SANY SRT95C Off-Highway Truck. Service Manual

fittings. Accidental release of pressure

will result in personal injury and property

damage.

A high pressure nitrogen pressure

regulator must be used with the charging

assembly. Failure to use a pressure

regulator could cause property damage,

personal injury, or death.

Filling oil

(Cylinder filled with oil initially, or

refilled with oil during maintenance)

Note: This method is recommended to fill
oil when the loss of oil in the suspension
cylinder is caused by some other reasons but
surface leakage. If surface leakage occurs,
the cylinder should be removed and replaced.
Return the suspension cylinder to factory for
repair. Unauthorized repair may influence its
quality.
Oil level of the suspension cylinder mounted
on mining truck can be checked and adjusted
according to the following steps:

Note 1:

During the operation of mining truck,

the charged nitrogen in the cylinder tends to
be mixed with oil. When the nitrogen pressure
is released, oil will be released from the
suspension cylinder in the form of foams.

Note 2:

To detect oil level correctly, nitrogen

must be completely discharged from
the cylinder body. This operation can be
completed by evacuating gas or by sustaining
frame properly with cushion block to keep
cylinder in the open state for more than 24
hours. This operation is required only when
surface leakage or deviation excessive.

Note 3:

This procedure should be performed

after the suspension cylinder is installed
on mining truck. If it is not installed, the
suspension cylinder should be placed with a
proper supporting form and fastness before
this procedure is operated.
1. Position the truck in a level work area. The

Rear Suspension System

truck must be parked stably without applying
friction brake system.
2. Lift up the truck until the suspension
completely extends. Use jack or cushion

blocks to fix mining truck. At the moment, the

distance A between the center of pin and end
cap of guide sleeve is equal to 517.5mm(See
Fig.5 ).
3. Remove the cap from nitrogen charging
valve  (1,  Fig.1)  at  the  top  of  the  cylinder.
Turn the hex out on the valve 1/4 to 1/2 turn
counter-clockwise and depress the valve core
to release the nitrogen .
4.  Connect  a  vacuum  pump  to  the  charge
valve to perform the vacuum pumping.
5. Start vacuum pumping and monitor this
process until all gas is pumped out. When
the color of oil in the suspension cylinder is
darkened homogeneity, it indicates that it is
pumped out.
Note: It is not allowed to pump the oil from the
suspension cylinder.
6. Stop vacuum pumping.
7. Slowly lower down the frame to make the
dimension “A”(the distance between the center
of pin and end cap of guide sleeve ,See Fig.5)
equal to 348mm.
8. Release all residual gas pressure in the
suspension cylinder as step 3.
9. With cylinder rod in its right position (“A” =
348mm), open plug(2, Fig.5) and pay attention
to  oil  flows  or  not.  If  no  oil  flows,  fill  oil
according to the following requirements when
oil level is lower.
10.  Remove  the  plug  (2,Fig.5)and  charge
valve (1,Fig.5) from the piston rod. Attach hose
from a pressure pump filled with hydraulic
oil specified  in chapter36.1“LUBRICATION
AND MAINTENANCE” to oil fill port(2,Fig.5).
The approximate volume required for initial oil
charging of each front suspension cylinder is
about 19.5L.
Note: In a cold region, a synthetic hydraulic

Rear Suspension System

fluid(Conoco/Philips synthetic R&O or similar

products) is recommended as a substitute

product. This fluid should have the following

characteristic:
ISO viscosity grade: 46; solidification
temperature: -70°C (-55°C); PAO synthetic
agent, allowing to use normal insulation
device.
12. Fill the cylinder until oil flows free of air
bubbles from charging valve (1, Fig5) port. It
may be necessary to wait 30 or more minutes
after nitrogen pressure has been released to
clear the foam which has formed inside the
cylinder.

13. Remove oil fill equipment, reinstall plug (2,

Fig5) and nitrogen charging valve (1, Fig5) in
the ports .
14. Charging suspension cylinder with the
nitrogen according to the following procedure.
Note:If vacuum pumping have not be done
before oil filling, oil fill should accord to the
following procedure in order to exhaust the air
of cylinder:
a.  Remove the plug  in piston rod and plug in
the cylinder tube assy. meanwhile the charge
valve should not be removed.
b.  Attach oil fill equipment to the plug port
and fill the cylinder until oil flows free of air
bubbles from plug port. Reinstall plug  in the
port of cylinder tube assy. and remove nitrogen
charging valve in the ports .

c. Go on filling the cylinder with the plug port.

Stop oil filling until the oil flows free of air
bubbles from charge valve port, and remove

oil fill equipment. Reinstall plug and nitrogen

charging valve in the ports .
15. Charging suspension cylinder with the
nitrogen according to the following procedure.

Charging nitrogen

WARNING

Nitrogen can only be charged when the

suspension cylinder is installed to the

mining car.Use dry nitrogen to charge

cylinder. Do not use a gas such as oxygen

which , if used by mistake for pressurizing,

will explode violently when coming into

contact with oil or grease, possibly causing

personal injury and property damage.

Numbers in parentheses refer to Fig.5, unless

otherwise specified.

Please use the tool assembly including tee

fitting(4, Fig.6), hose (8, Fig.6), cutoff valve (5,

Fig.6) and charging joint(9, Fig.6) for charging
the left and right suspension cylinder. Tool
assembly is detailed in Fig.6 nitrogen charging
tool.
Note: Use the gas pressure regulator installed
on  the  nitrogen  cylinder  to  protect  the
pressure gauge (The nitrogen cylinder is not
supplied with the nitrogen charging assembly).
An  accurate  and  reliable  pressure  gauge
is very critical to the correct adjustment of
suspension.
Note:  When  the  charge  valve  protecting
cover is removed, no residual gas pressure
is allowed. If any, the protecting cover can
be removed after the pressure is completely
discharged.
1. Position the truck at a safe and flat road
surface. The  truck  must  be  parked  stably
without  applying  friction  brake  system  of
mining truck.
2. Remove cover of the charge valve carefully
because residual gas pressure may exist.
3. Connect the charge component (closing
the cut-off valve) to charge valve(1,Fig.5) on
suspension  cylinder  and  the  gas  pressure
regulator on the nitrogen cylinder.

Rear Suspension System

The user should provides the nitrogen

cylinder and pressure regulator.

Fig.6 Nitrogen inflation tool

1. Elbow

6. Pipe joint

2. Bleeder valve

7. Pipe joint

3. Pressure gauge 8. Line

4. Tee piece

9. Nitrogen charging joint

5. Cut-off valve

10. Pipe joint

1) Connect the hoses of two ends installed
with the Nitrogen charging joint(3, Fig.5) to
the charge valves(1,Fig.5)of rear suspension
cylinder respectively.
2) Connect the other end to the nitrogen
cylinder.
4. Adjust the gas pressure regulator to about
2000kpa.

Note:

Protect the pressure gauge carefully

to avoid excessive pressure. The pressure is
easy to exceed 7000kpa.
5. Charge the suspension cylinders according
to the following steps:
a. Rotate the small hex nut on the charge
valve  (1,Fig.5)  of  suspension  cylinder
counterclockwise  for  two  or  three  turns  to
make the internal valve move away from the
seat.
b. Rotate the “T” handle of nitrogen charge
joint  (3,Fig.5)  clockwise  until  it  cannot  be
turned any more. Open the check valve of

inflation joint.
c. Open the cut-off valve (4,Fig.5), and inflate

the suspension cylinders at both sides with

the same pressure. During the inflation, open

slowing and intermittently close the cut-off
valve (4,Fig.5) until the distance A between the
center of pin and end cap of guide sleeve is
equal to 455mm (the allowable range of error
is 10mm).
d. When the height ‘A’ is reached (Fig.5), turn
off the pressure regulator (6, Fig.5) on the
nitrogen cylinder, close the cut-off valve(4,
Fig.5), rotate the hex nut on the charge valve
(1, Fig.5) of suspension cylinder clockwise
and close the internal valve. Rotate the “T”
handle of nitrogen charge joint (3, Fig.5)
counterclockwise until it cannot be turned any
more.

Note 1

: In the charging process, the gas

should be slowly added and the flow of gas
should be periodically stopped to allow the
suspension cylinders in the left and right sides
to reach balance. The correct process will vary

Rear Suspension System

with the equipment, materials and operators.

No excessive inflation is allowed; otherwise, it

will lead to the excessive extension of cylinder

body and damage of fixing bolts on the piston.

Note 2

: To check the pressure of nitrogen

cylinder (5, Fig.5), close the cut-off valve (4,
Fig.5), turn on the gas pressure regulator (6,
Fig.5) slowly on the gas cylinder and observe
the reading of the pressure gauge (7, Fig.5).
The pressure in the gas cylinder must be
higher than 7000kpa.

Note 3

: To check the pressure in the cylinder,

turn off the gas pressure regulator on the gas
cylinder, open the cut-off valve (4, Fig.5) and
observe the reading of the pressure gauge (7,
Fig.5).
Note 4: If height of unload isn’t correct, repeat
the  previous  procedure  to  add  or  reduce
charging pressure by the increment of 150kpa.
The  increment  is  a  critical  parameter  for
suspension cylinder charging to get a correct
height of no-load state.
Note 5: If the mining truck operated in the
colder  environment,  it  is  recommended  to
raise the height of unload state by 10~20mm
to compensate for the effect of temperature
reduction.
6. Close the cut-off valve and turn off the gas
pressure regulator.
7.  Remove  the  inflation  device  and  check
nitrogen charge valves (1) for leakage with
soapy water.

Note:

In case of any leakage in the spool of

charge valve:
1) Check the torque of spool. The torque

should be 0.35 - 0.45N•m.

2) If the leakage cannot be stopped, check the
spool for damage or contamination. Replace it
if necessary. All suspension cylinder pressure
should be released before the spool is
removed with oil charging assembly.
8. Install the cover of charge valve. The torque

is 4.5 - 5.5N•m.

9. Run the mining truck about 24 hours,
perform the procedure of inspect un-
load height again, and make adjustment if
necessary.

Note:

On new or rebuilt cylinders, the seals

and wipers may grip the piston rods tighter
and make it difficult to obtain the correct
height shown in Fig.4. If this happens, the
cylinders should be charged as accurately as
possible. In addition, the height of suspension
cylinder should be checked again according
to the following table after the truck runs for
several days. The cylinder pressure shown
in table.1 is guide only. Cylinders should be
charged according to the height 'A' specified
in the Fig.5 and NOT solely on the basis of
monitoring cylinder pressure.

Tab.2 Rear Cylinder charging height and

pressure

Cylinder height

'A'

Cylinder pressure

Truck

empty

A=455mm

1.5MPa

Truck

loaded

A=366mm

10MPa

Maintenance

Visually check suspension cylinder heights
daily(Fig.1-6&Tab.3). Lubricate the suspension
cylinders at service intervals and with lubricant

specified in Chapter 36.1 “LUBRICATION AND

MAINTENANCE”.

Tab.3 Special torque specifications

Fig. No. Item No.

Name

Torque

(N•m)

Bolt

333

Bolt

136

Radiator Guard

Fig.1 Breakdown drawing of Radiator Guard

1.Bolt

8.Fog lamp shield

2.Washer

9.Washer

3.Sealing plate

10.Bolt

4.Bolt

11.Company logosrt

5.Washer

12.Radiating net cover

6.Nut

13.Bolt

7.Hood frame

14.Washer

22 RADIATOR GUARD

22.1 Radiator Guard

4
5

Radiator Protective Cover

Overview

Radiator guard provides necessary defence for
the radiator front the truck, the serried mesh
guarantees necessary airflow to the radiator
fan.The removable upper cover plate provides
convenience of maintenance and overhaul.

Removal

Numbers in parentheses refer to Fig.1, unless

otherwise specified.

Note:

Approximate weight of radiator guard

assembly is

280Kg

1.Position the truck in a level work area, apply
the parking brake and block all wheels.
2.Remove bolts(13),washers(5), 22 in all.
3.Remove grid mesh(12).
4.Remove bolts(13),washers(14) that under
the hood frame,7 in all.
5.Remove bolts(4),washers(5),nuts(6)the two
sides of the hood frame,4 in all.
6.Remove hood frame(7).

Installation

Numbers in parentheses refer to Fig.1, unless

otherwise specified.

Note

:Tighten all fasteners to standard

torques in 36.2, 'STANDARD BOLT AND NUT
TORQUE
SPECIFICATIONS'.
Approximate weight of radiator guard
assembly is 280Kg.
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.

Body And Mounting

Fig.1 - Exploded View of Body and Mounting

5 4

9 10 11

21
23

35 36

37 38

31 32 33

23 BODY AND MOUNTING

23.1 Body and Mounting

1.Body

22.Rubber splashboard

2.Right front guard

23.Plate

3.Washer

24.Washer

4.Washer

25.Nut

5.Bolt

26.Shim

6.Left front guard

27.Shim

7.Exhaust device

28.Brace piece axial pin

8.Nut

29.Plate

9.Washer

30.Mounting plate

10.Washer

31.Washer

11.Bolt

32.Washer

12.Shim

33.Bolt

13.Shim

34.Bar

14.Shim

35.Shim

15.Shim

36.Shim

16.Damping pad

37.Shim

17.Brace piece axial pin

38.Washer

18.Plate

39.Cotter pin

19.Bolt

40.Pin

20.Bolt

41.Safety pin

21.Washer

42.Inserted pin

Body And Mounting

Overview

Numbers in parentheses refer to Fig.1.
Longitudinal 'V' floor which gives the body
rigidity and a low centre of gravity.The body
reinforced by wide channel-section stiffeners.
The body is pivoted at Brace piece axial pins
(28) at the rear of the frame and is operated
by two stage hoist cylinders mounted outside
the frame rails. The hoist cylinders raise the
body to a tipping angle of 60° in 16 seconds
and power down the body in 15 seconds.

Operation

The body control joystick, mounted at the
left hand side of the drivers' seat, provides
electricity signal for operating body control
valve which controls the way of entering oil
and so make up shifts and downshifts of body.
The four operating positions of the body
control joystick from front to rear are: Lower,
Float, Hold and Raise.

Raising the Body

Before raising the body, allow the engine to
slow to idle, make sure the rear wheels are
on firm level ground, shift the transmission
to Neutral and hold the truck stationary by
Parking brake control.
Move the body control joystick back to the
'Raise' position and accelerate the engine. The
body can be stopped at any point by moving
the joystick to 'Hold'. Decelerate the engine
as the last stages of the body hoists begin
to extend to slow the raising speed as the
hoists approach their maximum extensions.
When the body has been raised to the desired
height, move the control joystick to the 'Hold'
position until the body is to be lowered.

Lowering the body

To lower the body, move the control joystick to
the 'Float' position to allow the body's weight
to lower it to the frame. Body descent can be
stopped at any position by moving the joystick

Body And Mounting

back to the 'Hold' position. If the body does not
begin to lower by its own weight, such as after
dumping downgrade, move the control joystick
all the way forward to the 'Lower' position
and power the body downward until it begins
lowering by gravity. Then move the joystick to
'Float' to allow the body to lower the rest of the
way to the chassis. Make sure that the body is
completely lowered and the control lever is in
'Float' before releasing the brakes and moving
the truck.

Removal

Numbers in parentheses refer to Fig.1.

Note

: Approximate weight of body (1) is

13,631kg.

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.

1. Position the truck in a level work area, apply
the parking brake and block all wheels.
2. Raise body (1) and install body safety pins
(41).
3.  Remove  bolts  (19),  washers  (10)  and
plates(18) securing hoist cylinder mounting
pins  to  body  (1).  Do  not  remove  cylinder
mounting pins (17) at this stage.
4. Remove body safety pins (41) and lower
body (1) to rest on the frame rails.
5.  Support body hoist cylinders from the rear
of the truck to prevent them swinging back on
removal of cylinder mounting pins. Remove
cylinder mounting pins (17) and allow body
hoist cylinders to rest against the chassis.
6. Remove plates(28),bolts (5) and washers
(3) securing body brace piece axial pins(28).

Body And Mounting

Remove body brace piece axial pins(28) and
shims (26&27) from body (1) and pin mounting
bores. Using suitable lifting equipment, sling
body (1) and remove from the truck.

Note

: Do not remove damping pads (16) and

shims (14 & 15)unless damping pads (16) are
being replaced.
7. If required, remove nuts (8) , washers (9
& 10) and bolts (11) securing damping pads
(16) and shims (12

、

15) to body (1).

Remove and discard damping pads (16) and
shims (12

、

15).

Note

: Do not remove damping pads (16) and

shims (12

、

15)

，

unless damping

pads (16) are being replaced.

Installation

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.

Note

: Tighten all fasteners to standard

torques in 36.2, STANDARD BOLT AND NUT
TORQUE SPECIFICATIONS.

Note

: Approximate weight of body (1)

134,631k.
1. Ensure body Brace piece axial pins (28)
and bores in body (1) are thoroughly cleaned
with a suitable solvent. Coat Brace piece axial
pins (28) and bores in body (1) with a suitable
anti-seize compound.
2. Using suitable lifting equipment, sling body
(1) and centralize over the frame.
3. Align Brace piece axial pins (28) bores in
body (1) with mounting bores in the frame.
Install body Brace piece axial pins (28) and

Body And Mounting

secure with plates (29),bolts (5) and washers
(3).
4. Remove lifting equipment from rear lifting
points on body (1) and raise the front end
of body (1) to provide access to install body
hoist cylinders. Position wooden blocks (or
suitable stands) on the frame rails and lower
body (1) to rest on the blocks. Remove lifting
equipment from body (1).
Start the engine and using the body control
lever, extend the body hoist cylinders until
mounting holes are aligned with mounting
bores on body (1).Secure both body hoist
cylinders to body (1). Refer to chapter 14.5,
'LIFITING CYLINDER '.
5. Raise body (1), remove blocks and lower
body (1).
6. Install the body damping pads (16 ) and
shims (12

、

15) as described under'

BODY SHIMMING PROCEDURE'.
7. Ensure body (1) is centralized on the frame
rails,  remove  body  brace  piece  axial  pins
(28) .Adjust brace piece axial pins (28) with
shims (26 & 27) as described described under
'BODY SHIMMING PROCEDURE'.
Check  for  correct  clearance  and  secure
body brace piece axial pins (28) with plates
(29),bolts (5) and washers(3).
8. Install the damping pads (16 ) and shims
(12

、

15 ) on the frame guides

as described under 'BODY SHIMMING
PROCEDURE'.
9. Raise and lower body (1) and check for
correct clearance at body brace piece axial
pins (28) and body guides.
10.Weld the exhaust device on the body,

check the flue through lifting and dropping the

body.

Body shimming procedure

Numbers in parentheses refer to Fig.1.

Note

: Tighten all fasteners to standard

torques in 36.2, STANDARD BOLT AND NUT
TORQUE SPECIFICATIONS.

Body And Mounting

Note

: Damping pads (16) should be checked

every 250 hours and should be adjusted if
necessary.

Note

: When it becomes necessary, damping

pads (16) should be replaced as a set to
maintain load distribution along the chassis.
Existing body pads will have taken a
compression 'set' and a new pad shimmed to
match existing pads will not carry its share of
the load, resulting in uneven load distribution
along the chassis.

Note

: The frame guides should also be

inspected and rebuilt as necessary at this
time.
1. Raise body (1) clear of the frame and
position damping pads (16) roughly in position
on the frame rails. Lower body (1) onto body
damping pads (16).
2. Shim the two rear damping pads (16) with
shims(12

、

15) until body brace piece

axial pins (28) are just touching at the top of
body (1) bores.
3. Shim remaining damping pads (16) with
shims (12

、

15 ) to ensure body (1)

is resting parallel on the frame. Ensure all
residual damping pads(16) joint with frame.
4. Secure damping pads (16) and shims
(12

、

15) to body (1) with bolts (11),

washers (9&10), nuts (8).
5. Centralize body (1) on the frame rails, and
measure the clearance between inside of

the brace piece axial pin seat and flange end

face of frame .Remove body brace piece axial
pins(28), install shims of frame (26 , 27,or 26 &
27 ), ensure clearance of 0.5 -1.0mm between
inside of the brace piece axial pin seat and

flange end face of frame .Secure brace piece

axial pins(28) with plates(29),bolts(5) and
washers(3) .
6. Centralize body (1) on the frame rails,
measure clearance between frame limiter and
body limiter. Fix shim ,choose a suitable one
from 12, 13, 14, 15 or combining each of them
onto the body limiter with nuts (8),washers

Body And Mounting

SANY SRT95C Off-Highway Truck. Service Manual - page 26