall the transmission to rear axle driveline to the rear axle.

STEP 7 Reinstall tires


64ST14

Liquid Cooled Multi-Disc BrakeDisassembly

DANGER The procedures described here must be followed exactly. Failure to do so may result in personal injury. High internal spring tensions are basic to the brake's design. This makes improper disassembly of the brake unit very dangerous. Have all necessary tools available and be familiar with the procedures before starting the disassembly.

Caution The front cover and backing plate must be “backed out” slowly to relieve inner spring tension. If these steps are not followed precisely, personal injury may result.

DANGER Outer Brake Housing Cover is under 40,000 Ibs compressed spring pressure and extreme caution must be taken in removing this cover. Brake cover bolts must be removed cautiously and evenly. Do not remove bolts one (1) at a time.

N o t e For further information on how to assemble or disassemble the liquid cooled multi-disc brakes please read the maintenance and service manual for the Posi-Stop brakes.

N o t e The pictures in this manual illustrate the disassembly/assembly procedures with the brake unit dismounted from the axle. If you are performing these procedures with the brake assembly still mounted on the axle, make certain to exercise care in keeping all parts as clean as possible to avoid contamination.

STEP 1 Multi disc brake removed from axle as an assembly. Brake face seal removed.

Multi disc brake

N o t e Face seal in one axle end must not be mixed with face seal on the opposite axle end.

STEP 2 Eight bolts were run out from the cover, but not free of threaded holes. Never take the bolts out of threaded holes all the way until spring pressure is completely relieved.Four (4) bolts were then carefully removed simultaneously a thread or two at a time. An added precaution would be to leave six (6) bolts in place and removed evenly and carefully.

Bolts removed from brake cover

STEP 3 A lifting tool was fabricated to remove the brake cover and also hold friction disc and reaction disc in place.

Atlas Copco 65

Lifting tool

STEP 4 Install the lifting tool and clamp inner teeth of friction disc to hold in place. Remove cover bolts.

Lifting toll installed,

STEP 5 Lift cover off of brake housing.

STEP 6 Remove inner piston seal assembly.

N o t e Some units will have sealing ring and back-up rings. Remove sealing rings.

Remove inner piston.

STEP 7 Remove reaction plate. This remained in housing when cover was removed.

Remove reaction plate

STEP 8 Remove brake piston.

STEP 9 Remove outer cover “O” ring seal.

Remove the “O” ring seal

STEP10 Remove brake cover inlet and outlet “O” rings two (2) places.

Remove brake cover

STEP11 Remove piston pressure ring.

STEP12 Remove brake apply springs. Remove friction and reaction disc from brake cover.


66ST14

Remove brake apply springs.

STEP13 Remove outer piston seal assembly.

N o t e Some units will have sealing ring and back-up rings. Remove sealing rings.

Remove outer piston seal assembly

Cleaning and InspectionClean all parts thoroughly using a solvent type cleaning fluid. Parts should be immersed in cleaning fluid and moved up and down slowly until all old lubricant and foreign matter is dissolved and parts are thoroughly cleaned.

InspectionMake a careful and thorough inspection of all parts. You can avoid costly failures at a later date by identifying and replacing all parts showing wear or fatigue. Carefully inspect all piston seal surfaces, grooves, edges of grooves, as well as housing bore and outer diameter of piston. The importance of careful and thorough inspection of all parts cannot be overstressed.

Housing, Covers, etc.Make sure that all housings, covers, and bearing caps are thoroughly cleaned and that mating surfaces are free of nicks or burrs. Check all parts for cracks or other conditions which could result in oil leaks or failure.

Piston and Housing SealsReplacement of seals is more economical when unit is disassembled than premature overhaul to replace these parts at a future time. Further loss of lubricant through a worn seal may result in failure of other more expensive parts of the assembly. Sealing members should be handled carefully, particularly when being installed. Cutting or scratching seriously impairs its efficiency. Apply a film of lubricant to the brake piston and all sealing rings to facilitate reassembly.

Atlas Copco 67

AssemblyN o t e For further information on how to

assemble or disassemble the liquid cooled multi-disc brakes please read the maintenance and service manual for the Posi-Stop brakes.

STEP 1 For step one (1) to six (6) of the assembly of the Posi-Stop see the steps for disassembly in reversed order (step 13 to 8).

STEP 2 Position first the friction plate (teeth on inner diameter) in the brake cover. Install first the reaction plate (teeth on outer diameter) in the brake cover. Alternate friction and reaction discs until three (3) or six (6) each has been installed. You will start with a friction disc and end with a reaction disc. Install lifting eye and clamping tool to hold discs in position. (3 or 6 plate to be determined by model number.)

Brake Assembly

STEP 3 Install inner piston seal assembly. See step six (6) of the disassembly sequence.

STEP 4 Install cover and disc assembly on brake housing.

N o t e Align inlet and outlet holes in cover with holes in brake housing.

Install cover and disc assembly

STEP 5 Install Loctite #262 to threaded holes in brake housing. Install brake cover to brake housing bolts. Run bolts down evenly until bottom of clamp hits on pressure plate. Remove clamp and lifting eye. Continue installing bolts evenly until cover is tight against housing.

Brake Assembly

STEP 6 Tighten bolts 175-190 ft. ibs. torque [240-260 N.m.].

Tighten bolts


68ST14

Tire Mounting Procedures

The arrow shows the direction that wheel parts can fly, with explosive force, if installed improperly or if parts are damaged.

Tire and rim servicing can be dangerous, and should be done by trained personnel using proper tools and procedures.

DANGER Failure to comply with these procedures may result in faulty positioning of the tire and/or rim. Air pressure and heat from normal operation are adequate to cause rapid disassembly, with explosive force, if the parts are damaged or improperly installed.

Tire and Wheel Safety

If the tire and wheel assembly is removed from the vehicle, always put it into a tire inflation cage before adding air.

Earthmover Rim Locking Wheel Flange With Heavy Duty Driver

Cutaway view of a rim and wheel.

DemountingSTEP 1 Block wheels not being serviced.

STEP 2 Using a jack, hoist, or other suitable method, raise the vehicle until the wheel to be serviced just clears the ground.

DANGER Ensure that the method used to elevate the scooptram is stable and capable of raising and supporting the weight. If the tire being removed is on an oscillating axle, be sure to block the carrier.

STEP 3 Crib or securely block the vehicle before proceeding with wheel removal.

DANGER Do not attempt to remove any rim or wheel components such as lugs or wheel clamps before all pressure in the tire is exhausted. A broken rim part under pressure can blow apart and cause severe injury or death.

STEP 4 Remove the valve core and exhaust all air from the tire. Stand clear or to the side during deflation.

Atlas Copco 69

STEP 5 Check the valve stem by running a piece of wire through the stem to make sure it is not plugged before proceeding with wheel service.

DANGER Do not look into the valve stem while clearing restrictions.

STEP 6 Remove the wheel using a hoist and sling capable of supporting the load.

DANGER Use caution when removing wheels or heavy rim components. Stand to one side and keep hands and fingers clear when using demounting tools. The tool may slip and cause injury.

STEP 7 Demount tire from wheel using accepted shop practices.

MountingReview safety warnings and cautions for dismounting before beginning work.

STEP 1 Verify articulation locking bar is secured between both frame mounts and Do Not Operate tag is in place on Off/On/Start switch.

STEP 2 Verify all blocking and cribbing is securely in place.

STEP 3 Clean all wheel and hub mounting surfaces. Remove all dirt, grease or paint before installing wheel.

STEP 4 Replace the wheel using a hoist and sling or forklift capable of safely supporting the load. Make sure the valve stem is aligned with any clearance slot in the axle hub.

STEP 5 Install mounting hardware and secure the tire and rim in accordance with the torque settings specified in the Appendix.

STEP 6 Once the tire is mounted, lower the vehicle to the ground, using jacks, hoists or other suitable method.

STEP 7 Remove all cribs and blocks.

STEP 8 Remove and stow articulation lock.

STEP 9 Remove Do Not Operate tag from Off/On/Start switch.

Wheel InspectionInspect wheel components for defects, observing the following precautions:

STEP 1 Clean rims and repaint to prevent corrosion and to facilitate inspection and tire mounting. Be very careful to clean all dirt and rust from the lock ring and gutter. This is important to secure the lock ring in its proper position. A filter on the air inflation equipment to remove the moisture from the air line helps prevent corrosion. The filter should be checked periodically to be sure that it is working properly. Parts must be clean for a proper fit, particularly the gutter section which holds the lock ring in proper position.

STEP 2 Check the rim for cracks. Replace all cracked, badly worn, damaged, and severely rusted components with new parts of the same size and type. Replace a component when condition is in doubt. Parts that are cracked, damaged, or excessively corroded are weakened. Bent or repaired parts may not engage properly.

STEP 3 Don’t re-inflate a tire that has been run flat without first inspecting the tire, tube, flap, rim, and wheel assembly. Double check the side ring, flange, bead seat, lock ring, and o-ring for damage and make sure that they are secure in the gutter before installation. Components may have been damaged or dislocated during the time the tire was run flat or seriously under-inflated.

STEP 4 Do not, under any circumstances, attempt to re-work, weld, heat, or braze any rim components that are cracked, broken, or damaged. Replace them with new parts, or spare parts that are not cracked, broken, or damaged and which are of the same size and type. Heating a part may weaken it to the extent that it is unable to withstand forces of inflation or operation.

STEP 5 Make sure the correct parts are being assembled. If you are not sure about the proper mating of rim and wheel parts, consult a rim and wheel chart.


70ST14

Mismatched RimsImproper rim selection can cause these operating problems:

• Tire Slippage

• Excessive Flexing

• Tube Pinching

• Overheating

• Valve Stem Tear Outs

• Sidewall Failure

• Ply Separation

• Blowouts

DANGER Mismatched rim parts are dangerous.

Most rims look alike but all vary somewhat in certain design features. It is these differences between rims of different types that make “part mixing” a hazardous business. A close, proper fit between rim parts is essential to long tire life as well as to operating safety.

Very often side-rings, flanges, and lock rings of different types appear to be properly seated, but actually wide gaps are present, frequently difficult to see. The rim cross-sections above show correct, safe matchings of rim parts, as well as mismatched rings and bases which almost always create an unsafe operating condition.

Mounting and Inflating SafetyObserve the following precautions during mounting and inflation:

• Inflate all tires in a safety cage, then use safety chains or an equivalent restraining device during inflation. Mis-assembled parts may fly apart dur-ing inflation.

• Don’t inflate a tire before all components are properly in place. With the tire in a safety cage and safety chains or equivalent restraining devices installed, inflate to approximately 10 psi (.69 bar). Recheck the components for proper assembly. If the assembly is not proper, deflate the tire and correct the problem.

• NEVER hammer on an inflated or partially inflated tire/rim assembly. If the assembly is not proper at 10 psi (.69 bar), deflate the tire and cor-rect the problem. Don’t try to seat rings or other components by hammering while the tire is inflated or partially inflated. Properly matched and assembled components will seat without tap-ping.

• Don't hammer on rims or components with steel hammers. Use rubber, lead, plastic, or brass faced mallets if it is necessary to tap un-inflated compo-nents together.

• Never sit on or stand in front of a tire and rim assembly that is being inflated. Use a clip-on fit-ting or connector with an in-line valve so that the person inflating the tire can stand to the side of the tire.

• Stand clear when using a cable or chain sling. The cable or chain may break, lash out, and cause injury.

• Never attempt to weld on an inflated tire/ rim assembly or on a rim assembly with a deflated tire.

• Never mix parts of one type rim with those of another. Mis-matched parts may appear to fit, but when inflated, can fly apart with explosive force.

• Never add or remove an attachment or otherwise modify a rim (especially by welding or brazing) unless the tire has been removed and you have received approval from the rim manufacturer. Modification or heating of a rim or one of its parts may weaken it.

Mounting and Inflating ProceduresSTEP 1 Install tire on the wheel. Complete assembly

of wheel components.

STEP 2 Align driver pockets in bead seat band and base.

Atlas Copco 71

STEP 3 Insert driving key into driver pocket on base.

STEP 4 Make certain that all parts are properly aligned before inflation.

STEP 5 When properly aligned, the bead seat band and pocket will move out and lock the drive key during inflation.

STEP 6 Mount completed wheel and tire assembly on the axle, then tighten lugs to the specified torque.

STEP 7 Remove cribbing or blocks and lower the vehicle.

STEP 8 Check that tire is inflated to the specified pressure following the applicable precautions listed above.

N o t e Outboard drivers are on those rims used in high torque and/or low inflation pressure applications, preventing circumferential movement of the rim components. Rim assemblies with an “M” or “L” near the end of the style designation (part number) are so equipped.


72ST14

Wheel Nut TorqueWheel nuts must be tightened in an alternating pattern.

Wheel nuts are to be tightened to the correct torque upon initial installation or reinstallation on the scooptram.

Wheel nuts are to be checked for correct torque every four (4) hours for the first twelve (12) hours of operation.

Wheel nuts are to be checked for correct torque every eight (8) hours for the next thirty-two (32) hours of operation. Thereafter, check wheel nuts every one hundred (100) hours, or weekly.

Important Before mounting and torquing, remove all paint, dirt and rust from both sides of wheels at mating surfaces around lug bolt holes. These areas must be clean. Also, clean axle wheel end surfaces which mate with back side of wheels. Proper torque cannot be maintained unless these surfaces are clean and free of paint, dirt or grease.

Operating PrecautionsObserve the following precautions when putting the scooptram back in service:

STEP 1 Don't use undersized rims. Use recommended rim for tire. Consult catalogs for proper tire/rim matching.

STEP 2 Don't overload or over-inflate tire/rim assemblies. Check your rim assemblies if special operating conditions are required. Excessive overload can cause damage to the tire and rim assembly.

STEP 3 Never install a tube in a tubeless tire/rim assembly when the rim is suspected of leaking. Loss of air pressure through fatigue, cracks, or other fractures in a tubeless rim warns you of a potential rim failure. This safety feature is lost when tubes are used with leaking rims. Continued use may cause the rim to burst with explosive force.

STEP 4 Always inspect rims and wheels for damage during tire checks. Early detection of potential rim failures may prevent serious injury.

STEP 5 Never add or remove an attachment or otherwise modify a rim (especially by heating, welding, or brazing) unless the tire

has been removed and approval has been received from the rim manufacturer. Modification or heating of a rim or one of its parts may weaken it so that it cannot withstand forces created by inflation or operation.

RecappingFor some off-road operations, such as mucking and hauling, recapping tires can be cost effective alternative to replacement with new tires. Most tires are generally recappable, depending on how well they have been inspected during their service life.

The deciding factor is the severity of the job the tire must do. Some jobs are too tough for recapped tires. High speed, overloading, and long service at low inflation pressure all take too much life out of the cord body for it to last longer than the life of one tread.

On large tires with wire in the body, recapping is advantageous. Modern recappers can recap wire and will replace the wire, if necessary.

Atlas Copco 73

Chapter 5: Main Frame

Introduction This section contains removal and replacement instructions for the following components:

• Major components on the load frame other than the power train, hydraulic systems, and electrical system.

• Major components on the power frame other than the power train, hydraulic systems, and electrical system.

• Separating and reconnecting the load frame and the power frame.

Wherever possible, procedures are presented in the sequence required for orderly removal; that is, if an item must be removed before another item can be removed, that item is covered first.

Load FrameRemoving the BucketRemove the bucket as follows:

DANGER Depending on the scooptram model, the bucket could weigh up to 6800 kilograms (15,000 lbs.). Do not reach or lean underneath the bucket unnecessarily.

Bucket lowered to stops. Note that the back of the bucket is not supported by the ground at this point. Some procedures may require that the bucket be supported by a wooden pallet or other support device.

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STEP 1 Block all tires.

STEP 2 Lower the boom until it is resting on its stops.

STEP 3 Roll the bucket back until the bottom of the bucket is parallel with the ground.

STEP 4 Place suitable support blocks, or a palette, under the bucket so that it rests on the supports.

DANGER The bucket is extremely heavy. Severe injury or death may result if the support blocks are not strong enough to hold the weight of the bucket.

STEP 5 Roll the bucket down until it is resting on the supports, level but not on the ground.

Important Make sure that the entire bucket is resting on support blocks.

STEP 6 Disconnect the Dog-bones from the bucket by removing the trunnion caps from the bucket end.

STEP 7 Remove the trunnion caps from the main boom pins on the bucket.

STEP 8 Remove all the tire blocks.

STEP 9 Back the vehicle away from the bucket or hoist the bucket from in front of the vehicle.

Replacing the BucketReinstall the bucket in the reverse order of removal.

Removing the Z-Bar

Follow these instructions to remove the Z-Bar from the boom assembly:

DANGER The Z-Bar is extremely heavy. Take care to NOT place any one under or around an unsupported Z-Bar assembly.

STEP 1 Park the Scooptram on a flat hard surface. Rest the tip of the bucket on the ground.


N o t e It is not necessary to remove the bucket to remove the Z-Bar.

Atlas Copco 75

STEP 3 Remove the dump cylinder guard.

STEP 4 Remove the stem-end pin of the dump cylinder on the Z-Bar.

STEP 5 With a suitable hoist, lift the dump cylinder stem-end up out of the Z-Bar.

STEP 6 Place suitable support blocks under the raised dump cylinder and lower onto the blocks.

STEP 7 Remove the dog-bones from the bottom end of the Z-Bar and lower to the ground.

STEP 8 Set the Z-Bar aside on a suitable support.

STEP 9 Attach a hoist chain to the Z-Bar dump end and remove the trunnion caps from the Z-Bar swivel mount. Hoist the Z-Bar out of the way and place on a suitable support.

Reinstalling the Z-BarFollow the removal procedures in reverse order.

Removing the BoomRemove the boom as follows:

DANGER Depending on the scooptram model, the boom could weigh up to 5670 kilograms (12,500 lbs.). Do not reach or lean underneath the boom without it being properly supported.

STEP 1 Park the Scooptram on a flat hard surface.


STEP 3 Follow the procedures for removing the bucket.

STEP 4 Follow the procedures for removing the Z-Bar.

STEP 5 Support the dump cylinders with suitable blocks using the load frame as support. Do not rest the blocks on the boom cross section.

STEP 6 Hydraulically lift the boom until it is high enough for the hoist cylinder stem- end pins to clear the front tires. Prop the boom up so that it is securely supported with proper weight rated stands.


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STEP 7 To disconnect the hoist cylinders, first place a brace between the cylinder and the load frame. Remove the pin and place on a clean surface. It is not necessary to remove the hoist cylinders from the load frame in order to take off the boom.

STEP 8 Connect three chains, which are fastened to three lifting points on the boom, to the lifting hoist hook. Make sure that the chain lengths are adjusted to lift the boom squarely.

Connect the three lifting chains to these points.

STEP 9 Remove the pins from the boom base end swivel mount.

STEP10 Hoist the boom assembly off of the load frame and set it so that it is securely supported.

Replacing the boomReinstall the boom in the reverse order of removal.

Atlas Copco 77

Power FrameRemoving and Replacing HoodsN o t e The following procedures are generalized

so for all of the hoods on the scooptrams.

DANGER The scooptram hoods are heavy. Do not reach or lean underneath any hood unnecessarily when the hood is raised without first installing the hood prop.

Hood Removal

Remove the hoods as described in the following steps:

STEP 1 Park the Scooptram on a flat hard surface and turn the engine off.


STEP 3 Rig a hoist capable of lifting the hood above the scooptram.

STEP 4 Unlatch the hood.

STEP 5 Lift the hood and install the support.

STEP 6 Disconnect the gas support struts on both sides.

STEP 7 Remove the hinge bolts.

STEP 8 Slowly lift the hood with the hoist, making sure it does not strike the frame or catch on any components nearby and place the hood on blocks in a safe location away from the work area.

Hood ReplacementReplace the hood in reverse order.

Important Always install the hood latches after servicing the Scooptram.


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Separating the Load & Power FramesSeparationIn order to separate the load frame and the power frame all tension must be removed from the articulation joint. Separate as follows:

STEP 1 Place blocks in front of and behind all wheels.

STEP 2 Relieve all hydraulic pressure. See “Relieving Hydraulic Pressure” on page 97.

STEP 3 Disconnect and remove the midship driveline.

STEP 4 Install two maintenance stands at the rear of the power frame. Adjust until they are tight against the frame.

STEP 5 Attach chains from a hoist to the lifting points on the load frame and raise the front end of the power frame.

STEP 6 Place a maintenance stand under the front of the power frame and lower the vehicle.

STEP 7 Disconnect the hydraulic lines between the load and power frames. immediately cap or plug each line and connector.

STEP 8 Disconnect the electrical lines between the power and load frames at the power frame junction box.

STEP 9 Disconnect the steering cylinders from the load frame by removing the cylinder-to-load frame (stem end) pins.

STEP10 Perform either of the following:

10A Place a dolly capable of carrying the weight of the load frame under the back of the frame. If the vehicle is not on a concrete surface, place a steel sheet on the ground on which to roll the dolly. The steel sheet must be of sufficient size to allow the load frame to move forward approximately 1 meter (3 feet).

10B Position a hoist over the front of the load frame. The hoist must be capable of carrying the weight of the back of the load frame, and must be capable of moving approximately 1 meter (3 feet) with the load frame. Rig a sling to lift the frame.

STEP11 Adjust the height of the dolly or hoist so that the weight is removed from the articulation joint and remove the trunnion caps from both the top joint and bottom joint.

STEP12 Remove the blocks from the load frame wheels.

STEP13 Move the load frame forward approximately 1 meter (3 feet).

Atlas Copco 79

STEP14 Place blocks in front of and behind the load frame wheels.

STEP15 Securely support the back of the load frame with a maintenance stand or wooden blocks.

ReconnectionReconnect the load frame and the power frame as follows:

N o t e This procedure assumes that the vehicle is in the same condition and position as at the end of the frame separation procedure.

STEP 1 Remove the maintenance stand or wooden blocks from beneath the back of the load frame.

STEP 2 Remove the blocks from in front of and behind the load frame wheels.

STEP 3 Move the load frame backward until aligned with the articulation pins.

STEP 4 Install the trunnion caps

STEP 5 Adjust the height of the rear of the load frame as necessary for proper articulator pin alignment.

STEP 6 Place blocks in front of and behind the load frame wheels.

STEP 7 Insert the lower articulation pin. Re-install the pin retaining cap. Lubricate each articulation pin and retaining cap bolt, and screw in all bolts. Do not tighten.

STEP 8 Check the positions of all articulation pin caps If both pins and all caps are in proper position, properly torque the bolts to according to specification.

STEP 9 Remove the dolly and its fittings from beneath the load frame or remove the hoist and its fittings from the frame.

STEP10 Replace the midship driveline.

STEP11 Reconnect the steering cylinders.

STEP12 Unplug and reconnect the hydraulic lines.

STEP13 Remove the maintenance stands from beneath the power frame.

STEP14 Make sure the parking brake is set.

STEP15 Remove all blocks from all wheels.

Articulation Pins

1. Pin Cap Bolts2. Pin Cap3. Bearing Retainer Plate Bolts4. Bearing Retainer Plate5. Retainer Plate Seal6. Split Spacer7. Spacer8. Bearing Cone9. Bearing Cup

10. Hinge Plate11. Spacer Ring12. Articulation Pin13. Pin Shoulder

The scooptram is supplied with taper roller articulation pins. Installation and removal of the articulation pins is not required to disconnect the two frames. However during the life of the scooptram, it may be necessary to remove the hinge pins.

Important The taper bearing cones and bearing cup are a matched set. If the bearing is damaged or worn, replace the whole bearing assembly.

N o t e Atlas Copco recommends replacing both the upper and lower hinge pin bearing at the same time.

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Pin RemovalDANGER The articulation pins are very heavy and could cause injury or death if mishandled. Always use a hoist to position the pin into the hinge bore. Also take care when removing the top pin.


STEP 2 Disconnect the load and power frame as instructed previously.

DANGER The order of pin removal does not matter. If the bearings are going to be reassembled, tag them as they are taken apart so that they will be replaced in their previous position.

Pin removing directions

STEP 3 If removing the bottom pin, place a stand under the pin, if removing the upper pin, attach a hoist to the pin.

STEP 4 Loosen and remove the pin cap bolts and lift off the pin cap. Place the pin cap and bolts aside so that they may be reused.

STEP 5 Loosen and remove the bearing retainer plate lock nuts and bolts.

STEP 6 Carefully lift off the bearing retainer plates (both sides) and set aside for reuse.

STEP 7 Slide off the split spacer and the small spacer,

set both aside for reuse.

STEP 8 Remove the bearing cone. Note the position of the cone, and tag with placement if the bearing will be reused.

STEP 9 Depending on pin, either lower or lift the pin from the hinge plate bore. Set the pin aside for reuse.

STEP10 Slide the spacer ring and bearing cone off of the pin. If being reused, set aside and tag with position of the bearing.

STEP11 Remove the bearing cup from the hinge plate and set aside if being reused.

Pin InstallationDANGERThe articulation pins are very heavy and could cause injury or even death if mishandled. Always use a hoist to position the pin into the hinge bore. Also take care when removing the top pin.

Important The hinge bearings are matched with the bearing cup. Take care when installing the hinge bearing to keep the sets of bearings together.

STEP 1 Install the bearing retainer plate seals into the retainer plates.

STEP 2 Pack both bearing cones with grease before installing.

STEP 3 Press one bearing cone onto the pin, taper towards the middle of the pin. Make sure that the cone is seated on the pin shoulder.

STEP 4 Press the spacer ring onto the pin and seat on the bearing cone.

STEP 5 Press the bearing cup into the hinge plate bore.

N o t e If freeze fitting insert for easy installation, install two or more bolts with flat washers on underside of hinge plate to prevent insert from falling out.

STEP 6 Slip the pin, with one cone and spacer

Atlas Copco 81

installed, into the hinge bore until the bearing is seated into the bearing cup.

N o t e The pin may need to be supported at this stage.

STEP 7 Press remaining bearing cone onto pin, taper towards the center of the pin, until it is seated in the bearing cup.

STEP 8 Slip the small spacer onto the pin.

STEP 9 Slip the split spacer onto pin.

STEP10 Bolt pin cap onto pin assembly using washers and bolts.

STEP11 Slide upper bearing retaining plate over pin and bolt onto hinge. Torque to the proper value. See “Torque Specifications” on page 132

STEP12 Bolt lower bearing retaining plate onto hinge. Torque to the proper value. See “Torque Specifications” on page 132


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Follow the procedures to reconnect the load and power frames from the previous section. Stops

Atlas Copco scooptrams are designed for the weight of the load to be carried against the stops.

N o t e Not applicable to vehicles equipped with Ride Control.

Either improper operating technique or worn, missing, or improperly installed stops can result in a number of problems.

The most common problems related to missing or defective stops are:

• Blown or leaking seals.

• Cylinder seals leaking.

• Cylinder barrel failure.

• Main control valve seals leaking.

• Structural damage.

All vehicles are shipped from the factory with stops installed.

When installing a new bucket, be sure to verify the stop positioning. A slight misalignment can cause damage.

When the vehicle is being operated without stops in place, or with stops that are hammered out, or with improperly installed stops, the load will be supported by the cylinder barrel, load frame, boom, or a combination of the three.

If the stops are missing or badly worn, the cylinder stem can bottom out in the barrel. With the load supported by the barrel, any vertical movement of the load (such as occurs during travel) will cause the piston to pound the base of the barrel. This will ultimately result in failure of the cylinder, particularly at the weld around the end cap and possibly at the cylinder mount as well.

Steering Stops

The steering stops prevent damage to the vehicle.

The steering stops are installed to limit travel of the steering cylinders to prevent them from bottoming out

Atlas Copco 83

in either direction. The stops also keep the bogie and chassis from hitting each other and causing damage.

Oscillating Axle Stops

The oscillating axle stop limits the oscillation of the rear axle 8° - 10° (depending on the vehicle) in each direction.

Bucket Rollback Stop

Bucket stop when lowered boom.

The bucket stop works when the boom are lowered and if you raise the boom the cylinder stop will be used.

The purpose of the bucket rollback stop is to limit travel of the stab cylinder and prevent it from bottoming out. The stop also help prevent the operator from stressing the boom arms, which can lead to cracking.

Bucket Rollover (Dump) StopsIf the boom are raised to the top the mechanical stop will be used and if you lower the boom the cylinder stop will be used.

The purpose of the bucket rollover stop(s) is to limit travel of the stab cylinder and prevent it from over

extending. The stop(s) also help prevent boom arm cracking, which can result from the operator slamming the bucket against the arms.

Bucket Stops (Pads)A pad is located on the Z-bar to act as bucket a stop. The purpose of the rear bucket pad is to prevent the dump cylinders from bottoming out when the bucket is fully lowered.


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Atlas Copco 85

Chapter 6: Hydraulic Systems

Introduction This section covers the theory of operation; description of common components (reservoirs, hoses, tubes, cylinders, etc.) found in a typical vehicle hydraulic system and general maintenance and troubleshooting information.

The primary purpose of the hydraulic system is to transmit power from the engine to the various working and control systems on the vehicle.

DefinitionsExpression Description

Hoist The function to lift and lower the boom.

Dump The function to tilt and roll back the bucket.

EOD Eject Or Dump. A special version of the bucket with a push plate that pushes the load out of the bucket. This can be done with horizontal bucket.

LS-pressure Load Sensing Pressure or Load Pressure. The pressure signal that is fed back to the pump. It is the highest load pressure from the functions that are activated.

Δp Delta Pressure. The difference between the LS-pressure and the pump pressure. The pump is controlled to keep this pressure difference constant, and the Δp is set by an adjustment screw on the pump controller.

Stand-by pressure

The Δp pressure when all the valves are closed and no flow is delivered from the pump. On some pumps can the Δp vary with the flow, and is normally highest at zero flow = stand by pressure.

Expression Description

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Standard SystemAll of the hydraulic subsystems share the same tank.

• Steering system

• Dump & hoist system

• Brake system

• EOD (option)

• Tow hook with brake release (option)

The hydraulic system includes the following components:

• Pumps

• Cylinders

• Accumulators

• Tank and Filters

• Hoses and Tubing

• Control Valves

• Hydraulic Oil Cooler

Steering, Hoist, Dump & EODThe functions for Steering, Hoist, Dump and EOD are connected into one Load Sensing system (LS-system) that has two LS-pumps with variable displacement that work in parallel. The control valves are spool type valves that are electric proportionally controlled with priority for Steering.

The Dump circuit has a bucket float function and the Hoist circuit has an optional Ride Control system.

Brake SystemThe brakes are spring applied and released with hydraulic pressure.

The brake accumulator is continuously charged by a variable, pressure compensated pump (constant pressure pump). The service brake is controlled with an electronic foot pedal. The brake pressure is regulated by an electric proportionally controlled valve that regulates the RVB (Relay Valve Brake).

The park brake valve is an on/off solenoid valve. Both the service brake valve and the park brake valve needs current to release the brakes.

The brake system has a hand pump and manual override on the brake valves to release the brakes.

There is an optional tow hook brake release system for recovery of the vehicle.

Cooling & Filtration SystemThe hydraulic oil is cooled in an air cooler and the brakes are wet disk type and cooled with hydraulic oil.

Two gear pumps circulate the oil in the combined cooling and filtration circuit.

The hydraulic oil is filtered through a full flow return filter.

Maximum Pressure cut off

A limitation in the pump that forces the pump to swivel back if the pressure gets over the set value. The pressure level is set by an adjustment screw on the pump controller.

Flow Sharing

A function in the main valve that reduces the speed of all functions equally if the available pump flow is smaller then the demanded flow (when the pump bottoms out). All the functions share the available flow and no function stops if.

Expression Description

Atlas Copco 87

System componentsVariable Piston Pumps

Pumps convert mechanical energy into hydraulic energy.

There are two identical pumps (VPLS1 and 2) that are connected together at the main valve (VMC) and works in parallel. The pumps are variable axial piston pumps that have a load sensing controller with maximum pressure cut off function.

There are two adjustment screws on each pump, one for maximum pressure cut off (the lower one) and one for setting the delta pressure, Δp (also called stand-by pressure). The Δp is the difference between the highest load pressure (LS pressure) and the pump pressure, and the pump is regulating to keep this difference constant. The Δp can be measured by measuring the pressure out from the pump and the LS- pressure back to the pump. The difference between these pressures is the Δp.

The VPLS2 is set to a little bit higher Δp and will control the flow until it bottoms out, then the VPLS1 start to swash out and controls the flow up to maximum flow. The reason for this is that only one pump at the time shall regulate the flow. If both pumps are regulating at the same time, they can disturb each other and cause oscillation in the flow. The check valves between each pump and the main valve (VMC) are also important to prevent the pumps from disturbing each other.

Cylinders

Cylinders are the “muscles” of the hydraulic circuit.

The cylinder does the work of the hydraulic system. It converts the fluid power from the pump into mechanical power.

Double-acting cylinders provide force in both directions.

Steering Cylinders

Steering Cylinder

The steering cylinders are double-acting cylinders which provide force in both directions. All cylinders have a chrome plated stem.

Dump Cylinder

Dump cylinder

The dump cylinder is a double-acting cylinder with a chrome plated stem.

Hoist Cylinders

Hoist cylinder stems

The hoist cylinders are double-acting cylinders which provide force in both directions.


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Accumulators

1. Gas Valve2. Nitrogen3. Piston4. Hydraulic Oil

The accumulator consists primarily of a shell, piston, gas valve, and seals. The area above the piston is pre-charged with dry nitrogen gas.

When the accumulator is being charged, oil at system pressure enters the chamber below the piston. This pressure acting on the bottom of the piston moves the piston up. As the piston travels up, the nitrogen gas is compressed, increasing the pressure above the piston. The piston will be forced up until the pressure on both sides of the piston are equal.

The accumulators should be checked during vehicle service to assure proper pre-charge pressure is available. An accumulator with low or no pre-charge will cause excess cycling of the accumulator charging valve and excess temperature in the hydraulic system.

A piston-type pneumatic accumulator uses dry nitrogen to pre-charge the cylinder and store energy.

The accumulator has a free floating piston which separates the oil from the nitrogen gas. A piston seal is used to prevent any leakage past the piston.

Tank and FiltersHydraulic TankThe hydraulic tank has several functions in the hydraulic system:

• Stores hydraulic oil.

• Cools hydraulic oil.

• Allows air to separate from the oil.

• Allows contamination to settle to the bottom of the tank.

• Contains the return line filter.

Breather and Filter

1. Tank air breather2. Return filter cap

Tank Air BreatherThe air breather on the hydraulic tank filters the air going in and out of the tank. It also has an over pressure function, with a relief valve that lets air out only if the pressure gets over a set level. It also has a check valve that opens to let air into the tank as soon as there is vacuum in the tank.

There is a button on the breather to release the over pressure in the tank for maintenance in the system.

Hydraulic Oil Fi l terThe hydraulic oil is filtered through a tank mounted full flow return filter and the oil in the tank shall be clean. The only oil that is coming into the tank unfiltered is drain lines from components that are sensitive to pressure in the drain port.

It is important that the tank is filled through the return filter to avoid any contamination entering the tank.

When the filter starts to get clogged, a pressure switch (B139) reacts and a warning appears on the display in the cabin.

The filter has a by-pass valve that opens if the pressure drop over the filter element gets too high. The by-pass valve opens at a higher pressure level then the pressure switch setting.

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Atlas Copco 89

Control ValvesThe Atlas Copco Scooptram employs a series of valves that are integral to the operation of the scooptram’s hydraulic system. The valves may include the following:

• Main control valve

• Auxiliary valve

Main Control Valve (VMC)

1. Dump2. Hoist3. EOD4. Steering

The control valve for Steering, Hoist, Dump and EOD is an electric proportionally controlled spool type valve with load sensing and flow sharing functions.

The valve is a section built spool valve with a combination of smaller sections for Steering and EOD, and larger sections for Hoist and Dump. EOD and steering uses one spool each while two spools are used for each of the functions Hoist and Dump.

The two spools each used for Dump and Hoist are identical. They are controlled by one solenoid pilot valve that deliver the same pilot pressure to both spools. The outlet ports are connected together by the bolt on blocks, so there are only two ports for each function. The reason for dual spools is to minimize the pressure drop through the valve.

The valve block consists of three parts; the small spool valve sections, the mid inlet and the large spool valve sections.

Main control valve

One of the pumps is connected to the mid inlet and the other pump is connected to the top end of the valve block. Internally are these ports connected and feed all functions in parallel.

Auxiliary Valve (AUV)

Auxiliary valve.

The auxiliary valve directs the pressure and flow of hydraulic oil for the following:

• Supplies brake system

• Directs pressure to bucket float and ride control solenoid valves in the boogie junction block (BJB)

• Charges the Brake System Accumulator

The auxiliary valve is an aluminum machined manifold that houses the check valve cartridges for brake control and brake accumulator. The cartridges can easily be removed for replacement or service.

The auxiliary valve has two (2) pressure check ports that allow monitoring of supply pressure and accumulator pressure. Hydraulic oil is sent directly to the auxiliary valve from the brake pump.

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Steering, Hoist, Dump & EOD system

Steering, hoist, dump and EOD system

The functions for steering, hoist, dump and EOD are connected into one load sensing system (LS-system). This means that the variable pumps only deliver the flow needed for the activated functions and at a pressure level that is a little bit higher then the highest load.

The system has two LS-pumps with variable displacement that work in parallel. The control valves are spool type valves that are electric proportionally controlled with priority for Steering.

The main valve has a Flow Sharing function and if the demand for oil flow is higher then the maximum pumpflow, the speed of the functions are reduced equally and they share the available oil flow. The only function that is not sharing its flow is the Steering. Thesteering function always has priority over the other functions and takes the flow that is needed.

The dump circuit has a bucket float function and the hoist circuit has an optional ride control system.

Atlas Copco 91

Dump & Hoist FunctionsBoom UpWhen the operator moves the boom control lever for boom up operation, the spool in the Main Control valve shifts. Oil flows from the pressure port to the base end of the hoist cylinders to raise the boom.

Oil from the stem end of the cylinders is routed back through the Main Control valve to the hydraulic tank.

Boom DownTo return the boom to its stops, the operator can move the boom control lever to the power down position. This shifts the main control valve to direct pressure from the inlet to the stem end of the hoist cylinders.

Oil from the base end of the cylinders returns through the dump system.

Bucket floatIn the Boogie Junction Block (BJB) are two pilot operated check valves connected to the Dump circuit, one to each side of the Dump cylinder (CBT). When the solenoid valve Y803 is activated, pressure from the brake pump (VPLS2) is used to pilot these two check valves open, and connecting both ports of the cylinder to tank. The bucket can now move freely, or "float" on the ground when driving. Note that the bucket should be placed flat on the ground before activating the bucket float to avoid any dangerous situations.

Ride Control (option)In the Boogie Junction Block (BJB) are two load control valves connected to the Hoist circuit, one to each side of the Hoist cylinders (CBL). When the solenoid valve Y802 is activated, pressure from the brake pump (VPLS2) is used to pilot these two load control valves open. The base end of the Hoist cylinders are now connected to the ride control accumulator (ACC2), and the rod end of the cylinders are connected to tank. The gas volume in the accumulator is now acting as a spring and the boom can move relative to the machine. This gives a smoother ride and reduces the stresses on the machine.

If the pressure in the hoist cylinders is higher than the pre charge pressure in the accumulator, oil will move from the cylinders into the accumulator until the pressures are equal, and the boom will fall down a bit. Therefore should the ride control be activated before the boom is lifted off the stops to avoid that the boom drops a bit.

Brake SystemAll braking systems require energy on demand to be applied to the friction devises that stop the vehicle. This energy must be stored so that it is available when needed. Generally speaking, energy is stored in two ways: with compressed gas or fluid or with springs.

With a valve installed between the energy storage device and the friction device, you have a simple braking system.

SAHR Brake System

The SAHR brake system, reverses the process of engaging and disengaging brakes. Springs apply the brakes, and hydraulic pressure releases them.

The brake uses existing wet disc brake technology. The wheel hub is splined to, and rotates with the friction discs, which are sandwiched between steel stationary discs, which, in turn, are splined to the axle housing.

The disc pack is totally enclosed from the environment, and is immersed in oil. This arrangement is the same as used on the standard wet disc brakes.

Each wheel end is an independent brake system. Industrial coil springs are arranged in the annulus previously occupied by the (hydraulic) application


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piston. They are contained in individual pockets and compressed by a single large annular piston.

The springs cause the piston to act upon the disc pack composed of the alternating stationary and rotating discs.

Application of hydraulic pressure to the working area of the piston causes it to retract, further compressing the springs, freeing the disc pack, and allowing the wheel to turn. This pressure must be maintained during normal operation.

Loss of system pressure for whatever reasons allows the springs to immediately apply full braking energy. This allows for the elimination of all redundant systems.

Service application for retarding the vehicle or slowing to a stop is accomplished by simply controlling the pressure level. Control is effected by the operator's brake pedal.

The disc brake assemblies are mounted just inboard of the wheel end planetaries on both front and rear drive axles.

Brake System ComponentsThe major components of the brake system are:

• Brake Pump

• Auxiliary Valve

• Hydraulic Accumulator

• Brake Control Treadle Valve

• Brake Solenoid Valve

• Brake Assemblies

• Brake Cooling Manifold

• Hydraulic Cooling System

Brake System OperationThe brakes are spring applied and released with hydraulic pressure.

The brake accumulator is continuously charged by a variable, pressure compensated pump (constant pressure pump). The service brake is controlled with an electronic foot pedal and the brake pressure is regulated by an electric proportionally controlled valve.

The park brake valve is an on/off solenoid valve. Both the service brake valve and the park brake valve needs current to release the brakes.

The brake system has a hand pump and manual override on the brake valves to release the brakes.

There is an optional tow hook brake release system for recovery of the vehicle.

Pump (VPLS2)The brake system is supplied by a pressure compensated variable piston pump (constant pressure pump). The pump is controlled to maintain a constant pressure and is connected to the brake accumulator via a check valve in the Auxiliary Valve Block (AUV). When the pressure in the accumulator starts to drop, the pump swash out and charges the accumulator back to the pressure level set on the pump controller.

This means that the accumulator charge pressure is set by the adjustment screw on the pump controller.

Accumulator (ACC1)The pump is, via a check valve in the Auxiliary Valve Block (AUV), connected to an accumulator which in turn supplies the brake system with pressurized oil. An accumulator is used to enable the brake system to consume high momentary oil flow for releasing the brakes and the pump can be sized to supply the maximum average flow that is needed during normal operation.

If the pump stops to deliver oil for any reason, there is enough oil left in the accumulator to use the brake a couple of times. If the pressure in the accumulator is too low, the brakes are applied by the control system.

Auxiliary Valve Block (AUV)The auxiliary valve block connects the different components in the brake system together. It contains a number of check valves and two test ports.

Test port TP1 shows the brake accumulator pressure

Test port TP2 shows the brake pump pressure.

Brake ApplicationBrake OperationWhenever the electrical power is cut off, by either engine shut down or power failure, the brakes are automatically applied.

Service Brake OperationWhen the foot pedal is actuated, the service brake is activated by the service brake valve (SVB), this is an electric controlled proportional pressure reducing

Atlas Copco 93

valve. With no current, the regulated pressure is zero and the brakes are on. The pressure is increasing proportionally with the current and the pressure level when the brakes are fully released is set in the control system. This valve is a pilot valve for the service brake relay valve (RVB) that is a larger valve that can handle the maximum flow to and from the brakes. The relay valve is also a pressure reducing valve that is reducing the pressure to the same pressure level that is created by the solenoid valve.

The brake pressure that goes out to the brakes can be measured on the pressure test port on the Brake Junction Block (BRJ3).

Park Brake OperationWhen the Park Brake button in the operator compartment is pressed, the park brake function is achieved by the park brake solenoid valve (PBV) that is piloting the pilot operated check valves CT2 and CT4 in the auxiliary valve (AUV). When the park brake valve is energized, pressurized oil from the accumulator is used to open the CT2 which supplies the service brake valve with pressurized oil from the accumulator and close the CT4 which is the tank connection. When the current is removed from the park brake valve, the CT2 closes the supply of oil to the service brake valve and the CT4 connect the service brake valve to tank and there are no longer any pressure that can keep the brakes released and the brakes are applied by the springs in each brake.

Brake Cooling

During operation, the oil flows into the brake cavity through the inlet port, floods the brake cavity with oil and exits back to the hydraulic tank through the outlet port.

Brake Release for TowingTo tow a machine that has not the ability to release the brakes by the control system, the brakes have to be manually released.

First, there has to be pressure in the brake accumulator (ACC1). If there is not enough pressure, it has to be pumped up by using the hand pump (HPB). When there is enough pressure in the accumulator, the park brake valve (PBV) and service brake valve (SVB) have to be manually activated by pushing a screwdriver in the release hole in the cabin dash.

Brake release hole

The brakes are released as long as the button is pressed. There is enough oil in the accumulator to release the brakes a couple of times.

Hand Operated Hydraulic Pump

The hand-operated hydraulic pump is double acting, pumping on both the push and pull cycle.

The hand pump (HPB) is used for releasing the brakes when the normal brake pump (VPLS2) is not functioning. The oil is pumped from the tank to the accumulator via a check valve. The hand pump has an integrated relief valve that limits the maximum pressure from the hand pump.


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Tow Hook with Brake Release (Option)

Tow Hook Lever

The brake release tow hook is an optional system designed to allow the Atlas Copco Scooptram to be towed without a vehicle operator and when the engine is not running.

The tow hook has a mechanical lever that compress a cylinder (CTHS) when applying a pulling force to the tow hook. The oil is pressed from the cylinder into the tow hook accumulator (ACC3) and to the pilot to close check valve (PCV1) which closes the connection from the brakes to tank. The pressure is also fed via the tow hook valve (THV), to the brake J-block (BRJ3) and out to each brake.

As the vehicle is towed, pressure on the tow hook lever along with the oil pressure in the accumulator maintains the oil pressure in the brake system. When the chain is loosened around the tow hook, springs push the hydraulic cylinder piston down to reset the tow hook lever.

Tow Hook System ComponentsThe brake release tow hook system includes the brake release manifold, tow hook accumulator, tow hook cylinder, and tow hook lever.

Brake Release ManifoldThe brake release manifold components provide the means for the tow hook system to bypass the auxiliary valve when the vehicle is not running. It also allows the tow hook system to be bypassed when the vehicle is in operation. The manifold houses the following units:

• Circuit replenishing check valve

• Hydraulic shuttle valve

Circuit Replenishing Check Valve

The circuit replenishing check valve keeps the built up pressure from the tow hook cylinder in the accumulator. When the cylinder is not being used, the valve allows the free flow of oil to the tank.

Hydraulic Shuttle Valve

The hydraulic shuttle valve is responsible for allowing either system to be bypassed depending on the flow of oil in the system. If the vehicle is stopped and the engine is not running, the valve closes off the auxiliary valve so that the tow hook can be used. If the engine is running, the tow hook system is bypassed.

Tow Hook Accumulator

Tow hook accumulator

The tow hook accumulator stores hydraulic oil pressure so that when the tow hook system is employed enough pressure is maintained in the brake system to keep the brakes released.

Atlas Copco 95

Tow Hook Cylinder

When the tow hook cylinder is actuated by the tow hook lever, oil is forced into the brake system and tow hook accumulator. This oil flow provides enough oil pressure to charge the accumulator and release the brakes.

Air bleed, optional tow hook systemTransmission pressure force the check valve CT1 in the tow hook valve (THV) opens and connects the system to the tank. This connection to the tank is needed to bleed the tow hook system on air.

The engine needs to be running and there has to be an over pressure in the hydraulic tank, this can be achieved by lifting the boom to the top, rolling back the bucket and lowering it again and rolling out the bucket. Then the air bleed valve on the tow hook cylinder needs to be opened until clear oil comes out.

Deaeration of brakes

Air bleed, front brakes

Air bleed, rear brakes

Each brake housing has a remote air bleed valve. At first start up and after maintenance that brings air into the system, the air needs to be removed. Air in the system result in a slower response and makes the system consume more oil. At first start up with a lot of air in the system, the oil flow to the brakes can result in a pressure drop in the accumulator to a level that is lower then minimum allowed pressure, and the brakes are applied again by the control system. The brakes can be manually released by pushing the brake release button in the cabin and bleed each brake housing at the same time.


96ST14

Cooling systemSystem principleThe hydraulic oil is cooled in an air cooler and the brakes are wet disk type and cooled with hydraulic oil.

Two gear pumps circulate the oil in the combined cooling and filtration circuit.

FiltrationThe hydraulic oil is filtered through a full flow return filter.

Hydraulic Oil Cooler (CO2)The cooler is mounted in the rear of the machine. It is downstream of the radiator and the charge air cooler. See “Coolers” on page 33.

Cooling pumps (FCP)Two gear pumps are circulating the oil in the circuit for cooling the hydraulic oil and pumping oil to and from the hydraulic oil cooled brakes.

Brake CoolingThe smaller gear pump (FCP) is pumping the oil from the hydraulic tank to the cooler (CO2). After the cooler is a relief valve (CVP1) that limits the pressure on the oil to the brake housings on the wheel ends. At high rpm and/or at cold oil, a part of the flow is going through the relief valve directly to the tank.

The return lines from the brakes can contain contamination and wear particles from the brake disks, and are also sensitive for counter pressure. Therefore are the return lines from the brake housings connected to a Junction Block (BRJ4), and the larger of the gear pumps is pumping the return oil from this Junction Block through the return filter (FIR) into the tank to assure that no contamination from the brakes enter the tank. This way, more oil is pumped from the Junction Block (BRJ4) then is coming from to the block from the brakes. The extra oil is taken from the tank connection to assure that no oil is going unfiltered to the tank.

Atlas Copco 97

General Maintenance Procedures

DANGER The Hydraulic System contains accumulators that store energy after the engine has shut down. Depressurize the system before performing maintenance.

N o t e The use of any safety procedures given in this section do not preclude any other safety practices contained in this manual or the Safety manual.

Before StartingCheck Cleanliness

• Area around the vehicle

• Power units, pipe connections, components

• Hydraulic fluids

• Parts from stock

Do not mix Fire Retardant Fluid (FRF) with standard hydraulic fluids.

Protective internal paint coatings, if used, must be compatible with the hydraulic fluid used.

Be sure all parts are on hand.

Parts from storage can develop a build-up of resin from protective oils and grease. This resin should be dissolved with solvent before the part is installed.

Make use of lifting eye bolts and transportation equipment.

Do not use force. In order to prevent radial forces and tension on pipelines and components, ensure that pipelines are firmly secured.

Do not use putty or Teflon tape as a sealing material, as this can lead to contamination and thus malfunctions.

Make sure hose lines are correctly laid. Rubbing and touching of the lines must be avoided.

Ensure availability of correct fluids. See “Fluids and Lubrication” on page 129.

Relieving Hydraulic PressureBefore conducting any service on the hydraulic system, follow these procedures:

STEP 1 Park the scooptram on a flat level surface and block all wheels.

STEP 2 Install the articulation lock.

STEP 3 Lower the boom so that it is resting on its stops and roll the bucket down so that the blade is resting on the ground.

STEP 4 Release the brake accumulator pressure. This is done by pressing a screwdriver in the "brake pressure release" hole inside the cab several times to release pressure.

STEP 5 Depress the hydraulic tank relief valve to relieve the built up tank pressure.

DANGER Hydraulic pressure is still dangerously high in the cylinders and hoses. Use extreme caution while removing a hose flange to a cylinder.

Before Removing Any HoseSTEP 1 Clean immediate area around any hydraulic

component to be serviced to prevent contamination.


98ST14

STEP 2 Label hose to facilitate assembly and diagnostics.

STEP 3 Have plug prepared to cap each hose to be removed.

STEP 4 Return lines are open to tank, therefore the entire hydraulic tank can drain if they are not adequately plugged. Often it is useful to apply a vacuum (5-7 psi / 340-480 kPa) on the hydraulic tank at the breather to prevent oil leakage, but a plug will still be necessary to prevent contaminate from getting sucked into the lines.

Pressure Setting Checks and AdjustmentsSetting Dump and Hoist and Steering Pressure

PLM screw

STEP 1 Turn the PLM screw two (2) turns clockwise to open the counter pressure valve.

STEP 2 Put a pressure manometer (Pman) on the pump pressure port.

STEP 3 Start the engine and run it on idle.

STEP 4 Adjust the stand by pressure on VPLS1 to 20 ± 1 bar with screw (1).

STEP 5 Adjust the stand by pressure on VPLS2 to 23 ± 1 bar with screw (3).

STEP 6 Activate boom down, all the way down to boom stop and hold it there.

STEP 7 Adjust the max pressure on VPLS1 to 285 ± 2 bar with screw (2).

STEP 8 Adjust the max pressure on VPLS2 to 290 ± 2 bar with screw (4).

STEP 9 Put a Pman on port B411:2 on QCV2, located on the load frame.

STEP10 Adjust the PLM screw to 280 ± 2 bar.

Setting Brake Pressure

STEP 1 Put a Pman on port B410 on the QCV1.

STEP 2 Start the engine and run it on idle.

STEP 3 Adjust the pressure to 138 ± 2 bar with the lower adjustment screw on pump VPLS2.

12

3

4

Atlas Copco 99

Hydraulic System StartupThis procedure addresses the initial start-up of the vehicle hydraulic system.

N o t e For vehicles without accumulator charging systems, pilot-operated systems, or piston pumps, ignore the applicable instructions.

STEP 1 After assembling the vehicle, but before filling the hydraulic tank, disconnect the inlet and outlet lines of the accumulator charging valve. Connect these lines together with a union or jumper hose.

STEP 2 Fill the case(s) of the piston pump(s) with clean hydraulic oil.

STEP 3 Fill the hydraulic tank with clean hydraulic oil.

STEP 4 Bleed the air out of the pump suction line(s).

STEP 5 Loosen the connection(s) at the pump inlet(s) and allow the line(s) to gravity fill.

STEP 6 Cycle the cylinders to work the air out of the system, but do not pump over relief until the relief valves are set.

STEP 7 Refill the hydraulic tank.

STEP 8 Shut down the vehicle and reconnect the accumulator charging valve.

STEP 9 Restart the vehicle and set the pilot pressure.

STEP10 Cycle the cylinders that couldn’t be cycled in step 8.

STEP11 Refill the hydraulic tank.

STEP12 Set the relief valve(s) and piston pump compensator(s).

Preparation for Trial RunN o t e (Applicable after overhaul of major

component after failure during service).

Prior to start-up the following check list should be run.

STEP 1 Check that Hydraulic Oil Tank is clean.

STEP 2 Check that hydraulic lines have been cleaned and are installed correctly.

STEP 3 Check that all couplings and flanges are tightened.

STEP 4 Check that all components are correctly connected in accordance with installation drawings or circuit diagrams.

STEP 5 Check that hydraulic accumulators are properly charged with nitrogen.

N o t e It is recommended that the gas charge be noted on the accumulator itself (e.g. by a

label) and in the circuit diagram, so that a check may be made in the future when required.

STEP 6 Check engine and pump are correctly assembled and aligned.

STEP 7 Check that hydraulic filters are of specified pore size.

STEP 8 Check that all fluids are as specified and filled up to maximum level.

Trial RunSTEP 1 Clear the area of all unauthorized personnel.

Only personnel directly required to test the vehicle should be present.

STEP 2 Check that all shut-off valves are fully open.

STEP 3 Check that the direction of rotation of the engine matches that of the pump.

3A Start the vehicle.

3B Slowly move forward a few feet.

3C Check rotation. (counter clockwise while facing pump input shaft).

STEP 4 Check position of directional valves and, if necessary, move into required position.

STEP 5 Fill pump housing with fluid.

STEP 6 All pump cavities should be full and tank pressurized.

STEP 7 Check operating function of hydraulic system without load.

STEP 8 When normal system operating temperature has been reached, test system under load. Gradually increase pressure.

STEP 9 Check monitoring and measuring devices.

N o t e Jerky movements indicate the presence of air in the system. The system is completely bled when all functions can be carried out smoothly and continuously and there is no foaming on the surface of the fluid. In practice, it has been found that foaming should have ceased 1 hour after start-up, at the latest.

STEP10 Check fluid temperature.

STEP11 At normal operating temperature, check flow restriction indicators while operating dump and hoist controls.

STEP12 Compare measured values with specified performance parameters (pressure, speed and setting of other control components).

STEP13 If restriction due to contamination is found, flush the hydraulic system in order to prevent


100ST14

premature failure of system components. Check filter back pressure.

STEP14 Listen for noise.

STEP15 Check fluid level; add if necessary.

STEP16 Check setting of pressure relief valves.

STEP17 Check for leakage.

STEP18 Shutdown the vehicle.

STEP19 Tighten all fittings, even if there is no evidence of leakage.

DANGER Tighten only when the system is not under pressure.

Atlas Copco 101

Removal and Replacement ProceduresSteering Cylinder Removal and Replacement

Steering cylinder

Steering Cylinder Removal

STEP 1 Follow the procedures to relieve the hydraulic pressure. See “Relieving Hydraulic Pressure” on page 97.

DANGER Extreme caution must be used when removing a hydraulic hose from a cylinder.

STEP 2 Disconnect all cylinder hoses. Clean, label and plug all cylinder and hose connections.

STEP 3 Attach a hoist or some type of rigging rated for the weight of the cylinder to support the cylinder.

STEP 4 Loosen and remove the bottom trunnion cap and bolts.

STEP 5 Loosen and remove the top trunnion cap bolts but do not remove the cap. Hold it in place on the cylinder eye to keep the pin from slipping.

DANGER Keep fingers and hands clear from the pin area while removing the trunnion caps. Severe hand injury could result if the pin inadvertently slips down to the cylinder eye.

STEP 6 Hoist the cylinder out of the way and place it on the shop floor or a suitable work stand.

Steering Cylinder Instal lat ionFollow the removal steps in reverse order.

Operate the scooptram to bleed any air out of the system prior to putting the machine into service.

Dump Cylinder Removal and Replacement

Dump Cylinder

The dump cylinder will require some sort of lifting device to support, lift and lower the cylinder to the ground. Determine how the cylinder will be handled before removing, then do the following.


STEP 2 Remove the dump cylinder guard.

STEP 3 Support the dump cylinder with a hoist and sling.


102ST14

STEP 4 Remove the pin that connects the dump cylinder to the Z-bar.

STEP 5 With a suitable hoist, lift the dump cylinder stem-end up out of the Z-bar cradle.

STEP 6 Start the engine and retract the dump cylinder stem.

DANGER Hydraulic fluid may be under pressure. When removing a hydraulic hose from a cylinder, safety glasses and heavy gloves must be worn.


STEP 8 Detach cylinder base and lift cylinder from vehicle.

STEP 9 Place on suitable surface for service.

Dump Cylinder Instal lat ion

Reassemble in reverse order.

STEP 1 Clamp base end pin first.

STEP 2 Position stem pin in place.

STEP 3 Use hoist to extend cylinder into the Z-bar.

Hoist Cylinder Removal and Replacement

Hoist cylinders

Hoist Cylinder RemovalThe hoist cylinders will require some sort of lifting device to support and lower the cylinder to the ground. Determine how the cylinder will be handled before removing, then do the following.

DANGER Depending on the scooptram model, the boom could weigh up to 5670 kilograms (12,500 lbs.). Do not reach or lean underneath the boom unnecessarily.

STEP 1 Park the scooptram on a flat level surface, block all wheels, and install the articulation lock.

STEP 2 Raise the boom and place support stands, rated for the boom weight, beneath it. Lower the boom until all of its weight is supported by the stands.


STEP 4 Secure the hoist cylinders in place (to prevent them from swinging free once pins are removed).

N o t e Make sure cylinder is free of grease or oil before securing with strap to prevent it from slipping.

DANGER Hydraulic fluid may be under pressure. When removing a hydraulic hose from a cylinder. Safety glasses and heavy gloves must be worn.


STEP 6 With cylinder secured in place remove first the stem pin, then the base pin. Be careful of free swinging cylinder ends. Retract stem rod

Atlas Copco 103

back into cylinder before removing base pin.

STEP 7 If machine has trunnion caps (shoulder collars), remove bolts to remove collars and leave pin inside cylinder until cylinder is on stable surface.

N o t e It is not necessary to remove the bucket to remove the hoist cylinders. However, the bucket must be secured so that it does not become a hazard once the boom has been raised.

Hoist Cylinder Instal lat ionReassemble in reverse order. Clamp base end pin first. Position stem pin in place and use hoist to extend cylinder into the boom clamp.

Operate the scooptram to bleed any air in the system prior to placing it back into service.

Hydraulic Pump Removal and Replacement

Pumps are located on the transmission.


STEP 2 Remove the hoses and plug lines and ports on the pump.

STEP 3 Remove the mounting bolts, and slide the pump off the forward pump stub shaft.

STEP 4 Cover open stub shaft assembly to keep clean

Pump Instal lat ionInstall the components in reverse order, torque hardware to specified values.

When assembly has been correctly completed, proceed with start-up and functional testing.

Hydraulic Valve Removal and Replacement

The main control valve is attached to the hydraulic tank.

DANGER The main control valve is extremely heavy. Care must be taken to avoid injury or death while removing the valve. Use a hoist rated for the weight of the valve to lift and support it during the removal & installation process.

Valve Removal

STEP 1 Steam clean the area around the valve to be removed.

Important Make sure the area around the valve is clean and free of debris. Valves are susceptible to damage from dirt or grime being introduced into the hydraulic system due to dirty service conditions.

STEP 2 Relieve all hydraulic pressure. See “Relieving Hydraulic Pressure” on page 97.

STEP 3 Disconnect, cap or plug, and label all hydraulic hoses to the valve.

STEP 4 Cap or plug the inlets, pressure ports, and pilot ports to prevent contamination.


104ST14

STEP 5 Attach a hoist cable to the valve for support while removing the mounting bolts.

STEP 6 Loosen and remove the valve mounting bolts.

STEP 7 Hoist the valve to a work bench, do not place the valve in a position where it could be damaged.

Valve ReplacementTo replace a valve, follow the removal procedures in reverse.

Valve Cartr idge Removal & Service

Important The most common cause of failure is dirt in the hydraulic oil.

• Dirt which lodges in the working parts and inter-feres with their operation.

• Dirt introduced due to filter bypass

Most cartridges can be cleaned without altering their settings.

To check and clean a cartridge which is not functioning:STEP 1 Remove the cartridge from the cavity.

STEP 2 Inspect for visible contaminants and carefully remove obvious particles.

STEP 3 Through the nose of the cartridge, manually operate the inner working parts several times. Use a piece of plastic tubing to avoid damaging soft seats, sharp edges, finished surfaces or the screen protecting the pilot orifice. All parts should move freely. If possible, do this with the cartridge submerged in clean mineral spirits.

STEP 4 After “flushing,” blow dry with clean filtered air.

STEP 5 Replace seals if indicated, using the appropriate service kit.

STEP 6 Dip the cartridge in clean hydraulic oil, then reinstall the cartridge, tighten to specified torque and re-test.

STEP 7 If this procedure does not eliminate the problem, replace with a new factory-tested cartridge.

N o t e Service kits are available for the cartridges. Contact your Atlas Copco dealer for information on cartridge seal replacement and or cartridge replacement.

Hydraulic ManifoldsIt is not necessary to remove any valve manifolds from the scooptram since the functional part is a cartridge. Se “Valve Cartridge Removal & Service” på sida 104.

• J-Block

• Auxiliary Valve

If it becomes necessary to remove a valve manifold, follow these generalized instructions:

STEP 1 Relieve the hydraulic pressure. See “Relieving Hydraulic Pressure” on page 97.

STEP 2 Vent and drain the hydraulic tank into suitably sized reservoir, the reuse of fluid is not recommended.

STEP 3 Clean, label, disconnect and plug all hoses and harnesses to the manifold.

STEP 4 Loosen and remove the bolts that secure the manifold.

STEP 5 Remove the manifold.

Manifold ReplacementFollow the removal procedures in reverse.

Atlas Copco 105

Chapter 7: Electrical Systems
E10
E30 LOADFRAME SECTION

E20 POWERFRAME SECTION

X3

X4

ME1

FE2

B359

B355

B410

B348 (OPT)

(CAN POWERED)

STEER SENSOR

STEER SENSOR

D511X12

D511X18B420a (OPT)

B420b (OPT)

EMERG STOPSWT (OPT)

133B

EMERG STOPSWT (OPT)

133A

D511X20/15

FUEL SHUTOFF

Y226(OPT)

D510X23a

BEACON

BEACONH390B

H390A

STATUS

STATUS

PG2

X2B

X2A

X2

D511X7

D512X13

D51

1X13

FE4

D51

1X20

ME7

FE5

D51

0X13

OPERATORSCOMPARTMENTMAIN BULKHEAD

CD P

LAYE

R X6

DC C

ON

24/1

2VG

4

12 V

OUT

PUT X12

WIP

ER R

EAR M

4

WIP

ER F

RONT

M3

SPEA

KERS

X8,

X9

WAS

HERS

M5A

,M5B

DOM

E LI

GHT

H23

4

6

6

6

6

6

6

66

6

6 6 6 6 6 6 6 6

6

6

OPERATORS COMPARTMENT OUTSIDE CAB

6

66

66

66

6

REAR

HIGH

BEAM

H185

H121

BACKUP STROBE

BACKUP ALARM

H230

H231A

H230A

H185

H121X1

BOOM LIGHT

LOADING LIGHTS

H228a

H227a

H227b

H228b

H227a

X3

H228A-B

H227bBOOM LIGHT

LOW

REAR

HIGH

BEAM

H231B

H230BLOW

H231

6

6

System DesignPower SupplyTwo 12V batteries are connected in series with cable W20K to give a 24VDC power source. The two terminals, plus and minus are connected to the ISO switch (S300) through cables W20H and J.

Battery plus and minus are referred to as power and ground in circuits downstream from the ISO switch. Electrical system power is connected from ISO switch, terminal 3 to power terminal in component box A20, and then distributed out to the different parts of the electrical system.

Charging CircuitThe alternator is connected to the same side of the ISO switch as the batteries to make it possible to shut the machine down with the ISO switch. The charge current from the alternator is charging the batteries through cables W20H and J.

Power CircuitsNon-keyed PowerNon-keyed power is always present on the machine as long as the ISO switch (S300) is in ON position. Non keyed power is used for starter, fuel heater, Hydraulic fill motor, TCU, ECU, Rear- and boom lights, backup

alarm and fuel shutoff valve, Auxiliary outlet and checkfire module.

Keyed PowerWhen the vehicle main power switch (S300) is turned on keyed-, non keyed- and protected power is connected to the vehicle. Turning the system power main switch (S101) in OFF position deactivates relay K100 which turns off keyed- and protected power.

Protected PowerProtected power is supplied from voltage conditioner (G3), located on the main dash harness (A10). The voltage conditioner is used for supply of RCS control system components such as decoders and I/O modules.

G3 has a power input and an ignition input. Both inputs must be powered to get a power output. G3 is supplied with keyed power (010) from circuit breaker S8 (10A) on the power input and keyed power (007) on the ignition input. This input is controlled by the RRC MU unit (D520) which activates pulse relay K102 that disconnects the power on the ignition input of voltage conditioner (G3) in 2 seconds through a normally closed set of contacts.

Power GridThe power grid is a five wire power bus that supplies power to I/O-modules D510, D511 and Relay box X3.

Chapter 7: Electrical SystemsService Manual

106ST14

The five wires in the bus are: protected-, non keyed-, keyed power and two ground wires (002).

GroundingThe battery minus is grounded to chassis ground through the ISO switch via starter ground terminal and engine ground (cables W20A, B and C). The alternator is grounded through cable W20G from starter ground terminal. Electrical system ground is connected from ISO switch, terminal 1 to ground terminal in component box A20, and then distributed out to the different parts of the electrical system.

Atlas Copco 107

System ComponentsBatteries

Batteries

The vehicle is powered from two 12V lead acid batteries.

Alternator

Alternator

The batteries are charged by a 170 A alternator, driven by the diesel engine. The change voltage is 28.8VDC.

Starter

Starter

The starter is connected downstream of the ISO switch, through cables W20E and D, and is protected by a 700A fuse (F120). The starter solenoid is controlled by the start relay (K301) located inside component box A20. K301 is activated by output X20 in I/O D510 located beside component box A1. The start procedure is described later in this chapter.

RCS ComponentsThe control system’s components are described in the control System chapter. See “Chapter 8: Control System” on page 117.

Switches and Circuit BreakersISO Switch (S300)

ISO switch

The ISO switch (S300) controls the main power and powers up the RCS control system. S300 have three pair of contacts, 1-2: battery minus, 3-4: battery plus, 5-6: RCS control system start.

RCS On Switch (S101) & Off Switch (S102)When the machine is powered up, it is possible to turn the power to the control system on and off with the RCS on/off switches (S101/S102). Pressing the RCS on switch activates relay K100, and Keyed- and protected power is connected to the machine. Pressing the RCS on switch deactivates relay K100 which turns off the power to the control system, e.g. protected and keyed power.

If the control system is idle with the engine turned off for a preset period of time (default 20 minutes), the control system is automatically shut down.

Circuit BreakersControl system components such as I/O modules (D510, D511), decoder (D540), display (D501), RRC MU (D520) and door switch (B418) are supplied by protected power. The supply source is a voltage conditioner (G3). G3 has two supply inputs that need power to activate the power output. The voltage conditioner is protected by circuit breakers S20 and S21.

Park Brake Switch (S138)

Park brake switch


108ST14

The park brake solenoid must be energized to release the brakes. The signal to the solenoid is an output from I/O module D511 that runs through a normally open contact on the park brake switch.

See “Parking brake” on page 7 in the operator’s manual for information on how to operate the parking brake.

Main Brake Switch (B422)

The brake pedal (B422) has a limit switch that is activated when the pedal is pushed to 90% of the pedal rotation range. The limit switch then closes a circuit to the main brake valve (Y201) and the hydraulic brake system is drained to tank, and brakes applied.

Air Filter Switch (B360)

The air filter switch is sending a sinking signal to I/O D510 input X15A when it senses an increased pressure drop over the filter. This results in a warning icon on the operator’s display.

Transmission Filter Switch (B435)The transmission filter switch is located by the filter behind the hydraulic hatch. The switch sends a sinking signal to I/O module D511 input X24A when it senses an increased pressure drop over the filter. This results in a warning icon on the operator’s display.

Hydraulic Filter Switch (B139)

The hydraulic filter switch sends a sinking signal to I/O module D511 input X24 when it senses an increased pressure drop over the filter. This results in a warning icon on the operator’s display.

Bucket Position Sensor (B405)The bucket position sensor is used for the load weighing and ride control options to give a reference signal to the RCS control system of what position the bucket is in. The sensor is connected to analogue input X16 on I/O module D512 through the Interface box X4.

Boom Position Sensor (B406)The boom position sensor is used for the load weighing and ride control options to give a reference signal to the RCS control system when the boom is in a certain position. The sensor is connected to analogue input X17 on I/O module D512.

Atlas Copco 109

System functionsPower Up VehicleThe RCS system starts to boot up when the ISO switch (S300) is turned on. The power up is performed through activation of time delay relay K201 (RCS Start Relay). K201 then activates relay K100 (Master Power Relay) a couple of seconds. When K100 is activated, it latches and powers up the complete electrical system with keyed- and protected power. When the RCS system has finished the boot sequence (after app. 20 seconds), the vehicle is ready for the operator to push the engine on key.

Engine On

Engine on key

Pressing and holding the engine on key activates the starter to crank the engine. This is indicated by flashing the key LED, provided no starter lock-out conditions are active. If any starter lockout conditions are active, the key is ignored and the operator notified on the display.

If all conditions are met to start the engine, the starter keep cranking until the engine starts, or the operator releases the starter key. When the engine is running, the LED indicates this by a steady light on.

To start up the engine, the park brake has to be applied, the gear has to be in neutral, all operator controls at idle position and fire suppression must not have been activated since boot up.

Cab door open or closed does not affect startup. When the conditions above are met, pushing the engine on key enables engine on, activate the starter output and flash start engine push button LED. The starter output is reset if engine speed rises above 600rpm, the start engine push button is released or engine speed stays below 600 RPM for more than 10 seconds. The engine on key LED indicates running engine by steady light.

Engine OffPressing the engine on key while the LED is on stops the engine and the LED is turned off. A hold time of 1 second is required.

The engine is shut done by disabling the engine on signal (circuit 439 from I/O output D510:X20a). The

engine on key LED is turned off to indicate stopped engine.

Shut Down VehicleThe engine is turned off by pressing engine on key on the operator keypad. Through this the RCS-system deactivates the engine run relay (K300) by deactivation of decoder D541 output. It is then safe to turn off the ISO switch (S300).

Alternatively the system power main switch (S101) can be turned in off position to shut down the control system.

Vehicle LightsCabin Work Lights

Canopy front lights

The cabin work lights are split into two canopy front lights (H232A & B) and one canopy rear light (H232C). They are supplied with non keyed power (006) from circuit breaker S6 located on main dash harness (A10). The lights are controlled from the operator's keypad through output Dout22 (front lights) & Dout20 (rear light) on decoder D540 through relays K107 (front lights) and K106 (rear lights). K106 and K107 are located on main dash harness (A10).

Rear Lights

The four rear lights are split into two low beam (H230A & B) and two high beam (H231A & B) lights. They are supplied with keyed power (040) by circuit breaker S4 located on main dash harness (A1). The lights are controlled from operator's keypad through output (X2A&B) on I/O Module D510 and relays K1 & K2. I/O Module D510 is located beside component box A1.


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Boom Lights

Boom light

The two boom lights (H227A & B) are supplied with non keyed power from the power grid (011). The circuit is protected by circuit breaker S6 (15A) located on main dash harness (A10). The lights are controlled from operator's keypad through output (X2) on decoder D512 and relay X3/K1 located in relay box X3.

Load Lights

Load lights

The two load lights (H231A & B) lights are supplied with keyed power from the power grid (080). The circuit is protected by circuit breaker S9 (10A) located on main dash harness (A10). The lights are controlled from operator's keypad through output (X2) on decoder D512 and relay X3/K2 located in relay box X3.

Drift Light (H234)

Drift light

The drift light (H233) is supplied with keyed power (110) by circuit breaker S11 located on main dash harness (A10). The light activates when keyed power is applied on the machine.

Dome LightThe dome light is located on the ceiling of the operator's compartment. It has two states; on and off and is supplied with non keyed power (011) from circuit breaker S6 (15A).

Status Beacon (H390)

Status beacon

The status beacons H390A (front) and H390B (rear) are used for status indication of operational mode on the machine. Colors used are red and green. They are supplied with protected power (070) from main dash harness (A10). The activation of the different colors is made by outputs from I/O module D511 X20 A&B located in the midship area on the power frame.

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Backup Alarm

1. Backup strobe2. Audio alarm

The backup includes backup strobe (H185) and backup audio alarm (H121) and are supplied with keyed power (040) by circuit breaker S4 located on main dash harness (A10). The strobe and audio alarm are controlled from the operator's keypad through output X5B on I/O module D510 and relay K3. K3 is located in relay box X1.

Horn

Horn

Pressing and holding the horn key on the keypad activates the horn. The horn is active until the key is released again. Horn signal output is digital output X22 on I/O module D512.

Diagnostic Outlets

1. Transmission diagnostic connector2. Engine diagnostic connector

There are two diagnostic outlets on the operator's panel for connecting external diagnostic tools to the machine, Transmission diagnostic X137 and Engine diagnostic

X138. The connectors have connection with the J1939 bus.

CD Player

CD player

The audio system consists of the CD player X6 and two speakers X8 (left) and X7 (right). The CD player is supplied by non keyed power (011) for internal memory circuits and keyed power (110) for on/off.

Socket Outlet 12VThe socket outlet is intended to be used to connect auxiliary equipment to the electrical system. The outlet is supplied from DC converter 24/12V (G4). The converter is connected to non keyed power (011) which results in that the outlet is powered as long as the ISO switch (S300) is ON.

Wipers & Washers

Rear wiper

There are two wipers with window washer pumps on the machine. Wiper motor M3 with washer M5A are located at front window (door window), and Wiper motor M4 with washer M5B are located at rear window. Front wiper- washer motors are controlled by wiper switch S105 and rear wiper- washer motors are controlled by wiper switch S104. The wiper switches have four states:

• Off

• Intermittent delay

• Low speed

• High speed

The washer motors are activated by pushing the wiper switch knob.

1 1 2

1

2


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Air ConditionThe air condition unit (X9) is supplied with keyed power (120) by circuit breaker S12 located on main dash harness (A10). The system is utilized by three controls. The A/C switch (S502) where the system is activated, the blower switch (S501) where the fan is turned on and the fan speed is set and the temp selector (S500) where the desired temperature is set. The A/C compressor is controlled by output K on the A/C unit. The signal activates the A/C clutch (S816) located on the A/C compressor. There is A/C pressure switch (B363) in the circuit which disconnects the A/C clutch if the pressure in the coolant system becomes too low.

Door InterlockThe door interlock is a function that disconnects the hydraulic pilot pressure to the steering valves when the door is opened and the vehicle speed is below 4 km/h. The system is designed with a proximity switch (B418) that senses the door position, and breaks the circuit to the door interlock relay (K118) which contact in series with the armrest interlock (B419) breaks the AIL-signal on decoder D540. The signal is connected to decoder (D540) input (Din3). D540 is located on main dash harness (A10).

Lincoln Lube (X5)

The Lincoln lube control unit (X5) is controlling the automatic greasing of bearings on the machine. The control unit is controlled from PWM output X20 on I/O module D512. There is also a level signal to digital input X15 on I/O module D512. This signal results in a warning icon on the operator’s display.

Hydraulic Oil Fill Motor

1. Hydraulic oil fill motor2. Hydraulic oil fill switch3. Hydraulic oil fill hose

The hydraulic oil fill motor (X11) drives the pump used for pumping hydraulic oil to the hydraulic oil tank. X11 is connected to non keyed power (005) from component box (A20). The motor is protected by fuse F20 (25A) located inside the component box (A20).

The motor is controlled by a spring-loaded switch (S1) that activates a relay (R1) to supply power to it. S1 and R1 are located in the Hydraulic oil fill control box (X11).

Fuel HeaterThe fuel heater (S814) is built in the fuel pro filter and connected to non keyed power (005) from component box (A1). It is protected by fuse F1 (15A) located inside the component box (A1).

The fuel heater is automatically controlled by temperature switch S184 that is also built in the fuel pro filter.

1 2 3

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General Maintenance Diagnosis & Calibration The electrical system of diesel powered equipment requires periodic inspection and maintenance.

Important Always turn off the battery disconnect switch (as a minimum precaution) whenever working on an electrical problem on the vehicle.

N o t e It is highly recommended to disconnect all battery cables and place all fuses and circuit breakers in the open position when doing any extensive electrical work on the vehicle.

WARNING Never disconnect the leads between battery, alternator, and voltage regulator when the engine is running.

In order to achieve a properly functioning and reliable electrical system it is important that periodic checks are made to inspect for:

• Water, oil and dirt intrusion

• Corrosion of wiring terminals and devices

• Excessive wear on wire insulators due to vibration, tension or excessive heat

Whenever repairing an electrical harness or device, use the manufacturers recommended tools such as wire crimpers and insertion and removal tools. An electrical repair done improperly will not only reduce the system’s reliability, but may contribute to further electrical damage.

Wire harnesses should never be disconnected by pulling or yanking on the wires themselves. This can lead to a premature failure of the wire terminal, contact or the connector itself.

It is also important to disconnect all electronic components that might be susceptible to damage caused by welding.

DANGER Always make sure that the welding machine is earth grounded before attempting to perform any electric welding.

Never interchange the battery connections.

When washing the engine, protect the alternator and voltage regulator from water.

BatteriesBattery Booster CablesConnect red cable (positive) to positive battery post on dead battery, and positive post on fully charged battery. Connect black cable (negative) to negative post on dead battery. Connect black cable to the negative post on fully charged battery. Leave engine of charging vehicle running when starting a vehicle with a dead battery.

When disconnecting cables, disconnect the cable from the fully charged battery first.

WARNING If cables are connected wrong on a vehicle, the alternator can be seriously damaged.

Storage of Lead Acid BatteriesBecause of their corrosive behavior, all batteries, when placed in storage, will begin to discharge slowly. If allowed to go unchecked, the average battery will discharge to the point of nonrecovery in about 6 to 8 months.


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Removing and Replacing Electrical Components

Battery Isolation Switch

To replace the switches, lights, relays, fuses, circuit breakers, horn, and solenoids follow these general procedures:

• Disconnect the battery by turning off the main (bat-tery isolation) switch.

• Ensure that the replacement unit is a 24 volt OEM compatible part.

• Use care to replace the wiring connectors to their correct receptacle on the new part.

N o t e All of the electrical connectors are designed so that they can only be attached to their receptacle in one way. Do not attempt to force any connectors on to any receptacles.

Battery

Battery cover in the raised position.

Battery RemovalSTEP 1 Set the battery disconnect switch to off.

STEP 2 Open the battery compartment.

STEP 3 Remove the negative connector from the battery “A” (the battery to the front).

STEP 4 Remove the positive connector from the battery “A.”

STEP 5 Attach a battery lift sling to the battery and remove it from the battery compartment.

STEP 6 Repeat the process for battery “B.”

Battery ReplacementSTEP 1 Attach a battery lift sling to battery “B” and

place it in the battery compartment.

STEP 2 Reinstall the positive connector on battery “B.”

STEP 3 Reinstall the negative connector on battery “B.”

STEP 4 Repeat steps 1-3 for battery “A.”

STEP 5 Close the battery compartment.

STEP 6 Set the battery disconnect switch to on.

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Alternator

Alternator

Alternator RemovalSTEP 1 Set the battery disconnect switch to off.

STEP 2 Disconnect the electrical connectors from the alternator.

STEP 3 Loosen the alternator belt adjustment and remove the drive belt.

STEP 4 Remove the bolt that secures the adjustment mechanism to the alternator.

STEP 5 While holding the alternator, remove the two bolts that secure it to the engine bracket.

STEP 6 Remove the alternator.

Alternator ReplacementSTEP 1 Place the alternator in position on the engine

bracket and insert the two bolts that secure it to the bracket. Screw on the two nuts and tighten these moderately tight.

STEP 2 Reinstall the bolt that secures the adjustment mechanism to the alternator and tighten it moderately tight.

STEP 3 Reinstall the alternator drive belt and tighten the alternator belt adjustment to the belt specifications.

STEP 4 Torque the adjustment mechanism bolt and the engine bracket bolts to 34 N-m (25 ft-lb).

STEP 5 Reconnect the electrical connectors to the alternator.

STEP 6 Set the battery disconnect switch to on.

Starter

Starter

Starter RemovalSTEP 1 Disconnect the battery by turning the master

(battery isolation) switch off.

STEP 2 Disconnect the positive lead on the battery.

STEP 3 Disconnect the starter wiring and lay aside.

STEP 4 Remove the starter mounting bolts and pull the unit out.

Starter ReplacementReplace using the same steps in reverse.

Engine SensorsDANGER Coolant temperature is extremely hot and can scald or burn exposed skin. Take care to let the engine cool prior to replacing any sensor on or around the engine.

Sensor RemovalSTEP 1 Let the engine cool.

STEP 2 Disconnect the battery by turning off the main (battery isolation) switch.

STEP 3 Ensure that the replacement unit is a 24 volt OEM compatible part.

STEP 4 Have the new sensor standing by within easy reach.

STEP 5 Use the correct size wrench to unscrew the sensor.

Sensor Replacement STEP 1 After removing the old sensor, replace with the

new sensor immediately.

STEP 2 Use care to replace the wiring connectors to their correct receptacle on the new part.

STEP 3 Clean up any drainage.


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Engine Diagnostic InterfacesAll problems that occur with the engine are stored in the ECM’s memory. The ECM diagnostic interface is located in the operator’s compartment and can be accessed with a Diagnostic Data Reader (DDR).

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Chapter 8: Control System

DDEC 4ECU

D601 D602CONTROLLER

TCU E10 OPERATORS COMPARTMENT

E30 LOADFRAME SECTIONE20 POWERFRAME SECTION

6

IntroductionThe ST14 control system or RCS (Rig Control System) is electronic and built on CAN-bus technology. The RCS governs and monitors the functions of the Scooptram.

ModulesA full featured system consists of the following main modules:

• 1 Display module

• 3 I/O modules

• 1 Transmission Control Unit (TCU)

• 1 Engine Control Unit (ECU)

• 1 Decoder modules

• 1 Encoder module

• 1 Remote control mobile unit (option)

The ECU and TCU are connected to the display over a J1939 drive train CAN network, while the other components sit together on a CAN open network.

D501 Display ModuleThe display module is the main computational module and displays information like input values and warnings to the operator. Errors and warnings are shown and may be examined further.

D540 Decoder ModuleThe decoder modules decode pedal positions, buttons and switches. It also drives the push button board LEDs.

D510, D511 & D512 I/O modulesThe I/O modules decodes signals from sensors and switches into input values. They also handle output to solenoids and on/off functions like relays.

D602 TCUThe TCU handles all transmission functionality, i.e. shifting gear and selecting direction of motion. Status information can be obtained from the TCU, like transmission status, speed etc. over the J1939 bus.

Error messages and codes from the TCU are shown to the operator on the display module.

D601 ECUThe ECU handles all engine functionality, i.e. controlling engine RPM and monitoring engine status. Engine status information is broadcasted on the J1939 bus.

Error messages and codes from the ECU are shown to the operator on the display module.

D520 Remote control machine unit (option)The D520 module, called machine unit (MU), bridges radio commands to CANOpen and vice versa.

Chapter 8: Control SystemService Manual

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Module placement

D512 I/O moduleD510 I/O moduleA1 Box

D602 TCUD601 ECU

D576 Steering sensorD511 I/O module

D501 Display moduleD540 Decoder (behind panel)D520 Machine unit (under seat)

D512

D601

D602

D510 A1

D511D576

D501D540

D520

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MenusAccess levelsThis section discusses service menus. See the Operator’s manual for information about the operator’s menus.

Logging inImportant The service menus are for service

personnel that have completed Atlas Copco's training for the RCS system. Incorrect handling can cause system malfunctions. A user code is required to access the service menus. Only authorized service personnel may have access to this user code.

STEP 1 Start from the Main menu.

STEP 2 Select the “User” button in the “Operator” menu and confirm by pressing Enter. A log-in box will now be displayed.

STEP 3 Enter your authorization code using the arrow keys and confirm with Enter. A message shows if the code is valid (User approved) or not (User unknown).

STEP 4 Return to the main menu using the Escape key.

Menu structureThe control system comprises a number of different menus for setting parameters, diagnostics, etc. The following illustration and table show the structure of the control system menus. Several of the menus deal with standard functions found on all rigs while others are connected to an option and are therefore only found on rigs that have that particular equipment.

The direct selection menus are menus associated with a button on the operator panel. By pressing one of these buttons you can jump straight to the associated menu, irrespective of where you are in the menu structure.

See the Operator’s manual for information on direct selection menus.

SettingsNumerical valuesMany settings are made by changing a numerical value, e.g. setting the date and time on the Administration menu.

Menu Diagnostics, Administration

M1 OperatorM1.1 UserM1.2 LanguageM1.3 DisplayM1.4 UnitsM1.5 Brake testM1.6 Converter StallM1.7 RCS shutdown

M2 VehicleM2.1 InformationM2.2 Load weigh (opt.)M2.2.1 SettingsM2.3 Ride control (opt.)

M3 HydraulicsM3.1 Info

M4 DrivetrainM4.1 Info

M5 DiagnosticsM5.1ModulesM5.1.1 TCUM5.1.2 ECUM5.1.3 Disp D501M5.1.4 Decoder D540M5.1.4.1 ActuationsM5.1.4.1.1 ActuationsM5.1.4.1.1.1 SensorsM5.1.5 Encoder D576M5.1.6 Left Joystick LeversM5.1.7 Right Joystick LeversM5.1.8 IO D510M5.1.8.1 ActuationsM5.1.8.1.1 ActuationsM5.1.8.1.1.1 SensorsM5.1.9 IO D511M5.1.9.1 ActuationsM5.1.9.1.1 ActuationsM5.1.9.1.1.1 SensorsM5.1.10 IO D512M5.1.10.1 ActuationsM5.1.10.1.1 SensorsM5.1.11 MU D520 (opt.)M5.2 LeversM5.3 PedalsM5.4 AdministrationM5.5 Passwords

M6 LogM6.1 SaveM6.2 Save AllM6.3 Event LogM6.4 DTC log

D Direct selection menusD1 Vehicle informationD2 EngineD3 TransmissionD4 Operator settingsD5 Brake test


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STEP 1 Move the cursor to the current numerical value using the arrow keys. The entire value will be highlighted.

STEP 2 Press the enter button. One individual number will now be highlighted in another color.

STEP 3 Increase the value with the up-arrow key and lower the value with the down-arrow key. In certain cases the numerical value may have several digits. In such cases, change one digit at a time. Use the left and right arrow keys to move the cursor to the desired digit.

STEP 4 Confirm the change to the numerical value with Enter.

M1.7 RCS shutdown

Menu Operator, RCS shutdown

This setting determines after how many minutes of inactivity the RCS shall shut down.

M2.2 Load weigh (opt.)

Menu Vehicle, Load weigh

The load weighing function can be calibrated from this menu. To do so, preform the following steps:

STEP 1 Move the machine to a level surface.

STEP 2 Empty the bucket.

STEP 3 Enter the “Load weigh” menu.

STEP 4 Press the “Empty” button on the display.

STEP 5 Lower the boom and roll back the bucket. The screen says "Rollback empty bucket and raise boom".

STEP 6 Apply full throttle.

STEP 7 Raise the boom (full actuation on joystick) until the screen says "Empty bucket calibration done". If the display does not say that, start over from step 4.

STEP 8 Place a known reference weight (9000 - 11000 kg) in the bucket.

STEP 9 Enter the weight of the reference weight in the “Calibration weight” input box.

STEP10 Press the “Loaded” button on the display.

STEP11 Lower boom and roll back the bucket. The screen says "Enter calibration load weight, raise boom with bucket rolled back"

STEP12 Apply full throttle.

STEP13 Raise the boom (full actuation on joystick) until the screen says "Bucket calibration done". If the display does not say that, start over from step 10.

M2.2.1 Settings

Menu Vehicle, Load weigh, Settings

This is the settings menu for the load weigh function.

• Hoist Diffpres (bar) Current differential pressure (base pressure - rod pressure in the hoist cylinder). This is the value that the load in the bucket is calculated from.

• Boom Angle (degrees) The current angle of the boom.

• Boom Angle @ Load The boom must be below this value before a new load can be performed.

• Boom Angle @ Sample This is the point where the load weight is calcu-lated (the diffpressure is sampled to calculate the load in the bucket).

• Bucket Position Current value on the bucket (dump) cylinder posi-tion.

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• Bucket Speed Calculated speed of the bucket.

• Bucket Pos @ Load Position for the bucket when it is being loaded / mucking position.

• Bucket Pos @ Dump When the bucket position is below this value, the bucket is considered to be dumped. Dumping the bucket accumulates the load to the accumulated value and increases the bucket count by one, if auto accumulation is active.

• Min hoist diffpressure to consider bucket loaded In the statistics log, the distance travelling with load is calculated based on this value. A pressure above this value is considered a bucket with load. Below this value the bucket is considered empty.

M2.3 Ride Control (opt.)

Menu Vehicle, Ride Control

This menu contains settings that apply for both the automatic and manual use of the Ride Control option.

• Engage at vehicle speed Speed at which automatic ride control, if acti-vated, will engage.

• Disengage at boom angle, high The Ride Control option is only possible to acti-vate within a certain hoist angle range. This value is the highest angle at which the function is possi-ble to activate.

• Disengage at boom angle, low The Ride Control option is only possible to acti-vate within a certain hoist angle range. This value is the lowest angle at which the function is possi-ble to activate.

• Autolift boom angle This is the angle to which the boom will be lifted when automatic Ride Control is used.

• Calculated boom angle Current boom angle.

Diagnostics

Menu Diagnostics, Modules

The electronic modules included in the system, together with their status, are shown in the Modules menu.

If there are no faults then all modules shall be marked green. If a fault arises in the system, e.g. CAN communication or power supply to a module is interrupted, then the module in question will be marked in red.

Any module can be selected using the arrow keys. The module will then be highlighted in black. More information on that module can be displayed by pressing Enter.

Actuations & SensorsThe module diagnostics menu is also visible for the operator. The difference at the service login level is that it is possible to view actuation and sensor information for the three I/O modules and the decoder.

In the IO D510 information view for example their is an “Actuations” button.

Menu Diagnostics, Modules, IO D510


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The “Actuations” button leads to a menu that displays the actuations for some parameters connected to the D510 I/O module.

Menu Diagnostics, Modules, IO D510, Actuations

If you press the “Actuations” button from this menu, more actuations are shown.

Menu Diagnostics, Modules, IO D510, Actuations, Actuations

From the second “Actuations” menu you can press the “Sensors” button and sensor values will be shown.

Menu Diagnostics, Modules, IO D510, Actuations, Actuations, Sensors

M5.4 Administration

Menu Diagnostics, Administration

In the top part of the administration menu the following information is shown:

• Rig type

• Rig number

• System software version and revision

Date and time are displayed on the bottom right. The values can be adjusted. See “Numerical values” on page 119 for instructions on how to change numerical values.

In the bottom left corner are buttons for saving and loading system parameters to/from a USB stick.

Saving parametersTo save the control system’s current parameters, do as follows:

STEP 1 Go to menu Diagnostics, Administration.

STEP 2 Insert a USB stick.

STEP 3 Press the “Save parameters” button.

STEP 4 A box will appear, that says “Save Started”.

STEP 5 When it says “Save Ok”, the parameters have been saved to the USB stick.

Loading parametersTo load parameters from a USB stick to the control system, do as follows:

STEP 1 Go to menu Diagnostics, Administration.

STEP 2 Insert a USB stick containing the new parameter files.

STEP 3 Press the “Load parameters” button.

N o t e The parameters from the USB stick will override the current parameters in the control system.

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STEP 4 A box will appear, that says “Load Started”.

STEP 5 When it says “Load Ok”, the parameters from the USB stick have been loaded into the control system.

M5.5 Passwords

Menu Diagnostics, Password

In this menu it is possible to change your password. To change the password do as follows:

STEP 1 Press enter on the “Change password” button.

STEP 2 Enter your desired new password with the arrow keys and confirm with enter.

STEP 3 Enter the new password once more and confirm with enter.

N o t e If you have lost and forgotten your password, contact your local Atlas Copco representatives.

M6 Log

Menu Log

The log menu and its sub menus are much the same at Site service level as at operator’s level. The Save menu is different however.

M6.1 Save

Menu Log, Save

When you are logged in at Site service level you can save two more logs compared to the operator, “Maintenance log” and “Assert log”.

The Assert log is reset every time the machine is shut down.

N o t e When saving logs for fault finding, always save the Assert log before shutting down the machine.

Logs

Statist ics logThe statistics log, also called Basic log, contains statistics about the machine such as accumulated number of buckets, avg. temps, fuel consumed and total power-on hours.

The statistics log is created at the first start of the machine and is not lost at power off.

Production logThe production log is available as an option, called Extended production data logging. It contains the same sort of data as the statistics log, but can be reset every time it is saved. This way it can be used to show the results from every shift.

Maintenance logThe maintenance log monitors and records abnormal values for engine, hydraulics and load weighing parameters.

It requires that a USB stick is plugged in. If no USB stick is plugged in, no maintenance log will be saved.

If a USB stick is plugged in, the maintenance log will be saved automatically every five minutes.


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Assert logThe assert log contains information about internal system errors and warnings that can be used by developers when troubleshooting.

If the assert log is to be saved it needs to be done before the vehicle is shut down. It is reset at power off.

Event logThe event log stores errors, warnings and information messages. The log always contains the latest 500 events.

The event log is not lost at power off.

DTC logThe DTC log contains error messages from the engine and transmission control units.

If the DTC log is to be saved it needs to be done before the vehicle is shut down. It is reset at power off.

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Software updateThis section describes how to update the control system’s main software.

N o t e The software should only be updated if an error has been discovered and verified and an update is believed to correct this.

PreparationsSTEP 1 Contact your local Atlas Copco

representative to get updated software files.

STEP 2 Copy the files to a USB stick for code loading and replace the files on the USB stick with the new ones.

STEP 3 Boot the machine, log in and go to Diagnostics\Administration.

STEP 4 Insert another USB stick and save the current parameters by pressing “Save parameters”.

UpdateSTEP 5 Turn off the control system and plug in the

code loading USB stick.

STEP 6 Boot the machine and make sure the code loading process starts, by selecting alternative “2. Load new program code”. The display says “Reboot system” when code loading is done.

STEP 7 Turn off the control system.

STEP 8 Remove the USB stick and turn the control system back on again.

STEP 9 Log in and go to Diagnostics\Administration.

STEP10 Insert the USB stick with the previously saved parameters and load them to the control system by pressing “Load parameters”.

After updateSTEP11 Calibrate the pedals.

STEP12 Check for warnings on the Diagnostics\Modules menu.

STEP13 Check that all functions work properly.

STEP14 Perform a brake test.


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Atlas Copco 127

Chapter 9: Vehicle Specifications

Performance Related Data

Engine

Upbox

Transmission

Axles

Vehicle WeightVaries by options

kg lbs

Empty 38,000 83,776Axle load, front end 19,100 42,108Axle load, rear end 18,900 41,668

Scoop Capacity kg lbs

Tramming 14,000 30,864Breakout force, mechanic 18,240 40,212Breakout force, hydraulic 22,300 49,163

Operat ing Times seconds (±1)

Boom Raising Time 7.6Boom Lowering Time 4Bucket Dump Time 1.8Cycle time 15

Speed ( level ground)

Actual performance may vary

Bucket empty (kph / mph)

Bucket loaded(kph / mph)

1st Gear 5.2 / 3.2 4.9 / 3.02nd Gear 10.0 / 6.2 9.5 / 5.93rd Gear 17.1 / 10.6 16.1 / 10.04th Gear 28.5 / 17.7 26.3 / 16.3

Detroit Diesel engine Series 60 DDEC

Power rating at 2100 rpm

243 kW / 325 hp

Maximum torque at 1350 rpm

1560 nm

MSHA part 7 ventilation rate

7.8 m³/sec

Ventilation particulate index

5.2 m³/sec

Superior T825 1:1 gear ratio

Dana T40000 Power shift transmission

224-313 kW / 300-420 hk

4 speed shifting forward/reverse

Dana 53R

Differential, front end Standard

Differential, rear end No slip

Rear Axle Oscillation ±8º

Chapter 9: Vehicle SpecificationsService Manual

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Brakes

Tires

Hydraulics

Stability

Noise Level

Electrical System

Fuel tank

Turning radius data

Bucket data

Accumulator precharge pressure (N2)

Fully enclosed, force cooled,

multiple wet disc at each wheel end

SAHR system Service, parking and emergency

brakes

Description Notes

Bridgestone 26,5 x 25, 32 Ply, L5S Std.- Tire pressure 6.2±0.2 barMichelin 26,5R25m XMine, D2

RadialOpt.

- Tire pressure 6.2±0.2 bar

Description Notes

Rexroth, heavy duty piston pumps

A10VO

Two steer cylinder, chrome plated stems

Diameter, 105 mm

Two boom cylinders, chrome plated stems

Diameter, 200 mm

One dump cylinder, chrome plated stems

Diameter, 230 mm

System pressure 276 Bar

Hydraulic tank capacity 218 L

Filtration, return line 12 µm

Electric hydraulic oil filling pump 24 V

Test conditions Bucket fully loaded, boom down

Maximum safe side slope for operation

11°

With Cab, High Idle < 80 dB

Description Notes

Voltage, system start & accessories 24 V

Alternator 24 V / 140 amp

Control system Atlas Copco RCS

Master switch (Battery isolation) Lockable

Starter Delco 42MT

Vehicle running l ights - Front lights, 2 on boom, 2 for truck loading

4 x 70W

- Rear lights, 2 high beam, 2 low beam

4 x 70W

- Cab lights 3 x 70W

- Centre hinge light 1 x 70W

BatteriesVoltage 24 V

Temp range -40ºC to 90ºC / -40ºF to 194ºF

Cold starting (EN) 900 A

Cold starting (EN) at -18ºC / 0ºF

800 A

Reserve capacity 100 min at 25ºC / 77ºF

Capacity (20h) / Ah 50

Spec. Sealed gel cells

Description Notes

Fuel tank capacity 390 L

Anti-siphon fuel supply Yes

Description Notes

Max turning angle, left and right 44º

- Bucket outer corner 7105 mm

- Inner back tire 3415 mm

- Rear back corner 6600 mm

Description std

Material density (kg/m³) 1800 2000 2200 2400 2600

Volume, nominal heaped (m³)

7.8 7.0 6.4 5.8 5.4

Width, bucket (mm) 2800 2800 2800 2800 2800

Description Bar PSI

Brake acc 83 ± 2 1200 ± 30Ride control acc 100 ± 5 1450 ± 70Tow hook acc 76 ± 2 1100 ± 30

Atlas Copco 129

Fluids and LubricationSelection of the proper quality of fuel, coolant, lubricating oils, and grease improves efficiency and extends the life of vehicle components.

Fluid CapacitiesThe following capacities are approximate. Always follow the fill procedures outlined within the respective chapters.

Diesel Fuel Quality and SelectionThe quality of fuel oil used is a very important factor in getting satisfactory engine performance, long engine life, and acceptable exhaust emissions levels. Fuels meeting the properties of ASTM Designation D 975 (Grades 1D and 2-D) have provided satisfactory performance. The ASTM D 975 specification does not adequately define the characteristics necessary for fuel quality. The properties listed in the fuel oil selection chart have provided optimum engine performance.

It is important that only fuel meeting the OEM recommendations be used.

Engine liters / gallons

Oil capacity with filter change 36 / 9.5

Fuel TankComponent capacity 390 / 103

Cooling SystemSystem capacity 65 / 17

TransverterComponent refill capacity 65 / 17

Up BoxComponent refill capacity 2.0 / 0.53

AxlesFront or rear differential capacity 50.2 / 13.3

Planetary ends (each) 9.5 / 2.5

Hydraulic TankTank capacity supports the steering, braking, hydraulic cooling, dumping, and filtering systems.

218 / 58


130ST14

Fuel Oil Selection Chart Engine Coolant Specifications

Engine Coolant

Lubricating Oil SpecificationsThe oil filled in the ST14 is good for operation in ambient temperature from -20°C (-5°F) up to +35°C (+95°F). For extreme hot or cold working condition contact your authorized Atlas Copco dealer or the OEM Service manual.

Grease

General Fuel Classif ication

ASTMStandard

No. 1 ASTM 1-D

No. 2 #ASTM 2-D

API Gravity, @ 60ºF / 16ºC

D 287 40 - 44 33 - 37

Specific Gravity, @ 60°F / 16°C

D1298 0.806 - 0.825

0.0835 - 0.855

Flash Point (°F / °C, Min.)

D93 100 / 38 125 / 52

Viscosity, Kinematic(cSt @ 100°F / 40°C)

D 445 1.3 - 2.4 1.9 - 4.1

Sulphur wt% Maximum for On-Road Use ‡

D2622 0.05 0.05

Cloud Point † D 2500 See Note See Note

Cetane Number, Min. † D 613 45 45

Cetane Index, Minimum †

D4737 40 40

Distillation % Vol. Recovery, (°F / °C)IBP, Typical*10% Typical*50% Typical*90% Maximum95% Maximum*Recovery Volume, % Minimum*

D 86

350 / 177385 / 196425 / 218500 / 260 550 / 288

98

375 / 191430 / 221510 / 256625 / 329671 / 355

98

Water & Sediment, % Maximum

D 2709 0.05 0.05

Ash, % Maximum D482 0.01 0.01

Carbon Residue on 10%, wt%, Maximum

D524 0.15 0.15

Copper Corrosion, Maximum 3h

D130 No. 3 No. 3

Accelerated Storage Stability, Maximum*

D2274 15mg/L 15mg/L

Dupont Pad Test, Rating Maximum*

TM-F21-61 ##

7 7

Lubricity, gm, Minimum* SLWT 2800 2800

* Not specified in ASTM D 975† Differs from ASTM D 975‡ The sulphur content of diesel fuel for off road use is 0.5% maximum. This fuel is dyed red.§ Scuffing load, ball on cylinder wear test, higher values indicate less wear and greater lubricity.## Alternate test method predicting fuel stability. The visual rating is related to amount of particulate collected, on a scale of 1 (clean) to 20 (dirty).# No. 2 diesel fuel may be used in city coach engine models which have been certified to pass Federal and California emission standards.Note: The cloud point should be 10ºF (6ºC) below the lowest expected fuel temperature to prevent clogging of fuel filters by wax crystals.See also the OEM engine manual for specific recommendations.

Parameter Max Allowed(ppm)

Notes

Chlorides 40 Water with salt softeners is not recommended.

Sulfates 100Total Dissolved Solids

340

Total Hardness 170 Magnesium & CalciumNitrates >800 Add SCA additive if below

this concentration.pH 5.5 - 9.0

Type Concentration Ratio

antifreeze/water

Notes

Ethylene Glycol

30/70 - 60/40 For temperatures from 15°C to -51°C. Detroit Dieselrecommends 50/50 ratio.

Propylene Glycol

30/70 - 60/40 For temperatures from 15° C to -51° C 50/50 ratio only for Caterpillar engines. Not approved for Detroit Diesel engines other than Series 40, 50 and 60.

Methoxy Propanal

50/50 Not recommended.

Description Brand Spec SAE

Hydraulic oil Shell Donax TD GL-4 10W-30Engine Shell Rimula

Super15W-40

Transmission

Shell Donax TC MIL-PRF-2104G

30

Up-box Shell Donax TC MIL-PRF-2104G

30

Axles Shell Spirax AX GL-5 85W-140Note: For technical specification see : www.shell.com

Specification Brand Notes

NLGI No. 2 Shell - Limona LX2 For driveline support bearings

Shell - Retina HDX2

For slide bearings in boom and bucket links, rear axle cradle and articulation bearings. Used in Lincoln pump

Note: For technical specification see : www.shell.com

Atlas Copco 131

Air Condition RefrigerantRefrigerant Type Weight of Refrigerant

134A 1.7 kg


132ST14

Torque SpecificationsA single bolt that is not tightened correctly can lead to failure of the other bolts. Maintaining the torque values from the following charts will help to protect vehicle reliability.

Use the Correct Tool for the JobMechanical torque wrenches are based upon leverage and have limitations. Hydraulic torque tools are more efficient in tight quarters, and can apply high torque values quickly and safely.

Torque Values by Bolt Size & ThreadScopeThis specification applies only to hardware that meets SAE J429 for Grade 5 and Grade 8 (ISO Property Class 8.8 or 10.9) for U.S. and Metric Hardware. This specification only applies unless otherwise specified and when noted on a drawing.

Definit ions Dry: Plated or plain hardware that is clean with no applied or residual lubrication.Oil: Single or Multi-grade petroleum based engine oils (typically SAE 30W or 15W40) can be used for thread lubrication.Moly Paste: Thread lubricant with approximately 65% molybdenum disulfide content used to lubricate the threads of high strength fasteners to reduce the torque requirement to generate the correct bolt tension. Acceptable compounds include Loctite Moly-Paste. Other similar compounds should be checked to ensure that their K-Factor matches that listed above.

High Strength It is recommended that all high strength (SAE Grade 8 or ISO Class 10.9) hardware be torqued to spec using either oil or moly paste as a lubricant.

TolerancesAll bolt torque values tabulated in this specification have a tolerance of ±10%.

Unif ied Coarse Thread (UNC)This chart shows standard bolt torques to be applied unless

otherwise specified.

Grade 5 Dry Oil

Size Thds/In N-m ft-lbs N-m ft-lbs1/4 20 11 8 8 6

5/16 18 23 17 18 133/8 16 42 31 31 23

7/16 14 66 49 50 371/2 13 102 75 77 57

9/16 12 148 109 111 825/8 11 203 150 153 1133/4 10 362 267 271 2007/8 9 582 429 437 3221 8 873 644 655 483

1 1/8 7 1236 912 927 6841 1/4 7 1745 1287 1308 9651 3/8 6 2287 1687 1715 12651 1/2 6 3037 2240 2278 16801 3/4 5 4788 3532 3591 2649

Unif ied Coarse Thread (UNC)This chart shows standard bolt torques to be applied unless otherwise specified. Lubrication with oil or moly-paste is preferred for grade 8 hardware.

Grade 8 Dry Oil Moly Paste

Size Thds/In

N-m ft-lbs N-m ft-lbs N-m ft-lbs

1/4 20 16 12 12 9 9 75/16 18 34 25 24 18 20 153/8 16 60 44 45 33 35 26

7/16 14 95 70 70 52 57 421/2 13 144 106 108 80 87 64

9/16 12 209 154 156 115 125 925/8 11 287 212 216 159 172 1273/4 10 510 376 382 282 306 2267/8 9 822 606 617 455 493 3641 8 1232 909 923 681 739 545

1 1/8 7 1746 1288 1310 966 1048 7731 1/4 7 2463 1817 1848 1363 1478 10901 3/8 6 3229 2382 2421 1786 1937 14291 1/2 6 4287 3162 3214 2371 2572 18971 3/4 5 6760 4986 5070 3740 4056 2992

Atlas Copco 133

Unified Fine Thread (UNF)This chart shows standard bolt torques to be applied unless

otherwise specified.

Grade 5 Dry Oil

Size Thds/In N-m ft-lbs N-m ft-lbs1/4 20 14 10 9 7

5/16 18 26 19 19 143/8 16 47 35 35 26

7/16 14 75 55 56 411/2 13 115 85 87 64

9/16 12 164 121 123 915/8 11 230 170 172 1273/4 10 403 297 302 2237/8 9 643 474 481 3551 8 954 704 716 528

1 1/8 7 1387 1023 1040 7671 1/4 7 1932 1425 1449 10691 3/8 6 2604 1921 1954 14411 1/2 6 3416 2520 2562 1890

Unified Fine Thread (UNF)This chart shows standard bolt torques to be applied unless otherwise specified. Lubrication with oil or moly-paste is preferred for grade 8 hardware.

Grade 8 Dry Oil Moly Paste

Size Thds/In


1/4 20 19 14 14 10 11 85/16 18 37 27 27 20 22 163/8 16 66 49 50 37 41 30

7/16 14 106 78 79 58 64 471/2 13 163 120 122 90 98 72

9/16 12 232 171 174 128 140 1035/8 11 325 240 244 180 195 1443/4 10 569 420 427 315 342 2527/8 9 910 669 681 502 547 4011 8 1349 995 1011 746 809 597

1 1/8 7 1958 1444 1468 1083 1174 8661 1/4 7 2728 2012 2046 1509 1636 12071 3/8 6 3677 2712 2758 2034 2206 16271 1/2 6 4822 3557 3617 2668 2893 2134

Metric Coarse ThreadThis chart shows standard bolt torques to be applied unless otherwise specified.

Grade 8.8 Dry Oil

Size(mm)

Pitch(mm)

N-m ft-lbs N-m ft-lbs

4 1 3 2 3 25 1 7 5 4 36 1 11 8 8 68 1 26 19 19 14

10 2 52 38 38 2812 2 89 66 66 4914 2 142 105 107 7916 2 221 163 165 12218 3 305 225 228 16820 3 430 317 323 23822 3 587 433 441 32524 3 744 549 557 41127 3 1090 804 817 60330 4 1478 1090 1109 81833 4 2012 1484 1509 111336 4 2584 1906 1939 1430

Metric Coarse ThreadThis chart shows standard bolt torques to be applied unless otherwise specified. Lubrication with oil or moly-paste is preferred for grade 10.9 hardware.

Grade 10.9 Dry Oil Moly Paste

Size(mm)

Pitch(mm)


4 1 4 3 3 2 3 25 1 9 7 7 5 5 46 1 15 11 11 8 9 78 1 37 27 27 20 22 16

10 2 72 53 54 40 43 3212 2 126 93 94 69 76 5614 2 201 148 150 111 121 8916 2 310 229 233 172 187 13818 3 430 317 323 238 258 19020 3 607 448 456 336 365 26922 3 828 611 629 458 498 36724 3 1049 774 788 581 630 46527 3 1539 1135 1155 852 923 68130 4 2086 1539 1566 1155 1253 92433 4 2840 2095 2130 1571 1704 125736 4 3648 2691 2736 2018 2189 1615


134ST14

www.atlascopco.com/retc

19, 9852 1825 01 service manual st14 dd

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