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ServiceInstructions

Atlas Copco Wagner Inc.

Section 1Introduction

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Description

The Wagner Scooptram consists of a Power Frame and a Load Frame connected by an articu-lating joint that permits 45-degree turns, in com-bination with an oscillating joint that permits the units to tilt relative to each other to accommo-date uneven surfaces.The Power Frame includes the diesel engine and a powershift transmission. The canopy has been approved by U.S. government authorities and satisfies FOPS standards in accordance with pamphlets ISO 3471 and SAE J1040C.The boom, the bucket, and the front axle are mounted on the load frame. The bucket may be either of a standard design or an eject-o-dump design consisting of a push plate assembly con-trolled by the operator.The entire vehicle is designed for maximum durability and easy maintenance.

This manual is intended to be used in conjunc-tion with the Operators Manual and Parts Cata-log for this vehicle. Use only Wagner approved replacement parts when servicing Wagner prod-ucts.

This manual provides you with a generalized overview and theory of operation of various components and systems on the scooptram. It also covers all routine service by service hour maintenance interval . By using this manual you will be able to under-stand how complex systems work, how to trou-bleshoot problems in operation, and how to safely and effectively remove and replace worn or damaged components.This manual does not deal with component rebuilding. Wagner recommends that component level repair be conducted through Atlas Copcos worldwide dealer network.

E-O-D, Rock Torque, Rock Tough, SAHR, Scooptram, Scoopy, and Teletram are trademarks of Atlas Copco Wagner Inc.

1995, Atlas Copco Wagner Inc.P.O. Box 20307 Portland, OR 97220-0307 USA

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Wagner Scooptrams Service Manual IntroductionIntroduction 3

Safety 13

General Safety Precautions 14Safety During Maintenance 14Parking the Scooptram and Stopping the En-gine 16Burn, Fire, and Explosion Prevention 16RollOver Protective Structure (ROPS) and Falling Object Protective Structure (FOPS) 17Tire and Wheel Safety 17Safety Signs 17

General Maintenance 19

Independent Oil Analysis 20Electric Welding 20Hydraulic System Cleanliness 21Daily or Shift Schedule (Walk-Around) 2150 - 100 Hour Maintenance Schedule 28250 Hour Maintenance Schedule 32400 Hour Maintenance Schedule 331000 Hour Maintenance Schedule 382000 Hour Maintenance Schedule 454000 Hour Maintenance Schedule 45 Fuel System 48Fuel System Components 48Typical Deutz Fuel System 52Typical Detroit Diesel Fuel System 53General Maintenance Information 54Engine Oil System 55System Operation 55 55System Components 55Air Supply System 58Air Cleaner Operation 58Air Exhaust System 60

69Removing the Cooling System Package 69Removing the Transmission Oil Radiator 70Removing the Transmission Oil Tube and Shell Heater/Cooler 70Removing the Engine Coolant Radiator 70Removing the Purifier 71Removing Fuel Filters 71Removing Fuel Valves or Lines 72Removing Fuel Tank 72Electronic Engine Control System 73Removing the Engine Package 73

Power Train 77

Transmission System 78Torque Converter Theory Of Operation 80Transmission & Torque Converter 81Transmission Control Valve 82Transmission Charge Pump 83Transmission/Converter Oil Filter 83Transmission/Converter Oil Cooler 83Auxiliary Cooling Pump 83Transmission Modulator Valve 84Drivelines 87General Maintenance Information 88Wheels And Tires 92Type of Differential 94Removal & Replacement 95Transmission Cooling System 95Removing the Transmission 95Axles 100Tire Demounting And Mounting Procedures 101Inspection 104Wheel Nut Torque 109Operating Precautions 109Recapping 110Tire Storage 1105566071301 07-96 7

Cooling System 68Engine Accessories Removal & Replacement

Section 6 Frame 111

Introduction Service Manual Wagner ScooptramsRemoving the bucket 112Removing the boom 112Separating the Load Frame from the Power Frame 113Stops 118Installation 119

Section 7 Hydraulics 123

Hydraulic System 124Theory of Operation 124Pumps 124Starting New Pumps 125Cylinders 126Accumulators 127Accumulator Charging Valve 129Tank and Filters 130Hydraulic Reservoir (Tank) 130Oil Filters 130Internal Filter Cartridge with Indicator 131Off-line Hydraulic Filter 131Hoses and Tubing 131Monostick Steering Schematic 134Wheel Steering System Schematic 135Steering System 136System Operation 136Flow Amplified Steering 137Steering Valve 138SPC50 Steering Control Valve 138Wheel Steering Pilot Valve 139Priority Flow Divider Valve 140Bi-Directional Control Valve 140Pressure Reducing Valve 141Pressure Relief Valve 141Cushion Valve 141Demand Valve 142Dump and Hoist System 143Dump and Hoist Components 144Pilot Control Valve 144

System Checks & Pressures 146Brake System 146SAHR Brake System Operation 147System Pressures & Flows 149Brake System Components 149SAHR Brake 149Park Brake Control Valve 150Park Brake Relay Valve 151Secondary Mode Pressure Switch 151Accumulator Pressure Gauge 151Foot Pedal Control Valve 152Emergency Tow System 153Emergency Tow System Components 154Hand-Operated Hydraulic Pump 154Relay Override Button 154Hydraulic Check Valve 154Brake Cooling System 155System Operation 155Brake Cooling System Components 15765 PSI Check Valve 157Hydraulic Oil Cooler 15720 PSI Check Valve 158Sump Cooled Brake Assembly 158Multi-disc Liquid Cooled Brake Assembly 158Hydraulic Throttle System 159Throttle Treadle Valve 160Throttle Control Cylinder 160System Schematic 160General Maintenance Information 161Servicing After Overhaul 161Level of Oil in Reservoir 162Importance of Cleanliness 162Oil Changes 163Oil Storage and Handling 164Prevention of Foaming 165Hydraulic Oil Change After Failure 165Troubleshooting 168Basic Causes of Hydraulic System Failures 8 07-96 5566071301

Pilot Pressure (Sequence) Valve 144Main Control Valve 145Load-check valve function: 146

168Eliminating Air From the System 169Checking for Component Failure 170

Wagner Scooptrams Service Manual IntroductionChecking Hydraulic Systems for Leaks 170Leak Problem Areas 171SAE 4-Bolt Split Flange Connection 173Pipe Thread Leaks 174Removal and Replacement Procedures 174Steering Cylinder Removal 175Dump Cylinder Removal 176Hoist Cylinder Removal 177Pump Removal 177Preparation for trial run 178Trial Run 178

Electrical 181

Theory of Operation 182Electrical Ladder Diagram 182Electrical Wiring Diagram 183Electrical System Components 183Wiring Harnesses 183Master (Battery Isolation) Switch 183Component Box 184Park Brake Switch 184Charging & Ignition System 184Instrument Panel and Controls 186Light System 186Horn and Alarm Systems 186Options 187Engine System 187Transmission System 187General Maintenance Information 188Batteries 188Factors affecting battery life 191Detecting Potential Failures 192Cell charge test 193Using Battery Booster Cables 194Storage Of Lead Acid Batteries 194Alternators 194Removal and Replacement 195Electrical Glossary 196

Fire Suppression System 202Actuator 204Cartridge Receiver/Expellant Gas Cartridge 205Dry Chemical Tank 205Nozzles 205General Maintenance Information 205

Troubleshooting 207

Engine 208 213 215

Appendix 231

Specifications 232Pressure Settings 259Electrical System 264Batteries 265Recommended Torques SAE (U.S.) 266Recommended Torques SAE (Metric) 267Fluids and Lubrication Specifications 268Diesel Fuel Specifications 268International Fuel Specifications 268Fuel Oil Selection Chart 269Lubricating Oil Specifications 270Engines 270Transmissions and Converters 271Axles 271Viscosity Grade / Ambient Temperature Charts 272Wagner Hydraulic Fluid Specifications 274 274Grease Specification 275 275Coolant Specifications 275Water Quality 275Antifreeze 276Cross Reference List 2765566071301 07-96 9

Miscellaneous Systems 201

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This safety alert symbol means Attention! Become Alert! Your Safety Is Involved. All personal safety messages in this manual and the safety decals on the

vehicle are identified by this symbol.The safety messages that are shown in this man-ual include a signal word. That word shows the degree or level of hazard. The signal words are DANGER, WARNING, and CAUTION.DANGER indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury.WARNING indicates a potentially hazardous situation that, if not avoided, can result in death or serious injury.CAUTION indicates a potentially hazardous sit-uation that, if not avoided, can cause minor or moderate injury.IMPORTANT indicates information to the operator that may prevent potential damage to the vehicle.NOTE indicates information that may be useful to the operator.

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

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Safety Service Manual Wagner ScooptramsGeneral Safety PrecautionsBefore performing any maintenance on the Scooptram, review the following safety precau-tions. Theyre included for your protection.Always observe the following general safety rules during operation of the vehicle. Also observe the safety rules set forth in the work place and develop additional rules as particular mine applications may require for safe opera-tion. Read and carefully follow all instructions as

outlined in the Operator and Service manu-als.

Make sure that all operating controls and indicators are functioning properly.

Never use controls as mounting assists. Never stand while operating the vehicle. Avoid wearing loose clothing when operat-

ing the vehicle or working around engines and other moving or rotating equipment.

Never allow riders. Never leave the vehicle unless the brakes are

set.

Block wheels when parked. Never smoke around fuel. Always shutdown engine when refueling

vehicle. Always know the location of the nearest fire

extinguisher. Check safety system shutdown prior to each

shift. Watch out for others - They may not be

watching out for you.

Safety During MaintenanceWARNING: Incorrect maintenance or service can cause injury or death. If you

do not understand a procedure, service, or adjustment, contact your Wagner sales company or dealer for more information.Before you service this Scooptram, always put a DO NOT OPERATE tag in the cab on the steer-ing control. If applicable, remove the key from the Scooptram.

DE02I011.EP

Do not make unauthorized modifications to this Scooptram. Before you drill holes, cut, or weld on this Scooptram, always contact your Atlas-Copco Wagner sales company or dealer for authorization first.Before you perform service, always wear the correct protective items. Face protection, safety shoes, heavy gloves, etc. may be required.Wear eye or face protection when using a ham-mer. Chips or debris can cause eye injury. When driving hardened pins, use a hammer with a soft face.If you must perform service under the Scoop-

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tram, always engage the parking brake and block the front and rear of each wheel.

Wagner Scooptrams Service Manual SafetyNever enter the articulation area of the Scoop-tram unless you have first installed the articula-tion locking bar.Always consult the proper section of the service manual before performing maintenance.Perform maintenance in a safe area away from vehicle traffic, with a stable roof area and ade-quate ventilation. The vehicle should be on level ground when performing maintenance. Before you start, make sure that the wheels are blocked.Before performing any maintenance in the artic-ulation area of the vehicle:1. Make sure the articulation (swivel) locking

bar is connected between the load frame and power frame to prevent the vehicle from articulating.

2. Remove the key from the OFF/ON/START switch, if applicable, and hang a DO NOT OPERATE tag on the switch.

3. Turn the MASTER (battery disconnect) switch to OFF and hang with a DANGER tag.

Stop engine before adjusting or repairing engine or engine-driven equipment.If you must service the Scooptram with the engine running, have a second person help you. The second person must be in the operators seat during any servicing or adjustment.To prevent hearing damage, wear ear protection devices when working inside an enclosed room with the motor running.Make sure that all pressure is vented prior to working on any fluid system.When you check for a high pressure hydraulic leak, always use cardboard or paper to locate the leak.

Keep your hands and body away from the leak. If this fluid is injected into your skin, see a doc-tor immediately and have the fluid removed.Stay away from rotating or moving parts. Make sure to re-install guards over all exposed rotating parts. Never work under a raised hood unless the hood is secured with a prop bar.Wear protective glasses, clothing, hard hat, res-pirator, or other protective items when necessary.Insulate all electrical connections and discon-nected wiresPressurized air for cleaning the vehicle should not exceed 30 psi (20 kPa). Wear protective face shield and clothing.Use proper tools. Replace broken or damaged servicing equipment.Remove all tools, electrical cords and other loose items from the vehicle before startingLocking bar should be re-stowed and secured on pin mounts when work is complete.Wipe up spilled oil.Provide a safe and adequate method for waste oil disposal.Store oily rags in fireproof containers. Do not leave rags on engine.Never store flammable liquids near the engine.Before performing any work under a raised boom, perform the following:1. Empty the bucket and set the park brake.2. Place a safety bar under the boom, and have

bucket in full dump position.3. Shut down the engine.4. Turn the on/off and master switches to off

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WARNING: Hydraulic fluid injected into your skin can cause severe injury or death. 5. Block the wheels.

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Safety Service Manual Wagner ScooptramsImportant: Do not attempt to make repairs to components of the vehicle without full under-standing of the component and system. Always use the service manual when working on the vehicle.

Parking the Scooptram and Stopping the EngineWhen you stop and park the Scooptram, make sure the area is safe and level.1. Make sure the bucket is completely down

with the bucket blade on the ground.2. Engage the parking brake, stop the engine,

put all controls in neutral, and remove the key, if one is available.

3. Release the seat belt.4. Exit the Scooptram.Important: If you must park the Scooptram on a grade, always put the front of the Scooptram toward the bottom of the grade with the bucket up against the sidewall, if possible. Make sure the Scooptram is parked behind an object that will not move. Engage the parking brake and put blocks on the downhill side of each tire.

Burn, Fire, and Explosion Prevention

WARNING: Batteries contain acid. Severe burns can result if acid comes in

contact with your skin or your eyes,. If you do get acid on you by accident, flush with water for at least 15 minutes and see a doctor immedi-ately.

WARNING: Sparks or flame can cause gas from the batteries to explode.

When working on the Scooptrams electrical system, always:1. Disconnect the negative (-) battery cable first

and when reconnecting, connect the negative (-) battery cable last.

2. Do not short across the battery terminals to check a charge. Sparks can cause an explo-sion.

3. Do not weld, grind, or have an open flame near a battery.

4. When you charge a battery, always remove the caps and have good ventilation.

5. If the engine must be jump started, refer to the Operator manual for the correct proce-dure.

On water cooled engines, hot coolant in the radi-ator can rush out if you remove the radiator cap too quickly. Always allow the radiator to cool before removing the cap. Turn the radiator cap to the first notch to vent any pressure in the system. After all pressure has been released, remove the cap.All fuels and most lubricants are flammable. Always handle with care.Store all oil-soaked rags or other flammable material in an approved protective container. Always use nonflammable cleaning solvent to clean parts.Always have a good fire extinguisher on your Scooptram. Make sure the fire extinguisher is serviced according to the manufacturers instruc-tions.If your fire extinguisher has been used, always make sure to recharge or replace the fire extin-guisher before you operate the vehicle again.

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Remove all trash or debris from the Scooptram. Check the engine area, especially around the exhaust.

Wagner Scooptrams Service Manual SafetyIf the Scooptram has had a fuel or oil leak, repair the leak and clean the Scooptram before operat-ing.

WARNING: Ether starting fluid can explode and can cause injury or death.

If ether is used to start the engine in cold weather, only use in accordance with the manu-facturers recommendations. Always use face protection when you use ether starting fluid. Note: Atlas Copco Wagner does not recommend the use of ether starting fluid.Before welding or using a torch on the scoop-tram, always clean the area around your work first.Check the electrical system for loose wires, con-nections, or frayed insulation. Repair or replace damaged parts.

RollOver Protective Structure (ROPS) and Falling Object Protective Structure (FOPS)Your scooptram may have a RollOver Protective Structure (ROPS) or Falling Object Protective Structure (FOPS). Our ROPS are designed to provide operator protection in a rollover by con-trolling the bending of the structure. The FOPS provides the operator protection from falling debris.If your Scooptram is so equipped, a ROPS or FOPS label is attached to the exterior of the structure on the forward side. The ROPS or FOPS serial number, Scooptram weights, approval numbers, model number, and engine model and serial numbers are on this label.Do not modify a ROPS or FOPS structure. Mod-ifications such as welding, drilling holes, cutting,

structural damage, contact your Atlas-Copco Wagner sales company or dealer before attempt-ing any repairs. (See Product Service Bulletin PSB-339.)Do not add attachments to the Scooptram that will cause the total weight of the Scooptram to exceed the total gross weight shown on the ROPS or FOPS label.The seat belt is an important part of the ROPS system. Always fasten and adjust the seat belt before you operate this Scooptram.

WARNING: If you roll this scooptram over and you do not have the seat belt fas-tened, you may be seriously injured or

killed.If you have any questions about the ROPS or FOPS on your Scooptram, contact your Atlas-Copco Wagner sales company or dealer.

Tire and Wheel SafetyWARNING: Tires and wheels can explode and cause injury or death.

Always keep yourself and others out of the dan-ger areas of tires and wheels. Stand on the roll-ing surface (tread) side of a tire when you perform service.Always inflate the tires to the recommended pressure. If the tire and wheel assembly is removed from the scooptram, always put it into a tire inflation cage before adding air.

Safety SignsWARNING: Injury or death can result if a safety sign is missing and instructions are not followed.

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or adding attachments, can weaken the structure, void the ROPS/FOPS certification, and reduce your protection. If your ROPS or FOPS has

Replace all missing or damaged signs. Keep the signs clean. Contact your Atlas-Copco Wagner sales company or dealer for new safety signs. To

Safety Service Manual Wagner Scooptramsclean a sign, use only a soft cloth, water, and soap. Do not use solvent, gasoline, etc.Important: The meanings of all safety signs are described in the introduction to the Operators Manual. There are also locator diagrams show-ing the location of all safety signs. (Additional diagrams are provided for European Community [EC] customers, showing the location of all safety guards.) The scooptram should never be operated without all safety signs and guards in place. If a safety or instructional sign is on a part that must be replaced, make sure the same sign(s) is on the new part. Contact your Atlas-CopcoWagner sales company or dealer for new signs.18 07-96 5566071301

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Maintenance

General Maintenance Service Manual Wagner ScooptramsGeneral Maintenance InformationThis section complements and expands upon information contained in the preventive mainte-nance section of your operators manual.Safe, efficient operation of the vehicle depends on the proper maintenance of the engine, drive train, chassis and all related systems.Regular inspections must be made to see that the all system components are in safe operating con-dition. All bolts, nuts, screws, and other fasteners must be in place, properly tightened, and secured. Special care must be taken when making repairs and replacing components. Use only new parts as furnished by Atlas Copco Wagner Inc. Use only new fluids, filters and gaskets and have all mating surfaces clean and in proper condi-tion.The labeled diagram in your operators manual shows all maintenance check points. Because of individual mine requirements, some check points on your vehicle may not be located as shown. If so, consult your supervisor for addi-tional supporting literature.

Record KeepingGood record keeping is essential to a proper maintenance program. Each scheduled mainte-nance form should be checked off as the inspec-tion 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 mainte-nance supervisor for approval and retention in a

equipment condition on an individual or fleet basis. Good records enable maintenance personnel to identify and evaluate problem and/or high cost areas which can then be targeted for improve-ments or solutions.Good record keeping will identify certain items on the schedules which may need to occur more or less often, depending upon the vehicles oper-ating environment. 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.

Independent Oil AnalysisAtlas-Copco Wagner highly recommends the regular use of an oil analysis program. Regular oil analysis can indicate problems and approach-ing maximum wear limits significantly before they are discovered by system performance checks. The objective of a preventative maintenance program is diagnosis and repair before failure. Good sampling techniques and independent lab-oratory analysis are considered primary elements of a good program. Important: Oil analysis is not to be used to determine if oil can be re-used past recom-mended service life. Change oil during recom-mended service intervals even when oil analysis shows oil to be up to standards. A comprehen-sive analysis program can aid in establishing optimum service intervals.

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vehicle maintenance file.Accurately recorded maintenance forms will give maintenance personnel an overview of

Important: Use caution in electric welding on the Scooptram. Serious damage to the engine

Wagner Scooptrams Service Manual General Maintenancecontrol computer and the battery isolator can occur.

Before any electric welding on the Scooptram, perform the following:1. Open the battery compartment.2. Set the MASTER (battery disconnect)

switch to the OFF position.3. Connect the welding machine ground clamp

on the vehicle as closely as possible to the point at which the welding is to be done.

Hydraulic System Cleanliness Important: Foreign matter of any kind will cause problems in hydraulic systems. Absolute cleanliness is essential for all work done on the Scooptram hydraulic systems. Always follow these six primary rules regarding cleanliness in maintenance operations on the hydraulic sys-tems:

1. Steam clean the area of the Scooptram on which the work will be performed.

2. Wipe all hose and pipe connections before opening any connections.

3. Remove all loose paint before opening any connections.

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

5. Flush any unsealed hose or pipe with hydraulic oil before installing it in the sys-tem.

6. Install all hoses, pipes, valves, or cylinders immediately after unplugging or uncapping connections.

Periodic Scheduled MaintenancePeriodic scheduled maintenance is required to keep your vehicle in peak operating condition. Included below is a recommended schedule of maintenance and inspection, based on vendor recommendations and Wagner Service Depart-ment experience. The timely scheduling and completion of these periodic inspections and procedures will deter-mine the availability and reliability of a particu-lar vehicle. Therefore, proper maintenance scheduling is a critical factor in the effective use of maintenance resources and the availability of production equipment.All periodic maintenance is designed to be per-formed in an adequately equipped complete maintenance facility by trained personnel.Each successive schedule builds on the previous schedules. They are cumulative in nature. For example, when performing the 400 Hour mainte-nance schedule, the mechanic will first perform the Daily/Shift schedule, then the 50/100 Hour and 250 Hour schedules, and finally meet the requirements of the 400 Hour schedule.Important: If your mine is operating its vehicle more than one shift per day, the Daily schedule should be performed Each Shift.

Daily or Shift Schedule (Walk-Around)Prior to each shift, the operator (or maintenance personnel) should conduct a thorough walk-around inspection of the vehicle to assure it is in sound condition and can be operated safely.Debris should be cleaned from the vehicle to minimize wear and damage from abrasive con-5566071301 07-96 21

tamination. Regular inspection and care of the vehicle usually results in decreased downtime and greater reliability.

General Maintenance Service Manual Wagner ScooptramsWhen the daily shift maintenance and walk-around is performed by the vehicle operator, any defects or problems that are found should be reported to maintenance personnel for correc-tion.Record the hourmeter reading. Keep this meter in good working condition since it will assist you in accurately scheduling preventative main-tenance.

Power Train System ChecksSafe and efficient operation of the vehicle, including the control of toxic fume emissions, depends on the proper maintenance of the engine and its related systems.FuelCheck that the fuel tank is full at the beginning of each shift. A full tank prevents condensation and keeps water from collecting in the tank.When fueling the vehicle, make sure the area around the filler tube is clean and that the vehi-cle is sitting on level ground.Always refuel the vehicle with the engine shut-down.Use only diesel fuel recommended by the engine manufacturer that gives satisfactory engine oper-ation. The flash point must not be less than 38C (100F) or the sulfur content greater than .5% by weight. Keep fuel clean. Precautions should be taken to keep the fuel free from dirt and water.

CAUTION: The surface temperature of hydraulic oil tank can reach temperatures of up to 60 C (140 F) after vehicle has

been operating. If vehicle has not been allowed to cool down before refueling, spillage of fuel onto tank could result in a flash fire.When filling the fuel tank underground, fuel

of incombustible materials while awaiting trans-fer to fuel tanks.Check the primary fuel filter (or fuel/water sepa-rator). Loosen the drain cock and drain off water or sediment that accumulates in the bottom of the filter bowl. Tighten the drain cock securely.Check to see the emergency fuel shut off valve is in the open position.Inspect the secondary fuel filters for leakage or damage. Check for loose fittings or mounting hardware.Make a visual inspection of the fuel injection pump and injector lines to assure that no fuel leaks are present. Any leakage is not only a potential fire hazard, but also could result in rough running or lack of power. Fuel leaks must be noted and reported.Drive BeltsCheck the tension of the drive belts by pressing with a thumb on the belt half way between the pulleys. The belts should not move more than 13-19 mm (1/2 - 3/4 in). Report any loose or worn belt to maintenance personnel. When belt replacement is necessary, belts must be replaced as a complete set. Never replace a single belt since the new belt will carry all the load and fail rapidly.Engine OilCheck engine oil level. The engine lubricating oil should be kept between the FULL and ADD marks on the dipstick. It is important that the dipstick is read correctly and only the required quantity of oil is added. To accurately check the oil level, the engine should have been stopped long enough to allow for the oil to drain off engine internal parts (at least 5 minutes for Deutz engines, 10 minutes for Cater-

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should be transported in strong, tight metal con-tainers with positive closing devices. Store fuel containers in closed compartments constructed

pillar engines and 20 minutes for Detroit Diesel engines). This eliminates the possibility of over-

Wagner Scooptrams Service Manual General Maintenancefilling. Too high a level of oil in the sump is often indicated by a smoky exhaust.When checking the oil level, make sure that the area around the dipstick is clean and the vehicle is setting on level ground.Pull out the dipstick, wipe it with a non-fraying rag, push it in as far as it will go and then with-draw it again. The coating of oil should extend to the upper mark. If it reaches the lower mark only, oil must be added immediately. Note: Do not add engine oil until level is below the ADD mark on the dipstick. A major cause of engine oil consumption on a Detroit engine is overfilling the crankcase. Note: Dipsticks on Deutz engines use both Dot and Dash markings. Dash marks are for check-ing oil level after engine has been running (2-20 minutes after shutdown).Note: On Caterpillar engines with newer dip-sticks the correct oil level is indicated by the FULL RANGE zone marked immediately below Full on the dipstick, with the engine stopped. Add oil when the level indicates below this zone, in the ADD OIL portion of the dipstick. Note: Some engines will have dipsticks with two dots following the words FULL and ADD. Cor-rect engine oil level is indicated between these dots. Do not use the words as indicating marks. Some dipstick may be stamped on both sides of the blade. One side is for checking with the Engine Stopped and the other side is for check-ing with the Engine Idling Hot Oil. Be sure to read the correct side of the dipstick as the levels are not the same for the engine stopped and for idling. (Refer to the applicable engine manual for additional guidance.)

Important: Failure to promptly add oil when indicated may result in serious engine damage due to piston and bearing seizure.Once the vehicle has been started, record engine oil pressure on Shift Maintenance Report.Air Intake and ExhaustNote: An adequate supply of clean, filtered air is necessary to maintain correct fuel/air ratios, resulting in a cleaner burning engine. Free flow of air to the intake must not be restricted in any way. The maximum pressure drop through the intake system, at full throttle and no load, at 2200 rpm should not exceed specified engine manufacturers recommendations. Important: Always service the air filter system with the engine stopped. You can damage the engine severely with dust and debris.Dry Type FiltersEach shift, check the air cleaner service indica-tors, usually located at the outlet connection of the filter assembly. The indicator on your vehicle may be one of two types. The first has a calibrated scale in inches of water (in. H2O). A Yellow visual reference is also pro-vided to indicate when within specifications. As the air filter becomes restricted with dust, the reading on the scale will increase. The filter should be cleaned or changed when the scale reads above 20 inches or when it indicates Red. Reset the indicator when the element is replaced.The second type of indicator will show either a Green or Clear window when the filter is clean. The indicator will show a Red window when the filter is restricted. If Red appears in the window, clean or replace the air filter element. Be sure to press the reset button on the indicator. 5566071301 07-96 23

Important: Air filter indicator can be damaged if stepped on. Care should be taken when work-ing around air filter housing.

General Maintenance Service Manual Wagner ScooptramsOil Bath FiltersEach shift before starting the engine, the pre-cleaner bowl on vehicles equipped with oil bath air cleaners must be emptied of any accumulated dirt or dust. In extremely dusty conditions, the pre-cleaner may have to be emptied more often. Never allow the plastic bowl to become more than half full.Depending on operating conditions, the Oil Bath filter may require cleaning and re-filling.1. Remove the oil bowl and filter element. Be

careful not to damage the rubber seal.2. Clean the bowl, and properly dispose of dirty

oil and sludge. 3. Rinse filter element in diesel fuel and allow

to dry.4. Clean filter housing, if required, and inspect

rubber seals. Replace, if necessary.5. Fill the oil bowl with clean engine oil to the

mark indicated on the bowl, insert the filter element, and re-install in housing.

Note: Engine should be shutdown for at least 10 minutes prior to servicing filter.Intake Piping and HosesCheck all clamps for tightness and visually inspect hoses, piping and rubber connections for cracks and holes.Evacuator ValveCheck and clean the evacuator valve before every shift. Press sides of rubber valve to allow discharge of dust or dirt. Make sure there is no obstructions inside the evacuator valve. Check the evacuator valve more often when you

Exhaust Water ScrubberNote: Some vehicles may be equipped with a batch type exhaust scrubber.The water make-up tank should be refilled at the start of each shift and again throughout the shift, as necessary.When refilling the scrubber tank, it should be filled to approximately the level of the perfo-rated plate visible inside the tank.Important: Do not overill the scrubber. Overfill will result in large amounts of water thrown out of the scrubber when the engine is started, and can result in excessive back pressure in the engine.Following the end of each operating shift, the scrubber drain plug should be opened and the tank flushed with clean water. To do this:1. Remove filler cap (or plug) and open drain

valve (or plug) on scrubber tank.2. Insert water hose into filler hole and flush

out tank with clean water under pressure. Continue flushing until sludge and solid deposits are removed and the draining water is clear.

3. Inspect zinc anode attached to the filler cap (or plug). Replace as necessary.

4. Close the drain valve (or reinstall the plug) and fill the tank.

5. Replace the filler cap (or plug) and refill the scrubber tank.

Engine CoolantOn most vehicles the operator is provided with engine high temperature or low coolant indica-24 07-96 5566071301

operate in severe dust or wet conditions. tion and protection. However, it is good practice to visually check coolant level prior to each shift.

Wagner Scooptrams Service Manual General MaintenanceWARNING: Hot coolant can rush out of the radiator or coolant reservoir and cause serious burns. Check the coolant

level only when the system is cool. If you add coolant, turn the radiator or reservoir cap to the first notch and wait for the pressure to release. Remove the cap and add the coolant.The method for checking coolant level may vary by vehicle, and will depend on the type of radia-tor and model engine.Vertical Flow RadiatorTo check the water /coolant level in the radiator;Slowly turn the radiator cap to relieve pressure.Remove the cap and view the coolant level. Coolant should be within 13 mm (1/2 inch) of the bottom of the fill pipe.Note: On some radiators, a sight glass may be provided.Add clean water/coolant as required. (See speci-fication table for proper mixture.)Cross Flow RadiatorCheck the water /coolant level in the radiator by viewing the surge tank sight glass. Coolant level should be observable from the upper sight glass.Note: On some vehicles equipped with DDEC Series 60 engines, a sight glass is not always provided. Coolant level is automatically moni-tored and a low level condition will be indicated by the Red Stop Engine light.Add clean water/coolant as required.

WARNING: Do not remove the cap from the radiator. Check and fill through the surge tank only.

Drive Train System ChecksTorque Converter and Transmission Oil

WARNING: Crushing hazard. Operator can be injured or killed if the vehicles hydraulic steering is actuated while oper-

ator is in the articulation area. Always install the locking bar, pinning it in the Locked position before servicing the vehicle.Important: The transmission oil level must be checked at operating temperature, approxi-mately 82 - 93 C (180 -200 F).Check that the parking brake is applied.Engage the transmission in SECOND gear and depress the throttle pedal to achieve a converter stall. Repeat this action until the converter tem-perature gauge reads 180 F.Important: Do not stall the converter for more than 30 seconds at a time. Rapid buildup of excessive heat can damage the seals.Shift the transmission to NEUTRAL. With the engine running at idle, check the transmission oil level:Note: On most vehicles, a dipstick and fill tube are located under a hinged cover at the center of the vehicle, although this may vary. Correct level is at the FULL mark on the dip-stick (or upper sight glass). Make sure that the area around the dipstick is clean before check-ing. Never overfill the transmission.Record Convertor/Transmission oil pressure on Shift Maintenance Report.Oil CoolerOn air cooled engines, the transmission oil cooler should be checked each shift for leaks and buildup of dirt on the cooling fins.

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General Maintenance Service Manual Wagner ScooptramsWheels and TiresWARNING: Tires and wheels can explode and cause injury or death. Always keep yourself and others out of the danger

areas of the tires and wheels. Stand on the tread side of a tire when you perform service.Make a visual inspection of the wheel studs and nuts. Check for loose, damaged, or missing studs and nuts. Report any damage to maintenance personnel for corrective action.Check the general condition of the tires. Check each tire for deep cuts, breaks or loose tread. Look for exposed cord. Report any damage to maintenance personnel for corrective action.Visually check for proper inflation of the tires. BrakesTest the service brakes. Place the transmission selector lever in second gear forward and firmly press the service brake pedal and hold. Release the park brake. Slowly press the throttle pedal to the floor. The service brakes should keep the vehicle from moving.Test the parking brakes. With the transmission selector lever in second gear forward, push in the park brake knob. Slowly press the throttle pedal to the floor. The parking brakes should keep the vehicle from moving.

Chassis / Frame ChecksVisually inspect the driveline and the midship area for cracks or missing components.Check for any leaks.Inspect hoses, wiring, and general condition of vehicle and components.In the articulation area, inspect the condition of the steering stops. Do not operate the vehicle

WARNING: Crushing hazard. Operator can be injured or killed if the vehicles hydraulic steering is actuated while oper-

ator is in the articulation area. Always install the locking bar and pin in the Locked position before servicing the vehicle.Check the condition of the bucket and boom stops.

WARNING: Do not walk under the raised bucket. Always make sure the bucket is properly supported, as stated in

the operator's manual, before walking or work-ing beneath it!With the bucket raised, visually inspect for leaks, missing hardware, and general condition.Report any visible defects to maintenance per-sonnel prior to operating the vehicle.LubricationLubricate each grease point shown in the shift maintenance diagram every shift or every 50 hours as indicated. Use a high pressure gun, except as indicated on the lubrication checks.The following points must be greased prior to each shift: Dump cylinder pins stem and base end pins Hoist cylinder pins stem and base end pins Steering cylinder stem and base end pins Bucket pins Boom pins Z-link pins Articulation pins Oscillation bearingOn vehicles equipped with automatic central

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with damaged or missing stops. Check articula-tion pins are properly lubricated and not missing hardware.

lubrication, check the level of the grease reser-voir before each shift.

Wagner Scooptrams Service Manual General MaintenanceHydraulic System ChecksCheck the hydraulic oil level every shift.Park the vehicle on a level surface and put the boom in the LOWERED position with the bucket rolled back on the stops.Stop the engine and allow time for accumulator to bleed down.Vent the reservoir by loosening the filler cap (or depressing the bleeder valve) on top of the tank.Check the hydraulic oil in the hydraulic tank with all cylinders retracted. Upper sight glass (or sight gauge) should show the bead floating inside the gauge.Report to maintenance personnel if oil does not appear in upper sight gauge.Note: Hydraulic reservoir can be filled either through the filler cap or through a quick discon-nect fitting, using the accompanying hose and hand pump, depending on the model vehicle.Vehicles equipped with internal cartridge-type filters have a sight gauge that indicates when service is needed. Vehicles equipped with external return filter assemblies may also have a restriction indicator.Check filter indicators each shift to ensure that hydraulic oil filters are functioning properly. Service is required when the indicator is in the red position. If the gauge shows in change filter zone, report to maintenance personnel for cor-rective action.

Electrical System ChecksCheck that all circuit breakers and fuses are properly set. An electrical component box containing ther-

150 amp breakers are equipped with an internal contact that prohibits reset while the fault still exists, even if the circuit breaker is manually held in the reset position.The lower amperage (1-40 amp) breakers are push-pull which allows for manually isolating particular circuits for troubleshooting.All breakers are manually reset. Should an elec-trical fault occur, try resetting the appropriate breaker. If the breaker cannot be reset, contact maintenance personnel to resolve the problem before continuing operation.

Control System ChecksOnce the engine is started, you should conduct the following checks and tests prior to operating the vehicle to make sure the vehicle is function-ing properly.Check bucket and boom operation.Actuate the bucket control and hoist control lever. Check for excessive play in the controls. Check for full, free movement of the boom and bucket through their entire cycles.Check vehicle lights.Set the light switches to the ON position and check that the front and rear lights are function-ing properly.Check the operation of the throttle, transmission and steering controls to make sure they are func-tioning properly.Check converter/transmission oil pressure. With the engine at low idle (650 rpm) the engine oil pressure gauge should read 11.6-14.5 psi (80-100 kPa). At 1200-2500 rpm pressure should be 58-72 psi (400-500 kPa).5566071301 07-96 27

mal/magnetic circuit breakers provides primary protection for the electrical system should the first-line load breakers or fuses fail. These 30-

General Maintenance Service Manual Wagner Scooptrams50 - 100 Hour Maintenance ScheduleNote: Operating schedules and weekly vehicle hours vary. Atlas-Copco Wagner weekly mainte-nance recommendations are usually based on 100 hours. Maintenance personnel should refer to each vehicle or fleet maintenance history file to determine optimum interval.Perform the Daily/Shift maintenance schedule prior to beginning this maintenance schedule.Clean the vehicle thoroughly, especially the oil coolers and radiator.

Power Train System ChecksFuelReplace the fuel filters every 100 hours of opera-tion.Wipe clean the exterior of both fuel filters and the area around each filter.Turn the fuel line shutoff valve 90 degrees to the OFF position.Turn each filter counterclockwise and remove from the filter head. Discard the old filters.Use a clean cloth and wipe the mounting surface of each filter. Make sure this area is clean.Apply a thin layer of clean oil to the gasket of each new filter.Fill each new filter with clean diesel fuel and install each filter.Turn each filter clockwise to install. When the gasket of each filter touches the filter head, con-tinue to tighten each filter 2/3 turn.Note: It may be necessary to bleed air from the fuel system

Operate the hand primer pump until you see air free fuel coming out of the plug hole.Note: On Deutz and Caterpillar engines, this is a separate pump with knurled knob. Turn knob counter-clockwise to unlock, before pumping. On Detroit Diesel engines, priming pump is a pushbutton on top of the primary fuel filter.Install the bleed plug(s) and start the engine. Run at idle speed and check for fuel leaks. Continue priming if the engine fails to start immediately.

CAUTION: When performing any checks or maintenance on the fuel system, be cer-tain to clean up all fuel that has spilled on

the engine or vehicle.Engine OilEngine oil and engine oil filter should be changed after every 100 hours of operation.The drain interval may be gradually increased, or decreased, following the recommendations of an independent oil analysis laboratory or the oil supplier (based upon the oil sample analysis) until the most practical oil change period has been established.Oil changes should be made when the engine is warm, as the oil will drain more completely than when cold.

CAUTION: Engine oil can reach temper-atures exceeding 104 C (220F). Do not change oil immediately following engine

shutdown.Select a container sufficient to hold the entire amount of oil in the system and place underneath the oil pan drain. Proceed with removing the crankcase oil drain plug. After the oil has drained off, clean and

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To bleed air from the Fuel System:Remove the air bleed plug(s) on the top of the primary fuel filter.

reinstall the drain plug.

Wagner Scooptrams Service Manual General MaintenanceRemove the oil filters by turning counterclock-wise using a strap wrench or filter removal tool.Discard the filters.Clean the filter sealing surface with a clean cloth.Apply clean oil to the gasket of each new filter.Fill each new filter with new engine oil and install each filter.Turn each filter clockwise until the gasket makes contact with the filter base. Continue to turn the filter 2/3 turn by hand.Fill the crankcase through the filler tube to the top dipstick mark. Start the engine and run at idle speed and check the engine oil pressure. Then, check for oil leaks around the filter.Stop the engine and check the engine oil level after a few minutes.Note: On vehicles equipped with Detroit Diesel two-stroke engines, use of a single weight oil is required.Crankcase BreatherInspect the crankcase breather to assure than the mesh element is not clogged. Remove the breather and clean if it is found to be restricted.Air Intake and ExhaustCheck the piping as well as all connections and mounts for tightness, leaks, cracks, or holes. Replace gaskets and rubber connections as needed. If the system looks damaged, inspect it thoroughly to insure that there are no leaks that could admit dirty air into the engine.The air intake system is provided with test ports for measuring vacuum. A visual check should be made to insure that plugs are installed.

mends initially checking the primary (or outer) air filter visually every shift to determine proper inspection and change interval. Replace the primary (or outer) filter element when air restriction is in the red or every 100 hours of operation.Loosen and remove the air filter cover.Loosen and remove the primary (or outer) filter element wing nut and remove the element.Inspect filter gasket surface and replace if needed.Install a new primary (or outer) element. Rotate the element as you tighten the wing nut to make sure there is a good gasket seal.Reset filter service indicator.Start the engine, if the filter service indicator indicates red again, replace the secondary (or inner) filter element.Note: Air filter restriction indicators are subject to damage in the course of vehicle operation and maintenance. Visually inspecting filter will ensure proper change interval.Oil Bath FiltersInspection and change interval may be increased to weekly, as determined by operating condi-tions.Pre-Cleaner

Note: Some vehicles may be equipped with an Air Intake Pre-cleaner for operation in extreme environments.Pre-cleaner should be inspected periodically for dust and dirt buildup. This will help prolong the life of the air filters.Loosen and remove pre-cleaner from air filter housing.5566071301 07-96 29

Dry Type FiltersReplacement of primary filter will vary accord-ing to operating conditions. Wagner recom-

Shake or blow out with air to remove any dirt or dust that has accumulated.Re-install in vehicle.

General Maintenance Service Manual Wagner ScooptramsEngine CoolantInspect radiator hoses for loose fittings, leaks and damaged condition.Test coolant for proper additives concentration and water quality levels.Note: Add/replenish supplemental corrosion inhibitor if indicated by test results.Fan Hub AssemblyIf cooling fan hub is supplied with a grease fit-ting, apply one (1) hand pump of grease. Do not over grease. Shaft seals will be blown out by excessive greasing.

Drive Train System ChecksTorque Converter and Transmission Transmission BreatherInspect the transmission breather, which is located on top of the transmission. Check for blockage. Remove and clean if restricted.Check the transmission filter indicator. If it is in the red zone, the filter must be replaced.Inspect the converter breather, which is located on top of the converter. Check for blockage. Remove and clean if restricted.AxlesCheck oil level for each axle differential and all planetary wheel ends as indicated below. (See specification tables for proper oil type.)Important: Check fluid levels when oil is cold. Do not check with hot oil, as incorrect level will be indicated.Visually inspect axle oscillating bushings for excessive wear and overall condition. Check that the oscillating mounting cap bolts and axle mounting bolts are torqued to specifica-

DifferentialPark the vehicle on a level surface, apply the parking brake, and stop the engine.Let vehicle to stand 5 minutes to allow oil to set-tle to normal level.Remove the oil level plug. The oil level must be up to the bottom of the plug hole. Add oil as required.Install the oil level plug and check the other dif-ferential.PlanetaryWith the vehicle on a level surface, move the vehicle forward or back until the oil level/drain plug is horizontal with the wheel centerline and the direction arrow is pointing down.Apply the parking brake, and stop the engine.Remove the oil level/drain plug. The oil level must be up to the bottom of the plug hole. Add oil as required.Install the oil level/drain plug and check the other planetaries.Axle BreathersCheck axle breathers for blockage. They should be cleaned if plugged or restricted. They are located on top of each axle housing.BrakesNote: Some vehicles (ST-3.5) equipped with Rock Torque axles have self-contained brake coolant reservoirs. Check fluid level at same interval as Differentials and Planetaries.Park the vehicle on a level surface, apply the parking brake, and stop the engine.Let vehicle to stand 5 minutes to allow oil to set-tle to normal level.Remove one of the two oil level plugs. The oil 30 07-96 5566071301

tion.level must be up to the bottom of the plug hole. Add oil as required.

Wagner Scooptrams Service Manual General MaintenanceInstall the oil level plug and check the other brakes. Plug torque is 81-102 N-m (60-75 ft. lb). Note: Oil level plugs are located on the inside wheel hub and may be difficult to reach. Use of special tools may be required.Wheels and TiresCheck tire pressure. Maintain pressure at recom-mended level.

WARNING: Tires and wheels can explode and cause injury or death. Always keep yourself and others out of the danger

areas of the tires and wheels. Stand on the tread side of a tire when servicing.Note: The vehicle must be empty before servic-ing the tires.Use a long hose and self-attaching air valve fit-ting so that you can be outside of the danger zone when checking or inflating the tires.Always check tire pressure when tire is cold.If the tire and wheel assembly is removed from the vehicle, always put it into a tire inflation cage before adding air.Deflate the tire before attempting to repair tire tread or removing foreign objects.Be aware that in extremely cold temperatures, inflation pressures will vary from those listed in this manual. Contact your Atlas-Copco Wagner sales company or dealer.Inspect for missing nuts or studs. Replace any damaged or missing wheel retaining hardware with Grade 8 or equivalent.Check wheel nut torque. Proper torque is indi-cated in the Appendix.

Chassis / Frame Checks

Check steering cylinder mounting pins and bushings for wear or excessive clearances. If any pin free-play exceeds 3.175 mm (1/8 in.), replace pin and/or bushing, or repair pin bore as required.Check all boom, bucket and steering stops for wear and cracks. Wear should not exceed 1.59 mm (1/16 in.) from original condition.LubricationGrease all driveline slip-joints and U-joints (50 - 100 hours).Grease the driveline flange bearings and steering column U-joint and bearing (50 - 100 hours).

Electrical System ChecksBatteriesCheck electrolyte level (50 - 100 hours).Note: Frequency of battery maintenance depen-dent on type of battery (i.e. Conventional, Low-Maintenance or Maintenance-Free).Check and record battery voltage level (50 - 100 hours).Inspect and clean terminals.Check that hold down brackets are tight and in good condition.

Hydraulic System ChecksVisually inspect all plumbing lines and piping connections for leakage and/or breaks and replace as necessary. Visually inspect all hydraulic hoses for tears, buckling, and leaks. Inspect hydraulic tank breather valve for block-age, and clean if necessary.Check accumulator pre-charge pressure. Pres-

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Check articulation and steering pin cap bolt torque.

sure should be 1200 100 psi (8300 690 kPa).To test pre-charge pressure in the accumulator:

General Maintenance Service Manual Wagner Scooptrams1. Start the vehicle and observe the brake hydraulic pressure build up on the accumula-tor pressure gauge.

2. Shutdown the vehicle once pressure has sta-bilized.

3. Pump either the SAHR brake override button or the brake pedal, depending on your vehi-cle. System pressure should fall gradually to 1200 psi (8300 kPa), then drop immediately to zero.

Pre-charge pressure can also be checked using the Wagner Accumulator Pre-charging tool. (See Hydraulics, Section 6.)Note: On vehicles with more than one accumula-tor, pre-charge pressure must be tested at each accumulator, using the pressure gauge on the Wagner Accumulator Pre-charging tool.

Electrical System ChecksBatteriesEach week, the battery should be checked and cleaned.Ensure that battery tops are kept clean and free of dirt and electrolyte. Check that all terminals and connectors are clean and tight. Replace any wire or cable with damaged insulation. Make sure that the battery box cover is secured before vehicle is placed in operation.Clean battery with a weak solution of baking soda and warm water. Ensure no cleaning solu-tion reaches electrolyte in battery.Fill all battery cells with distilled water to inside top of battery.

CAUTION: Avoid contact with electro-lyte. Acid burns! Personal injury can

Ensure integrity of hold-downs, and replace if in doubt.

WARNING: When working around bat-teries, avoid any sparks and/or flame. Hydrogen gas given off by batteries is

explosive.

Fire Suppression System ChecksInspect over-all condition of hoses, discharge nozzles, and activator valve for damage, block-age, or any sign of possible failure. Nozzles should be filled with silicone grease or plastic blow-off caps. Actuator and expellant cartridge seals and disks must be intact. Repair as needed.Check level of dry chemical extinguisher tank(s). Extinguishers should contain an active charge of not less than five pounds (2.3 kg) nom-inal weight.

250 Hour Maintenance Schedule Perform Daily/Shift Maintenance Schedule.Perform 50 - 100 Hour Maintenance Schedule.Engine CoolantReplace the coolant system filter every 250 hours of operation or when the cooling system is drained, flushed and refilled. Rotate the two filter shutoff valves clockwise to the OFF position. Use a strap wrench and turn the filter counter-clockwise to remove. Discard the old filter.Use a clean cloth and clean the filter mounting area on the filter head.Apply a thin layer of clean grease or oil to the gasket of the new filter.ACW0 0073.pict

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result.Check battery hold-downs for tightness, and clean if needed with solution used on battery.

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

Wagner Scooptrams Service Manual General MaintenanceRotate the two filter shutoff valves counterclock-wise to the OPEN position.

Drive Train System ChecksTorque Converter and Transmission Stall and Idle Speed testsTwo stall speeds need to be measured:

(a) Converter(b) Converter with dump actuated

To test converter stall:Start engine and operate hydraulic controls until hydraulic oil temperature is at operating temper-ature (66 C / 150 F). To heat the hydraulic system to operating tem-perature, roll the bucket back against the stops until the overpressure relief valve lifts, then release. Continue cycling the system in this man-ner until operating temperature is reached.Note: To determine hydraulic oil temperature, any probe type temperature gauge may be inserted into the tank. If a gauge is not available, assume an average cycling time of 10 - 15 min-utes. This will vary, depending on the size of the vehicle and ambient operating conditions.Place the vehicle in its highest forward gear. With park brake applied, depress throttle pedal completely down and observe Converter Oil Temperature gauge. When gauge reads 88 C (190 F) measure and record engine RPM using phototachometer or DDEC reader.

CAUTION: Do not hold stall for more than a few seconds.

With steering in neutral repeat the test with the dump rolled back against the stops and the dump control lever held back.To test idle speeds, place vehicle in neutral. With

Release throttle pedal and allow engine speed to drop. Measure and record Low Idle engine RPM

400 Hour Maintenance Schedule Perform Daily/Shift Maintenance Schedule.Perform 100 Hour Maintenance Schedule.Perform 250 Hour Maintenance Schedule.

Power Train System ChecksFuelCheck fuel tank for water and sediment.Loosen the drain plug on the bottom of the fuel tank and check for presence of water or sedi-ment.

CAUTION: If the fuel tank is full, there will be pressure on the drain plug. To remove the water, only loosen the plug.

Do not remove the plug.

Engine Intake and Exhaust ValvesValve Adjustment (Deutz only):The valve clearance adjustment should be checked every 400 operating hours (more often under severe operating conditions).Note: Deutz stipulates a first oil change and then every 500 hours.Improper valve clearances can cause rough engine running, power loss, and incomplete combustion.When adjusting valves, follow the instructions outlined in the engine manufacturers service manual.

Drive Train System Checks

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throttle pedal completely depressed, measure and record High Idle engine RPM.

Transmission OilChange the transmission oil filter(s) every 400 hours of operation.

General Maintenance Service Manual Wagner ScooptramsImportant: Oil and filter(s) should be changed anytime there are signs of contamination or burnt appearance. Always clean the outside of the filter(s) and the area around the filter(s) before changing.With the engine stopped, turn each filter counter-clockwise and remove. Discard the old filters.Use a clean cloth and wipe the filter mounting surface on the filter head.Apply a coat of transmission oil to the seal of each new filter and fill each filter with transmis-sion oil.Install the new filter(s) and turn until the seal contacts the filter head. Continue to turn each fil-ter clockwise 3/4 turn.Note: Use of a catch basin or container is rec-ommended when changing filter(s).Oil CoolerOn air cooled engines, the transmission oil cooler should be externally cleaned every 400 hours using high-pressure steam or by properly soaking in a cold cleansing agent. Note: Make sure to cover the injection pump, alternator, voltage regulator and starter motor to protect them from moisture. After wet-clean-ing, let the engine run long enough to evaporate all water to avoid rust problems.Compressed air can be used for dry-cleaning by starting from the exhaust-air side. Clean all dirt blown into the air cowling space after using compressed air.Transmission BreatherEvery 400 hours, remove and clean the breather with solvent. Blow dry with compressed air and re-install.Brakes

Emergency brake application will occur when converter oil pressure and/or brake accumulator pressure is lost. Test the accumulator pressure switch to ensure proper operation. To test:

1. Disconnect the electrical connection to the accumulator pressure switch.

2. With accumulators above 1400 psi (9650 kPa), test continuity between the C (#2) and NO (#1) terminals. Circuit should indicate closed.

3. Test continuity between the C (#2) and NC (#3) terminals. Circuit should indicate open.

4. With the same continuity hook-ups, pump the brake pedal with the engine shutdown. Observe the accumulator pressure gauge. Continuity should reverse when accumulator pressure drops below 1400 psi (9650 kPa). The C (#2) -NO (#1) circuit should indi-cate open and the C (#2) - NC (#3) cir-cuit should indicate closed.

5. Replace the switch if continuity does not shift at the proper pressure.

6. Re-connect the pressure switch connector.Test the converter pressure switch to ensure proper operation. To test:

1. Start the engine.2. Disconnect the electrical connection to the

converter pressure switch.3. With converter pressure above 60 psi (415

kPa), test continuity between the C (#2) 34 07-96 5566071301

Test all automatic brake apply functions.and NO (#1) terminals. Circuit should indicate closed.

Wagner Scooptrams Service Manual General Maintenance4. Test continuity between the C (#2) and NC (#3) terminals. Circuit should indicate open.

5. With the same continuity hook-ups, shut-down the engine. Observe the converter pressure gauge. Continuity should reverse when converter pressure drops below 60 psi (415 kPa). The C (#2) -NO (#1) circuit should indicate open and the C (#2) - NC (#3) circuit should indicate closed.

6. Replace the switch if continuity does not shift at the proper pressure.

7. Re-connect the pressure switch connector.Note: On some older vehicles, the converter pressure switch may not be easily accessible. To test for proper operation of the switch, place the vehicle in neutral, with the engine running. Release the Park Brake. With the vehicle still in neutral, shutdown the engine and observe the converter pressure switch. The brakes should apply as the pressure drops below 60 psi. Reset the Park Brake.

Chassis / Frame ChecksInspect all power and load frame welds for cracks, or broken welds. Check for any bent or warped frame components.Repairs should be made immediately for opti-mum safety. Repairs must be as recommended by Atlas Copco Wagner Inc. in writing and be performed buy a certified welder to current AWS standard.

WARNING: To prevent a possible weak-ening of the structure, obtain written approval from the manufacturer before

welding, cutting, drilling, bolting or installing

Articulation JointCheck bearings for looseness.The hinge pin needs to be checked for end play, and if end play is evident, adjustment is neces-sary. Refer to Articulation Pins on page 115 for instructions on proper adjustment.Driveline Slip-Joints Check driveline bolt torques. (See specified torque values in Appendix.)Driveline Yokes and Flange BearingsCheck driveline bolt torques. Check flange bear-ing caps for looseness and tighten if necessary. (See specified torque values in Appendix.)Inspect the spline shaft and slip yoke when the drive shaft assembly is removed for universal joint maintenance.Replace the drive shaft if the splines are galling, becoming loose, or the spline shaft shows signs of twisting.When driveline is removed for servicing, rotate the flange bearing and note any roughness. Replace if bearing is found to be rough.Driveline Universal-JointCheck for proper torque setting on universal joint bearing caps. If found loose, install new Grade 8 capscrews on clean threads and tighten to correct torque.Important: Do not use lock washers, lock plates, or lock wires to secure capscrews on uni-versal joint bearings.Important: Applying proper torque to bearing cap fasteners is the best method to ensure that the capscrews do not loosen. Improper torque can cause universal joint failure.

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an attachment or device to the mounting or before altering the cab/canopy or its mounting in any way.

Note: Torque settings apply to clean, non-coated threads. Torque settings do not apply to plated bolts. Grade 8 identification is 6 radial dashes,

General Maintenance Service Manual Wagner Scooptrams60 degrees apart on head of capscrew. Bolt thread class to be SAE standard Class 2.Check universal joints and support bearings for excessive heat immediately after vehicle is shut-down after a work cycle. Excessive heat, more than 38 C (100 F) above ambient temperature is a sign of friction and deteriorating bearings.Check the universal joints for wear as follows:Grasp the universal joint center cross (spider) with one hand. With the other hand, work the drive shaft up and down (or back and forth) at 90 to each of the trunnion axes. Check for looseness (sideways) between the trunnion and the bearing cap.Check all four trunnions in this manner. If loose-ness is detected at any of the trunnions, replace the universal joint as an assembly.Note: Do not confuse end-to-end play between opposite bearing with excessive wear. Some thrust movement is normal.Engine and Transmission MountsInspect mounts for cracks. Inspect for missing or cracked mounting bolts. Inspect condition of rubber mounting pads. Keep pads free of oil.Oscillation BearingsCheck oscillation cradle to frame bushings and thrust washers for vertical movement and end play.To check cradle bushings:Using a suitable lifting device, raise the rear of the vehicle until the wheels are off the ground.Observe for movement of the axle. If excessive drop is seen when the vehicle weight is removed from the wheels, replace the cradle bushingsTo check thrust washers:With the vehicle securely supported by blocks or

Insert a pry bar between the frame and the cra-dle. With the pry bar, attempt to shift the cradle.If excessive movement is detected, replace the thrust washers.Note: Excessive wear of the thrush washers and bushings is often indicated audibly during vehi-cle operation by a loud metal on metal clunk.Important: Daily lubrication of the bushings is essential to the prevention of premature oscilla-tion bearing wearout. Ensure that an amount of grease sufficient to flush out the existing lubricant is supplied dur-ing each lubrication cycle to remove contami-nants. Check to make sure enough grease is being distributed to the bushings and is actually exiting from the bushing housing area. Failure to properly flush the bushing housing area will allow dirt and contaminants to adhere to the bushing and harden . This will lead to wearing away of the metal and eventual weld repair and bore-lining of the axle housing to correct.

Hydraulic System ChecksReplace the hydraulic oil filters every 400 hours of operation or when indicated.The system must be shut down and tank pressure released to be sure no positive pressure remains on the fluid in the filter. Important: On vehicles with both suction and return line filters, you must change both filters as a set. Do not change just one filter. To change filter(s):1. Vent the system by loosening the filler cap or

depressing the relief valve.2. For vehicles having two filters, turn each fil-

ter counterclockwise and remove. Discard 36 07-96 5566071301

a maintenance stand, remove the wheels from the axle.

the old filters.

Wagner Scooptrams Service Manual General Maintenance3. Use a clean cloth and wipe the filter mount-ing surface for each filter.

4. Apply a thin layer of clean grease or oil to the seal of each new filter.

5. Install both filters. Turn each filter clockwise until the seal touches the filter head. Con-tinue to turn each new filter for 1/2 to 2/3 turn.

6. Start the engine and run at idle speed. Check each filter for oil leaks.

7. Stop the engine and check the hydraulic oil level.

On vehicles with the hydraulic filter located in the hydraulic tank, the filter is accessed from the top. The bleed port is used to relieve pressure inside the filter body before removing the head assembly. 1. Loosen the bleed valve on the filter housing

top to relieve suction pressure. Turning the fitting in a counter-clockwise direction opens the valve.

2. Remove the filter housing top by unscrewing the hex nut, or loosening the band clamp.

3. Ensure the indicator valve operates correctly by pushing down on both indicator posts. Posts should move freely.

4. Remove indicator valve assembly by lifting the two indicator posts.

5. Remove the element assembly from the body assembly and discard the element.

6. Remove O-ring from the head assembly and inspect for cuts or excessive wear and replace if necessary.

7. Wipe head assembly O-ring with clean cloth,

8. Check seal on the indicator valve assembly for cuts or excessive wear and replace if nec-essary.

9. If applicable, wipe optional magnet assem-bly with clean cloth to remove all ferrous particles.

10. Place a new filter element into the housing assembly.

Important: When changing filter ensure that it has completely filled with hydraulic oil prior to closing the filter housing and starting the vehi-cle. Air pockets can cause cavitation and dam-age the hydraulic pump.11. Reinstall indicator valve assembly in filter

housing and replace housing top. Hex nut type filter assembly requires 102 N-m (75 ft-lbs) of torque.

12. Start the engine and run at idle speed. 13. Stop the engine and check the hydraulic oil

level.If leakage appears at top of the body, replace the head assembly O-ring. If this does not stop the leakage, the body may be nicked or distorted by over torquing, and should be repaired or replaced. If the body is welded into the reservoir, straighten or repair flare as required. Consult factory if major problem exists.If leakage appears around the hex nut, remove snap ring and remove hex nut from the head assembly. Remove O-ring and inspect for nicks or cuts and replace if necessary. Wipe hex nut and O-ring groove. Then oil and replace O-ring, insert hex nut into head assembly and replace snap ring.The optional power-fill port is used to fill the reservoir through the filter without removing the 5566071301 07-96 37

Apply a thin layer of clean grease or oil to the O-ring and reinstall on the head assem-bly.

head assembly. An O-ring fitting can be screwed into this port and oil pumped under pressure through the filter and into the system.

General Maintenance Service Manual Wagner ScooptramsIn the rare instance the threads on the bolt become damaged, consult your Atlas Copco Wagner service representative for repair instruc-tions if housing assembly cannot be replaced.CylindersInspect all hydraulic cylinders for signs of dam-age or leakage. Check mountings for cracks and pins and bush-ings for wear and excessive clearances.Cylinders need to be checked for leaks, scored, bent or damaged stems and condition of eye bushings.Dump/Hoist and SteeringTest and record dump/hoist and steering cycle times.

1000 Hour Maintenance Schedule Perform Daily/Shift Maintenance Schedule.Perform 100 Hour Maintenance Schedule.Perform 250 Hour Maintenance Schedule.Perform 400 Hour Maintenance Schedule.

Power Train System ChecksFuelDrain and flush the fuel tank. 1. Loosen the drain plug on the bottom of the

fuel tank and drain fuel into a proper con-tainer.

CAUTION: If the fuel tank is full, there will be pressure on the drain plug. Recom-mend draining tank with low fuel level.

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

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

5. Bleed all air from the fuel system.EnginePressure wash engine block and radiator (or blower screen on Deutz equipped vehicles). Drive BeltsReplace engine drive (V-belts) to alternator and fan. Air Intake and ExhaustManifoldsInspect the cylinder head(s) and the intake and exhaust manifolds.Check bolts or capscrews for correct torque, according to the engine manufacturers specifi-cations.Check that manifolds are secure and properly sealed to cylinder head(s). Check also that mani-folds are free of holes or cracks and that no oil leaks and/or coolant leaks are present. Make replacements or repairs as necessary.Dry Type FiltersReplace the inner (or secondary) filter element after 1000 hours in the vehicle, or if the outer element has been replaced and the service indi-cator still shows RED with the engine running.Important: Do not attempt to clean the inner filter element, always replace the element with a new one.

1. Remove the filter cover.2. Remove the outer filter.3. Remove the wing nut for the inner filter and

remove the filter.4. Inspect filter gasket surface and replace if

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

needed.5. Replace the inner filter, install the outer fil-

ter, and install the filter cap.

Wagner Scooptrams Service Manual General MaintenanceDiesel Purifier1. Loosen/remove purifier housing retaining

clamps. Slide out purifier.2. Wire brush inlet and outlet faces of purifier

to remove carbon buildup.3. Using low pressure air (200 kPa / 30 psi),

blow through outlet side of purifier.4. Continue steps 2and 3 until the inlet and out-

let faces are clean.5. Completely soak purifier in a non-flammable

cleaning solution (one hour).6. Blow low pressure air (200 kPa / 30 psi)

through outlet side of purifier to remove dirty solvent.

7. Repeat steps 5 and 6 until the purifier is as clean as possible.

8. Flush purifier through outlet side using high pressure water (340 kPa / 50 psi max) and air dry.

9. Reinstall purifier in the reverse position of how it was previously installed.

Note: If high pressure steam is available, it may be substitute for the solvent solution. Steam clean through the outlet side, keeping nozzle 5 cm (2 in) away from the catalyst.Compression CheckCheck and record compression. If the recorded readings are not within specifications for the engine application, repair as necessary.

Drive Train System ChecksTransmission OilChange the transmission oil every 1000 hours.

Remove the drain plug and oil strainer assembly. Drain all the transmission oil.Note: Use of a catch basin or container is rec-ommended when changing oil.Replace the transmission oil filters and clean the strainer assembly and breather.Install the drain plug and strainer and add new oil to FULL mark. (See lubrication specification tables.)Start the engine and run at idle for a few minutes with the transmission in NEUTRAL. Check for oil leaks.Check the transmission oil level once oil temper-ature has reached normal operating range. Level should be between the ADD and FULL mark.Clutch Pressure Clutch pressure should be checked regularly. A drop in pressure will allow the clutch plates to slip, which increases friction and causes wearout of the clutch disc. Check at low engine idle (500-600 rpm) with oil temperature 82-93 C (180-200F). Pressure should be between 180 - 220 psi (1240-1520 kPa) or 240 - 280 psi (1650-1930 kPa), depend-ing on the model transmission.Attach a calibrated pressure gauge to the trans-mission charging pump pressure port. (Refer to the manufacturers service manual for location.) Start the vehicle and shift the transmission lever into forward (or reverse), then shift through all the gears. Record the pressure reading for each gear. All speed clutch pressures must be within 5 psi (34 kPa) of each other. If clutch pressure var-ies more than 5 psi (34 kPa) in any one gear, repair the clutch.Attach the gauge to the transmission forward 5566071301 07-96 39

Clean the area around the transmission oil filler tube and drain plug.

clutch pressure port and shift direction from for-ward to reverse and record the pressure. Repeat

General Maintenance Service Manual Wagner Scooptramsthis test with the gauge attached to the transmis-sion reverse clutch pressure port.Note: Atlas-Copco Wagner Scooptrams are equipped with modulated shift transmissions. Due to the combination of clutch leakage, piston bleed orifice flow rate and flow limiting orifices, directional clutch pressures can be as much as 30 psi (200 kPa) lower than system pressure.Engine speed must remain constant during the entire leakage test. Another test that may help warn of failing clutches before the 5 psi (34 kPa) pressure vari-ance shows up is the pressure drop test. In this test, the drop in pressure and the speed of return to original pressure is monitored. When the transmission is shifted into gear, the needle on the transmission/converter oil pressure gauge will drop off quickly as oil enters the clutch. As the clutch fills, the needle will slowly return to original reading.With oil temperature at 82-93 C (180-200F) and the engine at idle, go through each gear and note the drop in pressure and the speed of recov-ery back to original pressure. The clutch that may drop to a lower pressure and/or return to original pressure slower than the others should be suspect and may signal the need to make a pressure test with the master gauge.Note: Larger size clutch packs (usually 1st and 2nd gears), will fall off to a lower pressure than smaller size clutches (forward and reverse and higher gears), and will also return more slowly to the original reading. Be sure to compare read-ings of the same size clutches.AxlesAdjust wheel bearing pre-load following axle manufacturers recommendation in the vendor

Change the oil of the differentials and planetar-ies every 1000 hours of operation.Note: Draining of oil is best accomplished after vehicle has been operated and oil has warmed up. Use of a catch basin or container is recom-mended when changing oil.DifferentialPark the vehicle on a level surface, apply the parking brake, and stop the engine.Remove the oil drain plugs and completely drain each differential.Install the oil drain plugs.Remove the oil level plug and put new oil in each differential. (See lubrication specification tables.) The oil level must be up to the bottom of the oil level plug hole.Install the oil level plug.PlanetaryWith the vehicle on a level surface, move the vehicle forward or back until the oil level/drain plug is at the bottom of the hub.Apply the parking brake, and stop the engine.Remove the oil level/drain plug.After all the oil has been drained, reposition the vehicle so that the oil level/drain plug is in the level check position.Put new oil into the planetary. (See lubrication specification tables.) The oil level must be up to the bottom of the oil level/drain plug hole.Install the oil level/drain plug, then repeat proce-dure with the other planetaries.BrakesNote: On vehicles not equipped with force-cooled brakes and having self-contained brake coolant reservoirs, brake coolant oil level must 40 07-96 5566071301

service manual. (See Product Service Bulletins 280 and 355.)

be checked/changed. Perform at same interval as Differentials and Planetaries.

Wagner Scooptrams Service Manual General MaintenancePark the vehicle on a level surface, apply the parking brake, and stop the engine.Let vehicle to stand 5 minutes to allow oil to set-tle to normal level.Remove both oil level plugs and oil drain plug. (Both oil level plugs must be removed to allow for easy filling of the housing.) Replace drain plug and add new oil until it reaches the bottom of the oil level plug holes. (See lubrication specification tables.)Install the oil level plugs and repeat process for the other brakes.Note: Oil level plugs are located on the inside wheel face and may be difficult to reach. Use of special tools may be required.

Hydraulic System ChecksChange the hydraulic oil and clean/replace the reservoir breather every 1000 hours of operation.Raise the boom to its full height so that the pis-tons will be extended in the hoist cylinders. Move the bucket to its full dump position so that the piston will be extended in the stabilizer cyl-inder.Note: In these positions the hydraulic oil in the cylinders will be below the pistons and will drain more completely.Secure the boom with a chain hoist or by securely blocking the boom and bucket assem-bly with support stands.

CAUTION: Perform this step carefully to prevent the possibility of an accident. With the oil drained there will be nothing

to support the boomVent the reservoir by loosening the filler cap on

CAUTION: Make sure the hydraulic oil is just warm from operation before you drain the oil. Hydraulic oil temperature

can reach 121 C (250F).Select a container sufficient to hold the entire amount of oil in the system and place underneath the reservoir drain. Remove the drain plug from the reservoir and drain the oil.Disconnect the hoist and stabilizer cylinders hoses at the lowest points so as to completely drain the cylinders.Clean the inside of the reservoir. If it is difficult to clean, use a mixture of five parts fuel oil to one part of clean lubricating oil. Be sure to flush out the bottom of the tank. Make sure that all of the flushing solution is removed from the reser-voir.Disconnect any other hoses that might trap hydraulic oil in the system and shift the hydrau-lic control levers to permit any oil in the control valves to drain.Replace the hydraulic filter(s).Re-connect all hoses and fittings previously dis-connected.Install the reservoir drain plug.Pump new oil into the hydraulic reservoir. (See lubrication specification tables.)Important: On vehicles with internal filter car-tridge, ensure that the filter has completely filled with hydraulic oil prior to closing the filter housing and starting the vehicle. Air pockets can cause cavitation and damage the hydraulic pump. Wagner recommends filling the tank through the filter on these vehicles.Start the engine, cycle dump/hoist and steering

ACW0 0073.pict

ACW0 0073.pict5566071301 07-96 41

top of the tank. and check for oil leaks.Stop the engine and check the hydraulic oil level.

General Maintenance Service Manual Wagner ScooptramsCharge Valve Kick-In and Kick-OutCheck and record kick-in and kick-out pressures on the accumulator charging valve.Attach pressure gauge between the charging valve and the main accumulator, or use the accu-mulator pressure gauge mounted in the opera-tors compartment. Start and run the vehicle. Observe gauge and record highest pressure reading attained (kick-out). Cycle brakes. Observe and record the lowest pressure reading before pressure starts to increase (kick-in). Pressures should be:Kick-in 1600 psi (11030 kPa)Kick-out 2000 psi (13790 kPa)If these readings are not observed, the charge valve needs adjustment. Follow adjustment pro-cedure:Note: Hydraulic oil must be at operating tem-perature (66 C / 150 F).1. Shut off engine. 2. Remove cap and loosen the adjustment

screw locking nut on regulator section of the charge valve.

3. Using an Allen wrench or screw driver, turn the adjustment screw. Turn counter-clock-wise to reduce pressure and clockwise to increase pressure. Turning adjustment screw will automatically adjust both kick-in and kick-out pressures.

4. Restart vehicle.5. Bleed off accumulator pressure by cycling

park brake knob, and recheck pressures. When the correct kick-out pressure is

Steering and Dump Main ReliefAdjusting pressure setpoints is accomplished in the same manner as with the charging valve. An adjustment screw locking nut and adjustment screw is provided for each pressure setting. Remove cap and loosen locking nut. Turn counter-clockwise to reduce