19, 9852 1825 01 service manual st14 dd (1)

Atlas Copco ScooptramST14Service manualPM nr 9852 1825 012007-11

SAFETY INSTRUCTIONS

Before starting, read all instructions carefully.

Special attention must be paidto information alongsidethis symbol.

Only use genuine Atlas Copco parts.

1250 0071 04

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

This applies in particular to trademarks, model denominations, part numbers and drawings.Atlas Copco Rock Drills ABSE-70191 rebro, Sweden

Atlas Copco I

ck the hydraulic oil

Transmission, Bolt Connection . . . . . . . . . 13Upbox, Breather . . . . . . . . . . . . . . . . . . . . . 13

Hydraulic Oil Change .Stop the engine and cheTable of ContentsChapter 1: SafetyReference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Chapter 2: Preventive MaintenanceService Management . . . . . . . . . . . . . . . . . . . . . . . . 3

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

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

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

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

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

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

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

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

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

Powerframe . . . . . . . . . . . . . . . . . . . . . . . 12Low Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . 12High Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Stall Speed . . . . . . . . . . . . . . . . . . . . . . . . . 13Transmission, breather . . . . . . . . . . . . . . . . 13

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

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

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

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

. . . . . . . . . . . . . . . 23

Table of ContentsService manual

IIST14level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Hydraulic Oil Filter . . . . . . . . . . . . . . . . . . . 23Hyd Oil Pressure . . . . . . . . . . . . . . . . . . . . . 24Air Filter, Safety Cartridge . . . . . . . . . . . . . 24Air Filter, Indicator . . . . . . . . . . . . . . . . . . . 24Axles, Differentials and Planetaries . . . . . . 25

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Atlas Copco IIIRolling Radius and Tire Sizing . . . . . . . . . 54Example: . . . . . . . . . . . . . . . . . . . . . . . . 54Driving Practices: . . . . . . . . . . . . . . . . . 55

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

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

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

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

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

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


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

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

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

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

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


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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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


IVST14Variable Piston Pumps . . . . . . . . . . . . . . . . . . . 87Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Atlas Copco VRCS On Switch (S101) & Off Switch (S102) . . . . . . . . . . . . . . . . . 107

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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


VIST14Operating Times . . . . . . . . . . . . . . . . . 127Speed (level ground) . . . . . . . . . . . . . . 127

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Atlas Copco 1Chapter 1: SafetyReferenceN o t e Always read the information under Safety

before starting to use the Scooptram or starting maintenance work.

1250 0099 89

Chapter 1: SafetyService Manual

2ST14

Atlas Copco 3

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

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

Clean the machine before each shift, remove rocks

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

6. Battery switch7. Engine Oil Level Dipstick

5 6 7from the loadframe and prevent dirt from get into the hydraulic system by checking valves and other hydraulic components. Dirt in the hydraulic system will cause damage.Chapter 2: Preventive Maintenance 1 2 3 4

Chapter 2Service M

4ST14: Preventive Maintenanceanual

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

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

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

Electric WeldingImportant Use caution in electric welding.

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

Perform the following before any electric welding:

STEP 1 Open the battery compartment.

STEP 2 Turn the battery switch to the OFF position.

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

Hydraulic System Cleanliness Important Foreign matter of any kind will

cause problems in hydraulic systems, making absolute cleanliness essential.

The six primary rules for hydraulic systems cleanliness.

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

Remove all loose paint before opening any con-nections.

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

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

Always fill the hydraulic tank through the return filter with the electric refill pump. Flush any unsealed hose or pipe with hydraulic oil before installing it in the system.

as Copco 5Atl

Independent Oil AnalysisAtlas Copco recommends the establishment of an oil analysis programme. Regular oil analysis can indicate problems and the approach of maximum wear limits, before they are discovered by system performance checks.

The objective of a preventative maintenance program is diagnosis and repair before failure. Good sampling techniques and independent laboratory analysis are considered primary elements of a good program.

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

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

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

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

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

STEP 2 Shut down the engine.

STEP 3 Apply the park brake.

STEP 4 Block the wheels

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

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

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

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

Maintenance Intervals

Chapter 2: Preventive MaintenanceServi

6ST14ce Manual

Every 250 Hours Operation

Item Task Special Instructions CheckAxle, breather Inspect and check for

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

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

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

Driveline, upbox - gearbox Check for loose and missing bolts

Driveline, loadframe - gearbox - powerframe

Check for loose and missing bolts

Low idle Check idle Idle shall be 80025 rpmHigh idle Check idle Idle shall be 216050 rpmStall idle Check idle Idle shall be 183050 rpmTransmission, breather Inspect and check for

damageTransmission, bolt connection

Check bolts connection and rubber damper

Upbox, breather Inspect and check for damage

Battery Check battery connections and that they are mounted correctly

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

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

Hyd oil tank, breather Inspect and check for damage

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

Brake acc, precharge press

Check precharge press Pressure should be 832 bar

Ride control acc, precharge press


Tow hook acc, precharge press


Brake release Perform a brake release test

Pressure should be over 83 bar

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

Filter Element on page 16.Exhaust system Inspect mounting and

check for leakage Save log and parameter files

Save and archive log and data files

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

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

Doors and hoods Lubricate, check function and ware

Steering and bucket stop Check functionDriveline, between upbox and transmission

lubricatelubricationMidship driveline lubrication

lubricate

Atlas Copco 7Front axle lubrication lubricateRear axle lubrication lubricateEngine fan hub bearing lubricate

Chapter 2: Preventive MaintenanceService Manual

8ST14Every 500 Hours Operation

Item Task Special Instructions CheckAxel, bolt connection Check bolt torques Front: UNC 1, Grade 8, moment 3220 Nm

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

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

Bolt connections, engine cradle - powerframe

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

Transmission, bolt connection

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

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

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

Engine cooling, hoses and pipes

Check hoses and couplings for wear and damages

Engine coolant, filter Change filterBolt connection, engine mount

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

Expander shafts, loadframe and boom

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

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

damage Trunnions and pins, boom z-bar


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


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

as Copco 9Atl

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

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

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

Service Kits

Bearing Kits

Gasket and Seal Kits

Repair Kits

Accessory kits

Contact your local Atlas Copco representative for further information.

Chapter 2: Preventive MaintenanceServ

10ST14ice Manual




Item Task Special Instructions CheckTransmission, oil and filter change

Change oil and filter. Clean the strainer

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

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

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

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

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

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

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

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

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

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

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N eAtl

New or Reconditioned ComponentsUnder f irst shift ( hour)

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

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

After f irst shif t (8 hours)

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

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


After 250 hours operation

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

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

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

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

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

Expander Shafts, Z-bar

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

w C o m p o n e n t sCheck torque. It should be M30, Grade 10.9 and 1570 Nm

Chapter 2Service M

12ST14

r s: Preventive Maintenanceanual

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

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

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

Axle, Bolt Connection

Check bolts

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

Axle, Differential

Differential plug

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

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

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

Axle, Planetary Gears

1. Drain plug2. Arrow

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

STEP 2 Apply the parking brake.

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

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

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

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

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

approximately 80 C.

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

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

STEP 4 Idle should be around 80025 rpm.

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

1

2

2 5 0 H o uSTEP 4 Install the oil level plug and check the other differential.

as Copco 13Atl

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

approximately 80 C.

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

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

STEP 4 High idle should be around 216050 rpm with no load

Stall Speed

Menu Operator, Converter Stall

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

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

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

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

STEP 5 Stall speed should be around 183050 rpm.

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

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

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

Transmission, breather

Transmission breather

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

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

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

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

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

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

2 5 0 H o u r s

Chapter 2: Preventive MaintenanceService M

14ST14

r sanual

AC, Cab Unit

AC filter in the cab unit

Replace the AC filter.

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

damage.

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

Lubricate all hinges.

Hyd Oil Tank, Breather

Hydraulic oil tank breather

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

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

Hyd Oil Filter Switch

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

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

Brake Acc, Precharge Press

Brake accumulator

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

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

STEP 3 Connect a manometer to the valve.

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

STEP 5 Check the pressure on the manometer, it should be 832 bar.

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

STEP 7 Put back the hood and the valve protection.

2 5 0 H o u

Atlas Copco 15

2 5Ride Control Acc, Precharge Press

Ride control accumulator

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

The pressure should be 1005 bar.

Tow Hook Acc, Precharge Press

Tow hook accumulator

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

The pressure should be 762 bar.

Brake Release

Brake release hole

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

STEP 1 Lower the boom to the ground.

STEP 2 Stop the engine.

STEP 3 Block all wheels.

Manometer connection point on the junction block, BRJ3.

STEP 4 Connect a manometer to the BRJ3 valve.

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

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

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

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

Engine Oil

1. Engine oil fill2. Engine oil level dipstick

Check oil level when machine is standing on flat surface.Switch off the engine and allow the oil to drain

1 2

0 H o u r sTo tow a machine that has not the ability to release the brakes by the control system, the brakes have to be manually released.

down from the engines internal parts for some minutes. This eliminates the risk of overfilling.


16ST14

2 5 0 H o u r sPush the dipstick completely down and pull out. The oil level must be between the ADD and FULL marks on the dipstick.

Fill up the oil engine to FULL-mark.

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

Engine Oil Filter

Engine filter, always replace the filter when changing oil.

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

STEP 2 Discard the filters.

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

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

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

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

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

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

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

Air Filter, Filter Element

Filter element

STEP 1 Remove the air filter cover.

STEP 2 Remove the outer filter.

STEP 3 Inspect filter gasket surface and replace if needed.

STEP 4 Install a new primary element.

Exhaust System

Exhaust system

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

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

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

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

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

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

Module TCU D602 shows diagnostics and comments about the transmission.

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

Atlas Copco 17Module JoyR D561 shows information about right lever function.

Module JoyL D560 shows information about left lever function.

Module ENC D576 shows steering angle.

About other modules are only status showed.

For more information. See Diagnostics on page 121.

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

Wheel Bolts and Nuts

Wheel nuts

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

Doors and Hoods

Hinges on the hydraulic door

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

Steering and Bucket Stop

Driveline, Between Upbox and Transmission Lubrication

Lubrication point

Lubricate this point.

Midship Driveline Lubrication

Lubrication point

Lubricate this point.

Front axle lubrication

Lubricate the nipples on the front axle yoke.

2 5 0 H o u r sCheck function and that the speed is slowing down just before it reach the end position. Check that steering goes soft against the stop.

Chapter 2Service M

18ST14


Rear axle lubrication

Lubricate the nipples on the rear axle yoke.

Engine fan hub bearing

Lubrication hose

Lubricate the fan hub bearing through this nipple.

2 5 0 H o u

opco 19Atlas C

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

Repeat 250 Hours

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

Bolt dimension for front axle is UNC 1, Grade 8, moment 3220 Nm.

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

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

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

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

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

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

AC, cab unit

AC filter

Fuel Filter

Fuel filter

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

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

STEP 2 Drain the fuel until the reservoir is empty.

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

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

STEP 5 Install the new filter and O-rings.

STEP 6 Reinstall the protective casing.

STEP 7 Fill with fuel through the ventilation cover.

STEP 8 Start the engine.

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

5 0 0 H o u r sChange the AC filter in the cab.

Chapter 2: Preventive MaintenanceService M

20ST14

r sanual

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

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

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

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

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

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

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

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

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

Load and powerframe

Look for frame cracks at major stress points.

Check frames for damage that could cause down time.

Trunnions and Pins, Boom Z-bar

Bolts on Z-bar

Bolts on Z-bar

Check torque it should be Grade 10.9 and 1569 Nm

Trunnions and Pins, Bucket

Bolts on bucket

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

5 0 0 H o u

Atlas Copco 21

5 0 0Trunnions and Pins, Steering

Steering bolts

Check torque it should be Grade 10.9 and 1569 Nm

Trunnions and Pins, Swivel

Bolts on the swivel

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

H o u r s

Chapter 2Service M

22ST14


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

Repeat 250 Hours

Repeat 500 Hours

Transmission, Oil and Filter Change

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

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

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

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

Transmission oil filter are located behind the hydraulic hatch

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

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

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

Check transmission oil level

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

Transmission oil dip stick, on top of the transmission.

1

2

3

1 0 0 0 H o u

Atlas Copco 23Upbox, Oil Filter

Upbox oil filter

Always replace the filter when changing transmission oil.

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

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

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

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

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

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

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

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

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

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

STEP 7 Disconnect the hoist and dump cylinders

drain the cylinders.

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

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

STEP10 Replace the hydraulic filter.

STEP11 Re-connect all hoses and fittings previously disconnected.

STEP12 Install the reservoir drain plug.

STEP13 Pump new oil into the hydraulic reservoir.

Important Always use the electric refill pump when filling up.

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

Stop the engine and check the hydraulic oil level.

Hydraulic Oil Filter

Hyd oil filter

Always replace the filter when changing oil or when indicated.

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

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

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

1 0 0 0 H o u r shoses at the lowest points so as to completely


24ST14

1 0 0 0 H o u r sSTEP 3 Remove O-ring from the head assembly and inspect for cuts or excessive wear and replace if necessary. Inspect the head assembly for wear or cracks.

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

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

STEP 5 Start the engine and run at idle speed.

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

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

Actuations/Sensors".

STEP 2 Start engine and activate boom down.

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

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

Air Filter, Safety Cartridge

Change the safety cartridge.

STEP 1 Remove the air filter cover.

STEP 2 Remove the outer filter.

STEP 3 Inspect filter gasket surface and replace if needed.

STEP 4 Install a new primary element.

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

STEP 2 Let the engine go on idle.

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

Atlas Copco 25

2 0 0 0 H o u r sE v e r y 2 0 0 0 H o u r s Repeat Daily

Repeat 250 Hours

Repeat 500 Hours

Repeat 1000 Hours

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

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

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

Differential

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

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

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

STEP 4 Replace the oil drain plugs.

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

STEP 6 Replace the oil level plug.

Differential drain plug

Planetary

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

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

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

STEP 3 Remove the oil level/drain plug.

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

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

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

Planetary drain plug at bottom

AlternatorSTEP 1 Start the engine.

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

STEP 3 Stop engine.

STEP 4 Replace the alternator if necessary.


26ST14

2 0 0 0 H o u r sEngine CoolantDrain, flush, and refill the engine coolant every 2000 hours of operation. After cleaning the system, replace the coolant filter.

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

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

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

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

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

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

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

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

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

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

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

Atlas Copco 27

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

Repeat 250 Hours

Repeat 500 Hours

Repeat 1000 Hours

Repeat 2000 Hours

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

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

Fuel Tank Drain and flush the fuel tank.

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

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

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

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

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

STEP 5 Bleed all air from the fuel system.

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

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

DDEC Reader

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

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

Fuel HosesReplace all fuel hoses.

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

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



28ST14

Atlas Copco 29

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

The power unit is supported by the following systems:

Fuel System

Engine Oil System

Cooling System

Air Intake System

Exhaust System

Electrical System

Upbox

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

The fuel system is supported by the following system:

Fuel Tank

Fuel Filter/Water Separator

Fuel Pump

ECM Cooling

Sensors

Electronic Unit Injectors Check valve

Fuel CoolerChapter 3: Power Unit

Chapter 3: Power UnitService M

30ST14anual

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

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

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

Important Always use the strainer when filling the tank.

Fuel tank strainer

Fuel Filter

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

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

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

Fuel Pump

1. Fuel Outlet2. Fuel Pump Housing3. Fuel Inlet

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

ECM Cooling

1

2 3 4 5 6 7 8

1

2

3

1

2

3

2

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

1. Diesel in2. Diesel out

as Copco 31Atl

The ECM is cooled with diesel fuel.

Fuel sensors

1. Pressure sensor2. Temperature sensor

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

Injectors

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

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

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

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

Permits continuous fuel flow for component cool-ing.

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

Opening the poppet valve ends injection.

The duration of valve closure determines quantity of fuel injected.

The solenoid only controls how much fuel will be delivered.

Calibration codes

1. Part number2. Calibration code

All DDEC III injectors contain injector calibration codes.

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

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

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

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

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

1

2

1

2

3

4

5

1

2solenoid. The EUI performs four functions:

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

Chapter 3Service M

32ST14: Power Unitanual

Check Valve

1. Output2. Input

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

Fuel Cooler

The fuel cooler is mounted on the grille door.

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

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

The major components in the Scooptram engine oil system are:

Oil Pump

Oil Filters

Oil Pressure & Temperature sensors

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

Oil Filters

Change the oil filters every 125 hours.

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

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

1

2

as Copco 33Atl

Cooling System

Engine and cooling package

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

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

See Chapter 4: Power Train on page 47.

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

Engine, combustion air cooler

Fuel and hydraulic cooler

Hydraulic cooler and AC condensor

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

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

A 50/50 mix of quality fully formulated, inhibited propylene glycol antifreeze and water may also be used if it provides required freeze, boil over, and

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

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

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

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

CoolersThe engine cooling package houses the following coolers.

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

1

2

3

4

5 6inhibitor protection. Do not mix ethylene glycol and propylene glycol antifreeze. Flush the cooling system thoroughly before replacing ethylene glycol with propylene glycol antifreeze.

5. Transmission cooler (option)6. Hydraulic cooler

Chapter 3Service M

34ST14: Power Unitanual

Air Intake System

Air cleaner

The air intake system fulfills two primary functions:

Provides clean, contaminant free combustion air to the engine.

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

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

Air Cleaner

Air cleaner

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

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

Engine Air Filter Restriction Indicator

Engine air filter restriction indicator

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

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

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

Turbo Charger

The turbocharger is mounted on the engine.

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

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

The pictures below explain the engine intake air and

exhaust flow.

Atlas Copco 35Engine air flow1. Air inlet2. Compressor3. Charge air cooler4. Cylinder5. Exhaust mainfold and cylinder head porting6. Turbine7. Turbine exhaust outlet

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

Engine exhaust air flow

Compressed air flow

Fresh air

Exhaust System

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

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

The exhaust system is composed of:

Silencer

Particle filter

Heat shields

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

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

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

Chapter 3: Power UnitService Manual

36ST14Exhaust Heat Shields

Heat Shielding

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

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

Engine electrical system function1. Input2. Analysis3. Output

The engines electrical system consists of:

ECU

EUI

Temp sensors

Pressure sensors

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

The ECU have the following connections:

1. Injector harness connector2. Engine harness connector

1 2

3 54

3. Vehicle interface harness connector4. Communication harness connector

as Copco 37Atl

5. Power harness connector

Temperature & pressure sensorsThe following sensors are connected to the engines electrical system:

Temperature Oil (OTS)

Fuel (FTS)

Coolant (CTS)

Air (ATS)

Pressure Oil (OPS)

Fuel (FPS)

Turbo (TBS)

Other Timing reference (TRS)

Syncronous reference (SRS)

Throttle position (TPS)

Coolant level (CLS) (located on surge tank)

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

Upbox

Upbox

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

This is how the lubrication of the upbox works:

Upbox lubrication circuit

ChaptServic

38ST14er 3: Power Unite Manual

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

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

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

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

DANGER If the engine has been running within the previous hour,

19, 9852 1825 01 service manual st14 dd (1)

Documents

engine oil filter

hydraulic oil filter

hydraulic oil transmission

upbox transmission

loadframe transmission

transmission lubrication

air filter

hours operation