SANY SRT95C Off-Highway Truck. Service Manual

cathode when installing the battery.

5 Maintenance

5.1 The battery cover has an indicator that
can display battery load. When the indicator is
green, the battery can be used normally.
When the indicator is black, the battery should
be charged timely. When the indicator is white,
the battery should be immediately replaced.
5.2 The battery short of power during the use
should be charged timely.
5.3 The battery must not overcharge during
the use and charging.
5.4  The  battery  may  produce  gas  during
charging. Check the exhaust hole of battery at
regular intervals to prevent blocking which can
lead to explosion.
5.5 Regularly check the connecting parts for
firmness and end post surface for cleanness
to ensure good contact.
5.6 The battery that will not been used for
a long time (more than 15 days in general)
should be removed from the truck and stored
in a ventilative and dry place. The battery
should  be  charged  for  each  3-6  months
(depending  on  whether  the  indicator  turns
black).
5.7  Do  not  open  or  loosen  battery  cover
without authorization.
5.8 Please contact the distributor for a solution
if a battery is suspected of a problem.

Specifi c Components and Models

60125384

Battery switch

A242200000057

Battery 31750T

Battery And Installation

Cables And Harnesses

Fig.1 Harness Of Front Lamp

35 CABLES AND HARNESSES

右前转向灯/示宽灯

右近/远光灯

搭铁

AMP8

针接头

SX1

公

喇叭

左近/远光灯1

左近/远光灯

左前转向/示宽灯

Connector to direction /side marker lamp F,L

Connector to dipped /high beam light L2

Connector to dipped /high beam light L1

Earth

Connector to horn

Connector to dipped /high beam light R1

Connector to dipped /high beam light R2

Connector to direction /side marker lamp F,L

8-core Plug SX1

Connector to dipped /high beam light L3

左近/远光灯3

Fog lamp F,L

左前雾灯灯

右前雾灯灯

Fog lamp F,LR

Connector to dipped /high beam light R3

右近/远光灯3

AMP3

针接头公

3-core Plug

Cables And Harnesses

Fig.2 Harness Of Rear Lamp

右后示宽灯/右制动灯/右后转向指示灯

右后雾灯

尾灯系统搭铁

AMP8

针接头

SX2

公

缓行灯

左后示宽灯/左制动灯/左后转向指示灯

左后雾灯

Earth

8-core Plug SX2

Connector to fog lamp B,L

Connector to side marker/brake/Indicator lamp B,L

Connector to retarder lamp

Connector to fog lamp B,L

Connector to side marker/brake/Indicator

lamp B,R

3-core Plug

AMP3

针接头公

Reversing lamp/ reversing alarm

倒车灯/倒车报警器

Hoist limit switch

举升接近开关

Fig.3 Harness Of Truck Body

Cables And Harnesses

AMP8

针接头

SX1

母

针接插件

SX3-A

公

针接插件

SX4-A

公

举升比例电磁阀

下降比例电磁阀

刹车接近开关

转向蓄能器压力传感器

左后照灯

液压缓行比例电磁阀

停车电磁阀

驻车电磁阀

前制动蓄能器压力传感器

驻车压力传感器

后制动蓄能器压力传感器

下降到位接近开关

右后照灯

燃油液位传感器

变速箱压力传感器

缓行推杆

变速箱温度传感器

浮动电磁阀

AMP8

针接头

SX2

母

变速箱油滤器压力传感器

转向回油温度传感器

转向回油压力开关

盘制动冷却回油温度传感器

缓行手柄

蜂鸣器

举升手柄

针接插件

SX4-B

母

针接插件

SX3-B

母

变速箱缓行

翘板开关

Connector to brake proximity switch

Steering accumulator pressure sensor

31-pin plug SX3-A

29-pin plug SX4-A

Connector to disc brake

cooling oil

returning temperature sensor1

Connector to retarder

joystick

Connector to left rear light

Lower to proximity switch

Connector to right rear light

Lower proportional soleniod valve

Hoist proportional soleniod valve

Hydraulic

retarder

proportional switch

Connector to stop solenoid valve

8-pin Socket SX1

Connector to park soleniod valve

Connector to fuel level sensor

31-pin plug SX3-B

29-pin plug SX4-B

8-pin Socket SX2

Connector to hoist joystick

Buzzer

Transmission retader rocker switch

Connector to

steering

oil return pressure switch

Connector to transmision fuel level sensor

Connector to brake accumulator pressure sensor B

Connector to brake accumulator pressure sensor F

Connector to steering oil returning temperature sensor

Connector to retarder pushrod

Connector to transmision pressure sensor

Connector to transmission temperature sensor

Connector to park pressure sensor

Connector to float soleniod valve

Ⅰ

AMP3

针接头母

3-pin Socket

AMP3

针接头母

3-pin Socket

Installation and connection of harness

1. The harness of the truck should be
protected properly. It should be protected from
touching projecting corner, sharp edge or
abrasive surface. When the harness passes
through a hole, a sleeve should be provided
for protection.

2. The harness should be fixated properlyevery

200 to 400 mm. It is not allowed to fixate
the wire harness too tightly. It should not be

fixated near oil, water and gas pipelines.

3. There should be a proper distance between
the wire harness and the heat source,
including the exhaust system, oil cooler, water
tank, heater, radiator and so on, or effective
heat insulation measures should be taken.
4. If the harness is too long, then it should

be effectively bundled up for fixation so as to

avoid friction due to the relative motion.
5. When the electric welding and the gas
welding are in progress, the harness should

be protected effectively from spark and flame.

6. If the harness is not installed or adjusted
properly, the electronic connection signals
passing through the harness may be disrupted.
It may lead to control failure of transmission or
periodically produce some unnecessary error

codes which are difficult to detect. Therefore,

the harness should be installed properly.

Detection and determination of circuit

faults of harness

1. Detection and determination of harness
burn-out fault.
All harness burn-outs happen suddenly with a
fast burning speed. In the burned-out circuit,
there is generally no fuse device. The rule of
harness burn-out is: In the circuit of the power
supply system, the harness is burned out till
the ground circuit is reached. The place where
the burned-out harness and the intact harness
join is considered to be ground. If the harness
is burned out till the connecting part of a piece
of electrical equipment, then it indicates that

Cables And Harnesses

this electrical equipment is faulty.
2. Detection and determination of short circuit,
open circuit and poor contact among circuits
a.  The  harness  is  externally  extruded  or
shocked  and  insulation  layers  of  wires  in
the harness are damaged, which results in
the short circuit among wires, out-of-control
of some pieces of electrical equipment and
burning out of fuses. When determining the
cause, the harness connectors which are at
both ends of the electrical equipment and the
control  switch  can  be  disassembled. After
that, a multimeter can be used to detect short
circuit.
b.  Open  circuit  of  wires.  Except  obvious
fracture, common faults occur mainly between
wire and wire terminal. For some wires with
open circuit, the outer insulation layer and
the  wire  terminal  are  intact,  but  the  core
thread in the wire and the wire terminal have
disconnected. In order to find the reason, a
multimeter can be used to test the circuit, or a
tension test can be conducted for the wire and
the wire terminal suspected of open circuit.
In the process of the tension test, if the wire
insulation layer is elongated by degrees, it can
be determined that this wire is disconnected.
c. Poor contact of the circuit. This kind of fault
occurs mainly inside connectors. When this
fault occurs, electrical equipment cannot work

normally. In order to find the reason, connect

this  electrical  equipment  with  the  power
supply, touch or pull related connectors of
this electrical equipment. When a connector
is touched, this electrical equipment can work
normally  sometimes  but  abnormally  some
other times; it indicates that there is something
wrong with this connector.
3. Replacement of harness assembly
External examination
The  model  of  new  harnesses  should  be
as same as original truck model. The wire
terminal is connected reliably with the wire.
Pull each connector and wires to check for

Cables And Harnesses

such phenomena as looseness or separation.
Compare the new harness with the original
one. For example, the colors, size and terminal
should be basically consistent. If there is any
doubt, a multimeter can be used to test. Only
after ensuring intactness can this wire harness
be used for replacement.

Cables

warning

Be careful of dangerous hydrogen and

the sulphuric acid solution. Check the

required voltage and polarity of the cable

connected with discharged batteries.

The battery may blow due to a too-high

voltage, misconnected cables, open fire,

lighted cigar, or other ignition source, thus

resulting in fire. Keep fire source far away

from the battery. Your body should be over

the battery. Glasses should always be worn

to avoid burning.

Caution: When the mode of jumper cables is
used to start the engine, it should be ensured
that two trucks don't contact each other and

the cable with the same specifications as the

original truck should be used. If the engine is
started by jumper cables, the following steps
should be followed:
1. Connect one end of jumper cable, usually
the red end, to the positive (+) terminal rod of
the uncharged battery.
2. Connect the other end of the cable above
to the positive (+) terminal rod of the auxiliary
power supply or the charged battery.
3. Connect one end of the second cable,
usually the black end, to the negative (-)
terminal rod of the auxiliary battery.
Connect the other end of the original cable
connected with the negative electrode to the
ground terminal of the truck frame. As it is far

Cables And Harnesses

Others

36 OTHERS

36.1 Lubrication and Maintenance

36.1.1 Lubrication and maintenance

WARNING

The truck is equipped with engine and

transmission oil sump, thus enabling it to

drive on a road with a gradient of no more

than 30° (60%). In case of a bigger gradient,

please consult the manufacturer.

Lubrication  is  a  main  part  of  preventive
maintenance.  Its  operation  procedure,
lubricant types as well as application cycles
are all of great significance to extending the
efficient service life of a truck. Lubrication of
moving parts at regular intervals can minimize
the possibility of mechanical faults.
All  the  recommended  specifications  for
replacement and maintenance intervals are
determined according to the general working
conditions.  In  case  of  severe  phenomena
such as over-heating, oxidation or pollution
of  lubricant  during  operation,  change  the
lubricant  more  frequently  to  prevent  the
aforesaid phenomena from happening again.
Lubricant  replacement  and  maintenance
period should be determined according to the
sampling of specific working conditions and
suggestions by the supplier of lubricant.
All  the  joints,  blocking  covers  and  screw
covers should be cleaned thoroughly so as to
prevent dirt from entering. Lubricant should
remain at the working temperature when the
system discharges.

Note

: Check whether the oil volume falls within

the specified working scope on the basis of
liquid level indicated by oil gauge, liquidometer
or oil level screw cover. Otherwise, no system
is allowed to go into operation.

Table of lubrication and maintenance

The small dots in the following Fig.indicate
the  parts  that  have  to  be  lubricated  and
maintained. The digits on the left hand side
indicate  the  lubrication  and  maintenance
interval.
The  digits  in  Fig.1  should  match  with  the
numbers correspondingly in the lubrication
and maintenance table.

Fig.38-1 Lubrication and maintenance points

Others

Lubrication and Service Chart

Interval

hours

Ref.

Points

Identification

Service Instructions

No. of

Points

Lubricant

Service/Quantities

Engine

Check oil level. Add if
low.

As Required

Transmission

Check oil level. Add if
low.

HTF

As Required

Hydraulic Tank(Hoist/
Cool)

Check oil level. Add if
low.

As Required

Hydraulic Tank(Steer/
Brake)

Check oil level. Add if
low.

As Required

Remote water tank

Check oil level. Add if
low.

Antifreeze

see page chapter 35

"Remote water tank

and pipe installation"

Filter(Steer/Brake)

Cooling Fan

Visually inspect for
debris and damage.

Drive Belts

Visually inspect all
belts.

Ref Engine Manual

8&9

Front and Rear Ride
Cylinders

Visually inspect
heights.

Ref "Ride cylinder" and

"Rear ride system"

Air Cleaner Restriction
W/Light

Check. Replace
element if reqd.

Refer to “Air Cleaner

Service ”

Air Cleaner Vacuator
Valve(s)

Check for proper
operation.

Fuel Filter/Water
Separator

Drain water and
sediment.

Tyres

Check condition.
Check pressures
when tyres are cold.

Ref " Front wheel

assembly" and "Rear

wheel assembly"

Controls, Instruments
and W/Lights

Check for proper
operation.

General Inspection

Check for leaks and
worn/damaged parts.
Repair/replace as
required.

Others

Rear Ride Cylinders

Lube

EP,NLGI

Steering Cylinder
Bushings

Lube

EP,NLGI

Low Pressure Filter

Lube

EP,NLGI

A-Frame Nose
Spherical Bushing

Lube

EP,NLGI

Banjo Stabilizer
Spherical Bushings

Lube

EP,NLGI

Body Hinge Pins

Lube

EP,NLGI

Body Hoist Bushings Lube

EP,NLGI

A-sharp Arm

Lube

EP,NLGI

Front Ride Cylinders Lube

EP,NLGI

Crank pin

Lube

EP,NLGI

21 Cross shaft

Lube

EP,NLGI

250

Engine

Drain and refill.

Engine Oil Filters

Replace filters.

Ref Engine Manual

Engine Fuel Filters

Replace filters.

Ref Engine Manual

Engine Coolant
Additive

Check DCA
concentration and
replenish.

DCA4

Ref Engine Manual

Engine Coolant
Filter(s)

Replace filter(s) if
required.

Engine Crankcase
Breather

Clean

Ref Engine Manual

Engine Cooling Fan

Check condition.

Engine Power Takeoff

Check oil level. Add if
low.

EPL

Wheel Planetaries

Check oil level. Add if
low.

EPL

Differential Breather

Clean.

EPL

Transmission Breather Clean.

Alternator Drive Belt

Check belt tension.
Adjust if required.

Ref Engine Manual

Accessory Drive Belts

(if fitted)

Check belt tension.
Adjust if required.

Ref Engine Manual

Air Cleaner

Clean the primary
cleaner

Front Brake Pads

Check wear. Replace
as required.

Others

1000

Return filter of

hoisting system

Replace filter

Return filter of

steering system

Replace filter

Filter of steering
pipeline

Replace filter

Filter of cooling
pipeline

Replace filter

Filter of brake van

Replace filter

Breath valve of
steering

Replace breath
valve

Breath valve of
hoisting

Replace breath
valve

1200

Transmission

Drain and refill.

HTF

Transmission Oil Filter Replace element.

Engine PTO

Drain,clean and refill

Differential

Drain,clean and refill

Wheel Planetaries

Drain and refill

2000

Fuel Tank

Drain and refill

Diesel

Rear Brake Packs

Drain and refill

3000

Hydraulic Tank(steer/
brake)

Change,clean and

refill

Hydraulic Tank(hoist/
cool)

Change,clean and

refill

Suction filter of

hoisting system

Replace filter

Suction filter of

steering system

Replace filter

Suction filter of

cooling system

Replace filter

4000

Cooling System

Drain, flush and refill

Antifreeze

Front Wheel Bearing

Inspect , readjust
gap,replace the
grease as the case
may be.

*EP NLGI

Others

36.1.2 Other maintenance

As required

Seat safety belt-Check the condition and
replace if it is damaged.

Note

: Replace it for every three years despite

its conditions.
Windshield and wiper-Check the wiper arm
and replace if it is damaged. Fill the cleanser
water tank and keep the water accumulator
upright.

Rim nut- Adjust the torsion to 690 N•m (510 lb/
ft) after working for 10 h for the first time, then

check the torsion for each 50 hours.

Every 10 hours of operation

Walk around the truck for inspection –check
according to chapter 4.
Engine-visually check the engine for damage,
bolt fracture, looseness and abnormal noise.
Engine air cleaner-check the air cleaner
air intake steel pipe, hose and pipe clamp.
Replace the filter if the air filter resistance
warning turns on. Clean the dust collection
valve daily, check and remove the dust in
such valve; the dedusting lip opening can be
opened and kept flexible after the engine is
shut down.

Caution

: Maintain the air cleaner more

frequently in a dusty working place.
Expansion water tank-check the cooling liquid

level and refuel if it is low; fill the cooling liquid

into the water tank and keep the liquid level at

the bottom of filling neck.

Note

: Check DCA4 density after plenty of

cooling liquid is filled because the low density

may damage the engine; the excessive
antifreeze liquid may lead to the deposition of
silicate, see chapter 35 'Remote Water Tank
and Pipeline Installation' of the Maintenance
Manual.
Steering, braking and hoist systems - Check
whether each system can work normally prior
to operation of the truck.

Steering hydraulic oil tank filter-keep the truck

Others

empty, release the brake, run the engine with
the speed of 1,500 RPM, rotate the steering
wheel with 1 r/s after the oil temperature is
normal, replace the filter if the filter warning
light is on.
Rear disc brake cooling oil filter-replace the
filter when the indicator shows that the oil
surface has reached the limit position.

New or overhauled part after working for

150 hours for the first time

Transmission - Discharge oil, replace the filter
and refill oil.

Differential mechanism-drain the oil and refuel
with new oil.
Hub reducer- drain the oil and refuel with new
oil.

Every 250 hours of operation

Filling point of oiler – instill engine oil throttle
connecting rod, articulating pin and other
moving parts.
Cooling liquid filter-replace the filter. Refer to
chapter 35 'Remote Water Tank and Pipeline
Installation' in the Maintenance Manual,

correctly select the cooling liquid filter to keep

proper additive DCA4 density in the cooling
system.
Cooling liquid additive-check and supplement
DCA4 according to chapter 35 'Remote
Water Tank and Pipeline Installation' in the
Maintenance Manual.
Cooling fan-visually check the fan blade for
cracking, rivet looseness or bending, check
fan installation and tightness and replace the
damaged fan.

Note

: The correct tension of fan belt is kept by

spring belt. Therefore, it is not necessary to
check or adjust the belt tension.
Driving belt-visually check each driving belt and
replace the cracked or worn belt. Adjust the
worn and slipping belt. The correct installation
and tensioning of belt can reduce belt and
belt wheel wearing. Refer to chapter 5 'Engine

Others

SANY SRT95C Off-Highway Truck. Service Manual - page 31