ST1030 TRAINING
Brake System
Objectives
You will know the Atlas Copco Scooptram
ST 1030, from the inside and the outside,
including hydraulic & electrical systems, safety,
and basic maintenance routines.
Content
Overview Brakes
Safety Steering
Engine and fuel system Dump and hoist
Transmission and axles Electrical system
Hydraulics introduction General maintenance
Brake System
Components
Pump
Filter
Service Brake
Remote Test Ports
Fan Motor
Accumulators
Transducers
Pressure Switch
SAHR (Posi Stop) Brakes
Auxiliary Valve
Aux Valve Cartridges
Aux Valve Torques
Brake System pressures
Brake System
Components
Steering side (front): Gear width; 1.25 inch and 80 L @ 2100 engine rpm
Brake side (rear): Gear width 0.75 inch and 51 L @ 2100 engine rpm
Brake System
High Pressure Filter
10 Micron
Brake System
Service Brake
Brake System
Remote Test Ports
1 2 3 4 5
1. Steering, Dump & Hoist Main pressures 4. Brake Accumulator Pressure
2. Brake Cooling Pressure 5. Brake Accumulator Pressure
3. Brake Release Pressure
Brake System
Hydraulic Fan Motor
Gear Motor
Anti- cavitations valve
Iron casting
Seal Drain
Displacement 19.7CC
Brake System
Accumulators
Piston Type
Brake Accumulator Tow Hook Accumulator
Capacity: 3.57 L Capacity: 1.69 L
re- Load: 82.7 Bar (Nitrogen) Pre- Load: 82.7 Bar (Nitrogen)
Brake System
Transducers
Transmission Transducer
Park Brake Pressure Switch
Brake Transducer
Brake System
Transducer
Brake accumulator transducer
Accumulator Transducer
400
350
300
250
200
Bar
150
100 XX
50
0
-50 0 0,5 1 1,5 2 2,5 3 3,5 4 4,5 5
Volt
Volt bar psi
0.5 0 0
1.45 82.4 1200
1.60 96.5 1400
1.76 110.3 1600
2.08 137.9 2000
Brake System
Component positions
11 7 9
8 6 10 5
1 2 4
3
. Front Axle Manifold 5. Brake Accumulator 9. Primary Brake solenoid
. Service Brake Valve 6. Aux Valve 10. Rear Axle Manifold
. Brake Cooling Manifold 7. High Pressure Brake Filter
. Tow Hook Accumulator 8. Brake Release J-Block
Brake System
SAHR (Posi Stop)
Brake System
SAHR (Posi Stop)
tlas Copco/ Wagner
pring Applied Hydraulic Released
rake Assembly
Brake System
SAHR (Posi Stop)
Main Body
Front Cover
Pressure
Supply Port
Stationary
Plates Piston
Friction Disc Springs
Face Seal Spring Cover
Axle Housing
Hub Seal
Hub Bearing
Spindle
Side Shaft
Brake System
SAHR (Posi Stop)
Brake System
Auxiliary Valve
Auxiliary Valve Functions • Brake release/un-release
• Brake Accumulator charge • Hydraulic Fan Drive
• Pilot Pressure • Brake/Hydraulic Cooling
Brake System
Auxiliary Valve
1
7
8
2
9
3
10
4
11
5 12
6
Aux Valve 5. Charge Valve 9. Pilot Pressure Valve
Secondary Brake Solenoid 6. 0.02 Orifice 10. Relief Valve
Pilot Controlled Check Valves 7. Filter 11. Air Bleed & Start-Up Valve
Check Valve 8. Spring Applied Check Valve 12. Priority Flow Control Valve
Brake System
Auxiliary Valve Cartridges
Auxiliary Valve Cartridges
Additional and deeper information regarding the cartridges functions which also can be
useful when repairing cartridges.
Brake System
Auxiliary Valve Torques
Hex lbs. Nm Thread
7/8 25/30 36/41 M16
3/4 25/30 36/41 M16
7/8 30/35 41/47 M20
1 1/8 45/50 61/68 1”-14UNS
1¼ 150/160 203/216 M36
1 5/8 350/375 474/508 M48
AUXILIARY VALVE OPERATION
Brake System
Ignition turned
to “on” position.
Engine starting.
Brake System AUXILIARY VALVE
AUXILIARY VALVE
Brake System
AUXILIARY VALVE
Brake System
Brake System AUXILIARY VALVE
Transmission Press
Ignition
Power S 11 Gauge Cluster
30-C K112 PR Loss Signal Accumulator Press
P/B P34 PLC
PLC
Shown Released X10
30-B P34-B P34-A Press Loss Latch relay 002 -
K216B1
Sec P/B Relay
P34-B
P34-C
K216B2
K216A
30-G Primary P/B
Solenoid
30-F 33-D Y216A
Start inhibit
Relay
S112 Sec P/B
P/B Test switch Solenoid
030
Y216B
B351 P/B Press Switch
P/B Light 002 -
PLC
Y11
ST1030 MK2 (Brake System At Rest)
Transmission Press
Ignition
Power S 11 Gauge Cluster
30-C K112 PR Loss Signal Accumulator Press
P/B P34 PLC
PLC
Shown Applied X10
30-B P34-B P34-A Press Loss Latch relay 002 -
K216B1
Sec P/B Relay
P34-B
P34-C
K216B2
K216A
30-G Primary P/B
Solenoid
30-F 33-D Y216A
Start inhibit
Relay
S112 Sec P/B
P/B Test switch Solenoid
030
Y216B
B351 P/B Press Switch
P/B Light 002 -
PLC
Y11
ST1030 MK2 (Ignition Turned ON & P/B Applied)
Transmission Press
Ignition
Power S 11 Gauge Cluster
30-C K112 PR Loss Signal Accumulator Press
P/B P34 PLC
PLC
Shown Applied X10
30-B P34-B P34-A Press Loss Latch relay 002 -
K216B1
Sec P/B Relay
P34-B
P34-C
K216B2
K216A
30-G Primary P/B
Solenoid
30-F 33-D Y216A
Start inhibit
Relay
S112 Sec P/B
P/B Test switch Solenoid
030
Y216B
B351 P/B Press Switch
P/B Light 002 -
PLC
Y11
ST1030 MK2 (Engine Running & System press Normal)
Transmission Press
Ignition
Power S 11 Gauge Cluster
30-C K112 PR Loss Signal Accumulator Press
P/B P34 PLC
PLC
Shown Released X10
30-B P34-B P34-A Press Loss Latch relay 002 -
K216B1
Sec P/B Relay
P34-B
P34-C
K216B2
K216A
30-G Primary P/B
Solenoid
30-F 33-D Y216A
Start inhibit
Relay
S112 Sec P/B
P/B Test switch Solenoid
030
Y216B
B351 P/B Press Switch
P/B Light 002 -
PLC
Y11
ST1030 MK2 (Release P/B)
Transmission Press
Ignition
Power S 11 Gauge Cluster
30-C K112 PR Loss Signal Accumulator Press
P/B P34 PLC
PLC
Shown Released X10
30-B P34-B P34-A Press Loss Latch relay 002 -
K216B1
Sec P/B Relay
P34-B
P34-C
K216B2
K216A
30-G Primary P/B
Solenoid
30-F 33-D Y216A
Start inhibit
Relay
S112 Sec P/B
P/B Test switch Solenoid
030
Y216B
B351 P/B Press Switch
P/B Light 002 -
PLC
Y11
ST1030 MK2 (System Press Loss)
Transmission Press
Ignition
Power S 11 Gauge Cluster
30-C PR Loss Signal Accumulator Press
K112
P/B P34 PLC
PLC
Shown Applied X10
30-B P34-B P34-A Press Loss Latch relay 002 -
K216B1
Sec P/B Relay
P34-B
P34-C
K216B2
PLC
X7 Y7 K216A
30-G Primary P/B
Solenoid
30-F 33-D Y216A
Start inhibit
Relay
S112 Sec P/B
P/B Test switch Solenoid
030
Y216B
B351 P/B Press Switch
P/B Light 002 -
PLC
Y11
ST1030 MK2 (Test P/B with Test Switch Pos.1)
Transmission Press
Ignition
Power S 11 Gauge Cluster
30-C PR Loss Signal Accumulator Press
K112
P/B P34 PLC
PLC
Shown Applied X10
30-B P34-B P34-A Press Loss Latch relay 002 -
K216B1
Sec P/B Relay
P34-B
P34-C
K216B2
PLC
X7 Y7 K216A
30-G Primary P/B
Solenoid
30-F 33-D Y216A
Start inhibit
Relay
S112 Sec P/B
P/B Test switch Solenoid
030
Y216B
B351 P/B Press Switch
P/B Light 002 -
PLC
Y11
ST1030 MK2 (Test P/B with Test Switch Pos.2)
Brake System
Brake System
Turn ignition on.
Start engine.
Brake System
Brake System
RELEASING THE
PARK BRAKE
Brake System
PARK BRAKE RELEASED
APPLY SERVICE BRAKE
Brake System
APPLYING THE
PARK BRAKE
Brake System
APPLYING THE
PARK BRAKE
Brake System
RELEASE PARK BRAKE
MANUALLY FOR TOWING
Brake System
Brake Pressures
Check Bar PSI
Brake cooling check valve
1 15
Trans press loss, Emerg steering pump & acc press switch 4 60
5
Hydraulic cooler check valve 75
Pilot pressure dump hoist & steering 24 350
Tow hook accumulator pre-charge of nitrogen 76 1100
Brake accumulator pre-charge of nitrogen 83 1200
1400
Accumulator brake pressure loss 96
1400
Park brake pressure switch 96
Wheel end brake pressure 103 1500
Brake accumulator kick in 110 1600
Brake accumulator kick out 138 2000
Aux valve relief 207 3000
Brake System
Park Brake Test Procedure
1. Start the ST1030.
2. Ensure no one is around the machine – carry out the normal safety procedures.
3. Keep the park brake switch pushed in, (i.e.) in the applied position.
4. Select forward or reverse gear, whichever is the safer option.
5. Select 2nd gear by turning the “maximum gear selector” switch to second gear.
6. Turn the test switch to the left into position one (1) and hold to test the primary brake solenoid.
7. Make sure and confirm that the gear selector display shows 2nd gear.
8. Slowly increase the engine RPM to full throttle – the machine must not move. If it does, immediately stop
the test and report the defect to the maintenance department. If in order, continue with the next step.
9. Release the throttle pedal.
10. Turn the test switch to the right into position two (2) and hold to test the secondary brake solenoid.
11. Slowly increase the engine RPM to full throttle – the machine must not move. If it does, immediately stop
the test and report the defect to the maintenance department. If in order, continue with the next step.
12. Release the throttle pedal.
13. Release the test switch.
14. Select neutral. Reselect desired gear range/selection by turn the “maximum gear selector” switch.
15. Apply the park brake or resume work.
The Park Brake Test Switch is a three position switch, which is spring loaded to neutral position
(middle position).
Brake System
Service Brake Test Procedure
1. Make sure the park brake is applied.
2. Put the machine in second gear, in forward or reverse, whichever is the safer.
3. Firmly press the service brake pedal fully and hold.
4. Turn the test switch into any position and hold, release park brake.
5. Slowly increase the engine RPM to full throttle. The service brakes should prevent the machine from
moving whilst at full RPM. If it does, immediately stop the test and report the defect to the maintenance
department. If in order, continue with the next step.
6. Release the accelerator pedal
7. Select neutral. Reselect desired gear range/selection by turn the “maximum gear selector” switch.
8. Apply the park brake or resume work.
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