SANY SRT95C Off-Highway Truck. Service Manual

Brake Pipeline And Joint

16 BRAKE PIPELINE AND

JOINT

16.1 Brake System Accumulator

Overview

Two accumulators are utilized in the brake
system. They are used for the front and rear
brake loops respectively. Wherein, the rear
brake accumulator is additionally utilized to
maintain the constant pressure in the parking
brake loop to ensure that the parking brake is
released during the running of truck.
The accumulator is of piston type with the
pre-charged nitrogen pressure of 1.6 MPa

(230 psi). It is composed of an inflation valve,

end covers, a cylinder body and pistons. The
inflation valve is provided with interlocking
function. It can be opened by loosening the
locking nut for the convenience of checking
the pre-charged pressure or inflate the
accumulator.

Operating principle

The  piston  is  equivalent  to  a  separator.  It
divides  the  interior  of  cylinder  body  into
two  mutually  isolated  parts. The  part  near
the inflation valve side stores the pre-filling
nitrogen; the other part can accommodate
the pressure oil liquid which is supplied from
the brake pump via the one way valve on the
steering valve group . The pressure switch on
brake valve group is used for monitoring the
accumulator pressure.

Fig.1Brake system accumulator

16.2 Brake Valve Group

Overview

See Fig.1. The brake valve group is installed in
the hydraulic pipeline near the ring beam in the
inner side of left longitudinal beam of frame.
The major components are: Filter(1), Pressure
reducing valve(2), Relief valve(3), Pilot to shift
valve(4), Solenoid valve(5), Pressure reducing
valve(6), Solenoid valve(7) and Proportional
pressure reduce valve. The Brake valve group

distributes hydraulic oil flow from the steering

pump, to the pedal valve, front and rear
brake circuit accumulators and parking brake
at the rear wheels. The valve also provides
appropriate returns to the steering and brake
control tank for the hydraulic oil.

Operating principle

See Fig.2.
The hydraulic oil enters the port 'P' of brake
valve group from the steering pump. The oil
pressure pushes the check valve and allow the

oil flow to the front brake accumulator via the

port 'ACC1' and to the rear brake accumulator

via the port 'ACC2'.The hydraulic oil flows out

of the brake valve group via the port 'B1' and

flows to the port 'P1' of pedal valve. It flows to

the port 'P2' of pedal valve via the port 'B2' of
brake valve group.

Electromagnetic valve sleeve – turned off

When the emergency brake is applied, YV1
isn't energized. The oil flow runs out of the
brake valve group via the port 'A' and goes to
the port 'PX' of pedal valve and the emergency
brake is applied.

Electromagnetic valve sleeve - turned on

When the emergency brake is applied, YV1 is

energized. The oil flows out of the port 'RB1',
The oil flow runs out via the pressure reducing

valve and the parking brake is released.

Brake Pipeline And Joint

Fig.1

1. Filter
2. Pressure reducing valve
3. Relief valve
4. Pilot to shift valve
5. Solenoid valve
6. Pressure reducing valve
7. Solenoid valve
8. Proportional pressure reduce valve
9. Shuttle valve
10. Shuttle valve
11. Check valve
12. Check valve

Pressure switch

The pressure switch in the position of port
'PS1' and 'PS2' signals the instrument alarm
indicator, when the pressure drops below
13.1MPa. The instrument alarm indicator will

flash.

Parking brake pressure switch 'PS3' sends
a signal to illuminate the parking brake light.
When the pressure in the parking brake circuit
drops below 6.5MPa. The instrument alarm

indicator will flash.

Disassembly

1. Park the truck in a horizontal working
area, apply the parking brake, shut down the
engine, continuously operate the pedal valve
and release the pressure of brake power
accumulator.
2. Chock the wheels and set the main switch
of power accumulator into the 'OFF' position.
3. Remove and mark the electrical connectors
of electromagnetic coil and pressure switch.

warning

After the engine is shut down, some

pressure will still exist in the brake system.

Continuously operate the pedal valve.

Perform the work on the brake system only

after the pressure is removed. Otherwise, it

will result in personal injuries.

To prevent personal injury and property

loss, ensure that wheels are chocked and

fixed properly. The sufficient capability

should be possessed and work should be

performed safely.

4. Use a proper solvent to clean the multi-way
valve assembly and surrounding area. Ensure
that all of the hydraulic pipelines connected to
the brake multi-way valve are properly marked
to facilitate the installation. Use a proper
container to receive the leakage oil, and plug

Brake Pipeline And Joint

G12

PS3 G14

YV2

YV1

G10

ACC2

ACC1

PS1

PS2

RB3

RB1

8.3MPa

FB2

RB2

YV3

FB1

G11

G13

0.4

⑴

⑵

⑶

⑷

⑸

⑹

⑺

⑻

⑼

⑽

⑾

⑿

Fig.2

all open pipelines.
5. Remove the fastening and installation

parts fixing the brake multi-way valve onto the

mounting cross beam of driver's cab. Remove
the assembly from the truck.

Installation

Note:

Tighten all fasteners according to

Section 'Technical Conditions for Tightening
Torque of Standard Bolts and Nuts'.

Note:

Tighten the hydraulic pipelines equipped

with the end face seal joint. Replace all
O-rings.
1. Place the brake valve group assembly onto
the front support of ring beam, and use the

installation parts to fix it properly.

2.  Remove  the  plug  from  the  hydraulic
pipeline.  Connect  it  to  the  brake  valve
group  according  to  the  signs  made  during
disassembly.
3. Connect the electrical connectors to the
electromagnetic coil and the pressure switch.
4. Check the liquid level of steering and brake
control oil tank according to the correct liquid
level  specified  in  the  'Steering  and  brake

control oil tank' and the technical specifications

for oil in the 'Lubrication system'. Refill oil if
necessary.
5. Set the main switch of accumulator into the
'ON' position, remove the chocks, start up the
engine and warm up the hydraulic oil to the
operating temperature.
6. Check the brake valve group and hydraulic
pipeline joints for the presence of leakage, and
tighten them.
7. Shut down the engine, and apply the
parking brake after it is ensured that the
traveling brake is completely applied.
8. After the brake and engine shutdown are
repeated for several times, check whether the
same times of releasing are achieved.
9. Check all joints again for the leakage, and
tighten them if necessary.
10. Remove the body safety pin shaft and

Brake Pipeline And Joint

Frame And Installation

Fig.1-Exploded View of Frame Assembly

1 7 F R A M E A N D

INSTALLATION

17.1 Frame and Installation

1.Right front support assembly

9.Gearbox lower guard

2.Tie rod units

10.Left lengthening beam assembly

3.Right-hand longitudinal pull rod

11.Outer longitudinal pull rod

4.Lower guard

12.Left-hand longitudinal pull rod

5.Right lengthening beam assembly

13.Left and front support assembly

6.Rear platform

14.Engine lower guard

7.Damping pad

15.Frame assembly

8.Ladder of platform

Frame And Installation

Remove

The following steps provided should be
followed for disassembly of the components

as illustrated in the figure:

WARNING

To prevent personal injury and property

damage, be sure wheel chocks, blocking

materials and lifting equipment are

properly secured and of adequate capacity

to do the job safely.

1. Position the vehicle in a level work area,
apply the parking brake and switch off the
engine.
2. Turn  steering  wheel  in  both  directions
several  times  to  relieve  pressure  in  the
steering circuit. Block all road wheels.
3. Attach  a  suitable  lifting  device  to  the
component and remove mounting hardware.
Remove the component from the vehicle.

Installation

WARNING

To prevent personal injury and property

damage, be sure wheel chocks, blocking

materials and lifting equipment are

properly secured and of adequate capacity

to do the job safely.

Caution

: Tighten all the fasteners according

to section 36.2 'TIGHTENING MOMENT
TECHNICAL CONDITIONS OF STANDARD
BOLT AND NUT'.
Using a suitable lifting device, align the
component to be installed in position on the
frame. Secure the component securely to the
frame with mounting hardware removed during
removal.

Frame And Installation

Maintenance

Inspection

Inspect the frame and attached parts at
intervals not exceeding 250 hours for cracked
or broken welds and bending/twisting of the
frame. Any defects found should be repaired
before they progress into major failures.
Contact your dealer for recommended weld
and repair instructions.

Welding

Note

: It is important that the electrical

connections are disconnected in the following
order to prevent damage to the electrical
components:

WARNING

Welding and flame cutting cadmium

plated metals produce odourless fumes

which are toxic. Recommended industrial

hygiene practice for protection of the

welding operator from the cadmium fumes

and metallic oxides requires enclosure

ventilation specifically designed for the

welding process.

1. Disconnect battery equalizer ground cables.
2. Disconnect battery cables from terminal

posts (ground cable first).

3.  Disconnect  battery  equalizer  positive
cables.
4. Disconnect electrical connections at the
ECU.
After welding, reconnect all of the above in the
reverse order.
Electric  arc  welding  is  recommended  for
all  chassis  welding.  Since  the  nature  and
extent  of  damage  to  the  frame  cannot  be
predetermined, no definite repair procedure
can be established. As a general rule however,
if parts are twisted, bent or pulled apart, or a

Frame And Installation

frame is bent or twisted, no welding should
be done until the parts are straightened or
realigned.
Successfully welded repairs will depend to
a great extent upon the use of the proper
equipment, materials and the ability of the
welder. The Service Department can be
consulted regarding the feasibility of welding
repairs.

Caution

: In principle, it is not allowed to weld

anything to frame casually. Particularly, it is
prohibited to weld anything on the upper and

lower flanges of the front and rear longitudinal

beams and it is strictly forbidden to splash any
weld slag on them.

Painting

A check of the condition of the paint should be
made approximately twice a year and chassis
repainted if necessary.
If painting of the actual frame of the unit is
required, thoroughly clean the areas to be
painted. Apply a primer coat of red oxide and

then a finish coat of polyurethane enamel.

To keep rust and corrosion to a minimum,
periodic painting of abrasions and other
exposed metal areas on the frame is highly
recommended.

Special tools

No special tools are required for the operation
steps illustrated in this chapter and refer to
36.3 'MAINTENANCE TOOLS' for the No. of
general maintenance tools which are available
from agents of manufacturers.

Fig.1 Front Driveline Installation

1. Output flange

4. Driveline assembly

2. Bolt

5. Input flange

3. Universal joint

18 DRIVELINE INSTALLATION

18.1 Front Driveline Assembly

Overview

The function of the driveline is to transmit
rotating power from one point to another in a
smooth and continuous action while allowing
a degree of movement or misalignment of the
components it connects.
The drivelines must operate through constantly
changing relative angles between the
components they are mounted to and must
also be capable of changing length while
transmitting torque.
A typical driveline consists of universal joints
which allow some misalignment and permit
the driveline to pivot in any direction, and, a
light rigid hollow slip yoke and splined shaft
assembly forming a slip joint.
The slip joint accommodates length variations
generated during operation, preventing tension
or compression loads from causing serious
damage to the components.

Note

: Extra care should be taken when

handling the driveline since chips, dents, burrs
or deformity on any rotating mass creates

Driveline Installation

vibration and excessive wear during any
operation.

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.

Rotating shafts can be dangerous. You

can snag clothes, skin, hair, hands, etc.

This can cause serious injury or death. Do

not go under a vehicle when the engine is

running.

Note

: Extra care should be taken when

handling drivelines since carelessness can
result in premature failure of the components.
Chips, dents, burrs, or any other deformity
of  universal  joints  will  prevent  accurate
mating. This will cause misalignment, which is
accompanied by vibration and excessive wear.
1. Position the truck in a level work area, apply
the parking brake and switch off the engine.
2. Turn  steering  wheel  in  both  directions
several  times  to  relieve  pressure  in  the
steering circuit. Block all road wheels. Set the
battery in the 'off' position.
3. Match mark universal joints (3) and their
mating  surfaces  to  ensure  correct  mating
alignment when installing driveline assembly
(4).
4. Support driveline assembly (4) with suitable
lifting equipment and remove bolts (2) securing

universal joints(3) to output flange(1).

5. Remove bolts (2) securing universal

joints(3) to input flange(5).

6. Remove driveline assembly (4). If necessary
tap driveline assembly (4) from its mating

Driveline Installation

components with a soft faced hammer.

Note

: Access to driveline assembly can be

obtained from underneath the truck.

Disassembly

Numbers in parentheses refer to Fig.1.
1. Remove bolts (2) securing universal
joints(3) to driveline assembly(4), remove
universal joints(3).

Inspection

1. Clean all metal parts in a suitable solvent
and dry all parts with compressed air.
2. Inspect universal joints for excessive wear.
Replace if wear is excessive.
3. Inspect splines of shaft and yoke for nicks,
burrs and excessive wear. Replace if wear is
excessive or splines are nicked. Burrs may be

removed with a fine file or medium India stone.

4. Check the surfaces of the components that
universal joints mate against for parallelism.
Refer to Fig.2.
5. Check the condition of mounting bolts and
replace if required.

Assembly

Numbers in parentheses refer to Fig.1.

Universal Joint

1. Use bolts (2) securing universal joints(3) to
driveline assembly(4). Tighten bolts (2) to a

torque of 280N•m (207lb-ft).

Installation

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.

Rotating shafts can be dangerous. You

can snag clothes, skin, hair, hands, etc.

Keep the

ground clean

Spirit level

Maximum allowable

clearance 0.2mm

Apply pressure

here

Fig.2 - Checking Parallelism

Driveline Installation

This can cause serious injury or death. Do

not go under a vehicle when the engine is

running.

Note

: Extra care should be taken when

handling drivelines since carelessness can
result in premature failure of the components.
Chips, dents, burrs, or any other deformity of
universal joints and yoke will prevent accurate
mating with the crosses and bearings. This will
cause misalignment, which is accompanied by
vibration and excessive wear.
1. Using suitable lifting equipment, position
driveline assembly (4) on the truck and align
match marks on universal joints (3) with those
on its mating surfaces.
2. Apply Loctite 242 to the threads of bolts (2)
and secure universal joints (3) to their mating
surfaces with bolts (2). Tighten bolts (2) to a

torque of 280N•m (207lb-ft).

3. Ensure the parking brake is applied and
start the engine. Remove wheel blocks from
all road wheels.

Maintenance

Lubrication

Lubricate driveline with either a hand-
operated or a pressure grease gun. Refer to
Section 38.1, 'Lubricate and maintenance', for
recommended lubricant and service intervals.

Periodic inspection

Use a small pry bar to check companion
flange yokes for looseness. If loose, drop
one end of the driveline and twist the yoke to
check backlash between splines and yokes.
Replace any yoke that does not fit snugly.
Using a small pry bar, check the universal
joints for play. If loose, replace the universal
joints. Check splines at slip joint, replace yoke
if excessively worn.

Driveline Installation

Fig.3 Rear Driveline Installation

1. Output flange

4. Driveline Assembly

2. Bolt

5. Input flange

3. Universal joint

18.2 Rear Driveline Assembly

Overview

The function of the driveline is to transmit
rotating power from one point to another in a
smooth and continuous action while allowing
a degree of movement or misalignment of the
components it connects.
The drivelines must operate through constantly
changing  relative  angles  between  the
components they are mounted to and must
also  be  capable  of  changing  length  while
transmitting torque.
A typical driveline consists of universal joints
which allow some misalignment and permit
the driveline to pivot in any direction, and, a
light rigid hollow slip yoke and splined shaft
assembly forming a slip joint. The slip joint
accommodates length variations generated
during  operation,  preventing  tension  or
compression  loads  from  causing  serious
damage to the components.

Note

: Extra care should be taken when

handling the driveline since chips, dents, burrs
or deformity on any rotating mass creates
vibration and excessive wear during any
operation.

Driveline Installation

SANY SRT95C Off-Highway Truck. Service Manual - page 23