SANY SRT95C Off-Highway Truck. Service Manual

warning

To prevent personal injury and property

damage, be sure wheel blocks, blocking

materials and lifting equipment are

properly secured and of sufficient capacity

to do the job safely.

1. Place the truck in a flat area, apply parking

brake and shut down the engine.
2. The steering wheel turns for several circles
in the two directions to relieve the pressure in
steering system. Block all wheels, except the
one to be raised. Use wooden blocks 100 mm
x 100 mm (4 in x 4 in) or larger.
3. Support the truck with jack for removal of
tyre, but do not jack up the truck.
4. Completely deflate tyre by removing valve
cap and core. Check valve stem by running a
piece of wire through the stem to make sure it is
not plugged. See warning under 'Preparation
for servicing' .
5. Loosen the nut (11) on the wheel hub. But
do not remove from the stud (9).
6. Jack the truck up only as high as necessary
to remove wheel from truck, and place safety
blocks under the frame.
7. Support the tyre with a chain or rope of

sufficient strength attached to a suitable lifting

device. Remove the nut(11) and clamp(10)
from the wheel stud (9). Remove wedge band
(8) and lift tyre and rim assembly clear.
8. If inner tyre and rim assembly is being
removed, remove spacer band (7), attach a
lifting device to tyre and rim assembly, and
remove from truck.

Dismounting tyre from rim

Numbers in parentheses refer to Fig.2, unless

otherwise specified.

Note

: The following instructions are applicable

to use of hand tools. For procedures and
tooling required to dismount the tyre from the

2 3

Fig.2 Rim assembly

1. Outer flange

4. Rim

2. Bead Seat Band

5. Inner flange

3. Lock ring

Rear Wheel Assembly

rim, using hydraulic tools, contact the tyre
manufacturer.

warning

When lifting tyre from rim, be sure the

device is of sufficient capacity and properly

secured to do the job safely.

1. Completely deflate tyre if not done
previously. See warning under 'Preparation for
servicing' . Tape valve threads to protect from
damage, leaving valve end open to avoid any
possibility of trapping air inside the tyre.
2. As shown in Fig.3, break outer tyre bead

loose by placing the flat hooked end of a pry

bar, into one of the breaking slots (C) between

the bead seat band (2) and outer flange (1). A

length of pipe slipped over straight end of bar
will increase leverage. Twist straight end of
bar around toward tyre to break this portion of
bead. Another person may now insert another
pry bar of the same type into the slot between
the bead seat band (2) and outer flange (1),
and with the same twisting action, hold the

space gained with the first pry bar. Move first

pry bar all the way around the wheel, twisting
and following up with second pry bar, until
inner tyre bead is loose.
3. Start bead seat band (2) in away from lock
ring (3) by placing hooked end of pry bar in
groove of rim (4), between ends of lock ring,
and prying up with bar. Using two tools, as in
Step 2, work completely around wheel.
4. Pry lock ring (3) out in same manner by
starting at prying notch (B) in wheel, and work
all the way around wheel with the two pry
bars.
5. Remove and discard the O-ring (5, see
Fig.1).
6. After removing lock ring (3), pry out and
remove bead seat band (2). Outer flange (1)
can be removed now.

Fig.3 Pry Bar

Rear Wheel Assembly

7. Similar breaking slots are provided on the
inside of rims. The inner bead on the back
side of the tyre may be broken by using the
same method as in Step 2, for the outer bead.
If the wheel assembly is still on the truck,
another method which can be used is to place
a small jack between the inner flange and
some solid part of the frame. By extending the
jack, pressure is exerted, which forces the tyre
bead off the rim seat. Work around the wheel
until the bead is broken at all points.
8. Use a proper lifting device to lift tyre away
from rim. The dismantling of tyre is completed
in such a way.

Note

: If tyre and rim is on truck, and no lifting

device is available, the tyre can be separated
off the rim as follows: force bottom of tyre
outward as far as possible; lower jack enough
to allow weight of tyre to rest on ground; force
top of tyre out as far as possible; raise jack to
original height and repeat the above until tyre
is off rim.

Inspection

Tyre

Check interior surface of the tyre to determine
its condition. Inspect for cuts or fabric breaks
that have penetrated the tyre body. Inspect
closely for any sharp, pointed objects that may
have penetrated the tyre body but is invisible
from the outside. All dust, dirt, water or other
foreign matter should be cleaned from the
inside of the tyre.
Replace valve core assembly if condition is
questionable.

Rim assembly

Overload, improper tyre inflation, rough terrain,

high speed, accidents, dirt accumulation and
corrosion will reduce service life of rims and
rim components. It is recommended that
rims be inspected, as below, not less than at
every tyre change and, as the warranty limit
approaches, consideration be given to rim

Fig.4 Breaking Typical Tyre Bead Loose

Rear Wheel Assembly

replacement.

warning

N e v e r m i x c o m p o n e n t s o f o n e

manufacturer's rims with those of another.

Using the rim base of one manufacturer

with the lock ring of another or vice

versa is dangerous. The lock ring of one

may not fully engage with the lock ring

groove of the other. Always consult the

rim manufacturer for proper matching and

assembly instructions.

Also, use of damaged, worn out, or

improperly rim assemblies is a very

dangerous practice. Failure to comply

with the above warnings could result in

explosions from tyre pressure causing

serious personal injury and property

damage.

1. Clean all rust and dirt from rim parts.
2. Coat parts with primer paint, allow thorough
drying before assembling.
3. Inspect rim assemblies (Fig.2) for bent,
cracked, distorted, battered, and rusted
parts which may have resulted from abusive
practices outlined above. Replace any
damaged parts with new parts.
4. Discard 'O' ring and replace with a new one.

Note

: Handle 'O' rings carefully, as damage

will prevent an airtight seal for tyre inflation.

Mounting tyre on rim

Numbers in parentheses refer to Fig.2, unless

otherwise specified.

warning

When lifting tyre onto rim, be sure the

device is of sufficient capacity and properly

secured to do the job safely.

Rear Wheel Assembly

1. If tubeless tyre valve assembly was
removed from rim, install this assembly in the
rim valve hole and tighten securely.
2. Whether the rim (4) is on or off the truck,
tyre installations are performed in basically the
same manner. For off-truck installations, lay
the rim on blocks with 'O' ring groove up. The

rim should be just off the floor enough so the

tyre rests on the rim and does not touch the

floor. The blocks should not extend more than

13 mm (0.5 in) beyond the rim base, so they

won’t interfere with inner flange (5).
3. Install the inner flange (5) onto the rim (4).

4. Before assembly of tyre to rim, lubricate
both tyre beads and new 'O' ring (5, Fig.1)
with a thin solution of vegetable base soap
and water. Make sure tyre valve assembly is
securely in place. Lower the tyre onto the rim,

seating tyre firmly against inner flange (5).
5. Install outer flange (1) on rim (4).

6. Install bead seat band (2) on rim (4).
7. Install lock ring (3) in groove of rim (4).
Use pry bar for this operation, as illustrated in
Fig.5.
8. Force bead seat band (2) past 'O' ring
groove in rim (4) by prying, or with lift truck
forks. Use blocking between the forks and tyre
to prevent tyre damage. Lubricate area of rim
adjacent to 'O' ring groove with a thin solution
of soap and water or another approved
lubricant which is not harmful to rubber. Avoid
using an excessive amount of lubricant. Insert
a new 'O' ring (5, Fig.1) in the groove of the
rim behind the lock ring.
9. Lift tyre upwards to effect a seal between
bead seat band (2) and 'O' ring (5, Fig.1). In
some cases the tyre will automatically spring
out, if this step is neglected,

Mounting tyre and rim assembly on wheel

Numbers in parentheses refer to Fig.1.

Fig.5 Installation of Lock Ring

Rear Wheel Assembly

warning

Be sure lifting equipment is of sufficient

capacity and properly secured to do the

job safely.

1. Support inner tyre and rim assembly with a
chain or rope sling attached to an overhead
lifting device and slide onto wheel (4) of the
truck. Side with lock ring (6) and bead seat
band (3) should be facing outward.
2. Install outer tyre and rim assembly in the
same manner, except with bead seat band (3)
and lock ring (6) facing inward, toward spacer
band (7). Install wedge band (8).
3. Install clamps (10) and nuts (11) on studs (9).
Gradually tighten wheel nuts opposite each
other, until all nuts are snug, torque tighten
wheel nuts (11) to 1000 N. M-1300 N. M.
Re-tighten nuts after a few hours operation.

Note

: The fastener torque should be checked

regularly, particularly on new truck or newly-
installed wheels, to maintain the required
wheel rim-clamp load. A newly installed wheel
or a new truck should be checked at 30 day

intervals until rim fasteners show no significant

torque loss from the previous check. After
that, a 90 day torque check interval should be
adequate.

Tyre inflation

warning

To prevent personal injury and property

damage, the tyre and rim assembly should

be placed in a safety cage before inflating.

If no safety cage is available or tyre is on

the truck, the tyre and rim assembly should

be wrapped with safety chains or with

cables before inflating.

Even with these precautions remember

that air-blast is a potential hazard. Tyre

Rear Wheel Assembly

inflation should be carried out away from

busy working areas.

To prevent personal injury and property

damage, never stand or sit in front of a

mounted tyre during tyre inflation. Use

a clip-on air chuck with a long hose and

stand to one side while the tyre is being

inflated.

To prevent personal injury and property

damage, always prevent flammable vapours

that could produce tyre explosions, from

being pumped into tyres during inflation,

by observing the following precautions:

1. Use an air compressor and reservoir

located inside a heated building, when

available, so that alcohol, methanol, or

other flammable antifreeze liquids are not

needed in the air tanks to prevent moisture

freezing in the tank and lines in subfreezing

temperatures.

2. Make sure that paints, lacquers, paint

thinners, or similar materials that produce

volatile, flammable vapours are not used or

stored near the air intake of the compressor

that supplies the air for inflating tyres. The

compressor should be isolated from all

such sources of flammable vapours.

3. Be sure to thoroughly flush and blow off

all flammable solvents used for cleaning

the air compressor inlet screen before

using the compressor for tyre inflation, or

any other purpose.

4. Do not charge batteries, near the air

inlet of a compressor used for inflating

tyres. Charging batteries produces highly

explosive hydrogen gas which can be

readily drawn into a nearby compressor

inlet and pumped into the tyre.

5. Never exceed the specified concentration

of alcohol when adjusting the alcohol

vaporiser, or adding alcohol to the auxiliary

air tank, used on machine air systems to

prevent freezing or moisture condensate

in below-freezing temperatures. Excessive

Rear Wheel Assembly

Fig.6 Tyre Inflation Safety Cage

Fig.7 Nitrogen Tyre Inflation Kit

alcohol, added to the air tanks can produce

flammable vapours that will be pumped

into a tyre when this air supply is used for

tyre inflation if the tyre inflation kit is not

equipped with a moisture filter.

6. Another source of hazardous flammable

vapours in tyres is the tyre bead lubricant.

Always use bead lubricants that do not

introduce flammable vapours into the tyre.

Inflation

Note

: To prevent moisture corrosion of internal

rim parts, use tyre inflation equipment with an

air filter that removes moisture from the air
supply, when available,
1. If the tyre is off the truck, it should be placed

in a safety cage before inflating. See Fig.6.

2. Inflate all tyres with ratings of 16-ply and
above to 0.52 Mpa to seat beads and seal
'O' ring, then adjust to the recommended
pressure.
3. For recommended operating air pressure,

refer to the chart 'Tyre Inflation Pressures'.

Nitrogen tyre inflation

Note

: All Warnings and procedures under

'Tyre Inflation' will apply, except for differences

covered by this passage.
In certain environments it is recommended
that tyres be inflated with dry nitrogen gas,
and that the resulting oxygen content of the
inflation does not exceed 5%. All machines
whose  tyres  are  factory  inflated  with  dry
nitrogen gas will be identified by a decal on
the body or frame.
Nitrogen gas improves tyre pressure retention,
increases  tyre  life  by  reducing  carcass
oxidation  from  within,  minimizes  rim  rust
and has no detrimental effects on the tyre. It
also reduces the potential of a tyre explosion
because it is an inert gas and will not support
combustion inside the tyre.
The same tyre inflation pressure used for air

Rear Wheel Assembly

inflation should be used for nitrogen inflation.
Tyre valves formerly used with air inflation are

entirely satisfactory for use with nitrogen gas.

Nitrogen tyre inflation kit

warning

DO not use charging assembly for tyre

inflation because this assembly does not

include a pressure regulator, safety relief

valve, and adequate pressure gauging

which is mandatory for tyre inflation. Tyre

volume is as much as 90 times greater than

the average accumulator volume and it

takes very much longer to inflate a tyre - up

to 40 minutes or more for very large tyres.

Nitrogen gas cylinders used to inflate tyres

are generally charged to approximately

15.2Mpa. A tyre blowout or rim failure could

occur if inflation equipment is not properly

used. Proper nitrogen charging equipment

and personnel training can avoid over

inflation.

1. A nitrogen tyre inflation kit is available from

your dealer and consists of the following.
Refer to Fig.7.
a. Pressure regulator, 0 – 1.3 Mpa, with two
dual pressure gauges.
b. Safety relief valve, 0.86 Mpa, that will
assure an upper limit to the pressure available

for tyre inflation.

c . A 1 5 l e n g t h o f f l e x i b l e h o s e w i t h

interconnecting fittings. On the tyre end of the

hose is a large bore quick connect.
2. The pressure regulator is connected to a
nitrogen compressed gas cylinder available
from local suppliers.
3. The usual procedure for using this type of
equipment is as follows:

a. Connect nitrogen tyre inflation kit to nitrogen

compressed gas supply. DO not connect quick

Rear Wheel Assembly

connect to the tyre valve at this time.
b. Open valve on nitrogen supply.
c.  With  flexible  hose  and  quick  connect
connected  to  nitrogen  tyre  inflation  kit
assembly but not connected to the tyre, adjust
pressure regulator so that its output pressure
is  not  more  than  0.14Mpa  higher  than  the

desired tyre inflation pressure.

d. Connect quick connect to the tyre valve.
The tyre will now inflate. Tyre pressure can
be monitored by observing the gauge at the
pressure regulator.
e. When desired inflation pressure has been
achieved, back off the regulator or close the
valve on the compressed gas cylinder.
f. Remove the quick connect and adjust the
tyre pressure with the tyre gauge in the usual
manner.

Re-inflation of a mounted tyre

To re-inflate a tyre with dry nitrogen gas which
is now inflated with air, proceed as follows:
1. Deflate the tyre until the air in tyre reaches

the atmospheric pressure.
2. Re-inflate the tyre using only dry nitrogen
gas to 0.41Mpa gauge as a minimum, or to
bead-seating pressure as a maximum.
3. Adjust to the service inflation pressure
required:
a. If the required service inflation pressure is
less than 0.41Mpa remove the quick connect
and adjust the pressure with the tyre gauge in
the usual manner.
b. If the required service inflation pressure is
greater than 0.41Mpa, continue inflating with
dry nitrogen gas only, to the pressure level
required. Then remove the quick connect and
adjust the pressure with the tyre gauge in the
usual manner.

New tyre mounts and remounts

To newly mount or remount a tyre to rim,
use only dry nitrogen gas; this includes the
pressure required to seat the beads. After

Rear Wheel Assembly

seating the tyre beads, remove the quick
connect and adjust the pressure with the tyre
gauge in the usual manner.

Note

: Although a little more nitrogen gas

is  used  to  seat  beads  than  that  used  for
reinflation  of  a  mounted  tyre,  its  cost  is
generally  negligible  in  comparison  to  the
time and labour saving and, longer tyre life
achievable with the reduced oxygen content
which results.

Hydraulic bead breaking tool

The hydraulic bead breaking tool illustrated
in Fig.8 is specifically designed to break tyre
beads on rusted rims, and is available from
your dealer. Refer to Special Tools. It can
be used on rims having pry bar slots. The
recommended procedure for using this tool is
described below.
1. Prepare for dismantling tyres according to
the necessary steps in the ‘Preparation for
servicing’ and ‘Dismantling tyre from Rim’.
2. Completely deflate tyre if not done
previously. See warning under 'Preparation for
servicing'. Tape valve threads to protect from
damage, leaving valve end open to avoid the
possibility of trapping air inside the tyre.
3. Place the lip of the hydraulic tool in one of

four breaking slots between the flange and the

bead seat band.
4. Adjust locking screw to a position which will
hold the tool in a line perpendicular to the face
of the rim.
5. Close valve on the hydraulic pump and
apply pressure to take up the slack in the
tool and rim parts. This will cause the tool to
tilt slightly downward. Release pressure and
adjust the screw again so that the tool will be
perpendicular to the rim when under pressure.

6. Apply enough pressure to move the flange

back approximately 13 mm (0.5 in) and hold
this distance by dropping a nut, or similar
object, in the space between the flange and
the bead seat band.

Fig.8 Typical Hydraulic Bead Breaking Tool

Rear Wheel Assembly

7. Release pressure and move the tool around
the rim in either direction. Insert lip of tool
between bead seat band and flange. Repeat
cycle until 3/4 of the rim circumference has
been covered. Apply pressure at this point
until bead breaks loose.
8. Remove lock ring, bead seat band and
flange as described under 'Dismounting tyre
from rim'.
9. After lock ring, bead seat band and rim
flange have been removed, inner bead must
be broken loose according to Steps 3-7 for
breaking outer bead.

warning

Whenever a tyre is exposed to excessive

heat such as a truck fire or overheated

brakes the hazard of a subsequent violent

tyre explosion must be recognized. All

persons must avoid approaching the truck

so as not to be physically endangered in

the event of an explosion of the tyre and

rim parts. The truck should be moved to

a remote area, but only when this can be

done with complete safety to the operator

operating or towing the truck. All other

persons should stay clear of the truck.

The fire or overheated brakes, wheel, etc.

should be extinguished or cooled from a

safe distance. Do not attempt to extinguish

the fire or cool the machine by use of hand-

held fire extinguishers.

If it is absolutely necessary to approach a

truck with a suspect tyre, approach only

from the front or the back. Stay at least

15 m (50 ft) from the tread area. Keep

observers out of the area and at least 460

m (1 500 ft) from the tyre sidewall. Refer to

Fig.9. The tyre should be allowed at least

8 hours cooling time after the machine is

shut down or the fire extinguished before

approaching closer.

There is always a possibility of a tyre

Fig.9 Do Not Approach Tyre in Shaded Area

At least 15m

At least 360m

Rear Wheel Assembly

explosion whenever the smell of burning

rubber or excessively hot brakes is

detected. The danger is also present when

a fire on the truck reaches the tyre and

wheel area. Under such conditions, all

personnel must avoid approaching the

truck in a manner that could result in injury

should an explosion actually occur. Move

the truck to a remote area only if it can be

done without endangering the operator or

other personnel in the area.

DO not weld on or heat rim components.

For several years the company and tyre

and rim manufacturers have warned

users never to weld rim components with

the tyre mounted on the rim. The gases

that build up inside the tyre during arc

welding or heating on rim components can

ignite, resulting in one of these explosive-

like failures of the tyre and rim. It is

recommended to scrap the part if heat is

necessary to repair any rim component.

Tyre maintenance

Tyre repairs

Prompt repair of tyre injuries will prevent small
injuries from enlarging and causing tyre failure.
Use the best tyre repair facilities available.
If good repair facilities are not available,
have the nearest dealer make the necessary
repairs.
Minor cuts, snags, or punctures should be
repaired upon discovery. Skive with a sharp
pointed knife around any cut in the tyre tread
area that is of sufficient depth or shape to
hold pebbles or dirt. The angle of the skive

should be no more than sufficient to expel all

foreign material and should extend no deeper
than the breaker. The skive should go to the
bottom of the hole. Tyres with shallow cuts, if
treated promptly, may be allowed to continue
in service. If the cut extends deeper into the
tyre carcass, the tyre should be removed for

Rear Wheel Assembly

repair. Ordinary tubeless tyre punctures can
be repaired without removing the tyre from
the rim. Use tyre repair plugs and follow the
directions given by the manufacturer.
The tyre must be removed from the rim to
repair larger punctures or cuts. Irregular
shaped punctures or cuts less than 13 mm in
size can be repaired with a plug and hot patch.
Insert a repair plug into the hole to keep out
moisture and to back up the hot patch. Trim

the plug off flush with the inside of the casing,

buff, and apply the hot patch according to
the instructions supplied with the hot-patch
equipment.
Punctures 13 mm or larger, large cuts, or
bruise breaks require sectional or reinforced
vulcanized repair. Cover the repair patch with
a layer of cushion gum after application to the
tubeless tyre to ensure an airtight repair. Any
cords of the inside ply that are exposed in
bugging and are not covered with repair patch
must be coated with cushion gum to prevent
air leakage into the carcass plies on tubeless
tyres.

Recapping and retreading

There are two general methods employed in
restoring the tread surface of off-the-highway
tyres: recapping and retreading.
A recapped tyre has a new tread cured right
over the old tread surface.
A retreaded tyre has the old tread removed
entirely and a new tread cured directly onto
the body of the tyre. A tyre can be recapped
or retreaded if the cord body is free of cuts,
bruises and separation, and is thoroughly
sound, including previous repairs.

Tyre Care

To obtain maximum service from off-the-
highway tyres, a few common-sense
precautions should be followed.

Rear Wheel Assembly

Maintain correct inflation

Most tyre damage are caused by improper

inflation. Both over-inflation and under-inflation

are detrimental to tyre life. Tyre pressure
should be checked daily, preferably before
the truck is placed in operation, see the

instructions in 'Tyre Inflation Pressures'.

The valve cores should be checked for leaks.
Keep in mind that valve cores are delicate
mechanisms that wear out in service; therefore,
they should be replaced when they become
worn. Each tyre should be equipped with a
valve cap to prevent dirt from damaging the
valve core and causing air leakage.

Maintain good haul roads

Because haul roads are considered temporary
roads, they are frequently neglected. The
better the haul road, the longer the tyre and
machine life of off-the-highway equipment.

Note

: Although it takes time and effort to

maintain good haul roads, delay and cost of
tyre and machine breakdowns caused by poor
haul roads is many times greater.

Inspect tyres regularly

A  systematic  plan  for  tyre  inspection  will
more than pay for itself in lowered tyre costs
per  hour  of  operation. All  tyres  should  be
checked  regularly  for  cuts,  bruises,  fabric
breaks, excessive or uneven wear, embedded
foreign matter, and any other damage which
can be repaired. A considerable increase in
tyre service can be realized if tyre injuries
are repaired before they have progressed to
the irreparable stage. The rim mounting nuts
should be checked periodically and tightened
to the recommended torque.

Prevent overloading

Mining dump trucks are designed to carry a
maximum allowable payload.

Note

: Excessive loading will overstress both

the machine and tyres and shorten the life of

Rear Wheel Assembly

both.

Prevent tyre contact with oil

Prevent tyre contact with petroleum products.
Rubber that is exposed to oil, petrol, or grease
becomes soft and spongy and deteriorates
rapidly. Always avoid driving truck equipped
with rubber tyres through a puddle of petrol,
fuel oil, lubricating oil, or grease. Never let a
tyre stand in an oil or grease spot overnight.

Store tyres properly

The best of care given to tyres in service by
operators and maintenance personnel can
be completely nullified by careless storage.
Time is not the only contributing factor to the
deterioration of rubber products. Therefore,
tyres that are to be stored must be protected
from light, heat, oils, dirt, moisture and ozone.
Stored tyres should be carefully covered with a
tarpaulin or some other suitable material, such
as opaque plastic sheets, to prevent contact
with the contaminants listed.

Proper handling of tubeless tyres and rims

Tubeless tyres should be stored vertically.
Horizontal stacking may compress the tyre
walls  making  inflation  difficult.  If  tyres  are
stored in racks, the lower supporting members
should provide as broad a surface as possible
to the tyre tread to avoid a concentration of
load.
The beads of tubeless tyres must be protected
from damage or a faulty air seal will result. Do
not use hooks, cables, or chains in contact
with the tyre beads when lifting these tyres.
If forklift trucks are used for handling, they
should be equipped with broad, well rounded
arms  to  distribute  the  load  and  prevent
damage to the tyre bead. When handle tyres
with  the  fork  truck,  do  not  scrape  the  fork
across the bead.
Tubeless  tyre  rims  perform  an  important
function  as  part  of  the  assembly  air  seal.

Rear Wheel Assembly

SANY SRT95C Off-Highway Truck. Service Manual - page 13