19, 9852 1825 01 Service Manual ST14 DD

Atlas Copco Scooptram
ST14 Service manual
PM nr 9852 1825 01 2007-11
SAFETY INSTRUCTIONS
Before starting, read all instructions carefully. Special attention must be paid to information alongside this symbol. Only use genuine Atlas Copco parts.
1250 0071 04
Copyright 2007, Atlas Copco Rock Drills AB, Sweden Any 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 Rock Drills AB SE-70191 rebro, Sweden
Atlas Copco I
Table of Contents
Chapter 1: Safety Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Chapter 2: Preventive Maintenance Service Management . . . . . . . . . . . . . . . . . . . . . . . . 3 Requirements for Use in Demanding Environments. . . . . . . . . . . . . . . . . . . . . . . . . . 3 Special Tools are Required for High Torque Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Before Performing Maintenance . . . . . . . . . . . . 4 Electric Welding. . . . . . . . . . . . . . . . . . . . . . . . . 4 Hydraulic System Cleanliness . . . . . . . . . . . . . . 4 Independent Oil Analysis . . . . . . . . . . . . . . . . . . 5 General Safety When You Service the Vehicle . 5 Every 250 Hours Operation . . . . . . . . . . . . . 6 Every 500 Hours Operation . . . . . . . . . . . . . . . . 8 Atlas Copco Service Kits . . . . . . . . . . . . . . . . . . 9 Every 1000 Hours Operation . . . . . . . . . . . 10 Every 2000 Hours Operation . . . . . . . . . . . 10 Every 5000 Hours Operation . . . . . . . . . . . 10 New or Reconditioned Components . . . . . . . . 11 Under first shift ( hour) . . . . . . . . . . . . . . . . . 11 Cooling Fan Drive Belt . . . . . . . . . . . . . . . 11 After first shift (8 hours) . . . . . . . . . . . . 11 Wheel Bolts and Nuts . . . . . . . . . . . . . . . . . 11 Cooling Fan Drive Belt . . . . . . . . . . . . . . . 11 After 250 hours operation . . . . . . . . . . . 11 Trunnions and Pins, Boom Z-bar . . . . . . . . 11 Trunnions and Pins, Bucket . . . . . . . . . . . . 11 Trunnions and Pins, Steering . . . . . . . . . . . 11 Trunnions and Pins, Swivel . . . . . . . . . . . . 11 Expander Shafts, Loadframe and Boom. . . 11 Expander Shafts, Z-bar . . . . . . . . . . . . . . . . 11 Bolt Connection, Engine Mount. . . . . . . . . 11 Axle Breather . . . . . . . . . . . . . . . . . . . . . . . 12 Axle, Bolt Connection . . . . . . . . . . . . . . . . 12 Axle, Differential . . . . . . . . . . . . . . . . . . . . 12 Axle, Planetary Gears . . . . . . . . . . . . . . . . . 12 Driveline, Upbox - Transmission . . . . . . . . 12 Driveline, Loadframe - Transmission Powerframe . . . . . . . . . . . . . . . . . . . . . . . 12 Low Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 High Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Stall Speed . . . . . . . . . . . . . . . . . . . . . . . . . 13 Transmission, breather . . . . . . . . . . . . . . . . 13 Transmission, Bolt Connection . . . . . . . . . 13 Upbox, Breather . . . . . . . . . . . . . . . . . . . . . 13 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 AC, Cab Unit . . . . . . . . . . . . . . . . . . . . . . . 14 Cab and Cab Door . . . . . . . . . . . . . . . . . . . 14 Hyd Oil Tank, Breather . . . . . . . . . . . . . . . 14 Hyd Oil Filter Switch . . . . . . . . . . . . . . . . . 14 Brake Acc, Precharge Press . . . . . . . . . . . . 14 Ride Control Acc, Precharge Press . . . . . . 15 Tow Hook Acc, Precharge Press . . . . . . . . 15 Brake Release. . . . . . . . . . . . . . . . . . . . . . . 15 Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . 15 Engine Oil Filter. . . . . . . . . . . . . . . . . . . . . 16 Air Filter, Filter Element . . . . . . . . . . . . . . 16 Exhaust System . . . . . . . . . . . . . . . . . . . . . 16 Save log and parameter files . . . . . . . . . . . 16 CAN Modules . . . . . . . . . . . . . . . . . . . . . . 16 Clean the machine . . . . . . . . . . . . . . . . . . . 17 Wheel Bolts and Nuts. . . . . . . . . . . . . . . . . 17 Doors and Hoods . . . . . . . . . . . . . . . . . . . . 17 Steering and Bucket Stop . . . . . . . . . . . . . . 17 Driveline, Between Upbox and Transmission Lubrication . . . . . . . . . . . . . . . . . . . . . . . 17 Midship Driveline Lubrication. . . . . . . . . . 17 Front axle lubrication . . . . . . . . . . . . . . . . . 17 Rear axle lubrication . . . . . . . . . . . . . . . . . 18 Engine fan hub bearing . . . . . . . . . . . . . . . 18 Axle, Bolt Connection . . . . . . . . . . . . . . . . 19 Driveline, Upbox - Transmission . . . . . . . . 19 Driveline, Loadframe - Transmission Powerframe . . . . . . . . . . . . . . . . . . . . . . . 19 Bolt connections, Engine Cradle Powerframe . . . . . . . . . . . . . . . . . . . . . . . 19 Transmission, bolt connection . . . . . . . . . . 19 AC, cab unit . . . . . . . . . . . . . . . . . . . . . . . . 19 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Engine Cooling, Hoses and Pipes . . . . . . . 19 Engine Coolant, Filter . . . . . . . . . . . . . . . . 20 Expander Shafts, Loadframe and Boom . . 20 Expander Shafts, Z-bar. . . . . . . . . . . . . . . . 20 Load and powerframe . . . . . . . . . . . . . . . . 20 Trunnions and Pins, Boom Z-bar . . . . . . . . 20 Trunnions and Pins, Bucket . . . . . . . . . . . . 20 Trunnions and Pins, Steering . . . . . . . . . . . 21 Trunnions and Pins, Swivel . . . . . . . . . . . . 21 Transmission, Oil and Filter Change . . . . . 22 Upbox, Oil Filter . . . . . . . . . . . . . . . . . . . . 23 Hydraulic Oil Change . . . . . . . . . . . . . . . . 23 Stop the engine and check the hydraulic oil
II
ST14 Table of Contents Service manual
level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Hydraulic Oil Filter . . . . . . . . . . . . . . . . . . . 23 Hyd Oil Pressure . . . . . . . . . . . . . . . . . . . . . 24 Air Filter, Safety Cartridge . . . . . . . . . . . . . 24 Air Filter, Indicator . . . . . . . . . . . . . . . . . . . 24 Axles, Differentials and Planetaries . . . . . . 25 Differential. . . . . . . . . . . . . . . . . . . . . . . 25 Planetary . . . . . . . . . . . . . . . . . . . . . . . . 25 Alternator. . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Engine Coolant . . . . . . . . . . . . . . . . . . . . . . 26 Hoses and Couplings . . . . . . . . . . . . . . . . . . 27 Fuel Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Fuel Injectors. . . . . . . . . . . . . . . . . . . . . . . . 27 Fuel Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Air Intake. . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Cooling Fan Drive Belt . . . . . . . . . . . . . . . . 27 Chapter 3: Power Unit Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 ECM Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Fuel sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Injectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Calibration codes. . . . . . . . . . . . . . . . . . . . . 31 Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Fuel Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Engine Oil System . . . . . . . . . . . . . . . . . . . . . . . . . 32 Lubricating Oil Pump . . . . . . . . . . . . . . . . . . . . 32 Oil Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Oil Pressure & Temperature sensors. . . . . . . . . 32 Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Coolant Recommendations . . . . . . . . . . . . . . . . 33 Coolers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Air Intake System . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Engine Air Filter Restriction Indicator . . . . . . . 34 Turbo Charger . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Exhaust System. . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Silencers / Catalyst . . . . . . . . . . . . . . . . . . . . . . 35 Particle filter (Optional) . . . . . . . . . . . . . . . . . . 35 Exhaust Heat Shields . . . . . . . . . . . . . . . . . . . . 36 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 ECU. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Temperature & pressure sensors . . . . . . . . . . . . 37 Temperature. . . . . . . . . . . . . . . . . . . . . . . . . 37 Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Other . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Upbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Replacing Engine Support Systems . . . . . . . . . . . . 38 R&R Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Removing the Engine Package . . . . . . . . . . 38 Replacing the Engine Package . . . . . . . . . . 40 Remove the Engine Cooling Package. . . . . . . . 41 Replace the Cooling Package . . . . . . . . . . . . . . 42 Remove Hydraulic & Fuel Coolers . . . . . . . . . 42 Replace Hydraulic & Fuel Coolers. . . . . . . . . . 42 Remove Exhaust System Components . . . . . . . 42 Replace the Exhaust System . . . . . . . . . . . . . . . 43 Replace Fuel System Components . . . . . . . . . . 43 Remove Fuel Filter . . . . . . . . . . . . . . . . . . . 44 Replace Fuel Filters . . . . . . . . . . . . . . . . . . 44 Remove Fuel Cooler . . . . . . . . . . . . . . . . . . 44 Replace Fuel Cooler . . . . . . . . . . . . . . . . . . 44 Remove Fuel Valves, Solenoid and Lines . 44 Replace Fuel Valves, Solenoid and Lines. . 44 Removing the Fuel Tank. . . . . . . . . . . . . . . 44 Replace the Fuel Tank . . . . . . . . . . . . . . . . 45 R&R Electronic Engine Control System . . . . . 45 Removing the ECM . . . . . . . . . . . . . . . . . . 45 Replacing the ECM. . . . . . . . . . . . . . . . . . . 45 Chapter 4: Power Train Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Converter. . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Transmission Controller APC 200 . . . . . . . 49 Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Charge Pump . . . . . . . . . . . . . . . . . . . . . 50 Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Solenoids . . . . . . . . . . . . . . . . . . . . . . . . 50 Transmission Oil Temperature . . . . . . . . . . 51 Checking Transmission Control Pressure . . 51 Flow and Fluids. . . . . . . . . . . . . . . . . . . . . . 51 Driveline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Universal Joint Bearings . . . . . . . . . . . . . . . 52 Driveline Support Bearings. . . . . . . . . . . . . 52 Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . 53 Wheel and Tire Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . 54 Proper Inflation . . . . . . . . . . . . . . . . . . . . . . 54 Over-inflation results in: . . . . . . . . . . . . 54 Under-inflation results in: . . . . . . . . . . . 54
Atlas Copco III
Rolling Radius and Tire Sizing . . . . . . . . . Example: . . . . . . . . . . . . . . . . . . . . . . . . Driving Practices: . . . . . . . . . . . . . . . . . Replace Powertrain Components . . . . . . . . . . . . . . Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . Remove . . . . . . . . . . . . . . . . . . . . . . . . . Reinstall . . . . . . . . . . . . . . . . . . . . . . . . Transmission Tube-in-shell Cooler . . . . . . Remove . . . . . . . . . . . . . . . . . . . . . . . . . Reinstall . . . . . . . . . . . . . . . . . . . . . . . . Transmission Oil Filter. . . . . . . . . . . . . . . . Remove . . . . . . . . . . . . . . . . . . . . . . . . . Reinstall . . . . . . . . . . . . . . . . . . . . . . . . Transmission Solenoids . . . . . . . . . . . . . . . Remove . . . . . . . . . . . . . . . . . . . . . . . . . Reinstall . . . . . . . . . . . . . . . . . . . . . . . . Driveline. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Phasing the Driveline . . . . . . . . . . . . . . . . . Installing the Drive Shaft . . . . . . . . . . . . . . Yokes and Bearing Mounts . . . . . . . . . . . . Installing Driveline Guards . . . . . . . . . . . . Upbox to Transmission Driveline . . . . . . . Remove . . . . . . . . . . . . . . . . . . . . . . . . . Reinstall . . . . . . . . . . . . . . . . . . . . . . . . Transmission to Rear Axle Driveline . . . . . Remove . . . . . . . . . . . . . . . . . . . . . . . . . Reinstall . . . . . . . . . . . . . . . . . . . . . . . . Midship Driveline. . . . . . . . . . . . . . . . . . . . Remove . . . . . . . . . . . . . . . . . . . . . . . . . Reinstall . . . . . . . . . . . . . . . . . . . . . . . . Midship-to-Transmission Driveline . . . . . . Remove . . . . . . . . . . . . . . . . . . . . . . . . . Reinstall . . . . . . . . . . . . . . . . . . . . . . . . Midship to Front Axle . . . . . . . . . . . . . . . . Remove . . . . . . . . . . . . . . . . . . . . . . . . . Reinstall . . . . . . . . . . . . . . . . . . . . . . . . Axles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Axle. . . . . . . . . . . . . . . . . . . . . . . . . . Remove . . . . . . . . . . . . . . . . . . . . . . . . . Reinstall . . . . . . . . . . . . . . . . . . . . . . . . Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . Remove . . . . . . . . . . . . . . . . . . . . . . . . . Reinstall . . . . . . . . . . . . . . . . . . . . . . . . Liquid Cooled Multi-Disc Brake . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . Housing, Covers, etc. . . . . . . . . . . . . . . Piston and Housing Seals . . . . . . . . . . .
54 54 55 56 56 56 57 57 57 58 58 58 58 58 58 58 58 59 59 59 59 60 60 60 60 60 60 61 61 61 61 61 61 61 61 62 62 62 62 62 63 63 63 64 64 66 66 66 66
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Tire Mounting Procedures . . . . . . . . . . . . . . . . 68 Tire and Wheel Safety . . . . . . . . . . . . . . . . 68 Earthmover Rim Locking Wheel Flange With Heavy Duty Driver . . . . . . . . . . . . . . . . . 68 Demounting . . . . . . . . . . . . . . . . . . . . . . . . 68 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Wheel Inspection . . . . . . . . . . . . . . . . . . . . 69 Mismatched Rims. . . . . . . . . . . . . . . . . . . . 70 Mounting and Inflating Safety . . . . . . . . . . 70 Mounting and Inflating Procedures . . . . . . 70 Wheel Nut Torque . . . . . . . . . . . . . . . . . . . 72 Operating Precautions . . . . . . . . . . . . . . . . 72 Recapping. . . . . . . . . . . . . . . . . . . . . . . . . . 72 Chapter 5: Main Frame Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Load Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Bucket. . . . . . . . . . . . . . . . . . . . Replacing the Bucket . . . . . . . . . . . . . . . . . Removing the Z-Bar. . . . . . . . . . . . . . . . . . Reinstalling the Z-Bar . . . . . . . . . . . . . . . . Removing the Boom . . . . . . . . . . . . . . . . . Replacing the boom . . . . . . . . . . . . . . . . . . Power Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and Replacing Hoods . . . . . . . . . . . Hood Removal . . . . . . . . . . . . . . . . . . . Hood Replacement . . . . . . . . . . . . . . . . . . . Separating the Load & Power Frames . . . . . . . . . . Separation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reconnection . . . . . . . . . . . . . . . . . . . . . . . . . . Articulation Pins . . . . . . . . . . . . . . . . . . . . . . . Pin Removal . . . . . . . . . . . . . . . . . . . . . . . . Pin Installation . . . . . . . . . . . . . . . . . . . . . . Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering Stops . . . . . . . . . . . . . . . . . . . . . . . . . Oscillating Axle Stops . . . . . . . . . . . . . . . . . . . Bucket Rollback Stop . . . . . . . . . . . . . . . . . . . Bucket Rollover (Dump) Stops . . . . . . . . . . . . Bucket Stops (Pads) . . . . . . . . . . . . . . . . . . . . . Chapter 6: Hydraulic Systems Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . Expression . . . . . . . . . . . . . . . . . . . . . . Steering, Hoist, Dump & EOD . . . . . . . . . . . . Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling & Filtration System . . . . . . . . . . . . . . System components . . . . . . . . . . . . . . . . . . . . . . . .
73 73 73 74 74 75 75 76 77 77 77 77 78 78 79 79 80 80 82 82 83 83 83 83
85 85 85 86 86 86 87
IV
Variable Piston Pumps . . . . . . . . . . . . . . . . . . . 87 Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Steering Cylinders . . . . . . . . . . . . . . . . . . . . 87 Dump Cylinder . . . . . . . . . . . . . . . . . . . . . . 87 Hoist Cylinders . . . . . . . . . . . . . . . . . . . . . . 87 Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Tank and Filters . . . . . . . . . . . . . . . . . . . . . . . . 88 Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . 88 Breather and Filter. . . . . . . . . . . . . . . . . . . . 88 Tank Air Breather . . . . . . . . . . . . . . . . . 88 Hydraulic Oil Filter . . . . . . . . . . . . . . . . 88 Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . 89 Main Control Valve (VMC) . . . . . . . . . . . . 89 Auxiliary Valve (AUV). . . . . . . . . . . . . . . . 89 Steering, Hoist, Dump & EOD system . . . . . . . . . . 90 Dump & Hoist Functions . . . . . . . . . . . . . . . . . 91 Boom Up . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Boom Down . . . . . . . . . . . . . . . . . . . . . . . . 91 Bucket float . . . . . . . . . . . . . . . . . . . . . . . . . 91 Ride Control (option) . . . . . . . . . . . . . . . . . 91 Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 SAHR Brake System . . . . . . . . . . . . . . . . . . . . 91 Brake System Components . . . . . . . . . . . . . . . . 92 Brake System Operation . . . . . . . . . . . . . . . . . . 92 Pump (VPLS2) . . . . . . . . . . . . . . . . . . . . . . 92 Accumulator (ACC1) . . . . . . . . . . . . . . . . . 92 Auxiliary Valve Block (AUV) . . . . . . . . . . 92 Brake Application . . . . . . . . . . . . . . . . . . . . . . . 92 Brake Operation . . . . . . . . . . . . . . . . . . . . . 92 Service Brake Operation . . . . . . . . . . . . . . . 92 Park Brake Operation . . . . . . . . . . . . . . . . . 93 Brake Cooling . . . . . . . . . . . . . . . . . . . . . . . 93 Brake Release for Towing. . . . . . . . . . . . . . . . . 93 Hand Operated Hydraulic Pump . . . . . . . . . 93 Tow Hook with Brake Release (Option). . . . . . 94 Tow Hook System Components . . . . . . . . . 94 Brake Release Manifold . . . . . . . . . . . . 94 Tow Hook Accumulator . . . . . . . . . . . . 94 Tow Hook Cylinder . . . . . . . . . . . . . . . . 95 Air bleed, optional tow hook system . . . 95 Deaeration of brakes . . . . . . . . . . . . . . . . . . . . . 95 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 System principle . . . . . . . . . . . . . . . . . . . . . . . . 96 Filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Hydraulic Oil Cooler (CO2) . . . . . . . . . . . . . . . 96 Cooling pumps (FCP) . . . . . . . . . . . . . . . . . . . . 96 Brake Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . 96 General Maintenance Procedures . . . . . . . . . . . . . . 97 Before Starting . . . . . . . . . . . . . . . . . . . . . . . . . 97
Check Cleanliness . . . . . . . . . . . . . . . . . . . . 97 Relieving Hydraulic Pressure . . . . . . . . . . . . . . 97 Before Removing Any Hose. . . . . . . . . . . . . . . 97 Pressure Setting Checks and Adjustments . . . . 98 Setting Dump and Hoist and Steering Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Setting Brake Pressure . . . . . . . . . . . . . . . . 98 Hydraulic System Startup . . . . . . . . . . . . . . . . . 99 Preparation for Trial Run . . . . . . . . . . . . . . . . . 99 Trial Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Removal and Replacement Procedures . . . . . 101 Steering Cylinder Removal and Replacement. . . . . . . . . . . . . . . . . . . . . . 101 Steering Cylinder Removal . . . . . . . . . 101 Steering Cylinder Installation . . . . . . . 101 Dump Cylinder Removal and Replacement. . . . . . . . . . . . . . . . . . . . . . 101 Dump Cylinder Installation. . . . . . . . . 102 Hoist Cylinder Removal and Replacement102 Hoist Cylinder Removal . . . . . . . . . . . 102 Hoist Cylinder Installation . . . . . . . . . 103 Hydraulic Pump Removal and Replacement. . . . . . . . . . . . . . . . . . . . . . 103 Pump Installation . . . . . . . . . . . . . . . . 103 Hydraulic Valve Removal and Replacement . 103 Valve Removal . . . . . . . . . . . . . . . . . . 103 Valve Replacement . . . . . . . . . . . . . . . 104 Valve Cartridge Removal & Service. . 104 Hydraulic Manifolds . . . . . . . . . . . . . . . . . 104 Manifold Replacement . . . . . . . . . . . . 104 Chapter 7: Electrical Systems System Design . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . 105 Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . 105 Power Circuits . . . . . . . . . . . . . . . . . . . . . . . . 105 Non-keyed Power . . . . . . . . . . . . . . . . . . . 105 Keyed Power . . . . . . . . . . . . . . . . . . . . . . . 105 Protected Power . . . . . . . . . . . . . . . . . . . . 105 Power Grid . . . . . . . . . . . . . . . . . . . . . . . . 105 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . 106 System Components . . . . . . . . . . . . . . . . . . . . . . . 107 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 RCS Components . . . . . . . . . . . . . . . . . . . . . . 107 Switches and Circuit Breakers . . . . . . . . . . . . 107 ISO Switch (S300) . . . . . . . . . . . . . . . . . . 107
Atlas Copco V
RCS On Switch (S101) & Off Switch (S102) . . . . . . . . . . . . . . . . . Circuit Breakers . . . . . . . . . . . . . . . . . . . . Park Brake Switch (S138) . . . . . . . . . . . . Main Brake Switch (B422). . . . . . . . . . . . Air Filter Switch (B360). . . . . . . . . . . . . . Transmission Filter Switch (B435) . . . . . Hydraulic Filter Switch (B139) . . . . . . . . Bucket Position Sensor (B405) . . . . . . . . Boom Position Sensor (B406) . . . . . . . . . System functions . . . . . . . . . . . . . . . . . . . . . . . . . Power Up Vehicle . . . . . . . . . . . . . . . . . . . . . Engine On. . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Off . . . . . . . . . . . . . . . . . . . . . . . . . . . Shut Down Vehicle . . . . . . . . . . . . . . . . . . . . Vehicle Lights . . . . . . . . . . . . . . . . . . . . . . . . Cabin Work Lights . . . . . . . . . . . . . . . . . . Rear Lights . . . . . . . . . . . . . . . . . . . . . . . . Boom Lights . . . . . . . . . . . . . . . . . . . . . . . Load Lights. . . . . . . . . . . . . . . . . . . . . . . . Drift Light (H234) . . . . . . . . . . . . . . . . . . Dome Light. . . . . . . . . . . . . . . . . . . . . . . . Status Beacon (H390). . . . . . . . . . . . . . . . Backup Alarm . . . . . . . . . . . . . . . . . . . . . . . . Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostic Outlets . . . . . . . . . . . . . . . . . . . . . CD Player . . . . . . . . . . . . . . . . . . . . . . . . . . . . Socket Outlet 12V . . . . . . . . . . . . . . . . . . . . . Wipers & Washers . . . . . . . . . . . . . . . . . . . . . Air Condition . . . . . . . . . . . . . . . . . . . . . . . . . Door Interlock . . . . . . . . . . . . . . . . . . . . . . . . Lincoln Lube (X5) . . . . . . . . . . . . . . . . . . . . . Hydraulic Oil Fill Motor . . . . . . . . . . . . . . . . Fuel Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . General Maintenance Diagnosis & Calibration . . Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery Booster Cables . . . . . . . . . . . . . . . Storage of Lead Acid Batteries. . . . . . . . . Removing and Replacing Electrical Components Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery Removal . . . . . . . . . . . . . . . . . . . . Battery Replacement . . . . . . . . . . . . . . . . Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator Removal . . . . . . . . . . . . . . . . . Alternator Replacement . . . . . . . . . . . . . . Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starter Removal . . . . . . . . . . . . . . . . . . . . Starter Replacement . . . . . . . . . . . . . . . . . Engine Sensors . . . . . . . . . . . . . . . . . . . . . . . .
107 107 107 108 108 108 108 108 108 109 109 109 109 109 109 109 109 110 110 110 110 110 111 111 111 111 111 111 112 112 112 112 112 113 113 113 113 114 114 114 114 115 115 115 115 115 115 115
Sensor Removal . . . . . . . . . . . . . . . . . . . . 115 Sensor Replacement . . . . . . . . . . . . . . . . . 115 Engine Diagnostic Interfaces . . . . . . . . . . . . . 116 Chapter 8: Control System Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D501 Display Module . . . . . . . . . . . . . . . . . . D540 Decoder Module. . . . . . . . . . . . . . . . . . D510, D511 & D512 I/O modules. . . . . . . . . . . . . . . . . . . . . . . . . D602 TCU . . . . . . . . . . . . . . . . . . . . . . . . . . . D601 ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . D520 Remote control machine unit (option) . Module placement . . . . . . . . . . . . . . . . . . . . . Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Access levels . . . . . . . . . . . . . . . . . . . . . . . . . Logging in . . . . . . . . . . . . . . . . . . . . . . . . . . . Menu structure . . . . . . . . . . . . . . . . . . . . . . . . Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Numerical values . . . . . . . . . . . . . . . . . . . M1.7 RCS shutdown . . . . . . . . . . . . . . . . . . . M2.2 Load weigh (opt.) . . . . . . . . . . . . . . . . . M2.2.1 Settings . . . . . . . . . . . . . . . . . . . . M2.3 Ride Control (opt.) . . . . . . . . . . . . . . . . Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . Actuations & Sensors . . . . . . . . . . . . . . . . M5.4 Administration . . . . . . . . . . . . . . . . . . . Saving parameters . . . . . . . . . . . . . . . . . . Loading parameters . . . . . . . . . . . . . . . . . M5.5 Passwords . . . . . . . . . . . . . . . . . . . . . . . M6 Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M6.1 Save . . . . . . . . . . . . . . . . . . . . . . . . Logs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Statistics log . . . . . . . . . . . . . . . . . . . . Production log . . . . . . . . . . . . . . . . . . Maintenance log . . . . . . . . . . . . . . . . . Assert log . . . . . . . . . . . . . . . . . . . . . . Event log. . . . . . . . . . . . . . . . . . . . . . . DTC log . . . . . . . . . . . . . . . . . . . . . . . Software update . . . . . . . . . . . . . . . . . . . . . . . . . . Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . Update . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . After update . . . . . . . . . . . . . . . . . . . . . . . . . .
117 117 117 117 117 117 117 117 118 119 119 119 119 119 119 120 120 120 121 121 121 122 122 122 123 123 123 123 123 123 123 124 124 124 125 125 125 125
Chapter 9: Vehicle Specifications Performance Related Data . . . . . . . . . . . . . . . 127 Vehicle Weight. . . . . . . . . . . . . . . . . . 127 Scoop Capacity. . . . . . . . . . . . . . . . . . 127
VI
Operating Times . . . . . . . . . . . . . . . . . 127 Speed (level ground) . . . . . . . . . . . . . . 127 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 Upbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 Transmission . . . . . . . . . . . . . . . . . . . . . . . 127 Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 Dana 53R . . . . . . . . . . . . . . . . . . . . . . . 127 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . 128 Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 Test conditions. . . . . . . . . . . . . . . . . . . 128 Noise Level . . . . . . . . . . . . . . . . . . . . . . . . . . 128 Electrical System. . . . . . . . . . . . . . . . . . . . . . . 128 Description. . . . . . . . . . . . . . . . . . . . . . 128 Vehicle running lights . . . . . . . . . . . . . 128 Batteries . . . . . . . . . . . . . . . . . . . . . . . . 128 Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 Description. . . . . . . . . . . . . . . . . . . . . . 128 Turning radius data . . . . . . . . . . . . . . . . . . . . . 128 Description. . . . . . . . . . . . . . . . . . . . . . 128 Bucket data . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 Description. . . . . . . . . . . . . . . . . . . . . . 128 Accumulator precharge pressure (N2) . . . . . . 128 Fluids and Lubrication . . . . . . . . . . . . . . . . . . 129 Fluid Capacities. . . . . . . . . . . . . . . . . . . . . 129 Engine . . . . . . . . . . . . . . . . . . . . . . . . . 129 Fuel Tank. . . . . . . . . . . . . . . . . . . . . . . 129 Cooling System . . . . . . . . . . . . . . . . . . 129 Transverter. . . . . . . . . . . . . . . . . . . . . . 129 Up Box. . . . . . . . . . . . . . . . . . . . . . . . . 129 Axles . . . . . . . . . . . . . . . . . . . . . . . . . . 129 Hydraulic Tank . . . . . . . . . . . . . . . . . . 129 Diesel Fuel Quality and Selection . . . . . . . 129 Fuel Oil Selection Chart . . . . . . . . . . . . . . 130 General Fuel Classification . . . . . . . . . 130 Engine Coolant Specifications . . . . . . . . . 130 Engine Coolant . . . . . . . . . . . . . . . . . . . . . 130 Lubricating Oil Specifications. . . . . . . . . . 130 Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 Air Condition Refrigerant . . . . . . . . . . . . . 131 Torque Specifications . . . . . . . . . . . . . . . . . . . 132 Use the Correct Tool for the Job . . . . . . . . 132 Torque Values by Bolt Size & Thread . . . 132 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . 132 Definitions . . . . . . . . . . . . . . . . . . . . . . 132 High Strength. . . . . . . . . . . . . . . . . . . . 132 Tolerances . . . . . . . . . . . . . . . . . . . . . . 132 Unified Coarse Thread (UNC) . . . . . . 132
Unified Coarse Thread (UNC) . . . . . . 132 Unified Fine Thread (UNF) . . . . . . . . 133 Unified Fine Thread (UNF) . . . . . . . . 133 Metric Coarse Thread . . . . . . . . . . . . . 133 Metric Coarse Thread . . . . . . . . . . . . . 133
Atlas Copco 1
Chapter 1: Safety
Reference
N o t e Always read the information under Safety
before starting to use the Scooptram or starting maintenance work.
1250 0099 89
ST14 Chapter 1: Safety Service Manual
Atlas Copco 3
Chapter 2: 4Preventive Maintenance 1 2 3
5
The main filter bay contains: 1. 2. 3. 4. 5. Engine Oil Fill Fire Suppression Manual Actuator Fuel filter Oil filter upbox Fuel Fill
6 7
6. Battery switch 7. Engine Oil Level Dipstick
Service Management
Safe 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 Environments

The 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.
ST14 Chapter 2: Preventive Maintenance Service Manual
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.
Install all hoses, pipes, valves, or cylinders immediately after unplugging or uncapping connections. Always fill the hydraulic tank through the return filter with the electric refill pump.
Special Tools are Required for High Torque Settings

Always 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 Welding
Important 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 STEP STEP
1 Open the battery compartment. 2 Turn the battery switch to the OFF position. 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 connections. 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.
Atlas Copco 5
Maintenance Intervals Independent Oil Analysis

Atlas 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 Vehicle

Read the safety and information decals on the vehicle. Also read and understand this operators 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. 2 Shut down the engine. 3 Apply the park brake. 4 Block the wheels 5 Turn the Ignition Switch and Master Switch to OFF position. 6 If you must service the vehicle in the articulation area with the engine running, always place the Articulation Lock in the LOCKED position.
STEP STEP STEP STEP
STEP
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.
Every 250 Hours Operation

Item Axle, breather Axle, bolt connection Axle, differential Task Inspect and check for damage Check for damage Check oil level Special Instructions Check
Axle, planetary gears
Check oil level
Check all the bolts on front and rear axles 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. 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 Driveline, loadframe gearbox - powerframe Low idle High idle Stall idle Transmission, breather Transmission, bolt connection Upbox, breather Battery
AC, cab unit Cab and cab door Hyd oil tank, breather Hyd oil filter switch Brake acc, precharge press Ride control acc, precharge press Tow hook acc, precharge press Brake release Engine oil Engine oil filter Air filter, filter element Exhaust system Save log and parameter files CAN modules Clean the machine Wheel bolts and nuts Doors and hoods Steering and bucket stop Driveline, between upbox and transmission lubrication Midship driveline lubrication
Check for loose and missing bolts Check for loose and missing bolts Check idle Check idle Check idle Inspect and check for damage Check bolts connection and rubber damper Inspect and check for damage Check battery connections and that they are mounted correctly Control and change filter Check bolt torques and lubricate hinges Inspect and check for damage Check alarm function Check precharge press Check precharge press Check precharge press Perform a brake release test Change the engine oil Change the engine oil filter Change the filter Inspect mounting and check for leakage Save and archive log and data files Check for error codes Clean entire unit Check bolt and nuts torques Lubricate, check function and ware Check function lubricate
Idle shall be 80025 rpm Idle shall be 216050 rpm Idle shall be 183050 rpm
Torque should be M22, Grade 10.9 and 622Nm.
Perform a alarm test. See Hyd Oil Filter Switch on page 14 . Pressure should be 832 bar Pressure should be 1005 bar Pressure should be 762 bar Pressure should be over 83 bar Oil capacity is 36 liters Always replace the filter when changing oil Change the filter in the element. See Air Filter, Filter Element on page 16 .
Remove rocks from the loadframe Torque should be UNC , Grade 8 and 383 Nm on bolts and nuts
lubricate
Atlas Copco 7
Front axle lubrication Rear axle lubrication Engine fan hub bearing
lubricate lubricate lubricate

Item Axel, bolt connection Task Check bolt torques Special Instructions Front: UNC 1, Grade 8, moment 3220 Nm Rear: M24, Grade 10.9, moment 790 Nm Torque should be M12 Grade 10.9 and 88 - 102 Nm Torque should be UNC , Grade 8 and 149-163 Nm. Torque should be M24, Grade 10.9 and 790 Nm. Torque should be UNC 7/8, Grade 8 and 620 Nm Check
Driveline, upbox - gearbox Driveline, loadframe gearbox - powerframe Bolt connections, engine cradle - powerframe Transmission, bolt connection AC, cab unit Fuel filter Engine cooling, hoses and pipes Engine coolant, filter Bolt connection, engine mount Expander shafts, loadframe and boom Expander shafts, z-bar Load and power frame Trunnions and pins, boom z-bar Trunnions and pins, bucket Trunnions and pins, steering Trunnions, swivel
Check bolt torques Check bolt torques Check bolt torques Check bolt torques Change filter Check filter and change it if necessarry Check hoses and couplings for wear and damages Change filter Check bolt torques
Check fuel level in the filter and change filter if necessary.
Front: UNC 5/8, Grade 8 and 215 Nm Rear: M20, Grade 10.9 and 455 Nm Torque should be M30, Grade 10.9 and 1570 Nm Torque should be M30, Grade 10.9 and 1570 Nm
Check bolt torques Check bolt torques Check machine frame for damage Check bolt torques Check bolt torques Check bolt torques Check bolt torques
Torque should be M30, Grade 10.9 and 1569 Nm Torque should be M30, Grade 10.9 and 1569 Nm Torque should be M30, Grade 10.9 and 1569 Nm Torque should be M24, Grade 10.9 and 790 Nm
Atlas Copco 9
Atlas Copco Service Kits

Protect 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.
10

Item Transmission, oil and filter change Task Change oil and filter. Clean the strainer Upbox, oil filter Hyd oil change Hyd oil, filter Hyd oil pressure Air filter, safety cartridge Air filter, indicator Change filter Change oil Change filter Check system pressure Change the filter Test indicator function Special Instructions 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. Always replace the filter when changing oil. Always use the electric refill pump when filling up. Oil capacity is 218 liters. Always replace the filter when changing oil. Perform a hyd oil pressure test. See Hyd Oil Pressure on page 24. Change the filter in the element. See Air Filter, Check
Safety Cartridge on page 24

Item Axel, differential Axel, planetary gear Alternator Engine coolant Task Drain and change oil Drain and change oil Test function Clean and refill coolant Special Instructions Check oil level when machine is standing on flat surface. Check oil level when machine is standing on flat surface. Voltage should be between 24-27V Check

Item Hoses and couplings Fuel tank Fuel injectors Fuel hoses Air intake Cooling fan drive belt Task Replace all hoses Drain and clean Check function and change if necessary Replace all hoses Replace hose Change drive belt Special Instructions Check
Atlas Copco 11
New Components
New or Reconditioned Components

Under first shift ( hour)
Bolt Connection, Engine Mount

Check torque. It should be; Front: UNC 5/8, Grade 8 and 215 Nm Rear: M20, Grade 10.9 and 455 Nm
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. 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 first shift (8 hours)
Wheel Bolts and Nuts

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

After 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 250 hours operation
Trunnions and Pins, Boom Z-bar

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

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

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

Expander Shafts, Loadframe and Boom

Expander Shafts, Z-bar

12
250 Hours
Maintenance Procedures by Interval

Every 250 Hours
Repeat Daily
Axle, Planetary Gears
1 2
Axle Breather
Check 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.
1. Drain plug 2. Arrow STEP
Axle, Bolt Connection

STEP 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. 2 Apply the parking brake. 3 Remove the oil level/drain plug. The oil level must be up to the bottom of the plug hole. Add oil as required. 4 Install the oil level/drain plug and check the other planetaries.
STEP
Check bolts
Driveline, Upbox - Transmission

Make sure no bolt is missing or loose. Make sure there is not any loose play in the drivelines and bearings
Check all bolts on front and rear axle that hold the axle to the frame for damage. Change if necessary.
Axle, Differential
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 Idle
STEP
1 Start the engine and make sure it is warm, approximately 80 C. 2 Engine speed, temperature and oil pressure is shown in "F2" menu on display. 3 Let the engine be on low idle (no load) and write down the rpm. 4 Idle should be around 80025 rpm. the engine and even the upbox, transmission and driveline.
STEP
Differential plug STEP
STEP
1 Park the vehicle on a level surface, apply the parking brake, and stop the engine. 2 Let vehicle to stand 5 minutes to allow oil to settle to normal level. 3 Remove the oil level plug. The oil level must be up to the bottom of the plug hole. Add oil as required. 4 Install the oil level plug and check the other differential.
STEP
STEP
Important If the rpm is to low it could damage
STEP
STEP
Atlas Copco 13
250 Hours
High Idle
STEP
Transmission, breather
1 Start the engine and make sure it is warm, approximately 80 C. 2 Engine speed, temperature and oil pressure is shown in "F2" menu on display. 3 Push down the throttle all the way and wait until the engine has full rpm and write down the rpm. 4 High idle should be around 216050 rpm with no load
STEP
STEP
STEP
Stall Speed
Transmission breather
Check that the breather is working correctly and are not damaged.
Transmission, Bolt Connection

Menu Operator, Converter Stall STEP
Check bolt connections and rubber damper that holds the transmission into the powerframe.
1 Go to menu "Operator/Converter Stall" and make sure that stall speed rpm is set to 2200 rpm at engine rpm. 2 Adjust if necessary. Mark Converter stall check box and press Enter. 3 Second gear will automatically be chosen and the park brake will activate. Press and hold down the throttle pedal during the test. 4 When engine and transmission is at normal operating temperature approximately 80 C, read and write down rpm. 5 Stall speed should be around 183050 rpm. 6 Release the throttle pedal and let the engine run at low idle for a while. 7 Un-mark "converter stall" check box or release and apply the park brake to get out of Converter stall. 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.
Upbox, Breather
Check that the breather is working correctly and are not damaged.
STEP
Battery
Check 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.
STEP
STEP
STEP STEP
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
STEP
N o t e You may need do this test more then one
14
250 Hours
AC, Cab Unit Hyd Oil Filter Switch
AC filter in the cab unit
Replace the AC filter.
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.
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.
Brake Acc, Precharge Press
Hyd Oil Tank, Breather
Brake accumulator STEP
1 The pressure on the accumulator hydraulic side must be drained before checking the precharge pressure. 2 Remove the protection over the valve and then remove the hood. 3 Connect a manometer to the valve. 4 Open the valve on the accumulator through loose the valve nut. 5 Check the pressure on the manometer, it should be 832 bar. 6 Close the valve again with the valve nut and remove the manometer. 7 Put back the hood and the valve protection.
STEP 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.
STEP STEP
STEP
STEP
STEP
Atlas Copco 15
250 Hours
Ride Control Acc, Precharge Press 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 STEP STEP
1 Lower the boom to the ground. 2 Stop the engine. 3 Block all wheels.
Ride control accumulator
Perform a precharge pressure test. See Brake Acc,

Precharge Press on page 14
The pressure should be 1005 bar.
Tow Hook Acc, Precharge Press

STEP STEP
Manometer connection point on the junction block, BRJ3.
4 Connect a manometer to the BRJ3 valve. 5 Remove the screw that protect the hole in the panel. 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. 7 Then remove the screwdriver and check the that the pressure goes down to zero. 8 Then repeat this test a couple of times to control that the brakes working properly.
STEP
STEP
STEP Tow hook accumulator
Perform a precharge pressure test. See Brake Acc,

Precharge Press on page 14
Engine Oil
The pressure should be 762 bar.
Brake Release
1
1. Engine oil fill 2. Engine oil level dipstick 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.
Check oil level when machine is standing on flat surface.Switch off the engine and allow the oil to drain down from the engines internal parts for some minutes. This eliminates the risk of overfilling.
16
250 Hours
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.
Air Filter, Filter Element
WARNING Engine oil can reach temperatures

exceeding 104C (220F). Do not change oil immediately following engine shutdown.
Engine Oil Filter

Filter element STEP STEP STEP
1 Remove the air filter cover. 2 Remove the outer filter. 3 Inspect filter gasket surface and replace if needed. 4 Install a new primary element.
Engine filter, always replace the filter when changing oil. STEP
STEP
1 Remove the oil filters by turning counterclockwise using a strap wrench or filter removal tool. 2 Discard the filters. 3 Clean the filter sealing surface with a clean cloth. 4 Apply clean oil to the gasket of each new filter. 5 Fill each new filter with new 15W-40 engine oil and install each filter. 6 Turn each filter clockwise until the gasket makes contact with the filter base. Continue to turn the filter 2/3 turn by hand. 7 Fill the crankcase through the filler tube to the top dipstick mark. 8 Start the engine and run at idle speed and check the engine oil pressure. Then, check for oil leaks around the filter. 9 Stop the engine and check the engine oil level after a few minutes.
Exhaust System
STEP STEP
Exhaust system
STEP
Check exhaust system for damage and leakage. Check bolt connection and check that clamps are not loose.
STEP
Save log and parameter files

Save 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.
STEP
STEP
CAN Modules
STEP STEP
STEP
1 Go to menu "Diagnostics/Modules". 2 Check that all modules have green color, which indicates that it is no faults. 3 If some module are colored in red, mark it and press enter for more information.
STEP
STEP
Module TCU D602 shows diagnostics and comments about the transmission. Module ECU D601 shows diagnostics and comments about errors on the engine.
Atlas Copco 17
250 Hours
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 .
Driveline, Between Upbox and Transmission Lubrication
Clean the machine

Clean the hole machine with high pressure washer or if it is possible with steam washer.
Wheel Bolts and Nuts
Lubrication point
Lubricate this point.
Midship Driveline Lubrication
Wheel nuts
Check torque on the wheel bolts and nuts. It should be UNC , Grade 8 and 383 Nm on bolts and nuts.
Lubrication point
Doors and Hoods
Lubricate this point.
Front axle lubrication
Lubricate the nipples on the front axle yoke. Hinges on the hydraulic door
Lubricate all hinges on doors and hoods. Check function and locking device.
Steering and Bucket Stop

Check function and that the speed is slowing down just before it reach the end position. Check that steering goes soft against the stop.
18
250 Hours
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.
Atlas Copco 19
500 Hours
Every 500 Hours

Repeat Daily Repeat 250 Hours
Fuel Filter
Axle, Bolt Connection

Check torque on all bolts on front and rear axle that hold the axle to the frame. Bolt dimension for front axle is UNC 1, Grade 8, moment 3220 Nm. Bolt dimension for rear axle is M24, Grade 10.9, moment 790 Nm.
Driveline, Upbox - Transmission

Check the torque on the driveline bolts between upbox and transmission. Bolt dimension is M12 Grade 10.9, and moment 88 102 Nm.
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.
Driveline, Loadframe Transmission - Powerframe

Check the torque on the driveline bolts between loadframe, transmission and powerframe. Bolt dimension is UNC , Grade 8, and moment 149 - 163 Nm.
Bolt connections, Engine Cradle Powerframe

Check the torque on the bolts that holds the engine cradle in to the powerframe. Bolt dimension is M24, Grade 10.9 and 790 Nm.
STEP
1 Clean both fuel filters and the area around each filter. 2 Drain the fuel until the reservoir is empty. 3 Turn each filter anti-clockwise and remove the filter head. Discard the old filters. 4 Use a clean cloth and wipe the mounting surface of each filter. Make sure this area is clean. 5 Install the new filter and O-rings. 6 Reinstall the protective casing. 7 Fill with fuel through the ventilation cover. 8 Start the engine.
STEP STEP
Transmission, bolt connection

Check the torque on the bolts that holds the transmission in to the powerframe. Bolt dimension is UNC 7/8, Grade 8 and 620 Nm.
STEP
STEP STEP STEP STEP
AC, cab unit
Engine Cooling, Hoses and Pipes

Check hoses, pipes and couplings for wear and damages.
AC filter
Change the AC filter in the cab.
20
500 Hours
Engine Coolant, Filter
Replace the coolant system filter every 500 hours of operation or when the cooling system is refilled.
STEP
Trunnions and Pins, Boom Z-bar
1 Rotate the two filter shutoff valves clockwise to the OFF position. 2 Use a strap wrench and turn the filter counterclockwise to remove. Discard the old filter. 3 Use a clean cloth and clean the filter mounting area on the filter head. 4 Apply a thin layer of clean grease or oil to the gasket of the new filter. 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. 6 Rotate the two filter shutoff valves counterclockwise to the OPEN position.
Bolts on Z-bar
STEP
STEP
STEP
STEP
STEP
Expander Shafts, Loadframe and Boom

Expander Shafts, Z-bar

Bolts on Z-bar
Load and powerframe
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

Look for frame cracks at major stress points.
Check frames for damage that could cause down time.
Atlas Copco 21
500 Hours
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
22
1000 Hours
Every 1000 Hours

Repeat Daily Repeat 250 Hours Repeat 500 Hours
STEP
4 Install the drain hoses and strainer and add new oil to FULL mark. 5 Start the engine and run at idle for a few minutes with the transmission in NEUTRAL. Check for oil leaks. 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.
STEP
STEP
Transmission, Oil and Filter Change
2 3
1. Transmission Strainer 2. Transmission Oil Drain Hoses 3. Upbox Strainer STEP 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.
1 Clean the area around the transmission oil filler tube and drain hoses. 2 Remove the drain hose and oil strainer assembly. Drain all the transmission oil. 3 Replace the transmission oil filters and clean the strainer assembly and breather.
STEP
STEP
Transmission oil dip stick, on top of the transmission.
Transmission oil filter are located behind the hydraulic hatch
Atlas Copco 23
1000 Hours
Upbox, Oil Filter
STEP
drain the cylinders. 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. 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. Replace the hydraulic filter. Re-connect all hoses and fittings previously disconnected. Install the reservoir drain plug. Pump new oil into the hydraulic reservoir.
Always use the electric refill pump when filling up . STEP14
STEP
Upbox oil filter
STEP10 STEP11
Always replace the filter when changing transmission oil.
Hydraulic Oil Change

Change the hydraulic oil and clean/replace the reservoir breather every 1000 hours of operation.
STEP
STEP12 STEP13
Important
1 Raise the boom to its full height so that the pistons will be extended in the hoist cylinders. 2 Move the bucket to its full rolled back position so that the piston will be extended in the dump cylinder. cylinders will be below the pistons and will drain more completely.
Start the engine, cycle dump/hoist and steering and check for oil leaks.
STEP
Stop the engine and check the hydraulic oil level.
N o t e In these positions the hydraulic oil in the
Hydraulic Oil Filter
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.
Hyd oil filter
DANGER Check the temperature of

hydraulic oil before draining. Hydraulic oil temperature can reach 121 C (250F).
STEP
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
5 Select a container sufficient to hold the entire amount of oil in the system and place underneath the reservoir drain. 6 Remove the drain plug from the reservoir and drain the oil. 7 Disconnect the hoist and dump cylinders hoses at the lowest points so as to completely
STEP
1 Depress the bleed valve relief button on the tank breather to relieve tank pressure. Remove the filter head by unscrewing it. 2 Remove the filter element from the body assembly and discard it.
STEP
STEP
24
1000 Hours
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. 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. 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.
Air Filter, Safety Cartridge
STEP
Important When changing filter ensure that it
Change the safety cartridge. STEP STEP STEP
STEP STEP
5 Start the engine and run at idle speed. 6 Stop the engine and check the hydraulic oil level.
1 Remove the air filter cover. 2 Remove the outer filter. 3 Inspect filter gasket surface and replace if needed. 4 Install a new primary element.
Hyd Oil Pressure

STEP
1 Go to menu "Diagnostics/Modules/D512/ Actuations/Sensors". 2 Start engine and activate boom down. 3 Pressure for sensor B411:1 shall be 278 - 280 bar which is normal system pressure on the machine. 4 The pressure can also be checked with a calibrated manometer to the measure socket for sensor B411:1 and then activate boom down.
STEP
STEP STEP
Air Filter, Indicator

STEP STEP STEP
1 Remove the air intake on the filter. 2 Let the engine go on idle. 3 Cover one part on the intake and check that the indicator alarms. Check that the alarm appears on the display.
STEP
Atlas Copco 25
2000 Hours
Every 2000 Hours

Repeat Daily Repeat 250 Hours Repeat 500 Hours
STEP STEP STEP
vehicle forward or back until the oil level/ drain plug is at the bottom of the hub. 2 Apply the parking brake, and stop the engine. 3 Remove the oil level/drain plug. 4 After all the oil has been drained, reposition the vehicle so that the oil level/drain plug is in the level check position. 5 Put new oil into the planetary. The oil level must be up to the bottom of the oil level/drain plug hole. 6 Install the oil level/drain plug, then repeat procedure with the other planetaries.
Repeat 1000 Hours
Axles, Differentials and Planetaries

The 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.
STEP
STEP
N o t e Drain oil after vehicle has warmed up.

Always drain into a catch basin or container. D i ff e r e n t i a l
STEP
1 Park the vehicle on a level surface, apply the parking brake, and stop the engine. 2 Place adequate receptacle under the axle to receive drained oil. 3 Remove the oil drain plugs and completely drain each differential. 4 Replace the oil drain plugs. 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. 6 Replace the oil level plug.
STEP STEP Planetary drain plug at bottom
STEP
STEP
Alternator
STEP STEP
STEP STEP
1 Start the engine. 2 Go to menu "Vehicle/Information" and note charger voltage that should be between 24 27V dependent on the condition on the batteries. 3 Stop engine. 4 Replace the alternator if necessary.
STEP
Differential drain plug
Planetary
STEP
1 With the vehicle on a level surface, move the
26
2000 Hours
Engine Coolant
Drain, 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. 2 Remove the coolant reservoir cap (if applicable). 3 After all coolant is removed, close the drain valves. 4 Add a cleaning solution to the cooling system and fill the system with clean water. Follow the directions included with the cleaning solution. 5 After you drain the cleaning solution from the cooling system, flush with clean water. 6 Remove and replace the cooling system filter with a new precharge filter. 7 Fill the cooling system with premixed coolant (No supplemental coolant additive). 8 Start the engine and run at idle speed for two minutes. Check for leaks during this period. 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.
STEP
STEP
STEP
STEP
STEP
STEP
STEP
STEP
Atlas Copco 27
5000 Hours
Every 5000 Hours

Repeat Daily Repeat 250 Hours Repeat 500 Hours Repeat 1000 Hours Repeat 2000 Hours
Hoses and Couplings

Replace 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.
DDEC Reader
Fuel Tank
Drain and flush the fuel tank.
STEP
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.
1 Loosen the drain plug on the bottom of the fuel tank and drain fuel into a proper container.
Fuel Hoses
Replace all fuel hoses.
DANGER If the fuel tank is full, there

will be pressure on the drain plug. Recommend draining tank with low fuel level.
STEP
Air Intake
Change all hoses between the filter housing and the turbo charger.
2 Flush tank with clean diesel fuel. Make sure that all contaminants are dislodged and removed from the tank. 3 Remove any feed line screens or strainers, clean and re-install. 4 Re-install fuel tank drain plug and re-fill tank with diesel fuel. 5 Bleed all air from the fuel system.

Replace 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. 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)
STEP
STEP
STEP
Fuel Injectors
Check 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.
28
Atlas Copco 29
Chapter 3: Power Unit
Introduction
This 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
30
ST14 Chapter 3: Power Unit Service Manual
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.
1
Fuel flow 1. 2. 3. 4. 5. 6. 7. 8. Fuel tank Fuel filter Fuel pump ECM Temperature and pressure sensors Engine injectors Check valve Cooler
Fuel Tank
The 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.
Fuel Pump
1
Important
Always use the strainer when filling the tank.
3
1. Fuel Outlet 2. Fuel Pump Housing 3. Fuel Inlet Fuel tank strainer
Fuel Filter
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 1
2 3 2
1. Fuel Filter 2. Shut off valve 3. Water Drain Knob 1. Diesel in 2. Diesel out
Atlas Copco 31
The ECM is cooled with diesel fuel.
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 cooling.
Fuel sensors
1 2
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.
1. Pressure sensor 2. Temperature sensor
Opening the poppet valve ends injection. The duration of valve closure determines quantity of fuel injected.
The temperature and pressure sensors are located on the right hand side of the engine, close to the starter.
The solenoid only controls how much fuel will be delivered.
Injectors
1 4
Calibration codes
1 2 5 2
1. Part number 2. Calibration code
All DDEC III injectors contain injector calibration codes. 3

1. 2. 3. 4. 5. Injector Solenoid Fuel Inlet Injector Spray Nozzle Injector Follower Spring Injector Body
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.
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 efficient injection.
32
Check Valve
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. 1 2 The major components in the Scooptram engine oil system are: Oil Pump Oil Filters Oil Pressure & Temperature sensors
1. Output 2. Input
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.
The check valve is placed in front of the engine and its function is to prohibit fuel from reversing direction.
Fuel Cooler
Oil Filters
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.
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 sensors

The sensor for oil pressure is located on the right hand side, in front of the engine together with the temperature switch.
Atlas Copco 33
Cooling System
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.
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.
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.
Coolers
The engine cooling package houses the following coolers.
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 2 3 1
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 Recommendations
Use 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 6038M 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.
1. 2. 3. 4.
Fuel cooler AC condensor (option) Intercooler Water cooler
5
5. Transmission cooler (option) 6. Hydraulic cooler
34
Air Intake System
Engine Air Filter Restriction Indicator
Air cleaner
Engine air filter restriction indicator
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. importance to engine life and performance.
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.
Important The air cleaner is of vital
Air Cleaner
Turbo Charger
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.
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.
Atlas Copco 35
Exhaust System
Engine air flow 1. 2. 3. 4. 5. 6. 7. Air inlet Compressor Charge air cooler Cylinder Exhaust mainfold and cylinder head porting Turbine Turbine exhaust outlet 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 / Catalyst
The 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.
Turbo air flow 1. 2. 3. 4. 5. 6. Ambient air inlet Compressor wheel Compressed air discharge Exhaust gas inlet Turbine wheel Turbine exhaust gas discharge
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.
Engine exhaust air flow Compressed air flow Fresh air
36
Exhaust Heat Shields
Electrical system
The engines 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 function 1. Input 2. Analysis 3. Output
The engines electrical system consists of:

Heat Shielding
ECU EUI Temp sensors Pressure sensors
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.
ECU
The ECU is located between the engine and the upbox, beneath the surge tank. The ECU have the following connections:
1
1. Injector harness connector 2. Engine harness connector
3. Vehicle interface harness connector 4. Communication harness connector
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5. Power harness connector
Upbox
Temperature & pressure sensors

The following sensors are connected to the engines 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)
Upbox
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.
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
38
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 engines 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.
Removing the Engine Package
STEP
1 Remove the engine hood.
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. 1
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.
STEP 1. Slip Yoke 2. Brake Accumulator
2 Disconnect the transmission driveline on the slip yoke at the upbox. 3 Remove the brake accumulator and mounting bracket.
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 reinstalled.
STEP
1
1. Shut off valve STEP
4 Turn the fuel shut off valve to the off position.
Atlas Copco 39
STEP
5 Disconnect and immediately cap the line that connects the oil pan to drain hose. 6 Disconnect the inlet fuel line from the fuel tank.
STEP
STEP12 STEP13 STEP
Loosen the four engine cradle bolts. Prepare an adequate hoist with spreader bars and chains. Use the three lifting eyes to hoist the engine package out of its compartment.
7 Disconnect the wiring harness from the engine ECM.
STEP14
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. 9 Disconnect the air intake tubes from the air cleaner to the engine. Remove the heat shield from the turbo. Disconnect the exhaust and turbo tubes.
STEP15
Attach a hoist chain to the lifting eye of the radiator brace at the front of the engine.
STEP
STEP10 STEP 11
STEP16
Attach hoist chains to the two lifting eyes located on each side at the back of the engine.
40
STEP
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.
3 Reinstall the two bolts that secure the front engine mount (center) to the power frame, but do not tighten. 4 Reinstall the two bolts that secure each rear engine mount (left and right) to the power frame, but do not tighten. 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
STEP
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. dampers placed between frame and engine cradle) need to be replaced when worn or damaged.
STEP
6 Remove the chains, spreader bar, and hoist from above the engine.
N o t e Engine cradle grommets (vibration
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
7 Reinstall the engine to transmission driveline.
Atlas Copco 41
STEP
8 Reconnect the electrical wiring harness to the engine ECM. 9 Reconnect the inlet fuel line from the fuel tank. Reconnect the oil drain hose. Turn the fuel shut off valve to the on position. Reinstall the clamp that secures the front end of the exhaust system head pipe to the turbocharger. Reinstall the engine hoods.
STEP
STEP
Remote Radiator Drain
STEP10 STEP 11 STEP12
3 Place a suitable receptacle below the engine coolant radiator and drain all engine coolant.
STEP13
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
STEP
4 Disconnect the air hoses that connect to the charge air cooler. 5 Disconnect and cap all coolant hoses from the radiator.
STEP
Engine Hoods STEP
2 Remove the complete Air filter.

STEP
6 Remove the fan shroud and fan.
42
STEP
5 Reinstall the hoses that connect to the engine block and oil cooler. 6 Reinstall the hoses that connect to the charge air cooler. 7 Close the engine coolant radiator drain cock. If the engine block was drained, close the two drains on the engine. 8 Fill the radiator with the proper coolant mixture. See Engine Coolant on page 130 . 9 Reinstall the engine hood.
STEP
STEP
STEP
STEP
STEP
7 Remove the upper end support bracket.
Remove Hydraulic & Fuel Coolers

Remove the radiator as follows:
STEP
8 Install lift eyes on top of radiator and place hoist hook.
STEP STEP
1 Open the engine radiator protective doors. 2 Disconnect and immediately cap the lines that connect the radiator to the hydraulic system. 3 Remove the bolts that secure the radiator to the cooling system shell. 4 Remove the radiator.
STEP STEP
9 Loosen and remove the bolts from the radiator located on the bottom of the engine package cradle. Lift the cooling system package clear of the scooptram and store it in a safe location.
STEP
STEP10
Replace Hydraulic & Fuel Coolers

Reinstall the radiator in the reverse order of removal.
Replace the Cooling Package

Reinstall the cooling system package as follows:
STEP
Remove Exhaust System Components

Some vehicles are equipped with catalytic exhaust purifiers. The purifier and the silencer do not require periodic maintenance.
1 Using the hoist and lifting chains arrangement used in the removal, lift the cooling system package into position on the engine cradle. 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. 3 Reinstall the radiator support arm. 4 Reinstall the fan and fan shroud.
STEP
STEP STEP
Atlas Copco 43
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 section of the head pipe to the rear section connections. 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.

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 System

Reinstall the component in the reverse order of removal.
Replace Fuel System Components

Remove 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
44
Remove Fuel Filter
STEP
2 Remove the cover on the side of the Intercooler. 3 Remove the bolts and then remove the cooler.
STEP
Replace Fuel Cooler

Reinstall the fuel cooler in reverse order of removal. 1 2 3 4
Remove Fuel Valves, Solenoid and Lines
1. 2. 3. 4.
Fuel Filter Collar Shut off valve Water Drain Knob
Remove the fuel filters as follows:

STEP STEP
1 Clean the fuel filter and the surrounding area. 2 Turn the fuel shut off valve 90 degrees to the OFF position. 3 Drain the fuel out of the filter by opening the drain knob. 4 Remove the clear cover by turn the collar counter clockwise and remove it.
Fuel Lines
Remove a fuel valve or line as follows:

STEP
STEP
1 Clean the fuel valve or ends of the fuel line and the surrounding area. 2 Always close the shut off valve (turn to OFF position) before removing any parts. 3 Disconnect the component and remove it.
STEP
STEP
STEP
Replace Fuel Filters

Reinstall the fuel filters as follows:
STEP
Replace Fuel Valves, Solenoid and Lines

Reinstall a fuel valve or line as follows:
STEP
1 Wipe the mounting surface for the filter with a clean cloth. 2 Apply a thin layer of grease to each filter gasket. 3 Fill each filter with clean diesel fuel. 4 Install the filter on the filter mount and close the cover by turning the collar clockwise. 5 Turn the shut-off valves the ON position. 6 Start the engine, run it at idle speed, and check for fuel leaks.
STEP
1 Make certain that the connections are clean, both on the component to be installed and the components to which it connects. 2 Install the component. 3 Turn the fuel valve to the ON position. 4 Start the engine, run it at idle speed, and check for fuel leaks.
STEP STEP
STEP STEP STEP
STEP STEP
Removing the Fuel Tank

Remove the fuel tank as follows:
STEP STEP
Remove Fuel Cooler

Remove the fuel cooler as follows:
STEP
1 Close the fuel shut-off valve to the fuel tank. 2 Place a suitable receptacle under the fuel drain of the tank, remove drain plug and drain
1 Disconnect and immediately cap the hoses.
Atlas Copco 45
the tank.
STEP
2 Re-install the bolts that secure the tank to the power frame. See Torque Specifications on page 132 . 3 Remove the hoist and the chains. 4 Remove all temporary seals from fittings and outlets. 5 Open the fuel valve to the tank. 6 Start the engine, run it at idle speed and check for fuel leaks.
STEP STEP
STEP STEP
STEP
3 Disconnect and remove the batteries and all electrical cables.
R&R Electronic Engine Control System

Removing the ECM
STEP
4 Remove the Upbox hoses and remove the Ansul system and hoses. 5 Remove the engine oil fill hose. 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. 7 Take up the slack in the chains, but do not lift the tank yet. 8 Remove the bolts that attach the fuel tank to the power frame. 9 Lift the tank from the frame and set it on blocks in a safe location. Remove the receptacle from under the power frame. Close the fuel valve of the tank and temporarily seal all fittings and outlets.
STEP
STEP STEP
1 Remove the fuel hoses and plug them immediately. 2 Disconnect the cables from the ECM. 3 Unscrew the four (4) screw that holds the ECM. an integral part of the engine package. Refer to the engine manual for removal and replacement information.
STEP STEP
STEP
STEP
N o t e The engine electronic control system is
STEP
STEP10
Replacing the ECM

Reinstall the component in the reverse order of removal.
STEP 11
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.
46
Atlas Copco 47
Chapter 4: Power Train
Introduction
Power 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.
48
ST14 Chapter 4: Power Train Service Manual
Components
1
1. Front Axle 2. Front Driveline 3. Driveline Support Bearing 4. Midship Driveline
10
11
7. Rear Driveline 8. Rear Axle 9. Upbox to Transverter Driveline 10.Up Box 11.Engine
5. Transmission to Midship Driveline 6. Transmission
Transmission
Transmission manual
The transmission manual including in the documentation will tell you more about the transmission details and repairing.
Converter
An 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:
Transmission
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.
The Transmission consists of: Converter APC200 Transmission hydraulics
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.
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 operators compartment. The transmission electrically defaults to neutral whenever the vehicle is shut off, or if a problem with the transmission develops during operation.
Atlas Copco 49
Transmission Controller APC 200
Wire B01 B02 B03 B04 B05 B06 B07 B08 B09
Pin L1 M1 N1 P1 R1 S1 L2 M2 N2 P2 R2 S2 L3 M3 N3 P3 R3 S3
Func VFS4+ ANI4 VFS5+ ANI5 VFS6+ ANI6 CANL CANH RXD TXD SS3 SPWR DIGIN6 DIGIN7 DIGIN8 DIGIN9 ANI3 SGND
Type HbrgA Sns HbrgB Sns Pwm Sns Comm Comm Comm Comm Sns Pwr Ptp Ptp Ptp Ptp Ptp Gnd
Description
5V Reference voltage out
CAN Lo CAN Hi RS232 RXD RS232TXD
The APC 200 controller, located at service bay.
B10 B11 B12 B13 B14 B15 B16 B17 B18
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.
Switched Battery Plus
VFS Ground
Hydraulics
1 2
3 4
The connections back of the APC are as follow:
1. 2. 3. 4. 5.
Cooler Filter Transmission Chargepump Sight gauge
Connections back on the APC 200.
The transmission system is lubricated with transmission oil that is also used to actuate the gear changes when the transmission solenoids activate.
50
The transmission system is composed of the following systems: Charge pump Oil cooler Oil filter Solenoids
Filter
Charge Pump
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.
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
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
Transmission cooler
Solenoids
The gear selection switches is a rotary type that allow the operator to interface with the transmission.
1
1. Oil drain 2. 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.
Atlas Copco 51
Flow and Fluids
Transmission Oil Temperature

The 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.
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 Scooptrams 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.
Checking Transmission Control Pressure

Clutch 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
52
With oil temperature at 80-95 C (175-200F) 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.
Universal Joint Bearings
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.
Bearing
Driveline
The 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.
Universal joints employ various types of bearing tap assemblies. They are specified on any particular scooptram based on their torque loading capabilities.
Driveline Support Bearings

Drive 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.
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 .
Remote lubrication on the powerframe, to lube the bearings.
Atlas Copco 53
Remote lubrication on the load frame, to lube the bearings.
Rear axle
Axles
Important The front and rear axle has grease

fitting located on the input shaft thats 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
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.
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:
Front axle
Road Maintenance Wheel and Tire Inspection and Maintenance Air Pressure Inspection Rolling Radius & Tire Sizing Driving Practices
54
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
Rapid center wear Cut growth Poor re-tread ability
Under-inflation 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.
Wheel and Tire Inspection and Maintenance

Wheels 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.
Rolling Radius and Tire Sizing

Important 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 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 Inflation
The 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 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. E x a m p le : 30" RR tire +/- 4% = 31.2" RR to 28.8" RR.
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-inflation results in: Excessive cutting Lower impact resistance
Atlas Copco 55
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.
56
Replace Powertrain Components

Before start working with the machine, always read Safety Awareness manual and Operator manual to work with and park the vehicle correctly.
STEP
3 Remove all electrical wiring on the transmission and bulkhead on cab. 4 Disconnect the engine to transmission driveline from the transmission. 5 Disconnect the transmission to midship and rear drivelines. 6 Mount on two (2) lifting devices.
STEP
STEP
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.
STEP
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.
STEP Lifting devices
7 Release the six (6) bolts that hold the transmission mounts.
Transmission
Remove 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 Remove Before start working with the machine, always read Safety Awareness manual.
STEP
Four of the six bolts. 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. 2 Remove and plug all hoses that are connected to the transmission.
8 Lift up the transmission really slow and make sure its not get caught anywhere.
STEP
Atlas Copco 57
radiator, ensuring that the retaining clamps are also reinstalled to the appropriate hose.
STEP10
Reinstall the hood above the transmission compartment. After starting the engine, check the transmission oil level and leaks in the system.
STEP11
Transmission Tube-in-shell Cooler
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
45
9 Put it safe on a stand on the floor and make sure it cant fall over.
Reinstall Install the transmission as follows:

STEP
6
1. 2. 3. 4. 5. 6. 7. Hydraulic oil in connector Heat exchanger shell housing Hydraulic oil out connector Coolant out connector Coolant in connector Oil drain Water drain
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. 2 Remove the hoist, transmission lift spreader bar, chains, and lift fittings. 3 Reinstall the bolts that secure each transmission mounting bracket to the power frame. 4 Reinstall the driveline sections. 5 Reconnect the electrical harness to the transmission. 6 Reinstall the dump/hoist, steering, and brake pumps. Reconnect the hydraulic lines and their retainer clamps to the pumps. 7 Uncap or unplug and reinstall the hydraulic lines and their retainer clamps that run above the transmission. 8 Fill the transmission with proper oil. 9 Replace the transmission/hydraulic/fuel cooling radiator and the lines that feed the
STEP
Remove
STEP
STEP
1 Place separate containers under the vehicle to collect engine coolant and hydraulic oil. 2 Remove the air cleaner assembly as a unit. 3 Remove the heat exchanger protective shield. 4 Drain the engine coolant & transmission oil from the tube-in-shell cooler. 5 After the transmission oil has been drained, remove the connectors. 6 After the coolant has been drained, remove the coolant connectors. 7 Unfasten the bolts to the retaining brackets and remove the unit. 8 Clean up residual fluids before installing the replacement.
STEP STEP STEP
STEP STEP
STEP
STEP
STEP
STEP
STEP
STEP STEP
STEP
58
Reinstall Reinstall by reversing the removal steps.
Transmission Solenoids
Transmission Oil Filter
Transmission oil filter, hydraulic hatch Solenoids on the transmission
Remove
STEP STEP
1 Open hatch in service bay hydraulic. 2 Use a tool to turn the filters counter clockwise.
Remove Before start working with the machine, always read Safety Awareness manual.
STEP STEP STEP
1 Remove the right rear wheel. 2 Remove the inspection hatch. 3 Remove the nine (9) bolts holding the valve section and remove the valve. valve.
N o t e Be careful with the sealings behind the

Installation instructions for the transmission filter
Reinstall
STEP
Reinstall Reinstall the component in the reverse order of removal.
1 Fill the new filter with transmission oil and lubricate the sealing. 2 Turn it clockwise and tighten it only by hand first. 3 Use a tool to tighten it 1/2 turn more.
STEP
N o t e Make sure all the sealings are correct in

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

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. 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.
N o t e Do not use lock washers, lock plates or
Installing Driveline Guards

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.
Driveline guards.
Installing the Drive Shaft

Install 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.
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.
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.
DANGER Always make sure there is a

driveline guard installed around or over the midship drive shaft. This guard provides protection for the operator.
Yokes and Bearing Mounts N 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.
60
Upbox to Transmission Driveline
Transmission to Rear Axle Driveline
Driveline between upbox and transmission
Driveline between transmission and rear axle
Remove and reinstall the upbox to transmission driveline as outlined in the following paragraphs. Remove
STEP
Remove and replace the transmission to rear axle 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. 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. 3 Wrap several layers of masking tape around the bearings on the front universal joint cross. 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. 5 Remove the driveline section.
1 Wrap several layers of masking tape around the bearings on the rear universal joint cross. 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. 3 Wrap several layers of masking tape around the bearings on the rear universal joint cross. 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. 5 Remove the driveline section.
STEP
STEP
STEP
STEP
STEP
STEP
STEP
STEP
Reinstall
STEP
Reinstall
STEP
1 Place the upbox to transmission driveline section in approximate position. 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. 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. 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. 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 .
1 Place the transmission to rear axle driveline in approximate position. 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. 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. 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 .
STEP
STEP
STEP
STEP
STEP
STEP
STEP
Atlas Copco 61
Midship Driveline
Remove and replace the midship driveline as outlined in the following paragraphs. Remove
Remove
STEP
1 Wrap several layers of masking tape around the bearings on the front universal joint cross. 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. 3 Wrap several layers of masking tape around the bearings on the rear universal joint cross. 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. 5 Remove the driveline section.
STEP
STEP
STEP
Midship driveline STEP
STEP
1 Wrap several layers of masking tape around the bearings on the rear universal joint cross. 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. 3 Wrap several layers of masking tape around the bearings on the rear universal joint cross. 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. 5 Remove the driveline section.
Reinstall
STEP STEP
STEP
1 Place the driveline in approximate position. 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. 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. 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 .
STEP
STEP
STEP
STEP
STEP
Reinstall
STEP
1 Place the midship driveline in approximate position. 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. 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. 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 Front Axle

Remove
STEP
STEP
1 Wrap several layers of masking tape around the bearings on the front universal joint cross. 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. 3 Wrap several layers of masking tape around the bearings on the rear universal joint cross. 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. 5 Remove the driveline section.
STEP
STEP
STEP
STEP
STEP
Midship-to-Transmission Driveline
Remove and replace the midship-to-transmission driveline as outlined below.
STEP
62
Reinstall
STEP
Important Be sure the hoist is capable of

lifting the axle.
STEP
1 Place the driveline in the approximate position. 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. 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. 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 .
STEP
7 Remove the nuts from the bolts that secure the axle to each side of the axle hanger.
STEP
STEP
Bolts STEP
8 Lower the axle to the dolly. 9 Detach the hoist and roll out the dolly. Reattach the hoist to lift the axle up on to stands for service.
Axles
Front Axle
Remove and replace the front axle as outlined in the following paragraphs. Remove
STEP STEP
STEP
STEP10
Reinstall
STEP
1 Remove tires. 2 Relieve all pressure from the hydraulic system by venting at the breather and/or loosening the tank cap. 3 Disconnect the midship to front axle driveline from the front axle. 4 Disconnect the brake and brake cooling lines from the wheel ends. Immediately cap or plug each line or connection.
STEP STEP 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. 2 Lift the axle into position. 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. 4 After all bolts are in position and snug, torque in alternating sequence to proper value. See
Axle, Bolt Connection on page 19
STEP
STEP
STEP
5 Uncap or unplug and reconnect the brake and brake cooling lines. 6 Reinstall the midship to front axle driveline to the front axle. 7 Reinstall tires.
STEP
STEP
Brake cooling lines STEP STEP
5 Place a dolly under the axle. 6 Secure a hoist with spreader bar to the axle.
Atlas Copco 63
Rear Axle
Remove and replace the rear axle as outlined in the following paragraphs. Remove
STEP STEP
STEP
9 Detach the hoist and roll out the dolly. Reattach the hoist to lift the axle up on to stands for service.
STEP10
Reinstall
STEP
1 Remove tires 2 Bleed all pressure from the hydraulic system by venting at the breather and/or loosening the tank cap. 3 Disconnect the transmission to rear axle driveline. 4 Disconnect the brake and brake cooling lines from the wheel ends. Immediately cap or plug each line or connection.
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. 2 Lift the axle into position. 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. 4 After all bolts are in position and snug, torque in alternating sequence to proper value. See Axle, Bolt Connection on page 19 . 5 Uncap or unplug and reconnect the brake and brake cooling lines. 6 Reinstall the transmission to rear axle driveline to the rear axle. 7 Reinstall tires
STEP STEP
STEP
STEP
STEP
STEP
STEP
STEP
Brake cooling lines, and the bolts on step 7 to the right. STEP STEP
5 Place a dolly under the axle. 6 Secure a hoist with spreader bar to the axle. lifting the axle.
Important Be sure the hoist is capable of

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.
64
Liquid Cooled Multi-Disc Brake

Disassembly
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.
STEP
1 Multi disc brake removed from axle as an assembly. Brake face seal removed.
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.
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
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.
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.
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
Bolts removed from brake cover
3 A lifting tool was fabricated to remove the brake cover and also hold friction disc and reaction disc in place.
Atlas Copco 65
Remove reaction plate Lifting tool STEP STEP STEP
8 Remove brake piston. 9 Remove outer cover O ring seal.
4 Install the lifting tool and clamp inner teeth of friction disc to hold in place. Remove cover bolts.
Remove the O ring seal Lifting toll installed, STEP STEP STEP10
5 Lift cover off of brake housing. 6 Remove inner piston seal assembly. up rings. Remove sealing rings.
Remove brake cover inlet and outlet O rings two (2) places.
N o t e Some units will have sealing ring and back-
Remove brake cover STEP11 STEP12
Remove piston pressure ring. Remove brake apply springs. Remove friction and reaction disc from brake cover.
Remove inner piston. STEP
7 Remove reaction plate. This remained in housing when cover was removed.
66
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 Seals Replacement 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.
Remove brake apply springs. STEP13
Remove outer piston seal assembly. back-up rings. Remove sealing rings.
N o t e Some units will have sealing ring and
Remove outer piston seal assembly
Cleaning and Inspection

Clean 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. Inspection Make 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.
Atlas Copco 67
Assembly 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.
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). 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.)
STEP
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 Brake Assembly STEP STEP
3 Install inner piston seal assembly. See step six (6) of the disassembly sequence. 4 Install cover and disc assembly on brake housing. holes in brake housing.
6 Tighten bolts 175-190 ft. ibs. torque [240-260 N.m.].
STEP
N o t e Align inlet and outlet holes in cover with
Tighten bolts
68
Tire Mounting Procedures
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. The arrow shows the direction that wheel parts can fly, with explosive force, if installed improperly or if parts are damaged.
Demounting
STEP STEP
1 Block wheels not being serviced. 2 Using a jack, hoist, or other suitable method, raise the vehicle until the wheel to be serviced just clears the ground.
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.
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.
STEP
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 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. 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. 3 Dont 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 oring 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. 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. 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.
7 Demount tire from wheel using accepted shop practices.
Mounting
Review safety warnings and cautions for dismounting before beginning work.
STEP 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. 2 Verify all blocking and cribbing is securely in place. 3 Clean all wheel and hub mounting surfaces. Remove all dirt, grease or paint before installing wheel. 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. 5 Install mounting hardware and secure the tire and rim in accordance with the torque settings specified in the Appendix. 6 Once the tire is mounted, lower the vehicle to the ground, using jacks, hoists or other suitable method. 7 Remove all cribs and blocks. 8 Remove and stow articulation lock. 9 Remove Do Not Operate tag from Off/On/ Start switch.
STEP
STEP
STEP
STEP
STEP
STEP
STEP
STEP STEP STEP
Wheel Inspection
Inspect wheel components for defects, observing the following precautions:
70
Mismatched Rims
Improper rim selection can cause these operating problems: Tire Slippage Excessive Flexing Tube Pinching Overheating Valve Stem Tear Outs Sidewall Failure Ply Separation Blowouts
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 components together. Never sit on or stand in front of a tire and rim assembly that is being inflated. Use a clip-on fitting 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.
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 Procedures

STEP
1 Install tire on the wheel. Complete assembly of wheel components.
Mounting and Inflating Safety

Observe 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 during inflation. Dont 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 correct the problem. Dont 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 tapping. 2 Align driver pockets in bead seat band and base.
STEP
Atlas Copco 71
STEP
3 Insert driving key into driver pocket on base.
STEP
5 When properly aligned, the bead seat band and pocket will move out and lock the drive key during inflation. 6 Mount completed wheel and tire assembly on the axle, then tighten lugs to the specified torque. 7 Remove cribbing or blocks and lower the vehicle. 8 Check that tire is inflated to the specified pressure following the applicable precautions listed above. 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.
STEP
STEP
STEP
N o t e Outboard drivers are on those rims used
STEP
4 Make certain that all parts are properly aligned before inflation.
72
Wheel Nut Torque

Wheel 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.
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.
Recapping
For 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.
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 Precautions
Observe 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. 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. 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. 4 Always inspect rims and wheels for damage during tire checks. Early detection of potential rim failures may prevent serious injury. 5 Never add or remove an attachment or otherwise modify a rim (especially by heating, welding, or brazing) unless the tire
STEP
STEP
STEP
STEP
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.
Load Frame
Removing the Bucket
Remove 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.
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.
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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ST14 Chapter 5: Main Frame Service Manual
STEP STEP STEP
1 Block all tires. 2 Lower the boom until it is resting on its stops. 3 Roll the bucket back until the bottom of the bucket is parallel with the ground. 4 Place suitable support blocks, or a palette, under the bucket so that it rests on the supports.
STEP
8 Remove all the tire blocks.
STEP
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. resting on support blocks.
STEP
Important Make sure that the entire bucket is
9 Back the vehicle away from the bucket or hoist the bucket from in front of the vehicle.
Replacing the Bucket

Reinstall the bucket in the reverse order of removal.
Removing the Z-Bar
Follow these instructions to remove the Z-Bar from the boom assembly:
STEP
6 Disconnect the Dog-bones from the bucket by removing the trunnion caps from the bucket end.
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. 2 Block all tires. to remove the Z-Bar.
STEP
N o t e It is not necessary to remove the bucket
STEP
7 Remove the trunnion caps from the main boom pins on the bucket.
Atlas Copco 75
STEP STEP
3 Remove the dump cylinder guard. 4 Remove the stem-end pin of the dump cylinder on the Z-Bar. 5 With a suitable hoist, lift the dump cylinder stem-end up out of the Z-Bar. 6 Place suitable support blocks under the raised dump cylinder and lower onto the blocks.
STEP STEP
8 Set the Z-Bar aside on a suitable support. 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.
STEP
STEP
Reinstalling the Z-Bar

Follow the removal procedures in reverse order.
Removing the Boom

Remove the boom as follows:

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 STEP STEP
1 Park the Scooptram on a flat hard surface. 2 Block all tires. 3 Follow the procedures for removing the bucket. 4 Follow the procedures for removing the ZBar. 5 Support the dump cylinders with suitable blocks using the load frame as support. Do not rest the blocks on the boom cross section. 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.
STEP
STEP
STEP
STEP
7 Remove the dog-bones from the bottom end of the Z-Bar and lower to the ground.
76
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. 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.
STEP
Connect the three lifting chains to these points. STEP
9 Remove the pins from the boom base end swivel mount. Hoist the boom assembly off of the load frame and set it so that it is securely supported.
STEP10
Replacing the boom

Reinstall the boom in the reverse order of removal.
Atlas Copco 77
Power Frame
Removing and Replacing Hoods
N 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
STEP STEP
7 Remove the hinge bolts. 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 Replacement
Replace the hood in reverse order.
Important Always install the hood latches

after servicing the Scooptram.
Remove the hoods as described in the following steps:

STEP
1 Park the Scooptram on a flat hard surface and turn the engine off. 2 Block all tires. 3 Rig a hoist capable of lifting the hood above the scooptram. 4 Unlatch the hood. 5 Lift the hood and install the support.
STEP STEP
STEP STEP
STEP
6 Disconnect the gas support struts on both sides.
78
Separating the Load & Power Frames

Separation
In 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. 2 Relieve all hydraulic pressure. See Relieving Hydraulic Pressure on page 97 .
STEP
STEP
8 Disconnect the electrical lines between the power and load frames at the power frame junction box.
STEP STEP
3 Disconnect and remove the midship driveline. 4 Install two maintenance stands at the rear of the power frame. Adjust until they are tight against the frame. 5 Attach chains from a hoist to the lifting points on the load frame and raise the front end of the power frame. 6 Place a maintenance stand under the front of the power frame and lower the vehicle.
STEP
9 Disconnect the steering cylinders from the load frame by removing the cylinder-to-load frame (stem end) pins. Perform either of the following:
STEP10
STEP
STEP
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
STEP
7 Disconnect the hydraulic lines between the load and power frames. immediately cap or plug each line and connector.
STEP12
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. Remove the blocks from the load frame wheels. Move the load frame forward approximately 1 meter (3 feet).
STEP13
Atlas Copco 79
STEP14
Place blocks in front of and behind the load frame wheels. Securely support the back of the load frame with a maintenance stand or wooden blocks.
Articulation Pins
1 2 3 4 5 6 7 8 9 10 11 8 12 13 5 4 3
STEP15
Reconnection
Reconnect 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. 2 Remove the blocks from in front of and behind the load frame wheels. 3 Move the load frame backward until aligned with the articulation pins. 4 Install the trunnion caps 5 Adjust the height of the rear of the load frame as necessary for proper articulator pin alignment. 6 Place blocks in front of and behind the load frame wheels. 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. 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. 9 Remove the dolly and its fittings from beneath the load frame or remove the hoist and its fittings from the frame. Replace the midship driveline. Reconnect the steering cylinders. Unplug and reconnect the hydraulic lines. Remove the maintenance stands from beneath the power frame. Make sure the parking brake is set. Remove all blocks from all wheels.
STEP
STEP
STEP STEP
STEP
STEP
STEP
STEP
STEP10 STEP 11 STEP12 STEP13
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
Pin Cap Bolts Pin Cap Bearing Retainer Plate Bolts Bearing Retainer Plate Retainer Plate Seal Split Spacer Spacer Bearing Cone Bearing Cup Hinge Plate Spacer Ring Articulation Pin 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.
STEP14 STEP15
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 Removal
DANGER 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 STEP STEP
set both aside for reuse. 8 Remove the bearing cone. Note the position of the cone, and tag with placement if the bearing will be reused. 9 Depending on pin, either lower or lift the pin from the hinge plate bore. Set the pin aside for reuse. Slide the spacer ring and bearing cone off of the pin. If being reused, set aside and tag with position of the bearing. Remove the bearing cup from the hinge plate and set aside if being reused.
STEP
1 Block all tires. 2 Disconnect the load and power frame as instructed previously.
STEP10
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.
STEP11
Pin Installation
DANGER The 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. 2 Pack both bearing cones with grease before installing. 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. 4 Press the spacer ring onto the pin and seat on the bearing cone. 5 Press the bearing cup into the hinge plate bore.
STEP
STEP
STEP
STEP
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. 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. 5 Loosen and remove the bearing retainer plate lock nuts and bolts. 6 Carefully lift off the bearing retainer plates (both sides) and set aside for reuse. 7 Slide off the split spacer and the small spacer,
STEP
STEP
STEP
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. 6 Slip the pin, with one cone and spacer
STEP
STEP
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.
STEP10
Bolt pin cap onto pin assembly using washers and bolts.
STEP
8 Slip the small spacer onto the pin.
STEP11
Slide upper bearing retaining plate over pin and bolt onto hinge. Torque to the proper value. See Torque Specifications on page
132
STEP
9 Slip the split spacer onto pin.
STEP12
Bolt lower bearing retaining plate onto hinge. Torque to the proper value. See Torque
Specifications on page 132
82
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.
extending. The stop(s) also help prevent boom arm cracking, which can result from the operator slamming the bucket against the arms.
Oscillating Axle Stops
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.
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) Stops

If 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
84
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.
Expression EOD
Description 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. 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. Delta Pressure. The difference between the LSpressure and the pump pressure. The pump is controlled to keep this pressure difference constant, and the p is set by an adjustment screw on the pump controller. The p pressure when all the valves are closed and no flow is delivered from the pump. On some pumps can the p vary with the flow, and is normally highest at zero flow = stand by pressure.
LS-pressure
Definitions
Expression Hoist Dump Description The function to lift and lower the boom. The function to tilt and roll back the bucket. Stand-by pressure
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ST14 Chapter 6: Hydraulic Systems Service Manual
Expression Maximum Pressure cut off
Description 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. 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.
Brake System
The 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.
Flow Sharing
Standard System
All of the hydraulic subsystems share the same tank. Steering system Dump & hoist system Brake system EOD (option) Tow hook with brake release (option)
Cooling & Filtration System

The 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.
The hydraulic system includes the following components: Pumps Cylinders Accumulators Tank and Filters Hoses and Tubing Control Valves Hydraulic Oil Cooler
Steering, Hoist, Dump & EOD

The 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.
Atlas Copco 87
System components
Variable Piston Pumps
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
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, p (also called stand-by pressure). The p 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 p 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 p. The VPLS2 is set to a little bit higher p 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.
Dump cylinder
The dump cylinder is a double-acting cylinder with a chrome plated stem.
Hoist Cylinders
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.
Hoist cylinder stems
The hoist cylinders are double-acting cylinders which provide force in both directions.
88
Accumulators
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. 2. 3. 4.
Gas Valve Nitrogen Piston Hydraulic Oil
1
1. Tank air breather 2. Return filter cap
The accumulator consists primarily of a shell, piston, gas valve, and seals. The area above the piston is precharged 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.
Ta n k A i r B r e a t h e r The 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 Filter The 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.
Tank and Filters

Hydraulic Tank
The hydraulic tank has several functions in the hydraulic system: Stores hydraulic oil. Cools hydraulic oil.
Atlas Copco 89
Control Valves
The Atlas Copco Scooptram employs a series of valves that are integral to the operation of the scooptrams hydraulic system. The valves may include the following: Main control valve Auxiliary valve
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 (VMC)
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)
4
Auxiliary valve.
The auxiliary valve directs the pressure and flow of hydraulic oil for the following:
1. 2. 3. 4. Dump Hoist EOD Steering
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 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 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.
90
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 pump flow, 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. The steering 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 Functions

Boom Up
When 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.
Brake System
All 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.
Boom Down
To 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 float
In 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.
With a valve installed between the energy storage device and the friction device, you have a simple braking system.
SAHR Brake System
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.
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
92
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.
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.
Brake System Components

The 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
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 System Operation

The 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.
Brake Application
Brake Operation
Whenever the electrical power is cut off, by either engine shut down or power failure, the brakes are automatically applied.
Service Brake Operation

When 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).
Brake Release for Towing

To 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.
Park Brake Operation

When 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 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
Brake Cooling
The hand-operated hydraulic pump is double acting, pumping on both the push and pull cycle.
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.
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.
94
Tow Hook with Brake Release (Option)
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 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.
To w H o o k A c c u m u l a t o r
Tow Hook System Components

The brake release tow hook system includes the brake release manifold, tow hook accumulator, tow hook cylinder, and tow hook lever. B r a k e R e l e a s e M a n if o l d The 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
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
To w H o o k C y l i n d e r
Deaeration of brakes
Air bleed, front brakes
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 system Transmission 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.
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.
96
Cooling system
System principle
The 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.
Filtration
The 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 Cooling
The 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.
Relieving Hydraulic Pressure

Before conducting any service on the hydraulic system, follow these procedures:
STEP
1 Park the scooptram on a flat level surface and block all wheels. 2 Install the articulation lock. 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 STEP
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 Starting
Check Cleanliness
Area around the vehicle Power units, pipe connections, components Hydraulic fluids Parts from stock
STEP
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 .
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 Hose

STEP
1 Clean immediate area around any hydraulic component to be serviced to prevent contamination.
98
STEP
2 Label hose to facilitate assembly and diagnostics. 3 Have plug prepared to cap each hose to be removed. 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.
STEP
6 Activate boom down, all the way down to boom stop and hold it there. 7 Adjust the max pressure on VPLS1 to 285 2 bar with screw (2). 8 Adjust the max pressure on VPLS2 to 290 2 bar with screw (4).
STEP
STEP
STEP
STEP
Pressure Setting Checks and Adjustments

Setting Dump and Hoist and Steering Pressure
STEP
9 Put a Pman on port B411:2 on QCV2, located on the load frame. Adjust the PLM screw to 280 2 bar.
STEP10
Setting Brake Pressure
PLM screw STEP
1 Turn the PLM screw two (2) turns clockwise to open the counter pressure valve. 2 Put a pressure manometer (Pman) on the pump pressure port. 3 Start the engine and run it on idle. 1 2
STEP STEP
STEP
STEP
1 Put a Pman on port B410 on the QCV1. 2 Start the engine and run it on idle.
3 4
STEP
4 Adjust the stand by pressure on VPLS1 to 20 1 bar with screw (1). 5 Adjust the stand by pressure on VPLS2 to 23 1 bar with screw (3).
STEP
STEP
3 Adjust the pressure to 138 2 bar with the lower adjustment screw on pump VPLS2.
Atlas Copco 99
Hydraulic System Startup

This procedure addresses the initial start-up of the vehicle hydraulic system.
label) and in the circuit diagram, so that a check may be made in the future when required.
STEP
N o t e For vehicles without accumulator

charging systems, pilot-operated systems, or piston pumps, ignore the applicable instructions.
STEP
6 Check engine and pump are correctly assembled and aligned. 7 Check that hydraulic filters are of specified pore size. 8 Check that all fluids are as specified and filled up to maximum level.
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. 2 Fill the case(s) of the piston pump(s) with clean hydraulic oil. 3 Fill the hydraulic tank with clean hydraulic oil. 4 Bleed the air out of the pump suction line(s). 5 Loosen the connection(s) at the pump inlet(s) and allow the line(s) to gravity fill. 6 Cycle the cylinders to work the air out of the system, but do not pump over relief until the relief valves are set. 7 Refill the hydraulic tank. 8 Shut down the vehicle and reconnect the accumulator charging valve. 9 Restart the vehicle and set the pilot pressure. Cycle the cylinders that couldnt be cycled in step 8. Refill the hydraulic tank.
STEP
Trial Run
STEP
STEP
1 Clear the area of all unauthorized personnel. Only personnel directly required to test the vehicle should be present. 2 Check that all shut-off valves are fully open. 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
STEP STEP
STEP STEP
STEP
STEP STEP
STEP
4 Check position of directional valves and, if necessary, move into required position. 5 Fill pump housing with fluid. 6 All pump cavities should be full and tank pressurized. 7 Check operating function of hydraulic system without load. 8 When normal system operating temperature has been reached, test system under load. Gradually increase pressure. 9 Check monitoring and measuring devices. 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.
STEP STEP
STEP
STEP10
STEP
STEP 11 STEP12
STEP
Set the relief valve(s) and piston pump compensator(s).

STEP
Preparation for Trial Run

N 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 STEP
N o t e Jerky movements indicate the presence of
1 Check that Hydraulic Oil Tank is clean. 2 Check that hydraulic lines have been cleaned and are installed correctly. 3 Check that all couplings and flanges are tightened. 4 Check that all components are correctly connected in accordance with installation drawings or circuit diagrams. 5 Check that hydraulic accumulators are properly charged with nitrogen.
STEP13 STEP10 STEP11
STEP
Check fluid temperature. At normal operating temperature, check flow restriction indicators while operating dump and hoist controls. Compare measured values with specified performance parameters (pressure, speed and setting of other control components). If restriction due to contamination is found, flush the hydraulic system in order to prevent
STEP
STEP12
STEP
N o t e It is recommended that the gas charge be

noted on the accumulator itself (e.g. by a
100
premature failure of system components. Check filter back pressure.

STEP14 STEP15 STEP16 STEP17 STEP18 STEP19
Listen for noise. Check fluid level; add if necessary. Check setting of pressure relief valves. Check for leakage. Shutdown the vehicle. 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 Procedures

Steering Cylinder Removal and Replacement
Dump Cylinder Removal and Replacement
Steering cylinder
St e e r i n g C y l i n d e r R e m o v a l
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
Dump Cylinder
2 Disconnect all cylinder hoses. Clean, label and plug all cylinder and hose connections. 3 Attach a hoist or some type of rigging rated for the weight of the cylinder to support the cylinder. 4 Loosen and remove the bottom trunnion cap and bolts. 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.
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
STEP
1 Follow the procedures to relieve the hydraulic pressure. See Relieving Hydraulic Pressure on page 97 .
STEP
STEP
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.
STEP STEP
2 Remove the dump cylinder guard. 3 Support the dump cylinder with a hoist and sling.
St e e r i n g C y l i n d e r I n s t a l la t i o n Follow the removal steps in reverse order. Operate the scooptram to bleed any air out of the system prior to putting the machine into service.
102
Hoist Cylinder Removal and Replacement
STEP
4 Remove the pin that connects the dump cylinder to the Z-bar.
Hoist cylinders
Hoist Cylinder Removal The 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.

model, the boom could weigh up to 5670 kilograms (12,500 lbs.). Do not reach or lean underneath the boom unnecessarily.
STEP
STEP
5 With a suitable hoist, lift the dump cylinder stem-end up out of the Z-bar cradle. 6 Start the engine and retract the dump cylinder stem.
STEP
1 Park the scooptram on a flat level surface, block all wheels, and install the articulation lock. 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. 3 Follow the procedures to relieve the hydraulic pressure. See Relieving Hydraulic Pressure on page 97 . 4 Secure the hoist cylinders in place (to prevent them from swinging free once pins are removed). 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
STEP
7 Disconnect all cylinder hoses. Clean, label and plug all cylinder and hose connections. 8 Detach cylinder base and lift cylinder from vehicle. 9 Place on suitable surface for service.
STEP
STEP
STEP
STEP
N o t e Make sure cylinder is free of grease or

DANGER Hydraulic fluid may be
under pressure. When removing a hydraulic hose from a cylinder. Safety glasses and heavy gloves must be worn.
STEP
Dump Cylinder Installation Reassemble in reverse order.

STEP STEP STEP
1 Clamp base end pin first. 2 Position stem pin in place. 3 Use hoist to extend cylinder into the Z-bar.
5 Disconnect all cylinder hoses. Clean, label and plug all cylinder and hose connections. 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
STEP
Atlas Copco 103
back into cylinder before removing base pin.

STEP
Pump Installation Install the components in reverse order, torque hardware to specified values. When assembly has been correctly completed, proceed with start-up and functional testing.
7 If machine has trunnion caps (shoulder collars), remove bolts to remove collars and leave pin inside cylinder until cylinder is on stable surface. 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.
N o t e It is not necessary to remove the bucket Hydraulic Valve Removal and Replacement
Hoist Cylinder Installation Reassemble 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
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. Va l v e R e m o v a l
STEP
1 Steam clean the area around the valve to be removed. 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.
Important Make sure the area around the

Pumps are located on the transmission. STEP
1 Follow the procedures to relieve the hydraulic pressure. See Relieving Hydraulic Pressure on page 97 . 2 Remove the hoses and plug lines and ports on the pump. 3 Remove the mounting bolts, and slide the pump off the forward pump stub shaft. 4 Cover open stub shaft assembly to keep clean
STEP
STEP
2 Relieve all hydraulic pressure. See Relieving Hydraulic Pressure on page 97 . 3 Disconnect, cap or plug, and label all hydraulic hoses to the valve. 4 Cap or plug the inlets, pressure ports, and pilot ports to prevent contamination.
STEP
STEP
STEP
STEP
104
STEP
5 Attach a hoist cable to the valve for support while removing the mounting bolts. 6 Loosen and remove the valve mounting bolts. 7 Hoist the valve to a work bench, do not place the valve in a position where it could be damaged.
STEP
5 Replace seals if indicated, using the appropriate service kit. 6 Dip the cartridge in clean hydraulic oil, then reinstall the cartridge, tighten to specified torque and re-test. 7 If this procedure does not eliminate the problem, replace with a new factory-tested cartridge. cartridges. Contact your Atlas Copco dealer for information on cartridge seal replacement and or cartridge replacement.
STEP STEP
STEP
STEP
Va l v e R e p l a c e m e n t To replace a valve, follow the removal procedures in reverse. Va l v e C a r t r id g e R e m o v a l & Se rv i c e
N o t e Service kits are available for the
Hydraulic Manifolds
It is not necessary to remove any valve manifolds from the scooptram since the functional part is a cartridge. Se Valve Cartridge Removal & Service p sida 104. J-Block Auxiliary Valve
If it becomes necessary to remove a valve manifold, follow these generalized instructions:
Important The most common cause of failure

is dirt in the hydraulic oil. Dirt which lodges in the working parts and interferes with their operation. Dirt introduced due to filter bypass
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. 3 Clean, label, disconnect and plug all hoses and harnesses to the manifold. 4 Loosen and remove the bolts that secure the manifold. 5 Remove the manifold.
Most cartridges can be cleaned without altering their settings.
STEP
To check and clean a cartridge which is not functioning:

STEP STEP
STEP
1 Remove the cartridge from the cavity. 2 Inspect for visible contaminants and carefully remove obvious particles. 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. 4 After flushing, blow dry with clean filtered air.
STEP
Manifold Replacement Follow the removal procedures in reverse.
STEP
STEP
Atlas Copco 105
Chapter 7: Electrical Systems

E10 E20 POWERFRAME SECTION
HIGH REAR BEAM LOW
H230A H231A H230
6 6 6
OPERATORS COMPARTMENT
OUTSIDE CAB
6 6
STATUS BEACON
H390B
6
BACKUP STROBE
H185
6
H185 H121
H121
X1
STATUS BEACON
H390A
X2A X2B
BACKUP ALARM
HIGH REAR BEAM LOW
H231B H231
X2
H230B
6
FE5 ME1
6
CD PLAYER X6
6
G4
6
12 V OUTPUT X12
6
WIPER REAR M4
6
WIPER FRONT M3
6
WASHERS M5A,M5B
6 6
DOME LIGHT H234
OPERATORS COMPARTMENT MAIN BULKHEAD
ME7
FE2
DC CON 24/12V
FE4
SPEAKERS X8,X9
FUEL SHUTOFF (OPT) Y226 D510X23a
PG2
E30 LOADFRAME SECTION
D510X13
6
B359
D511X13 D511X20
X4 X3
(CAN POWERED) D512X13
B355
B410
D511X20/15 EMERG STOP SWT (OPT) 133B
B348 (OPT)
6 6 6 6
D511X7
EMERG STOP SWT (OPT) 133A
H227a
H227a
BOOM LIGHT D511X12

H228a
STEER SENSOR B420a (OPT)
D511X18
LOADING LIGHTS
6
STEER SENSOR B420b (OPT)
X3
H228A-B
H228b
H227b
H227b
BOOM LIGHT
System Design
Power Supply
Two 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.
alarm and fuel shutoff valve, Auxiliary outlet and checkfire module.
Keyed Power
When 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 Power
Protected 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.
Charging Circuit
The 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 Circuits
Non-keyed Power
Non-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
Power Grid
The power grid is a five wire power bus that supplies power to I/O-modules D510, D511 and Relay box X3.
106
ST14 Chapter 7: Electrical Systems Service Manual
The five wires in the bus are: protected-, non keyed-, keyed power and two ground wires (002).
Grounding
The 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 Components
Batteries
Switches and Circuit Breakers

ISO Switch (S300)
Batteries
The vehicle is powered from two 12V lead acid batteries.
Alternator
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)

Alternator
The batteries are charged by a 170 A alternator, driven by the diesel engine. The change voltage is 28.8VDC.
Starter
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 Breakers
Control 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.
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.
Park Brake Switch (S138)
RCS Components
The control systems components are described in the control System chapter. See Chapter 8: Control System on page 117 .
Park brake switch
108
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 operators manual for information on how to operate the parking brake.
Hydraulic Filter Switch (B139)
Main Brake Switch (B422)
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 operators 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.
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.
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.
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 operators 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 operators display.
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System functions
Power Up Vehicle
The 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 key LED is turned off to indicate stopped engine.
Shut Down Vehicle

The 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.
Engine On
Vehicle Lights
Cabin Work Lights
Engine on key
Canopy front lights
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.
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
Engine Off
Pressing 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
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
Drift Light (H234)
Drift light
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.
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 Light
The 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).
Load Lights
Status Beacon (H390)
Load lights Status beacon
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.
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
X138. The connectors have connection with the J1939 bus.
CD Player
2
CD player
1. Backup strobe 2. 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.
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.
Horn
Socket Outlet 12V

The 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
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
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
1. Transmission diagnostic connector 2. 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
The washer motors are activated by pushing the wiper switch knob.
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Air Condition
The 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.
Hydraulic Oil Fill Motor
Door Interlock
The 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).
1
1. Hydraulic oil fill motor 2. Hydraulic oil fill switch 3. 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).
Lincoln Lube (X5)
Fuel Heater
The 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.
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 operators display.
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General Maintenance Diagnosis & Calibration

The electrical system of diesel powered equipment requires periodic inspection and maintenance.
Batteries
Battery Booster Cables
Connect 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.
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 If cables are connected wrong on a

vehicle, the alternator can be seriously damaged.
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
Storage of Lead Acid Batteries

Because 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.
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 systems 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.
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Removing and Replacing Electrical Components
Battery
Battery cover in the raised position.
Battery Removal
STEP Battery Isolation Switch STEP STEP
1 Set the battery disconnect switch to off. 2 Open the battery compartment. 3 Remove the negative connector from the battery A (the battery to the front). 4 Remove the positive connector from the battery A. 5 Attach a battery lift sling to the battery and remove it from the battery compartment. 6 Repeat the process for battery B.
To replace the switches, lights, relays, fuses, circuit breakers, horn, and solenoids follow these general procedures: Disconnect the battery by turning off the main (battery 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. 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.
STEP
STEP
STEP
N o t e All of the electrical connectors are
Battery Replacement
STEP
1 Attach a battery lift sling to battery B and place it in the battery compartment. 2 Reinstall the positive connector on battery B. 3 Reinstall the negative connector on battery B. 4 Repeat steps 1-3 for battery A. 5 Close the battery compartment. 6 Set the battery disconnect switch to on.
STEP STEP
STEP STEP STEP
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Alternator
Starter
Starter
Starter Removal
Alternator STEP
Alternator Removal
STEP STEP
1 Disconnect the battery by turning the master (battery isolation) switch off. 2 Disconnect the positive lead on the battery. 3 Disconnect the starter wiring and lay aside. 4 Remove the starter mounting bolts and pull the unit out.
STEP STEP
1 Set the battery disconnect switch to off. 2 Disconnect the electrical connectors from the alternator. 3 Loosen the alternator belt adjustment and remove the drive belt. 4 Remove the bolt that secures the adjustment mechanism to the alternator. 5 While holding the alternator, remove the two bolts that secure it to the engine bracket. 6 Remove the alternator.
STEP
STEP
Starter Replacement
Replace using the same steps in reverse.
STEP
STEP
Engine Sensors
DANGER 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.
STEP
Alternator Replacement
STEP
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. 2 Reinstall the bolt that secures the adjustment mechanism to the alternator and tighten it moderately tight. 3 Reinstall the alternator drive belt and tighten the alternator belt adjustment to the belt specifications. 4 Torque the adjustment mechanism bolt and the engine bracket bolts to 34 N-m (25 ft-lb). 5 Reconnect the electrical connectors to the alternator. 6 Set the battery disconnect switch to on.
Sensor Removal
STEP STEP
1 Let the engine cool. 2 Disconnect the battery by turning off the main (battery isolation) switch. 3 Ensure that the replacement unit is a 24 volt OEM compatible part. 4 Have the new sensor standing by within easy reach. 5 Use the correct size wrench to unscrew the sensor.
STEP
STEP
STEP
STEP
STEP
STEP
STEP
Sensor Replacement
STEP
STEP
1 After removing the old sensor, replace with the new sensor immediately. 2 Use care to replace the wiring connectors to their correct receptacle on the new part. 3 Clean up any drainage.
STEP
STEP
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Engine Diagnostic Interfaces

All problems that occur with the engine are stored in the ECMs memory. The ECM diagnostic interface is located in the operators compartment and can be accessed with a Diagnostic Data Reader (DDR).
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Chapter 8: Control System

E20 POWERFRAME SECTION E30 LOADFRAME SECTION
ECU DDEC 4 D601
TCU CONTROLLER D602
E10 OPERATORS COMPARTMENT
Introduction
The 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.
D510, D511 & D512 I/O modules

The I/O modules decodes signals from sensors and switches into input values. They also handle output to solenoids and on/off functions like relays.
Modules
A 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)
D602 TCU
The 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 ECU
The 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.
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 Module

The 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.
D520 Remote control machine unit (option)

The D520 module, called machine unit (MU), bridges radio commands to CANOpen and vice versa.
D540 Decoder Module

The decoder modules decode pedal positions, buttons and switches. It also drives the push button board LEDs.
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ST14 Chapter 8: Control System Service Manual
Module placement
D512
D601 D510 A1 D602
D512 I/O module D510 I/O module A1 Box
D602 TCU D601 ECU
D501
D540
D576
D511
D520
D576 Steering sensor D511 I/O module
D501 Display module D540 Decoder (behind panel) D520 Machine unit (under seat)
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Menus
Access levels
This section discusses service menus. See the Operators manual for information about the operators menus.
M1 Operator M1.1 User M1.2 Language M1.3 Display M1.4 Units M1.5 Brake test M1.6 Converter Stall M1.7 RCS shutdown M3 Hydraulics M3.1 Info M2 Vehicle M2.1 Information M2.2 Load weigh (opt.) M2.2.1 Settings M2.3 Ride control (opt.)
Logging in
Important 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 STEP
M4 Drivetrain M4.1 Info
1 Start from the Main menu. 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). 4 Return to the main menu using the Escape key.
M5 Diagnostics M5.1Modules M5.1.1 TCU M5.1.2 ECU M5.1.3 Disp D501 M5.1.4 Decoder D540 M5.1.4.1 Actuations M5.1.4.1.1 Actuations M5.1.4.1.1.1 Sensors M5.1.5 Encoder D576 M5.1.6 Left Joystick Levers M5.1.7 Right Joystick Levers M5.1.8 IO D510 M5.1.8.1 Actuations M5.1.8.1.1 Actuations M5.1.8.1.1.1 Sensors M5.1.9 IO D511 M5.1.9.1 Actuations M5.1.9.1.1 Actuations M5.1.9.1.1.1 Sensors M5.1.10 IO D512 M5.1.10.1 Actuations M5.1.10.1.1 Sensors M5.1.11 MU D520 (opt.) M5.2 Levers M5.3 Pedals M5.4 Administration M5.5 Passwords
M6 Log M6.1 Save M6.2 Save All M6.3 Event Log M6.4 DTC log D Direct selection menus D1 Vehicle information D2 Engine D3 Transmission D4 Operator settings D5 Brake test
STEP
Settings
Numerical values
Many settings are made by changing a numerical value, e.g. setting the date and time on the Administration menu.
Menu structure
The 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 Operators manual for information on direct selection menus.
Menu Diagnostics, Administration
120
STEP
1 Move the cursor to the current numerical value using the arrow keys. The entire value will be highlighted. 2 Press the enter button. One individual number will now be highlighted in another color. 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. 4 Confirm the change to the numerical value with Enter.
STEP STEP
6 Apply full throttle. 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. 8 Place a known reference weight (9000 11000 kg) in the bucket. 9 Enter the weight of the reference weight in the Calibration weight input box. Press the Loaded button on the display. Lower boom and roll back the bucket. The screen says "Enter calibration load weight, raise boom with bucket rolled back" Apply full throttle. 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.
STEP
STEP
STEP
STEP
STEP
STEP10 STEP11
M1.7 RCS shutdown

STEP12 STEP13
M2.2.1 Settings
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, 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 calculated (the diffpressure is sampled to calculate the load in the bucket). Bucket Position Current value on the bucket (dump) cylinder position.
Menu Vehicle, Load weigh
The load weighing function can be calibrated from this menu. To do so, preform the following steps:
STEP STEP STEP STEP STEP
1 Move the machine to a level surface. 2 Empty the bucket. 3 Enter the Load weigh menu. 4 Press the Empty button on the display. 5 Lower the boom and roll back the bucket. The screen says "Rollback empty bucket and raise boom".
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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.
Calculated boom angle Current boom angle.
Diagnostics
Menu Diagnostics, Modules
M2.3 Ride Control (opt.)
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 & Sensors

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 activated, will engage. Disengage at boom angle, high The Ride Control option is only possible to activate within a certain hoist angle range. This value is the highest angle at which the function is possible to activate. Disengage at boom angle, low The Ride Control option is only possible to activate within a certain hoist angle range. This value is the lowest angle at which the function is possible to activate. Autolift boom angle This is the angle to which the boom will be lifted when automatic Ride Control is used.
The 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
122
The Actuations button leads to a menu that displays the actuations for some parameters connected to the D510 I/O module.
M5.4 Administration
Menu Diagnostics, Administration Menu Diagnostics, Modules, IO D510, Actuations
In the top part of the administration menu the following information is shown: Rig type Rig number System software version and revision
If you press the Actuations button from this menu, more actuations are shown.
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.
Menu Diagnostics, Modules, IO D510, Actuations, Actuations
Saving parameters
To save the control systems current parameters, do as follows:
STEP STEP STEP STEP STEP
From the second Actuations menu you can press the Sensors button and sensor values will be shown.
1 Go to menu Diagnostics, Administration. 2 Insert a USB stick. 3 Press the Save parameters button. 4 A box will appear, that says Save Started. 5 When it says Save Ok, the parameters have been saved to the USB stick.
Loading parameters
Menu Diagnostics, Modules, IO D510, Actuations, Actuations, Sensors
To load parameters from a USB stick to the control system, do as follows:

STEP STEP
1 Go to menu Diagnostics, Administration. 2 Insert a USB stick containing the new parameter files. 3 Press the Load parameters button. override the current parameters in the control system.
STEP
N o t e The parameters from the USB stick will
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STEP STEP
4 A box will appear, that says Load Started. 5 When it says Load Ok, the parameters from the USB stick have been loaded into the control system.
M6.1 Save
M5.5 Passwords
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.
Menu Diagnostics, Password
The Assert log is reset every time the machine is shut down.
In this menu it is possible to change your password. To change the password do as follows:
STEP
N o t e When saving logs for fault finding,

always save the Assert log before shutting down the machine.
1 Press enter on the Change password button. 2 Enter your desired new password with the arrow keys and confirm with enter. 3 Enter the new password once more and confirm with enter. password, contact your local Atlas Copco representatives.
Logs
St a t i s t i c s l o g The 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. P ro du c t i on l og The 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 log The 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.
STEP
STEP
N o t e If you have lost and forgotten your
M6 Log
Menu Log
The log menu and its sub menus are much the same at Site service level as at operators level. The Save menu is different however.
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Assert log The 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 log The 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 log The 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 update
This section describes how to update the control systems main software.
STEP13 STEP14
Check that all functions work properly. Perform a brake test.
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.
Preparations
STEP
1 Contact your local Atlas Copco representative to get updated software files. 2 Copy the files to a USB stick for code loading and replace the files on the USB stick with the new ones. 3 Boot the machine, log in and go to Diagnostics\Administration. 4 Insert another USB stick and save the current parameters by pressing Save parameters.
STEP
STEP
STEP
Update
STEP
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. 7 Turn off the control system. 8 Remove the USB stick and turn the control system back on again. 9 Log in and go to Diagnostics\Administration. Insert the USB stick with the previously saved parameters and load them to the control system by pressing Load parameters.
STEP STEP
STEP
STEP10
After update
STEP 11 STEP12
Calibrate the pedals. Check for warnings on the Diagnostics\Modules menu.
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Chapter 9: Vehicle Specifications
Performance Related Data

Ve h i c l e We i g h t
Varies by options Empty Axle load, front end Axle load, rear end 38,000 19,100 18,900 kg 14,000 18,240 22,300 83,776 42,108 41,668 lbs 30,864 40,212 49,163 kg lbs
Engine
Detroit Diesel engine Power rating at 2100 rpm Maximum torque at 1350 rpm MSHA part 7 ventilation rate Ventilation particulate index Series 60 DDEC 243 kW / 325 hp
1560 nm
7.8 m/sec 5.2 m/sec
Scoop Capacity
Tramming Breakout force, mechanic Breakout force, hydraulic
Upbox
Superior T825 1:1 gear ratio
O p e r a t in g Ti m e s
Boom Raising Time Boom Lowering Time Bucket Dump Time Cycle time
seconds (1) 7.6 4 1.8 15 Bucket empty Bucket loaded (kph / mph) (kph / mph) 5.2 / 3.2 10.0 / 6.2 17.1 / 10.6 28.5 / 17.7 4.9 / 3.0 9.5 / 5.9 16.1 / 10.0 26.3 / 16.3
Transmission
Dana T40000 Power shift transmission 224-313 kW / 300-420 hk
Sp eed ( l e v e l gro u n d)
Actual performance may vary 1st Gear 2nd Gear 3rd Gear 4th Gear
4 speed shifting forward/reverse
Axles
Dana 53R
Differential, front end Differential, rear end Rear Axle Oscillation Standard No slip 8
128
ST14 Chapter 9: Vehicle Specifications Service Manual
Brakes
Fully enclosed, force cooled, multiple wet disc at each wheel end SAHR system Service, parking and emergency brakes
Ve h i c l e r u n n i n g l i g h t s
- Front lights, 2 on boom, 2 for truck loading - Rear lights, 2 high beam, 2 low beam - Cab lights 4 x 70W 4 x 70W 3 x 70W 1 x 70W
Tires
Description Bridgestone - Tire pressure Michelin - Tire pressure 26,5 x 25, 32 Ply, L5S 6.20.2 bar 26,5R25m XMine, D2 Radial 6.20.2 bar Opt. Notes Std.
- Centre hinge light
Batteries
Voltage Temp range Cold starting (EN) 24 V -40C to 90C / -40F to 194F 900 A 800 A 100 min at 25C / 77F 50 Sealed gel cells
Hydraulics
Description Rexroth, heavy duty piston pumps Two steer cylinder, chrome plated stems Two boom cylinders, chrome plated stems One dump cylinder, chrome plated stems System pressure Hydraulic tank capacity Filtration, return line Electric hydraulic oil filling pump Notes A10VO
Cold starting (EN) at 18C / 0F Reserve capacity Capacity (20h) / Ah Spec. Diameter, 105 mm
Fuel tank
Diameter, 200 mm Description Fuel tank capacity Anti-siphon fuel supply 276 Bar 218 L 12 m 24 V Max turning angle, left and right - Bucket outer corner Notes 390 L Yes Diameter, 230 mm
Turning radius data

Description Notes 44 7105 mm 3415 mm 6600 mm
Stability
Test conditions Maximum safe side slope for operation Bucket fully loaded, boom down 11
- Inner back tire - Rear back corner
Bucket data
Description Material density (kg/m) Volume, nominal heaped (m) Width, bucket (mm) std 1800 2000 2200 2400 2600 7.8 7.0 6.4 5.8 5.4
Noise Level
With Cab, High Idle < 80 dB
2800 2800 2800 2800 2800
Electrical System
Description Voltage, system start & accessories Alternator Control system Master switch (Battery isolation) Starter Notes 24 V 24 V / 140 amp Atlas Copco RCS Lockable Delco 42MT
Accumulator precharge pressure (N2)

Description Brake acc Ride control acc Tow hook acc Bar 83 2 100 5 76 2 PSI 1200 30 1450 70 1100 30
Atlas Copco 129
Fluids and Lubrication

Selection of the proper quality of fuel, coolant, lubricating oils, and grease improves efficiency and extends the life of vehicle components.
Fluid Capacities
The following capacities are approximate. Always follow the fill procedures outlined within the respective chapters. Engine
Oil capacity with filter change liters / gallons 36 / 9.5
F ue l Ta nk
Component capacity 390 / 103
Cooling System
System capacity 65 / 17
Tra n s v e r t e r
Component refill capacity 65 / 17
Up Box
Component refill capacity 2.0 / 0.53
Axles
Front or rear differential capacity Planetary ends (each) 50.2 / 13.3 9.5 / 2.5
H y d r a u l i c Ta n k
Tank capacity supports the steering, braking, hydraulic cooling, dumping, and filtering systems. 218 / 58
Diesel Fuel Quality and Selection

The 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.
130
Fuel Oil Selection Chart

General Fuel Classification
API Gravity, @ 60F / 16C Specific Gravity, @ 60F / 16C Flash Point (F / C, Min.) Viscosity, Kinematic (cSt @ 100F / 40C) Sulphur wt% Maximum for On-Road Use Cloud Point Cetane Number, Min. Cetane Index, Minimum Distillation % Vol. Recovery, (F / C) IBP, Typical* 10% Typical* 50% Typical* 90% Maximum 95% Maximum* Recovery Volume, % Minimum* Water & Sediment, % Maximum Ash, % Maximum Carbon Residue on 10%, wt%, Maximum Copper Corrosion, Maximum 3h Accelerated Storage Stability, Maximum* ASTM No. 1 Standard ASTM 1-D D 287 D1298 D93 D 445 D2622 D 2500 D 613 D4737 D 86 350 / 177 385 / 196 425 / 218 500 / 260 550 / 288 98 D 2709 D482 D524 D130 D2274 0.05 0.01 0.15 No. 3 15mg/L 7 2800 375 / 191 430 / 221 510 / 256 625 / 329 671 / 355 98 0.05 40 - 44 0.806 0.825 100 / 38 1.3 - 2.4 0.05 See Note 45 40 No. 2 # ASTM 2-D 33 - 37 0.0835 0.855 125 / 52 1.9 - 4.1 0.05 See Note 45 40
Engine Coolant Specifications

Parameter Chlorides Sulfates Total Dissolved Solids Total Hardness Nitrates pH Max Allowed (ppm) 40 100 340 170 >800 5.5 - 9.0 Magnesium & Calcium Add SCA additive if below this concentration. Notes Water with salt softeners is not recommended.
Engine Coolant
Type Concentration Ratio antifreeze/water 30/70 - 60/40 Notes
Ethylene Glycol Propylen e Glycol
For temperatures from 15C to -51C. Detroit Diesel recommends 50/50 ratio. 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. Not recommended.
30/70 - 60/40
Methoxy Propanal
50/50
Lubricating Oil Specifications

0.01 0.15 No. 3 15mg/L 7 2800 Transmissio n Up-box Axles
The oil filled in the ST14 is good for operation in ambient temperature from -20C (-5F) up to +35C (+95F). For extreme hot or cold working condition contact your authorized Atlas Copco dealer or the OEM Service manual.
Description Hydraulic oil Engine Brand Shell Donax TD Shell Rimula Super Shell Donax TC Shell Donax TC Shell Spirax AX MIL-PRF2104G MIL-PRF2104G GL-5 Spec GL-4 SAE 10W-30 15W-40 30 30 85W-140
Dupont Pad Test, Rating TM-F21Maximum* 61 ## Lubricity, gm, Minimum* SLWT
* 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 10F (6C) below the lowest expected fuel temperature to prevent clogging of fuel filters by wax crystals. See also the OEM engine manual for specific recommendations.
Note: For technical specification see : www.shell.com
Grease
Specification NLGI No. 2 Brand Notes 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 Refrigerant

Refrigerant Type 134A Weight of Refrigerant 1.7 kg
132
Torque Specifications
A 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.
Unified Coarse Thread (UNC)

This chart shows standard bolt torques to be applied unless otherwise specified. Grade 5 Size 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1 1/8 1 1/4 1 3/8 1 1/2 1 3/4 Thds/In 20 18 16 14 13 12 11 10 9 8 7 7 6 6 5 N-m 11 23 42 66 102 148 203 362 582 873 1236 1745 2287 3037 4788 Dry ft-lbs 8 17 31 49 75 109 150 267 429 644 912 1287 1687 2240 3532 N-m 8 18 31 50 77 111 153 271 437 655 927 1308 1715 2278 3591 Oil ft-lbs 6 13 23 37 57 82 113 200 322 483 684 965 1265 1680 2649
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 high torque values quickly and safely.
Torque Values by Bolt Size & Thread

Scope This 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. Definitions 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 MolyPaste. Other similar compounds should be checked to ensure that their K-Factor matches that listed above. H i g h St r e n g t h 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. To l e ra n c e s All bolt torque values tabulated in this specification have a tolerance of 10%.
Unified 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 Size 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1 1/8 1 1/4 1 3/8 1 1/2 1 3/4 Thds/ In 20 18 16 14 13 12 11 10 9 8 7 7 6 6 5 Dry N-m 16 34 60 95 144 209 287 510 822 1232 1746 2463 3229 4287 6760 ft-lbs 12 25 44 70 106 154 212 376 606 909 1288 1817 2382 3162 4986 N-m 12 24 45 70 108 156 216 382 617 923 1310 1848 2421 3214 5070 Oil ft-lbs 9 18 33 52 80 115 159 282 455 681 966 1363 1786 2371 3740 Moly Paste N-m 9 20 35 57 87 125 172 306 493 739 1048 1478 1937 2572 4056 ft-lbs 7 15 26 42 64 92 127 226 364 545 773 1090 1429 1897 2992
Atlas Copco 133
Unified Fine Thread (UNF)

This chart shows standard bolt torques to be applied unless otherwise specified. Grade 5 Size 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1 1/8 1 1/4 1 3/8 1 1/2 Thds/In 20 18 16 14 13 12 11 10 9 8 7 7 6 6 N-m 14 26 47 75 115 164 230 403 643 954 1387 1932 2604 3416 Dry ft-lbs 10 19 35 55 85 121 170 297 474 704 1023 1425 1921 2520 N-m 9 19 35 56 87 123 172 302 481 716 1040 1449 1954 2562 Oil ft-lbs 7 14 26 41 64 91 127 223 355 528 767 1069 1441 1890
M e t r i c C o a r s e T hr e a d
This chart shows standard bolt torques to be applied unless otherwise specified. Grade 8.8 Size (mm) 4 5 6 8 10 12 14 16 18 20 22 24 27 30 33 36 Pitch (mm) 1 1 1 1 2 2 2 2 3 3 3 3 3 4 4 4 N-m 3 7 11 26 52 89 142 221 305 430 587 744 1090 1478 2012 2584 Dry ft-lbs 2 5 8 19 38 66 105 163 225 317 433 549 804 1090 1484 1906 N-m 3 4 8 19 38 66 107 165 228 323 441 557 817 1109 1509 1939 Oil ft-lbs 2 3 6 14 28 49 79 122 168 238 325 411 603 818 1113 1430
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 Size 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1 1/8 1 1/4 1 3/8 1 1/2 Thds/ In 20 18 16 14 13 12 11 10 9 8 7 7 6 6 Dry N-m 19 37 66 106 163 232 325 569 910 1349 1958 2728 3677 4822 ft-lbs 14 27 49 78 120 171 240 420 669 995 1444 2012 2712 3557 N-m 14 27 50 79 122 174 244 427 681 1011 1468 2046 2758 3617 Oil ft-lbs 10 20 37 58 90 128 180 315 502 746 1083 1509 2034 2668 Moly Paste N-m 11 22 41 64 98 140 195 342 547 809 1174 1636 2206 2893 ft-lbs 8 16 30 47 72 103 144 252 401 597 866 1207 1627 2134
M e t r i c C o a r s e T hr e a d
This 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 Size (mm) 4 5 6 8 10 12 14 16 18 20 22 24 27 30 33 36 Pitch (mm) 1 1 1 1 2 2 2 2 3 3 3 3 3 4 4 4 Dry N-m 4 9 15 37 72 126 201 310 430 607 828 1049 1539 2086 2840 3648 ft-lbs 3 7 11 27 53 93 148 229 317 448 611 774 1135 1539 2095 2691 N-m 3 7 11 27 54 94 150 233 323 456 629 788 1155 1566 2130 2736 Oil ft-lbs 2 5 8 20 40 69 111 172 238 336 458 581 852 1155 1571 2018 Moly Paste N-m 3 5 9 22 43 76 121 187 258 365 498 630 923 1253 1704 2189 ft-lbs 2 4 7 16 32 56 89 138 190 269 367 465 681 924 1257 1615
134
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ST14 Service manual

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Atlas Copco Rock Drills AB SE-70191 rebro, Sweden

ST14 Table of Contents Service manual

Atlas Copco III

ST14 Table of Contents Service manual

ST14 Table of Contents Service manual

ST14 Chapter 1: Safety Service Manual

Chapter 2: 4Preventive Maintenance 1 2 3

Requirements for Use in Demanding Environments

ST14 Chapter 2: Preventive Maintenance Service Manual

Special Tools are Required for High Torque Settings

Before Performing Maintenance

Hydraulic System Cleanliness

Maintenance Intervals Independent Oil Analysis

N o t e Oil analysis is not to be used to

General Safety When You Service the Vehicle

STEP STEP STEP STEP

ST14 Chapter 2: Preventive Maintenance Service Manual

Every 250 Hours Operation

Axle, planetary gears

Check oil level

Torque should be M22, Grade 10.9 and 622Nm.

lubricate lubricate lubricate

ST14 Chapter 2: Preventive Maintenance Service Manual

Every 500 Hours Operation

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

Atlas Copco Service Kits

Contact your local Atlas Copco representative for further information.

ST14 Chapter 2: Preventive Maintenance Service Manual

Every 1000 Hours Operation

Safety Cartridge on page 24

Every 2000 Hours Operation

Every 5000 Hours Operation

New or Reconditioned Components

Bolt Connection, Engine Mount

Cooling Fan Drive Belt

Wheel Bolts and Nuts

Cooling Fan Drive Belt

Trunnions and Pins, Boom Z-bar

Trunnions and Pins, Bucket

Trunnions and Pins, Steering

Trunnions and Pins, Swivel

Expander Shafts, Loadframe and Boom

Expander Shafts, Z-bar

ST14 Chapter 2: Preventive Maintenance Service Manual

Maintenance Procedures by Interval

Axle, Planetary Gears

Axle, Bolt Connection

Driveline, Upbox - Transmission

Driveline, Loadframe Transmission - Powerframe

Differential plug STEP

Important If the rpm is to low it could damage

Transmission, Bolt Connection

N o t e Dry batteries is used as standard on the

N o t e You may need do this test more then one

ST14 Chapter 2: Preventive Maintenance Service Manual

AC filter in the cab unit

Replace the AC filter.

Cab and Cab Door

Brake Acc, Precharge Press

Hyd Oil Tank, Breather

Brake accumulator STEP