Atlas Copco MineTruck MT2010 Service Guide 9852178701a EN

Description

Contents:
Chapter 1: Introduction To The Mt2010
Vehicle Description
Hazard Protection
Vehicle Graphics
Service Guide Safety Alerts
Time Saver Messages
Chapter 2: Safety Awareness
Protect Yourself And Your Coworkers
Primary Safety Procedures
Park In Relaxed-Mode
Master Switch
Articulation Safety Lock
Dump Box Safety Support
Relieving Hydraulic Pressure
Relaxed-Mode Procedures
General Safety Procedures
A Well-Maintained Vehicle Is A Safer Vehicle
Personal Protection
Hydraulic Fluid
Vehicle Guards
Tools And Receptacles
Dump Box Caution
Parking The Mine Truck
Burn, Fire, And Explosion Prevention
Electrical Hazards
Coolant Hazards
Flammable Liquids & Debris
Ether Starting Fluid
Vehicle Labeling
Cabin Rops And Fops
Seat Belts
Tyre And Wheel Safety
Tyre Inflation Cage
Wheel Assembly
Lifting The Vehicle With A Floor Jack
Front Axle Jack Points
Rear Axle Jack Points
Lifting The Vehicle With A Crane
Side View Of Lift Points
Transporting The Mine Truck
Chapter 3: Preventive Maintenance
Service Management
Rugged Usage Requirements
High Torque Settings Require Specialty Tools
Independent Oil Analysis
Hourmeter Display
Record Keeping
Management Of Driver Inspection & Reporting
Shift Inspection Checklist
Atlas Copco Service Kits
Shift Report
Check Before Starting Engine
Comments
Check After Starting Engine
Comments
Maintenance Intervals
As Required
Every Day At Each Shift
Daily Lube Items
Every 125 Hours Of Operation
Every 500 Hours Of Operation
Every 250 Hours Of Operation
Every 2,000 Hours Of Operation
Every 5,000 Hours Of Operation
Every 1,000 Hours Of Operation
Engine Air Filter Restriction Indicator
Engine Air Filters
Hydraulic Tank
Service Procedures By Interval
As Required Service
Radiators & Coolers
Fuel Cooler
Engine Radiator & Front Grille Coolers
Structural Integrity
Circuit Breakers And Fuses
Daily/Shift Requirements
Fire Extinguisher
Daily Lube Points
Auto Lube And Remote Lube
Fluid Leaks
Fuel Level
Fuel/Water Separator
Engine Oil
Engine Coolant
Air Filter Evacuator Valve
Transmission Oil
Cold Oil Check
After Start-Up Check
Hot Oil Check
Hydraulic Oil Reservoir
Tyres
125 Hours Of Operation
Air Intake Primary Filter Element
Air Intake And Exhaust
Primary (Outer) Filter
Precleaner
Differential And Planetaries
Differential
Planetary
Driveline Slip-Joints
Wheels
Hydraulic Hoses
Fire Suppression System
Batteries
Hydraulic Tank Breather & Filter
Transmission
Axles
Steering And Dump Cylinders
Autolube System (Optional)
Lube System Connectors
250 Hours Of Operation
Engine Oil And Filters
Changing The Engine Oil
Engine Oil Drain
Engine Oil Filters
Fuel Filters
Engine Coolant
Transmission/Engine Stall Speeds
500 Hours Of Operation
Fuel Hoses And Tubing
Engine Fan Assembly
Radiators & Coolers
Front Coolers
Fuel Cooler
Transmission Oil Filters
Transmission Oil Cooler
Oil Testing
Differential And Planetaries
Differentials
Planetaries
Drivelines
Driveline Universal-Joint
Hydraulic System
Fuel Tank
Dump Cylinders
Mine Truck Frame
Dump Box
Dump And Steering Cycle Times
Specified Steering Times
Specified Dumping Cycle Times
Articulation Joints
1,000 Hours Of Operation
Engine Mounts
Radiators
Transmission Oil
Exhaust System
Exhaust Purifier
Exhaust Heat Shielding
Differential & Planetaries
Differential
Planetary
Hydraulic System
Hydraulic Tank
Inspection Cover
Hydraulic Oil Tank Breather
System Pressures
Fuel Tank
Fire Suppression System
2,000 Hours Of Operation
V-Belts
Sahr Brakes
Air Intake And Exhaust Systems
Engine Cooling System
5,000 Hours Of Operation
Engine And Transmission Mounts
Engine
Fuel Lines
Coolant Hoses
Intake Hoses
Electrical System
Hydraulic Hoses
Oil Coolers
Chapter 4: Power Unit
Engine Support Systems
Fuel System
Fuel System Components
Fuel System Operation
Fuel Tank
Fuel/Water Separator And Filter
Fuel Pump
Lubrication System
Oil Pump
Oil Filters
Oil Cooler
Engine Oil Dipstick & Fill Tube
Engine Oil Pressure Gauge
Electronic Unit Injectors (Eui) And Engine
Control Module (Ecm)
Cooling System
Cooling System Function
Coolant Recommendations
Corrosion Inhibitor For Engine Cooling
Air Intake System
Purpose Of The Air Intake System
Air Cleaner
Air Intake System Removal
Reinstalling The Intake Tubes
Engine Air Filter Restriction Indicator
Engine Air Filters
Exhaust System
Exhaust Silencers & Purifiers
Turbocharger
Removal And Replacement Of Major Components
Vehicle Preparation
Exhaust System
Removal Of The Exhaust System
Replacement Of Exhaust System
Turbocharger
Radiator Cooling Package
Removing The Cooling Package
Cooling Package Reinstallation
Transmission Oil Cooler
Tube And Shell Cooler Removal
Tube And Shell Cooler Replacement
Fuel System
Removing Fuel Filter
Replacing Fuel Filter
Removing Fuel Valves And Lines
Reinstalling Fuel Valves And Lines
Engine Package
Engine Removal Steps
Engine Replacement
Chapter 5: Power Train
Power Train Components
Transmission
Shift Selector
Torque Converter
Lock-Up Clutch
Drivelines
Universal Joint Bearings
Driveshaft Support Bearings
Axles
Primary Reduction
Secondary Reduction
Wheels And Tires
Road Maintenance
Tyre Inspection & Maintenance
Wheel Inspection & Maintenance
Recommended Tyre Pressures
Over-Inflation Results In
Under-Inflation Results In
Static Loaded Radius
Tyre Size Example:
Driving Practices
Drivers Can Reduce Tyre Costs By
Mounting And Storage
Component Removal And Replacement
Vehicle Preparation
Transmission
Transmission Removal
Transmission Installation
Drivelines
Phasing The Driveline
Installing The Driveshaft
Yokes And Bearing Mounts
Installing Driveline Guards
Driveline Removal & Installation
Removal:
Installation:
Axles
Axle Removal Preparation Steps
Front Axle Removal
Front Axle Replacement
Rear Axle Removal
Rear Axle Replacement
Sahr Brakes
Disassembly
Cleaning And Inspection
Housing, Covers, Etc
Piston And Housing Seals
Assembly Of The Sahr Brakes
Tyre Removal & Replacement
Changing Tires
Front Axle Jack Points
Rear Axle Jack Points
Demounting And Mounting
Demounting
Inspection
Mounting And Inflating
Wheel Nut Torque
Operating Precautions
Recapping
Chapter 6: Main Frame
Introduction
Power Frame
Hood Removal
Hood Replacement
Load Frame
Dump Box
Lifting Eyes
Installing Lifting Eyes
Dump Box Removal
Dump Box Replacement
The Load & Power Frame Connection
Separation
Reconnection
Articulation Pins
Pin Removal
Pin Installation
Stops
Steering Stops
Dump Box Guides
Front Axle Oscillating Stops
Chapter 7: Hydraulic Systems
Introduction
Hydraulic System Components
Cylinders
Dump Cylinders
Steering Cylinders
Accumulators
Accumulator Pre-Charge
Hydraulic Pumps
Hydraulic Gear Pumps
Hydraulic Valves
Charge Valve
Brake Solenoid Valve
Dump Control Valve
Main Relief Function
Load Check Valve Function
Steering Control Valve
Steering Main Control Valve
Steering Pilot Control Valve
Priority Valve
Adjust The Priority Valve As Follows:
Hoses And Tubing
Hydraulic Tank
Hydraulic Tank Suction Filter
Hydraulic Filtration
Off-Line Hydraulic Filters
Brakes
Hydraulic System Operation
Dump System
Box Up
Box Float
Box Power Down
Steering System
Over-Pressure Protection
Park Brake System
Charging Mode
Non-Charging Mode
Brakes Released
Brakes Applied
Service Brake Operation
Park Brake Operation
Hydraulic Maintenance
Servicing After Overhaul
Oil Level In Reservoir
Importance Of Cleanliness
Hydraulic Oil Changes
Oil Storage And Handling
Prevention Of Foaming
Hydraulic Oil Change After Failure
Hydraulic Tank Inspection
Repair
Suction Filter
Changing The Filter Element
Servicing Filters And Strainers
Establishing A Schedule
Brake Pedal Adjustment
Adjustment Of Pedal Deadband
Cylinder Inspection
Adjusting Cylinder Packing
Hydraulic Component Removal And Replacement
105
Relieving Hydraulic Pressure
Pump Priming
Priming The Steering/Dump Pump
Priming The Brake Pump
Bleeding The Brakes
Valve Relief Settings
Adjusting The Pressure
Dump Cylinders
Dump Cylinder Removal
Dump Box Cylinder Installation
Steering Cylinders
Steering Cylinder Installation
Accumulators
Brake Accumulator
Brake Accumulator Removal
Transmission Accumulator Removal
Accumulator Replacement
Hydraulic Pumps
Pump Removal
Pump Installation
Valves
Valve Removal
Valve Replacement
Charge Valve Cartridge Removal/Service
Hydraulic Manifolds
Manifold Replacement
Hoses And Tubing
Assembling Fittings To Hoses
System Pressure
Accumulator Cycling
Dump Box Performance
Steering Control
Brake System Pressure Settings
Chapter 8: Electrical Systems
Circuit Schematics
Electrical Ladder Diagram
Electrical Wiring Diagram
Electrical System Components
Wiring Harness
Master Switch (Battery Isolation)
Component Box
Circuit Breakers
Battery
Alternator
Starter
Cabin Controls
Vehicle Driving Lights
Horn
Vehicle Computerized Control Units
Programmable Logic Controller
Engine Control Module
System Sensors
Turbo Boost Sensor
Fuel Pressure Sensor
Oil Pressure Sensor
Coolant Pressure Sensor
Crankcase Pressure Sensor
Coolant Temperature Sensor
Fuel Temperature Sensor
Air Temperature Sensor
Oil Temperature Sensor
Coolant Level Sensor
Throttle Position Sensor
Diagnostic Interfaces
Diagnostic Data Reader
Check Engine And Stop Engine Lights
Communication Links
Data Collection Unit
Gauges
The Mini-Message Center
Mini-Message Center Codes
General Maintenance Information
Arc Welding
Computerized Diagnostic Systems
Programmable Logic Control
Plc Codes
Diagnostic Data Reader
Batteries
Installation
Periodic Service
Cable Terminals And Hold Downs
Battery Fluid
Tropical Climates
Factors Affecting Battery Life
Detecting Potential Failures
Visual Inspection
Hourmeter Reading
Testing
Cell Charge Test: Hydrometer
Cell Charge Test: Capacity Tester
Cell Charge Test: Booster Cables
Storage Of Lead Acid Batteries
Alternators
Slip Rings
Removal And Replacement
Transducers
Engine Sensors
Starter
Batteries
Battery Removal
Battery Replacement
Alternator
Alternator Removal
Alternator Replacement
Chapter 9: Controls & Indicators
Introduction
Diagnostic Coupler
Hand Controls
Steering Control
Dump Control
Park Brake Switch
Sahr Brake Override System
Brake Release
Dual-Purpose Hand Pump
Master Switch (Battery Isolation)
Component Box
Foot Controls
Sahr Brake Pedal
Throttle Control
Driver’s Seat Controls
Armrest Controls
Backrest Control
Seat Height Adjustment
Front / Rear Seat Adjustment Control
Operator Weight Control
Chapter 10: Optional Systems
Fire Suppression System
Emergency Use
In The Event Of Fire
Fire Suppression Components
Actuator
Cartridge Receiver
Dry Chemical Tank
Nozzles
Portable Fire Extinguisher
General Maintenance
Monthly
Semi-Annual
Chapter 11: Troubleshooting Strategies
Symptoms And Solutions
Engine Symptoms
Transmission
Axles
Drivelines
Wheels And Tyres
Articulation
Hydraulic System
Sahr Brakes
Park Brake
Electrical System
Chapter 12: Vehicle Specifications
Performance Related Data
Engine
Vehicle Weight Range
Operating Times
Steering And Oscillation
Speed (Loaded)
Hydraulic Pressure
Brake Pressure
Tyres
Capacities
Fuel Tank
Cooling System
Transmission
Axles
Converter
Hydraulic Tank
Fluids And Lubrication
Diesel Fuel Quality And Selection
Fuel Oil Selection Chart
General Fuel Classification
Engine Coolant Specifications
Lubricating Oil Specifications
Engine
Transmission
Axles
Grease
Ambient Temperature Charts
Engine
Axles
Acw Hydraulic Fluid
Torque Specifications
Use The Correct Tool For The Job
Torque Values By Component
Alternator To Engine
Alternator
Articulation Pins
Axles
Driveline U-Joints
Engine Mounts
Engine Radiator
Hydraulic Filter
Hydraulic Pump
Sahr Brakes
Transmission Mounts
Torque Values By Bolt Size & Thread
Scope
Definitions
High Strength
Tolerances
Wheels
Unified Coarse Thread
Unified Coarse Thread
Unified Fine Thread
Unified Fine Thread
Metric Coarse Thread
Metric Coarse Thread
Torque Values For Electrical Connectors
Terminal Block Wire Connections
Deutsch Connectors With Bulk Head Nut
Binding Screws & Slotted Screws
Iso Switch Nut
Connectors With Hexagonal Socket Screws
Harting Connectors With Screw Terminals