SANY SRT95C Off-Highway Truck. Service Manual

Installation

Numbers in parentheses refer to Fig.1.

WARNING

To prevent personal injury and property

damage, be sure wheel chocks and lifting

equipment are properly secured and of

adequate capacity to do the job safely.

1. Using suitable lifting equipment, position oil
cooler (31) to mounting bracket, and secure
oil cooler (31) to mounting bracket with nut (4)
, bolts (1,29) and washers (2,3) .
2. Secure oil inlet pipe assembly (9) and oil
outlet pipe assembly (34) to oil cooler (31) with

' O ' ring (5), flange(6) , washers (7)and bolts

(8).
3. Secure water outlet tube assembly (17) to
port ' A ' with clamps (14).
4. Secure water inlet tube assembly (33) to
port ' D ' with bolts (18) , washers (7) and
gasket (32).
5. Fill transmission with transmission oil

specified in Section 36.1,' LUBRICATION AND

MAINTENANCE '.
6. Ensure all drain cocks on the cooling
system are securely locked and fill cooling

system with coolant as specified in chapter 32,

' RADIATOR AND MOUNTING '.
7. Start the engine and check for leaks.

Tighten lines and fittings as required.

8. Remove wheel blocks from all road wheels.

Special tools

There are no special tools required for
procedures outlined in this section. Refer to
36.3,' SERVICE TOOLS '.

Transmission Cooling Piping Mounting

Fig.1 Radiator And Mounting

1.Radiator assembly

10.Clamp

19.washer

2.Clamp

11.Cross pipe assembly

20.Bolt

3.Inlet pipe

12.Washer

21.Cooler

4.Inlet pipe

13.Bolt

22.washer

5.Inlet pipe

14.Outlet pipe

23.Damper

6.Elbow

15.Nut

24.Sleeve

7.Outlet pipe

16.Washer

25.Support Rod

8.Outlet pipe

17.Plate

26.Nut

9.Hose

18.Damper

27.Washer

Radiator And Mounting

10 11

15 16 22

24 23 22

1619

27 26

32.1 Radiator and Mounting

Overview

Numbers in parentheses refer to Fig.1, unless

otherwise specified.

Radiator assembly (1) is mounted at the front
of the chassis in front of the engine cooling
fan.
A fan shroud assembly comprising of shroud
and ring improves the engine cooling fan
efficiency and avoid to injury the engine
cooling fan Radiator assembly (4) includes two
parts, the narrow part Is for the compressed
air cooling and the other Is for the cylinder, the
oil brake, and the gearbox cooling.

Removal

Numbers in parentheses refer to Fig.1, unless

otherwise specified.

Remove the components as following:
1. Position the vehicle in a level work area,
apply the parking brake and shutdown the
engine. Turn the steering wheel in both
directions several times to relieve pressure in
the steering system. Block all road wheels.

2. Depress pressure relief button on filler cap
and remove filler cap from filler neck.

3. With a suitable container in position, open
drain cock at the bottom of radiator assembly
(4) and drain the cooling system. Close drain
cock securely when coolant is completely
drained.
4. Slacken clamps of hose connected to the
water tank, remove the hose for sealing and
tag them correctly.
5. Slacken clamps (2) and remove inlet pipe
(3, 4, 5) away from the radiator top container
connections. Cap open pipe ends to prevent
entry of dirt.
6. Slacken clamps (10) and slide the hose (9)
away from cross pipe assembly (11).
7. Slacken clamps (2) and remove outlet pipe

32 RADIATOR AND MOUNTING

Radiator And Mounting

(7, 8, 14).Cap open pipe ends  to prevent
entry of dirt.
8.  Remove  bolts  (13)  and  washers  (12)
securing  cross  pipe  assembly  (11)  to  the
frame.
9.  Remove  bolts(13),washers(12,27)  and
nuts(26)  securing  cooler  (21)  to  radiator
assembly (1).
10. Remove nuts (15), washers
(16), washers  (19), washers  (23), sleeves (24)
and  flexible mounts  (22). Remove support
rods  (25)  from  radiator  assembly  (1)  and
chassis brackets.
11. Attach suitable lifting equipment to radiator
assembly (1) and  remove nuts(15),washers
(16,19), plates(17), dampers(18), and bolts(20)
securing  radiator  assembly(1)  to  chassis
brackets. Remove radiator assembly(1).

Installation

Numbers in parentheses refer to Fig.1, unless

otherwise specified.

1.Using suitable lifting equipment to radiator
assembly  (1),  position  plates(17)and
dampers(18) on  flexible mounts and secure
with bolts(20), washers (16,19) and nuts(15).
2.Install nuts (15), washers (16,19), washers
(22), damper (23), sleeves (24) , on end of
support rods (25) and secure support rods (25)
to mounting brackets on  radiator side  frames
and truck frame with nuts (18).
3.Position cooler (21) on radiator assembly (1)
and secure with bolts (13),washers (12,27)
and nuts(24).
4.Position cross pipe assembly (11) on frame
and secure with bolts (13) and washers (12).
5.Secure  outlet  pipe  (7)  to  Elbow  (6)  and
radiator assembly (1) with clamps (2).
6.Secure  outlet  pipe  (8,14)  to  cross  pipe
assembly (11) and radiator assembly  (1) with
clamps (2).
7. Secure hose (9) to engine and cross pipe
assembly (11) with clamps (10).
8.Position  inlet  pipe  (3,  4,  5)  on  radiator

Radiator And Mounting

32.2 Condenser Assembly

Fig.2 Installation and breakdown drawing of condenser

1. Bolt

6. Bracket

11.Liquid reservoir support

2. Washer

7. Bolt

12.Nut

3. Washe

8. Washer

13.Bolt

4.Nut

9.Washer

14.Pinboard

5.Condenser

10.Liquid reservoir assembly

Radiator And Mounting

7 8 9

Radiator And Mounting

Remvoal

See the fig.2 for the numbers in the brackets.

1. Install use plugs defend the end of the
refrigerant hoses.
2. Loosen the bolt (13), washer (8

、

9) and nut

(12), take off the liquid reservoir support (11)
from the pinboard (14).
3. Loosen the bolt (7), washer (8

、

9) and nut

(12), take off the liquid reservoir assembly(10)
from the liquid reservoir support (11).
4. Loosen the bolt (1), washer (2

、

3) and nut

(4), take off the condenser (5) from the bracket
(6).

Installation

See the fig.2 for the numbers in the brackets.

1. Fasten the condenser (5) in the bracket (6)
by the bolt (1), washer (2

、

3) and nut (4).

2. Fasten the liquid reservoir assembly(10) in
the liquid reservoir support (11) by the bolt (7),
washer (8

、

9) and nut (12).

3. Fasten the liquid reservoir support (11) in
the pinboard (14) by the bolt (7), washer (8

、

and nut (12).
4. Take off the plugs and connect the
refrigerant hoses.

Radiator And Mounting

32.3 Liquid Accumulator Assembly

Fig.3 Installation and breakdown drawing of liquid accumulator

1. Bolt

4. Liquid accumulator assembly

2. Lockwasher

5. Liquid accumulator support

3. Washer

6. Bolt

Water Tank Mounting And Lines

11 11

33 WATER TANK MOUNTING AND LINES

Fig.1 water tank mounting and lines

1. Clip

9. Clip

2. Make-up line

10. Deaeration line

3. Make-up line

11. Deaeration line

4. Bolt

12. Bolt

5. Washer

13. Nut

6. Nut

14. Washer

7. Water tank

15. Clamp

8. Overflow tubing

Removal

WARNING

To prevent personal injury and property

damage, be sure wheel chocks and lifting

equipment are properly secured and of

adequate capacity to do the job safely. Be

sure the water tank has cooled and the

coolant has drained, which can result in

a loss of coolant and possible personal

injury.

1. Slacken clip (9) off water tank (7), and

disconnect overflow tubing (8) from water tank

(7).
2.  Slacken  clip  (1,  9)  off  radiator,  and
disconnect Make-up Line (2, 3) and Deaeration
Line (10) from water tank (7).
3. Remove bolts (12), nuts (13), washers (14)
and clamp (15) securing Make-up Line (2).
4.  Slacken  clip  (1,  9)  off  water  tank  (7),
identify and disconnect Make-up Line (2, 3),
Deaeration Line (10) from water tank (7).
5. Slacken clip (9) off engine, and disconnect
Deaeration Line (11) from engine.
6. Slacken clip (9) off water tank (7), identify
and  disconnect  Deaeration  Line  (11)  from
water tank (7).

7. Disconnect electrical connection from float

level Switch.
8. Remove bolts (4), washers (5) and nuts (6)
securing water tank (7) to the platform. Attach
suitable lifting equipment to water tank (7) and
remove water tank (7) from the platform.

Installation

1. Using suitable lifting equipment, position
water tank (7) on the platform and secure with
bolts (4) and washers (5) and nuts (6).
2. Secure make-up Line (2, 3) and deaeration
Line (10, 11) to water tank (7) with clip (1, 9).
3. Secure make-up Line (2) with bolts (12),

Water Tank Mounting And Lines

nuts (13), washers (14) and clamp (15).
4. Secure make-up Line (2, 3) and deaeration
Line (10) to radiator with clip (1, 9).
5. Secure deaeration Line (11) to engine with
clip (9).

6. Secure Overflow Tubing (8) to water tank (7)

with clip (9).

7. Connect electrical connection to float level

switch.

Maintenance

Refer  to  Section  COOLING  SYSTEM  for
recommended  preventive  maintenance
procedures,  service  intervals  and  coolant
selection procedures.

Internal cleaning - water tubes

If scale deposits are present inside the water
tubes of the radiator, it is necessary to use
a suitable scale remover such as 'Powdered
Scale Solvent', or equivalent. This material is a

free-flowing powder, inhibited to prevent attack

on the cooling system materials.
For general cleaning use it is recommended
to use a concentration of 50 - 100 kg/m³ of
water at a temperature of up to 60° C. Rapid
circulation or agitation with compressed air will
reduce the time for cleaning.

Note

: If scale deposits within the radiator are

exceptionally heavy, concentrations up to 200
kg/m³ may be used.
The most convenient method of use is to
prepare a concentrated solution by mixing the
powder in hot water in a tank and then adding
the concentrated solution to water contained
in the radiator.

Note

: The solvent must always be added

carefully to water, not water to solvent.

External Cleaning

Note

: If a build up of dirt is apparent during

routine inspection, the following cleaning
procedure should beadopted.
1. Direct a steam jet at 100 - 300 kN/m², or

Water Tank Mounting And Lines

compressed air at 500 - 700 kN/m² on to the
faces of the radiator core assembly.
2. Liberally brush a liquid detergent on to
those surfaces which were not satisfactorily
cleaned at step 1. Leave to soak for at least 1
hour.
3. Apply a high pressure steam jet at 100 - 300
kN/m², or compressed air at 500 - 700 kN/m²
on to the treated surfaces, forcing the fouling
material out from the radiator core assembly.
4. Leave radiator core assembly to dry before
reinstalling the cooling equipment.

Note

: In the case of grossly fouled surfaces

which are not cleaned adequately in steps 1
through 4, the following procedure may be
used.
5. Ensure that the radiator core assembly is
dry.
6. Liberally brush on to both sides of the
radiator core assembly an emulsifying cleaner
such as 'Gunk', or equivalent, and leave to
soak for at least 1 hour.
7. Apply a high pressure steam jet at 100 -300
kN/m², or compressed air at 500 - 700 kN/
m² on to the treated surfaces, from several
different angles, forcing the fouling material
out from the radiator core assembly.
8. For surfaces with stubborn deposits, it may
be necessary to repeat steps 5 through 7,
brushing the surfaces between stages using a
stiff bristle brush.
9. Leave radiator core assembly to dry before
reinstalling the cooling equipment.

Special tools

There are no special tools required for
procedures outlined in this section. Refer
to Section 38.2, SERVICE TOOLS, for part
numbers of general service tools required.

Water Tank Mounting And Lines

Battery And Installation

Fig.1 Battery and Installation

1. Battery

6. Connector

11. Screw

16. DC contactor

2. Washer

7. Fuse

12. Washer 17. Washer

3. Washer

8. Fuse base

13. Washer

18.Washer

4. Nut

9. DC contactor 14. Nut

19.Nut

5. Battery switch

10. Fuse base

15. Screw

34 BATTERY AND INSTALLATION

Battery And Installation

Battery instruction

SRT95C off-highway truck uses four VARTA
maintenance free batteries, of which two
are connected in series and then in parallel,
in order to provide 24V power supply to the
engine.

1 Safety

1.1 The  battery  contains  strong  corrosive
sulfuric acid and it should be kept away from
children. The  user  should  wear  protective
glasses and rubber gloves when using the
battery.  Clean  with  large  quantity  of  clean
water if the eye, skin or clothes has contacted
sulfuric acid. The seriously injured user should
be sent to the hospital.
1.2 The hydrogen and oxygen produced by
battery during charging may explode when
meeting open flame or if the exhaust port is
blocked. Therefore, the battery should be kept

away from open flame and avoid short circuit.

1.3 The battery housing made of polypropylene
is flammable and should be kept away from

open fire.

1.4 Please follow the cautions on the label
strictly in battery use and maintenance.

2 Storage

1. The  battery should be kept in a dry, clean
and well-ventilated room with the temperature
of  5-25°C  and  be  kept  away  from  direct
sunshine  and  at  least  2m  away  from  heat
source.
2. The battery should not be reversed or laid
down. Additionally,  it  should  not  bear  any
mechanical shock and stress.

3 Charging

The constant voltage and constant current
charging method can both be applied.
However, the constant voltage charging
method is recommended.
3.1 Charging battery
3.1.1 Constant voltage charging method

Charge  the  battery  with  constant  voltage
(between  26V  and  28V)  till  the  charging
current reaches zero. During the process of
charging the charging current is large initially
and decrease gradually. The battery generates
a little of gas and consumes a small amount of
water. Therefore, constant voltage charging
method is usually applied to maintenance free
lead-acid battery.
3.1.2 Constant current charging method
Charge till the voltage reaches 27.6V with 1/20
current (A) of C20 rated capacity of battery
and keep on charging for 2-3 hours. In this
charging procesure, compared with constant
voltage charging method the charging current
is  smaller  initially  and  can  not  damage
chlorideplate. The temperature of electrolyte
increase at the end of charging because the
batteries charged completely the electrical
energy are consumed in water electrolysis. So
this charging method is not recommended.
3.2. When the battery is charged, the positive
electrode of the charger should be connected
with the positive electrode of the battery while
the negative electrode of the charger should
be  connected  with  the  negative  electrode
of the battery. Reverse charging is strictly
forbidden.
3.3.  In  the  process  of  charging,  when  the
electrolyte in the battery has a temperature
of  more  than  35°C,  the  charging  voltage
or  charging  current  should  be  reduced
accordingly so as to protect the electrolyte
splashing.

4 Installation

4.1 The batteries of this series only apply to
the starting of engine.
4.2 Keep the end post clean before battery
installation. The wiring should be firm and
reliable. Do not knock the end post, in order to
avoid acid leakage of battery.
4.3 Connect battery anode to engine anode
before connecting battery cathode to engine

Battery And Installation

SANY SRT95C Off-Highway Truck. Service Manual - page 30