MT 5020/6020 TRAINING

Controls & Electrical System

MT 6020/5020

You will know the Atlas Copco Minetrucks

MT 6020/5020, from the inside and the out,
including hydraulic & electrical systems, safety
and basic maintenance routines.

Content
Overview Brakes System
Safety Dump and Steering System
Hydraulics Introduction General Maintenance
Controls & Electrical System
Engine & Fuel System
Transmission and Axles
 Control system & Electrical system

•The electrical system used in MT- 5020 and MT-6020 is working on 24 volts.

The electrical system in MT-5020/6020 consists of:

 The batteries, wiring harness and the master switch
 The instrument panels
(with gauges, switches and indicators)
 The electrical component box
 The PLC, TCU and ECM
 Fuses and relays
 The vehicle lights and etc.

The electrical system also supports various microprocessors that monitor and control vehicle efficiency and alert
the driver to possible problems.
 Control system & Electrical system

•Two series connected 12V batteries mounted on the front of the cabin.
•The battery system is a series of two 12 volt batteries that provide the 24
volts for the operation of the starter and ECM initialization.
•A battery isolation switch is located in the battery
compartment and when turned to the OFF position
disconnects the electrical system from the battery and
alternator.
•The main purpose of the switch is to disconnect the
battery from the vehicle so that maintenance can be
safely conducted on the vehicle.

Starter:
The starter system is made up of three (3) solenoids.
The first, located in the vehicle cabin, lets current flow to the on-board control units when the key is turned to the on position.
The second, located in the component box, opens the circuit to the battery to engage the starter solenoid.
The last, located on the starter itself,
Turn always the battery isolation switch to the OFF position before maintenance,
replacing of the electrical components, welding etc.
 Electrical system

Electrical. system – Shows layout and orientation of electrical components.

The electrical wiring -Schematic provides exact information of all system and component wiring connections.
Ladder Diagram

The electrical ladder/circuit diagram illustrates the logic of a given circuit, providing
a conceptual overview.
Ladder – Shows how everything is connected, wire by wire.
Following Electrical diagrams in the new
MT6020MkII manuals

Start on page 17
New design of Electrical System
 Wire # matches Wire is going to Sheet 10 of 55 Circuit
Circuit Breaker 6 Circuit Breaker Grid Reference 1/A Description
From Sheet 8 of 55

To Sheet 13 of 55
Circuit description
Grid Reference 7/B
From Sheet 10 going to Sheet 11
Grid reference 8/C
 To Sheet 12 of 55
Grid references 7/E, 7/D & 7/C

From sheet 13 of 55
From Sheet 11 of 55
 2 3 1

7
8 9 10 11 12 13 14

1) Coolant level sensor

2) Primary & secondary park brake solenoids & 10) Retarder solenoid
Park brake switch 11) Component box
3) Instrument panels 12) Transmission filter restriction switch
4) PLC,ECU, relays, & receptacles 13) Drop box temp sensor
5) Batteries & 800 amp start fuse 14) Drop box cooling fan
6) Main isolator
7) Cab up prox
8) Brake circuit pressure switches and transducers
9) Air conditioning receiver/dryer & pressure switch

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 13 1 2 3
12

11 7

10 9 8

1) Centre J block 9) Transmission spider harness, solenoids, & sump oil

temperature sensor
2) Transmission oil temperature sensor
10) Hydraulic tank temperature sensor
3) Up box temp, Up box & Drop box pressure sensors
11) Hydraulic tank level sensor
4) PLC& ECU
12) Tub up prox
5) Air conditioning compressor
13) Rear J block
6) Front J block
7) Fuel level sensor
8) Fuel cooler
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 Control system

 Vehicle Computerized Control Units:

 Programmable Logic Controller (PLC)
 Engine Electronic Control Module (ECM)
 Transmission Electronic Control Unit (ECU / TCU)
 Gauge cluster

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 Control system
Programmable Logic Control - PLC
The PLC is located under panel behind the steering column.
The programmable logic controller (PLC) is a microprocessor that receives input
from the operator, the engine ECM, the transmission ECU, the DCU, a cabin
position proximity switch and the dump box position limit switch.
 The PLC outputs to the transmission ECU, the engine ECM, the parking brake
solenoid, the exhaust brake solenoid and controls the Box Up indicator on the
dash panel.
The PLC operates on a ladder logic program to monitor the dump box position,
operate the back-up alarms and lights, and to either release or set the parking
brake.

1. Stops
2. Fuses
3
3. Main module (PLC)
7 4. Input module
5. Output module
6. Up&Dropbox opto switches
PLC Part Number 5 7. Relays
4 6 8. IO-module
1
8
PLC Program
Number 1 2

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 Programme Logic Control (PLC)

When the conditions are right the PLC sends power to the solenoids that control the auxiliary valve.
It also has other functions for the truck.
If a series of lights on the PLC fail, check the following before replacing the PLC unit: All wiring to the PLC,
Engine Status Relay, Pressure Loss Relay, Cabin tilt, Box up

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 Control system There are 3 general sections to all PLC:
INPUT, CONTROLLER, and OUTPUT.
LEDs on the PLC INPUT -The input section consists of: integrated
inputs, or extension inputs that machine input
devices will be wired to, like limit switches, or
transistor sensors. When the input voltage reaches
its specified level the input becomes active. Once
active, the input can be read by controller.
CONTROLLER - The controller is the main unit.
Several CPU modules are…………available
depending on the demands of your application.
OUTPUTS - The third section is the outputs.
Based on the condition of the inputs, the controller
will judge which outputs should turn on, to activate
machine devices like lights, buzzers, relays,
solenoids, or motors.
•X = Inputs
•Y = Outputs All numbers on the right of the PLC has a light
•COM = Power supply behind it and 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 Program connections / Settings
EEPROM VR1
Connection
ON/OFF

VR2

PC Connection

VR1 & VR2 – Variable Analog Potentiometers

On the MT 6020/5020 used only VR1 for Neutral Brake Apply

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3
 Control system
PLC

4
 Control system
PLC

5
 Control system
Engine Electronic Control Module - ECM
The ECM is computerized logic control device that provides overall
engine management.
The engine’s electrical system is controlled by an ECM (Electronic
Control Module). The ECM reads data from all the sensors on the
engine and tells the Select Injector how to operate.

The ECM controls engine sped and power, injection timing,

governing, torque shaping, cold start logic, fuel delivery, diagnostics
and engine safeguards.
The ECM system includes following components:
Electronic control module, Engine speed sensor, Engine wiring
harness, System sensors, Diagnostic interfaces,
The ECM sensor system is designed to provide information
Communication links.
about the engine various performance with following sensors:
Turbo Boost sensor (Intake manifold pressure sensor)
Fuel Pressure Sensor
Oil Pressure Sensor
Crankcase Pressure Sensor
Coolant Temperature sensor
Fuel Temperature sensor
Air temperature Sensor
Oil Temperature sensor
Coolant level Sensor
Throttle position Sensor
Turbo speed sensor

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 Control system
Transmission Electronic Control Unit -
ECU

The transmission electronic control unit (ECU), is located under a panel behind the steering column.
 The transmission ECU is a microcomputer that processes the inputs then sends electronic signals to the
appropriate solenoids on the transmission control valve, which in turn controls the operation of the
transmission and has a direct connection to the PLC and direct link with ECM.
When the operator makes a gear range selection, the transmission checks the engine speed from the ECM,
the output speed from a sensor in the dropbox, transmission oil pressure, and conditions broadcast from the
PLC. Once it is satisfied that there are no problems, the ECU enacts a series of calculations based on its
programming and inputs that activates the appropriate control valve solenoids to achieve the selected gear
range.
The ECU receives and processes information defining:
Shift selector position, Throttle position, Sump temp., Input speed, Turbine speed and Transmission
output speed.
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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

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Control system
Gauge Cluster

Gauge cluster unit replaces the Data

collection unit (DCU) and data
gauge package which were found in
the previous MT5010, MT5020 &
MT6020 models
1
 Display error codes:
Note: The system will only display Active fault codes. Inactive will require connection of PC based
Diagnostic Tools.
To show the error display, press the “Mode” button until “FAULTS” is shown in the display, then press
“Set” button.
•If there are no faults present the display will dis-play “NONE”.
•If there are faults present, the first received fault will be displayed in the following manner:
Note: The display will cycle between 3 screens for the current fault. Each display will be displayed for
3 seconds before displaying the next display.
STEP1 Source - “SRC XXX” the display will display the numeric source address of the device with
the current fault. SRC 00 is the source code for the Engine ECM.
STEP2 Suspect Parameter Number - “SPN XXX” The display will display the numeric SPN of the
fault.
STEP3 Parameter Identifier - “FMI XX” (Failure Mode Identifier) defines what kind of failure
occurred in a PID or SID. The display will display the numeric value for the fault.
For more information about the fault codes, See “Systems Diagnostics”.
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 FMI - Failure Mode Identifier (identifierare för felläge) (the SAE J1939/J1587 type of failure detected)

PID - Parameter Identification Descriptions (beskrivningar av parameteridentifikation) (as defined in the SAE
J1587 standard, Parameter Identifier)

SID - Subsystem Identification Descriptions (beskrivningar för identifikation av delsystem) (as defined in the
SAE J1587 standard, Subsystem Identifier)

SPN – Suspect Parameter Number (as defined in the SAE J1939 standard)

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 Control system
Shift Selector

Shifter lockout release

Dump Control

Secundery Mode indicator

Secundery Mode Brake Override

On/Off button

Consule Display

Diagnostic Request Button

Parking Brake Button
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 Control system

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 Electrical, Instrument panels

1.Front lights
2.Load lights
3.Rear lights
4.Engine override
5.Brake test
6.Pressure setting
7.Cabin heater fan (option)
8.Windshield wiper/washer
9.Circuit breakers

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 Electrical, Instrument panels
1.Emergency steering, low pressure (optional)
2.Left turn signal indicator (optional)
3.Right turn signal indicator (optional)
4.Emergency steering, high pressure
(optional)
5.Digital speedometer
6.Dropbox pressure & oil level
7.Transmission filter
8.Upbox pressure
9.Stop engine
10.Upbox/dropbox temperature
11.Engine maintenance
12.Lubrication pump level low option)
13.Diagnostic coupler

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 Electrical, Instrument panels

1.Display
2.Heater temperature knob (optional)
3.Emergency steering and engine
overspeed warning buzzer
4.Engine overspeed warning
5.Ignition

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 Control system

Monitor in the cab

The camera capture the angles not visible from the operators cabin.

Rear camera
The dump box/rear camera system provides added safety during operation of the Minetruck.
The back-up alarm, in the rear of the vehicle, is turned on whenever the transmission is placed in reverse.
The audio alarm will be accompanied by a blinking yellow light to insure the attention of by-standers.

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 Electrical system
The component box is located under the cabin.
There are usually two groups of circuit breakers, located in the
instrument panel, and in the component box under the cabin.
The circuit breakers are designed to pop out when an electrical
overload condition exists.

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1
2
 Control system
Accum. Press Transducer Transmission Press
0-3000 psi Transducer
0-800 psi
Brake light pressure switch is NC. It Secondary Park
sends a signal to X2 on the PLC, tells Brake Solenoid
the PLC the brakes are applied when
there is below 800psi in the brake lines
to the wheel ends, brings the brake
lights on.

Park brake pressure switch is NO. It

sends a signal to X13 on the PLC, tells
the PLC that there is sufficient pressure to
keep the brakes released. If 1400psi is
not achieved writhen 3 seconds of the
park brake switch being pulled (X14 on
the PLC is energised), Y16 will de
energise and the brakes will apply. Primary Park
Have no function at the moment! Brake Solenoid

The transducers convert pressure to

current (power) for the gauges via
Park Brake Brake Light another computer called the DCU.
Press Switch Pressure Switch
1400 psi 500-1750 psi

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 Control system
Accumulator Transducer
Volt bar psi
400 0.5 0 0
350
300
1.45 82.4 1200
250 1.60 96.5 1400
200
1.76 110.3 1600
Bar

150
100
50
2.08 137.9 2000
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 1.60 13.8 200
30
1.93 17.9 260
Bar

20
10
0
-10 0 0,5 1 1,5 2 2,5 3 3,5 4 4,5 5
Volt

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