2522100363.3 en-US MT2010 Service Manual

Minetruck MT2010
Service
Original instructions
2016-12-22 | No: 2522100363.3 en-US
Minetruck MT2010 Table of Contents
Table of Contents
1 Safety ..................................................................................................................... 7
1.1 Safety First.................................................................................................................................. 7
2 Preventive Maintenance ....................................................................................... 9

2.1 Service Management ................................................................................................................. 9
2.2 Requirements for Use................................................................................................................ 9
2.2.1 Demanding Environments ........................................................................................................ 9
2.2.2 Special Tools .......................................................................................................................... 10
2.3 Before Performing Maintenance............................................................................................. 10
2.3.1 Cleanliness ............................................................................................................................. 10
2.3.2 Welding................................................................................................................................... 11
2.4 Independent Oil Analysis ........................................................................................................ 11
2.5 Record Keeping........................................................................................................................ 12
2.6 General Safety .......................................................................................................................... 12
2.6.1 When Servicing Vehicle.......................................................................................................... 12
2.6.2 After Servicing the Vehicle ..................................................................................................... 13
2.7 Contact Details ......................................................................................................................... 13
2.8 Maintenance Intervals.............................................................................................................. 16
2.8.1 Every 125 Hours Operation .................................................................................................... 16
2.8.4 Every 1000 Hours Operation .................................................................................................. 19
2.8.7 New or Reconditioned Components....................................................................................... 21
2.8.8 Running-In, First 125 Hours ................................................................................................... 21
2.9 Maintenance Procedures by Interval...................................................................................... 22
2.9.1 Every 125 Hours..................................................................................................................... 22
2.9.2 Every 250th Hour.................................................................................................................... 35
2.9.3 Every 500th Hour.................................................................................................................... 48
2.9.4 Every 1000th Hour.................................................................................................................. 64
2.9.5 Every 2000 Hours................................................................................................................... 74
2.9.6 Every 5000 Hours................................................................................................................... 75
2.10 Maintenance Procedures by Calendar Time.......................................................................... 77
2.10.1 Daily and Shift ........................................................................................................................ 77
2.10.2 Every Six Months.................................................................................................................... 77
2.10.3 Every Five Years .................................................................................................................... 77
3 Hydraulic System ................................................................................................ 79

3.1 Introduction .............................................................................................................................. 79
3.2 System Components ............................................................................................................... 79
3.2.1 Cylinders................................................................................................................................. 80
3.2.2 Accumulators.......................................................................................................................... 83
3.2.3 Hydraulic Pumps .................................................................................................................... 86
3.2.4 Hydraulic Tank........................................................................................................................ 86
3.2.5 Hydraulic Filtration.................................................................................................................. 87
3.2.6 Control Valves ........................................................................................................................ 87
3.3 System Functions .................................................................................................................... 93
3.3.1 Dump System ......................................................................................................................... 93
3.3.2 Teletram Unloading System (Option) ..................................................................................... 94
3.3.3 Steering System ..................................................................................................................... 96
3.3.4 Brake System ......................................................................................................................... 97
3.3.5 Emergency Steering (Option) ................................................................................................. 99
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3.4 General Maintenance Procedures ........................................................................................ 101

3.4.1 Before Starting...................................................................................................................... 101
3.4.2 Relieving Hydraulic Pressure ............................................................................................... 102
3.4.3 Before Removing Any Hose ................................................................................................. 102
3.4.4 Preparation for Hydraulic System Start Up........................................................................... 103
3.4.5 Hydraulic System Start Up ................................................................................................... 103
3.4.6 Hydraulic Oil ......................................................................................................................... 103
3.4.7 Brake Pedal Adjustment ....................................................................................................... 104
3.4.8 Cylinder Inspection ............................................................................................................... 105
3.4.9 Pressure Settings and Adjustments ..................................................................................... 105
3.5 Replace Hydraulic Components ........................................................................................... 111
3.5.1 Safety ................................................................................................................................... 111
3.5.2 Steering Cylinder .................................................................................................................. 112
3.5.3 Dump Cylinder...................................................................................................................... 113
3.5.4 Hydraulic Pumps .................................................................................................................. 115
3.5.5 Hydraulic Valve..................................................................................................................... 116
4 Power Unit ......................................................................................................... 119

4.1 Introduction ............................................................................................................................ 119
4.2 Fuel System ............................................................................................................................ 120
4.2.1 Fuel System Components .................................................................................................... 120
4.2.2 Fuel Flow .............................................................................................................................. 120
4.2.3 Fuel Tank.............................................................................................................................. 121
4.2.4 Fuel Supply Pump ................................................................................................................ 122
4.2.5 Injectors and ECM ................................................................................................................ 123
4.2.6 Fuel Filter.............................................................................................................................. 124
4.3 Engine Oil System.................................................................................................................. 125
4.3.1 Lubrication Pump.................................................................................................................. 125
4.3.2 Oil Filter ................................................................................................................................ 126
4.3.3 Oil Cooler.............................................................................................................................. 127
4.3.4 Oil Dipstick and Fill ............................................................................................................... 128
4.4 Cooling System ...................................................................................................................... 129
4.4.1 General................................................................................................................................. 129
4.4.2 Cooling System Function...................................................................................................... 129
4.4.3 Coolant Recommendations .................................................................................................. 131
4.4.4 Corrosion Inhibitor ................................................................................................................ 132
4.5 Air Intake System ................................................................................................................... 133
4.5.1 Overview............................................................................................................................... 133
4.5.2 General................................................................................................................................. 134
4.5.3 Function................................................................................................................................ 135
4.5.4 Air Filter ................................................................................................................................ 136
4.5.5 Turbo Charger ...................................................................................................................... 136
4.6 Exhaust System ..................................................................................................................... 139
4.6.1 General................................................................................................................................. 139
4.6.2 Catalytic Converter ............................................................................................................... 140
4.7 Electrical System ................................................................................................................... 140
4.7.1 Engine Control Module (ECM).............................................................................................. 140
4.7.2 Temperature and Pressure Sensors .................................................................................... 143
4.8 Replacing Power Unit Components ..................................................................................... 144
4.8.1 General................................................................................................................................. 144
4.8.2 Exhaust System.................................................................................................................... 145
4.8.3 Radiator Cooling Package.................................................................................................... 146
4.8.4 Air Intake System ................................................................................................................. 147
4.8.5 Engine Package ................................................................................................................... 148
4.8.6 Fuel System Components .................................................................................................... 150
4.8.7 Electronic Control Module .................................................................................................... 151
5 Electrical System .............................................................................................. 153
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5.1 Introduction ............................................................................................................................ 153

5.1.1 Circuit Schematics................................................................................................................ 153
5.2 System Components ............................................................................................................. 154
5.2.1 General................................................................................................................................. 154
5.2.2 Harness ................................................................................................................................ 154
5.2.3 Battery Isolation Switch ........................................................................................................ 154
5.2.4 Component Box.................................................................................................................... 156
5.2.5 Circuit Breakers .................................................................................................................... 158
5.2.6 Batteries ............................................................................................................................... 158
5.2.7 Alternator .............................................................................................................................. 158
5.2.8 Starter................................................................................................................................... 159
5.2.9 Canopy/Cab Controls ........................................................................................................... 159
5.2.10 Vehicle Running Lights......................................................................................................... 161
5.2.11 Signal Horn........................................................................................................................... 162
5.2.12 Reversing Alarm ................................................................................................................... 163
5.3 Vehicle Computerised Control Units.................................................................................... 163
5.3.1 General................................................................................................................................. 163
5.4 General Maintenance Diagnosis & Calibration ................................................................... 167
5.4.1 General................................................................................................................................. 167
5.4.2 Computerized Diagnostic Systems....................................................................................... 168
5.4.3 Batteries ............................................................................................................................... 169
5.4.4 Alternator .............................................................................................................................. 172
5.5 Replace Electrical Components ........................................................................................... 174
5.5.1 General................................................................................................................................. 174
5.5.2 Transducers.......................................................................................................................... 174
5.5.3 Engine Sensors .................................................................................................................... 174
5.5.4 Starter................................................................................................................................... 174
5.5.5 Batteries ............................................................................................................................... 175
5.5.6 Alternator .............................................................................................................................. 175
5.6 Display .................................................................................................................................... 176
5.6.1 Settings................................................................................................................................. 177
5.6.2 Fault Codes .......................................................................................................................... 177
5.6.3 Warning Lights...................................................................................................................... 177
5.6.4 Directional Lights .................................................................................................................. 178
5.6.5 Parameters ........................................................................................................................... 178
6 Power Train........................................................................................................ 181

6.1 Power Train Components...................................................................................................... 181
6.1.1 Transmission ........................................................................................................................ 181
6.1.2 Cardan Shafts....................................................................................................................... 182
6.1.3 Axles..................................................................................................................................... 184
6.1.4 Rims and Tires ..................................................................................................................... 186
6.2 Replacing Power Train Components ................................................................................... 188
6.2.1 Transmission ........................................................................................................................ 189
6.2.2 Cardan Shafts....................................................................................................................... 191
6.2.3 Axles..................................................................................................................................... 194
6.2.4 SAHR Brakes ....................................................................................................................... 195
6.2.5 Tyre Mounting Procedures ................................................................................................... 196
7 Main Frame ........................................................................................................ 201

7.1 Introduction ............................................................................................................................ 201
7.2 Replacing Load Frame Components.................................................................................... 201
7.2.1 General................................................................................................................................. 201
7.2.2 Dump Box............................................................................................................................. 202
7.3 Replacing Power Frame Components ................................................................................. 206
7.3.1 General................................................................................................................................. 206
7.3.2 Hoods and Covers................................................................................................................ 206
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7.4 Separating Load and Power Frames .................................................................................... 207

7.4.1 Separation ............................................................................................................................ 207
7.4.2 Reconnection........................................................................................................................ 210
7.4.3 Articulation Pins.................................................................................................................... 211
7.5 Stops ....................................................................................................................................... 213
7.5.1 General................................................................................................................................. 213
7.5.2 Steering Stops ...................................................................................................................... 213
7.5.3 Dump Box Guides ................................................................................................................ 214
7.5.4 Front Axle Oscillating Stops ................................................................................................. 214
7.5.5 Stops, Upper and Lower Tailgate ......................................................................................... 214
8 Troubleshooting................................................................................................ 215
8.1 Symptoms and Solutions ...................................................................................................... 215
8.1.1 Transmission Symptoms ...................................................................................................... 215
8.1.2 Axles Symptoms................................................................................................................... 217
8.1.3 Cardan Shaft ........................................................................................................................ 218
8.1.4 Tires and Rims ..................................................................................................................... 219
8.1.5 Articulation............................................................................................................................ 219
8.1.6 Hydraulic Systems................................................................................................................ 219
8.1.7 Brakes .................................................................................................................................. 224
8.1.8 Parking Brake ....................................................................................................................... 225
8.1.9 Electrical System .................................................................................................................. 226
8.2 Cummins Diagnostic Screen Fault Codes on UIP .............................................................. 231
9 Machine Specification ...................................................................................... 291

9.1 Performance Related Data .................................................................................................... 291
9.1.1 Tramming Capacity .............................................................................................................. 291
9.1.2 Operating Times ................................................................................................................... 291
9.1.3 Engine .................................................................................................................................. 291
9.1.4 Transmission ........................................................................................................................ 292
9.1.5 Axles..................................................................................................................................... 292
9.1.6 Brakes .................................................................................................................................. 292
9.1.7 Tires...................................................................................................................................... 292
9.1.8 Hydraulics............................................................................................................................. 293
9.1.9 Emergency Steering ............................................................................................................. 293
9.1.10 Capacities............................................................................................................................. 293
9.1.11 Cab Pressurizer Filter........................................................................................................... 293
9.2 Steering and Oscillation ........................................................................................................ 294
9.3 Accumulator Precharge Pressure (N2) ................................................................................ 295
9.4 Tightening Torques................................................................................................................ 295
9.4.1 Use the Correct Tool for the Job .......................................................................................... 295
9.4.2 Torque Values by Bolt Size & Thread .................................................................................. 295
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Minetruck MT2010 1 Safety
1 Safety
1.1 Safety First
! NOTE: Always read the information in the Safety Manual before starting to use the
Minetruck or starting maintenance work.
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Minetruck MT2010 1 Safety
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Minetruck MT2010 2 Preventive Maintenance
2 Preventive Maintenance
2.1 Service Management
Safe, efficient operation of the vehicle depends on the proper maintenance of the engine,
power train, chassis and all related systems. Regular inspections must be made to see that
all system components are in safe operating condition. Special care must be taken when
making repairs and replacing components. Use only new parts as furnished by Atlas
Copco.
The labelled diagrams shows all maintenance check points. Because of individual mine re-
quirements, some check points on the vehicle may not be located as shown. If so, consult
a supervisor for additional supporting literature.
For further information on fluids and greases, see document "Fluids and greases" included
in the documentation supplied.
2.2 Requirements for Use
2.2.1 Demanding Environments

The MT2010 has been designed for rugged use in a demanding environment. Reliability
can be increased by maintaining factory specified service intervals and by always tighten-
ing bolts, during repair and replacement of components, to the proper torque values. Use
only new fluids and filters, and make sure that all mating surfaces are clean and in sound
condition.
Clean the vehicle before each shift, remove rocks from the load frame and prevent dirt
from getting into the hydraulic system by checking valves and other hydraulic components.
Dirt in the hydraulic system will cause damage.
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All bolts, nuts, screws, and other fasteners must be in place and properly secured. The
torque of major components should be checked periodically as specified in the service
schedules.
2.2.2 Special Tools

Always use the correct tool for the job. Mechanical torque wrenches are based on leverage
and have limitations. Hydraulic torque tools are more efficient in tight quarters, and can ap-
ply high torque values quickly and safely. Contact your Atlas Copco representative for
more information.
2.3 Before Performing Maintenance
WARNING
Before performing any maintenance on the vehicle the Safety Manual must be
read and understood!
2.3.1 Cleanliness
Hydraulic System
! NOTE: Foreign matter of any kind will cause problems in hydraulic systems, making
absolute cleanliness essential.
The six primary rules for hydraulic systems cleanliness.

n Clean the area where the work shall be carried out if there is dirt or other waste there.
Wipe clean all hose and pipe connections before opening any connections.
n Remove all loose paint before opening any connections.
n Plug or cap any hose, pipe, valve, or cylinder immediately after opening a connection.
n Flush any unsealed hose or pipe with hydraulic oil before installing it in the system.
n Install all hoses, pipes, valves, or cylinders immediately after unplugging or uncapping
connections.
Fuel System
NOTICE
Cleanliness is essential in all work that is done on the Minetruck fuel system.
Always follow these rules regarding cleanliness in maintenance operations on
the fuel system.
n Steam clean the area of the Minetruck on which the work is performed if there is a sub-
stantial accumulation of dirt or other debris.
n Wipe clean hose and pipe connections before opening any connection.
n Remove all loose paint before opening any section of the head pipe to the rear section
connections.
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n Plug or cap any hose or connection immediately after opening it.

n Flush any unsealed hose or pipe with clean fuel before installing it in the system.
2.3.2 Welding
Perform the following before any electric welding:
WARNING
u This machine is painted with both polyester powder type paint and solvent-based, oxi-
rane-ester finishing paint, which contains hazardous substances.
u Upon heating, the paint emits hazardous substances which can cause eye irritation,
eczema, respiratory problems and, in severe cases asthma or other injurious health
disease.
u Welding, grinding and other hot work that can heat the paint can only be carried out
where sufficient ventilation can be arranged. Also, use personal protection such as:
respiratory aids, eye protection, and gloves.
NOTICE
Use caution when welding. Serious damage to the motor control computer, the
battery isolation switch and other electrical components may occur.
NOTICE
It is important to disconnect all electrical components that can be susceptible to
damage caused by welding.
1. Open the battery compartment.
2. Turn the battery isolation switch to the OFF position.
3. Connect the welding vehicle ground clamp on the vehicle as closely as possible to the
point at which the welding is to be done.
2.4 Independent Oil Analysis

Atlas Copco recommends the establishment of an oil analysis program. Regular oil analy-
sis can indicate problems and the approach of maximum wear limits before the system per-
formance checks discover them.
The objective of a preventative maintenance program is diagnosis and repair before failure.
Good sampling techniques and independent laboratory analysis are considered primary el-
ements of a good program.
! NOTE: An extensive analysis program can help to identify the optimum service inter-
vals.
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2.5 Record Keeping

Good record keeping is essential to a proper maintenance program. Each scheduled main-
tenance form must be checked off as the inspection or procedure is completed. Quantities
of replenished lubricants and fluids, and pressure and flow readings, must be recorded.
All discrepancies must be recorded whether remedied or pending. Operators and mechan-
ics must sign off forms and return them to maintenance supervisor for approval and reten-
tion in a vehicle maintenance file.
Good records enable maintenance personnel to identify and evaluate problems and/or
high-cost areas which can then be targeted for improvements or solutions.
Finally, good maintenance records aid in the planning and scheduling of maintenance and
repair procedures. This result in the efficient use of maintenance resources and maximum
equipment reliability and availability.
2.6 General Safety
2.6.1 When Servicing Vehicle

Read the safety and information decals on the vehicle. Also read and understand the Oper-
ator’s Manual. The operation of this vehicle must be understood before performing mainte-
nance.
Do not attempt repairs that are fully not understood. See attached Service Manual for fur-
ther information or contact your Atlas Copco sales company or dealer for more information.
Before performing any maintenance on the Minetruck, review the following safety precau-
tions. They are included for personal protection.
1. Fully empty the dump box. Make sure that the dump box is down (or the Teletram
components are fully retracted) and the tailgate is lifted.
2. Park the vehicle in a straight line on a hardened flat surface.
3. Apply the parking brake.
4. Shut down the motor.
5. Wait a few minutes to allow the computer to cycle through its routine for switching off
the engine.
6. Turn the battery isolation switch to OFF position.
7. If the vehicle must be serviced in the articulation area with the engine running, always
place the Articulation Lock in the LOCKED position.
NOTE: If the vehicle must be serviced with the engine running, a

! qualified assistant must be in the operator seat during the proce-
dure.
8. Before the vehicle is serviced, always put a "Do Not Operate" tag in the cabin on the
steering wheel or joystick.
9. Block the wheels.
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2.6.2 After Servicing the Vehicle
Vehicle Safety Guards

After maintenance, check that all safety guards have been installed over all exposed rotat-
ing parts before returning the vehicle into service.
2.7 Contact Details

Country Address Phone and Fax Number
Argentina Juncal 2869 Phone: +54 (0)11 4898-4100

B1640 GRE Martinez, Buenos Fax: +54 (0)11 4898-4166
Aires
Australia 47 Enterprise Street Phone: +61 - (0)7 49 52 61 11

Paget, Mackay Fax: +61 - (0)7 49 52 60 66
71-73 Enterprise Drive Phone: +61 - (0)2 49 49 49 00
Beresfield, Newcastle Fax: +61 - (0)2 49 49 49 99
Austria Postfach 108 A-1111 Wien Phone: + 43- (0)1 -76 01 20

Fax: + 43 - (0)1 - 769 56 72
Bolivia Av. 20 de Octubre Nº 2665, Edi- Phone: +591 (2) 21 12 000

ficio Torre Fax: +591 (2) 21 17 801
Azul 2° Piso Oficina 201
La Paz, Bolivia.
Brazil Av. Eng. Eusébio Stevaux Phone: + 55 - (0)11 - 56 87 88 00

1600, S. Paulo, SP, Brazil Fax: + 55 - (0)11 - 55 24 61 10
Cep. 04696-000
Canada 200 Mumford Road Phone: + 1 - 705 673 67 11

Walden Industrial Park Fax: + 1 - 705 692 31 01
Lively, Ontario P3Y 1L2
Chile Panamericana Norte 5001 - Phone: + 56 - (02)-442 3600

Conchali Fax: +56 - (0)2 - 623 51 31
Santiago,Chile
6553935 Conchali
China / Hong Kong P O Box 1516 Phone: + 852 - 27 97 66 00

Shatin Central Post Office Fax: + 852 - 23 41 43 13
New Territories
CMT International S-105 23 Stockholm Phone: + 46 - (0)8 - 743 80 00

Fax: + 46 - (0)8 - 644 90 45
Colombia Cra. 85D No. 46A-65 Bod. 6 Phone: +57 - (0)1 - 419 92 00
Bogotá - Colombia Fax: +57 - (0)1 - 419 92 22
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Czech Republic Prumyslová 10 Phone: + 420 - 225 434 000

Praha 10. Postcode 102 00 Fax: + 420 - 225 434 009
Finland Tuupakankuja 1 Phone: + 358 - (0)9 - 296 64 41

Fl-01740 Vantaa Fax: + 358 - (0)9 - 296 42 18
France B P 27055 Saint Quen l’Aumône Phone: + 33 - (0)1 - 39 09 30 00

FR-95052 Cergy Pontoise Fax: + 33 - (0)1 - 39 09 30 49
Cedex
Germany Postfach 10 02 25 Phone: + 49 - (0)201 - 217 70

D-45002 Essen Fax: + 49 - (0)201 - 217 74 54
Ghana P O Box 10071 Phone: + 233 - (0)21 77 45 12

Accra North Fax: + 233 - (0)21 77 61 47
Great Britain P O Box 79 Phone: + 44 – (0)1442 - 22 21 00

Hemel Hempstead Fax: + 44 - (0)1442 - 23 44 67
GB - Herts HP2 7HA
Greece 93, Koropiou - Varis Avenue Phone: +30 - (0)1 - 349 96 00

GR - 194 00 Koropi, Athens Fax: +30 - (0)1 - 345 4783
Hong Kong P O Box 1516 Phone: + 852 - 27 97 66 00

Shantin Central Post Office Fax: + 852 - 23 41 43 13
New Territories
India Sveanagar Phone: + 91- (0)20 -39 85 24 15

Bombay Pune Road Fax: + 91 - (0)20 - 271 459 48
Dapodi
Pune 411 012
Indonesia P O Box 7021/JKS CCE Phone: +62 - (0)21 - 780 10 08

Jakarta 120 75 Fax: +62 - (0)21 - 780 18 37
Iran PO Box 13145-1311 Phone: +98 - (0)21 - 66 93 77 11

Tehran 1345654551 Fax: +98 - (0)21 - 66 92 73 14
Ireland Kylemore Road Phone: +353 - (0)1 - 450 5978

Bluebell Fax: +353 - (0)1 - 456 7686
IE - Dublin 12
Italy Casella Postale 77 Phone: + 39 - (0)2 - 61 79 91

IT-20092 Cinisello Balsamo MI Fax: + 39 - (0)2 - 61 79 95 20
Japan Sumitomo Fudosan Shipa Bldg 4 Phone: + 81 - (0)3 - 57 65 78 90

IIF Fax: + 81 - (0)3 - 57 65 31 99
13-4 Shiba 2-chome
Minato-Ku Tokyo 105-0014
Kenya P O Box 400 90 Phone: + 254 – (0)20 - 660 50 00

00100 - Nairobi Fax: + 254 – (0)20 - 82 52 15
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Korea C.P.O. Box 8354 Phone: + 82 – (0)2 - 21 89 40 00

Seoul Fax: + 82 – (0)2 - 522 82 39
Malaysia 26 Jalan Anggerik Mokara 31/47 Phone: + 60 – (0)3 - 51 23 88 88

Kota Kemuning, Seksyen 31 Fax: + 60 –(0)3 - 51 23 89 49
40460 Shah Alam
Selangor Darul Ehsan
Mexico Blvr. Abraham Lincoln No 13 - Phone: + 52 – 55 - 22 82 06 00

Col. Los Fax: + 52 – 55 - 53 90 83 78
Reyes Zona Industrial
C.P: 54073 Tlalnepantla
Estado de México
México
Marocco P O Box 13 844 Phone: + 212 – 22 - 60 00 40

20 100 Casablanca Fax: + 212 – 22 - 60 05 22
Norway P O Box 334 Phone: + 47 – 64 - 86 03 00

N-1401 Ski Fax: + 47 – 64 - 86 03 30
Peru Francisco Graña 150-152 Phone: + 51 – 1 4116100

Urb. Santa Catalina, Lima 13, Fax: + 51 – 1 2247126
Perú
Philippines P O Box 1373 MCPO Phone: + 63 – (0)2 - 843 0535 - 39

1200 Makati City Fax: + 63 – (0)2 - 843 0242
Poland (Sales) ul. Katowicka 32 Sales Phone: + 48 –(0)32 - 608 90 20

PL-40-173 Katowice Fax: + 48 –(0)32 - 608 90 20
(Service) ul. Krzywa 3 Service Phone: + 48 –(0)76 845 80 90
59-100 Polkowice Fax: + 48 –(0)76 - 845 80 99
Portugal Apartado 14 Phone: + 351 – 21- 416 85 00

PT-2796-953 Linda-a-Velha Fax: + 351 – 21 - 416 01 66
Saudi Arabia P. O. Box 7330 Phone: + 966 – (0)2 - 693 33 57

Jeddah 21462 Fax: + 966 – (0)2 - 693 28 92
Singapore Jurong Point Phone: + 65 – 68 62 28 11

P O Box 438 Fax: + 65 – 68 63 60 98
Singapore 639456
South Africa P O Box 14110 Phone: + 27 – (0)11 - 821 90 00

Witfield 1467 Fax: + 27 – (0)11 - 821 92 02
Spain Apartado, 24 Phone: + 34 – 91 - 627 91 00

E-28820 Coslada Fax: + 34 - 91 - 627 9239
(Madrid)
Sweden SE-10523 Stockholm Phone: + 46 - (0)8 - 743 80 00
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Fax: + 46 - (0)8 - 743 92 47
Switzerland Büetigenstrasse 80 Phone: + 41 – (0)32 - 374 14 14

CH-2557 Studen/Biel Fax: + 41 –(0)32 – 374 13 00
Taiwan P O Box 14-45,Chungli Phone: + 886 – (0)3 - 479 68 38

Tao yuen Hsien Fax: + 886 – (0)3 - 479 68 20
Thailand 125 Moo 9, Wellgrow Industrial Phone: + 66 – (0)38 - 56 29 00

Estate Fax: + 66 – (0)38 - 56 29 01
Bangna - Trad Km. 36
Bangwua, Bangpakong
Chachoengsao 24180
Turkey Istasyon Arkasi Phone: + 90 – (0)216 - 581 05 81

34940 Tuzla Fax: + 90 – (0)216 - 581 05 82
Istanbul
Ukraine 9, Moskovskiy Avenue Phone: + 380 - 44 - 499 18 70

building 3 Fax: + 380 - 44 - 499 18 77
04073 Kiev, Ukraine Phone: + 380 - 564 - 04 93 83
Leonida Borodicha 17, Fax: + 380 - 564 - 04 93 83
50048, Kryvyi Rig, Ukraine
USA PO Box 1159 Phone: + 1 - 303 - 287 88 22

Commerce City CO 80022 Fax: + 1 - 303 - 217 28 39
USA
Venezuela Apartado 76111 Phone: + 58 – (0)212 - 256 23 11

Caracas 1071 Fax: + 58 –(0)212 - 257 18 10
Vietnam Nr. 42,Street 37, Thao Dien Phone: + 84 - (0)8 - 898 96 38

Ward Fax: + 84 - (0)8 - 898 96 37
District 2
Ho Chi Minh City
Zambia P O Box 11291 Phone: + 260 – (0)2 - 31 12 81, 31 30 15

Chingola Fax: + + 260 – (0)2 - 31 38 77
Zimbabwe P.O. Box CY 935, Causeway Phone: + 263 – (0)4 - 62 17 61

Fax: + 263 – (0)4 - 62 17 94
2.8 Maintenance Intervals
2.8.1 Every 125 Hours Operation
Pos. Action Special Instructions Check
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Air Filter, Filter Element Change filter Change primary filter element. No-
tice! Change sooner if restriction
indicator shows restriction.
Drive belts Check tension and wear
Axle, breather Inspect and check for

damage
Axle, differential Check the oil level In-

spect and clean
breathers
Axle, planetary gear Check the oil level In-

spect and clean
breathers
Cardan shaft slip joint Check and lubricate
Wheel bolts and nuts Inspect and check for

damage
Hydraulic hoses Inspect for rubbing and

chaffing
Pressurizer filter Inspect and clean air fil- Cabin Only

ter
Fire suppression Sys- Check

tem (option)
Batteries Inspect and clean Voltage should read 13.5 V ±2 V

(27 ±4 V across the pair)
Hydraulic oil tank, Inspect and check for

breather damage
Hydraulic oil tank, filter Check

indicator
Transmission, breather Inspect and check for

damage
Lincoln auto lubrication Check grease level
Lubrication system con- Inspect

nectors
Teletram, steering, and Check

dump cylinders
Steering stops, stops Check

for tailgate and dump
box guides
Oscillating axle stops Inspect
17 No: 2522100363.3 en-US

Engine oil Change oil
Engine oil filter Change filter
Fuel filter Replace
Engine coolant Test
Radiator hoses Inspect
Batteries Check electrolyte level
Clean the vehicle Clean the whole vehicle Remove rocks
Stall speed Check idle
Brake accumulator, pre- Check pre-charge pres- Pressure: 83 ±3.5 bar

charge pressure sure
Emergency steering Check pre-charge pres- Pressure: 30 ±3.5 bar.

acc, precharge press sure
(Option)
Damping accumulator Check pre-charge pres- Pressure: 50 ±3.5 bar

for steering cylinders, sure
only for steering wheel
(option)
Cabin pressurizer Review the pressurisa-

tion system
Cardan shafts Inspect
Fire extinguisher (op- Loosen powder

tion)
Dump Box Safety Sup- Lubricate and inspect,

port and check for damage
Articulation lock Inspect and check for

damage
Wiggins, breather filter Inspect and check for

(option) damage
Fuel hoses Inspect
Engine fan assembly Inspect
Transmission, filter Change filter
Transmission, bolt con- Check bolt torques See "Tightening Torques" on page
nection 178.
18 No: 2522100363.3 en-US

Radiator Inspect and check

torques
Differentials and plane- Test oil

taries
Axle, bolt connection Check torque See "Tightening Torques" on page

178.
Attachment plate Check torque See "Tightening Torques" on page

178.
Engine Check torques See "Tightening Torques" on page

Articulation joint 178.
Articulation joint-pillow
Cardan shafts Inspect and check See "Tightening Torques" on page

torque 178.
Cardan shaft universal- Inspect and clean See "Tightening Torques" on page
joint 178.
Hydraulic high-pressure Replace hydraulic high-

oil filter pressure oil filter
Hydraulic oil filter Change filter
Hydraulic oil Take oil sample
Fuel tank Drain water
Pressurizer filter Change filter Cabin Only
AC, cabin unit Change filter Cabin Only
Dump cylinder Inspect and check See "Tightening Torques" on page

torque 178.
Dump Box Safety Sup- Inspect and check See "Tightening Torques" on page
port torque 178.
Load and Power Frame Check for damage General control
Engine coolant filter Change filter
Operating times Measure and record Dump and steering
Articulation joints Check
Wheel bolts and nuts Check torques
Wiggins, breather filter Change filter

(option)
Engine crankcase Check and clean

breather
19 No: 2522100363.3 en-US

Engine mountings Check Check rubber grommets and

torques
See "Tightening Torques" on page
178.
Radiator Inspect and clean
Drive belts, engine fan, Change drive belt See attached OEM documentation
and alternator for further information.
Drive belts, AC com- Change drive belt See attached OEM documentation
pressor (option) for further information.
Transmission Change oil Take oil sample

Clean breather
Exhaust System Inspect and clean
Differential Change oil
Planetary Change oil
Hydraulic oil and filter Replace
Hydraulic pressure Check and record
Hydraulic oil tank Clean

breather
Fire suppression sys- Inspect components See attached Safety Manual and
tems attached digital OEM documenta-
tion for further information.
Fuel tank Drain and flush
Drive belts Inspect/change See OEM documentation for more

information.
Air intake and exhaust Inspect

system
Engine cooling system Change coolant
Fire inspection Risk analysis
Fire suppression sys- Inspect Checking by authorized service

tems company
Transmission mount- Check

ings
20 No: 2522100363.3 en-US

Engine Check and replace Test thermostat

Test electrical system
Hoses and couplings Replace all hoses
Oil cooler Flush
Fuel Injectors Check function
2.8.7 New or Reconditioned Components
After First Shift (8 hours)
Wheel Bolts and Nuts

Check torque.
Engine Belt
After replacing a worn belt, check the belt tension after 1/2 hour of operation and again af-
ter 8 hours of operation.
2.8.8 Running-In, First 125 Hours
Differential
n Change oil. See "Axle, differential" on page 36.
Planetary Gears
n Change oil. See "Axle, planetary gears" on page 36.
21 No: 2522100363.3 en-US

2.9 Maintenance Procedures by Interval
2.9.1 Every 125 Hours
Air Filter, Filter Element
Air Filter
Filter Element
22 No: 2522100363.3 en-US

NOTE: Air filter restriction indicators are subject to damage while vehicle operation and
! maintenance. Visually inspecting indicator for damage and the filter itself ensures
proper change interval.
Change Filter
1. Loosen and remove the air filter cover.
2. Loosen and remove the outer filter element wing nut and remove the element.
3. Inspect filter gasket surface and replace if needed.
4. Install a new primary element. Rotate the element as tightening the wing nut to make
sure that there is a good gasket seal.
5. Reset filter service indicator.
6. Start the engine. If the filter service indicator indicates red again, replace the safety
(inner) filter element.
23 No: 2522100363.3 en-US

Drive Belts
V-belts
Check for Damage

Check the drive belts for excessive wear, cracks, and stretching.
Check Tension
1. Park the vehicle, apply the parking brake, and stop the engine.
2. Check the tension of the drive belts with your hand.
! NOTE: The belts must be taut and spring-loaded when you press
them with your hand.
3. Observe the operation of the drive under its highest load condition (usually starting).
24 No: 2522100363.3 en-US

NOTE: A slight bowing of the slack side of the drive indicates ade-
! quate tension. If the slack side remains tight during the peak load,
the drive is too tight. If a V-belt slips, it is too loose.
4. Replace the drive belts if they are too loose.
! NOTE: Replace all belts in a set when one is worn.
Axle, Breather
Inspect and Check for Damage

Check that the front and rear axle breathers are not damaged or blocked.
A. Rear axle breather
25 No: 2522100363.3 en-US

Axle, Differential
A. Oil level plug
Check Oil Level

1. Park the vehicle on a level surface, apply the parking brake, and stop the motor.
2. Let vehicle to stand 5 minutes to allow the oil to settle to normal level.
3. Remove the oil level plug. The oil level must be up to the bottom of the plug hole. Fill
with oil when necessary. See "Fluids and lubricating greases" for correct oil specifica-
tions.
4. Install the oil level plug and check the other differential.
26 No: 2522100363.3 en-US

Axle, Planetary Gears
A. Oil level plug
Check Oil Level

1. With the vehicle on a level surface, move the vehicle forward or back until the oil level
plug is horizontal with the wheel centre line.
2. Apply the parking brake and stop the engine.
3. Remove the oil level plug. The oil level must be up to the bottom of the plug hole. Fill
with oil when necessary. See "Fluids and lubricating greases" for correct oil specifica-
tions.
4. Install the oil level plug and check the other planetaries.
27 No: 2522100363.3 en-US

Cardan Shaft Slip Joint
A. Cardan shaft slip-joint grease fitting

n Lubricate all cardan shaft slip-joints and U-joints.
See "Fluids and lubricating greases" for correct lubricating grease specifications.
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Wheel nuts
Inspect and check wheel bolts and nuts for damage. Replace if necessary.
29 No: 2522100363.3 en-US

Hydraulic Hoses
Hydraulic hoses
n Inspect all hydraulic hoses and tubing for chaffing, leaks, or excessive wear.
n Look for signs of oil leaks around the hose couplings. Check the pump mounting areas
for leakage.
Pressurizer, Filter
Pressurizer filter
30 No: 2522100363.3 en-US

Clean and Inspect

The pressurizer filter is located behind the cabin.
Clean the filter intake area and inspect the filter. Replace if damaged or clogged.
Fire Suppression Systems

n Inspect the fire suppression system to assure it is in good operating condition.
n Inspect over-all condition of hoses, discharge nozzles and activator valve for damage,
blockage, or any sign of possible failure. Nozzles must be capped with silicone grease
or plastic blow-off caps that come loose when the fire suppression system in activated.
Actuator and expellant cartridge seals and disks must be intact. Repair as needed.
n Check the level in the pressurized fire extinguisher tanks for dry chemicals. The fire
extinguishers must contain an active charge of at least five pounds nominal weight.
n Check the nameplate for readability.
n Replace any broken or missing lead and wire seals, and record the date of inspection.
See the documentation of the manufacturer for more information.
Battery
Batteries
Clean and Inspect
DANGER
When working around batteries, avoid sparks and flames. Hydrogen gas given
off by batteries is explosive.
31 No: 2522100363.3 en-US

CAUTION
Avoid contact with electrolyte. Acid burns! Personal injury can result.
! NOTE: Make sure that the battery compartment cover is secured before vehicle is
placed in operation.
Check that the batteries are mounted correctly and the battery connections are tightened
and have not started to corrode.
Also check that all cables to the alternator, starter and all the other electrical components
are not damaged or started to wear out.
Ensure that battery tops are kept clean and free of dirt and electrolyte. Replace any wire or
cable with damaged insulation.
Clean battery with a weak solution of baking soda and warm water. Ensure that no clean-
ing solution reaches electrolyte in battery.
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.
Fill all battery cells with distilled water to inside top of battery.
Check the battery voltage, each battery output should read 13.5 V ±2 V (27.0 V ±4 V as
one pair).
Hydraulic Oil Tank, Breather
Hydraulic oil tank breather

Check that the breather is working correctly and is not damaged.
Clean the breather if dirty or blocked.
32 No: 2522100363.3 en-US

Hydraulic Oil Tank, Filter Indicator
Hydraulic oil filter indicator

Check the indicator on the filter head. Change filter if the indicator is tripped.
Transmission, Breather
Transmission breather
33 No: 2522100363.3 en-US

Check the transmission breather for blockage. It must be cleaned if plugged or restricted.
Lincoln Auto Lubrication
Lubrication tank
Check grease level in the lubricating tank.
If the level is below the "add" line, fill with grease. See "Fluids and lubricating greases" for
correct lubricating grease specifications.
Lubrication System Connectors

Check all lubrication connectors throughout the vehicle.
34 No: 2522100363.3 en-US

Teletram, Steering, and Dump Cylinders
Dump cylinder mounting pins

Check the cylinder mounting pins and bushings for wear or excessive clearances. If any
pin free-play exceeds 3.175 mm (1/8 in.), replace pin and/or bushing, or repair pin bore as
required.
Steering Stops, Stops for Tailgate

Check the steering stops, stops for tailgate and dump box guides for wear and cracks.
Wear should not exceed 3.175 mm (1/8 in.) from original condition.
Oscillating Axle Stops

Inspect the axle stops for damage.
2.9.2 Every 250th Hour

n Repeat 125 hours
35 No: 2522100363.3 en-US

Engine Oil
A Topping up with engine oil
B Engine oil level dipstick
! NOTE: Oil changes should be made when the engine is warm, as the oil drain more
completely.
Change Oil
Check the oil level when the vehicle is standing on a level surface.
1. Switch off the engine and allow the oil to drain down from the internal engine parts for
some minutes. This action eliminates the risk of overfilling.
36 No: 2522100363.3 en-US

Body plate
2. Remove the body plate to access the engine drain plug.
3. Select a container sufficient to hold the entire amount of oil in the system and place
underneath the oil pan drain.
4. Proceed with removing oil drain plug for the oil pan. After the oil has drained off, clean
and fit the oil drain plug.
5. Fill new engine oil through the valve cover. See "Fluids and lubricating greases" for
correct oil specifications.
6. Push the dipstick down and pull out. The oil level must be between the ADD and
FULL marks on the dipstick.
7. Fill up the engine oil to FULL-mark.
37 No: 2522100363.3 en-US

Engine Oil Filter
Engine oil filter
Change Filter
! NOTE: Always replace filter when changing oil.
1. Remove the oil filter by turning it anticlockwise using a strap wrench or filter removal
tool.
2. Discard the filter.
3. Clean the filter sealing surface with a clean cloth.
4. Apply clean oil to the gasket of the new filter.
5. Fill the new filters with new engine oil and fit them. See "Fluids and lubricating
greases" for correct oil specifications.
6. Turn the filter clockwise until the gasket makes contact with the filter base. Continue
to turn the filter 2/3 turn by hand.
7. Start the engine and run at idle speed.
8. Check the engine oil pressure.
9. Then, check for oil leaks around the filter.
10. Stop the engine and check the engine oil level after a few minutes.
38 No: 2522100363.3 en-US

Fuel Filter
A Primary Fuel Filter
B Secondary Fuel Filter
NOTICE
Change the primary fuel filter every 250 hours or earlier if needed. If the fuel
reaches the red line, the filter has to be changed.
Change Primary Filter

1. Clean the fuel filter housing and the surrounding area.
39 No: 2522100363.3 en-US

2. Turn the fuel shut-off valve 90º to the OFF position.
3. Drain the fuel out of the filter by opening the drain knob.
4. Close the drain knob.
5. Remove the clear cover by turning the collar anticlockwise and remove it.
6. Remove all filter parts.
! NOTE: Make sure that the sealing is removed.
7. Wipe the mounting surface for the filter with a clean cloth.
8. Apply a thin layer of grease to each filter gasket.
9. Install the filter and its parts on the filter mounting and close the cover by turning the
collar clockwise.
10. Turn the shut-off valve to the ON position.
11. Turn on the ignition and operate the lift pump 3–4 cycles. It is audibly noticeable when
the pump starts working with the fuel.
12. Start the engine, run it at idle speed, and check for fuel leaks.
Change Secondary Filter

1. Clean the fuel filter and the surrounding area.
2. To loosen the filter, turn it clockwise.
3. Wipe the mounting surface for the filter with a clean cloth.
4. Apply a thin layer of grease to each filter gasket.
5. Refit the filter by turning it anticlockwise.
NOTICE
Do not pre-fill filter!
6. Fill the filter by using the hand pump.
Engine Coolant
Test coolant for proper additive concentration and water quality levels.
See "Fluids and lubricating greases" for correct coolant specifications.
! NOTE: Change coolant filter if necessary.
40 No: 2522100363.3 en-US

Radiator Hoses
Inspect radiator hoses for loose fittings, leaks, and damaged condition.
Batteries
Check electrolyte level. Electrolyte-specific gravity: 1.275–1.285; recharge at 1.250.
Clean Vehicle
Clean the whole vehicle with high-pressure cleaning or if it is possible with steam washer.
Remove rocks from the load frame.
Stall Speed
Check Idle
The stall test provides important information about engine power and transmission clutch
integrity. The following steps are designed to help gaining the most accurate engine rpm
measurements.
1. Start the engine and allow it to warm up to normal operating temperature.
2. With parking brake applied, shift the transmission to the highest forward gear or re-
verse and depress the throttle pedal to the floor.
3. Observe and record the engine rpm at the point where the engine rpm no longer in-
creases. Hold the throttle pedal for a short period to make sure the rpm will not go
higher. Record the number for a comparison with future tests.
NOTICE
Do not hold stall for more than a few seconds.
Contact an authorized Atlas Copco dealer if the engine rpm goes higher and does not
"stall" at a certain rpm.
If the rpm trend drops more than 100 rpm check the engine oil filters and fuel filter for re-
striction before contacting Atlas Copco for service information.
41 No: 2522100363.3 en-US

Check Pre-Charge Pressure in Accumulators
Accumulator Recommended pressure N2
A Brake accumulator 83±3.5 bar
B Damping accumulator for steering cylinders, 50±3.5 bar

only for steering wheel (option)
C Emergency steering accumulator (option) 30±3.5 bar
1. The pressure on the accumulator hydraulic side must be drained before checking the
pre-charge pressure. See "Relieving Hydraulic Pressure" on page 107.
2. Remove the valve protection.
3. Connect a manometer to the valve.
4. Open the valve on the accumulator by loosening the valve nut.
5. Check the pressure on the pressure gauge in accordance with the previous table.
6. Close the valve with the valve nut and remove the manometer.
7. Refit the cover and valve protection.
Cardan Shafts
n Inspect for wear or damage.
n Check for departure from the surrounding components such as hose and cable con-
nections.
42 No: 2522100363.3 en-US

Fire Extinguisher (Option)
Fire extinguisher on left-hand side.
Fire extinguisher on right-hand side.

Loosen the powder by shaking the container several times.
43 No: 2522100363.3 en-US

Review Pressurisation
A. Pressurizer
Check the following points to ensure that the cabin is correctly pressurized. There should
only be clean air inside the cabin when the door is closed and the machine is being used.
Minor leakage in the seals lets air out of the cabin and prevents unfiltered air from coming
in.
If any of these points are not in good condition, then report them to the maintenance de-
partment for immediate repair.
1. Make sure that the fan motor for the pressurizer starts when necessary.
2. Check that pressurizer filter pre-cleaner is fitted and undamaged. Replace it if neces-
sary.
3. Check the insert in the filter canister and make sure that it is clean and free of holes.
44 No: 2522100363.3 en-US

4. Check the filter canister and ensure that the filter is properly sealed in the canister.
Check that the fan and the engine are sealed against the canister and that there are
no leaks between the filter and the output hose.
5. Inspect the hose and tubes from the filter assembly to the cabin. There must be no
kinks or clamped points on the hose, and no holes in the hose. All connections must
have clamps and be air tight.
6. Check that the air flow to the cabin interior is steady and strong.
7. Inspect and check pressurizer drainage.
8. Check all windows and make sure that the seals are intact.
9. Check that there are no holes in the cabin.
Check the door and make sure that it is not warped and the seal is fitted firmly all around
(dust tracks on the metal surface indicate that the air is moving in the area and that the
seal is not working).
Dump Box Safety Support
Lubrication
A. Grease nipple, dump box safety support

Lubricate the dump box safety support. See "Fluids and lubricating greases" for correct lu-
bricating grease specifications.
45 No: 2522100363.3 en-US

Inspection and Checking
Dump box safety support in stowed position

Inspect the dump box safety support and its internal components regarding damage.
Replace the dump box safety support as required.
Articulation Lock
Articulation lock in storage position.
46 No: 2522100363.3 en-US

Articulation lock in locked position.

Inspect the articulation lock regarding damage which would make it unsuitable for use.
Replace the articulation lock if necessary.
47 No: 2522100363.3 en-US

Wiggins, Breather Filter (Option)
A Drain hose
B Breather filter
Check that the breather is working correctly and is not damaged.

Clean the breather if dirty or blocked.
Check drain hose and clean if necessary.

n Repeat 125 hours
n Repeat 250 hours
Fuel Hoses
Look for damage to the hose covers: indications of twisting, worn, crimped, brittle, cracked,
or leaking lines.
48 No: 2522100363.3 en-US

Hoses that have worn covers or damaged metal reinforcement should be considered un-
serviceable and replaced.
Engine Fan Assembly
Fan assembly
Inspect the engine fan assembly for excessive wear and damage.
Check the idler bearings and sealed bearings for wear or excessive play.
49 No: 2522100363.3 en-US

Transmission, Filter
Transmission, filter
Change Filter
NOTICE
Oil and filter should be changed anytime there are signs of contamination or if
the oil has a burned appearance. Clean the filter and the area around the filter.
1. With the engine stopped, turn the filter anticlockwise and remove. Discard the old fil-
ter.
NOTE: Atlas Copco encourages the examination of the contents of

! oil filters before disposal. Contaminants in the filter can alert main-
tenance personnel to potential service problems.
2. Use a clean cloth and wipe the filter mounting surface on the filter head.
3. Apply a coat of transmission oil to the seal of the new filter and fill it with transmission
oil.
4. Install the new filter and turn until the seal contacts the filter head. Continue to turn
the filter clockwise 3/4 turn.
50 No: 2522100363.3 en-US

! NOTE: Use of a catch basin or container is recommended when

changing the filter.
Transmission, Bolt Connection

Check the torque on the bolts that holds the transmission to the power frame.
See "Tightening Torques" on page 178.
Radiator
A Engine radiator and transmission cooler
B Hydraulic oil cooler
n Check the tightening torque of the retaining bolts. See "Tightening Torques" on page
178.
n View the hydraulic oil through the sight glass on the flow indicators by the hydraulic
tank. Check for a constant stream, clear fluid, and a lack of bubbles.
n Check engine radiator, transmission cooler, and hydraulic oil cooler fins for damage,
wear, and dirt build-up.
Differentials and Planetaries
Test Oil
Oil testing is a important part of a Minetruck maintenance program. Results of tests can be
used to determine how a particular system is operating and possibly when it fails. Prevent-
ing the failures can reduce repair costs and Minetruck down time.
51 No: 2522100363.3 en-US

1. Operate the Minetruck for a short period.
2. Park the Minetruck on a flat level surface, set the parking brake and block all wheels.
3. Place a "Do Not Operate" tag in the cabin.
4. Let the Minetruck rest for at least 5 minutes before checking the oil.
5. Loosen and remove the level plug from the differential or planetary.
6. The oil level should be at the bottom of the plug threads.
7. If an oil testing kit is available, follow the instructions. If an oil testing kit is not used,
obtain an appropriate container with a lid to store the oil for testing.
8. Retrieve enough oil for testing and replace the differential or planetary oil plug.
Axle, Bolt Connection
Axle, bolt connection
Check Torque
Check torque on all bolts on front and rear axle that hold the axle to the frame.
Bolt torques: See "Tightening Torques" on page 178.
52 No: 2522100363.3 en-US

Attachment Plate
Check Torque
Tie plate mounting bolts

If the axle and tie plate bolts are not torqued and checked during normal operation, the tie
plate may break or crack.
Bolt torques: See "Tightening Torques" on page 178. 1 2
53 No: 2522100363.3 en-US

Cardan Shafts
Articulation area cardan shaft

n Check cardan shaft bolt torques.
n Inspect the spline shaft and slip yoke when the drive axle assembly is removed for uni-
versal joint maintenance.
n Replace the drive axle if the splines are galling, becoming loose, or the spline shaft
shows signs of twisting.
n When the cardan shaft is removed for servicing, rotate the flange bearing and note any
roughness. Replace if the bearing is rough.
54 No: 2522100363.3 en-US

Cardan Shaft Universal-joint
Cardan shaft universal-joint

n Check for proper torque setting on universal joint trunnion caps. If found loose, install
new Grade 8 cap screws on clean threads and tighten to correct torque.
! NOTE: Always replace loose cap screws with new ones.
NOTICE
Do not use lock washers, lock plates, or lock wires to secure cap screws on
universal joint bearings.
NOTICE
Applying proper torque to trunnion cap fasteners is the best method to ensure
that the cap screws do not loosen. Improper torque can cause universal joint
failure.
NOTE: Torque settings apply to clean, non-coated threads. Torque settings do not ap-
! ply to plated bolts. Grade 8 identification is 6 radial dashes, 60º apart on head of cap
screw. Bolt thread class to be SAE standard Class 2.
n Check universal joints and support bearings for excessive heat immediately after vehi-
cle is shut down after a work cycle. Excessive heat, more than 38 °C (100 °F) above
ambient temperature is a sign of friction and deteriorating bearings.
n Check the universal joints for wear as follows:
55 No: 2522100363.3 en-US

l Grasp the universal joint centre cross (spider) with one gloved hand. With the
other hand, work the drive axle up and down (or back and forth) at 90º to each
of the trunnion axes. Check for looseness (sideways) between the trunnion
and the trunnion cap.
l Check all four trunnions in this manner. If looseness is detected at any of the
trunnions, replace the universal joint as an assembly.
! NOTE: Do not confuse end-to-end play between opposite bearing with excessive wear.
Some thrust movement is normal.
Hydraulic High-Pressure Oil Filter
Replace Hydraulic High-Pressure Oil Filter
! NOTE: Replace the hydraulic high-pressure oil filter every 500 hours or when the red
filter indicator appears.
! NOTE: The filter is bypassed when the red filter indicator appears.
1. Relieve the hydraulic pressure.
56 No: 2522100363.3 en-US

See topic “Hydraulic Pressure.”
2. Press the bleed valve relief button on the tank breather to relieve tank pressure.
3. Remove the filter housing cover.
4. Replace the filter insert with a new one.
5. Install the filter housing cover.
6. Start and run the engine at idle speed.
7. Stop the engine.
8. Check the hydraulic oil level.
Hydraulic Oil Filter
Hydraulic oil filter
Change Filter
1. Relieve all hydraulic pressure. See "Relieving Hydraulic Pressure" on page 107.
2. Loosen and lift the filter housing from the tank.
3. Remove the filter bypass and filter element.
4. Replace the filter with a new element.
5. Fit the filter bypass and housing.
6. Tighten to the correct torque.
57 No: 2522100363.3 en-US

Hydraulic Oil
Oil Test
Test the hydraulic oil for particulate concentration and the type of particulate matter in the
oil (Spectroanalysis). The information gained by these tests will not only help to prevent
component damage, but forewarn if a component is wearing excessively and contaminat-
ing the hydraulic system.
Fuel Tank
Drain Water
Check fuel tank for water and sediment.
Place a suitable container under the fuel drain.
Loosen the drain plug on the bottom of the fuel tank and drain water and dirt. Do not com-
pletely drain tank.
CAUTION
If the fuel tank is full, there will be pressure on the drain plug. To remove the
water, only loosen the plug. Do not remove the plug.
Pressurizer, Filter
Pressurizer filter
Change the pressurizer filter.
58 No: 2522100363.3 en-US

! NOTE: Depending on the mine conditions. Change the filter more often if necessary.
AC, Cabin Unit
AC filter
Change the AC-filter in the operator’s cabin.
59 No: 2522100363.3 en-US

Dump Cylinder
Dump cylinder
Check dump cylinder mounting pins and bushings for wear or excessive clearances. If any
pin free-play exceeds 3.175 mm (1/8 in.), replace pin and/or bushing, or repair pin bore as
required.
60 No: 2522100363.3 en-US

Dump Box Safety Support
A Dump Box Safety Support
B Set screw
C Adjusting nut
Check the position of the safety support as follows:

n Adjust the set screw so that safety support is locked when the box is lowered.
n Adjust the adjusting nut so that there is play when the box is resting on the safety sup-
port.
Check the tightening torque for the safety support set screw (B) and adjusting nut (C).
Load and Power Frame

n Look for frame cracks at major stress points.
n Check frame for damage that could cause down time.
n Inspect all dump box welds for cracks and broken welds. Check for any bent or warped
box components. Check the position of the box stops and guides.
Report any structural damage, immediately to your local Atlas Copco representative.
DANGER
To prevent a possible weakening of the structure, obtain written approval from
Atlas Copco before welding, cutting, drilling, bolting or installing an attachment
or device to the vehicle.
61 No: 2522100363.3 en-US

Engine Coolant Filter
Engine coolant filter
Change Filter
1. Remove the filter by turning it anticlockwise using a strap wrench or filter removal tool.
2. Discard the filter.
3. Clean the filter sealing surface with a clean cloth.
4. Turn the filter clockwise until the gasket makes contact with the filter base. Continue
to turn the filter 2/3 turn by hand.
Operating Times
Dump and Steering

Test and record dump and control cycle times.
Specified control times:
n Low idle — 14 ±2 seconds
n High idle — 5 ±1 second
Specified Dumping Cycle Times
n Box raising — 14 seconds ±1 second
n Box lowering — 7 seconds ±1 second
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Articulation Joints
Upper articulation joint

n Check bearings for looseness.
n Check the hinge pin for end play, and adjust if necessary.
n Adjust by retorquing the trunnion bolts. If there is still play in the hinge, replace the pin
and assembly. Inspect the frame bore for possible wear and damage. Contact your lo-
cal Atlas Copco representative for articulation hinge pin kits.

Check tightening torques on the wheel bolts and nuts.
! NOTE: Tighten the wheel nuts in accordance with the inner studs thread, M20. Tight-
ening torque: 500–520 Nm.
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Wiggins, Breather Filter (Option)
Wiggins, breather filter
Change Wiggins, Breather Filter

Unscrew the cover of the breather filter and replace with a new filter cartridge. The filter
cartridge is integrated into the cover.

n Repeat 125 hours
n Repeat 250 hours
n Repeat 500 hours
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Engine Crankcase Breather
Engine crankcase breather

Inspect the crankcase breathers, which are located on the engine valve cover, to assure
that the mesh element is not clogged. Pull breather and clean if it is restricted.
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Engine Mountings
Engine mounting bolts

n Inspect condition of rubber mounting pads. Replace the pads if they are cracked, worn,
or missing. Keep pads free of oil.
n Inspect mounts for cracks.
n Inspect for missing or cracked mounting bolts.
n Check engine mounting bolt torque.
Radiator
Steam clean or power wash all radiator fins. Take care not to damage the fins. Inspect the
radiators for leaks and damage.
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Drive Belts
Drive Belts, Engine Fan, and Alternator
A Alternator drive belt
B Engine fan drive belt
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Drive Belts, AC Compressor (Option)
A. Drive belt AC compressor

Replace the drive belts.
Transmission
! NOTE: Always replace filter when changing oil.
Change Oil
1. Place an adequate container under the vehicle.
2. Clean the area around the transmission oil filler tube and drain plug.
3. Remove the drain plug and oil strainer assembly. Drain all the transmission oil.
4. Clean the strainer assembly and breather.
5. Install the drain plug and strainer and add new oil to full mark. See "Fluids and lubri-
cating greases" for correct oil specifications.
6. Fit the transmission filters.
7. Start the engine and run at idle for a few minutes with the transmission in neutral.
Check for oil leaks.
8. Check the transmission oil level once oil temperature has reached normal operating
range. Level should be between the ADD and FULL mark.
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Exhaust System
A. Catalytic converter
n Clean the exterior of the catalytic converter from oil and dirt.
n Inspect the exhaust system for leaks, wear, or damage.
Axle, Differential
NOTE: Draining of oil is best accomplished after the Minetruck has been operated and
! oil has warmed up. Use of a catch basin or container is recommended when changing
oil.
Change Oil, Differential

1. Park the vehicle on a level surface, apply the parking brake, and stop the motor.
2. Let the vehicle stand 5 minutes to let the oil level settle.
3. Place adequate receptacle under the drain.
4. Remove the oil drain plugs and completely drain each differential.
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A. Oil drain plug, rear axle
5. Install the oil drain plugs.
6. Remove the oil level plug and put new oil in each differential. The oil level must be up
to the bottom of the oil level plug hole. See "Fluids and lubricating greases" for correct
oil specifications.
7. Refit the oil level plug.
Axle, Planetary Gears
NOTE: Draining of oil is best accomplished after the Minetruck has been operated and
! oil has warmed up. Use of a catch basin or container is recommended when changing
oil.
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Change Oil, Planetary
Oil drain plug
1. With the vehicle on a level surface, move the vehicle forward or back until the oil
level/drain plug is at the bottom of the hub.
2. Apply the parking brake, and stop the engine.
3. Place adequate receptacle under the drain.
4. Remove the oil drain plug.
5. After all the oil has been drained, fit the drain plug.
6. Reposition the vehicle so that the level/drain plug is in the level check position.
7. Fill new oil into the planetary gear. The oil level must be up to the bottom of the oil
level plug hole. See "Fluids and lubricating greases" for correct oil specifications.
8. Install the oil level plug, then repeat procedure with the other planetaries.
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Hydraulic Oil and Filter
A Hydraulic tank breather
B Filler cap and seal
C Upper sight glass
D Lower sight glass
! NOTE: Always change filter when changing oil!
Change Oil
1. Select a container sufficient to hold the entire amount of oil in the system and place
under the reservoir drain.
2. Relieve the hydraulic pressure. See "Relieving Hydraulic Pressure" on page 107.
3. Remove the drain plug from the reservoir and drain the oil.
4. Disconnect the dump cylinder hoses at the lowest points to drain the cylinders.
5. Clean inside the reservoir. If it is difficult to clean, use a mixture of five parts diesel
fuel oil to one part of clean lubricating oil. Be sure to flush out the bottom of the tank.
Make sure that all the flushing solution is removed from the reservoir.
6. Disconnect any other hoses that might trap hydraulic oil in the system and shift the
hydraulic control levers to permit any oil in the control valves to drain.
7. Replace the hydraulic filters. See "Hydraulic oil filter" on page 32.
8. Reconnect all hoses and fittings previously disconnected.
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9. Install the tank drain plug.
10. Refill the hydraulic system with clean, new hydraulic oil. See "Fluids and lubricating
! NOTE: Always use the filler cap when adding fluid to the hydraulic tank because it
routes through a filter.
Hydraulic Oil Pressure
Check System Pressure

The following pressures must be checked:
n Steering relief pressure
n Dump relief pressure
n Accumulator charging valve pressure
See "Pressure Settings and Adjustments" on page 110 for instructions on how to check the
pressures.
Hydraulic Oil Tank Breather

1. Relieve the hydraulic pressure. See "Relieving Hydraulic Pressure" on page 107.
2. Remove the hydraulic tank breather and inspect it for damage and dirt build-up.
3. Clean the breather by soaking it in a cleaning solution and blowing it out with com-
pressed air.
4. Fit the breather filter.

See attached Safety Manual and attached digital OEM documentation for further informa-
tion.
Fuel Tank
Drain and Flush

1. Loosen the drain plug on the bottom of the fuel tank and drain the fuel into a proper
container.
! NOTE: If the fuel tank is full, there is pressure on the drain plug.
We recommend draining the tank when fuel level is low.
2. Flush tank with clean diesel fuel. Make sure that all contaminants are dislodged and
removed from the tank.
3. Remove any feed line screens or strainers, clean, and reinstall.
4. Put back the fuel tank drain plug and refill the tank with diesel fuel.
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5. Bleed all air from the fuel system by loosening the fuel pump fitting and allowing the
air to vent.

n Repeat 125 hours
n Repeat 250 hours
n Repeat 500 hours
n Repeat 1000 hours
Drive Belts
Inspect
Inspect all the engine and fan assembly belts. Replace if worn, stretched, cracked, or dam-
aged.
Air Intake and Exhaust System

Remove the wing nut for the safety filter and remove the filter.
1. Inspect filter gasket surface and replace if needed.
2. Fit the primary filter, fit the safety filter, and fit the filter cap.
3. Inspect the cylinder head(s) and the intake and exhaust manifolds.
4. Check bolts or cap screws for correct torque, according to the engine OEM specifica-
tions.
5. Check that the manifold is secured and properly sealed to the cylinder head(s). Also
check that the manifold lacks any holes or cracks and that there are no oil and/or
coolant leaks. Make replacements or repairs as necessary.
Engine Cooling System
Clean and Refill Coolant
CAUTION
If the engine coolant temperature is high, be careful when opening the refill cap.
Hot coolant can rush out and may cause burn injury.
NOTE: If the cooling system is drained, flushed, and refilled with new coolant, use a
! product suitable to a maintenance program that preserves the correct concentration of
Supplemental Coolant Additive (SCA).
1. Position a suitable container under the cooling system drain valve.
2. Open the engine coolant drain cap that is located in the right front corner of the radia-
tor mount.
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3. Remove the surge tank cap.
4. After all coolant is drained, replace the drain cap.
5. Add a cleaning solution to the cooling system and fill the system with clean water. Fol-
low the directions included with the cleaning solution.
6. Drain the cleaning solution from the cooling system, and flush with clean water.
7. Fill the cooling system with pre-mixed coolant. See "Fluids and lubricating greases"
for correct engine coolant specifications.
8. Start the engine and run at idle speed for two minutes. Check for leaks during this pe-
riod.
9. Stop the engine and check the coolant level. Add coolant to raise the level up to be
visible in the sight window.
Fire Inspection
Check that no new risk areas have been added to the vehicle. If so, a new risk analysis
should be carried out and the system that is modified by an authorized service company.

Call an authorized service company for the maintenance of the fire suppression system.

n Repeat 125 hours
n Repeat 250 hours
n Repeat 500 hours
n Repeat 1000 hours
n Repeat 2000 hours
Transmission Mountings
Inspect mounts for cracks.
Inspect for missing or cracked mounting bolts.
Inspect condition of rubber mounting pads. Replace the pads if they are cracked, worn, or
missing.
Keep pads free of oil.
Check transmission mounting bolt torque.
Engine
n Test engine thermostat and replace seals.
n Test alternator and starter for voltage and amperage. Replace it if necessary. See
"Chapter 7: Electrical System" on page 119.
Hoses and Couplings

n Replace all rubber intake hoses and clamps. This insures clean air reaching the en-
gine.
n Replace all hydraulic system, engine fuel, and coolant system hoses.
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Oil Cooler
Flush
1. Drain the transmission oil system thoroughly.
2. Disconnect all hydraulic lines and clean.
3. Thoroughly clean the oil cooler by back-flushing it with clean oil and compressed air
until all foreign material has been removed. The cooler should be flushed in the oppo-
site direction of normal flow to clean it.
! NOTE: Do not use flushing compounds to clean the cooler.
4. Fit and refill with the correct oil. See "Fluids and lubricating greases" for correct oil
specifications.
Fuel Injectors
Check function on the fuel injectors and replace if necessary.
Start the function test with the software Cummins Insite or ask the local Cummins service
for help to locate problems with the fuel injectors.
! NOTE: Consult the local Cummins dealer or the Cummins Service Manual for more de-
tailed information regarding valve adjustment.
Cummins Quick Check QC5100

The Cummins QC5100 may also be used to check if there are any problems with the injec-
tors. Read how to use it in the Cummins service manual.
For more information on the fuel injectors, see Cummins service manual.
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2.10 Maintenance Procedures by Calendar Time
2.10.1 Daily and Shift
Pos Action Special Instructions Check
Power LED Check visually that the power

LED is green and steady-on
LEDs Check visually that all other

LEDs are off (not steady-on
or pulsing)
Sounder Sounder is silent
2.10.2 Every Six Months
Ansul fire-extinguishing sys- Maintenance every six

tem months by an Authorized AN-
SUL distributor or a Tyco Fire
Protection Products trained
and authorized person to
perform maintenance.
2.10.3 Every Five Years
ANSUL fire-extinguishing Replace the protracting actu-

system ation device.
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78 No: 2522100363.3 en-US

Minetruck MT2010 3 Hydraulic System
3 Hydraulic System
3.1 Introduction
This chapter presents a summary of hydraulic theory that is applied to specific system ca-
pabilities, and includes instructions for the removal and replacement of major components.
Hydraulic fluid provides system pressure for steering, braking, dumping, and cooling, and
lubricate close-tolerance mechanisms. The primary purpose of the hydraulic system is to
transmit power from the engine to the various working and control systems of the machine.
The MT2010 uses a fixed-displacement hydraulic pump with open-centre valves. The en-
gine drives the pump via the torque converter. With no control functions operating, hy-
draulic fluid flows through the system and back to the hydraulic tank. Operating a control
activates specific valves that redirect oil to the targeted component. When the mechanism
reaches its limit of travel, system pressure increases until the main pressure control valve
opens. Oil is then directed, at minimal pressure, back to the hydraulic tank. Pressure on
the pump side of the pressure control valve remains at the level that is designated by the
pressure control valve set-point, until readjusted.
For further information on fluids and lubricants, see document "Fluids and lubricants" in-
cluded in the documentation supplied.
3.2 System Components

The MT2010 hydraulic system includes the following:
n Cylinders
n Accumulators
n Tank
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n Pumps
n Valves
n Hoses and tubing
n Suction filter
n SAHR Brakes
3.2.1 Cylinders
The cylinder does the work of the hydraulic system. It converts the pressure from the pump
into mechanical power in the cylinders. The cylinders are the muscles of the hydraulic cir-
cuit.
Double-acting cylinders provide force in both directions. Hydraulic fluid enters at one end of
the cylinder to extend it, and at the other end to retract it. Oil from the unpressurized end of
the cylinder returns to the hydraulic tank.
Dump Cylinders
Dump cylinder
The dump cylinders are double-acting, telescoping hydraulic cylinders with a chrome stem.
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Steering Cylinders
Steering cylinder
The steering cylinders are double-acting cylinders which provide force in both directions.
Teletram Cylinders
A. Tailgate cylinder
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B. Cylinder, first box step

The Teletram cylinders are double-acting cylinders which provide force in both directions.
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3.2.2 Accumulators
1 Charging valve
2 Gas cap
3 Nitrogen
4 Body
5 Piston
6 Hydraulic cap
Hydraulic accumulators are used to store energy and maintain a smooth flow of oil to the
following systems during vehicle operation:
n Brakes
n Emergency steering (optional)
n Front axle suspension (Minetruck)
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n Boom suspension (Scooptram option)

n Tow hook brake release (Scooptram option)
The accumulator consists primarily of a shell, piston, gas valve, and seals. The area above
the piston is precharged with dry nitrogen gas.
When the accumulator is being charged, oil (at system pressure) enters the chamber be-
low the piston. This pressure, acting on the bottom of the piston, moves the piston up. As
the piston travels up, the nitrogen gas is compressed, increasing the pressure above the
piston. The piston is forced up until the pressure on both sides of the piston are equal.
The accumulators should be checked during vehicle service to ensure that proper
precharge pressure is available. An accumulator with low or no precharge causes excess
cycling of the accumulator charging valve and excess temperature in the hydraulic system.
A piston-type pneumatic accumulator uses dry nitrogen to precharge the cylinder and store
energy.
The accumulator has a free floating piston which separates the oil from the nitrogen gas. A
piston seal is used to prevent any leakage past the piston zone.
Operation
1. The accumulator is empty and neither gas nor hydraulic sides are pressurized.
2. The accumulator is precharged.
3. The hydraulic system is pressurized. System pressure exceeds precharge pressure

and fluid flows into the accumulator.
4. System pressure peaks. The accumulator is filled with fluid to its design capacity. Any
further increase in hydraulic pressure would be prevented by a relief valve in the sys-
tem.
5. System pressure falls. Precharge pressure forces fluid from the accumulator into the
system.
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6. Minimum system pressure is reached. The accumulator has discharged its designed
maximum volume of fluid back into the system.
Hydraulic Accumulators
NOTICE
Only an individual with the prescribed training must perform work with pressure
vessels. Only nitrogen gas (N2) can be used.
! NOTE: The pre-charge pressure is specified on each accumulator sign.
Technical Data
System Function Pre-charge Pressure N2 Volume
Brake accumulator 83±3.5 bar 3.6 litres
Emergency steering accumulator 30±3.5 bar 15.2 litres

(optional)
Damping accumulator for steer- 50±3.5 bar 0.5 litres

ing cylinders, only for steering
wheel (option)
Drain Hydraulic Pressure

The accumulators are drained of hydraulic pressure by releasing the system pressure. . Al-
ways measure to check that the hydraulic system is depressurized before intervention.
Drain Nitrogen Gas

1. Ensure that the pressure is drained on the hydraulic side.
2. Remove the nipple protection on the accumulator.
3. Connect the nipple from the drain/filler equipment. See the enclosed OEM manual for
instructions.
4. Drain the accumulator of gas in accordance with the instructions.
5. Disconnect the equipment and install the nipple protection.
Charge Nitrogen Gas

Accumulators are pre-charged with nitrogen gas at a specified pressure. The pressure is
different depending on system function.
1. Ensure that the pressure is drained on the hydraulic side.
2. Remove the nipple protection on the accumulator.
3. Connect the nipple from the drain/filler equipment.
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4. Fill the accumulator with N2 to the specified pre-charge pressure.
5. Disconnect the equipment and install the nipple protection.
6. Bleed the hydraulic system and the accumulator circuit.
3.2.3 Hydraulic Pumps

Hydraulic oil flow is supplied to the working cylinders by a pump.
The MT2010 is equipped with two fixed displacement gear pumps one for the brake cool-
ing system, the other for steering and dump systems.
Hydraulic Gear Pumps

Most machines typically have three systems requiring a hydraulic pump - steering, dump
box/teletram and braking. The pump converts mechanical energy from an engine or elec-
tric motor into hydraulic energy.
! NOTE: A fourth system, transmission, also uses a gear pump and is located on the
torque converter, along with the hydraulic system pumps.
Atlas Copco uses single and tandem hydraulic gear pumps, depending on the application.
A tandem pump (that is, with two pumping sections) is usually plumbed so one section
supplies a designated system (for example, the steering system) while the other section
supplies a second (the dump or brake) system. A second, single stage pump provides flow
for the remaining system.
! NOTE: In the following descriptions of the various hydraulic systems (steering, dump-
ing, braking) and components, pumps are referred to by the specific function they fulfil.
3.2.4 Hydraulic Tank

The hydraulic tank has several functions in the hydraulic system:
n Stores hydraulic oil
n Cools hydraulic oil
n Allows air to separate from the oil
n Allows contamination to settle to the bottom of the tank
n Contains the return line filter
n It is equipped with a filter and breather check valve assembly to maintain pressure in
the tank to 0.35 bar. This helps force the oil to the suction side of the pumps.
Hydraulic Suction Filter

The suction filter is installed on top of the hydraulic tank. All hydraulic oil that is supplied to
the brake, steering and dump pump passes through the filter. The filter is a 25-micron ele-
ment.
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3.2.5 Hydraulic Filtration

Despite utmost care in the handling and dispensing of the hydraulic fluid, it is probable that
some foreign particles find their way into the hydraulic fluid. Because such particles are apt
to be abrasive in nature and detract from both the operation and life of the hydraulic
pumps, motors, and valve, Atlas Copco always incorporates filters in its hydraulic systems.
The actual placement of the filter in the system to achieve maximum filtering efficiency de-
pends entirely on the circuit design. Correspondingly, periodic replacement of fully contam-
inated filter media must be made to maintain overall efficiency.
When the filter restriction indicator shows red, the filter should be replaced.
Maintaining a clean hydraulic system is important. Contaminated oil can score or com-
pletely freeze a precisely fitted valve spool. Dirty oil can damage the small tolerances of
finely machined surfaces. A grain of sand in a small guide opening can put the whole ma-
chine out of operation.
Dust from the surrounding air is a major source of contamination. Another source of con-
taminants is the machine itself. During normal operation, the machine generates burrs,
dust, and chips from metal to metal contact between moving parts.
A properly maintained oil filter can save significant cost by preventing premature equip-
ment failure and replacement.
Off-Line Hydraulic Filters

Sometimes off-line hydraulic filter(s) are used to provide partial flow filtration of hydraulic
oil. The filter can be plumbed into any of the hydraulic systems. The filter is equipped with
a 0.2-0.35 bar bypass pressure control valve and a visual restriction indicator. Restriction
indicators help to determine when a filter needs replacement. The filter element requires
changing when the restriction indicator shows red.
3.2.6 Control Valves

The Atlas Copco Minetruck employs a series of valves that are integral to the operation of
Minetruck’s hydraulic system. The valves may include the following:
n Charging valve
n Dump control valve
n Brake solenoid valve
n Steering control valves
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Charging Valve
Charging valve
The charging valve is located below the cab towards the front of the machine.
The charging valve consists of four cartridge valves within a valve body. They include:
n Pressure control valve
n Bleed valve
n Vented flow control
n Charging valve
This allows repair and maintenance of the valve without removing the complete valve body.
The main pressure control valve is pre-set for over-pressure protection of the system.
The air bleed and start-up valve reduces power requirements and facilitate pump priming
during startup.
The vented flow control valve controls the priority flow of the oil to the accumulators, and
has a fixed orifice (2–3 gpm/7.6-11.4 litre/m).
The charging valve regulates the pressure with which the accumulators are charged. The
engagement pressure is set at 110 bar and the disengagement pressure at 138 bar.
If electric power is removed from the solenoid, the valve closes and the brakes apply.
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Dump Control Valve
Dump control valve

The dump control valve is located behind the transmission oil filter access panel, within the
left-hand articulation area.
The dump control valve controls the flow of oil to the dump cylinders. This valve is oper-
ated manually via a lever that is connected to the dump valve. The lever is located to the
right of the operator.
The control valve has a main pressure control valve set at 155 bar, and a combination anti-
cavitation and port pressure control valve at each work port. The dump spool is equipped
with a float position which opens both dump cylinder ports to the tank when the lever is
placed in the detente position.
Main Relief Function

The main relief is set at 155 bar and is included to prevent overloading of the main hy-
draulic circuit.
Load Check Valve Function

Allows pressure to buildup gradually within the valve to match load demand. The load
check prevents reverse flow and supports the load. When the system pressure matches
the load pressure, the check valve opens, porting the fluid to the cylinder.
Pilot Control Valve (Steering Wheel Steering)

For steering wheel steering, a pilot control valve inside the cab controls the dump valve.
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Joystick Control Valves
Brake Solenoid Valve

The truck is equipped with two series-mounted brake valves. Both valves must be ener-
gized to release the brake.
The current to both brake solenoid valves is disconnected when the parking brake is ap-
plied. There is then no oil flow from the accumulator to the brake control valve (foot brake
control valve).
Both brake solenoid valves are energized when the parking brake switch is activated. The
stored oil pressure in the accumulator is then directed to the brake control valve. The oil
flows through the spool out through all four hubs and releases the brakes, allowing the
hubs to turn freely (unless the brake control valve is applied).
Steering Control Valve
The steering control valve is located in the power frame articulation area, opposite the hy-
draulic tank.
The steering control valve combines the functions of the main steering valve and a cushion
valve into one component. It uses the 15.2-bar hydraulic system pilot pressure to shift the
main spool, which ports hydraulic system main pressure to the steering cylinders.
Steering Main Control Valve

The main control valve consists of the following components:
n Main Spool Valve
n Port Relief Valve
n Main Relief Valve
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The main spool is spring centered to neutral and is shifted in either direction by pilot pres-
sure from the steering pilot valve. When shifted, the spool controls oil flow to and from the
steering cylinders allowing the vehicle to articulate.
The port relief valves protect the cylinders, hoses, and the main control valve from shock
loads or pressure spikes.
The main pressure relief valve controls the maximum operating pressure in the steering
system. The pressure is set at 165 bar.
Steering Pilot Control Valve

The pilot control valve is located in the operator cab. This valve is a three position valve
which is spring entered to the neutral position. When the lever is activated, the pilot pres-
sure valve sends oil pressure to activate the main control valve spool. Pushing the joystick
away from the operator allows the machine to articulate away from the operator. Pulling the
joystick towards the operator allows the machine to articulate towards the operator.
Priority Valve
This valve is used to firstly ensure that priority oil flow is sent to the steering system and
secondly to control the steering speed. Oil flow from the steering and dump pump enters
the "P" port and passes through an opening which is externally adjustable. All oil that
passes through the opening is delivered to the main control valve through for the steering
through port "CF". The remaining flow goes out to the dump system through port "EF" via
the compensator spool.
Adjust the priority valve as follows:
1. Ensure that the machine and the oils are at operating temperature.
2. Ensure that the area around the machine is clear and of adequate size.
3. Select neutral, release the parking brake.
4. Turn machine fully to any one side.
5. Accelerate engine to full rpm.
6. Move joystick fully to the opposite side and measure the time in seconds it takes for
the machine to fully lock in the opposite direction. The time in seconds should be 5–6
seconds. If not, release the throttle pedal, apply the parking brake, and loosen the
lock screw on the orifice shaft and turn a little in any direction.
7. Repeat steps 5–6 until the correct time is achieved.
8. Release throttle pedal.
9. Apply parking brake.
10. Tighten orifice lock screw.
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Steering Control Valves
Cab
Positioning of primary and secondary brake solenoid valve
Canopy
Positioning of primary and secondary brake solenoid valve
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Cushion Valve
Cushion valve
The cushion valve protects the cylinders, hoses, and the steering control valve from shock
loads or pressure spikes.
Relief Valve
The main pressure relief valve controls the maximum operating pressure in the steering
system. The pressure is set at 165 bar.
3.3 System Functions
3.3.1 Dump System

Oil flow developed by the steering or dump pump is delivered to the inlet port of the dump
control valve, from the priority valve "EF" port, along with oil exiting the HPCO port on the
main steering control valve.
The two open-centre spools allow the oil to flow through the valve and back to the hy-
draulic tank when both spools are in the neutral position.
On systems using a pilot control valve to actuate the dump control valve, oil flow is sup-
plied from the pilot pressure (sequence) valve in the brake system, at 21 bar ±1.5.
The load in the dump box determines the system pressure, with a maximum system pres-
sure of 155 bar. Should a sudden external load be applied to the dump cylinder while
raised, creating a spike in the system above 172 bar, the relief valve in the dump control
valve opens, directing the oil back to the hydraulic tank.
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Box Up
On the MT2010, the operator moves the dump box lever for box up operation. The pilot
pressure valve shifts down the spool in the dump control valve. Oil flows from the pressure
port to the base end of the cylinders to raise the dump box.
Oil from the stem end of the cylinders is routed back through the dump control valve to the
hydraulic tank.
Box Float
When the operator places the dump lever in the float position, all ports to the tank are
open. The result is that the weight of the dump box slowly lowers the dump box onto its
stops.
Box Power Down

To speed the return of the dump box to its stops, the operator can move the dump lever to
the power down position. The main control valve is shifted to the extreme upward position
and directs pressure from the inlet to the stem end of the dump cylinders.
Oil from the lower end of the cylinder returns to the tank through the dump control valve.
3.3.2 Teletram Unloading System (Option)
Components
Feed Pump
Main pump that is used to supply both steering and unloading functions.
Main Valve
Controls the extend and retract functions for all unloading functions.
Diverter Valve
Shifts the hydraulic pressure from the tailgate to the push plate or first box step and back.
Diverter Shifting Cylinder

Uses pilot pressure to shift the main valve.
Dump Box Components

The teletram dump system has three control devices that perform an unloading function.
n Tailgate (two cylinders)
n First box step
n Push plate
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Unloading Cycle
A Limit switch, tailgate closed
B Limit switch, tailgate open
C Limit switch, tailgate open
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1. When the lever for the main dump valve is pulled backward, the flow is routed to the
tailgate cylinders and pressure is built up inside them. This results in the tailgate
opening.
2. A limit switch (A) is activated when the tailgate has been fully opened. The pressure is
routed to the cylinders for the tailgate and the cylinders for the box and push plate.
When the tailgate reaches its mechanical stop, pressure is built up in the cylinders for
the box and push plate. When there is sufficient pressure the box and push plate are
extended outward.
3. Press the lever for the main dump valve forward to retract the system. A limit switch
(C) is activated when the box and push plate have been fully retracted. The pressure
is then routed to the cylinders for the tailgate and the cylinders for the box and push
plate.
4. Pressure is built up in the tailgate cylinders when the box and push plate reaches
their mechanical stops, and when the pressure is sufficient the tailgate closes.
5. The operator is informed via the display when the system is fully retracted.
3.3.3 Steering System
! NOTE: Also
Joystick Steering
The steering system for the machine is a pilot operated joystick system which uses hy-
draulic oil pressure to turn the machine. As the operator pushes the joystick, a low-pres-
sure flow of hydraulic oil is directed to the steering spool on the main control valve. This pi-
lot pressure pushes the spool open and allows the high-pressure oil from the steering
pump to fill the steering cylinders. As one cylinder is hydraulically extended, the other is hy-
draulically retracted, articulating the machine.
Over-Pressure Protection
Should a shock load be applied (that is, striking the rib) and the pressure in any port of the
steering cylinder exceed system design limits, an internal relief in the Steering Control
valve opens. Which allows the high-pressure oil to be vented from the affected port back to
the hydraulic tank. The cylinder either retracts or extends (depending on the affected port).
Wheel Steering
The steering system for the machine is an orbital system that uses hydraulic oil pressure to
turn the machine.
Oil pressure, which is supplied by the steering pump, goes through the steering orbital and
is directed to the dump system, through the HPCO port.
Actuating the steering wheel shifts the spool in the orbitrol steering valve. Depending on
the direction of turn, oil then continues on to either the left (L) or right hand (R) port of the
steering orbitrol.
As the operator continues turning the wheel, oil is supplied through the steering orbital
spool to either the left or right steering cylinder.
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When the machine reaches the limit of full movement and touches the end position, the
pressure increases and the overpressure limiter opens and the flow reaches the tank.
Over-Pressure Protection
Should a shock load be applied (that is, striking the rib) and the pressure in any port of the
steering cylinder exceed system design limits, an internal relief in the Cushion valve opens.
Which allows the high-pressure oil to be vented from the affected port back to the hydraulic
tank. The cylinder either retracts or extends (depending on the affected side).
There is also a main pressure control valve in the system, which protects the pump.
3.3.4 Brake System

All brake systems require energy on demand to be applied to the friction devises that stop
the vehicle. This energy must be stored so that it is available when needed. Generally
speaking, energy is stored in two basic ways: with compressed gas or fluid or with springs.
With a valve installed between the energy storage device and the friction device, it makes
a simple brake system.
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Brake Release
Hydraulic Hand Pump
A Hydraulic hand pump
B Hand pump handle
To release the brakes, use the hand pump until reaching approximately 138 bar in the ac-
cumulator. The pump has a built-in pressure control valve to prevent over pressurizing.
Releasing the override control immediately vents system pressure from the brake assem-
blies to the hydraulic tank and reapply the brakes.
Parking Brake System

Oil flow from the brake pump is directed to the accumulator charging valve. Which, in turn,
depending upon system load, direct most the oil to either the accumulators or the brake
cooling and pilot circuit steering.
When the steering system is not in use, most of the flow passes through the Pilot Pressure
valve to the hydraulic oil cooler and on to the hubs to cool the brake discs. Bypass check
valves protect the oil cooler and the hub seals from over pressurization.
Charging Mode
When the accumulator pressure drops to 110 bar +/- 0.5, the accumulator charging valve
sends oil to the brake accumulator. Once 138 bar +/- 0.5 is reached, the accumulator
charging valve shifts back to the non-charging mode. The accumulators now have 138 bar
stored for releasing the brakes.
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Non-Charging Mode
The oil from the pump flows into the accumulator charging valve through priority flow con-
trol valve and out through the "out" port. Then into the inlet side of the pilot pressure valve
where pressure of 21 bar is directed to the steering pilot system. The remainder of the oil is
then directed to the brake cooling system.
Brakes Released
When the Parking Brake solenoid valve is energized, brake accumulator pressure flows to
the foot brake control valve. The oil flows through the spool, out to all four (4) hubs and re-
leases the brakes, allowing the hubs to turn freely.
Brakes Applied
Service Brake Operation
When the foot pedal is actuated, the flow of oil to the hubs is gradually cut off and the oil at
the hubs is allowed to return to the hydraulic tank. The hub SAHR brakes then apply, slow-
ing and stopping the machine.
Parking Brake Operation (Joystick Steering)
When the parking brake solenoid valve is deenergized, the brake accumulator pressure
flow is shut off to the foot brake control valve. At the same time allowing oil in the hubs to
flow back to the tank, applying the brakes.
Parking Brake Operation (Wheel Steering)
The truck is equipped with two series-mounted brake valves. Both valves must be ener-
gized to release the brake.
The current to both brake solenoid valves is disconnected when the parking brake is ap-
plied. There is then no oil flow from the accumulator to the brake control valve (foot brake
control valve).
Both brake solenoid valves are energized when the parking brake switch is activated. The
stored oil pressure in the accumulator is then directed to the brake control valve where the
oil flows through the spool out through all four hubs and releases the brakes. Which allow-
ing the hubs to turn freely (unless the brake control valve is applied).
3.3.5 Emergency Steering (Option)

The emergency steering system (option) is a function that makes it possible to steer the
machine if the hydraulic fluid is drained from the pumps. This function allows the operator
to swing sideways safely.
Testing Emergency Steering System

To test the operation of the emergency steering system, the following steps must be fol-
lowed. When the ignition is switched off, the stored pressure in the accumulators is
drained.
1. The function of the pressure switch, the warning lamp, and buzzer is verifying its func-
tion to the operator every time the ignition is turned on. The warning lamp and buzzer
are activated until the emergency steering accumulators are filled. Then the pump is
getting pressure to the accumulators and the lamp and buzzer turn off. Turn the bat-
tery isolation switch, turn the engine ignition switch on but do not start the engine.
Now the emergency steering lamp and the buzzer should be on in the operator cab. If
they are not on, they must be checked and the fault repaired.
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2. With the engine off: Open cover above the front axle and remove the coil from the
dump valve solenoid on the emergency steering valve block.
3. Start the machine and let the Emergency Steering accumulators charge up to the
maximum pressure.
4. Once this has been done, shut down the machine and turn off the battery isolation
switch.
5. Go to the emergency steering valve block and fully back out the needle valve. This al-
lows the charging valve oil to bypass to tank. The truck is only able to turn on the
stored oil pressure in the accumulators.
WARNING
Following action is a potentially dangerous operation and must
be done in a large open space with no obstacles. If the
emergency steering is not working properly, then the machine
is rolling with no steering capability. The operator must be
ready to quickly push the parking brake control valve.
6. Start the engine and release the parking brake. Let the machine roll slowly straight
forward and then articulate fully to one side, then go straight forward again. If the ma-
chine is able to carry out this procedure, then the emergency steering accumulators
are working properly.
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7. If everything is working correctly, set the parking brake and switch off the machine.
Turn the battery isolation switch off.
8. Go to the emergency steering valve block and close the needle valve. Connect the
coil to the dump valve solenoid on the emergency steering valve block.
3.4 General Maintenance Procedures
DANGER
The Hydraulic System contains Accumulators that store energy after the motor
has shut down. Depressurize the system before performing Maintenance.
DANGER
All hydraulic systems gradually lose pressure and present a crushing hazard for
maintenance personnel working within the confines of the machine, possibly
unaware of the gradual settling.
NOTICE
Long service life and functional reliability of hydraulic components are
dependent on proper maintenance.
! NOTE: The use of any safety procedures given in this section does not preclude any
other safety practices that are contained in this manual or the Safety manual.
3.4.1 Before Starting

Check cleanliness:
n Area around the machine
n Power units, pipe connections, components
n Hydraulic fluids
n Parts from stock
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! NOTE:
Do not mix Fire Retardant Fluid (FRF) with standard hydraulic fluids.
Protective internal paint coatings, if used, must be compatible with the hydraulic fluid used.
Be sure that all parts are on hand.
Parts from storage can develop a buildup of resin from protective oils and lubricant. This
resin must be dissolved with solvent before the part is installed.
Use lifting eye bolts and transportation equipment.
Do not use force. To prevent radial forces and tension on pipelines and components, en-
sure that pipelines are firmly secured.
Do not use putty or Teflon tape as a sealing material, as this can lead to contamination and
thus malfunctions.
Make sure that hose lines are correctly laid. Rubbing and touching of the lines must be
avoided.
Make sure that the correct oils are available. See "Fluids and lubricating greases" for cor-
rect oil specifications.
3.4.2 Relieving Hydraulic Pressure

Before conducting any service on the hydraulic system, follow these procedures:
1. Park the Minetruck on a flat level surface and block all wheels.
2. Lower the dump box to its stops.
3. Shut down the motor.
4. Slowly open the filler cap. There is then the sound of escaping air. When this stops,
remove cap completely to be sure that all pressure has been removed. Replace cap
and secure tank. Pressure can also be released by opening the pet tap on the filter
housing. After pressure has been released, make sure that the pet tap is properly
tightened.
5. Cycle the brake override several times to relieve the brake accumulator pressure. The
drop in pressure is seen on the accumulator pressure gauge. Once all pressure is re-
lieved - turn off the ignition and battery isolation switch.
6. Cycle the dump lever a few times to relieve all pressure from the dump cylinders.
DANGER
Hydraulic pressure is still dangerously high in the cylinders and hoses. Use
extreme caution while removing a hose flange to a cylinder.
3.4.3 Before Removing Any Hose

1. Clean immediate area around any hydraulic component to be serviced to prevent con-
tamination.
2. Label hose to facilitate assembly and diagnostics.
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3. Have plug ready to cap each hose to be removed.
4. Return lines are open to tank, therefore the entire hydraulic tank can drain if they are
not adequately plugged. Often it is useful to apply a vacuum (3.4-4.8 bar/5–7 psi) on
the hydraulic tank at the breather to prevent oil leakage, but a plug will still be neces-
sary to prevent contaminate from getting sucked into the lines.
3.4.4 Preparation for Hydraulic System Start Up
! NOTE: Applicable after replacement or overhaul of components in the hydraulic sys-

tem.
Before start up, the following check list must be run.
1. Check that hydraulic oil tank is clean.
2. Check that hydraulic lines have been cleaned and are installed correctly.
3. Check that all couplings and flanges are tightened.
4. Check that all components are correctly connected in accordance with installation
drawings or circuit diagrams.
5. Check that hydraulic accumulators are properly charged with nitrogen.
6. Check that hydraulic filters are of specified pore size.
7. Check that all fluids are as specified and filled up to maximum level.
3.4.5 Hydraulic System Start Up

This process addresses the initial start-up of the hydraulic system after a gear pump re-
placement.
1. Fill the hydraulic tank with clean hydraulic oil.
2. Pressurize the hydraulic tank to max. 0.35 bar (5 psi).
3. Bleed the air out of the pumps suction line(s) on the test port on the suction tube.
4. Refill the hydraulic tank if necessary.
5. Start the engine and let idle for 1-2 minutes.
6. Stop the engine.
7. Refill the hydraulic tank.
8. Set the pump pressure.
3.4.6 Hydraulic Oil
Oil Level
Maintaining sufficient oil in the hydraulic tank is always a significant factor in successful op-
eration. During operation a certain amount of oil can be lost due to:
n Normal seepage
n Escape of oil vapor
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In addition, leaks in the system may develop during operation. Daily or shift checks of the
hydraulic oil level allow prompt identification and correction of any problem.
If the oil level is neglected and allowed to fall, problems may occur which hamper efficient
performance of systems:
n If the oil level becomes too low, air may be drawn into the pump suction and contribute
to foaming. It may also cause cavitation, which can decrease the operating life of the
pump.
n Less oil in the system results in an increase in oil temperature due to the loss of heat
dissipating capacity. Such a rise in temperature imposes harder working conditions on
the pump, fluid motor and other moving parts such as control valves.
n A low oil level means an increased amount of air in the tank. That increases the rate of
oil oxidation and causes the loss of the initial properties of the oil.
! NOTE: When checking oil levels, be sure to distinguish between cold and hot levels,
which prevents over-filling.
Oil Storage and Handling

The manufacturers of hydraulic fluids are careful that no contaminants enter the fluid be-
fore the time that it reaches the customer plant. The same care must be followed in its stor-
age, handling, and use.
Dirt, water, lint, and contaminants of any kind can seriously impair the action of a hydraulic
system. This results in operational problems and excessive wear on both the pump and
valve components. To prevent the introduction of impurities into the fluid, the following
rules should be carefully observed:
n Store drums on their sides and under protective cover. Water collecting on the top of a
drum, even though it is sealed, gradually works its way through the bung seals and
into the fluid.
n Before opening a drum, clean the top carefully so that dirt not falls into the fluid.
n Inspect and keep cleaning all containers and equipment used for storage and dispens-
ing of hydraulic fluids.
n Before adding oil to a hydraulic system, wipe off the fill plug with a clean, lint-free cloth.
n Make certain that the fluid reservoir is protected against the admission of contami-
nants. Possible openings, which may provide entrance and must be checked include
fill plugs, inspection plate, vents, missing reservoir cover bolts, and seals around pipes
which extend through the cover of the reservoir.
Prevention of Foaming
Excessive foam in the hydraulic fluid, usually caused by one or more of the following:
n Oil level in the reservoir is too low, allowing the pump to draw air into the system.
n A leak in the suction line joints.
n The use of an improper type of hydraulic medium or a fluid that is too viscous.
n Deterioration of the fluid or the presence of harmful contaminants.
3.4.7 Brake Pedal Adjustment

Hub pressure is 103 bar and can be checked at the J-block. Pressure is adjustable using
the brake pedal heel stop.
104 No: 2522100363.3 en-US

To adjust, with machine on a level surface, release the parking brake. Put the machine in
first gear and roll the machine forward, adjusting pedal heel stop up until the service brakes
start to drag.
Then turn stop back down until machine rolls free and brakes are no longer dragging. Then
turn the stop 1/ 4 of a turn in and lock the lock nut.
! NOTE: Whenever the SAHR brake valve is replaced, it should be tested for dead band
and adjusted as necessary.
3.4.8 Cylinder Inspection

Check cylinders for pin and bushing wear. Repair is required when pin and bushing exceed
3.2-mm wear or movement.
n Check cylinder for damage to barrel and stem.
n Carefully inspect the inside surface of the cylinder and the condition of the pistons.
n When assembling the cylinder, use new packing, support rings, O-ring, and wiper ring.
Replace any part that is worn or damaged.
n Thoroughly wash all the parts of the cylinder assembly in a suitable solvent.
n Dry them with a clean, lint free cloth or with compressed air.
The steering stops must be checked at least every 250 hours or less. If they wear exces-
sively or break off, they can damage the steering cylinder, pins, and bushings, caused by
bottoming the cylinder out.
3.4.9 Pressure Settings and Adjustments
DANGER
Always install the articulation locking bar prior to testing any pressures on the
Minetruck.
WARNING
Pressure settings and adjustments require two (2) people. NEVER leave the
Minetruck running without a qualified operator in the cab.
Pump Priming and Adjustments
Prime Brake Pump

Whenever the pressure is relieved from the brake pump, a priming procedure must be fol-
lowed before the Minetruck can be operated.
1. Loosen and open (but do not remove the fitting all the way) the suction line to the
steering and dump pump.
105 No: 2522100363.3 en-US

A Brake pump outlet
B Brake pump housing
C Brake pump inlet
2. Pressurize the hydraulic tank either by filling it with hydraulic oil or by pumping air into
it through the quick fill disconnect.
3. Keep the fitting open until all the air is relieved out of the suction line.
4. After the line has been bled, tighten the fitting bolts on the pump.
NOTICE
Make sure that the O-Ring is properly seated and not being
pinched when the fitting is being retightened. Also, this is a
good time to inspect the O-Ring for damage before tightening
the fitting.
NOTICE
Make sure that there is oil at the pump inlet before starting the
engine at first start-up after pump replacement.
Prime Steering or Dump Pump

Whenever the steering or dump pump suction line is removed, prime it before operating the
Minetruck.
106 No: 2522100363.3 en-US

Follow the same procedure as listed for the brake pump.
Bleed Brakes
The MT2010 uses Spring Applied Hydraulic Release (SAHR) brakes that have a built-in
safety function. Hydraulic pressure forces open the SAHR brakes, allowing the axles to ro-
tate. The loss of hydraulic pressure causes the spring applied brakes to close, stopping the
machine. Therefore, if a brake line is cut, the machine stops.
Detail of remote brake bleed valve
CAUTION
The brakes must be bled while the engine is running, therefore the following
safety precautions are important.
1. Park the truck in a straight line on a level, hardened surface.
2. Block the wheels.
3. Place the articulation lock into the locked position.
4. Have a co-worker sit behind the wheel, engine running, with the parking brake off and
the foot brake not pressed.
107 No: 2522100363.3 en-US

Rear brake bleed valves
Installed bleed hose
5. Begin with the rear brakes. Position one end of the bleed hose in a bucket containing
hydraulic fluid.
CAUTION
It is important to secure the loose end of the bleed hose so that
it does not hang loose.
6. Screw in the other end of the hose on the bleed valve.
7. Bleed the brakes until the system is free of air bubbles.
8. Loosen and remove the bleed hose and continue to the next bleed valve.
108 No: 2522100363.3 en-US

Front brake bleed valves
9. After the rear brakes have been bled, move on to the front brakes.
10. After all four of the brakes have been bled, the machine can be returned to service.
Dump Valve Relief Settings

The dump and steering valves are fitted with over pressure control valves that will direct
the over pressure oil back to the tank. Each valve is equipped with a test port so that the
relief setting can be monitored. The following procedure is generalized and can be used for
both valves.
CAUTION
No pressure control valve should be set higher than the factory setting.
NOTICE
The main relief test and adjustment must be accomplished with the hydraulic oil
at operating temperature and the engine at high idle.
! NOTE: Test one valve at a time using the valve test port.
1. Plug the test gauge into the valve test port.
109 No: 2522100363.3 en-US

A Adjustment screw
B Dump valve test port
A Charging valve test port
B Adjustment screw
2. Start the Minetruck engine and let idle until the hydraulic oil has reached operating
temperature.
3. If checking the steering relief, articulate the mine truck, fully at idle speed, then in-
crease RPM to maximum. Keeping the steering control valve activated, observe, and
record the pressure. It should be 165 ±3 bar.
110 No: 2522100363.3 en-US

4. If checking the dump main relief, raise the dump box all the way up with the engine at
high idle and hold the dump lever forward. Check and record the pressure. It should
be 165±3 bar.
NOTE: It is not necessary to move the pressure gauge from the

! steering valve to the dump valve when checking the dump system
pressure, due to the Atlas Copco "Power Beyond" system.
Adjust Pressure
If the pressure is outside of the range, the main relief must be adjusted.
1. With the valve actuated, dump box up or steering engaged against articulation lock,
and the engine running at high idle, loosen, and remove the adjustment screw cover.
Steering valve relief adjustment screw
2. Loosen the locking nut.
3. Turn the adjustment screw until the pressure is applicable to the correct value.
4. Tighten the locking nut with the pressure now set correctly.
5. Replace the adjustment screw cover and observe the pressure gauge for a short pe-
riod to make sure that the setting is stabilized at the correct value.
3.5 Replace Hydraulic Components
3.5.1 Safety
The following procedures are intended to help with the removal of the major hydraulic com-
ponents. If service is required on an individual component, contact an authorized Atlas
Copco sales company or dealer for information.
First check cleanliness:
n Area around the vehicle
n Power units, pipe connections, components
n Hydraulic fluids
n Parts from stock
111 No: 2522100363.3 en-US

Watch out for contamination. Dampness or dirt from the surrounding environment must not
be allowed to enter the hydraulic tank. Fill tank only via a filter, preferably via system filters
or portable filter stations with fine filters (10 microns).
Do not mix Fire Retardant Fluid (FRF) with standard hydraulic fluids.
Protective internal paint coatings, if used, must be compatible with the hydraulic fluid used.
Be sure that all parts are on hand.
Parts from storage can develop a build-up of resin from protective oils and grease. This
resin must be dissolved with solvent before the part is installed.
Use lifting eye bolts and transportation equipment.
Do not use force. To prevent radial forces and tension on pipelines and components, en-
sure that pipelines are firmly secured.
Do not use putty or Teflon tape as a sealing material, as this can lead to contamination and
thus malfunctions.
Make sure that hose lines are correctly laid. Rubbing and touching of the lines must be
avoided.
Make sure that the correct oils are available. See "Fluids and lubricating greases" for cor-
3.5.2 Steering Cylinder
Remove Steering Cylinder
DANGER
When the articulation lock cannot be used, all hydraulic pressure in the
accumulators must be discharged before starting work on the steering cylinders.
112 No: 2522100363.3 en-US

1. Articulate the vehicle so that the cylinder to be removed is fully extended.
2. Follow the procedures to relieve the hydraulic pressure. See "Relieving Hydraulic
Pressure" on page 107.
3. Disconnect all cylinder hoses. Clean, label, and plug all cylinder and hose connec-
tions.
4. Attach a hoist or some type of rigging rated for the weight of the cylinder to support
the cylinder.
NOTICE
Protect the cylinder rod from damage during removal. Do not
place the jack stand on any machined surface of the cylinder.
5. Loosen and remove the retaining bolts and caps on each end of the cylinder.
6. Remove both cylinder pins.
7. Hoist the cylinder out of the way and place it on the shop floor or a suitable work
stand.
Reinstall Steering Cylinder

Follow the removal steps in reverse.
Operate the Minetruck to bleed any air out of the system before starting work with the vehi-
cle.
3.5.3 Dump Cylinder
Remove Dump Cylinder
DANGER
The dump cylinders are heavy and pose a crushing hazard. Use a hoist or jack
capable of supporting the cylinders before disconnecting them.
DANGER
The dump box must be securely supported before relieving pressure. Always
install the dump box support stand when working under a raised box.
113 No: 2522100363.3 en-US

The dump cylinders require a lifting device to support and lower the cylinder to the ground.
Determine how the cylinder is handled before removing.
1. Raise the dump box several centimetres and support the cylinders so they do not bot-
tom out and wedge in their respective clamps.
2. Lower the box onto the supports with the dump lever in float position to prevent pres-
sure build-up in the cylinder.
3. Secure the cylinders in place.
! NOTE: Make sure that cylinder is free of grease or oil before secur-
ing with strap to prevent it from slipping.
5. Disconnect all cylinder hoses. Clean, label, and plug all cylinder and hose connec-
tions.
6. Disconnect, label, and plug the lubricating lines to both cylinder pins.
7. Loosen and remove the pin retaining bolts and nuts and remove the top pin.
NOTICE
Be careful not to damage the dump cylinder pin lubrication line
connector during removal and replacement.
114 No: 2522100363.3 en-US

8. With the cylinder supported by an appropriately rated hoist or stand, loosen and re-
move the bottom retaining pin bolts and nuts.
9. Hoist the cylinder to the floor. Place the cylinder in an area away from traffic so that it
can safely be stored or serviced.
Refit Dump Cylinder

Refit the cylinder in reverse order.
1. Refit cylinder with all stems fully retracted.
2. Place lower pin first. Once all hydraulic hoses are connected, it is easy to extend the
cylinders slowly by using the dump lever. To position the cylinder to insert the top re-
tainer pins, insert and tighten pin retainer bolts and nuts.
3.5.4 Hydraulic Pumps
Remove Pump
2. Remove the hoses and plug lines.
3. Remove the mounting bolts, and slide the pump off the forward pump stub shaft.
4. Cover open stub shaft assembly to keep clean.
Replace Pump
Refit the pump in reverse order.
n Tighten hardware to proper values.
n When assembly has been correctly completed, proceed with priming, start-up, and
functional testing.
115 No: 2522100363.3 en-US

3.5.5 Hydraulic Valve
Remove Hydraulic Valve

The following procedures are generalized and apply to the removal or replacement of most
valves.
CAUTION
Some valves are very heavy. Care must be taken to avoid injury while removing
them.
1. Steam clean the area around the valve to be removed.
NOTICE
Make sure that the area around the valve is clean and free of
debris. Valves are susceptible to damage from dirt or grime
being introduced into the hydraulic system due to dirty service
conditions.
3. Disconnect, cap or plug, and label all hydraulic hoses to the valve.
4. Cap or plug the inlets, pressure ports, and pilot ports to prevent contamination.
5. Attach a hoist cable to the valve for support while removing the mounting bolts.
6. Loosen and remove the valve mounting bolts.
7. Lift the valve up onto a workbench. Do not place the valve in a position where it can
be damaged.
Reinstall Hydraulic Valve

Refit the valve in reverse order.
Service of Valve Cartridge
NOTICE
The most common cause of failure is dirt in the hydraulic oil.
n Dirt which lodges in the working parts and interferes with their operation.
n Dirt introduced due to filter bypass.
Most cartridges can be cleaned without altering their settings.
To check and clean a cartridge which is not functioning:
1. Remove the cartridge from the cavity.
116 No: 2522100363.3 en-US

2. Inspect for visible contaminants and carefully remove obvious particles.
3. Through the nose of the cartridge, manually operate the inner working parts several
times. Use a piece of plastic tubing to avoid damaging soft seats, sharp edges, fin-
ished surfaces or the screen protecting the pilot orifice. All parts should move freely. If
possible, do this with the cartridge submerged in clean mineral spirits.
4. After "flushing", blow dry with clean filtered air.
5. Replace seals if indicated, using the appropriate service kit.
6. Dip the cartridge in clean hydraulic oil, then fit the cartridge, tighten to specified tight-
ening torque and retest.
7. If this procedure does not eliminate the problem, replace with a new factory-tested
cartridge.
NOTE: Service kits are available for the cartridges. Contact your
! Atlas Copco dealer for information on cartridge seal replacement
and or cartridge replacement.
Remove Hydraulic Manifolds

It is not necessary to remove any valve manifolds from the Minetruck since the functional
part is a cartridge. See "Service of valve cartridge" on page 130.
If it becomes necessary to remove a valve manifold, follow these generalized instructions:
2. Bleed the hydraulic tank, and drain it into a tank of appropriate size. The oil is not suit-
able for reuse.
3. Clean, label, disconnect, and plug all hoses and harnesses to the manifold.
4. Loosen and remove the bolts that secure the manifold.
5. Remove the manifold.
Reinstall Hydraulic Manifolds

Follow the removal procedures in reverse order.
117 No: 2522100363.3 en-US

118 No: 2522100363.3 en-US

Minetruck MT2010 4 Power Unit
4 Power Unit
4.1 Introduction
This section covers all the major components of the power unit. This section will not cover
any major rebuild or disassembly of the engine itself.
For information about service and repair on the engine, see OEM manuals.
The power unit is supported by the following systems:
n Fuel system
n Engine oil system
n Electrical system
n Cooling system
n Air intake system
n Exhaust system
119 No: 2522100363.3 en-US

4.2 Fuel System

Efficient engine operation depends upon correct 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 these factors are, however, none is more important than the quality of
the fuel. Diesel fuel must meet strict requirements and specifications.
4.2.1 Fuel System Components

The fuel system is composed of:
n Fuel tank
n Fuel Pump
n Fuel filter
n Check valves
n Supply and return lines
n Control valve
n Fuel heat exchanger
4.2.2 Fuel Flow

Fuel is drawn from the tank by the fuel lift pump via the fuel/water separator filter. Fuel is
then pumped through the secondary filter into the fuel chamber in the cylinder head to
each Electronic Unit Injector (EUI). Excess from the filter then flows out from the fuel cham-
ber through a restrictor and check valve to the fuel cooler for cooling. The fuel then flows
back to the diesel tank.
Fuel supply lines provide fuel for injection and cooling. The injectors supply fuel to the com-
bustion chamber.
The engine Electronic Control Module (ECM) receives data (such as temperature and
speed), analyses this data, and modulates the fuel system accordingly to ensure efficient
engine operation. The signal that the ECM sends to the electronic unit injector determines
the timing and amount of fuel that is delivered to the engine.
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4.2.3 Fuel Tank
A Refueling
B Fuel tank meter
The fuel tanks on any diesel installation are as important as the other components of the
fuel system. The fuel supply tank and fuel lines must receive the same careful mainte-
nance that the other parts of the engine and fuel system receive.
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Carelessness when filling fuel tanks can allow dirt to get into the fuel system. It takes little
dirt to damage fuel injection pumps and injectors, and the repair of these engine compo-
nents can be expensive.
NOTICE
Always use the strainer when filling the tank.
! NOTE: Fuel is taken from the bottom fittings on a fuel tank to provide the most air-free
fuel as possible and to utilize the full tank capacity.
4.2.4 Fuel Supply Pump
Fuel Pump
The fuel pump supplies fuel to the injectors through the filter and the engine ECM during
engine operation.
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4.2.5 Injectors and ECM
Fuel injector
ECM
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The Electronic Unit Injector (EUI) is a lightweight, compact unit that injects diesel fuel di-
rectly into the combustion chamber. The amount of fuel that is injected and the start of in-
jection timing is determined by the engine electronic control module (ECM). The ECM
sends a command pulse which activates the injector solenoid valve. The EUI has four func-
tions:
n Creates the high-fuel pressure required for efficient injection.
n Meters and injects the exact amount of fuel required to handle the load.
n Atomizes the fuel for mixing with the air in the combustion chamber.
n Permits continuous fuel flow for component cooling.
Engine combustion is obtained by injecting, under pressure, a small quantity of accurately
metered and finely atomized fuel oil into the cylinder. Metering and timing of the fuel is ac-
complished 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 trapped in the in-
jector body and under the plunger. The continuous fuel flow through the injector prevents
air pockets in the fuel system and cools those injector parts that are subjected to high com-
bustion temperatures.
4.2.6 Fuel Filter
A Primary Fuel Filter
B Secondary Fuel Filter
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NOTICE
Only use fuel which is free from dirt particles and water to extend life of the fuel
system.
The life and effective operation of any diesel fuel system depends upon fuel which is free
from dirt particles and water. Diesel fuels are higher in viscosity than gasoline because
diesel fuels must be able to provide lubrication for many parts of the fuel system. However,
diesel fuels also contain more gums and abrasive particles which are difficult to extract dur-
ing refining. Therefore, be sure to use filters that meet OEM specifications.
The fuel filters are located in the front of the cabin or canopy. The fuel filter canister con-
tains a single-use cartridge. The bottom of the canister has a drainage tap for releasing the
water and the sediment that collect at the bottom of the filter shell.
4.3 Engine Oil System

The major components in the Minetruck engine oil system are:
n Oil Pump
n Oil filter
n Oil cooler
n Oil fill and dipstick
n Pressure gauge
4.3.1 Lubrication Pump

The oil lubrication pump is a gear driven pump that is mounted at the front right-hand side
of the cylinder block. It is gear driven off the engine crankshaft.
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4.3.2 Oil Filter
Engine oil filter

On the MT2010, the engine oil filter is mounted behind the oil dipstick tube on the right-
hand side of the engine, below the air intake canisters. The filter is the disposable spin-on
type that requires changing every time the engine oil is changed.
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4.3.3 Oil Cooler
Oil cooler
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4.3.4 Oil Dipstick and Fill
A Topping up with engine oil
B Engine oil level dipstick
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4.4 Cooling System
4.4.1 General
Radiator fan assembly

The radiator and the thermo regulated fan disperse the heat that the engine generates. A
centrifugal type water pump circulates the engine coolant. Two thermostats fully block the
flow of coolant for fast engine warmup and to regulate temperature. To obtain better com-
bustion the charge air cooler uses engine coolant to control the temperature of the intake
air.
4.4.2 Cooling System Function
Normal Operating
When the engine is at normal operating temperature, the coolant passes from the cylinder
block up through the cylinder head, through the thermostat housing and into the upper por-
tion of the radiator.
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The coolant then passes through a series of tubes. The revolving fan and the motion of the
vehicle creates an air flow there which is lowering the coolant temperature.
Cold Start
Upon starting a cold engine or when the coolant is below operating temperature, the closed
thermostats direct coolant flow from the thermostat housing through the bypass pipe to the
water pump. Coolant is recirculated through the engine to aid engine warmup.
When the thermostat opening temperature is reached, coolant flow is divided between the
radiator inlet and the bypass tube. When the thermostats are open, all the coolant flows to
the radiator inlet.
The engine coolant absorbs the heat, developed as a result of the combustion process in
the cylinders, from component parts such as the valves and pistons which are surrounded
by water jackets.
In addition, the heat that is absorbed by the oil is also removed by the engine coolant in the
oil-to-water oil cooler.
Pressurized System
A pressurized cooling system permits higher temperature operation than a nonpressurized
system. It is important that:
n The cooling system is kept clean and leak-free
n The filler cap and pressure relief mechanisms are properly installed and operate cor-
rectly
n The coolant level is properly maintained.
As the engine temperature increases, the coolant and air in the system starts to expand
and build pressure. The valve in the radiator pressure cap unseats and allows the coolant
to flow into the surge tank. When the engine starts to cool down, the air and coolant con-
tract, causing a void and creating a vacuum in the system. The vacuum unseats another
valve in the radiator pressure cap, allowing the coolant to flow back into the expansion tank
or radiator.
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4.4.3 Coolant Recommendations
Coolant tank sight glass

Atlas Copco recommends using either a 50/50 mixture of good quality water and fully for-
mulated antifreeze or fully formulated coolant when filling the cooling system.
The fully formulated antifreeze or coolant must meet TMC RP329 or TMC RP330 specifica-
tions.
Good-quality water is important for cooling system performance. Excessive levels of cal-
cium and magnesium contribute to scaling problems and excessive levels of chlorides and
sulphate cause cooling system corrosion.
Water Quality
Calcium Magnesium (Hardness) Maximum 170 ppm as (CaCo3 + MgCO3)
Chloride 40 ppm as (Cl)
Sulphate 100 ppm as (SO4)
For further information on fluids and greases, see document "Fluids and greases" included
in the documentation supplied.
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4.4.4 Corrosion Inhibitor
Corrosion inhibitor filter

The corrosion inhibitor filter is located in front of the engine, and offers extra protection
when used with the correct coolant.
In extremely hot environments, clean, soft, properly inhibited water may be used if supple-
mental corrosion inhibitors are also added in the right concentration. If water is used, sup-
plemental coolant additive levels should be increased from 3% to 6% by volume.
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4.5 Air Intake System
4.5.1 Overview
1 Inlet for unfiltered and dirty air
2 Plastic tube around the filter
3 Pre-separation process
4 Clean and filtered air outlet
5 Outlet valve for pre-separated particles
Process
1. Unfiltered and dirty air is sucked into the air intake system.
2. The plastic tube around the filter reinforces the pre-separation process by leading the
air into a rotary motion.
3. Clean air is transferred through the filter outlet.
4. Pre-separated particles are transferred to the outlet valve.
Maintenance
Regularly check that no dirt and particles are visible inside the air intake pipe to the turbo
or the pipes to the charge air cooler.
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4.5.2 General
Air intake canister

The air intake system fulfils two primary functions:
n Provides clean, contaminant-free combustion air to the engine.
n Provides forced-air cooling to the engine and various sub-systems.
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4.5.3 Function
1 Dirty outside air inlet
2 Filtered Air to Engine
3 Primary filter element
4 Safety Filter
5 Evacuation valve
The function of the air filter is to remove abrasive airborne particles from the air, furnishing
a supply of clean air to the engine. The air filter is of vital importance to engine life and per-
formance.
In the event of accidental perforation of the primary filter, the safety element protects the
engine. It also protects the engine during service of the primary element.
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4.5.4 Air Filter
NOTICE
Always service the air filter system with the engine stopped. The engine can be
severely damaged with dust and debris.
An adequate supply of clean, filtered air is necessary to maintain correct fuel and air ratios,
resulting in a cleaner burning engine.
Free flow of air to the intake manifold must not be restricted in any way. The maximum
pressure drop through the intake system, at full throttle and no load (approximately 2200
rpm) should not exceed specified engine manufacturer’s recommendations.
The filter should be cleaned or replaced when the "change filter" message is shown in the
gauge cluster display.
4.5.5 Turbo Charger
Turbo Charger
The turbocharger is designed to increase the overall efficiency of the engine.
Oil for lubricating the turbocharger is supplied under pressure through an external oil line
extending from the oil filter adapter to the top of the centre housing.
The following figures explain the engine intake air and exhaust flow.
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Engine air flow
1 Air Intake
2 Compressor
3 Charge Air Cooler
4 Cylinder
5 Exhaust Manifold and Cylinder Head Porting
6 Turbine
7 Turbine Exhaust Outlet
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Turbo air flow
1 Ambient Air Inlet
2 Compressor Wheel
3 Compressed Air Discharge
4 Exhaust Gas Inlet
5 Turbine Wheel
6 Turbine Exhaust Outlet
n Engine Exhaust Air Flow
n Compressed Air Flow
n Fresh Air
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4.6 Exhaust System
4.6.1 General
Exhaust outlet with heat shield

The purpose of the exhaust system is to discharge engine exhaust gases in a safe direc-
tion, purify exhaust, and to reduce engine noise.
The exhaust system is composed of:
n Silencers
n Tubing
n Catalytic converter
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4.6.2 Catalytic Converter
A Catalytic converter
B Exhaust silencer
The exhaust silencer acts in the same manner as a silencer on a car. A double-walled con-
struction together with a special gasket reduces the engine noise that is emitted by the
combustion cycles without suppressing the exhaust gas flow. Back pressure that is caused
by an exhaust restriction could lead to engine damage. The silencers should therefore be
inspected frequently and serviced or replaced when a restriction is detected.
The catalytic converter reduces the amount of carbon monoxide, hydrocarbons, and diesel
odor that is emitted from the combustion process of the engine.
4.7 Electrical System
4.7.1 Engine Control Module (ECM)

The ECM is located on the engine, on the left-hand side of the machine.
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Location of the ECM

The ECM has the following connections:
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A Supply voltage
B Engine socket/connector
C OEM socket/connector
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4.7.2 Temperature and Pressure Sensors
A Fuel pressure
B Thermostat (on the rear)
C Engine coolant temperature (on the rear)
D Intake manifold, pressure
E Ambient air, pressure
F Crankshaft position
G Oil pressure
H ECM (engine control module)
I Fuel pump control device
J Camshaft position
The following sensor components are connected to the engine electrical system:
n Oil Temperature
n Coolant level
n Intake manifold, pressure, and temperature
n Ambient air pressure
n Engine position / Crankshaft rotation speed
n Water in fuel
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n Throttle pedal
n Engine oil pressure
n Engine coolant temperature
n Fuel pump control device
n Common rail pressure
n Camshaft position
4.8 Replacing Power Unit Components
4.8.1 General
NOTE: This section contains removal and replacement instructions covering the en-
! gine and its support systems. Maintenance procedures on the engine are included in
the engine’s Service manual. Preventive maintenance is covered in this manual. See
"Chapter 2: Preventive Maintenance" on page 3.
Before starting work on the vehicle:

n Always read the "Safety manual" and the "Operator’s Manual" to work with and park
the vehicle correctly.
n Install articulation lock prior to lifting the vehicle.
n Attach a "Do Not Operate" tag to the ignition switch.
DANGER
Kneel the machine. See "Relieving Hydraulic Pressure" on page 107.
DANGER
Not preparing the machine properly can cause death or serious injury.
! NOTE: Hydraulic pressure will still be high. Use extreme caution while removing hy-
draulic components.
WARNING
If the engine has been running within the previous hour, the temperature of the
radiators can be high enough to cause serious burns.
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4.8.2 Exhaust System
CAUTION
The exhaust system reaches extremely high temperatures when the vehicle is in
use. Allow at least 30 minutes for the engine to cool before removing the exhaust
cover panels.
Remove Exhaust System
A Exhaust Shields
B Hood
1. Remove all the exhaust hoods and heat shields from the exhaust tubes.
2. Loosen the exhaust tube clamps.
3. Loosen and remove the exhaust mounting bolts.
4. Remove the exhaust system and place on a shop bench or on the floor.
Refit Exhaust System

CAUTION
Replace the heat wrap if it is torn or if it has been in contact with fluid.
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4.8.3 Radiator Cooling Package
WARNING
If the engine has been running within the previous hour, the temperature of the
radiators can be high enough to cause serious burns.
NOTICE
Steam clean the radiator and engine compartment prior to removing anything
from the cooling package.
Remove Cooling Package
A Engine radiator and transmission cooler
B Hydraulic oil cooler
1. Place a suitable container under the radiator drain port hose and slowly remove the
drain plug. The cooling system holds about 140 litres.
2. Remove the top engine to radiator coolant tubes from the radiator.
3. Remove the lower engine to radiator coolant tubes.
4. Remove the fan belts from the fan drive and tension pulleys.
5. Attach a lifting device to the lifting eye on the top of the radiator housing.
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6. Loosen and remove the mounting bolts on both sides of the radiator.
7. Lift the radiator package out of the engine compartment, taking care to make sure that
all lines and wiring are clear and not hung up on the cooling package, and place on
the shop floor. Take care not to lay the radiator assembly flat, rather stand it up so
that the radiator itself is protected from damage.
Reinstall Cooling Package

Inspect all rubber tubing for wear or damage. Replace with new ones if worn.
When the radiator cooling package is refitted, replace the coolant with new clean fluid. See
"Fluids and lubricating greases" for correct coolant specifications.
4.8.4 Air Intake System
Intake tube clamps
NOTICE
Before removing the air intake system from the engine, steam clean the area
around the intake tubes. It is important to keep all dust and debris away from the
intake manifolds and tubes when removing them from the engine.
Remove Air Intake System

1. Remove the engine compartment cover.
2. Loosen the clamps that hold the intake manifold to the intake manifold of the engine.
3. Pull the rubber tubes from the intake manifold tubes.
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Reinstall Air Intake System

NOTICE
Before fitting the rubber tubes, inspect them for damage or excessive wear.
Install new tubes if damage is found.
NOTICE
As with the removal procedures, make sure that no dirt or dust is introduced to
the intake system when fitting the tubes.
4.8.5 Engine Package
DANGER
Safety Precaution
u The engine package is heavy. Do not reach or lean underneath the engine as it is be-
ing removed or reinstalled.
CAUTION
Do not remove the engine package until it has cooled.
Remove Engine Package

1. Steam clean the engine and engine compartment.
2. Remove the exhaust system covers, the torque converter to transmission cardan
shaft cover and the engine compartment cover.
3. Follow the procedures to remove the exhaust tubes from the engine.
4. Follow the procedure to remove the fuel lines.
5. Follow the procedures to disconnect the cooling hoses and tubes from the engine.
6. Disconnect the torque converter to transmission cardan shaft.
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A.Brake cooling pump
7. Remove the brake cooling pump. There is no need to disconnect the hydraulic hoses
from the pump.
! NOTE: There is engine oil in the pump pad area, take care to col-
lect the oil in an appropriate container while removing the pump.
8. Disconnect and label all electrical connections. Be sure to move the wiring harnesses
clear from the engine and make sure that they will not be hung up when the engine is
lifted out of the frame.
! NOTE: While it is a good idea to drain all the engine oil, it is not
necessary to drain the oil before removing the engine.
9. Loosen and remove the engine mounting bolts.
10. With a hoist appropriate to the engine weight, lift the engine out of the engine com-
partment and place on an engine stand.
Refit Engine Package

After servicing the engine, clean it thoroughly before refitting.
1. If the crankcase oil was drained, replace with new engine oil and new oil filters.
2. Replace the engine coolant with new coolant. See "Fluids and lubricating greases" for
correct coolant specifications.
3. Tighten the engine mounting bolts to the proper torque.
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4.8.6 Fuel System Components
DANGER
Diesel fuel is highly flammable. Do not smoke while servicing the engine, also
take care to not expose the fuel system to an open flame.
WARNING
It is dangerous to loosen a pressure pipe! The fuel pressure can be up to 1950
bar!
Service and repair is only to be done on the low-pressure fuel lines. The high-pressure
lines are only to be serviced by authorised personnel.
When working with fuel lines it is important to maintain high cleanliness, to prevent failure
on fuel pumps and injectors. See "Fuel system" on page 5.
Remove Fuel Filters

For information about removing and replacing the fuel filter, See "Fuel filter" on page 23.
Remove Fuel Valves and Lines

Remove a fuel valve or line as follows:
1. Clean the fuel valve or ends of the fuel line and the surrounding area.
2. If the component to be removed is after the secondary fuel filter, turn the filter fuel line
valve to the OFF position.
3. Disconnect the component and remove it.
Refitting Fuel Valves and Lines

1. Make certain that the connections are clean, both on the component to be replaced
and the components to which it connects.
2. Install the component.
3. Turn the fuel valve to the ON position.
4. Prime the fuel system.
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4.8.7 Electronic Control Module
Removing ECM
The ECM is on the right-hand side of the engine.
1. Disconnect the cables from the ECM.
2. Unscrew and remove the four (4) screws that hold the ECM.
NOTE: The electronic control module is an integral part of the en-

! gine package. Refer to the engine manual for removal and replace-
ment information.
Refitting ECM
Reinstall the component in the reverse order of removal.
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Minetruck MT2010 5 Electrical System
5 Electrical System
5.1 Introduction
Atlas Copco Minetrucks use a 24-Volt electrical system. Onboard computers control electri-
cal and hydraulic components. An environmentally sealed wiring harness connects the
subsystems that support efficient performance.
When the machine is started, various microprocessors perform diagnostic routines and
promptly report discrepancies to the operator via alarms and lights. As the Minetruck is
driven, sensors continuously monitor conditions and send data to the control systems that
evaluate and make adjustments.
When the engine is running, the alternator provides the necessary electrical current to
power the systems and to maintain a charge on the batteries.
5.1.1 Circuit Schematics

n The electrical ladder diagram illustrates the logic of a given circuit, providing a concep-
tual overview.
n The electrical wiring schematic provides exact information of all system and compo-
nent wiring connections.
Electrical Ladder Diagram

The electrical ladder diagram is a representation of the logical operation of the machine
and not a physical representation of the harnesses.
It provides the most effective means of viewing the complete electrical system and its inter-
actions with other system devices. It is also a valuable tool for diagnosing and trou-
bleshooting electrical problems.
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Once a problem has been isolated from the overall system, use the specific harness and
component drawings and wiring diagrams to resolve the issue.
Electrical Wiring Diagram

All electrical circuits on Atlas Copco machines are numbered in the following manner:
n Circuit numbers change only when they have made a transition through an electrical
component, such as a relay coil, knob, or switch contact.
n Circuit numbers do not change when they cross devices such as tie points, terminal
blocks, or connectors.
Electrical ladder and wiring diagrams are provided in the Atlas Copco Parts Books.
5.2 System Components
5.2.1 General
The machine electrical system includes:
n Wiring harness
n Component box
n Battery isolation switch
n Charging and ignition system
n Machine running lights
n Horn
The electrical system also supports various microprocessors that monitor and control ma-
chine efficiency and alert the operator to possible problems.
5.2.2 Harness
The machine is equipped with a sealed electrical system designed to withstand operating
temperatures of 90 °C and surges up to 300 volts.
The wiring splices are dip soldered and protected with waterproof heat shrink tubing. In ar-
eas where abrasions can occur, the wiring harnesses are protected with a braided sleeve
or spiral wind.
5.2.3 Battery Isolation Switch
NOTICE
Turn the battery isolation switch to OFF position before welding on the
Minetruck. Failure to disconnect the battery from the electrical system before
welding causes severe damage to the computerized components of the engine
and electrical system.
! NOTE: Turning the battery isolation switch off while the machine is turned on can
cause a catastrophic failure to the electronic modules.
The battery isolation switch is located outside the canopy or cab. When turned to the off
position the electrical system is disconnected from the battery and alternator. The knob is
protected from the environment by its sealed housing.
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The main purpose of the knob is to disconnect the battery from the machine so that main-
tenance can be safely conducted on the machine.
n Turn the knob to the left to switch off
n Turn to the right to connect
Canopy, Battery Isolation Switch
Cab, Battery Isolation Switch
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5.2.4 Component Box

The component box houses circuit breakers for the ECM, alternator, and the control panel.
It also contains the starter solenoid, accumulator pressure switch, torque converter pres-
sure switch, parking brake pressure switch, brake light pressure switch, and the transmis-
sion clutch pressure switch.
See the electrical ladder diagram in the Parts Book for information that is specific to this
machine.
Canopy
Component box (A1) on the right-hand side of the operator
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Component box (A20) near Battery Isolation Switch
Cab
Component box (A1) behind operator seat
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Component box (A20) near Battery Isolation Switch
5.2.5 Circuit Breakers

There are two groups of circuit breakers that are located in component box A1 and A20.
Extra circuit breakers may be in the electrical circuit if optional equipment requires.
The circuit breakers are designed to pop out when an electrical overload condition exists.
When it happens, the operator must inform the maintenance personnel. A tripped fuse can
be a symptom of a serious problem. The tripped circuit should be checked before placing
the Minetruck back in service.
5.2.6 Batteries
The battery system is two series-connected 12-volt batteries that provide 24 volts for driv-
ing the starter motor and initialization of the ECM. A fuse on battery positive cable protects
the starter motor from overloads. The battery isolation switch is attached to the negative
cable to isolate the battery and alternator from the electrical system.
5.2.7 Alternator
The alternator is a fully enclosed unit that has a built-in regulator and it is brushless. The
alternator has two functions, it provides electrical current for machine operation and
charges the battery as the machine is operating. The battery charging function requires
about 20% of the full load capacity of the alternator. The alternator is over-sized to provide
this margin when the engine is running at high idle.
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5.2.8 Starter
The starter system is made up of two relays and a solenoid that allows electrical current to
flow through the system.
The first relay (K100) is located in the control panel in the machine canopy or cabin. It al-
lows current to flow to the on-board control units when the ignition is turned to the "ON" po-
sition.
The second relay (K301) is in the component box A20. It opens the circuit between the bat-
teries and the starter motor solenoid to engage the starter solenoid, actuating the starter
motor, and gears to engage the engine flywheel.
5.2.9 Canopy/Cab Controls

The machine has different types of controls that are enclosed from environmental influ-
ence. See attached Operator’s Manual for additional information.
Parking Brake
Parking brake
The parking brake button/indicator illuminates when the parking brake is applied.
The MT2010 is equipped with an electronic brake latching safety circuit. The circuit acti-
vates the parking brake automatically. Either upon loss of brake accumulator pressure
(96.5 bar), low torque converter oil pressure (4.1 bar), or when power to the parking brake
solenoid is interrupted. To release the parking brake after it has set automatically, push the
parking brake button, then pull the parking brake button out.
The following are the reasons that the computer systems apply the parking brake:
n Electrical failure
n Transmission pressure drops
n Accumulator pressure drops
n Transmission in neutral
Whenever a failure causes the parking brake to be applied, the parking brake button must
be pushed to reset the circuit after solving the problem.
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SAHR Brake Override Button
Canopy, brake override button
Cab, brake override button

The SAHR brake override system releases the brakes for towing. To tow the machine,
press and hold down the override button in the operator cab. There must be an accumula-
tor pressure of at least 10.3 bar in order for the override system to work.
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The system consists of an on-board manual hydraulic pump for pressurizing the accumula-
tor and an SAHR brake override. The system is activated from the operator seat by push-
ing and holding the button.
If there is not enough pressure available in the accumulators, use the hand pump to
recharge the accumulator pressure. The pump has a built-in safety valve to prevent over-
pressurizing the brake housings.
Releasing the override button immediately vents hub pressure to the hydraulic tank, apply-
ing the brakes.
CAUTION
Care should be taken not to push the SAHR brake override button when entering
or exiting the vehicle. This will cause accidental release of the brakes.
CAUTION
There must be a operator in the cab of the Minetruck when towing.
NOTE: If towing the Minetruck a long distance, it might be necessary to use the hy-
! draulic hand pump several times, to maintain enough pressure to keep the parking
brakes released.
5.2.10 Vehicle Running Lights

The headlights of the vehicle are placed for optimum safety and work performance.
The headlights are installed on the front of the vehicle and on the rear of the load frame.
The headlights are positioned so that optimum visibility can be maintained. They are also
adjustable for easier aiming.
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Rear running lights
5.2.11 Signal Horn

The horn is located in the front of the Minetruck and is activated by a pushbutton on the
control panel.
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5.2.12 Reversing Alarm
A Reversing alarm
B Warning back-up beacon
The back-up alarm, in the rear of the vehicle, is activated when the transmission is placed
in reverse. A flashing yellow light accompanies the audible alarm to ensure that bystanders
are aware of the vehicle.
5.3 Vehicle Computerised Control Units
5.3.1 General
The computerized control units are the brains of the vehicle. They are responsible for mon-
itoring the engine performance, the transmission gears, system status, inputs from the ve-
hicle operator, and the output of all diagnostic data. The computerized control units include
the following:
n Programmable Logic Controller (PLC)
n Engine Electronic Control Module (ECM)
n Gauge cluster (UIP)
Programmable Logic Controller

The programmable logic controller (PLC) is a microprocessor that receives input from the
operator, the engine ECM, and the UIP. The PLC outputs to the gear shift solenoids, the
gear indicator, the brake, and torque converter lock-up solenoids.
The PLC operates on a ladder logic program to operate the back-up alarms and head-
lights, and to either release or apply the parking brake. The parking brake activation pro-
gram relies on four (4) criteria that are continuously monitored:
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Pos. Parameter
Parking brake Activation by operator
Transmission pressure 4.1 bar
Accumulator pressure 96.5 bar
Power failure Failure or battery isolation switch activation
If a system pressure falls below its normal parameter, the parking brake is set. The parking
brake solenoid is continuously energized while the vehicle is in operation. If electrical cur-
rent is removed from the solenoid, the parking brakes are applied. The parking brake acts
to remove the power when pressed by the operator.
Electronic Control Module
ECM
The engine electronic control module (ECM) is an engine-mounted computerized logic con-
trol device that provides overall engine management.
The ECM continuously performs diagnostic checks and monitors other engine systems.
The ECM controls engine speed and power, injection timing, governing, torque shaping,
cold start logic, fuel supply, diagnostics, and engine safeguards.
The ECM system includes the following components:
n Electronic Control Module
n Engine Speed Sensor
n Engine Wiring Harness
n System sensors
n Diagnostic interfaces
n Communication links
See OEM documentation, Atlas Copco system diagram, and the attached Atlas Copco
spare parts catalogue for further information.
164 No: 2522100363.3 en-US

System Sensors
The ECM sensor system is designed to provide information about the engine various per-
formance characteristics. The ECM uses the information to regulate the engine efficiency,
give diagnostic data, and to activate engine safeguards. Consult the OEM engine manuals
for sensor locations. Typical engine sensors include:
Turbo boost sensor
The turbo boost sensor gives the ECM information on the exhaust system for use in smoke
control.
Fuel pressure sensor
The fuel pressure sensor provides the ECM with data concerning the fuel pressure which
allows the system to warn the operator of impending power loss.
Oil pressure sensor
The oil pressure sensor activates the engine protection system when the pressure is out-
side the safe operating parameters.
Coolant pressure sensor
The coolant pressure sensor informs the ECM when the coolant pressure becomes too
low, which is in turn relayed to the operator.
Crankcase pressure sensor
When the crankcase pressure becomes too high, the pressure sensor tells the ECM to ini-
tialize engine protection safeguards.
Coolant temperature sensor
The coolant temperature sensor monitors coolant temperature and indicates to the ECM
when the temperature becomes too high. The ECM then activates the engine protection
system when the temperature exceeds specified parameters.
Fuel temperature sensor
The fuel temperature sensor measures fuel temperature for the ECM and EUI. Fuel con-
sumption calculations and input compensation is based on the information that is provided
by the fuel temperature sensor.
Air temperature sensor
Hot idle speed and injection timing calculations are affected by inputs from the air tempera-
ture sensor. The ECM adjusts to improve cold starts and reduce white smoke emissions
that are based on the input signals of the air temperature sensor.
Oil temperature sensor
The oil temperature sensor feeds information to the ECM about the operating oil tempera-
ture which, when too high, allows the ECM to activate the engine protection systems.
Coolant level sensor
The ECM receives the coolant level from the coolant level sensor and initializes engine
protection measures when the coolant level gets too low.
Throttle position sensor
The throttle system is a function of the engine ECM and operates in the same way as a
sensor. As the foot activated variable position sensor is engaged by the operator, a signal
is sent to the ECM. The ECM adjusts fuel injection and timing, which is based on the input,
thus accelerating the vehicle or slowing it down.
165 No: 2522100363.3 en-US

Diagnostics Interfaces
All problems that occur with the engine are stored in the ECM memory. The ECM diagnos-
tic interface is located in the operator cab under the control panel and can be accessed
with a Cummins Quick Check.
Canopy, diagnostic coupler
Cab, diagnostic coupler

Communication Links
166 No: 2522100363.3 en-US

The engine ECM has two external data links, the first to the Cummins Quick Check and the
second goes to instrumentation. ECM internal communication lines are connected to sen-
sors and control units on the engine.
Gauge
The gauge cluster is installed in the control panel. It is equipped with warning lights that are
illuminated so that the operator can see the warnings in dark conditions. The warnings are
also shown on the display. The gauges receive data from the ECM and depending on their
purpose, display information as a dial type gauge.
! NOTE: There is much information that is displayed in a digital read out on the gauge
cluster. Scroll through to get to the correct area.
5.4 General Maintenance Diagnosis & Calibration
5.4.1 General
The electrical system of diesel-powered equipment requires periodic inspection and main-
tenance.
NOTICE
Always turn off the battery isolation switch (as a minimum precaution) whenever
working on an electrical problem on the machine.
NOTE: It is highly recommended to disconnect all battery cables and place all fuses
! and circuit breakers in the open position when doing any extensive electrical work on
the machine.
WARNING
Never disconnect the leads between battery, alternator, and voltage regulator
when the engine is running.
To achieve a properly functioning and reliable electrical system it is important that periodic
checks are made to inspect for:
n Water, oil, and dirt intrusion
n Corrosion of wiring terminals and devices
n Excessive wear on wire insulators due to vibration, tension, or excessive heat
Whenever repairing an electrical harness or device, use the manufacturers recommended
tools such as wire crimpers and insertion and removal tools. An electrical repair that is
done improperly will not only reduce the system’s reliability, but may contribute to further
electrical damage.
Wire harnesses should never be disconnected by pulling or yanking on the wires them-
selves. This can lead to a premature failure of the wire terminal, contact, or the connector
itself.
167 No: 2522100363.3 en-US

It is also important to disconnect all electronic components that might be susceptible to

damage caused by welding.
DANGER
Always make sure that the welding machine is grounded before attempting to
perform any electric welding
Never interchange the battery connections.

When washing the engine, protect the alternator and voltage regulator from water.
5.4.2 Computerized Diagnostic Systems
General
There are some diagnostic interfaces in the Minetruck computerized electrical systems.
The programmable logic control has a visual illuminated display. The engine ECM has a
Cummins Quick Check that can be plugged in, and diagnostic text in the gauge cluster.
Programmable Logic Controller
NOTICE
The PLC needs at least 20 V to function. If the voltage is lower than 20 V, then the
PLC does not function and the "Power" and "Run" lamps will not be illuminated.
NOTE: If the power does fail and the outage applies the parking brake and not button
! activation then the parking brake lamp flashes. To reset the brake system, the button
must be cycled ON and OFF with the engine running.
The PLC is located in the main component box in the operator cab and can be accessed
by removing the mounting screws in the cover of the box. The function of the PLC can be
checked by observing the LEDs on the outer casing of the unit. As an input is made by ap-
plying or releasing the parking brake, activating the gear shift or a corresponding light is il-
luminated. The following charts indicate the numerical code that is displayed by the PLC:
! NOTE: The numbers in the <> brackets indicate that the light is not illuminated.
Failure
If a series of lights on the PLC fail, check the following before replacing the PLC unit:
n All wiring to the PLC
n Motor Status Relay
n Pressure Loss Relay
Both relays are located in component box A1,
The following table shows the inputs and outputs of the PLC:
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Input Description Output Description
X0 Y0 Torque converter lock solenoid
X1 Torque converter rotation speed Y1 Reverse (R61)

input signal
X2 Tachometer input Y2
X3 Neutral brake apply Y3 First gear (611)
X4 Y4 Second gear (612)
X5 Y5 Third gear (613)
X6 Locking knob Y6 Neutral (NTS)
X7 Parking brake Y7 Parking brake solenoid (33)
X10 Y10 Light interlock (option)
X11 Y11 Parking brake indicator
X12 Engine status Y12 Ashanti lights off (option)
X13 3rd and 4th gear block out Y13 Signal Horn
X14 Transmission reverse Y14
X15 Transmission forward Y15 Secondary parking brake solenoid

(36)
X16 Transmission in neutral Y16
5.4.3 Batteries
The batteries are located under a hood between the front wheels.
Selecting and installing the batteries is the first step to maintaining high performance.
Installation
1. Be sure the battery to be installed has a capacity at least equal to the electrical re-
quirements of the machine. An under capacity battery results in poor performance
and premature failure.
2. Be sure the battery, whether wet or dry, is at full charge when installed.
3. When installing, avoid physical abuses and over-tightening or under-tightening of the

battery hold-down.
Periodic Service
1. Maintain electrolyte level to cover top of plates. Do not over-fill.
2. Keep the battery terminals, cables, and battery top clean. A lubricant that is not metal-
based covering the cable pole clamp reduces acid corrosion.
3. Be sure that battery cables are secure and in good condition.
4. Check periodically for container, cover, cable, and post damage.
169 No: 2522100363.3 en-US

5. Test periodically with hydrometer or OCV tester to determine call state of charge, or
load tester for overall battery condition.
6. Check machine generating system to prevent over-charge or under-charge damage.
7. Check condition and tightness of battery hold-down.
Cable Terminals and Hold Downs

Battery acid can corrode terminals and expose cable.
On machines that are equipped with voltage regulators, the alternator voltage is main-
tained within a narrow range. The resistance due to corrosion keeps the battery from re-
ceiving the proper charging current and gradually causes an under-charged, sulfated bat-
tery.
n Corroded contact surfaces of all clamp terminals and battery terminal posts should al-
ways be cleaned with a wire brush to ensure a perfect contact. Keep corrosion on ter-
minals from dropping into battery cells.
n It is good practice when replacing terminals to lubricant them with a heavy mineral or
petroleum lubricant. Do not apply an excessive amount.
n Do not hammer clamp terminals onto battery posts. It can result in severe damage to
the hard rubber cell covers and sealing compound.
n Replacement cables should be of sufficient length to reach the terminal posts without
causing undue strain on the post and covers. Cables that are too taut causes damage
to posts, and cause sealing compound to crack, leaking acid.
n The battery should rest level in the container and be fastened securely in place by a
suitable hold-down. Tighten hold-downs evenly from each end to prevent distorting or
breaking the container.
n Before connecting the cables, check the polarity of the terminals of the battery to be
sure that the battery is not reversed. The tapered positive terminal of the battery is 1.6
mm (1/16 in.) larger at the top than the negative terminal, and that the opening of the
positive cable clamp is correspondingly larger.
n Connect the "grounded" terminal last. Be careful not to place clamp terminals and ca-
bles in such a position that they interfere with removal of vent plugs or hold-downs.
Battery Fluid
n Water used in the batteries must be distilled. Do not use mineral waters.
n Adding water to a cell lowers the specific gravity of the electrolyte, but it does not
mean that the cell has lost any of its charge.
n Watch for batteries that require excessive water. The need for excessive water may be
an indication of a charging system which is out of adjustment. It could indicate that the
battery is being subjected to the damaging effects of over-charging.
Tropical Climate
Batteries that are operated at high temperatures in tropical climates are usually provided
with electrolyte of about 1.225 specific gravity (Sp. Gr.) when fully charged. The weaker the
acid, the less damaging to separator fins and battery fins and results in longer battery life.
A tropical climate is defined as an environment in which the water never freezes.
Factors Affecting Battery Life

n Over-charging
n Under-charging
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n Lack of water
n Freezing of electrolyte
n Age
n Daily maintenance
n Improper installation
n Improper Capacity (Installation of a battery with a lower capacity than the electrical de-
mands of the machine)
Detecting Potential Failures

Few batteries fail without some warning. Identifying the signs of potential battery failure,
through visual inspection and testing, increases battery service life and may prevent
greater trouble or expense later.
Visual Inspection
The outside appearance of a battery is an important indicator for judging its performance
and expected life. Signs of potential battery failure include:
n Age
n Cracked container
n Leaking acid
n Cracked or raised cell covers
n Loose or corroded terminal posts or cable connections
Testing
Potential battery failures are not always detectable from visual inspection. You cannot see
a bad cell, so all batteries must be tested approximately once a month to reveal the hidden
defects that cause battery failure. Several easy tests can be made as follows:
Cell Charge Test: Hydrometer

1. Turn off all headlights and accessories.
2. Remove cell cover caps. Do not add water now.
3. Fill hydrometer several times until float rides free.
4. Take readings from each cell. Return electrolyte to cell.
5. Record and interpret readings as follows:
a. All cells read above 1.230 SP.GR. and specific gravity readings in each within 50
points. Battery is OK!
b. Cells that are read below 1.230 SP.GR and specific gravity readings within 50
points. Battery needs recharge (and retest).
c. A spread greater than 50 points SP.GR. between cells. Battery is at point of fail-
ure. Replace.
Cell Charge Test: Capacity Tester

1. Take specific gravity reading. Do not test battery with specific gravity readings below
1.230 at 27 °C (80 °F). Recharge the battery, then proceed with capacity test.
171 No: 2522100363.3 en-US

2. Connect tester clips to battery posts. Red to positive, black to negative.
3. Set the slider to VOLT. Read the pole voltage on the upper scale. Minimum reading
for 12-volt battery: 12.6 volts.
4. Set the slider to AMP. Turn control knob to the right until (yellow) ammeter scale
reads the battery ampere hour capacity. If ampere hour capacity of battery is un-
known, use 50-ampere hour rating for 12-volt battery. Hold for 15 seconds only.
5. Set slide switch to VOLTS position, and read voltage under load scale. Minimum
reading for 12 voltage battery is 9.6 volts.
a. If test reading is in green (or OK) section of the voltage under load scale, the bat-
tery is in good condition.
b. If test reading is in red (or LOW) section and specific gravity of all cells is above
1.230, the battery is wearing out and should be replaced. If specific gravity of
cells is below 1.230, recharge the battery and retest.
c. If test reading drops down to near zero and one or more cells bubbles, battery is
not serviceable and should be replaced.
Cell Charge Test: Booster Cables

1. Connect red cable (positive) to positive battery post on dead battery, and positive post
on fully charged battery.
2. Connect black cable (negative) to negative post on dead battery. Connect black cable
to the negative post on fully charged battery. Leave engine of charging vehicle run-
ning when starting a vehicle with a dead battery.
When disconnecting cables, disconnect the cable from the fully charged battery first.
CAUTION
If cables are connected wrong on a vehicle, the alternator can be seriously
damaged.
Storage of Lead Acid Batteries

Because of their corrosive behavior, all batteries, when placed in storage, begins to dis-
charge slowly. If allowed to go unchecked, the average battery discharges to the point of
non-recovery in about 6–8 months.
As the battery sits, the sulphuric acid generated by the chemical reaction taking place in-
side the battery core begins to warp the battery plates. If electric current (charging) is not
directed into the battery to reverse this process the battery plates will warp beyond repair,
and render the battery useless. It is recommended to charge the stored batteries at least
once every 4–6 weeks.
5.4.4 Alternator
Alternators normally require little servicing. They should be tested at least once a year to
ensure that they are providing the proper voltage and amperage. If an alternator fails to
meet specifications, it must be replaced.
172 No: 2522100363.3 en-US

Servicing an alternator, instead of replacement, is usually limited to replacing the brushes

and cleaning the slip rings.
Because of the high load capacity and inertia of the heavy rotor that is usually used, proper
belt tension on an alternator is important. Improperly adjusted, worn, or damaged drive
belts are a major cause of alternator failure.
Belt tension should be adjusted according to the engine manufacturer recommendations.
Slip Rings and Brushes

The slip rings are cleaned with a 400 grain (or finer) polishing cloth.
! NOTE: Never use emery cloth to clean slip rings.
If the slip rings are out-of-round or the brushes are worn close to the holders, then the al-
ternator is removed and repaired or replaced.
Precautions to be observed when servicing systems using alternators:
n Reversed battery connection damages the rectifiers, vehicle wiring, or other compo-
nents of the charging system.
n Battery polarity must be checked with a voltmeter to assure that it conforms to the re-
quired. Note which terminal post is connected to ground before reinstalling a battery.
All units have negative ground.
n If booster batteries are used for starting, they must be connected properly to prevent
damage to the system.
n Make sure the negative (-) terminal of the booster battery is connected to the negative
(-) terminal of the machine battery, and the positive (+) terminals are connected to-
gether.
n Care must be taken when connecting a “fast charger.”
n Remove the battery ground strap before charging. It is not advisable to attempt to start
the vehicle by using the “fast charger” as a booster under any condition.
n Do not attempt to polarize the alternator. No polarization is required. Any attempt to do
so results in damage to the alternator, regulator, or circuits.
n The field circuit must not be grounded at any point.
n Grounding of the field damages the regulator. Be careful when working near the elec-
trical system.
n Grounding of the alternator output terminal damages the alternator and circuit compo-
nents.
n The regulator must be equipped with a circuit breaker. If not equipped, then the termi-
nal is “HOT” even when the system is not in operation. Grounding can cause consider-
able damage.
n Do not ground the adjusting tool to the regulator base when adjusting voltage unit or
other regulator components.
n The adjusting tool must be insulated.
n Be careful to use the batteries of higher-than-system voltage, either to boost a battery
of lower voltage or in starting.
n Never leave the higher voltage battery in the system. When used for boosting, discon-
nect the vehicle battery ground. When used for starting, disconnect the high-voltage
battery when machine is started.
n Alternators must not be operated on open circuit with the field winding energized. High
voltages result, causing possible rectifier failure. Make sure that all connections are se-
cure.
173 No: 2522100363.3 en-US

5.5 Replace Electrical Components
5.5.1 General
To replace the gauges, switches, lights, relays, fuses, circuit breakers, horn, and solenoids
follow these general procedures:
n Disconnect the battery by switching off the battery isolation switch (isolation of the bat-
tery).
n Ensure that the replacement unit is a 24-volt OEM compatible part.
n Use care to replace the wiring connectors to their correct receptacle on the new part.
NOTE: All the electrical connectors are designed so that they can only be attached to
! their receptacle in one way. Do not attempt to force any connectors on to any recepta-
cles.
5.5.2 Transducers
1. Disconnect the battery by turning off the circuit breaker (battery isolation switch).
2. Relieve the hydraulic pressure.
3. Ensure that the replacement unit is a 24 volt OEM compatible part.
4. Use care to replace the wiring connectors to their correct receptacle on the new part.
CAUTION
The hydraulic system is a high-pressure circuit, over 140 bar. The pressure must
be bled off before replacing the transducers.
5.5.3 Engine Sensors

1. Let the engine cool.
2. Disconnect the battery by turning off the circuit breaker (battery isolation switch).
3. Ensure that the replacement unit is a 24-volt OEM compatible part.
4. Use care to replace the wiring connectors to their correct receptacle on the new part.
CAUTION
Coolant temperature is hot and can scald or burn exposed skin. Take care to let
the engine cool prior to replacing any sensor on or around the engine.
5.5.4 Starter
1. Disconnect the battery by turning the battery isolation switch off.
2. Disconnect the positive lead on the battery.
174 No: 2522100363.3 en-US

3. Disconnect the starter wiring and lay it aside.
4. Remove the starter mounting bolts and pull the unit out.
5.5.5 Batteries
Remove Battery
1. Set the battery isolation switch to OFF.
2. Open the battery box.
3. Remove the negative connector from the battery "A".
4. Remove the positive connector from the battery "B".
5. Remove the cable connecting both batteries to one another.
6. Remove battery hold down clamps.
7. Attach a battery lift sling to the battery and remove it from the battery box.
Replace Battery
1. Attach a battery lift sling to each battery and place it in the battery box.
2. Place and secure hold down claps.
3. Install connecting cable to both batteries.
4. Install the positive connector on the battery "B".
5. Install the negative connector on the battery "A".
6. Close the battery box.
7. Set the battery isolation switch to ON.
5.5.6 Alternator
Remove Alternator
1. Remove the batteries according to instruction:
CAUTION
Always remove the batteries before removing the alternator.
Even if the battery isolation switch is in off position there is
power in the alternator.
2. Set the battery isolation switch to OFF.
3. Disconnect the electrical connectors from the alternator.
4. Loosen the alternator belt adjustment and remove the drive belt.
5. Remove the bolt that secures the adjustment mechanism to the alternator.
175 No: 2522100363.3 en-US

6. While holding the alternator, remove the two bolts that secure it to the motor mount.
7. Remove the alternator.
Replace Alternator
1. Place the alternator in position on the engine bracket and insert the two bolts that se-
cure it to the bracket. Screw on the two nuts and tighten moderately tight.
2. Reinstall the bolt that secures the adjustment mechanism to the alternator and tighten
it moderately tight.
3. Reinstall the alternator drive belt and tighten the alternator belt adjustment to the belt
specifications.
4. Torque the adjustment mechanism bolt and the engine bracket bolts.
5. Reconnect the electrical connectors to the alternator.
6. Set the battery isolation switch to ON.
5.6 Display
176 No: 2522100363.3 en-US

5.6.1 Settings
Display Settings
1 Display
2 Mode button
3 Set button
Use the "Mode" button to scroll through the different settings in the display settings. When
the desired setting is found, use the "Setting" button to show the value.
5.6.2 Fault Codes
! NOTE: The system only displays Active fault codes. Inactive requires connection of
PC-based Diagnostic Tools.
To show the error display, press the "Mode" button until "FAULTS" is shown in the display,
then press "Set" button.
n If there are no faults present, the screen displays "NONE".
n If there are faults present, the first received fault is displayed in the following manner:
! NOTE: The screen cycles between three screens for the current fault. Each screen will
be displayed for 3 seconds before displaying the next screen.
1. Source - the "SRC XXX" screen displays the numeric source address of the device
with the current fault. SRC 00 is the source code for the Engine ECM. SRC 03 is the
source code for the Transmission TCU.
2. Suspect Parameter Number - The "SPN XXX" screen displays the numeric SPN of
the fault.
3. Parameter Identifier - The "FMI XX" screen displays the numerical value for the fault.
5.6.3 Warning Lights
Warning Indicators Color Input Pin Wire
Axle Temp and Press Red Sourcing J1-15
Check Transmission Amber Sinking J1-4
Wait to start (Preheat) Amber J1939 J1-3 J1939
177 No: 2522100363.3 en-US

Engine coolant White J1939 J1939
Check Engine Amber J1939 J1939
Stop Engine Red J1939 J1939
Ride Control Green Sourcing J1-16 RDC
Dropbox Temperature Red Sinking J1-1
Hydraulic Level and Tempera- Red Sinking J1-5 48

ture
Box Up / Tailgate White Sourcing J1-17
Parking brake Red Sinking J1-11 31
RRC Active Amber Sourcing J1-13 RRC
Torque Converter Lock Up Green Sourcing J1-14
Change filter CHG/FLT Sinking J1-12 45
5.6.4 Directional Lights
Directional Indicators Color Input Pin Wire
Reverse Amber Sinking J2-8 61R_INV
Forward Amber Sinking J2-7 61R_INV
Neutral Amber Sinking J2-6 61R_INV
Automatic Amber Sinking J2-9
Manual Amber Sinking J2-10
5.6.5 Parameters
Parameters Display Input Value Range
Transmission Temperature TRS_TMP 950-26 Ohm 0–150 °C
Transmission Pressure TRS_PRS 0.5-4.5 Volt 0–28 Bar
Engine temperature ENG_TMP J1939 Digital 0–120 °C
Engine oil pressure ENG_OIL J1939 Digital 0–8 Bar
Voltage VOLTAGE 20-32 Volt 0–32 V
Brake Accumulator Pressure ACC_PRS 0.5-4.5 Volt 0–276 Bar
Fuel level FUEL_LV 240-30 Ohm 0–100 %
Hydraulic Temperature HYD_TMP 950-26 Ohm 0–120 °C
Vehicle Speed SPEED J1939
Engine RPM TACH J1939 Digital 0–3000 RPM
178 No: 2522100363.3 en-US

Turbo Pressure TURBO J1939 Digital 0–2 Bar
Throttle pedal position ACC_POS J1939 Digital 0–100 %
Engine load ENGLOAD J1939 Digital 0–100 %
Remote Throttle Pedal REM_ACC J1939 Digital 0–100 %
Engine Torque ENG_TRQ J1939 Digital 0–100 %
Fuel rate FUEL_RT J1939 Digital 0–50 L/H
Barometric Pressure BAR_PRS J1939 Digital
Intake manifold temperature MAN_TMP J1939 Digital 0–150 °C
Change Engine Air Filter CHG_FLT Sinking Gnd
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180 No: 2522100363.3 en-US

Minetruck MT2010 6 Power Train
6 Power Train
6.1 Power Train Components

The power train is engineered to perform reliably within the close quarters and harsh condi-
tions inherent in underground mining.
The power train includes the following:
n Transmission
n Cardan shafts
n Axles
n Rims and Tires
The external engine to upbox connection is reinforced with a strong brace for added rigid-
ity, and is firmly supported through shock resistant pads to the main frame.
6.1.1 Transmission
The transmission that is used is a "Full Powershift". Selection of gear, direction, and speed
take place electrically by push buttons that are on the steering joystick.
Transmission components include:
n Control valves
n Torque converter
n Lock-up clutch
n Gear sets
n Hydraulic clutches
181 No: 2522100363.3 en-US

Gear Selector Switch

The gear selector switch is an electro-mechanical control unit.
Torque Converter
The torque converter consists of three elements:
n Impeller
n Turbine
n Stator
The impeller is the input element and is driven directly by the engine. The turbine is the
output element and is hydraulically driven by the impeller. The stator is the reaction ele-
ment (the torque increasing element). When the impeller is rotating faster than the turbine
the torque converter amplifies the torque. When the turbine approaches the speed of the
impeller, torque multiplication stops and the torque converter functions as a fluid coupling.
Lock-Up Clutch
The lockup clutch is located inside the torque converter and consists of three elements:
n Piston
n Clutch plate
n Push plate
The piston and backplate are driven by the engine. The clutch plate, which is located be-
tween the piston and the push plate, is splined to the torque converter turbine. The lockup
clutch is hydraulically engaged and released in response to electronic signals from the
PLC. The lockup clutch engages when the vehicle or equipment reaches a predetermined
speed.
Connection of the lockup clutch provides a direct drive from the engine to the transmission
gearing. This eliminates torque converter slippage to provide maximum fuel economy. The
lockup clutch releases at lower speeds (and momentarily during shifts).
When the lock-up clutch is released, drive from the engine is transmitted hydraulically
through the torque converter to the transmission’s gearing. The lockup clutch also releases
when the PLC detects certain undesirable conditions.
6.1.2 Cardan Shafts

The purpose of the cardan shaft is to transmit power from the engine to the drive axles. At-
las Copco equipment uses both non-telescoping and telescoping drive axles, and drive
axle support bearings.
All the drive axles have a universal joint that is at each end to permit pivoting and accom-
modate angularity between two intersecting shafts.
Telescoping shafts have a splined slip joint to compensate for movement between the con-
nected components.
When a telescoping shaft runs at an angle to its mating shaft or yoke, it slips in and out
slightly. It does this to compensate for the working action of the universal joint as it rotates.
The slip joint accommodates these variations by telescoping at the spline portion of the
shaft. The slip joint shaft is necessary in the swivel hinge area of the Minetruck. The articu-
lation point of the Minetruck which allows the vehicle to turn. The drive axle telescoping
feature eliminates tension forces that could develop in conventional designs.
182 No: 2522100363.3 en-US

Universal Joint Bearings
Universal joint bearings

Universal joints employ various types of bearing assemblies. They are specified on any
particular Minetruck that is based on their torque loading capabilities.
Drive Axle Support Bearings

Drive axle support bearings are used at locations where a cardan shaft passes through a
frame bulkhead, usually at the amidships area or in the middle of a long span.
Cardan shaft support bearings are mounted to a frame cross member. These bearings re-
quire regular lubrication and are provided with lube fittings for that purpose.
The support bearings are lubricated directly unless the truck has the remote lube option.
183 No: 2522100363.3 en-US

Drive axle support bearing with remote lube
6.1.3 Axles
The front and rear axles have spiral bevel type ring gear and pinion with further reduction
provided by planetary gear set within the wheel hub.
For additional information about how to repair the axles: see the attached digital OEM doc-
umentation for additional information.
184 No: 2522100363.3 en-US

Rear axle
All the including parts for the axles are found in the spare parts catalogue.
Primary Reduction
The spiral bevel pinion and ring gear transmit power through the centre differential pinions,
side gears and to the drive axles. The spiral bevel differential assembly is mounted on ta-
pered roller bearings. The tapered roller bearings are adjusted by positioning of the two
threaded adjusting nuts that are mounted in the differential carrier and cap assembly. The
tapered roller pinion bearing preload is adjusted and maintained by a hardened and preci-
sion ground spacer that is positioned between inner and outer bearings.
Secondary Reduction
In the wheel hub, a self-centring sun gear is spline fitted to the drive axle and drives three
planetary pinion gears. These gears in turn mesh with and react against a rigidly mounted
internal ring gear. The planet gears rotate on needle roller bearings that are mounted on
hardened and ground pins that are located in the planet carrier which in turn drives the
wheel hub. Positive lubrication keeps all moving parts that are bathed in lubricant to reduce
friction, heat, and wear.
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6.1.4 Rims and Tires
Tires
An effective wheel and tyre maintenance programme can pay significant dividends in im-
proved productivity and longer tyre life.
This chapter identifies several major areas to consider in establishing a tyre and wheel
maintenance program:
n Rim and tyre inspection and maintenance
n Air pressure inspection
n Rolling radius and tyre sizing
n Driving practices
The following are important, but are not covered within this chapter:
n Records maintenance
n Mechanical and driver training
n Access to rim and tyre handling equipment
n Road maintenance and tyre life
Inspection and Maintenance

Wheels must be visually inspected for signs of rust, cracking or other damage that would
reduce their reliability. Small rocks and dirt get into shallow cuts in the tread and if ne-
glected are gradually pounded through the cord body. Neglected cuts can cause separa-
tion of tread and/or plies.
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 that is lodged in the cut.
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Then use a sharp, narrow-bladed knife and cut away the rubber around the cut to form a
cone-shaped cavity extending to the bottom of the cut. The sides of the cavity should be
slanted enough to prevent stones from wedging into it.
Tires with tread cuts treated in this manner may be continued in service without danger of
further growth of these injuries.
Large cord body breaks over 1/3 of the width of the tyre cannot be economically repaired
for use in normal service.
! NOTE: Keep tires free from oil, grease, and fuel. Never clean tires with petroleum
products. If a petroleum product gets on a tyre, promptly flush off or wipe off with water.
Correct Tyre Inflation

The importance of correct inflation in off-road tires cannot be overemphasized. Poor tyre
maintenance almost always results in under-inflated tires and therefore unnecessary tyre
expense.
! NOTE: Inflation pressures are based on the standard Minetruck configuration and the
off-road rating by the tyre and rim association Inc.
Over-Inflation Results In:

n Excessive cutting
n Lower impact resistance
n Rapid centre wear
n Cut growth
n Poor retread ability
Under-Inflation Results In:

n Ply and tread separation as a result of excessive heat build-up.
n Cracking and excessive flexing.
n Bead failures from excessive strain.
n Tubeless liner separation from heat.
n Rapid wear from tread disfiguration.
n Rapid wear from heat reduces the resistance to cutting and wear of the tread rubber
compound.
Rolling Radius and Tyre Sizing
NOTICE
Never fit different-sized tires on a Minetruck.
When the rolling radius of tires on the same axle is different, they are not rotating at the
same speed. This sets up a continuous stress on the axle components which is relieved by
tyre skid.
When the rolling radius difference occurs between the front and rear axles on a four-wheel
drive vehicle, this additional stress is amplified throughout the entire power train.
187 No: 2522100363.3 en-US

Improper inflation is the most common cause of a difference in rolling radius. Two identical
tires which are not equally inflated have a different rolling radius.
Other reasons for a difference in the rolling radius would be the use of different-sized tires
or unequally worn tires on the vehicle.
Atlas Copco Inc. recommends that the tyre rolling radius tolerances be matched as shown
in the following equation:
! NOTE: If the difference is larger than 2%, one side of the no-spin disengages (the
smaller tyre). The other side carries all the torque.
Example:
30" RR tyre +/- 4% = 31.2” RR to 28.8” RR.
Driving Practices
A proper tyre maintenance program and maintaining haulage ways in good condition can-
not guarantee optimum service life of tires. Poor driving practices are a major cause of ex-
cessive wear and permanent damage.
Drivers can help to reduce tyre costs by:
n Avoiding obstacles and keeping away from chuck holes or other hazards, which can
damage tires.
n Not climbing or driving up on the ore pile. Such practice subjects tires to cutting and
concentrated impact.
n Preventing excessive braking. Heat developed by braking may be transferred to the
tyre beads (and/ or inner liner of tubeless tires) causing these areas to become
charred or cracked.
n Not letting tires rub against side walls or against barriers erected to facilitate unloading.
n Avoiding taking turns at high speeds and driving in the lowest gear applicable.
! NOTE: The driver who drives carefully and who makes a reasonable attempt to pre-
vent tyre damage saves a substantial amount of money on tyre costs.
6.2 Replacing Power Train Components

n Always read the "Safety manual" and the "Operator’s Manual" to work with and park
the vehicle correctly.
n Install articulation lock before lifting the vehicle.
DANGER
Release the brake accumulator pressure and the hydraulic tank pressure. See
"Relieving Hydraulic Pressure" on page 107.
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DANGER
Not preparing the vehicle properly can cause death or serious injury.
! NOTE: Hydraulic pressure is still high. Use extreme caution while removing hydraulic
components.
WARNING
Hot surfaces! Allow all components to cool before initiating removal procedures.
6.2.1 Transmission
Remove Transmission
DANGER
The transmission is very heavy. Do not allow anybody under the transmission
when it is raised.
NOTICE
Before removing the transmission assembly, steam clean the area around the
component.
! NOTE: Always tag and plug each hose as it is removed to prevent contamination of the
hydraulic system and transmission and to facilitate the refitting of the components.
! NOTE: Identify and label all hoses and wiring before removing them from the transmis-
sion. This allows the faster fitting of the transmission.
1. Disconnect, cap, and tag all hoses to the pumps on top of the transmission.
189 No: 2522100363.3 en-US

Hose connections on top of the transmission
2. Disconnect, cap, and tag the transmission cooling hoses.
3. Remove the input, the front axle, and the rear axle cardan shafts. See "Remove and
install cardan shafts" on page 71.
4. Disconnect all necessary hoses or valves preventing easy removal.
5. Disconnect and tag all electrical lines to the transmission.
6. Attach the lifting cables around the transmission firmly.
7. Remove all mounting bolts.
8. Lift the transmission carefully out of the frame.
9. Place the transmission package on a suitable stand or work bench.
Fit Transmission
Fit the transmission package in the reverse order to removal.
NOTICE
Take care not to crush the hydraulic tubes that are attached to the frame on the
right-hand side of the transmission compartment.
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6.2.2 Cardan Shafts
DANGER
Make certain that all wheels are blocked securely before removing a cardan shaft
section.
NOTE: Most cardan shaft sections are removed and replaced in similar manners. How-
! ever, for ease in locating procedures and precise coverage of minor differences, the
following paragraphs contain procedures for each cardan shaft section.
NOTE: In each of the following replacement procedures, the procedure assumes that
! the Minetruck is in the same condition and position as at the conclusion of the associ-
ated removal procedure.
191 No: 2522100363.3 en-US

Phasing Cardan Shaft
Check the drive axle

When a splined shaft is assembled to a slip yoke, the splines must be aligned so that the
yokes at either end of the shaft are in the same plane, that is, "in phase". Drive axles are
phased and balanced at the factory and are "marked" for correct assembly with match
marks at the yoke flange ends and on the output shaft.
Lubricate the splines thoroughly, and assemble and "phase" the shaft correctly.
Misphasing the drive axle can cause vibration throughout the cardan shaft, contributing to
bearing failure.
Installing Drive Axle

Install the drive axles with the slip yoke toward the source of power (torque). Reverse in-
stallation if doing it provides better access to the lube fitting on the slip yoke.
! NOTE: The lube fitting on each of the universal joints and the fitting on the slip yoke
should all be on the same side of the shaft for ease of servicing.
Yokes and Bearing Mountings

Precondition 1. To assemble the cross and bearing assembly to a yoke, insert the key of one trunnion
cap into the keyway of the yoke flange.
2. Insert the key of the opposite trunnion cap into the yoke. The trunnion cap has ma-
chined surface keyway, so some compression of the seals may be required to seat
the second bearing. This can be done using a C clamp, tapping with a soft hammer,
or by using hand pressure.
! NOTE: Do not use bearing mounting cap screws as jacking screws

to seat the bearing in the yoke.
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3. Once the bearings are properly seated, insert the cap screw fasteners and torque
them to the proper values using a suitable torque wrench.
NOTE: Do not use lock washers, lock plates, or lock wire to secure
! the fasteners. These devices do not prevent the fasteners from
loosening. Proper torquing is the most reliable method of securing
fasteners.
Installing Cardan Shaft Guards

Cardan shaft guards help restrain a drive axle when a universal joint fails. The guard pre-
vents the drive axle from rotating out of control within the frame of the Minetruck and dam-
aging other components, and causing possible injury to personnel.
If the Minetruck lacks cardan shaft guards, it is recommended that these devices are fabri-
cated and installed on the Minetruck or ordered from Atlas Copco.
DANGER
Always make sure that there is a cardan shaft guard that is installed around or
over the midship drive axle. This guard provides protection for the driver.
Remove and Install Cardan Shafts
NOTICE
It is always a good idea to clean the work area before removing or fitting a
component.
! NOTE: The midship cardan shaft must be disassembled to be removed. To fit the car-
dan shaft, it must first be phased to ensure correct balance.
Auto Removal
1. Remove any cardan shaft guards that could be in the way of the removal steps.
2. Wrap several layers of masking tape around the bearings on the front universal joint
cross.
3. Remove the bolts that secure the front universal joint cross to the output component
yoke. Make certain that the tape holds the bearings in place on the cross.
4. Wrap several layers of masking tape around the bearings on the rear universal joint
cross.
5. Remove the bolts that secure the rear universal joint cross to the input component
shaft yoke. Make certain that the tape holds the bearings in place on the cross.
6. Remove the cardan shaft section.
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Installation
1. Place the cardan shaft section in approximate position.
2. Reinstall the bolts that secure the rear universal joint cross to the input component
shaft yoke, but do not tighten yet. Remove the tape from the bearings on the cross.
3. Reinstall the bolts that secure the front universal joint cross to the output component
yoke, but do not tighten yet. Remove the tape from the bearings on the cross.
4. Inspect the positions of the bearings. If all are in the correct position, torque the bolts.
See "Tightening Torques" on page 178.
6.2.3 Axles
DANGER
Ensure that the method used to elevate the vehicle is stable and capable of
raising and supporting the weight.
DANGER
The Minetruck must be placed on cribs or suitable supports before removing the
axles.
DANGER
The axles must be supported before removal from the vehicle.
Removal Preparation
1. Relieve all pressure from the hydraulic system by venting at the breather and/or loos-
ening the tank cap.
2. Clean the axle and surrounding area with a power washer or steam cleaner. Take
care not to damage hoses or wires while cleaning the area.
3. Disconnect, cap, or plug all hydraulic lines from both wheel ends.
4. Remove the cardan shaft following the steps that are outlined in See "Remove and in-
stall cardan shafts" on page 71.
5. Drain differential and planetaries. See "Remove and install cardan shafts" on page
71.
Remove Front Axle

1. Locate two flat level surfaces under the front frame where jacks can be placed to
raise the power frame of the vehicle.
2. Raise the Minetruck until the tires are no longer touching the ground.
194 No: 2522100363.3 en-US

3. Remove the tires.
4. Place suitable supports under the vehicle and axle making sure that the front end is
stable and not rocking on the supports.
5. With the axle supported, loosen and remove both suspension cylinder trunnion caps.
6. Lower the axle slowly to the ground taking care not to entangle any electrical lines or
hydraulic hoses as the axle assembly is lowered.
7. Slide the axle out from under the vehicle and place it on stands for disassembly.
Fit Front Axle

Follow the removal steps in reverse order.
Tighten all bolts.
! NOTE: The SAHR brake system will need to be bled after the system has been recon-
nected. See "Relieving Hydraulic Pressure" on page 107.
Remove Rear Axle

Precondition 1. Raise the dump box to give better clearance to the rear axle.
DANGER
Install the dump box support stand prior to working in the axle
area.
2. Loosen and remove the axle mounting bolts.
3. Slowly lower the axle, taking care to keep it from becoming entangled in hoses and
wires, to the floor so that it can be set aside.
4. Pull the axle out from under the rear frame and place it on the floor or an appropriate
stand.
Fit Rear Axle

Fit the rear axle in the reverse order to removal. Tighten the mounting bolts.
! NOTE: The SAHR brake system will need to be bled after the system has been recon-
nected. See "Relieving Hydraulic Pressure" on page 107.
6.2.4 SAHR Brakes

See OEM instructions for disassembly and assembly of the SAHR brakes.
195 No: 2522100363.3 en-US

6.2.5 Tyre Mounting Procedures
General
DANGER
Tyre and rim servicing can be dangerous, and should be done by trained
personnel using proper tools and procedures.
DANGER
Failure to comply with these procedures may result in faulty positioning of the
tyre and/or rim. Air pressure and heat from normal operation are adequate to
cause rapid disassembly, with explosive force, if the parts are damaged or
improperly installed.
196 No: 2522100363.3 en-US

The arrow in the image shows the direction that wheel parts can fly, with explosive force, if
installed improperly or if parts are damaged.
Tires and Wheels, Safety

If the tyre and wheel assembly is removed from the vehicle, always put it into a tyre infla-
tion cage before adding air.
Wheel Inspection
Precondition p Inspect wheel components for defects, observing the following precautions:
1. Clean rims and repaint to prevent corrosion and to facilitate inspection and tyre
mounting. Be careful to clean all dirt and rust from the lock ring and gutter. It is impor-
tant to lock the lock ring into the correct position. A filter on the air pump equipment to
remove moisture from air lines helps to prevent corrosion. The filter should be
checked periodically to be sure that it is working properly. Parts must be clean for a
proper fit, particularly the gutter section which holds the lock ring in proper position.
2. Check the rim for cracks. Replace all cracked, badly worn, damaged, and severely
rusted components with new parts of the same size and type. Replace a component
when condition is in doubt. Parts that are cracked, damaged, or excessively corroded
are weakened. Bent or repaired parts may not engage properly.
3. Do not reinflate a tyre that has been run flat without first inspecting the tyre, tube, flap,
rim, and wheel assembly. Double check the side ring, flange, bead seat, lock ring,
and O-ring for damage and make sure that they are secure in the gutter before infla-
tion. Components may have been damaged or dislocated during the time the tyre was
run flat or seriously under-inflated.
4. Do not, under any circumstances, attempt to rework, weld, heat, or braze any rim
components that are cracked, broken, or damaged. Replace them with new parts, or
spare parts that are not cracked, broken, or damaged and which are of the same size
and type. Heating a part may weaken it when it is unable to withstand forces of infla-
tion or operation.
Dismantling
1. Block wheels not to be serviced.
2. Use jacks, hoisting, or another suitable method to raise the vehicle until the wheel to
be serviced just clears the ground.
DANGER
Ensure that the method used to elevate the Minetruck is stable
and capable of raising and supporting the weight. If the tyre to
be removed is on an oscillating axle, be sure to block the
carrier.
3. Crib or securely block the vehicle before proceeding with wheel removal.
197 No: 2522100363.3 en-US

DANGER
Do not attempt to remove the wheel rim or wheel components
such as flanges or wheel clamps until all pressure has been
released from the tyre. A damaged wheel rim part under
pressure can burst and cause severe injury or fatality.
4. Remove the valve core and exhaust all air from the tyre. Stand clear or to the side
during deflation.
5. Check the valve stem by running a piece of wire through the stem to make sure that it
is not plugged before proceeding with wheel service.
WARNING
Do not look into the valve stem while clearing restrictions.
6. Remove the wheel using a hoist and sling capable of supporting the load.
CAUTION
Use caution when removing wheels or heavy rim components.
Stand to one side and keep hands and fingers clear when
using demounting tools. The tool may slip and cause injury.
7. Remove the tyre from rim using accepted workshop practices.
Mounting
Precondition p Review safety warnings and cautions for dismounting before beginning work.
1. Verify articulation locking bar is secured between both frame mountings and the "Do
Not Operate" tag is in place on the ignition switch.
2. Verify that all blocking and cribbing is securely in place.
3. Clean all wheel and hub mounting surfaces. Remove all dirt, grease, or paint before
installing wheel.
4. Replace the wheel using a hoist and sling or forklift capable of safely supporting the
load. Make sure that the valve stem is aligned with any clearance slot in the axle hub.
5. Install mounting hardware and secure the tyre and rim in accordance with the torque
settings.
6. Once the tyre is mounted, lower the vehicle to the ground, using jacks, hoists or other
suitable method.
7. Remove all cribs and blocks.
8. Remove and stow articulation lock.
9. Remove the "Do Not Operate" sign from the ignition switch.
198 No: 2522100363.3 en-US

Mismatched Rims
Improper rim selection can cause these operating problems:
n Tyre slippage
n Excessive flexing
n Tube pinching
n Overheating
n Valve stem tear outs
n Sidewall failure
n Ply separation
n Blowouts
DANGER
Mismatched rim parts are dangerous.
Most rims look alike but all vary slightly in certain design features. It is these differences
between different types of wheel rims that make "mixing parts" an unsafe approach. It is
important that the wheel rim parts actually fit together to give the tyre a long service-life
and safe function.
Often side-rings, flanges, and lock rings of different types appear to be properly seated, but
wide gaps are present, frequently difficult to see. The rim cross-sections above show cor-
rect, safe matchings of rim parts, and mismatched rings and bases which almost always
create an unsafe operating condition.
Wheel Nut Torque

Wheel nuts must be tightened in an alternating pattern.
Wheel nuts are to be tightened to the correct torque upon initial installation or reinstallation
on the Minetruck.
Wheel nuts are to be checked for correct torque every four (4) hours for the first twelve (12)
hours of operation.
Wheel nuts are to be checked for correct torque every eight (8) hours for the next thirty-two
(32) hours of operation. Thereafter, check wheel nuts every one hundred (100) hours, or
weekly.
NOTICE
Before mounting and torquing, remove all paint, dirt, and rust from both sides of
wheels at mating surfaces around lug bolt holes. These areas must be clean.
Also, clean axle wheel end surfaces which mate with rear side of wheels. Proper
torque cannot be maintained unless these surfaces are clean and free of paint,
dirt, or grease.
Recapping
For some off-road operations, such as mucking and hauling, recapping tires can be cost ef-
fective alternative to replacement with new tires. Most tires are generally recappable, de-
pending on how well they have been inspected during their service life.
199 No: 2522100363.3 en-US

The deciding factor is the severity of the job the tyre must do. Some jobs are too tough for
recapped tires. High speed, overloading, and long service at low inflation pressure all take
too much life out of the cord body for it to last longer than the life of one tread.
On large tires with wire in the body, recapping is advantageous. Modern recappers can re-
cap wire and replaces the wire, if necessary.
Operating Precautions
Precondition p Observe the following precautions when putting the Minetruck back in service:
1. Do not use undersized rims. Use recommended rim for tyre. Consult catalogues for
proper tyre/rim matching.
2. Do not overload or over-inflate tyre/rim assemblies. Check the rim assemblies if spe-
cial operating conditions are required. Excessive overload can cause damage to the
tyre and rim assembly.
3. Never install a tube in a tubeless tyre/rim assembly when the rim is suspected of leak-
ing. Loss of air pressure through fatigue, cracks, or other fractures in a tubeless rim
warns of a potential rim failure. This safety feature is lost when tubes are used with
leaking rims. Continued use may cause the rim to burst with explosive force.
4. Always inspect rims and wheels for damage during tyre checks. Early detection of po-
tential rim failures may prevent serious injury.
5. Never add or remove an attachment or otherwise modify a rim (especially by heating,

welding, or brazing) unless the tyre has been removed and approval has been re-
ceived from the rim manufacturer. Modification or heating of a rim or one of its parts
may weaken it so that it cannot withstand forces that are created by inflation or opera-
tion.
200 No: 2522100363.3 en-US

Minetruck MT2010 7 Main Frame
7 Main Frame
7.1 Introduction
The main frame consists of two sections, the power frame and the load frame. The two
sections are united by an articulation joint. The power frame section provides control for
the load frame section.
This chapter covers the separation and reconnection of the power frame and the load
frame.
This chapter also contains removal and replacement instructions for the following:
n Major components on the power frame other than the power unit, power train, hy-
draulic systems, and the electrical system.
n Major components on the load frame other than the power train, hydraulic systems,
and electrical system.
7.2 Replacing Load Frame Components
7.2.1 General
n Always read the "Safety manual" and the "Operator’s Manual" in order to work with
and park the vehicle correctly.
DANGER
201 No: 2522100363.3 en-US

DANGER
WARNING
7.2.2 Dump Box
Dump Box, lifting eye

During the course of the Minetruck life, it may become necessary to remove the dump box
for various repairs. The wear on the lifting eyes in the dump box is hard. Therefore it may
become necessary to install new lifting eyes in the dump box to complete the vehicle ser-
vice.
! NOTE: Atlas Copco installs lifting eyes in the factory for shipping only!
WARNING
Do not use the factory installed lifting eyes unless they have been inspected and
certified to be safe by a qualified engineer.
202 No: 2522100363.3 en-US

Lifting Bails
Installing Lifting Eyes

Since the dump box is extremely heavy and therefore dangerous to lift, the installation of
the lifting eyes is important.
WARNING
Through use, the dump box may wear and not be structurally sound enough to
weld on. Inspect the suggested locations of the lift eye points for structural
integrity before placing the lift eyes.
NOTICE
The following installation procedures are for reference only. Consult local
engineering standards and procedures before attempting to install any lifting
eyes.
1. Empty the dump box of all debris.
2. Locate the specified areas where the lifting eyes will be welded to the dump box.
3. Prepare the selected lifting eye locations for welding.
4. Follow the locally approved procedures for welding a 10 mm fillet weld all of the way
around the base of each lifting eye.
Remove Dump Box
DANGER
The dump box is very heavy and poses a crushing hazard. Do not work under the
raised dump box without the support stand installed.
1. Empty the dump box.
2. Locate a lifting device and position the Minetruck under the lifting device so that it can
safely lift the dump box.
3. Shut the engine off, apply the parking brake, and block the wheels.
4. Follow the instructions to install lifting eyes.
203 No: 2522100363.3 en-US

Lift of dump box
5. Attach lift chains that are rated to the lifting eyes. Make sure that the dump box is bal-
ances evenly when lifted.
WARNING
Use only the properly rated chains or straps for lifting the
dump box. Do not use a damaged chain or strap.
6. Disconnect and cap the lubrication lines to the dump box pivot pins immediately.
7. Loosen and remove the dump cylinder pin retainer bolts at the dump box end of both
cylinders.
8. Remove dump cylinders.
! NOTE: Hook a strap around the top end of the cylinders, to ensure
that the cylinders do not "fall" when removed, as they are heavy.
WARNING
Never allow anyone to walk under any object that is hoisted.
Never allow anyone to ride in the dump box at any time.
204 No: 2522100363.3 en-US

Dump box cylinder head
9. Remove the dump box pivot pins.
A Dump box pivot pin lubricating lines
B Retainer bolt for trunnion cap for dump box pivot pin
10. Carefully lift the dump box off of the load frame and place on a flat hardened surface.
Refit Dump Box

Refit the dump box in reverse order to removal.
205 No: 2522100363.3 en-US

7.3 Replacing Power Frame Components
7.3.1 General
n Always read the "Safety manual" and the "Operator’s Manual" in order to work with
and park the vehicle correctly.
DANGER
DANGER
WARNING
7.3.2 Hoods and Covers
DANGER
The Minetruck hoods are heavy. Do not reach or lean underneath any hood
unnecessarily when the hood is raised without first installing the hood properly.
NOTICE
The top cover hoods are not as heavy as the engine hood. However, it is always
better to use a lifting device to lift the hoods away from the engine.
! NOTE: The following procedures are generalized for all of the hoods and covers on the
Minetruck.
206 No: 2522100363.3 en-US

Remove Hood
Engine hood
1. Park the Minetruck on a flat hard surface and switch off the engine.
2. Block all wheels.
3. Rig a hoist capable of lifting the engine compartment hood above the Minetruck.
4. Unlatch the hood.
5. Lift the hood.
6. Remove the hinges.
7. Slowly lift the hood with the hoist, making sure that it does not strike the frame or
catch on any components nearby. Place the hood on blocks in a safe location away
from the work area.
Refit Hood
Refit the hood in reverse order to removal.
NOTICE
Always install the hood latches after servicing the Minetruck.
7.4 Separating Load and Power Frames
7.4.1 Separation
To separate the load frame and the power frame all tension must be removed from the ar-
ticulation joint.
207 No: 2522100363.3 en-US

1. Position wheel chocks at the front and rear of the wheels.
2. Relieve all pressure in the hydraulic system. See "Relieving Hydraulic Pressure" on
page 107.
Articulation Cardan Shaft
3. Disconnect or remove the midship cardan shaft. See "Remove & install cardan shafts"
on page 71.
4. Install two maintenance stands on the rear of the power frame.
5. Place jack under the front of the power frame.
Connections for the hydraulic lines between the load frame and power frame
6. Disconnect the hydraulic lines between the load frame and power frame. Immediately
cap or plug each line and connector.
208 No: 2522100363.3 en-US

Steering cylinder trunnion caps
7. Disconnect the steering cylinders from the power frame by removing the cylinder pin
retainer bolts and pins.
8. Perform either of the following:
a. Place a dolly capable of carrying the weight of the front of the load frame under
the front of the load frame. Place a steel sheet on the ground on which to roll the
dolly if the Minetruck is not on a concrete surface.
! NOTE: The steel sheet must be of sufficient size to allow the

load frame backward, approximately 1 meter.
b. Position a hoist over the front of the load frame. The hoist must be capable of
carrying the weight of the front of the load frame. The hoist must be capable of
moving backward approximately 1 meter (3 feet) with the load frame.
9. Rig a sling to lift the load frame.
10. Adjust the height of the dolly or hoist so that the weight is removed from the articula-
tion joint.
11. Remove the bolts that attach the articulation pin to the hinge plate.
12. Remove the bolts that attach the articulation pin to the pin trunnion caps and remove
the pin.
NOTE: With some pin designs, the articulation pin does not bolt di-
! rectly to the hinge plate. The retaining cap uses two sets of bolts,
one set attaches the retaining cap to the pin, and the other set at-
taches the retaining cap to the hinge plate.
13. Remove the wheel chocks from the load frame wheels.
14. Move the load frame backwards approximately 1 meter.
15. Position wheel chocks at the front and rear of the rear wheels on the load frame.
209 No: 2522100363.3 en-US

16. Securely support the front of the load frame with wooden blocks.
7.4.2 Reconnection
! NOTE: This procedure assumes that the Minetruck is in the same condition and posi-
tion as at the end of the frame separation procedure.
1. Remove the wooden blocks from beneath the front of the load frame.
2. Remove the wheel chocks from in front of and behind the load wheels on the load
frame.
3. Move the load frame backward until aligned with the articulation pins.
4. Adjust the height of the load frame as necessary for proper pin alignment to the artic-
ulation lock.
5. Insert the lower pin. Reinstall the pin retaining cap. Lubricate each articulation pin and
retaining cap bolt and screw in all bolts. Do not tighten.
6. Install top pin (same as above).
7. Position wheel chocks in front of and behind the rear chassis wheels.
8. Check the positions of the articulation pins. If both pins and all caps are in proper po-
sition, properly torque the bolts.
9. Remove the dolly and its fittings from beneath the front of the load frame or remove
the hoist and its fittings from the frame.
10. Fit the centre cardan shaft.
11. Reconnect the steering cylinders.
12. Unplug and reconnect the hydraulic lines.
13. Remove the maintenance stands from beneath the power frame.
14. Make sure that the parking brake is applied.
15. Remove all wheel chocks from all wheels.
210 No: 2522100363.3 en-US

7.4.3 Articulation Pins
A Washer and cap screw
B Pin retainer
C Bearing holder
D Bearing cup
E O-ring
F Set screw
G Articulated joint
211 No: 2522100363.3 en-US

Atlas Copco Minetrucks are supplied with taper roller articulation pins. Installation and re-
moval of the articulation pins is not required to disconnect the two frames. However during
the life of the Minetruck, it may be necessary to remove the hinge pins.
NOTICE
The bearing spacer, cup, and cone are matched set. If the bearing is damaged or
worn, replace the whole bearing assembly. Atlas Copco recommends replacing
both the upper and lower hinge pin bearing at the same time.
Pin Removal
WARNING
The articulation pins are very heavy and could cause injury or even death if
mishandled. Always use a hoist to position the pin into the hinge bore. Also take
care when removing the top pin.
1. Disconnect the load frame and power frame. See "Separating Load Frame and Power
Frame" on page 85.
NOTE: The order of pin removal does not matter. If the bearings
! are going to be fitted, then tag them as they are taken apart so that
they will be replaced in their previous position.
2. If removing the bottom pin, place a stand under the pin, if removing the upper pin, at-
tach a hoist to the pin.
3. Loosen and remove the pin cap screws and lift off the pin retainer. Place the pin re-
tainer and screws aside so that they may be reused.
4. Loosen and remove the bearing retainer plate lock nuts and bolts.
5. Carefully lift off the bearing retainer plates (both sides) and set aside for reuse.
6. Push off the spacer ring and the small washer. Set both aside for reuse.
7. Remove the bearing cone. Note the position 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 reused, set aside and tag with
position of the bearing.
10. Remove the bearing cup from the hinge plate and set aside if reused.
212 No: 2522100363.3 en-US

7.5 Stops
7.5.1 General
The Minetruck is designed for the weight of the load to be carried against the stops. Either
improper operating technique or worn, missing, or improperly installed stops can result in
several problems. The most common problems that are related to missing or defective
stops are:
n Blown cylinder seals
n Cylinder barrel failure
n Main control valve seals leaking
n Structural damage
All vehicles are shipped from the factory with stops installed.
When mounting a new dump box, the position of the stops must be checked. A small mis-
alignment can cause material damage.
When the vehicle is operated without stops that are hammered out, or improperly installed,
the load will be supported by the cylinder barrel, load frame, or both.
If the stops are missing or badly worn, the cylinder stem can bottom out in the barrel. With
the load supported by the barrel, any vertical movement of the load (such as occurs during
tramming) causes the piston to pound the base of the barrel. This result in failure of the
cylinder ultimately, particularly at the weld around the end cap and possibly at the cylinder
mountings as well.
7.5.2 Steering Stops
The steering stops are installed to limit the travel of the steering cylinders and to prevent
them from bottoming out in either direction. The stops also keep the load and power
frames from hitting each other and causing damage.
The steering stops are solid steel blocks which are welded in the articulation joint of the ve-
hicle.
213 No: 2522100363.3 en-US

7.5.3 Dump Box Guides
A. Dump Box Guides

The purpose of the rear dump box guides is to minimise side-to-side movement of a loaded
dump box during tramming over rough and irregular roadways. The guides are generally
not adjustable as they are welded in proper position during assembly at the factory.
7.5.4 Front Axle Oscillating Stops

These stops limit the amount of oscillation and are welded in on the underside of the power
frame.
7.5.5 Stops, Upper and Lower Tailgate

Teletram machines that are equipped with tailgate use upper and lower stops on the dump
box to limit the movement of the cylinder.
214 No: 2522100363.3 en-US

Minetruck MT2010 8 Troubleshooting
8 Troubleshooting
8.1 Symptoms and Solutions

The following tables help to isolate problems should they occur. The tables are labeled ac-
cording to system function or component location. Refer to the index to locate the appropri-
ate pages for adjustment, repair, or removal and replacement procedures.
Proper maintenance prevents many problems from occurring. For instance, many prob-
lems with the cooling system can be headed off by maintaining the proper levels of corro-
sion inhibitors with Supplemental Coolant Additive (SCA).
This chapter is only intended for use as general reference. See the original component
manual for further information. For further information on fluids and greases, see document
"Fluids and greases" which is supplied with the documentation.
8.1.1 Transmission Symptoms
Condition Possible Cause Solution
Erratic oil pressure Low oil level Add oil to proper level
Suction tube fitting Replace O-ring fitting
Suction manifold O-ring not seal- Replace O-ring

ing
Foreign object in suction port Remove object and check for other con-
tamination
Excessive oil pressure Sticking main regulator valve Replace main regulator valve
Faulty spring Replace main regulator
Low oil pressure in all Sticking main regulator valve Replace main regulator valve
gears
Control valve body gasket leaking Replace gaskets
Charge pump defective Replace pump
Internal disconnect seal damage Replace seal and install correctly

or installed incorrectly
215 No: 2522100363.3 en-US

Faulty main regulator valve Replace regulator assembly
Control valve body cracked Replace control valve body
Low pressure in one Broken seal ring on input end of Replace seal ring
gear but fine in others clutch assembly
Bore sleeve worn Replace bore sleeves
Outer or inner piston seal leaking Replace seals
Machine does not move Voltage to wrong solenoids on Check wiring and connectors. Check
control valve transmission schematic
Transmission damage Rebuild transmission
No voltage to all solenoids Check wiring, controller, and connec-

tors.
Low or no transmission Transmission bypass valve defec- Replace transmission bypass valve
pressure tive
Transmission hub seal ring not Replace seal ring

sealing
Charge pump defective Replace charge pump
Filter or filter oil lines Hose bends too sharp Reroute hoses
are releasing oil
Defective hose Replace hose
Faulty main regulator valve Change valve and change filter and oil
System plumbing incorrect Correct plumbing
Filter O-ring faulty Change filter
Excessive noise Charge pump defective Replace pump
Excessive backlash in gear train Replace bearings and inspect for defec-
tive gears
Auxiliary driven pump bad Remove pump and check for noise
Blows oil out of dipstick Transmission over filled with oil Drain to proper level. Check front seal
or breather on auxiliary driven hydraulic pump if
equipped
Converter seal ring damaged Remove transmission and install a new

seal ring on converter hub
Transmission pressure Converter sprag clutch is dam- Disassemble and inspect converter
checks okay, but has no aged or installed wrong
power and possibly
Converter pressure control valve Replace pressure control valve
overheating
broken
Transmission overheat- Converter stalling Shift to lower gear

ing
Oil level too high Drain to proper level. Check front seal
on auxiliary driven hydraulic pump if
equipped
216 No: 2522100363.3 en-US

Engine overheating Check engine coolant
Transmission cooler lines defec- Replace lines

tive
Transmission cooler dirty Clean cooler
Clutch slipping Check clutch pressure
Oil leaking from engine Converter front cover seal leaking Replace seal
fly wheel or weep hole
Converter hub seal or O-ring dam- Replace seal
in transmission bell
aged
housing
Converter not properly positioned Check motor converter pilot bushing
within bell housing, causing con- length against machine manufacture
verter and seal to leak standards
8.1.2 Axles Symptoms
Excessive vibration Broken gear teeth, worn bearings Replace gear or bearings. See also car-
dan shafts.
Excessive noise Incorrect or insufficient lubricant Check level, fill with proper type and
grade of lubricant. See also cardan
shafts. See "Fluids and lubricating
greases" for correct lubricant specifica-
tions.
Hub bearings scored or rough Replace bearings
Gear teeth in planetary chipped Replace gear
Lubricant leaks Lubricant level too high Drain and fill to proper level with proper
type and grade of lubricant.
Lubricant foams excessively Drain and fill with correct type and
grade of lubricant
Worn or broken oil seal Replace oil seal
Restricted differential breather Clean vent
Loose nuts or bolts Tighten nuts and bolts
Lubricant leaking out of Restricted breather vent. Worn or Clean vent

breather broken seals in axles Too high
pressure on the brake cooling re-
turn
Overheating Low lubricant level Find source of leak and repair
Ring and pinion adjustment too Adjust

tight
Faulty bearing Replace bearings
217 No: 2522100363.3 en-US

Abnormal noise when Worn differential side gears and Replace

turning pinions
Low lubricant level Find source of leak and repair
Loose nuts on differential casings Tighten nuts to specified torque
Insufficient drive train clearance
Worn or improperly lubricated

bearings
Machine does not move Worn or broken shaft splines Replace shaft
Transmission oil low Add transmission oil. See "Fluids and

lubricating greases" for correct oil spec-
ifications.
Abnormal disc wear Incorrect oil Correct oil with additives must be used.
See "Fluids and lubricating greases" for
correct oil specifications. See attached
digital OEM documentation for further
information.
Axle leakage Incorrect or insufficient lubricant Check the hydraulic oil (for correct oil
including additives, see "Fluids and
Damaged seals greases" for correct oil specifications),
Loose bolts brake cooling circuit, brake cooling
pump. See attached digital OEM docu-
mentation for further information.
8.1.3 Cardan Shaft
Excessive vibration or Drive train bent or out of balance Clean drive train. Check clearance with
noise nearby components. Balance drive
train. If cardan shaft is bent or dam-
aged, replace.
Excessive vibration or Loose mounting Replace cap screws and tighten to

noise proper torque
Worn or poorly lubricated bearings Test for looseness. If crosses are loose,
replace cross and bearings as an as-
Insufficient clearance
sembly
Excessive wear of cross Poor alignment or run-out Check alignment, run-out, and balance.
bearing assemblies Repair or replace, as required.
Cardan shaft unbalanced Check for missing balance weights or

cardan shaft distortion. Check dynamic
balance. Rebalance. Replace distorted
cardan shaft.
Cardan shaft does not Joint failure Replace

transmit power
Damaged splines
218 No: 2522100363.3 en-US

Damaged yoke
8.1.4 Tires and Rims
Tire leak Defective valve Tighten parts
Tire cuts Repair tire damage
Damaged O-ring Replace O-ring
Leakage between tire bead trim Remove the tire from the wheel rim.
Clean the tire bead at the wheel rim
contact area. Clean the wheel rim.
Check the tire bead wire. Replace de-
fective parts. Install the tire with the cor-
rect lubricant.
Cracked rim or weld Replace defective part.
8.1.5 Articulation
Excessive or unusual Loose articulation bearings Reshim and adjust preload

noises
Contamination in articulation bear- Disassemble and repair
ing or steering cylinder seals
Contact between power frame and Check for correct installation of articula-
load frame hinge plates tion assembly
Worn articulation bearing Check that articulation bearings are in-

tact
Worn or damaged articulation pin Replace
Worn guide pins Replace
Excessive movement in Loose articulation pin Check pre-load and adjust

articulation
Loose guide pins
Excessive articulation bearing Replace

wear
Worn steering pins
8.1.6 Hydraulic Systems
Poor performance or Reservoir low on oil Add oil. See "Fluids and lubricating
failure greases" for correct oil specifications.
External leakage Check that line pressures with full load

are within normal range
219 No: 2522100363.3 en-US

Load too heavy
Restriction in hydraulic line Check lines to locate obstruction. Re-

move obstruction or replace line. Re-
move any obstruction or replace the
line.
Pressure control valve not operat- Clean and adjust valve. Disassemble
ing properly and repair. Replace.
Worn cylinder or seals Disassemble and repair or replace
Defective pump Flow test pump. Replace pump if nec-

essary.
Excessive oil foaming Improper type or viscosity oil Drain hydraulic system and refill with
proper oil.
Leak on suction side of pump Locate and repair leak
Worn pump Flow test pump. Replace pump if nec-

essary.
Oil temperature too high Low oil in system Fill with oil. See "Fluids and lubricating
Hydraulic oil cooler plugged or Check oil cooler

dirty
Improper type or viscosity oil Drain hydraulic system and refill with
proper oil. See "Fluids and lubricating
Excessive cycling of load See the Operator’s Manual for proper

technique.
Worn pump Replace pump.
Foreign material in sys- Filters clogged and bypassed Check restriction indicator and replace
tem filter(s) in necessary
Contaminated or bad oil Drain and flush hydraulic system. Install

the filter(s) and fill with clean oil. See
"Fluids and lubricating greases" for cor-
Damaged cylinders Disassemble, inspect, and repair or re-

place component.
Worn or damaged pump
Insufficient pressure Faulty charging valve. Internal Disassemble and inspect. Repair or re-
leakage past seals or cylinders place as necessary.
Worn pump Measure and record the pump flow and

pressure. If out of specification, replace
pump.
220 No: 2522100363.3 en-US

Insufficient or no flow Oil too cold or incorrect viscosity. Drain and flush hydraulic system. Install
Pump will not prime. the filter(s) and fill with clean oil. See
Pump intake line from reservoir re- Check lines to locate obstruction. Re-
stricted move obstruction or replace line.
Faulty pump drive seal Replace seals.
Pump drive axle sheared or disen- Disassemble the pump and inspect.
gaged
Worn pump Replace pump
Leaking oil Worn or faulty hose line Replace
Incorrect or damaged fittings Clean or replace
Dirt or paint on or under seals Clean or replace
Loose seal plates Clean and tighten
Cut or damaged seals Replace
Excessive pump noise Low oil supply Fill reservoir

or cavitation
Obstruction in suction line Check pump inlet line. Remove obstruc-
tion or replace line. Check all hose cou-
plings and connections.
Air in oil supply to pump Locate air entry point and repair.
Excessive foaming Drain the hydraulic system and fill with

oil of the correct type and viscosity. See
Engine operated at high speed Warm up hydraulic system by cycling

with cold hydraulic oil hydraulic controls.
Oil viscosity too high Drain the hydraulic system and fill with
oil of the correct type and viscosity. See
Pump components not properly Check shaft seal and bearings for dam-
aligned. age. Replace parts as required. Align
pump correctly.
Hydraulic hand pump Check valve malfunctioning Verify check valve function, replace if
feels loose while pump- necessary
ing
The hydraulic system Accumulator Precharge is too low Verify Accumulator pressure, adjust
cuts in and out too or too high pressure, check accumulator piston for
rapidly when brake excessive wear
pedal valve is actuated
221 No: 2522100363.3 en-US

Pilot control is slow to Low pilot pressure Verify pilot pressure, adjust if neces-
respond sary.
Normal hydraulic re- Low pilot pressure Verify pilot pressure, adjust if neces-
sponse but requested sary.
function is too slow
Pump flow volume low Flow test pump, adjust flow rate, re-
place worn pump
Hydraulic hose is hard Aerated oil in system from cavita- Replace the hose and check for air in
and cracking tion the system, drain oil and replace with
fresh oil. See "Fluids and lubricating
Check main control valve spools
The hydraulic hose is Exposure to intense cold while the Replace hose with an appropriate cli-
cracked both internally 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 impulse Replace hose with a higher SAE im-
examination of the wire condition pulse 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 rat-
burst but there is no in- ing for circuit
dication of multiple bro-
Hydraulic circuit malfunction caus- Change hose, identify circuit problem,
ken wires the entire
ing unusual, high-pressure condi- examine check valves and port pres-
length of the hose
tions sure control valves
The hydraulic hose has Hose cover degradation due to ex- Replace hose, remove corrosive mate-
burst and examination cessive wear or exposure to corro- rial from area--the following are causes
shows that the reinforc- sive material of hose cover damage: Abrasion, cut-
ing wires are rusted and ting, battery acid, steam cleaners,
the cover has been chemical cleaning solutions, muriatic
damaged or cut acid, salt water, heat, extreme cold.
The hydraulic hose has Violation of minimum hose bend Check the bend radius specification,
burst on the outside of a radius change hose, and either reroute or re-
bend and appears to be place with a hose designed for the bend
elliptical in the bent sec- radius required
tion
The hydraulic pump is Violation of minimum hose bend Check hose bend radius, reroute hose,
noisy and hot, the pres- radius check oil for aeration (this situation can
sure line from the pump result in cavitation)
is hard and brittle
The hydraulic hose is Twisting force exerted on the hy- Check components for looseness caus-
flattened out in one or draulic hose ing torquing on the hose
two areas and is kinked
or twisted
222 No: 2522100363.3 en-US

The hose tube has bro- High vacuum, wrong hose for cir- Replace hose with a proper rated hose
ken loose from the rein- cuit
forcement and the inner
Minimum hose bend radius is vio- Check radius, reroute hose, replace
diameter of the hose
lated hose after straightened.
has collapsed. The
hose may protrude into
the hose coupling
The hydraulic hose has Improper assembly of the hose Replace with a properly assembled
burst 6–8 inches away coupling hose
from fitting. Wire rein-
forcement is rusted and
the cover is not cut or
damaged
There are blisters on Improper assembly of the hose Replace the hose with a properly as-
the outer cover of the coupling sembled hose
hose. The blisters con-
tain oil
The hydraulic hose Use of incorrect fitting on the hose Replace fitting and hose with proper
blew out of the hose hose assembly---Use same manufac-
coupling turer products and make sure that hose
and fitting are rated for each other
Incorrect assembly of hose and fit- Replace burst hose with a correctly as-
ting sembled hose and fitting package
Incorrect hose length Replace hose with a new hose of

proper length
The hose tube is se- Tube of the hose is incompatible Replace with proper rated hose for an
verely degraded with with the hydraulic fluid oil-based hydraulic system
traces of extreme
swelling. Sometimes Excessive heat generated by the Check hydraulic circuits for malfunction,
the tube can be flushed hydraulic system, or improper heat replace hose with a proper rated hose
away. 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 The hose is trying to shorten un- Replace with a longer hose
the fitting because of a der pressure and has not enough
crack in the steel tube length to do so
next to the braze on a
split flange shoulder
A spiral reinforced hose Hose too short to accommodate Replace with a longer hose
has burst and literally the change in length while it was
split open with the wire pressurized.
exploded and badly tan-
gled
223 No: 2522100363.3 en-US

Hose is badly flattened Kinked hose Replace hose and check for cause of
out in the burst area. kinking. Reroute if necessary to save
future hoses
Hose leaks profusely Hose bend radius exceeds mini- Replace and reroute the hose
but has not burst mum causing high-pressure ero-
sion of inner tube
Contamination in the hydraulic Change the hydraulic oil and filter. See
fluid "Fluids and lubricating greases" for cor-
rect oil specifications. Also replace the
hose. Look for cause of contamination.
The hydraulic hose has Not necessarily a high-pressure Replace with a longer hose
been pulled out of the problem--hose too short for appli-
hose coupling cation
8.1.7 Brakes
Brakes chatter Improper type or viscosity oil. Drain the hydraulic system and
fill with the correct oil. See "Flu-
ids and lubricating greases" for
correct oil specifications.
Insufficient hydraulic oil flow to Check oil level in hydraulic tank.

the hubs. Check return line flow from hubs.
Check pump performance.
Brakes release too slowly Brake pedal not returning to fully Disassemble and inspect valve.
released position Oil return port Repair or replace valve as re-
of brake control valve is required.
stricted or plugged.
Brakes do not release. Brake pedal valve sticking. Disassemble and inspect valve.
Repair or replace valve as re-
quired.
Restriction in hydraulic lines. Check lines to locate obstruc-

tion. Remove obstruction or re-
place line.
Parking brake engaged. See parking brake troubleshoot-

ing.
Insufficient accumulator pres- Check accumulator charging

sure. valve for proper operation. En-
sure that brake pump is perform-
ing properly.
Brakes pull or drag (one or more Brake pedal valve travel adjust- Adjust pedal travel.
assemblies do not release fully). ment incorrect.
Insufficient oil pressure to one or Check hydraulic lines for leaks.

more hubs. Install test gauge to determine
location of problem.
224 No: 2522100363.3 en-US

Brakes apply intermittently. Brake pedal valve sticking. Disassemble and inspect valve.
Repair or replace valve as re-
quired.
Low accumulator pressure. Check accumulator charging

valve for proper operation. En-
sure that brake pump is perform-
ing properly.
Restriction in hydraulic lines. Check lines to locate obstruc-

tion. Remove obstruction or re-
place line.
Parking brake solenoid applied. Check the parking brake’s posi-

tion. Check the parking brake’s
electrical circuit for proper opera-
tion (buttons/knobs, wiring, sole-
noid valve, time delay relay).
Low torque converter pressure. See Transmission Troubleshoot-

ing.
Brakes do not apply. Hydraulic pressure at hubs does Check system for blockage of
not relieve flow.
Brakes overheat. Excessive cycling of charging Check system for leaks.

valve.
Brakes applied. Ensure that brake pump is per-

forming properly.
High hydraulic oil temperature. See Hydraulic System Trou-

bleshooting.
Excessive brake pedal travel. Brake pedal out of adjustment. Adjust travel.
Service brakes not holding dur- Improper test procedure. Check that machine is in proper
ing tramming. test gear.
Brake pedal heel stop out of ad- Adjust heel stop.

justment.
Brake pedal valve not stroking. Disassemble valve and inspect.

Check hydraulic system for pos-
sible particulate contamination.
8.1.8 Parking Brake
Parking brake not hold- Improper test procedure Check that the machine is in the correct
ing during tramming. test gear.
Hydraulic pressure at hubs does Check system for blockage of flow

not relieve.
Parking brake does not Improper control position Check parking brake switch in proper
release position
225 No: 2522100363.3 en-US

Loss of hydraulic pressure Check indicating circuit, if applicable.

(See Hydraulic System Troubleshoot-
ing).
Loss of electrical signal Loss of electrical signal
8.1.9 Electrical System
Dash indicating light(s) does not No power Check that battery isolation
illuminate switch is turned on.
Check charge on battery.
Check for tripped circuit break-
ers.
Check for faulty ignition switch.
Check for faulty ignition sole-
noid.
Check for faulty battery isolation
switch.
Check for broken or loose wires
and connections.
Circuit breaker or fuse open Reset and close.
Broken or loose wire or connec- Repair or replace.

tion
Programmable Logic Control Check PLC LED inputs and out-

(PLC) failure puts.
Verify PLC program.
Replace PLC.
Engine does not turn over No power See previous
Low battery charge Check specific gravity. Replace

if battery does not hold charge.
Faulty start switch Replace
Starter safety switch open Place transmission in neutral

and apply parking brake.
High resistance in circuit Clean and tighten all connec-

tions.
Defective starter motor Starter Replace

solenoid defective
Engine turns over but does not Fault in electrical shutdown cir- Check circuit components for
start. * Check for fuel and verify cuit fault.
shut-off valve position
Fault in engine ECM system Refer to OEM Troubleshooting
Manual.
226 No: 2522100363.3 en-US

Starter motor sluggish. High resistance in circuit Check battery terminals for cor-
rosion.
Clean and tighten all connec-
tions.

If extreme cold conditions, warm
battery before starting.
Excessive load or drag on en- Check the oil for correct viscos-
gine. ity. See "Fluids and lubricating
greases" for correct oil specifica-
tions. In the event of cold condi-
tions, warm the engine oil before
starting.
Defective starter motor Carry out fault finding on the en-

gine’s subsystems to locate
problem.
Replace.
Starter solenoid switch chatters. High resistance in circuit Check battery terminals for cor-
rosion.
Clean and tighten all connec-
tions.

If extreme cold conditions, warm
battery before starting.
Faulty starter solenoid Replace solenoid or solenoid

wiring.
Low engine power (See Engine Fault in engine ECM system Refer to OEM Troubleshooting
troubleshooting). Manual.
Lost connection to ECM injectors Check injector connections.
Low battery output Electrolyte level low Add distilled water to proper
level.
Defective battery cell Replace battery

Damaged battery case
Slipping drive belts Adjust belt tension. Replace

belts, if necessary.
Electrical circuits energized with Turn off all switches when en-
engine off. gine shutdown.
High resistance in circuit. Check and clean all terminals

and grounds.
Defective wiring Replace
227 No: 2522100363.3 en-US

Faulty alternator Check and adjust regulator.

Check and tighten mounting.
Check pulley alignment.
Check for grounded field circuit.
Replace alternator.
Starter Motor Armature does not Battery discharged Recharge battery.

rotate or rotates too slowly.
Battery defective Have battery checked (or re-
placed) by maintenance person-
nel.
Battery terminals loose or cor- Tighten terminals, clean, and put

roded acid-resisting protective lubricant
on terminals and poles.
Starting motor terminals or car- Trace defective spot and repair.

bon brushes grounded (short cir-
cuit).
Carbon brushes have no contact Check, clean, or renew brushes.

with the commutator or are Clean brush holder.
jammed in the brush holders.
Brushes worn, broken, fouled by
dirt or oil.
Start switch defective (burnt or Replace start switch.

loose connections).
Solenoid switch in starting motor Repair or replace solenoid

defective. switch.
Excessive voltage drop in circuit. Check wiring, clean, and tighten

connections. Replace any bro-
ken cables or wires.
Pinion fails to mesh when arma- Pinion fouled with dirt. Clean
ture rotates.
Pinion or rim gear teeth dam- Remove burr by filing.
aged, burred.
Starting motor functions properly Battery insufficiently charged. Recharge battery.

until pinion meshes, then stops.
Insufficient brush pressure. Check brushes, springs, and
holders.
Solenoid switch in starting motor Repair or replace solenoid

defective. switch.
Excessive voltage drop in circuit. Check wiring and connections.
Start switch fails to cut out. Solenoid switches damaged. Disconnect jumper cable imme-
diately at battery or at the start-
ing motor.
Replace defective button, or
have button or starter motor re-
paired.
228 No: 2522100363.3 en-US

Pinion or flywheel gear badly Return spring broken or tired. Clean thoroughly. Remove burr
fouled or damaged. from tooth edges by filing. Have
starting motor repaired.
Over-charged battery Charge voltage too high Check and adjust or replace the
charger
Incorrect pulley used on alterna- Replace with pulley of correct

tor size.
Battery uses an excessive Battery over-charged See previous

amount of water
Rapid burn-out of light bulbs. Battery over-charged. See previous
Low or intermittent alternator Dirty or worn alternator commu- Clean or repair commutator or
output. tator. replace armature.
Slipping drive belt. Adjust drive belt.
Malfunctioning regulator Adjust or replace regulator.
Lights dim Batteries low. Charge batteries
Poor ground Provide a clean, tight ground
Loose connection Tighten all connections
One (1) electrical gauge not op- Bad connection at gauge, con- Make a positive connection
erating nector plug, or sender.
Sender defective Replace

Gauge defective
Ignition "ON" - no gauges or Dead battery. Recharge or replace battery.

lights working
Loose connection from battery to Tighten connection.
control panel.
Broken wire between battery and Repair or replace wire.

control panel.
Brakes do not release Lost connection Check wiring
Parking brake not operating Check wiring, replace circuit

properly breaker.
PLC malfunction Check LED on PLC, verify PLC

programming, replace the PLC.
Emergency stop system in effect Check PLC status, verify hy-

draulic and transmission oil pres-
sures.
Pressure loss relay malfunction Check wiring connections, re-

place the relay.
Transmission does not engage Switch in the joystick dump/lift Check wiring, connections, verify
in Forward, Reverse, or Neutral lever does not work circuit breaker integrity, replace
circuit breaker.
229 No: 2522100363.3 en-US

Lost connection Check connections and wiring to

transmission from PLC
PLC malfunction Verify PLC operation, replace

PLC
Transmission ECU failure Check with a diagnostic device

or gauge
Transmission does not engage Failed selector switch Check wiring and connections to
in gear or appears not to engage switches
in gear. First to Third.
Lost connection Check connections from PLC to
transmission
Failed bulb in gear button Check bulb, verify PLC opera-

tion.
PLC malfunction Verify PLC operation, replace

PLC.
ECU failure Check with a diagnostic device

or gauge.
Transmission shifts roughly or Calibration problem Check calibration

slow
Headlights do not work Broken wiring Verify the integrity of the wiring
and splice or replace faulty
wiring
Loose connection Check connections and recon-

nect or replace the connectors
Light relay failed Verify the failure, replace the re-

lay
Lamp button does not work Verify the failure and replace the
switch
Horn does not sound Lost or loose connection Check wires and connections,
replace if faulty
Faulty horn Replace the horn
Backup light alarm or backup Lost connection Check wiring and connections,
light does not work replace if faulty
Faulty alarm Replace the alarm
Faulty beacon light Replace the beacon light.
Faulty reverse switch Replace the circuit breaker.
PLC malfunction Check wiring and connections,

verify PLC failure, replace the
PLC
Gauges do not work Faulty wiring or connections Check the wires and connec-
tions, repair wires and replace
connectors.
230 No: 2522100363.3 en-US

Gauge pointers move back and Faulty wiring or connections Check the cables to the gauges
forth in a windshield wiper mo- from the gauge cluster. Check
tion. the connections, repair cables,
reinstall contacts.
Data lines between gauge and Check the data line to see if they
gauge cluster are incorrectly in- have been reversed.
stalled
Loss of power to the gauge clus- Check the power supply to the
ter gauge cluster.
Gauges malfunctioning Verify and replace faulty gauges.
Pressure gauge reads wrong or Transducer is malfunctioning Verify the fault and replace the
is erratic. transducer.
Gauge is malfunctioning Check wiring and gauge connec-

tions, replace the gauge.
Gauge cluster is malfunctioning Verify the malfunction, check

connections, check for faulty
programming, replace the gauge
cluster.
Temperature gauge gives incor- Temperature sensor is faulty Verify the fault and replace the
rect reading or is erratic. sensor.
Gauge is malfunctioning Check wiring and gauge connec-

tions, replace the gauge.
Gauge cluster is malfunctioning Verify the malfunction, check

connections, replace the gauge
cluster.
8.2 Cummins Diagnostic Screen Fault Codes on UIP

SPN (J1939 FMI (J1939 Light Colour Fault Code Cummins Output
SPN) FMI) (Lamp) Description
27 2 Amber 957 EGR Valve Po- Possible low

sition - Data er- power. EGR
ratic, intermit- valve will be
tent, or incor- closed.
rect. Intermit-
tent EGR posi-
tion information
is being re-
ceived by the
electronic con-
trol module
(ECM).
27 13/13 Amber 2348 EGR valve Possible low

failed auto- power. Power
matic calibra- will be re-
231 No: 2522100363.3 en-US

tion procedure moved from

- out of calibra- the EGR valve
tion. motor.
27 2/2 Amber 1228 EGR Valve Po- Possible low

sition - Data er- power. EGR
ratic, intermit- valve will be
tent, or incor- closed.
rect. Intermit-
tent EGR posi-
tion information
is being re-
ceived by the
electronic con-
trol module
(ECM).
27 3/3 Amber 2271 Exhaust Gas Possible low

Re-circulation power. Power
(EGR) Valve will be re-
Position Sen- moved from
sor Circuit - the EGR valve
Voltage Above motor.
Normal or
Shorted to
High Source.
High signal
voltage de-
tected at the
EGR valve po-
sition sensor
circuit.

(EGR) valve will be re-
position sensor moved from
circuit - voltage the EGR valve
below normal motor.
or shorted to
low source.
Low signal
voltage de-
tected at the
EGR valve po-
sition sensor
circuit.
84 1/18 Amber 1892 Wheel—Based Engine speed

Vehicle Speed limited to Maxi-
— Data Valid mum Engine
but Below Nor- Speed without
232 No: 2522100363.3 en-US

mal Opera- VSS parameter

tional Range value. Cruise
— Moderately control, Gear-
Severe Level. Down Protec-
The ECM lost tion, and Road
the vehicle Speed Gover-
speed signal. nor will not
work.
84 10/10 Amber 242 Vehicle Speed Engine speed

Sensor Circuit limited to maxi-
Tampering Has mum engine
Been Detected speed without
- Abnormal VSS parameter
Rate of value. Cruise
Change. In- control, gear-
valid or inap- down protec-
propriate vehi- tion, and road
cle speed sig- speed gover-
nal. Signal indi- nor will not
cates an inter- work.
mittent connec-
tion or VSS
tampering.
84 2/2 Amber 241 Vehicle Speed Engine speed

Sensor Circuit limited to Maxi-
- Data Erratic, mum Engine
Intermittent, or Speed without
Incorrect. The VSS parameter
ECM lost the value. Cruise
vehicle speed control, Gear-
signal. Down Protec-
tion, and Road
Speed Gover-
nor will not
work.
91 19 Red 287 SAE J1939 Engine may

Multiplexing only idle or en-
Throttle Pedal gine will not
or Lever Sen- accelerate to
sor System Er- full speed.
ror - Received
Network Data
Error. The
OEM vehicle
electronic con-
trol unit
(VECU) de-
233 No: 2522100363.3 en-US

tected a fault
with its throttle
pedal.
91 3/3 Red 131 Throttle Pedal Severe derate

or Lever Posi- in power output
tion Sensor of the engine.
Circuit - Emergency
Shorted to steering mode
High Source. only.
High voltage
detected at
throttle pedal
or lever posi-
tion sensor cir-
cuit.
91 4/4 Red 132 Throttle pedal Severe derate

or lever posi- in power output
tion sensor cir- of the engine.
cuit - Voltage Emergency
below normal, steering mode
or shorted to only.
low source.
Low voltage
detected at
throttle pedal
or lever posi-
tion sensor sig-
nal circuit.
093 2 Amber 528 Auxiliary Alter- Torque curve

nate Torque setting defaults
Validation to default
Switch - Data curve.
Erratic, Inter-
mittent, or In-
correct. An er-
ror has been
detected in the
alternate
torque switch
circuit.
94 1 Amber 2216 Fuel Pump De- None or possi-

livery Pressure ble engine
High - Data noise associ-
Valid but ated with
Above Normal higher injection
Operational pressures (es-
Range - Mod- pecially at idle
erately Severe or light load).
234 No: 2522100363.3 en-US

Level. The
ECM has de-
tected that fuel
pressure is
higher than
commanded
pressure.
94 2 Amber 268 Injector Meter- The ECM will

ing Rail 1 Pres- estimate fuel
sure - Data Er- pressure, and
ratic, Intermit- power is re-
tent, or Incor- duced.
rect. the ECM
has detected
that the fuel
pressure signal
is not chang-
ing.
94 0/18 Amber 2215 Injector Meter- Possibly hard

ing Rail 1 Pres- to start, low
sure - Data power, or en-
Valid but Be- gine smoke.
low Normal
Operational
Range - Mod-
erately Severe
Level. The
ECM has de-
tected that fuel
pressure is
lower than
commanded
pressure.
94 0/18 Amber 2215 Fuel Pump De- Possibly hard

livery Pressure to start, low
Low - Data power, or en-
low Normal
Operational
Range - Mod-
erately Severe
Level. The
ECM has de-
tected that fuel
pressure is
lower than
commanded
pressure.
235 No: 2522100363.3 en-US

97 0/15 Amber 418 Water-In-Fuel Possible white

Indicator - Data smoke, loss of
Valid but power, or hard
Above Normal starting.
Operational
Range - Least
Severe Level.
Water has
been detected
in the fuel filter.
97 3/3 Amber 428 Water-in-Fuel None on per-

Indicator Sen- formance. No
sor Circuit - water-in-fuel
Voltage Above warning avail-
Normal or able.
Shorted to
High Source.
High voltage
detected at the
water-in-fuel
circuit.
97 4/4 Amber 429 Water-in-Fuel None on per-

Indicator Sen- formance. No
sor Circuit - water-in-fuel
Voltage Below warning avail-
Normal or able.
Shorted to Low
Source. Low
voltage de-
tected at the
water-in-fuel
circuit.
98 0 Red 688 Engine Oil Possible low

Level — Data power, exces-
Valid But sive smoke, oil
Above Normal dilution, con-
Operational tamination, or
Range — Most severe engine
Severe Level. damage. The
High oil level engine may
has been de- derate.
tected by the
oil level sen-
sor.
98 1 Red 253 Engine Oil The engine

Level — Data may derate.
Valid But Be- Possible low oil
low Normal pressure, pos-
236 No: 2522100363.3 en-US

Operational sible severe

Range — Most engine dam-
Severe Level. age.
Very low oil
level has been
detected by the
oil level sen-
sor.
98 3 Amber 498 Engine Oil No protection

Level Sensor for low engine
Circuit — Volt- oil level.
age Above
Normal, or
Shorted to
High Source.
High signal
voltage de-
tected at en-
gine oil level
sensor circuit.
98 4 Amber 499 Engine Oil No protection

Level Sensor for low engine
Circuit — Volt- oil level.
age Below
Normal, or
Shorted to Low
Source. Low
signal voltage
detected at en-
gine oil level
sensor circuit.
98 1/17 Maintenance 471 Engine Oil The engine

Level — Data may derate.
Valid But Be- Possible low oil
low Normal pressure, pos-
Operational sible severe
Range — engine dam-
Least Severe age.
Level. Low oil
level has been
detected by the
oil level sen-
sor.
100 3 Amber 135 Oil Pressure None on per-

Sensor Circuit formance. No
- Voltage engine protec-
Above Normal, tion for oil
or Shorted to pressure.
237 No: 2522100363.3 en-US

High Source.
High signal
voltage de-
tected at the
engine oil pres-
sure sensor
circuit.
100 1/1 Red 415 Engine Oil Progressive

Pressure - power derate
Data Valid but increasing in
Below Normal severity from
Operational time after alert.
Range - Most If the Engine
Severe Level. Protection
Oil pressure Shutdown fea-
signal indicates ture is enabled,
that oil pres- engine will shut
sure is below down 30 sec-
the engine pro- onds after the
tection critical red STOP light
limit. starts flashing.
Marine: Cali-
bration depen-
dent.
100 1/1 Red 415 Engine Oil Progressive

Pressure - power derate
Below Normal severity from
Operational time after alert.
Range - Most If the Engine
Severe Level. Protection
Oil pressure Shutdown fea-
signal indicates ture is enabled,
oil pressure is engine will shut
below the en- down 30 sec-
gine protection onds after the
critical limit. red STOP light
starts flashing.
100 1/18 Amber 143 Engine Oil None on per-

Pressure - formance.
Data Valid but
Below Normal
Operational
Range - Mod-
erately Severe
Level. Engine
oil pressure
signal indicates
engine oil pres-
238 No: 2522100363.3 en-US

sure is below
the engine pro-
tection warning
limit.
100 2/2 Amber 435 Oil Pressure None on per-

Switch Sensor formance. No
Circuit - Data engine protec-
Erratic, Inter- tion for oil
mittent or In- pressure.
correct. An er-
ror in the en-
gine oil pres-
sure switch
signal was de-
tected by the
ECM.
100 4/4 Amber 141 Oil Pressure None on per-

Sensor Circuit formance. No
- Voltage Be- engine protec-
low Normal, or tion for oil
Shorted to Low pressure.
Source. Low
signal voltage
detected at the
engine oil pres-
sure sensor
circuit.
102 2 Amber 433 Intake manifold Derate in

pressure sen- power output
sor circuit - of the engine.
data incorrect.
An error in the
intake manifold
pressure sen-
sor signal was
detected by the
ECM.
102 2/2 Amber 2973 Intake Manifold Engine power

Pressure Sen- derate.
sor Circuit -
Data Erratic,
Intermittent or
Incorrect. The
ECM has de-
tected an in-
take manifold
pressure signal
that is too high
239 No: 2522100363.3 en-US

or low for cur-

rent engine op-
erating condi-
tions.
102 3/3 Amber 122 Intake Manifold Derate in

Pressure Sen- power output
sor Circuit - of the engine.
Voltage Above
Normal or
Shorted to
High Source.
High signal
voltage de-
tected at the
intake manifold
pressure sen-
sor circuit.
102 4/4 Amber 123 Intake Manifold Derate in

Pressure Sen- power output
sor Circuit - of the engine.
Voltage Below
Normal or
Shorted to Low
Source. Low
signal voltage
detected at the
intake manifold
pressure sen-
sor circuit.
103 18 Amber 687 Turbocharger Engine power

number 1 derate. The
speed low - ECM uses esti-
warning level. mated tur-
Low turbocharger
bocharger speed.
speed detected
by the ECM.
103 0/16 Amber 595 Turbocharger Engine power

Number 1 derate. The
Speed High - ECM uses an
Data Valid but estimated tur-
Above Normal bocharger
Operational speed.
Range - Mod-
erately Severe
Level. High tur-
240 No: 2522100363.3 en-US

bocharger
speed has
been detected.

Speed Low - ECM uses an
Below Normal bocharger
Operational speed.
Range - Mod-
erately Severe
Level. Low tur-
bocharger
speed detected
by the ECM.

Speed Low - ECM uses an
Below Normal bocharger
Operational speed.
Range - Mod-
erately Severe
Level. Low tur-
bocharger
speed detected
by the ECM.

Speed Invalid derate.
Rate of
Change De-
tected - Abnor-
mal Rate of
Change. The
turbocharger
speed sensor
has detected
an erroneous
speed value.
105 2 Amber 436 Intake Manifold The ECM cal-

1 Temperature culates the
— Data Erratic, temperature in
Intermittent, or the engine’s in-
Incorrect. The take manifold.
intake mani-
fold’s tempera-
ture sensor is
241 No: 2522100363.3 en-US

reading an er-
ratic value at
initial key-on.
105 10 Amber 1848 Intake Manifold The ECM cal-

1 Temperature culates the
— Abnormal temperature in
Rate of the engine’s in-
Change. The take manifold.
intake mani-
fold’s tempera-
ture sensor is
not responding
to a change in
engine operat-
ing conditions.
105 0/0 Red 155 Intake Manifold Progressive

1 Temperature power derate
- Data Valid increasing in
but Above Nor- severity from
mal Opera- time after alert.
tional Range - If the Engine
Most Severe Protection
Level. Intake Shutdown fea-
manifold air ture is enabled,
temperature engine will shut
signal indicates down 30 sec-
intake manifold onds after the
air temperature red stop light
above engine starts flashing.
protection criti-
cal limit.
105 0/15 None 2964 Intake Manifold Progressive

Temperature power derate
High - Data increasing in
Valid but severity from
Above Normal time of alert.
Operational
Range - Least
Severe Level.
Intake manifold
air temperature
signal indicates
intake manifold
air temperature
above engine
protection
warning limit.
242 No: 2522100363.3 en-US

105 0/16 Amber 488 Intake Manifold Progressive

1 Temperature power derate
- Data Valid increasing in
but Above Nor- severity from
mal Opera- time of alert.
tional Range -
Moderately Se-
vere Level. In-
take manifold
air temperature
signal indicates
intake manifold
air temperature
above engine
protection
warning limit.
105 3/3 Amber 153 Intake Manifold Possible white

Air Tempera- smoke. Fan
ture Sensor will stay ON if
Circuit - Volt- controlled by
age Above the ECM. No
Normal or engine protec-
Shorted to tion for intake
High Source. manifold air
High signal temperature.
voltage de-
tected at intake
manifold air
temperature
circuit.
105 4/4 Amber 154 Intake Manifold Possible white

Air Tempera- smoke. Possi-
ture Sensor ble white
Circuit - Volt- smoke. Fan
age Below will stay ON if
Normal or controlled by
Shorted to Low the ECM. No
Source. Low engine protec-
signal voltage tion for intake
detected at in- manifold air
take manifold temperature.
air temperature
circuit.
108 2 Amber 295 Barometric Engine power

Pressure — derate.
Data Erratic,
Intermittent, or
Incorrect. The
ambient air
243 No: 2522100363.3 en-US

pressure sen-
sor is reading
an erratic value
at initial key-
on.
108 3/3 Amber 221 Barometric Engine power

sor Circuit -
Voltage Above
Normal, or
Shorted to
High Source.
High signal
voltage de-
tected at baro-
metric pres-
sure circuit.
108 4/4 Amber 222 Barometric Engine power

sor Circuit -
Voltage Below
Normal, or
Shorted to Low
Source. Low
signal voltage
detected at
barometric
pressure cir-
cuit.
110 2 Amber 334 Engine Coolant The ECM will

Temperature - estimate en-
Data Erratic, gine coolant
Intermittent, or temperature.
Incorrect. The
engine coolant
temperature
reading is not
changed with
engine operat-
ing conditions.
110 0/0 Red 151 Engine Coolant Progressive

Temperature - power derate
Above Normal severity from
Operational time of alert. If
Range - Most Engine Protec-
Severe Level. tion Shutdown
Engine coolant feature is en-
244 No: 2522100363.3 en-US

temperature abled, engine

signal indicates will shut down
engine coolant 30 seconds af-
temperature ter red stop
above engine light starts
protection criti- flashing.
cal limit.
110 0/15 None 2963 Engine Coolant Progressive

Temperature power derate
High - Data increasing in
Valid but severity from
Above Normal time of alert.
Operational
Range - Least
Severe Level.
Engine coolant
temperature
signal indicates
that coolant
temperature is
above the en-
gine coolant
temperature
engine protec-
tion warning
limit.
110 0/16 Amber 146 Engine Coolant Progressive

Temperature - power derate
Above Normal severity from
Operational time of alert.
Range - Mod-
erately Severe
Level. Engine
coolant tem-
perature signal
indicates that
coolant tem-
perature is
above the en-
gine coolant
temperature
engine protec-
tion warning
limit.
110 3/3 Amber 144 Engine Coolant Possible white

Temperature 1 smoke. Fan
Sensor Circuit will stay ON if
- Voltage controlled by
245 No: 2522100363.3 en-US

Above Normal ECM. No en-

or Shorted to gine protection
High Source. for engine
High signal coolant tem-
voltage or perature.
open circuit de-
tected at en-
gine coolant
temperature
circuit.
110 4/4 Amber 145 Engine Coolant Possible white

Temperature 1 smoke. Fan
Sensor Circuit will stay ON if
- Voltage Be- controlled by
low Normal or ECM. No en-
Shorted to Low gine protection
Source. Low for engine
signal voltage coolant tem-
detected at en- perature.
gine coolant
temperature
circuit.
111 1 Amber 235 Coolant Level - Progressive

Data Valid but power derate
Below Normal increasing in
Operational severity from
Range - Most time of alert. If
Severe Level. the Engine
Low engine Protection
coolant level Shutdown fea-
detected. ture is enabled,
engine will shut
down 30 sec-
onds after the
red stop light
starts flashing.
111 1/18 Amber 197 Coolant Level - None on per-

Data Valid but formance.
Below Normal
Operational
Range - Mod-
erately Severe
Level. Low en-
gine coolant
level detected.
111 3/3 Amber 195 Coolant Level None on per-

Sensor Circuit formance.
- Voltage
246 No: 2522100363.3 en-US

Above Normal
or Shorted to
High Source.
High signal
voltage de-
tected at en-
gine coolant
level sensor
circuit.
111 4/4 Amber 196 Coolant Level None on per-

Sensor Circuit formance.
- Voltage Be-
low Normal or
Shorted to Low
Source. Low
signal voltage
detected at the
engine coolant
level sensor
circuit.
157 0 Amber 449 Injector Meter- None or possi-

ing Rail Num- ble power in-
ber 1 Pressure terruption as-
- Data Valid sociated with
But Above Nor- dump valve re-
mal Operating set.
Range - Most
Severe Level.
Fuel pressure
signal indicates
that fuel pres-
sure has ex-
ceeded the
maximum limit
for the given
engine rating.
157 0 Amber 1911 Injector Meter- None or possi-

ing Rail Num- ble engine
ber 1 Pressure noise associ-
- Data Valid ated with
But Above Nor- higher injection
mal Operating pressure (es-
Range - Most pecially at idle
Severe Level. or light load).
Fuel pressure Engine power
signal indicates is reduced.
that fuel pres-
sure has ex-
ceeded the
247 No: 2522100363.3 en-US

maximum limit
for the given
engine rating.
157 1 Amber 2249 Injector Meter- Possibly hard

ing Rail 1 Pres- to start, low
sure - Data power, or en-
low Normal
Operational
Range - Most
Severe Level.
The ECM has
detected that
fuel pressure is
lower than
commanded
pressure.
157 2 Amber 554 Injector Meter- The ECM will

ing Rail 1 Pres- estimate fuel
sure - Data Er- pressure and
ratic, Intermit- power is re-
tent, or Incor- duced.
rect. the ECM
has detected
that the fuel
pressure signal
is not chang-
ing.
157 3 Amber 451 Injector Meter- Power and or

ing Rail Num- speed derate.
ber 1 Pressure
Sensor Circuit
- Voltage
Above Normal
or Shorted to
High Source.
High signal
voltage de-
tected at rail
fuel pressure
sensor circuit.
157 4 Amber 452 Injector Meter- Power and or

ing Rail Num- speed derate.
ber 1 Pressure
Sensor Circuit
- Voltage Be-
low Normal or
Shorted to Low
248 No: 2522100363.3 en-US

Source. Low
signal voltage
detected at the
rail fuel pres-
sure sensor
circuit.
157 0/16 Amber 553 Injector Meter- None or possi-

ing Rail 1 Pres- ble engine
sure - Data noise associ-
Valid but ated with
Above Normal higher injection
Operational pressure (es-
Range - Mod- pecially at idle
erately Severe or light load).
Level. The Engine power
ECM has de- is reduced.
tected that fuel
pressure is
higher than
commanded
pressure.
166 2 None 951 Power imbal- Possible low

ance between power, rough
different cylin- idle, or misfire.
ders. Power
imbalance be-
tween different
cylinders has
been detected
by the ECM.
167 0/16 Amber 596 Electrical Amber warning

Charging Sys- light illumi-
tem Voltage nated until high
High - Data battery voltage
Valid but condition is
Above Normal corrected.
Operational
Range - Mod-
erately Severe
Level. High
battery voltage
detected by the
battery voltage
monitor fea-
ture.
167 1/1 Red 598 Electrical Red light illumi-

Charging Sys- nated until very
tem Voltage low battery
249 No: 2522100363.3 en-US

Low - Data voltage condi-

Valid but Be- tion is cor-
low Normal rected.
Operational
Range - Most
Severe Level.
Very low bat-
tery voltage
detected by the
battery voltage
monitor fea-
ture.
167 1/18 Amber 597 Electrical Amber light will

Charging Sys- light until low
tem Voltage battery voltage
Low - Data condition is
Valid but Be- corrected.
low Normal
Operational
Range - Mod-
erately Severe
Level. Low bat-
tery voltage
detected by the
battery voltage
monitor fea-
ture.
168 0/16 Amber 442 Battery 1 Volt- Possible elec-

age - Data trical damage
Valid but to all electrical
Above Normal components.
Operational
Range - Mod-
erately Severe
Level. ECM
supply voltage
is above the
maximum sys-
tem voltage
level.
168 1/18 Amber 441 Battery 1 Volt- Engine may

age - Data stop running or
Valid but Be- be difficult to
low Normal start.
Operational
Range - Mod-
erately Severe
Level. ECM
supply voltage
250 No: 2522100363.3 en-US

is below the
minimum sys-
tem voltage
level.
190 2 None 2321 Engine Crank- Engine can ex-

shaft Speed/ hibit misfire as
Position - Data control
Erratic, Inter- switches from
mittent, or In- the primary to
correct. Crank- the backup
shaft engine speed sensor.
speed sensor Engine power
intermittent is reduced
synchroniza- while the en-
tion. gine operates
on the backup
speed sensor.
190 0/0 Red 234 Engine Crank- Fuel injection

shaft Speed/ disabled until
Position - Data engine speed
Valid but fails below the
Above Normal overspeed
Operational limit.
Range - Most
Severe Level.
Engine speed
signal indicates
engine speed
above engine
protection limit.
190 2/2 Amber 689 Engine Crank- Engine can run

shaft Speed/ rough. Possibly
Position - Data poor starting
Erratic, Inter- capability. En-
mittent, or In- gine runs using
correct. Loss of backup speed
signal from sensor. Engine
crankshaft sen- power is re-
sor. duced.
251 12/2 Amber 1689 Real-Time None on per-

Clock Power formance. Data
Interrupt - Data in the ECM will
Erratic, Inter- not have accu-
mittent or In- rate time and
correct. The date informa-
Real-Time tion.
251 No: 2522100363.3 en-US

clock power
has been inter-
rupted.
251 2/2 Amber 319 Real-Time None on per-

Clock Power formance. Data
Interrupt - Data in the ECM will
Erratic, Inter- not have accu-
mittent or In- rate time and
correct. The date informa-
Real-Time tion.
clock power
has been inter-
rupted.
411 11 None 1716 Auxiliary Tem- Possible en-

perature Sen- gine power de-
sor Input 1 Cir- rate.
cuit - Root
Cause Not
Known. High
temperature
detected by the
OEM tempera-
ture sensor.
411 0/16 Amber 2359 Exhaust Gas EGR valve will

Recirculation be closed.
(EGR) Differ-
ential Pressure
Sensor - Data
Valid but
Above Normal
Operating
Range - Mod-
erately Severe
Level. EGR dif-
ferential pres-
sure sensor
failed auto-
matic calibra-
tion procedure
or EGR differ-
ential pressure
reading not
valid for engine
operating con-
ditions.
411 3/3 Amber 2273 EGR valve dif- EGR valve will
ferential pres- be closed.
sure sensor
252 No: 2522100363.3 en-US

circuit - shorted
high. High volt-
age detected
on the EGR
differential
pressure sen-
sor circuit.
411 4/4 Amber 2274 EGR valve dif- EGR valve will
ferential pres- be closed.
sure sensor
circuit - shorted
low. Low signal
voltage de-
tected on the
EGR valve dif-
ferential pres-
sure sensor
circuit.
412 3 Amber 2375 EGR Tempera- EGR valve will

ture Sensor be closed.
Circuit - Volt-
age Above
Normal or
Shorted to
High Source.
High signal
voltage de-
tected at the
EGR tempera-
ture sensor cir-
cuit.
412 0/15 None 2961 Exhaust Gas Engine power

Recirculation derate until the
(EGR) temper- EGR tempera-
ature - data ture is under
valid but above the maximum
normal operat- limit.
ing range, least
severe level.
412 0/16 Amber 2962 Exhaust Gas Severe fueling

Recirculation derate to bring
(EGR) temper- EGR tempera-
ature - data ture under the
valid but above maximum limit.
normal operat-
ing range,
moderately se-
vere level.
253 No: 2522100363.3 en-US

412 4/4 Amber 2376 Recirculation EGR valve will

Exhaust Gas be closed.
(EGR) Tem-
perature Sen-
sor Circuit -
Voltage Below
Normal or
Shorted to Low
Source. Low
signal voltage
detected at the
EGR tempera-
ture circuit.
441 3 Amber 293 Auxiliary Tem- None on per-

perature Sen- formance.
sor Input 1 -
Voltage Above
Normal, or
Shorted to
High Source.
High signal
voltage or
open circuit de-
tected at the
OEM auxiliary
temperature
circuit.
441 4 Amber 294 Auxiliary Tem- None on per-

perature Sen- formance.
sor Input 1 Cir-
cuit - Voltage
Below Normal,
or Shorted to
Low Source.
Low signal
voltage de-
tected at OEM
auxiliary tem-
perature cir-
cuit.
441 14 Red 292 Auxiliary Tem- Possible en-

perature Sen- gine power de-
sor Input 1 - rate.
Special In-
structions.
558 13/13 Red 432 Throttle Pedal Engine will

or Lever Idle only idle.
Validation Cir-
254 No: 2522100363.3 en-US

cuit - Out of
Calibration.
Voltage at idle
validation on-
idle and off-idle
circuit does not
match throttle
pedal position.
558 2/2 Amber 431 Throttle Pedal Engine will

or Lever Idle only idle.
Validation Cir-
cuit - Data Er-
ratic, Intermit-
tent, or Incor-
rect. Voltage
detected simul-
taneously on
both idle vali-
dation and off-
idle validation
switches.
608 2 None 412 SAE J1587/ None on per-

J1922 data link formance. De-
- can not trans- vices on the
mit. Communi- J1587/J1922
cation between data link possi-
the ECM and bly will not op-
another device erate.
on the J1587/
J1922 data link
has been lost.
611 2 Amber 523 Auxiliary Inter- The intermedi-

mediate (PTO) ate speed con-
Speed Switch trol switch may
Validation - not operate
Data Erratic, correctly.
Intermittent, or
Incorrect. The
position of the
intermediate
speed control
switch 1 does
not match the
position of the
intermediate
speed control
validation
switch.
255 No: 2522100363.3 en-US

611 11/31 Amber 757 Engine Control Possible no

Module Data noticeable per-
Lost - Condi- formance ef-
tion Exits. Se- fects, engine
vere loss of dying or hard
data from the starting. Fault
ECM. information,
trip informa-
tion, and main-
tenance moni-
tor data can be
inaccurate.
611 4/4 Amber 238 Sensor Supply Possible hard

3 Circuit - Volt- starting and
age Below rough running.
Normal, or
Shorted to Low
Source. Low
voltage de-
tected on the
+5 volt sensor
supply circuit
to the engine
speed sensor.
612 2 Red 115 Engine Mag- Fuelling to the

netic Crank- injectors is dis-
shaft Speed/ abled, and the
Position lost engine can not
both of two sig- be started.
nals - Data Er-
ratic, Intermit-
tent, or Incor-
rect. The ECM
has detected
that the pri-
mary engine
speed sensor
and the backup
engine speed
sensor signals
are reversed.
625 2 Amber 1633 Komnet None on per-

Datalink Can- formance.
not Transmit -
Data Erratic,
Intermittent, or
Incorrect.
Communica-
tions within the
256 No: 2522100363.3 en-US

OEM datalink
network is in-
termittent.
625 9 Red 291 Proprietary The immo-

Datalink Error biliser anti-theft
(OEM/Vehicle system will not
Datalink) — operate prop-
Abnormal Up- erly. The en-
date Rate. The gine may not
ECM cannot start.
communicate
with the immo-
biliser anti—
theft system.
627 12 Amber 351 Injector Power Possible

Supply - Bad smoke, low
Intelligent De- power, engine
vice or Compo- misfire, and/or
nent. The ECM engine will not
measured in- start.
jector boost
voltage is low.
627 2/2 Amber 434 Power Supply Possible no

Lost With Igni- noticeable per-
tion On - Data formance ef-
Erratic, Inter- fects or engine
mittent or In- dying or hard
correct. Supply starting. Fault
voltage to the information,
ECM fell below trip informa-
6.2 VDC motion, and main-
mentarily, or tenance moni-
the ECM was tor data can be
not allowed to inaccurate.
power down
correctly (re-
tain battery
voltage for 30
seconds after
switching off).
627 2/2 None 1117 Power Lost Possible no

without Ignition noticeable per-
Off - Data Er- formance ef-
ratic, Intermit- fects or engine
tent or Incor- dying or hard
rect. Supply starting. Fault
voltage to the information,
ECM fell below trip informa-
257 No: 2522100363.3 en-US

6.2 volts motion, and main-

mentarily, or tenance moni-
the ECM was tor data can be
not allowed to inaccurate.
power down
correctly (re-
tain battery
voltage for 30
seconds after
switching off).
629 12/12 Red 111 Engine Control Engine may

Module - criti- not start.
cal internal fail-
ure. Error inter-
nal to the ECM
related to
memory hard-
ware failures or
internal ECM
voltage supply
circuits.
629 12/12 Amber 343 Engine Control No perfor-

Module Warn- mance effects
ing Internal or possible se-
Hardware Fail- vere power de-
ure - Bad Intel- rate.
ligent Device
or Component.
630 13 Red 342 Electronic Cali- None on per-

bration Code formance.
Incompatibility
- Out of Cali-
bration. An in-
compatible cal-
ibration be-
tween the pri-
mary and sec-
ondary OEM
installed ECM
has been de-
tected.

Module Cali- noticeable per-
bration Pro- formance ef-
gram Memory fects, engine
(RAM) Corrup- dying or hard
tion - Condition starting. Fault
information,
258 No: 2522100363.3 en-US

Exists. Severe trip informa-

loss of data tion, and main-
from the ECM. tenance moni-
tor data can be
inaccurate.

Module Data noticeable per-
Lost - Data Er- formance ef-
ratic, Intermit- fects, engine
tent or Incor- dying or hard
rect. Severe starting. Fault
loss of data information,
from the ECM. trip informa-
tion, and main-
tenance moni-
tor data can be
inaccurate.
633 11/31 Amber 2311 Fueling Actua- Possible low

tor Number 1 power.
Circuit Error
Conditions Ex-
ists. Fuel pump
actuator circuit
resistance too
high or too low.
639 2 None 426 SAE J1939 None on per-

data link - can- formance.
not transmit. J1939 devices
Communica- possibly do not
tion between operate.
the ECM and
another device
on the SAE
J1939 data link
has been lost.
639 9 Amber 285 SAE J1939 One or more

Multiplexing multiplexed de-
PGN Timeout vices will not
Error - Abnor- operate prop-
mal Update erly. One or
Rate. The more symp-
Cummins ECM toms will occur.
did not receive
a multiplex
message from
an OEM VECU
259 No: 2522100363.3 en-US

within the time

limit or did not
receive it at all.
639 9 None 427 J1939 Datalink Engine speed

- Abnormal Up- will ramp down
date Rate. and remain at
Communica- idle.
tion between
the electronic
control module
(ECM) and an-
other device on
the SAE J1939
data link has
been lost.
639 13 Amber 286 Data Link At least one

J1939 Configu- multiplexed de-
ration Error - vice will not op-
Out of Calibra- erate properly.
tion. The ECM
expected infor-
mation from a
multiplexed de-
vice but only
received a por-
tion of the nec-
essary infor-
mation.
640 14 Red 599 Auxiliary Com- Engine will

manded Dual shut down.
Output Shut-
down - Special
Instructions.
The engine
protection limit
has been ex-
ceeded for the
dual outputs
calibrated lim-
its.
641 3 Amber 2385 VGT Actuator - Variable geom-

Voltage Above etry tur-
Normal or bocharger may
Shorted to be in either the
High Source. open or closed
Open circuit or position.
high voltage
detected at tur-
260 No: 2522100363.3 en-US

bocharger con-
trol valve cir-
cuit.
641 4 Amber 2384 VGT Actuator - Variable geom-

Voltage Below etry tur-
Normal or bocharger will
Shorted to Low go to the open
Source. Low position.
voltage de-
tected at tur-
bocharger con-
trol valve cir-
cuit.
641 0/15 None 9122 Variable geom- Possible low

etry tur- power. Power
bocharger ac- to turbocharger
tuator over actuator will be
temperature limited.
(calculated) -
data above
normal range -
least severe
level.
641 5/5 Amber 2383 Variable Ge- Possible low

ometry Tur- power. Power
bocharger ac- removed from
tuator circuit - the tur-
current below bocharger ac-
normal, or tuator motor.
open circuit.
647 3 Amber 2377 Fan Control The fan may

Circuit - Volt- stay on contin-
age Above uously or not
Normal or run at all.
Shorted to
High Source.
Open circuit or
high voltage
detected at the
fan control cir-
cuit.
647 4/4 Amber 245 Fan Control The fan can

Circuit - Volt- possibly stay
age Below on continu-
Normal or ously or not
Shorted to Low run at all.
Source. Low
signal voltage
261 No: 2522100363.3 en-US

detected at the
fan control cir-
cuit when com-
manded on.
651 5 Amber 322 Injector Sole- Engine can

noid Driver misfire or pos-
Cylinder 1 Cir- sibly run rough.
cuit - Current
Below Normal,
or Open Cir-
cuit. High re-
sistance or no
current de-
tected at Num-
ber 1 injector
DRIVER or
RETURN pin.
651 7 Amber 1139 Injector Sole- Engine will

noid Driver shut down.
Cylinder 1 -
Mechanical
System Not
Responding
Properly or Out
of Adjustment.
Unintended fu-
eling detected
in cylinder
number 1.

cuit - Current
Below Normal,
or Open Cir-
cuit. High re-
sistance or no
current de-
tected at Num-
ber 2 injector
driver or return
pin.

Cylinder 2 -
Mechanical
System Not
Responding
262 No: 2522100363.3 en-US

Properly or Out
of Adjustment.
Unintended fu-
eling detected
in cylinder
number 2.

cuit - Current
Below Normal,
or Open Cir-
cuit. High re-
sistance or no
current de-
tected at Num-
ber 3 injector
or return pin.

Cylinder 3 -
Mechanical
System Not
Responding
Properly or Out
of Adjustment.
Unintended fu-
eling detected
in cylinder
number 3.

cuit - Current
Below Normal
or Open Cir-
cuit. High re-
sistance or no
current de-
tected at Num-
ber 1 injector
driver or return
pin.

Cylinder 4 -
Mechanical
System Not
263 No: 2522100363.3 en-US

Responding
Properly or Out
of Adjustment.
Unintended fu-
eling detected
in cylinder
number 4.

cuit - Current
Below Normal,
or Open Cir-
cuit. High re-
sistance or no
current de-
tected at Num-
ber 5 injector
DRIVER or
RETURN pin.

Cylinder 5 -
Mechanical
System Not
Responding
Properly or Out
of Adjustment.
Unintended fu-
eling detected
in cylinder
Number 5.

cuit - Current
Below Normal,
or Open Cir-
cuit. High re-
sistance or no
current de-
tected at Num-
ber 6 injector
DRIVER or
RETURN pin.

Cylinder 6 -
264 No: 2522100363.3 en-US

Mechanical
System Not
Responding
Properly or Out
of Adjustment.
Unintended fu-
eling detected
in cylinder
Number 6.
677 3/3 Amber 584 Starter Relay Either the en-

Circuit - Volt- gine will not
age Above start or the en-
Normal or gine will not
Shorted to have starter
High Source. lockout protec-
Open circuit or tion.
high voltage
detected at
starter lockout
circuit.
677 4/4 Amber 585 Starter Relay The engine will

Circuit - Volt- not have
age Below starter lockout
Normal or protection.
Shorted to Low
Source. Low
voltage de-
tected at
starter lockout
circuit.
697 3 Amber 2557 Auxiliary PWM Can not control

Driver Number transmission.
1 - Voltage
Above Normal
or Shorted to
High Source.
High signal
voltage de-
tected at the
analogue
torque circuit.
697 4 Amber 2558 Auxiliary PWM Can not control

Driver Number transmission.
1 - Voltage Be-
low Normal or
Shorted to Low
Source. Low
signal voltage
265 No: 2522100363.3 en-US

detected at the
analogue
torque circuit.
702 3 Amber 527 Auxiliary Input/ None on per-

Output 2 Cir- formance.
cuit Voltage
Above Normal
or Shorted to
High Source.
High signal
voltage or
open circuit
has been de-
tected at the
auxiliary input
and output 2
circuit.
703 3 Amber 529 Auxiliary Input/ None on per-

Output 3 Cir- formance.
cuit - Voltage
Above Normal,
or Shorted to
High Source.
High signal
voltage has
been detected
at the auxiliary
input/output 3
circuit.
703 11 Amber 779 Auxiliary Possible en-

Equipment gine power de-
Sensor Input rate.
#3 (OEM
Switch) - Root
Cause Not
Known.
703 11 None 1639 Auxiliary Possible en-

Equipment gine power de-
Sensor Input rate.
Number 3
(OEM Switch) -
Root Cause
Not Known.
723 2 Amber 778 Engine Speed Possibly poor

Sensor starting capa-
(Camshaft) Er- bility. Engine
ror - Data Er- power derate.
ratic, Intermit-
266 No: 2522100363.3 en-US

tent, or Incor-
rect. The ECM
has detected
an error in the
camshaft posi-
tion sensor sig-
nal.
723 2 2322 None Backup Engine Automotive

Speed/Position and marine ap-
Sensor Num- plications: Pos-
ber 2 - Data sible low
Erratic, Inter- power.
mittent, or In-
correct.
Camshaft en-
gine speed
sensor inter-
mittent syn-
chronization.
723 7/7 Amber 731 Engine Speed Engine will run

Sensor/Posi- derated. Ex-
tion Camshaft cessive smoke,
and Crankshaft hard start, and
Misalignment - rough idle pos-
Mechanical sible.
System Not
Responding
Properly or Out
of Adjustment.
Mechanical
misalignment
between the
crankshaft and
camshaft en-
gine speed
sensors.
729 3 Amber 2555 Intake Air The intake air

Heater Number heaters may
1 Circuit - Volt- be ON or OFF
age Above all the time.
Normal or
Shorted to
High Source.
High voltage
detected at the
intake air
heater signal
circuit.
267 No: 2522100363.3 en-US

729 4 Amber 2556 Intake Air The intake air

Heater Number heaters may
1 Circuit - Volt- be ON or OFF
age Below all the time.
Normal or
Shorted to Low
Source. Low
voltage de-
tected at the
intake air
heater signal
circuit.
974 19 Red 288 SAE J1939 The engine will

Multiplexing not respond to
Remote Throt- the remote
tle pedal or throttle. Engine
Lever Data Er- may only idle.
ror - Received The primary or
Network Data cabin throttle
Error. The pedal may be
OEM vehicle able to be
electronic con- used.
trol unit
(VECU) de-
tected a fault
with the remote
accelerator.
974 3/3 None 133 Remote Throt- Remote throttle

tle Pedal or pedal will not
Lever Position operate. Re-
Sensor 1 Cir- mote throttle
cuit - Voltage pedal position
Above Normal will be set to
or Shorted to zero percent.
High Source.
High voltage
detected at re-
mote throttle
pedal position
circuit.
974 4/4 Red 134 Remote Throt- Remote throttle

tle pedal or pedal will not
Lever Position operate. Re-
Sensor 1 Cir- mote throttle
cuit- Voltage pedal position
Below Normal, will be set to
or Shorted to zero percent.
Low Source.
Low voltage
268 No: 2522100363.3 en-US

detected at re-
mote throttle
pedal position
signal.
1043 3/3 Amber 387 Throttle pedal Engine will

or Lever Posi- only idle.
tion Sensor
Supply Voltage
Circuit - Volt-
age Above
Normal or
Shorted to
High Source.
High voltage
detected at
sensor supply
circuit for the
throttle pedal
or lever posi-
tion sensor.
1043 4/4 Amber 284 Engine Speed/ Possible hard

Position Sen- starting and
sor (Crank- rough running.
shaft) Supply
Voltage Circuit
- Voltage Be-
low Normal or
Shorted to Low
Source. Low
voltage de-
tected on the
ECM voltage
supply line to
engine speed
sensor.
1043 4/4 Amber 443 Throttle pedal Engine will

or Lever Posi- only die.
tion Sensor
Supply Voltage
Circuit - Volt-
age Below
Normal or
Shorted to Low
Source. Low
voltage de-
tected at sen-
sor supply cir-
cuit to the
269 No: 2522100363.3 en-US

throttle pedal
or lever posi-
tion sensor.
1072 3 Amber 2366 Engine Brake Engine brake

Actuator Circuit on cylinders 1,
Number 1 - 2, and 3 can
Voltage Above not be acti-
Normal or vated or ex-
Shorted to haust brake
High Source. will not oper-
Open circuit or ate.
high voltage
detected at the
engine brake
solenoid num-
ber 1 signal cir-
cuit.

Actuator Driver on cylinders 1,
1 Circuit - Volt- 2, and 3 can
age Below not be acti-
Shorted to Low haust brake
Source. Low will not oper-
voltage de- ate.
tected at the
engine brake
solenoid num-
ber 1 signal cir-
cuit.

Voltage Below not be acti-
Shorted to Low haust brake
Source. Low will not oper-
voltage de- ate.
tected at the
engine brake
solenoid num-
ber 1 signal cir-
cuit.

Voltage Above not be acti-
Normal or vated.
270 No: 2522100363.3 en-US

Shorted to
High Source.
Open circuit or
high voltage
detected at the
engine brake
solenoid num-
ber 2 signal cir-
cuit.

Voltage Below not be acti-
Normal or vated.
Shorted to Low
Source. Low
voltage de-
tected at the
engine brake
solenoid num-
ber 2 signal cir-
cuit.
1075 3 Amber 2265 Electric Lift Engine can be

Pump for En- difficult to start.
gine Fuel Sup-
ply Circuit -
Voltage Above
Normal, or
Shorted to
High Source.
High voltage or
open detected
at the fuel lift
pump signal
circuit.
1075 4 Amber 2266 Electric Lift Engine can be

Pump for En- difficult to start.
gine Fuel Sup-
ply Circuit -
Voltage Below
Normal, or
Shorted to Low
Source. Low
signal voltage
detected at the
fuel lift pump
circuit.
271 No: 2522100363.3 en-US

1079 3/3 Amber 386 Sensor Supply Engine power

Voltage num- derate.
ber 1 Circuit -
Voltage Above
Normal or
Shorted to
High Source.
High voltage
detected at
sensor supply
number 1 cir-
cuit.

Voltage Num- derate.
ber 1 Circuit -
Voltage Below
Normal or
Shorted to Low
Source. Low
voltage de-
tected at sen-
sor supply
number 1 cir-
cuit.

2 Circuit - Volt- derate.
age Above
Normal or
Shorted to
High Source.
High voltage
detected at
sensor supply
number 2 cir-
cuit.

Voltage Num- derate.
ber 2 Circuit -
Voltage Below
Normal, or
Shorted to Low
Source. Low
voltage de-
tected at the
sensor supply
number 2 cir-
cuit.
272 No: 2522100363.3 en-US

1137 2 Amber 497 Multiple Unit Multi-Unit syn-

Synchroniza- chronization
tion Switch - feature is dis-
Data Erratic, abled.
Intermittent, or
Incorrect.
Multi-Unit syn-
chronous ON/
OFF switch
and Multi-Unit
synchronous
complimentary
ON/OFF switch
have different
values in the
ECM.

Number 1 derate.
Compressor
Inlet Tempera-
ture Sensor
Circuit - Volt-
age Above
Normal or
Shorted to
High Source.
High signal
voltage de-
tected at the
turbocharger
compressor in-
let air tempera-
ture circuit.

Number 1 derate.
Compressor
Inlet Tempera-
ture Sensor
Circuit - Volt-
age Below
Normal or
Shorted to Low
Source. Low
signal voltage
detected at the
turbocharger
compressor in-
let air tempera-
ture sensor cir-
cuit.
273 No: 2522100363.3 en-US

1188 7 Amber 545 Turbocharger 1 Engine power

Wastegate derate.
Control — Me-
chanical Sys-
tem Not Re-
sponding Prop-
erly or Out of
Adjustment. In-
take manifold
pressure has
exceeded the
maximum limit
for the given
engine rating.
1195 2 Red 269 Antitheft Pass- The motor will

word Valid In- not start.
dicator — Data
Erratic, Inter-
mittent, or In-
correct. Engine
ignition attempt
without authori-
sation from im-
mobilizer anti-
theft device.
1209 2/2 Amber 2554 Exhaust pres- Engine power

sure sensor derate. Ex-
circuit - data haust Gas Re-
erratic, inter- circulation
mittent, or in- (EGR) valve
correct. An er- will be closed.
ror in the ex-
haust pressure
sensor signal
was detected
by the ECM.
1209 3/3 Amber 2373 Exhaust gas Engine will be

pressure sen- derated.
sor circuit -
shorted high.
High voltage
detected at the
exhaust gas
pressure sen-
sor circuit.
1209 4/4 Amber 2374 Exhaust gas Engine power

pressure sen- derate.
sor circuit -
274 No: 2522100363.3 en-US

shorted low.
Low voltage
detected on
the exhaust
gas pressure
sensor exhaust
circuit.
1322 11/31 Amber 1718 Engine Misfire Possible low

for Multiple power, rough
Cylinders — idle, or misfire.
Condition Ex-
ists. Engine
misfire has
been detected
in multiple
cylinder num-
bers.

Cylinder 1- power, rough
Condition Ex- idle, or misfire.
ists. Engine
misfire has
been detected
in cylinder
number 1.

Cylinder 2 - power, rough
ists. Engine
misfire has
been detected
in cylinder
number 2.

ists. Engine
misfire has
been detected
in cylinder
number 3.

ists. Engine
misfire has
275 No: 2522100363.3 en-US

been detected
in cylinder
number 4.

ists. Engine
misfire has
been detected
in cylinder
number 5.

ists. Engine
misfire has
been detected
in cylinder
number 6.
1347 3 Amber 272 High Fuel Engine will run

Pressure Sole- poorly but will
noid Valve Cir- be severely de-
cuit - Voltage rated. Rail
Above Normal pressure will
or Shorted to be higher than
High Source. commanded.
Electronic fuel
control actua-
tor shorted
high.
1347 4 Amber 271 High Fuel 0

Pressure Sole-
noid Valve Cir-
cuit - Voltage
Below Normal
or Shorted to
Low Source.
Electronic fuel
control actua-
tor shorted low.
1347 7 Amber 275 Fuel Pumping Engine will not

Element Num- run or possible
ber 1 (Front) - low power.
Mechanical
System Not
Responding
Properly or Out
of Adjustment.
276 No: 2522100363.3 en-US

1347 7 Amber 281 Fuel Pump Engine will not

Pressurising run or possible
Unit 1 - Me- low power.
chanical Sys-
tem Not Re-
sponding Prop-
erly or Out of
Adjustment.
Imbalance in
the pumping
detected be-
tween the front
and the rear
pump piston.
1378 11/31 Amber (Main- 649 Change Lubri- None on per-

tenance cating Oil and formance;
Flashout) Filter - Condi- maintenance
tion Exists. reminder only.
Change engine
oil and filter.
1388 3 Amber 297 Auxiliary Pres- None on per-

sure Sensor In- formance.
put 1 Circuit -
Voltage Above
Normal, or
Shorted to
High Source.
High signal
voltage de-
tected at the
OEM pressure
sensor circuit.
1388 4 Amber 298 Auxiliary Pres- None on per-

sure Sensor In- formance.
put 1 Circuit -
Voltage Below
Normal, or
Shorted to Low
Source. Low
signal voltage
or open circuit
detected at the
OEM pressure
sensor circuit.
1388 14 Red 296 Auxiliary Pres- Possible en-

sure Sensor In- gine power de-
put 1 - Special rate.
Instructions
277 No: 2522100363.3 en-US

1590 2 None 784 Loss of com- Adaptive cruise

munication control will not
with adaptive operate. Cruise
cruise control. control possi-
The ECM trig- bly will not op-
gers this fault erate properly.
when the
"heartbeat" sig-
nal from the
data bus is not
received.
1761 1 Amber 1673 Catalyst Tank Catalyst solu-

Level — Data tion injection
Valid but Be- into the af-
low Normal tertreatment
Operational system is dis-
Range — Most abled.
Severe Level.
No catalyst so-
lution has been
detected in the
catalyst solu-
tion tank.

Level Sensor tion injection
— Data Erratic, into the af-
Intermittent, or tertreatment
Incorrect. Cat- system is dis-
alyst solution abled.
level is not
changing with
engine operat-
ing conditions.

Circuit — Volt- into the af-
age Above tertreatment
Normal or system is dis-
Shorted to abled.
High Source.
High signal
voltage de-
tected at the
catalyst tank
level sensor
circuit.
278 No: 2522100363.3 en-US

1761 1/18 Maintenance 1671 Catalyst Tank None on per-

Level — Data formance.
Valid but Be-
low Normal
Operational
Range — Mod-
erately Severe
Level. Low cat-
alyst solution
level has been
detected in the
catalyst solu-
tion tank.
1761 4/4 Amber 1668 Catalyst Tank Catalyst solu-

Circuit — Volt- into the af-
age Below tertreatment
Normal or system is dis-
Shorted to Low abled.
Source. Low
signal voltage
detected at the
catalyst tank
level sensor
circuit.
2789 0/15 None 2346 Turbocharger Engine power

Turbine Inlet derate.
Temperature
(Calculated) -
Data Valid but
Above Normal
Operational
Range - Least
Severe Level.
Turbocharger
turbine inlet
temperature
has exceeded
the engine pro-
tection limit.
2790 0/15 None 2347 Turbocharger Engine power

Compressor derate.
Outlet Air Tem-
perature (Cal-
culated) - Data
Valid but
Above Normal
Range - least
severe level.
279 No: 2522100363.3 en-US

2791 0/15 None 9121 Exhaust Gas EGR valve will

Recirculation be closed.
(EGR) Valve
Actuator Over
Temperature
(Calculated) -
Data Above
Normal Range
- least severe
level.
2791 3/3 Amber 2352 EGR Valve Possible low

Control Circuit power. Power
- Voltage will be re-
Above Normal moved from
or Shorted to the EGR valve
High Source. motor.
High voltage
detected at the
EGR valve mo-
tor circuit.

- Voltage Be- removed from
low Normal or EGR valve mo-
Shorted to Low tor.
Source. Low
voltage de-
tected at the
EGR valve mo-
tor circuit.

- Current Be- removed from
low Normal or EGR valve mo-
Open Circuit. tor.
High voltage or
open circuit de-
tected at the
EGR valve mo-
tor circuit.

Recirculation power. Power
(EGR) Valve will be re-
Control - Me- moved from
chanical Sys- the EGR valve
tem Not Re- motor.
sponding Prop-
erly or Out of
280 No: 2522100363.3 en-US

Adjustment.
EGR valve mo-
tor does not re-
spond or is
slow to re-
spond.
2795 2 Amber 958 VGT Position Possible low

Sensor - Data power. Power
erratic, inter- to turbocharger
mittent, or in- actuator will be
correct. Inter- limited.
mittent variable
geometry tur-
bocharger
(VGT) position
information is
being received
by the elec-
tronic control
module (ECM).
2795 13/13 Amber 2388 Variable Ge- Variable Ge-

ometry Tur- ometry Tur-
bocharger ac- bocharger Pos-
tuator position sible low
failed auto- power. Vari-
matic calibra- able Geometry
tion procedure Turbocharger
- out of calibra- actuator will re-
tion. main either
open or closed.
2795 2/2 Amber 1229 VGT Position Possible low

Sensor - Data power. Power
erratic, inter- to turbocharger
mittent, or in- actuator will be
correct. Inter- limited.
mittent variable
geometry tur-
bocharger
(VGT) position
information is
being received
by the elec-
tronic control
module (ECM).
2795 4/4 Amber 2381 Turbocharger Possible low

position sensor power. Power
circuit - shorted will be re-
high. High sig- moved from
281 No: 2522100363.3 en-US

nal voltage de- the tur-

tected at the bocharger ac-
turbocharger tuator motor.
position sensor Turbocharger
circuit. will be open.

position sensor power. Power
circuit - shorted will be re-
low. Low signal moved from
voltage de- the tur-
tected at the bocharger ac-
turbocharger tuator motor.
position sensor Turbocharger
circuit. will be open.

(EGR) valve will be re-
control circuit - moved from
current above the EGR valve
normal or motor.
grounded cir-
cuit. Excess
current de-
tected at the
EGR valve mo-
tor output cir-
cuit.

actuator motor power. Power
circuit - current will be re-
is above nor- moved from
mal. Excessive the tur-
current de- bocharger ac-
tected at the tuator motor.
turbocharger
actuator motor
circuit.

actuator motor power. Power
- the mechani- will be re-
cal system is moved from
not responding the tur-
properly or is bocharger ac-
out of adjust- tuator motor.
ment. Tur-
bocharger ac-
tuator is not re-
282 No: 2522100363.3 en-US

sponding or is
slow to re-
spond.
3031 2 Amber 1679 Catalyst Tank Default tem-

Temperature perature value
— Data Erratic, used for cata-
Intermittent, or lyst solution
Incorrect. The temperature.
catalyst solu-
tion tempera-
ture sensor is
not changing
with engine op-
erating condi-
tions.

Temperature perature value
— Voltage used for cata-
Above Normal lyst tank tem-
or Shorted to perature.
High Source.
High signal
voltage or
open circuit de-
tected at the
catalyst tank
temperature
sensor circuit

Temperature perature used
— Voltage Be- for catalyst so-
low Normal or lution tempera-
Shorted to Low ture.
Source. Low
signal voltage
detected at the
catalyst solu-
tion tempera-
ture sensor cir-
cuit.
3050 0 Amber 1687 Catalyst Over Catalyst solu-

Temperature tion injection
— Data Valid into the af-
but Above Nor- tertreatment
mal Opera- system is dis-
tional Range abled.
— Most Se-
vere Level.
283 No: 2522100363.3 en-US

Very high tem-

peratures have
been detected
in the af-
tertreatment
system.
3050 11/31 Amber 1664 Catalyst Miss- Catalyst solu-

ing — Condi- tion injection
tion Exists. The into the af-
aftertreatment tertreatment
catalyst in the system is dis-
exhaust sys- abled.
tem is not
present.
3241 2 Amber 1667 Exhaust Gas Possible emis-

Temperature 1 sions non-com-
— Data Erratic, pliance. De-
Intermittent, or fault tempera-
Incorrect. The ture value used
exhaust gas for exhaust gas
temperature temperature
Number 1 sen- Number 1.
sor is not
changing with
engine operat-
ing conditions.

Circuit — Volt- pliance. De-
age Below fault tempera-
Normal or ture used for
Shorted to Low catalyst inlet
Source. High temperature.
signal voltage
detected at the
catalyst inlet
temperature
sensor circuit

Shorted to Low catalyst inlet
Source. Low temperature.
signal voltage
detected at the
284 No: 2522100363.3 en-US

catalyst inlet
temperature
sensor circuit.

— Abnormal pliance. De-
Rate of fault tempera-
Change. The ture value used
catalyst inlet for catalyst in-
temperature let tempera-
sensor is not ture.
responding to
a change in
engine operat-
ing conditions.
3241 0/15 None 1717 Exhaust Gas Possible en-

Temperature 1 gine power de-
— Data Valid rate.
but Above Nor-
mal Opera-
tional Range
— Least Se-
vere Level.
High catalyst
inlet tempera-
ture has been
detected.
3241 11/31 Amber 1663 Catalyst Inlet Catalyst solu-

Temperature tion injection
Sensor into the af-
Swapped with tertreatment
Outlet Temper- system is dis-
ature — Fault abled.
Condition Ex-
ists. The inlet
and outlet cat-
alyst tempera-
ture sensor
connections
are swapped.

— Data Erratic, pliance. De-
Intermittent, or fault tempera-
Incorrect. The ture value used
exhaust gas for exhaust gas
temperature temperature
Number 2 sen- Number 2.
285 No: 2522100363.3 en-US

sor is not
changing with
engine operat-
ing conditions.

age Above fault tempera-
Shorted to Low catalyst outlet
Source. High temperature.
signal voltage
detected at the
catalyst outlet
temperature
sensor circuit.

Shorted to Low catalytic con-
Source. Low verter’s ex-
signal voltage haust gas tem-
detected at the perature.
catalytic con-
verter’s ex-
haust gas tem-
perature sen-
sor circuit.

— Abnormal pliance. De-
Rate of fault tempera-
Change. The ture value used
catalyst outlet for catalyst out-
temperature let tempera-
sensor is not ture.
responding to
a change in
engine operat-
ing conditions.
3361 9 Amber 1711 Dosing Control Catalyst solu-

Unit Datalink tion injection
— Abnormal into the af-
Update Rate. tertreatment
Datalink com- system is dis-
munications abled.
286 No: 2522100363.3 en-US

between the
ECM and the
catalyst dosing
unit has been
interrupted.
3361 12 Amber 1681 Catalyst Dos- Catalyst solu-

ing Control tion injection
Unit — Bad In- into the af-
telligent Device tertreatment
or Component. system is dis-
An internal er- abled.
ror has been
detected in the
catalyst dosing
control unit.
3362 11/31 Amber 1682 Catalyst Catalyst solu-

Reagent Dos- tion injection
ing Unit Input into the af-
Lines - Condi- tertreatment
tion Exists. An system is dis-
error has been abled.
detected by the
catalyst dosing
control unit.
3363 4 Amber 1684 Catalyst Tank Catalyst tank

Heater Circuit heater will be
— Voltage Be- disabled.
low Normal or
Shorted to Low
Source. Low
signal voltage
detected at the
catalyst tank
heater relay
sensor circuit.
3363 0/16 Amber 1713 Catalyst Tank None on per-

Heater Circuit formance.
— Data Valid
But Above Nor-
mal Operating
Range — Mod-
erately Severe
Level. The cat-
alyst tank
heater is con-
tinuously in the
on position.
287 No: 2522100363.3 en-US

3363 1/18 Amber 1712 Catalyst Tank None on per-

Heater Circuit formance. Cat-
— Data Valid alyst solution
But Below Nor- injection into
mal Operating the aftertreat-
Range — Mod- ment system
erately Severe may be dis-
Level. The cat- abled if the cat-
alyst solution alyst solution is
temperature frozen.
did not in-
crease when
the catalyst
tank heater
was com-
manded on.
3449 3 Amber 1683 Catalyst Tank Catalyst tank

Heater Circuit heater will be
— Voltage disabled.
Above Normal
or Shorted to
High Source.
High signal
voltage de-
tected at the
catalyst tank
heater relay
sensor circuit.
3489 3 Amber 1697 After treatment Catalyst solu-

Number 1 Air tion injection
Enable Actua- into the af-
tor — Voltage tertreatment
Above Normal system is dis-
or Shorted to abled.
High Source.
High signal
voltage has
been detected
at the catalyst
air solenoid cir-
cuit.
3489 4 Amber 1698 After treatment Catalyst solu-

Number 1 Air tion injection
Enable Actua- into the af-
tor — Voltage tertreatment
Below Normal system is dis-
or Shorted to abled.
Low Source.
Low signal
288 No: 2522100363.3 en-US

voltage has
been detected
at the catalyst
air solenoid cir-
cuit.
Missing 0/16 Amber 124 Intake Manifold Engine power

1 Pressure derate.
Sensor Circuit
- Data Valid
but Above Nor-
mal Opera-
tional Range -
Moderately Se-
vere Level. In-
take manifold
pressure has
exceeded the
maximum limit
for the given
engine rating.
Missing 0 Red 148 Throttle Pedal Severe derate

tion Sensor 1 of the engine.
— Data Valid Emergency
But Above Nor- steering power
mal Opera- only.
tional Range
— Most Se-
vere Level. A
frequency
higher than
1500 Hz has
been detected
in the fre-
quency
damper’s input
to the ECM.
Missing 1 Red 147 Throttle Pedal Severe derate

tion 1 Sensor of the engine.
Circuit Fre- Emergency
quency — steering power
Data Valid But only.
Below Normal
Operational
Range — Most
Severe Level.
A frequency
lower than 100
289 No: 2522100363.3 en-US

Hz has been
detected in the
frequency
damper’s input
to the ECM.
290 No: 2522100363.3 en-US

Minetruck MT2010 9 Machine Specification
9 Machine Specification
9.1 Performance Related Data
9.1.1 Tramming Capacity
Cab Canopy Teletram
Payload [kg] 20,000 20,000 17,800
Material density [t/m3] 2.2 2.2 2.0
Volume, heaped [m3] 9.0 9.0 8.9
Volume, semi-heaped 8.0 8.0 8.1

[m3]
Volume, struck [m3] 7.0 7.0 7.3
9.1.2 Operating Times
seconds (±1)
Box raising time 14.2 ±1
Box lowering time 7 ±2
Control time (high idle speed) 5.2 ±1
Push plate out (Teletram) 12.0 ±1
Push plate in (Teletram) 11.0 ±1
9.1.3 Engine
Cummins diesel engine QSL9
Horse power 300
291 No: 2522100363.3 en-US

Diesel engine power (2100 rpm) 224 kW
Torque (1350 rpm) 1369 Nm
Displacement 8.9 litres
High Idle 2240 ±50 rpm
Low Idle 700 ±25 rpm
Stall speed 1939 ±100 rpm
9.1.4 Transmission
Dana 6000 series transmission, 4 speed shifting forward/reverse
[bar] [psi]
Transmission Oil Pressure 14 ±1.5 200 ±20
9.1.5 Axles
Rock tough 457
[litre] [gallons]
Differential (each) 28 7.4
Planetary (each) 5 1.3
9.1.6 Brakes
[bar] [psi]
Service brake pressure 103 ±3.5 1500 ±50
Accumulator Pre-Charge 83 ±3.5 1200 ±50
Charging valve connection 110 ±3.5 1600 ±50
Charging valve kick-out 138 ±3.5 2000 ±50
Charging valve connection, with emer- 120 ±3.5 1750 ±50

gency steering
Charging valve kick-out, with emer- 150 ±3.5 2180 ±50

gency steering
9.1.7 Tires
Front Rear
[bar] [psi] [bar] [psi]
18.00R25XKD1A 4.5±0.2 65 ±3 6.0±0.2 87 ±3
292 No: 2522100363.3 en-US

9.1.8 Hydraulics
Description [litre] [gallons]
Hydraulic tank capacity 240 63
Pressure [bar] [psi]
Dump, main relief/compensator pres- 155 ±3.5 2250 ±50

sure
Teletram, main relief pressure 138 ±3.5 1980 ±50
Dump, pilot pressure 21 ±3.5 300 ±50
Steering, main relief/compensator pres- 165 ±3.5 2400 ±50

sure
Steering, pilot pressure 15 ±3.5 220 ±50
9.1.9 Emergency Steering
Pressure [bar] [psi]
Accumulator emergency steering pre- 30 ±3.5 435 ±50

charge
Dampening emergency steering cylin- 50 ±3.5 725 ±50

ders pre-charge (only for wheel steer-
ing)
9.1.10 Capacities
Description [litre] [gallons]
Engine oil capacity with filter change 24 6.3
Fuel tank component capacity 375 99
Radiator - cold fill 40 10.5
Transmission and torque converter 70 18.5
Lubricant general 3.8 1
9.1.11 Cab Pressurizer Filter

Specification for cab pressurizer filter
293 No: 2522100363.3 en-US

9.2 Steering and Oscillation

Description
Turning angle (each way) 45º
Hub to hub distance (mm) (@4623 mm W.B.) left or right turn 3581
Hub to hub distance (mm) (@4242 mm W.B.) left or right turn 3214
294 No: 2522100363.3 en-US

Front axle oscillation 10º
9.3 Accumulator Precharge Pressure (N2)

Description [bar] [psi]
Brake accumulator 83 ±3.5 1200 ±50
Emergency steering accumulator 30 ±3.5 435 ±50
Damping accumulator for steering cylin- 50 ±3.5 725 ±50

ders (only for steering wheel)
9.4 Tightening Torques

A single bolt that is not tightened correctly can lead to failure of other bolts. Maintaining the
torque values from the following charts help to protect machine reliability.
9.4.1 Use the Correct Tool for the Job

Mechanical torque wrenches are based on leverage and have limitations. Hydraulic torque
tools are more efficient in tight quarters, and can apply high torque values quickly and
safely.
9.4.2 Torque Values by Bolt Size & Thread
Scope
This specification applies only to hardware that meets SAE J429 for Grade 5 and Grade 8
(ISO Property Class 8.8 or 10.9) for U.S. and Metric Hardware. This specification only ap-
plies unless otherwise specified and when noted on a drawing.
Definitions
Dry Plated or plain hardware that is clean with no applied or

residual lubrication.
Oil Single or multi-grade petroleum-based engine oils (typically

SAE 30 W or 15W40) can be used for thread lubrication.
Moly Paste Thread lubricant with approximately 65% molybdenum disul-

fide content, used to lubricate the threads of high strength
fasteners to reduce the torque requirement and generate the
correct bolt tension. Acceptable compounds include Loctite
Moly-Paste. Other similar compounds should be checked to
ensure that their K-Factor matches the points listed.
High Strength
It is recommended that all high strength (SAE Grade 8 or ISO Class 10.9) hardware is
torqued to spec using either oil or moly paste as a lubricant.
295 No: 2522100363.3 en-US

Tolerances
All bolt torque values that are tabulated in this specification have a tolerance of ±10%.
Unified Coarse Thread (UNC)

This chart shows standard bolt torques to be applied unless otherwise specified.
! NOTE: Lubrication with oil or moly-paste is preferred for grade 8 hardware
Size Grade 5 Grade 8

(mm)
Dry Oil Dry Oil Moly Paste
N-m ft-lbs N-m ft-lbs N-m ft-lbs N-m ft-lbs N-m ft-lbs
1/4 11 8 8 6 16 12 12 9 9 7
5/16 23 17 18 13 34 25 24 18 20 15
3/8 42 31 31 23 60 44 45 33 35 26
7/16 66 49 50 37 95 70 70 52 57 42
1/2 102 75 77 57 144 106 108 80 87 64
9/16 148 109 111 82 209 154 156 115 125 92
5/8 203 150 153 113 287 212 216 159 172 127
3/4 362 267 271 200 510 376 382 282 306 226
7/8 582 429 437 322 822 606 617 455 493 364
1 873 644 655 483 1232 909 923 681 739 545
1 1/8 1236 912 927 684 1746 1288 1310 966 1048 773
1 1/4 1745 1287 1308 965 2463 1817 1848 1363 1478 1090
1 3/8 2287 1687 1715 1265 3229 2382 2421 1786 1937 1429
1 1/2 3037 2240 2278 1680 4287 3162 3214 2371 2572 1897
1 3/4 4788 3532 3591 2649 6760 4986 5070 3740 4056 2992
Unified Fine Thread (UNF)

! NOTE: Lubrication with oil or moly-paste is preferred for grade 8 hardware
Size Grade 5 Grade 8

(mm)
296 No: 2522100363.3 en-US

1/4 14 10 9 7 19 14 14 10 11 8
5/16 26 19 19 14 37 27 27 20 22 16
3/8 47 35 35 26 66 49 50 37 41 30
7/16 75 55 56 41 106 78 79 58 64 47
1/2 115 85 87 64 163 120 122 90 98 72
9/16 164 121 122 91 232 171 174 128 140 103
5/8 230 170 172 127 325 240 244 180 195 144
3/4 403 297 302 223 569 420 427 315 342 252
7/8 643 474 481 355 910 669 681 502 547 401
1 954 704 716 528 1349 995 1011 746 809 597
1 1/8 1387 1023 1040 767 1958 1444 1468 1083 1174 866
1 1/4 1932 1425 1449 1069 2728 2012 2046 1509 1636 1207
1 3/8 2604 1921 1954 1441 3677 2712 2758 2034 2206 1627
1 1/2 3416 2520 2562 1890 4822 3557 3617 2668 2893 2134
Metric Coarse Thread

! NOTE: Lubrication with oil or moly-paste is preferred for grade 10.9 hardware.
Size Grade 8.8 Grade 10.9

(mm)
4 3 2 3 2 4 3 3 2 3 2
5 7 5 4 3 9 7 7 5 5 4
6 11 8 8 6 15 11 11 8 9 7
8 26 19 19 14 37 27 27 20 22 16
10 52 38 38 28 72 53 54 40 43 32
12 89 66 66 49 126 93 94 69 76 56
14 142 105 107 79 201 148 150 111 121 89
16 221 163 165 122 310 229 233 172 187 138
18 305 225 228 168 430 317 323 238 258 190
20 430 317 323 238 607 448 456 336 365 269
22 587 433 441 325 828 611 629 458 498 367
297 No: 2522100363.3 en-US

24 744 549 557 411 1049 774 788 581 630 465
27 1090 804 817 603 1539 1135 1155 852 923 681
30 1478 1090 1109 818 2086 1539 1566 1155 1253 924
33 2012 1484 1509 1113 2840 2095 2130 1571 1704 1257
36 2584 1906 1939 1430 3648 2691 2736 2018 2189 1615
298 No: 2522100363.3 en-US

9 Machine Specification
299 No: 2522100363.3 en-US

2016-12-22 | No: 2522100363.3
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Minetruck MT2010

2 Preventive Maintenance ....................................................................................... 9

3 Hydraulic System ................................................................................................ 79

iii No: 2522100363.3 en-US

3.4 General Maintenance Procedures ........................................................................................ 101

4 Power Unit ......................................................................................................... 119

5 Electrical System .............................................................................................. 153

iv No: 2522100363.3 en-US

5.1 Introduction ............................................................................................................................ 153

6 Power Train........................................................................................................ 181

7 Main Frame ........................................................................................................ 201

v No: 2522100363.3 en-US

7.4 Separating Load and Power Frames .................................................................................... 207

9 Machine Specification ...................................................................................... 291

vi No: 2522100363.3 en-US

1.1 Safety First

7 No: 2522100363.3 en-US

8 No: 2522100363.3 en-US

2.1 Service Management

2.2 Requirements for Use

2.2.1 Demanding Environments

9 No: 2522100363.3 en-US

2.2.2 Special Tools

2.3 Before Performing Maintenance

The six primary rules for hydraulic systems cleanliness.

10 No: 2522100363.3 en-US

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

1. Open the battery compartment.

2. Turn the battery isolation switch to the OFF position.

2.4 Independent Oil Analysis

11 No: 2522100363.3 en-US

2.5 Record Keeping

2.6 General Safety

2.6.1 When Servicing Vehicle

2. Park the vehicle in a straight line on a hardened flat surface.

3. Apply the parking brake.

4. Shut down the motor.

6. Turn the battery isolation switch to OFF position.

NOTE: If the vehicle must be serviced with the engine running, a

9. Block the wheels.

12 No: 2522100363.3 en-US

2.6.2 After Servicing the Vehicle

Vehicle Safety Guards

2.7 Contact Details

Argentina Juncal 2869 Phone: +54 (0)11 4898-4100

Australia 47 Enterprise Street Phone: +61 - (0)7 49 52 61 11

Austria Postfach 108 A-1111 Wien Phone: + 43- (0)1 -76 01 20

Bolivia Av. 20 de Octubre Nº 2665, Edi- Phone: +591 (2) 21 12 000

Brazil Av. Eng. Eusébio Stevaux Phone: + 55 - (0)11 - 56 87 88 00

Canada 200 Mumford Road Phone: + 1 - 705 673 67 11

Chile Panamericana Norte 5001 - Phone: + 56 - (02)-442 3600

China / Hong Kong P O Box 1516 Phone: + 852 - 27 97 66 00

CMT International S-105 23 Stockholm Phone: + 46 - (0)8 - 743 80 00

13 No: 2522100363.3 en-US

Czech Republic Prumyslová 10 Phone: + 420 - 225 434 000

Finland Tuupakankuja 1 Phone: + 358 - (0)9 - 296 64 41

France B P 27055 Saint Quen l’Aumône Phone: + 33 - (0)1 - 39 09 30 00

Germany Postfach 10 02 25 Phone: + 49 - (0)201 - 217 70

Ghana P O Box 10071 Phone: + 233 - (0)21 77 45 12

Great Britain P O Box 79 Phone: + 44 – (0)1442 - 22 21 00

Greece 93, Koropiou - Varis Avenue Phone: +30 - (0)1 - 349 96 00

Hong Kong P O Box 1516 Phone: + 852 - 27 97 66 00

India Sveanagar Phone: + 91- (0)20 -39 85 24 15