MT 5020&6020 Trainee Binder

Minetruck™ MT6020/MT5020
Overview
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Objectives
You will know the Atlas Copco Minetrucks

MT 5020/6020, from the inside and out, including
hydraulic & electrical systems, Safety, basic
maintenance routines and troubleshooting.
Content
Overview Transmission and axles
Safety Brake system
Hydraulics introduction D/H & Steering system
Control & Electrical System General maintenance
Engine and fuel system Options
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Minetruck™ MT6020 & MT5020
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Machine Specifications
Technical specification leaflet contains information on

– Capacities and motion times
– Turning radius
– Dimensions and weights
– List of optional equipment
– and more…
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Minetruck MT6020 & MT5020
Technical specifications
MT6020
3263
2829
991
13°
453
3514 1975 (3700)

5675
MT5020
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Technical specifications
MT6020
3204
3440
11227
MT5020
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Minetruck MT6020
Turning radius
5084
5933
3
R93
79
22
R4
5084 2000 X 45° CHAMBER
5933
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Minetruck MT5020
Turning radius
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Grade & Speed performance MT-6020
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Grade & Speed performance MT-5020
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MT-5020 without tele dump and heater.
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Dump boxes & Dimensions and Weights MT-6020 /5020
MT6020 MT5020
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Technical data
Engine
– MT6020 Cummins QSK19-C760, Tier 1/Stage I A
– MT5020 Cummins QSK19-C650, Tier 1/Stage I
– MT6020 MSHA rating at 2.100 rpm 567 kW
– MT5020 MSHA rating at 2.100 rpm 485 kW
– Max torque at 1.300 rpm 3084 Nm
– Displacement 19 liters
– Cooling Water/antifreeze
MSHA part 7 Ventilation

– Ventilation rate 1274 m3/min
– Particulate index 934 m3/min
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Technical data
Capacity MT6020
– Payload 60 000 kg
– Volume at 2.0 t/m3 Wagner Semi-Heaped 29.7 m3
Capacity MT5020
– Payload 50 000 kg
– Volume at 2.0 t/m3 Wagner Semi-Heaped 25.0 m3
Box Raise Time

– Time 15 Seconds
Electrical system
– System voltage 24-volt starting, 24-volt accessories
– Alternator,high output 100A
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Technical data
Transmission/converter Allison M6610AR

– Planetary, automatic 6 speeds forward/2 speeds reverse with
integral single stage converter with automatic lock up
Retarder
– Fully hydraulic retardation on transmission
MT6020 Axles Kessler 111/ MT5020 Axles Kessler 106

– Spiral bevel differential, full floating, dual planetary reduction wheel
end drive
– Conventional front & rear diffrential
Kessler Up- and Dropbox (Force Cooled and Lubricated)

– Both is power transmitted trough a 1:1 gear ratio box
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Technical data
Brake system
– Service SAHR®
Spring-applied, hydraulically released; fully enclosed, force-cooled
multiple wet discs at each wheel end
– Parking and emergency SAHR®
– Hydraulic retarder
Tires
– Tubeless, radial, lug tread design for underground mine service
– Tire size: 35/65 R33** VSNT E4
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Technical data
Steering
– Articulated hydraulic power steering, pilot-operated, hydraulic rotary
servo (wheel) control
– Turning angle + - 42.5°(each way)
– System pressure 20.7 MPa
Hydraulic system
– Cylinders Double-acting
– Steer cylinders 160mm
– Dum cylinders 177,8mm
– Suspension cylinders 125mm
– Pumps Heavy duty gear type
– Filtration
– Piston Pump Return line: 4 micron(µm)
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Technical data
Tank capacities
– Fuel MT-6020 844 litres(67L/Hour)
– Fuel MT-5020 644 liters(57L/Hour)
– Hydraulic 238 litres
– Fuel filtration 10 micron(µm)
Suspension
– Front-axle oscillating suspension “A” frame with hydraulic
suspension cylinders and accumulator cushioning
– Degrees of oscillation Total 20°(10°each side)
– Suspension travel at axle 140 mm
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Technical data
Operator’s arrangement
– Forward-facing seat and controls in enclosed cab,ISOROPS/FOPS certified
– Grammar eat with retractable seat belts
– Air conditioner
– Trainer seat
– Back up video monitor
Matching Scooptram: ST1520
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MT 5020/6020 TRAINING
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Objectives

Content
Safety Brake system
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Safety
Always READ THE MANUAL before operating and working with the
Minetruck.
Minetruck.
Follow your safety regulations and check-lists!
Use your PPE (Personal Protective Equipment)
Never service the machine alone!
Follow safe procedures, specially if:
– Engine is on
– Hydraulics pumps running
– Hydraulics system pressurised
– Power supply connected and main switch on
Report all damages and defects immediately!

Take notice of the signs – make sure you KNOW what they mean.
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Safety
Built-in mechanisms
SAHR brakes – requires pressure to release breaks

Machine stops
A Roll Over Protective Structure (ROPS)
A Falling Object Protective Structure(FOPS)
And more…
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Safety
ROPS A Roll Over Protective Structure
FOPS A Falling Object Protective Structure
ROPS and FOPS

A Roll Over Protective Structure (ROPS) protects the
operator in a rollover by controlling the bending of the
structure. A Falling Object Protective Structure
(FOPS) protects the operator from falling debris.
The ROPS and FOPS label is attached to the dash near

the windshield. The ROPS and FOPS serial number,
Minetruck weights, approval numbers and model
number are on this label.
WARNING
Do not add attachments to the
vehicle that will exceed the gross weight
shown on the ROPS and FOPS label.
WARNING
No welding or cutting is allowed
on a ROPS/FOPS structure without
approval or the ROPS/FOPS is no longer
valid.
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Safety
Warnings
The manuals contain warnings. The warnings

are in boxes and contain a safety message, a
warning symbol and a title
Different degrees of warning titles are
– “Danger” – imminent risk of serious injury
– “Warning” – risk of serious injury
– “Caution” – risk of injury or damage
Also other headings

– “Important” – risk of damage
– “Note” – useful information
The Danger heading indicates an imminent risk of serious or

lethal injury if the warning is not heeded.
The Warning heading indicates a risk or dangerous course of

action that can lead to serious or lethal injury if the warning is
not heeded.
The Caution heading indicates a risk or dangerous course of

action that can lead to personal injury or damage to property if
the warning is not heeded.
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Safety
Warning signs examples
Crushing hazard
– Swinging and crushing parts
keep out during operation!
Boom crushing hazard

– Moving and rotating parts
Potential energy hazard

– Risk of explosion
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Safety
Warning signs examples
High pressure hazard

– Danger of scalding and pressure
release pressure before the cap can be removed!
Hot surface hazard

– Danger of hot surface
do not touch the surface!
Falling objects hazard

– Danger of falling objects
keep out of the area!
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Safety
Danger! – Stored energy hazard

This symbol is stamped in each SAHR brake housing
Never attempt service on the SAHR brakes without first
reading the applicable information in the service manual
The springs in the SAHR brake are under extreme compression

and improper disassembly methods can result in serious
personal injury and equipment damage
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Safety
Articulation Safety Lock Dump Box Safety Support
Dump box support installed.
Articulation locking bar in the

locked position.
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Safety
Emergency Exit From Cabin Fly-Rock Window Guard
Pull the ring to remove the emergency cable, The rear window is protected from
then push glass out of the window frame. flying rock by a shield.
In the event of an emergency, the driver
can exit through the windshield or
through the side windows.
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Safety
Engine Fan Guard
Drive Shaft Guards Exhaust Cover
If a U-joint fails, this Stay away from rotating, Exhaust Cover Location
guard restrains the drive shaft. moving or hot parts.
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Safety
Working with wheels and tires
DANGER!
Tires and wheels can explode and cause severe injury or death!
Always inflate the tires to the recommended pressure.
Check each tire for deep cuts, loose thread or exposed cord.
Report any damage to the maintenace department.
Incorrect modification or rework to wheel rim or parts

may result in failure, severe injury or even death!
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Safety
Working with wheels and tires
If the tire and wheel assembly is removed from the vehicle,

put it into a tire inflation cage before adding air.
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Safety
Acoustic Warnings
Reverse Alarm Reverse Alarm
Brake lights Brake lights
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Safety Before performing maintenanceon Minetruck.
Prepare the vehicle using the procedures below.
Master Switch Do Not Start Engine tag
1. Park the Minetruck in a straight line on a hardened flat surface,

follow the procedures in the manual.
2. Before working on the vehicle, always put a Do Not Operate tag
in the cab on the steering wheel or lever.
3. Empty the box and lower it to the stop pad or safety support.
4. Set the park brake.
5. Shut down the engine.
6. Wait a few minutes to allow the computer to cycle through its
engine shutdown routine, then turn the master Switch OFF.
7. Block the wheels.
8. Always install the articulation locking pin in the LOCKED position
before servicing the vehicle, even if the engine is not running.
9. If the vehicle must be serviced in the load frame area, install the
dump box safety support.
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Safety
Before starting & after starting on the Minetruck, perform our Daily Check
Power Frame Load Frame Cab

– Engine oil – Manual grease points – Lights
– Hoses & Couplings – Strobe, Horn
– Fuel level
– Rim & Tires – AC cab unit
– Hoses & Couplings – Cab & door
– Damage
– Engine V-belts & Pulleys – Chair
– Bolts
– Engine air filter – Electrical functions
– Coolant level – Alarms & Warnings
– Brake test
– Transmission oil
– Ansul
– Upbox & Dropbox oil
– Door grease points
– Hydraulic oil – Alarms & Horn
– Battery – Damages
– Fire extinguisher
– Lincoln lube
– Manual grease points
– Rim & Tires
– Damage
– Bolts
In the manuals you can find all information that you need for
Preventive Maintenance
Make sure everything is in place and fixed

– Grease levels, points
– Damage
– Clean
– Fluid level
– Belts
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Safety
Never enter the articulation area
of the vehicle until the articulation lock
Risk area 2m bar has been installed.
2m
2m
2m
1250 0203 25
Always carry out the fault finding
or the work with great care and accuracy when working in the risk areas.
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Safety
In case of fire
Always follow your local fire fighting regulations!

Make sure you know where to find fire fighting equipment
Only attempt to put out the fire if there is no risk of personal injury
Personal health comes first – Equipment can always be replaced
Stop the vehicle, apply park brake and shut down the engine
Engage the fire suppression system (available as option)
Use the fire extinguisher to put out the fire if the fire suppression
system in any case is not enough
If possible, without danger
– turn off the master switch and turn off the fuel supply
Evacuate the fire scene as soon as possible

– Fire causes lack of oxygene very fast, especially in a mine environment
NOTE - Local fire fighting regulations always overrides this procedure!
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Safety
Fire Extinguisher
Location of Fire Extinguisher
Pressure Gage
Check regularly that the needle on the gauge

is within the green zone and make sure that
the fire extinguisher is replaced as soon as
the needle approaches the red zone.
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Safety
Fire fighting Activate the fire fighting system by
Manual Fire
Suppression System
1 – Pulling out the spring clip

If the vehicle has the manual Fire 2 – Pressing down the activator
Suppression System, immediately follow
these steps after detecting a fire on the
vehicle.
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Safety
Fire Suppression Components
Actuator
Dry Chemical
Tank
Expellant Gas
Union Cartridge
Assembly
Nozzle
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Safety
Hydraulic Suspension Safety Suspension System Relief Valve
The suspension relief valve is located

1. Locknut.
at the back of the engine,
2. Allen wrench opening in cartridge barrel.
in front of the upbox.
DANGER
To avoid a crushing hazard, always relieve the suspension system
hydraulic pressure before entering internal areas of the vehicle.
DANGER
Before relaxing the suspension system, make sure that all personnel
are clear from the minetruck and that they are aware that the vehicle will
be lowered.
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Hydraulic Introduction
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Objectives

Content
Safety Brake system
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Retarder
Dump
Suspension
Aux Valve
Cab Tilt
Steering
Pumps
Brakes
Tank
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Hydraulic System
Hydraulic System
Steering
Dump
SAHR Brakes/ Brake Cooling
Upbox/ Dropbox
Transmission
Suspension
Hydraulic Tank Fill
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Hydraulic System
Hydraulic oil tank
Breather
Tank Capacity 238L

Return Filter
Return filter 4 micron
Sight glass
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Hydraulic System
How hoses are defined
Part number Designation

103 5500 2001 00 1 HOSE ASSEMBLY FA8744N N N 0300
Ref no Quantity
HOSE ASSY BASE NUMBER
SIZE OF END FITTING W/LOWER CODE NUMBER(FC5050)
SIZE OF HOSE (N= -20)
SIZE OF OPPOSITE END FITTING (FC5054)
HOSE ASSY LENGHT (LAST DIGIT IN1/8` S)
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Hydraulic System
Steering System Dump System
Dump/Steer Pump Dump/Steer Pump

Orbital Valve Pilot Dump Valve
Steering Valve Dump Valve
Steering Cylinders Dump Cylinders
Hydraulic Steer Stops Auxiliary Valve
Auxiliary Valve
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Hydraulic System
Dump/Steer Pump
Max. Operating System Pressure: 200 Bar
Max. Operating temperature: +100°C/+200°F
325.5 l/Min (86 GPM) at 2300RPM
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Hydraulic System
Orbital Steering Valve
Max. Operating Temperature 100°C
Recommended flow 20 l/min 5
1
4 2
1.Right turn
2.Left turn
3.Direct Mechanical link
4.Return to Tank Line
5.Pressure Inlet
The wheel steering valve is a hydrostatic unit that is controlled by the

steering wheel. The steering valve is either installed in the steering
column assembly under the steering wheel in the operato
compartment or on the other side of the bulkhead between the
operator’s compartment and the engine tub.
Turning the steering wheel actuates three main parts of the valve:
The control spool
The control sleeve
The metering rotor
The metering rotor has a direct mechanical link to the steering
wheel.When the steering wheel is turned in either direction, the spool
begins to rotate and becomes aligned with the sleeve.
Further rotation will direct oil flow from the pilot valve to the steering
valve and out the right or left direction port to the steering cylinders.
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Hydraulic System
Main Steering Valve
The steering control valve combines the functions of the main

steering valve, priority flow valve and cushion valve into one
component.
– It makes use of 18.98-20.7 bar (275-300 psi) hydraulic
system pilot pressure to shift the main spool, which ports
hydraulic system main pressure to the steering cylinders
– End or pilot notches on the spool require continuous flow
through the valve, while pilot pressure is applied.
– When the operator returns the steering control wheel (or
stick) to its normal, or centered position, pilot flow to the valve
stops, and spring pressure returns the valve spool to center
position.
CHECK PILOT PRESSURE
– FIT GAUGE INTO TEST PORT ON THE PILOT PRESSURE
VALVE.
– PRESSURE MUST BE 275 – 300psi (19-20,7 bar) PSI AT
FULL THROTTLE.
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Hydraulic System
Main Steering Valve
This adjustment
screw reaches
through the
access hole to
the right
Check Adjust the
pressure pressure
CHECK STEERING SYSTEM MAIN RELIEF PRESSURE.
-FIT GAUGE INTO TEST PORT ON THE STEERING CONTROL VALVE

-PRESSURE MUST BE 3000 psi/207 bar AT FULL RPM.
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Hydraulic System
Dump Control Valve
Check
Pressure
Adjust the
pressure
CHECK DUMP SYSTEM MAIN RELIEF PRESSURE.

-FIT GAUGE INTO TEST PORT ON THE DUMP CONTROL
VALVE
-PRESSURE MUST BE MT-6020 3100 psi/214 bar and MT-5020
2500 psi/172 bar AT FULL
RPM.
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Hydraulic System
Main Dump Valve
The dump control valve controls the flow of oil to the

dump cylinders.
– This valve is operated by the control lever through
the pilot control valve, dump valve, and to the dump
cylinders.
– It has a main relief valve set at MT-5020 172.5 bar
(2500 psi), and MT-6020 214bar (3100 psi) a
combination anti-cavitation and port relief valve at
each work port.
– The dump spool is equipped with a float position
which opens both dump cylinder ports to the tank
when the pilot valve is placed in the detente position.
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Hydraulic System
Auxiliary Valve Adjust the
pressure
Port locartion
for check
pressure
The auxiliary valve is located below the cabin towards the

front of the vehicle.
The auxiliary valve has a SAE J1502 diagnostic coupler that
allows electronic access to the operation of the electronic
functions of the valve.
Hydraulic oil is sent directly to the auxiliary valve from the
brake pump.
Once system pressure of 138 bar (2000psi) is achieved, the
brake pump will de-stroke and stop the flow to the auxiliary
valve, but will continue to maintain system pressure.
The pressure reducing valve supplies pilot oil to the steering,
dump/hoist and retarder control valves.
The pressure reducing valve steps the 138 bar (2000 psi) oil
pressure down to 18.98-20.7 bar (275-300 psi).
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Hydraulic System
Variable Displacement Pump for SAHR Brake & Suspension Systems
Max. Operating Pressure: 250 Bar

Max. Operating Temperature: 90°C
Max. Operating Speed: 3000 RPM
Max. Rotation Flow: 60 l/min at 2200RPM
Port locartion
for check
pressure
Relife
Adjust the
adjustment
pressure
screw
Port locartion
for check
brake cooling
pressure
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Hydraulic System
Hydraulic Steer Stops
Left side
Right side
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Hydraulic System
Brake Cooling
Rated flow at 2400RPM
– 1st Section: 50 l/min
Brake Cooling Pump
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Central Lubrication System
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Central Lubrication System On time: 2 minutes minimum
30 minutes maximum
in 2 minutes increments
Off time: 1 hour minimum

15 hours maximum
in 1 hour increments
Pump output: 2.4 cm³ - 0.146 cui

Output connection: 8mm – 1/8” NPT female
Max rekommended
Operating pressure: 248 bar – 3600psi
Lubricant: Greases up to NLGI grade 2
Temperature range:
From -25°C / -13°F to +70°C
/ +158°F
Grease fill
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Central Lubrication System
Timer Settings
OFF TIME CAN ON TIME CAN

BE ADJUSTED BE ADJUSTED
TO 15 VALUES TO 15 VALUES
LED MARKED
LED MARKED
BATTERY,
MOTOR,
LIGHTS UP LIGHTS UP
WHEN WHEN PUMPING
POWER LUBRICANT
IS APPLIED
TO PC
BOARD
DEPRESSING THIS
BUTTON FOR 2
SECONDS, INITIATES A
MANUAL LUBE EVENT
IMPORTANT: DO NOT USE THE (0) ZERO,

SETTINGS ON EITHER TIMERS
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MT 6020/5020
Controls & Electrical System
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Objectives

Content
Safety Brake system
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Electrical system Ladder Diagram
Electrical. system – Shows layout and orientation of electrical

components.
Ladder – Shows how everything is connected, wire by wire.
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Electrical system
Computerized Diagnostic System
There are a number of diagnostic interfaces in the minetruck

computerized electrical systems.
The programmable logic control has a visual lighting display, the
engine ECM has a diagnostic data reader that can be plugged in,
and the transmission ECU has an interface for a computer
diagnostic program.
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Control system
Engine Electronic Control Module-ECM
ECM
– The ECM is computerized logic control device that provides
overall engine management.The ECM controls engine sped
and power, injection timing, governing, torque shaping, cold
start logic, fuel delivery, diagnistics and engine safeguards.
– The ECM system includes folowing components: Electronic
cocntrol module, Engine speed sensor, Engine wiring
harness, System sensors, Diagnostic interfaces,
Communication links.
– The ECM sensor system is designed to provide information
about the engine various performancewith following sensors:
– Turbo Boost sensor, Fuel Pressure Sensor, Oil Pressure
Sensor, Crankcase Pressure Sensor, Coolant
Temperature sensor, Fuel Temperature sensor,
– Air temperature Sensor, Oli Temperature sensor, Coolant
level Sensor, Throttle position Sensor.
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Control system
LEDs on the PLC
X = Inputs
Y = Outputs
COM = Power supply
LED´s on the PLC
The PLC has several inputs and outputs:

X = Inputs
Y = Outputs
COM: Power supply
All numbers on the right of the PLC (Shown on the illustration)

has a light behind it. This light will lit when the Input/Output is
active. There are also three other lights on the PLC that shows:
- Power, If the PLC has power
- Run, if the PLC ON or OFF. It might have power then the
“power light” will lit but no the “run light“ will not lit until the PLC is
switched ON
- Error, This will lit if there is an error on the PLC
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Control system
PLC Connections
PLC: Programmable Logical Controlle
– The PLC is a microprocessor that receives input from the

operator, ECM, ECU, DCU, a cabin position proximity switch
and the dump box position limit switch.
– The PLC output to the ECU, ECM, park brake solenoid,
exhaust brake solenoids, controls box up indicator on the
panel.
– The PLC have lot of functions in this machine.
– To interpreter the inputs from the gear selector and the shift
buttons to “tell” the TRANS.ECU what to do.
– To “flash” the light in the park brake button if the brakes are
not OK to release.
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Control system
PLC Program connections / Settings
EEPROM VR1
Connection
ON/OFF
VR2
PC Connection
VR1 & VR2 – Variable Analog Potentiometers
PLC Program connections /Settings

– There are two connections on the PLC and they are used for
the following:
– EEPROM Connection: The EEPROM connection is used to
connect an EPPROM with the program for the PLC.
EEPROM is permanent memory also, the program is retained
with no battery connected.
– It is easy to make changes to EEPROM, because it is
electrically erasable. On-line changes are not allowed.
– VR1 & VR2 – Variable Analog Potentiometers
– On the MT 6020/5020 used only VR1 for Neutral Brake
Apply
– PC Connection: This is where you can connect a PC to

upload or download the software from the PLC (This is
suppose to be done by Atlas Copco only)
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Control system
PLC- Programmable Logic Control
1 1
2 3 5 6 7
1. Stop
2. Fuse
3. Input module
4. Plc-output module
5. Input module
6. Output module
7. Relay
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Control system
PLC
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Control system
PLC
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Control system
PLC
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Control system
PLC
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Control system
PLC
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Control system
TRANSMISSION/ ECU
TRANSMISSION ELECTRONIC CONTROL UNIT – ECU:

– The ECU contains the microcomputer which is the brain of the control
system.
– The CEC2 control system consists of five major components connected
by customer-furnished wiring harnesses:
– • Electronic Control Unit (ECU)
– • Engine throttle position sensor (or direct electronic communication)
– • Three speed sensors(The speed sensor is mounted on the dropbox
input shaft and sends speed data to the ECU)
– • Remote shift selector(The lever shift selector is an electro-mechanical
control)
– •Valve body (The electronically controlled transmission’s hydraulic
circuits and valves are controlled by a series of solenoids mounted on
the transmission’s electro-hydraulic valve body.
– These solenoids are activated and deactivated by electrical signals
generated by the ECU)
– The throttle position sensor (or engine-to-transmission communication

link), speed sensors, and shift selector transmit information to the ECU.
– The ECU processes this information and then sends signals to actuate
specific solenoids located on the transmission.
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Control system
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Control system
TRANSMISSION/ ECU
The electronic control system is programmed to inform the operator of a

problem with the transmission system and automatically take action to
protect the operator, vehicle, and transmission.
When the Electronic Control Unit (ECU) detects a problem condition, the
ECU restricts shifting, turns on the CHECK TRANS light on the instrument
panel, and registers a diagnostic code.
For example, the Low Battery Voltage numeric code is 13,the Check Transmission light
will flash once then pause, then flash three more times in succession.
– Diagnostic codes can be read and cleared by two methods:

– •With the Pro-Link® 9000 Diagnostic Data Reader. The use of the Pro-Link® 9000
diagnostic tool is described in the instruction manual furnished with each tool.
– •With the pushbutton or lever shift selector.
– Lever Shift SelectorTo Begin the Diagnostic Process:
– •Bring the vehicle to a stop at a safe location.
– •Apply the parking brake.To Display Stored Codes:
– •Press the DISPLAY MODE button once to access the diagnostic display mode.
– •Observe the digital display for codes (codes will appear one digit at a time)
– Clearing Codes:
– •Active Indicators — Press and hold the MODE button for 3 to 5 seconds until the
MODE indicator (LED) flashes.
– •Inactive Indicators — Press and hold the MODE button for 8 to 10 seconds until the
MODE indicator (LED) flashes.
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Control system
TRANSMISSION/ ECU
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Control system
TRANSMISSION/ ECU
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Control system
TRANSMISSION/ ECU
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Control system
TRANSMISSION
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Control system
Data Collection Unit - DCU
DCU: Data Collection Unit

– The DCU collects information from various internal sources to
operator instrumentation. The DCU is linked with the
wehicle`s public communication bus which allows it to send
and recive information.
– The DCU is composed of the following:
– Engine coolant tem., Eng. oil press., Eng. ECM data, Fuel
level, Accum. press, Trans. Pressure,Trans. temp.
sensor, Hydraulic tank temp. sensor.
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Control system
Shift Selector
Shifter lockout release

Dump Control
Secundery Mode indicator
Secundery Mode
On/Off button
Consule Display
Diagnostic Request Button
Shift Selector is an electro-mechanical coctrol unit.

The shift selector are provided with 6 forwrd drive(D)
range, 2 reverse(R) range and neutral(N) position.
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Control system
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Control system Load lt.
Left panel Front lt.

Rear lt.
Engine diag. Conn.
Engine override Brake test switch

switch
Fuse CB1,CB5,
CB6,CB10
Wiper/washer switch
Engine diagnostic code
switch
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Control system
Left panel
1. Stop engine
2. Check engine
3. Eng.coolant level 1 2 3 4 5 6
4. Trans filter
5. Check trans
6. Stgr pump hi press
7. Box up/gate down
8. Hyd level
9. Axle wrng
10. Dbox wrng
7 8 9 10 11 12
11. Upbox wrng
12. Strg pump lo press
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Control system
Left panel
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Control system Buzzer
Center panel Turn signal indicators Engine overspeed lt.
Tachometer
Hour meter
Speedometer
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Control system Ignition switch
Heater
Right panel Pressurizer
Trans. Oil temp Fuel
Hyd.temp
Engine water temp.
Voltmeter
Engine oil press.

Trans. Press. Hyd. Accum. Press.
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Control system
Cummins ECM
Starter
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Control system
Transmission Press Transducer
Accum. Press Transducer
Park Brake
Press Switch
Brake Press Switch
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Control system
Volt bar psi
Accumulator Transducer 0.5 0 0
1.45 82.4 1200
400
350 1.60 96.5 1400
300
250 1.76 110.3 1600
Bar
200
150
2.08 137.9 2000
100
50
0
-50 0 0,5 1 1,5 2 2,5 3 3,5 4 4,5 5
Volt
Transmission Transducer
Volt bar psi
60 0.5 0 0
50 0.83 4.2 60
40
30
1.60 13.8 200
Bar
20 1.93 17.9 260

10
0
-10 0 0,5 1 1,5 2 2,5 3 3,5 4 4,5 5
Volt
33
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Diesel Engine
Cummins QSK19
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Objectives

Content
Safety Brake system
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Diesel Engine
Cummins QSK19
Power rating at 2100 rpm 650HP / 485kw (MT-5020)

Power rating at 2100 rpm 760HP / 567kw (MT-6020)
Low idle 700 rpm (±25)
High idle 2190 rpm (±50)
Converter stall 1910 rpm(±150) MT-6020
Converter stall 1812 rpm((±150) MT-5020
Max. torque at 1300 rpm 3084 Nm
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Diesel Engine
Service Bay
Air Restrictor Indicator
Fuel Filter Upbox Filter
Front Brake Bleeders Fuel Priming Pump

Fuel Filter AutoLube Grease Fill
Engine Oil Filter Brake Fluid Filter
Engine Oil Filter Fuel Level Sensor
Fuel Quick Fill
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Diesel Engine
Radiator ambient capability estimated with 50/50 glycol

– Standard ambient 38°C / 101°F
– High ambient 48°C / 120°F
Capacity
– Radiator 140L / 37Gal
– Coolant (only engine) 41,6L / 11Gal
– Engine 61L / 16Gal
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Diesel Engine
Oil/Coolant check and drainage
Engine oil level dipstick

Engine oil filling
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Diesel Engine
Oil/Coolant check and drainage
Engine oil drain plug

Coolant drain plug
Coolant sight glass
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Diesel Engine
Components
Air Conditioning
Compressor
Brake Cooling
Pump
Fuel pump ECM Starter
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Diesel Engine
Components
Turbo
Alternator
Engine Oil Cooler
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Diesel Engine Intake Manifold
Pressure Sensor
Intake Manifold
Temperature Sensor
Sensors
Coolant Temperature Sensor
Engine Speed Sensor
Fuel Timing Pressure

Sensor
Actuator
Fuel Rail Pressure

Sensor
Oil Pressure Sensor
Pressure Sensor
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Diesel Engine
Fuel System
Fuel system operation
– Fuel is drawn from the tank through a fuel supply check valve
that maintains suction when the fuel filters are removed for
service.
– Fuel is then pumped to an electronic control valve that
distributes the flow as needed. Fuel supply lines provide fuel
for injection and cooling.
– The injectors supply fuel to the combustion chamber, and
are cooled by a separate flow that returns to the fuel tank.
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Diesel Engine
Fuel System 1. Fuel manifold front
2. Injector
3. Fuel manifold rear
2
4. Fuel drain line
3 4
14 1 5. Fuel drain line8engine to fuel tank)
6. Fuel control valve supply line
7. Electronic fuel control valve
5
8. Fuel inlet line
13 9. Fuel filters with water separation
6 10. Fuel inlet line(tank to fuel filters)
12 11. Fuel pump
7 12. Fuel supply check valve
11 13. Fuel rall supply line
14. Fuel timing supply line
9
10
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Diesel Engine
Fuel System
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Diesel Engine
Lubricating System
1. Oil cooler elements

2. Turbocharger oil supply
3. Oil cooler housing
4. Lubricating oil pump
5. Lubricating oil pump regulator
6. Oil suction tube
7. Oil to filter head
8. Turbocharger oil drain
Engine oil can reach

temperatures exceeding 104°C (220°F).
Do not change oil immediately
after engine shutdown.
Filter head oil in Filter head oil out
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 minetruck engine oil system

are:
– Oil pump
– Oil cooler
– Oil filters
– Oill fill & dipstick
– Pressure gauge
Oil lubrication pump is a gear driven pump mounted at the

front right hand side of the cylinder block and is gear driven off
the engine crankshaft.
It is the heart of the engine oil system and is equipped with an
inlet screen located in the oil pan to strain out contaminants.
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Diesel Engine
Cooling System 1/3
Cooling System
– Pressurized engine coolant is drawn from the lower portion of
the radiator by the water pump and is forced through the oil
cooler,
– into the charge air cooler, and into the cylinder block.
– When the engine is at normal operating temperature,
– the coolant passes from the cylinder block up through the
cylinder head, through the thermostat housing and into the
upper portion of the radiator.
The coolant then passes through a series of tubes where the
coolant temperature is lowered by the air flow created by the
revolving fan and the motion of the vehicle.
– When the thermostat opening temperature is reached,
coolant flow is divided between the radiator inlet and the
bypass tube.
– When the thermostats are completely open, all of the coolant
flows to the radiator inlet.
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Diesel Engine
Cooling System 2/3
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Diesel Engine
Cooling System
1. Coolant out of aftercooler

2. Coolant to aftercooler
3. Cylinder liner
4. Water pump
5. Coolant bypass from thermostat
6. Water inlet
7. Water filter
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Diesel Engine
Engine Cooling Fan Drive
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Diesel Engine
Exhaust system
Exhaust system Exhaust silencer
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 tubing and the purifier.
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 exhaust purifier is a catalyzer with particle reducing
function.
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Diesel Engine
Air intake system
Filter
Filter indicators
The Air supply system fulfills two primary functions:
AIR FILTER
– Provides clean, contaminant free combustion air to the
engine. Provides forced-air cooling to the engine and/or
various sub-systems.
INDICATORs
– The air filter restriction indicator is located in the service bay
between air filters.
– When intake air restriction has reached the allowed trip point,
the indicator will show Red. This notifies the operator that the
filter requires changing. W
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Diesel Engine
Turbo system
Turbo charger
The turbocharger consists of a turbine wheel and shaft, a compressor

wheel, and a center housing that serves to support the rotating assembly,
bearings, seals, a turbine housing, and a compressor housing.
The turbocharger is mounted on the engine and 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.
– Power to drive the turbocharger is extracted from the energy in the

engine exhaust gas.
– The gases are discharged into the exhaust system after passing
through the turbine housing.
– The compressor wheel, in the compressor housing, is mounted on the
opposite end of the turbine wheel shaft and rotates with the turbine wheel.
– The compressor wheel draws in clean air, compresses it, and delivers high pressure
air through the intake manifold to the engine cylinders.
– Oil for lubricating the turbocharger is supplied under pressure through an external oil
line extending from the oil filter adapter to the top of the center housing.
– From the oil inlet in the center housing, the oil flows through the drilled oil passages in
the housing to the shaft bearings, thrust ring, thrust bearing, and back-plate or thrust
plate.
– The oil returns by gravity to the engine oil pan through an external oil line extending
from the bottom of the turbocharger center housing to the cylinder block.
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MT5020/6020
ECM
INPUT ANALASYS OUTPUT
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Diesel Engine
The electronic unit injector
Solenoid
The electronic injector
– The electronic unit injector (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 huw mush fuel will be delivered.
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Diesel Engine
Engine sensors
Temperature
- Oil temperature
- Coolant temperature
- Intake manifold temperature
Pressure:
- Oil pressure (before and after filter)
- Ambient air pressure
- Intake manifold boost pressure
Others:
- Engine position sensor
- Coolant level (Located on serge tank)
- Water in fuel sensor (Located on fuel filter)
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Diesel Engine
Sensor range
Engine sensors
– 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 the ECM is able to tell the difference between low
oil pressure and a faulty wire leading to the low oil pressure
sensor.
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Diesel Engine
Troubleshooting Cummins Quickcheck
Cummins Insite
Diagnostic tools Quickserve online
– Two tools are available to connect to the ECM system for diagnostic
purposes.
– The Quickcheck QC5100 is a hand held tool that is compact and
rugged
– Cummins Insite software is available for Windows based computers.
– Both tools communicate to the ECM via the 2 wire CAN/J1939 and
J1708.
– The acronyms that follow have code numbers identifying which system
or component is generating information on the common data link, and
are used in troubleshooting fault codes.
– MID (Message Identifier Description) defines what major component
the microprocessor is sending data about - engine, transmission, ABS,
ect.
– PID (Parameter Identification description) defines a component or
system within the major component - oil pressure sensor, coolant level
sensor, etc.
– SID (Subsystem Identifier Description) similar to PID. Defines a field
repairable and identifiable component within a system - fuel injectors
– FMI (Failure Mode Identifier) defines what kind of failure occurred in a
PID or SID
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Sensor wiring
– Explain how to see the difference between a temperature
sensor and a pressure sensors in the diagrams.
– 2 cables = Temperature sensor

– 3 cabled = Pressure sensor
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MT5020/6020
Transmission and Axles
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Objectives

Content
Safety Brake system
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Kessler
Drivelines matched Suspension Drop box
for maximum system
power transfer
Kessler
Up box
Cummins
Kessler QSK19
axles Allison engine
with M6610AR
SAHR Transmission
brakes
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Allison H6610 AR
Clutch/Charge pressure: 11-15 bar(160-220psi)
Transmission
– M6610AR is an electronically controlled automatic
transmission that has bee combined with the torque
converter in one unit.
– Transmission components include an Electronic Control Unit
(ECU), a control valve, hydraulic torque converter, a lock-up
clutch, planetary gear sets, and hydraulic clutches.
– The Electronic Control Unit (ECU) uses information gathered
by the throttle position sensor and the output speed sensor to
determine how it will respond to operator control of the shift
selector
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Automatic Transmission
Planetary gearing provides smooth shifting

Automatic gear selection
Automatic converter lockup
Benefits…
Stops powertrain abuse
Less heat and more power to the ground
Higher speed on grade
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Transmission dipstick
Transmission fill
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Transmission and Axles Main connector
for Solenoids
Solenoid Body
Turbin Speed Sensor
Lockup and Temperature

Trim Boost sensor Sensor
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Impeller Speed Sensor
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High Clutch
Lockup
Pressure Main Pressure Pressure
Low Clutch Old C2 Press Lockup
Pressure Do Not Use Feed
Splitter Low
Reverse
Pressure
Pressure
Intermediate
Pressure Splitter High
Pressure
Trim Boost
Pressure
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LockUp Control Valve Retarder Control Valve
Allison M6610 with automatic shifting. 6 gears forward and 2

reverse. Hydraulic retarder controlled by foot pedal in cabin.
– The lockup clutch is located inside the torque converter and

consists of three
– elements—a piston, a clutch plate, and a backplate. The
piston and backplate are
– driven by the engine. The clutch plate, located between the
piston and backplate, is
– splined to the converter turbine.
– The hydraulic retarder is used to slow the vehicle on

curves or downgrades.
– The retarder consists of a vaned rotor splined to the turbine
shaft and mounted in a
– sealed housing.
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The torque converter consists of three elements — pump,

turbine, and stator.
– The pump is the input element and is driven directly by the
engine.
– The turbine is theoutput element and is hydraulically driven
by the pump.
– The stator is the reaction (torque multiplying) element.
– The planetary gear train consists of four constant-mesh

planetary gear sets. The
– forward set is the splitter and the three rear sets are the
intermediate, low, and reverse.
– These planetaries are combined with six clutches to provide
six forward ranges and
– two reverse ranges.
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Transmission cooling circuit
– When the Truck is starting , the engine coolant passing

through the heat exchanger warms the hydraulic fluid.
– After the hydraulic oil heats up, the engine coolant cools the
hydraulic fluid.
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Upbox and Dropbox Lubrication & Cooling
Reservoir
The dropbox has a external pump located on the upbox, which

draws oil from the sump in the dropbox.
The oil continues on to the coller and filter before entering the
dropbox applying oil to all the bearings and gears.
The dropbox is cooled by an oil to air inter-cooler. As the engine
turns the transmission and dropbox, oil is pumped through the
cooler then back into the dropbox.
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Upbox Kessler W1616.2
Breather Line
Cooling Output
Pressure Line Suction Line From

To Dropbox Dropbox
Pressure Line
To Dropbox Sensor
Pressure Line
To Upbox
Pressure Line
To Upbox Sensor
Return Line
Upbox Temperature To Dropbox
Sensor
– The upbox transfers engine output over the front driveline,

allowing the minetruck to maintain its low height clearance.
– Engine output is transmitted on a one-to-one ratio to the
transmission.The upbox has a rubber coupler that bolts to the
engine flywheel.
– The upbox gear case is supported by a bell housing that
protects the rubber coupler and flywheel assembly.
– The external engine-to-upbox connection is reinforced with a
strong brace for added rigidity, and is firmly supported
through shock resistant pads to the mainframe.
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Upbox / Dropbox Gear Pumps
Approx. 27 cm3 per revolution

without restriction
Approx. 24 cm3 per revolution
with cooler and filter for up- and
dropbox
Pressure Suction
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Upbox
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Upbox
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Dropbox Kessler 1618.2
Common Breather with Upbox
Inlet Dropbox pump
Allison speed sensor
Power output
Sight glass oil level
– The drop box is mounted to the transmission and

dispenses output power to the front and rear axles.
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Dropbox
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Dropbox
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Driveline
Grease
Greasing Points point
Grease
point
Grease Grease
point point
Grease
point
Grease
point
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Axles
MT6020 / MT5020
Front
– Kessler 111 & 106
– Conventional front and rear
differential
– Front-axle oscillating suspension
frame with hydraulic
– All wheel drive
– SAHR Brake
Rear
– Kessler 111 & 106
– Conventional front and rear
differential
– All wheel drive
– SAHR Brake
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Minetruck MT5020/6020 Kessler Axels
Same axle in the front and rear

– Conventional (open) differentials for both
Dual planetary gears on the wheel ends for improved

torque control
SAHR Brakes upgraded in the new axles with higher
capacity
Benefits….
Longer life
Easy installation
Easy to maintain
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Front and Rear Axles
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Suspension
Front Suspension
Front axle auto-leveling

suspension and
oscillation
Benefits…
Smooth ride for
operator
– Less fatigue means
greater productivity
Allows faster haul

speeds over uneven
ground conditions
Suspension System
– Suspension is a hydro-pneumatic system that serves to
improve operator comfort and vehicle handling while
minimizing frame stress.
– The system is capable of operating at infinitely adjustable
pressures, within its’ range, to compensate for variable loads
and maintain a constant frame height.
Major components of the suspension system include the

hydraulic tank, suspension system leveling valve,suspension
system cylinders, suspension system accumulators, an
auxiliary valve, and a manual bleed down valve.
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Suspension
Suspension Accumulators
1. Air Valve
2. Upper Housing
3. Nitrogen Pre-Charge
4. Lower Housing
5. Piston
6. Hydraulic Oil
A hydraulic accumulator consists primarily of a shell, piston, air valve, and

seals.
– The area above the piston is precharged with dry nitrogen gas to
approximately 82.8 bar (1200 psi).
When the accumulator is charging, oil at system pressure enters the

chamber below the piston.
– This pressure acting on the bottom of the piston moves the piston up.
As the piston travels up, the nitrogen gas compresses, increasing the
charge pressure above the piston.
– The piston will be forced up until the pressure on both sides of the
piston are equal.
The accumulators should be checked during vehicle overhaul to assure the

proper precharge pressure is available.
An accumulator with low or no precharge will cause excess cycling of the

accumulator charging valve and excess temperature in the hydraulic
system.
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MT5020/6020
Brake System
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Objectives

Content
Safety Brake system
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Brake System
Brakes
Cooling
Tank
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SAHR Brakes
Benefits…
– No adjustments needed
– Eliminates redundant park brake
– Increases vehicle safety
– Safest brake in mining industry
SAHR = Spring Applied Hydraulic Released
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SAHR Brakes
FRONT
COVER MAIN BODY
PRESSURE
SUPPLY PORT
STATIONARY
PLATES
PISTON
FRICTION
PLATES SPRINGS
SPRING
FACE COVER
SEAL
AXLE
HOUSING
HUB SEAL
HUB
BEARING
SPINDLE
SIDESHAFT
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Brake System
Brake Pedal
Adjust screw
Pressure is adjustable using the brake pedal heel stop. To

adjust, with vehicle on a level surface,start the engine and
release the park brake.
Put the vehicle in 1st gear and roll the vehicle forward at low
idle, adjusting pedal heel stop up until the service brakes
start to drag.
Then turn stop back down until vehicle rolls free and brakes
are no longer dragging. Then turn the stop 1/4 of a turn in
and lock jam nut.
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SAHR Brakes
Oil pressure
A B
Springs
Disc
Brakes Released
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Brake System
Auxiliary Valve
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Brake System
Auxiliary Valve
Auxiliary Valve Side One
1.Test Port 1, Brake Pump

2.Test Port 3, Pilot pressure
3.Pilot solenoid supply pressure
4.Hand Pump Check Valve
5.Brake pump check valve
6.Suspension Check Valve
7.Pilot solenoid return
8.Redundant brake valve
9.Pressure reducing
11.Pilot operated brake valve
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Brake System
Auxiliary Valve
Auxiliary Valve Side Two
1.Brake Accumulator
2.Hand Pump for Releasing Brake
3.Brake Pump
4.Accumulator Pilot Pressure Test Port 2
5.Steering
6.Dump
7.Suspension
8.Optional
9.System pressure
10.Return to Tank
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Brake System
Auxiliary Valve
Auxiliary Valve Side Three
1.Pilot solenoid return

2.Park Brake Pressure Switch
3.Park Brake Open
Check Valve & Close Check Valve
4.Redundant brake close check valve
5.Tank
6.Pilot operated brake valve
7.Retarder
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Brake System 1
1.Air Valve
Accumulators
2.Upper Housing
3.Nitrogen Pre-Charge 2
4.Lower Housing
5.Piston 3
6.Hydraulic Oil
4 5
Danger! – Potentional energy hazard
Use extreme caution when working with hydraulic systems
Always read the service manual before conducting any

maintenance or troubleshooting in the hydraulic system
Ignoring important safety information can cause severe injury or even death!
The brake accumulator is located behind the right rear motor mount.
– A hydraulic accumulator consists primarily of a shell, piston, air valve,
and seals.
– The area above the piston must be pre-charged with dry nitrogen to a
pressure of 82.8 bar (1200 psi).
When the accumulator is charging, oil at system pressure enters the

chamber below the piston.
– This pressure acting on the bottom of the piston moves the piston up.
– As the piston travels up, the nitrogen gas compresses, increasing the
charge pressure above the piston.
– The piston will be forced up until the pressure on both sides of the
piston are equal.
– This oil will remain at this pressure until a fluid path is opened.
The accumulators should be checked during vehicle overhaul to assure the

proper precharge pressure is available.
An accumulator with low or no precharge will cause excess cycling of the

accumulator charging valve and excess temperature in the hydraulic
system.
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Brake System
Variable Displacement Pump for SAHR Brake & Suspension Systems
Max. Operating Pressure: 250 Bar

Max. Operating Speed: 3000 RPM
Max. Rotation Flow: 60 l/min at 2200RPM
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Brake System
Manual Brake Release
Manual
Primary and secondary brake is both fail to safe. Brake
Primary
Release
park
brake
valve
Manual
park
brake
switch
Secondary park brake

valve
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Brake System
Brake Cooling

Rated flow at 2400RPM
Brake Cooling
Pump
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Brake System
Engine Start
Engine Start
– Oil flow from the brake pump is directed to the Accumulator
Charge valve which, in turn, depending upon system load,
– will direct the majority of the oil to either the accumulators or
the brake cooling and dump/hoist systems.
– When the dump/hoist system is not in use, most of the flow
passes through the Pilot Pressure valve to the hydraulic oil
cooler, and on to the wheel ends, to cool the brake disks.
– Bypass check valves protect the oil cooler and the wheel
end seals from over pressurization.
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Brake System
Brakes Released
Brake released
– When the Park Brake solenoid valve is energized, brake
accumulator pressure flows to the auxiliary valve, this oil
pressure then holds check valve 6 closed and check valve 5
open.
– The stored oil pressure in the brake accumulator is then
directed to the foot brake control valve where the oil flows
through the spool, out to all four (4) wheel ends, and releases
the brakes, allowing the wheel ends to turn freely.
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Brake System
Service Brake
Applied
Brakes Applied
– When the foot pedal is actuated, the flow of oil to the wheel
ends is gradually cut off and the oil at the wheel ends is
enabled to return to the hydraulic tank.
– The wheel end SAHR brakes then apply, slowing and
stopping the vehicle.
– When the park brake solenoid valve is de-energized, the
brake accumulator pressure flow is shut off to the auxiliary
valve, allowing check valve 5 to close,shutting off oil supply
to the foot brake control valve. At the same time check valve
6 is directed to open, allowing the brake release oil that’s in
the wheel ends to flow back to the tank,applying the brakes.
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Brake System
Primary Solenoid
Failure
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Title style Arial Bold 30 pt
Subtitle Arial Bold 20 pt (copy and paste this text)
Text style Arial 20 pt

– Indent 1, Arial 18 pt
Indent 2, Arial 16 pt

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Brake System
BRAKE TESTING
The park brake

The service brake
The neutral brake
Testing the Park Brake:

Testing the park and service brake is always performed on a flat surface, not on/in any declines or ramps:
Start the machine.
Ensure no one is around the machine – carry out the normal safety procedures.
Apply the park brake and push and hold the service brake pedal with foot.
Turn the brake test switch left to position 1. Hold the brake test switch in the rotated position for the duration of the test for
solenoid one.
Pusch the transmission selector in drive the display panel of gear show 3nd gear.
Release the service brakes and slowly press the throttle pedal to the floor– the machine must not move. If it does,
immediately stop the test and report the defect to the maintenance department. If in order, continue with the next
step.
Release the throttle pedal.
Select neutral.
Testing the Service Brakes:
Apply the service brakes by fully depressing the brake pedal.
Turn the brake test switch left to position 1.Hold the brake test switch in the rotated position for the duration of the test for
solenoid one.
Place the transmission selector in drive. Verify that the display panel on the gear selector panel reads 3..
Release the park brake.
Slowly increase the engine rpm to maximum. The service brakes should prevent the machine from moving whilst at full rpm.
If it does not, immediately stop the test and report the defect to the maintenance department. If in order, continue
with the next step.
Release the accelerator pedal.
Select neutral and begin normal operation.
Testing the Neutral Brake:
After carrying out the park and service brake tests, ensure a safe area or a brake test ramp is available.
Safe area:
Drive machine in forward or reverse at a speed fast enough to ensure machine has enough momentum and select neutral, the
machine will not stop immediately due to the neutral brake delay as per the Atlas Copco specification. The brakes should apply
after +/- 3 seconds. If the brake application time is incorrect, it should be rectified.
Test ramp:
Park on top of the test ramp, select forward or reverse gear and any speed gear and start driving down the ramp. Select neutral,
the brakes should apply in about +/- 3 seconds.
If the brake application time is incorrect, report it to the maintenance team for re-adjustment.
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MT 6020/5020 Training
D/H and Steering system
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Objectives

Content
Safety Brake system
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Dump System
Raise 15s
Lower 7s
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Dump System
MT5020 MT6020
Playload 50 000kg Playload 60 000kg
Volume 25.0m3 Volume 29,7m3
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Dump System
Left panel
T- tank port
P- pressure port
B- raise port
A- power down&float port
The Dump Control lever has 4 positions:

1 Dump Box Up--To raise the dump box the control lever must be pulled
towards you.
The speed at which the box raises is controlled by how far back you pull the
dump lever, and by idle speed.
2 Hold--The amount the dump box is raised is controlled by how long the
dump lever is held back. To raise the box a few feet off of its
stops, pull the lever towards you and then letgo. The box will raise then stop
when the lever is let go.
3 Float--To lower the dump box slowly using gravity to pull it down, push the
dump lever forward or away from you until the Dump Box Up light goes out.
4 Power Down--To lower the dump box quickly with hydraulic power, push
the dump lever forward until it locks in place, this detente isin the fully
forward (away from you) range of
the lever. This will cause the hydraulic systemto pull the dump box down
until it reaches its stops on the load frame. When loading, the transmission
gear selector lever
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Dump System
Dump cylinders
The dump cylinders are double-acting, telescoping hydraulic

cylinders with a chrome stem, one-piece screw-on piston with
self-locking nut.
– They are able to withstand pressures up to 207 bar (3000
psi).
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Dump System
Dump Control Valve
The dump control valve controls the flow of oil to the dump
cylinders. This valve is operated by the control lever through the
pilot control valve, dump valve, and to the dump cylinders.
It has a main relief valve set at 172.5 bar (2500 psi), and a
combination anti-cavitation and port relief valve at each work port.
The dump spool is equipped with a float position which opens
both dump cylinder ports to the tank when the pilot valve is
placed in the detente position.
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Dump System
Dump & Steering pump
325.5 l/Min (86 GPM) at 2300RPM
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Dump System
Dump Circuit Neutral
Dump System
– Oil flow developed by the dump section of the pump is
delivered to the inlet port of the dump control valve, along
with oil exiting the HPCO port on the main steering control
valve.
– The two (2) open-center spools allow the oil to flow through
the valve and back to the hydraulic tank when both spools
are in the neutral position.
– On systems using a pilot control valve to actuate the dump
control valve, oil flow is supplied from the pilot pressure
(sequence) valve in the steering system, at 17.25 ± 1.38 bar
(250 ± 20 psi).
– The system pressure is determined by the load in the dump
box, with a maximum system pressure of 207 bar (3000 psi).
Should a sudden external load be applied to the dump
cylinder while raised, creating a spike in the system above
207 bar (3000 psi), the relief valve in the dump control valve
will open, directing the oil back to the hydraulic tank.
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Dump System
Dump circuit box up
Box Up
– On the MT5020 / MT6020, the operator moves the dump box
control lever for box up operation.
– The spool in the dump control valve is shifted down by the
pilot pressure valve. Oil flows from the pressure port to the
base end of the cylinders to raise the dump box.
– Oil from the stem end of the cylinders is routed back through
the dump control valve to the hydraulic tank.
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Dump System
Dump circuit box power down
Box Power Down

– To speed the return of the dump box to its stops, the operator
can move the dump control lever to the power down position.
– This shifts the main control valve to the extreme upward
position and directs pressure from the inlet to the stem end of
the dump cylinders.
– Oil from the base end of the cylinders returns through the
dump control valve, unseating the check ball in the control
valve and returns to tank.
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Steering components
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Steering System
Steering wheel & Steering cylinder
Steering wheel
The steering cylinders are also double-acting cylinders which

provide force in both directions.
They converts the fluid power from the pump to the mechanical
power.
Hydraulic fluid enters at one end of the cylinder to extend it, and
at the other end to retract it.
Oil from the unpressurized end of the cylinder returns to the
hydraulic tank.
The wheel steering system uses an orbital steering valve with a

load sensing port and hydraulic line installed as part of the
Priority Flow Divider valve.
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Steering System
Main Steering Valve
The steering control valve combines the functions of the main

steering valve, priority flow valve and cushion valve into one
component.
It makes use of 18.98-20.7 bar (275-300 psi) hydraulic system
pilot pressure to shift the main spool, which ports hydraulic
system main pressure to the steering cylinders
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Steering System
Orbital Steering Valve
Max. Operating Temperature 100°C
Recommended flow 20 l/min
1
5
4
2
3
1.Right Turn
2.Left turn
3.Direct Mechanical link
4.Return to Tank Line
5.Pressure Inlet
Turning the steering wheel actuates three main parts of the

valve:
The control spool
The control sleeve
The metering rotor
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Steering System
Steering stop valves
The steering stop valves are placed in the steering pilot

lines
to help cushion the steering action of the minetruck.
When the articulation angle reaches a certain point, a
bolt head attached to the truck frame comes in contact
with the steering stop valve spool.
This causes the pilot pressure to be vented back to the
tank, stopping the steering cylinders from
retracting/extending.
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Steering System
Steering & Dump pump
325.5 l/Min (86 GPM) at 2300RPM
The MT5020 / MT6020 is equipped with two types of pump, a

fixed displacement gear pump and an axial-piston variable
displacement pump.
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Steering System
Steering Circuit During Start-Up
Start up
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Steering System
Steering Circuit Engine Running
Engine running
– The wheel steering system uses an orbital steering valve with
a load sensing port and hydraulic line installed as part of the
Priority Flow Divider valve.
– Some units may also be equipped with a Cushion valve, in
place of port reliefs in the Steering Control valve, to protect
against over-pressurization of the cylinders.
– When the steering system is not in use, flow from the
steering pump travels through the Orbital Steering valve to
the dump Main Control valve.
– Turning the steering wheel actuates the Orbital Steering
valve and sends some of the flow through the steering circuit.
– The amount of flow is determined by how fast the wheel is
turned.
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Steering System
Steerning Turning Left
Left Turn
– Turning the steering wheel in a counterclockwise direction
shifts the valve, shutting off flow to the dump system.
– Oil flow unseats the check ball and exits out port “A” to the
steering cylinders. Port “B” becomes common with the port
– to the hydraulic tank, allowing oil returning from the steering
cylinders to enter the steering valve and be returned to tank.
– Oil flow entering the stem end of the cylinder encounters
resistance and becomes pressure, forcing the piston toward
the base of the cylinder thus retracting the cylinder.
– Oil at the base end of the cylinder exits through the base port
back through the cushion valve and steering valve where it is
directed to the hydraulic tank.
– This function is reversed when oil is supplied to the base end
of the cylinder.
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Steering System
Service Brake Released
Pressure
To tank
RED = HIGH PRESSURE = CLUTCH PRESSURE

BLUE = LOW PRESSURE = LUBE PRESSURE
GREEN = SUCTION / DRAIN LINES
Cushion valve
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General Maintenance
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Objectives

Content
Safety Brake system
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MT5020/6020
General Maintenance
Always read and understand Service and Operators manual before

operating and working with the Minetruck
In the manuals you can find all information that you need for
Preventive Maintenance
– Make sure everything is in place and Fixed
– Grease levels, points
– Damage
– Clean (rocks inside the frame)
– Fluid level
– Belts
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MT5020/6020
General Maintenance
Maintenance Intervals
125 Hours Operation
250 Hours Operation
500 Hours Operation
1000 Hours Operation
The regular care a vehicle receives by its operator is generally rewarded by decreased down time
and greater reliability.
The following maintenance and lubrication procedures can be performed on the job site with a
minimum of shop tools.
At the beginning and end of every shift, look for loose or damaged hoses and fittings. Check for
loose nuts, bolts and electrical wiring connections.
Check for signs of fresh oil around fittings and under the vehicle. At the first sight of damage or oil
leakage, notify maintenance personnel.
Scheduled preventive maintenance and lubrication are required to provide safe and efficient
operation of the vehicle.
Follow the lubrication and maintenance chart carefully and make sure that all points are serviced
correctly and on time.
Good record keeping is essential for an effective maintenance program. Scheduled maintenance
forms should be checked off as the inspection or procedure is completed.
– Safe operation of the vehicle requires that all systems be in top operating condition.
– If the vehicle is damaged, something is not adjusted correctly, or if there are missing parts, the
problem must be corrected before the vehicle returns to duty.
– Read the safety messages in this manual, the safety signs on the vehicle, and the operator
manual provided with the vehicle.
– Make sure that all warning signs are in place, and that they are clean and legible.
DANGER
– The articulation area of the vehicle presents a crushing hazard. See the safety section for
proper use of the articulation locking mechanism.
– Stop the engine before adjusting or repairing the engine or engine-driven equipment.
– If you must service the vehicle with the engine running, have a second person help you.
– The second person must be in the operator’s seat during any servicing or adjustment.
– Never work under a raised box unless the box is secured with a prop bar.
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MT 5020/6020
– Turn the ignition switch and master switch to the off position.
– Block the wheels.
– Always install the articulation locking pin in the locked
position before servicing the vehicle.
Management of Driver Inspection & Reporting

– The following shift report form will help with the monitoring of
daily vehicle maintenance activities.
– Daily reporting helps to control costs of supplies and provides
early warning for problems that could result in major damage
to vehicle systems.
– Accurate shift maintenance reports can identify problems
before costly repairs become necessary.
– Clean out chassis compartments and operator area. Note
general vehicle condition.
– Check for mechanical damage and loose or leaking
components. Report faults to the maintenance department.
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MT5020/6020
Maintenance Intervals
As Required
Good record keeping is essential to a proper maintenance

program. Each scheduled maintenance form should be checked
off as the inspection or procedure is completed.
Quantities of replenished lubricants and fluids, and pressure
and flow readings, should be recorded.
All discrepancies should be recorded whether remedied or
pending. Operators and mechanics should sign off forms and
return
them to maintenance supervisor for approval and retention in a
vehicle maintenance file.
Good records enable maintenance personnel to identify and
evaluate problem and/or
high cost areas which can then be targeted for improvements or
solutions.
Finally, good maintenance records aid in the planning and
scheduling of maintenance and repair procedures,
which result in the efficient use of maintenance resources and
maximum equipment reliability and availability
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MT5020/6020
Every Day at Each Shift
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MT5020/6020
Daily Lube Items
Break-In at First 125 Hours
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Every 125 Hours of Operation
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MT5020/6020
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MT5020/6020
Every 2000Hours of Operation
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Front Right Filter Bay
The main filter bay is located at the

right front corner of the vehicle.
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MT5020/6020
The Main Filter Bay
The main filter bay contains
1. Fuel Filter Canister with Water Separator

2. Upbox filter
3. Fuel Filter
4. Engine Oil Filter Canister
5. Engine Oil Filter Canister
6. Fuel Tank Fill
7. Engine Cooling Corrosion Inhibitor Filter
8. AutoLube Grease Fill
9. Brake Fluid Filter
10. Fuel Tank Gauge
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MT5020/6020
Service Bay
Air Restrictor Indicator
Fuel Filter Upbox Filter
Front Brake Bleeders Fuel Priming Pump

Fuel Filter AutoLube Grease Fill
Engine Oil Filter Brake Fluid Filter
Engine Oil Filter Fuel Level Sensor
Fuel Quick Fill
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MT5020/6020
Rear Brake Bleeders
Differential oil level plug Differential drain plug
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MT5020/6020
Drain Plug
Planetary oil level

plug
Planetary oil drain

plug
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MT5020/6020
Left Access-Panel Cabin Front Access Panels
The panel swings out and contains

the following:
Transmission Filter Electronic Cable Access
Dropbox Cooler
Dropbox Cooling Filter (behind gummifender)
Air Conditioning Filter
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MT5020/6020Engine Radiator & Front Grille Coolers
1. Hydraulic Oil Cooler for Steering, Dump & Hoist, and Brakes
2. Upbox Cooler
Dropbox Cooler 3. Flow Indicator for the Upbox Cooler
Fuel Cooler
The dropbox oil cooler is located

The fuel cooler is located next
behind the left access panel.
to the rear air filter.
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MT5020/6020
Inspect Structural Integrity Check Circuit Breakers and Fuses
Inspect the cabin, frame and dump box. Check the circuit breakers and reset any
that are tripped.
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MT5020/6020
Drain Fuel/Water Separator Engine Oil, Check Level Engine Coolant, Check Level
Water Drain Valves Surge Tank Coolant-

Level Sight Glass
Engine Oil Fill
Engine Oil Dipstick
Check oil level when machine is standing on flat surface.

1. Switch off the engine and allow the oil to drain down from the
engine’s internal parts for some minutes.This eliminates the
risk of overfilling.
2. Push the dipstick completely down and pull out. The oil level
must be between the ADD and FULL marks on the dipstick.
3. If necessary, Fill up the oil engine to FULL-mark.
Surge tank, be careful while opening if the engine is hot..

Self dearation.
Sight glass
Drain plug
Recommendations is use 50/50 mix of high quality, glycol
antifreeze and water or formulated coolant.
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MT5020/6020
Check & Clean Air Filter Evacuator Valves Check Air-Intake Restriction Indicators
There are two air intake restriction indicators

and they are located above the filter bay.
Evacuator Valves
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MT5020/6020
Upbox & Dropbox Oil, Check Level Hydraulic Oil, Check Level Transmission Oil, Check Level
1. Refill
1. Transmission dipstick
2. Sight glass 2. Transmission Filler Tube
1. Upper Hydraulic Tank Sight Gauge

2. Lower Hydraulic Tank Sight Gauge
3. Quick-Connect Coupler for filling hydraulic oil
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MT5020/6020
DRIVELINE MAINTENANCE
Yokes Must Be In line

– When a splined shaft is assembled to a slip yoke, the
splines must be aligned so that the yokes at either end of the
shaft are in the same plane, or “in phase”.
– When the shaft is assembled with the yokes in different
planes, the driveline will be “out of phase”.
– Drive shafts are phased and balanced at the Factory and are
“marked” for correct assembly with match marks at the yoke
flange ends and on the propeller shaft.
– Lubricate the splines thoroughly, and properly assemble and
“phase” the shaft. Misphasing the drive shaft can cause
vibrations throughout the driveline, contributing to bearing
failure
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MT5020/6020 Fluids
13/49
0017 5201 11 – Spirax AX 85W-140

5507 0325 00 – Rimula Super Shell 15W-40
5506 9683 00 – Donax TD 10W-30
0017 5201 50 – Spirax ASX 75W-140
5507 0440 00 – Super duty grease
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MT5020/6020
Atlas Copco Service Kits
5530 0850 00 125hrs kit

5530 0849 00 250hrs kit
5530 0848 00 500hrs kit
5530 0847 00 1000hrs kit
Protect your vehicle and maintain

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

– Protect your vehicle and maintain your warranty with Atlas
Copco Service Kits. Reduce time spent with inventory and
shipping:
– The 1,000 hour Consumable Kit includes all of the service
items to support one MT5020 / MT6020 through the first
1,000 hours.
– The 1,000 hour Maintenance Kit includes only items for
routine maintenance at the 1,000 hour interval.
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We are committed to your
superior productivity through
interaction and innovation.
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Minetruck™ MT6020/MT5020

You will know the Atlas Copco Minetrucks

Technical specification leaflet contains information on

3514 1975 (3700)

MT-5020 without tele dump and heater.

MSHA part 7 Ventilation

Box Raise Time

Transmission/converter Allison M6610AR

MT6020 Axles Kessler 111/ MT5020 Axles Kessler 106

Kessler Up- and Dropbox (Force Cooled and Lubricated)

Matching Scooptram: ST1520

You will know the Atlas Copco Minetrucks

Report all damages and defects immediately!

SAHR brakes – requires pressure to release breaks

ROPS A Roll Over Protective Structure

FOPS A Falling Object Protective Structure

ROPS and FOPS

The ROPS and FOPS label is attached to the dash near

The manuals contain warnings. The warnings

Also other headings

The Danger heading indicates an imminent risk of serious or

The Warning heading indicates a risk or dangerous course of

The Caution heading indicates a risk or dangerous course of

Boom crushing hazard

Potential energy hazard

High pressure hazard

Hot surface hazard

Falling objects hazard

Danger! – Stored energy hazard

The springs in the SAHR brake are under extreme compression

Dump box support installed.

Articulation locking bar in the

Emergency Exit From Cabin Fly-Rock Window Guard

Drive Shaft Guards Exhaust Cover

Incorrect modification or rework to wheel rim or parts

If the tire and wheel assembly is removed from the vehicle,

Reverse Alarm Reverse Alarm

Brake lights Brake lights

Master Switch Do Not Start Engine tag

1. Park the Minetruck in a straight line on a hardened flat surface,

Power Frame Load Frame Cab

Make sure everything is in place and fixed

Always follow your local fire fighting regulations!

Evacuate the fire scene as soon as possible

NOTE - Local fire fighting regulations always overrides this procedure!

Location of Fire Extinguisher

Check regularly that the needle on the gauge

1 – Pulling out the spring clip

Hydraulic Suspension Safety Suspension System Relief Valve

The suspension relief valve is located

You will know the Atlas Copco Minetrucks

Tank Capacity 238L

Part number Designation

SIZE OF END FITTING W/LOWER CODE NUMBER(FC5050)

SIZE OF HOSE (N= -20)

SIZE OF OPPOSITE END FITTING (FC5054)

HOSE ASSY LENGHT (LAST DIGIT IN1/8` S)

Steering System Dump System

Dump/Steer Pump Dump/Steer Pump

The wheel steering valve is a hydrostatic unit that is controlled by the

The steering control valve combines the functions of the main

CHECK STEERING SYSTEM MAIN RELIEF PRESSURE.

-FIT GAUGE INTO TEST PORT ON THE STEERING CONTROL VALVE

CHECK DUMP SYSTEM MAIN RELIEF PRESSURE.

MT 5020&6020 Trainee Binder

MT 5020&6020 Trainee Binder