SANY SRT95C Off-Highway Truck. Service Manual

Removal

Numbers in parentheses refer to Fig.3.

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
components with a soft faced hammer.

Note

: Access to driveline assembly can be

obtained from underneath the truck.

Driveline Installation

Disassembly

Numbers in parentheses refer to Fig.3.
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.4.
5. Check the condition of mounting bolts and
replace if required.

Universal joint

Numbers in parentheses refer to Fig.1.

Spider

1. Use bolts (2) securing universal joints(3) to
driveline assembly(4). Tighten bolts (2) to a
torque of 470N. M (348lb-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. This can cause serious

injury or death. Do not go under a vehicle

when the engine is running.

Driveline Installation

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 470 N•m (348lb-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
36.1, ' 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.

Special tools

There are no special tools required for
procedures outlined in this section. Refer to
Section 36.3, ' Service Tools '.

Driveline Installation

Fig.1 - Exploded View of Air Cleaner

1. Air cleaner body

4. Cover assembly

2. Primary element

5. Latch

3. Safety element

6. Vacuator valve

19 AIR CLEANER AND MOUNTING

19.1 Air Cleaner and Mounting

Air Cleaner And Mounting

Overviev

Numbers in parentheses refer to Fig.1, unless

otherwise specified.

There are three, dual dry element type air
cleaner assemblies mounted on the platform
to the right hand side of the cab. Air cleaner
assemblies prolong engine life by removing
grit, dust and water from the air as it enters the
engine. Grit and dust combined with engine
oil, forms a highly abrasive compound which
can destroy the engine in a comparatively
short period of time.
A  rubber  vacuator  valve  (6)  attached  to
cover assembly (4) in a downward position,
ejects grit, dust and water while the engine
is running. Vacuator valve (6) minimizes the
need for daily servicing. Even though vacuator
valve (6) is normally under a slight vacuum
when the engine is running, pulsing of the
vacuum opens and closes vacuator valve (6)
expelling grit, dust and water as they collect.
When the engine is stopped, vacuator valve (6)
opens and expels any accumulated grit, dust
or water.
An electrical air restriction gauge indicates
when air restriction levels reach the maximum
allowable limit. When air restriction levels are
reached the circuit closes and a restriction
indicator light located on the dash panel (Fig.2)
illuminates.  This  light  shows  at  a  glance
when the system air flow is being restricted
indicating that primary element (2) should be
serviced.
Air  restriction  gauge  automatically  resets
after each air cleaner assembly is serviced.
Safety  element  (3)  is  installed  in  each  air
cleaner assembly inside of primary element
(2). This  element  increases  the  reliability
of the air cleaner’s protection of the engine
from airborne dirt. It protects the engine from
dirt admitted by a damaged primary element
(2), or dirt that might be dropped into the air
cleaner  assembly  while  servicing  primary
element (2).

STOP

Fig.2 Air Cleaner Restriction Indicator Light

Air Cleaner And Mounting

Fig.3- Exploded View of Air Cleaner Mounting

1. Elbow

10. Bracket

2. Intake tube

11. Bracket

3. Intake tube

12. Clamp

4. Support assembly

13. Bolt

5. Air cleaner

14. Nut

6. Mounting band

15. Washer

7. Plenum chamber

16. Clamp

8. Tube

17. Tube

9. Mounting band

Air Cleaner And Mounting

Maintenance

Numbers in parentheses refer to Fig.1, unless

otherwise specified.

WARNING

Always shutdown the engine before

servicing air cleaner.

The air cleaner elements should be serviced
only when the maximum allowable restriction
has been reached, as indicated by air cleaner
restriction  indicator  light.  The  elements
should not be serviced on the basis of visual
observation as this would lead to over service.
When restriction readings finally indicate a
change, remove primary element (2) carefully
and  clean/replace  as  required.  Refer  to
'Primary Element'.
Never attempt to clean safety element (3).
Change safety element (3) after every third
primary  element  (2)  service.  Make  sure
vacuator valve (6) is not damaged or plugged
and  that  the  joint  with  cover  assembly  (4)
is not broken. If vacuator valve (6) is lost or
damaged, replace it to maintain pre-cleaner
efficiency and normal filter element service
life. Check condition of clamps (12, 11, Fig.3),
mounting band (6, Fig.3),  elbow (1, 17, Fig.3),
tube (2, 3, 8, Fig.3), and plenum chamber (7,
Fig.3). Tighten/replace as necessary.

Air Cleaner Assembly

Numbers in parentheses refer to Fig.1, unless

otherwise specified.

Note

: Air cleaner body (1) should be

thoroughly cleaned twice a year. Do not apply
heat in any form to air cleaner body (1).
1. Release latches (5) on cover assembly (4)
and remove cover assembly from air cleaner
body (1).
2. Remove primary element (2) and safety
element (3) from air cleaner body (1).

Air Cleaner And Mounting

3. Slacken clamps (16, Fig.3).
4. Remove bolts (13, Fig.3) and washers (15,
Fig.3) securing the air cleaner assembly to the
platform. Disconnect tube (8, Fig.3) from air
cleaner body (1).
5. Remove the air cleaner assembly from the
platform for cleaning.
6. Open mounting bands (9) and remove
from air cleaner body (1). Open clamp on cap
assembly (6, Fig.3) and remove cap assembly
from air cleaner body (1).
7. Blank off air cleaner body (1) outlets with
tape or cardboard. Reach inside body with a
compressed air nozzle or brush and remove
dust from the body.
8. Remove all loose dust from air cleaner body
(1) and remove tape or cardboard from body
outlets.

Note

: Assembly and installation of the

air cleaner assembly is the reverse of
disassembly and removal.

Primary Element

Numbers in parentheses refer to Fig.1.
Although  a  paper  primary  element  (2)  is
used, it is possible to clean it so that it can be
reused. The number of times one element can
be reused depends on the type of dirt on the
element and the care exercised in cleaning.
The life of a properly cleaned element will
be approximately as long as that of a new
element for the first one or two cleanings.
After that, the life of the element will gradually
decrease  with  each  cleaning;  however,
it  should  perform  satisfactorily  through
approximately six cleanings, providing it does
not rupture. Visually determine the condition
of primary element (2) and choose either the
compressed air or washing method.
1. Release latches (5) on cover assembly (4)
and remove cover assembly from air cleaner
body (1).
2.  Remove  primary  element  (2)  from  air
cleaner body (1).

Air Cleaner And Mounting

3. Using a damp cloth and a suitable solvent,
wipe out all excess dust from air cleaner body
(1) and allow to dry.
4. If the major contaminant on primary element
(2) is light dust, direct a jet of compressed air,
not exceeding 6.9 bar (100 lbf/in2), against
the pleats of the element. The air jet should
be directed in the opposite direction of normal
operating air flow. Move the air jet up and
down the pleats, holding the air nozzle 25
mm (1.0 in) away from the pleats, to prevent
rupturing the element with either the nozzle or
air jet.
5. In cases where the dust cake on primary
element (2) contains oil or carbon, air will
not clean effectively. Using manufacturers
recommended solution and warm water,
not exceeding 48° C (120° F), soak primary

element (2) for fifteen minutes. Element should

be gently agitated to assist cleaning process.

Note

: It is possible to modify an old agitator

type washing machine for primary element
(2) cleaning. Do not soak or agitate primary

element (2) in the solution for more than fifteen

minutes. Prolonged exposure softens vertical
seams in the element.
6. Rinse washed element thoroughly with a
low pressure stream of water, not exceeding
0.7 bar (10 lbf/in2), opposite from the normal

air flow, until rinse water runs clear.

7. Air dry primary element (2) thoroughly
before returning it to service. Drying is a slow
process which may be hastened by exposing
element to slowly circulating heated air.
Heated air temperature should not exceed
46o C (115o F). Drying time can be reduced to
about three hours with heated air. Do not use
a light bulb for drying. Do not use compressed
air on a wet element.

Note

: Replace paper elements after six

cleanings or two years in service, whichever
comes first. Mark each cleaned element to
show total cleanings to date.
8. After primary element (2) is thoroughly dried,

Air Cleaner And Mounting

inspect for damage or ruptures, especially
close to the end caps. To detect paper
ruptures, place a bright light bulb inside the
element and rotate element slowly. Inspection
of element on the outside will disclose any
holes where concentrated light shines through.
Even the smallest hole will pass dust to the
engine and may result in costly engine repairs.
9. Install primary element (2) in air cleaner
body (1).
10. Install cover assembly (4) on air cleaner
body (1) and secure with latches (5).

Secondary Element

Numbers in parentheses refer to Fig.1.
Since safety element (3) is protected from
contamination by primary element (2), it needs
no periodic cleaning and should be replaced
only after every third primary element (2)
service.
1. With primary element (2) removed from air
cleaner body (1), remove safety element (3).
2. Remove any dust dislodged into air cleaner
body (1) outlet and, using a damp cloth and a
suitable solvent, wipe out all excess dust from
air cleaner body (1) and allow to dry.
3. Install new safety element (3) followed by
primary element (2) in air cleaner body (1).
4. Install cover assembly (4) on air cleaner
body (1) and secure with latches (5).

Recommendations

Numbers in parentheses refer to Fig.3.
1. Under no condition should the vehicle be
operated without both filter elements in each
air cleaner assembly.
2. It is very important that tubes (2, 3, 8), tube
assembly (12) and elbow (1, 17) from the air
cleaner assembly to the engine be airtight or
the purpose of the air cleaner will be completely
defeated. All clamps (12, 16) and Mounting
Band (6, 9) should be checked frequently and
tightened to prevent leaks.
3. Keep new or cleaned filter elements on

Air Cleaner And Mounting

hand for replacement to prevent unnecessary
downtime of the vehicle.

Measuring air restriction

Numbers in parentheses refer to Fig.3.
As a dry air cleaner element becomes loaded
with dust, the vacuum on the engine side of
the air cleaner (air cleaner outlet) increases.
This  vacuum  is  generally  measured  as
'restriction  in  mm  (inches)  of  water'. The
recommended  maximum  allowable  intake
restrictions at rated speed and load are as
follows:
a. 380 mm-H2O (15 in-H2O) with clean filter
elements.
b. 635 mm-H2O (25 in-H2O) with dirty filter
elements. While the air restriction gauge sends
a signal to indicate the need for servicing, it
does not give as precise a measurement as a
water manometer or vacuum gauge.

Water manometer

1. Remove protective cap and disconnect
harness at air restriction gauge. Remove air
restriction gauge from elbow.
2. Hold water manometer vertically and fill
both legs approximately half full of water.
Connect one of the upper ends to elbow by

means of a flexible hose.

3. With the manometer held vertically and the
engine drawing maximum air, the difference in
height of the water columns in the two legs is
measured as the air cleaner restriction.
4. If the restriction exceeds the levels indicated,
engine performance will be affected. Primary

filter element should be cleaned or replaced.

Vacuum gauge

a. Remove protective cap and disconnect
harness at air restriction gauge. Remove air
restriction gauge from elbow.
b. Connect the hose from the vacuum gauge
to elbow and with the engine drawing maximum
air, take a note of the reading on the gauge.

Air Cleaner And Mounting

Exhaust System Assembly

6 10

6 6

9 9

10 10

Fig.1 Exhaust System and Mounting

1.Connector

11.Plate

2.Gasket

12.Exhaust tube assembly

3.Exhaust tube

13.Fixed clamp

4.Exhaust tube

14.Exhaust tube

5.Bolt

15.U-bolt

6.washer

16.Bolt

7.Fixed clamp assembly

17.Support assembly

8.Bolt

18.Support

9.Washer

19.U-bolt

10.Nut

20 EXHAUST SYSTEM ASSEMBLY

20.1 Exhaust System Assembly

Removal

Numbers in parentheses refer to Fig.1.

WARNING

To prevent personal injury and property

loss, ensure that the wheels are chocked in

a desired way and the chock and the hoist

equipment have sufficient strength and

hoist capacity and are fixed properly for

ensuring work safety.

Remove the Exhaust system in the following
order:
1. Position the vehicle in a level work area,
apply the parking brake and shutdown the
engine.
2. Turn the steering wheel in both directions
several  times  to  relieve  pressure  in  the
steering system. Block all road wheels.
3. Attach  suitable  lifting  equipment    to
exhaust  tube  assembly  (12)  and  remove
connector(1)

，

gasket (2)securing exhaust

tube (3) and exhaust tube assembly(4) to
exhaust tube assembly (12).Remove Fixed
clamp (13)

，

securing exhaust tube assemly

(12) to Fixed clamp (13) and frame

。

remove

exhaust tube assembly (12).
4. Attach suitable lifting equipment to exhaust
tube (14) and remove bolt (16)

，

washer (6,

9),nut(10)and U-bolt(15) securing exhaust
tube (14) to the platform.Remove exhaust tube
(14) from the truck.
5. Attach suitable lifting equipment to exhaust
tube

（

3) and remove washer (6, 9),nut(10)

and U-bolt(19) securing exhaust tube(3)
to support(18).Remove connector(1)

，

gasket (2)securing exhaust tube(3) to
turbocharger,remove exhaust tube

（

3) from

the truck.
6. Attach suitable lifting equipment to exhaust
tube (4) and remove washer (6, 9),nut(10)
and U-bolt(19) securing exhaust tube(4)

Exhaust System Assembly

to support(18).Remove connector(1)

，

gasket(2)securing exhaust tube(4)to
turbocharger,remove exhaust tube

（

4) from

the truck.
7. Storage the pats removed from truck
carefully.

Note

:Please protect the outlet of turbocharger

after removed the exhaust tube (3) and the
exhaust tube (4).

Installation

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.

1. Attach suitable lifting equipment to exhaust
tube (4) and tighten connector (1)

，

gasket (2)

securing exhaust tube (4) to the turbocharger.
Tighten washer (6, 9),nut(10)and U-bolt (19)
securing exhaust tube(4) to support (18).
2. Attach suitable lifting equipment to exhaust
tube (3) and tighten connector (1)

，

gasket (2)

securing exhaust tube (3) to the turbocharger.
Tighten washer (6, 9),nut(10)and U-bolt (19)
securing exhaust tube (3) to support (18).
3. Attach suitable lifting equipment to exhaust
tube (14) and tighten bolt(16),washer (6, 9),nut
(10)and U-bolt(15) securing exhaust tube(14)
to the platform.
4. Attach suitable lifting equipment to exhaust
tube assembly (12) and tighten connector(1)

，

gasket (2)securing exhaust tube assembly(12)
to exhaust tube(3)and exhaust tube(4).Tighten
Fixed  clamp(13)  securing  exhaust  tube
assembly(12)  and  exhaust  tube(14)  to  the
frame.
5. Check  and  tighten  all  the  fasteners  if
necessity.

Exhaust System Assembly

SANY SRT95C Off-Highway Truck. Service Manual - page 24