SANY SRT95C Off-Highway Truck. Service Manual

PREFACE

Dear users:
Thank you very much for purchasing mining
dump truck which is famous product of
SANY Mining Equipment co. , ltd ! We will be

providing you ' first class products, first class
quality and first class service' .

All  of  parts  of  machine  are  easily  worn,
loosened and damaged if machine has been
used for a long time, so the regular inspection,
maintenance and servicing for machine that
are very important and useful way to your
machine for exert its performance and working
with stable, safety extending its service life.
We provided this manual book for you and it's
makes easily to inspection, maintenance and
servicing for machine.
The manual book has contained particular
specification and illumination to inspection,
maintenance,  repairing  of  all  parts  of  the
SRT95C and introducing some diagnosis and
resolving ways to regular malfunction. There
are  methods  and  steps  for  repairing  and
servicing are recommended and provided in
manual book. There are also provided some
special tools are designed for repairing or
some especial place of the machine.
Please  read  this  manual  book  carefully,
included all of cautions and notes to minimize
the human injuries and deaths or machine
damages  duo  to  the  incorrect  operation
methods. The operator has to know that there
are not illuminate all of danger situation with
cautions and notes which happened during
the servicing when you uses some tools are
not recommended, everybody has to ensure
of self-safety and machine safety first before
repairing.

OVERVIEW

Important safety notes

Does  the  maintenance  and  servicing  in
correctly for the machine safe and reliable are
very important. There are description and all
recommends are useful for the maintenance
and servicing. In addition, there some special
tools  are  designed  for  maintenance  and
operation, they are recommended when the
maintenance and servicing.
In  order  to  minimize  the  possibility  of
human  injuries  and  casualties  or  damage
of  equipment  due  to  improper  maintaining
method, this Manual and the important notes
and  various  warnings  in  it  should  be  read
through carefully! It is also required to learn
the potential dangers of each method that the
details are not provided in these warnings and
notes, that are hard to foresee and that come
to mind during the process of maintenance.
Therefore,  when  adopting  a  maintenance
procedure or tool that is not recommended,
all operators must ensure that the maintaining
method can ensure the safety of their own and
the truck.

Safety warning sign

Following the safety information

indicated on the sign may help avoid possible
human injuries or death.
2. The sign is only used for warning you the
potential danger of human injuries.

Danger rating

A multi-level danger rating system is often
used to indicate potential dangers of human
injuries. The  following  symbols  and  notes
are  used  together  for  expresses  the  level
of  dangerous, symbols and notes are used
independent  for  expresses  the  loss  and
protection of properties. The symbols of the
manual has the same effect with the symbols,

notes, cautions and labels of the agreement
of the machine.

Danger

It indicates an emergent

and dangerous situation, which may lead to
deaths or serious injuries if it is not avoided.

Warning

It indicates a potentially

dangerous situation, which may lead to deaths
or serious injuries if it is not avoided.

Caution

It indicates a dangerous

situation, which may lead to minor or moderate
injuries if it is not avoided.
The caution is used independent for indicated
potential dangerous situation without the
symbols, it could be makes the properties loss
if is not avoided.

General

Incorrect operation is very dangerous, so be
sure to read the Manual carefully before any
maintenance operation.
1. Before filling grease or repairing, read all
notes about the truck.
2. Safety boots and helmets must be worn
during operation. Do not wear unfitted work
clothes, and button up the clothes.

• Wear safety goggles while striking with a

hammer.

• Wear safety goggles when smashing stones

with a stone crasher.
3. When it is required to perform welding
o p e r a t i o n , t h e o p e r a t o r m u s t b e a n
experienced ones who has received training.
During the operation, the operator must wear

or use welding gloves, baffle, goggles, working

cap, and work clothes which things suitable for
the welding operation.
4. When the two operators are worked
together, they are has to follow the operation
procedures such as : informed the guy who
working together on site and has to hang the
label up which wrote the' repairing ' on it at

Overview

obviously place.
5. Storing all of tools properly and know that
how to use them.
6. Get a proper place in the workshop that
used to store tools and parts when they are
removed out of the machine. The store has
to keeping clean, oil-free and no smoking in
there.

warning

During the operation, the old parts,

repaired parts which performance has

been weakened that are prohibited to using

again, they will be effected the performance

of the machine seriously, and even lead

to severe damage to equipment or human

injury.

Preparation for operation

7. When the refilling and repairing the
machine, the truck must be parked on a solid
and horizontal ground. Place chocks for the
wheels to prevent the truck motion.
8. Before operation, it is required to drop to
the ground those parts and components that
are possible to slide down. If it is impossible,
such as : suspension cylinders and body etc
that are has to block by chocks to prevent
them drop out form the machine, in addition,
shutdown of the power, locked all of lever and
hanged the caution up at obviously place.
9. Before the disassembling or assembling
operation, chocks, jacks or other things to
support the truck.
10. Cleaning all of dirt things around of the
whole truck and uses armrest, ladder or stair
to mounting or dismounting truck. If no armrest
or ladder can be used, a jack horse with safe
base may be used.

Notes during operation

11. When the disassembling the feeding cover,

Overview

discharge cover and liquidometer, the operator
has to wear safety goggles and sideways
body to avoid liquid spray out during the cover
opening. Caution : discharge the pressure
from the hydraulic, water and air-compress
system before to disassembling them.
12. The water and oil system are very hot
when the engine shutdown. Pay attention ! Do
not touch them with hands.
Before any operation in the oil or water
system, wait for oil or water system cooled off
before start the operation.
13. Before operation, cut off electricity and
remove the battery wires. Removing the wires

from the cathode joints of the battery first.

14. A hoisting machine or crane may be used
to lift a cumbersome component.
Check the wire rope, chain and hoist hook to
prevent dangers.
It is required to use a hoisting device with

sufficient hoist power.

• Erect the hoisting device at the correct

place. The hoisting machine or crane should
be operated slowly to prevent its components
getting collided with other parts.  It is prohibited
to stand under the lifting machine when the
hoisting machine or crane are working.
15. When  removing  the  cover  which  with
internal pressure or spring inside, it has to
unscrew the bolts at two opposite directions to
release the pressure gradually. Then unscrew
all of  bolts slowly and remove the cover out of
machine.
16. Be  slowly  when  disassembling  the
structure parts from the machine, do not make
mistake of operated to cut or damaged the
wires, because the damaged wires may cause

fire.

17. When operator to disassembling the piping
system, operator has to avoid fuel or grease
get out of the machine, if fuel or grease
dropped on the ground, rub if off immediately

because that would makes worker slid or fire.

18. Do not use gasoline to clean any parts.

This is a general rules. Pay greater attention
when cleaning an electric parts.
19. Pay attention to reinstall all parts into their
original positions.
When using a new part to replace a damaged
one, put the new and old ones separately to
avoid mis-installation because they are mixed.
When installing of hoses and wires, it is
required to ensure that all hoses and wires will
be not damaged due to contact and wear with
other parts during the operation of the truck.
20. When installing of a high-pressure hose,
it is required to make sure that the hose does
not get twisted. It is very dangerous to damage
pipes, so be careful to install a high-pressure
pipe. It is also required to check whether the
connecting parts are installed in a correct way.
21. Tighten up a part to the given torque when
assembling or installing it. Pay great attention
to install a protective piece like baffle and a
party involving intense vibration and high-
speed revolution, and check whether they are
installed in a correct way.
22. When the two components needs to align

with two holes, do not put hand or finger into

any hole so as to avoid dangers.
23. Before checking the oil pressure, check
whether the measuring instrument is installed
correctly.
24. Cracking or disintegration of both tyres
and rim or either of them may result to
serious injuries or casualties. Abide by the
suggestions in instruction manual provided
by manufacturers or read the specification
provided by tyre supplier for reference strictly.

Storing of truck

In order to avoid damaging any parts of the
truck, pay great attention to keeping truck
for a short period or non-temporarily. On the
period of the storing the truck, if there are no
necessary ways to protecting all components
that will wastes more money for maintenance
of machine and delay the truck returned to

work.

Temporary storing

The company requires taking the following
preventive measures when the storing period
of the truck is within 30 days:
1. Fully inspection, checking of the vehicle
and make some necessary maintenances

and modifications for preparing to use vehicle

when the expired of storing date has been
arrived.
2. Lubrication – Lubricate the truck thoroughly
according to the requirements specified in
Chapter  'CENTRALIZED  LUBRICATION
SYSTEM' of the Manual.
3. Parking  –  After  cleaning  the  truck
thoroughly, park it on a level ground which is
solid and dry, and then apply parking brake.
Remember  that  there  should  not  be  any
grease or oil on the ground because such
substance will make all tyres to expired.
4. Battery  –  If  the  local  temperature  is
moderate,  the  battery  may  be  keep  in  the
truck, and it may be recharged for using it
again if it is not used after 30 days. If possible,
send the battery to a workshop for inspection
and recharging, and ensure that it can be fully
charged by way of micro-current charging.
Keep the battery at a place free of encroaching
severe temperature under the cold or torrid
climate.
5. Rust protection – Clear off all rust over the
truck,  and  additionally,  cover  the  exposed
metal surface of the truck with quality rust
inhibitor.
6. Oil tank – Fill the fuel tank and hydraulic
oil tank to prevent moisture inside the oil tank
from getting condensed.
7. Tyre  –  Inflate  all  tyres  to  the  correct
pressure. During the period of storing, inspect
the pressure about once each two weeks.
8. Engine – Refer to the maintenance manual
of engine to learn the complete procedure for
storing the engine less than 30 days.

9. Transmission – Feed oil into the oil sump of
the transmission to the correct level.

Long-term storing within six months

When the truck is kept for over 30 days but
less than six months, the following steps must
be followed:
1. Inspection and maintenance – Follow the
procedures for temporary storing.
2. Lubrication – Follow Step 2 for temporary
storing.
3. Parking  –  Follow  Step  3  for  temporary
storing, and chock up the truck with sleepers
to keep the tyres off the ground.
4. Battery  –  Remove  the  battery  from  the
truck, keep it at an appropriate place, and
check it at least each 30 days (charge it once
or connect it to a micro-current charger upon
each inspection).
5. Rust  protection  –  Follow  Step  5  for
temporary storing.
6. Oil  tank  –  Follow  Step  6  for  temporary
storing.

7. Tyre – Deflate the tyres to 0.7 bar (10 pound

per square inch) after chock up the truck as
required in Step 3, clear all grease on the
tyres, and use suitable outer covers to protect
the tyres and keep them away from direct
sunshine and water erosion.
8. Transmission – Refer to the maintenance
manual of transmission to learn the complete
procedure for keeping it over 30 days.
9. Engine – Refer to the maintenance manual
of engine to learn the complete procedure for
storing it over 30 days.
10. Ventilator and respirator – remove all
ventilating holes and respirators and block
off all openings with covers; use waterproof
rubberized fabric to cover the ventilation holes
and respirators even if it is impossible.

Storing for over six months

When the truck is kept for over six months, the
following steps must be followed:

Others – storing of truck

Note

: In addition to the steps for the keeping

period less than six months, follow the following
additional requirements:
1. Lubrication – Lubricate the truck thoroughly
according to the instructions in Chapter
'CENTRALIZED LUBRICATION SYSTEM' of
the Manual.
2. Wheel bearing – remove, clean, inspect and
re-assemble all wheel bearings.

Caution

: Repeat the above steps once each

six months during the storing period.

Release of storing

1. Lubrication – Lubricate the truck thoroughly
according  to  the  instructions  in  Chapter
'CENTRALIZED LUBRICATION SYSTEM' of
the Manual.
2. Battery  –  Install  the  battery  and  check
whether  it  is  charged  full.  If  it  is  not  full,
recharge it as required.
3. Tyre – In reference to Chapter  'FRONT

WHEEL ASSEMBLY' of the Manual, inflate the

tyres to the normal pressure.
4. Fuel and hydraulic oil tank – Discharge the
oil left inside the oil tank, feed oil into it to the
correct level, take off the blanking cover of the
respirator, and install the respirator that has
been cleaned thoroughly.
5. Draining valve and respirator – Remove all
seals and screw cover at the joining part of
respirators, and then install all respirators and
draining valves.
6. Engine – Refer to the maintenance manual
of  engine  and  release  engine  keeping  as
provided.
7. Painting  –  Check  whether  the  truck  get
rusted or not and spray paint storing.
8. Transmission – Refer to the maintenance
m a n u a l   o f   t r a n s m i s s i o n   a n d   r e l e a s e
transmission storing as provided.

Reading Guide

Arrangement of chapters

The manual book which used to guide how to

does maintenance and fix the damaged truck.

there some contents is different, so please in
accordance with type of the truck to read it.
This Manual consists of the following chapters:
38 chapters in total, including: Front Wheel
Assembly,  front  axle  assembly,  Rear Axle
Assembly  and  Installation,  Rear  Wheel
Assembly, Installation of Engine, Transmission
and Mounting, Fender and platform mounting,
Cab and Mounting, Hydraulic Steering Pipeline
of  Operator’s  Cab,  Operator’s  Cab  Brake
Pipeline and Joint, Air Conditioning Pipeline
Installation, Fuel Tank and Mounting, steering
Pipeline and Joint, Hosit Pipeline and Joint,
Hydraulic Oil Tank Assembly, Brake Pipeline
and  Joint,  Transmission  retarder  control,
Frame and Installation, Driveline Installation,
Air  Cleaner  and  Mounting,  xhaust  System
Assembly, Rear Suspension System, radiator
Guard,  Body  and  Mounting,  Illumination
Lamp and Installation, Power Module, Hoist
Cylinder and Installation, Arrangement Plan
of SRT95C, Centralized Lubrication System,
Transmission Oil Filter Assembly, Disc Brake
Cooling System Pipeline and Joint, Brake Oil
Cooler and Installation, Oil Cooler Assembly,
Radiator and Mounting, Water Tank Mounting
and lines, Battery and Installation, Cables and
Harnesses, etc.

Distribution and Timely Revision

If there is any supplement or change to the
Manual, the relevant contents will be sent to
SANY Mining Equipment Co., Ltd. so that the
latest information may be got before operation.

Signs

In order to bring into full play the Manual, the
following signs are used regarding important
safety and quality requirements.

Sign

Item

Description

Safety

Pay special attention to
safety during operation

★

Caution

During  operation,  pay
special  attention  to  the
technical  requirements
and other notes to ensure
that the operation quality
may reach the standard.

Weight

It  is  required  to  pay
attention to the weight of
system  components  in
selecting  the  wire  rope
and operation posture.

Tightening
torque

U p o n a s s e m b l y, p a y
special attention to the
tightening torque of com-
ponents.

Coating

Parts required to coat
binding agent and lubri-
cating grease

O i l a n d
water

The parts for feeding
engine oil, water and fuel.

Discharge

The parts for discharging
oil or water and discharg-
ing volume.

Notes on hoist

If a component cannot be move off the truck
with a hoist machine, the following inspection
must be carried out:
1) Check  whether  all  tightening  bolts  at
the  component  to  be  moved  off  has  been
unscrewed.
2) Check  whether  there  are  any  other
components hindering the removal of the part.

Wire rope

1) Choose wire ropes according to the weight
of the part on the hoist machine and in
reference to the table below:

Reading Guide

Wire rope

Rope diameter

Permitted load

tons

9.8

11.5

13.7

1.4

12.5

15.7

1.6

21.6

2.2

27.5

2.8

35.3

3.6

43.1

4.4

22.4

54.9

5.6

98.1

176.5

274.6

392.2

The permitted load value is 1/6 or 1/7 of the
rupture strength of wire rope.

warning

The cumbersome components (above

25kg) that must be lifted with a hoisting

machine like crane is described in the

section 'Disassembly and Assembly'. All

parts over 25kg should be marked with

signs.

2) The wire rope must be hung between the
hooks.
If the wire rope is hung at an end of the hook,
it may escape from the hook, thus resulting in
serious accidents.
The middle part of the hook has the greatest
strength.
3) It is prohibited to use only a wire rope, and
it is required to use at least two ropes to wind
around the heavy for hoisting.

100%

88%

79%

71%

41%

SAD00479

warning

Only a rope is used, it may cause the

heavy to revolve during the process of

hoisting, and the wire rope get loosened

or the heavy slide away from original

binding position, hence causing dangerous

accident.

4) When hoisting a heavy heavy, the hoisting
angle of the wire rope and hook should not
be too large. When two or more wire ropes
are used to hoist an heavy, the stress borne
by each wire rope will increase with the
increasing hoisting angle. The table below
shows the changes in the permitted load value
at different angles when two wire ropes, each
of which may hoist 1000kg to the maximum,
are used to lift a heavy object.
When the two ropes are hoisted vertically,
they may lift 2000kg in total; when the hoisting
angle reaches 120°, the loading weight can
only reach 1000kg. On the other hand, at the
hoisting angle of 150°, when the two wire
ropes hoist 2000kg load, the stress they bear
will reach 4000kg.

Hoisting angle

Load weight

SANY SRT95C Off-Highway Truck. Service Manual - page 1