SANY SRT95C Off-Highway Truck. Service Manual

SUSPENSION  CYLINDER',  check  the
half  shaft  surface  and  internal  parts  and
components of left suspension cylinder for
damages.
4.  Check  the  lower  shaft  of  steering  arm
assembly(4)and  the  mounting  holes  of
steering cylinder and tie rod for wearing.If
damaged,repair or replacement is required.
5. Check each bearing of A-arm(7) for wearing
and looseness.

Installation

1.  According  to  Section  2.1.4"FRONT
SUSPENSION CYLINDER",restore the left
suspension cylinder assembly.
2.  Fix  steering  arm(4)in  the  lower  end  of
suspension cylinder(1)and tighten it up.
3.  Press  the  bearing(8)into  the  large-end
bearing hole of left A-arm(7)and use the A-arm
baffle(9)

、

bolt

（

）

and washer

（

）

press it tightly.Press the bearing

（

）

into the

small-end hole of left A-shape arm

（

）

and

clamped tightly by retainer ring

（

）

4. Insert the lower shaft of left steering arm
assembly

（

）

into the bearing

（

）

and left

A-shape arm

（

）

.Use the steering arm baffle

（

）、

bolt

（

）

and washer

（

）

to press

it tightly.thread the locking steel wire

（

）

and tighten it up.Retain the hex head side of
bolt

（

）

5. According to Section2.1.2"FRONT BRAKE
ASSEMBLY AND INSTALLATION",restore the
left front brake system and brake clearance
adjustment.
6.According to Section2.1.1"FRONT WHEEL
AND INSTALLATION",restore the front hub
and bearing clearance adjustment.
7.It is also allowed to complete Step 5 and 6
after the front suspension cylinder is installed
onto the ring beam.The sepuence depends on

specific situation.

Maintenance

According to the requirements in the

Front Axle Assembly

preventative maintenance manual, lubricate all
articulating points of the front axle on a regular
basis.

2.1.1 Front wheel and installation

Brake calipers

18,19

4,5

10,11

Fig.1 Sectional View of Front Wheel Assembly

1. Front wheel

8. Cover

15. Bushing

2. Bearing

9. Gasket

16. Plate

3. Bearing

10. Bolt

17. Bolt

4. Bolt

11. Washer

18. Bolt

5. Lockwire

12. Snap ring

19. Washer

6. Plate

13. Washer

20. Brake disc

7. Shim pack

14. Oil seal

Front Axle Assembly

Overview

The wheel is mounted on the axle spindle with
two tapered roller bearings mounted in the
hub. The brake disc is bolted to the wheel.
The tyre and rim assembly is mounted on the
wheel with clamps and nuts.

The wheel itself is a large cylindrical casting
with the bearing bores and other finished
surfaces machined after the wheel is cast.

Removal and Disassembly

Numbers in parentheses refer to Fig.1.

warning

To prevent personal injury and property

damage, be sure wheel blocks, blocking

materials and lifting device are properly

secured and of sufficient capacity to do the

job safely.

warning

To prevent personal injury and property

damage, completely deflate tyre by removing

the valve cap and core. Insert a thin wire
through the valve to be sure the valve is not

plugged. Even a flat tyre, in some cases, will
retain sufficient air pressure to blow off a rim

component with enough force to cause injury
or death.

1. Block the front and rear of all wheels, except
the one to be raised. Jack up or lift machine
so its weight is no longer on that wheel.
2. Deflate tyre completely, and remove the
tyre and rim assembly from the wheel. Follow
instructions under 'Removing Tyre and Rim
Assembly'. Refer to Section 1, Front Wheel
Assembly.
3. Relieve the pressure in the braking system.

Front Axle Assembly

Refer to Section 2.1.2, FRONT BRAKE
ASSEMBLY AND INSTALLATION. Disconnect
brake hydraulic line at brake caliper.
4. Remove brake caliper. Refer to Section
2.1.2, FRONT BRAKE ASSEMBLY AND
INSTALLATION.
5. Remove bolts (10) and washers (11) which
secure cover (8) to wheel (1). Remove cover
(8) and gasket (9).
6. Remove lockwire (5), bolts (4), plate (6) and
shim pack (7) from spindle. Retain shim pack
(7).
7. With suitable lifting equipment, pull wheel (1)
off of spindle, being careful that outer bearing
cone (3) does not fall.
8. If required, remove bolts (18) and washers
(19) securing brake disc (20) to wheel (1), and
remove brake disc.
9. Remove the bolts (17) which secure the
plate (16) to wheel, remove the plate(16).
10. Remove oil seal (14), using hammer and
soft drift.
11. Remove snap ring (12). Tap out washer
(13) and remove inner bearing (2) cone from
wheel.

Note

: Bearing cups and cones must always be

replaced as a matched set, never separately.
12. If required, remove bearing (2 & 3) cups
from wheel (1), by driving out with a soft drift.

warning

Be sure to use a soft drift and take care

when driving in bearing cups with a drift,

to avoid personal injury from chips or

fragments.

13. During operation, oil seal (14) rides on
bushing (15) which is shrunk on spindle to
provide a smooth contact surface for the seal.
If the bushing is found to be rough or worn,
remove bushing (15).

Inspection

Front Axle Assembly

1. Thoroughly clean all metal components,
except bearing cones, in a suitable solvent.
Dry with compressed air and coat all threaded
components with light oil to facilitate assembly.
2. Clean bearings in volatile mineral spirits
and wipe dry with a lint free cloth. Lubricate
lightly with light oil and spin by hand, to check
for wear and roughness. Replace with new
bearings if excessively worn, or if operation is
rough or noisy.
3. Inspect all machined surfaces of all parts
for scoring, pitting, corrosion and burring.
Resurface or replace with new parts as
necessary.
4. Inspect all threaded components, and repair
or replace as necessary.

Assembly and installation

Numbers in parentheses refer to Fig.1.

warning

To  prevent  personal  injury  and  property
damage,  be  sure  wheel  blocks,  blocking
materials  and  lifting  device  are  properly

secured and of sufficient capacity to do the job

safely.

1. If removed, heat bushing (15) to 170 -
205° C to expand it for installation. If heating
equipment is not available, heat the bushing
evenly to 205° C (400° F). This takes about 1
minute, using a torch with a heating tip. Use a
Tempilstik or other temperature gauge to make
sure the bushing is hot enough. Slide heated
bushing (15) on spindle and tap lightly with a
hammer to seat it.

Note

: Do not apply flame directly to bushing.

Place bushing on steel plate and apply flame

to centre of plate, to evenly distribute heat.
2. If removed, install bearing (2 & 3) cups
in their respective wheel (1) bearing bores
with care to avoid damaging their raceways.

Front Axle Assembly

Installation by press fit at ambient temperature

is best. Note that the cups must seat fully
against  the  shoulders  of  the  cup  bores  in
the wheel hub to assure retention of bearing
adjustment.  If  carbon  dioxide,  or  dry  ice,
freezing  of  the  cup  is  used,  remember  to
permit the cup and hub to warm to ambient
temperature after insertion and then to tap
them with a soft steel drift and hammer to
seat.
3.  Lubricate  the  bearings  with  lubricant
specified  in  Section  36.1,  'LUBRICATION
AND MAINTENANCE '. Do not pack bearings
solidly with lubricant, as too much is harmful.
Fill wheel cavity not less than one-third to not
more than one-half full with lubricant.
4. If removed, install brake disc (20) on wheel
(1) and secure with bolts (18) and washers
(19). Tighten bolts (18) to a torque of 1850-
1900 N·m.
5. Install inner bearing (2) cone, washer (13),
snap ring (12) and oil seal (14) in wheel end
facing spindle. Seal lip must be facing out.
6. Install the plate (16) and secure with the
bolts (17).
7. With suitable lifting equipment slide wheel
(1) assembly onto spindle.
8. Install outer bearing (3) cone on spindle and
seat in outer bearing (3) cup.

Note

: Ensure all dirt, grease, and oil is

completely removed from plate (6), shims (7)
and end of spindle to allow accurate setting of
the bearing pre-load.
9. Install plate (6), without shims (7) on end of
spindle, and secure with six bolts (4). Tighten
bolts (4) evenly in equal increments to 'initial
seating bolt torque' as specified in 'Bearing
Adjustment Table', while rotating and bumping
the wheel (1) assembly.
10. Remove bolts (4) and tap wheel (1)
assembly to free bearings.
11. Reassemble plate (6) without shims (7)
and using only two bolts (4) located 180°apart,
adjacent to the gauging holes in plate (6).

Front Axle Assembly

Tighten bolts (4) evenly in equal increments to

'Gauging Bolt Torque', as specified in 'Bearing

Adjustment Table', while rotating and bumping
wheel (1) assembly.
12. Determine gap between plate (6) and end
of spindle at both gauging holes. To determine
gap, use a depth micrometer in both gauging
holes to measure distance from outer face of
plate (6) to end of spindle. Measure thickness
of plate (6) with a micrometer. Subtract plate
thickness reading from depth gauge readings.
13. Average the two readings, obtained at Step
12, in increments of 0.025 mm (0.001 in) and
round off to the next higher 0.025 mm (0.001
in). This is the average gap. The required shim
pack (7) thickness is equal to the average gap
plus the tabulated constant as shown in the
'Bearing Adjustment Table'.
14. Install the required shim pack (7), plate
(6) and bolts (4) on the end of spindle.
Tighten bolts (4) evenly in equal increments

to 'Final Bolt Torque', as specified in 'Bearing

Adjustment Table', while rotating and bumping
the wheel (1) assembly. Secure bolts (4) with
lockwire (5).
15. Install gasket (9) and cover (8) and secure
to wheel (1) with bolts (10) and washers (11).
16. Install brake caliper, connect brake
hydraulic line and bleed braking system. Refer
to Section 2.1.2, 'FRONT BRAKE ASSEMBLY
AND INSTALLATION'.
17. Install tyre and rim assembly as described
under 'Mounting Tyre and Rim Assembly on
Wheel'.

Table of special torque

Initial seating bolt torque

Gauging bolt

Shim pack thickness

Final bolt torque

No. of

Bolts

N. M

No. of

Bolts

N. M

No. of

Bolts

N. M

135

Ave. Gap

+0.203

Ave. Gap

+0.008

390

Front Axle Assembly

2.1.2 Front brake assembly and

installation

6,7

5,6

3,4

1. Brake head

5. Bolt

2. Mounting plate

6. Washer

3. Bolt

7. Bolt

4. Washer

8. Brake disc

Fig.2-4 Installation of front brake

Front Axle Assembly

Operation overview

This service brake is of dry disc and caliper
type. The caliper is designed for use with

hydraulic oil meeting the specification Section

36.1 ‘LUBRICATION AND MAINTENANCE’.
Warning: It is not allowed to use synthetic

brake fluid.

Break head is bolted to a mounting plate on
the spindle. Brake disc is bolted to the wheel.
There are one set of brake head and one
brake disc at each wheel.
Each caliper brake head assembly consists of
one torque plate, two brake pads(one on each
side of the disc) and six brake pistons(three on
each side of the disc).
The brake is driven by the hydraulic oil
entering the internal oil supplying passage of
brake head. The piston bores on each side of
the torque plate are interconnected through
internal passages.
When braking is applied, oil pressure forces
the pistons against the brake pads which are
synchronously forced against each side of the
brake disc, slowing or stopping the disc and
wheel rotation.

Routine inspection

1.Inspect the brake pads for wear.If the
thickness of the friction material on the brake
pad is worn down to 3mm, the brake pad must
be replaced.
2.Inspect the brake disc for wear. Measure
the thickness of the brake disc at three points
which are in the annular area contacted with
the brake pad friction material, then determine
the average disc thickness.
If the average disc thickness is 22 mm or less,
the disc must be replaced. Refer to Chapter
1, 'FRONT WHEEL ASSEMBLY', for the break
disc replacement instructions.

Deflection of brake disc

The maximum allowable defection of brake

Front Axle Assembly

disc is 0.76mm when disc speed is below 100
rpm. If defection exceeds this value, replace
the brake disc or repair hub referring to
Chapter 1'FRONT WHEEL ASSEMBLY '.

warning

Continually using the break pads that

should have been repleaced when worn

to limits, will result in loss of braking and

possible catastrophic failure.

3 4

5 6

Fig.2-5 Disassembly of brake head

1. Housing

6. Seal ring

11. Brake pad

2. Dust boot

7. Backup ring

12. Bolt

3. Backup ring

8. Washer

13. Washer

4. Seal ring

9. Bolt

14. Bleeder valve

5. Piston

10. Cover plate

Front Axle Assembly

Remove and installation of brake pad

Refer to Fig.2-5 for numbers in brackets.
1. Place the truck in a flat work area, apply
parking  brake  and  shut  down  engine  and
rotate steering wheel towards both directions
for several times to release the pressure of
steering system.
2.  Chock  wheels  for  safety.  Set  the  main
switch of accumulator into the ‘OFF’ position,
and  remove  the  type  and  rim  referring  to
Section 1.1 ‘Front Wheel Assembly’.
3. Remove the check plate through loosing
the bolt (12) and washer (13) from one end
of brake head (the left and right positions of
check plate are not interchangeable).
4. Attach  a  bleeder  line  and  open  bleeder
valve(14).Insert  screwoperator  or  crowbar
between brake pads and brake disc to press
the pistons (5) into piston bores in the housing
as far as possible. Then close the bleeder
valve.
5. Rotate the brake pads (11) out of the open
end of brake head.
6.  Inspect  the  position  of  piston  (5)  for  oil
leakage, and the dust boot (2) for damage.
7.  Install  new  brake  pad(11)  with  friction
material to press brake disc tightly, and rotate
it into brake head.
8. Install the check plate in the position where

it was removed. Ensure that the flat tail seat in

grooves of the check plate, then use bolt(12)
and  washer(13)to  fasten  the  check  plate.
Tighten bolts(12)to a torque of 1000N·m.
9. Press down brake pedal until the brake
pads(5) presses brake disc tightly.
10. After  new  brake  pads  are  installed  on
the  truck,  the  following  operations  should
be  performed  to  achieve  optimal  brake
performance:
a. Drive the truck at the speed of 8~15 km/h
and apply braking. Increase pressure until the
truck produces dragging noise. In this process,
any occurrence of smoke or odor from the

Front Axle Assembly

brake pads is nomal.

Caution

: After stopping, measure the

temperature of brake disc with infrared
electronic thermometer.
b. Continuously cycle this process until the
temperature of brake disc reaches 315-370°C.
c. Repeat Steps a and b when the temperature
of brake disc is lower than 95°C.
d. When brake disc is cooled to less than
10°C above the ambient temperature, repeat
Steps a and b until the brake pads achieve the
brake performance according with applicable
goverment regulations.

warning

To prevent personal injury and accident

occuring, ensure that position the truck

firmly and lifting equipment is of sufficient

capacity before removing the brake pads.

Use extreme caution to prevent personal

injury when removing wheels. The

procedure must be adhered to as described

in Chapter 1'Front Wheel Assembly'.

Hands or fingers should be kept away

from the clearance between brake disc

and brake head piston to prevent personal

injury.

warning

Proper oil level should be maintained in the

hydraulic oil tank for steering and brake

control. Refer to Chapter 15 'Hydraulic Oil

Tank Assembly'.

Disassembly and assembly of brake

Refer to Fig.2-5 for numbers in brackets,

unless otherwise specified.

1. Position the truck in a level work area, apply
parking brake and shut down the engine.
2. Turn steering wheel in both directions

Front Axle Assembly

for  several  times  to  release  steering
system pressure. Press down brake pedal
continuously to release the pressure in brake
accumulators.  Chock  the  truck    for  safety.
Remove tyres according to the requirements
in Chapter 1'Front Wheel Assembly'.
3. Carefully loosen brake pipes at base of
both accumulators to check that pressure has
released. Then retighten brake pipes.
4. Remove hydraulic oil inlet line at brake
head assembly. Plug the line and brake head
to prevent entry of dirt.
5. Remove the bolt (3, Fig.1) and the washer
(4,  Fig.1).  Then,  remove  the  brake  head
assembly onto a workbench.
6. Disassemble the brake head assembly in
order of serial numbers. If necessary, maintain
and service the seal rings (4 and 6), backup
rings (3 and 7) and the dust boot (2). The parts
(12, 13 and 14) can be left in the housing (1).
7. New dust boot (2), seal rings (4 and 6)
and  backup  rings  (3  and  7)  are  contained
in the repair kit. Their quantity is enough to
reassemble a caliper brake head. All parts in
repair kit are utilized to replace damaged parts
every time the brake head is reassembled.
8. Inspect the brake pad (1) according to the
requirements of Step 1 in ‘Routine inspection’.
9. Clean the housing (1) and ensured that
no  solvent  remains  in  the  oil  passages  or
grooves. Inspect the dust boot, seal grooves
and  the  step  areas  between    grooves  for
damage or cracks. Small cracks or scratches
can  be  blended  with  crocus  cloth.  If  the
housing (1) is excessively corroded or the dust
boot and seal grooves are damaged, it should
be replaced. It is prohibited to repair the brake
head.
10. Inspect the piston (5) for small scratches
and  cracks,  and  blend  them  with  crocus
cloth. If severe cracks or scratches occur to
the piston or its chrome plate is worn off, the
piston should be replaced.

Front Axle Assembly

warning

To ensure the personal and property safety,

ensure that the truck is parked stably and

the anti-moving facilities are safe and

reliable so as to guarantee the operation

safety. At the same time, ensure that the

hoist device has sufficient hoist capacity.

Use extreme caution to prevent personal

injury when removing wheels. The

procedure must be adhered to as described

in Chapter 1'Front Wheel Assembly'.

To prevent unnecessary personal injuries,

release brake system pressure according

to operating procedure. In this operating

process, great care should be taken.

Assembly

Refer to Fig.2-5 for numbers in brackets,

unless otherwise specified.

Caution

: Refer to the specifications in Section

38.2 'Technical Conditions for Tightening
Moments of Standard Bolts and Nuts' for the
tightening torque of the fasteners which are

not especially specified.

warning

It is prohibited to use brake fluid.

1. Use petroleum base lubricating oil or
vaseline to lubricate the seal rings (4 and 6)
and the piston (5).
2. Install the seal ring (4), dust boot (2) and
backup ring (3) into the piston bore of housing
(1), and lubricate them according to Step 1.
3.Install the piston (5) into the housing (1) in
the following method. Install the lubricated
piston (5) in the specified position at a small
angle into the backup ring (3) and the piston
bore. Spread out the backup ring to make its
bore larger than external circumference of

Front Axle Assembly

the piston so that the piston can be rotated.
Inspect the forward extension between the
piston  and  the  backup  ring  along  external
c i r c u m f e r e n c e .   E n s u r e   t h a t   e x t e r n a l
circumference  lip  of  the  packing  retainer
remains in the groove in the piston bore.
4. After  the  piston  (5)  is  inserted  into  the
backup ring (3), the piston can be aligned by
feel over the seal ring (6) and one rotating
thrust force can be applied by hands to install
the piston into seal ring.
5.  When  assured  pistons  (5)  are  through
seal  ring(3),  pressure,  other  than  hand
pressure, may be used to press pistons (5)
the remainder of the way into the piston bores.
Snap open end of dust boot (2) into groove of
piston.
6. Install the seal ring (6) and backup ring
(7)  on  the  open  end  of  piston  bore  in  the
housing(1).
7. Subsequently, install the cover plate (10)
onto the housing with bolt (9) and washer (8).

Tighten the bolt (9) to a torque of 380 N•m.

8. If the brake disc (8, Fig.1) is excessively
worn, it should be replaced according to the
requirements in ‘Routine inspection’ in this
section. Refer to Chapter 1 'Front Wheel
Assembly' for the relevant replacement
instructions.

Installation

Refer to Fig.2-4 for numbers in brackets,

unless otherwise specified.

C a u t i o n

: R e f e r t o t h e S e c t i o n 3 6 . 2

'TECHNICAL CONDITIONS FOR BOLTS
AND NUTS ' for the tightening torque of the

fasteners which are not especially specified.

warning

To prevent personal injury and property

loss, ensure that the truck is chocked

and reliably stopped to ensure safe work.

Ensure that hoist device has sufficient

Front Axle Assembly

hoist capacity.

Use extreme caution to prevent personal

injury when removing wheels. The

procedure must be adhered to as described

in Chapter 1'Front Wheel Assembly'.

1. Install the washer (6) onto the bolt (5).
2.  Position  the  brake  head  assembly  over
brake  disc  to  align  with  connecting  hole
on  brake  mounting  plate. Then  screw  the
assembled  bolt  (5)  and  washer  (6)  into
housing through the mounting plate. Tighten

the bolt (5) to a torque of 610 N•m.

3. Remove plugs from brake head and
hydraulic oil inlet passages and reconnect
hydraulic oil circuit at the brake head.
4. Bleed the brake system according to the
requirements below the heading 'Bleeding' in
this section.
5. Install types and rims, referring to Chapter
1'Front Wheel Assembly'.

Bleeding

Refer to Fig.2-5 for numbers in brackets

warning

To prevent personal injury and property

loss, ensure that the truck is chocked and

reliably stopped to ensure safe work.

To achieve satisfactory braking, all the air in
brake hydraulic lines should be eliminated
according to the following requirements:
1. Refer to the requirements in Chapter 15
'Hydraulic Oil Tank Assembly', and check
the oil level in the oil tank as required. If
the oil level is low, add oil. The oil selected

should meet the specifications recommended

i n S e c t i o n 3 6 . 1 ' L U B R I C AT I O N A N D
MAINTENANCE'.
2. Connect a clean bleeder hose to bleeder

Front Axle Assembly

SANY SRT95C Off-Highway Truck. Service Manual - page 4