ST 1010 SM

Atlas Copco Wagner Inc.
Scooptram L.H.D.
®
Service Instructions
Working harder. And Smarter™.

These instructions are intended for service Become familiar with this manual, under-
technicians. Users of Atlas Copco equipment stand it and use it. Read all instructions care-
should first attend an Atlas Copco training fully before servicing and operating the
course on the safe and proper use and ser- vehicle. These instructions will help you
vice of our vehicles. understand the vehicle, its capabilities and
limitations, and the proper service and repair.
Before servicing the vehicle, completely read
through the operating instructions and the Contact your authorized Atlas Copco dealer
service manual, paying particular attention for information on the Atlas Copco Factory
to all safety instructions. Service School.
Use only Atlas Copco replacement parts
when performing maintenance or repairs on
your equipment.
This manual is your guide to the correct ser-
vice and maintenance of Atlas Copco Scoop-
tram ST1010
E-O-D, Rock Tough, SAHR, Scooptram, Scoopy, Strong-

Back Bucket, and Teletram are registered trademarks of
Atlas Copco Wagner Inc. Atlas Copco is a registered trade- CALIFORNIA
mark of Atlas Copco AB.
Proposition 65 Warning
© 2000 Atlas Copco Inc. All Rights Reserved. Diesel engine exhaust and some of its con-
stituents are known to the State of California
Atlas Copco Wagner Inc. to cause cancer, birth defects, and other
P.O. Box 20307 reproductive harm.
Portland, OR 97220-0307
Atlas Copco Scooptrams

Description how to safely and effectively remove and
replace worn or damaged components.
The Atlas Copco Scooptram consists of a
Power Frame and a Load Frame connected This manual does not deal with component
by an articulating joint that permits 45- rebuilding. Atlas Copco recommends that
degree turns, in combination with an oscillat- component level repair be conducted
ing joint that permits the units to tilt relative through Atlas Copco’s worldwide dealer net-
to each other to accommodate uneven sur- work.
faces.
Terminology
The Power Frame includes the diesel engine
and an automatic transverter. The canopy has This safety alert symbol
been approved by U.S. government authori- means Attention! Become
ties and satisfies FOPS standards in accor- Alert! Your Safety Is
dance with pamphlets ISO 3471 and SAE Involved. All personal
J1040C. safety messages in this man-
ACW00073.pict
The boom, the bucket, and the front axle are ual and the safety decals on
mounted on the load frame. The bucket may the vehicle are identified by this symbol.
be either of a standard design or an eject-o- The safety messages that are shown in this
dump design consisting of a push plate manual include a signal word. That word
assembly controlled by the operator. shows the degree or level of hazard. The sig-
The entire vehicle is designed for maximum nal words are DANGER, WARNING, and
durability and easy maintenance. All items to CAUTION.
be maintained on a scheduled basis are easily DANGER indicates an imminently hazard-
accessible and identifiable. ous situation that, if not avoided, will result
This manual is intended to be used in con- in death or serious injury.
junction with the Operator’s Manual and WARNING indicates a potentially hazard-
Parts Catalog for this vehicle. Use only Atlas ous situation that, if not avoided, can result
Copco approved replacement parts when ser- in death or serious injury.
vicing Atlas Copco products.
CAUTION indicates a potentially hazardous
The Operator’s Manual covers all routine situation that, if not avoided, can cause
service by maintenance interval: daily, minor or moderate injury.
weekly, monthly, and quarterly.
IMPORTANT indicates information to the
This manual provides you with a generalized operator that may prevent potential damage
overview and theory of operation of various to the vehicle.
components and systems on the scooptram.
NOTE indicates information that may be
By using this manual you will be able to useful to the operator.
understand how complex systems work, how
General safety precautions are listed in the
to troubleshoot problems in operation, and
safety section of this manual. Specific safety

precautions are put in the body of the manual
where specific hazards exist. Safety signs are
also put on the vehicle to warn against poten-
tial exposure to hazards that can be incurred
during the reasonable use or operation of the
vehicle.
All possible circumstances that may involve
a potential hazard can not possibly be
included in this manual. Therefore, you must
make a judgement that an operation, service
procedure, etc., will be safe for you and oth-
ers around you. If you damage the vehicle,
know that something is not adjusted cor-
rectly, or know there are missing parts, make
sure that the damage, adjustment, or missing
parts are repaired, adjusted, or replaced
before you continue to operate.
Read the safety messages in this manual, the
safety signs on the vehicle and the safety
manual provided with the vehicle. Make sure
that all warning signs are in place, and that
they are clean and legible.
A warning sign locator diagram is included
later in this section. See the Parts Catalog for
part numbers if you need to replace worn or
missing signs. Contact your Atlas Copco
Wagner Inc. sales company or authorized
dealer if you have any questions.

Table of Contents
Description.......................................................................................................4
Terminology.....................................................................................................4
Safety
General Safety Precautions ..............................................................................21
Safety During Maintenance .............................................................................21
Parking the Scooptram and Stopping the Engine ............................................24
Burn, Fire, and Explosion Prevention..............................................................24
RollOver/Falling Object Protective Structure (ROPS/FOPS) .........................25
Tire and Wheel Safety .....................................................................................25
Safety Signs .....................................................................................................26
Preventive Maintenance
General Maintenance .......................................................................................27
Record Keeping ...............................................................................................27
Independent Oil Analysis.................................................................................27
Electric Welding ..............................................................................................28
Hydraulic System Cleanliness .........................................................................28
Perform Maintenance On Level Ground..........................................................28
Install Articulation Locking Bar ......................................................................28
General Safety When You Service the Vehicle...............................................29
Never Work Under An Unsupported Boom ....................................................30
Using the HourMeter (MMC)..........................................................................30
Shift Maintenance Report ................................................................................31
Operator Shift Maintenance Checklist.............................................................32
Maintenance Schedules....................................................................................33
As Required .....................................................................................................33
Shift/Daily Requirements ................................................................................34
Daily Lubrication Items ...................................................................................36
ST1010 Lube Schematic ..................................................................................37
125 Hour Requirements ...................................................................................38
1000 Hour Requirements .................................................................................41
Maintenance Intervals......................................................................................44
As Required .....................................................................................................44
Engine Air Filter Restriction Indicator ............................................................44
Radiator............................................................................................................44
Atlas Copco Scooptrams 7

Table of Contents
Cab, Bucket, Frames, and Hoses .....................................................................44

Circuit Breakers and Fuses ..............................................................................45
Windshield Wipers ..........................................................................................45
Before Each Shift.............................................................................................45
Fuel ..................................................................................................................45
Engine Oil ........................................................................................................45
Transverter Oil .................................................................................................46
Transfer Case Oil .............................................................................................46
Primary Fuel Filter/Water Separator................................................................47
Hydraulic Reservoir .........................................................................................47
Tires .................................................................................................................48
Fire Extinguisher..............................................................................................48
Engine Drive Belts...........................................................................................49
Air Filter Evacuator Valve...............................................................................49
Cooling System................................................................................................49
Hydraulic Restriction Indicator........................................................................50
Vehicle Lights..................................................................................................50
Batteries ...........................................................................................................50
Daily Lube Items .............................................................................................51
Engine Oil .......................................................................................................52
Engine Air Filters.............................................................................................52
Engine Coolant ................................................................................................53
Batteries ...........................................................................................................53
Hydraulic Reservoir Breather ..........................................................................54
Transverter Breather ........................................................................................54
Axle Breathers .................................................................................................54
Differentials .....................................................................................................55
Planetaries ........................................................................................................55
Wheels .............................................................................................................55
Driveline Slip Joints.........................................................................................55
Articulation Pin Caps.......................................................................................56
Fire Suppression System..................................................................................56
Fuel Filters .......................................................................................................56
Hydraulic Hoses and Fixtures..........................................................................57
Accumulator Pre-Charge Pressure...................................................................57
Axle Mounts ....................................................................................................58
Steering, Boom, and Bucket Rollback Stops ...................................................58
Fuel Tank Fillers ..............................................................................................58
Engine/Transverter Idle and Stall Speeds ........................................................58
8 Atlas Copco Scooptrams

Table of Contents

Fuel Tank .........................................................................................................59
Engine Coolant Filter.......................................................................................59
Transverter Oil Filters......................................................................................60
Hydraulic Oil Filter..........................................................................................60
Bucket and Steering Cycle Times....................................................................61
Drive Belts .......................................................................................................61
Engine Crank Case Pressure ............................................................................61
Cylinders ..........................................................................................................61
Hinge Points and Mounts.................................................................................62
Fuel tank ..........................................................................................................63
Transverter .......................................................................................................63
Axles, Differentials, and Planetaries................................................................63
Hydraulic Reservoir .........................................................................................64
Hydraulic Pressures and Flows........................................................................65
Radiator and Cooler Core ................................................................................65
Engine and Fan Belts .......................................................................................65
Engine Air Filter ..............................................................................................66
Air Intake and Exhaust ....................................................................................66
Fire Suppression ..............................................................................................66
Cooling System................................................................................................68
Engine Tune-Up...............................................................................................68
Alternator .........................................................................................................68
Engine and Transverter Mounts.......................................................................69
U-joints ............................................................................................................69
Thermostat and Seals .......................................................................................69
Hoses................................................................................................................69
Power Unit
Introduction......................................................................................................71
Fuel System......................................................................................................71
Theory of Operation.........................................................................................72
Fuel System Components ................................................................................72
Filters ...............................................................................................................72
Pumps...............................................................................................................73
Fuel Pump ........................................................................................................73
Fuel Tank .........................................................................................................74
Electronic Unit Injectors (EUI) and Engine Control Module (ECM)..............74

Table of Contents
Fuel Cooler ......................................................................................................75

Engine Oil System ...........................................................................................75
System Components ........................................................................................75
Lubricating Oil Pump ......................................................................................75
Oil Filters .........................................................................................................75
Engine Oil Pressure Gauge ..............................................................................75
Engine Electrical System .................................................................................76
Cooling System................................................................................................76
Coolant Recommendations ..............................................................................77
Air Intake System ............................................................................................77
Restriction Indicators .......................................................................................78
TurboChargers .................................................................................................79
Exhaust System................................................................................................81
Silencers...........................................................................................................81
Purifiers (Optional) ..........................................................................................81
Exhaust Heat Shields .......................................................................................81
Engine Accessories Removal & Replacement.................................................81
Removing the Engine Cooling System Package..............................................82
Reinstalling the Cooling System Package .......................................................83
Removing the Transverter/Hydraulic/Fuel Radiator .......................................83
Reinstalling the Transverter/Hydraulic/Fuel Oil Radiator...............................84
Exhaust System................................................................................................84
Removing the Exhaust System ........................................................................84
Reinstalling the Exhaust System......................................................................86
Fuel System......................................................................................................86
Removing Fuel Filters ....................................................................................86
Reinstalling Fuel Filters...................................................................................86
Removing Fuel Valves or Lines ......................................................................87
Reinstalling Fuel Valves or Lines....................................................................87
Removing Fuel Tank .......................................................................................87
Reinstalling the Fuel Tank ...............................................................................87
Electronic Engine Control System...................................................................88
Engine ..............................................................................................................88
Removing the Engine Package ........................................................................88
Reinstalling the Engine Package......................................................................89
Power Train
Introduction......................................................................................................91
Transverter .......................................................................................................91
Transverter Theory of Operation .....................................................................91
Transverter Component Description................................................................92

Table of Contents
Torque Converter .............................................................................................92

Transverter .......................................................................................................93
Transverter Electronic Control Unit (ECU).....................................................93
Programmable Logic Control (PLC) and Transverter Selector Switches........94
Transverter System ..........................................................................................94
Control Valve...................................................................................................94
Charge Pump....................................................................................................94
Transverter Oil Filter .......................................................................................94
Transverter Oil Cooler .....................................................................................95
Up Box .............................................................................................................97
Drivelines.........................................................................................................98
Component Description ...................................................................................98
Universal Joint Bearings .................................................................................98
Driveline Support Bearings .............................................................................99
Axles ................................................................................................................99
Primary Reduction ...........................................................................................99
Secondary Reduction .......................................................................................99
Wheels And Tires ............................................................................................99
General.............................................................................................................99
Inspection And Maintenance ...........................................................................100
Tires .................................................................................................................100
Wheels .............................................................................................................101
Air Pressure Maintenance ................................................................................101
Recommended Tire Pressures..........................................................................101
Proper Inflation ................................................................................................101
Tire Rolling Radius..........................................................................................102
Driving Practices..............................................................................................102
Removal & Replacement .................................................................................103
Transverter/Accessories...................................................................................103
Transverter Cooling System ............................................................................103
Replacing the Transverter Cooling Radiator ...................................................103
Removing the Transverter ...............................................................................103
Reinstalling the Transverter.............................................................................104
Upbox Assembly/Disassembly Procedures .....................................................104
Removing the Upbox from the Engine ............................................................104
Installing the Upbox on the Engine .................................................................106
Upbox Disassembly Procedures ......................................................................106
Upbox Assembly Procedures...........................................................................106
Drivelines.........................................................................................................107
Phasing the Driveline.......................................................................................108

Table of Contents
Installing the Drive Shaft .................................................................................108

Yokes and Bearing Mounts..............................................................................108
Installing Driveline Guards..............................................................................108
Upbox to Transverter Driveline .......................................................................109
Transverter to Front Axle Driveline ................................................................109
Midship Driveline ............................................................................................110
Midship-to-Flange Bearing Driveline..............................................................110
Flange Bearing to Front Axle Driveline ..........................................................111
Axles ................................................................................................................111
Front Axle ........................................................................................................111
Rear Axle .........................................................................................................112
SAHR Brake Assembly/Disassembly..............................................................113
Disassembly .....................................................................................................113
Cleaning and Inspection...................................................................................116
Assembly of the SAHR Brakes .......................................................................116
Tire Demounting And Mounting Procedures ..................................................120
Demounting .....................................................................................................120
Mounting..........................................................................................................121
Inspection.........................................................................................................121
Mounting and Inflating ....................................................................................123
Wheel Nut Torque............................................................................................125
Operating Precautions......................................................................................125
Recapping ........................................................................................................126
Tire Storage......................................................................................................126
Mounting for Storage.......................................................................................126
Frame
Introduction......................................................................................................127
Load Frame ......................................................................................................127
Removing the bucket .......................................................................................127
Replacing the bucket........................................................................................128
Removing the Z-Bar ........................................................................................128
Reinstalling the Z-Bar......................................................................................129
Removing the boom.........................................................................................129
Replacing the boom .........................................................................................130
Power Frame ....................................................................................................130
Removing and Replacing Hoods .....................................................................130
Removing the Fuel Tank..................................................................................131
Replacing the Fuel Tank ..................................................................................132
Separating and Reconnecting the Load and Power Frames.............................132
Separating the Load Frame from the Power Frame .........................................132

Table of Contents
Reconnecting the Load Frame and the Power Frame ......................................134

Articulation Pins ..............................................................................................134
Pin Removal.....................................................................................................135
Pin Installation .................................................................................................136
Stops.................................................................................................................137
Steering Stops ..................................................................................................138
Oscillating Axle Stops .....................................................................................138
Bucket Rollback Stops.....................................................................................138
Bucket Rollover (Dump) Stops........................................................................138
Bucket Stops (Pads) .........................................................................................138
Boom Stops......................................................................................................138
Inspection and Maintenance ............................................................................138
Installation .......................................................................................................139
Steering Stops ..................................................................................................139
Oscillating Axle Stops .....................................................................................139
Bucket Rollback Stops.....................................................................................139
Bucket Rollover (Dump) Stops........................................................................140
Bucket Stops (Pads) .........................................................................................140
Boom Stops......................................................................................................140
Hydraulics
Hydraulic System.............................................................................................141
Standard System ..............................................................................................141
Pumps...............................................................................................................142
Hydraulic Gear Pumps.....................................................................................142
Cylinders ..........................................................................................................142
Steering Cylinders............................................................................................143
Stabilizer (Dump) Cylinder .............................................................................143
Hoist Cylinders ................................................................................................143
Accumulators ...................................................................................................144
Accumulator Pre-Charge .................................................................................145
Brake Release Tow Hook Accumulator ..........................................................145
Tank and Filters ...............................................................................................145
Hydraulic Reservoir (Tank) .............................................................................145
Inspection.........................................................................................................145
Repair...............................................................................................................146
Oil Filters .........................................................................................................146
Internal Filter Cartridge with Indicator............................................................147
Hoses and Tubing ............................................................................................147

Table of Contents
Control Valves .................................................................................................148

Main Control Valve .........................................................................................149
Priority Valve...................................................................................................150
Auxiliary Valve ...............................................................................................150
Hydraulic System Cooler.................................................................................151
MonoStick Steering System Operation............................................................152
Steering System Components: .........................................................................152
Wheel Steering System Operation ...................................................................153
Wheel Steering System Components...............................................................154
Dump and Hoist System ..................................................................................157
System Operation.............................................................................................157
Boom Up..........................................................................................................157
Bucket Float .....................................................................................................157
Boom Power Down..........................................................................................157
Load Check Valve Function ............................................................................158
Dump and Hoist Components..........................................................................158
Brake System ...................................................................................................158
SAHR Brake ...................................................................................................158
SAHR Brake System Operation ......................................................................160
Accumulator Charge Kick In/Kick Out ...........................................................160
Brake Application ............................................................................................161
Service Brake Operation ..................................................................................161
Park Brake Operation.......................................................................................161
Emergency Brake Operation............................................................................161
Brake System Components ..............................................................................161
Accumulator Pressure Gauge...........................................................................161
Foot Pedal Control Valve ................................................................................161
Brake Cooling System .....................................................................................162
Brake Cooling System Components ................................................................162
Hydraulic Oil Cooler .......................................................................................162
Hydraulic Fan ..................................................................................................162
Brake Cooling Manifold ..................................................................................162
Multi-disc Liquid Cooled Brake Assembly .....................................................163
Emergency Tow System ..................................................................................163
Emergency Tow System Components .............................................................163
Hand-operated Hydraulic Pump ......................................................................163
Relay Override Button .....................................................................................163
Hydraulic Accumulator....................................................................................163
Accumulator Charged ......................................................................................164

Table of Contents
Accumulator Not Charged ...............................................................................164

Brake Release Tow Hook ................................................................................164
Tow Hook Operation .......................................................................................164
Brake Release Manifold...................................................................................164
Tow Hook Accumulator ..................................................................................165
Tow Hook Cylinder .........................................................................................165
Tow Hook Lever ..............................................................................................165
General Maintenance Information ...................................................................165
Servicing After Overhaul.................................................................................165
Level of Oil in Reservoir .................................................................................166
Importance of Cleanliness ...............................................................................166
Oil Changes......................................................................................................167
Oil Storage and Handling ................................................................................168
Prevention of Foaming.....................................................................................169
Hydraulic Oil Change After Failure ................................................................170
Servicing Filters and Strainers .........................................................................170
Establishing a Schedule ...................................................................................171
Brake Pedal Adjustment .................................................................................171
Cylinder Inspection..........................................................................................171
Troubleshooting ...............................................................................................171
Safety ...............................................................................................................172
Basic Causes of Hydraulic System Failures ....................................................172
System Overheat Protection.............................................................................172
Eliminating Air From the System ....................................................................173
Checking for Component Failure ....................................................................174
Checking Hydraulic Systems for Leaks...........................................................174
Finding the Leak Location ...............................................................................175
Leak Problem Areas.........................................................................................175
Problem:...........................................................................................................177
SAE 4-Bolt Split Flange Connection...............................................................177
Problem (1): .....................................................................................................177
Problem (2): .....................................................................................................177
Pipe Thread Leaks ...........................................................................................178
Remember ........................................................................................................179
Removal and Replacement Procedures............................................................179
Before Starting .................................................................................................179
Relieving Hydraulic Pressure ..........................................................................179
Before removing any hose: ..............................................................................180
Pressure Setting Checks and Adjustments.......................................................180
Steering and Dump Pilot Valve .......................................................................182

Table of Contents
Hydraulic Drift.................................................................................................182
Pump Flows .....................................................................................................182
Steering Cylinder Removal and Replacement .................................................183
Steering Cylinder Removal..............................................................................183
Steering Cylinder Installation ..........................................................................183
Dump Cylinder Removal and Replacement ....................................................183
Dump (Stabilizer) Cylinder Removal ..............................................................183
Dump Cylinder Installation .............................................................................184
Hoist Cylinder Removal and Replacement......................................................184
Hoist Cylinder Removal ..................................................................................184
Hoist Cylinder Installation...............................................................................185
Pump Removal and Replacement ....................................................................185
Pump Installation .............................................................................................185
Valves ..............................................................................................................185
Valve Replacement ..........................................................................................185
Valve Cartridge Removal/Service ...................................................................185
Hydraulic Manifolds ........................................................................................186
Manifold Replacement.....................................................................................186
Preparation for Trial Run .................................................................................186
Start-up.............................................................................................................186
Trial Run ..........................................................................................................187
Electrical System
Vehicle Electrical Systems ..............................................................................191
Wiring Harnesses .............................................................................................191
Master (Battery Isolation) Switch....................................................................191
Component Box ...............................................................................................191
Park Brake Switch ...........................................................................................191
Charging and Ignition System .........................................................................192
Battery..............................................................................................................192
Alternator .........................................................................................................192
Engine Control Module ...................................................................................192
Starter...............................................................................................................192
Computerized Control Units ............................................................................193
Programmable Logic Control (PLC) ...............................................................193
Engine Electronic Control Module System (ECM) .........................................193
Electronic Unit Injectors ..................................................................................194
System Sensors ................................................................................................194
Diagnostic Interfaces .......................................................................................196
Communication Links......................................................................................196

Table of Contents
Transverter System (ECU)...............................................................................197

Electronic Control Unit....................................................................................197
Data Collection Unit (DCU) ............................................................................198
Vehicle Instrumentation, Lights, and Horn .....................................................198
Vehicle Instrumentation...................................................................................198
Gauges .............................................................................................................198
Dash Lights ......................................................................................................199
Gear Selector Buttons ......................................................................................199
Park Brake Switch Indicator ............................................................................199
Switches ...........................................................................................................200
Vehicle Lights..................................................................................................200
Horn .................................................................................................................200
Electronic Safeguards ......................................................................................201
Computerized Diagnostic Systems ..................................................................203
Programmable Logic Control (PLC) ...............................................................203
Engine ECM Diagnostics.................................................................................204
SEL and CEL ...................................................................................................205
Diagnostic Data Reader (DDR) .......................................................................206
Battery Care .....................................................................................................206
Installation .......................................................................................................206
Periodic Service ...............................................................................................206
Cable Terminals and Hold Downs...................................................................206
Battery Fluid ....................................................................................................207
Tropical Climates.............................................................................................207
Factors affecting battery life ............................................................................208
Detecting Potential Failures.............................................................................209
Cell charge test.................................................................................................210
Using battery booster cables ............................................................................211
Storage Of Lead Acid Batteries .......................................................................211
Alternators .......................................................................................................211
Removing and Replacing Electrical Components ...........................................212
Transducers ......................................................................................................213
Engine Sensors.................................................................................................213
Starter...............................................................................................................213
Battery..............................................................................................................213
Removal ...........................................................................................................213
Replacement.....................................................................................................213
Alternator .........................................................................................................214
Removal ...........................................................................................................214
Replacement.....................................................................................................214

Table of Contents
ST1010 Transverter Calibration Procedures...................................................214
Miscellaneous Systems
Fire Suppression System..................................................................................217
Sequence of Events ..........................................................................................218
Fire Starts .........................................................................................................218
Operator Activates Actuator ............................................................................218
Dry Chemical Distribution...............................................................................218
Dry Chemical Discharged................................................................................219
Hand Portable Fire Extinguisher......................................................................219
In The Event Of Fire ........................................................................................219
Actuator ...........................................................................................................219
Cartridge Receiver/Expellant Gas Cartridge ...................................................220
Dry Chemical Tank..........................................................................................220
Nozzles.............................................................................................................220
Monthly............................................................................................................221
Semi-annual .....................................................................................................221
Check Fire System ...........................................................................................221
Automatic Checkfire System ...........................................................................221
Checkfire Control Module ...............................................................................222
Diagnostic Lights .............................................................................................223
Ride Control Systems ......................................................................................223
Ride Control System Components...................................................................224
Ride Control Manifold.....................................................................................224
Accumulator.....................................................................................................224
Troubleshooting
Specifications
ST1010.............................................................................................................253
.........................................................................................................................254
ST1010 Hydraulic Pump Flows.......................................................................255
Stability ............................................................................................................255
Noise Level ......................................................................................................255
Maximum Allowable Back Pressure ...............................................................255
Bucket Dump Angles ( +/- 3°).........................................................................256

Table of Contents
Steering Stops (Hub to Hub Centering Distance) ............................................256

Engines.............................................................................................................256
Transverters .....................................................................................................256
Axles ................................................................................................................256
Transfer Cases..................................................................................................257
Torque Values..................................................................................................257
.........................................................................................................................261
Wheel Nut Torque Values ...............................................................................261
Fluids and Lubrication Specifications .............................................................261
International Fuel Specifications .....................................................................262
Fuel Oil Selection Chart ..................................................................................263
Lubricating Oil Specifications .........................................................................264
Engines.............................................................................................................264
Transverters .....................................................................................................264
Axles ................................................................................................................264
Hydraulic Fluid ................................................................................................265
Grease Specification ........................................................................................266
Coolant Specifications .....................................................................................266
Cross Reference List ........................................................................................268

Table of Contents

Section 1 Safety
General Safety Precautions • Check safety system shutdown prior to
each shift.
Before performing any maintenance on the
scooptram, review the following safety pre- • Watch out for others - They may not be
cautions. They’re included for your protec- watching out for you.
tion.
Safety During Maintenance
Always observe the following general safety
rules during operation of the vehicle. Also WARNING: Incorrect mainte-
observe the safety rules set forth in the work nance or service can cause injury
place and develop additional rules as particu- or death. If you do not understand
ACW00073.pict
lar mine applications may require for safe a procedure, service, or adjust-
operation. ment, contact your Atlas Copco sales com-
pany or dealer for more information.
• Read and carefully follow all instructions
as outlined in the Operator and Service Before you service this scooptram, always
manuals. put a DO NOT OPERATE tag in the cab on
the steering control. If applicable, remove
• Make sure that all operating controls and
the key from the scooptram.
indicators are functioning properly.
• Never use controls as mounting assists.
• Never stand while operating the vehicle. DO NOT
• Avoid wearing loose clothing when oper-
OPERATE
ating the vehicle or working around
engines and other moving or rotating
equipment. Reason
• Never allow riders.

• Never leave the vehicle unless the brakes
are set.
• Block wheels when parked. Signature
• Never smoke around fuel. Do not make unauthorized modifications to

• Always know the location of the nearest this scooptram. Before you drill holes, cut, or
fire extinguisher. weld on this scooptram, always contact your
Atlas Copco Scooptrams Service Instructions 21

Safety
Atlas Copco sales company or dealer for power frame to prevent the vehicle from
authorization first. articulating
Before you perform service, always wear the
correct protective items. Face protection,
safety shoes, heavy gloves, etc. can be 1
required.
Wear eye or face protection when using a
hammer. Chips or debris can cause eye
injury. When driving hardened pins, use a
hammer with a soft face.
If you must perform service under the scoop-
tram, always engage the parking brake and
block the front and rear of each wheel. 1. ST1010 Articulation Lock Installed
Never enter the articulation area of the 1. Remove the key from the IGNITION
scooptram unless you have first installed the switch, if applicable, and hang a DO
articulation locking bar. NOT OPERATE tag on the switch.
Always consult the proper section of the ser- 2. Turn the MASTER (battery disconnect)
vice manual before performing maintenance. switch to OFF and hang with a DAN-
GER tag.
Perform maintenance in a safe area away
from vehicle traffic, with a stable roof area Stop engine before adjusting or repairing
and adequate ventilation. The vehicle should engine or engine-driven equipment.
be on level ground when performing mainte- If you must service the scooptram with the
nance. Before you start, make sure that the engine running, have a second person help
wheels are blocked. you. The second person must be in the opera-
Before performing any maintenance in the tor’s seat during any servicing or adjustment.
articulation area of the vehicle: To prevent hearing damage, wear ear protec-
Make sure the articulation (swival) locking tion devices when working inside an
bar is connected between the load frame and enclosed room with the motor running.
Make sure that all pressure is vented prior to
working on any fluid system.
When you check for a high pressure hydrau-
lic leak, always use cardboard or paper to
locate the leak.
WARNING: The hydraulic system
contains accumulators. Always
ACW00073.pict depressurize the system before per-
forming maintenance.
22 Atlas Copco Scooptrams Service Instructions

Safety
WARNING: Hydraulic fluid

injected into your skin can cause
ACW00073.pict severe injury or death.
Keep your hands and body away from the
leak. If this fluid is injected into your skin,
see a doctor immediately and have the fluid
removed.
Stay away from rotating or moving parts.
Make sure to re-install guards over all
exposed rotating parts.
Never work under a raised hood unless the
hood is secured with a prop bar.
Wear protective glasses, clothing, hard hat,
respirator, or other protective items when
necessary.
Insulate all electrical connections and dis-
connected wires
Pressurized air for cleaning the vehicle
should not exceed 30 psi (20 kPa). Wear pro-
tective face shield and clothing.
Use proper tools. Replace broken or dam- Before performing any work under a raised
aged servicing equipment. boom, perform the following:
Remove all tools, electrical cords and other 1. Empty the bucket and set the park brake.
loose items from the vehicle before starting
2. Place a safety bar under the boom, and
Locking bar should be restowed and secured have bucket in full dump position.
on pin mounts when work is complete. 3. Shut down the engine.
Wipe up spilled oil. 4. Turn the on/off and master switches to
Provide a safe and adequate method for off position.
waste oil disposal. 5. Block the wheels.
Store oily rags in fireproof containers. Do IMPORTANT: Do not attempt to make
not leave rags on engine. repairs to components of the vehicle without
Never store flammable liquids near the full understanding of the component and sys-
engine. tem. Always use the service manual when
working on the vehicle.

Safety
Parking the Scooptram and Stopping 2. Do not short across the battery terminals
the Engine to check a charge. Sparks can cause an
explosion.
When you stop and park the scooptram,
make sure the area is safe and level. 3. Do not weld, grind, or have an open
flame near a battery.
1. Make sure the bucket is completely
down with the bucket blade on the 4. When you charge a battery, always
ground. remove the caps and have good ventila-
tion.
2. Engage the parking brake, stop the
engine, put all controls in neutral, and 5. If the engine must be jump started, refer
remove the key, if one is available. to the Operator manual for the correct
procedure.
3. Release the seat belt.
On water cooled engines, hot coolant in the
4. Exit the scooptram.
radiator can rush out if you remove the radia-
IMPORTANT: If you must park the scoop- tor cap too quickly. Always allow the radia-
tram on a grade, always put the front of the tor cool before removing the cap. Turn the
scooptram toward the bottom of the grade radiator cap to the first notch to vent any
with the bucket up against the rib, if possi- pressure in the system. After all pressure has
ble. Make sure the scooptram is parked been released, remove the cap.
behind an object that will not move. Engage
All fuels and most lubricants are flammable.
the parking brake and put blocks on the
Always handle with care.
downhill side of each tire.
Store all oil-soaked rags or other flammable
Burn, Fire, and Explosion Prevention material in an approved protective container.
WARNING: Batteries contain Always use nonflammable cleaning solvent

acid. Severe burns can result if to clean parts.
acid comes in contact with your
ACW00073.pict Always have a good fire extinguisher on
skin or your eyes,. If you do get your scooptram. Make sure the fire extin-
acid on you by accident, flush with water for guisher is serviced according to the manu-
at least 15 minutes and see a doctor immedi- facturer’s instructions.
ately.
If your fire extinguisher has been used,
WARNING: Sparks or flame can always make sure to recharge or replace the
cause gas from the batteries to fire extinguisher before you operate the vehi-
ACW00073.pict explode. cle again.
When working on the scooptram’s electrical Remove all trash or debris from the scoop-
system, always: tram. Check the engine area, especially
1. Disconnect the negative (-) battery cable around the exhaust.
first and when reconnecting, connect the
negative (-) battery cable last.

Safety
If the scooptram has had a fuel or oil leak, holes, cutting, or adding attachments, can
repair the leak and clean the scooptram weaken the structure, void the ROPS/FOPS
before operating. certification, and reduce your protection. If
WARNING: Ether starting fluid your ROPS or FOPS has structural damage,
can explode and can cause injury contact your Atlas Copco sales company or
or death. dealer before attempting any repairs.
ACW00073.pict
If ether is used to start the engine in cold Do not add attachments to the scooptram that
weather, only use in accordance with the will cause the total weight of the scooptram
manufacturer’s recommendations. Always to exceed the total gross weight shown on
use face protection when you use ether start- the ROPS or FOPS label.
ing fluid. The seat belt is an important part of the
NOTE: Atlas Copco does not recommend ROPS system. Always fasten and adjust the
the use of ether starting fluid. seat belt before you operate this scooptram.
Before welding or using a torch on the WARNING: If you roll this scoop-
scooptram, always clean the area around tram over and you do not have the
your work first. ACW00073.pict seat belt fastened, you may be seri-
ously injured or killed.
Check the electrical system for loose wires,
connections, or frayed insulation. Repair or If you have any questions about the ROPS or
replace damaged parts. FOPS on your scooptram, contact your Atlas
Copco sales company or dealer.
RollOver/Falling Object Protective
Structure (ROPS/FOPS) Tire and Wheel Safety
Your scooptram may have a RollOver Pro- WARNING: Tires and wheels can
tective Structure (ROPS) or Falling Object explode and cause injury or death.
Protective Structure (FOPS). Our ROPS are ACW00073.pict
designed to provide operator protection in a

Always keep yourself and others out of the
rollover by controlling the bending of the
danger areas of tires and wheels. Stand on
structure. The FOPS provides the operator the rolling surface (tread) side of a tire when
protection from falling debris.
you perform service.
If your scooptram is so equipped, a ROPS or
Always inflate the tires to the recommended
FOPS label is attached to the exterior of the
pressure.
structure on the forward side. The ROPS or
FOPS serial number, scooptram weights, If the tire and wheel assembly is removed
approval numbers, model number, and from the scooptram, always put it into a tire
engine model and serial numbers are on this inflation cage before adding air.
label.
Do not modify a ROPS or FOPS structure.
Modifications such as welding, drilling

Safety
Safety Signs
WARNING: Injury or death can
result if a safety sign is missing
ACW00073.pict and instructions are not followed.
Replace all missing or damaged signs. Keep
the signs clean. Contact your Atlas Copco
sales company or dealer for new safety signs.
To clean a sign, use only a soft cloth, water,
and soap. Do not use solvent, gasoline, etc.
IMPORTANT: The meanings of all safety
signs are described in the introduction to the
Operator’s Manual. There are also locator
diagrams showing the location of all safety
signs . (Additional diagrams are provided
for EC customers, showing the location of all
safety guards.) The scooptram should never
be operated without all safety signs and
guards in place. If a safety or instructional
sign is on a part that must be replaced, make
sure the same sign(s) is on the new part.
Contact your Atlas Copco sales company
dealer for new signs.

Section 2 Preventive Maintenance
General Maintenance All discrepancies should be recorded
whether remedied or pending. Operators and
The regular care a vehicle receives by its mechanics should sign off forms and return
operator is generally rewarded by decreased them to maintenance supervisor for approval
down time and greater reliability. With the and retention in a vehicle maintenance file.
help of the information in this section, you
Accurately recorded maintenance forms will
should be able to maintain your Scooptram
give maintenance personnel an overview of
at top operating efficiency. All maintenance
equipment condition on an individual or fleet
and lubrication procedures given can be per-
basis.
formed on the job site with a minimum of
shop tools. Good records enable maintenance personnel
to identify and evaluate problem and/or high
At the end of every shift, look for loose or cost areas which can then be targeted for
damaged hoses and hose fittings. Check for improvements or solutions.
loose nuts, bolts and electrical wiring con-
Good record keeping will identify certain
nections. Check for signs of fresh oil around
items on the schedules which may need to
fittings and under the vehicle. At the first
occur more or less often, depending upon the
sight of damage or oil leakage, notify main-
vehicle’s operating environment.
tenance personnel.
Finally, good maintenance records aid in the
Scheduled preventive maintenance and lubri- planning and scheduling of maintenance and
cation are required to provide safe and effi- repair procedures, which result in the effi-
cient operation of the vehicle. Follow the cient use of maintenance resources and max-
Lubrication and Maintenance Chart carefully imum equipment reliability and availability.
and make sure that all points are serviced
correctly and on time. Independent Oil Analysis
Record Keeping Atlas Copco Wagner highly recommends the
regular use of an oil analysis program. Regu-
Good record keeping is essential to a proper lar oil analysis can indicate problems and
maintenance program. Each scheduled main- approaching maximum wear limits signifi-
tenance form should be checked off as the cantly before they are discovered by system
inspection or procedure is completed. Quan- performance checks.
tities of replenished lubricants and fluids,
The objective of a preventative maintenance
and pressure and flow readings, should be
program is diagnosis and repair before fail-
recorded.
ure. Good sampling techniques and indepen-

dent laboratory analysis are considered which the work will be performed if
primary elements of a good program. there is a substantial accumulation of dirt
IMPORTANT: Oil analysis is not to be used or other debris.
to determine if oil can be re-used past recom- 2. Wipe all hose and pipe connections
mended service life. Change oil during rec- before opening any connections.
ommended service intervals even when oil
3. Remove all loose paint before opening
analysis shows oil to be up to standards. A
any connections.
comprehensive analysis program can aid in
establishing optimum service intervals. 4. Plug or cap any hose, pipe, valve, or cyl-
inder immediately after opening a con-
Electric Welding nection.
Important: Use caution in electric welding 5. Flush any unsealed hose or pipe with
on the scooptram. Serious damage to the hydraulic oil before installing it in the
engine control computer and the battery iso- system.
lator can occur. 6. Install all hoses, pipes, valves, or cylin-
Before any electric welding on the scoop- ders immediately after unplugging or
tram, perform the following: uncapping connections.
1. Open the battery compartment. 7. Always fill the hydraulic reservoir

through the return filter.
2. Set the MASTER (battery disconnect)
switch to the OFF position. Perform Maintenance On Level
3. Disconnect the engine power harness Ground
(two connectors below the battery dis-
The vehicle should be on level ground when-
connect switch).
ever possible for maintenance. Before you
4. Connect the welding machine ground start, make sure the parking brake has been
clamp on the vehicle as closely as possi- applied and the wheels are blocked. Keep the
ble to the point at which the welding is to vehicle well clear of traffic lanes.
be done.
Install Articulation Locking Bar
Hydraulic System Cleanliness
An articulation (or swivel) locking bar is
Important: Foreign matter of any kind will attached to the frame on the right hand side
cause problems in hydraulic systems. Abso- of the bogie. Before performing any
lute cleanliness is essential for all work done maintenance in the pivot area of the vehicle,
on the scooptram hydraulic systems. Always make sure this bar is connected between the
follow these six primary rules regarding bogie and power frame to prevent the vehicle
cleanliness in maintenance operations on the from pivoting
hydraulic systems:
1. Steam clean the area of the scooptram on

eye or face protection, ear protection, safety

shoes, hard hat, heavy gloves, etc.
1
Before performing any maintenance on the
Scooptram, review the following safety pre-
cautions. They're included for your protec-
tion.
1. Empty the bucket completely and lower
it to the ground.
2. Shut down the engine.
3. Apply the park brake.
1. ST1010 Articulation Lock Installed
4. Block the wheels
5. Turn the Ignition Switch and Master
Switch to OFF position.
1
6. If you must service the vehicle in the
articulation area with the engine running,
always place the Articulation Locking
Bar in the LOCKED position.
1. ST1010 Articulation Lock Stowed
General Safety When You Service the

Vehicle
Read the safety and information decals on
the vehicle. Also read and understand this
operator’s manual. You must understand the
operation of this vehicle before performing
maintenance.
Do not attempt repairs that you do not under-
stand. See the service manual for this vehicle
or see your Atlas Copco Wagner sales com-
pany or dealer for more information.
Use the correct safety clothing and safety
equipment. It may be required that you use

Never Work Under An Unsupported

Boom
DO NOT
OPERATE
Reason
Signature
7. Before you service the vehicle, always

put a DO NOT OPERATE tag in the
cab on the steering wheel or lever. Then,
remove the key if one is available.
If you must service the vehicle with the
engine running, have a second person help
you. The second person must be in the opera-
tor’s seat during the service or adjustment.
Using the HourMeter (MMC)

The Mini-Message Center (MMC) default
screen is the hourmeter. The MMC displays
the amount of time the engine has actually
run. The meter shows hour increments and
cannot be reset to zero. Check the hourmeter

often to make sure all required services are

done at the correct interval. Shift Maintenance Report
Vehicle Model
Vehicle Number
Date Shift No
Hour Meter Reading
Clearly state any mechanical failures on
RES SEL this vehicle at end of each shift.
Fluids Added
Engine qts
Transmission qts
Shift Maintenance Report Hydraulic Tank qts
Shown here is a sample shift maintenance Hydraulic Brake Reservoirs qts
report form. A shift maintenance report form OK Defect
must be used to report defects found when
making shift maintenance checks at the Trans Clutch Pressure
beginning of each shift. Engine Oil Pressure
Your company may have a different report- Air Pressure (Tires)
ing method, however, it is recommended that Volt Meter
this form be filled out at the end of each shift
and returned to your supervisor. Accurate Remarks:
shift maintenance reports can help your com-
pany anticipate maintenance problems and
take action to prevent costly failures.
Name: No:
Operator Signature
Supervisor Signature

Operator Shift Maintenance Checklist nance report form to report mechanical

defects.
A recommended check list is given to assist
you in developing a sound shift maintenance Clean out chassis compartments and opera-
program if one has not been developed by tor area. Note general vehicle condition.
your company. Perform these checks at the Check for mechanical damage and loose or
beginning of each shift. Use the shift mainte- leaking components. Report faults to mainte-
nance department.
Equipment No. Month Day Shift No. Operator
Service Description
Before Starting Engine - Check The Following:
Engine Crankcase (Check Oil Level - Look For Leaks)
Engine Air Cleaner (Check Indicator. Clean Or Change)
Engine V-belts And Pulleys (Check Adjustment And Wear)
Radiator (Check Coolant Level. Look for Leaks)
Fuel Tank (Fill-check For Leaks)
Primary Fuel Filter (Drain Off Water)
Exhaust Scrubber (If Used) — (Flush/refill, Look For Leaks)
Surge Tank (Look For Leaks)
Hydraulic Tank (Check Level - Look For Leaks)
Transfer Case (Check Oil Level)
Battery (Check Electrolyte Level)
Tires (Check Condition And Pressure)
Hoses (Look For Leaks Or Damage)
Fire Extinguisher (Check Indicator)
After Starting Engine — Check The Following
Engine (Does It Sound Normal?)
Cooling System (Look For Leaks Or Radiator Blockage)
Oil Leaks (Look for leaks)
Fuel Leaks (Look for leaks)
Transverter (Check Oil Level With Engine Warm And Idling)
Air Intake System (Look For Leaks Or Damage)

Service Description
Exhaust System (Look For Leaks And Excessive Smoke)
Park/emergency Brake (Test Against Engine Power)
Service Brakes (Test Against Engine Power)
Horn (Check Operation)
Lights (Clean Lenses And Check Operation)
Control Levers (Check Operation)
Maintenance Schedules
As Required
Item Task Special Instructions

Engine air filter Check and service Check the restriction indica-
tor periodically during your
shift. Report to maintenance
if there is an indication of a
restriction.
Radiator Clean Remove all dirt and debris
from the engine radiator.
Also clean the hydraulic
cooler.
Cab, bucket, and frames Check for damage, missing Report any cracks or damage
parts or cracks found prior to operating the
vehicle
Circuit breakers and fuses Reset or replace If a circuit breaker does not
reset, notify maintenance for
assistance.
Windshield wipers and Replace blades, Refill
washer fluid (on cab- washer reservoir
equipped vehicles)

Shift/Daily Requirements

Fuel Check gauge for proper The Scooptram has two fuel
fuel level gauges, one in the cab and
the other located on the tank.
Refill the tank after your
shift. Atlas Copco recom-
mends maintaining a full
tank to decrease water build
up.
Engine Check the engine oil level Push the dipstick completely
down and pull out. The oil
level must be between the
ADD and FULL marks on
the dipstick.
If the oil level is below the
ADD mark, add oil to raise
the oil level up to the FULL
mark on the dipstick.
Transverter Check the transverter oil Check the oil level when the
level transverter is at normal oper-
ating temperature.
Transfer Case Check transfer case oil Check transfer case prior to
level starting the engine
Fuel water separator Check for water, drain if Turn knob at bottom of sight
necessary glass to drain the water
Hydraulic reservoir Check the oil level The oil level must be visible
in the upper sight glass.
Check the oil level with the
bucket down and the oil at
operating temperature.


Tires Check condition, air pres- Check each tire for deep
sure, and that the tires are cuts, breaks or loose tread.
all the same size (same Look for exposed cord.
rolling radius) Report any damage to the
maintenance department for
corrective action
Fire extinguisher Check for charge Check the seal and charge
indicator
Alternator drive belt Check tension and wear Check the tension of the
drive belts by pressing with
the thumb halfway between
the pulleys. The belts should
not deflect more than 13-19
mm (1/2”-3/4”).
Engine fan drive belt Check tension and wear Check the tension of the
drive belts by pressing with
the thumb halfway between
the pulleys. The belts should
not deflect more than 13-19
mm (1/2”-3/4”).
Air filter evacuator valve Squeeze rubber cover to
discharge dirt
Engine air filter Check filter restriction If the indicator shows red,
indicator have the filter serviced.
Cooling system Check the coolant reservoir
level
All hinge pins Inspect for damage and
excessive wear.
Hydraulic Filter Restriction Check If the red indicator knob is
Indicator visible, report to mainte-
nance to have the filter
changed.


Vehicle Lights Check Walk around the Scooptram,
make sure all lights are oper-
ating and they are aimed
properly.
Battery Electrolyte level Check, refill Check electrolyte level in the
battery cells.
Hydraulic Controls Check function Test the dump and hoist, and
the steering for proper func-
tion.
Instruments and Gauges Check function Report to maintenance when-
ever the gauge needles sweep
back and forth in a wind-
shield wiper motion.
Daily Lubrication Itemsa

Oscillator Bearings Lubricate Give one (1) to two (2)
Driveline Support Bearing Lubricate squirts at the remote lube
site. Inspect the bearing seals
to ensure that grease is get-
ting to the bearings.
Bucket Pins Lubricate Give on (1) or two (2) squirts
Z-Bar Pivot Pin or until grease comes out of
the bushing area.
Dog-Bone
a. When operating the Scooptram in wet conditions, bearings and pins should be lubricated more often than once each
shift.

ST1010 Lube Schematic
Brake Bleeder
Valves
Manual Lube
Points

125 Hour Requirements

Engine oil Change the engine oil and When installing the new fil-
replace the engine oil filter, make sure that the rubber
ter(s) gasket is lubricated. Screw
on new filters until the gasket
contacts the mount and there
is no side to side movement,
then rotate the filter by hand
2/3 turn to tighten.
Engine air filter Replace the primary (outer) • Remove old element gen-
filter tly.
• Clean the inside of the
filter housing.
• Clean the filter gasket
sealing surfaces of the
housing and cover.
• Check old filter for
uneven dirt patterns.
• Check integrity of new
filter
• Make sure new filter is
installed and seating
properly.
Check connections and ducts
for air tight fit.
Engine Coolant Test supplemental coolant
additive
Batteries Check voltage balance, Voltage should read 13.5V
check fluid level, clean bat- ±.2V
tery terminals and connec- (27.0 ±.4V across the pair)
tions
Hydraulic reservoir breather Inspect and clean
Transverter breather Inspect and clean


Axle breathers Inspect and clean Inspect the breather remote
lines for damage
Differentials Check the oil level Check oil level at level plug
Planetaries Check the oil level with lettering right side up.
Oil level should be at the bot-
tom threads, but not spilling
out when the plug is
removed.
Wheels Check nut torque See the torque chart in the
Specifications section for the
proper value
Driveline slip joints Grease Give on (1) or two (2) squirts
Fan hub bearing Grease or until grease comes out of
the bushing area.
Articulation pin caps Check bolt torques See the torque chart in the
Specifications section
Fire Suppression System check dry chemical level,
gas cartridges, and nozzles
Fuel Filters Replace
Hydraulic Hoses and Fix- Inspect
tures
Accumulator Pre-Charge Check
Pressure
Axle Mounts Inspect
Steering Stops Inspect for excessive wear
Boom Stops or damage
Bucket Rollback Stops
Drivelines Inspect for wear or dam-
age, check for clearances
with hydraulic hoses


Fuel tank fillers Clean strainers
Engine/Transverter idle and Measure and record
stall speeds
Articulation Pins Lubricate Give one (1) to two (2)
squirts at the remote lube
site. Inspect the bearing seals
to ensure that grease is get-
ting to the bearings.

Fuel tank Check for water and sedi-
ment, drain and clean
Engine coolant filter Replace the coolant filter
Transverter oil filters Replace
Hydraulic oil filters Replace
Bucket and steering cycle Measure and record
times


Drive belts Check, replace, or adjust • Check for cracks or
excessive stretching of
belt.
• Replace all belts in a set
when one is worn.
• After replacing a worn
belt, check the belt ten-
sion 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”)
Articulation joint Check bearings for loose- See the Service Manual for
ness instructions on how to check
looseness
Engine Mounting Bolts Check torques See the torque chart in the
Transverter Mounts Service Manual Appendix
section for your specific
All Trunnion Cap Bolts vehicle.
Axle Mounting Bolts
Oscillation Mounting Bolts
Transfer Case Mounting
Bolts

Fuel tank Drain and flush
Transverter Change oil, clean breather,
and clean suction screen


Transverter Check clutch pressures
Axles Change oil of each differ-
ential and planetary and
clean the breathers
Hydraulic reservoir clean/replace the reservoir
breather
Hydraulic pressures measure and record
Hydraulic drift measure and record
Radiator and cooler core clean
Engine fan belts replace
Engine air filter replace the secondary
(inner) element
Air intake and exhaust check compression and
manifold tightness; clean
exhaust purifier
Fire Suppression Inspect, verify operation

Cooling system drain, flush and refill the
cooling system
Alternator Test voltage output, inspect

Engine and transverter check bolt torque and
mounts check/replace rubber grom-
mets
U-joints replace
Fuel injectors test/replace


Thermostat and seals replace
Hoses replace all hydraulic sys- IMPORTANT: Order
tem and engine fuel, air, replacement pressure hoses
and coolant hoses from your Atlas Copco Parts
Catalog. For safety reasons,
Pressure hoses must never be
replaced with hoses of a
lower rating.

Maintenance Intervals of the indicator will become red when the fil-
ter is restricted and requires service.
Note: Whenever conducting engine mainte-
nance, the engine manufacturer’s service
and operator’s manuals should be referred to 1
for correct procedures.
As Required
Engine Air Filter Restriction Indicator
NOTE: An adequate supply of clean, filtered 2
air is necessary to maintain correct fuel/air
ratios, resulting in a cleaner burning engine.
Free flow of air to the intake must not be
restricted in any way. The maximum pressure
drop through the intake system, at full throt-
tle and no load (approximately 2200 rpm)
should not exceed specified engine manufac-
turer’s recommendations. 1. Reset Button
2. Service Indicator Windo
IMPORTANT: Always service the air filter
After the filters have been cleaned or
system with the engine stopped. You can
replaced, reset the indicator by depressing
damage the engine severely with dust and
the button on the top of the indicator.
debris.
Periodically during your shift check the air Radiator
intake restriction indicator. A clear area, or Clean all debris that obstructs free air flow
service indicator window, around the middle through the radiators.
Cab, Bucket, Frames, and Hoses
Look for signs of frame cracks or damage
that might lead to a system malfunction.
Check for any evidence of oil leakage or
crimped hydraulic hoses. Check for any pos-
sible fire hazards such as pooled fuel, oil
leaking on the exhaust system, or grease
build-up near sources of high heat.

Circuit Breakers and Fuses Fuel

Fuel level should be checked at the start of
1 each shift. An electronic fuel gauge provides
fuel levels. See the Gauges section for a
description of the fuel gauge.
NOTE: Most engine manufacturers recom-
2 mend that the fuel tank be kept full to prevent
condensation in the tank.Atlas Copco recom-
mends refilling the tank(s) at the end of each
shift.
IMPORTANT: Always shutdown engine
1. Component Box
when refueling vehicle or working on fuel
2. Circuit Breakers
system.
The component box contains circuit breaker
and fuses or re-settable circuit breakers. Engine Oil
In the instrument panel, the lower amperage

breakers are “push-pull” which allows for
manually isolating circuits for troubleshoot-
ing.
All breakers are manually reset. If an electri-
1
cal fault occurs try resetting the appropriate 2
breaker. If the breaker cannot be reset, con-
tact maintenance personnel to resolve the
problem before continuing operation.
Windshield Wipers
You should check the windshield wiper 1. Engine Oil Dipstick
blades periodically throughout the shift to 2. Engine Oil Filler Tube
make sure they are not worn, cracked or bro- The engine lubricating oil should be at the
ken. FULL mark on the dipstick. To accurately
check the oil level, stop the engine and allow
Before Each Shift for the oil to drain off engine internal parts
(at least 20 minutes). This eliminates the
Windshield Wipers and Washer Fluid (on
possibility of overfilling. When checking the
cab-equipped vehicles) oil level, make sure that the area around the
Before each shift you should make sure the dipstick is clean and the vehicle is on level
reservoir is full of washer fluid. ground.

Push the dipstick completely down and pull stick tube serves as the fill tube. Vehicles
out. The oil level must be between the ADD with hydrostatic transverters are equipped
and FULL marks on the dipstick. with sight glasses located on the hydraulic
reservoir tank. A fill cap is located on top of
If the oil level is below the ADD mark, add
the reservoir.
oil to raise the oil level up to the FULL mark
on the dipstick. IMPORTANT: The transverter oil level must
be checked at operating temperature.
Note: Do not add engine oil until level is
below the ADD mark on the dipstick. A ST-1010 27° - 49° C (80° - 120° F)
major cause of engine oil consumption on an Correct level is at the FULL mark on the dip-
Atlas Copco engine is overfilling the crank- stick (or upper sight glass). Make sure that
case. the area around the dipstick is clean before
IMPORTANT: Failure to promptly add oil checking. Never overfill the transverter.
when indicated may result in serious engine
Transfer Case Oil
damage due to piston and bearing seizure.
Transverter Oil
1
1
1. Transverter Dip Stick and Filler Tube 1. Transfer Case Dipstick

With the engine running at idle, check the Check the oil level in the transfer case every
transverter oil level: shift as part of pre-start checks. The oil level
Park the vehicle on a level surface. should be between the ADD and FULL
marks on the dip stick. Add or drain if neces-
Apply the parking brake. sary to achieve proper level.
Shift the transverter to NEUTRAL and run
the engine at idle speed.
NOTE: On most vehicles, a dipstick and fill
tube are located under a hinged cover at the
center of the vehicle, although this may vary.
For vehicles with Funk transverters, the dip-

Primary Fuel Filter/Water Separator Hydraulic Reservoir
1. Upper Sight Glass

1 2. Lower Sight Glass
Check the hydraulic oil level every shift.
Park the vehicle on a level surface and put
the bucket blade on the ground.
1. Drain Cock
Stop the engine and allow time for accumu-
On the Atlas Copco Scooptrams, the Primary lator to bleed down.
fuel filter also acts as a fuel/water separator.
It should be checked before each shift. Vent the reservoir by loosening the filler cap
(or depressing relief valve) on top of the
Inspect bottom view glass on filter. tank.
If water is present, open the drain valve on Check the hydraulic oil in the hydraulic tank
the bottom of the fuel filter and drain water with all cylinders retracted. The hydraulic oil
from the fuel filter. level should be visible in the upper sight
Close the drain valve. glass.
NOTE: Fuel tank should be full when the Report to maintenance if oil does not appear
vehicle is parked for longer than 4 hours to in the glass at all.
prevent condensation in the tank. Note: The hydraulic reservoir can be either
through the filler cap or through a quick dis-
connect fitting, using the accompanying hose
and hand pump, depending on the model
vehicle.
Check the reservoir breather before each
shift.

Tires Always check pressure when the tire is cold.

Always inflate tires to the recommended
pressure.
In extremely cold temperatures, inflation
pressures will vary from those listed below.
Contact your Wagner sales company or
dealer.
Avoid operation when the vehicles has been
parked for a long time in temperatures below
-40°F (-40°C).
WARNING: Never mix different size
wheel parts. Never use damaged
wheel rims or parts. Incorrect modi-
fication or rework to wheel rim or parts may
result in failure, injury, or death.
Check to make sure that all tires are the same
size, or at least have the same rolling radius.
WARNING: Tires and wheels can
explode and cause injury or death. Deflate the tire before attempting to repair
Always keep yourself and others out tire tread or removing foreign objects.
of the danger areas of the tires and wheels.
Fire Extinguisher
Stand on the tread side of a tire when you
perform service. Ensure that a fire extinguisher is secured to
The vehicle must be empty before servicing the vehicle and that the indicator shows that
the tires. it is serviceable.
Stand on the tread side of the tire when ser-

vicing.
Check each tire for deep cuts, breaks or loose
tread. Look for exposed cord. Report any
damage to the maintenance department for
corrective action.
Use a long hose and self-attaching air valve
fitting so that you can be outside of the dan-
ger zone when inflating the tires.
If the tire and wheel assembly is removed
from the vehicle, always put it into the tire
inflation cage before adding air.

Engine Drive Belts evacuator valve more often when the vehicle
is operating in severe dust or wet conditions.
Cooling System
1. Coolant Level Sight Gauge
Inspect the engine fan belts before each shift. Check the coolant level in the radiator by
Inspect for cracking, wear, or looseness. viewing the surge tank sight glass. Add clean
coolant as required.
Check the tension of the drive belts by press-
ing with the thumb halfway between the pul- WARNING: Do not remove the cap
leys. The belts should not deflect more than from the radiator. Check and fill
13-19 mm (1/2”-3/4”). If any belt is loose or through the surge tank only.
worn, report to maintenance personnel for When operating in cold weather, make sure
corrective action. that the antifreeze content is adequate. Add a
Air Filter Evacuator Valve 50/50 mixture of coolant (ethylene glycol),
with correct supplemental coolant additives
as required.
Note: Always pre-mix the solution before you
fill or add to the system. Do not allow nitrite
1 concentration to exceed 2400 ppm (parts per
million) or drop below 800 ppm.
1. Evacuator Valve
Check and clean the evacuator valve before
every shift. Make sure there is no obstruc-
tions inside the evacuator valve. Check the

Hydraulic Restriction Indicator Batteries
1 1
1. Hydraulic Filter Restriction Indicator 1. Battery Cell Cover

On the hydraulic return filter head, a red
knob pops out when a restriction in the filter
Check the battery electrolyte level in each
exists. You should check to make sure the
battery cell prior to operating the vehicle.
red knob is not extended prior to operating
Make sure that the engine is not running, that
the scooptram.
the articulation lock is installed, and that the
Vehicle Lights park brake is applied.
The electrolyte level in the battery cells must
be at least be at the bottom of the filler tube
for the cell. If it is below the tube opening,
add enough distilled water to bring the level
up to the tube.
Inspect the battery for damage, excessive
acid build up on the terminals, corrosion,
cracks to battery housing, and worn or frayed
battery cables.
WARNING: The batteries pose a
During your initial walk around inspection potential explosion hazard. Do not
of the Scooptram, look at the vehicle lights. lean over the batteries while check-
Check that they are all in place, are working, ing the electrolyte levels. The battery electro-
and that they are aimed in the right direction. lyte is an acid and will burn when it comes in
Check the wiring to the lights, note any dam- contact with your skin and eyes. Wear appro-
aged wiring and notify maintenance when a priate protective clothing and equipment
light does not work. when servicing the batteries.

Daily Lube Items 8. Right-Hand Hoist Cylinder Stem End Pin

9. Right-Hand Hoist Cylinder Base End Pin
The following items must be lubricated at 10. Driveline Support Bearing
the beginning of each shift: 11. Left-Hand Boom to Load Frame Pin
• Front and Rear Oscillators (Rear Axle) 12. Left-Hand Steering Cylinder Stem End
Pin
• Top and Bottom Articulation Hinge
Hydraulic Tank Door Lube Site
• Driveline Support Bearings
• Bucket Pins
• Boom Pins 1 2 3
• Dogbone Pins
• Steering Cylinder Pins
IMPORTANT: When operating the Scoop- 4
tram in wet conditions, it is necessary to lube
6 5
the pins more often than once per shift.
On the ST1010, the lube points for the above
1. Forward (Power Frame Axle) Oscillator
are remoted to two areas on the right hand Bearing
side of the machine 2. Rearward (Power Frame Axle) Oscillator
Articulation Area Lube Site Bearing
3. Bottom Articulation Hinge Bearing
1 2 3 4 4. Top Articulation Hinge Bearing
5 5. Driveline Support Bearing
12 6 6. Rear Brake Bleeders (DO NOT
GREASE)
11 7 125 Hour Requirements

10 9 8 Conduct Daily/Shift Maintenance
1. Left-Hand Boom to Bucket Pin

2. Left-Hand Hoist Cylinder Base End Pin
3. Left-Hand Hoist Cylinder Stem End Pin
4. Stabilizer Cylinder Base End Pin
5. Right-Hand Boom to Load Frame Pin
6. Right-hand Steering Cylinder Stem End
Pin
7. Right-Hand Boom to Bucket Pin

Engine Oil Clean the filter sealing surface with a clean

cloth.
1 Apply clean oil to the gasket of each new fil-
ter.
Fill each new filter with new 15W-40 engine
oil and install each filter.
Turn each filter clockwise until the gasket
makes contact with the filter base. Continue
to turn the filter 2/3 turn by hand.
Fill the crankcase through the filler tube to
1. ST1010 Oil Filters the top dipstick mark.
Engine oil and engine oil filter should be Start the engine and run at idle speed and
changed after every 100 hours of operation. check the engine oil pressure. Then, check
for oil leaks around the filter.
The drain interval may be gradually
increased, or decreased, following the rec- Stop the engine and check the engine oil
ommendations of an independent oil analysis level after a few minutes.
laboratory or the oil supplier (based upon the Engine Air Filters
oil sample analysis) until the most practical
oil change period has been established. The air intake system is provided with test
ports for measuring vacuum. A visual check
Oil changes should be made when the engine
should be made to insure that plugs are
is warm, as the oil will drain more com-
installed.
pletely than when cold.
Replace the outer air cleaner filter element
CAUTION: Engine oil can reach tempera-
when air restriction is in the red or every 125
tures exceeding 104° C (220°F). Do not
hours of operation.
change oil immediately following engine
shutdown. The following steps describe filter removal
procedures:
Select a container sufficient to hold the entire
amount of oil in the system and place under-
neath the oil pan drain.
Proceed with removing the crankcase oil
drain plug. After the oil has drained off,
clean and reinstall the drain plug.
Remove the oil filters by turning counter-
clockwise using a strap wrench or filter
removal tool.
Discard the filters.

1. Loosen and remove the air filter cover. 5. Reset filter service indicator.
2. Loosen and remove the outer filter ele- 6. Start the engine, if the filter service indi-
ment wing nut and remove the element. cator indicates red again, replace the
inner filter element.
Engine Coolant
Inspect radiator hoses for loose fittings, leaks
and damaged condition.
Test coolant for proper additives concentra-
tion and water quality levels.
Batteries
3. Inspect filter gasket surface and replace

if needed.
Each week, the battery should be checked

and cleaned.
4. Install a new primary element. Rotate the
Ensure that battery tops are kept clean and
element as you tighten the wing nut to
free of dirt and electrolyte. Check that all ter-
make sure there is a good gasket seal.
minals and connectors are clean and tight.

Replace any wire or cable with damaged Hydraulic Reservoir Breather

insulation. Make sure that the battery box
cover is secured before vehicle is placed in
operation.
Clean battery with a weak solution of baking
soda and warm water. Ensure no cleaning
solution reaches electrolyte in battery.
Fill all battery cells with distilled water to
inside top of battery.
Check electrolyte level.
Note: Frequency of battery maintenance Inspect hydraulic tank breather valve for
dependent on type of battery (i.e. Conven- blockage, and clean if necessary.
tional, Low-Maintenance or Maintenance-
Free). Transverter Breather
Check and record battery voltage level
CAUTION: Avoid contact with electrolyte.
Acid burns! Personal injury can result.
Check battery hold-downs for tightness, and
clean if needed with solution used on battery.
Ensure integrity of hold-downs, and replace
if in doubt.
WARNING: When working around
batteries, avoid any sparks and/or
flame. Hydrogen gas given off by
ACW00073.pict
Inspect the transverter breather, which is
batteries is explosive. located on the dip stick tube. Check for
blockage. Remove and clean if restricted.
Axle Breathers
Check axle breathers for blockage. They
should be cleaned if plugged or restricted.
They are located on top of each axle housing.

Differentials With the vehicle on a level surface, move the

vehicle forward or back until the oil level/
drain plug is horizontal with the wheel cen-
terline and the direction arrow is pointing
down.
Apply the parking brake, and stop the
engine.
Remove the oil level/drain plug. The oil
level must be up to the bottom of the plug
hole. Add oil as required.
Install the oil level/drain plug and check the
Check oil level for each axle differential. other planetaries.
IMPORTANT: Check fluid levels when oil is
Wheels
cold. Do not check with hot oil, as incorrect
level will be indicated.
Park the vehicle on a level surface, apply the
parking brake, and stop the engine.
Let vehicle to stand 5 minutes to allow oil to
settle to normal level.
Remove the oil level plug. The oil level must
be up to the bottom of the plug hole. Add oil
as required.
Install the oil level plug and check the other
differential. Inspect for missing nuts or studs. Replace
any damaged or missing wheel retaining
Planetaries hardware with Grade 8 or equivalent.
Check wheel nut torque. Proper torque can
1 be found in the torque charts in the Specifi-
cations section.
Driveline Slip Joints
Grease all driveline slip-joints. Apply one
(1) or two (2) pumps of grease.
IMPORTANT: Do not overgrease. Shaft
seals will be blown out by excessive greas-
ing.
1. Planetary Oil Check Plug

Fan Hub BearingIf cooling fan hub is sup- Fire Suppression System
Inspect over-all condition of hoses, discharge
nozzles, and activator valve for damage,
blockage, or any sign of possible failure.
Nozzles should be capped with silicone
grease or plastic blow-off caps. Actuator and
expellent cartridge seals and disks must be
intact. Repair as needed.
Check level of pressurized dry chemical
extinguisher tank(s). Extinguishers should
contain an active charge of not less than five
plied with a grease fitting, apply one (1)
pounds (2.3 kg) nominal weight.
hand pump of grease.
Fuel Filters
IMPORTANT: Do not overgrease. Shaft seals
will be blown out by excessive greasing.
Articulation Pin Caps
Check articulation and steering pin trunnion

cap bolt torque.
Check steering cylinder mounting pins and 1. Secondary Fuel Filter (ST1010)
bushings for wear or excessive clearances. If
any pin free-play exceeds 3.175 mm (1/8 Replace the fuel filters every 125 hours of
in.), replace pin and/or bushing, or repair pin operation.
bore as required. Clean both fuel filters and the area around
Check all boom, bucket and steering stops each filter.
for wear and cracks. Wear should not exceed Turn the two fuel line shutoff valves 90
1.59 mm (1/16 in.) from original condition. degrees to the OFF position.

Turn each filter counterclockwise and Hydraulic Hoses and Fixtures

remove from the filter head. Discard the old
filters.
Use a clean cloth and wipe the mounting sur-
face of each filter. Make sure this area is
clean.
Apply a thin layer of clean oil to the gasket
of each new filter.
Fill each new filter with clean diesel fuel and
install each filter.
Turn each filter clockwise to install. When Check all plumbing lines and piping connec-
the gasket of each filter touches the filter tions for leakage and/or breaks and replace
head, continue to tighten each filter 2/3 turn. as necessary.
Note: It may be necessary to bleed air from Check all hydraulic hoses for tears, buckling,
the fuel system and leaks.
To bleed air from the Fuel System: Accumulator Pre-Charge Pressure
Remove the air bleed plug(s) on the top of
Check accumulator pre-charge pressure.
the primary fuel filter.
Pressure should be 1200± 100 psi (83 ±6.9
Operate the hand primer pump until you see bar).
air free fuel coming out of the plug hole.
To test pre-charge pressure in the accumula-
Note: The priming pump is a push-button on tor, start the vehicle and allow the hydraulic
top of the primary fuel filter. system pressure to build up. Watching the
Install the bleed plug(s) and start the engine. accumulator pressure gauge, pump the brake
Run at idle speed and check for fuel leaks. pedal. System pressure should fall gradually
to 1200 psi (83 bar), then drop immediately
Continue priming if the engine fails to start to zero.
immediately.
Pre-charge pressure can also be checked
CAUTION: When performing any checks or using the Atlas Copco Accumulator Pre-
maintenance on the fuel system, be certain to charging tool. (See instructions for pre-
clean up all fuel that has spilled on the charging the accumulator in Section?).
engine or vehicle.
Note: On vehicles with more than one accu-
mulator, pre-charge pressure must be tested
at each accumulator, using the pressure
gauge on the Atlas Copco Accumulator Pre-
charging tool.

Axle Mounts Fuel Tank Fillers
Check axle oscillating bushings for exces-

sive wear and overall condition.
Check that the oscillating mounting cap bolts
and axle mounting bolts are torqued to speci-
fication.
Steering, Boom, and Bucket Rollback Clean the fuel tank filler screen assembly.
Stops
Remove the screen by gently pulling it out of
the filler tube.
Blow off any dirt from the inside of the
screen. If there is dirt build up, clean with
diesel fuel if there is a sludge build-up.
Engine/Transverter Idle and Stall Speeds
The transverter stall test is conducted to
check the operation of the transverter
clutches.
Inspect all stops for excessive wear or dam- Two stall speeds need to be measured:
age. See the Frame section for further infor- A. Transverter
mation and locations of stops.
B. Transverter and dump
250 Hour Requirements To test transverter stall:
Conduct Daily/Shift Maintenance Start engine and operate hydraulic controls
until hydraulic oil temperature is at operating
Conduct 125 Hour Maintenance temperature (66° C / 150° F).

Place the vehicle in its highest forward gear. Loosen the drain plug on the bottom of the
With park brake applied, depress throttle fuel tank and check for presence of water or
pedal completely down and observe Trans- sediment.
verter Oil Temperature gauge. When gauge CAUTION: If the fuel tank is full, there will
reads 88° C (190° F) measure and record be pressure on the drain plug. To remove the
engine RPM using photo-tachometer or water, only loosen the plug. Do not remove
DDEC reader. the plug.
CAUTION: Do not operate the transverter
Engine Coolant Filter
at full throttle speed for more than thirty (30)
seconds. Do not allow the transverter tem-
perature to exceed 250° F (121°C).
Transverter and Dump stall:
Repeat the transverter test with the dump
rolled back against the stops and the dump
control lever held back.
Engine Idle Speed
Engine Idle speed tests allow the engine per-

formance to be checked without the engine
ECM being involved. The idle speed test
information should be checked and docu-
mented regularly so that comparisons can be
made. Replace the coolant system filter every 500
hours of operation or when the cooling sys-
To test idle speeds, place vehicle in neutral.
tem is drained, flushed and refilled.
With throttle pedal completely depressed,
measure and record High Idle engine RPM. Rotate the two filter shutoff valves clockwise
to the OFF position.
Release throttle pedal and allow engine
speed to drop. Measure and record Low Idle Use a strap wrench and turn the filter coun-
engine RPM. terclockwise to remove. Discard the old fil-
ter.
500 Hour Requirements Use a clean cloth and clean the filter mount-
Conduct Daily/Shift maintenance ing area on the filter head.
Conduct 125 Hour maintenance Apply a thin layer of clean grease or oil to
the gasket of the new filter.
Conduct 250 Hour maintenance
Turn the new filter clockwise onto the filter
Fuel Tank base until the filter gasket makes contact.
Check fuel tank for water and sediment. Continue to turn the new filter 2/3 turn.

Rotate the two filter shutoff valves counter- nation or burnt appearance. Clean the fil-
clockwise to the OPEN position. ter(s) and the area around the filter(s).
Engine Intake and Exhaust Valves With the engine stopped, turn each filter
counterclockwise and remove. Discard the
The valve clearance adjustment should be
old filters.
checked at least every month or 400 operat-
ing hours (more often under severe operating Use a clean cloth and wipe the filter mount-
conditions). ing surface on the filter head.
Improper valve clearances can cause rough Apply a coat of transverter oil to the seal of
engine running, power loss, and incomplete each new filter and fill each filter with trans-
combustion. verter oil.
When adjusting valves, follow the instruc- Install the new filter(s) and turn until the seal
tions outlined in the engine manufacturer’s contacts the filter head. Continue to turn
service manual. each filter clockwise 3/4 turn.
Release springs or unscrew bolts to remove Note: Use of a catch basin or container is
the cover. Unscrew bolts to remove the bowl recommended when changing filter(s).
by means of a 22 mm per foot tubular span-
Hydraulic Oil Filter
ner or puller, applying a clockwise turn.
Clean the bowl. When reassembling, make Replace the hydraulic oil filter every 500
sure that seals are properly seated. Renew hours of operation or when indicated.
any defective seals.
The hydraulic suction type filter system uses
Transverter Oil Filters 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:
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
1 assembly and discard it.
3. Remove O-ring from the head assembly
1. Transverter Oil Filter and inspect for cuts or excessive wear
Change the transverter oil filter(s) every 500 and replace if necessary. Inspect the head
hours of operation. assembly for wear or cracks.
IMPORTANT: Oil and filter(s) should be
changed anytime there are signs of contami-

4. Wipe head assembly O-ring with clean Drive Belts

cloth, Apply a thin layer of clean grease
or oil to the O-ring and reinstall on the
head assembly.
IMPORTANT: When changing filter ensure
that it has completely filled with hydraulic
oil prior to closing the filter housing and
starting the vehicle. Air pockets can cause
cavitation and damage the hydraulic pump.
5. Start the engine and run at idle speed.
6. Stop the engine and check the hydraulic
oil level.
If leakage appears at top of the body, replace
the head assembly O-ring. If this does not
stop the leakage, the body may be nicked or
distorted by over torquing, and should be Check the tension of the drive belts by press-
repaired or replaced. Consult Atlas Copco if ing with a thumb on the belt half way
a major problem exists. between the pulleys. The belts should not
move more than 13-19 mm (1/2 - 3/4 in).
The power-fill port is used to fill the reser-
Adjust belt tension if necessary.
voir through the filter without removing the
head assembly. Also the Scooptram is When belt replacement is necessary, belts
equipped with a hand pump assembly that must be replaced as a complete set. Never
routs the hydraulic oil through the filter. replace a single belt since the new belt will
carry all the load and fail rapidly.
In the rare instance the threads on the filter
head become damaged, consult your Atlas Engine Crank Case Pressure
Copco service representative for repair
instructions if housing assembly cannot be Check and record the engine crank case pres-
replaced. sure.
Bucket and Steering Cycle Times Cylinders
Test and record dump/hoist and steering Inspect all hydraulic cylinders for signs of
cycle times. damage or leakage.
Check mounts for cracks and pins and bush-
ings for wear and excessive clearances.
Cylinders need to be checked for leaks,
scored, bent or damaged stems and condition
of eye bushings.

Hinge Points and Mounts Axle Mounting Bolts and Oscillation Bearings
Refer to the torque charts in the Specifica- Inspect all axle mounting bolts for wear,
tions section of this manual. damage, and cracking. Check the bolt
torques.
Articulation Joint
Check oscillation cradle to frame bushings
Check articulation joint for looseness. and thrust washers for movement and end
Since the joint cannot be adjusted, if play is play. If any lateral movement is detected in
found it is necessary to replace the whole the cradle bushings, replace bushings and
bearing assembly. See Section 6: Frame for thrust washers. Replace thrust washers with
articulation joint bearing replacement. the same part number that is stamped on the
old thrust washers.
Engine and Transverter Mounting Bolts
No end play should exist in cradle bushings.
If end play is observed, replace thrust wash-
ers and adjust with adjusting nut.
Transfer Case Mounting Bolts
1. Rear Engine Mounts (Rubber Grom-

mets) 1
Inspect mounts for cracks. Inspect for miss-
ing or cracked mounting bolts. Inspect con-
dition of rubber mounting pads. Keep pads
free of oil.
All Trunnion Cap Bolts
Inspect the trunnion caps on all hinge points

on the cylinders, Z-Bar, bucket, and frame
for excessive wear, damage, or cracking.
Check the bolt torques. See the torque charts 1. Transfer Case Flywheel Mounting Bolts
in the Specifications section. Inspect the transfer case flywheel housing
for damage or cracks. Check mounting bolt
torques. The torques are 112-126 N-M (83-
93 ft-lb.).

1000 Hour Requirements Remove the drain plug and oil strainer
assembly. Drain all the transverter oil.
Conduct Daily/Shift maintenance
Fuel tank
Drain and flush the fuel tank.
1. Loosen the drain plug on the bottom of
the fuel tank and drain fuel into a proper
container.
CAUTION: If the fuel tank is full, there will
be pressure on the drain plug. Recommend Note: Use of a catch basin or container is
draining tank with low fuel level. recommended when changing oil.
2. Flush tank with clean diesel fuel. Make Replace the transverter oil filters and clean
sure that all contaminants are dislodged the strainer assembly and breather.
and removed from the tank. Install the drain plug and strainer and add
3. Remove any feed line screens or strain- new oil to FULL mark.
ers, clean and re-install. Start the engine and run at idle for a few min-
4. Re-install fuel tank drain plug and re-fill utes with the transverter in NEUTRAL.
tank with diesel fuel. Check for oil leaks.
Bleed all air from the fuel system. Check the transverter oil level once oil tem-
perature has reached normal operating range.
Transverter Level should be between the ADD and
FULL mark.
Change the transverter oil every 1000 hours.
Clean the area around the transverter oil Axles, Differentials, and Planetaries
filler tube and drain plug. 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 plane-
taries every 1000 hours of operation.
Note: Draining of oil is best accomplished
after vehicle has been operated and oil has

warmed up. Use of a catch basin or con- Install the oil level/drain plug, then repeat
tainer is recommended when changing oil. procedure with the other planetaries.
Differential Hydraulic Reservoir
Park the vehicle on a level surface, apply the Change the hydraulic oil and clean/replace
parking brake, and stop the engine. the reservoir breather every 1000 hours of
operation.
Remove the oil drain plugs and completely
drain each differential. Raise the boom to its full height so that the
pistons will be extended in the hoist cylin-
ders.
Move the bucket to its full dump position so
that the piston will be extended in the stabi-
lizer cylinder.
Note: In these positions the hydraulic oil in
the cylinders will be below the pistons and
will drain more completely.
Secure the boom with a chain hoist or by
securely blocking the boom and bucket
Install the oil drain plugs.
assembly with support stands.
Remove the oil level plug and put new oil in
CAUTION: Perform this step carefully to
each differential. The oil level must be up to
prevent the possibility of an accident. With
the bottom of the oil level plug hole.
the oil drained there will be nothing to sup-
Install the oil level plug. port the boom.
Planetary Vent the reservoir by loosening the filler cap
on top of the tank.
With the vehicle on a level surface, move the
vehicle forward or back until the oil level/ CAUTION: Make sure the hydraulic oil is
drain plug is at the bottom of the hub. just warm from operation before you drain
the oil. Hydraulic oil temperature can reach
Apply the parking brake, and stop the 121° C (250°F).
engine.
Select a container sufficient to hold the entire
Remove the oil level/drain plug.
amount of oil in the system and place under-
After all the oil has been drained, reposition neath the reservoir drain.
the vehicle so that the oil level/drain plug is Remove the drain plug from the reservoir
in the level check position.
and drain the oil.
Put new oil into the planetary. The oil level Disconnect the hoist and stabilizer cylinders’
must be up to the bottom of the oil level/ hoses at the lowest points so as to completely
drain plug hole.
drain the cylinders.

Clean the inside of the reservoir. If it is diffi- • Sequence Valve

cult to clean, use a mixture of five parts fuel
• Cooler Check Valves
oil to one part of clean lubricating oil. Be
sure to flush out the bottom of the tank. • Charge Pump Pressure
Make sure that all of the flushing solution is • Hydraulic Drift
removed from the reservoir.
• Pump Flows
Disconnect any other hoses that might trap
hydraulic oil in the system and shift the See the Hydraulics section for procedures to
hydraulic control levers to permit any oil in check the pressures.
the control valves to drain. Radiator and Cooler Core
Replace the hydraulic filter(s).
Re-connect all hoses and fittings previously
disconnected.
Install the reservoir drain plug.
Pump new oil into the hydraulic reservoir.
IMPORTANT: On vehicles with internal fil-
ter cartridge, ensure that the filter has com-
pletely filled with hydraulic oil prior to
closing the filter housing and starting the
vehicle. Air pockets can cause cavitation and Check the engine radiator, hydraulic oil
damage the hydraulic pump. Wagner recom- cooler, the fuel cooler and the hydraulic fan
mends filling the tank through the filter on fins for damage, wear, and dirt build up.
these vehicles.
Clean the radiators periodically to keep dirt
Start the engine, cycle dump/hoist and steer- build up from closing off the fins.
ing and check for oil leaks.
Check the hoses and tubing that attach to the
Stop the engine and check the hydraulic oil radiators for damage, leaks, or excessive
level. wear.
Hydraulic Pressures and Flows Check the engine radiator mounting bolt
torques.
The following pressure checks must be
made: Engine and Fan Belts
• Charge Valve Kick-In and Kick-Out Steam clean engine block and radiator.
• Steering and Dump Main Relief Crankcase Breather
• Steering and Dump Port Relief Remove and clean the steel mesh pad with
• Steering and Dump Pilot Pressure clean fuel oil.

Drive Belts Diesel Purifier
Replace engine drive (V-belts) to alternator 1. Loosen/remove purifier housing retain-

and fan. ing clamps. Slide out purifier.
Engine Air Filter 2. Wire brush inlet and outlet faces of puri-
fier to remove carbon buildup.
Replace the inner (or secondary) filter ele-
ment after 1000 hours in the vehicle, or if the 3. Using low pressure air (2 bar / 30 psi),
outer element has been replaced and the ser- blow through outlet side of purifier.
vice indicator still shows RED with the 4. Continue steps 2and 3 until the inlet and
engine running. outlet faces are clean.
IMPORTANT: Do not attempt to clean the 5. Completely soak purifier in cleaning
inner filter element, always replace the ele- solution (one hour).
ment with a new one.
6. Blow low pressure air (2 bar / 30 psi)
1. Remove the filter cover. through outlet side of purifier to remove
2. Remove the outer filter. dirty solvent.
3. Remove the wing nut for the inner filter 7. Repeat steps 5 and 6 until the purifier is
and remove the filter. as clean as possible.
4. Inspect filter gasket surface and replace 8. Flush purifier through outlet side using
if needed. high pressure water (3.4 bar / 50 psi max)
and air dry.
5. Replace the inner filter, install the outer
filter, and install the filter cap. 9. Reinstall purifier in the reverse position
of how it was previously installed.
Air Intake and Exhaust
Note: If high pressure steam is available, it
Manifolds may be substitute for the solvent solution.
Steam clean through the outlet side, keeping
Inspect the cylinder head(s) and the intake
nozzle 5 cm (2 in) away from the catalyst.
and exhaust manifolds.
Check bolts or capscrews for correct torque, Fire Suppression
according to the engine manufacturer’s spec- Inspect fire suppression system to ensure
ifications. that system is charged and operable:
Check that manifolds are secure and prop- 1. Note general appearance for mechanical
erly sealed to cylinder head(s). Check also damage or corrosion.
that manifolds are free of holes or cracks and
that no oil leaks and/or coolant leaks are 2. Check that nameplate is readable.
present. Make replacements or repairs as 3. Remove fill cap assembly. Inspect gasket
necessary. and threads.

4. Check pressure relief vent in fill opening 16. Remove cartridge from remote actuator,
for obstructions. and examine disc. Seal should not be
5. Make certain extinguisher is filled with ruptured.
free-flowing Ansul dry chemical. Level 17. Weigh cartridge. Replace if weight is 7 g
should be no more than 3 inches from the (1/4 oz.) less than weight stamped on
bottom of the fill opening. cartridge.
6. Re-install the fill cap. Hand tighten. 18. Inspect threads on cartridge and in
7. Remove cartridge from extinguisher and receiver/actuator for nicks, burrs, cross
examine disc. Seat should not be rup- threading, rough, or feather edges.
tured. 19. Check pressure vents in remote actuator
8. Weigh cartridge. Replace if weight is 1/4 for obstructions.
oz. less than weight stamped on car- 20. Examine cartridge receiver gasket for
tridge. elasticity. Clean and coat lightly with a
9. Inspect threads on cartridge and in good grade of high heat-resistant grease.
receiver/actuator for nicks, burrs, cross Return cartridge to remote actuator.
threading, rough, or feather edges. Hand tighten.
10. Check pressure vents in receiver/actuator 21. Replace any broken or missing lead and
for obstructions. wire seals and record date of inspection.
11. Examine cartridge receiver gasket for To return your system to service after use:
elasticity. Clean and coat lightly with a 1. Pull ring on safety/relief valve to relive
good grade of high heat-resistant grease. actuator system pressure.
Return cartridge to receiver/actuator.
2. Disconnect actuation system hose at car-
Hand tighten.
tridge receiver/actuator assembly.
12. Disengage bursting disc union and open
3. Open bursting disc union assembly.
bracket clamp.
4. Remove extinguisher from bracket.
13. Lift extinguisher partially out of bracket
and examine bursting disc. It should be 5. Replace ruptured bursting disc with new
installed with full disc side facing extin- disc.
guisher. Make sure disc is properly 6. Full disc side must face extinguisher.
seated and undamaged.
7. Fill extinguisher to rated capacity with
14. Check piping (hose), fittings and nozzles dry chemical specified on nameplate.
for mechanical damage and cuts.
8. Clean fill opening threads and gasket
15. Check nozzle openings. Nozzles should seating surface.
be capped or closed with silicone grease.
9. Secure fill cap. Hand tighten.
10. Remove cartridge guard assembly.

11. Remove empty cartridge. Remove the coolant reservoir cap (if applica-
12. Make certain receiver/actuator puncture ble).
pin is fully retracted. After all coolant is removed, close the drain
Note: Weigh new cartridge. Weight must be valves.
within 7 g (1/4 oz.) of weight stamped on Add a cleaning solution to the cooling sys-
cartridge. tem and fill the system with clean water. Fol-
13. Screw fully charged cartridge (part num- low the directions included with the cleaning
ber specified on nameplate) into receiver/ solution.
actuator assembly. Hand tighten. After you drain the cleaning solution from
14. Replace cartridge guard. the cooling system, flush with clean water.
15. Secure extinguisher in bracket. Remove and replace the cooling system filter
with a new precharge filter.
16. Assemble bursting disc union. Wrench
tighten. Fill the cooling system with premixed cool-
ant (No supplemental coolant additive).
17. Connect actuator system hose at car-
tridge receiver/actuator assembly. Start the engine and run at idle speed for two
Wrench tighten. minutes. Check for leaks during this period.
Stop the engine and check the coolant level.
2000 Hour Requirements Add coolant as required to raise the level up
to the top of the sight window (or within 0.5
Conduct Daily/Shift maintenance in / 13mm of the radiator fill pipe for vehi-
Conduct 125 Hour maintenance cles not equipped with surge tanks).
Conduct 250 Hour maintenance Ensure the two filter shutoff valves are fully
counter clockwise in the OPEN position.
Conduct 1000 Hour maintenance Engine Tune-Up
Cooling System As long as the engine is running smoothly

and no problems are encountered, an engine
Drain, flush, and refill the engine coolant tune-up is not necessary. However, a check
every 2000 hours of operation. After clean- of the intake and exhaust valve clearances
ing the system, replace the coolant filter. and the injector heights should be conducted.
Note: If the cooling system is drained, See the engine manufacturer manuals for
flushed, and refilled with new coolant, use a further information.
precharge filter instead of the service filter to Alternator
ensure the correct concentration of Supple-
mental Coolant Additive (SCA). Test alternator and starter for voltage and
amperage. Replace if necessary.
Open the radiator drain valve/cap and the
two drain valves on the engine.


Conduct Daily/Shift maintenance
Engine and Transverter Mounts
Check mounting bolts for proper torque.
(See specified torque values in the Specifica-
tions section)
Replace rubber mounting pads.
U-joints
All pin joints must be inspected. If any are
found to be worn out, replace pin and bush-
ings and repair bores as required.
Thermostat and Seals
Replace the thermostats and seals every
5000 hours.
Hoses
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.


Section 3 Power Unit
Introduction Fuel System
Efficient engine operation depends upon cor-
rect operating practices and proper protective
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 specifi-
cations.
Diesel fuel has two (2) basic functions in an
engine. First, of course, it is the source of
This section will cover all of the major com-
energy for all of the work done by the
ponents of the power unit. It will discuss
engine. Second, it lubricates many parts of
each component as it pertains to moving the
the fuel system.Today’s fuel pump and injec-
Atlas Copco Scooptram. This section will
tor parts are precision made to provide accu-
not cover any major rebuild or disassembly
rate metering and fuel injection. Many of
of the engine itself. For information concern-
these closely fitted parts depend entirely
ing the engine, see your authorized Atlas
upon fuel oil for lubrication. If a fuel does
Copco dealer.
not have good lubricating qualities, these
The power unit consists of the following sys- parts will soon be damaged and will need to
tems: be replaced.
• Fuel System An additional function of diesel fuel in some
• Lubrication System systems is to act as a coolant for various
parts of the fuel injection system. Excessive
• Electrical System fuel, not utilized by the injector, is circulated
• Cooling System back to the fuel tank. This circulation of fuel
not only cools the various parts of the injec-
• Air Intake System tion system, it also warms the fuel in the tank
• Exhaust System slightly. This preheated fuel helps to ensure
more complete combustion, particularly dur-
ing cold weather operation.

Power Unit
Theory of Operation 6. Fuel Tank

7. Primary Fuel Filter/Water Separator
Fuel is drawn from the lower-most fitting on 8. Fuel Primer Pump
the fuel tank, through the primary fuel filter, 9. Fuel Pump
and into the fuel pump which then supplies
all of the fuel through the secondary fuel fil- The fuel system is composed of the follow-
ters, to the electronic unit injectors. The fuel ing:
is then supplied to the individual cylinders of • Filters
the engine. Excess or unused fuel is returned
• Pumps
to the fuel tank.
• Fuel Tank
Note: Fuel is taken from the bottom fittings
on a fuel tank to provide the most air free • Electronic Unit Injectors
fuel as possible and to utilize the full tank • Electronic Control Module
capacity.
• Fuel Cooler
Fuel System Components Filters
2
1 Primary Filter/Water Separator
3
9
8 4 2
1
7
3
1. Water Separator Sight Glass

1. Cylinder Head
2. Primary Filter
2. Electronic Unit Injectors
3. Water Drain Knob
3. Electronic Control Module
4. Fuel Cooler (ST1010) The life and effective operation of any diesel
5. Secondary Fuel Filter fuel system depends upon fuel which is free

Power Unit
from dirt particles and water. Diesel fuels are Pumps

higher in viscosity than gasoline because
Hand Primer Pump
diesel fuels must have the ability to provide
lubrication for many parts of the fuel system.
However, diesel fuels also contain more 1
gums and abrasive particles which are diffi-
cult to extract during refining. Therefore, an
efficient fuel filter or filters are provided by
engine manufacturers.
The primary filter is located between the fuel
tank and the fuel supply pump. The primary
filter contains a cartridge which is made of
filter media and is equipped with a draincock
at the bottom for draining water and sedi- 1. Hand Primer Pump
ment which collects at the bottom of the fil-
The primer pump is used to pull diesel from
ter shell. This should be done whenever
the fuel tank and deliver it to the injector
water can be seen in the clear filter bowl.
pump prior to starting the engine.It is also
Secondary Fuel Filter used when the engine runs out of fuel, to
bleed air from the system. On DDEC
engines, the priming pump is a push-button
on top of the primary fuel filter (above).
1
Fuel Pump
3
2
3
2
1. Primary Fuel Filter
2. Secondary Fuel Filter 1
3. Fuel Shut-Off Valve
The secondary fuel filter is located between
the fuel lift pump and the injectors. The sec- The fuel pump is located on the intake side
ondary filter removes additional impurities of the engine and is driven by the bull gear. It
from the fuel before it enters the injectors. supplies fuel flow to the injectors through
the secondary filters and the engine ECM
during engine operation.

Power Unit
Fuel Tank 5. Fuel Inlet
The fuel tanks on any diesel installation are The Electronic Unit Injector (EUI) is a light-
as important as the other components of the weight, compact unit that injects diesel fuel
fuel system. Maintenance personnel some- directly into the combustion chamber. The
times have a tendency to overlook this fact. amount of fuel injected and the beginning of
It is up to the fuel supply tank and fuel lines injection timing is determined by the engine
to store and transport the fuel from one part Electronic Control Module (ECM). The
of the system to another without failures and ECM sends a command pulse which acti-
without the possibility of air getting into the vates the injector solenoid. The EUI per-
system. Therefore, they must receive the forms four functions:
same careful maintenance that the other parts • Creates the high-fuel pressure required
of the engine and fuel system receive. for efficient injection.
Carelessness when filling fuel tanks can • Meters and injects the exact amount of
allow dirt to get into the fuel system. It takes fuel required to handle the load.
very little dirt to damage fuel injection
• Atomizes the fuel for mixing with the air
pumps and injectors, and the repair of these
in the combustion chamber.
engine components can be expensive.
• Permits continuous fuel flow for compo-
Electronic Unit Injectors (EUI) and nent cooling.
Engine Control Module (ECM)
Engine combustion is obtained by injecting,
1 under pressure, a small quantity of accu-
2 rately metered and finely atomized fuel oil
into the cylinder. Metering and timing of the
fuel is accomplished by the ECM which
actuates the solenoid poppet valve to stop the
free flow of fuel through the injector. When
the solenoid poppet valve closes, fuel is
3 trapped in the injector body and under the
plunger. The continuous fuel flow through
5 the injector prevents air pockets in the fuel
system and cools those injector parts sub-
jected to high combustion temperatures.
4 Fuel Lines
The Detroit Diesel engine, with its electronic

engine controls and electronic injectors, has
1. Injector Solenoid
no injector pump and is plumbed with flexi-
2. Injector Follower Spring
ble hose in place of rigid fuel lines. The fuel
3. Injector Body
pump is used to deliver fuel to the injectors,
4. Injector Spray Nozzle
each of which measures and injects the cor-

Power Unit
rect amount of fuel required to handle the Oil Filters

load.
ST1010 Oil Filters
Fuel Cooler
The fuel cooler, part of the hydraulic cooling
radiator, cools the diesel fuel as it flows back
to the tank.
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.
On the Scooptram engine the oil filters are
located on the right hand side of the engine,
System Components
below and to the rear of the turbocharger.
The major components in the Scooptram The filters are the disposable spin-on type
engine oil system are: that require changing every time the engine
oil itself is changed, usually every 100-150
• Oil pump.
hours, depending on the manufacturer’s
• Oil filters. specifications.
• Pressure gauge. Engine Oil Pressure Gauge
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 Atlas Copco Scooptram is equipped

with a LED oil gauge with warning lights

Power Unit
that indicate abnormal conditions. If a gauge trical system. See the Electrical Section for
light comes on, stop the vehicle in a safe further discussion on the Acmes role.
location and report the problem to mainte-
nance personnel. The Scooptram is also Cooling System
equipped with a Stop Engine Light (SEL)
and a Check Engine Light (CEL) that illumi- On the Atlas Copco Scooptram, the engine
nate when the oil pressure drops too low. The and engine cooling package is mounted on a
engine ECM also ramp the engine power cradle that can be removed from the vehicle
down to save its internal components. as one unit.
It is not necessary to drain the engine coolant
Engine Electrical System to remove the entire engine and radiator
package.
The electrical system consists of the follow-
ing components: The cooling systems on board the Atlas
Copco Scooptrams are composed of the fol-
• Cranking Motor
lowing systems:
• Battery Charging Generator (Alternator)
• Engine, combustion air intercourse (a
• Voltage Regulator (normally integral to dual cooler system that includes the
the alternator) engine radiator and an air-to-air heat
• Batteries exchanger that cools combustion intake
air.)
• Ignition Switch
• Cranking Motor Relay
The battery stores electrical energy. The
starter converts electrical energy from the
battery into mechanical energy, then trans-
fers the mechanical energy to the engine as a
rotational force. The alternator converts
mechanical energy from the engine to elec-
trical energy. This electrical output of the
alternator is transferred to the battery to be
stored for later use. The wiring links the bat-
tery to the starter, and the alternator to the
battery. The DDEC system power source
must be directly from the battery. The elec-
trical system provides a balanced system to
meet all operating requirements.
The engine Electronic Control Module
(ECM) is an integral part of the vehicle elec-

Power Unit
• Transverter/Fuel cooler, hydraulic cooler A 50/50 mix of quality fully formulated,

(a three section oil-to-air heat exchanger inhibited propylene glycol antifreeze and
with blower). water may also be used if it provides
required freeze, boil over, and inhibitor pro-
1 tection. Do not mix ethylene glycol and pro-
pylene glycol antifreeze. Flush the cooling
system thoroughly before replacing ethylene
glycol with propylene glycol antifreeze.
A 50% Power Cool antifreeze/water solution
is normally used as a factory fill. Concentra-
tions over 67% are not recommended
because of poor heat transfer capability,
adverse freeze protection and possible sili-
cate dropout. Concentrations below 33%
1. Fuel Cooler (ST1010)
offer little freeze, boil over or corrosion pro-
The engine radiator/air intake cooler is an tection.
integral package, installed in front of the
If (IEG) or pre-charged inhibited propylene
engine. The second component is located on
glycol (IPC) is not used, Detroit Diesel
the underside of the midframe compartment
Maintenance Product supplement I inhibitors
hood.
must be added to the coolant at initial fill.
Note: On scooptrams, the engine faces away Inhibitor levels in all coolants used must be
from the front of the vehicle. Any position maintained at proper concentration thereaf-
description given relative to the engine will ter.
be the opposite in relation to the scooptram.
Antifreeze solution should be used year-
CAUTION: If the engine has been running round to provide freeze and boil over protec-
within the previous hour, the temperature of tion as well as a stable environment for seals
the engine components, the coolant, the oil, and hoses.
and radiators can be high enough to cause In extremely hot environments, clean, soft,
serious burns. Allow the engine and the
properly inhibited water may be used if
entire cooling system to cool before initiating Detroit Diesel Maintenance Product supple-
removal procedures. mental corrosion inhibitors are also added in
Coolant Recommendations the right concentration. If water is used, sup-
plemental coolant additive levels should be
Use genuine Detroit Diesel Power Cool or an increased from 3% to 6% by volume.
equivalent fully formulated, inhibited ethyl-
ene glycol (IEG)-base coolant (low silicate
Air Intake System
formulation) that meets or exceeds the stan-
dard of either the GM 6038-M formulation The air intake system fulfills two (2) primary
(GM 1899-M performance), or ASTM D functions:
4985 requirements.

Power Unit
1. Provides clean, contaminant free com- 1. Pre-Cleaner

bustion air to the engine. 2. Dirty Outside Air Inlet
3. Primary Filter
2. Provides forced-air cooling to the engine
4. Safety Filter
and/or various sub-systems.
5. Clean Filtered Air to Turbos then Engine
Air Cleaner Operation The Scooptram engines use an engine driven

fan blade to circulate air through the engine
The function of the air cleaner is to remove cooling radiator. This radiator also serves as
abrasive airborne particles from the air, fur- the combustion air after cooler.
nishing a supply of clean air to the engine.
Major manufacturers of engines have stated Restriction Indicators
that anywhere from 1 tablespoon to 1 cup of As the air cleaner element becomes dirty the
dust ingested into a diesel engine can ruin flow of air to the engine will become
that engine. The air cleaner is of vital impor- restricted. This can limit engine perfor-
tance to engine life and performance. mance. Visual inspection of the filters is not
On Detroit Diesel engines, the combustion always sufficient for determining replace-
air flows through a turbo-charger, driven off ment. In some cases, there may be little
engine exhaust air, and an after-cooler before visual indication of dirt, yet the filter may be
entering the cylinders. In addition to com- internally plugged with very fine particles.
bustion air, Atlas Copco Scooptrams rely on
forced air cooling to dissipate various engine 1
heat loads.
ST1010 Air Cleaner
2
2
3
4
1. Reset Button
2. Service Indicator
Restriction indicators are provided as an
5 easy reference to the operator that the engine

Power Unit
is not getting the necessary amount of intake that serves to support the rotating assembly,
air. bearings, seals, a turbine housing, and a
The type of indicator can vary and may or compressor housing. The center housing has
may not indicate the amount of vacuum (in connections for oil inlet and oil outlet fit-
inches of water). All restriction indicators tings. The rotating assembly consists of a
are color coded. Normal indication is indi- turbine wheel and shaft assembly, piston
cated by a Yellow, Green or Clear indicating ring(s), thrust spacer, compressor wheel, and
window. When intake air restriction has wheel retaining nut. The rotating assembly is
reached the allowed trip point, the indicator supported on two pressure-lubricated bear-
will show Red. This notifies the operator that ings that are retained in the center housing
the filter requires changing. by snap rings. Internal oil passages are
drilled in the center housing to provide lubri-
It is important that operators and mainte-
cation to the turbine wheel shaft bearings,
nance personnel remember to reset these
thrust washer, thrust collar, and thrust spacer.
indicators after each filter change.
The turbine housing is a heat-resistant alloy
The maximum vacuum trip point is shown casting that encloses the turbine wheel and
below. provides a flanged engine exhaust gas inlet
Trip Point and an axially located turbocharger exhaust
Engine (in. H20 / mm Hg) gas outlet. The turbine housing is secured to
Detroit Diesel 25 / 46.7 the turbine end of the center housing.
TurboChargers The gases are discharged into the exhaust

system after passing through the turbine
housing. The compressor wheel, in the com-
pressor housing, is mounted on the opposite
end of the turbine wheel shaft and rotates
with the turbine wheel. The compressor
wheel draws in clean air, compresses it, and
delivers high pressure air through the intake
manifold to the engine cylinders. 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 turbocharger is designed to increase the

overall efficiency of the engine. Power to
drive the turbocharger is extracted from the
energy in the engine exhaust gas. The turbo-
charger consists of a turbine wheel and shaft,
a compressor wheel, and a center housing

Power Unit
3
7
9 6
8
1
2
1. Engine Exhaust flow

2. Compressed Air Flow
3. Charge Air Cooler
4. Engine Cylinder
5. Exhaust Gas Discharge
6. Turbine Exhaust Outlet
7. Turbo Compressor Wheel
8. Ambient Air Inlet
9. Turbine
10. Ambient Air Inlet
From the oil inlet in the center housing, the
oil flows through the drilled oil passages in
the housing to the shaft bearings, thrust ring,
thrust bearing, and back-plate or thrust plate.
The oil returns by gravity to the engine oil
pan through an external oil line extending
from the bottom of the turbocharger center
housing to the cylinder block.

Power Unit
Exhaust System Purifiers (Optional)

ST1010 Exhaust System The exhaust purifiers reduce the amount of
carbon monoxide, hydrocarbons, and diesel
odor that is emitted from the combustion
process of the engine.
2
1 Exhaust Heat Shields
3 The exhaust heat shields are installed on all

Atlas Copco Wagner Scooptrams to protect
personnel when they are conducting service
on or around the engine. They also provide
4 some protection for the exhaust system from
debris while the scooptram is operating.
Engine Accessories Removal &

Replacement
1. Exhaust Flex Tube
2. Top Hat Note: This section contains removal and
3. Purifier replacement instructions covering the engine
4. Silencer and its accessories. All maintenance proce-
dures on the engine proper are included in a
The purpose of the exhaust system is to dis-
separate engine manual.
charge engine exhaust gases in a safe direc-
tion, purify exhaust, and to reduce engine The procedures in the following paragraphs
noise. describe removal and replacement of the var-
ious engine accessory components and of the
The exhaust system is composed of silenc-
engine as a package.
ers, purifiers, tubing, and the turbo-charger.
Wherever possible, procedures are presented
Silencers in the sequence required for orderly removal;
The exhaust silencers act in the same manner that is, if an item must be removed before
as the mufflers on a car. A double wall con- another item can be removed, that item is
struction along with special packing act to covered first.
reduce engine noise radiating from the com- WARNING: Block all wheels, set
bustion cycles while not restricting exhaust the parking brake, remove the key (if
flow. Back pressure caused by an exhaust available) from the ignition switch,
ACW00073.pict
restriction could lead to engine damage, and place a Do Not Operate tag on the steer-
therefore the silencers should be inspected ing wheel or Off/On/Start switch before per-
often and serviced/replaced when a restric- forming maintenance on the power train
tion is detected. systems.

Power Unit
Removing the Engine Cooling System 3. Disconnect the air hoses that connect to
Package the charge air cooler.
The engine/intake radiator can be removed
from the engine cradle package without dis-
turbing the other engine components.
Remove the cooling system package as fol-
lows:
1. Remove the engine hoods.
4. Disconnect and cap all coolant hoses

1
from the radiator.
1. Engine Hoods
2. Place a suitable receptacle below the
engine coolant radiator and drain all
engine coolant.
5. Remove the fan shroud and fan.
1. ST1010 Radiator Drain Cock

Power Unit
6. Remove the upper end support bracket. 2. Reinstall the lock nuts that fasten the bot-
tom 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 hoses that connect to the
engine block and oil cooler.
5. Reinstall the hoses that connect to the
charge air cooler.
6. Close the engine coolant radiator drain
7. Install lift eye on top of radiator and cock. If the engine block was drained,
place hoist hook. close the two drains on the engine.
8. Loosen and remove the lock nuts from 7. Fill the radiator with the proper coolant
the radiator mounting bolts located on mixture.
the bottom of the engine package cradle. 8. Reinstall the engine hoods.
Removing the Transverter/Hydraulic/Fuel
Radiator
Remove the radiator as follows:
1. Raise and support the midship compart-
ment cover.
9. Lift the cooling system package clear of

the scooptram and store it in a safe loca-
tion.
Reinstalling the Cooling System Package
Reinstall the cooling system package as fol-
lows:
2. Disconnect and immediately cap the
1. Using the hoist and lifting chains
lines that connect the radiator to the
arrangement used in the removal, lift the
transverter, fuel system, and hydraulic
cooling system package into position on
system.
the engine cradle.
3. Remove the bolts that secure the radiator
to the cooling system shell.

Power Unit
4. Remove the radiator.

Reinstalling the Transverter/Hydraulic/
Fuel Oil Radiator
Reinstall the radiator in the reverse order of
removal.
Exhaust System
Your scooptram may be equipped with either
a water exhaust scrubber or a catalytic
exhaust purifier. The water exhaust scrubber
requires routine maintenance. The catalytic 2. Remove the step plate.
exhaust purifier does not require operator
maintenance.
Removing the Exhaust System
WARNING: The exhaust system is
extremely hot and should be allowed
to cool prior to removing any com-
ACW00073.pict
ponents.
Remove the Exhaust System as follows:
3. Remove the lower bolts to the exhaust

1 shield.
1. Exhaust System Heat Shield

1. Follow the Hood Removal instructions to
remove the Left-Hand side engine hood.

Power Unit
4. Remove the upper bolts to the heat

shield.
6. Remove the exhaust system upper clamp.

7. Remove the two bolts on the lower muf-
fler clamp.
5. Remove the turbo-charger cover.
8. Remove the muffler.

Power Unit
Reinstalling the Exhaust System Removing Fuel Filters

Reinstall the muffler in the reverse order of
removal.
Fuel System
2
Remove and reinstall the fuel system compo-
nents as outlined in the following para-
1
graphs.
CAUTION: If the engine has been running 3
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 4
before initiating removal procedures.
CAUTION: Cleanliness is absolutely essen-
tial in all work done on the scooptram fuel
system. Always follow these rules regarding 1. Fuel Primer Pump
cleanliness in maintenance operations on the 2. Primary Fuel Filter
fuel system. 3. Fuel Shut-Off Valve
4. Secondary Fuel Filter
• Steam clean the area of the scooptram on
which the work will be performed if Remove the fuel filters as follows:
there is a substantial accumulation of dirt 1. Clean the fuel filters and the surrounding
or other debris. area.
• Wipe clean hose and pipe connections 2. Turn the two fuel line valves 90 degrees
before opening any connection. to the off position.
• Remove all loose paint before opening 3. Turn each filter counterclockwise and
any section of the head pipe to the rear remove it.
section connections.
Reinstalling Fuel Filters
• Plug or cap any hose or connection
immediately after opening it. Reinstall the fuel filters as follows:
• Flush any unsealed hose or pipe with fuel 1. Wipe the mounting surface for each filter
before installing it in the system. with a clean cloth.
2. Apply a thin layer of grease to each filter
gasket.
3. Fill each filter with clean diesel fuel.

Power Unit
4. Install each filter on the filter mount, these tanks may be “drop-in” and fastened to
turning it clockwise. After the filter gas- the frame with bolts. To remove a drop-in
ket contacts the mount, continue to turn fuel tank as follows:
the filter two thirds of a turn.
1. Close the fuel shut-off valve to the fuel
5. Turn the two fuel line valves to the on tank.
position.
2. Place a suitable receptacle under the fuel
6. Start the engine, run it at idle speed, and drain of the tank, open the drain valve (or
check for fuel leaks. remove drain plug), and drain the tank.
Removing Fuel Valves or Lines 3. Position a hoist over the fuel tank and rig
chains from the hoist hook to the lifting
Remove a fuel valve or line as follows: rings at the front and rear of the tank.
1. Clean the fuel valve or ends of the fuel 4. Take up the slack in the chains, but do
line and the surrounding area. not lift the tank yet.
2. If the component to be removed is after 5. Remove the bolts that attach the fuel tank
the fuel filters, turn the two filter fuel line to the Power Frame.
valves to the off position. If the compo-
nent to be removed is before the fuel fil- 6. Lift the tank from the frame and set it on
ters, turn the fuel shut-off valve to the off blocks in a safe location.
position. 7. Remove the receptacle from under the
3. Disconnect the component and remove power frame.
it. 8. Close the fuel valve of the tank and tem-
Reinstalling Fuel Valves or Lines porarily seal all fittings and outlets.
Reinstall a fuel valve or line as follows: Reinstalling the Fuel Tank
1. Make certain that the connections are Reinstall the fuel tank as follows:
clean, both on the component to be 1. Lift the tank from the storage position
replaced and the components to which it and place it on the frame.
connects.
2. Re-install the bolts that secure the tank to
2. Install the component. the power frame. Torque the bolts to 380
3. Turn the fuel valve(s) to the on position. N-m (280 ft-lb).
4. Start the engine, run it at idle speed, and 3. Remove the hoist and the chains.
check for fuel leaks. 4. Remove all temporary seals from fittings
Removing Fuel Tank and outlets.
5. Open the fuel valve to the tank.
Many Atlas Copco vehicles incorporate the
hydraulic and fuel tanks into the major weld-
ment structure. However, on some units,

Power Unit
Electronic Engine Control System 3. Remove the rear upper cross member.
The engine electronic control system is an
integral part of the engine package. Refer to
the engine manual for removal and replace-
ment information.
Engine
WARNING: The engine package
could weigh more than 1134 kilo-
grams (2500 pounds). Do not reach
ACW00073.pict
or lean underneath the engine as it is being

4. Disconnect the transverter driveline on
removed or re-installed.
the slip yoke at the transfer case.
CAUTION: 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.
Removing the Engine Package
Remove the engine package as follows:
1. Turn the master battery isolation switch
to the “OFF” position.
5. Remove the brake accumulator and

mounting bracket (ST1010 only).
6. Turn the filter fuel line inlet valve to the
off position. Turn the fuel tank valve(s)
to the off position.
7. Disconnect the inlet fuel line from the
fuel filter block.
8. Disconnect the wiring harness from the
2. Remove the engine hoods. engine ECM
9. Disconnect the air intake tubes from the
air cleaner to the engine.
10. Disconnect the exhaust and turbo tubes.

Power Unit
11. Remove the four (4) engine cradle bolts. 2. While watching carefully to make certain
that it does not catch on any engine com-
partment 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.
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
12. Use the lifting eyes to hoist the engine rear engine mount (left and right) to the
package out of its compartment. The lift- power frame, but do not tighten.
ing eyes are bolted to the engine, two (2)
at the rear right and left hand sides, and 5. Inspect the engine position. If it is in the
on the front engine cooler brace. correct position, tighten the four engine
mount bolts to their proper torque. See
13. While watching carefully to make certain the torque chart in the Specifications sec-
that it does not catch on any engine com- tion of this manual.
partment items, lift the engine clear of
the engine compartment and place it 6. Remove the chains, spreader bar, and
securely on blocks or a support structure hoist from above the engine.
on the floor. 7. Reinstall the engine-transverter drive-
line.
Reinstalling the Engine Package
8. Reconnect the electrical wiring harness
Reinstall the engine as follows: to the engine ECM.
1. Using the same hoist, spreader bar, and 9. Reconnect the inlet fuel line from the
chains as were used for removal, lift the fuel filter block.
engine package from the blocks or sup-
port structure to a point above its posi- 10. Turn the filter fuel line inlet valve to the
tion in the engine compartment. on position. Turn the fuel tank valve(s) to
the on position.
NOTE: Engine cradle grommets (vibration
dampers placed between frame and engine 11. Reinstall the clamp that secures the front
cradle) need to be replaced when worn or end of the exhaust system head pipe to
damaged. the turbocharger.
12. Reinstall the engine hoods.

Power Unit

Section 4 Power Train
Introduction
1 2
3
4 5
9 8
7 6
1. UpBox Transverter
2. Upbox to Transverter Driveline
3. Transverter Transverter Theory of Operation
4. Midship Driveline
5. Rear Axle The transverter is an electronically con-
6. Rear Driveline trolled automatic transmission/torque con-
7. Driveline Support Bearing verter that is employed by a series of push
8. Front Driveline buttons or selector switch located in the
9. Front Axle operator’s compartment. Power from the die-
sel engine is transmitted directly from the
The power train is composed of the follow-
engine flywheel through the upbox (ratio of
ing items:
1:1) to the transverter whose output shafts
• Transverter transmit power via drivelines to the front and
• Upbox rear differentials. The bevel gear and bevel
pinion of each differential convey power
• Drivelines through the differential to the free floating
• Axles axles. The planetary final drive sun gears are
splined to the axles. As the axles rotate,
• Wheels and Tires planet gears, mounted in the carrier, are
forced to walk around the stationary ring

Power Train
gear, imparting rotation to the hub and wheel selects a gear, information is transmitted
which is attached to it. from the selector switch to through the Pro-
grammable Logic Control (PLC) to the
The transverter electrically defaults to neu-
transverter ECU and is stored until the oper-
tral whenever the vehicle is shut off, the park
ator selects a direction. Once the direction is
brake is applied, or if a problem with the
indicated and the park brake is released, the
transverter develops during operation.
transverter automatically steps itself up to
When the operator turns the ignition switch the selected gear as vehicle speed is
to the “ON” position, the transverter Elec- increased.
tronic Control Unit (ECU) begins a self
check, then when the engine is started the Transverter Component Description
transverter is ready for a gear range and
direction selection. When the operator
1 2
1. Transverter Oil Filter • Transverter Electronic Control Unit

2. Transverter (ECU)
3. Output Shaft
• Programmable Logic Control (PLC)/
4. Electronic Control Unit
Gear Selectors
The transverter system is made up of certain
components that work together as one unit. Torque Converter
The following are key parts of the transverter A torque converter is a hydrodynamic sys-
system: tem that transmits energy from an engine to a
• Torque Converter transmission through the use of hydraulic oil.
• Transverter

Power Train
Hydrodynamic systems are based on the activate the direction and speed clutches.
principle that a fluid in motion has force. The regulator valve is a hardened spool in a
A torque converter consists of three ele- tight-fitting bore. A spring keeps the spool
ments: seated until oil pressure overcomes the
spring force. Then the spool moves to expose
• A rotating impeller which causes oil a port through which oil can be directed
within it to flow outward by centrifugal through a line to the converter inlet port.
force.
Once in the converter, the oil is sent into the
• A turbine which is driven by the flowing converter support through the impeller bear-
oil ing.
• A stator to increase torque. The blades of the turbine, impeller, and sta-
The impeller is connected to the engine fly tor are designed to circulate oil from the
wheel. It rotates the entire time the engine is impeller to the turbine, through the stator,
running. The turbine is connected to the and back to the impeller. This circulation
transverter by gears and a prop shaft. makes the turbine and impeller to rotate in
the same direction.
So long as no demand (load) is placed on the
scooptram (transverter is in neutral), the oil, Since the torque converter and the transmis-
the impeller, and the turbine rotate as one sion are combined into one unit oil is passed
mass at whatever RPM the engine is turning. between the two internally.
When a load is applied to the scooptram Transverter
(either the hydraulic or drive train system), it
The transverter uses electrohydraulic valves
reduces the turbine speed. The impeller con-
to control its operation. The solenoids con-
tinues to rotate at the same RPM as the
trolling the transverter clutches (solenoids A
engine. This causes oil to flow from the
through D and 1 through 4) are driven by a
impeller through the turbine.
pulse width modulated signal that produces
The stator intercepts the oil so that its force proportional pressure/flow changes. When a
is redirected against the blades of the impel- gear setting is chosen, the ECU derives pulse
ler in the same direction as the impeller is activation and duration to change the gears
already rotating. This increases torque. or direction.
When the engine is running, a charging Transverter Electronic Control Unit
pump draws oil from the transmission sump (ECU)
and sends it through filters to the pressure
regulating valve in the control cover, which The purpose of the transverter ECU is to
is mounted on top of the transmission. Oil control the functions of the transmission.
travels from the regulating valve to the trans- Upshifting, down shifting, and control of the
mission clutches and to the converter. disconnect are main functions of the ECU.
Other functions include the ability to drive a
The pressure regulating valve is closed until speedometer and the ability to communicate
pressure is applied to the transmission to with a diagnostic device. The ECU uses vari-

Power Train
ous information sources to operate. It takes gear changes when the transmission sole-
input from the engine ECM about engine noids open the spools. The transverter sys-
rpm, it receives input from the operator via tem is composed of the control valve, charge
the gear selection controls, and monitors pump, oil filter, and transverter oil cooler.
transmission output. When the operator
selects a gear, a computer program derives Control Valve
the best action to take considering the infor- The control valve directs oil under pressure
mation it has been given. If an error has been to the desired speed or directional clutches.
detected, the ECU will command the trans- A pressure regulating valve maintains the
mission to remain in neutral. Also if a prob- proper pressure needed to actuate the
lem develops during operation of the vehicle, clutches.
the ECU will automatically ramp down to
neutral. If no errors exist, the transverter When the transverter direction switch is in
ECU will calculate a speed ratio between the the neutral position, with the engine running,
engine rpm and the transverter output and the direction selector spool assembly in the
shift to the appropriate gear. If the operator control valve blocks the flow of oil from the
selects third gear, the transverter will shift pressure regulating valve. Shifting the trans-
from neutral to first then second and finally mission control lever to either forward or
third as the vehicle is accelerated. Also if the reverse moves the direction selector spool
direction is changed by the operator, the accordingly, allowing hydraulic oil to the
transverter ECU will shift down to neutral as appropriate clutch. Shifting the transmission
the vehicle slows, then change directions (or speed) control lever moves the speed
when the vehicle has stopped. selector spool accordingly, allowing hydrau-
lic oil to the appropriate clutch.Once in the
Programmable Logic Control (PLC) and clutch drum, oil goes to the rear of the piston
Transverter Selector Switches bore, forcing the piston and disc against the
back-plate. This forces the disc to engage,
The PLC is a computerized module located
locking the clutch drum and drive shaft
behind the dash in the operator’s compart-
together, so they turn as a single unit.
ment. It takes input from the operator
through the gear selector switches and trans- Charge Pump
fers the information to the transverter ECU.
The PLC is also responsible for operation of The transverter charge pump is directly
the park brake system. mounted on the converter and supplies the
converter with 50 gpm (189 liter/m) of oil @
The gear selection switches are either push 2000 rpm.
button type or selector lever that allows the
operator to interface with the transverter. Transverter Oil Filter
After oil leaves the charging pump and
Transverter System before it moves to the pressure regulating
The transverter system is lubricated with valve, it is sent through a filter to remove
hydraulic oil that is also used to actuate the impurities from the fluid.

Power Train
This is a 10 micron filter and should be returned to its original position and oil to the
changed each time the system oil is changed clutch is supplied at normal operating pres-
or as indicated by the service indicator. sure.
Transverter Oil Cooler
Towing
The friction of torque multiplication in the
WARNING: Towing this vehicle
torque converter causes the oil to heat up, so
improperly can cause serious injury
it is routed to the transmission sump through ACW00073.pict
or death. If this vehicle is disabled,

an oil cooler and lubrication distributor
block the front and rear of each wheel and
which bring the oil back to normal operating
use the recommended procedure in this man-
temperature.
ual.
The transverter cooler is mounted on the
The following instructions are for moving
midship compartment door and air is sucked
the disabled vehicle a short distance to a safe
through it by an oil driven fan.
repair area. If the Scooptram must be moved
To insure proper cooling of the transmission a long distance, transport it on a suitable
circuit, the cooler must be inspected daily to trailer.
assure it is not damaged or leaking. It should
IMPORTANT: Do not tow vehicle more
be cleaned weekly to avoid a build up of dirt
than one mile. Do not exceed 3.3 km/hr (2
that can restrict the flow of air past the cool-
m.p.h.)
ing fins.
1. Block the vehicle at all wheels to prevent
The best method for cleaning the oil cooler is
movement.
to use a high-pressure steam jet. A cold
cleansing agent will also work if allowed to 2. It is recommended that the towing vehi-
soak in properly before being hosed off with cle be at least as big as your scooptram.
a strong water jet. The towing vehicle must have enough
brake capacity, weight and power to con-
Note: When using a cold water or steam
trol both vehicles considering the terrain
spray, make sure to cover the injection pump,
and distance involved.
alternator, voltage regulator and starter
motor as protection. After wet-cleaning, let 3. Inspect the towing bar or towing cable to
the engine run long enough to evaporate all make sure there is no damage and that
water to avoid rust problems. the bar or cable is in good condition.
Make sure that the bar or cable is strong
Compressed air can be used for dry-cleaning
enough for the towing conditions taking
by starting from the exhaust-air side. Clean
into consideration whether the towed
all dirt blown into the air cowling space after
vehicle is loaded, unloaded, on a grade,
using compressed air.
or stuck in the mud.
Shell and tube oil coolers should be drained
and cleaned once a year.

Power Train
4. Connect a towing bar or towing cable of 10. Gradually and smoothly begin moving
sufficient size. If towing with a cable, a the vehicle to prevent overloading the
shield must be provided on the towing towing bar or cable.
vehicle and on the truck if an operator is 11. Reapply park brake and chock all wheels
present during the towing operations. when vehicle is parked.
The shield must be strong enough to pro-
tect both operators if the cable should
Checking oil temperature
break.
5. To provide control and braking while The oil temperature of the gear box is moni-
moving the disabled vehicle downhill, a tored by a temperature sensor and gauge. A
larger towing vehicle and a solid towing maximum temperature of 120° C (248° F) at
bar are recommended. The Articulation the converter outlet may not be exceeded.
Lock must be installed in the LOCKED Under normal service conditions, higher
position. Additional vehicles may be temperatures will not be reached, unless a
required at the rear of the disabled vehi- problem exists.
cle. If the temperature exceeds 120° C (248° F),
6. If the disabled vehicle is to be towed the scooptram must be stopped and inspected
downhill and must be steered, it is neces- for external oil leakage. Let the engine idle at
sary to have a towing vehicle at the front 1200 to 1500 RPM with the transverter in
and a vehicle at the rear to control the neutral.
rear of the disabled vehicle. The Articu- Under this condition, the temperature should
lation Lock must be in the STORED drop quickly (in about 2 to 3 minutes) to nor-
position if this procedure is followed. mal values. If this does not occur, there is a
7. Disconnect the front and rear drivelines problem in the system which must be cor-
at the axles. It is important to secure the rected before operations can be continued.
drivelines so they do not interfer with the
spinning of the axle yokes. Checking Control Pressure
IMPORTANT: The transverter will be dam- Clutch pressure should be checked regularly.
aged if the drivelines are not disconnected. A drop in pressure will allow the clutch
plates to slip, which increases friction and
8. Disengage the parking brake. Refer to causes wearout of the clutch disc.
See “SAHR Brake Override Procedures”
in Section 3. Check at low engine idle (500-700 rpm) with
oil temperature 82°-93° C (180°-200° F).
Note: The parking brake must be disengaged Pressure should be between 240-280 psi
before you move the vehicle or damage to the
(16.5-19.3 bar), depending on the model
tires or vehicle may occur.
transverter.
9. Carefully remove wheel chocks.
Attach a calibrated pressure gauge to the
transverter charging pump pressure port.

Power Train
(Refer to the manufacturer’s service manual sure. The clutch that may drop to a lower
for location.) pressure and/or return to original pressure
slower than the others should be suspect and
Start the vehicle and shift into forward (or
reverse), then shift through all the gears. may signal the need to make a pressure test
Record the pressure reading for each gear. with the master gauge.
All speed clutch pressures must be within 5 Note: Larger size clutch packs (usually 1st
psi (.34 bar) of each other. If clutch pressure and 2nd gears), will fall off to a lower pres-
varies more than 5 psi (.34 bar) in any one sure than smaller size clutches (forward and
gear, repair the clutch. reverse and higher gears), and will also
Attach the gauge to the transverter forward return more slowly to the original reading.
Be sure to compare readings of the same size
clutch pressure port and shift direction from
forward to reverse and record the pressure. clutches.
Repeat this test with the gauge attached to
the transverter reverse clutch pressure port. Up Box
Note: Atlas Copco Scooptrams are equipped
with modulated shift transmissions. Do to the 2 3
combination of clutch leakage, piston bleed
orifice flow rate and flow limiting orifices,
directional clutch pressures can be as much
as 30 psi (2.1 bar) lower than system pres-
sure.
Engine speed must remain constant during
the entire leakage test.
Another test that may help warn of failing
clutches before the 5 psi (.34 bar) pressure
variance shows up is the pressure drop test. 1
In this test, the drop in pressure and the
speed of return to original pressure is moni-
tored. When the transmission is shifted into
gear, the needle on the transmission/con- 4
verter 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. 1. Up Box
2. Dipstick
With oil temperature at 82°-93° C (180°-
3. Engine to Transverter Driveline Coupling
200° F) and the engine at idle, go through
4. Upbox Bell Housing
each gear and note the drop in pressure and
the speed of recovery back to original pres-

Power Train
The upbox transfers engine output over the slightly. It does this to compensate for the
front driveline, allowing the scooptram to working action of the universal joint as it
maintain its low height clearance. The up rotates. The slip joint accommodates these
box transmits engine output on a one to one variations by telescoping at the spline por-
ratio to the transverter. tion of the shaft. The slip joint shaft is partic-
The upbox is composed of a Drive Plate, a ularly necessary in the swivel hinge area of
Pump Pad, and the Driveline Coupling. The the scooptram; the articulation point of the
drive plate is the engine mounting area and scooptram which allows the scooptram to
shaft, a flex plate between the engine and turn. The drive shaft’s telescoping feature
upbox disperses engine vibration. The pump eliminates tension forces that could develop
in conventional drive shafts.
pad is a hydraulic pump mount on the upbox
housing. On the Scooptram, the SAHR brake
variable displacement axial piston pump is Component Description
mounted to the pump pad. The driveline cou- Universal Joint Bearings
pling provide the engine output connection
to the engine to transverter driveline.
Drivelines
Theory of Operation
The purpose of the driveline is to transmit
power from the engine to the drive axles.
Atlas Copco Wagner equipment uses both
non-telescoping and telescoping drive shafts,
and drive shaft support bearings. All of the Universal joints employ various types of
drive shafts have a universal joint located at bearing tap assemblies. They are specified
each end to permit pivoting, and accommo- on any particular scooptram based on their
date angularity between two (2) intersecting torque loading capabilities.
shafts. Telescoping shafts have a splined slip
joint to compensate for movement between
the connected components.
During normal operation, the chassis,
engine, transverter, and axles all experience
some movement relating to surface irregular-
ities and varying stress loads. Each time
these conditions are encountered, a change in
the overall length of the drive shaft occurs.
When a telescoping shaft runs at an angle to
its mating shaft or yoke, it will slip in and out

Power Train
Driveline Support Bearings by positioning of the two threaded adjusting

nuts mounted in the differential carrier and
cap assembly. The tapered roller pinion bear-
ing pre-load is adjusted and maintained by a
hardened and precision ground spacer posi-
tioned between inner and outer bearings.
Secondary Reduction
In the wheel hub, a self-centering sun gear is
spline fitted to the axle shaft and drives three
1
planetary pinion gears. These gears in turn
mesh with and react against a rigidly
1. Driveline Support Bearing mounted internal ring gear. The planet gears
Drive shaft support bearings are used at loca- rotate on needle roller bearings mounted on
tions where a driveline passes through a hardened and ground pins located in the
frame bulkhead, usually at the amidships planet carrier which in turn drives the wheel
area; or in the middle of a long span. hub. Positive lubrication keeps all moving
parts bathed in lubricant to reduce friction,
Driveline support bearings are generally heat, and wear.
flange type bearings that are bracket
mounted to a frame cross member.
Wheels And Tires
These bearings require regular lubrication
and are provided with lube fittings for that General
purpose. Most support bearings are lubri-
cated directly, but in some cases a remote Tires are the single most expensive mainte-
access lube line and fitting is installed for nance item on a scooptram. As a result, an
convenience of servicing. effective wheel and tire maintenance pro-
gram can pay big dividends in improved pro-
ductivity and longer tire life.
Axles
The material in this section will not attempt
The front and rear axles have spiral bevel to establish a detailed tire maintenance pro-
type ring gear and pinion with further reduc- gram, but will identify several major areas to
tion provided by planetary gear set within consider in establishing your own mainte-
the wheel hub. nance program. They include: Road Mainte-
Primary Reduction nance, Wheel and Tire Inspection and
Maintenance, Air Pressure Inspection, and
The spiral bevel pinion and ring gear trans- Tire Sizing Policy.
mit power through the center differential pin-
ions, side gears, and to the axle shaft. The Other areas not included in this section, but
spiral bevel differential assembly is mounted must be included as an integral part of any
on tapered roller bearings which are adjusted maintenance programs, are: Records Mainte-

Power Train
nance, Personnel Training (both mechanic Inspection And Maintenance

and driver), and Wheel and Tire Handling
Equipment. Tires
Road Maintenance
Efficient and systematic maintenance of
haulageways is very important, but is usually
overlooked as a means of improving tire life.
Conscientious maintenance prevents excess
road crown and ensures prompt repair of ruts
or chuckholes, and removal of rock spillage
or sharp objects imbedded in the road sur-
face. Maintaining proper drainage of the
haulageway will prevent water from accu-
mulating and hiding tire damaging road haz-
ards.
Maintenance of loading and dumping areas
is just as important as the haulageway. The
same hazards outlined above will put a tire
out of service just as quickly in these areas as
on the haulageway.
Failure to make regular inspections and

repairs when needed will result in unrepair-
able damage to the cord body.
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.

Power Train
The sides of the cavity should be slanted sized fender bolts can be another cause of
enough to prevent stones from wedging into premature wear.
it. Tires with tread cuts treated in this manner
may be continued in service without danger Wheels
of further growth of these injuries. Wheels should be visually inspected for
Large cord body breaks over 1/3 of the width signs of rust, cracking or other damage that
of the tire cannot be economically repaired would reduce their reliability. If any of these
for use in normal service. conditions are observed, take the necessary
corrective action. Damaged wheels under
When the damage is repairable, it should be pressure are dangerous and can cause severe
determined whether the anticipated remain- personal injury.
ing service life of the tire justifies the cost of
the required repair. Tire repair records have Air Pressure Maintenance
shown that the older the tire, the less service
is received from repairs. Recommended Tire Pressures
Keep tires free from oil, grease, and fuel. A maintenance program that ignores fre-
Rubber quickly absorbs petroleum products quent checking of tire inflation pressures can
and then swells and becomes soft and cause the tire to operate at temperatures
spongy. The damage is permanent and fatal. which exceed the tire capabilities and may
Never clean tires with petroleum products or result in premature tire failure.
allow tires to stand in puddles of (or areas
A slow loss of inflation pressure is normal.
saturated with) petroleum products. If a
Unless lost pressure is restored, there will be
petroleum product does get on a tire,
a reduction in tire service life. Measure pres-
promptly flush off or wipe off with water.
sure when tire is cold.
Maintain ample tire-to-scooptram clearance.
Inflation pressures are based on the standard
Maintenance personnel should carefully
scooptram configuration; a 8 kph (5 mph)
check all tires on each scooptram to make
maximum speed; and the off-road rating by
sure the tires will not rub against any part of
the Tire and Rim Association, Inc.
the scooptram, either on straight-away driv-
ing or on turns. Failure to ensure ample Proper Inflation
clearance results in premature tire replace-
ment. The importance of correct inflation in off-
road tires cannot be over-emphasized. Poor
Wedged stones are one source of trouble. tire maintenance almost always results in
Proper maintenance requires stones or other underinflated tires, and, therefore, unneces-
objects which have become wedged between sary tire expense.
the tire and scooptram to be removed
promptly to prevent serious tire damage. A Over-inflation results in:
permanent rock “kicker” should be installed 1. Excessive cutting.
on the scooptram, if necessary. Improperly
2. Lower impact resistance.

Power Train
3. Rapid center wear. with less air in it will have to turn more revo-
4. Cut growth. lutions to cover a given distance than the tire
with more air in it.
5. Poor re-treadability.
Other reasons for a difference in the rolling
Under-inflation results in: radius would be the use of different sized
tires, or unequally worn tires, on the vehicle.
1. Ply and tread separation as a result of
excessive heat build up. Atlas-Copco Wagner, Inc. recommends that
the tire rolling radius tolerances be matched
2. Cracking and excessive flexing.
as shown in the following table:
3. Bead failures from excessive strain.
Note: If the mis-match is larger than 2%,
4. Tubeless liner separation from heat. one side of the no-spin will disengage (the
5. Rapid wear from tread disfiguration. smaller tire). The other side will carry all of
the torque.
6. Rapid wear from heat, reducing the cut
resistance and wearing ability of the Example:
tread rubber compound. 30" RR tire +/- 4% = 31.2" RR to 28.8" RR.
Tire Rolling Radius Driving Practices

Another important item to consider in your A proper tire maintenance program and
tire maintenance program is the rolling maintaining haulageways in good condition
radius of the tires on a vehicle. cannot guarantee optimum service life of
IMPORTANT: NEVER put different sized tires. Poor driving practices are a major
tires on a scooptram. cause of excessive wear and permanent dam-
age.
When the rolling radius of tires on the same
axle is different, they are not traveling at the Drivers can help to reduce tire costs by:
same speed. The tire with the smaller rolling Avoiding obstacles and keeping away from
radius is traveling faster than the one with chuckholes or other hazards, which can dam-
the larger rolling radius. This sets up a con- age tires.
tinuous stress on the axle components which
is relieved by tire skid. When the rolling Not climbing or driving up on the ore pile.
radius difference occurs between the front Such practice subjects tires to cutting and
and rear axles on a four-wheel drive vehicle concentrated impact. Operators should lower
this additional stress is amplified throughout the bucket when approaching the ore pile, to
the entire drivetrain. clear the work area.
Improper inflation is the most common Preventing excessive braking. Heat devel-
cause of a difference in rolling radius. Two oped by braking may be transferred to the
identical tires which are not equally inflated beads (and/or inner liner of tubeless tires),
will have a different rolling radius. The tire

Power Train
causing these areas to become charred or tor. The cooling system is bolted to the mid-
cracked. ship compartment door. Air is pulled through
the radiator system by a fan that is driven by
Not letting tires rub against side walls or
hydraulic oil passing through its turbines. To
against barriers erected to facilitate unload-
ing. remove the cooling radiator:
1. Secure the compartment door and place
Avoiding taking turns at high speeds and
suitable containers to collect hydraulic
driving in the lowest gear applicable.
oil, transverter oil and fuel.
The driver who drives carefully and who
2. Drain the cooler system, making sure
makes a reasonable attempt to prevent tire
that the fuel and oils are separated.
damage saves a substantial amount of money
on tire costs. 3. Remove the bolts holding the radiator
system in place.
Removal & Replacement 4. Carefully lower the radiator system to a
stand on the shop floor.
Transverter/Accessories
Replacing the Transverter Cooling
Wherever possible, procedures are presented Radiator
in the sequence required for orderly removal;
that is, if an item must be removed before Replace the radiator by reversing the
another item can be removed, the first item is removal steps.
covered first. Removing the Transverter
WARNING: Block all wheels, set
Remove and replace the transverter assembly
the parking brake, remove the key
as outlined in the following paragraphs.
from the ignition switch, and place
a “Do Not Operate” tag in the NOTE: It is important to identify and label
operator’s compartment before performing all hoses and wiring prior to removing them
maintenance on the power train systems. from the transverter. This will allow the
speedy re-installation of the transverter.
CAUTION: If the scooptram has been in
operation within the previous hour, the tem- 1. Remove the rear driveline from under the
perature of the engine, the engine cooling scooptram.
and exhaust systems, and the transverter 2. Place a suitable container below the
components can be high enough to cause transverter and drain the oil. After the oil
serious burns. Allow all components to cool is out of the transverter, replace the drain
before initiating removal procedures. plug.
Transverter Cooling System 3. Disconnect and cap the hoses to the

cooler fan assembly and remove the
The transverter cooling system consists of cooling fan assembly and compartment
the transverter oil radiator, the fuel cooling hood.
radiator, and the hydraulic oil cooling radia-

Power Train
4. Remove and cap the hydraulic hoses to stand and, taking care that it does not
the pumps and transverter. It may be nec- catch on anything, lower it into the
essary to remove all hoses in the trans- power frame until the mounting brackets
verter compartment. set solidly on the frame.
5. Remove the upper cross-member that is 2. Remove the hoist, transverter lift
situated in the midship compartment. spreader bar, chains, and lift fittings.
6. Disconnect the wiring harness from the 3. Reinstall the bolts that secure each trans-
transverter and lay aside. Make sure the verter mounting bracket to the power
harness is clear of the working area. frame.
7. Disconnect the engine to transverter 4. Reinstall the driveline sections.
driveline from the transverter.
5. Reconnect the electrical harness to the
8. Disconnect the midship and rear drive- transverter.
lines.
6. Reinstall the dump/hoist, steering, and
9. Remove the bottom and top mounting brake pumps. Reconnect the hydraulic
bolts. lines and their retainer clamps to the
10. Attach a lift eye to the front plate of the pumps.
transverter. Use the threaded holes 7. Uncap or unplug and reinstall the
behind the dip-stick mounting bracket. hydraulic lines and their retainer clamps
11. Use the top lift eyes to hoist the trans- that run above the transverter.
verter unit out of its compartment. 8. Fill the transverter with proper oil.
NOTE: It is important to make sure that the 9. Replace the transverter/hydraulic/fuel
transverter hoisting chains are adjusted so cooling radiator and the lines that feed
that the transverter is lifted evenly out of the the radiator, ensuring that the retaining
compartment. clamps are also reinstalled to the appro-
12. While lifting the transverter out of the priate hose.
vehicle, take care to ensure the unit does 10. Reinstall the hood above the transverter
not catch on any hydraulic hoses or wir- compartment.
ing.
11. After starting the engine, check the trans-
13. Place the transverter in a safe location on verter oil level and leaks in the system.
a stand or on the shop floor.
Upbox Assembly/Disassembly
Reinstalling the Transverter
Procedures
Install the transverter as follows:
Removing the Upbox from the Engine
1. Using the same hoist, spreader bar,
chains, and lift fittings as used in It is not necessary to remove the engine in
removal, lift the transverter from its order to remove the upbox. The following

Power Train
steps assume that the engine is still in the 5. Remove the bolts that hold the hydraulic
machine. fan in place. Lift the fan and secure so
that it does not interfere with upbox
WARNING: The upbox is
extremely heavy. A hoist rated for removal.
the weight of the upbox must be
used to lift the component from the
machine. Care must be taken to avoid injury
while removing the upbox.
1. Park the Scooptram on a flat level sur-
face.
2. Set the Parking brake and shut the engine
off.
3. Chock the tires. Let the engine cool
down until it is safe to remove the upbox. 6. Remove the upbox driveline guard.
WARNING: The upbox operates at 7. Disconnect the upbox to transverter driv-
high temperatures. Care must be eline at the upbox end. Secure the drive-
taken when removing the upbox. line out of the way so it does not interfere
4. Open the cooler fan hood and secure it so with the upbox removal.
that it is not in the way of the upbox area.
8. Disconnect and cap the fire suppression

hoses (if equiped) and secure them out of
the way.

Power Train
9. Unbolt the upbox bell housing. 5. Remove the bolts and washers holding
the housing halves together. Separate the
housings.
6. Remove the gear assemblies. Record
which assemblies are located at each
location in the housing.
7. Remove the shaft seals.
8. Scrape the gasket material off of the cast-
ing halves.
9. Remove bearing cups in the housing at
10. Attach a lifting harness to the upbox and each location where a new gear/shaft
lift the upbox slightly to loosen it from assembly will be installed. If there are no
the engine. race removal holes in casting, the cup
11. Pull the upbox away from the engine will need to be pried out of the casting.
until the gear shaft is no longer in the 10. Identify the number and thickness of
coupler. shims under bearing cup. Record the
12. Lift the upbox out of the upbox compart- total shim thickness for each bearing cup
ment. removed.
13. Place the upbox on a suitable stand or the Upbox Assembly Procedures
floor. Take care not to prop the upbox in IMPORTANT: Assembly should be done in
a manner where it might fall. a clean area to prevent contamination of the
Installing the Upbox on the Engine ccomponents.
To install the upbox, follow the removal pro- NOTE: Make sure all castings and compo-
cedure in reverse. Torque the bell housing nents are clean and free of oil before
bolts to 45 N-m (33 ft-lb). attempting assembly of the upbox.
1. Install the new shims into casting hous-
Upbox Disassembly Procedures
ing at each location where a new cup will
1. Follow the procedures to remove the be installed. The thickness of the shims
upbox from the engine. should equal the thickness of the shims
removed from the pocket recorded dur-
2. Drain the oil from the upbox by remov-
ing disassembly.
ing the drain plug.
2. Install the new bearing cup in the hous-
3. Remove the engine adapter and adapter
ing. Be sure that the cup is pressed fully
ring.
into housing until seated against shims
4. Remove the mechanic’s flange. against housing shoulder.

Power Train
3. Insert one gear/shaft assembly into gear- 12. Install new shaft seals, one on each input
box and output position. Use some sort of
4. Install the dowel pins, bolt casting halves protector over the splines to prevent seal
together, and torque the bolts to 35 - 40 from being damaged. Be certain the seal
ft-lbs. (no Loctite is needed at this time) lip is property engaged with the shaft
diameter. Use Loctite Superflex on seal
5. To check bearing preload, measure rota- O.D.
tional torque of the input gear/shaft
assembly in the housing. The torque 13. Install adapter ring.
reading should be between 10 - 30 in lbs. 14. Mount the engine adapter housing
6. If torque is not within the specified (engine side). Install 3/4-1 0 bolts and
range, remove cup and adjust shim thick- torque to 230 - 250 ft-lbs.
ness. Each 0.001 inch of shim is approxi- 15. Before installing mechanics flange, lube
mately 3 in lbs of rotational torque. spline with Mobil grease Moly 52. Install
7. Remove bolts and washer holding cast- mechanics flange. Prime and apply Loc-
ing housing together and separate. tite 262 to threads. Torque 3/4-1 0 bolts
to 230 - 250 ft-lb.
8. Repeat steps 5 through 9 until all bearing
pockets have correct bearing preload. 16. Fill unit with HD 8OW90 oil to full mark
on oil level indicator.
9. Lay one side of the housing face down.
Insert all gear/shaft assemblies into the Drivelines
housing bearing cup (same locations
used in steps 5-9), including new gear/ Most driveline sections are removed and
shaft assemblies. replaced in somewhat similar manners.
However, for ease in locating procedures and
10. Clean mating surfaces of both housing precise coverage of minor differences, the
halves. Install dowel pins. Prime both following paragraphs contain procedures for
casting halves and apply Loctite 515 each driveline section.
Gasket Eliminator to one (1) housing
half. CAUTION: Removing any driveline section
reduces the effectiveness of the parking
11. Position housing halves together. Insert brake. Make certain that all wheels are
3/8-16 socket head cap screws with blocked securely before removing a driveline
washers and tighten. Torque to 35 - 40 ft section.
lbs.
Note: In each of the following replacement
procedures, the procedure assumes that the
scooptram is in the same condition and posi-
tion as at the conclusion of the associated
removal procedure.

Power Train
Phasing the Driveline Yokes and Bearing Mounts

Note: 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.
Yokes Must Be In Line 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.
2. Insert the key of the opposite bearing cap
into the yoke. The bearing cap has
machined surfaces keyway, so some
When a splined shaft is assembled to a slip
compression of the seals may be required
yoke, splines must be aligned so that the
to seat the second bearing. This can be
yokes at either end of the shaft are in the
done using a C clamp, tapping with a soft
same plane, that is “in phase”. When the
hammer, or by using hand pressure.
shaft is assembled with the yokes in different
planes, the driveline will be “out of phase”. Note: Do not use bearing mounting cap-
Drive shafts are phased and balanced at the screws as jacking screws in order to seat the
Factory and are “marked” for correct assem- bearing in the yoke.
bly with match marks at the yoke flange ends 3. Once the bearings are properly seated,
and on the propeller shaft. insert the capscrew fasteners and torque
Lubricate the splines thoroughly, and prop- them to the proper values using a suitable
erly assemble and “phase” the shaft. Mis- torque wrench.
phasing the drive shaft can cause vibrations Note: Do not use lockwashers, lockplates or
throughout the driveline, contributing to lockwire to secure the fasteners. These
bearing failure. devices will not prevent the fasteners from
Installing the Drive Shaft loosening. Proper torquing is the most reli-
able method of securing fasteners.
Install drive shafts with the slip yoke toward
the source of power (torque). Reverse instal- Installing Driveline Guards
lation if doing it provides better access to the Driveline guards help restrain a drive shaft
lube fitting on the slip yoke. when a universal joint fails. The guard pre-
Note: The lube fitting on each of the univer- vents the drive shaft from rotating out of
sal joints and the fitting on the slip yoke control within the frame of the scooptram
should all be on the same side of the shaft for and damaging other components, and caus-
ease of servicing. ing possible injury to personnel.
If the scooptram does not have driveline
guards, it is recommended that these devices

Power Train
be fabricated and installed on the scooptram, 2. Reinstall the bolts that secure the rear
or ordered from Atlas Copco Wagner, Inc. universal joint cross to the transverter
input shaft yoke, but do not tighten yet.
WARNING: Always make sure
Remove the tape from the bearings on
there is a driveline guard installed
the cross.
around or over the midship drive
shaft. This guard provides protec- 3. Remove the bolts that secure the rear
tion for the operator. universal joint cross to the transverter
front output shaft yoke. Make certain that
Upbox to Transverter Driveline the tape holds the bearings in place on
Remove and replace the converter to trans- the cross.
verter driveline as outlined in the following 4. Reinstall the bolts that secure the front
paragraphs. universal joint cross to the converter
Removal: yoke, but do not tighten yet. Remove the
tape from the bearings on the cross.
1. Wrap several layers of masking tape
around the bearings on the front univer- 5. Reinstall the bolts that secure the drive-
sal joint cross. line carrier bearing to the power frame.
2. Remove the bolts that secure the front 6. Inspect the positions of the bearings. If
universal joint cross to the upbox yoke. all are in the correct position, torque the
Make certain that the tape holds the bear- bolts to their proper setting (see Appen-
ings in place on the cross. dix).
3. Wrap several layers of masking tape Transverter to Front Axle Driveline

around the bearings on the rear universal Remove and replace the transverter to front
joint cross. axle driveline as outlined in the following
4. Remove the bolts that secure the rear paragraphs.
universal joint cross to the transverter Removal:
input shaft yoke. Make certain that the
tape holds the bearings in place on the 1. Wrap several layers of masking tape
cross. around the bearings on the front univer-
sal joint cross.
5. Remove the driveline section.
2. Remove the bolts that secure the front
Reinstallation:
universal joint cross to the front axle
1. Place the upbox to transverter driveline input shaft yoke. Make certain that the
section in approximate position. 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.

Power Train
4. Remove the bolts that secure the rear 3. Wrap several layers of masking tape
universal joint cross to the transverter around the bearings on the rear universal
front output shaft yoke. Make certain that joint cross.
the tape holds the bearings in place on 4. Remove the bolts that secure the rear
the cross. universal joint cross to the oscillator
5. Remove the driveline section. front yoke. Make certain that the tape
holds the bearings in place on the cross.
Reinstallation:
5. Remove the driveline section.
1. Place the transverter to front axle drive-
line in approximate position. Reinstallation:
2. Reinstall the bolts that secure the rear 1. Place the midship driveline in approxi-
universal joint cross to the transverter mate position.
front output shaft yoke, but do not
2. Reinstall the bolts that secure the rear
tighten yet. Remove the tape from the
universal joint cross to the oscillator
bearings on the cross.
front yoke, but do not tighten yet.
3. Reinstall the bolts that secure the front Remove the tape from the bearings on
universal joint cross to the front axle the cross.
input shaft yoke, but do not tighten yet.
3. Reinstall the bolts that secure the front
Remove the tape from the bearings on
universal joint cross to the transverter
the cross.
rear output shaft yoke, but do not tighten
4. Inspect the positions of the bearings. If yet. Remove the tape from the bearings
all are in the correct position, torque the on the cross.
bolts to their proper setting (see Appen-
4. Inspect the positions of the bearings. If
dix).
all are in the correct position, torque the
Midship Driveline bolts their proper setting (see Appendix).
Remove and replace the midship driveline as Midship-to-Flange Bearing Driveline
outlined in the following paragraphs.
Remove and replace the midship-to-flange
Removal: bearing driveline as outlined below.
1. Wrap several layers of masking tape Removal:
around the bearings on the front univer- 1. Wrap several layers of masking tape
sal joint cross. around the bearings on the front univer-
2. Remove the bolts that secure the front sal joint cross.
universal joint cross to the transverter 2. Remove the bolts that secure the front
rear output shaft yoke. Make certain that universal joint cross to the oscillator rear
the tape holds the bearings in place on yoke. Make certain that the tape holds
the cross. the bearings in place on the cross.

Power Train
3. Wrap several layers of masking tape 3. Wrap several layers of masking tape
around the bearings on the rear universal around the bearings on the rear universal
joint cross. joint cross.
4. Remove the bolts that secure the rear 4. Remove the bolts that secure the rear
universal joint cross to the axle input universal joint cross to the axle pinion
shaft yoke. Make certain that the tape shaft yoke. Make certain that the tape
holds the bearings in place on the cross. holds the bearings in place on the cross.
5. Remove the driveline section. 5. Remove the driveline section.
Reinstallation: Reinstallation:
1. Place the driveline in approximate posi- 1. Place the driveline in the approximate
tion. position.
2. Reinstall the bolts that secure the rear 2. Reinstall the bolts that secure the rear
universal joint cross to the axle input universal joint cross to the axle pinion
shaft yoke, but do not tighten yet. shaft yoke, but do not tighten yet.
Remove the tape from the bearings on Remove the tape from the bearings on
the cross. the cross.
3. Reinstall the bolts that secure the front 3. Reinstall the bolts that secure the front
universal joint cross to the oscillator rear universal joint cross to the axle output
yoke, but do not tighten yet. Remove the shaft yoke, but do not tighten yet.
tape from the bearings on the cross. 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 4. Inspect the positions of the bearings. If
bolts to their proper setting (see Appen- all are in the correct position, torque the
dix). bolts to their proper setting (see Appen-
dix).
Flange Bearing to Front Axle Driveline
Remove and replace the flange bearing to Axles
front axle driveline as outlined below.
Note: In each of the following replacement
Removal: procedures, the procedure assumes that the
scooptram is in the same condition and posi-
1. Wrap several layers of masking tape tion as at the conclusion of the associated
around the bearings on the front univer- removal procedure.
sal joint cross.
Front Axle
2. Remove the bolts that secure the front
universal joint cross to the axle output Remove and replace the front axle as out-
shaft yoke. Make certain that the tape lined in the following paragraphs.
holds the bearings in place on the cross.

Power Train
Removal: Rear Axle

1. Relieve all pressure from the hydraulic Remove and replace the rear axle as outlined
system by venting at the breather and/or in the following paragraphs.
loosening the tank cap.
Removal:
2. Disconnect the flange bearing to front
axle driveline from the front axle. 1. Bleed all pressure from the hydraulic
system by venting at the breather and/or
3. Disconnect the brake and brake cooling loosening the tank cap.
lines from the wheel ends. Immediately
cap or plug each line or connection. 2. Disconnect the transverter to rear axle
driveline.
4. Place a hoist above the axle and rig a
sling to lift the axle. 3. Disconnect the brake and brake cooling
lines from the wheel ends. Immediately
IMPORTANT: Be sure the hoist is capable cap or plug each line or connection.
of lifting the axle.
4. Place a hoist above the axle and rig a
5. Remove the nuts from the bolts that sling to lift the axle.
secure the axle to each side of the axle
hanger. IMPORTANT: Be sure the hoist is capable
of lifting the axle.
6. Lift the axle and place it on the axle
stand. 5. Remove the nuts from the bolts that
secure the entire axle assembly, which
Reinstallation: includes the oscillating cradle, to each
1. Using the same hoist and sling used in side of the axle hanger.
removal, lift the axle from the axle stand 6. Lift the axle assembly and place it on the
and set it in place. axle stand.
2. Reinstall the bolts that secure the axle to Reinstallation:
each side of the hanger and tighten but
do not torque the nuts at this time. 1. Using the same hoist and sling used in
removal, lift the axle assembly from the
3. Torque the nuts to their proper setting, axle stand and set it in place.
then install a lock nut over the nut on
each of the bolts and torque it to its 2. Reinstall the bolts that secure the axle
proper setting. See Appendix for the assembly to each side of the hanger and
appropriate bolt torques. tighten but do not torque the nuts at this
time.
4. Uncap or unplug and reconnect the brake
and brake cooling lines. 3. Torque the nuts to their proper settings,
then install a lock nut over the nut on
5. Reinstall the flange bearing to front axle each of the bolts and torque it to its
driveline to the front axle. proper setting. See the torque table in the
Appendix for proper settings.

Power Train
4. Uncap or unplug and reconnect the brake cover plate.

and brake cooling lines.
5. Reinstall the transverter to rear axle driv-
eline to the rear axle.
SAHR Brake Assembly/Disassembly

Disassembly
WARNING: The procedures
described here must be followed
exactly. Failure to do so may result
in personal injury. High internal spring ten-
sions are basic to the SAHR brake’s design.
This makes improper disassembly of the
brake unit very dangerous. Have all neces-
sary tools available and be familiar with the
procedures before starting the disassembly.
CAUTION: The front cover and backing
plate must be “backed out” slowly to relieve
inner spring tension. If these steps are not NOTE: The pictures in this manual illustrate
followed precisely, personal injury may the disassembly/assembly procedures with
result! the brake unit dismounted from the axle. If
you are performing these procedures with
NOTE: The front cover is under spring pres- the brake assembly still mounted on the axle,
sure for approximately the first inch of bolt make certain to exercise care in keeping all
travel unless pressure (1500 psi) is applied parts as clean as possible to avoid contami-
to release the brake. If pressure is applied to nation.
the brake (by using a port-a-power, for
example), the bolts can simply be loosened 2. Remove quad sealing ring from the hous-
and removed. ing.
1. Back-out the bolts from the front cover

plate by loosening each bolt 1/2 to 1 turn
at a time in a crisscross pattern until all
bolts are removed. Then lift off the front

Power Train
3. Remove disks from the brake housing. 5. Begin by removing every other bolt.
Then slowly release the backing plate by
loosening the remaining bolts 1/2 to 1
turn at a time in a crisscross pattern.
Make certain to criss-cross when loosen-
ing the bolts to minimize stress on the
backing plate. Continue slowly loosening
the bolts 1/2 to 1 turn at a time until all
but three or four equally spaced bolts are
removed. These bolts will hold the unit
together when you flip it over.
4. Flip the brake assembly over.
6. Once you’ve flipped the unit over,

remove the remaining bolts and lift the
CAUTION: This step will release the spring housing off the springs and backing
force, proceed with care. plate.

Power Train
7. Remove springs from the brake housing. 10. Tap the piston from the housing with a
rubber mallet. Separate the piston from
the housing.
8. Remove the 0-ring from the backing

plate.
11. Remove outer piston seal & expander

ring from the piston.
9. Remove the port 0-rings from the brake

housing.

Power Train
12. Remove inner piston seal and expander Check for cracks or other conditions which
ring from the housing. could result in oil leaks or failure.
Piston and Housing Seals
You should always use new Atlas Copco

Wagner replacement seals when rebuilding
the SAHR brake. Handle all sealing mem-
bers carefully. Cutting, nicking, or over-
stretching can result in premature failure.
Assembly of the SAHR Brakes
1. Install expander ring and outer piston
seal in the piston. Do not over-stretch or
cut the rings.
Cleaning and Inspection

Cleaning
Clean all parts thoroughly using a solvent.

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
2. Install expander ring and inner piston
seal in the brake housing.
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.
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.

Power Train
3. Insert the piston into the brake housing. 5. Insert 0-ring onto backing plate.
Use a press of C-clamps to install the pis-
ton evenly and to prevent seal damage.
The piston must enter the housing
evenly.
6. Insert springs into the backing plate.

There are two sizes of springs. Install so
that the tops are even.
4. Clean all holes in the backing plate.
7. Lower housing & piston assembly onto

backing plate. Be sure to index the hous-
ing to the backing plate so the ports and
dowel holes all line up.

Power Train
8. Insert and partial tighten three or four 11. Install all mounting bolts with Loctite
bolts through the backing plate into the #262.
housing. Evenly space these bolts to dis-
tribute the load as the brake unit is being
turned over.
IMPORTANT: Slowly tighten the backing

plate onto the housing by turning each bolt
1/2 to 1 turn in a criss-crossing pattern. Do
9. Turn the assembly over. not use an impact wrench.
12. Just before the backing plate contacts the
housing, install roll pin(s) through back-
ing plate into mating holes in the hous-
ing. Continue tightening until the
backing plate is snug against the brake
housing.
13. Torque the bolts to 407-447 N-m (300-
330 ft./lbs).
10. Install 0-rings into the port grooves.

Power Train
14. Finish installing roll pins. Then flip the 16. Insert quad sealing ring into the housing.
assembly over.
15. Install stationary and friction disks from 17. Set the front plate back on the housing,
the brake housing. and insert and tighten the bolts. Torque
the bolts to 407-447 N-m (300 -330 ft-
lbs).
CAUTION: Be certain that a stationary disk

is placed against the piston first. A friction
disk against the piston will damage the pis-
ton.
NOTE: To properly secure the front plate to

the housing, either pressurize the brake to
release it and simply install all bolts, or
tighten bolts in a crisscross pattern 1/2 to I
turn at a time.

Power Train
Tire Demounting And Mounting 2. Attach a Do Not Operate tag to the Off/
Procedures On/Start switch.
WARNING: Tire and rim servicing 3. Block wheels not being serviced.
can be dangerous, and should be 4. Using a jack, hoist, or other suitable
done by trained personnel using
ACW00073.pict
method, raise the vehicle until the wheel

proper tools and procedures. to be serviced just clears the ground.
WARNING: Failure to comply with WARNING: Ensure that the method
these procedures may result in faulty used to elevate the scooptram is sta-
positioning of the tire and/or rim,
ACW00073.pict
ble and capable of raising and sup-

ACW00073.pict
and cause the assembly to burst with explo- porting the weight. If the tire being removed
sive force, sufficient to cause serious physi- is on an oscillating axle, be sure to block the
cal injury or death. carrier.
The following illustration shows a cross-sec- 5. Crib or securely block the vehicle before
tion of the wheels. proceeding with wheel removal.
Earthmover rim locking wheel flange with WARNING: DO NOT attempt to
heavy duty driver. remove any rim or wheel compo-
nents such as lugs or wheel clamps
ACW00073.pict
before all pressure in the tire is exhausted. A

broken rim part under pressure can blow
apart and cause severe injury or death.
6. Remove the valve core and exhaust all
air from the tire. Stand clear or to the side
during deflation.
7. Check the valve stem by running a piece
of wire through the stem to make sure it
is not plugged before proceeding with
1. Rim Base Weldment wheel service.
2. Bead Seat
3. Lock Ring
WARNING: DO NOT look into the
4. Flange
valve stem while clearing restric-
5. O-Ring
ACW00073.pict
tions.
6. Heavy Duty Driver 8. Remove the wheel using a hoist and sling
7. Locking Wheel Flange capable of supporting the load.
Demounting CAUTION: Use caution when removing
wheels or heavy rim components. Stand to
1. Connect articulation lock to the frame one side and keep hands and fingers clear
mounts prior to lifting the vehicle. when using demounting tools. The tool may
slip and cause injury.

Power Train
9. Demount tire from wheel using accepted sion and to facilitate inspection and tire
shop practices. mounting. Be very careful to clean all
dirt and rust from the lock ring and gut-
Mounting
ter. This is important to secure the lock
Review safety warnings and cautions for dis- ring in its proper position. A filter on the
mounting before beginning work. air inflation equipment to remove the
moisture from the air line helps prevent
1. Verify articulation locking bar is secured
corrosion. The filter should be checked
between both frame mounts and Do Not
periodically to be sure that it is working
Operate tag is in place on Off/On/Start
properly. Parts must be clean for a proper
switch.
fit, particularly the gutter section which
2. Verify all blocking and cribbing is holds the lock ring in proper position.
securely in place.
2. Check the rim for cracks. Replace all
3. Clean all wheel and hub mounting sur- cracked, badly worn, damaged, and
faces. Remove all dirt, grease or paint severely rusted components with new
before installing wheel. parts of the same size and type. Replace a
4. Replace the wheel using a hoist and sling component when condition is in doubt.
or forklift capable of safely supporting Parts that are cracked, damaged, or
the load. Make sure the valve stem is excessively corroded are weakened. Bent
aligned with any clearance slot in the or repaired parts may not engage prop-
axle hub. erly.
5. Install mounting hardware and secure the 3. Don’t re-inflate a tire that has been run
tire and rim in accordance with the flat without first inspecting the tire, tube,
torque settings specified in the Appen- flap, rim, and wheel assembly. Double
dix. check the side ring, flange, bead seat,
lock ring, and o-ring for damage and
6. Once the tire is mounted, lower the vehi- make sure that they are secure in the gut-
cle to the ground, using jacks, hoists or ter before installation. Components may
other suitable method. have been damaged or dislocated during
7. Remove all cribs and blocks. the time the tire was run flat or seriously
under-inflated.
8. Remove and stow articulation lock.
9. Remove Do Not Operate tag from Off/
On/Start switch.
Inspection
Inspect wheel components for defects,
observing the following precautions:
1. Clean rims and repaint to prevent corro-

Power Train
4. Do not, under any circumstances, 5. Make sure the correct parts are being
attempt to re-work, weld, heat, or braze assembled. If you are not sure about the
any rim components that are cracked, proper mating of rim and wheel parts,
broken, or damaged. Replace them with consult a rim and wheel chart.
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.
2
Correct
2
1
3 3
6
4
1 3
4 Incorrect
1 1 8 2
7
5
8
1 6 4 1
2
5
7
1. Base Improper rim selection can cause these oper-

2. Side Ring ating problems:
3. Proper Fit
• Tire Slippage
4. Lock Ring
5. Improper Fit • Excessive Flexing
6. Flange
• Tube Pinching
7. Loose Fit
8. Bead Seat Too High • Overheating
WARNING: Mismatched rim parts • Valve Stem Tear Outs
are dangerous!!! • Sidewall Failure
• Ply Separation

Power Train
• Blowouts inflated or partially inflated. Properly

Most rims look alike but all vary somewhat matched and assembled components will
in certain design features. It is these differ- seat without tapping. If a part is tapped, it
ences between rims of different types that or the tapping tool may fly out with
make “part mixing” a hazardous business. A explosive force. Check to make sure all
close, proper fit between rim parts is essen- components are properly seated prior to
tial to long tire life as well as to operating inflation.
safety. • Don't hammer on rims or components
Very often side-rings, flanges, and lock rings with steel hammers. Use rubber, lead,
of different types appear to be properly plastic, or brass faced mallets if it is nec-
seated, but actually wide gaps are present, essary to tap un-inflated components
frequently difficult to see. The rim cross-sec- together. The use of steel hammers may
tions above show correct, safe matchings of damage the components being hammered
rim parts, as well as mismatched rings and and cause an improper fit.
bases which almost always create an unsafe • Never sit on or stand in front of a tire and
operating condition. rim assembly that is being inflated. Use a
clip-on fitting or connector with an in-
Mounting and Inflating line valve so that the person inflating the
tire can stand to the side of the tire, not in
Observe the following precautions during front or in back of the tire assembly.
mounting and inflation:
• Stand clear when using a cable or chain
• Inflate all tires in a safety cage, then use sling. The cable or chain may break, lash
safety chains or an equivalent restraining out, and cause injury.
device during inflation. Mis-assembled
parts may fly apart during inflation. • Never attempt to weld on an inflated tire/
rim assembly or on a rim assembly with
• Don’t inflate a tire before all components a deflated tire. Heat from welding will
are properly in place. With the tire in a cause a sudden, drastic rise in pressure
safety cage and safety chains or equiva- which could result in an explosion with
lent restraining devices installed, inflate the force of a bomb. The heat from weld-
to approximately 10 psi (.69 bar). ing can also cause deflated tires to catch
Recheck the components for proper fire.
assembly. If the assembly is not proper,
deflate the tire and correct the problem. • Never mix parts of one type rim with
those of another. Mis-matched parts may
• NEVER hammer on an inflated or par- appear to fit, but when inflated, can fly
tially inflated tire/rim assembly. If the apart with explosive force.
assembly is not proper at 10 psi (.69 bar),
deflate the tire and correct the problem. • Never add or remove an attachment or
Don’t try to seat rings or other compo- otherwise modify a rim (especially by
nents by hammering while the tire is welding or brazing) unless the tire has
been removed and you have received

Power Train
approval from the rim manufacturer. 4. Make certain that all parts are properly
Modification or heating of a rim or one aligned before inflation.
of its parts may weaken it.
1. Install tire on the wheel. Complete
assembly of wheel components.
2. Align driver pockets in bead seat band
and base.
5. When properly aligned, the bead seat

band and pocket will move out and lock
the drive key during inflation.
3. Insert driving key into driver pocket on

base.
6. Mount completed wheel and tire assem-

bly on the axle, then tighten lugs to the
specified torque.
7. Remove cribbing or blocks and lower the
vehicle.

Power Train
8. Check that tire is inflated to the specified 1. Don’t use undersized rims. Use recom-
pressure following the applicable precau- mended rim for tire. Consult catalogs for
tions listed above. proper time/rim matching.
Note: Outboard drivers are on those rims 2. Don’t overload or over-inflate tire/rim
used in high torque and/or low inflation assemblies. Check your rim assemblies if
pressure applications, preventing circumfer- special operating conditions are required.
ential movement of the rim components. Rim Excessive overload can cause damage to
assemblies with an “M” or “L” near the end the tire and rim assembly.
of the style designation (part number) are so 3. Never run a scooptram on one tire of a
equipped.
dual assembly. The carrying capacity of
the single tire and rim is dangerously
Wheel Nut Torque exceeded, and operating a scooptram in
Wheel nuts must be tightened in an alternat- this manner can result in damage to the
ing pattern. rim and tire assembly.
Wheel nuts are to be tightened to the correct 4. Never install a tube in a tubeless tire/rim
torque upon initial installation or reinstalla- assembly when the rim is suspected of
tion on the scooptram. leaking. Loss of air pressure through
fatigue, cracks, or other fractures in a
Wheel nuts are to be checked for correct tubeless rim warns you of a potential rim
torque every four (4) hours for the first failure. This safety feature is lost when
twelve (12) hours of operation. tubes are used with leaking rims. Contin-
Wheel nuts are to be checked for correct ued use may cause the rim to burst with
torque every eight (8) hours for the next explosive force.
thirty-two (32) hours of operation. Thereaf- 5. Always inspect rims and wheels for dam-
ter, check wheel nuts every one hundred age during tire checks. Early detection of
(100) hours, or weekly. potential rim failures may prevent seri-
IMPORTANT: Before mounting and torqu- ous injury.
ing...Remove all paint, dirt and rust from 6. Never add or remove an attachment or
both sides of wheels at mating surfaces otherwise modify a rim (especially by
around lug bolt holes. THESE AREAS heating, welding, or brazing) unless the
MUST BE CLEAN. Also, clean axle wheel tire has been removed and approval has
end surfaces which mate with back side of been received from the rim manufacturer.
wheels. Proper torque cannot be maintained Modification or heating of a rim or one
unless these surfaces are clean and free of of its parts may weaken it so that it can-
paint, dirt or grease. not withstand forces created by inflation
or operation.
Operating Precautions
Observe the following precautions when put-
ting the scooptram back in service:

Power Train
Recapping blue paint, will provide indirect lighting in

the daytime which is not injurious.
For some off-road operations, such as muck-
ing and hauling, recapping tires can be cost Wagner does not recommend the storage of
effective alternative to replacement with new tires out of doors. Where this is necessary,
tires. Most tires are generally recappable, whether in transit or stationary storage, tires
depending on how well they have been should be protected from the elements by an
inspected during their service life. opaque waterproof covering. Such tires
should be inspected before mounting to be
The deciding factor is the severity of the job sure they are clean, dry, and free of foreign
the tire must do. Some jobs are too tough for objects.
recapped tires. High speed, overloading, and
long service at low inflation pressure all take
Mounting for Storage
too much life out of the cord body for it to
last longer than the life of one tread. When a scooptram is to be stored for a
On large tires with wire in the body, recap- period of time, the mounted and inflated tires
ping is advantageous. Modern recappers can should be blocked up to remove the load, and
recap wire and will replace the wire, if nec- the inflation pressure should be reduced to l5
essary. psi (1 bar).
Storage of scooptrams should be under
Tire Storage cover, if possible, and each tire should be
protected from the elements by an opaque
The most important factor about tire storage waterproof covering.
is to use the tires which have been in stock
the longest period of time. If it is not possible to block up the scoop-
tram, the tire inflation pressure should be
If tires are to be stored for a considerable increased to 25% above the rated psi for the
length of time, the ideal condition is a cool, actual load on the tire in the storage condi-
dry, and dark location, free from air currents. tion. The tires should be checked every two
While low temperatures are not objection- weeks for proper inflation.
able, high room temperature (over 26.7° C /
80° F) is detrimental and should be avoided. The surface area under each scooptram in
storage should be firm, reasonable level,
Always keep the floor clean and free of oil well drained, and free of all oil, fuel, or
and grease. Rubber quickly absorbs petro- grease. A 1/4 inch to 3/ 4 inch (6.4-19.1 mm)
leum products and then swells and becomes layer of clean gravel under each tire is desir-
soft and spongy. able if the area is not paved. Storage should
Particular care should be taken to store tires not be permitted on blacktop or oil stabilized
away from electric motors as they generate surfaces.
ozone which causes rapid aging of the rub- Tires must be inflated to the proper operating
ber. Keep the storage room dark, or free from pressure before returning a stored scooptram
direct sunlight. Windows, if given a coat of to service.

Section 5 Frame
Introduction 1. Lower the boom until it is resting on its
stops.
This section contains removal and replace-
ment instructions for the following compo- 2. Roll the bucket back until the bottom of
nents: the bucket is parallel with the ground.
• Major components on the Load Frame

other than the power train, hydraulic sys-
tems, and electrical system.
• Major components on the Power Frame
other than the power train, hydraulic sys-
tems, and electrical system.
• Separating and reconnecting the Load
Frame and the Power Frame.
Wherever possible, procedures are presented
in the sequence required for orderly removal; 3. Place suitable support blocks, or a pal-
that is, if an item must be removed before ette, under the bucket so that it rests on
another item can be removed, that item is the supports.
covered first. WARNING: The bucket is extremely
heavy. Severe injury or death may
Load Frame result if the support blocks are not
ACW00073.pict
strong enough to hold the weight of the

WARNING: Block all wheels,
bucket.
remove the key from the ignition
switch, and place a Do Not Operate
ACW00073.pict
WARNING: Place support blocks,

tag on the steering wheel (or lever) before or palette, under the entire bucket
removing the bucket or boom. making sure that it is stabilized and
ACW00073.pict
not rocking.
Removing the bucket
4. Roll the bucket down until it is resting on
Remove the bucket as follows: the supports, level but not on the ground.
WARNING: Depending on the IMPORTANT: Make sure that the entire
scooptram model, the bucket could bucket is resting on the support blocks.
weigh up to 6800 kilograms (15,000
ACW00073.pict
lbs.). Do not reach or lean underneath the

bucket unnecessarily.
Rev. 9608 Atlas Copco Scooptrams Service Instructions 127

Frame
5. Disconnect the Dog-bones from the one under or around an unsupported Z-Bar
bucket by removing the trunnion caps assembly.
from the bucket end. 1. Park the Scooptram on a flat hard sur-
face. Rest the tip of the bucket on the
ground.
Note: It is not necessary to remove the
bucket to remove the Z-Bar.
2. Remove the stabilizer cylinder guard.
6. Remove the trunnion caps from the main

boom pins on the bucket.
7. Back the vehicle away from the bucket

or hoist the bucket from in front of the 3. Remove the stem-end trunnion caps of
vehicle. the stabilizer cylinder on the Z-Bar.
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:
WARNING: The Z-Bar is extremely
heavy. Take care to NOT place any
ACW00073.pict
128 Atlas Copco Scooptrams Service Instructions Rev 9608

Frame
4. With a suitable hoist, lift the stabilizer Removing the boom

cylinder stem-end up out of the Z-Bar
Remove the boom as follows:
trunnion cradle.
WARNING: Depending on the
5. Place suitable support blocks under the
scooptram model, the boom could
raised stabilizer cylinder and lower onto
weigh up to 5670 kilograms (12,500
ACW00073.pict
the blocks.
lbs.). Do not reach or lean underneath the
6. Remove the dog-bones from the bottom boom without it being properly supported.
end of the Z-Bar and lower to the ground.
1. Park the Scooptram on a flat hard sur-
face.
2. Follow the procedures for removing the
bucket.
3. Follow the procedures for removing the
Z-Bar.
4. Support the stabilizer cylinders with suit-
able blocks using the load frame as sup-
port. Do not rest the blocks on the boom
cross section.
7. Attach a hoist chain to the Z-Bar stabi-
lizer end and remove the trunnion caps 5. Hydraulically lift the boom until it is
from the Z-Bar swivel mount. Hoist the high enough for the hoist cylinder stem-
Z-Bar out of the way. end pins to clear the front tires. Prop the
boom up so that it is securely supported
with proper weight rated stands.
6. To disconnect the hoist cylinders, first
place a brace between the cylinder and
the load frame then loosen the split cap
screw and pound a wedge into the gap to
release the pressure on the pin Remove
the pin and place on a clean surface. It is
not necessary to remove the hoist cylin-
ders from the load frame in order to take
off the boom.
7. Connect three chains, which are fastened
Reinstalling the Z-Bar to three lifting points on the boom, to the
Follow the removal procedures in reverse lifting hoist hook. Make sure that the
order. chain lengths are adjusted to lift the
boom squarely.
Rev 9608 Atlas Copco Scooptrams Service Instructions 129

Frame
8. Remove the trunnion caps from the 5. Lift the hood and install the support.
boom base end swivel mount and pull the
pins from the assembly.
9. Hoist the boom assembly off of the load
frame and set it so that it is securely sup-
ported.
Replacing the boom
Reinstall the boom in the reverse order of
removal.
Power Frame
Removing and Replacing Hoods 6. Disconnect the gas support struts on both
sides.
The following procedures are generalized so
for all of the hoods on the scooptrams.
WARNING: The scooptram hoods
are heavy. Do not reach or lean
underneath any hood unnecessarily
ACW00073.pict
when the hood is raised without first install-

ing the hood prop.
Hood Removal
Remove the hoods as described in the fol-
lowing steps:
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.

Frame
7. Remove the hinge bolts. 2. Place blocks in front of and behind all
wheels.
3. Remove any hoods that are in the way.
Follow the hood removal procedures.
4. Turn the fuel cut-off switch to the OFF
position.
1. Fuel Cut-off Switch in the OFF Position

5. Place a suitable clean container under the
fuel tank drain plug and slowly remove
8. Slowly lift the hood with the hoist, mak- the plug. Let the tank drain completely.
ing sure it does not strike the frame or 6. Label, remove, and cap the fuel lines at
catch on any components nearby and the tank. Move the hoses out of the way
place the hood on blocks in a safe loca- so they will not become entangled with
tion away from the work area. the tank.
Hood Replacement
Replace the hood in reverse order.

IMPORTANT: Always install the hood
latches after servicing the Scooptram.
Removing the Fuel Tank
The following steps are not specific to a par-
ticular model but are generalized to cover the
basic removal steps.
1. Park the Scooptram on a flat level sur- 7. Disconnect the fuel gauge wiring.
face.

Frame
8. Attach a lifting device rated to lift around before separating the Load Frame and the
450 kg (1000 lbs) to the lift points on the Power Frame.
tank.
Separating the Load Frame from the
Power Frame
2
In order to separate the Load Frame and the
Power Frame all tension must be removed
from the articulation joint. Separate as fol-
lows:
1. Place blocks in front of and behind all
1 wheels.
2. Follow the procedures in Section 6:
Hydraulics to relieve all hydraulic pres-
1. Fuel Tank Lift Eyes sure.
2. External Fuel Gauge (See Step 7)
3. Disconnect or remove the midship drive-
WARNING: The scooptram fuel line.
tank is heavy. Do not reach or lean
underneath the tank unnecessarily
ACW00073.pict
while it is being hoisted from the machine.

9. Loosen and remove the tank mounting
brackets and bolts.
10. Lift the fuel tank out of its compartment
making sure that any hoses or wires are
clear and not tangled with the tank.
11. Place the tank on the shop floor or work
stand so that it rests evenly and will no 4. Install two maintenance stands at the rear
tip over. of the Power Frame. Adjust until they are
Replacing the Fuel Tank tight against the frame.
Follow the removal steps in reverse order of 5. Attach chains to the lifting points on the
disassembly. Load Frame and take enough strain with
the lifting hoist to raise the front end of
the Power Frame.
Separating and Reconnecting
the Load and Power Frames 6. Place a maintenance stand under the
front of the Power Frame and lower the
WARNING: Remove the ignition vehicle.
key, and place a Do Not Operate tag
ACW00073.pict
on the steering wheel (or lever)

Frame
7. Disconnect the hydraulic lines between 9. Disconnect the steering cylinders from
the Load and Power Frames. Immedi- the Load Frame by removing the cylin-
ately cap or plug each line and connector. der-to-load frame (stem end) pins.
8. Disconnect the electrical lines between 10. Perform either of the following:
the power and load frames at the power (1) Place a dolly capable of carrying the
frame junction box. 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 approxi-
mately 1 meter (3 feet).
(2) Position a hoist over the front of the
Load Frame. The hoist must be capa-
ble of carrying the weight of the back
of the Load Frame, and must be capa-
ble of moving approximately 1 meter
(3 feet) with the Load Frame. Rig a
sling to lift the frame.
10. Adjust the height of the dolly or hoist so
that the weight is removed from the artic-
ulation joint and remove the trunnion
caps from both the top joint and bottom
joint.
11. Remove the blocks from the Load Frame
wheels.

Frame
12. Move the Load Frame forward approxi- 8. Check the positions of all articulation pin
mately 1 meter (3 feet). caps If both pins and all caps are in
proper position, properly torque the bolts
13. Place blocks in front of and behind the
Load Frame wheels. to according to specification.
14. Securely support the back of the Load 9. Remove the dolly and its fittings from
beneath the Load Frame or remove the
Frame frame with a maintenance stand or
wooden blocks. hoist and its fittings from the frame.
10. Replace the midship driveline.
Reconnecting the Load Frame and the
Power Frame 11. Reconnect the steering cylinders.
Reconnect the Load Frame and the Power 12. Unplug and reconnect the hydraulic
Frame as follows: lines.
NOTE: This procedure assumes that the 13. Remove the maintenance stands from
vehicle is in the same condition and position beneath the Power Frame.
as at the end of the frame separation proce- 14. Make sure the parking brake is set.
dure.
15. Remove all blocks from all wheels.
1. Remove the maintenance stand or
wooden blocks from beneath the back of Articulation Pins
the Load Frame.
Atlas-Copco Wagner Scooptrams are cur-
2. Remove the blocks from in front of and
rently supplied with taper roller articulation
behind the Load Frame wheels.
pins. Installation and removal of the articula-
3. Move the Load Frame backward until tion pins is not required to disconnect the
aligned with the articulation pins. two frames. However during the life of the
4. Install the trunnion caps scooptram, it may be necessary to remove
the hinge pins. The following explanation
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.

Frame
will provide sufficient information to accom- 11. Hinge Plate Bore

plish the pin removal and replacement. 12. Spacer Ring
13. Pin Shoulder
3 1 14. Articulation Pin
IMPORTANT: The taper bearing cones and
bearing cup are a matched set. If the bearing
2 is damaged or worn, replace the whole bear-
ing assembly.
4
IMPORTANT: Atlas Copco recommends
5 replacing both the upper and lower hinge pin
bearing at the same time.
7 6
Pin Removal
8
WARNING: The articulation pins
10 are very heavy and could cause
9
injury or even death if mishandled.
Always use a hoist to position the
12 pin into the hinge bore. Also take care when
11
removing the top pin.
8 14 1. Disconnect the load and power frame as
instructed previously.
5 NOTE: The order of pin removal does not

13 matter. If the bearings are going to be reas-
sembled, tag them as they are taken apart so
4 that they will be replaced in their previous
position.
1
2. If removing the bottom pin, place a stand
under the pin, if removing the upper pin,
attach a hoist to the pin.
1. Bearing Retainer Plate Bolts 3. Loosen and remove the pin cap bolts and
2. Pin Cap lift off the pin cap. Place the pin cap and
3. Pin Cap Bolts bolts aside so that they may be reused.
4. Bearing Retainer Plate
4. Loosen and remove the bearing retainer
5. Retainer Plate Seal
plate lock nuts and bolts.
6. Split Spacer
7. Spacer 5. Carefully lift off the bearing retainer
8. Bearing Cone plates (both sides) and set aside for reuse.
9. Bearing Cup
10. Hinge Plate

Frame
6. Slide off the split spacer and the small 5. Press the bearing cup into the hinge plate
spacer, set both aside for reuse. bore.
7. Remove the bearing cone. Note the posi-
tion of the cone, and tag with placement
if the bearing will be reused.
8. Depending on pin, either lower or lift the
pin from the hinge plate bore. Set the pin
aside for reuse.
9. Slide the spacer ring and bearing cone off
of the pin. If being reused, set aside and
tag with position of the bearing.
10. Remove the bearing cup from the hinge NOTE: If freeze fitting insert for easy instal-
plate and set aside if being reused. lation, install two or more bolts with flat
washers on underside of hinge plate to pre-
Pin Installation
vent insert from falling out.
WARNING: The articulation pins 6. Slip the pin, with one cone and spacer
are very heavy and could cause installed, into the hinge bore until the
injury or even death if mishandled. bearing is seated into the bearing cup.
Always use a hoist to position the
pin into the hinge bore. Also take care when NOTE: The pin may need to be supported at
removing the top pin. this stage.
IMPORTANT: The hinge bearings are 7. Press remaining bearing cone onto pin,
matched with the bearing cup. Take care taper towards the center of the pin, until
when installing the hinge bearing to keep the it is seated in the bearing cup.
sets of bearings together.
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.

Frame
8. Slip the small spacer onto the pin. 11. Slide upper bearing retaining plate over
pin and bolt onto hinge. Torque to the
following:
• ST1010: 109 N-M (80 ft-lbs)
.
9. Slip the split spacer onto pin.
12. Bolt lower bearing retaining plate onto

hinge. Torque to
• ST1010: 109 N-M (80 ft-lbs)
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.
10. Bolt pin cap onto pin assembly using
washers and bolts. Note: 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 miss-
ing or defective stops are:
• Blown or leaking seals.
• Cylinder seals leaking.
• Cylinder barrel failure.

Frame
• Main control valve seals leaking. vent it from bottoming out. The stop(s) also
• Structural damage. help prevent the operator from stressing the
boom arms, which can lead to cracking.
All vehicles are shipped from the factory
with stops installed. Spare or replacement Bucket Rollover (Dump) Stops
buckets are not however, and stops will have The purpose of the bucket rollover stop(s) is
to be installed at the mine. When installing a to limit travel of the stab cylinder and pre-
new bucket, be sure to verify stop position- vent it from over extending. The stop(s) also
ing. A slight misalignment can cause dam- help prevent boom arm cracking, which can
age. result from the operator slamming the bucket
When the vehicle is being operated without against the arms.
stops, stops that are hammered out, or
Bucket Stops (Pads)
improperly installed stops, the load will be
supported by the cylinder barrel, load frame, A pad is located on the Z-bar to act as bucket
boom, or a combination of the three. If the a stop. The purpose of the rear bucket pad is
stops are missing or badly worn, the cylinder to prevent the dump cylinders from bottom-
stem can bottom out in the barrel. With the ing out when the bucket is fully lowered.
load supported by the barrel, any vertical These stops are welded into position at the
movement of the load (such as occurs during factory.
travel) will cause the piston to pound the
base of the barrel. This will ultimately result Boom Stops
in failure of the cylinder, particularly at the The purpose of the boom stop(s) is to pre-
weld around the end cap and possibly at the vent the boom cylinders from bottoming out
cylinder mount as well. when the boom is fully lowered. They also
Steering Stops provide protection to both the boom arms
and the load frame. These stops are welded
The steering stops are installed to limit travel into position at the factory.
of the steering cylinders to prevent them
from bottoming out in either direction. The Inspection and Maintenance
stops also keep the bogie and chassis from Every 100 hours, all stops must be inspected.
hitting each other and causing damage.
Look for worn or missing stops. When wear
Oscillating Axle Stops is evident, measure the contact surface of the
stop.
The oscillating axle stop limits the oscilla-
tion of the rear axle 8° - 10° (depending on Allowable gap:
the vehicle) in each direction. Steering Stops 3.2 mm (1/8 inch)
Bucket Rollback Stops Bucket Dump Stops 1.6 mm (1/16 inch)
The purpose of the bucket rollback stop(s) is Bucket Rollback Stops 1.6 mm (1/16 inch)
to limit travel of the stab cylinder and pre- Boom Stops 3.2 mm (1/8 inch)

Frame
If the contact surface of a stop exceeds Installation

allowable wear, repair or replace the stop.
General Positioning
Note: Another method for determining stop
When installing new stops, always position
wear is to raise the boom a few feet and roll
them in the same basic location as installed
the bucket back until the dump cylinder bot-
by the factory. These locations have been
toms. Then measure the distance from the
determined to be the most effective for that
front of the cylinder barrel to the end of the
machine.
stem. Roll the bucket forward, lower the
boom to the stops, then roll the bucket back Final Positioning
to its stops. Measure the distance from the
Steering Stops
front of the barrel to the end of the cylinder
stem and compare the two measurements. The best method for properly positioning a
The dimension taken with the bucket against steering stop is to measure the center-to-cen-
the stops should exceed the first measure- ter distance between the axles with the vehi-
ment by at least 1/32 inch (.8 mm). cle fully articulated. This distance cannot be
If a stop is found missing, do not operate the greater than 12.7 mm (1/2 inch) than the
unit until a new stop has been installed. vehicle’s specified distance.
Check to make sure that the welds on the IMPORTANT: This distance cannot be less
stops are not cracked. If cracked, repair than the specified distance.
crack by: Oscillating Axle Stops
• remove old weld by air-arcing or scarf- To determine the final position, place the
ing vehicle on support stands to allow free
• preheating material to 120°-150° C movement of the axles. Move (oscillate) the
(250°-300° F) to remove moisture axle upward, in accordance with the angle
specified (See Appendix). Install the stops,
• re-weld using a low hydrogen weld rod
ensuring that full contact is made across the
(7018 or equivalent)
mating surfaces of the stop and axle.
Check to make sure stops always make good
and full contact. Bucket Rollback Stops
Check that the dump and rollback stops hit 1. With the boom on its stops, fully retract
the boom at the same time when dumping or the stabilizer cylinder.
rolling the bucket back. 2. Extend the cylinder stem until the dis-
WARNING: When working around an ele- tance between the cylinder face and the
vated boom, ALWAYS make sure the boom is centerline of the stem end pin (at Z-bar)
securely blocked. measures 836 mm (33 inches).

Frame
3. Place the stop(s) so that complete surface that they are square with the side plates and
to surface contact occurs between the the axle housing.
bucket and the stop and tack weld in
Flush Contact
place.
4. Reposition the boom and bucket and Once the final stop position is established,
weld in place. Make sure that the boom shape and orient the stop(s) so they will
and bucket are properly supported. make contact along the full mating surface of
the frame or mating stop. Stops that have less
5. Reposition the boom and bucket and than full surface contact will have more
weld in place. Make sure that the boom rapid wear and required more frequent
and bucket are properly supported. replacement.
Bucket Rollover (Dump) Stops
1. Fully raise the boom.
WARNING: When working around
an elevated boom, ALWAYS make
ACW00073.pict
sure the boom is securely blocked.

2. Using a protractor, roll the bucket for-
ward until it is at the specified angle.
3. Insert the stop(s) on the Z-bar so that
complete surface to surface contact
occurs between the boom and the stop
and tack weld in place on the bucket.
4. Reposition the boom and bucket and
weld in place.
Bucket Stops (Pads)
Relocate stops at existing pad position and
weld into place.
Boom Stops
The boom stops on this vehicle are located
above the axle housing, on either side of the
boom. When replacing, install the stops so

Section 6 Hydraulics
Hydraulic System When the component being actuated reaches
its limit of travel, system pressure increases
This section covers the theory of operation; until the main relief valve lifts. Oil is then
description of common components (reser- directed (at minimal pressure) back to the
voirs, hoses, tubes, cylinders, etc.) found in a hydraulic tank. Pressure on the pump side of
typical vehicle hydraulic system; and general the relief valve remains at the level desig-
maintenance and troubleshooting informa- nated by the relief valve set-point, until the
tion. control is repositioned.
Also included are descriptions of specific On the Atlas Copco Scooptram, hydraulic oil
hydraulic systems found in the Atlas Copco is suctioned through either the steering/brake
Scooptram family. tandem pumps or the dump/hoist pump. Oil
Instructions for the proper removal and flows from the brake pump to the auxiliary
replacement of key components are pro- valve then to the brake system. At the auxil-
vided. iary valve, pilot pressure for the operator
controls, accumulator charging, and routing
Theory of Operation for the hydraulic cooling system is provided.
From the steering pump section, the oil flows
The primary purpose of the hydraulic system to the priority valve then to the steering
is to transmit power from the engine to the spool on the main control valve. Hydraulic
various working and control systems on the oil suctioned through the dump/hoist pump
vehicle. flows to the priority valve to either the hoist
Standard System spool or the dump spool on the main control
valve. The oil flow from the main control
Most vehicles use a fixed-displacement valve activates the cylinders.
hydraulic pump with open-center valves.
Starting the engine drives the pump. With no System Components
control functions operating, hydraulic fluid
(oil) flows freely through the system and The hydraulic system for the Atlas Copco
back to the hydraulic tank. System pressure Scooptram is made up of the following com-
is minimal. ponents:
Operating a control activates the applicable • Pumps

valve(s) in the system. The valve(s) then re- • Cylinders
directs oil to the component to be actuated.
• Accumulators
• Tank and Filters
Rev. 9608 Atlas Copco Scooptrams Service Instructions 141

Hydraulics
• Hoses and Tubing On the Scooptram, the steering and brake

pumps are tandem hydraulic gear pumps.
• Control Valves
One supplies hydraulic oil to the steering
• Hydraulic Oil Cooler spool on the main control valve and the other
• Steering System supplies oil to the auxiliary valve.
• Dump and Hoist System The dump/hoist pump sends the flow of oil
to the main control valve and provides oil to
• Brake System both the dump spool and the hoist spool.
• Emergency Tow System Note: In the following descriptions of the
various hydraulic systems (steering, dump/
Pumps hoist, brake) and components, pumps will be
Hydraulic fluid flow is supplied to the work- referred to by the specific function they ful-
ing cylinders by a pump. fill.
Hydraulic Gear Pumps Cylinders
The cylinder does the work of the hydraulic

system. It converts the fluid power from the
pump to the mechanical power. Cylinders
are the “arms” of the hydraulic circuit.
Most vehicles typically have three systems Double-acting cylinders provide force in
requiring a hydraulic pump; steering, dump/ both directions. Hydraulic fluid enters at one
hoist, and braking. The pump converts end of the cylinder to extend it, and at the
mechanical energy from an engine or electric other end to retract it. Oil from the unpres-
motor into hydraulic energy. surized end of the cylinder returns to the
Atlas Copco uses single and tandem hydrau- hydraulic tank.
lic gear pumps, depending on the applica-
tion. A tandem pump (i.e., with two pumping
sections) is usually plumbed so one section
supplies a designated system (e.g., the steer-
ing system) while the other section supplies
a second (the dump or brake) system. A sec-
ond, single stage pump provides flow for the
remaining system.

Hydraulics
Steering Cylinders Hoist Cylinders

The hoist cylinders are double-acting cylin-
ders which provide force in both directions.
The steering cylinders are double-acting cyl-

inders which provide force in both direc-
tions.
Stabilizer (Dump) Cylinder
1. Dump Cylinder
2. Hoist Cylinders
The stabilizer cylinder is a double-acting
cylinder with a chrome plated stem, and one-
piece screw on piston with self-locking nut.

Hydraulics
Accumulators
4
5 6 7 8
3
10
2
1. Charging When the accumulator is charging, oil at sys-

2. Discharging tem pressure enters the chamber below the
3. Air Valve piston. This pressure acting on the bottom of
4. Upper Housing the piston moves the piston up. As the piston
5. Nitrogen Pre-Charge (1200 psi) travels up, the nitrogen gas compresses,
6. Piston increasing the charge pressure above the pis-
7. Hydraulic Oil ton. The piston will be forced up until the
8. Lower Housing pressure on both sides of the piston are
9. Oil In equal.
10. Oil Out
This oil will remain at this pressure until a
Hydraulic accumulators are used to store fluid path is opened. Opening a fluid path
energy and maintain a smooth flow of oil to (such as operating the park brake valve)
the brakes during vehicle operation. reduces the pressure below the piston. The
The number of accumulators and their size higher pressure above the piston will now
depends upon vehicle model and application. move the piston down until the pressure on
The larger the machine the more the volume both sides of the piston is equal.
of oil required to activate the braking system. The downward movement of the piston will
Vehicles equipped with the SAHR brake provide flow in the system until the fluid
system have one master accumulator. path is closed, or the piston bottoms in the
The accumulator consists primarily of a shell.
shell, piston, air valve, and seals. The area The accumulators should be checked during
above the piston is pre-charged with dry vehicle overhaul to assure proper pre-charge
nitrogen gas to approximately 1200 psi pressure is available. An accumulator with
(8300 kPa). low or no pre-charge will cause excess

Hydraulics
cycling of the accumulator charging valve Brake Release Tow Hook Accumulator
and excess temperature in the hydraulic sys-
The brake release tow hook accumulator is
tem.
charged when the tow hook release arm is
Accumulator Pre-Charge depressed. The accumulator is pre-charged
with dry nitrogen to 800 psi.
A piston-type pneumatic accumulator uses
dry nitrogen to pre-charge the cylinder and
Tank and Filters
store energy. This energy is used to operate
the vehicle brakes if a failure occurs in the Hydraulic Reservoir (Tank)
brake hydraulic system.
The hydraulic tank has several functions in
The accumulator must be pre-charged with the hydraulic system:
dry nitrogen to a pressure of 1200 psi (8300
kPa) to operate. Pre-charging is performed at • Stores hydraulic oil.
the factory and should not be necessary in • Cools hydraulic oil.
the field. Accumulators that undergo repair
• Allows air to separate from the oil.
or replacement will be charged in the field.
• Allows contamination to settle to the bot-
IMPORTANT: Use dry nitrogen only to
tom of the tank.
pre-charged the accumulator. Dry nitrogen
does not mix with oil. It is non-combustible. • Contains the return line filter.
It will not cause oxidation or condensation • Is equipped with a filter/breather check
within the accumulator and is not harmful to valve assembly to maintain back pres-
the piston seal. Do NOT use air or any com- sure in the tank to 5 psi (34 kPa). This
bustible gas as these may cause oxidation helps force the oil to the suction side of
and condensation. Oxidation and condensa- the pumps and minimizes ingestion of
tion are harmful to the oil piston seal and the moisture and dirt.
accumulator.
Inspection
Note: When pre-charging an accumulator
on the vehicle make sure the oil side of the Check the oil level in the hydraulic tank at
accumulator has zero pressure. Operate the the beginning of each shift. The boom must
vehicle brakes while charging the accumula- be down on its stops and bucket rolled back
tor to bleed off oil pressure and ensure that against its stops to read proper oil level. Oil
the accumulator piston goes to the oil end of should be in both sight glasses when tank is
the accumulator. full.
The accumulator has a free floating piston The vehicle can be operated if oil is visible
which separates the oil from the nitrogen in only the lower sight gauge, but under no
gas. Packing is used to prevent any leakage circumstances should a vehicle be operated
past the piston. when oil is not visible in the lower sight
gauge.
Check tank for damage or cracks.

Hydraulics
Repair 5. After completing the welding operation,

remove all traces of the noncombustible
Since the reservoir is basically a container
material which was put in the tank to pre-
for storing hydraulic oil, it rarely requires
vent an explosion.
repair. The reservoir should be cleaned from
time to time as outlined in “Oil Changes” on Oil Filters
page 167.
Outlet
Occasionally a crack may form in a wall or
in one of the tubes or baffles in the reservoir.
When this happens, the reservoir must be 25
repaired. If you decide that the crack can be PSI
welded, there are certain safety precautions P

that you should take.
Remember that although hydraulic oil is not
Inlet
an explosive, it is combustible. Therefore,
before welding a crack in the reservoir, pro-
ceed as follows: Despite utmost care in the handling and dis-
1. Thoroughly drain all hydraulic oil from pensing of the hydraulic fluid it is probable
the tank and system. that some foreign particles will find their
way into the hydraulic fluid. Because such
2. Remove all of the removable parts from particles are apt to be abrasive in nature and
the inside of the reservoir. will detract from both the operation and life
3. Clean the reservoir thoroughly. This can of the hydraulic pumps, motors and valve,
be done adequately with steam. Avoid Atlas Copco always incorporates filter(s) in
the use of toxic cleaners. If chemicals of its hydraulic systems.
any type are used, be sure to clean the The actual placement of the filter in the sys-
tank in a well ventilated area and wear tem to achieve maximum filtering efficiency
protective clothing and goggles. depends entirely on the circuit design. Corre-
4. Before welding, fill the tank with a non- spondingly, periodic replacement of fully
combustible material such as carbon contaminated filter media must be made to
dioxide gas or dry nitrogen to prevent the maintain overall efficiency.
possibility of injury from an explosion. If
neither of these gases are available, use
clean water.
CAUTION: Never use oxygen. Oxygen is a
basic ingredient of fire and its use can
increase the chance and severity of combus-
tion occurring.

Hydraulics
Internal Filter Cartridge with Indicator Dust from the surrounding air is a major
source of contamination. Another source of
1 2 contaminants is the vehicle itself. During
normal operation, the vehicle generates
burrs, dust and chips from metal to metal
contact between moving parts.
A properly maintained oil filter can save sig-
nificant cost by preventing premature equip-
ment failure and replacement.
Hoses and Tubing

Hydraulic fluid flows to the various working
1. Restriction Indicator and control components through fixed tubing
2. Return Filter Cap (with removal nut) and flexible hoses. Hydraulic fluid leaks and
A 10-micron hydraulic oil return filter is the entry of dirt and other foreign matter
located in the hydraulic tank. Most of the oil most often occurs with these hoses, tubing
returning to the hydraulic tank must pass and their fittings.
through this filter prior to re-entering the In order to prevent leakage, vibration, and
system. abrasion of lines and hoses, and also to pro-
When oil is being introduced to the hydraulic vide a neat, orderly hydraulic system, certain
system either through the quick disconnect rules should be followed when replacing
coupler or the hand pump, it is routed hoses and lines.
through the filter prior to entering the tank. • Replace lines and hoses in the same posi-
Most oil in the system flows through the fil- tions they were before removal. The
ter as it returns to the tank. routing of hydraulic lines has been
A red pop-out indicator is located on the fil- planned to prevent exposure to excessive
ter head and will show when the filter is vibration and abrasion. Many problems
restricted. can be avoided by installing lines in the
same position whenever replacement
Maintaining a clean hydraulic system is
becomes necessary.
important.
• Avoid sharp bends in hoses and tubing.
Contaminated oil can score or completely
Sharp bends in hydraulic lines act as
freeze a precisely fitted valve spool.
restrictions and will cause overheating.
Dirty oil can ruin the close tolerance of
• When a hose line must be bent for instal-
finely finished surfaces.
lation, always check the minimum bend
A grain of sand in a tiny control orifice can radius with the manufacturer’s catalog. If
put a whole machine out of operation. the manufacturer’s specification is not
available, avoid bending the hose to a

Hydraulics
radius smaller than ten times the outside hoses exactly, restriction or leakage will
diameter of the hose. result.
• In areas where hose flexing will occur • Always use the proper tools. Never use
during operation of the equipment, a tools such as a pipe wrench on hose or
larger minimum bend radius is neces- tubing fittings. Instead, use flare nut
sary. wrenches when possible, and when they
• When installing tubing or piping, the are not available, use an open end
ideal bend radius is 2 1/2 to 3 times the wrench of the correct size.
inside diameter. • Do not over-tighten fittings. If you
• Keep lines as short as possible. The tighten them the proper amount, they will
longer the line, the more the internal seal and not leak. Never attempt to keep
resistance. Therefore, avoid replacing them from leaking by using sealing com-
lines with new ones that are longer than pounds.
the originals. Do not try to shorten lines • Always cap or plug a line or hose and the
so that you must use sharp bends to make fitting from which it was removed when-
them reach the point of connection. Mea- ever you disconnect them.This is the best
sure the original line carefully. Then method for preventing the entrance of
replace it with a line of the same length. dirt into the system. Never use rags or
• Hoses can decrease in length a small waste material for plugging lines or com-
amount when pressurized. Therefore, ponents of the system. Lint can be just as
never cut a hose so short that when it is harmful as other types of dirt.
installed it has no bend whatsoever.
Allow a slight bend so that the hose can Control Valves
shorten in length when it is pressurized. The Atlas Copco Scooptram employs a
• Use proper clamps, adapters, and fittings. series of valves that have reduced the num-
If brackets are not used to support hoses ber of hoses and has placed important com-
as recommended by the manufacturer, ponents together. The valves are integral to
abrasion will result from hoses rubbing the operation of the scooptram’s hydraulic
against each other and against various system and allow easier maintenance as well
parts of the equipment. This shortens the as faster repair times. The valves include the
life of the hoses, resulting in premature following:
replacement. • Main control valve
• Be sure that hose clamps are the correct • Priority valve
size. A loose clamp is no better than no
clamp at all. The hose can move back • Auxiliary valve
and forth in a loose clamp, causing abra- • Brake treadle valve included in the
sion. Be sure to use only recommend fit- SAHR brake section.
tings. If the fittings do not match the

Hydraulics
Main Control Valve main control valve is composed of the steer-

1 2 ing valve, the dump valve, the hoist valve,
the EOD valve (optional), two inlet ports and
one outlet port. Two (2) port relief valves are
3 located on the inlet ports and are set at 3500
psi. As hydraulic oil is feed to the valve it is
sent directly to either the steering, dump, or
4 hoist system. The following are components
of the main control valve:
5 • Steering Spool
• Dump Spool
6 • Hoist Spool
7
• EOD Spool (optional)
• Inlet Port (Steering)
8 • Inlet Port (Dump/Hoist)
• Outlet Port
9
• Pressure Relief Valves
The outlet port allows the flow of hydraulic
10 oil to be sent through a filter and back into
the tank.
The pressure relief valves provide over pres-
sure protections for the dump/hoist an steer-
ing systems. The relief pressures are 3250
1. Anti-cavitation Check Valves
for the steering system and 3500 for the
2. Dump Port Reliefs
dump/hoist system.
3. Dump Spool
4. EOD Spool (Optional) Anti-cavitation protection is built into the
5. Hoist Port Relief spool system to prevent the flow of shock
6. Hoist Spool pressure back through the pumps. Instead,
7. Dump and Hoist Main Relief the over-pressure (shock pressure) is
8. Steering Port Reliefs returned to the tank through the relief sys-
9. Steering Spool tem.
10. Steering Main Relief
The main control valve is a four spool, pilot
operated, open center, control valve. The
tandem valve arrangement allows the
hydraulic system to be housed in one unit
which lends itself to easy accessibility. The

Hydraulics
Priority Valve Auxiliary Valve

2 3
1 4
5
PR
EF CF 7
11
The priority flow valve is an inline control
valve that is situated directly between the 10 9 8
hydraulic pumps and the main control valve.
As the flow of oil enters the inlet port and
pressure builds, a control orifice sends 1. Priority Valve
excess oil to the dump/hoist spools. The pri- 2. Accumulator Charging Valve
ority of flow goes to the steering system. Oil 3. Hand Pump Check Valve
flow enters the inlet port and passes through 4. Pilot Pressure Test Port
a controlled orifice. The size of the orifice 5. Pilot Operated Check Valve
can be varied externally. The pressure drop 6. Filter Cartridge
across the control orifice positions the com- 7. Pilot Pressure Valve
pensator piston to limit the flow that is deliv- 8. Cooling System Check Valve
ered to the steering system out the port 9. Start-up Valve
marked CF. 10. Main Relief Valve
The remaining flow goes to the dump and 11. Inlet Test Port
hoist system out the port marked EF. The auxiliary valve is located in the trans-
Flow through the valve to the steering sys- verter compartment and primarily provides
tem on the ST1010 is 64 liters/min (17 gpm) hydraulic oil pressure for the SAHR brake
on the at high idle. This allows the unit to system. The auxiliary valve has four other
steer from fully articulated left to fully artic- functions that include:
ulated right in 6 seconds at full RPM and • Providing Oil for the brake cooler.
vice versa. • Delivering drive oil for the transverter
cooler fan.
• Providing pilot pressure for the brake,
dump/hoist, and steering control systems.
• Charging the brake system accumulator.

Hydraulics
The auxiliary valve is a cast aluminum 1600 psi (11000 kPa) to 2000 psi (13800
machined manifold that houses a series of kPa) for safe and effective braking.
cartridges that provide the functions of the As oil is used in the brake system, the accu-
system. The cartridges can easily be mulator pressure drops. When it falls below
removed for replacement or serviced. The 1600 psi (11000 kPa), the charge valve will
cartridges include: re-charge the accumulators back to 2000 psi
• Relief valve (13800 kPa).
• Air bleed On the Atlas Copco Scooptram, the charge
valve is a cartridge located on the Auxiliary
• Vented flow control
valve. This allows repair and maintenance of
• Unloading valve the charging valve by easily replacing the
• Check valve cartridge.
• Sequence valve Hydraulic System Cooler

• Filter cartridge
• P.O. check valve
• Check valve
• P.C Check valve
• Solenoid pilot valve
The auxiliary valve has two (2) pressure
check ports that allow monitoring of supply
pressure and pilot pressure.
Hydraulic oil is sent directly to the auxiliary
valve from the brake pump. As pressure The hydraulic system cooler is located on the
builds in the system, a priority valve sends transverter hood and is attached to the trans-
the excess flow of oil through the hydraulic verter/fuel cooling radiator. A fan is driven
cooling fan, through a pressure reducing by the flow of hydraulic oil through a turbine
valve and to the steering, dump/hoist, and system which blows air through the radiator.
brake pilot control valves. The pressure To remove the hydraulic cooler, see the
reducing valve steps the 20,682 kPa (3000 instructions for replacing the Transverter
psi) oil pressure down to 2412 kPa (350 psi). cooling system.
Accumulator Charging Valve
The main purpose of this valve is to control

the charging rate of the accumulators. It
keeps the accumulators charged between

Hydraulics
MonoStick Steering System

Operation
The steering system for the Atlas Copco • Auxiliary Valve

Scooptram is a pilot operated monostick sys- • Steering Control
tem which uses hydraulic oil pressure to turn
• Steering Cylinders
the vehicle. As the operator pushes the stick,
a low pressure flow of hydraulic oil is
directed to the steering spool on the main
control valve. This pilot pressure pushes the
spool open and allows the high pressure oil
from the steering/brake pumps to fill the
steering cylinders. As one cylinder is
hydraulically extended, the other is hydrauli-
cally retracted, articulating the vehicle.
Steering System Components:
• Steering Pump
• Priority Valve

Hydraulics
Wheel Steering System Operation
2
3
4
6 5
1. Auxiliary Valve right when the operator turns the steering

2. Orbital Steering Valve wheel clock-wise and left when the wheel is
3. Bi-Directional Valve turned counter-clockwise. The same is true
4. Hydraulic Tank when in reverse. It is important to remember
5. Gear Pump that the bi-directional valve will remain in
6. Main Control Valve the last setting, forward or reverse, when the
The wheel (orbital) steering system allows transverter is switched to neutral.
the operator to turn the Scooptram by a steer-
ing wheel instead of a joystick. The speed
and degree of turn of the steering wheel
determines the degree to which the scoop-
tram turns. When the operator changes the
vehicle’s direction, forward or reverse, an
electronic solenoid linked to the PLC actu-
ates a spool in a bi-directional valve which
maintains the steering orientation for the
operator. In other words, when going for-
ward, bucket first, the Scooptram will turn

Hydraulics
Wheel Steering System Components
1. Bi-Directional Valve Orbital Valve

2. Steering Wheel
3. Orbital Valve
The wheel steering system is composed of
the following componenets:
• Orbital Valve
• Bi-Directional Valve
• Auxiliary Valve
• Main Control Valve
The wheel steering valve is a hydrostatic unit

that is controlled by the steering wheel. The
valve is installed in the steering column
assembly and mounted to the outside of the
foot box.

Hydraulics
Turning the steering wheel actuates three end of the other cylinder to set the proper
main parts of the valve: sequence for the turn selected.
• The control spool, Bi-Directional Valve
• The control sleeve, and
• The metering rotor.
The metering rotor has a direct mechanical

link to the steering wheel.
When the steering wheel is turned in either
direction, the spool begins to rotate and
becomes aligned with the sleeve. Further
rotation will direct oil flow from the pilot
valve to the steering valve and out the right
or left direction port to the steering cylinders.
For a given direction, the oil will flow into
the base end of one cylinder and into the rod
The bi-directional valve provides the control
to the steering system to allow the operator
to have true right and left movement of the
steering wheel to execute right and left turns

Hydraulics
whether traveling in reverse or forward

directions.
4
2 3
1
1. Forward Direction Spool End

2. Reverse Direction Spool End
3. Electronic Control (Both ends)
4. Spool Detent
When the forward direction is selected by

the operator, the Programmable Logic Con-
troller (PLC) energizes the Bi-Directional
valve solenoid which then moves the spool
to the forward end. The detent holds the
position of the spool until reverse is selected.
As the operator selects reverse, the spool is
moved to the reverse end in the same manner
as described above. If the operator selects
neutral, the valve spool detent keeps the
spool in the last direction setting. If the oper-
ator had the vehicle in forward and then
switches to neutral, the steering will operate
as if in forward. If the operator switches to
neutral after traveling in reverse, the steering
will function as if in reverse.

Hydraulics
Dump and Hoist System
System Operation from the pressure port to the base end of the
hoist cylinders to raise the boom.
The dump/hoist system is a pilot operated
joystick controlled hydraulic lift system. Oil from the stem end of the cylinders is
Hydraulic oil is pumped through the priority routed back through the Main Control valve
valve directly to the dump and hoist spools to the hydraulic tank.
on the main control valve then to the cylin-
Bucket Float
ders. As the operator moves the joystick, a
low pressure pilot oil is sent through the aux- When the operator places the Dump and
iliary valve to the dump or hoist spools . Hoist lever in float, or third position detent,
Depending on the action required by the all ports are open to tank. The result is that
operator, the dump or hoist spools open an the weight of the bucket slowly lowers the
allow high pressure oil to fill the cylinder. boom onto its stops.
Boom Up Boom Power Down
When the operator moves the boom control To speed the return of the boom to its stops,
lever for boom up operation, the spool in the the operator can move the boom control
Main Control valve shifts down. Oil flows lever to the power down position. This shifts
the Main Control valve to the extreme

Hydraulics
upward position and directs pressure from • With compressed gas or fluid (such as air
the inlet to the stem end of the hoist cylin- in a tank).
ders.
• With springs.
Oil from the base end of the cylinders returns
With a valve installed between the energy
through the dump system.
Load Check Valve Function
The load-check valve function is part of the
main control valve spool system. It allows
pressure to build up in the system to match
the load demand. This function prevents
reverse flow and supports the load. When the
load pressure is the same as the operating
pressure, the check valve opens porting the
oil to the cylinder.
storage device and the friction device, you
Dump and Hoist Components have a simple braking system.
The dump and hoist system consists of those SAHR Brake
components which control the raising and
lowering of the boom and the dumping and
roll-back of the bucket. They include:
• Dump/Hoist Pump
• Priority Valve
• Main Control Valve
• Auxiliary Valve
• Dump/Hoist Control Valve
• Dump Cylinder
• Hoist Cylinders The SAHR (Spring Applied, Hydraulically
Released) brake system, developed by Atlas
Brake System Copco Wagner, reverses the process of
engaging and disengaging brakes. Springs
All braking systems require energy on apply the brakes, and hydraulic pressure
demand to be applied to the friction devises releases them.
that stop the vehicle. This energy must be
stored so that it is available when needed. The SAHR brake uses existing wet disc
Generally speaking, energy is stored in two brake technology. The wheel hub is splined
basic ways: to, and rotates with the friction discs, which
are sandwiched between steel stationary

Hydraulics
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 stan-
dard wet disc brakes.
Each wheel end is an independent brake sys-
tem. Industrial coil springs are arranged in
the annulus previously occupied by the
(hydraulic) application piston. They are con-
tained 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 sta-
tionary and rotating discs.
Application of hydraulic pressure to the
working area of the piston causes it to
retract, further compressing the springs, free-
ing the disc pack, and allowing the wheel to
turn. This pressure must be maintained dur-
ing normal operation.
Loss of system pressure for whatever rea-
sons allows the springs to immediately apply
full braking energy. This allows for the elim-
ination of all redundant systems.
Service application for retarding the vehicle
or slowing to a stop is accomplished by sim-
ply controlling the pressure loss. Control is
effected by the operator’s brake pedal.
The SAHR disc brake assemblies are
mounted just inboard of the wheel end plane-
taries on both front and rear drive axles.
Each SAHR brake assembly applies approxi-
mately 40-tons of brake pressure per wheel
end when applied but only require 1100 psi
(7600 kPa) to release, and normal operating
pressure is 1500 psi (10300 kPa).

Hydraulics
SAHR Brake System Operation
Hydraulic oil is pumped to the brake system sure in the brake hubs build up pushing the
through the auxiliary valve. In the auxiliary brake springs off the stator plates, releasing
valve manifold, a priority valve decides the brakes. If for some reason the solenoid is
which way to send oil depending on the de-energized, by pressing the park brake or
operator demands. Oil not sent to the brake loss of electrical power, the oil pressure in
application system is split to the pilot con- the brake hubs is relieved and the brakes are
trols and the brake cooling system. All over applied. The treadle valve, or brake pedal,
pressure oil is relieved back to the tank via mechanically regulates the flow of oil to the
the suction filter. brakes.
When the vehicle is first turned on, the Accumulator Charge Kick In/Kick Out
hydraulic oil is sent to the accumulator
charge valve to charge the accumulator. When the accumulator pressure drops below
Once the accumulator pressure has reached 1600 psi (+/- 50psi) (11000 kPa) the charge
2000 psi (13800 kPa) oil is then routed vale kicks in and sends oil to the accumula-
through the brake solenoid, through the tor. Once the pressure is charged to 2000 psi
brake treadle valve and to the brake system. (13800 kPa), The charge valve kicks out and
When the brake solenoid is energized by oil bypasses the valve.
pulling the park brake button out, oil pres-

Hydraulics
Brake Application • Brake Cooling Manifold

Service Brake Operation • Hydraulic Cooling System
When the foot pedal is actuated, the flow of Accumulator Pressure Gauge
oil to the brake hubs is cut off and the oil at
Located in the operator compartment, the
the hubs is allowed to return to the hydraulic
gauge displays main accumulator pressure
tank. The SAHR brakes then apply, slowing
and should read between 1600-2000 psi
and stopping the vehicle.
(11000-13800 kPa) during operation.
Park Brake Operation
Foot Pedal Control Valve
When the Park Brake button in the operator
compartment is pressed, the Programmable
Logic Control (PLC) de-energizes the park
brake solenoid. Once the solenoid is de-ener-
gized, the flow of oil to the brake system is Tank
cut off and the SAHR brakes are applied. Delivery
Inlet
Emergency Brake Operation
Whenever the electrical power is cut off, by
either engine shut down or power failure, the
SAHR brakes are automatically applied. The
Programmable Logic Control (PLC) powers
the park brake solenoid and when there is no
signal to the solenoid, it closes and hydraulic
pressure is relieved in the brake hubs, apply- In the operator compartment is the foot-oper-
ing the brakes. The park brake button func- ated brake valve. This is a closed-center
tions through the PLC and when activated, (closed to tank), open to delivery pedal actu-
the PLC de-energizes the solenoid. ated, decrease modulating, hydraulic brake
valve.
Brake System Components The flow of oil from the brake pump through
the charge valve (charge kicked out) to the
The major components of the SAHR brake
system are: brake system is controlled by the PLC and
the brake solenoid. During normal operation,
• Brake Pump (See Pumps Section) the flow of oil goes through the open sole-
• Auxiliary Valve (See noid and is then controlled by the treadle
valve.
• Hydraulic Accumulator
When the pedal is depressed, the spool
• SAHR Brake Control Treadle Valve moves upward, stopping the input flow and
• Brake Solenoid Valve gradually allowing oil to return to the
hydraulic tank. The farther the pedal is
• Brake Assemblies

Hydraulics
depressed, the more oil flow is allowed to Hydraulic Oil Cooler

return to tank until spool is fully open and all
pressure is released, allowing the SAHR The hydraulic oil cooler is located under the
brakes to apply. transverter compartment hood. As the fan
pulls air through the coils in the radiator, the
hydraulic oil is cooled.
Brake Cooling System
Hydraulic Fan
The brake cooling system allows the brakes
to be immersed in cooled oil for better opera-
tion and safety of the scooptram.
System Operation
Hydraulic oil flows from the auxiliary valve
through the hydraulic oil cooler and into the
brake cooling manifold where it is stepped
down to a pressure less than 15 psi. A relief
valve, set at 15 psi, sends the over-pressure
oil back to the tank. Oil from the manifold
then fills the front and rear brake housings The hydraulic fan is located under the brake
immersing the brake discs in oil. As the fluid cooler in the transverter compartment. The
flows through the brake system it is returned fan is situated so that it pulls air through the
to the tank via the filter. radiator towards the ground. This arrange-
ment disperses the air flow to the ground and
Brake Cooling System Components not up into the operator’s compartment.
The brake cooling system is made up of a Brake Cooling Manifold

number of components used to control oil The brake cooling manifold houses the 15
flow and pressures to cool the friction plates psi (103 kPa) check valve. When pilot pres-
in the SAHR brake assemblies. sure oil enters the manifold, the check valve
The major components that make up the opens and allows a small amount of oil (15
brake cooling system are: psi) to pass into the brake lines, the over-
pressure oil is directed to the tank via the fil-
• Hydraulic oil cooler. ter.
• Hydraulic fan.
• Brake cooling manifold
• SAHR Brake Hubs (See SAHR Brakes
section)
• Auxiliary valve (See Auxiliary Valve
section)

Hydraulics
Multi-disc Liquid Cooled Brake Assembly Emergency Tow System Components

Hand-operated Hydraulic Pump
Pressure Out
Cross Section Thru
4 Plate Piston & Sealing Rings 2000 PSI
Inlet
Bleeder Screw Port
Tank
Cooling
Ports
Drain Port The hand-operated hydraulic pump is a dou-
ble acting pump with a displacement of 10
During operation, the oil flows into the brake ml (.604 in3).
cavity through the lower cooling port, floods
the brake cavity with oil and exits back to the This pump has a valve to open and close the
hydraulic tank through the upper cooling pressure port to tank port, as well as a built-
port. in relief valve that is preset at 1500 psi
(10300 kPa).
Emergency Tow System When activated, the pump sends oil to the
hydraulic accumulator.
When the vehicle has no power or has lost
hydraulic pressure and needs to be towed, Relay Override Button
the emergency tow system can be used to
release the SAHR brakes. The emergency The relay override button is a manual over-
tow system is composed of the relay override ride on the brake solenoid. It is located under
button (brake solenoid manual override), the dash in the operator’s compart-
hydraulic hand-pump, and the hydraulic ment.When the button is depressed, the sole-
accumulator. noid valve opens and the hydraulic oil can
flow to the brakes. The relay override button
must be continuously depressed to release
the brakes, once the button is no longer actu-
ated the brakes are applied.
Hydraulic Accumulator
The accumulator stores hydraulic pressure
and when the relay override button is
depressed, the accumulator releases oil to the
SAHR brakes. The hydraulic hand-pump
sends oil to charge the accumulator when

Hydraulics
there is not enough pressure to release the the tow hook lever pushes a hydraulic piston
brakes. which in turn charges the tow hook accumu-
lator and sends oil to the brake release mani-
System Operation fold. The shuttle valve on the manifold
bypasses the auxiliary valve and the flow of
Accumulator Charged oil goes directly through the brake treadle
If the hydraulic accumulator has been valve to the brake system. As the vehicle is
charged during operation of the vehicle, the towed, pressure on the tow hook lever along
relay override button can be depressed and with the oil pressure in the accumulator
the flow of hydraulic oil will release the maintains the oil pressure in the brake sys-
brakes. The vehicle can be towed as long as tem. When the chain is loosened around the
the relay override button is pressed. tow hook, springs push the hydraulic cylin-
der piston down to reset the tow hook lever.
Accumulator Not Charged
The hydraulic hand pump is used to charge System Components
the accumulators until the accumulator pres- The brake release tow hook system is made
sure gauge reads at least 1500 psi (10300 up of the following components:
kPa).
• Brake Release Manifold
Once the necessary pressure is achieved,
press the override button to send pressure • Tow Hook Accumulator
from the accumulators to the brake hubs to • Tow Hook Cylinder
release the brakes. • Tow Hook Lever
Brake Release Tow Hook Brake Release Manifold
The brake release tow hook is an optional The brake release manifold components pro-
system designed to allow the Atlas Copco vide the means for the tow hook system to
Scooptram to be towed without a vehicle bypass the auxiliary valve when the vehicle
operator and when the engine is not running. is not running. It also allows the tow hook
When a tow chain activates the tow hook system to be bypassed when the vehicle is in
accumulator, a shuttle valve in the brake operation. The manifold houses the follow-
release manifold stops the flow of oil to the ing units:
auxiliary valve, bypassing the brake solenoid • Circuit replenishing check valve
(relay override), and sends the flow of oil to • Relay valve
relieve the SAHR brakes.
• Hydraulic shuttle valve
Tow Hook Operation Circuit Replenishing Check Valve
The brake release tow hook is employed The circuit replenishing check valve keeps
when a tow chain is wrapped around the the built up pressure from the tow hook cyl-
hook. As the chain is tightened, pressure on inder in the accumulator. When the cylinder

Hydraulics
is not being used, the valve allows the free hook frame and swivels so that when the tow
flow of oil to the tank. hook is employed, the lever can push the cyl-
inder end creating hydraulic pressure.
Brake Relay Valve
The brake relay valve remains open when General Maintenance Information
the vehicle engine is running to allow the
Long service life and functional reliability of
brake system to by-pass the tow hook cylin-
hydraulic systems and their components are
der. The accumulator is charged only when
dependent on the correct maintenance. To
the brake release arm is pressed.
ensure efficient operation, it is important to
Hydraulic Shuttle Valve carefully review the following:
The hydraulic shuttle valve is responsible for • the special installation and operational
allowing either system to be bypassed instructions for the components
depending on the flow of oil in the system. If • the technical data contained in the data
the vehicle is stopped and the engine is not sheet or the overhaul manual
running, the valve closes off the auxiliary
valve so that the tow hook can be used. If the • the NFPA/ANSI/ISO recommendations
engine is running, the tow hook system is of non OEM components for material
bypassed. compatibility
Tow Hook Accumulator Servicing After Overhaul
The tow hook accumulator stores hydraulic 1. Check fluid level and for external leak-
oil pressure so that when the tow hook sys- age
tem is employed enough pressure is main- •Continuously during start-up.
tained in the brake system to keep the brakes
•Daily after start-up and at each shift
released.
change.
Tow Hook Cylinder •At each fuel fill thereafter.
When the tow hook cylinder is actuated by 2. Check filters
the tow hook lever, oil is forced into the
brake system and tow hook accumulator. •Check and, if necessary, replace if flow
This oil flow provides enough oil pressure to restriction indicates bypass of warm
charge the accumulator up to 1500 psi oil.
(10341 kPa) and provides oil pressure to •Daily during the first week.
release the brakes.
•After one week the filters should be
Tow Hook Lever replaced. Thereafter, replaced every
400 hours.
The tow hook lever is the device that actu-
ally comes in contact with the tow chain and 3. Service system fluid
the cylinder. The lever is situated in the tow

Hydraulics
•Servicing is dependent on several oper- 1. escape of oil vapor

ating factors:
2. normal seepage
•fluid service time. In addition, leakage may develop during
•operating temperature. operation. Daily or shift checks of the level
•volume of fluid. will allow prompt identification and correc-
tion of any problem.
Severely aged or contaminated fluid cannot
be improved by adding fresh fluid. If the oil level is neglected and allowed to
fall, problems may occur which will hamper
Fluid subjected to high operating tempera- efficient performance of systems:
tures can break down. Drain and refill fluid
more frequently when operating at (or in) 1. If the oil level becomes too low, air may
high temperature conditions. be drawn into the pump suction and con-
tribute to foaming. It may also cause cav-
Note: Measure operating temperature not itation, which can decrease the operating
only in the reservoir, but also in the region of life of the pump.
the pump bearings. Rising operating temper-
ature is an indication of increasing friction 2. Less oil in the system will result in an
and leakage. increase in oil temperature due to the loss
of heat dissipating capacity. Such a rise
Systems operated at less than full volumes in temperature will impose harder work-
allow for the buildup of water from conden- ing conditions on the pump, fluid motor
sation in the tank. and other moving parts such as control
Whenever the hydraulic tank is refilled or valves.
when oil is added to the system, it is impor- 3. A low oil level means an increased
tant to use the hand filler pump because it amount of air in the tank which will
pushes oil into the tank through the return increase the rate of oil oxidation and
filter. cause the loss of the oil’s initial proper-
If fluid quality is questionable, take samples ties.
of system fluid regularly for laboratory anal- When reading the level, be sure to distin-
ysis and have inspected for particle types, guish between running and idle levels. This
size and quantity. Document findings in prevents possible over-filling.
manual. If no sampling and analysis is per-
formed, replace fluid at interval specified in Importance of Cleanliness
the Wagner maintenance schedule. A hydraulic system, like a diesel fuel or
Level of Oil in Reservoir lubricating system, will provide many hours
of reliable service if properly maintained. A
Maintaining sufficient oil in the hydraulic hydraulic system which is not properly cared
reservoir at all times is a significant factor in for will have a limited service life.
successful operation. During operation a cer-
tain amount of oil may be lost due to: Heat, dirt, and foam are the three main
causes of hydraulic system failure. Of the

Hydraulics
three, dirt is the biggest problem. Dirt in a Contamination resulting from the deteriora-
hydraulic system has exactly the same effect tion of hydraulic oil additives cannot be
as it does in a fuel system. Most dirt is abra- completely controlled through preventative
sive, and once it has worked its way into the maintenance. The formation of such contam-
hydraulic system rapid wear of the compo- inants is accelerated when the hydraulic sys-
nents results. tem overheats. Therefore, if overheating is
If dirt is kept out of the hydraulic oil the var- prevented, the formation of soluble and
ious components of the hydraulic system insoluble products is reduced.
will remain clean. Thus, the problem is to However, even under the most careful main-
keep the oil clean. This is not difficult if cer- tenance, contamination due to oxidation,
tain basic precautions are followed: condensation, and the formation of acids
• Keep all hydraulic oil containers covered causes the oil to become harmful to hydrau-
so that dirt or water cannot enter. lic system components. Therefore, most
authorities agree that all of the hydraulic oil
• Use only equipment known to be clean should be drained from the system on a regu-
when transferring oil from storage tanks lar maintenance schedule. This is the only
to hydraulic system reservoirs. way to eliminate the accumulation of deteri-
• Set up and follow a definite maintenance oration products from the system.
program for filters and strainers. How frequently the system should be
• Adjust or replace packings and seals drained depends upon many factors. There-
when necessary. fore, it is always a good idea to rely on man-
ufacturer’s recommendations and on
Always remember that in addition to causing suggestions offered by oil company repre-
the parts of heavy equipment to move, sentatives.
hydraulic oil also provides lubrication and
cooling for the hydraulic system compo- Oil Changes
nents. When dirt or water gets into the
A good grade of hydraulic oil will stand up
hydraulic oil, all three of these functions are
for a relatively long period assuming that no
effected.
excessive contamination is allowed to occur
Ordinarily, oil can become exposed to two and the oil filler is maintained in good work-
types of contaminants: ing order. However, oil will not last indefi-
1. Dirt which attacks the hydraulic oil from nitely and regular oil changes are necessary
the outside. This includes dust, lint, rust, to maintain an efficient hydraulic system.
and scale. Because operating conditions will vary
2. Soluble and insoluble products which widely, the frequency that the hydraulic oil
form through oil additive deterioration. should be changed can vary.
The first group of contaminants can be con- Factors which influence oil change intervals
trolled by taking the precautions outlined are:
above. • operating temperature

Hydraulics
• relief valve setting Dirt, water, lint and contaminants of any

• presence of water, acids, or solid con- kind can seriously impair the action of a
hydraulic system, resulting in operational
taminant
problems and excessive wear on both the
• amount of make-up or fresh oil added pump and valve components. To prevent the
The only accurate way of determining when introduction of impurities into the fluid, the
the oil should be changed is by oil sample following rules should be carefully
analysis. observed:
When facilities for checking on the condition • Store drums on their sides and under pro-
of oil are not available or the quantity does tective cover. Water collecting on the top
not justify such work, an interval of 1000 of a drum, even though it is sealed, will
hours will usually provide a good factor of gradually work its way through the bung
safety. seals and into the fluid.
The preferred time for draining the reservoir • Before opening a drum, clean the top
and changing the oil is at the end of a day’s carefully so that dirt will not fall into the
run when the hydraulic fluid is thoroughly fluid.
warmed up. By draining when the oil is • Inspect and keep clean all containers and
warm and immediately after the system is equipment used for storage and dispens-
stopped, the used oil will usually carry off ing of hydraulic fluids.
the greatest quantity of impurities.
• Before adding oil to a hydraulic system,
It is also good practice to flush the reservoir wipe off the fill plug with a clean, lint-
and system for further removal of impurities free cloth.
before the fresh change of hydraulic fluid is
introduced. We recommend that regular • Make certain that the fluid reservoir is
hydraulic oil be used to clean pumps. protected against the admission of con-
taminants. Possible openings which may
When system is noticeably dirty, a small provide entrance and which should be
quantity (5 to 10%) of petroleum solvent checked include fill plugs, inspection
may be added to the flushing fluid to help plate, vents, missing reservoir cover
loosen up impurities in the system. Pumps bolts and seals around pipes which
may be run for a longer period to achieve the extend through the cover of the reservoir.
desired cleaning action.
Selecting the right hydraulic fluid is an
Oil Storage and Handling important step in securing the maximum per-
formance and service life from hydraulic
The manufacturers of hydraulic fluids are
equipment. For normal conditions of opera-
extremely careful that no contaminants enter
tion only mineral base oils should be used.
the fluid prior to the time that it reaches the
customer’s plant. The same care should be Animal or vegetable oils are unsuitable and
followed in its storage, handling and use. their tendency to oxidize and thicken in ser-
vice may foul the system and damage com-

Hydraulics
ponents. Water is particularly damaging and symptoms may develop such as cavitation at
it should never be permitted in the system. pump intake or a greater tendency to foam.
Various other fluids may be offered for use Viscosity index is another significant physi-
in hydraulic equipment but it is generally cal characteristic which measures the rate of
advisable to avoid them unless their use is change in viscosity of a fluid with changes in
specifically approved by the factory. temperature. A high viscosity index is desir-
The hydraulic fluid serves both as a lubricant able to limit the effects of temperature
to protect the rubbing surfaces of pumps and change.
fluid motors and as a medium of the efficient For a normal range of operating tempera-
transmission of hydraulic pressure. The tures a minimum viscosity index of 95 is rec-
requirements of lubrication have grown ommended. When start-up temperatures
more important with the higher temperatures below -1° C (30° F) prevail, a still higher
and pressures commonly encountered today viscosity index of 140 minimum is sug-
in hydraulic applications. gested.
Therefore, the use of additive agents to pro- Prevention of Foaming
vide greater protection against wear have
become a significant feature of modern Excessive foam in the hydraulic fluid may
hydraulic fluids. Other desirable characteris- occasionally become a problem, particularly
tics are good rust prevention qualities, resis- if this condition progresses to a point where
tance to oxidation and freedom from an appreciable amount of foam is drawn into
tendency to foam. the hydraulic pump. Foam is highly com-
pressible and can affect the output character-
Proper viscosity of the hydraulic fluid is an istics of the pump, causing irregular
important physical property which must be operation and premature failure.
suitable for the requirements of hydraulic
system to assure efficient operation. The cor- Excessive foam in the hydraulic fluid will
rect viscosity will also be influenced by the usually be caused by one or more of the fol-
temperature and pressure at which the sys- lowing:
tem operates. • Oil level in the reservoir is too low,
Fluids which are too light at the prevailing allowing air to be drawn by the pump
conditions of operation will permit increased into the system.
slippage (i.e., escape of fluid from the high • A leak in the suction line joints.
to low pressure side of pump or motor) and
• The use of an improper type of hydraulic
higher metallic friction with a greater rate of
medium or a fluid that is too viscous.
wear.
• Deterioration of the fluid or the presence
If the fluid used is too heavy, response to
of harmful contaminants.
controls will be slower, the operating tem-
perature of system may increase due to
higher fluid friction, and other unfavorable

Hydraulics
Hydraulic Oil Change After Failure A thin film of dirt covering the outside of the
paper pleats of the element is an indication
Ordinarily, the procedure outlined in Section
that dirt is starting to work its way through
3 for draining and refilling the hydraulic sys-
the element.
tem will prove to be adequate. However, if
the system is extremely dirty, or if the pump If dirt is just beginning to show at the root of
or some other component has failed, addi- each pleat, the element is due for a change.
tional measures must be taken.The following An element in this condition is still capable
steps are recommended. of trapping dirt, but it will start to restrict the
oil flow until oil by-passes the filter and is no
1. After disconnecting all hose connections
longer cleaned. Dirt will then be deposited
from each of the components, blow out
on the components of the hydraulic system,
the hoses thoroughly, using compressed
causing them to wear rapidly.
air.
Atlas Copco Wagner provides restriction
2. Remove the pump, cylinders, control
indicators on most of its filter installations
valves, and all other hydraulic compo-
for air intake, engine oil, and hydraulic sys-
nents.
tems. These indicators are color coded and
3. Disassemble and thoroughly clean them. tell you that a filter needs to be changed
4. Thoroughly flush all of the hoses and the when the indicator reads in the red area.
reservoir with fresh hydraulic oil. Some believe that the best way to know
5. Reassemble and install each of the when to replace hydraulic system filters is to
hydraulic components. wait until they become clogged. This is not
recommended for two reasons:
6. Fill the system through the return filter
with hydraulic oil. 1. When a filter becomes clogged, it no
longer does its job of keeping dirt out of
7. Operate the system through several the system.
cycles to flush out any remaining dirt or
metal particles. 2. Most hydraulic filter assemblies are
equipped with a by-pass valve which
8. Drain the entire system. allows the oil to by-pass a clogged filter
9. Replace all filter elements with new element.
ones. The by-pass valve ensures a continuous flow
10. Fill the system with new hydraulic oil of hydraulic fluid to the system. Also, with-
and bleed it as described above. out such a by-pass arrangement, oil being
forced into the filter under pressure could
Servicing Filters and Strainers blow a clogged filter to pieces. The small
One way to determine the need to change fil- particles would then flow through the sys-
ters is to actually remove and inspect the tem.
hydraulic filter element from time to time. Because of the presence of the by-pass valve,
more and more hydraulic oil will by-pass

Hydraulics
around the filter element as it fills up with pedal heel stop up until the service brakes
dirt. Thus, it cannot be determined from the start to drag.
performance of the hydraulic system when a
Then turn stop back down until vehicle rolls
filter has become clogged.
free and brakes are no longer dragging. Then
Establishing a Schedule turn the stop 1/4 of a turn in and lock jam
nut.
It is difficult to establish a time schedule for
servicing hydraulic system filters that will Note: Whenever the SAHR brake valve is
apply in all cases. This is because the rate of replaced, it should be tested for dead band
dirt accumulation in a filter is affected by the and adjusted as necessary.
following factors: Cylinder Inspection
• The cleanliness of the hydraulic oil when
Check cylinders for pin and bushing wear.
first placed in the system and the cleanli-
Repair is required when pin and bushing
ness of the make-up oil which has been
exceeds 1/8 in. (3.2 mm) wear or movement.
added.
Check cylinder for damage to barrel and
• The amount of dirt entering the system
stem.
due to carelessness when adding make-
up oil. Carefully inspect the inside surface of the
cylinder and the condition of the pistons.
• The dirt and dust conditions encountered
by the equipment on the job. When assembling the cylinder, use new
packing, backup rings, O-ring and wiper
• The condition of the hydraulic cylinder
ring. Replace any part that is worn or dam-
packing.
aged.
In a properly maintained system, the hydrau-
The steering stops must be checked at least
lic filter should only need changing with
every 250 hours or less. If they wear exces-
each change of hydraulic fluid (1000 hours).
sively or break off, they can cause severe
Use of oil analysis is recommended to deter-
damage to the steering cylinder, pins, and
mine the optimum interval. Wagner recom-
bushings, caused by bottoming the cylinder
mends changing filters every 400 hours until
out.
evidence indicates differently.
Brake Pedal Adjustment Troubleshooting
Wheel end pressure is 1500 psi (10300 kPa) Troubleshooting hydraulic systems involves
and can be checked at the J-block. Pressure starting at the beginning of the system and
is adjustable using the brake pedal heel stop. checking the operation of each part until the
trouble is found.
To adjust, with vehicle on a level surface,
release the park brake. Put the vehicle in 1st Section 10, Troubleshooting, contains a
gear and roll the vehicle forward, adjusting series of tables design to aid in troubleshoot-
ing all the systems found on your scooptram.

Hydraulics
Once you have found the area where the on expensive equipment. Always treat it as
trouble lies, it is then necessary to locate the such.
exact component in that area which is not
operating properly. Basic Causes of Hydraulic System
Failures
IMPORTANT: When servicing a hydraulic
system, think first —disassemble last!!! Before proceeding to troubleshooting charts,
it is important that you remember that the
It is not at all unusual for an untrained three most common causes of hydraulic sys-
mechanic to immediately start disassembling tem failures are dirt, heat, and foaming.
the hydraulic system when it is not working
correctly. This can increase the amount of The effect that dirty hydraulic oil can have
downtime for the vehicle many fold simply on a system has been described. Dirt can do
because the mechanic did not stop to think more damage than either heat or foam. How-
before acting. ever, heat and foam are also very damaging
to any hydraulic system.
Careful troubleshooting of a hydraulic sys-
tem pays off in saved time and work. Excessive heat can affect packing and seals.
Oil and air leaks form, and the effectiveness
Safety of the hydraulic system is quickly reduced.
Play it safe. More than one mechanic has Dirt is able to get into the system around
been injured when checking out a hydraulic damaged packing and seals, which further
system. Raising the boom and failing to sup- shortens the life of the system.
port it properly before draining the system System Overheat Protection
can be deadly.
Normally, overheating can be prevented by
Always remember that hydraulic systems following a few simple rules:
operate under high pressure. Sometimes it is
necessary to work on a line that is under 1. Always use a hydraulic oil of proper vis-
pressure. If so, be careful. Always shut down cosity. The use of an oil of greater vis-
the vehicle when possible. cosity than that recommended,
particularly in areas of low ambient tem-
Avoid shortcuts. This applies both to disas- peratures, will cause increased fluid fric-
sembly and assembly. If a hose or piece of tion and overheating.
tubing is supported in two places by clamps,
replace both of them even if you feel one
will do the job.
Always use the correct tools. Some parts of
the hydraulic system are easily damaged,
particularly if some makeshift tool is used
when a precision tool is required.
Use recommended service procedures. Don’t
experiment. Remember that you are working

Hydraulics
2. Always connect hoses and clip them into prevent air from getting into the system and
position according to manufacturers’ rec- causing foam.
ommendations. Rerouting a hose too
close to the unit’s transmission or engine Eliminating Air From the System
can cause the hose to overheat. This Adjust and replace packing and seals when
results in overheating of the hydraulic oil necessary. Failure to do so will eventually
passing through it. Also, avoid using result in air leaks. When replacing seals and
undersized hoses and be sure to install packing, use only those products recom-
the hoses so that there are no sharp mended by the manufacturer.
bends. These can increase friction and, as
When installing hoses, make sure they are
a result, raise the oil temperature.
properly supported. Vibrating hoses can
3. When pumps, cylinders, and other loosen connections and allow air to enter the
hydraulic system components become system.
worn, replace them. Worn parts allow
excessive oil slippage which in turn Periodically check all hose fittings and con-
requires the pumps to operate at full out- nections to make sure they are properly
put over long periods. This longer cycle tightened. A pressure leak is easy to recog-
increases the length of time during which nize because the oil will be visible. How-
fluid friction is generated within a sys- ever, a suction leak can occur with no visible
tem, increasing the oil temperature. signs.
4. Always keep the outside and inside of If in doubt, apply oil to the inlet hose joints,
the hydraulic system clean. Dirt on the one joint at a time. If pump noise, caused
outside of the system acts as an insula- from the presence of air, decreases when oil
tion and prevents normal oil cooling. Dirt is added to a certain joint, you know this
on the inside of the system causes wear joint is leaking air.
which results in oil slippage. When servicing or rebuilding various
Oil foaming is simply a condition where air hydraulic system components, make sure
that you are doing a good job. Packing that is
is mixing with the oil. This forms small bub-
bles which accumulate in various parts of the improperly installed will often leak. Sloppy
system. assembly procedures will result in unreliable
service and costly follow-up repairs.
When oil foams, it can overheat. This is
because the air in the oil increases in temper- Excessive air in a system can usually be rec-
ature when the oil is compressed. In other ognized by erratic and uneven operation of
words, as the air is compressed, the tempera- the hydraulic system. The air in the system
ture rises just as it would in an engine cylin- does not allow the oil to provide steady pres-
der. The hot air bubbles in turn heat the sure against the pistons, causing jerky opera-
surrounding oil. It is easy to see, therefore, tion. Therefore, if you should have this
that everything possible should be done to condition, look for air leaks in the system.

Hydraulics
Checking for Component Failure 5. The second basic check is to test the
cycle times of all hydraulically actuated
A failure of one or more components in the
systems. Below normal times will indi-
hydraulic system will usually result in one of
cate possible flow problems.
the following:
6. If the pressure or cycle times are below
1. The hydraulic system will slow down
specification, disconnect the hydraulic
and become sluggish
line on the outlet of the pump and install
2. It will lose pressure. a pressure gauge (and in-line flow meter)
The first rule in determining the root cause to determine if the pump is operating
of the problem is to never assume anything. correctly.
A careful step by step process is the best 7. Proper flow and pressure at the pump
method in identifying the source of a prob- outlet usually is an indication that there
lem. is not a problem with the pump. Begin
The first step should be to check the easiest isolating and testing individual systems
possibilities first. On the hydraulic system, and components until the problem is
this means checking the oil level in the tank. found.
Next, conduct a visual inspection of all Checking Hydraulic Systems for Leaks
hoses, fittings and linkages. Leaks are a common symptom of more
If no visual problems are evident, check that extensive troubles in a hydraulic system.
system pressure is within specifications. Hydraulic system leaks can be classified into
Pressure tests are usually made by attaching two major types: external leaks and internal
a pressure gauge at the pump or relief valve, leaks.
depending upon the particular system. To External Leaks
check the maximum hydraulic pressure out-
put for a system proceed as follows: External leaks on the pressure side of a
hydraulic system are easy to locate because
1. With the engine shut down, remove the
of the presence of hydraulic fluid. Neverthe-
pipe plug from the point at which the
less, it is important that the maintenance per-
gauge is to be attached and install the
sonnel and operator keep a close watch over
gauge.
the various components of the hydraulic sys-
2. Start the engine. tem in order to identify and correct pressure
3. Accelerate the engine to maximum rpm, leaks as soon as they start.
and operate the specific function in ques- External leaks which occur on the intake side
tion. Hold it in that position. of the pump are much more difficult to
4. Check the gauge reading to see if it con- detect. However, you can usually suspect
forms with the maximum oil pressure intake leaks in a system if any of the follow-
recommended by Atlas Copco Wagner ing five conditions are evident:
Inc. • Air bubbles in the hydraulic oil.

Hydraulics
• Erratic or jerky hydraulic system action. tion can also prove helpful in determining
• Overheating the source of internal leakage in a hydraulic
system.
• Excessive pressure in the reservoir.
The Basic Causes Of Fluid System Leakage
• Excessive pump noise. Are:
If any of these conditions exist, you should 1. Human Error.
first check all intake fittings and connections
for leaks. 2. Lack of Quality Control.
Remember that over-tightening can be even 3. Poor Protection of Components in Han-

more troublesome than under-tightening. dling.
The number of pound-feet recommended for 4. Difficult to reach Fitting Connections.
tightening a particular swivel nut will ensure
5. Improper Design of Piping or Routing
a tight seal and yet not be so tight as to result
in distortion of one or both fitting seals. 6. Poor Selection of Materials
Leaks on the intake side of the system can 7. Lack of Education
usually be detected by adding oil to the area
Finding the Leak Location
of the connection. If the pump noise caused
by aeration lessens or stops, you have found Identifying the exact location of a leak can
the connection where air is being taken into be difficult. To make sure that a leak is not at
the system. a higher point and draining down:
Internal Leaks 1. Wash and/or wipe down leakage area.
As the various components of a hydraulic 2. Watch for the leak to appear.
system wear, internal leakage within the 3. Place a paper towel or rag above the sus-
components occurs. A slight amount of inter- pected connection to catch any fluid
nal leakage can be tolerated. As leakage dropping from above.
increases however, system performance
begins to drop as hydraulic energy is lost. Remember — Seepers or weepers can be
This lost energy turns up in the form of heat, hard to locate.
which can degrade the oil and lead to prema- Leak Problem Areas
ture equipment failure. Therefore, it is
important that the hydraulic system be kept SAE 37° Flare Connection
in good working order. Causes:
A good mechanic can troubleshoot a hydrau- Most of the leaks on this connection are due
lic system and find the source of trouble to the lack of tightening (human error). You
without any unnecessary, time-consuming can’t tell if the nut has been tightened by just
disassembly. A careful study of trouble- looking at the connection. If it is more than
shooting charts in Section 9 will help you finger tight, you can’t tell from observation
develop this ability. The following informa- how much.

Hydraulics
Torque wrenches are good only when they Foreign particles in the Wash them off
are used. You must rely on the user to be sure joint
they get used on all joints and connections.
The user must depend on his memory to Cracked Seats Replace them
know if he has tightened all of the joints. Seat mismatching or not Replace the adapter
concentric with the
Cures:
threads
Here is a foolproof method of tightening. Deep nicks in the seats Replace faulty part
Anyone can tell if the joint was tightened
Excessive seat impres- Replace the part
and how much:
sion. This indicates too
1. Tighten nut finger tight until it seats. soft a material for high
2. Use an ink pen or marker to mark a line pressures. Threads will
lengthwise on the nut and extend it onto stretch under high pres-
the adapter. sure
3. Tighten the nut with a wrench, turning Phosphate treatment Replace faulty parts
the nut the amount shown in the follow- This is an etching pro-
ing chart. cess which if overdone
leaves a rough sandpa-
The difference (misalignment) of the marks per-like surface
will show how much the nut has been tight-
ened (or that it has been tightened). Chatter or tool mark — Replace faulty part
High and low spots on
Hose Size Rotate No. of Hex Flats seats
4 2-1/2
SAE 45° nuts
5 2-1/2
Causes:
6 2
8 2 When connected to an SAE 37° male flare
10 1-1/2 -2 fitting it will leak. The SAE 45° nut is too
long and will bottom on adapter hex in sizes
12 1
8 and 10 before the seats are tight.
16 3/4-1
Cures:
20 3/4-1
24 1/2-3/4 Use all SAE 37° flare parts.
What to do if the joint leaks after it has been Remember: Many of the leakage problems
tightened properly. on this type of connection won’t show until
the unit has had a few hours of service.
Disconnect the line and check for:
All items, except the first one in the above
Problem Corrective Action chart, are quality control problems which are

Hydraulics
usually found on parts supplied by the lowest This is to insure that the shoulder will make
bidder. contact with the mating accessory surface
SAE Straight Thread “O” Ring Seal. before the flange does.
The flange halves overhang the shoulder on
Problem:
the ends so that the bolts will clear the shoul-
Elbows loosen up after short service. der.
“O” ring leakage after short service. Problem (1):
“O” ring leakage after long service. Because of the shoulder protrusion and the
Instant leakage upon start up. flange overhang, the flanges tend to tip up
when the bolts are tightened on one end, in a
Causes: seesaw fashion. This pulls the opposite end
May be either human error or faulty parts. of the flange away from the shoulder and
when hydraulic pressure is applied to the
Cures: line, it pushes the shoulder back into a cock-
ing position.
Replace “O” ring seals and start over.
Causes:
Jam nut and washer must be to the back side
of the smooth portion of the elbow adapter. This connection is very sensitive to human
Lubricate the “O” ring — Very Important error and improper bolt torquing.
Thread into port until washer bottoms onto Cure:

seat face. All bolts must be installed and torqued
Note: Is the spot face large enough for the evenly. Finger tightening with the use of
washer? Does hex of the straight adapter fit feeler gauges will help to get the flanges and
Into spot face shoulder started squarely.
Position elbows by backing up the adapter. Problem (2):
Tighten jam nut. When the full torque is applied to the bolts,
SAE 4-Bolt Split Flange Connection the flanges often bend down until they bot-
tom on the accessory. This also causes the
The SAE 4-bolt split flange connection is a bolts to bend outward.
face seal. The shoulder which contains the
Cause:
seal must fit squarely against the mating sur-
face and be held there with even tension on Bending of the flanges and bolts tends to lift
all bolts. the flange off the shoulder in the center area
The shoulder protrudes past the flange between the long spacing of the bolts.
halves by.01 in. (.25 mm) to .03 in. (.76 When pipes and/or hoses are joined together
mm). with this connection, the conditions become
more sever because the spacing between

Hydraulics
mating flanges now is doubled and becomes Pipe Thread Leaks

.02 in. (.5 mm) to .06 in. (1.5 mm) gap. All
What to do if the joint leaks after it has been
conditions are now multiplied 100%.
tightened properly:
High torque is required on all bolts which
Disconnect the line and check for:
must be Grade 5 or better because much of
the torque is lost in overcoming the bending Problem Corrective Action
of the flanges and bolts. Connector not tight Tighten
Cure: Cracked port or con- Check for cracks
nector and replace defec-
Lubricate the “O” ring before assembly. All tive parts
mating surfaces must be clean. All bolts
must be evenly torqued. Don't tighten any Oversized threads in Inspect for proper
one bolt fully before going to the next one. port thread size
Because of the tolerance build up in all com- Undersized threads Inspect for proper
ponent parts plus the bolt bending, the flange on connector thread size
halves can move sideways. This can lessen Galled threads (torn Inspect and replace
the shoulder contact with the flange to zero threads) if necessary
in the center area between the long bolt spac- Damaged threads, Replace if damaged
ing.
nicks, cuts, etc.
When flanges have a large radius on the Threads not dry-seal Use “NPTF DRY-
edge, the leakage problem becomes even standard for hydrau- SEAL” standard
greater with the above conditions. lics
Remember: All flanges have a small break at Straight pipe threads Use “NPTF DRY-
edge to insure full contact with the shoulder instead of tapered SEAL” standard
flanges.
Contaminated Clean and inspect
In spite of all of the unfavorable conditions threads, dirt, chips,
with this design, has run high pressure etc.
impulse tests under lab conditions with up to
High vibration loos- Retighten connector
2 million cycles without failure of any com-
ening connection Check with engi-
ponent.
neering
These test were made on quality parts using
Heat expansion of Retighten while hot
standard 60 durometer “O” ring seals and
female threads
5000 psi (34500 kPa) pressure peaks. The
3000 psi (20800 kPa) designed connection Too tight, causing Check, replace
was used in the test with heat treated flanges. thread distortion

Hydraulics
Remember Protective internal paint coatings, if used,

must be compatible with the hydraulic fluid
Many of the leakage problems on this type of
used.
connection won’t show until the vehicle has
had a few hours of service. Be sure all parts are on hand.
Parts from storage can develop a build-up of
Removal and Replacement resin from protective oils and grease. This
Procedures resin should be dissolved with solvent before
WARNING: Block all wheels, the part is installed.
remove the ignition key, and place a Make use of lifting eye bolts and transporta-
ACW00073.pict
warning tag on the steering wheel tion equipment.

before performing maintenance on the
Do not use force. In order to prevent radial
hydraulic pumps and accessories.
forces and tension on pipelines and compo-
WARNING: The Hydraulic System nents, ensure that pipelines are firmly
contain Accumulators. Depressurize secured.
ACW00073.pict
the system before performing Mainte-

Do not use putty or Teflon tape as a sealing
nance.
material, as this can lead to contamination
NOTE: The use of any safety procedures and thus malfunctions.
given in this section do not preclude any
Make sure hose lines are correctly laid. Rub-
other safety practices contained in this man-
bing and touching of the lines must be
ual.
avoided.
Before Starting Ensure availability of correct fluids (ISO VG
Check cleanliness: DIN 51519)
• of the area around the vehicle Relieving Hydraulic Pressure

• of power units, pipe connections, compo-
Before conducting any service on the
nents
hydraulic system, follow these procedures:
• of hydraulic fluids
1. Park the scooptram on a flat level surface
• of parts from stock and block all wheels.
Watch out for contamination. Dampness or 2. Install the articulation lock.
dirt from the surrounding environment must
3. Lower the boom so that it is resting on its
not be allowed to enter the hydraulic reser-
stops and roll the bucket down so that the
voir. Fill reservoir only via a filter, prefera-
blade is resting on the ground.
bly via system filters or portable filter
stations with fine filters (10 micron). 4. Release the brake accumulator pressure
by depressing the park brake override
Do not mix Fire Retardant Fluid (FRF) with
switch.
standard hydraulic fluids.

Hydraulics
5. Depress the hydraulic tank relief valve to 2. Adjustment Screw (Allen Head)
relieve the built up tank pressure. Check and record kick-in and kick-out pres-
WARNING: Hydraulic pressure is sures on the accumulator charging valve.
still dangerously high in the cylinders Attach pressure test gauge to the accumula-
ACW00073.pict
and hoses. Use extreme caution while tor pressure test port or use the accumulator
removing a hose flange to a cylinder. pressure gauge mounted in the operator’s
Before removing any hose: compartment. See the Hydraulics section for
details on the Auxiliary Valve.
1. Clean immediate area around any
Start and run the vehicle. Observe gauge and
hydraulic component to be serviced to
record highest pressure reading attained
prevent contamination.
(kick-out).
2. Label hose to facilitate assembly and
Cycle brakes. Observe and record the lowest
diagnostics.
pressure reading before pressure starts to
3. Have plug prepared to cap each hose to increase (kick-in).
be removed.
Pressures should be:
4. Return lines are open to tank, therefore
Kick-in 1600 psi(110.3 bar)
the entire hydraulic tank can drain if they
are not adequately plugged. Often it is Kick-out 2000 psi(137.9 bar)
useful to apply a vacuum (5-7 psi / 340- If these readings are not observed, the charge
480 kPa) on the hydraulic tank at the valve needs adjustment. Follow adjustment
breather to prevent oil leakage, but a plug procedure:
will still be necessary to prevent contam-
inate from getting sucked into the lines. Note: Hydraulic oil must be at operating
temperature (66° C / 150° F).
Pressure Setting Checks and 1. Check and adjust the pressures with the
Adjustments engine running.
Charge Valve Kick-In and Kick-Out WARNING: The articulation lock
must be installed and an authorized
1 operator must remain in the vehicle
ACW00073.pict
cab at all times when the engine is running.

2. Loosen the adjustment screw locking nut
on regulator section of the charge valve
cartridge.
2
1. Adjustment Screw Locking Nut

Hydraulics
3. Using an Allen wrench or screw driver, Install a pressure gauge in the test port fitting
turn the adjustment screw. Turn counter- on the pressure port of the priority valve.
clockwise to reduce pressure and clock-
wise to increase pressure. Turning adjust-
ment screw will automatically adjust
both kick-in and kick-out pressures.
4. Adjust the pressure until the it reaches
13788 kPa (2000 psi).
1 2 3
5. Bleed off accumulator pressure by
cycling park brake switch, and recheck
pressures. When the correct kick-out
pressure is achieved, re-lock adjustment
screw. 1. Steering Pressure Test Port
Note: The kick-in pressure will automatically 2. Bypass Flow
adjust with the kick-out pressure. 3. Dump and Hoist Pressure Test Port
6. Re-install cap and tighten with wrench. Note: Atlas Copco recommends use of a cal-
ibrated test gauge. This will allow operator
Steering and Dump Main Relief to check the accuracy and calibration of
instrument panel gauge.
Adjusting pressure set-points is accom-
plished in the same manner as with the Start the engine. With hydraulic oil at operat-
charging valve. An adjustment screw locking ing temperature and the engine at high idle,
nut and adjustment screw is provided for steer the vehicle up against the stops and
each pressure setting. Remove cap and hold.
loosen locking nut. Turn counter-clockwise Record the indicated pressure and adjust if
to reduce pressure and clockwise to increase necessary.
pressure.
Remove pressure gauge from the steering
Note: Check that cap seal washer is present control valve and install it on the pressure
and in good condition. test port on the dump/hoist control valve.
With the engine at high idle, operate any
dump/hoist function to its limit of travel and
hold.
Record the indicated pressure and adjust if
necessary.
Note: Pressures should be within 50 psi (3.4
bar) of specified set-point.

Hydraulics
Steering and Dump Port Relief Sequence Valve
To check port relief pressures, both the steer- The sequence (pilot pressure) valve in the
ing and dump control valve main relief pres- hydraulic brake system is checked by attach-
sure settings must be adjusted to a point just ing a gauge at the quick disconnect fitting on
above the port relief set point. the valve. Record this reading. It should be
2413 kPa (350 psi) at low idle.
Place the boom in the fully raised position
with the bucket in the dump position and Cooler Check Valves
hold.
Install gauge between sequence valve and
Using an attached pressure gauge or the check that pressure is within specifications
accumulator pressure gauge mounted in the (448 kPa/65 psi).
operator’s compartment, slowly adjust both
the dump control and steering control valve Charge Pump Pressure
main relief set-points until it is just above the This pressure is measured at the test port on
specified port relief pressure. The highest the transverter and should be 240-280 psi
pressure that the valve can be adjusted to (16.5-19.3 bar).
indicates the port relief pressure.
Hydraulic Drift
Record the indicated pressure and adjust port
relief pressure to specified set-point, if nec- Check the bucket rollback drift following
essary. these procedures:
Reset steering and dump main relief pres- Park the vehicle on a flat surface.
sures to their specified set-points. With the boom lowered and resting on its
Steering and Dump Pilot Valve stops, roll the bucket back until it rests on the
Z-bar stops.
Install a pressure gauge in the test port fitting
on the auxiliary valve. See the Hydraulics Shut the engine off and let stand for 5 min-
section for details about the auxiliary valve. utes.
Measure the distance the bucket has rolled
Remove cap and loosen locking nut.
forward. If it is more than 1.6 cm (5/8”) in
Start the engine. With hydraulic oil at operat- five (5) minutes then there may be a problem
ing temperature and the engine at high idle, with a cylinder or the main control valve.
record the indicated pressure and adjust if
necessary. Pump Flows
Note: Some pilot valves utilize a shim type Use the following procedures to check the
adjustment in place of an adjusting screw. pump flows. See the Specifications section
These units usually do not require re-adjust- for proper flow rate for each pump.
ment. Adjustments are made by changing 1. Follow the procedures to relieve the
number or size of washers. hydraulic pressure.

Hydraulics
2. Install a flow meter in the line between 3. Attach a hoist or some type of rigging
the pump to be checked and the first rated for the weight of the cylinder to
valve in the system. Also, install a pres- support the cylinder.
sure gauge in the system main relief test
4. Loosen and remove the bottom trunnion
port, or use the hydraulic pressure gauge
cap and bolts.
on the gauge panel in the operator’s com-
partment. 5. Loosen and remove the top trunnion cap
bolts but do not remove the cap. Hold it
3. Start the engine and actuate the dump/
in place on the cylinder eye to keep the
hoist lever to warm up the system. check
pin from slipping. On the ST1010, this
the hydraulic level and add more oil if
will keep the oil from spilling out of the
necessary to replace lost oil from meter
pin.
installation.
6.
4. Be prepared to measure engine RPM.
WARNING: Keep fingers and hands
5. Once the oil has warmed, actuate to sys-
clear from the pin area while remov-
tem controls to relief and at the same
ing the trunnion caps. Severe hand
ACW00073.pict
time run engine to its governed RPM.

injury could result if the pin inadvertently
6. Record engine RPM, pump flow rate, slips down to the cylinder eye.
and hydraulic pressure.
7. Hoist the cylinder out of the way and
7. At the same engine RPM for the full load place on the shop floor or a suitable work
test, record flow and pressure while the stand.
system is not at relief. (No controls actu-
ated to relief.) Steering Cylinder Installation
8. If pump flows are not within 10% of Follow the removal steps in reverse order.
each other, the pump needs to be ser- For the ST1010, check oil filled pin oil levels
viced. add oil if necessary.
Operate the scooptram to bleed any air out of
Steering Cylinder Removal and the system prior to putting the machine into
Replacement service.
Steering Cylinder Removal
Dump Cylinder Removal and
1. Follow the procedures to relieve the Replacement
hydraulic pressure.
Dump (Stabilizer) Cylinder Removal
WARNING: Extreme caution must
be used when removing a hydraulic The dump cylinder will require some sort of
ACW00073.pict
hose from a cylinder. lifting device to support and lower the cylin-
der to the ground. Determine how the cylin-
2. Disconnect all cylinder hoses. Clean, der will be handled before removing, then do
label and plug all cylinder and hose con- the following.
nections.

Hydraulics
1. Follow the procedures to relieve the WARNING: Depending on the

hydraulic pressure. scooptram model, the boom could
ACW00073.pict
WARNING: Extreme caution must weigh up to 5670 kilograms (12,500

be used when removing a hydraulic lbs.). Do not reach or lean underneath the
ACW00073.pict
hose from a cylinder. boom unnecessarily.
2. Disconnect all cylinder hoses. Clean, Note: It is not necessary to remove the
label and plug all cylinder and hose con- bucket to remove the hoist cylinders. How-
nections. ever, the bucket must be secured so that it
does not become a hazard once the boom has
3. Attach a hoist or some type of rigging been raised.
rated for the weight of the cylinder to
support the cylinder. 1. Park the scooptram on a flat level sur-
face, block all wheels, and install the
Note: Leave base end return hose attached articulation lock.
until after cylinder rod has been retracted.
2. Raise the boom and place support stands,
4. With cylinder secured in place remove rated for the boom weight, beneath it.
first the stem pin, then the base pin. Be Lower the boom until all of its weight is
careful of free swinging cylinder ends. supported by the stands.
Retract stem rod back into cylinder
before removing base pin. 3. Follow the procedures to relieve the
hydraulic pressure.
5. Remove bolts to remove the trunnion
caps and leave pin inside cylinder until 4. Secure the hoist cylinders in place (to
cylinder is on stable surface. prevent them from swinging free once
pins are removed).
Dump Cylinder Installation
Note: Make sure cylinder is free of grease or
Reassemble in reverse order. Clamp base end oil before securing with strap to prevent it
pin first. Position stem pin in place and use from slipping.
hoist to extend cylinder into the bucket CAUTION: Hydraulic fluid may be under
clamp. pressure. Safety glasses and heavy gloves
must be worn.
Hoist Cylinder Removal and
Replacement 5. Disconnect all cylinder hoses. Clean,
label and plug all cylinder and hose con-
Hoist Cylinder Removal nections.
The hoist cylinders will require some sort of 6. With cylinder secured in place remove
lifting device to support and lower the cylin- first the stem pin, then the base pin. Be
der to the ground. Determine how the cylin- careful of free swinging cylinder ends.
der will be handled before removing, then do Retract stem rod back into cylinder
the following. before removing base pin.

Hydraulics
7. If machine has trunnion caps (shoulder The following procedures are generalized
collars), remove bolts to remove collars and apply to the removal/replacement of
and leave pin inside cylinder until cylin- both the steering and main control valves.
der is on stable surface.
Valve Removal
Hoist Cylinder Installation 1. Steam clean the area around the valve to
Reassemble in reverse order. Clamp base end be removed.
pin first. Position stem pin in place and use IMPORTANT: Make sure the area around
hoist to extend cylinder into the boom clamp. the valve is clean and free of debris. Valves
Operate the scooptram to bleed any air in the are susceptible to damage from dirt or grime
system prior to placing it back into service. being introduced into the hydraulic system
due to dirty service conditions.
Pump Removal and Replacement 2. Relieve all hydraulic pressure as
instructed in the section titled “Relieving
1. Follow the procedures to relieve the
Hydraulic Pressure.”
hydraulic pressure.
3. Disconnect, cap or plug, and label all
2. Remove the hoses and plug lines and
hydraulic hoses to the valve.
ports on the pump.
4. Cap or plug the inlets, pressure ports, and
3. Remove the mounting bolts, and slide the
pilot ports to prevent contamination.
pump off the forward pump stub shaft.
5. Attach a hoist cable to the valve for sup-
4. Cover open stub shaft assembly to keep
port while removing the mounting bolts.
clean
6. Loosen and remove the valve mounting
Pump Installation bolts.
Install in components in reverse order, torque 7. Hoist the valve to a work bench, do not
hardware to specified values. place the valve in a position where it
When assembly has been correctly com- could be damaged.
pleted, proceed with start-up and functional Valve Replacement
testing.
To replace a valve, follow the removal pro-
Valves cedures in reverse.
WARNING: Both the steering and Valve Cartridge Removal/Service
the main control valves are extremely
ACW00073.pict IMPORTANT: The most common cause of
heavy. Care must be taken to avoid
failure is dirt in the hydraulic oil.
injury or even death while removing the
valve. Use a hoist rated for the weight of the • Dirt which lodges in the working parts
valve to lift and support it during the and interferes with their operation.
removal/installation process. • Dirt introduced due to filter bypass

Hydraulics
Most cartridges can be cleaned without alter- way. See section for cartridge removal pro-
ing their settings. cedures.
To check and clean a cartridge which is not • J-Block
functioning:
• Auxiliary Valve
1. Remove the cartridge from the cavity.
If it becomes necessary to remove a valve
2. Inspect for visible contaminants and manifold, follow these generalized instruc-
carefully remove obvious particles. tions:
3. Through the nose of the cartridge, manu- 1. Relieve the hydraulic pressure following
ally operate the inner working parts sev- the instructions titled Relieving Hydrau-
eral times. Use a piece of plastic tubing lic Pressure.
to avoid damaging soft seats, sharp
2. Vent and drain the hydraulic tank into
edges, finished surfaces or the screen
suitably sized reservoir, the reuse of fluid
protecting the pilot orifice. All parts
is not recommended.
should move freely. If possible, do this
with the cartridge submerged in clean 3. Clean, label, disconnect and plug all
mineral spirits. hoses and harnesses to the manifold.
4. After “flushing,” blow dry with clean fil- 4. Loosen and remove the bolts that secure
tered air. the manifold.
5. Replace seals if indicated, using the 5. Remove the manifold.
appropriate service kit.
Manifold Replacement
6. Dip the cartridge in clean hydraulic oil,
then reinstall the cartridge, tighten to Follow the removal procedures in reverse.
specified torque and re-test.
Preparation for Trial Run
7. If this procedure does not eliminate the
problem, replace with a new factory- Start-up
tested cartridge. (Applicable after overhaul of major compo-
NOTE: Service kits are available for the nent after failure during service).
cartridges. Contact your Atlas Copco Wag- Prior to start-up the following check list
ner dealer for information on cartridge seal should be run.
replacement and or cartridge replacement.
1. Check that Hydraulic Oil Tank is clean.
Hydraulic Manifolds 2. Check hydraulic lines cleaned and cor-
It is not necessary to remove any valve man- rectly installed.
ifolds from the scooptram since the func- 3. Check that all couplings and flanges are
tional part is a cartridge. The following tightened.
manifolds can be removed in much the same

Hydraulics
4. Check that all components are correctly 6. If pilot “boost” pump is installed, start
connected in accordance with installation up; all pump cavities should be full and
drawings or circuit diagram. tank pressurized.
5. Check that hydraulic accumulators are 7. Check operating function of hydraulic
properly charged with nitrogen. system without load.
Note: It is recommended that the gas charge 8. When normal system operating tempera-
be noted on the accumulator itself (e.g. by a ture has been reached, test system under
label) and in the circuit diagram, so that a load. Gradually increase pressure.
check may be made in the future when
9. Check monitoring and measuring
required.
devices.
6. Check engine and pump are correctly
Note: Jerky movements indicate the presence
assembled and aligned.
of air in the system. By changing the pump’s
7. Check that hydraulic filters are of speci- displacement with the actuators in the
fied pore size. loaded or braked condition, certain air pock-
8. Check that all fluids are as specified and ets can be eliminated. The system is com-
filled up to maximum level. pletely bled when all functions can be
carried out smoothly and continuously and
there is no foaming on the surface of the
Trial Run
fluid. In practice, it has been found that
1. Clear the area of all unauthorized person- foaming should have ceased 1 hour after
nel. Only personnel directly required to start-up, at the latest.
test the vehicle should be present. 10. Check fluid temperature.
2. Check that all shut-off valves are fully 11. At normal operating temperature, check
open. flow restriction indicators while operat-
3. Check that the direction of rotation of the ing dump and hoist controls.
engine matches that of the pump. 12. Compare measured values with specified
- Start the vehicle. performance parameters (pressure, speed
and setting of other control components).
- Slowly move forward a few feet.
13. If restriction due to contamination is
- Check rotation. (counter clockwise
found, flush the hydraulic system in
while facing pump input shaft).
order to prevent premature failure of sys-
4. Check position of directional valves and, tem components. Check filter back pres-
if necessary, move into required position. sure.
5. Open pump suction valves - if necessary, 14. Listen for noise.
fill pump housing with fluid.
15. Check fluid level; add if necessary.
16. Check setting of pressure relief valves.

Hydraulics
17. Check for leakage.

18. Shutdown the vehicle.
19. Tighten all fittings, even if there is no
evidence of leakage.
WARNING: Tighten only when the
system is not under pressure.
ACW00073.pict

Section 7 Electrical System
Theory of Operation seconds. If there are any problems with the
system the lights will remain on after the
As with most vehicles an electrical system is engine starts. See Computerized Diagnostic
needed to furnish power to lights, horns, Systems for further information.
starter motors, and electronic control/moni- IMPORTANT: All information concerning
tor systems. In the Atlas Copco Scooptram a the engine electrical system is derived from
24 volt system powers most electrical com- the OEM manuals. For the purpose of expla-
ponents. The gauges use a 24V to12V con- nation, some engine electrical information
verter has been duplicated in this manual. Please
refer to the OEM engine manuals for com-
When the ignition key is turned to the “ON” plete information about the engine systems.
position, the battery energizes the engine
Electrical Control Module (ECM) which in
turn activates the Electronic Unit Injectors
(EUI). When the key is turned to the “start
engine” position, electrical current causes
the starter motor to engage the engine fly-
wheel, starting the engine. When the engine
reaches idle speed, the alternator begins to
generate the 24 volts necessary for vehicle
operation. The alternator also sends electri-
cal current to charge the battery.
The computerized electrical system continu-

ously monitors engine performance and
makes adjustments based on information
given by the operator and the system itself.
As the operator selects a gear and direction,
the engine ECM and transmission Electronic
Control Unit (ECU) communicate their
requirements to fulfill the demands of the
operator.
When the ignition key is turned to the ON

position, the Check Engine and Stop
Engine lights will illuminate for three (3)

Electrical System
Electrical System Components

Electrical System
The electrical system is composed of three Master (Battery Isolation) Switch

major operational units, two of which
The Master Switch is located on the fuel tank
directly involve the vehicle operator and ser-
operator’s side near the batteries and when
vice technicians. The third, the computerized
turned to the OFF position disconnects the
control units, is seemingly invisible to the
electrical system from the battery and alter-
operator but is the most essential to the vehi-
nator. The switch is protected from the envi-
cle operation. The electrical system compo-
ronment by its sealed housing. The main
nents are:
purpose of the switch is to disconnect the
battery from the vehicle so that maintenance
• Vehicle Electrical Systems
can be safely conducted on the vehicle.
• Computerized Control Units
• Instruments and Gauges IMPORTANT: Remember to turn the Mas-
ter Switch to the OFF position before weld-
Vehicle Electrical Systems ing on any part of the Scooptram.
Note: Turning the Master Switch to the OFF
The vehicle electrical systems include the position while the vehicle is turned on can
basic units that are needed for safety and cause a catastrophic failure to the electronic
normal operation of the scooptram. These modules.
systems include the wiring harnesses, circuit
breaker box, master (battery isolation) Component Box
switch, park brake switch, charging and igni-
tion systems, and the lights and horns/ The component box is an all metal compart-
alarms. ment designed to house key electrical con-
nections and circuit breakers. It is
Wiring Harnesses environmentally sealed and re-enforced from
falling rock damage. The compartment
The Atlas Copco Scooptram is equipped houses the circuit breakers for the ECM
with a sealed electrical system designed to injectors and the control panel. Circuit
withstand operating temperatures of 257° F breaker switches are located in the scoop-
(125° C) and surges up to 600 volts. The wir- tram operator’s compartment for the comput-
ing splices are dip soldered and protected erized control components and two (2)
with waterproof heat shrink tubing. Exposed options. See the Operator’s Manual for fur-
connections are coated with 3M #776 “con- ther information.
formal coating” to prevent corrosion and
possible shorts in the system. Internal con- Park Brake Switch
nections and terminal blocks are spray
coated with urethane. In areas where abra- The park brake switch is a push/pull button
sions can occur the wiring harnesses are pro- located on the control panel in the cab of the
tected with a hosebraided sleeve or spiral scooptram and when depressed actuates the
wrap. SAHR brakes. When pulled out, the park
brake solenoid is energized and the brakes

Electrical System
are released. The park brake system is inter- tion. An in-line fuse on the positive battery
locked with the engine so that the brakes cable protects the starter from overcurrent
cannot be inadvertently released when the conditions.The master (battery isolation)
vehicle is not running.The park brakes will switch is attached to the positive and nega-
be applied when any of the following occur: tive cables to isolate the battery and alterna-
tor from the electrical system.
• The park brake button is depressed.
• The ignition switch is turned to the “off” Alternator
position.
• The master switch is turned off. The alternator is a fully enclosed unit that
• The brake accumulator pressure falls has a built in regulator and is brushless. The
below 9652 kPa (1400 psi) or the trans- alternator has two (2) functions, it provides
verter charge pressure falls below 414 electrical current for vehicle operation and
kPa (60 psi). charges the battery as the vehicle is operat-
• Any time the electrical system is cut-off ing. The battery charging function requires
from the brake solenoid. about 20% of the alternator’s full load capac-
ity. The alternator is over-sized to provide
Note: Whenever the park brake is activated this margin when the engine is running at
by the Programmable Logic Control, the high idle.
indicator light in the switch will blink.
Engine Control Module
Charging and Ignition System
The ECM is energized when the ignition key
The charging and ignition system is made up is turned to the on position. It, in turn, sends
of the battery, alternator, ECM, and the a command pulse to the Electronic Unit
starter. Injectors (EUI) which delivers fuel to the
cylinders. The injectors are cam driven
Battery which provides the mechanical pressuriza-
tion of the fuel for combustion. See the Com-
1 puterized Control Units section.
2
Starter
A B
The starter system is made up of three (3)
solenoids that allow electrical current to flow
through the system. The first, located in the
1. Master (Battery Isolation) Switch
vehicle cab, lets current flow to the on-board
2. 24 Volts
control units when the key is turned to the on
The battery system is a series of two (2) 12 position. The second, located by the battery
volt batteries that provide the 24 volts for the isolation switchin the component box, opens
operation of the starter and ECM initializa- the circuit to the battery to engage the starter

Electrical System
solenoid. The last, located on the starter and the DCU, and outputs to the transverter
itself, allows electrical current to actuate the and the park brake solenoid. The PLC oper-
starter motor and gears to engage the engine ates on a ladder logic program to make gear
flywheel. and direction commands (based on the oper-
ator’s input) and to either release or set the
Computerized Control Units park brake. The park brake program relies on
two criteria that are continuously monitored:
1
• Park Brake Switch--pulled out or
4 depressed.
• Hydraulic/Transverter Pressure
• Engine status
• Park Brake pressure

3
2
If there is a pressure loss in either the
1. Data Control Unit hydraulic system, transverter system, or park
2. Transient Voltage Protection Module brake system, or the engine is not running,
3. transverter Electronic Control Unit the PLC will change states to apply the park
4. Programmable Logic Controller brake. Another relay from the engine ECM
changes state when the engine is running so
The computerized control units are the that the park brake can be released. Both
brains of the vehicle, they are responsible for relays are located behind the display panel in
monitoring the engine performance, the the operator’s compartment.
transverter gears and system status, inputs
from the vehicle operator, and output all Engine Electronic Control Module
diagnostic data. The computerized control System (ECM)
units include the following:
The engine electronic control module is an
• Programmable Logic Control (PLC) engine mounted computerized logic control
• Engine Electronic Control Module device that provides overall engine manage-
(ECM) ment. The ECM continuously performs diag-
• Transverter Electronic Control Module nostic checks and monitors other engine
(ECM) systems. The ECM uses an electronically
• Data Control Unit (DCU) erasable programmable read-only-memory
(EEPROM) to control engine speed and
Programmable Logic Control (PLC) power, injection timing, governing, torque
shaping, cold start logic, fuel delivery, diag-
The PLC is a microprocessor that receives nostics, and engine safeguards. The engine
input from the operator, the engine ECM, control logic provides directions for fuel

Electrical System
injection timing and duration which results 9. Battery

in precise fuel delivery. The ECM system 10. Timing Reference
consists of the following units: 11. Synch Reference
12. Throttle Position
• Electronic Control Module 13. Turbo-Boost Pressure
• Electronic Unit Injectors (EUI) 14. Air Inlet Pressure
• System Sensors 15. Oil Temperature
• Diagnostic Interfaces 16. Oil Pressure
• Communication Links 17. Coolant Temperature
18. Coolant Level
19. Fuel Temperature
1
Electronic Unit Injectors
10
The EUI is a solenoid operated valve system
that controls the timing and metering of fuel
11
4
injected into the engine cylinders. The cam/
12 3 rocker arm in the engine provides the
5
13 mechanical pump for the high pressure fuel
14
2 delivery. When the solenoid is closed, the
fuel injection function begins then ends
15
when the valve is opened. The duration of
6
16 the valve closure determines the amount of
17 fuel injected into the engine.
18
System Sensors
19 7
The ECM sensor system is designed to pro-
9 8 vide information about the engine various
performance characteristics. The ECM uses
the information to regulate the engine effi-
ciency, give diagnostic data, and to activate
the engine safeguards. The engine sensors
include:
1. SAE J1708 Communication Bus
2. Engine Electronic Control Module • Timing and synchronous reference sen-
3. Electronic Unit Injectors sors
4. Command Pulse
• Turbo boost sensor
5. Feedback
6. Diagnostic Data Link • Fuel pressure sensor
7. Stop Engine Light
• Oil pressure sensor
8. Check Engine Light

Electrical System
• Coolant pressure sensor Coolant Pressure Sensor
• Crankcase pressure sensor

The coolant pressure sensor informs the
• Fuel temperature sensor ECM when the coolant pressure becomes too
• Air temperature sensor low, which is in turn relayed to the operator.
• Coolant temperature sensor Crankcase Pressure Sensor
• Oil temperature sensor
When the crankcase pressure becomes too
• Coolant level sensor
high, the pressure sensor tells the ECM to
• Throttle position sensor initiate engine protection safeguards.
Timing and Synchronous Reference Sensors (TRS
Coolant Temperature Sensor
and SRS)
The coolant temperature sensor monitors

The TRS tells the ECM the crank position of
coolant temperature and indicates to the
the cylinders which indicates the engine
ECM when the temperature becomes too
rotation position, also it indicates when to
high. The ECM then activates the engine
fuel the cylinder. The SRS tells the ECM
protection system when the temperature
which cylinder is firing in the firing order.
exceeds specified parameters.
Turbo Boost Sensor
Fuel Temperature Sensor
The turbo boost sensor gives the ECM infor-

mation on the exhaust system for use in The fuel temperature sensor measures fuel
smoke control. temperature for the ECM and EUI. Fuel con-
sumption calculations and input compensa-
Fuel Pressure Sensor tion is based on the information provided by
the fuel temperature sensor.
The fuel pressure sensor provides the ECM
Air Temperature Sensor
with data concerning the fuel pressure which
allows the system to warn the operator of
Hot idle speed and injection timing calcula-
impending power loss.
tions are affected by inputs from the air tem-
Oil Pressure Sensor perature sensor. The ECM makes
adjustments to improve cold starts and
reduce white smoke emissions based on the
The oil pressure sensor activates the engine
air temperature inputs.
protection system when the pressure is out-
side the safe operating parameters.
Oil Temperature Sensor
The oil temperature sensor feeds information

Electrical System
to the ECM about the operating oil tempera- Engine Override Switch
ture which, when too high, allows the ECM
to activate the engine protection systems. When the operator presses the engine over-
ride switch while the engine is not running,
Coolant Level Sensor the check engine and stop engine lights will
blink a code. The stop engine light blinks
The ECM receives the coolant level from the any active codes and the check engine light
coolant level sensor and initiates engine pro- blinks the inactive or historic codes. For
tection measures when the coolant level gets instance, the no codes number is 25, when
too low. the operator presses the diagnostic request
button, the stop engine light will flash twice
Throttle Position Sensor then pause and then flash five times in suc-
cession if there are no active problems. If
The throttle system is a function of the there are no inactive codes, after a long
engine ECM and operates in the same way as pause the check engine light will flash the
a sensor. As the foot activated variable posi- same code. This allows the operator and ser-
tion switch is engaged by the operator, a sig- vice person to receive information about the
nal is sent to the ECM. The ECM adjusts fuel engine without the Diagnostic Data Reader
injection and timing based on the input, thus (DDR). If there are inactive codes but no
accelerating the vehicle or slowing it down. active codes, the check engine light will only
blink. See the Computerized Diagnostic Sys-
Diagnostic Interfaces tems section for a code chart.
All problems that occur with the engine are Communication Links
stored in the ECM’s memory. The ECM
diagnostic interface is located in the opera- The engine ECM has three external data
tor’s compartment and can be accessed with links, the first to the diagnostic data reader,
a Diagnostic Data Reader (DDR). Another the second goes to instrumentation and the
way the ECM can relay problems to the third is connected to the transverter. ECM
operator or service person is by pressing the internal communication lines are connected
Diagnostic Request button on the control to sensors and control units on the engine.
panel.
On the Atlas Copco scooptram, the commu-
Diagnostic Data Reader (DDR) nication link between the engine ECM and
the transverter Electronic Control Unit
The DDR is a hand held unit that reads the (ECU) allows the transfer of information
information from the ECM and displays the about engine status, transverter operations,
problem for the service person. The DDR and gear and direction inputs from the opera-
also shows whether the problem is active or tor.
inactive, some problem from the past opera-
tion of the vehicle. A public communication bus (SAE J1708)

Electrical System
links all of the units on a common line. This course of action that will automatically up-
allows data to be passed along to each unit, it shift or down-shift through the gears to the
also allows for additional equipment to be selected gear. If the reverse direction is
brought on-line. selected while the vehicle is in motion, the
transverter will down shift to neutral, then
Transverter System (ECU) change the direction of the vehicle.
The Atlas Copco scooptram is equipped with The default gear setting is neutral (neutral is
a transverter system that is actually a trans- considered a direction by the ECU), when
mission and torque converter combined as the service brake is applied and the vehicle is
one unit. The transverter is an electrohydrau- stopped, the transverter shifts to neutral.
lic system that is electrically controlled and When the vehicle is stopped, the transverter
uses hydraulic pressure to change gears and is in neutral and will not engage in a direc-
direction. The transverter electronic compo- tion until one is selected and the accelerator
nents are as follows: is depressed.
• Electronic Control Unit (ECU) If the ECU detects a problem within its sys-
tems, it will automatically shift down to neu-
• Transient Voltage Protection Module
tral and stay in neutral until the problem has
(TVP)
been rectified.
• Engine Speed magnetic Pickup (MPU)
Transient Voltage Protection Module (TVP)
• Transverter Output Speed MPU
• Operator Controls The TVP is responsible for providing electri-
Electronic Control Unit cal protection to ECU while the ignition
switch is in the ON position.
The transverter electronic control unit, ECU,
is a computerized control system that takes Engine Speed Magnetic Pickup (MPU)
input from an engine speed sensor, the PLC,
and an output speed module attached to the The engine speed magnetic pickup is located
transverter. The input data includes engine in the input housing of the transverter. It is
rpm, gear and direction commands from the responsible for providing the ECU with the
operator, and transverter speed from the out- engine rpm speed.
put speed module. Once the ECU receives
the input information, it employs computer- Transverter Output Speed MPU
ized logic program to select a proper course
of action. If, for example, the operator The transverter output speed, or vehicle trav-
selects third gear forward, the PLC will elling speed, is relayed to the ECU from the
transmit the selection to the ECU which will transverter output speed MPU. The sensor is
then look at the engine rpm and the travel- located in the rear of the transverter.
ling speed and calculate a corresponding

Electrical System
Operator Controls • Transverter Temperature Sensor

• Brake Temperature Sensor
The operator controls the gear setting
through a series of buttons or a selector
The DCU outputs data to individual gauges,
switch located in the operator’s compart-
the mini-message center (MMC) and the
ment. The PLC receives the gear selection
Programmable Logic Controller. The accu-
and transfers the selection to the transverter
mulator and transverter transducers send a
ECU.
signal to the DCU when their respective
pressure drops too low.The low pressure sig-
Auto/Manual Selector Switch
nal is then relayed to both a gauge and to the
PLC. From the PLC, the accumulator/trans-
The transverter system is equipped with a
verter pressure signal is directed to the park
normally open momentary push button
brake solenoid setting the brake.
switch that when held down, allows the
transverter to be operated in the manual
mode. By selecting the manual mode, the Vehicle Instrumentation, Lights,
transverter operates in the gear selected by and Horn
the operator. The main purpose of the switch
is to allow the operator to test the park The Atlas Copco Scooptram is equipped
brakes. with instruments, gauges, lights, and audio
alarm systems that are designed to serve the
Data Collection Unit (DCU) operator and service personnel in various
ways. The instruments and gauges allow the
The DCU is a data interlink that translates vehicle’s operation to be monitored, the
information from various internal sources to lights serve as safety devices as well as illu-
operator instrumentation. The DCU is linked minating the workplace, and the horn pro-
with the vehicle’s public communication bus vides an audio safety pre-caution.
which allows it to send and receive informa-
tion. The data received by the DCU is com- Vehicle Instrumentation
posed of the following:
The vehicle instrumentation is accom-
• Speedometer input (low frequency) plished by a series of gauges, lights, and
switches and are located on the display
• Engine Coolant Temperature panel, switch panel, and control panel in the
• Engine Oil Pressure operator’s compartment of the scooptram.
The information given by the instruments is
• Engine ECM data
useful for safe operation of the vehicle.
• Fuel level
• Accumulator Pressure Gauges
• Transverter Pressure The gauges are mounted in the display panel

Electrical System
and can be programmed to show most infor- Code Description

mation about the vehicle. They are equipped
with an LED warning light and are illumi- 07 Accumulator Pressure
nated so that the operator can see the gauge 08 Transverter Temperature
in dark conditions. The gauges receive data
from the DCU and, depending on their pur- 09 Coolant Temperature
pose, display information as a dial type 10 Oil Pressure
gauge. The Mini-Message Center (MMC) is
a digital read-out gauge that acts as the hour- 17 Battery Voltage
meter and a diagnostic display unit. The
MMC also has an audio alarm that sounds Dash Lights
when there is a problem detected by the on-
board computers. When a problem is The dash lights include the STOP ENGINE
detected, a numeric code is shown on the and CHECK ENGINE lights that are
MMC. designed to catch the operator’s attention
when there is a problem with the engine or
The Mini-Message Center power system. If the Check Engine Light
(CEL) becomes illuminated, a non-critical
operating limit has been reached and the
vehicle will need to be serviced. If the Stop
Engine Light (SEL) is illuminated with the
CEL, a critical problem has been detected
and the engine ECM will begin to ramp
RES SEL down the engine power in thirty (30) sec-
onds. The engine override button may be
pressed to stop the ramp down process for
thirty (30) more seconds.
The gauges run on a 12 volt system and CAUTION: If the Stop Engine And Check
require a DC/DC converter to power the sys- Engine Lights come on simultaneously there
tem. The DC/DC converter is located behind is a catastrophic engine problem and must be
the display panel. The following is a list of shut down as soon as possible.
codes displayed by the MMC:
Gear Selector Buttons
Code Description The gear selection buttons are illuminated to

01 Check Engine assist the operator.
02 Stop Engine Park Brake Switch Indicator

04 Fuel Level
The park brake switch is illuminated with an
06 Transverter Pressure independent light that comes on when the

Electrical System
park brake is applied. Even if the brakes are ond intervals.

set during an emergency, without the opera-
tor’s application, the light is turned on. If the Note: Depressing this button while the Stop
PLC applies the park brake, either by an Engine and Check Engine lights are illumi-
electrical fault or low transverter pressure, nated overrides the engine self-protection
the light in the park brake switch will blink measures. This could lead to severe engine
to indicate the fault. damage.
Switches The Park Brake button is an illuminated

push/pull type that activates the park brake
The selector switches are environmentally when it is depressed and releases the brakes
sealed two to three position rotary switches when it is pulled out.
that are housed in the dash panel. The starter
switch is a three position, spring return to Vehicle Lights
ON switch that allows the operator to ener-
gize the on-board computers and start the The vehicle lights are placed for optimum
engine. Depending on the options on the safety and work performance. They include
vehicle, the switches include on/off for light- the following:
ing, window wiper/washers, and ride control.
Buttons are also environmentally sealed rub- Component Location
ber covered push type buttons.
Boom Lights Two are mounted on the top
The park brake test button is located next to of the boom (part of front
the park brake button on the control panel. lights)
When activated, it overrides the automatic Front Lights Four lights mounted on can-
transverter and manually holds the vehicle in opy
a selected gear so that the drive through
brake test can be conducted. After a gear has Rear Lights Four lights mounted on the
been selected (second or third only), press rear grill
and hold the park brake test button and per- Backing One yellow blinking
form the drive through test. See the General Lights mounted on the rear right
Maintenance section for further instructions hand side
on the drive through brake test.
Horn
The engine override button serves two pur-
poses. When the engine is not running, the The horn is located in the articulation area
engine override switch allows diagnostic and is activated by a push button in the cab.
data to be displayed on the Stop Engine and The back-up alarm, in the rear of the vehicle,
Check Engine lights. When the engine is is turned on whenever the transverter is
running, the button allows the operator to placed in reverse. The audio alarm will be
override the engine ECM for thirty (30) sec- accompanied by a blinking yellow light to

Electrical System
insure the attention of by-standers. monitored within safe margins. The engine
ECM has its own program designed to pro-
Electronic Safeguards tect itself from damage and the transverter
ECU has self protective measures also built
With the computerized electronic control in. The following is a listing of possible
systems, a series of built-in safeguards exist faults and safeguards that exist in the scoop-
that enable the vehicle to be operated and tram electronics.
Fault Safeguard
Low Oil Pressure Engine Ramp Down
(Below 25 psi) The CHECK ENGINE and STOP ENGINE lights will
Engine Temperature too high illuminate. The MMC gives the code 10, and will
sound the audio alarm. The engine oil pressure gauge
(above 210 degrees F) LED will illuminate.
Low Fuel Engine Ramp Down
(1/8 tank and below) The CHECK ENGINE and STOP ENGINE lights will
illuminate. The MMC gives the code 09, and will
sound the audio alarm. The engine temperature gauge
LED will illuminate.
The MMC will display 08 error code, the fuel gauge
LED will be displayed, and if the engine dies due to
lack of fuel, the SAHR brakes will be applied.
Transverter Temperature is too high MMC will display the code 08 and the temperature
(above 250 degrees F) gauge LED will illuminate.
Transverter Oil Pressure too low The MMC will show the error code 06, the transverter
pressure gauge LED will show the alarm, and the park
(200 psi) brake light will come on. The SAHR brakes will be
Transverter ECU malfunction applied.
Transverter will automatically down-shift to neutral.
SAHR Brakes set /Accumulator The MMC will display the error code 07 and the park
Pressure to low (hydraulic oil pres- brake light will illuminate. The SAHR brakes will be
sure below 1400 psi) applied.
For the complete list of engine ECM diag- CAUTION: When the engine is not running
nostic codes, see the Computer Diagnostic or dies, the SAHR brakes will be applied.
Systems section.

Electrical System
Note: The transverter automatically defaults General Maintenance

to neutral whenever there is power loss or Information
when the oil pressure is too low.
The electrical system of diesel powered
The engine override switch allows the opera- equipment requires periodic inspection and
tor to override the engine ECM and self-pro- maintenance.
tective measures for thirty (30) seconds so Important: Always turn off the battery dis-
that the vehicle can be safely parked and shut connect switch (as a minimum precaution)
down. whenever working on an electrical problem
on the vehicle. It is highly recommended to
disconnect all battery cables and place all
fuses and circuit breakers in the open posi-
tion when doing any extensive electrical
work on the vehicle.
Important: Never disconnect the leads
between battery, alternator, and voltage reg-
ulator. when the engine is running.
In order to achieve a properly functioning
and reliable electrical system it is important
that periodic checks are made to inspect for:
• water, oil and dirt intrusion
• corrosion of wiring terminals and
devices
• excessive wear on wire insulators due to:
vibration, tension or excessive heat
Whenever repairing an electrical harness or
device, use the manufacturers recommended
tools for such work, specifically: wire crimp-
ers, insertion and removal tools. An electri-
cal repair done improperly will not only
reduce the system’s reliability, but may con-
tribute to further electrical damage.
Wire harnesses should never be disconnected
by pulling or yanking on the wires them-
selves. This can lead to a premature failure
of the wire terminal, contact or the connector
itself.

Electrical System
It is also important to disconnect all elec- a gear, direction, or setting/releasing the park
tronic components that might be susceptible brake, a corresponding light is illuminated.
to damage caused by welding. As the command is fulfilled, an output light
indicates the action taken by the PLC. The
Warning: Always make sure that the welding
following charts indicate the numeric code
machine is earth grounded before attempting
displayed by the ST1010 PLC:
to perform any electric welding.
Never interchange the battery connections. Light Input
When washing the engine, cover alternator
0 Forward
and voltage regulator against water splash.
1 Reverse
Computerized Diagnostic Systems 2 Neutral
There are a number of diagnostic interfaces 3 First Gear
in the scooptram computerized electrical 4 Second Gear
systems. The programmable logic control
has a visual lighting display, the engine ECM 5 Third Gear
has a diagnostic data reader that can be 6 Fourth Gear
plugged in, and the transverter ECU has an
7 Park Brake
interface for a computer diagnostic program.
10 Pressure Loss
Programmable Logic Control (PLC) 11 RRC (Optional)
12 Engine Status
13 RRC Park Brake
14 RRC Forward
15 RRC Reverse
16 Park Brake pressure switch N/C
1 17 Park Brake pressure switchN/O
1. LED Lights Lights Output

0 Forward
The PLC is located behind the electronic
component panel and can be accessed by 1 Reverse
removing the retaining bolts on the panel. 2 Neutral
The operation of the PLC can be checked by
observing the LED lights on the outer cover 3 First Gear
of the unit. As an input is made by selecting

Electrical System
Lights Output The diagram below shows the inputs and

outputs of the PLC.
4 Second Gear
5 Third Gear
6 Fourth Gear 6 10
4
7 Park Brake (on when released)
11
10 Front Lights (RRC only) 7 1 5
2
11 Park Brake indicator
8
13 Horn 12
If a series of lights on the PLC fail, check the 9

following before replacing the PLC unit: 3
• All wiring and fuses to the PLC

• Engine Status Relay
• Pressure Loss Relay
Programmable Logic Controller
Both relays are located in the dash behind
the display panel. See Section 10: Trouble- 1. Programmable Logic Controller
shooting section for further information. 2. Vehicle Operator
3. Data Collection Unit
4. Park Brake Solenoid
5. Transverter Electronic Control Unit
6. Direction/Neutral
7. Gear Selection
8. Park Brake Switch
9. Accumulator/Converter Pressure Loss
10. Park Brake Set/Release
11. Direction/Gear Selection
12. Diagnostic Interface
Engine ECM Diagnostics
The engine ECM is designed to give diag-

nostic data in two distinct manners. The first
is through the yellow Check Engine (CEL)
and Stop Engine Lights (SEL), and the sec-
ond is through a hand held Diagnostic Data
Reader (DDR) provided by the engine manu-

Electrical System
facturer. Flash Description

SEL and CEL 36 Oil pressure circuit low
37 Fuel pressure circuit high
When the ignition switch is turned to the on
38 Fuel pressure circuit low
position, and the engine is not running, the
SEL and CEL can display codes by a series 41 Too many SRS (missing TRS)
of blinking signals while the engine override 42 Too few SRS (missing SRS)
button is pressed. The SEL light will indicate 43 Coolant level low
active engine problems and the CEL will
44 Intercooler, coolant or oil temp. high
show any inactive or historic codes. The
chart below gives the numeric code and the 45 Oil pressure low
meaning: 46 Battery voltage low
47 Fuel pressure high
Flash Description
48 Fuel pressure low
13 Coolant level circuit low 52 A/D conversion fail
14 Intercooler, coolant or oil temp, high 53 EEPROM write or nonvolatile fail
15 Intercooler, coolant or oil temp, low 55 J1939 data link fault
16 Coolant level circuit high 56 J1587 data link fault
17 Bypass position circuit high 57 J1922 data link fault
18 Bypass position circuit low 58 Torque overload
21 TPS circuit high 61 Injector response time long
22 TPS circuit low 62 Digital output open or short to battery
23 Fuel temp. circuit high 63 PWM open or short to battery
24 Fuel temp.circuit low 64 Turbo speed circuit failed
25 No codes 67 Coolant pressure circuit high or low
26 Aux shutdown #1or #2 active 68 IVS switch fault, open or grounded
27 Air temp. circuit high circuit
28 Air temp. circuit low 71 Injector response time short
31 Aux output short or open circuit (high 72 Vehicle overspeed

side) 75 Battery voltage high
32 SEL short or open circuit 76 Engine overspeed with engine brake
33 Boost pressure circuit high 81 Oil level or crankcase pressure circuit
34 Boost pressure circuit low high
35 Oil pressure circuit high

Electrical System
Flash Description since the vehicle owner may have added

electrical equipment such as an air condi-
82 Oil level or crankcase pressure circuit tioner after the vehicle was purchased.
low
2. Be sure the battery, whether wet or dry, is
83 Oil level or crankcase pressure high
at full charge when installed.
84 Oil level or crankcase pressure low
3. When installing, avoid physical abuses
85 Engine overspeed and over-tightening or under-tightening
86 Water pump or baro. pressure circuit of the battery hold-down.
high
Periodic Service
87 Water pump or baro. pressure circuit
low 1. Maintain electrolyte level to cover top of
plates. Do not over-fill.
88 Coolant pressure low
Diagnostic Data Reader (DDR) 2. Keep terminal posts, cables, and battery
top clean. A non-metallic based grease
The DDR is a hand held computerized covering post and cable post clamp
device that plugs into a diagnostic connector reduces acid corrosion.
located on the control panel. The unit allows 3. Be SURE battery cables are secure and
service personnel to access the engine ECM in good condition.
and receive data and run diagnostic tests. For
further information concerning the engine 4. Check periodically for container, cover,
ECM diagnostic data reader, see the DDR cable and post damage.
manual or contact the engine manufacturer. 5. Test periodically with hydrometer or
OCV tester to determine call state of
Battery Care charge, or load tester for overall battery
condition.
Correct battery maintenance makes it possi-
ble for the customer to realize the battery’s 6. Check vehicle generating system to pre-
full potential in performance and life. Bat- vent over-charge or under-charge dam-
tery selection and installation is the very first age.
step in proper battery maintenance.
Check condition and tightness of battery
Installation
hold-down.
1. Be sure the battery to be installed has a
capacity at least equal to the electrical Cable Terminals and Hold Downs
requirements of the vehicle. An under
Battery acid can corrode terminals and
capacity battery will result in poor per-
expose cable. Corrosion increases resistance
formance and premature failure.
and restricts proper current flow to the starter
IMPORTANT: The original equipment and other electrical components.
requirement of the vehicle can be used as a
minimum guide, but is often not reliable

Electrical System
On vehicles equipped with voltage regula- be sure the battery is not reversed. Note
tors the alternator or generator voltage is that the tapered positive terminal of the
maintained within a narrow range. The resis- battery is 1.6 mm (1/16 in.) larger at the
tance due to corrosion keeps the battery from top than the negative terminal, and that
receiving the proper charging current and the opening of the positive cable clamp is
gradually causes an under-charged, sulfated correspondingly larger.
battery.
• Connect the “grounded” terminal last. Be
• Corroded contact surfaces of all clamp careful not to place clamp terminals and
terminals and battery terminal posts cables in such a position that they inter-
should always be cleaned with a wire fere with removal of vent plugs or hold-
brush in order to ensure a perfect contact. downs.
Keep corrosion on terminals from drop-
Battery Fluid
ping into battery cells.
• Water for use in batteries should be a
• It is good practice when replacing termi-
good grade of drinking water. Do not use
nals to grease them with a heavy mineral
mineral waters.
or petroleum grease. Do not apply an
excessive amount. • Adding water to a cell will lower the spe-
cific gravity of the electrolyte, but this
• Do not hammer clamp terminals onto
does not mean that the cell has lost any
battery posts. This can result in severe
of its charge.
damage to the hard rubber cell covers
and sealing compound. • Watch for batteries that require excessive
water. The need for excessive water may
• Replacement cables should be of suffi-
be an indication of a charging system
cient length to reach the terminal posts
which is out of adjustment. This could
without causing undue strain on the post
indicate that the battery is being sub-
and covers. Cables that are too taut will
jected to the damaging effects of over-
cause damage to posts, and cause sealing
charging.
compound to crack, leaking acid.
Tropical Climates
• The battery should rest level in the con-
tainer and be fastened securely in place Batteries operated at high temperatures in
by a suitable hold-down. Tighten hold- tropical climates are usually provided with
downs evenly from each end to prevent electrolyte of about 1.225 specific gravity
distorting or breaking the container. (Sp. Gr.) when fully charged. This milder
strength of acid is less deteriorating to sepa-
• Where a hold-down is fixed at one (1)
rators and plates and results in longer battery
end, care must be exercised to insure
life. A tropical climate is defined as a climate
proper seating of the battery prior to
in which water never freezes.
tightening the movable end.
Batteries can be fully charged and yet have
• Before connecting the cables, check the
different values of specific gravity. Values
polarity of the terminals of the battery to
are shown for batteries with a fully-charged

Electrical System
gravity of 1.280 and 1.260 as used for cold Under-charging

and temperate climates, and in the last col-
A battery operated in an under-charged con-
umn, values are shown for a battery with a
dition is not able to delivery full power. It is
fully-charged gravity of 1.225, as might be
also more likely to freeze during severe win-
used in tropical climates.
ter weather.
Factors affecting battery life
A battery operated with insufficient charge
Over-charging over a long period of time will develop a
Charging a battery greatly in excess of what layer of lead sulfate on the plates. This mate-
is required is harmful in several ways. It can: rial is dense, hard, and coarsely crystalline,
and is difficult to electro-chemically convert
• Severely corrode the positive plate grids. back to normal active material.
This leads to mechanical weakening and
loss of electrical conduction. Lead sulfate can also cause a strain in the
positive plates so that distortion or bowing of
• Decompose water of electrolyte into the plates, called buckling, may result.
hydrogen and oxygen gas.
Severely buckled plates will pinch the sepa-
- Gas bubbles tend to wash active rators at the plate corners or chafe the center
material from the plates and of the separators. This can result in perfora-
carry moisture and acid from tions of the separators and develop a short
the cells as a fine mist. circuit in the cell.
- Decomposition of water leaves Lead sulfate formed on the plates during dis-
acid more concentrated. Con- charge is relatively insoluble as long as the
centrated acid is harmful to cell specific gravity of the electrolyte indicates a
components, particularly at high substantially charged condition. However, if
temperatures over a prolonged allowed to drop much below this state, the
period of time. lead sulfate becomes increasingly soluble
• Create high internal heat which acceler- and, aided by temperature fluctuations of the
ates the corrosion of the positive plate electrolyte, may migrate over a considerable
grid, and damages separators and nega- period of time into the pores of the separa-
tives. High heat will also soften the seal- tors and deposit as a white crystalline mass.
ing compound and may distort the Subsequent charging may convert these crys-
battery container. talline deposits to metallic lead which may
• Cause severe buckling and warping of “short” the positive and negative plates
the positive plates with accompanying through the areas of the separators affected.
perforation of separators. These small shorts may cause a condition of
low cell voltage when the battery is charged.
• Cause damage by corrosion to cradle,
For this reason, automotive battery cells
cables, and other vital electrical and
should not be allowed to stand idle in a dis-
engine parts by forcing battery acid from
charged condition.
the cells.

Electrical System
Lack of water trolyte is not sufficient to restore the battery

to full capacity.
Water is essential for proper operation of a
lead-acid storage battery. Under normal con- Improper capacity
ditions of operation it is the only component Installation of a battery with a lower capacity
of the battery which is lost as the result of than the electrical demands of the vehicle
charging. It should be replaced as soon as the requires the battery to work harder than it
liquid level falls below the top of the separa- was designed for, causing premature battery
tors. failure.
If water is not replaced and the plates are Poor maintenance
exposed, the acid will reach a dangerously
high concentration that may char and disinte- A battery must be kept in good condition to
grate the separators, and may permanently deliver peak performance. This includes care
sulfate and impair the performance of the and maintenance of the vehicle’s electrical
plates. Plates cannot perform as designed systems, as well as the battery itself.
unless they are completely covered by the Improper installation
electrolyte.
Loose installation causes damage to all bat-
Sulfuric acid must never be added to a cell tery components due to excessive vibration.
unless it is known to have been lost. Improperly adjusted hold-downs may allow
Freezing of electrolyte the battery to bounce around in the cradle.
This may cause the bridges on which the ele-
The electrolyte of a battery in various states
ments rest to notch the bottom of the separa-
of charge will start to freeze at temperatures
tors or cause the plates to notch the bridge
indicated below. The given temperatures
tops. This will lead to a severe disarrange-
indicate the approximate points at which the
ment of the elements.
first ice crystals begin to appear in the elec-
trolyte solution. The solution does not freeze Tight installation can cause container and top
solid until a lower temperature is reached. cover damage by exerting excessive stress
Solid freezing of the electrolyte may crack on these parts. The bouncing of the battery
the container and damage the positive plates. may also crack or wear the container or
cause the sealing compound to open and leak
A 3/4 charged automotive battery is in no
acid. Leaking acid corrodes terminals and
danger of damage from freezing. Therefore,
cables, and results in high resistance at the
keep batteries at 3/4 charge or more, espe-
battery connection which weakens the bat-
cially during winter weather.
tery’s power and shortens its life.
Age
Detecting Potential Failures
Normal deterioration accompanies the aging
Few batteries fail without some advance
process. Repeated charging and discharging
warning.Identifying the signs of potential
slowly wear away active material in the
battery failure, through visual inspection and
plates until a point is reached where plate
testing, increases battery service life and
surface available for reaction with the elec-

Electrical System
may prevent greater trouble or expense at a - All cells read above 1.230
later date. SP.GR.and specific gravity
Visual inspection readings in each within 50
points. Battery is OK!
The outside appearance of a battery is an
- Cells read below 1.230 SP.GR
important indicator for judging its perfor-
and specific gravity readings
mance and expected life. Signs of potential
within 50 points. Battery needs
battery failure include:
to be recharged (and retested).
• cracked container
- A spread greater than 50 points
• leaking acid SP.GR. between cells. Battery is
• cracked or raised cell covers at point of failure. Replace.
• loose or corroded terminal posts or cable Note: Using a battery capacity tester (ESB
connections Model BSG-5)
• age • Take specific gravity reading. Do not test

battery with specific gravity readings
Hourmeter reading
below 1.230 at 27° C (80° F). Recharge
Check the vehicle hourmeter and mainte- the battery, then proceed with capacity
nance service records. 10,000 service hours test.
equals average battery life. • Connect tester clips to battery posts. Red
Testing to positive, black to negative.
Potential battery failures are not always • Set slide switch to VOLTS position.
detectable from visual inspection. You can- Read terminal voltage on top scale. Mini-
not see a bad cell, so all batteries should be mum reading for 12 volt battery: 12.6
tested approximately once a month to reveal volts.
the hidden defects that cause battery failure. • Set slide switch to AMPS position. Turn
Several easy tests can be made as follows: control knob to the right until (yellow)
Cell charge test ammeter scale reads the battery’s ampere
Using a Hydrometer hour capacity. If ampere hour capacity of
battery is unknown, use 50 ampere hour
1. Turn off all lights and accessories. rating for 12 volt battery. Hold for 15
2. Remove cell cover caps. Do not add seconds only.
water at this time. • Set slide switch to VOLTS position, and
3. Fill hydrometer several times until float read voltage under load scale. Minimum
rides free. reading for 12 voltage battery is 9.6
volts.
4. Take readings from each cell. Return
electrolyte to cell. - If test reading is in green (or
OK) section of the voltage
5. Record and interpret readings as follows:

Electrical System
under load scale, the battery is battery plates. If electric current (charging) is
in good condition. not directed into the battery to reverse this
- If test reading is in red (or process the battery plates will warp beyond
LOW) section and specific repair, and render the battery useless. It is
gravity of all cells is above recommended to charge the stored batteries
1.230, the battery is wearing out at least once every 4 to 6 weeks.
and should be replaced. If spe-
cific gravity of cells is below Alternators
1.230, recharge the battery and Alternators normally require little servicing.
re-test. They should be tested at least once a year to
- If test reading drops down to ensure that they are providing the proper
near zero and one or more cells voltage and amperage. If an alternator fails
bubble, battery is not service- to meet specifications, it should be replaced.
able and should be replaced. Servicing an alternator, instead of replace-
Using battery booster cables ment, is usually limited to replacing the
Connect red cable (positive) to positive bat- brushes and cleaning the slip rings
tery post on dead battery, and positive post Because of the high load capacity and inertia
on fully charged battery. Connect black cable of the heavy rotor that is usually used, proper
(negative) to negative post on dead battery. belt tension on an alternator is very impor-
Connect black cable to the negative post on tant. Improperly adjusted, worn or damaged
fully charged battery. Leave engine of charg- drive belts are a major cause of alternator
ing vehicle running when starting a vehicle failure.
with a dead battery.
Belt tension should be adjusted according to
When disconnecting cables, disconnect the the engine manufacturer’s recommendations.
cable from the fully charged battery first.
Note: Excessive alternator belt tension
CAUTION: If cables are connected wrong should be avoided to prevent damage to the
on a vehicle, the alternator can be seriously alternator bearings.
damaged.
Slip Rings and Brushes
Storage Of Lead Acid Batteries
The slip rings should be cleaned with a 400
Because of their corrosive behavior, all bat- grain (or finer) polishing cloth.
teries, when placed in storage, will begin to
IMPORTANT: Never use emery cloth to
discharge slowly. If allowed to go
clean slip rings.
unchecked, the average battery will dis-
charge to the point of nonrecovery in about 6 If the slip rings are out-of-round, or if the
to 8 months. brushes are worn close to the holders, the
alternator should be removed and either
As the battery sits, the sulfuric acid gener-
repaired or replaced.
ated by the chemical reaction taking place
inside the battery core begins to warp the

Electrical System
Precautions to be observed when servicing • Unless the regulator is equipped with a

systems using alternators: circuit breaker, this terminal is “HOT”
• Reversed battery connections may dam- even when the system is not in operation.
age the rectifiers, vehicle wiring, or other Grounding this can cause considerable
components of the charging system. damage.
• Battery polarity should be checked with • Do not ground the adjusting tool to the
a voltmeter to assure that it conforms to regulator base when adjusting voltage
that required. Note which terminal post is unit or other regulator components.
connected to ground before reinstalling a • The adjusting tool should be insulated.
battery. All units have negative ground.
• Care should be taken in the use of batter-
• If booster batteries are used for starting, ies of higher-than- system voltage, either
they must be connected properly to pre- to boost a battery of lower voltage or in
vent damage to the system. starting.
• Always make certain that the negative (-) • Never leave the higher voltage battery in
terminal of the booster battery is con- the system. When used for boosting, dis-
nected to the negative (-) terminal of the connect the vehicle battery ground.
vehicle battery, and that the positive (+) When used for starting, disconnect the
terminals are connected together. high voltage battery as soon as vehicle is
• Care should be taken when connecting a started.
“fast charger”. • Alternators must not be operated on open
• It is advisable to remove the battery circuit with the field winding energized.
ground strap before charging. It is not High voltages will result, causing possi-
advisable, under any condition, to ble rectifier failure. Make sure all con-
attempt to start the vehicle by using the nections are secure.
“fast charger” as a booster.
Removing and Replacing
• Do not attempt to polarize the alternator.
Electrical Components
No polarization is required. Any attempt
to do so may result in damage to the
To replace the gauges, switches, lights,
alternator, regulator, or circuits.
relays, fuses, circuit breakers, horn, and sole-
• The field circuit must not be grounded at noids follow these general procedures:
any point.
• Grounding of the field will damage the • Disconnect the battery by turning off the
regulator. Extra care MUST BE taken main (battery isolation) switch.
when working near this electrical system. • Ensure that the replacement unit is a 24
volt OEM compatible part.
• Grounding of the alternator output termi- • Use care to replace the wiring connectors
nal may damage the alternator and/or cir- to their correct receptacle on the new
cuit components. part.

Electrical System
NOTE: All of the electrical connectors are replacing any sensor on or around the
designed so that they can only be attached to engine.
their receptacle in only one way. Do not
attempt to force any connectors on to any Starter
receptacles.
1. Disconnect battery by turning the master
Transducers (battery isolation) switch off.
2. Disconnect the positive lead on the bat-
1. Disconnect the battery by turning off the
tery.
main (battery isolation) switch.
3. Disconnect the starter wiring and lay
2. Relieve the hydraulic pressure on the
aside.
entire system by cycling the SAHR brake
override valve repeatedly. The SAHR 4. Remove the starter mounting bolts and
brake override valve is located under the pull the unit out.
display panel and can be pressed with a
screwdriver to push the valve spool open. Battery
3. Ensure that the replacement unit is a 24 Remove and replace the batteries as follows:
volt OEM compatible part.
Removal
4. Use care to replace the wiring connectors
1. Set the battery disconnect switch to off.
to their correct receptacle on the new part
2. Open the battery compartment.
CAUTION: The hydraulic system is a high
pressure circuit, over 2000 psi. The pressure 3. Remove the negative connector from the
must be bled off before replacing the trans- battery “A.”
ducers. 4. Remove the positive connector from the
battery “A.”
Engine Sensors
5. Attach a battery lift sling to the battery
1. Let the engine cool. and remove it from the battery compart-
2. Disconnect the battery by turning off the ment.
main (battery isolation) switch. 6. (If a 24 volt system) repeat the process
3. Ensure that the replacement unit is a 24 for battery “B.”
volt OEM compatible part. Replacement
4. Use care to replace the wiring connectors 1. Attach a battery lift sling to battery “B”
to their correct receptacle on the new and place it in the battery compartment.
part.
2. Reinstall the positive connector on bat-
CAUTION: Coolant temperature is tery “B.”
extremely hot and can scald or burn exposed
skin. Take care to let the engine cool prior to 3. Reinstall the negative connector on bat-
tery “B.”

Electrical System
4. Repeat steps 1-3 for battery “A.” 5. Reconnect the electrical connectors to
5. Close the battery compartment. the alternator.
6. Set the battery disconnect switch to on. 6. Set the battery disconnect switch to on.
Alternator ST1010 Transverter Calibration

Procedures
Remove and replace the alternator as fol-
lows: 1. Park the scooptram on a flat surface and
block all wheels. Warm the vehicle until
Removal the temperature gauge reads approxi-
1. Set the battery disconnect switch to off. mately 50° C (130° F).
2. Disconnect the electrical connectors Note: On newer machines, once the calibra-
from the alternator. tion jumper has been installed, the trans-
verter ECU will automatically bring engine
3. Loosen the alternator belt adjustment and RPM up until the transverter temperature
remove the drive belt. reaches the appropriate temp for calibration.
4. Remove the bolt that secures the adjust- 2. Ensure all 24V power is OFF.
ment mechanism to the alternator.
3. If you do not have the diagnostic gear
5. While holding the alternator, remove the indicator gauge in the instrument panel,
two bolts that secure it to the engine you must remove the gauge panel and
bracket. plug your diagnostic gauge
6. Remove the alternator. (part#5572400100) in the four (4) posi-
tion Packard connector located behind
Replacement
the panel. If there is a gear indicator
1. Place the alternator in position on the gauge in your instrument panel, warm
engine bracket and insert the two bolts transverter oil temp and proceed to the
that secure it to the bracket. Screw on the next step.
two nuts and tighten these moderately
4. Install the 2 black jumpers (supplied with
tight.
cable) into connectors (wires marked X
2. Reinstall the bolt that secures the adjust- & Y) of the new diagnostic/calibration
ment mechanism to the alternator and cable. Plug the round grey 9 pin connec-
tighten it moderately tight. tor into the corresponding female con-
3. Reinstall the alternator drive belt and nector located beside the right hand side
tighten the alternator belt adjustment to of the operators seat.
the belt specifications. 5. Turn the power and the ignition switch to
4. Torque the adjustment mechanism bolt the ON position. The Gear Indicator
and the engine bracket bolts to 34 N-m Gauge should then read CAL (calibrate)
(25 ft-lb). Ensure Parking Brake is “applied”

Electrical System
6. Start the engine and install the remaining Note: Any error that appears in the display
gray 2 pin connector (wire Z) into the gauge during calibration will cause the pro-
diagnostic cable. The engine RPM cedure to be aborted, and the calibration
should immediately increase to 1600 process will have to be started again from
RPM. This is the required RPM to per- the beginning.
form calibration.
7. With the RPM at 1600 and the parking
Brake applied, select “FORWARD” on
the D/H Joystick. If the transverter oil
temperature is too low, an error code
“100” will appear in the gauge in place
of CAL. If this occurs, remove all the
jumpers in the diagnostic cable and per-
form converter stall to increase oil temp
as necessary and return to step 3. If tem-
perature is + 130F (50c) the gauge will
display C1H, then C2H, C3H, C4H
CAH, and CBH while calibrating each
clutch hold level. Once the clutch hold
calibration is complete, the gauge will
then display C1F, C2F, C3F, C4F, CAF,
and CBF while calibrating fast fill val-
ues.
Note: During the initial stages of the cali-
bration, a dashed line will appear on the
diagnostic gauge screen. This indicates that
the transverter has not reached temperature
(130° F) for calibration. The transverter will
initiate an auto-warming sequence until it
reaches calibration temperature.
8. When calibration is completed, the gauge
will display END. At this time the trans-
verter joystick should be placed in the
Neutral position and the grey (wire Z)
jumper removed so the engine RPM will
return to idle. Turn the keyswitch to the
off position and unplug the diagnostic
cable.
This completes the transverter calibration.

Electrical System

Section 8 Miscellaneous Systems
Fire Suppression System the wheel ends, the motor tub, the transmis-
sion, and the torque converter.
The fire suppression system is designed to
protect specific fire hazard areas on the vehi- Daily shift maintenance should include the
cle. It is intended to supplement, not replace, cleaning of areas where flammable materials
a sound fire prevention policy in your mine. and combustible debris may collect.
Fire prevention depends on regular inspec- System Operation

tion and maintenance of those areas on your
vehicle where a fire is most likely to start;
2 3
4
5
1. Actuators 5. Dry Chemical Tank

2. Pneumatic Cartridge Receiver 6. Union Assembly
3. Safety relief Valve 7. Nozzle
4. Expellant gas Cartridge

When the vehicle operator discovers a fire in Operator Activates Actuator

a protected area on the vehicle, he pulls the
safety ring pin and depresses the red button
on the manual actuator in the operator’s com-
partment.
Pressure from the actuator causes the fire
suppression system to operate.
The expellant gas pressure makes the dry
chemical extinguishing powder act like fluid.
The dry chemical powder is propelled
through the distribution hose after pressure
in the dry chemical tank reaches the point to The equipment operator pulls the safety ring
rupture the bursting disk. pin and depresses the red button on the man-
ual actuator in the operator’s compartment.
The dry chemical extinguishing agent is dis-
charged through the nozzles into the pro- Pressure from the actuator causes the fire
tected areas, suppressing the fire. suppression system to come into action.
Dry Chemical Distribution
Sequence of Events
Fire Starts
The expellant gas pressure fluidizes the dry

chemical extinguishing agent and propels it
The equipment operator discovers a fire has through the distribution hose once proper
started in a protected area on the vehicle. A pressure has been reached to rupture the
protected area is one where a fire suppres- bursting disk in the dry chemical tank.
sion nozzle is installed.

Dry Chemical Discharged System Components

The manually activated fire suppression sys-
tem consists of:
• Actuator
• Pneumatic Actuator/Cartridge Receiver
• Expellant Gas Cartridge
• Dry Chemical Tank
• Nozzles
Actuator
The dry chemical extinguishing agent is dis-
charged through the nozzles into the pro-
tected areas, suppression the fire.
Hand Portable Fire Extinguisher

It’s a good idea to have a reliable fire extin-
guisher mounted in all off-the-road vehicles,
particularly on diesel powered scoops and
trucks, whenever there is a possibility of haz-
ardous fire conditions.
Make sure that such extinguishers are firmly The actuator contains a sealed pressure car-
mounted in a readily accessible and safe tridge which, when activated by removing
place, All visual seals must be in place, and the ring pin and striking the red button, sends
the distributor certification tag must be pressure to the cartridge receiver to set the
attached and readable. system in operation.
Most systems installed by Wagner employ at
In The Event Of Fire
least one manual actuator installed in the
• Shut off the vehicle operator's compartment. Additional actuators
may be installed in other remote locations on
• Set the brakes
the vehicle.
• Pull the ring pin on the manual actuator
Wagner also offers systems which can be
• Strike the red button automatically actuated by either electric or
• Evacuate the vehicle pneumatic detection.
• Stand by with a fire extinguisher

Cartridge Receiver/Expellant Gas Dry Chemical Tank

Cartridge
Pneumatic Actuator
Cartridge Receiver
Safety
Relief
Valve
Expellant
Gas
Cartridge
Once the released pressure from the actuator

reaches the cartridge receiver, a seal in the
The dry chemical tank contains a dry powder
expellant gas cartridge is pierced by system
chemical fire retardant. It is fitted with a
pressure, and this gas is then transmitted to
bursting disc in the union assembly to pre-
the dry chemical tank.
vent the flow of the dry chemical until suffi-
A safety relief valve prevents excess actua- cient pressure has developed in the tank. The
tion pressure from building up in the car- expellant gas from the gas cartridge pressur-
tridge receiver. izes the dry chemical tank, causing the dry
chemical powder to act like a fluid. When
the proper pressure is reached, the disc rup-
tures, letting the gas/dry chemical mixture
flow to the nozzle(s).
Nozzles
The pressure at the nozzle(s) causes the pro-
tective cap to pop off or open (depending on
the kind of nozzle installed), and the dry
chemical to be discharged.
General Maintenance Information

All off-road heavy-duty vehicles pose some
fire hazards due to the heat generated in key
operating systems.

The following is a list of daily maintenance Replace any broken or missing lead and wire
checks that will help reduce the possibility of seals, and record the date of inspection.
fire on your vehicle. Semi-annual
• Make sure all oil and hydraulic fluid
Every 1000 operating hours the following
lines are in good condition. Replace
checks should be made:
defective or worn lines immediately.
The bursting disk in the union assembly
• Make sure all oil and hydraulic line fit-
should be checked for proper seating and
tings are properly tightened. Keep the fit-
that it is undamaged.
tings clean.
Weigh the remote actuator cartridge(s) pneu-
• Check that the brake systems are prop-
matic cartridge actuator/cartridge receiver.
erly adjusted.
Replace any cartridge if its weight is not
• Check that no oil or hydraulic fluid lines within 7 g (1/4 oz.) [14 g (1/2 oz.) for the
are in contact with possible ignition pneumatic cartridge actuator/cartridge
points (or hot spots). receiver] of the weight stamped on the car-
• Keep the vehicle clean. Remove all com- tridge.
bustible debris. Make certain extinguisher is filled with free-
• Maintain all electrical lines and connec- flowing Ansul dry chemical. Level should be
tions. Replace any defective electrical no more than 76 mm (3 in.) from the bottom
equipment or wiring. of the fill opening.
Monthly Check Fire System

Every 100 operating hours, the fire suppres-
sion system should be thoroughly inspected Automatic Checkfire System
to assure it is in good operating condition.
The automatic checkfire system uses a heat
Inspect over-all condition of hoses, dis- sensing cable that is placed in the engine
charge nozzles, and activator valve for dam- compartment and in the transverter compart-
age, blockage, or any sign of possible failure. ment. If a fire melts the cable housing and
Nozzles should be capped with silicone the two wires inside touch, making an elec-
grease or plastic blow-off caps. Actuator and trical connection, the fire suppression system
expellent cartridge seals and disks must be will discharge. An electro-pyro-technique
intact. Repair as needed. device, squib, in the actuator housing is con-
trolled by the checkfire module. When the
Check level of pressurized dry chemical detection cable circuit is opened by a fire, the
extinguisher tank(s). Extinguishers should control module sends an electrical current to
contain an active charge of not less than five the squib, causing it to discharge the sup-
(5) pounds, nominal weight. pression system. The system has a three (3)
Check the nameplate for readability. second delay from the time the detection
cable sends a fire alarm to when the control

module tells the squib to discharge the sys- following chart shows the alarm sequence on
tem. You must follow the “In Case of Fire the control module:
procedures” in the Safety section immedi-
ately once the fire suppression process
begins. Alarm Condition Action
Normal Operat- Green Battery Light
Checkfire Control Module ing Conditions flashes every three
(3) seconds
6 Low Battery Yellow Battery Light
Voltage flashes and the audio
alarm sounds every
three (3) seconds
2 DELAY 1
RESET
Fire Detected Red Alarm light
flashes and the audio
3 alarm sounds every
BATTERY second.
4 ALARM
System Discharg- Red Alarm light
DETECTION
RELEASE ing flashes three (3)
times per second and
5 the audio alarm
sounds rapidly.
Post Discharge Red Alarm light
flashes and the audio
alarm sounds every
1. Normal Battery Power LED six (6) seconds until
2. Low Battery Power LED the system is reset.
3. Alarm LED CAUTION: Once a fire has been detected
4. Detection Fault LED on the scooptram, you have only a brief
5. Release Fault LED amount of time to stop the vehicle, set the
6. Delay/Reset Switch park brake and get out before the fire sup-
The checkfire control module is located in pression system discharges.
the cab of the scooptram and is mounted near WARNING: Do not delay leaving
the manual fire protection activator. It is the Scooptram once a fire has been
equipped with LED lights and an audio detected and the vehicle has been
alarm that will sound whenever there is a fire ACW00073.pict
safely parked.
or problem with the detection system. The
Delay/Reset Switch
The delay/reset switch located on the check-

fire control module allows you to delay the

discharge of the fire suppressant chemical three (3) times per second until the problem
for three (3) seconds by pressing and releas- has been solved.
ing the switch. Holding down the switch
IMPORTANT: See the paragraphs titled
delays the discharge indefinitely until the
“In Case of Fire” in the Safety section for
switch is released.
what to do in case of fire on board the
WARNING: Do not ignore any Scooptram.
fire alarm, the delay/reset switch is
designed to allow you more time to
ACW00073.pict
Ride Control Systems
shut the scooptram down and get
out safely. The ride control systems are options that can
increase the efficiency of the Atlas Copco
The delay/reset switch also resets the system scooptram through operator comfort and
after the chemical discharge. vehicle/load safety. The scooptram comes
The third function of the delay/reset switch already plumbed for the ride control option
is to reset the system during normal opera- and can be easily installed by just adding a
tion while any alarms are received. For hose, control cartridges in the ride control
instance if the battery voltage falls too low, manifold, and an accumulator.
the delay/reset switch will silence the Yel-
low Battery Low alarm after the problem has Theory of Operation
been corrected or the battery recharged.
The Atlas Copco ride control system oper-
Diagnostic Lights ates through hydraulic pressure backed up
between an accumulator and the hoist cylin-
The checkfire control module includes two ders. This is accomplished by a series of
(2) diagnostic lights that provide you with a check valves that open the hydraulic circuit
means of monitoring the system integrity. between the hoist cylinders and the ride con-
The Yellow Detection light is activated by a trol accumulator. As the operator begins the
fault in the detection wiring that is located in tramming process and the ride control sys-
both the engine and transverter compart- tem is engaged, oil pressure is balanced
ments. If the wire becomes disconnected or between the hoist cylinders and the accumu-
separated, the Yellow Detection light will lator to compensate for the bouncing motion
flash and the audio alarm will sound every of the vehicle.
three (3) seconds.
When the scooptram is in motion and the
The Yellow Release light is activated when- bucket is loaded, oil pressure from the accu-
ever there is a fault in the release circuit of mulator is sent through a manifold to the
the system. Most specifically, when the
base end of the hoist cylinders. As pressure
squib is not correctly installed or when it has
in the base ends drop due to the rising of the
been previously fired. When a Release fault bucket in reaction to a bump, the pressure
condition exists the Yellow Release light from the accumulator builds the base end
will flash and the audio alarm will pulse cylinder pressure back up. When the boom
drops back down from the bump, oil is sent

to the stem end of the cylinders to compen-

sate for the relieving pressure. This activity
happens quickly and results in the “floating”
effect of the boom and bucket as the vehicle
chassis is moving up and down with the driv-
ing surface.
Ride Control System Components

The ride control system is composed of the
following units:
• Ride Control Manifold
• Accumulator
• Two position control switch
• Hydraulic hose
Ride Control Manifold
The ride control manifold houses the shuttle
valve, two check valves, a control solenoid,
and two test ports. The shuttle valve directs
the flow of oil to either the base end of the
hoist cylinders. The check valves stop the oil
from flowing out of the ride control system.
The control solenoid is activated by a switch
located in the operator’s compartment and
when energized it opens the ride control cir-
cuit to the accumulator. The test ports allow
the system to be checked for proper function.
The valves on the ride control manifold are
cartridges that can be easily removed for
cleaning or replacement.
Accumulator
The ride control accumulator is the shock
absorber of the system. When the system is
turned on, the accumulator sends oil to the
base end of the hoist cylinders to compensate
for the loss of pressure while the system is
operating. The accumulator is pre-charged to
3447 kPa (500 psi).

Section 9 Troubleshooting
The following tables will help you isolate Check Engine Light (CEL) can be used to
operational problems with your Scooptram reveal engine problem codes. Also, the use
should they occur. The tables are labeled of a Diagnostic Data Reader (DDR) will dis-
according to system function or component play most problems. See Section 8: Electri-
placement. Refer to the index to locate the cal Systems for the SEL/CEL codes. In some
appropriate pages for adjustment, repair, or cases it will be necessary to contact your
removal and replacement procedures. authorized Atlas Copco dealer for further
When troubleshooting the Detroit Diesel action.
engine, the Stop Engine Light (SEL) and
Engine
Condition Possible Cause Solution
Engine does not turn Electrical problem See electrical troubleshooting table.
over Starter problem Contact your authorized Atlas Copco
Internal engine problem dealer or see engine manufacturer’s
service manual.
Engine turns over but No fuel Fill fuel tank and prime fuel system
will not start. Dirty fuel filter(s) Install new filter(s).
Poor quality fuel Drain system and replace fuel fil-
Clogged or broken fuel ter(s). Refill system with good qual-
lines ity fuel.
Electrical problem. Clean, repair, or replace.
See electrical troubleshooting table.

Troubleshooting
Engine
Engine misfires or Air in fuel system Find leak and repair it.
runs roughly Fuel system not correctly Contact your authorized Atlas Copco
timed dealer or see engine manufacturer’s
Fuel pressure too low service manual.
Faulty injector(s) or pump Install new line.
Incorrect valve clearance
Bent or broken push rod
Leak or break in fuel line
between pump and injec-
tion valve
Engine stalls at low Low fuel pressure Contact your authorized Atlas Copco
rpm Idle rpm set too low dealer or see engine manufacturer’s
Faulty fuel injector(s) service manual.
Faulty fuel or injection Replace
pump Repair or replace.
Erratic engine speed Air in fuel system Find leak and repair.
Sticky governor linkage Clean thoroughly. Repair defective
Bad or poorly installed parts.
springs Repair or replace.

Troubleshooting
Engine
Low power Air in fuel system Find leak and correct it.
Poor quality fuel Drain system and replace fuel filter.
Low fuel pressure Refill system with good quality fuel.
Plugged or blocked fuel Contact your authorized Atlas Copco
filter(s) dealer or see engine manufacturer’s
Not set for proper applica- service manual.
tion Replace fuel filter(s).
Leaks in air intake system Contact your authorized Atlas Copco
Clogged air filter dealer or see engine manufacturer’s
Electrical problem service manual
Incorrect valve clearance Check pressure in the air intake man-
Faulty injector(s) or pump ifold. Repair or replace.
Stuck throttle linkage Replace
See electrical troubleshooting table.
Contact your authorized Atlas Copco
dealer or see engine manufacturer’s
service manual.
Check linkage.
Excessive vibration Loose bolt or nut on pulley Tighten bolt or nut.
or damper Replace.
Faulty pulley or damper
Fan blade out of balance
Excessive vibration Loose engine mounts Tighten all mounts. Replace defective
Engine needs adjustment components.
See Engine Misfires above.
Combustion knocking Poor quality fuel Drain system and replace fuel filter.
Faulty injector(s) or pump Refill system with good quality fuel.
Fuel system not correctly Contact your authorized Atlas Copco
timed dealer or see engine manufacturer’s
service manual.
Valves clicking Faulty valve springs Replace.

Low oil or poor lubrication Fill to correct level with proper oil
Incorrect valve clearance Contact your authorized Atlas Copco
Damaged valves dealer or see engine manufacturer’s
service manual.

Troubleshooting
Engine
Oil in cooling system Faulty oil cooler Install new core in the oil cooler.
Faulty head gasket Replace.
Mechanical knocking Connecting rod breaking Contact your authorized Atlas Copco
failure dealer or see engine manufacturer’s
service manual.
High fuel consumption Leak in fuel system Inspect for leaks and repair as needed.
Defective injectors, rough Contact your authorized Atlas Copco
running, etc. dealer or see engine manufacturer’s
Incorrect fuel injection service manual.
timing
Unusual loud valve Damaged camshaft Contact your authorized Atlas Copco
and valve drive noise Damaged valve lifters dealer or see engine manufacturer’s
Damaged valves service manual.
Rocker arm and valve Too much clearance Contact your authorized Atlas Copco
clearance problems Not enough lubrication dealer or see engine manufacturer’s
Worn rocker arm service manual.
Worn valve stem
Worn push rods
Word or damaged valve
lifters
Worn camshaft
Oil at exhaust Worn valve guides Contact your authorized Atlas Copco
Worn piston rings dealer or see engine manufacturer’s
service manual.
Coolant in engine oil Damaged oil cooler core Replace
Damaged head gasket
Cracked or defective cyl-
inder head
Excessive black or Clogged air filter Clean or replace filters
gray smoke Faulty fuel injection Contact your authorized Atlas Copco
valve(s). dealer or see engine manufacturer’s
Wrong fuel injection tim- service manual.
ing Drain system and replace fuel filter.
Faulty fuel ratio control Refill system with good quality fuel.
Poor quality fuel Clean or replace.
Restricted exhaust piping

Troubleshooting
Engine
Excessive white or Too much lube oil in en- Drain lube oil system and refill to
blue smoke gine proper level.
Misfiring or running rough See Engine Misfires above.
Wrong fuel injection tim- Contact your authorized Atlas Copco
ing dealer or see engine manufacturer’s
Worn valve guides service manual.
Worn piston rings
Damaged turbocharger oil
seal
Low oil pressure Bad pressure gauge Replace
Defective oil pump relief See Electrical Troubleshooting
valve Contact your authorized Atlas Copco
Defective oil pump suction dealer or see engine manufacturer’s
pipe service manual.
Defective oil pump
Worn camshaft or bearings
Worn crankshaft or bear-
ings
Worn bearing on idler gear
Dirty oil filter or cooler
Electrical problem
Fuel in lube oil
Low oil pressure Improper rocker arm ad- Contact your authorized Atlas Copco
justment dealer or see engine manufacturer’s
service manual.
High engine oil use Oil leaks Find and repair
Oil temperature too high Check operation and repair oil cooler
Worn valve guides as needed
Worn piston rings and cyl- Contact your authorized Atlas Copco
inder liners dealer or see engine manufacturer’s
Defective seal rings in the service manual.
turbocharger

Troubleshooting
Engine
High engine running Low coolant level Add coolant to proper level.
temperature Restricted/clogged engine Clean and/or repair
radiator Replace.
Defective pressure cap See your authorized Atlas Copco
Defective thermostat dealer or your engine service manual
Defective gauge for instructions.
Faulty water pump See Transverter Troubleshooting
Fan belts slipping See Electrical Troubleshooting.
Incorrect fuel injection
timing
Torque converter problem
Electrical problem
High engine running Exhaust gas leak into Contact your authorized Atlas Copco
temperature cooling system dealer or see engine manufacturer’s
service manual
Below normal engine Defective Thermostat Replace.
running temperature Improperly installed Install properly.
heater
Transverter
Erratic oil pressure Low oil level Add oil to proper level
Suction tube fitting Replace O-ring fitting
Suction manifold O-ring Replace O-ring
not sealing Remove object and check for other
Foreign object in suction contamination
port
Excessive oil pressure Sticking main regulator Replace main regulator valve
valve Replace main regulator
Faulty spring

Troubleshooting
Transverter
Low oil pressure in all Sticking main regulator Replace main regulator valve
gears valve Replace gaskets
Control valve body gasket Replace pump
leaking Replace seal and install correctly
Charge pump defective Replace regulator assembly
Internal disconnect seal Replace control valve body
damage or installed incor-
rectly
Faulty main regulator valve
Control valve body cracked
Low pressure in one Contaminated proportional Replace proportional solenoid/
gear but all right in oth- solenoid check suction screen for contami-
ers Broken wire to one sole- nation
noid, or dirty connection Repair wire
Broken seal ring on input Replace seal ring
end of clutch assembly Replace bore sleeves
Bore sleeve worn Replace seals
Outer or inner piston seal
leaking
Vehicle will not move Voltage to wrong solenoids Check wiring and connectors
on control valve (check Rebuild converter
transverter schematic) Check wiring, controller, and con-
Converter damage nectors
No voltage to all solenoids Check wiring and controller
Voltage to more than two Replace solenoid
solenoids
Proportional solenoid stuck
Low or no converter Converter bypass valve Replace converter bypass valve
pressure defective Replace seal ring
Converter hub seal ring not Correct offset dimension
sealing
Check converter offset
dimension

Troubleshooting
Transverter
Filter or filter oil lines Hose bends too sharp Reroute hoses
blow out Defective hose Replace hose
Main regulator valve faulty Change valve and change filter and
System plumbing incorrect oil
Filter O-ring faulty Correct plumbing
Replace filter
Excessive noise Charge pump defective Replace pump
Excessive backlash in gear Replace bearings and inspect for
train defective gears
Auxiliary driven pump bad Remove pump and check for noise
Blows oil out of dip- Transverter over filled with Drain to proper level. Check front
stick/breather oil seal on auxiliary driven hydraulic
Converter seal ring dam- pump if equipped
aged Remove transverter and install a
new seal ring on converter hub
Transverter overheating Converter stalling Shift to lower gear
Oil level too high Drain to proper level. Check front
Engine overheating seal on auxiliary driven hydraulic
Transverter cooler lines pump if equipped
defective Check engine coolant
Transverter cooler dirty Replace lines
Clutch slipping Clean cooler
Check clutch pressure
Transverter pressure Converter sprag clutch Disassemble and inspect converter
checks okay, but has no damaged or installed wrong Replace relief valve
power and possibly Converter relief valve bro-
overheating ken
Oil leaking from engine Converter front cover seal Replace seal
flywheel and/or weep leaking Replace seal
hole in transverter bell Converter hub seal or O- Check engine flywheel offset
housing ring damaged dimensions and converter pilot
Converter not properly bushing length against vehicle
positioned within bell hous- manufacture standards
ing causing converter and
seal to leak

Troubleshooting
Transverter
Transverter shifts rough Oil temperature sensor Check temperature sensor, replace
loose or wires damaged if necessary, check wires, correct
Calibration off faulty connections.
See Section 8: Electrical Systems
for the calibration procedures.
Axles
Excessive vibration Broken gear teeth, worn Replace gear or bearings. See also
bearings drivelines.
Excessive noise Incorrect or insufficient lu- Check level, fill with proper type
bricant and grade of lubricant. See also
Hub bearings scored or drivelines.
rough Replace bearings.
Gear teeth in planetary Replace gear.
chipped.
Lubricant leaks Lubricant level too high Drain and fill to proper level with
Lubricant foams excessive- proper type and grade of lubricant.
ly Drain and fill with correct type and
Worn or broken oil seal grade of lubricant.
Replace oil seal.
Lubricant leaks Restricted differential Clean vent.
breather vent Tighten nuts and bolts.
Loose nuts or bolts.
Lubricant leaking out of Restricted breather vent. Clean vent.
breather
Overheating Low lubricant level. Find source of leak and repair.
Ring and pinion adjustment Adjust.
too tight Replace bearings.
Faulty bearing

Troubleshooting
Axles
Abnormal noise when Worn differential side gears Replace
turning and pinions Find source of leak and repair
Low lubricant level Tighten nuts to specified torque
Loose nuts on differential (see driveslines)
casings
Insufficient driveline clear-
ance
Worn or improperly lubri-
cated bearings
Vehicle won’t move Worn or broken axle shaft Replace axle shaft
splines Add transverter oil
Transverter oil low
Drivelines
Excessive vibration or Driveline bent or out of bal- Clean driveline. Check clearance
noise ance with nearby components. Balance
driveline.
If driveline is bent or damaged,
replace.
Excessive vibration or Loose mounting Replace capscrews and tighten to
noise Worn or poorly lubed bear- proper torque.
ings Test for looseness. If crosses are
Insufficient clearance. loose, replace cross and bearings as
an assembly
Excessive wear of cross Poor alignment or run-out Check alignment, run-out and bal-
bearing assemblies. Driveline unbalanced ance. Repair or replace, as required.
Check for missing balance weights
or driveline distortion.
Check dynamic balance.
Rebalance
Replace distorted driveline.
Driveline does not Joint failure Replace
transmit power. Damaged splines
Damaged yoke

Troubleshooting
Wheels and Tires

Tire leak Defective valve Tighten parts
Tire cuts Repair tire damage
Damaged O-ring Replace O-ring
Leakage between tire bead Remove tire from rim. Clean tire
trim beads in rim contact area. Clean
rim. Inspect bead seat band.
Replace defective parts. Remount
tire using proper lubricant.
Tire Leak Cracked rim or weld Add Tyre Life
Replace defective part.
Articulation
Excessive or unusual Loose or worn trunnion Retorque, repair or replace.
noises caps Reshim and adjust preload
Loose articulation bearings Disassemble and repair
Contamination in articula- Check for correct installation of
tion bearing or steering cyl- articulation assembly.
inder seals Check articulation bearings for fail-
Contact between power ure. Replace.
frame and load frame hinge Replace
plates
Worn articulation bearing
Worn or damaged articula-
tion pin.
Worn steering pins
Excessive movement in Loose articulation pin Check pre-load
articulation Loose steering pins Replace
Excessive articulation bear-
ing wear
Worn steering pins

Troubleshooting
Hydraulic System
Poor performance or Reservoir low on oil Add oil
failure External leakage (see below)
Load too heavy Check that line pressures with full
Restriction in hydraulic load are within normal range.
line Check lines to locate obstruction.
Relief valve not operating Remove obstruction or replace line.
properly Clean and adjust valve.
Worn cylinder or seals Disassemble and repair.
Defective pump Replace.
Disassemble and repair or replace
Replace pump
Excessive oil foaming Improper type or viscos- Drain hydraulic system and refill
ity oil with proper oil.
Leak on suction side of Locate and repair leak.
pump Replace pump.
Worn pump
Excessive oil tempera- Low oil in system Add oil
ture Hydraulic oil cooler Check oil cooler.
plugged or dirty Drain hydraulic system and refill
Improper type or viscos- with proper oil.
ity oil (See the Operator’s Manual for
Excessive cycling of load proper technique)
Worn pump Replace pump.
Foreign material in sys- Filters clogged and Check restriction indicator and
tem bypassed replace filter(s) in necessary.
Contaminated or bad oil Drain and flush hydraulic system.
Damaged cylinders Replace filter(s) and re-fill with clean
Worn or damaged pump oil.
Disassemble, inspect and repair or
replace component.
Insufficient pressure Faulty charge valve Disassemble and inspect. Repair or
Internal leakage past seals replace as necessary.
or cylinders Measure and record pump flow and
Worn pump pressure. If out of specification,
replace pump.

Troubleshooting
Hydraulic System
Insufficient or no flow Oil too cold or wrong vis- Drain and flush hydraulic system.
cosity. Pump will not Replace filter(s) and re-fill with clean
prime. oil.
Pump intake line from res- Check lines to locate obstruction.
ervoir restricted Remove obstruction or replace line.
Faulty pump drive seal Replace seals.
Pump drive shaft sheared Disassemble the pump and inspect.
or disengaged Replace pump
Worn pump
Leaking oil Worn or faulty hose line Replace

Incorrect or damaged fit- Clean or replace
tings Clean and tighten
Dirt or paint on or under Replace.
seals
Loose seal plates
Cut or damaged seals
Excessive pump noise Low oil supply Fill reservoir
or cavitation Obstruction in suction line Check tank strainer and pump inlet
Air in oil supply to pump line. Remove obstruction or replace
Excessive foaming line.
Engine operated at high Check all hose fittings and connec-
speed with cold hydraulic tions.
oil Locate air entry point and repair.
Oil viscosity too high Drain hydraulic system and refill
Pump components not with proper type and viscosity oil.
properly aligned. Warm up hydraulic system by
cycling hydraulic control s.
Drain hydraulic system and refill
with proper type and viscosity oil.
Check shaft seal and bearings for
damage. Replace parts as required.
Align pump correctly.

Troubleshooting
Hydraulic System
Accumulator not charg- Priority valve malfunc- Verify malfunction, replace cartridge
ing but the fan is run- tioning
ning
Accumulator charge valve
malfunctioning
Hydraulic fan is not Hydraulic pump malfunc- Verify pump malfunction, replace
functioning tioning pump
Relief valve stuck open Verify valve problem, clean or
Air bleed not closing replace the valve cartridge
Verify, replace cartridge
No hydraulic control Filter in Auxiliary valve Check filter, clean or replace filter
functions assembly clogged (pilot cartridge
pressure filter
Hydraulic hand pump Check valve malfunction- Verify check valve function, replace
feels loose while pumping if necessary
ing
Hydraulic system cuts Accumulator Pre-charge is Verify Accumulator pressure, adjust
in and out too rapidly too low or too high pressure, check accumulator piston
when brake treadle for excessive wear
valve is actuated
Pilot control is slow to Low pilot pressure Verify pilot pressure, adjust if neces-
respond sary
Normal hydraulic Low pilot pressure Verify pilot pressure, adjust if neces-
response but requested Pump flow volume low sary
function too slow
Flow test pump, adjust flow rate,
replace worn pump
Hydraulic hose is hard Aerated oil in system from Replace hose and check for air in the
and cracking cavitation system, drain oil and replace with
fresh oil. Check main control valve
spools

Troubleshooting
Hydraulic System
The hydraulic hose is Exposure to intense cold Replace hose with an appropriate cli-
cracked both internally while the hose was flexed. mate/temperature rating.
and externally but the
elastomeric materials
are soft and flexible at
room temperature
The hose has burst and High frequency pressure Replace hose with a higher SAE
examination of the wire impulse condition. impulse test requirement.
reinforcement shows
random broken wires
running the length of the
hose
The hydraulic hose has Wrong hose strength Change hose with a proper strength
burst but there is no Hydraulic circuit malfunc- rating for circuit
indication of multiple tion causing unusual, high Change hose, identify circuit prob-
broken wires the entire pressure conditions lem, examine check valves and port
length of the hose. relief valves.
The hydraulic hose has Hose cover degradation Replace hose, remove corrosive
burst and examination due to excessive wear or material from area--the following are
shows that the reinforc- exposure to corrosive causes of hose cover damage: Abra-
ing wires are rusted and material sion, cutting, battery acid, steam
the cover has been dam- cleaners, chemical cleaning solu-
aged or cut. tions, muriatic acid, salt water, heat,
extreme cold.
The hydraulic hose has Violation of minimum Check the bend radius specification,
burst on the outside hose bend radius. change hose and either re-route or
bend and appears to be replace with a hose designed for the
elliptical in the bent sec- bend radius required.
tion
The hydraulic pump is Violation of minimum Check hose bend radius, re-route
noisy and very hot, the hose bend radius hose, check oil for aeration (this situ-
pressure line from the ation can result in cavitation)
pump is hard and brittle

Troubleshooting
Hydraulic System
The hydraulic hose is Twisting force exerted on Check components for looseness
flattened out in one or the hydraulic hose causing torquing on the hose.
two areas and is kinked
or twisted
The hose tube has bro- High vacuum, wrong hose Replace hose with a proper rated
ken loose from the rein- for circuit hose.
forcement and collapsed Minimum hose bend Check radius, re-route hose, replace
the inner diameter of the radius is violated hose after straightened.
hose. The hose may pro-
trude into the hose fit-
ting
The hydraulic hose has Improper assembly of the Replace with a properly assembled
burst six to eight inches hose fitting hose.
away from fitting, wire
reinforcement is rusted,
the cover is not cut or
damaged
There are blisters on the Incorrect assembly of the Replace hose with a properly assem-
outer cover of the hose. hose fitting bled hose.
The blisters contain oil.
The hydraulic hose blew Use of incorrect fitting on Replace fitting and hose with proper
out of the hose fitting the hose hose assembly---Use same manufac-
Incorrect assembly of hose turer products and make sure that
and fitting hose and fitting are rated for each
Incorrect hose length other.
Replace bursted hose with a correctly
assembled hose and fitting package.
Replace hose with a new hose of
proper length.

Troubleshooting
Hydraulic System
The tube of the hose is Tube of the hose may be Replace with proper rated hose for an
badly deteriorated with incompatible with the oil based hydraulic system.
evidences of extreme hydraulic fluid. Check hydraulic circuits for malfunc-
swelling. In some cases Excessive heat generated tion, replace hose with a proper rated
the tube may be par- by the hydraulic system, hose.
tially washed out. or improper heat tolerant
hose
The hydraulic hose has Hose is aged Replace with a new hose
burst, the cover is badly
deteriorated and the
hose cover surface is
crazed.
The hose is leaking at Hose is trying to shorten Replace with a longer hose
the fitting because of a under pressure and has not
crack in the steel tube enough length to do so
adjacent to the braze on
a split flange shoulder.
A spiral reinforced hose Hose too short to accom- Replace with a longer hose
has burst and literally modate the change in
split open with the wire length while it was pres-
exploded and badly tan- surized.
gled
Hose is badly flattened Kinked hose Replace hose and check for cause of
out in the burst area. kinking. Re-route if necessary to
save future hoses
Hose leaks profusely Hose bend radius exceeds Replace and re-route the hose
but has not burst minimum causing high Replace the hydraulic fluid and filter.
pressure erosion of inner Also replace the hose. Look for cause
tube of contamination.
Contamination in the
hydraulic fluid

Troubleshooting
Hydraulic System
The hydraulic hose has Not necessarily a high Replace with a longer hose
been pulled out of the pressure problem--hose
hose fitting not long enough for appli-
cation
SAHR Brakes
Inadequate braking Low hydraulic pressure at Check brake lines for leaks.
the wheel ends Install test gauge at wheel ends and
Restriction in hydraulic line check pressure.
Wheel end leakage. Adjust brake foot pedal control
Insufficient accumulator valve to specification.
pre-charge Check lines to locate obstruction.
Brake disks worn Remove obstruction or replace line.
Air in oil lines Identify leak location and repair or
Relief valve not function- replace faulty component.
ing properly Adjust pre-charge pressure to speci-
fication.
Replace
Check hydraulic lines for tightness
Check setting and adjust to specifi-
cation. Disassemble valve and
check for cleanliness. Repair or
replace valve, if required.
Brakes chatter Improper type or viscosity Drain hydraulic system and refill
oil with proper oil.
Insufficient hydraulic oil Check oil level in hydraulic tank.
flow to the wheel ends. Check return line flow from wheel
ends. Check pump performance.
Brakes release too Brake pedal not returning to Disassemble and inspect valve.
slowly fully released position Repair or replace valve as required.
Oil return port of brake con-
trol valve is restricted or
plugged.

Troubleshooting
SAHR Brakes
Brakes do not release Brake pedal control valve Disassemble and inspect valve.
sticking. Repair or replace valve as required.
Restriction in hydraulic Check lines to locate obstruction.
lines Remove obstruction or replace line.
Park Brake engaged (see Park Brake Troubleshooting)
Insufficient accumulator Check accumulator charging valve
pressure for proper operation. Ensure brake
pump is performing properly.
Brakes pull or drag (one Brake pedal control valve Adjust pedal travel.
or more assemblies do travel adjustment incorrect. Check hydraulic lines for leaks.
not release fully) Insufficient oil pressure to Install test gauge to determine loca-
one or more wheel ends tion of problem.
Brakes apply intermit- Brake pedal control valve Disassemble and inspect valve.
tently sticking. Repair or replace valve as required.
Accumulator pressure low Check accumulator charging valve
Restriction in hydraulic for proper operation.
lines Ensure brake pump is performing
Park Brake solenoid applied properly.
Check lines to locate obstruction.
Remove obstruction or replace line.
Check Park Brake control switch
position. Check Park Brake electri-
cal circuit for proper operation
(switch, wiring, solenoid, time
delay relay)
Brakes apply intermit- Convertor pressure low (see Transmission Troubleshooting)
tently
Brakes do not apply Hydraulic pressure at wheel Check system for blockage of flow.
ends will not relieve.

Troubleshooting
SAHR Brakes
Brakes overheat Excessive cycling of charge Check system for leaks. Ensure
valve brake pump is performing properly.
Brakes dragging (See Hydraulic System Trouble-
High hydraulic oil tempera- shooting)
ture
Excessive brake pedal Brake pedal out of adjust- Adjust travel.
travel ment.
Service brake will not Improper test procedure. Check that vehicle is in proper test
hold in drive Brake pedal heel stop out of gear (see Operator’s Manual).
adjustment. Adjust heel stop.
Brake pedal control valve Disassemble valve and inspect.
not stroking. Check hydraulic system for possi-
ble particulate contamination.
Park Brake
Park brake will not hold Improper test procedure. Check that vehicle is in proper test
in drive Hydraulic pressure at wheel gear (see Operator’s Manual).
ends will not relieve Check system for blockage of flow
Park brake does not Improper control position Check Park Brake Knob in proper
release Loss of hydraulic pressure position.
Loss of electrical signal Check indicating circuit, if applica-
ble.
(See Hydraulic System Trouble-
shooting)
Loss of electrical signal

Troubleshooting
Electrical System
Dash indicating light(s) No power Check that Master Isolation switch is
will not illuminate Circuit breaker or fuse turned on. Check charge on battery.
open Check for tripped circuit breakers.
Bulb burned out Check for faulty ignition switch.
Broken or loose wire or Check for faulty ignition solenoid.
connection Check for faulty Master Isolation
Programmable Logic Con- switch. Check for broken or loose
trol (PLC) failure wires and connections.
Reset/close.
Replace bulb
Repair or replace
Check PLC LED inputs and outputs
Verify PLC program
Replace PLC
Engine will not turn No power (see above)
over Low battery charge Check specific gravity. Replace if bat-
Faulty start switch tery will not hold charge.
Replace
Engine will not turn Starter safety switch open Place transmission in neutral and
over High resistance in circuit apply park brake.
Defective starter motor Clean and tighten all connections.
Starter solenoid defective Replace.
Engine turns over but Fault in electrical shut- Check circuit components for fault.
will not start. * Check down circuit (Refer to OEM Troubleshooting Man-
for fuel and verify Fault in engine ECM sys- ual)
shut-off valve position tem

Troubleshooting
Electrical System
Starter motor sluggish High resistance in circuit Check battery terminals for corrosion.
Low battery charge Clean and tighten all connections.
Excessive load or drag on Check specific gravity. Replace if bat-
engine. tery will not hold charge. If extreme
Defective starter motor cold conditions, warm battery prior to
starting.
Check oil for proper viscosity. If
extreme cold conditions, warm engine
oil prior to starting.
Trouble shoot engine subsystems to
locate problem.
Replace.
Starter solenoid switch High resistance in circuit Check battery terminals for corrosion.
chatters Low battery charge Clean and tighten all connections.
Faulty starter solenoid Check specific gravity. Replace if bat-
tery will not hold charge.
If extreme cold conditions, warm bat-
tery prior to starting.
Replace solenoid or solenoid wiring
Low engine power Fault in engine ECM sys- (refer to OEM Troubleshooting Man-
(See Engine trouble- tem (if applicable) ual)
shooting) Lost connection to ECM Check injector connections
injectors

Troubleshooting
Electrical System
Low battery output Electrolyte level low Add distilled water to proper level.
Defective battery cell Replace battery
Damaged battery case Adjust belt tension. Replace belts, if
Slipping drive belts necessary.
Electrical circuits ener- Turn off all switches when engine
gized with engine off. shutdown.
High resistance in circuit. Check and clean all terminals and
Defective wiring. grounds.
Faulty alternator Replace.
Check and adjust regulator.
Check and tighten mounting.
Check pully alignment.
Check for grounded field circuit.
Replace alternator.
Starter Motor Armature Battery discharged. Recharge battery.
does not rotate or Battery defective. Have battery checked (or replaced) by
rotates too slowly. maintenance personnel.
Battery terminals loose or
corroded. Tighten terminals, clean, and put
Starting motor terminals or acid-resisting protective grease on
carbon brushes grounded terminals and poles.
(short circuit). Trace defective spot and repair.
Carbon brushes have no Check, clean, or renew brushes. Clean
contact with commutator brush holder.
or are jammed in the brush Replace starting switch.
holders.
Repair or replace solenoid switch.
Brushes worn, broken,
Check wiring, clean, and tighten con-
fouled by dirt or oil.
nections. Replace any broken cables
Starting switch defective or wires.
(burnt or loose connec-
tions).
Solenoid switch in starting
motor defective.
Excessive voltage drop in
circuit.

Troubleshooting
Electrical System
Pinion fails to mesh Pinion fouled with dirt. Clean.
when armature rotates. Pinion or rim gear teeth Remove burr by filing.
damaged, burred.
Starting motor func- Battery insufficiently Charge battery.
tions properly until charged. Check brushes, springs, and holders.
pinion meshes, then Insufficient brush pressure. Repair or replace solenoid switch.
stops.
Solenoid switch in starting Check wiring and connections.
motor defective.
Excessive voltage drop in
circuit.
Starting switch fails to Solenoid switches dam- Disconnect starter cable immediately
cut out. aged. at battery or at the starting motor.
Replace defective switch, or have
switch or starting motor repaired.
Pinion or flywheel gear Return spring broken or Clean thoroughly. Remove burr from
badly fouled or dam- tired. tooth edges by filing. Have starting
aged. motor repaired.
Over-charged battery. Charge too high. Check and adjust or replace regulator.
Incorrect pulley used on Replace with pulley of correct size.
generator
Battery uses an exces- Battery over-charged. See above.
sive amount of water.
Rapid burn-out of light Battery over-charged. See above.
bulbs.
Low or intermittent Dirty or worn generator Clean or repair commutator or replace
generator output. commutator. armature.
Brush(es) sticking. Clean brush holders thoroughly.
Replace brushes if necessary.
Weak brush springs.
Replace springs.
Low or intermittent Slipping drive belt. Adjust drive belt.

generator output. Malfunctioning regulator Adjust or replace regulator.

Troubleshooting
Electrical System
Lights dim. Batteries low. Charge batteries.
Poor ground. Provide a clean, tight ground.
Loose connections. Tighten all connections.
One (1) electrical Bad connection at gauge, Make a positive connection.
gauge not operating. connector plug or sender. Replace.
Sender defective.
Gauge defective.
Ignition "ON" - no Dead battery. Recharge or replace battery.
gauges or lights work- Loose connection from Tighten connection.
ing. battery to dash panel. Repair or replace wire.
Broken wire between bat-
tery and dash panel.
Brakes won’t release Lost connection Check wiring
Park brake switch mal- Check wiring, replace switch

function
Check LED on PLC, verify PLC pro-
PLC malfunction gramming, replace the PLC
Emergency stop system in Check PLC status, verify hydraulic

effect and Transverter oil pressures
Pressure loss relay mal- Check wiring connections,

function
replace the relay
Start inhibit relay malfunc- Check wiring connections, replace the
tion relay
Transverter won’t Failed switch in Dump/ Check wiring, connections, verify
engage in Forward, Hoist control stick switch integrity, replace switch
Reverse, or Neutral Lost connection Check connections and wiring to
PLC malfunction transverter from PLC
Transverter ECU failure Verify PLC operation, replace PLC
Check with a diagnostic device or
gauge.

Troubleshooting
Electrical System
Transverter does not Failed selector switch Check wiring and connections to
engage in gear or Lost connection switches
appears not to engage Failed bulb in gear button Check connections from PLC to
in gear. First to Fourth PLC malfunction transverter
ECU failure Check bulb, verify PLC operation
Verify PLC operation, replace PLC
Check with a diagnostic device or
gauge.
Transverter shifts Calibration problem Check calibration

roughly or slow ECU failure Check with a diagnostic device or
gauge
Headlights do not work Broken wiring Verify the integrity of the wiring and
Loose connection splice or replace faulty wiring
Light relay failed Check connections and reconnect or
Light switch failed replace the connectors
Verify the failure, replace the relay
Verify the failure and replace the
switch
Horn does not sound Lost or loose connection Check wires and connections, replace
Faulty horn if faulty
Replace the horn
Backup light alarm/ Lost connection Check wiring and connections,
light does not work Faulty alarm replace if faulty
Faulty strobe light Replace the alarm
Faulty reverse switch Replace the strobe light
PLC malfunction Replace the switch
Check wiring and connections, verify
PLC failure, replace the PLC
Gauges do not work Faulty wiring or connec- Check the wires and connections,
tions repair wires and replace connectors
DC/DC 12 volt converter Check wires and connections, verify
malfunction converter failure, replace if necessary

Troubleshooting
Electrical System
Gauge pointers move Faulty wiring or connec- Check the wiring to the gauges from
back and forth in a tions the DCU. check the connections,
windshield wiper Data lines between gauge repair wiring, replace connectors
motion and DCU are incorrectly Check the data line to see if they have
installed been reversed
Loss of power to the DCU Check the power supply to the DCU
Gauges malfunctioning Verify and replace faulty gauges
Gauges go to zero and The DCU is malfunction- Replace the DCU
stay there ing
Pressure gauge reads Transducer is malfunction- Verify the fault and replace the trans-
wrong or is erratic ing ducer
Gauge is malfunctioning Check wiring and gauge connections,
DCU is malfunctioning replace the gauge
Verify the malfunction, check connec-
tions, check for faulty programming,
replace the DCU
Temperature gauge Temperature sensor is Verify the fault and replace the sensor
gives incorrect reading faulty Check wiring and gauge connections,
or is erratic Gauge is malfunctioning replace the gauge
DCU is malfunctioning Verify the malfunction, check connec-
tions, replace the DCU
MMC does not count Faulty wiring to MMC Check wires and connections, repair,
hours Battery and ignition lines replace faulty connectors
are crossed Check wiring, replace if shorted
MMC has no display MMC not receiving data Check wiring and connections, repair
or replace faulty connectors
MMC is missing seg- Faulty gauge Replace the gauge
ments on LCD, or
reset/select buttons do
not work
No backlighting on Crossed 12 volt backlight- Check wires, replace in proper con-
MMC or the gauges ing wires nectors

Troubleshooting

Section 10 Specifications
ST1010 Operating Pressure (Steering) 22,406 3250
Filtration 25 mic
Operating Weight kg lbs
Empty 26,762 59,000
Loaded 36,741 81,000 Tank Capacities ltr gal
Fuel 284 75
Hydraulic 189 50
Capacity kg lbs Coolant 38 10
Tramming 10,000 22,000
Breakout Force, Digging 31,750 70,000
Engine Displ Pwr
Breakout Force, Hydraulic 14,950 33,000
Detroit Diesel Series 50 8.5L 250
Operating Times Seconds

Transverter ltr gal
Boom Raising Time 7.6
Rock Tough TV100Q 19 5
Boom Lowering Time 3
Bucket Dump Time 2.2
Steering Time 6
Axles Diff Plan
Rock Tough ASD100 J 34.5L 4.7L
Speed (Loaded) km/hr mph

1st Gear 4.9 3.1
Brake System kPa psi
2nd Gear 8.0 5.0
Service Brake Pressure 9997- 1450-
3rd Gear 18.5 11.5 (SAHR) 10,686 1550
4th Gear 27 16.8 Charge Valve Kick-In 10,686- 1550-
11,400 1650
Charge Valve Kick-Out 13,400- 1950-
Steering and Oscillation Degrees 14,100 2050
Turning Angle 42.5 Accumulator Pre-Charge 7900- 1150-

8500 1250
Rear Axle Oscillation ±10
Hydraulic System kPa psi

Operating Pressure (Dump/Hoist) 20,682 3000

Specifications
Tires kPa psi

F/R F/R
18.00 X 25, 24ply, L-5S 655/552 95/80
18.00R X 25, Radial 655/552 95/80
Engine (Series 50)

Oil capacity with filter change: 26 liters (7 gallons)
Type of oil See specification tables
Fuel Tank
Capacity 321 liters (85 gallons)
Type of Fuel See specification tables
Cooling System
System capacity 37.8 liters (10 gallons)
Type of fluid See specification tables
Transverter
Oil refill capacity with filter change: 30 liters (8 gallons)
Rock Tough TV 100Q 28 liter (7.5 gallons) without filter
Axles
Axle Differential capacity (each):
Rock Tough ASD 100 J 34.5 liters (9 gallons)
Planetary ends (each) 4.7 liters (1.3 gallons)
Hydraulic Reservoir
Reservoir capacity 189 liters (50 gallons)
Alternate oil See specification tables

Specifications
Grease Fittings
Type of grease See specification tables
ST1010 Hydraulic Pump Flows
System Pump Liters/Min GPM

Steering 99.5 @ 2635 RPM 26.3 @ 2635 RPM
Dump and Hoist 120 @ 2635 RPM 31.8 @ 2635 RPM
Service Brake 59 @ 2635 RPM 15.6 @ 2635 RPM
Transverter Charge 95 @ 2100 RPM 25 @ 2100 RPM
Stability
Test conditions: Vehicle fully loaded, boom down, bucket rolled back
Applied Standards: ISO
Maximum safe side See vehicle technical records
slope for operation:
Noise Level
Test conditions Meets ISO Standards

Test Results See vehicle certification checklist
Maximum Allowable Back Pressure
Engine In. H2O MM Hg RPM Load

Detroit Diesel
Series 50 - 250 40.8 76.2 2100

Specifications
Bucket Dump Angles ( +/- 3°)

ST-1010 44°
Steering Stops (Hub to Hub Centering

Distance)
ST-1010 250.7cm
(98.7 inches)
Engines
Fuel
Rating Torque Disp Cooling Usage
Model Cyl Vehicle
(Kw/hp) (Nm /ft-lb) (l/cu-in) (m3-min/CFM) (l-hr/gal-
hr)
Detroit Diesel
Series 50 - 187 / 250 848 / 625 4 8.5 / 519 Water 47.9 / ST1010
250 (821 / 29000) 12.7
Transverters
Oil
Model Speeds Capacity Vehicle
Pressure (kPa/psi) Temperature (0C/ 0F)
(ltr/gal
Rock Tough
TV 100Q 4 1724/250 27-49/80-120 19/5 ST1010
Axles
Oil Capacity
Model Options Vehicle
Differential Planetaries
Rock Tough
ASD 100J 34.5ltr / 9gal 4.7ltr / 1.3gal No-Spin, LCB, SAHR ST1010
Rock Torque

Specifications
Transfer Cases
Model Oil Capacity Oil Type Vehicle

TC10 2.4 ltr/.64 gal Use EP 80/90 Oil ST1010
Torque Values Note: Use these recommended torque values

unless otherwise specified in the assembly
IMPORTANT: The following torque charts instructions.
apply to standard dry plated hardware.
Coarse Thread
Grade 5 Grade 8
D T T
Size Thds/In Clamp Load Torque Clamp Load Torque
(in.) (kips) N-M / (ft.lbs.) (kips) N-M / (ft.lbs.)
1/4 20 2.0 8/6 2.9 12 / 9
5/16 18 3.3 18 / 13 4.7 25 / 18
3/8 16 5.0 31 / 23 7.0 45 / 33
7/16 14 6.8 50 / 37 9.6 72 / 53
1/2 13 9.1 78 / 57 12.8 109 / 80
9/16 12 11.6 112 / 82 16.4 157 / 115
5/8 11 14.4 157 / 115 20.3 218 / 160
3/4 10 21.3 273 / 200 30.1 382 / 280
7/8 9 29.5 437 / 320 41.6 628 / 460
1 8 38.6 655 / 480 54.5 928 / 680
1 1/8 7 42.4 819 / 600 68.7 1324 / 970
1 1/4 7 53.8 1147 / 840 87.2 1856 / 1360
1 3/8 6 64.1 1502 / 1100 104.0 2443 / 1790
1 1/2 6 78.0 1993 / 1460 126.5 3235 / 2370
1 3/4 5 105.4 3140 / 2300 171.0 5105 / 3740
Formula: Torque=RDT
R=Friction Factor=0.15 for dry, plated hardware
For dry, unplated hardware, increase torque 33%
For plated hardware lubed with Fel-Pro C670, decreases torque by 13%
D=Nominal bolt diameter
T=Clamp Load
Clamp Load = 0.75XProof Load from SAE J429.

Specifications
FineThread
Grade 5 Grade 8
D T T
Size Thds/In Clamp Torque Clamp Torque
(in.) Load N-M / (ft.lbs.) Load N-M / (ft.lbs.)
(kips) (kips)
1/4 28 2.3 9/7 3.3 14 / 10
5/16 24 3.7 19 / 14 5.2 27 / 20
3/8 24 5.6 35 / 26 7.9 50 / 37
7/16 20 7.6 56 / 41 10.7 80 / 59
1/2 20 10.2 87 / 64 14.4 123 / 90
9/16 18 13.0 124 / 91 18.3 177 / 130
5/8 18 16.4 177 / 130 23.0 246 / 180
3/4 16 23.8 300 / 220 33.6 243 / 310
7/8 14 32.5 491 / 360 45.8 682 / 500
1 12 42.3 723 / 530 59.7 1024 / 750
1 1/8 12 47.5 914 / 670 77.0 1474 / 1080
1 1/4 12 59.6 1269 / 930 96.6 2061 / 1510
1 3/8 12 73.0 1706 / 1250 118.4 2785 / 2040
1 1/2 12 87.8 2239 / 1640 142.4 3644 / 2670
1 3/4 12 121.4 3617 / 2650 196.8 5869 / 4300
Formula: Torque=RDT
T=Clamp Load

Specifications
Coarse Thread
Class 8.8 Class 10.9
D T T
Size Thd Clamp Torque Clamp Torque
(mm) Pitch Load N-M / (ft.lbs.) Load N-M / (ft.lbs.)
(mm) (kips) (kips)
6 1 2.0 8/6 2.8 11 / 8
8 1 3.6 19 / 14 5.1 27 / 20
10 2 5.7 38 / 28 8.1 55 / 40
12 2 8.2 65 / 48 11.8 95 / 70
14 2 11.2 105 / 77 16.1 150 / 110
16 2 15.3 164 / 120 21.9 232 / 170
18 3 19.4 232170 26.8 328 / 240
20 3 24.8 328 / 240 34.2 464 / 340
22 3 30.7 450 / 330 42.5 628 / 460
24 3 35.7 573 / 420 49.4 792 / 580
27 3 46.4 846 / 620 64.2 1160 / 850
30 4 56.8 1147 / 840 78.6 1583 / 1160
33 4 70.1 1556 / 1140 96.1 2129 / 1560
36 4 82.6 1993 / 1460 114.3 2757 / 2020
Formula: Torque=RDT
T=Clamp Load
Clamp Load = 0.75XProof Load from Bossard.

Specifications
F O R U S E W IT H W IR E T E R M IN A T IO N S
T E R M IN A L B L O C K S
T h re a d S c re w T yp e S tu d & N u t T yp e
S ize N -M / (in -lb s .) N -M / (in -lb s .)
4 -4 0 --- .4 5 / 4 *
6 -3 2 1 / 9 .6 * 1 .4 / 1 2 *
8 -3 2 2 .1 / 1 6 * 2 .2 / 2 0 *
1 0 -3 2 2 .2 / 2 0 2 .8 / 2 5
1 /4 -2 0 3 .4 / 3 0 4 .3 / 3 8
3 /8 -1 6
M 10 --- 4 .3 / 3 8
* P e r M il-T -5 5 1 6 4 , g e n e ra l s p e c . fo r te rm in a l
b o a rd s
B IN D IN G S C R E W S & S L O T T E D S C R E W S
W ire B in d in g S c re w s S lo tte d S c re w s
S ize N -M / (in -lb s .) N -M / (in -lb s .)
(a w g )
1 4 -1 0 1 .4 / 1 2 2 .2 / 2 0
8 --- 3 .4 / 3 0
6 -4 --- 4 / 35
3 -4 /0 --- 4 .5 / 4 0
C O N N E C T O R S W IT H H A R T IN G C O N N E C T O R S
HEXAGONAL SOCKET SCREW S W IT H S C R E W T E R M IN A L S
S o c k e t s ize T ig h te n in g S c re w T ig h te n in g
(a c ro s s fla ts ) T o rq u e N -M / (in - (s ize ) T o rq u e N -M /
lb s .) (in -lb s .)
5 /3 2 11 / 100 M3 .5 / 4 .4 **
3 /1 6 1 3 .6 / 1 2 0 M6 .8 0 / 7 .0 **
7 /3 2 17 / 150
1 /4 20 / 175
5 /1 6 28 / 250 M5 1 .8 / 1 6 .0 **
3 /8 40 / 350
1 /2 51 / 450 ** P er D IN V D E 609; V D E 0627.
9 /1 6 68 / 600

Specifications
Wheel Nut Torque Values
Flat Nuts/
“BUDD” Type
Stud Size Hardened
Spherical Nuts
Washers
5/8 (.625) 240 - 260 N-M 325 - 375 N-M
(175 - 190 ft- (240 - 275 ft-
lbs) lbs)
3/4 (.750) 410 - 450 N-M 610 - 680 N-M
(300 - 330 ft- (450 - 500 ft-
lbs) lbs)
7/8 (.875) Rock Torque 815 - 950 N-M
Axles 495 - 522 (600 - 700 ft-
N-M (365 - 385 lbs)
ft-lbs)
Non Rock
Torque Axles
645 - 710 N-M
(474 - 525 ft-
lbs)
1 (1.00) 985 - 1085 N- 1015 - 1220 N-
M (725 - 800 M (750 - 900
ft-lbs) ft-lbs)
Fluids and Lubrication Specifications formance, long engine life, and acceptable
exhaust emissions levels. Fuels meeting the
Selection of the proper quality of fuel, lubri- properties of ASTM Designation D 975
cating oils and grease, and coolant is impor- (Grades 1D and 2-D) have provided satisfac-
tant to get efficient, trouble-free service from tory performance. The ASTM D 975 specifi-
your vehicle. Provided below are recom- cation does not adequately define the
mended specifications and the approximate characteristics necessary for fuel quality. The
quantities for each model vehicle. properties listed in the fuel oil selection chart
have provided optimum engine performance.
Diesel Fuel Specifications
It is important that only fuel meeting the
Quality and Selection manufacturer’s recommendations be used.
The quality of fuel oil used is a very impor- The following list shows fuels found world-
tant factor in getting satisfactory engine per- wide that may be acceptable*. Also listed are

Specifications
the recommended fuel characteristic specifi- International Fuel Specifications

cations for Deutz, Detroit Diesel and Cater-
pillar diesel engines. Specification Fuel Type
International Fuel Specifications US Military

MIL-L- marine oil
Specification Fuel Type 16884G
US Standard
ASTM D975 No. 1-D & No. 2-D
ASTM D396 diesel fuel oil * (Consult your manufacturer’s engine man-
ASTM D2880 No. 1 & No. 2 fuel oil ual for specific recommendations.)
No. 1-GT & No. 2-GT
gas turbine fuel
UK Standard
BS 2869 Class A1, A2 & B1
BS 2869 engine fuel
Class C2 & D burner
fuel
German Stan-
dard diesel fuel
DIN 51 601 E1 heating oil
DIN 51 603
Australian
Standard automotive diesel fuel
AS 3570
Japanese Stan-
dard Types 1, 2, 3 & 1(spl) &
JIS K2204 3(spl) gas oil
US Govern-
ment DF-1, DF-2 & DF-20
W-F-800C CONUS diesel
W-F-815C FS-1 & FS-2 burner fuel

Specifications
Fuel Oil Selection Chart

General Fuel ASTM No. 1 No. 2
Classification Standard ASTM 1-D ASTM No. 2-D
Gravity, °API # D 287 40 - 44 33 - 37
Flash Point D93 100 / 38 125 / 52
(°F / °C, Min.)
Viscosity, Kinematic D 445
(cSt @ 100°F / 40°C) 1.3 - 2.4 1.9 - 4.1
Cloud Point # D 2500 See Note 1 See Note 1
Sulfur Content
(wt%, Max.) D 129 0.5 0.5
Carbon Residue
(on 10%, wt%, Max.) D 524 0.15 0.35
Accelerated Stability D 2274 1.5 1.5
Total Insolubles
(mg/100 ml, Max.) #
Ash (wt%, Max.) D 482 0.01 0.01
Cetane Number, Min. + D 613 45 45
Distillation Temperature, D 86
(°/ oC)
IBP, Typical # 350 / 177 375 / 191
10% Typical # 385 / 196 430 / 221
50% Typical # 425 / 218 510 / 256
90% + 500 / 260 Max. 625 / 329 Max.
End Point # 550 / 288 Max. 675 / 357 Max.
Water & Sediment (%, Max.) D 1796 0.05 0.05
# Not specified in ASTM D 975
+ Differs from ASTM D 975
Note 1: The cloud point should be 10°F (6°C) below the lowest expected fuel temperature to
prevent clogging of fuel filters by crystals.
Note 2: When prolonged idling periods or cold weather conditions below 32°F (0°C) are en-
countered, the use of 1-D fuel is recommended. Number 1-D fuels should also be considered
when operating continuously at altitudes above 5000 ft.

Specifications
Lubricating Oil Specifications
Engines
SAE
Detroit Diesel API Spec Notes
Grade
Series 50 & 60 CF-4 15W-40 Use multigrade oil only. No single weight
oils.
HT/HS viscosity - 3.7cP minimum.
Transverters
SAEa
Model Spec Notes
Grade
TV 100Q C-4 10W Wagner recommends use of SAE 20 oil.

Use monoweight oils only.
Do not use oil with “EP” additives.
OW arctic fluid approved for cold-weather
conditions.
a. Grade of oil dependent on ambient air operating conditions. See Viscosity/Temp Range chart for selection of
proper weight oil.
Axles
SAEa
Model Spec Notes
Grade
Rock Tough GL-5 85W140 MIL-L-2105C qualified lubricants meet

Clark MS-8 specifications.
GL-4 SAE 90 oils with SCL additives also
acceptable.
a. Grade of oil dependent on ambient air operating conditions. See Viscosity/Temp Range chart for
selection of proper weight oil.

Specifications
Hydraulic Fluid
Description Specification Grade Notes
Tractor Hydraulic Wagner No. 100-2680- 15W-20 Paraffin based.

Fluid 005-R Meets following manufac-
turer’s specifications: Alli-
son C-4, Caterpillar TO-2,
John Deere J20A & C, Ford
ESN-M2C134-D.
Hydraulic Oil Wagner No. 100-2680- MIL-L-46152B and API CC
002-R qualified lubricants meet this
specification.
FR Hydraulic Fluid Wagner No. 100-2680- Invert emulsion type fire
007-R resistant fluid.
For use above 60°C only.
FR Hydraulic Fluid Wagner No. 100-2680- Invert emulsion type fire
008-R resistant fluid.
For use between 25°F and
60°F only.
Water -Glycol FR Wagner No. 100-2680- For use only in systems
Fluid 010-R designed for water-glycol.
Arctic Hydraulic Wagner No. 100-2680- OW-30 Multi-purpose synthetic
Fluid 009-R lubricant for use in sub-zero
conditions.

Specifications
Grease Specification
Specification Approved Vendors Notes
NLGL No. 2 Imperial Oil - Molub-Alloy Multipurpose Molybdenum grease

#777-2 with Lithium soap and EP additives.
Shell Oil - Super Duty Grease Any multipurpose grease containing
Mobil Oil - Mobil Grease 3-5% Molybdenum can be substituted.
Special
Coolant Specifications
Water Qualitya
Max Allowed
Parameter Notes
(ppm)
Chlorides 40 Water with salt softeners is not

recommended.
Sulfates 100
Total Dissolved Solids 340
Total Hardness 170 Magnesium & Calcium
Nitrates >800 Add SCA additive if below this
concentration.
pH 5.5 - 9.0 Cummins recommends pH of 8.5 -
10.5
a. Use of Distilled Water is recommended by all engine manufacturers.
Antifreezea
Concentration Ratio
Type Notes
antifreeze/water
Ethylene Glycol 30/70 - 60/40 For temperatures to -15° C & -

5°oC
Detroit Diesel recommends
50/50 ratio.

Specifications
Antifreezea
Concentration Ratio
Type Notes
antifreeze/water
Propylene Glycol 30/70 - 60/40 For temperatures to -15° C & -

51°C
50/50 ratio only for Caterpil-
lar engines.
Not approved for Detroit Die-
sel engines other than Series
40, 50 and 60.
Methoxy Propanal 50/50 Not recommended for use in
Detroit Diesel engines.
Not identified for use by Cat-
erpillar.
a. Use of high silicate and/or phosphate antifreeze is not recommended. Soluble oil and Chromate addi-
tives are not approved for use in Detroit Diesel engines.

Specifications
Cross Reference List
New Old Alternatives
CF-2 CD, CD-II, CD/TO-2 CD/SE, CD/SF, CD/SG, MIL-L-2104C & E, D4

CF-4 CE CF-4/SG, CE/SF, CE/SG, MIL-L-2104E, D4
CC CC/SE, CC/SF, MIL-L-2104B, MIL-L-46152A
Class Alternativesa
C-2, C-3 CD/SE, CD/SF, CD/SG, MIL-L-2104C & D, Conoco No. 6718 synthetic oil
C-4 Wagner Tractor Hydraulic Fluid No. 100-2680-005R, Caterpillar TO-2, John
Deere J20A & C, Ford ESN-M2C134-D
a. Variations in composition and properties can occur in oils, depending on manufacturer and location.
Contact your Atlas-Copco Wagner representative and your local oil supplier for additional informa-
tion.

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Atlas Copco Wagner Inc.

Working harder. And Smarter™.

E-O-D, Rock Tough, SAHR, Scooptram, Scoopy, Strong-

Atlas Copco Scooptrams

Atlas Copco Scooptrams

Atlas Copco Scooptrams

Atlas Copco Scooptrams 7

Cab, Bucket, Frames, and Hoses .....................................................................44

8 Atlas Copco Scooptrams

500 Hour Requirements ...................................................................................59

Atlas Copco Scooptrams 9

Fuel Cooler ......................................................................................................75

10 Atlas Copco Scooptrams

Torque Converter .............................................................................................92

Atlas Copco Scooptrams 11

Installing the Drive Shaft .................................................................................108

12 Atlas Copco Scooptrams

Reconnecting the Load Frame and the Power Frame ......................................134

Atlas Copco Scooptrams 13

Control Valves .................................................................................................148

14 Atlas Copco Scooptrams

Accumulator Not Charged ...............................................................................164

Atlas Copco Scooptrams 15

16 Atlas Copco Scooptrams

Transverter System (ECU)...............................................................................197

Atlas Copco Scooptrams 17

ST1010 Transverter Calibration Procedures...................................................214

18 Atlas Copco Scooptrams

Steering Stops (Hub to Hub Centering Distance) ............................................256

Atlas Copco Scooptrams 19

20 Atlas Copco Scooptrams

• Never allow riders.

• Never smoke around fuel. Do not make unauthorized modifications to

Atlas Copco Scooptrams Service Instructions 21

22 Atlas Copco Scooptrams Service Instructions

WARNING: Hydraulic fluid

Atlas Copco Scooptrams Service Instructions 23

WARNING: Batteries contain Always use nonflammable cleaning solvent

24 Atlas Copco Scooptrams Service Instructions

designed to provide operator protection in a

Atlas Copco Scooptrams Service Instructions 25

26 Atlas Copco Scooptrams Service Instructions

Atlas Copco Scooptrams 27

1. Open the battery compartment. 7. Always fill the hydraulic reservoir

28 Atlas Copco Scooptrams

eye or face protection, ear protection, safety

1. ST1010 Articulation Lock Stowed

General Safety When You Service the

Atlas Copco Scooptrams 29

Never Work Under An Unsupported

7. Before you service the vehicle, always

Using the HourMeter (MMC)

30 Atlas Copco Scooptrams

often to make sure all required services are

Atlas Copco Scooptrams 31

Operator Shift Maintenance Checklist nance report form to report mechanical

Equipment No. Month Day Shift No. Operator

32 Atlas Copco Scooptrams