MT 5020/6020 TRAINING

Brake system
Objectives

You will know the Atlas Copco Minetrucks

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

Content
Overview Brakes System
Safety Dump and Steering System
Hydraulics introduction General Maintenance
Control and Electrical System
Engine and Fuel System
Transmission and Axles
Brake System

Tank

Aux. valve
Brake pedal

Brakes

Pump

Hand pump

Filter
 Primary &Secondary Accumulator
and Park brake switch

PLC

Brake Brake
Auxiliary cooling release
valve test port test port
Brake System
Auxiliary Valve

The purpose of the auxiliary valve is to distribute oil flow and pressures for
the brake system, suspension system and the pilot systems, for the dump, and
steering. The valve body is made form a single block of machined aluminum
and has seven serviceable components, 7 relativity inexpensive cartridges.
Because each component in the auxiliary valve is serviceable it allows easy
repair and maintenance with out removing the complete valve body form the
machine. Note the stamping in the valve block.
Brake System
Auxiliary Valve

 Auxiliary Valve Side One

1.Test Port 1, Brake Pump

2.Test Port 3, Pilot pressure
3.Pilot solenoid supply pressure
4.Hand Pump Check Valve
5.Brake pump check valve
6.Suspension Check Valve
7.Pilot solenoid return
8.Redundant brake valve
9.Pressure reducing
11.Pilot operated brake valve
Brake System
Auxiliary Valve

 Auxiliary Valve Side Two

1.Brake Accumulator
2.Hand Pump for Releasing Brake
3.Brake Pump
4.Accumulator Pilot Pressure Test Port 2
5.Steering
6.Dump
7.Suspension
8.Optional
9.System pressure
10.Return to Tank
Brake System
Auxiliary Valve

 Auxiliary Valve Side Three

1.Pilot solenoid return

2.Park Brake Pressure Switch
3.Park Brake Open
Check Valve & Close Check Valve
4.Redundant brake close check valve
5.Tank
6.Pilot operated brake valve
7.Retarder
SAHR Brakes
 Benefits…
– No adjustments needed
– Eliminates redundant park brake
– Increases vehicle safety
– Safest brake in mining industry

SAHR = Spring Applied Hydraulic Released

SAHR Brakes
1) Piston
6
2) Stationary plates
3) Friction plates
3
4) Face seal or Duo seal
5) Springs
5
6) Brake seals

4 1

2
 SAHR Brakes 2 1
1) Piston

10 2) Stationary plates
3) Friction plates
6 4) Spindle

7 5) Hub
6) Face seal or Duo seal
5 7) Springs
8
4 8) Axel housing
3 9 9) Bearing

10) Stud

1
 Brake System
SAHR brake system

No pressure is sent to the Pressure is sent to the brake Pressure exceeds minimum
brake discs and brakes are discs but is not exceeding the required release pressure so
applied at all time forced by minimum required pressure. the brakes are released by
the springs inside housing. Brakes are still applied. the hydraulic pressure.

MT-5020/6020 requires approximately a minimum pressure of 1400 psi (96 bar) to release the brakes

2
 SAHR Brakes
1
Check lining wear 1) Brake bleed.
1) Actuate the brake. 2) Brake cooling in. 2

2) Detach the cap nut (at 5) and 3) Brake cooling out.

3
push the indicator pin to the 4) Brake release.
inside.
5) Brake lining wear 4
3) Check the brake lining wear. test point.
Note The 5
standout (X) of the indicator
pin shows the maximum
allowed residual lining wear. If
the end face of the indicator
pin is flush with the end face of
the thread bushing, the
maximum lining wear has been
reached and a brake check is
necessary.
4) If maximum lining wear has
been reached, contact your
local Atlas Copco
representative.

3
Service Brake Pedal Pedal valve
It is a proportional 2 position 3 port valve.
The brake release pressure is regulated here, the 2000psi inlet pressure
gets reduced to the 1200 - 1500psi brake release pressure. The pressure
is reduced by the spool position. When the pedal is in the brakes released
position and port P is flowing to port A, port T is slightly open and so
bleeds off the 500 - 800psi. The more port T is opened the more pressure
is bleed off. This can be fine tuned by adjusting the dead band.

It is a quick release check valve that dumps the pressure from the wheel
ends quicker when park brake has been applied by bypassing the spool
in the brake valve. With the brakes are applied port P will have 0 bar
and the spring will push the spool up blocking any flow for P to the A
port. At this point then wheel end pressure A will be open to the tank T.
Any pressure at the wheel ends will have two paths through the valve
back to tank . First is A to T and the second is A through the check valve
to P then back to tank.
When you release the brakes there will be 140 bar at P . Oil flow will go
from P to A and also to the top of the spool valve. The pilot pressure on
the top of the spool will over come the spring tension and move the
spool down. This is will partially block the P port and reduce the
pressure at A port. This is your regulated wheel end pressure. The
wheel end pressure at A is lower that the pressure P so the check is held
closed. Only when the pressure at P is lower that the A port will the
check valve open and drain wheel end pressure to tank (park brake
applied).

4
 Setting the deadband

The dead band is how much movement the pedal

requires to make the brakes apply.
It is adjustable using the brake pedal heel stop.
To adjust, put the vehicle on a level surface, start
the engine and release the park brake.
Put the vehicle in 1st gear and roll the vehicle
forward at low idle, adjusting pedal heel stop up
until the service brakes start to drag.
Then turn stop back down until vehicle rolls free
and brakes are no longer dragging.
Then turn the stop 1/4 of a turn in and lock jam
nut.
Correctly set dead band is a good way to monitor
the condition of the brakes. A low brake release
pressure means worn brakes.
Adjustment

5
 Brake System
Accumulators

The brake accumulator is located behind the right rear motor mount

A hydraulic accumulator consists primarily of a shell, piston, air valve, and seals.
The accumulator must be pre-charged with dry nitrogen to a pressure of 83 bar (1200 psi).
When the accumulator is charging, oil at system pressure enters the chamber below the piston.
This pressure acting on the bottom of the piston moves the piston up. As the piston travels up, the nitrogen gas
compresses, increasing the charge pressure above the piston.
The piston will be forced up until the pressure on both sides of the piston are equal.
This oil will remain at this pressure until a fluid path is opened.
 Opening a fluid path (such as operating the park brake valve) reduces the pressure below the piston.
The higher pressure above the piston pushes it down until the pressure on both sides of the piston is equal.
The downward movement of the piston provides flow in the system until the fluid path is closed or the piston bottoms
in the shell.

6
 Accumulators

NB: New accumulators are not pre-charged. This must be done on / before installation.
Important: Use dry nitrogen only to pre-charge the accumulator. Dry nitrogen does not mix
with oil. It is non-combustible. It will not cause oxidation or condensation within the
accumulator and is not harmful to the piston seal.
Note: When pre-charging an accumulator on the vehicle make sure the oil side
of the accumulator has zero pressure. Operate the vehicle brakes while
charging the accumulator to bleed off oil pressure and ensure that the
accumulator piston goes to the oil end of the accumulator.
7
 Accumulators
 Hydraulic accumulators used in MT6020/5020 brake systems are used to
store energy and maintain a smooth flow of oil to the brakes during vehicle
operation and is located beside the up box on the right hand side of the truck.
 The accumulator consists primarily of a shell, a free-floating piston, air valve
and seals.
 The area above the piston is pre-charged with dry nitrogen gas to
approximately 1200 psi (83 bar). When the accumulator is charging, oil at
system pressure enters the chamber below the piston. This pressure acting on
the bottom of the piston moves the piston up. As the piston travels up, the
nitrogen gas compresses, increasing the charge pressure above the piston.
The piston will be forced up until the pressure on both sides of the piston is
equal (2000psi). This oil will remain at this pressure while the brake charge
pump is operating, or a fluid path is opened with the pump stopped. Opening
a fluid path (such as operating the park brake valve) reduces the pressure
below the piston. The higher pressure above the piston will now move the
piston down until the pressure on both sides of the piston is equal. The
downward movement of the piston will provide flow in the system until the
fluid path is closed, or the piston bottoms in the shell.


8
 Brake System
Variable Displacement Piston Pump for SAHR Brake & Suspension Systems

 Max. Operating Pressure: 250 Bar

 Max. Operating Temperature: 90°C
 Max. Operating Speed: 3000 RPM
 Max. Rotation Flow: 60 l/min at 2200RPM

The brake pump is a variable displacement piston pump that maintains

hydraulic oil pressure to the suspension system and charges the brake
accumulators.

9
 Axial Piston Pump Counter Piston
Piston

Housing

Input shaft
Carrier

Swash plate
Compensator
(Pump controller)

Control piston

0
 Axial Piston Pump
Adjust system pressure

STEP1 Clean the test ports on the auxiliary valve.

STEP2 Attach a hydraulic pressure gauge to the brake accumulator test port.
STEP3 Clean the area around the adjustment covers on the brake pump.
STEP4 Remove the screw cap on the brake pump to expose the pressure control
adjustment screw.
STEP5 Loosen the locking nut on the pressure control adjustment screw.
STEP6 Loosen the pressure control adjustment screw 3 turns counter clockwise to
prevent too high pressures.
STEP7 Relieve the brake system pressure by pumping the service brake pedal with
the engine not running.
STEP8 Remove the screw cap on the differential pressure adjustment screw.
STEP9 Have an assistant start the minetruck and allow the brake system to build up
pressure.
STEP10 Loosen the locking nut on the differential pressure adjustment screw.
STEP11 Tighten the differential pressure adjustment screw all the way in. Then back
out 1/4 turn.
STEP12 Tighten the locking nut.
STEP13 Adjust the system pressure to 138 bar with the pressure control adjustment
screw.
TEP14 After the adjustment is completed, tighten the locking nuts and reinstall the
caps.

1
 Axial Piston Pump
Set relief pressure
The brake pump acts as a relief valve in that it has a built in over pressure relief port that sends hydraulic oil back to
the tank whenever there is an over-pressure condition. The relief is set at 165.6 bar (2400 psi) at the factory. Adjust
the setting if a new pump is installed or the existing pump is rebuilt.

STEP1 Relieve the brake system pressure by pumping the service brake pedal a few times with the engine NOT running.
STEP2 Clean the test ports on the auxiliary block.
STEP3 Attach a hydraulic pressure gauge to the brake test port.
STEP4 Clean the area around the adjustment covers on the brake pump.
STEP5 Loosen the locking nut on the adjustment screw.
STEP6 Tighten the adjustment screw all of the way in, then back out 1/4 turn.
STEP7 Tighten the locking nut and reinstall the cap.

2
 Axial Piston Pump Locking Nut
Adjusting screw

Procedure for setting the working pressure

Cap
Step 1 Relieve the brake system pressure by pumping the brake release button with the
ignition turned off.
Step 2 Attach a hydraulic pressure gauge to the brake test port.
Step 3 Remove the screw cap on the pump compensator valves to expose the adjustment
screws.
Step 4 Have an assistant start the mine truck and allow the brake system to build up
pressure. The system pressure should be 138 bar (2000 psi).
Note It may take a few minutes for the system pressure to stabilize after the brake system
pressure was relieved.
Step 5 If the system pressure does not stabilize at the above pressure, an adjustment to the Working relief
brake pump is necessary. Do not exceed 2500psi(172 bar) at any time. compensator
Step 6 Adjust the pressure by loosening the locking nut on the working relief compensator
and turning the adjustment screw in small increments. To raise the pressure, turn the
screw clock-wise. Make a note on how much the adjustment is wound in.
Note If the pressure does not increase within 1 full turn, the max relief compensator may be
set incorrectly. In this case reset the working pressure compensator to it’s original position
and follow steps on the max relief pressure setting procedure.
Step 7 Allow a few minutes after the first adjustment for the system pressure to re-
stabilize. If more adjustment is necessary, follow steps 6 and 7 until the appropriate
system pressure is achieved.
Step 8 After the adjustment is completed, tighten the locking nut until the adjusting screw Max relief
cannot turn. Test port compensator
Step 9 Watch the system pressure for a few minutes after the locking nut has been
tightened to make sure the pressure was not changed.
Step 10 Replace the adjustment screw cap.

3
 Axial Piston Pump Adjusting screw

Locking Nut
Procedure for setting the max relief pressure
Cap

Step 1 Follow steps 1 to 5 in the procedure for setting the working

pressure.
Step 2 Wind the working pressure compensator out two full turns and nip
the lock nut.
Step 3 loosen the max pressure compensator locknut and wind the
adjustment screw all of the way in, then back out one quarter (1/4) turn.
Step 4 Slowly wind the working pressure compensator in until the
pressure reaches 2500psi(172 bar).
Step 5 Wind the max relief pressure compensator out until the pressure Working relief
drops below 2300psi(158 bar) then in until 2400psi(165 bar) is obtained. compensator
Step 6 Wind the working relief pressure compensator out two until the
pressure drops to 1800psi(124 bar) then slowly increase the pressure to
2000psi(138 bar)
Step 7 After the adjustment is completed, tighten the locking nut until the
adjusting screw cannot turn.
Step 8 Watch the system pressure for a few minutes after the locking nut
has been tightened to make sure the pressure was not changed.
Step 9 Replace the adjustment screw cap.
Max relief
Test port compensator

4
 Axial Piston Pump
Pump priming
Whenever the brake pump suction line is removed, the brake pump
will need to be primed before operating the mine truck.
Important Do not operate the mine truck until the brake pump has
been primed. Severe damage to the pump will occur if it is allowed to
function improperly.

Step1 Loosen and remove the case drain line to the brake pump.
Step 2 Fill the pump with hydraulic oil until it is at the level of the
case drain fitting threads.
Note While the case drain hose is off of the pump drain port, inspect
the O-ring for wear or damage. Replace the O-ring prior to
completing the pump priming process.
Step 3 Replace the case drain hose but do not tighten.
Step 4 Pressurize the hydraulic tank either by filling it with
hydraulic oil or by pumping air into it through the quick fill
disconnect.
Step 5 When all of the air has escaped from the pump through the
case drain port, immediately tighten the hose connection to the Case Drain
pump.

Note Make sure that the O-Ring is properly seated and not being
pinched when the fitting is being re-tightened.
5
 Primary Brake Solenoid Located behind the dump leaver and under
the arm rest.
Both two are energised by Y16 from the
PLC to release the brakes.
Y16 energises pressure loss relay K112.
Relay K112 latches relays K106A & K106B,
power then flows thru the park brake switch
to the brake release solenoids
They can be overridden manually to release
the brakes, with the ignition power on or off.

Primary & secondary

park brake valve 3 /Pressure in
1
2

6
 Pressure Switches & Transducers
Brake light pressure switch is NC. It sends
a signal to X2 on the PLC, tells 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
PLC 5590 0062 00 AVO 10X & UP
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?
NOT used on MT-6020TierII?
The transducers convert pressure to
current (power) for the gauges via another
computer called the DCU. The DCU also
supplies the PLC information from the
transducers. X30 or X0 on the extra PLC.

7
 Gear pump Port location for
Brake Cooling pump check brake
cooling pressure

 Supplies oil to the brake charge pump via the

hydraulic pressure filter.
 Max. Operating Temperature: 80°C
 Max. Operating System Pressure: 3500psi
 Rated flow at 2100RPM ,95 lpm(25 GPM)

Brake cooling pump location

A gear pump mounted to the front of the engine. Supplies oil to the brake charge
pump as well as the brake cooling circuit.
The pressure will range from approx 25 psi ( 1,5 bar) at idle and up to 65psi (4,5
bar)at high idle unless the brake charge pump has demand for the oil (like
accumulator charging), then the pressure will drop away.

8
 Brake cooling manifold

100 psi
relief

9
 Brake circuit test ports
The brake release pressure is checked
at this test point, 1400psi(96 bar). It is
located inside the truck body on the
left hand side behind the front axel

The brake cooling pressure is

checked at this test point, low idle
25psi (1.5bar) and high idle 65psi
(4,5bar). It is located inside the truck
body on the left hand side in front of
the front axel. Oil must be hot to
check pressure.

The brake accumulator charge

pressure is set & checked at this test
point, 2000psi(138 bar). This pressure
is what is seen on the gauge in the
cabin

The brakes releasing pressure have to be checked at regular intervals, if needed adjust on the brake pedal.

0
 7

7 7
7

Click
1
 Turn engine on
Park brake applied

Oil flow to accumulator

and solenoids.
Build up Accumulator
pressure. Click
2
 7

Solenoids energise.
Oil flow to port 4.
Check valve 7 is closed.
Click
3
 7

Oil flow to port 2.

Check valve 6 is closed &
check valve 5 is opened.
Click
4
 7

Oil flows to the wheel ends

releasing the brakes.
Click
5
 7

One solenoid de-energised

Click
6
 7

No pilot pressure at port 4.

Check valve 7 opens.
Click
7
 7

The brakes apply and

accumulator pressure drops.
Click
8
 Brake apply

Engine running

9
 Brake released

Engine running

0
 Important: we always specify to use oils with a limited slip (LS) addition for the cooling of our wet disc brake in order to
provide the correct friction coefficient between lining and steel disc. For more info see OEM manual (Kessler manual).

1
 Pressure
Accumulator
charging
Return to tank

Brake
charge
pump Gear
pump

Brake cooling
manifold
Pressure
filter 100psi
relief

Heat
exchanger

2
 Brake System
Manual Brake Release
1

The hand pump can be used for two purposes. Use the selector
valve to toggle between brake release or cabin tilt.
•Push in the selector knob to tilt the cabin.
2
•Pull out the selector knob to release the brakes.

1. Selector Knob
2. Tilt Lever

To release the brakes manually

To release the brakes, use the hydraulic hand pump handle and
start pumping until reaching approximately 103 bar in the
accumulator.
The pump has a built-in relief valve to prevent over-pressurizing.
Releasing the override control will immediately vent system
pressure to the hydraulic tank and reset the brakes.

Before undertaking any work on the MT 6020 Brake circuit you must make sure the
wheel chocks are in place, all accumulator pressures are removed, the truck is isolated,
and personal danger/isolation tags are in place.
3
 Supply from
suspension
Charge accumulator
accumulator

Direction
control
valve

Lift cab
Lower
cab
Operate hand
pump

4
 Before undertaking any work on the MT 6020 Brake circuit you
must make sure the wheel chocks are in place, all accumulator
pressures are removed, the truck is isolated, and personal
danger/isolation tags are in place.

Who can tell me what the main components are on the Atlas
Copco MT6020 brake system?

1) VALVES
2) ACCUMULATOR
3) TRANSDUCERS & PRESSUE SWITCHS
4) PLC. Programmed Logic Control & DCU Data Collection Unit
5) SAHR BRAKE

5
 How the Brake test is performed
Always test the brakes before operating the vehicle.
1. Start the truck, Park bake on, Transmission in Neutral
2. Turn Test Switch to Pos 1, for the 1st solenoid
3. Holding Switch move gear lever to D (window will show 3) do not release switch during test.
4. Rev to 1900rpm for 3-4 seconds
5. Truck must not move. If truck moves stop test, isolate truck and contact
maintenance.
6. Park bake on, Transmission to Neutral
7. Turn Test Switch to Pos 2, for the 2nd solenoid
8. Holding Switch move gear lever to D (window will show 3) do not release switch during test.
9. Rev to 1900rpm for 3-4 seconds
10. Truck must not move. If truck moves stop test, isolate truck and contact maintenance.
11. Park bake on, Transmission to Neutral
12. Service brake, Turn Test Switch to Pos 1
13. Holding Switch move gear lever to D (window will show 3) do not release switch during test.
14. Place left foot on brake (apply the service brakes) & release Park Brake
15. Rev to 1900rpm for 3-4 seconds
16. Truck must not move. If truck moves stop test, isolate truck and contact maintenance.

NOTE: This procedure is a guide only. Refer to the operators manual for the correct procedure.
Caution must be used when testing the brakes. Never assume the brakes will hold the vehicle.
Ensure that everyone is clear before testing the brakes.

6
 We are committed to your superior
productivity through
interaction and innovation.