SANY SRT95C Off-Highway Truck. Service Manual

Proper care therefore must be taken not to
distort or mutilate the rim parts, because they
must mate properly to form part of the basic air
chamber. Since the rim base, bead seat band,

and flange are endless, distortion may prevent

easy assembly as well as possibly resulting in
no seal.
Never drop, tumble, or roll rim parts.
If rim parts are stored outdoors they should be
given a protective coat of a good commercial
primer.
Similar parts should be stacked neatly to
prevent distortion.
Babbitt or lead hammers, not sledge hammers,
should be used in assembling rims.
'O' rings are seals and should be carefully
stored in a cool, dry place where they will not
be damaged.
Valve cores also should be stored in a cool,
dry and clean place.

Special Tools

Refer to Section 38.3, SERVICE TOOLS, for
part numbers of special tools outlined in this
section and general service tools required.
These tools are available from your dealer.

Tyre Inflation Pressures

E3 tyres may be so roaded up to 48 km/h (30
mile/h), maximum, with a 30 minute cooling
stop after each 80 km (50 miles) or 2 hours
sustained operation - whichever occurs first
-  and  a  60  minute  cooling  stop  after  each
aggregate of 4 hours of operation.
E4 tyres may be so roaded up to 32 km/h (20
mile/h), maximum, with a 30 minute cooling
stop after each 32 km (20 miles) or 1 hour of
sustained operation - whichever occurs first
-  and  a  60  minute  cooling  stop  after  each
aggregate of 4 hours of operation.
Normal  inflation  pressure  of  bias  tyres
(27.00-49 48PR) is 0.575 Mpa. Specific job
conditions, terrain, haul road maintenance
and length, maximum and workday average

Rear Wheel Assembly

speed, job t-km/h (ton-mile/h) required and
tyre t-km/h (ton-mile/h) capacity, etc., may
require an increase in inflation pressure. It is
recommended that for tyres both listed and
unlisted the user consult the tyre manufacturer
and evaluate all job conditions in order to
make the proper selection.

Technical conditions of special torque

Fig.

NO.

Item

No.

Item

Name

Torque

N•m

lbf•ft

Nut

1000~1300

740~960

Tubeless Tyre Leak Diagnosis

Occasionally a tubeless off highway tyre/rim assembly may leak in field service. To determine cause
of leakage, the entire assembly including valve hardware, multi-piece rim assembly, 'O' ring and
tyre should be checked using a soap solution.
This table lists various causes of air loss and possible remedy.

Causes

Remedy

Defective valve

Tighten parts. Replace defective parts. Use
valve caps.

Cracked rim or weld

Replace defective parts

Warning

Do not attempt repair of wheel components.

Twisted or damaged 'O' ring

Replace 'O' ring (lubricate)

Tyre cuts and snags

Repair tyre damage

Bead area awl holes

Repair inner liner (preferred)

Rear Wheel Assembly

Leakage between tyre bead trim

With tyre removed from rim:
Clean tyre beads in rim contact area
Clean rim with wire brush
Inspect 5

tapered bead seat band and the rim

base in the bead seating area to determine if the
transverse weld trims are flat or concave.
Replace defective part.
Weld trim should follow rim contour.

Mount tyre using a lubricant such as Murphy's
Tyre and tube Mounting Compound, or
equivalent, on tyre beads and rim bead seat
area.

Rear Wheel Assembly

5 INSTALLATION OF ENGINE

5.1 Engine and Mounting

Overview

Numbers in parentheses refer to Fig.1.
For engine make, model and specification,

Fig.1 Engine and Mounting

1. Engine

11. Bolt

21. Nut

2. Engine - power takeoff

12. Washer

22. Bolt

3. Fan

13. Bolt

23. Washer

4. Double-gear pump

14. Bolt

24. Nut

5. Gear pump

15. Washer

25. Bolt

6. Rear mount

16. Bolt

26. Washer

7. Washer

17. Snubbing washer

27. Compressor

8. Washer

18. Shock mount

28. Crossmember

9. Bolt

19. Snubbing washer

29. Front support

10. Washer

20. Washer

Installation of Engine

refer  to  Section  36.4,  ‘Specifications
of  SRT95C  Mining  Truck’.  For  engine
servicing and repair data refer to the engine
manufacturers service manual. The engine
is mounted to the frame at three points by a
mounting assembly (28 and 29) at the front of
engine (1) and two rear mounts (6). Rubber
Shock  Mount  (18)  through  engine  mounts
provide sufficient flexibility to absorb varying
engine vibration and torsional loads. There

are four full-flow oil filters, two fuel filters and
two coolant filters mounted on the engine (1).

There are a alternator at the front right hand
side of engine, and two starting motors at the
rear left hand side of engine.

Removal

Numbers in parentheses refer to Fig.1.

warning

To prevent personal injury and property

damage, be sure wheel blocks, blocking

materials and lifting equipment are

properly secured and of adequate capacity

to do the job safely. High electrical current

can cause sparks and personal injury from

burns. Turn ignition key switch to the 'Off'

position before removing any components.

Remove battery ground cable first, and

reconnect last, to avoid damaging electrical

components.

Note

: Tag all cables, harnesses, lines and

pipes disconnected during removal to aid in
installation.
1. Position the vehicle in a level work area,
ensure the body is fully lowered, apply the
parking brake and switch off the engine.
2. Turn steering wheel several times to relieve
pressure in the steering circuit. Block all road
wheels.
3. Disconnect battery cables from battery

Installation of Engine

terminal ports before starting removal

procedures. Disconnect ground cable first.

The connectors of electric components should
be disconnected in the following order:
a. Disconnect the ground cable of battery
compensator
b. Disconnect battery cables from battery

terminal ports (Disconnect ground cable first)

c. Disconnect the positive cable of battery
compensator
d. Disconnect the connector of ECU
4. Remove mounting hardware securing the
hood on the vehicle. Remove hood assembly
from the vehicle.
5. Disconnect electrical connections from the
radiator guard and remove mounting hardware
securing the radiator guard on the vehicle.
Remove radiator guard from the vehicle.
6. Place a suitable container under the engine
drain port, remove drain plug and drain the oil.
After draining, reinstall drain plug in the engine
sump and tighten securely.

warning

Harmful gas. Before disconnecting any air

conditioner lines refer to Refrigerant

will rapidly freeze all objects with which

it comes into contact, and it can cause

serious damage to the skin and eyes.

7.  If  the  truck  is  equipped  with  an  air
conditioning  system,  evacuate  refrigerant
from the system and disconnect lines at the
compressor. Refer to Section 5.2, ‘Compressor
Installation’.
8. With suitable containers in position, open
drain cocks and drain coolant from the radiator
and engine (1) assembly. Close all drain cocks
after draining.
9. Identify cooling lines for ease of installation
and  with  suitable  containers  in  position,
disconnect cooling lines from engine (1). Cap

Installation of Engine

open line ends and fittings.

10. Using suitable lifting equipment, carefully
remove  the  radiator  assembly  from  the
vehicle. Refer to Chapter 32, ‘RADIATOR AND
MOUNTING’.
11. Disconnect and remove air cleaner intake
pipe from the engine turbocharger and air
cleaner.
12. Disconnect and remove exhaust tube from
the engine turbocharger.
13.  Disconnect  the  throttle  cable  from  the
engine (1).
14. Identify heater lines for ease of installation
and,  with  a  suitable  container  in  position,
disconnect heater lines from engine (1). Cap

open line ends and fittings.

15.  Close  fuel  shutoff  valve  at  filter  head,
identify  fuel  lines  for  ease  of  installation
and,  with  a  suitable  container  in  position,
disconnect fuel lines from engine (1). Cap

open line ends and fittings.

warning

Heavy assembly. To prevent personal injury

and property damage, be sure lifting device

is of adequate capacity and properly

secured to do the job safely.

16.Identify all electrical harnesses and cables
attached to engine (1) for ease of installation
and disconnect from engine (1).
17. Disconnect driveline from engine coupling
and secure clear of engine (1). Refer to
Chapter 19, ‘Transmission Shaft Installation’.
18. Remove the bolts (9) and the washers (7
and 8). Remove the double-gear pump (4) and
gear pump (5) from the engine power takeoff
(2) .

Note

: The hydraulic lines can be left attached

to the double-gear pump (4) and gear pump
(5).
19. Remove bolts (16), Snubbing washers

Installation of Engine

(17,19),  Shock Mounts(18), washers (20) and
nuts(21) securing Crossmember (28) to front
mounting (29). Remove bolts (16),  Snubbing
Washers(17,19), Shock Mounts (18), washers
(20)  and  nuts(21)  securing  rear  mounting
brackets (6) to the frame.
20.  Remove  the  disc  brake  oil  cooler  and
gearbox oil cooler from the Crossmember (28).
21. After the oil coolers are removed, remove
the bolt (22), washer (23) and nut (24). Remove
the Crossmember (28) from the frame.
22. Identify all electrical harnesses and cables
attached to engine (1) for ease of installation
and disconnect from engine (1).
23. Check to make certain that all necessary
line and electrical disconnections have been
made before lifting engine (1).
24. Carefully lift engine (1) assembly clear
of the frame and move to a clean work area.
Securely mount engine (1) assembly to a work
stand.

Disassembly

Numbers in parentheses refer to Fig.1.
1. If required, remove bolts (14) and washers
(15) securing front mount (29) to engine (1).
Remove front mount (29) .
2. If required, remove bolts (13) and washers
(12) securing rear mounts (6) to engine (1).
Remove rear mounts (6).
3.  If  required,  remove  bolts  (25)  and
washers  (26)  fixing  the  compressor  (27),
loosen compressor drive belt, Remove the
compressor (27) from the engine (1). Refer to
Section 5.2, ‘Compressor Installation’.
4.  Remove  bolts  (11)  and  washers  (10)
securing fan to engine (1) then remove fan.
5. Loosen the fan hub mounting bolts and
turn the adjusting rod anticlockwise enough to
allow slack in poly 'V' belts. Remove poly 'V'
belts.
6.  If  necessary,  the  shaft  coupling  can  be
removed from the flywheel after the power
takeoff assembly is removed. Refer to section

Installation of Engine

5.1.1, ‘Engine POWER TAKEOFF AND
INSTALLATION’.
7. Take down the bolt and washer from the
removed PTO. Remove the shaft coupling
from the engine (1).

8. When removing the filters, plug the ports to

avoid grit and dust enter engine, as described
under 'Maintenance'.
9. If necessary, Refer to the Engine Service
Manual.

Inspection

See Fig.1 for the numbers in brackets.
1. Inspect shock mounts (18) for damage and
replace if damaged.
2. Check all mounting components for cracks
and  excessive  wear.  Repair  or  replace  as
required.
3. Inspect shaft coupling, joint for wear or
damage and replace if necessary.
4. Replace all filters. Check all drive belts
for  tension  and  wear,  as  described  under
'Maintenance'.
5. Refer to the Engine Service Manual for
additional  engine  disassembly/assembly,
repair, adjustment and tune-up procedures.

Assembly

Numbers in parentheses refer to Fig.1.

Note

: Tighten all fasteners without special

torques specified to standard torques listed
in Section 38.2, STANDARD BOLT AND NUT
TORQUE SPECIFICATIONS.
1. Remove the caps and Position the new

filters, as described under 'Maintenance'.

2. If the oil filling pipe has already been

removed, Position the oil filling tube and filter
assembly to the engine and fix them with the

grip. And the secure the bolts, washers and
nuts.
3. Position the shaft coupling and power take-
off(2) to engine (1) , secure the bolts and
washers.
4. Install 'V' belts in the grooves of alternator

Installation of Engine

(56) and accessory drive pulley.

Note

: Alternator belt tension adjustment is

made after installation of engine (1) and the
radiator assembly.
5.Install poly 'V' belts to the fan pulley and
crankshaft pulley.
6.. Adjust poly 'V' belts by turning the adjusting
screw clockwise until the correct tension is
obtained. Refer to 'Drive Belt Adjustments'.
When correct tension is obtained tighten fan
hub mounting bolts to a torque of 101 - 126

N•m (75 - 93 lbf•

ft).

7. Position fan to fan pulley on engine (1)
and secure with bolts (11) and washers (10).
Tighten bolts 11) in a star shaped pattern to a

torque of 34 N•m (25 lbf•

ft).

8. Position the compressor assembly (27) on
the engine (1) and secure with bolts (25) and
washers (26).
9. Position the front support (29) on the engine
(1), and secure with bolts (14) and washers
(15).
10. Position the rear mounts (6)) on the engine
(1), and secure with bolts (13) and washers
(12).

Installation

Numbers in parentheses refer to Fig.1.

warning

To prevent personal injury and property

damage, be sure lifting device is properly

secured and of adequate capacity to do the

job safely.

Note

: Tighten all fasteners without special

torques specified to standard torques listed
in Section 38.2, STANDARD BOLT AND NUT
TORQUE SPECIFICATIONS.
1. Install the crossmember (28) on the chassis
mounts and secure with bolts (10), washers
(23) and nuts (23).

Installation of Engine

2. Attach suitable lifting equipment to engine
(1)  lifting  brackets  and  carefully  position
engine (1) assembly in the frame.
3. Secure crossmember (28) assembly and
rear mounts (6) to engine (1) with bolts (16),
Snubbing Washers (17), Shock Mounts (18),
Snubbing Washers (19), washers (20) and
nuts (21)). Install the disc brake oil cooler and
gearbox oil cooler to the crossmember (28).
4. Connect driveline to the engine coupling.
Refer to Chapter 19, FRONT DRIVELINES.
5. Install the double gear pump (4 and 5) to
the engine power take-off (2).
6.  Install  tandem  pump  on  power  takeoff
assembly and secure with mounting hardware.
Refer  to  Chapter  32,  ‘RADIATOR AND
MOUNTING’.
7. Remove caps from all cooling lines and
connect lines to the radiator assembly and

engine (1) assembly as identified at removal.

8. Install air cleaner intake pipe and exhaust
piping to engine turbocharger. Tighten
mounting clamps securely.

9. Remove caps from heater lines and fittings

and connect heater lines to engine (1) as

identified at removal.

10. Remove caps from fuel lines and fittings
and connect fuel lines to engine (1) as

identified at removal.

11. Connect all electrical harnesses and
cables to engine (1) (with the exception of

battery connections) as identified at removal.

12.  If  the  vehicle  is  equipped  with  air
conditioning,  connect  the  lines  at  the
compressor  as  identified  at  removal.  On
completion  of  engine  installation  the  air
conditioning system will require to be charged.
Refer to Section 5.2, ‘Compressor Installation’.
13.  Connect  all  electrical  harnesses  and

cables to engine (1) assembly as identified at

removal. Do not connect battery and battery
equalizer connections at this time.
14. Connect throttle control linkage to engine
(1) assembly.

Installation of Engine

15. Connect electrical connections as follows:
a. Connect electrical connections at the ECU.
b. Connect battery equalizer positive cables.
c. Connect battery cables to terminal posts
(ground cables last).
d. Connect battery equalizer ground cables.
16. Check that all electrical connections and
cables, all lines and components removed or
disconnected at removal have been reinstalled
correctly. Ensure all drain plugs and drain
cocks are tightly secured.
17. Fill engine (1) with lube oil specified in
Section Section 36.1, ‘LUBRICATION AND
MAINTENANCE’. Check oil level as described
under 'Maintenance
18. Start the engine and bring the engine oil to
operating temperature. Check all lines and
fittings  for  leaks  and  tighten  as  required.
Switch off the engine.
19. Using suitable lifting equipment, install
hood assembly into position on the vehicle.
Secure  hood  assembly  with  mounting
hardware removed at removal.
20. Install hood side assembly on the vehicle
and secure with mounting hardware removed
at removal.
21. Connect battery positive connections to
battery terminal posts. Connect battery earth
connections to battery terminal posts.
22. Ensure all lines, harnesses and cables are
secured with clips and clamps as removed
during removal. Ensure no lines are chaffing
on sharp edges or resting against areas where
heat will be evident. Ensure all drain plugs and
cocks are secured tightly.
23.  Fill  the  cooling  system  with  coolant
specified in Chapter 34, ‘Radiator Mounting’
Check  the  coolant  level  as  described  in
Chapter 34, ‘Radiator Mounting’.
24. Fill the engine with lube oil specified in
'Maintenance'. Check oil level as described
under 'Maintenance'.
25. Start up the engine and bring the engine
oil to operating temperature. Check all lines

Installation of Engine

and fittings for leaks and tighten as required.

26. Ensure parking brake is applied and
remove wheel blocks from all road wheels.

Maintenance

Numbers in parentheses refer to Fig.1.

Every 10 Hours (Daily)

Engine (1)

: Visually check engine for damage,

loose or frayed belts and listen for any unusual
noises. Check the turbocharger for leaks.

Engine (1) Oil Level

: Check engine oil level

and add oil if low. To allow checking before
starting as well as immediately after shutting
down the engine, the dipstick is provided with
two types of marks:

1. Dot Marks

- Before starting up after a major

shut down period the oil level should be up to
the top dot mark (cold level).
2.

Dash Marks

- Upon shutting down the

engine at low idling (wait 1 to 2 minutes) the
oil level should be up to, but not over, the top
dash mark (hot level).

Every 250 Hours

Engine (1)

: Drain engine oil and refill.

Refer to Section 36.1, ‘LUBRICATION AND
MAINTENANCE’.

Engine Water Pump

Inspect water pump drain hole and clean if
required.

Engine Oil Filters

: Replace oil filters as

follows:
1. Using filter wrench, remove and discard
both oil filters from engine (1). Inspect the

sealing surface of the filter to ensure that the
seal ring stayed with the filter. If not, remove it
from the filter adaptor.
2. Clean the filter adaptor with a clean, lint free

cloth.
3. Lightly coat new oil filter seal with clean
engine oil Refer to Chapter 29, ‘Lubrication
System’.

4. Start a new oil filter on the filter adaptor and

tighten it by hand until the seal touches the

Installation of Engine

adaptor filter head. Tighten an additional 2/3 of

a turn after contact.

Note

: Mechanical tightening of oil filters is not

necessary and will distort or crack the adaptor.

Tighten oil filters by hand only.
5. Repeat steps 3 and 4 for second oil filter.

6. Start and run the engine for a short period
and check for oil leaks. If any leaks are noted,
have them corrected.
7. After the engine has been stopped long
enough (approximately 20 minutes for the oil
from various parts of engine (1) to drain back
to the crankcase, check oil level and add oil
to bring it to the proper level on the dipstick.
Refer to Section 36.1, ‘LUBRICATION AND
MAINTENANCE’.

Fuel Filters

: Replace primary and secondary

fuel filters as follows:

Note

: There is a fuel system shut off valve

on the discharge side of secondary fuel filter.

Closing this valve will prevent loss of fuel

prime at time of filter replacement.
1. Close shut off valve at secondary fuel filter

and, using filter wrench, remove and discard

both fuel filters from engine (1).

2. Fill the replacement filters and coat the

gaskets slightly with clean fuel oil as specified

in Section 36.1, ‘LUBRICATION AND
MAINTENANCE’.
3. Start a new fuel filter on the filter adaptor
and tighten it by hand until the gasket contacts
the adaptor fully with no side movement of the
filter evident. Tighten an additional 1/2 of a
turn.

Note

: Mechanical tightening of fuel filters is

not recommended, and may result in seal and/
or cartridge damage. Tighten fuel filters by
hand only.

4. Repeat step 3 for second fuel filter.

5. Start the engine and check for leaks. If any
leaks are noted, have them corrected.

Coolant Filter

: Check condition of coolant

inhibitor as described in Chapter 32,
‘RADIATOR AND MOUNTING’.

Installation of Engine

Note

: There is a shut off valve at the coolant

inlet and outlet lines of coolant filter. Closing
these valves will enable coolant filter to be
replaced without an excessive loss of coolant.
1. Close shut off valves at coolant filter inlet
and outlet lines and, using filter wrench,

remove and discard coolant filter from engine

(1).

2. Clean the filter adaptor with a clean, lint free

cloth.
3. Lightly coat new coolant filter seal with

clean engine oil as specified in Section 36.1,

‘LUBRICATION AND MAINTENANCE’.

4. Start coolant filter on the filter adaptor and

tighten it by hand until the seal touches the

adaptor filter head. Tighten an additional 2/3 of

a turn after contact.

Note

: Mechanical tightening of coolant filter

is not necessary and will distort or crack the

adaptor. Tighten oil filters by hand only.

5. Open shut off valves at coolant filter inlet
and outlet lines.
6. Start the engine and check for leaks. If any
leaks are noted, have them corrected. Add
coolant as required. Refer to Chapter 32,
‘RADIATOR AND MOUNTING’.

Drive belt adjustments

Every 50 Hours: Check all drive belt tensions
and adjust if required. If vehicle is equipped
with air conditioning, compressor belts should
be checked and adjusted as described in
Section 5.2, ‘Compressor Installation’.

Every 2000 Hours

: Replace all drive belts.

Note

: Replace all belts in a set when one is

worn. Single belts of similar size should not
be used as a substitute for a matched belt set
as premature belt wear can result due to belt
length variation. All belts in a matched belt set

are within 0.81 mm (0.032 in) of their specified

centre distances.
Using belt tension gauge, adjust the belt
tension to the following values:

Fan - Poly 'V' Belt

Installation of Engine

Belt Tension 'New' - 3 340 N (750 lbf)
Belt Tension 'Used' - 2 450 - 3 340 N (550 -
750 lbf)

Alternator - 'V' Belt

Belt Tension 'New' - 556 N (125 lbf)
Belt Tension 'Used' - 445 N (100 lbf)

Note

: A belt is considered 'Used' if it has been

in service for 10 minutes or longer. If the used
belt tension is less than the minimum value,
tighten the belt to the maximum value.
Belts should be neither too tight nor too
loose. Belts that are too tight impose excess
loads on the crankshaft, fan and alternator
bearings, shortening both belt and bearing life.
Excessively overtightened belts can result in
crankshaft breakage. A loose belt will slip and
may cause damage to accessory components.

Special tools

Refer to Section 36.3 'MAINTENANCE
TOOLS', for part numbers of tools referenced
in this section, general service tools required,
and service tools which should be used in
conjunction with procedures outlined in the
engine manufacturers service manual. These
tools are available from your dealer.

Special torque requirement

Torque

Drawing

No.

No. Description

N·m

lbf·ft

Bolt

150

110

Bolt

81-95

60-70

Bolt

81-95

60-70

Fan

mounting

nut

101-126 75-93

Installation of Engine

SANY SRT95C Off-Highway Truck. Service Manual - page 14