Service Manual (English)

SRT95C Off-Highway Truck
SRT95C
Off-Highway Truck
Service Manual
WARNING
Read and follow the safety precautions and instructions in this manual and on the mac-
hine decals. Failure to do can cause serious injury, death or property damage. Keep this
manual with the machine for reading and future reference.
Service Manual A
Sany Group
SANY Mining Equipment
Kunshan Economic & Technological Developement Zone
Jiangsu Province, P. R. of China 215300
http://www. Sanyhe. Com
Tel: 0086-10-60738666
Fax: 0086-10-60738831
E-mail:[email protected]
2012 by Sany Group. All right reserved. No part of this publication may be reproduced,
used, distributed or disclosed except during normal operation of the machine as
described herein. All information included within this publication was accurate at the time
of publication. Product improvements, revisions, etc., may result in differences between
your machine and what is presented here. Sany Group assumes no liability. For more
information, Contact Sany Group.
B13T03ENAN1-SRT95C
B Service Manual
SRT95C Off-Highway Truck Preface
PREFACE
Dear users:
Thank you very much for purchasing mining
dump truck which is famous product of
SANY Mining Equipment co. , ltd ! We will be
providing you ' first class products, first class
quality and first class service' .
All of parts of machine are easily worn,
loosened and damaged if machine has been
used for a long time, so the regular inspection,
maintenance and servicing for machine that
are very important and useful way to your
machine for exert its performance and working
with stable, safety extending its service life.
We provided this manual book for you and it's
makes easily to inspection, maintenance and
servicing for machine.
The manual book has contained particular
specification and illumination to inspection,
maintenance, repairing of all parts of the
SRT95C and introducing some diagnosis and
resolving ways to regular malfunction. There
are methods and steps for repairing and
servicing are recommended and provided in
manual book. There are also provided some
special tools are designed for repairing or
some especial place of the machine.
Please read this manual book carefully,
included all of cautions and notes to minimize
the human injuries and deaths or machine
damages duo to the incorrect operation
methods. The operator has to know that there
are not illuminate all of danger situation with
cautions and notes which happened during
the servicing when you uses some tools are
not recommended, everybody has to ensure
of self-safety and machine safety first before
repairing.
Service Manual 1
Preface SRT95C Off-Highway Truck
Caution
The contents in the Maintenance Manual
are subject to change without notice. Please
contact the agent of SANY Mining Equipment
Co., Ltd. for the latest information.
2 Service Manual
SRT95C Off-Highway Truck Overview
OVERVIEW
Important safety notes
Does the maintenance and servicing in
correctly for the machine safe and reliable are
very important. There are description and all
recommends are useful for the maintenance
and servicing. In addition, there some special
tools are designed for maintenance and
operation, they are recommended when the
maintenance and servicing.
In order to minimize the possibility of
human injuries and casualties or damage
of equipment due to improper maintaining
method, this Manual and the important notes
and various warnings in it should be read
through carefully! It is also required to learn
the potential dangers of each method that the
details are not provided in these warnings and
notes, that are hard to foresee and that come
to mind during the process of maintenance.
Therefore, when adopting a maintenance
procedure or tool that is not recommended,
all operators must ensure that the maintaining
method can ensure the safety of their own and
the truck.
Safety warning sign
1. Following the safety information

indicated on the sign may help avoid possible
human injuries or death.
2. The sign is only used for warning you the
potential danger of human injuries.
Danger rating
A multi-level danger rating system is often
used to indicate potential dangers of human
injuries. The following symbols and notes
are used together for expresses the level
of dangerous, symbols and notes are used
independent for expresses the loss and
protection of properties. The symbols of the
manual has the same effect with the symbols,
Service Manual 3
Overview SRT95C Off-Highway Truck
notes, cautions and labels of the agreement

of the machine.
Danger It indicates an emergent

and dangerous situation, which may lead to
deaths or serious injuries if it is not avoided.
Warning It indicates a potentially

dangerous situation, which may lead to deaths
or serious injuries if it is not avoided.
Caution It indicates a dangerous

situation, which may lead to minor or moderate
injuries if it is not avoided.
The caution is used independent for indicated
potential dangerous situation without the
symbols, it could be makes the properties loss
if is not avoided.
General
Incorrect operation is very dangerous, so be
sure to read the Manual carefully before any
maintenance operation.
1. Before filling grease or repairing, read all
notes about the truck.
2. Safety boots and helmets must be worn
during operation. Do not wear unfitted work
clothes, and button up the clothes.
Wear safety goggles while striking with a
hammer.
Wear safety goggles when smashing stones
with a stone crasher.
3. When it is required to perform welding
operation, the operator must be an
experienced ones who has received training.
During the operation, the operator must wear
or use welding gloves, baffle, goggles, working
cap, and work clothes which things suitable for
the welding operation.
4. When the two operators are worked
together, they are has to follow the operation
procedures such as : informed the guy who
working together on site and has to hang the
label up which wrote the' repairing ' on it at
4 Service Manual
obviously place.
5. Storing all of tools properly and know that
how to use them.
6. Get a proper place in the workshop that
used to store tools and parts when they are
removed out of the machine. The store has
to keeping clean, oil-free and no smoking in
there.
warning
During the operation, the old pa r t s ,
repaired parts which performance has
been weakened that are prohibited to using
again, they will be effected the performance
of the machine seriously, and even lead
to severe damage to equipment or human
injury.
Preparation for operation

7. When the refilling and repairing the
machine, the truck must be parked on a solid
and horizontal ground. Place chocks for the
wheels to prevent the truck motion.
8. Before operation, it is required to drop to
the ground those parts and components that
are possible to slide down. If it is impossible,
such as : suspension cylinders and body etc
that are has to block by chocks to prevent
them drop out form the machine, in addition,
shutdown of the power, locked all of lever and
hanged the caution up at obviously place.
9. Before the disassembling or assembling
operation, chocks, jacks or other things to
support the truck.
10. Cleaning all of dirt things around of the
whole truck and uses armrest, ladder or stair
to mounting or dismounting truck. If no armrest
or ladder can be used, a jack horse with safe
base may be used.
Notes during operation

11. When the disassembling the feeding cover,
Service Manual 5
discharge cover and liquidometer, the operator

has to wear safety goggles and sideways
body to avoid liquid spray out during the cover
opening. Caution : discharge the pressure
from the hydraulic, water and air-compress
system before to disassembling them.
12. The water and oil system are very hot
when the engine shutdown. Pay attention ! Do
not touch them with hands.
Before any operation in the oil or water
system, wait for oil or water system cooled off
before start the operation.
13. Before operation, cut off electricity and
remove the battery wires. Removing the wires
from the cathode joints of the battery first.
14. A hoisting machine or crane may be used
to lift a cumbersome component.
Check the wire rope, chain and hoist hook to
prevent dangers.
It is required to use a hoisting device with
sufficient hoist power.
Erect the hoisting device at the correct
place. The hoisting machine or crane should
be operated slowly to prevent its components
getting collided with other parts. It is prohibited
to stand under the lifting machine when the
hoisting machine or crane are working.
15. When removing the cover which with
internal pressure or spring inside, it has to
unscrew the bolts at two opposite directions to
release the pressure gradually. Then unscrew
all of bolts slowly and remove the cover out of
machine.
16. Be slowly when disassembling the
structure parts from the machine, do not make
mistake of operated to cut or damaged the
wires, because the damaged wires may cause
fire.
17. When operator to disassembling the piping
system, operator has to avoid fuel or grease
get out of the machine, if fuel or grease
dropped on the ground, rub if off immediately
because that would makes worker slid or fire.
18. Do not use gasoline to clean any parts.
6 Service Manual
This is a general rules. Pay greater attention

when cleaning an electric parts.
19. Pay attention to reinstall all parts into their
original positions.
When using a new part to replace a damaged
one, put the new and old ones separately to
avoid mis-installation because they are mixed.
When installing of hoses and wires, it is
required to ensure that all hoses and wires will
be not damaged due to contact and wear with
other parts during the operation of the truck.
20. When installing of a high-pressure hose,
it is required to make sure that the hose does
not get twisted. It is very dangerous to damage
pipes, so be careful to install a high-pressure
pipe. It is also required to check whether the
connecting parts are installed in a correct way.
21. Tighten up a part to the given torque when
assembling or installing it. Pay great attention
to install a protective piece like baffle and a
party involving intense vibration and high-
speed revolution, and check whether they are
installed in a correct way.
22. When the two components needs to align
with two holes, do not put hand or finger into
any hole so as to avoid dangers.
23. Before checking the oil pressure, check
whether the measuring instrument is installed
correctly.
24. Cracking or disintegration of both tyres
and rim or either of them may result to
serious injuries or casualties. Abide by the
suggestions in instruction manual provided
by manufacturers or read the specification
provided by tyre supplier for reference strictly.
Storing of truck
In order to avoid damaging any parts of the
truck, pay great attention to keeping truck
for a short period or non-temporarily. On the
period of the storing the truck, if there are no
necessary ways to protecting all components
that will wastes more money for maintenance
of machine and delay the truck returned to
Service Manual 7
work.
Temporary storing
The company requires taking the following
preventive measures when the storing period
of the truck is within 30 days:
1. Fully inspection, checking of the vehicle
and make some necessary maintenances
and modifications for preparing to use vehicle
when the expired of storing date has been
arrived.
2. Lubrication Lubricate the truck thoroughly
according to the requirements specified in
Chapter 'CENTRALIZED LUBRICATION
SYSTEM' of the Manual.
3. Parking After cleaning the truck
thoroughly, park it on a level ground which is
solid and dry, and then apply parking brake.
Remember that there should not be any
grease or oil on the ground because such
substance will make all tyres to expired.
4. Battery If the local temperature is
moderate, the battery may be keep in the
truck, and it may be recharged for using it
again if it is not used after 30 days. If possible,
send the battery to a workshop for inspection
and recharging, and ensure that it can be fully
charged by way of micro-current charging.
Keep the battery at a place free of encroaching
severe temperature under the cold or torrid
climate.
5. Rust protection Clear off all rust over the
truck, and additionally, cover the exposed
metal surface of the truck with quality rust
inhibitor.
6. Oil tank Fill the fuel tank and hydraulic
oil tank to prevent moisture inside the oil tank
from getting condensed.
7. Tyre Inflate all tyres to the correct
pressure. During the period of storing, inspect
the pressure about once each two weeks.
8. Engine Refer to the maintenance manual
of engine to learn the complete procedure for
storing the engine less than 30 days.
8 Service Manual
9. Transmission Feed oil into the oil sump of

the transmission to the correct level.
Long-term storing within six months

When the truck is kept for over 30 days but
less than six months, the following steps must
be followed:
1. Inspection and maintenance Follow the
procedures for temporary storing.
2. Lubrication Follow Step 2 for temporary
storing.
3. Parking Follow Step 3 for temporary
storing, and chock up the truck with sleepers
to keep the tyres off the ground.
4. Battery Remove the battery from the
truck, keep it at an appropriate place, and
check it at least each 30 days (charge it once
or connect it to a micro-current charger upon
each inspection).
5. Rust protection Follow Step 5 for
temporary storing.
6. Oil tank Follow Step 6 for temporary
storing.
7. Tyre Deflate the tyres to 0.7 bar (10 pound
per square inch) after chock up the truck as
required in Step 3, clear all grease on the
tyres, and use suitable outer covers to protect
the tyres and keep them away from direct
sunshine and water erosion.
8. Transmission Refer to the maintenance
manual of transmission to learn the complete
procedure for keeping it over 30 days.
of engine to learn the complete procedure for
storing it over 30 days.
10. Ventilator and respirator remove all
ventilating holes and respirators and block
off all openings with covers; use waterproof
rubberized fabric to cover the ventilation holes
and respirators even if it is impossible.
Storing for over six months

When the truck is kept for over six months, the
following steps must be followed:
Service Manual 9
Others storing of truck

Note: In addition to the steps for the keeping
period less than six months, follow the following
additional requirements:
according to the instructions in Chapter
'CENTRALIZED LUBRICATION SYSTEM' of
the Manual.
2. Wheel bearing remove, clean, inspect and
re-assemble all wheel bearings.
Caution: Repeat the above steps once each
six months during the storing period.
Release of storing
according to the instructions in Chapter
'CENTRALIZED LUBRICATION SYSTEM' of
the Manual.
2. Battery Install the battery and check
whether it is charged full. If it is not full,
recharge it as required.
3. Tyre In reference to Chapter 'FRONT
WHEEL ASSEMBLY' of the Manual, inflate the
tyres to the normal pressure.
4. Fuel and hydraulic oil tank Discharge the
oil left inside the oil tank, feed oil into it to the
correct level, take off the blanking cover of the
respirator, and install the respirator that has
been cleaned thoroughly.
5. Draining valve and respirator Remove all
seals and screw cover at the joining part of
respirators, and then install all respirators and
draining valves.
of engine and release engine keeping as
provided.
7. Painting Check whether the truck get
rusted or not and spray paint storing.
8. Transmission Refer to the maintenance
manual of transmission and release
transmission storing as provided.
10 Service Manual
SRT95C Off-Highway Truck Reading Guide
Reading Guide
Arrangement of chapters
The manual book which used to guide how to
does maintenance and fix the damaged truck.
there some contents is different, so please in
accordance with type of the truck to read it.
This Manual consists of the following chapters:
38 chapters in total, including: Front Wheel
Assembly, front axle assembly, Rear Axle
Assembly and Installation, Rear Wheel
Assembly, Installation of Engine, Transmission
and Mounting, Fender and platform mounting,
Cab and Mounting, Hydraulic Steering Pipeline
of Operators Cab, Operators Cab Brake
Pipeline and Joint, Air Conditioning Pipeline
Installation, Fuel Tank and Mounting, steering
Pipeline and Joint, Hosit Pipeline and Joint,
Hydraulic Oil Tank Assembly, Brake Pipeline
and Joint, Transmission retarder control,
Frame and Installation, Driveline Installation,
Air Cleaner and Mounting, xhaust System
Assembly, Rear Suspension System, radiator
Guard, Body and Mounting, Illumination
Lamp and Installation, Power Module, Hoist
Cylinder and Installation, Arrangement Plan
of SRT95C, Centralized Lubrication System,
Transmission Oil Filter Assembly, Disc Brake
Cooling System Pipeline and Joint, Brake Oil
Cooler and Installation, Oil Cooler Assembly,
Radiator and Mounting, Water Tank Mounting
and lines, Battery and Installation, Cables and
Harnesses, etc.
Distribution and Timely Revision

If there is any supplement or change to the
Manual, the relevant contents will be sent to
SANY Mining Equipment Co., Ltd. so that the
latest information may be got before operation.
Signs
In order to bring into full play the Manual, the
following signs are used regarding important
safety and quality requirements.
Service Manual 11
Reading Guide SRT95C Off-Highway Truck
Sign Item Description

Pay special attention to
Safety safety during operation
During operation, pay

special attention to the
Caution
technical requirements
and other notes to ensure
that the operation quality
may reach the standard.
It is required to pay
attention to the weight of
Weight system components in
selecting the wire rope
and operation posture.
U p o n a s s e m b l y, p a y
Tightening special attention to the
torque tightening torque of com-
ponents.
Parts required to coat
Coating binding agent and lubri-
cating grease
The parts for feeding
Oil and
engine oil, water and fuel.
water
The parts for discharging
Discharge oil or water and discharg-
ing volume.
Notes on hoist
If a component cannot be move off the truck
with a hoist machine, the following inspection
must be carried out:
1) Check whether all tightening bolts at
the component to be moved off has been
unscrewed.
2 ) Check whether there are any ot h e r
components hindering the removal of the part.
Wire rope
1) Choose wire ropes according to the weight
of the part on the hoist machine and in
reference to the table below:
12 Service Manual
SRT95C Off-Highway Truck Reading Guide
Wire rope
Rope diameter Permitted load
mm kN tons
10 9.8 1
11.5 13.7 1.4
12.5 15.7 1.6
14 21.6 2.2
16 27.5 2.8
18 35.3 3.6
20 43.1 4.4
22.4 54.9 5.6
30 98.1 10
40 176.5 18
50 274.6 28
60 392.2 40
The permitted load value is 1/6 or 1/7 of the
rupture strength of wire rope.
warning
The cumbersome components (above
25kg) that must be lifted with a hoisting
machine like crane is described in the
section 'Disassembly and Assembly'. All
parts over 25kg should be marked with
signs.
2) The wire rope must be hung between the

hooks.
If the wire rope is hung at an end of the hook,
it may escape from the hook, thus resulting in
serious accidents.
The middle part of the hook has the greatest
strength.
3) It is prohibited to use only a wire rope, and
100% 88% 79% 71% 41%
it is required to use at least two ropes to wind
SAD00479
around the heavy for hoisting.
Service Manual 13
Reading Guide SRT95C Off-Highway Truck
warning
Only a rope is used, it may cause the
heavy to revolve during the process of
hoisting, and the wire rope get loosened
or the heavy slide away from original
binding position, hence causing dangerous
accident.
4) When hoisting a heavy heavy, the hoisting

angle of the wire rope and hook should not
be too large. When two or more wire ropes
are used to hoist an heavy, the stress borne
by each wire rope will increase with the
increasing hoisting angle. The table below
shows the changes in the permitted load value
at different angles when two wire ropes, each
of which may hoist 1000kg to the maximum,
are used to lift a heavy object.
When the two ropes are hoisted vertically,
Load weight
they may lift 2000kg in total; when the hoisting

angle reaches 120, the loading weight can
only reach 1000kg. On the other hand, at the
hoisting angle of 150, when the two wire
ropes hoist 2000kg load, the stress they bear Hoisting angle
will reach 4000kg.
14 Service Manual
SRT95C Off-Highway Truck Conversion Table
Conversion Table
Method to use the conversion table
The conversion table in section may provide simple number conversion. See the following
example for the detailed method to use the conversion table.
Example: Method to use the conversion table from mm to in.
1. Convert 55mm into in.
(1) At the No. 50 position in the left vertical column, select (A) for instance, and then draw a
horizontal line from (A).
(2) At the No. 5 position in the top transverse row, select (B) for instance, and then draw a vertical
line from (B).
(3) The crossing point of the two lines, (C) for instance, is the converted value from mm to in. So,
55mm=2.165in.
2. Convert 550mm into in.
(1) There is no 550 in the table, divide it by 10 (move the decimal point one digit to the left) to
convert it into 55mm.
(2) Repeat the above procedure to convert 55mm into 2.165in.
(3) Because the original value (550mm) is divided by 10, 2.165in should be multiplied by 10 (move
the decimal point one digit to the right) to return to the original value. Hence, 550mm=21.65in
Convert mminto in B 1mm=0.03937in

0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
C
A 50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Service Manual 15
Conversion Table SRT95C Off-Highway Truck
convert mm into in 1mm=0.03937in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
1kg=2.2046lb
convert kg into lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
16 Service Manual
convert L into U. S. Gal 1L=0.2642 U. S. Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
1L=0.21997 U.K. Gal

convert L into U.K. Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980

10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
Service Manual 17
convert kgm into ftlb 1kgm =7.233 ftlb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.50 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
18 Service Manual
convert kg/cm2 into lb/in2 1kg/cm2=14.2233lb/in2

0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
Service Manual 19
Measurement units
In this Manual, all measurement units are
metric units.
Relevant regular weight unit system is
indicated in braces { }.
Example:
kg { N }
kgm { Nm }
kg/cm2{ MPa }
mmHg { kPa }
mmH2O { kpa }
HP/r/min { kw/r/min }
g/HPh { g/kwh }
20 Service Manual
SRT95C Off-Highway Truck Table of Contents
TABLE OF CONTENTS
PREFACE 1
OVERVIEW 3
1 FRONT WHEEL ASSEMBLY 1-1
2 FRONT AXLE ASSEMBLY 2-1

2.1. Front Axle Assembly 2-5
2.1.1 Front wheel and installation 2-8
2.1.2 Front brake assembly and installation 2-14
2.1.3 Steering arm assembly 2-25
2.1.4 Front suspension cylinder 2-26
2.2 Steering Mechanism 2-49
3 REAR AXLE ASSEMBLY AND INSTALLATION 3-1

3.1 Rear Axle Assembly 3-6
3.1.1 Two stage planetary assembly and axle half 3-14
3.1.2 Rear wheel and installation 3-25
3.1.3 Main reducer and differential assembly 3-31
3.1.4 Rear axle housing assembly 3-54
3.1.5 Rear brake and installation 3-58
3.2 Rear Axle Mounting Part 3-92
4 REAR WHEEL ASSEMBLY 4-1

4.1 Rear Wheel Assembly 4-1
5 INSTALLATION OF ENGINE 5-1

5.1 Engine and Mounting 5-1
5.1.1 Engine - power takeoff 5-14
5.2 Installation of Compressor 5-22
6 TRANSMISSION AND MOUNTING 6-1

6.1 Transmission Mounting 6-1
6.2 Transmission retarder control 6-20
Service Manual I
Table of Contents SRT95C Off-Highway Truck
7 FENDER AND PLATFORM MOUNTING 7-1

7.1 Installation of Fender And Platform 7-1
8. CAB ACCESSORIES 8-1

8.1 Parts Assembly of Cab 8-6
8.1.1 Body of cab 8-9
8.1.2 Seat mounting assembly 8-13
8.1.3 Steering column mounting assembly 8-17
8.1.4 Accelerograph controller mounting assembly 8-20
8.1.5 Evaporator assembly 8-22
8.1.6 Harness of cab 8-26
8.1.7 Switches and instruments 8-29
9 HYDRAULIC STEERING PIPELINE OF OPERATORS CAB9-1

9.1 Steering Control Unit 9-1
9.2 Steering Valve Group 9-7
10 OPERATORS CAB BRAKE PIPELINE AND JOINT 10-1

10.1 Foot Valve 10-1
11 AIR CONDITIONING PIPELINE INSTALLATION 11-1

11.1 Air Conditioning Pipeline Installation11-1
12 FUEL TANK AND MOUNTING 12-1

12.1 Fuel Tank and Mounting 12-1
13 STEERING PIPELINE AND JOINT 13-1

13.1 Piston Pump 13-1
13.2 Cushion Valve Block 13-3
13.3 Oil Filter 13-5
14 HOSIT PIPELINE AND JOINT 14-1

14.1 Hoist Pump 14-1
14.2 Hoist Valve 14-2
14.3 Balanced Valve Group 14-5
14.4 Power Supply of Pilot Valve Group 14-8
14.5 Hoisting Cylinder and Installation 14-10
II Service Manual
SRT95C Off-Highway Truck Table of Contents
15 HYDRAULIC OIL TANK ASSEMBLY 15-1

15.1 Hydraulic Oil Tank Assembly 15-1
16 BRAKE PIPELINE AND JOINT 16-1

16.1 Brake System Accumulator 16-1
16.2 Brake Valve Group 16-2
17FRAME AND INSTALLATION 17-1

17.1 Frame and Installation 17-1
18 DRIVELINE INSTALLATION 18-1

18.1 Front Driveline Assembly 18-1
18.2 Rear Driveline Assembly 18-6
19 AIR CLEANER AND MOUNTING 19-1

19.1 Air Cleaner and Mounting 19-1
20 EXHAUST SYSTEM ASSEMBLY 20-1

20.1 Exhaust System Assembly 20-1
21 REAR SUSPENSION SYSTEM 21-1

21.1 Rear Suspension System 21-1
22 RADIATOR GUARD 22-1

22.1 Radiator Guard 22-1
23 BODY AND MOUNTING 23-1

23.1 Body and Mounting 23-1
24 ILLUMINATION LAMP AND INSTALLATION 24-1

24.1 Illumination Lamp and Installation 24-1
25 VEHICLE DETECTING SYSTEM 25-5

25.1 Transmission 25-6
26 ARRANGEMENT PLAN OF SRT95C 26-4
27 CENTRALIZED LUBRICATION SYSTEM 27-2

27.1 Manual Operation-Centralized Lubrication System 27-2
Service Manual III

Table of Contents SRT95C Off-Highway Truck
27.2 Automatic Centralized Lubrication System (optional configuration)

27-4
28 TRANSMISSION OIL FILTER ASSEMBLY 28-1
29 DISC BRAKE COOLING SYSTEM PIPELINE AND JOINT 29-1
30 BRAKE OIL COOLER AND INSTALLATION 30-1
31 TRANSMISSION COOLING PIPING MOUNTING 31-1
32 RADIATOR AND MOUNTING 32-2

32.1 Radiator and Mounting 32-2
32.2 Condenser Assembly 32-5
32.3 Liquid Accumulator Assembly 32-7
33 WATER TANK MOUNTING AND LINES 33-1
34 BATTERY AND INSTALLATION 34-1
35 CABLES AND HARNESSES 35-1
36 OTHERS 36-1
36.1 Lubrication and Maintenance 36-1
36.1.1 Lubrication and maintenance 36-1
36.1.2 Other maintenance 36-7
36.2 Technical Conditions for Bolts and Nuts 36-16
36.3 Maintenance Tools 36-22
36.4 List of Wearing Parts of SRT95C Mining Truck 36-27
36.5 Technical parameters 36-29
IV Service Manual
SRT95C Off-Highway Truck Front Wheel Assembly
1 FRONT WHEEL ASSEMBLY
10
2 3 4 6
5
Fig.1 Sectional view of wheel rim assembly
1. Flange 6. Lock ring

2. Rim 7. Clamp
3. Bead seat band 8. Nut
4. Valve stem assembly 9. Stud
5. O Ring 10. Wheel
Description
The front wheel assembly consists of tyre and
rim assembly, rim clamp and nut.
The tyre and rim assembly is designed to be
replaced with a pre-assembled tyre and rim.
Preparation for servicing
warning
Before loosening rim clamps or performing
any service on the tyre or rim components,
to prevent personal injury and property
damage, completely deflate tyre by
removing the valve cap and core. Insert
a thin wire through the valve to be sure
Service Manual 1-1

Front Wheel Assembly SRT95C Off-Highway Truck
the valve is not plugged. Even a flat tyre,

in some cases, will retain sufficient air
pressure to blow off a rim component with
enough force to cause injury or death.
warning
Gases that build up inside an air inflated
tyre mounted on a rim during welding or
heating of rim components can ignite,
causing an explosion of the tyre and rim
components. This warning also applies
to Nitrogen gas inflated tyres. Ignition will
not occur in a Nitrogen gas atmosphere;
but the pressure build up from the applied
heat may be sufficient to cause a blowout
severe enough to injure or kill. Never
weld or otherwise apply heat on rim
components with the tyre mounted on the
rim, whether the tyre is inflated or deflated,
to prevent injury or property damage
from the potential tyre explosion! Do not
attempt to repair rims or rim components
by welding or heating, even if the tyre is
not mounted on the rim. It is recommended
to scrap questionable rim parts unless
specific permission and repair procedures
are obtained in writing either from the
company or the rim manufacturer.
Removing Tyre and Rim Assembly

Numbers in parentheses refer to Fig.1.
If the tyre and rim assembly is to be replaced
with a pre-assembled tyre and rim assembly,
it is not necessary to remove the tyre from
the rim on the truck. The tyre and rim may be
removed from the truck as an assembly, and
transported to a more desirable location for
removing the tyre from the rim.
1-2 Service Manual

warning
To prevent personal injury and property
damage, be sure wheel blocks, blocking
materials and lifting equipment are properly
secured and of sufficient capacity to do the job
safely.
1. Place the truck in a flat area, apply parking

brake and shut down the engine.
2. The steering wheel turns for several circles
in the two directions to relieve the pressure in
steering system. Block all wheels, except the
one to be raised. Use wooden blocks 100 mm
x 100 mm (4 in x 4 in) or larger.
3. Support the truck with jack for removal of
tyre, but do not jack up the truck.
4. Completely deflate tyre by removing valve
cap and core. Check valve stem by running a
piece of wire through the stem to make sure it is
not plugged. See warning under 'Preparation
for servicing' . 4
B
5. Loosen the nut (8) on the wheel hub. But do 2 3 C
not remove from the stud (9).
1
6. Jack the truck up only as high as necessary 5
to remove wheel from truck, and place safety
blocks under the frame. A
7. Support the tyre with a chain or rope of
sufficient strength attached to a suitable lifting
device. Remove the nut(8) and clamp(7) from
the wheel stud (9). Lift tyre and rim assembly
clear.
Dismounting Tyre from Rim

Numbers in parentheses refer to Fig.2, unless
otherwise specified.
Fig.2 Rim assembly
Note: The following instructions are applicable
to use of hand tools. For procedures and 1. Outer fange 4. Rim
tooling required to dismount the tyre from the 2. Bead seat band 5. Inner flange
rim, using hydraulic tools, contact the tyre 3. Lock ring
manufacturer.
Service Manual 1-3

warning
When lifting tyre from rim, be sure the device
is of sufficient capacity and properly secured
Fig.3 Pry Bar
to do the job safely.
1. Completely deflate tyre if not done

previously. See warning under 'Preparation for
servicing' . Tape valve threads to protect from
damage, leaving valve end open to avoid any
possibility of trapping air inside the tyre.
2. As shown in Fig.3, break outer tyre bead
loose by placing the flat hooked end of a pry
bar, into one of the breaking slots (C) between
the bead seat band (2) and outer flange (1). A
length of pipe slipped over straight end of bar
will increase leverage. Twist straight end of
bar around toward tyre to break this portion of
bead. Another person may now insert another
pry bar of the same type into the slot between Fig.4 Breaking Typical Tyre Bead Loose
the bead seat band (2) and outer flange (1),
and with the same twisting action, hold the
space gained with the first pry bar. Move first
pry bar all the way around the wheel, twisting
and following up with second pry bar, until
inner tyre bead is loose.
3. Start bead seat band (2) in away from lock
ring (3) by placing hooked end of pry bar in
groove of rim (4), between ends of lock ring,
and prying up with bar. Using two tools, as in
Step 2, work completely around wheel.
4. Pry lock ring (3) out in same manner by
starting at prying notch (B) in wheel, and work
all the way around wheel with the two pry
bars.
5. Remove and discard the O-ring (5, see
Fig.1).
6. After removing lock ring (3), pry out and
remove bead seat band (2). Outer flange (1)
can be removed now.
7. Similar breaking slots are provided on the
inside of rims. The inner bead on the back
1-4 Service Manual

side of the tyre may be broken by using the

same method as in Step 2, for the outer bead.
If the wheel assembly is still on the truck,
another method which can be used is to place
a small jack between the inner flange and
some solid part of the frame. By extending the
jack, pressure is exerted, which forces the tyre
bead off the rim seat. Work around the wheel
until the bead is broken at all points.
8. Use a proper lifting device to lift tyre away
from rim. The dismantling of tyre is completed
in such a way.
Note: If tyre and rim is on truck, and no lifting
device is available, the tyre can be separated
off the rim as follows: force bottom of tyre
outward as far as possible; lower jack enough
to allow weight of tyre to rest on ground; force
top of tyre out as far as possible; raise jack to
original height and repeat the above until tyre
is off rim.
Inspection
Tyre
Check interior surface of the tyre to determine
its condition. Inspect for cuts or fabric breaks
that have penetrated the tyre body. Inspect
closely for any sharp, pointed objects that may
have penetrated the tyre body but is invisible
from the outside. All dust, dirt, water or other
foreign matter should be cleaned from the
inside of the tyre.
Replace valve core assembly if condition is
questionable.
Rim assembly
Overload, improper tyre inflation, rough terrain,
high speed, accidents, dirt accumulation and
corrosion will reduce service life of rims and
rim components. It is recommended that
rims be inspected, as below, not less than at
every tyre change and, as the warranty limit
approaches, consideration be given to rim
replacement.
Service Manual 1-5

warning
Never mix components of one
manufacturer's rims with those of another.
Using the rim base of one manufacturer
with the lock ring of another or vice
versa is dangerous. The lock ring of one
may not fully engage with the lock ring
groove of the other. Always consult the
rim manufacturer for proper matching and
assembly instructions.
Also, use of damaged, worn out, or
improperly rim assemblies is a very
dangerous practice. Failure to comply
with the above warnings could result in
explosions from tyre pressure causing
serious personal injury and property
damage.
1. Clean all rust and dirt from rim parts.

2. Coat parts with primer paint, allow thorough
drying before assembling.
3. Inspect rim assemblies (Fig.2) for bent,
cracked, distorted, battered, and rusted
parts which may have resulted from abusive
practices outlined above. Replace any
damaged parts with new parts.
4. Discard 'O' ring and replace with a new one.
Note: Handle 'O' rings carefully, as damage
will prevent an airtight seal for tyre inflation.
Mounting Tyre on Rim

warning
When lifting tyre onto rim, be sure the
device is of sufficient capacity and properly
secured to do the job safely.
1-6 Service Manual

1. If tubeless tyre valve assembly was

removed from rim, install this assembly in the 1 2 A
rim valve hole and tighten securely.

2. Whether the rim (4) is on or off the truck,
tyre installations are performed in basically the
same manner. For off-truck installations, lay
the rim on blocks with 'O' ring groove up. The
rim should be just off the floor enough so the
tyre rests on the rim and does not touch the
floor. The blocks should not extend more than
13 mm (0.5 in) beyond the rim base, so they
wont interfere with inner flange (5).
3. Install the inner flange (5) onto the rim (4). Fig.5 Installation of Lock Ring
4. Before assembly of tyre to rim, lubricate
both tyre beads and new 'O' ring (5, Fig.1)
with a thin solution of vegetable base soap
and water. Make sure tyre valve assembly is
securely in place. Lower the tyre onto the rim,
seating tyre firmly against inner flange (5).
5. Install outer flange (1) on rim (4).
6. Install bead seat band (2) on rim (4).
7. Install lock ring (3) in groove of rim (4).
Use pry bar for this operation, as illustrated in
Fig.5.
8. Force bead seat band (2) past 'O' ring
groove in rim (4) by prying, or with lift truck
forks. Use blocking between the forks and tyre
to prevent tyre damage. Lubricate area of rim
adjacent to 'O' ring groove with a thin solution
of soap and water or another approved
lubricant which is not harmful to rubber. Avoid
using an excessive amount of lubricant. Insert
a new 'O' ring (5, Fig.1) in the groove of the
rim behind the lock ring.
9. Lift tyre upwards to effect a seal between
bead seat band (2) and 'O' ring (5, Fig.1). In
some cases the tyre will automatically spring
out, if this step is neglected,
Mounting tyre and rim assembly on wheel

1. Support tyre and rim assembly with a chain
or rope sling attached to an overhead lifting
device and slide onto wheel (10) of the truck.
Service Manual 1-7

Side with lock ring (6) and bead seat band (3)
should be facing outward.
2. Install clamps (7) and nuts (8) on studs (9).
Gradually tighten wheel nuts opposite each
other, until all nuts are snug, torque tighten
wheel nuts (8) to 1000 N. M-1300 N. M.
Re-tighten nuts after a few hours operation.
Note: The fastener torque should be checked
regularly, particularly on new truck or newly-
installed wheels, to maintain the required
wheel rim-clamp load. A newly installed wheel
or a new truck should be checked at 30 day
intervals until rim fasteners show no significant
torque loss from the previous check. After
that, a 90 day torque check interval should be
adequate.
warning
Be sure lifting equipment is of sufficient
capacity and properly secured to do the
job safely.
Tyre Inflation
warning
damage, the tyre and rim assembly should
be placed in a safety cage before inflating.
If no safety cage is available or tyre is on
the truck, the tyre and rim assembly should
be wrapped with safety chains or with
cables before inflating.
Even with these precautions remember
that air-blast is a potential hazard. Tyre
inflation should be carried out away from
busy working areas.
damage, never stand or sit in front of a
mounted tyre during tyre inflation. Use
a clip-on air chuck with a long hose and
stand to one side while the tyre is being
1-8 Service Manual

inflated.
damage, always prevent flammable vapours
that could produce tyre explosions, from
being pumped into tyres during inflation,
by observing the following precautions:
1. Use an air compressor and reservoir
located inside a heated building, when
available, so that alcohol, methanol, or
other flammable antifreeze liquids are not
needed in the air tanks to prevent moisture
freezing in the tank and lines in subfreezing
temperatures.
2. Make sure that paints, lacquers, paint
thinners, or similar materials that produce
volatile, flammable vapours are not used or
stored near the air intake of the compressor
that supplies the air for inflating tyres. The
compressor should be isolated from all
such sources of flammable vapours.
3. Be sure to thoroughly flush and blow off
all flammable solvents used for cleaning
the air compressor inlet screen before
using the compressor for tyre inflation, or
any other purpose.
4. Do not charge batteries, near the air
inlet of a compressor used for inflating
tyres. Charging batteries produces highly
explosive hydrogen gas which can be
readily drawn into a nearby compressor
inlet and pumped into the tyre.
5. Never exceed the specified concentration
of alcohol when adjusting the alcohol
vaporiser, or adding alcohol to the auxiliary
air tank, used on machine air systems to
prevent freezing or moisture condensate
in below-freezing temperatures. Excessive
alcohol, added to the air tanks can produce
flammable vapours that will be pumped
into a tyre when this air supply is used for
tyre inflation if the tyre inflation kit is not
equipped with a moisture filter.
6. Another source of hazardous flammable
vapours in tyres is the tyre bead lubricant.
Service Manual 1-9

Always use bead lubricants that do not

introduce flammable vapours into the tyre.
Inflation
Note: To prevent moisture corrosion of internal

rim parts, use tyre inflation equipment with an
air filter that removes moisture from the air
supply.
1. If the tyre is off the truck, it should be placed
in a safety cage before inflating. See Fig.6.
2. Inflate all tyres with ratings of 16-ply and
above to 0.52 Mpa to seat beads and seal
'O' ring, then adjust to the recommended
pressure. Fig.6 Tyre Inflation Safety Cage
3. For recommended operating air pressure,
refer to the chart 'Tyre Inflation Pressures'.
Nitrogen tyre inflation

Note: All Warnings and procedures under
'Tyre Inflation' will apply, except for differences
covered by this passage.
In certain enviroNments it is recommended
that tyres be inflated with dry nitrogen gas,
and that the resulting oxygen content of the
inflation does not exceed 5%. All machines
whose tyres are factory inflated with dry
nitrogen gas will be identified by a decal on
the body or frame.
Nitrogen gas improves tyre pressure retention,
increases tyre life by reducing carcass
oxidation from within, minimizes rim rust
and has no detrimental effects on the tyre. It
also reduces the potential of a tyre explosion
because it is an inert gas and will not support
combustion inside the tyre.
The same tyre inflation pressure used for air
inflation should be used for nitrogen inflation. Fig.7 Nitrogen Tyre Inflation Kit
Tyre valves formerly used with air inflation are
entirely satisfactory for use with nitrogen gas.
1-10 Service Manual

Nitrogen tyre inflation kit
warning
DO not use charging assembly for tyre
inflation because this assembly does not
include a pressure regulator, safety relief
valve, and adequate pressure gauging
which is mandatory for tyre inflation. Tyre
volume is as much as 90 times greater than
the average accumulator volume and it
takes very much longer to inflate a tyre - up
to 40 minutes or more for very large tyres.
Nitrogen gas cylinders used to inflate tyres
are generally charged to approximately
15.2Mpa. A tyre blowout or rim failure could
occur if inflation equipment is not properly
used. Proper nitrogen charging equipment
and personnel training can avoid over
inflation.
1. A nitrogen tyre inflation kit is available from

your dealer and consists of the following.
Refer to Fig.7.
a. Pressure regulator, 0 1.3 Mpa, with two
dual pressure gauges.
b. Safety relief valve, 0.86 Mpa, that will
assure an upper limit to the pressure available
for tyre inflation.
c. A 15 length of flexible hose with
interconnecting fittings. On the tyre end of the
hose is a large bore quick connect.
2. The pressure regulator is connected to a
nitrogen compressed gas cylinder available
from local suppliers.
3. The usual procedure for using this type of
equipment is as follows:
a. Connect nitrogen tyre inflation kit to nitrogen
compressed gas supply. DO not connect quick
connect to the tyre valve at this time.
b. Open valve on nitrogen supply.
c. With flexible hose and quick connect
connected to nitrogen tyre inflation kit
Service Manual 1-11

assembly but not connected to the tyre, adjust

pressure regulator so that its output pressure
is not more than 0.14Mpa higher than the
desired tyre inflation pressure.
d. Connect quick connect to the tyre valve.
The tyre will now inflate. Tyre pressure can
be monitored by observing the gauge at the
pressure regulator.
e. When desired inflation pressure has been
achieved, back off the regulator or close the
valve on the compressed gas cylinder.
f. Remove the quick connect and adjust the
tyre pressure with the tyre gauge in the usual
manner.
Re-inflation of a mounted tyre

To re-inflate a tyre with dry nitrogen gas which
is now inflated with air, proceed as follows:
1. Deflate the tyre until the air in tyre reaches
the atmospheric pressure.
2. Re-inflate the tyre using only dry nitrogen
gas to 0.41Mpa gauge as a minimum, or to
bead-seating pressure as a maximum.
3. Adjust to the service inflation pressure
required:
a. If the required service inflation pressure is
less than 0.41Mpa remove the quick connect
and adjust the pressure with the tyre gauge in
the usual manner.
b. If the required service inflation pressure is
greater than 0.41Mpa, continue inflating with
dry nitrogen gas only, to the pressure level
required. Then remove the quick connect and
adjust the pressure with the tyre gauge in the
usual manner.
New tyre mounts and remounts

To newly mount or remount a tyre to rim,
use only dry nitrogen gas; this includes the
pressure required to seat the beads. After
seating the tyre beads, remove the quick
connect and adjust the pressure with the tyre
gauge in the usual manner.
Note: Although a little more nitrogen gas is
1-12 Service Manual

used to seat beads than that used for re-

inflation of a mounted tyre, its cost is generally
negligible in comparison to the time and labour
saving and, longer tyre life achievable with the
reduced oxygen content which results.
Hydraulic bead breaking tool

The hydraulic bead breaking tool illustrated
in Fig.8 is specifically designed to break tyre
beads on rusted rims, and is available from
your dealer. Refer to Special Tools. It can
be used on rims having pry bar slots. The Fig.8 Typical Hydraulic Bead Breaking Tool
recommended procedure for using this tool is
described below.
1. Prepare for dismantling tyres according to
the necessary steps in the Preparation for
servicing and Dismantling tyre from Rim.
servicing'. Tape valve threads to protect from
damage, leaving valve end open to avoid the
3. Place the lip of the hydraulic tool in one of
four breaking slots between the flange and the
bead seat band.
4. Adjust locking screw to a position which will
hold the tool in a line perpendicular to the face
of the rim.
5. Close valve on the hydraulic pump and
apply pressure to take up the slack in the
tool and rim parts. This will cause the tool to
tilt slightly downward. Release pressure and
adjust the screw again so that the tool will be
perpendicular to the rim when under pressure.
6. Apply enough pressure to move the flange
back approximately 13 mm (0.5 in) and hold
this distance by dropping a nut, or similar
object, in the space between the flange and
the bead seat band.
7. Release pressure and move the tool around
the rim in either direction. Insert lip of tool
between bead seat band and flange. Repeat
cycle until 3/4 of the rim circumference has
Service Manual 1-13

been covered. Apply pressure at this point

until bead breaks loose. At least 15m At least 360m
8. Remove lock ring, bead seat band and
flange as described under 'Dismounting tyre
from rim'.
9. After lock ring, bead seat band and rim
flange have been removed, inner bead must
be broken loose according to Steps 3-7 for
breaking outer bead.
warning
Fig.9 Do Not Approach Tyre in Shaded Area
Whenever a tyre is exposed to excessive
heat such as a truck fire or overheated
brakes the hazard of a subsequent violent
tyre explosion must be recognized. All
persons must avoid approaching the truck
so as not to be physically endangered in
the event of an explosion of the tyre and
rim parts. The truck should be moved to
a remote area, but only when this can be
done with complete safety to the operator
operating or towing the truck. All other
persons should stay clear of the truck.
The fire or overheated brakes, wheel, etc.
should be extinguished or cooled from a
safe distance. Do not attempt to extinguish
the fire or cool the machine by use of hand-
held fire extinguishers.
If it is absolutely necessary to approach a
truck with a suspect tyre, approach only
from the front or the back. Stay at least
15 m (50 ft) from the tread area. Keep
observers out of the area and at least 460
m (1 500 ft) from the tyre sidewall. Refer to
Fig.9. The tyre should be allowed at least
8 hours cooling time after the machine is
shut down or the fire extinguished before
approaching closer.
There is always a possibility of a tyre
explosion whenever the smell of burning
rubber or excessively hot brakes is
detected. The danger is also present when
a fire on the truck reaches the tyre and
1-14 Service Manual

wheel area. Under such conditions, all

personnel must avoid approaching the
truck in a manner that could result in injury
should an explosion actually occur. Move
the truck to a remote area only if it can be
done without endangering the operator or
other personnel in the area.
DO not weld on or heat rim components.
For several years the company and tyre
and rim manufacturers have warned
users never to weld rim components with
the tyre mounted on the rim. The gases
that build up inside the tyre during arc
welding or heating on rim components can
ignite, resulting in one of these explosive-
like failures of the tyre and rim. It is
recommended to scrap the part if heat is
necessary to repair any rim component.
Tyre maintenance
Tyre repairs
Prompt repair of tyre injuries will prevent small
injuries from enlarging and causing tyre failure.
Use the best tyre repair facilities available.
If good repair facilities are not available,
have the nearest dealer make the necessary
repairs.
Minor cuts, snags, or punctures should be
repaired upon discovery. Skive with a sharp
pointed knife around any cut in the tyre tread
area that is of sufficient depth or shape to
hold pebbles or dirt. The angle of the skive
should be no more than sufficient to expel all
foreign material and should extend no deeper
than the breaker. The skive should go to the
bottom of the hole. Tyres with shallow cuts, if
treated promptly, may be allowed to continue
in service. If the cut extends deeper into the
tyre carcass, the tyre should be removed for
repair. Ordinary tubeless tyre punctures can
be repaired without removing the tyre from
the rim. Use tyre repair plugs and follow the
Service Manual 1-15

directions given by the manufacturer.

The tyre must be removed from the rim to
repair larger punctures or cuts. Irregular
shaped punctures or cuts less than 13 mm in
size can be repaired with a plug and hot patch.
Insert a repair plug into the hole to keep out
moisture and to back up the hot patch. Trim
the plug off flush with the inside of the casing,
buff, and apply the hot patch according to
the instructions supplied with the hot-patch
equipment.
Punctures 13 mm or larger, large cuts, or
bruise breaks require sectional or reinforced
vulcanized repair. Cover the repair patch with
a layer of cushion gum after application to the
tubeless tyre to ensure an airtight repair. Any
cords of the inside ply that are exposed in
bugging and are not covered with repair patch
must be coated with cushion gum to prevent
air leakage into the carcass plies on tubeless
tyres.
Recapping and retreading

There are two general methods employed in
restoring the tread surface of off-the-highway
tyres: recapping and retreading.
A recapped tyre has a new tread cured right
over the old tread surface.
A retreaded tyre has the old tread removed
entirely and a new tread cured directly onto
the body of the tyre. A tyre can be recapped
or retreaded if the cord body is free of cuts,
bruises and separation, and is thoroughly
sound, including previous repairs.
Tyre care
To obtain maximum service from off-the-
highway tyres, a few common-sense
precautions should be followed.
Maintain correct inflation

Most tyre damage are caused by improper
inflation. Both over-inflation and under-inflation
are detrimental to tyre life. Tyre pressure
1-16 Service Manual

should be checked daily, preferably before

the truck is placed in operation, see the
instructions in 'Tyre Inflation Pressures'.
The valve cores should be checked for leaks.
Keep in mind that valve cores are delicate
mechanisms that wear out in service; therefore,
they should be replaced when they become
worn. Each tyre should be equipped with a
valve cap to prevent dirt from damaging the
valve core and causing air leakage.
Maintain good haul roads

Because haul roads are considered temporary
roads, they are frequently neglected. The
better the haul road, the longer the tyre and
machine life of off-the-highway equipment.
Note: Although it takes time and effort to
maintain good haul roads, delay and cost of
tyre and machine breakdowns caused by poor
haul roads is many times greater.
Inspect tyres regularly

A systematic plan for tyre inspection will
more than pay for itself in lowered tyre costs
per hour of operation. All tyres should be
checked regularly for cuts, bruises, fabric
breaks, excessive or uneven wear, embedded
foreign matter, and any other damage which
can be repaired. A considerable increase in
tyre service can be realized if tyre injuries
are repaired before they have progressed to
the irreparable stage. The rim mounting nuts
should be checked periodically and tightened
to the recommended torque.
Prevent overloading
Off-the-highway trucks are designed to carry a
maximum allowable payload.
Note: Excessive loading will overstress both
the machine and tyres and shorten the life of
both.
Prevent tyre contact with oil

Prevent tyre contact with petroleum products.
Service Manual 1-17

Rubber that is exposed to oil, petrol, or grease

becomes soft and spongy and deteriorates
rapidly. Always avoid driving truck equipped
with rubber tyres through a puddle of petrol,
fuel oil, lubricating oil, or grease. Never let a
tyre stand in oil or grease spot overnight.
Store tyres properly

The best of care given to tyres in service by
operators and maintenance personnel can
be completely nullified by careless storage.
Time is not the only contributing factor to the
deterioration of rubber products. Therefore,
tyres that are to be stored must be protected
from light, heat, oils, dirt, moisture and ozone.
Stored tyres should be carefully covered with a
tarpaulin or some other suitable material, such
as opaque plastic sheets, to prevent contact
with the contaminants listed.
Proper handling of tubeless tyres and rims

Tubeless tyres should be stored vertically.
Horizontal stacking may compress the tyre
walls making inflation difficult. If tyres are
stored in racks, the lower supporting members
should provide as broad a surface as possible
to the tyre tread to avoid a concentration of
load.
The beads of tubeless tyres must be protected
from damage or a faulty air seal will result. Do
not use hooks, cables, or chains in contact
with the tyre beads when lifting these tyres.
If forklift trucks are used for handling, they
should be equipped with broad, well rounded
arms to distribute the load and prevent
damage to the tyre bead. When handle tyres
with the fork truck, do not scrape the fork
across the bead.
Tubeless tyre rims perform an important
function as part of the assembly air seal.
Proper care therefore must be taken not to
distort or mutilate the rim parts, because they
must mate properly to form part of the basic air
chamber. Since the rim base, bead seat band,
1-18 Service Manual

and flange are endless, distortion may prevent

easy assembly as well as possibly resulting in
no seal.
Never drop, tumble, or roll rim parts.
If rim parts are stored outdoors they should be
given a protective coat of a good commercial
primer.
Similar parts should be stacked neatly to
prevent distortion.
Babbitt or lead hammers, not sledge hammers,
should be used in assembling rims.
'O' rings are seals and should be carefully
stored in a cool, dry place where they will not
be damaged.
Valve cores also should be stored in a cool,
dry and clean place.
Special tools
Refer to Section 38.3, SERVICE TOOLS, for
part numbers of special tools outlined in this
section and general service tools required.
These tools are available from your dealer.
Tyre inflation pressures

E3 tyres may be so roaded up to 48 km/h (30
mile/h), maximum, with a 30 minute cooling
stop after each 80 km (50 miles) or 2 hours
sustained operation - whichever occurs first
- and a 60 minute cooling stop after each
aggregate of 4 hours of operation.
stop after each 32 km (20 miles) or 1 hour of
Normal inflation pressure of bias tyres
(27.00-49 48PR) is 0.575 Mpa. Specific job
conditions, terrain, haul road maintenance
and length, maximum and workday average
speed, job t-km/h (ton-mile/h) required and
tyre t-km/h (ton-mile/h) capacity, etc., may
require an increase in inflation pressure. It is
recommended that for tyres both listed and
Service Manual 1-19

unlisted the user consult the tyre manufacturer

and evaluate all job conditions in order to
make the proper selection.
Technical conditions of special torque

Fig. Item Torque
Item Name
NO. NO. Nm lbfft
1 8 Nut 1000-1300 510
Tubeless Tyre Leak Diagnosis
Occasionally a tubeless off highway tyre/rim assembly may leak in field service. To determine cause of
leakage, the entire assembly including valve hardware, multi-piece rim assembly, 'O' ring and tyre should
be checked using a soap solution.
This table lists various causes of air loss and possible remedy.
Causes Remedy
Tighten and replace suspicious parts and use
Defective valve
valve core cap.
Replace defective parts.

Cracked rim or weld Warning
Do not repair rim parts (including welding and etc.).
Twisted or damaged 'O' ring Replace O-ring (Perform lubrication).

Tyre cuts and snags Repair damaged tyre.
Repair internal lining (It should be performed in
Bead area awl holes
priority).
With tyre removed from rim:
Clean tyre beads in rim contact area
Clean rim with wire brush
Inspect 5tapered bead seat band and the rim
base in the bead seating area to determine if the
transverse weld trims are flat or concave.
Leakage between tyre bead trim Replace defective part.
Weld trim should follow rim contour.
Mount tyre using a lubricant such as Murphy's Tyre

and tube Mounting Compound, or equivalent, on
tyre beads and rim bead seat area.
1-20 Service Manual

SRT95C Off-Highway Truck Front Axle Assembly
2 FRONT AXLE ASSEMBLY
7
6
5
4
9
1
10
Fig.1
1. Right front axle assembly 6. Washer

2. Steering mechanism 7. Brace piece axial pin
3. Left front axle assembly 8. Brace piece axial pin
4. Bolt 9. Separating sleeve
5. Washer 10. Brace piece axial pin
Service Manual 2-1

Front Axle Assembly SRT95C Off-Highway Truck
Overview and operating principle

The front axle that it is very important part for
vehicle which used to carrying, it connecting
with frame via the front suspension cylinders,
A-shape arm and steering crank. Its major
task is to transmit all the forces and moments
acting between the wheels and the frame,
alleviate the shock load transferred form road
surface to the frame,attenuate consequent
vibration of the carrying system and ensure
the running smoothness of the truck.It ensures
the ideal motion characteristics of wheels
in case of rough road surface and variable
load,and ensures the manipulation stability of
the truck. At the same time, it can utilize the
steering mechanism to deflect the wheels to a
certain angle so as to realize turning.
warning
The cylinder has fully pressure inside.
Before valve or joint is opened, pressure
should be released according to the
instructions in the section of Releasing
Suspension Cylinder Pressure. If it is
released suddenly, it will lead to personal
injuries and equipment damages.
Disassembly
See Fig.1 for the numbers in brackets.
1. Place the truck in a level work area. The
wheels must be chocked to ensure that the
truck will not slide. If it cannot,keep the truck
in the parking situation and shut down the
engine.
in the two directions to release the steering
system pressure. Chock the wheels and set
the main switch of battery into the "OFF"
position.
3. Refer to the part of "Releasing the Pressure
of Suspension Cylinder"in this chapter,and
2-2 Service Manual

release nitrogen pressure in the suspension

cylinders of the left and right front axle(1)(3).
4. Remove the connneting pin between the
steering mechanism(2)and the left/right fornt
axle(1)(3) to separate the steering mechanism
from the left and right front axles.
5. Remove the brace piece axial pin(7)(8)(10)
for the left and right front axles. As the same
time remove the separating sleeve(9).Use a
fork truck or crane to move them away.
warning
loss,ensure that wheel chocks and hoist
device have sufficient capability and are
correctly fixed to ensure safe work.
Inspection
1. Clean all connecting parts and holes
with a proper solvent and dry them with air-
compress. Check whether the articulating
hole bearing rotates normally and whether the
spacer ring and pin spindle are worn. If they
are worn, replace them with new ones.
Installation
1. Removes all of dirt things from the frame
and connecting holes of the frame and makes
them clean.
2.Lift and insert the left and right front axles
in position.Use the pin(7)to install the upper
articulating points for the front suspension of
the left and right front axles into the mounting
hole of ring beam.Install the A-arm articulating
hole onto the beam lower articulating point and
the front longitudinal beam articulating point of
frame via pin(8)(10)and the sleeve(9).
3. Connect the steering cylinder and steering
tie rod of steering mechanism(2)to the steering
arm assembly of left and right front axles(1)(3)
through pin.
4. According to the requirements for front
Service Manual 2-3

suspension in this chapter to filling gas or oil in

to the suspension cylinder.
5.According to the requirements for the
adjustment of steering tie rod in this
chapter,adjust the toe-in of front axle.
warning
loss, ensure that wheel chocks and hoist
device have sufficient capability and are
correctly fixed to ensure safe work.
Maintenance
According to the requirements in the
maintenance manual, lubricate all articulating
points of the front axle on a regular basis.
2-4 Service Manual

2.1. Front Axle Assembly
16
6
17
18 7
9
19
10
11
20 12
13
14
15
Fig.2
1. Front suspension cylinder 11.Bolt

2. Front brake and installation 12.Steering arm baffle
3. Installation of front hub 13.Washer
4. Steering arm assembly 14.Bolt
5. Washer 15.Steel wire
6. Bolt 16.Retainer ring
7. Left A-arm 17.Bearing
8. Bearing 18.Oil fitting
9. A-arm baffle 19.Bolt
10.Washer 20.Step assembly
Service Manual 2-5

Overview and operating principle

The left front axle (also applicable to the right
front axle) is a critical component of front axle,
bearing the shock transmitted from the frame
to the left part of front axle and attenuating the
vibration.It provides braking force to the front
axle. The left front axle can be divided into left
suspension cylinder, left steering arm, front
brake, hub and left/right A-arm for installation.
Disassembly
1.Place the left front axle levelly,remove the
anti-loosening steel wire15Bolt14
and washer13.Remove Steering arm
baffle12.Disengage left A-shape arm7
form the lower shaft of steering arm assembly
4.
2. After removed Bolt11washer10,
demolition A-shape arm baffle9, knock out
bearing8of left A-shape arm7.After
removed retainer ring16with pliers,knock
out bearing17of left A-shape arm7.
3.Open the cover of the front hub,remove
pressure plate form front axle of front
suspension cylinder1, pull down front hub
3.
4.Removed the screws of front brake and pull
down the fornt brake(2).
5.Removed the screws of bolt6washers
5and separate steering arm assembly4
from the front suspension cylinder1.
Inspection
1.According to Section 2.1.1"FORNT WHEEL
AND INSTALLATION",check the parts and
components in the front hub and its installation
for damages.
2.According to Section 2.1.2"FRONT BRAKE
ASSEMBLY AND INSTALLATION",check the
parts and components in the front brake and
its installation for damages.
3. According to Section 2.1.4 'FRONT
2-6 Service Manual

SUSPENSION CYLINDER', check the

half shaft surface and internal parts and
components of left suspension cylinder for
damages.
4. Check the lower shaft of steering arm
assembly(4)and the mounting holes of
steering cylinder and tie rod for wearing.If
damaged,repair or replacement is required.
5. Check each bearing of A-arm(7) for wearing
and looseness.
Installation
1. According to Section 2.1.4"FRONT
SUSPENSION CYLINDER",restore the left
suspension cylinder assembly.
2. Fix steering arm(4)in the lower end of
suspension cylinder(1)and tighten it up.
3. Press the bearing(8)into the large-end
bearing hole of left A-arm(7)and use the A-arm
baffle(9)bolt11and washer10to
press it tightly.Press the bearing17into the
small-end hole of left A-shape arm7and
clamped tightly by retainer ring16.
4. Insert the lower shaft of left steering arm
assembly4into the bearing8and left
A-shape arm7.Use the steering arm baffle
12bolt14and washer13to press
it tightly.thread the locking steel wire15
and tighten it up.Retain the hex head side of
bolt14.
5. According to Section2.1.2"FRONT BRAKE
ASSEMBLY AND INSTALLATION",restore the
left front brake system and brake clearance
adjustment.
6.According to Section2.1.1"FRONT WHEEL
AND INSTALLATION",restore the front hub
and bearing clearance adjustment.
7.It is also allowed to complete Step 5 and 6
after the front suspension cylinder is installed
onto the ring beam.The sepuence depends on
specific situation.
Maintenance
According to the requirements in the
Service Manual 2-7

preventative maintenance manual, lubricate all

articulating points of the front axle on a regular
basis.
2.1.1 Front wheel and installation
20 1
18,19
17
3
2
16 4,5
6
7
8
9
15
10,11
14
13
12
Brake calipers
Fig.1 Sectional View of Front Wheel Assembly
1. Front wheel 8. Cover 15. Bushing

2. Bearing 9. Gasket 16. Plate
3. Bearing 10. Bolt 17. Bolt
4. Bolt 11. Washer 18. Bolt
5. Lockwire 12. Snap ring 19. Washer
6. Plate 13. Washer 20. Brake disc
7. Shim pack 14. Oil seal
2-8 Service Manual

Overview
The wheel is mounted on the axle spindle with
two tapered roller bearings mounted in the
hub. The brake disc is bolted to the wheel.
The tyre and rim assembly is mounted on the
wheel with clamps and nuts.
The wheel itself is a large cylindrical casting

with the bearing bores and other finished
surfaces machined after the wheel is cast.
Removal and Disassembly

warning
materials and lifting device are properly
secured and of sufficient capacity to do the
job safely.
warning
damage, completely deflate tyre by removing
the valve cap and core. Insert a thin wire
through the valve to be sure the valve is not
plugged. Even a flat tyre, in some cases, will
retain sufficient air pressure to blow off a rim
component with enough force to cause injury
or death.
1. Block the front and rear of all wheels, except

the one to be raised. Jack up or lift machine
so its weight is no longer on that wheel.
2. Deflate tyre completely, and remove the
tyre and rim assembly from the wheel. Follow
instructions under 'Removing Tyre and Rim
Assembly'. Refer to Section 1, Front Wheel
Assembly.
3. Relieve the pressure in the braking system.
Service Manual 2-9

Refer to Section 2.1.2, FRONT BRAKE

ASSEMBLY AND INSTALLATION. Disconnect
brake hydraulic line at brake caliper.
4. Remove brake caliper. Refer to Section
2.1.2, FRONT BRAKE ASSEMBLY AND
INSTALLATION.
5. Remove bolts (10) and washers (11) which
secure cover (8) to wheel (1). Remove cover
(8) and gasket (9).
6. Remove lockwire (5), bolts (4), plate (6) and
shim pack (7) from spindle. Retain shim pack
(7).
7. With suitable lifting equipment, pull wheel (1)
off of spindle, being careful that outer bearing
cone (3) does not fall.
8. If required, remove bolts (18) and washers
(19) securing brake disc (20) to wheel (1), and
remove brake disc.
9. Remove the bolts (17) which secure the
plate (16) to wheel, remove the plate(16).
10. Remove oil seal (14), using hammer and
soft drift.
11. Remove snap ring (12). Tap out washer
(13) and remove inner bearing (2) cone from
wheel.
Note: Bearing cups and cones must always be
replaced as a matched set, never separately.
12. If required, remove bearing (2 & 3) cups
from wheel (1), by driving out with a soft drift.
warning
Be sure to use a soft drift and take care
when driving in bearing cups with a drift,
to avoid personal injury from chips or
fragments.
13. During operation, oil seal (14) rides on

bushing (15) which is shrunk on spindle to
provide a smooth contact surface for the seal.
If the bushing is found to be rough or worn,
remove bushing (15).
Inspection
2-10 Service Manual

1. Thoroughly clean all metal components,

except bearing cones, in a suitable solvent.
Dry with compressed air and coat all threaded
components with light oil to facilitate assembly.
2. Clean bearings in volatile mineral spirits
and wipe dry with a lint free cloth. Lubricate
lightly with light oil and spin by hand, to check
for wear and roughness. Replace with new
bearings if excessively worn, or if operation is
rough or noisy.
3. Inspect all machined surfaces of all parts
for scoring, pitting, corrosion and burring.
Resurface or replace with new parts as
necessary.
4. Inspect all threaded components, and repair
or replace as necessary.
Assembly and installation

warning
secured and of sufficient capacity to do the job
safely.
1. If removed, heat bushing (15) to 170 -

205 C to expand it for installation. If heating
equipment is not available, heat the bushing
evenly to 205 C (400 F). This takes about 1
minute, using a torch with a heating tip. Use a
Tempilstik or other temperature gauge to make
sure the bushing is hot enough. Slide heated
bushing (15) on spindle and tap lightly with a
hammer to seat it.
Note: Do not apply flame directly to bushing.
Place bushing on steel plate and apply flame
to centre of plate, to evenly distribute heat.
2. If removed, install bearing (2 & 3) cups
in their respective wheel (1) bearing bores
with care to avoid damaging their raceways.
Service Manual 2-11

Installation by press fit at ambient temperature

is best. Note that the cups must seat fully
against the shoulders of the cup bores in
the wheel hub to assure retention of bearing
adjustment. If carbon dioxide, or dry ice,
freezing of the cup is used, remember to
permit the cup and hub to warm to ambient
temperature after insertion and then to tap
them with a soft steel drift and hammer to
seat.
3. Lubricate the bearings with lubricant
specified in Section 36.1, 'LUBRICATION
AND MAINTENANCE '. Do not pack bearings
solidly with lubricant, as too much is harmful.
Fill wheel cavity not less than one-third to not
more than one-half full with lubricant.
4. If removed, install brake disc (20) on wheel
(1) and secure with bolts (18) and washers
(19). Tighten bolts (18) to a torque of 1850-
1900 Nm.
5. Install inner bearing (2) cone, washer (13),
snap ring (12) and oil seal (14) in wheel end
facing spindle. Seal lip must be facing out.
6. Install the plate (16) and secure with the
bolts (17).
7. With suitable lifting equipment slide wheel
(1) assembly onto spindle.
8. Install outer bearing (3) cone on spindle and
seat in outer bearing (3) cup.
Note: Ensure all dirt, grease, and oil is
completely removed from plate (6), shims (7)
and end of spindle to allow accurate setting of
the bearing pre-load.
9. Install plate (6), without shims (7) on end of
spindle, and secure with six bolts (4). Tighten
bolts (4) evenly in equal increments to 'initial
seating bolt torque' as specified in 'Bearing
Adjustment Table', while rotating and bumping
the wheel (1) assembly.
10. Remove bolts (4) and tap wheel (1)
assembly to free bearings.
11. Reassemble plate (6) without shims (7)
and using only two bolts (4) located 180apart,
adjacent to the gauging holes in plate (6).
2-12 Service Manual

Tighten bolts (4) evenly in equal increments to

'Gauging Bolt Torque', as specified in 'Bearing
wheel (1) assembly.
12. Determine gap between plate (6) and end
of spindle at both gauging holes. To determine
gap, use a depth micrometer in both gauging
holes to measure distance from outer face of
plate (6) to end of spindle. Measure thickness
of plate (6) with a micrometer. Subtract plate
thickness reading from depth gauge readings.
13. Average the two readings, obtained at Step
12, in increments of 0.025 mm (0.001 in) and
round off to the next higher 0.025 mm (0.001
in). This is the average gap. The required shim
pack (7) thickness is equal to the average gap
plus the tabulated constant as shown in the
'Bearing Adjustment Table'.
14. Install the required shim pack (7), plate
(6) and bolts (4) on the end of spindle.
Tighten bolts (4) evenly in equal increments
to 'Final Bolt Torque', as specified in 'Bearing
the wheel (1) assembly. Secure bolts (4) with
lockwire (5).
15. Install gasket (9) and cover (8) and secure
to wheel (1) with bolts (10) and washers (11).
16. Install brake caliper, connect brake
hydraulic line and bleed braking system. Refer
to Section 2.1.2, 'FRONT BRAKE ASSEMBLY
AND INSTALLATION'.
17. Install tyre and rim assembly as described
under 'Mounting Tyre and Rim Assembly on
Wheel'.
Table of special torque
Initial seating bolt torque Gauging bolt Shim pack thickness Final bolt torque
No. of No. of No. of

N. M N. M mm in N. M
Bolts Bolts Bolts
Ave. Gap Ave. Gap
6 135 2 135 6 390
+0.203 +0.008
Service Manual 2-13

2.1.2 Front brake assembly and

installation
6,7
5,6
3,4
2
1
Fig.2-4 Installation of front brake
1. Brake head 5. Bolt

2. Mounting plate 6. Washer
3. Bolt 7. Bolt
4. Washer 8. Brake disc
2-14 Service Manual

Operation overview
This service brake is of dry disc and caliper
type. The caliper is designed for use with
hydraulic oil meeting the specification Section
36.1 LUBRICATION AND MAINTENANCE.
Warning: It is not allowed to use synthetic
brake fluid.
Break head is bolted to a mounting plate on
the spindle. Brake disc is bolted to the wheel.
There are one set of brake head and one
brake disc at each wheel.
Each caliper brake head assembly consists of
one torque plate, two brake pads(one on each
side of the disc) and six brake pistons(three on
each side of the disc).
The brake is driven by the hydraulic oil
entering the internal oil supplying passage of
brake head. The piston bores on each side of
the torque plate are interconnected through
internal passages.
When braking is applied, oil pressure forces
the pistons against the brake pads which are
synchronously forced against each side of the
brake disc, slowing or stopping the disc and
wheel rotation.
Routine inspection
1.Inspect the brake pads for wear.If the
thickness of the friction material on the brake
pad is worn down to 3mm, the brake pad must
be replaced.
2.Inspect the brake disc for wear. Measure
the thickness of the brake disc at three points
which are in the annular area contacted with
the brake pad friction material, then determine
the average disc thickness.
If the average disc thickness is 22 mm or less,
the disc must be replaced. Refer to Chapter
1, 'FRONT WHEEL ASSEMBLY', for the break
disc replacement instructions.
Deflection of brake disc

The maximum allowable defection of brake
Service Manual 2-15

disc is 0.76mm when disc speed is below 100

rpm. If defection exceeds this value, replace
the brake disc or repair hub referring to
Chapter 1'FRONT WHEEL ASSEMBLY '.
warning
Continually using the break pads that
should have been repleaced when worn
to limits, will result in loss of braking and
possible catastrophic failure.
12
13
11
14
10
3
4 9
5
6
7
Fig.2-5 Disassembly of brake head
1. Housing 6. Seal ring 11. Brake pad

2. Dust boot 7. Backup ring 12. Bolt
3. Backup ring 8. Washer 13. Washer
4. Seal ring 9. Bolt 14. Bleeder valve
5. Piston 10. Cover plate
2-16 Service Manual

Remove and installation of brake pad

Refer to Fig.2-5 for numbers in brackets.
1. Place the truck in a flat work area, apply
parking brake and shut down engine and
rotate steering wheel towards both directions
for several times to release the pressure of
steering system.
2. Chock wheels for safety. Set the main
switch of accumulator into the OFF position,
and remove the type and rim referring to
Section 1.1 Front Wheel Assembly.
3. Remove the check plate through loosing
the bolt (12) and washer (13) from one end
of brake head (the left and right positions of
check plate are not interchangeable).
4. Attach a bleeder line and open bleeder
valve(14).Insert screwoperator or crowbar
between brake pads and brake disc to press
the pistons (5) into piston bores in the housing
as far as possible. Then close the bleeder
valve.
5. Rotate the brake pads (11) out of the open
end of brake head.
6. Inspect the position of piston (5) for oil
leakage, and the dust boot (2) for damage.
7. Install new brake pad(11) with friction
material to press brake disc tightly, and rotate
it into brake head.
8. Install the check plate in the position where
it was removed. Ensure that the flat tail seat in
grooves of the check plate, then use bolt(12)
and washer(13)to fasten the check plate.
Tighten bolts(12)to a torque of 1000Nm.
9. Press down brake pedal until the brake
pads(5) presses brake disc tightly.
10. After new brake pads are installed on
the truck, the following operations should
be performed to achieve optimal brake
performance:
a. Drive the truck at the speed of 8~15 km/h
and apply braking. Increase pressure until the
truck produces dragging noise. In this process,
any occurrence of smoke or odor from the
Service Manual 2-17

brake pads is nomal.

Caution: After stopping, measure the
temperature of brake disc with infrared
electronic thermometer.
b. Continuously cycle this process until the
temperature of brake disc reaches 315-370C.
c. Repeat Steps a and b when the temperature
of brake disc is lower than 95C.
d. When brake disc is cooled to less than
10C above the ambient temperature, repeat
Steps a and b until the brake pads achieve the
brake performance according with applicable
goverment regulations.
warning
To prevent personal injury and accident
occuring, ensure that position the truck
firmly and lifting equipment is of sufficient
capacity before removing the brake pads.
Use extreme caution to prevent personal
injury when removing wheels. The
procedure must be adhered to as described
in Chapter 1'Front Wheel Assembly'.
Hands or fingers should be kept away
from the clearance between brake disc
and brake head piston to prevent personal
injury.
warning
Proper oil level should be maintained in the
hydraulic oil tank for steering and brake
control. Refer to Chapter 15 'Hydraulic Oil
Tank Assembly'.
Disassembly and assembly of brake

Refer to Fig.2-5 for numbers in brackets,
unless otherwise specified.
1. Position the truck in a level work area, apply
parking brake and shut down the engine.
2. Turn steering wheel in both directions
2-18 Service Manual

for several times to release steering

system pressure. Press down brake pedal
continuously to release the pressure in brake
accumulators. Chock the truck for safety.
Remove tyres according to the requirements
3. Carefully loosen brake pipes at base of
both accumulators to check that pressure has
released. Then retighten brake pipes.
4. Remove hydraulic oil inlet line at brake
head assembly. Plug the line and brake head
to prevent entry of dirt.
5. Remove the bolt (3, Fig.1) and the washer
(4, Fig.1). Then, remove the brake head
assembly onto a workbench.
6. Disassemble the brake head assembly in
order of serial numbers. If necessary, maintain
and service the seal rings (4 and 6), backup
rings (3 and 7) and the dust boot (2). The parts
(12, 13 and 14) can be left in the housing (1).
7. New dust boot (2), seal rings (4 and 6)
and backup rings (3 and 7) are contained
in the repair kit. Their quantity is enough to
reassemble a caliper brake head. All parts in
repair kit are utilized to replace damaged parts
every time the brake head is reassembled.
8. Inspect the brake pad (1) according to the
requirements of Step 1 in Routine inspection.
9. Clean the housing (1) and ensured that
no solvent remains in the oil passages or
grooves. Inspect the dust boot, seal grooves
and the step areas between grooves for
damage or cracks. Small cracks or scratches
can be blended with crocus cloth. If the
housing (1) is excessively corroded or the dust
boot and seal grooves are damaged, it should
be replaced. It is prohibited to repair the brake
head.
10. Inspect the piston (5) for small scratches
and cracks, and blend them with crocus
cloth. If severe cracks or scratches occur to
the piston or its chrome plate is worn off, the
piston should be replaced.
Service Manual 2-19

warning
To ensure the personal and property safety,
ensure that the truck is parked stably and
the anti-moving facilities are safe and
reliable so as to guarantee the operation
safety. At the same time, ensure that the
hoist device has sufficient hoist capacity.
To prevent unnecessary personal injuries,
release brake system pressure according
to operating procedure. In this operating
process, great care should be taken.
Assembly
Caution: Refer to the specifications in Section
38.2 'Technical Conditions for Tightening
Moments of Standard Bolts and Nuts' for the
tightening torque of the fasteners which are
not especially specified.
warning
It is prohibited to use brake fluid.
1. Use petroleum base lubricating oil or

vaseline to lubricate the seal rings (4 and 6)
and the piston (5).
2. Install the seal ring (4), dust boot (2) and
backup ring (3) into the piston bore of housing
(1), and lubricate them according to Step 1.
3.Install the piston (5) into the housing (1) in
the following method. Install the lubricated
piston (5) in the specified position at a small
angle into the backup ring (3) and the piston
bore. Spread out the backup ring to make its
bore larger than external circumference of
2-20 Service Manual

the piston so that the piston can be rotated.

Inspect the forward extension between the
piston and the backup ring along external
circumference. Ensure that external
circumference lip of the packing retainer
remains in the groove in the piston bore.
4. After the piston (5) is inserted into the
backup ring (3), the piston can be aligned by
feel over the seal ring (6) and one rotating
thrust force can be applied by hands to install
the piston into seal ring.
5. When assured pistons (5) are through
seal ring(3), pressure, other than hand
pressure, may be used to press pistons (5)
the remainder of the way into the piston bores.
Snap open end of dust boot (2) into groove of
piston.
6. Install the seal ring (6) and backup ring
(7) on the open end of piston bore in the
housing(1).
7. Subsequently, install the cover plate (10)
onto the housing with bolt (9) and washer (8).
Tighten the bolt (9) to a torque of 380 Nm.
8. If the brake disc (8, Fig.1) is excessively
worn, it should be replaced according to the
requirements in Routine inspection in this
section. Refer to Chapter 1 'Front Wheel
Assembly' for the relevant replacement
instructions.
Installation
Caution: Refer to the Section 36.2
'TECHNICAL CONDITIONS FOR BOLTS
AND NUTS ' for the tightening torque of the
fasteners which are not especially specified.
warning
loss, ensure that the truck is chocked
and reliably stopped to ensure safe work.
Ensure that hoist device has sufficient
Service Manual 2-21

hoist capacity.
1. Install the washer (6) onto the bolt (5).

2. Position the brake head assembly over
brake disc to align with connecting hole
on brake mounting plate. Then screw the
assembled bolt (5) and washer (6) into
housing through the mounting plate. Tighten
the bolt (5) to a torque of 610 Nm.
3. Remove plugs from brake head and
hydraulic oil inlet passages and reconnect
hydraulic oil circuit at the brake head.
4. Bleed the brake system according to the
requirements below the heading 'Bleeding' in
this section.
5. Install types and rims, referring to Chapter
1'Front Wheel Assembly'.
Bleeding
Refer to Fig.2-5 for numbers in brackets
warning
loss, ensure that the truck is chocked and
reliably stopped to ensure safe work.
To achieve satisfactory braking, all the air in

brake hydraulic lines should be eliminated
according to the following requirements:
1. Refer to the requirements in Chapter 15
'Hydraulic Oil Tank Assembly', and check
the oil level in the oil tank as required. If
the oil level is low, add oil. The oil selected
should meet the specifications recommended
i n S e c t i o n 3 6 . 1 ' L U B R I C AT I O N A N D
MAINTENANCE'.
2. Connect a clean bleeder hose to bleeder
2-22 Service Manual

valve and put open end of the hose into a

clean container.
3. Press down the brake pedal, and gradually
unscrew the bleeder valve (14), which should
be kept open until the oil exhausting from the
bleeder valve is free from bubbles. Then screw
the bleeder valve, release the brake pedal
and remove the bleeder hose.
Caution: This system is equipped with the
accumulator which can still maintain system
pressure even when engine is shut down. If
system pressure is zero, it will be required to
start the engine before bleeding to pressurize
the system. Engine should be shut down
before bleeding procedure is performed.
warning
This brake system operates at high
pressure. The bleeder valve should be
loosened carefully.
4. Repeat Steps 1 - 3 on each brake head

assembly.
Maintenance
Every 10 hours of operation(Daily)
Inspect the brake assembly, ensure that all

connecting bolts are tightened and there is no
leakage. Inspect the boot for demage.
Refer to Chapter 15 'Hydraulic Oil Tank
Assembly', and check the oil level. If the oil
level is low, then add oil. The oil selected
should meet the specifications recommended
i n S e c t i o n 3 6 . 1 L U B R I C AT I O N A N D
MAINTENANCE.
Service Manual 2-23

Special tools
Refer to Section 38.3'Service Tools'.
Special torque specifications

Torque
Fig. No. No. Description
Nm
2-4 3 Bolt 1500~1550
2-4 5 Bolt 2250~2300
2-4 7 Bolt 1300~1360
2-5 9 Bolt 180~200
2-5 12 Bolt 1000~1050
2-24 Service Manual

2.1.3 Steering arm assembly
Fig.2-6 Left steering arm assembly
1. Steering arm welding body 2.Lower end pin 3. Key 4. Screw
Disassembly
Numbers in parentheses refer to Fig.2-6.
1. Remove screw (4).
2. Remove key (3) from keyway of steering
arm welding body (1).
3. Check wear condition of lower end pin(2),
if change needed, partly heating steering arm
welding body (1), remove lower end pin (2).
4. Place disassembled parts in a clean work
for assembly.
Assembly
Numbers in parentheses refer to Fig.2-6.
1. If change needed, partly heating steering
arm, assembly lower end pin (2), keeping
keyway aligned of lower end pin (2) with that
of steering arm.
Service Manual 2-25

2. Place key (3) into keyway of steering arm

welding body (1), keeping mounting holes of
key aligned with those of keyway.
3. Fasten key (3) with screw (4) , complete
assembly of steering arm assembly.
2.1.4 Front suspension cylinder
23
18
22 21 20 16
J1
J3
J2
2 1
7 6 19
27 14 15 13
24 12 11
17
26 25 9 4 5
10
3
8
Fig.1 Sectional view of front suspension cylinder
2-26 Service Manual

1.Snap ring 10.Bolt 19.Seal

2.Bearing 11.Plate 20.Buffer seal
3.Oil fitting 12.Bolt 21.Wear ring
4.Plug 13.Guide sleeve 22.Wear ring
5.Charge valve 14.Retainer ring 23.Piston
6.Piston rod 15.O-ring 24.Bolt
7.Ball 16.Retainer ring 25.Cylinder tube assy.
8.Clamp 17.Seal-wiper 26.Plug
9.Dust boot 18.Backup ring 27.Buffer stopper
Front suspension system Front

suspension cylinder
overview
The front suspension cylinder is mounted on
frame to support the front wheel and absorbs
road shock as the wheel travels over rough
and uneven surfaces. Oil and compressed
nitrogen fill the inside of cylinder tube.
The cylinder contains piston rod (6), guide
sleeve(13),cylinder tube(25) and piston (23).
Oil and compressed nitrogen fill the inside
of the cylinder. When the wheel hits a bump
on the ground, piston rod(6) is forced inward
in the cylinder. The pressurized nitrogen
compresses against the oil inside the cylinder.
As the nitrogen pressure builds up in the
cylinder, piston rod (6) slows down until it
stops. Nitrogen pressure causes piston rod
(6) to extend back to its original position. As
piston rod (6) is compressing, ball (7) is forced
off its seat, allowing the increased pressure to
fill the cavity between tube cylinder tube(25)
and piston rod (6) faster. As piston rod (6)
returns to the normal position, the pressure
in the cavity forces ball (7) against its seat.
Pressure in the cavity is forced to return only
through passage in the piston rod thereby
slowing and smoothing the return travel of the
piston rod(6).
Service Manual 2-27

warning
Pressurized cylinders. Release pressure
as described under 'Relieving Cylinder
Pressure'before removing valves or
fittings. Accidental release of pressure
will result in personal injury and property
damage.
To prevent personal injuries and property
losses, be sure that the air pressure in the
cylinder is completely released before the
suspension is dismantled. In addition, be
sure blocking and lifting equipment is of
Fig.2 Front suspension cylinder mounting
sufficient capacity and properly secured to
do the job safely.
1. Pin
2. pin
Removal
3. A-arm
Numbers in parentheses refer to Fig.2&3&4.
4. Pin
1.Position the truck in a level work area, apply
the parking brake and switch off the engine. 5. Front suspension cylinder
2.Turn the steering wheel in both directions
several times to relieve pressure in the
steering system. Block all road wheels.
3.Relieve nitrogen pressure from both front
suspension cylinders. Refer to Relieving
Cylinder Pressure, in this section.
4.Jack frame up at horse collar until front
suspension cylinder is fully extended.
5.Jack up front suspension cylinder until tyre is
off ground and block steering arm in position.
6.Remove front tyre and rim. Refer to
Chapter1 'FRONT WHEEL ASSEMBLY'.
7. Remove pins attaching tie rod and steering
cylinder to steering arm.Secure both tie rod
and steering cylinder away from the work
area. Refer to Section 2.2, "STEERING Fig.3 Disassembly and installation of front
MECHANISM". suspension
8.Position lift truck forks under front suspension
1. Front suspension cylinder
cylinder and block up front suspension cylinder
as shown in Fig.3. 2. Wooden blocking
9.Remove pin assembly (1, 2, 4,Fig.2) which 3. Lift truck forks
securing front suspension cylinder.
2-28 Service Manual

10.Carefully remove the front suspension

cylinder(5, Fig.2), A arm(3, Fig.2),and steering
arm(8, Fig.4)to a suitable work area for further
disassembly.
11. Follow procedures in Steps 4 through 10
above if the other front suspension cylinder is
to be removed.
Disassembly
warning
loss, be sure blocking and lifting
equipment is of sufficient capacity and
properly secured to do the job safely
Fig.4 Remove A-arm and steering arm

1. Remove A-arm.
a. Remove the bolt (1, Fig.4) and plate (2,
1. Bolt 6. A-arm
Fig.4).
2. plate 7. Bolt
b. Remove the A-arm (6, Fig.4).
c. Remove the bolt (3, Fig.4) and plate (4, 3. Bolt 8. Steering arm assembly
Fig.4) to separate the A-arm(6, Fig.4) and 4. plate 9. Front suspension cylinder
bearing(5, Fig.4). 5. Bearing
2. Remove steering arm.
After the A-arm is removed, remove eight
bolts(7, Fig.4) to separate the steering arm
(8, Fig.4) from suspension cylinder (9, Fig.4).
Remove flat key in keyway of the steering
arm.
3. Remove front wheel
Refer to Chapter 1 FRONT WHEEL
ASSEMBLY for the removal of front wheels.
4 Remove the front suspension cylinder
a.Remove clamp(8),bolts(10) and plate(11)
securing dust boot(9) to piston rod (6) and
guide sleeve(13), then remove dust boot(9).
b.Remove charge valve (5) and plug(4) from
piston rod(6). Drain oil from suspension
cylinder into a suitable container. Remove
Service Manual 2-29

bolts (12) securing guide sleeve (13) on

cylinder tube (25).
c.Securing the suspension cylinder in a proper
position for disassembly.
d.Install a lifting eye in the top of piston rod
(6) and attach to an adequate lifting device.
Slide piston rod (6), piston (23 ) and guide
sleeve(13) as an assembly out from top of
cylinder tube (25). Be careful not to damage
the surface of any component.
e.Remove bolts (24) securing piston (23)
to piston rod (6). Knock on the piston (23)
assembly with a soft hammer to remove it from
the end of piston rod (6).Remove wear ring (22)
from the piston (13).
f.Take out the ball (7) from the hole of piston
rod (6).
g.Note: Take care not to misplace ball (7).
h.Carefully fix piston rod on the base of press
machine and make the hole in the rod
end downwards. Separate piston rod (6) from
the guide sleeve (13). Be careful not to
damage the surface of components.
i.Remove and discard retainer rings(14) and
O-rings(15) from the outer groove of guide
sleeve(13). Then remove and discard snap
ring(15), seal-wiper (17),backup ring (18),
seal(19) ,buffer seal(20) and wear ring(21)
from the inner groove of guide sleeve (13).
j.Remove buffer stopper (27) from the guide
sleeve(13).
2-30 Service Manual

8 22
1 9
2 16
3 17
4 10 23
5 12
18
11
19
1 24
20
13
6 21
26
7 25
14 27
7 15
14
15
Fig.5 Disassembly and assembly drawing of front suspension cylinder
1.Snap ring 10.Bolt 19.Seal

2.Bearing 11.Plate 20.Buffer seal
3.Oil fitting 12.Bolt 21.Wear ring
4.Plug 13.Guide sleeve 22.Wear ring
5.Charge valve 14.Retainer ring 23.Piston
6.Piston rod 15.O-ring 24.Bolt
7.Ball 16.Retainer ring 25.Cylinder tube assy.
8.Clamp 17.Seal-wiper 26.Plug
9.Dust boot 18.Backup ring 27.Buffer stopper
Inspection and maintenance

1.Wash all parts thoroughly in a suitable
solvent. Dry all parts with compressed air.
Check all inner and outer grooves in guide
sleeve(13) and piston(23) for cleanliness.
2.Inspect cylinder tube (25), piston rod (6) ,
piston (23) and guide sleeve(13) for scores,
scuffing or small ridges in the walls. Use a fine
stone to smooth out any defective areas. If
damage is too extensive, replace with a new
Service Manual 2-31

part.
3.Inspect all cylinder assembly components
for signs of unusual distortion or excessive
wear. Replace defective components.
4.Inspect plug (426), Charge valve (5). If the
seal or part is damaged, replace with a new
part. Inspect steel ball(7). If they are damaged,
replace them in time.
5.Check the seating positions in piston rod(6)
and cylinder tube (25). If threads in any of
these parts are damaged, restore the threads.
Replace defective parts if necessary.
6.Inspect the holes of frame for abnormal
distortion or damage. They must be repaired
before the pin are installed.
7.Inspect wear ring (2122) and bearing for
excessive wear or damage. Replace them if is
damaged.
Note: The maintenance standard of bearing
(2), wear ring (21,22), buffer stopper(27) refer
to Fig. 1. and Tab.1.
Tab.1 Maintenance standard
No. Check item Criteria Remedy
Standard Tolerance Standard

Clearance limit
Clearance size clearance
Shaft Hole
between race Replace wear
J1
and ball of ring
bearing 115 0.085- 0.165 0.69
Clearance
between
-0.043 +0.272
J2 piston rod 200 0.043-0.368 0.4
-0.106 0
and wear
ring
Clearance
between -0.05 +0.072 Replace wear
J3 250 0.05-0.368 0.8
cylinder and -0.296 +0 ring
wear ring
2-32 Service Manual

Measuring method:
Measure protrusion and elongation of stopper.
Elongation :
Elongation Protrution
Max.5mm
Deformation Tube
Protrusion:
J4 of buffer Guide
Replace
Buffer
sleeve Min.15mm
stopper stopper
No cracks
Rod
Assembly
Note:Apply a light coating of clean hydraulic
oil to all components as they are assembled.
This facilitates the assembly procedure. Make
sure that all work is done in a clean area so
that no contaminants can get into the oil.
1.Install new snap ring (16), seal-wiper(17),
backup ring(18),seal (19) ,buffer seal(20)and
wear ring (21) into the corresponding groove
in the inner bore of guide sleeve (13). Before
seal-wiper is installed, waterproof glue should
be applied onto the external surface of frame.
2.Install new retainer rings (14) O-rings (15)
and buffer stopper(27) into the corresponding
groove on the external surface of guide sleeve
(13).
3.Use a proper seal ring expander or similar
tool to prevent the seal ring from damage.
Carefully install the guide sleeve (13) into
the piston rod (6). The large end should be
installed at first and sufficient space should
be provided to install the piston (23) into the
piston rod. Be careful not to damage seal.
Then install balls (7) into the corresponding
hole of piston rod (6).
Note: Fix these balls temporarily with a little
clean grease in the rest assembly procedure.
4.Install new wear ring (22) into the
corresponding hole of piston (23). Install
piston assembly to piston rod (6). Slide piston
assembly up piston rod (6) enough. Secure
piston (23) assembly to piston rod (6) with
Service Manual 2-33
bolts (24). Tighten bolts to torque of 136 Nm.

5.Install a lifting eye in the top of piston rod
Insert piston rod (6) , piston (23) and guide
sleeve(13) as an assembly (refer Fig.6)
through the top of cylinder tube assy.(25).
Pushing piston rod in until piston (23) bottoms
inside the cylinder tube. Be careful not to
damage the surface of any component.
Note: Because of close tolerances, care will
have to be taken when assembling piston rod
(6) and piston(23) assembly into cylinder tube
(25).
6.Secure guide sleeve (13) to cylinder tube
assy.(25) with bolts (12). Tighten bolts to
Fig.6 Piston rod component
torque of 136 Nm.
7.Install dust boot(9) with clamp(8) , bolts(10) 1. Piston rod 2. Guide sleeve
and plate(11) to secure it to piston rod (6) and 3. Piston
guide sleeve(13).
8.Install charge valve (5) and plug(4,26) on
suspension cylinder. The tighten torque of
charge valve is 50Nm. The tighten torque
of inflation valve core is 0.35~0.45Nm, the
tighten torque of inflation valve protecting
cover is 4.5 ~5.5Nm. Before installation,
inspect the seal rings of inflation valve and
plug for signs of damage, replace them in time
if they are damaged.
9.Install bearing(2) and snap rings (1) to the
hole of piston rod(6).
Note:the piston rod and piston assembly
should be installed into the cylinder tube
assembly with great care because the
tolerance is small.
Installation
1.Clean all parts surface of suspension
cylinder and frame to make them smooth.
2.Place cushion block on the fork of fork
truck as shown in Fig.3. Then locate the
front suspension cylinder assembly in the
installation position on frame. The weight
of suspension cylinder is over 765kg. If it
2-34 Service Manual

is charged with oil or fluid in advance, the

volume of oil or fluid will be 23L.
3.Secure front suspension cylinder (5,Fig2) to
frame with pin assembly(1,2,3, Fig3).After pins
are installed, use bolts and washers to lock
them.
4.Move away the installation equipment.
5.Connect brake hydraulic pipeline to brake
calipers and exhaust the brake system. Refer
to Section 2.1.2 FRONT BRAKE ASSEMBLY
AND INSTALLATION.
6.Install front tyre and rim assembly as
described in Chapter 1 'FRONT WHEEL
ASSEMBLY'.
7.Repeat Steps 1-6 to install the suspension
cylinder if the suspension cylinder on the other
side is removed.
8.Charge the suspension cylinder according to
the 'charging instructions'.
warning
loss, be sure blocking and lifting
equipment is of sufficient capacity and
properly secured to do the job safely.
Maintenance and adjustment

Periodic maintenance includes the following
steps:
1.Clean the device. Check the signs of wear,
damage or oil-gas leakage. Pay special
attention to the exposed part of piston rod
and inflation valve. Repair or replace them as
required.
Note:The dust boot is equipped with zipper
which can be replaced without remove
suspension cylinder or pin.
2.Check all parts for signs of wear or
looseness. In case of any looseness, repair or
replace them if necessary.
3. Inspect the exterior of suspension cylinder
for signs of oil leakage. Repair or replace
Service Manual 2-35

according to the requirements and add oil

again according to the method described in
the instructions.
Note: Refer to following procedure in this part
for detailed instructions of oil level inspections.
4. Check the relevant operating conditions of
suspension cylinder according to the following
method:
1)Run the truck and make that two suspension
cylinder can achieve a balance at the normal
operating temperature.
2) Position the empty truck on a flat ground.
Measure the distance A between the center
of pin and the end cap of guide sleeve as
shown in Fig.8. The value obtained should
be approximately 410mm(with the error
not exceeding 10mm; refer to Fig. 8). If the
distance is not in this range, check and
adjust the nitrogen pressure according to the
procedure below this part. The following signs
indicate that it is necessary to maintain the
interior of suspension:
a.There is sign of oil leakage in the
surrounding of suspension cylinder.
b. The gas column height changes frequently.
It is required to charge nitrogen.
Note 1: The reduction in the gas column
height is usually accompanied by the loss of
gas.
Note 2: At the circumstance of normal gas
column height, the offset of gas height
indicates that the oil is losing.
Note 3: The traveling or excessive elasticity
of gas will lead to repeated operation of
suspension cylinder.
3) After the suspension cylinder is inflated
to the correct height, apply the rated load,
park the truck on a flat ground, the distance
A between the center of pin and the end cap
of guide sleeve should be equal to 320mm
or higher. (If A is less than 320mm, check the
truck is overloaded or not. If not, deflate and
add oil, inflate gas again ).
Note 4: The unsmooth traveling or excessive
2-36 Service Manual

elasticity of gas column will lead to repeated

operation of suspension at its travel terminal.
Charging front suspension cylinder
warning
losses, ensure that the air pressure in the
do the job safely.
Relieving Cylinder Pressure
warning
Pressure' before removing valves or
damage.
Note:Truck must be unload and on a level

surface prior to relieving suspension cylinder
pressure.
1. Support the frame near the suspension
cylinder with blocking and/or a hydraulic jack
with adequate capacity.
2. Remove the cap from nitrogen charging
valve at the top of the cylinder. Turn the hex
nut on the valve 1/4 to 1/2 turn counter-
clockwise and depress the valve core. If no
gas escapes, continue to turn the hex nut in
1/4 turn increments until the nitrogen releases
as the valve core is depressed.
3.Remove blocking or release pressure on the
hydraulic jack and allow the trucks weight to
fully retract the suspension cylinder rod.
4.Depress nitrogen charging valve core again
Service Manual 2-37

to be sure all pressure has been relieved.

Note:Nitrogen leaving the cylinder will often
carry oil with it. This results form foaming
of the oil in the cylinder. The foaming takes
place as nitrogen which was dissolved in the
oil at high pressure expands at atmospheric
pressure. The oil lost in this operation must be
replaced in the charging operation. The longer
the oil is allowed to stand at atmospheric
pressure after discharging cylinder, the easier
it will be to purge cylinder of bubbles in the oil
when recharging.
warning
Pressurized cylinders. Keep valve core
depressed until all gas is bled from
cylinder. Failure to release all pressure
may result in personal injury or property
damage.
Charging Instructions
Note1: 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.
Note2:To ensure that both suspension
cylinders will be equally charged to the
required height specifications and equal
pressures, both cylinders should be charged
simultaneously. Also when front suspension
cylinders are being charged, both rear
suspension cylinders should be extended
equally. This can be accomplished by placing
equal thickness blocks between axle and
frame at the bump stops. It may be necessary
to raise frame slightly to install spacers. Be
sure to remove spacers when charging is
complete.
Note3:The pressure of a confined gas varies
directly with its temperature. Hence, extreme
2-38 Service Manual

changes in suspension cylinder ambient

temperature will change its nitrogen charge
volume and,consequently, its operating height.
It might be necessary, therefore, to add or
remove nitrogen to maintain proper cylinder
height as ambient temperature changes.
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
1. Position the truck in a level work area. The
truck must be parked stably without applying
friction brake system.
2. Jack frame up until front suspension
cylinder is fully extended. The dimension
Service Manual 2-39

A(See Fig.8,distance between the center of

pin and end cap of guide sleeve) is equal to
525mm when the cylinder is fully extended.
Secure front suspension cylinder in this
position.
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
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.8)
equal to 205mm.
8. Release all residual gas pressure in the
suspension cylinder as step 3.
9. With cylinder rod in its right position (A
= 205mm), open plugand 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 and charge valve
from the piston rod. Attach hose from a
pressure pump filled with hydraulic oil
specified in chapter36.1LUBRICATION
AND MAINTENANCE to oil fill port.The
approximate volume required for initial oil
charging of each front suspension cylinder is
about 23L.
Note: In a cold region, a synthetic hydraulic
fluid(Conoco/Philips synthetic R&O or similar
products) is recommended as a substitute
product. This fluid should have the following
characteristic:
2-40 Service Manual

ISO viscosity grade: 46; solidification

temperature: -70C (-55C); PAO synthetic
agent, allowing to use normal insulation
device.
11. Fill the cylinder until oil flows free of air
bubbles from charging valve 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.
12.Remove oil fill equipment, reinstall plug and
nitrogen charging valve in the ports .
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
13. Charging suspension cylinder with the
nitrogen according to the following procedure.
Charging nitrogen
warning
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.
Service Manual 2-41


To charge both cylinders simultaneously with
nitrogen, use the charging assembly which
including a tee fitting4Fig.7, line (8
Fig.7, Cut-off valve (5, Fig.7) and Nitrogen
charging joint (9, Fig.7) . Refer to Fig.7
'nitrogen charging tool.
The user provides the nitrogen cylinder and pressure regulator
Fig.7 Nitrogen charging assembly

1. Elbow 5. Cut-off valve 9. Nitrogen charging joint
2. Bleeder valve 6. Pipe joint 10. Pipe joint
3. Pressure gauge 7. Pipe joint
4. Tee piece 8. Line
2-42 Service Manual

Cut-off valve
When a single suspension cylinder is inflated,
only one side may be controlled.
The user provides the nitrogen cylinder,

pressure regulator and instruments.
Fig.8 Charge of Front Suspension Cylinder
1. Charge valve 3. Cut-off valve 5. Pressure regulator

2. charge joint 4. Nitrogen cylinder 6. Pressure gauge
A: The distance between center of pin and end cap of guide sleeve
Position for oil filling: A=205mm Empty : A=410mm Loaded: A=320mm
Service Manual 2-43

warning
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.
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.8) on
suspension cylinder and the gas pressure
regulator on the nitrogen cylinder.
1) Connect the hoses of two ends installed
with the Nitrogen charging joint(2,Fig.8) to
the charge valves(1,Fig.1)of front 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.
2-44 Service Manual

5. Charge the suspension cylinders according

to the following steps:
a. Rotate the small hex nut on the charge
valve (1, Fig.8) 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 (2, Fig.7) clockwise until it cannot be
turned any more. Open the check valve of
inflation joint.
c. Open the cut-off valve (3, Fig.8), and inflate
the suspension cylinders at both sides with
the same pressure. During the inflation, open
slowing and intermittently close the cut-off
valve (3, Fig.8) until the distance A between
the center of pin and end cap of guide sleeve
is equal to 395mm (the allowable range of
error is 10mm).
d. When the height A is reached (Fig.8), turn
off the pressure regulator (5, Fig.8) on the
nitrogen cylinder, close the cut-off valve(3,
Fig.8), rotate the hex nut on the charge valve
(1, Fig.8) of suspension cylinder clockwise and
close the internal valve. Rotate the T-shape
handle of nitrogen charge joint (2, fig.8)
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
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 (4, Fig.8), close the cut-off valve (3,
Fig.8), turn on the gas pressure regulator (5,
Fig.8)slowly on the gas cylinder and observe
the reading of the pressure gauge (6, Fig.8).
The pressure in the gas cylinder must be
higher than 7000kpa.
Service Manual 2-45

Note 3: To check the pressure in the cylinder,

turn off the gas pressure regulator on the gas
cylinder, open the cut-off valve (3, Fig.8) and
observe the reading of the pressure gauge (6,
fig.8).
Note 4: If height of unload isnt 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 charge 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 - 0.45Nm.
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 - 5.5Nm.
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.8. 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
2-46 Service Manual

several days. The cylinder pressure shown

in table.2 is guide only. Cylinders should be
charged according to the height 'A' specified
in the Fig.8 and NOT solely on the basis of
monitoring cylinder pressure.
Tab.2 Front Cylinder charging height and pressure

Cylinder height 'A' Cylinder pressure
Truck at Empty A=410mm 3.8MPa
Loaded A=320mm 7MPa
Maintenance
Visually check suspension cylinder heights
dailyFig8&Tab.2. 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 (Nm)
1&5 12 Bolt 136
1&5 24 Bolt 136
1&6 4 Plug 65
1&6 5 Plug 50
1&6 25 Charge valve 50
Service Manual 2-47

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2-48 Service Manual

2.2 Steering Mechanism
7
6
10
4
8 11
12
13
Fig.1 Steering mechanism
1. Tie rod assembly 6. Washer 11. Washer

2. Pin spacer 7. Bolt 12. Crank pin assembly
3. Dust cover 8. Steering cylinder 13. Crank assembly
4. Dust cover 9. Cylinder pin assembly
5. Tie rod pin assembly 10. Bolt
Service Manual 2-49

Description
Layout of steering mechanism refer to Fig.1.

There are two single stage, double acting
steering cylinders (8) installed on the truck.
These exert the necessary hydraulic force
on the steering arm assemblies (A) to pivot
the front wheels. Single stage, double acting
means that the piston rod can have oil applied
to either side, extending or retracting the
piston rod.
Steering cylinder (8) piston rod end is
connected to steering arm assembly (A),
positioned by pin spacer (2) , fixed to steering
arm assembly by tie rod pin assembly (5), bolt
(7) and washer (6).
Steering cylinder (8) base end is connected
to frame, positioned by pin spacer (2), fixed
to frame by cylinder pin assembly (9), bolt (7)
and washer (6).
Steering tie rod assembly (1) is positioned
by pin spacer (2), connected to steering arm
assembly (A) and crank pin assembly (13)
respectively through tie rod pin assembly (5),
bolt (7) and washer (6).
Removal

1. Position the truck in a level work area, be
sure the body is completely lowered, apply the
parking brake and switch off the engine.
several times to relieve pressure in
accumulator and steering system.
3. Block all wheels properly.
4. Switch the battery to the 'OFF' position.
Steering tie rod assembly

1. Support tie rod assembly (1) with suitable
lifting device.
2. Remove bolt(7) and washer (6). Remove tie
rod pin assembly (5) at one end of tie rod (1)
from left side steering arm assembly (A). At
2-50 Service Manual

the same time, remove pin spacer (2) and dust

cover(3).
3. Remove bolt(7) and washer (6). Remove
tie rod pin assembly (5) at another end of tie
rod (1) from crank assembly (13). At the same
time, remove pin spacer (2) and dust cover(3).
Complete the disassembly of left side steering
tie rod assembly (1).
4. Repeat Steps 1~3 to remove right side
steering tie rod assembly (1). Place the
disassembled parts in a clean work for
assembly.
Steering cylinder
5. Support steering cylinder (8) with suitable
lifting device.
6. Remove bolt(7) and washer (6). Remove tie
rod pin assembly (5) at the piston rod end of
steering cylinder (8) from left side steering arm
assembly (A). At the same time, remove pin
spacer (2) and dust cover(4).
7. Remove bolt(7) and washer (6). Remove
cylinder pin assembly (9) at the base end of
steering cylinder (8) from frame. At the same
time, remove pin spacer (2) and dust cover(4).
Remove left side steering cylinder (8).
1
8. Repeat Steps 5~7 to remove the right side
2
steering cylinder (8). Place the disassembled
parts in a clean work for assembly.
Steering crank assembly

9. Support crank assembly (13) with suitable
lifting device.
10. Remove bolt (10) and washer (11),using a
mild steel drift ,drive crank pin assembly(12)
out from crank housing of frame.
11. Remove crank assembly (13), Place
the disassembled parts in a clean work for
assembly.
1.Crank welding body
Disassembly
2.Crank inner spacer
Crank assembly Fig.2 Crank assembly

Disassembly of crank assembly refer to Fig.2
Service Manual 2-51

Crank assembly comprises of crank welding

body(1) and crank inner spacer (2), crank
assembly swing around crank pin assembly
after assembled. Check wear condition of
crank inner spacer (2), if bad condition,
change is needed.
1. Heating crank assembly partly.
2. Drive crank inner spacer (2) out from inner
bore of crank assembly, using tools such as
brass rod.
1 6
Fig.3 Tie rod assembly
1. Rod end bearing(Left-hand) 4. Bolt 7. Nut

2. Tie rod 5. Rod end bearing(Right-hand)
3. Tie rod clip 6. Washer

Disassembly of tie rod assembly refer to Fig.3
Tie rod assembly comprises of tie rod (2), left
rod end bearing (1), right rod end bearing (5),
tie rod clips(3) and fasteners, which can keep
alignment of front wheels with this adjustable
2-52 Service Manual

structure. With rod end bearing (1and 5)

screwed in, tie rod (2) is clamped by up and
down tie rod clips (3) and fixed by bolt (4), nut
(7), and washer (6).
1. Record the assembling length before
disassembly.
2. Remove tie rd clips (3) ,bolt (4), nut (7)and
washer (6) , take down rod end bearing (1and
5).
3. Place disassembled parts in a clean work
for assembly.
Assembly
Crank assembly
Disassembly of crank assembly refer to Fig.2
1. Heating crank assembly (1) partly.
2. Drive crank inner spacer (2) into inner bore
of crank assembly, using tools such as brass
rod.

1. Place tie rod (2) in a vice. Screw rod
end bearings (1 and 5) into tie rod (2) until
assembled length recorded is obtained.
2. After installation is completed, and front end
alignment is checked and corrected, assembly
up and down tie rod clips (3) and tighten nut (7)
, bolt(4) and washers (6).
Installation
Caution: Tighten all fasteners without special

torques specified to standard torques listed
in Section 36.2 Technical Conditions for
Tightening Torque of Standard Bolts and Nuts'.
Crank assembly
1. Supported with suitable lifting device,
assembly crank assembly (13) into crank
housing of frame.
2. Drive crank pin assembly (12) into crank
assembly (13) and crank housing of frame,
Service Manual 2-53

fixed onto frame by washer (11) and bolt(10).
Steering cylinder
3. Support steering cylinder (8) with suitable
lifting device.
4. Assembly base end of steering cylinder
(8) into frame, with pin spacer (2) and dust
cover(4) assembled ,insert cylinder pin
assembly (9),and fixed into frame by bolt(7)
and washer(6).
5. Assembly piston rod end of steering cylinder
(8) into left side steering arm (A), with pin
spacer (2), dust cover (4) assembled ,insert tie
rod pin assembly (5) ,and fixed into left side
steering arm (A) by bolt(7) and washer(6).
6. Repeat steps 3~5 to assembly right side
steering cylinder (8).

7. Support tie rod assembly (1) with suitable
lifting device, assembly into space between
crank assembly (13) and left side steering arm
assembly (A), keeping mounting hole aligned.
8. Assembly pin spacer (2) and dust cover
(3),insert tie rod pin assembly (5), fixed
into crank assembly (13) and steering arm
assembly (A) with bolt (7) and washer (6).
9. Repeat steps 7~8 to assembly right side
steering tie rod assembly (1).
Front end of truck
Centerline
Alignment
Numbers in parentheses refer to Fig.3. X
Correct front end alignment is dependent on
three basic fundamentals.
a. Caster-Forward and rearward tilt of the axle
assembly.
b. Camber-Outward tilt of the top of the front X+Y
wheels.
c. Toe-in - Inward turning of the front wheels.
Note: Caster and camber are built into the
truck and are not adjustable.
Fig.4 Plan View of Wheel Alignment
1. Check for toe-in only when the truck is
Wheel (toe-in) adjustment dimension:
empty and crank is centered. Use a slide bar
Y=8~12mm
attached to the wheel rim edge to make this
2-54 Service Manual

check, required toe-in refer to Fig. 4.

2. Loosen nut (7) and bolt (4) at each end of
tie rod assembly. Turn tie rod (2) with a pipe
pliers until correct toe-in dimension obtained,
refer to Fig.4.
3. When tie rod assembly lengths have
been established, fixed rod end bearings (1
and5) into tie rod (2) with nut (7), bolt (4) and
washers(6).
Maintenance
Every 50 Hours - Lubricate pin assemblies
with grease specified in Section 36.1
LUBRICATION AND MAINTENANCE.
Special tools
There are no special tools required for
procedures outlined in this section. Refer to
Section 36.3 MAINTENANCE TOOLS for part
numbers of general servicetools required.
Service Manual 2-55

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2-56 Service Manual

SRT95C Off-Highway Truck Rear Axle Assembly And Installation
3 REAR AXLE ASSEMBLY

AND INSTALLATION
Fig.3-1 Rear axle assembly and installation
1. Rear axle assembly 2. Rear axle mounting part
Overview of operating principle

See Fig.3-1 for the numbers in the brackets.
The rear axle assembly and installation
consist of the rear axle assembly (1) and rear
axle mounting part (2). The rear axle assembly
also connects the rear wheels to the chassis
through A-frame, Link, and the rear ride
cylinders. The rear axle assembly is centrally
mounted on the rear frame crossmember with
a tapered pin and component parts, which
allows the axle to oscillate as the truck moves
over uneven terrain.
Removal
1. Position the vehicle in a level work area,
apply the parking brake and switch off the
engine.
Service Manual 3-1

Rear Axle Assembly And Installation SRT95C Off-Highway Truck
2. Turn the steering wheel in both directions

steering system. Operate the treadle valve
continuously to relieve pressure in the braking
system. Block all road wheels.
3. Disconnect brake, cooling, breather and
lubrication lines. Drain all the lubricant from
the axle, brake assemblies and planetary
assemblies into suitable containers. See
Section 3.1.3 MAIN REDUCER AND
DIFFERENTIAL ASSEMBLY and Section 3.1.5
REAR BRAKE AND INSTALLATION, cap all
open lines and fittings to prevent entry of dirt.
Note: Avoid spilling lubricant on tyres, as it will
deteriorate the rubber.
4. Jack up or lift up the truck so that its weight
is not supported by the tyres any more.
Securely support the truck at this position.
5. Remove four bolts from the driveline flange
and swing-driveline away from the main
reducer and differential assembly. Punch mark
both flanges to facilitate installation. (See
chapter 19 Installation of Transmission Shaft.
6. If necessary, remove the tyre and rim
assembly according to the method in Chapter
4 REAR WHEEL ASSEMBLY.
warning
damage, be sure lifting equipment is of
adequate capacity and properly secured to
do the job safely.
7. Position a hydraulic jack under the axle at

the differential housing, being sure jack is of
suitable capacity and proportions to lift and
balance the axle assembly. Place wheeled
dollies at both ends of the axle for wheels to
rest on when the axle is lowered. Raise axle
just enough to take weight off centre tapered
pin.
8. Remove lower ends of rear ride cylinders.
3-2 Service Manual

Refer to Section 22, Rear suspension cylinder.

9. Dismantle the bolt, elastic washer, flat
washer and articulated shaft used for installing
Link on the frame, and remove the spacer
ring.
10. Remove the bolts and other parts for
connecting A-frame to the rear axle mounting
part on the frame assembly.
11. Drive tapered pin out of the chassis using
a soft drift. As tapered pin moves out, remove
spacers. Lower the axle assembly onto the
wheeled dollies and roll out from beneath the
vehicle.
12. Use the hoist device to lift the rear axle
assembly and place it onto the rear axle
assembly fixture.
Inspection
1. Clean all metal parts in a suitable solvent,
using a brush to clean bearings. Dry all parts
on a clean surface and allow bearings to dry
naturally. Make sure parts are free from dirt.
2. Check all inner and outer grooves for
cleanliness. Check components for cracks,
scores, blemishes or burrs. Use a fine stone to
smooth out defective areas. Replace any parts
that show excessive wear.
3. Inspect fittings, plugs, studs and their
seating positions for thread wear. If threads
in any of these parts are damaged, replace
parts.
4. Check bushings, bearings and snap
rings for wear or warped condition. Replace
defective parts.
5. Replace the used washer and damaged
O-ring.
Service Manual 3-3

warning
do the job safely.
Assembly
Note: Tighten all fasteners without special
in Section38.2 Standard bolt and nut torque
specifications. Tighten the connecting joint of
hydraulic pipeline and replace all 'O'rings.
1. After the rear axle assembly is completely
reassembled, use a proper hoist device to lift it
up and place it under the truck and align under
the chassis.
2. Using a hydraulic jack of suitable capacity
and proportions to lift and balance the axle
assembly, raise the axle assembly into position
in the chassis. Insert spacers and, using a soft
drift, drive in tapered pin.
3. Install rear ride cylinders to the chassis and
axle assembly as outlined in Section 22 'Rear
suspension cylinder'.
4. With the axle group securely fastened to
the rear ride cylinders and the two sections of
the chassis at Link and A-frame, release and
remove thehydraulic jack.
5. Align the punch marks, as marked during
removal, on the driveline and differential
flanges, and secure with four bolts. Refer to
Chapter 19 Installation of Transmission Shaft.
6. If removed, replace tyre and rim assemblies
as outlined in Section 4'REAR WHEEL
ASSEMBLY'.
7. Remove blanking caps and reconnect
all brake, cooling, breather and lubrication
lines. Refer to Section 3.1.5 'rear brake
assembly' and Section 3.1.3,'Main reduxer
and differential.
8. According to the contents specified
3-4 Service Manual

MAINTENANCE, add lubricating oil into the
rear axle housing, planetary assembly and
rear brake assembly.
9. Lubricate the rear axle assembly through
lube fittings with lubricant specified in Section
36.1'LUBRICATION AND MAINTENANCE' .
10. Refer to Section 3.1.5 REAR BRAKE
AND INSTALLATION for exhaust of the brake
system.
warning
do the job safely.
Maintenance
Correct lubrication is critical to routine
maintenance of planetary and axle shaft and
main reducer and differential assembly. Refer
to the lubrication interval and proper lubricant
specified in Section 36.1 LUBRICATION AND
MAINTENANCE.
Axle diagnosis
Noises originating in the tyres, transmission or
driveline might be attributed by mistake to
the axle. Therefore, all possible sources of
noise should be investigated before deciding
the axle is at fault. true axle noises may be
located by lifting or jacking the truck until all
driving wheels are clear of the floor or ground.
Securely block the truck in this position. Run
power train at moderate speed. Be certain
all tyres are off the ground and, to prevent
damage to the differential, see that neither
rear brake drags.
Service Manual 3-5

3.1 Rear Axle Assembly
Fig.3-2 Rear axle assembly
1. planetary assembly and axle shaft 4. Rear axle housing assembly

2. Rear hub assembly 5. Main reducer and differential assembly
3. Rear brake assembly

The rear axle assembly consists of the
planetary assembly and rear half shaft (1),
rear hub assembly (2), rear brake assembly
(3), rear axle housing assembly (4) and main
reducer and differential assembly (5). The
rear axle also connects the rear wheels to the
chassis through A-frame, link and the rear ride
cylinders. The rear axle assembly is centrally
mounted on the rear frame crossmember with
a tapered pin and component parts, which
allows the axle to oscillate as the truck moves
over uneven terrain.
3-6 Service Manual

Disassembly
engine.
steering system. Operate the treadle valve
continuously to relieve pressure in the braking
system. Block all road wheels.
3. Disconnect brake, cooling, breather and
lubrication lines. Drain all the lubricant from
the axle, brake assemblies and planetary
assemblies into suitable containers.
See Section 3.1.3 Main reducing device and
differential assembly and Section 3.1.5 REAR
BRAKE AND INSTALLATION, Cap all open
lines and fittings to prevent entry of dirt.
Note: Avoid spilling lubricant on tyres, as it will
deteriorate the rubber.
4. Jack up or lift up the truck so that its weight
is not supported by the tyres any more.
Securely support the truck at this position.
warning
do the job safely.
5. Remove four bolts from the driveline flange

and swing-driveline away from the differential.
Punch mark both flanges to facilitate
installation. (See chapter 19 Installation of
Transmission Shaft. )
6. If necessary, remove the tyre and rim
assembly according to the method in Chapter
4 REAR WHEEL ASSEMBLY.
7. Position a hydraulic jack under the axle at
the differential housing, being sure jack is of
suitable capacity and proportions to lift and
balance the axle assembly. Place wheeled
Service Manual 3-7

dollies at both ends of the axle for wheels to

rest on when the axle is lowered. Raise axle
just enough to take weight off centre tapered
pin.
8. Remove lower ends of rear ride cylinders.
Refer to Section 22, Rear suspension cylinder.
9. Dismantle the bolt, elastic washer, flat
washer and articulated shaft used for installing
link on the frame, and remove the spacer ring.
10. Remove nut, pin and washer used for
connecting A-frame to the frame assembly,
and remove the split bush from the tapered
pin.
11. Drive tapered pin out of the chassis using
a soft drift. As tapered pin moves out, remove
spacers. Lower the axle assembly onto the
wheeled dollies and roll out from beneath the
vehicle.
12. Use a hoist device to lift up the rear
axle assembly and place it on the rear axle
assembly placement fixture.
warning
do the job safely.
Disassembly
1. If the gear oil is not discharged, remove the
oil filling screw cover and the oil discharge
screw cover from the rear axle and the
planetary gear carrier first. Drain the gear oil
inside the rear axle assembly into a clean and
proper container.
2. Remove the thrust cover in the planetary
assembly and axle shaft (1), take down the
retainer ring, sun gear and axle shaft.
3. Remove the nut connecting the planetary
assembly and rear hub assembly (2). Then
remove the planetary assembly and discard
the O-ring installed on planetary gear carrier.
3-8 Service Manual

At the same time, use a proper hoist device

to lift the planetary assembly and place it on a
clean work bench.
4. Remove the rear hub assembly (2), use
a proper hoist device to lift up the rear
hub assembly (2) and place it on a clean
workbench.
5. Remove the nut connecting rear hub
assembly (2) and rear axle housing assembly
(4), then use a proper hoist device to lift the
rear brake assembly (3). Then remove the rear
brake assembly (3) and place it on a clean
workbench and discard the damaged O-ring.
6. Remove the nut for connecting the main
reducer and differential assembly (5) and the
rear axle housing assembly (4). At the same
time, use the proper hoist device to lift up the
main reducer and differential assembly (5) and
place it on a clean workbench.
7. If necessary, the A-frame can be dismantled.
warning
do the job safely.
Inspection
parts.
4. Check the bush, bearing and snap ring for
wearing or deformation. Replace the defective
Service Manual 3-9

parts and components.

5. Replace the used washer and the damaged
O-ring.
Assembly
See Fig.3-2 for the numbers in brackets.
specifications.
1. If the oil filling screw cover and oil drainage
screw cover are removed, then they should be
installed onto the axle housing.
2. Install the main reducer and differential
assembly (5) onto the axle housing. Use the
nut to fix and tighten it to the tightening torque
of 541Nm. Refer to Section 3.1.3 MAIN
REDUCER AND DIFFERENTIAL ASSEMBLY.
If the A-frame is removed, then install it onto the
axle housing. To assemble the main reducer
and differential assembly and A-frame, select
and use a proper hoist device to lift them up.
3. Install the rear brake assembly (3) onto the
rear axle housing assembly (4). In addition,
use the nut to fix it and tighten it to the
tightening torque of 1166Nm - 1193Nm. To
assemble the rear brake assembly, select and
use a proper hoist device to lift them up.
4. Use a proper hoist device to lift up the rear
hub assembly (2), and install it onto the rear
axle housing assembly (4).
5. Use a proper hoist device to lift up the
planetary assembly and install it onto the rear
hub assembly (2). Use the nut to fix it and
tighten it. The tightening torque is 650Nm.
6. Install the axle shaft into the rear axle
housing assembly (4) and insert the external
spline without circlip groove at its end into
the internal spline of differential axle shaft
bevel gear in the main reducer and differential
assembly (5). Then install the sun gear and
the retainer ring; finally install the thrust cover
and tighten up the bolts according to the
specified moment.
3-10 Service Manual

warning
do the job safely.
Installation
specifications. Tighten the connecting joint of
hydraulic pipeline and replace all 'O'rings.
1. After the rear axle assembly is completely
reassembled, use a proper hoist device to lift
it up and place it under the truck. Then align it
with the frame.
2. Using a hydraulic jack of suitable capacity
and proportions to lift and balance the axle
assembly, raise the axle assembly into position
in the chassis. Insert spacers and, using a soft
drift, drive in tapered pin.
3. Install the rear suspension cylinder onto
the frame and rear axle assembly. Refer to
Chapter 22 REAR SUSPENSION SYSTEM.
4. With the axle group securely fastened to
the rear ride cylinders and the two sections of
the chassis at Link and A-frame, release and
remove thehydraulic jack.
5. Align the punch marks, as marked during
removal, on the driveline and differential
flanges, and secure with four bolts. Refer to
Chapter 19 Installation of Transmission Shaft.
6. If removed, replace tyre and rim assemblies
as outlined in Section 4'REAR WHEEL
ASSEMBLY'.
7. Remove blanking caps and reconnect all
brake, cooling, breather and lubrication lines.
Refer to Section 3.1.5 'REAR BRAKE AND
INSTALLATION' and Section 3.1.3,'MAIN
REDUCER AND DIFFERENTIAL ASSEMBLY'.
8. According to the contents specified
Service Manual 3-11

MAINTENANCE, add lubricating oil into the
rear axle housing, planetary assembly and
rear brake assembly.
9. Lubricate the rear axle assembly through
lube fittings with lubricant specified in Section
36.1'LUBRICATION AND MAINTENANCE' .
10. See Section 3.1.5 REAR BRAKE AND
INSTALLATION for exhaust of the brake
system.
warning
do the job safely.
Maintenance
Correct lubrication is critical to routine
maintenance of planetary assembly and
axle shaft and main reducer and differential
assembly. Refer to the lubrication interval
and proper lubricant specified in Section 36.1
Axle diagnosis
Noises originating in the tyres, transmission or
driveline might be attributed by mistake to
the axle. Therefore, all possible sources of
noise should be investigated before deciding
the axle is at fault. true axle noises may be
located by lifting or jacking the truck until all
driving wheels are clear of the floor or ground.
Securely block the truck in this position. Run
power train at moderate speed. Be certain
all tyres are off the ground and, to prevent
damage to the differential, see that neither
rear brake drags.
3-12 Service Manual

Fault diagnosis system
Faults Cause Elimination
Check oil level and add the

Lubrication is insufficient or incorrect.
lubricating oil of the right type.
Noise
Wheel bearing is scratched or roughened. Replace the bearing.
Gear teeth in planetary chipped Replace the gear.
Oil level of lubricating oil is too high. Drain exce-ssive oil.
Lubricating oil contains too many foams. Add correct lubricating oil.
Loss of lubri-
Oil seal is worn or damaged. Replace the oil seal.
cating oil
Breather is clogged. Clean the breather.
Nut or bolt is loose. Tighten the nut or bolt.
Increase of
The differential housing brea-ther is clogged. Clean the breather.
lubricating oil
High temp- Check oil level and repl-ace it with
Lubricating oil is insufficient or incorrect.
erature of the lubricating oil of the right type.
planetary
Pinion bearings seized Replace the bearing.
mechanism
Service Manual 3-13

3.1.1 Two stage planetary assembly and

axle half
Fig.1 Sectional View of Two Stage Planetary Assembly
1. Hardened washer 16. Roller spacer 31. Sun gear retainer

2. Washer 17. Planetary carrier 32. Sun gear
3. Roller 18. Thrust plate 33. Lockwire
4. Roller 19. Thrust spacer 34. Cover
5. O-ring 20. Roller spacer 35. Planetary pinion
6. cover 21. Pin retainer 36. O-ring
7. Bolt 22. Planetary pinion 37. Primary planetary gear shaft
3-14 Service Manual

8. Bolt 23. Pinion pin 38. Ring gear

9. Bolt 24. Thrust washer 39. Carrier cover
10. Bolt 25. Ring gear carrier 40. Pin retainer
11. Screw 26. Ring gear retainer 41. Axle half
12. Bolt 27. Ring gear 42. Snap ring
13. Sun gear 28. Planetary carrier 43. Screw
14. Thrust plate 29. O-ring
15. Thrust spacer 30. Thrust washer
Plenetary assembly and axle shaft
Description and operation

The planetary gearing shown is a two -stage
planetary gear assembly. This assembly
contains two sun gears(13&32), two planetary
carriers (17&28) with planet pinions (22&35)
and two ring gears (27&38), to provide
compound gear ratio to the drive wheels. Axle
shaft (41) is driven by the differential and turns
the first sun gear (13) to which it is splined.
The sun gear (13) meshes with and rotates
the first stage planetary pinions (35)which turn
first stage planetary carrier(17) . First stage
planetary carrier(17)meshes with secondstage
sun gear(32) and planet pinions (22) mesh
with ring gear (27). The interaction of the first
stage sun gear (13), planet pinions (35) and
ring gear (38) causes first stage planetary
carrier (17) to rotate which, in turn, drives the
second stage sun gear (32). Second stage
sun gear (32) meshes with and rotates second
stage planetary pinions (22) which, in turn, are
meshed with ring gear (38). Since second
stage ring gear (38) is splined to the wheel
spindle it can not turn and forces the second
stage planetary carrier (28) to rotate. Hence,
two sets of planetary pinions (22&35) with
two different gear ratios interact with their
respective meshed parts resulting in planetary
carrier(28) being the output to the drive
wheels. These combined planetary sets,
therefore, provide a compound gear ratio to
Service Manual 3-15
multiply the torque applied to the drive wheel

by the axle shaft (41).
Planetary Gearing-Towing
Numbers in parentheses refer to Fig.1
warning
Be sure adequate steering and braking
pressure are available before towing to
prevent injury or damage enroute.
If the truck is to be towed, as in the case of a

breakdown, the axle shaft (41) and sun gear
(13)should be removed from the planetary
assemblies. The removal will prevent possible
damage to the power train components during
towing. The axle shaft(41) and sun gear(13)
can be removed easily by taking off the cover
(34) and simply sliding the axlf shaft(41),
together with sun gear(13), out of each
planetary assembly by hand. Be certain the
driving cover (34) are installed to protect the
planetary assemblies from road dust and dirt
while towing is in progress.
Removal and Disassembly

Note: The planetary assembly can be
removed from the wheel without removing the
tyre and rim assembly.
warning
do the job safely.
1. Position the vehicle in a level work area with

plug (6) at its lowest point. Apply the parking
brake and switch off the engine.
3-16 Service Manual


3. With a suitable container in position, remove
plug (6) and drain all lubricant from the
planetary assembly.
4. Remove bolts (8), cover (34) from carrier
cover(39). Remove and discard 'O' ring (5).
Planetary assembly.
5. Pull out sun gear(13), snap ring (42) and
axle shaft(41) assembly from planetary
housing. Remove snap ring (42) from axle
shaft (41) and remove sun gear(13) from the
axle shaft (41).
Thrust washer (24) is a press fit on the shoulder
of sun gear (13) and should be removed only
if worn or damaged.
6. Support the planetary assembly with
suitable lifting equipment and remove
planetary assembly mounting nuts from the
wheel studs. The planetary assembly can now
be removed from the wheel by threading three
set screws into the puller holes in planetary
carrier (28) to force the planetary assembly
outward. Set the planetary assembly on a
clean work surface with planetary carrier (28)
downward.
7. Remove and discard 'O' ring (36). Remove
ring gear assembly (26, 27, 9, & 25) from the
wheel spindle by removing lockwire, bolts, and
retainer plate attaching ring gear carrier (25)
to the spindle.
8. Match mark cover (39), ring gear (38), and
planetary carrier (28) to aid assembly. Remove
bolts (12) and hardened washers(1) and lift
carrier cover (39) and ring gear (38) from
planetary carrier (28). Remove and discard 'O'
rings (29) from carrier cover (39) and planetary
carrier (28).9. Lift up the component of primary
planetary gear carrier (17) from the secondary
planetary gear carrier (28).
9. Lift assembled first stage planetary carrier
(17) from planetary carrier (28).
10. Remove lockwire (33) from bolts (7).
Service Manual 3-17

Remove bolts (7) and Sun Gear Retainer (31)

from sun gear (32). Lift first stage planetary
carrier (17) from sun gear (32).
11. Remove lockwire (33), bolts (7) and pin
retainer (31) from planet pinion pins (37) in
planetary carrier (17) assembly. Remove
planet pins (37) from planetary carrier (17)
assembly.
12. Slide planet pinions (35), thrust plates
(14), thrust spacers (15), roller (3) and roller
spacers (16) from planetary carrier (17)
assembly. Use care to avoid dropping and/or
damaging rollers (3).
13. Turn planetary carrier (17) assembly over
and remove thrust washer (30).
14. Turn planetary carrier(28 ) over. Remove
lockwire (33), bolts (10) and pin retainer (21)
from pinion pins (23). Remove pinion pins (23)
from planetary carrier (28).
15. Slide planet pinions (22), thrust plates
(18), thrust spacers (19), rollers (4) and rollers
spacers (20) from planetary carrier (28).
16. If necessary, remove lockwire (33), bolts
(9) and Ring Gear Retainer (26) and separate
ring gear (27) and ring gear carrier (25).
Inspection
1. Clean all parts thoroughly in suitable solvent
and dry with moisture-free compressed air or
a clean, lint-free cloth. Allow rollers to air dry
and dip in clean planetary lubricant.
2. Inspect all parts for damage. Repair or
replace as necessary.
3. Inspect all pinions, gears and splines for
excessive wear, cracked or broken teeth and
pitted or scored surfaces. If replacing planet
pinions or sun gear, be sure the new pinions
or gear have the same number of teeth as the
old ones so torque multiplication will remain
the same.
4. Inspect roller for damage or excessive wear.
In addition, check for free fit in planet pinions
and on the planet pins. Replace any parts
3-18 Service Manual

which are in questionable condition.

5. Inspect for pitted, scored or worn thrust
surfaces and burrs on the two planetary gear
carriers (17&28) .
6. Inspect ring gear (27&38) and planetary
carrier (17&28) for cracks and wear.
Fig.2 Exploded View of Two-Stage Planetary Assembly
1. Hardened washer 16. Roller spacer 31. Sun gear retainer

2. Washer 17. Planetary carrier 32. Sun gear
3. Roller 18. Thrust plate 33. Lockwire
4. Roller 19. Thrust spacer 34. Cover
5. O-ring 20. Roller spacer 35. planetary gear
Service Manual 3-19

6. Plug 21. Pin retainer 36. O-ring

7. Bolt 22. Planetary pinion 37. Pinion pin
8. Bolt 23. Pinion pin 38. Ring gear
9. Bolt 24. Thrust washer 39. Carrier cover
10. Bolt 25. Ring gear carrier 39. Baffle
11. Screw 26. Ring gear retainer 41. Axle half
12. Bolt 27. Ring gear 42. Snap ring
13. Sun gear 28. Planetary carrier 43. Screw
14. Thrust plate 29. O-ring
15. Thrust spacer 30. Thrust washe
Assembling and installing

Numbers in parentheses refer to Fig.1and
Fig.2.
Note: Tighten all fasteners to standard torques
listed below.
Table of bolt torque (Unit: Nm)

Specifications
5.8 8.8 10.9 12.9
Grade
M6 6.1 9.8 14.7 17
M8 15 24 33 40
M10 29 47 65 79
M12 51 81 114 136
M14 80 128 181 217
M16 123 197 277 333
M18 172 275 386 463
M20 240 385 541 649
M22 324 518 728 874
M24 416 665 935 1120
M27 600 961 1350 1620
M30 819 1310 1840 2210
Note: If Ring Gear Carrier (25) is replaced, the

wheel bearing adjustment must be checked
and corrected as required, as described in
3.1.2 rear hub assembly.
3-20 Service Manual

warning
Assembling fixture
losses, the chocking material and the hoist
device should be firm and reliable and the
hoist device should have the sufficient
hoist capacity to prevent the component
assembly from falling down or the hoist Working platform
device from tipping over for safe operation.
Fig.3 First Stage Planet/Rollers Assembly

1. If disassembled, attach ring gear (27)
securely to ring gear carrier (25) with retainers
(26), bolts (9) and lockwire (33). Install ring 3. Roller 16. Roller spacer
gear and ring gear carrier assembly on the 14. Thrust Plate 35. Planetary Pinion
wheel spindle and attach securely with its 15. Thrust Spacer
etainer plate, bolts and lockwire. See Fig.1.
2. Install planet pinions (35) in planetary
carrier (17) as follows (See Figs 1 & 3):Place
thrust plates (14) on a flat surface, then place
planet pinion (35) on top of thrust plate (14).
See Fig.3. Insert thrust spacer (15) inside
planet pinion (35) then insert 22 rollers (3) as
a group in a circlerollers inside planet pinion
(35) and over roller spacer (16). Make certain
Assembling fixture
thrust spacer (15) is centred to the cage of

rollers (3)in a circlerollers. Then insert rollers
spacer (12), 22 roller (3) and thrust spacer (15)
to complete planet/roller assembly as shown
in Fig.3. Install the assembled planet pinion
with thrust plates (14) into planetary carrier
(17). Insert pinion pin (37) through planetary Working platform
carrier (17) and secure with pin retainer (40),

bolts (10) and lockwire (33).
Fig.4 Second Stage Planet/Rollers
3. According to Step 2, the rest two planetary
Assembly
pinion (35) are assembled. Repeat Step 2 to
assemble and install remaining two planet 4. Roller 20. Rollers Spacer
pinions (35) in planetary carrier (17). 18. Thrust Plate 35. Plandtary Pinion
4. Install planet pinions (22) in planetary
19. Thrust Spacer
carrier (28) as follows (See Figs. 1 & 4): Place
thrust plates (18) on a flat surface, then place
planet pinion (22) on top of thrust plate (18).
See Fig.4. Insert thrust spacer (19) inside
Service Manual 3-21

planet pinion (22) then insert 15 rollers (4) as

a group in a circlerollers inside planet pinion
(22) and over roller spacer (20). Make certain
thrust spacer (18) is centred to the cage of
rollers (4)in a circlerollers. Then insert rollers
spacer (20), 22 roller (3) and thrust spacer (19)
to complete planet/roller assembly as shown
in Fig.4. Install the assembled planet pinion
with thrust plates (18) into planetary carrier
(28). Insert pinion pin (23) through planetary
carrier (28) and secure with pin retainer (21),
bolts (10) and lockwire (33).
5. Assemble and install the remaining three
planet pinions (22) in planetary carrier (28) as
described in Step 4.
6. Position planetary carrier (28) on a clean,
level surface with its bolts circle upward.
7. Insert thrust washer (30) in planetary carrier
(28).
8. Install sun gear (32) in planetary carrier (28)
assembly so that its undercut teeth mesh with
the planetary carrier (17) internal teeth. Attach
sun gear (32) to planetary carrier (17) securely
with sun gear retainer (31), bolts (7) and
lockwire (33).
9. Install new 'O' ring (29) in planetary carrier
(28) groove and install ring gear (38) on
planetary carrier (28) as match marked at
'Disassembly'.
10. Install assembled planetary carrier (17)
and sun gear (32) in planetary carrier (28)
carefully meshing sun gear (32) and planet
pinion(22) teeth, and ring gear (38) and planet
pinion (35).
11. Insert new 'O' ring (29) in carrier cover (39)
and install carrier cover (39) on ring gear (38)
as match marked at 'Disassembly'.
12. Align bolt holes in planetary carrier (28)
ring gear (38) and carrier cover (39). Install
bolts (12) and hardened washers (1) and
tighten securely, using torque wrench.
13. Install a new 'O' ring (36) on planetary
carrier (28).
14. Attach suitable lift-eyes, sling, cables,
3-22 Service Manual

and/or other lifting equipment to the planetary

assembly and raise it into position for
installation on the wheel.
15. Align the teeth of the four planetary pinions
(22) with their mating teeth in ring gear (27)
and carefully insert the planetary assembly
to the wheel so that planetary carrier (28)
mates with the wheel, as match marked at
'Disassembly'. Use care to prevent damage to
'O' ring(36).
16. Install nuts on wheel studs and tighten
securely.
Note: If removed from sun gear (13), thrust
washer (24) must be pressed onto the sun
gear shoulder until completely bottomed on
the gear.
17. If removed, install sun gear (13) on axle
shaft (41) and secure with snap ring (42).
Insert shaft and sun gear assembly into the
39
spindle, carefully mating the teeth of sun gear Inspect the vertical
(13) and planet pinions (35), and, axle shaft distancebetween
the two faces
(41) teeth with the differential side gears. 40
18. Push axle shaft (41) and sun gear (13) Inspect the vertical
distancebetween
inward as far as they will go. With a steel the two faces
rule and straight edge, measure from cover
mounting surface on carrier cover (39) to the
end of axle shaft (41). Note as dimension 'A'.
See Fig.5.
19. Next, lay cover (34) on flat surface and
again use a straight edge and steel rule Fig.5 Measuring dimension A
to measure the height of the inside raised
39. Cover Carrier 41. Axle Half
surface of cover (34). Note as dimension 'B'.
See Fig.6.
20. Subtract dimension 'B' from dimension 'A'
and the clearance should be within 2 - 11 mm.
Note: If the end play is too small, the axlf 34 Cover plate
shaft(41) is not pushed completely into
the differential side gear. If the end play is
greater than the allowable maximum, either
the axlf shaft(41) end or the cover, or both
are excessively worn. To correct this, replace
Fig.6 Measuring dimension B
cover (34) first. If the end play is still too great,
a new axlf shaft must be installed.
21. Install new 'O' ring (5) on cover (34) and
Service Manual 3-23

attach cover securely to carrier cover (39) with

bolts (8). Then install the screw (43).
22. Rotate the wheel until the 'oil-level'
markings on the planetary cover are
horizontal. Fill the planetary to plug (6) level,
with lubricant Install plug (6)and washer(2)
and screw (11) and tighten securely.
3-24 Service Manual

3.1.2 Rear wheel and installation
Fig.1 Sectional View of Drive Wheel Assembly
1. Rear wheel 8. Inner seal housing

2. Ring gear carrier 9. Spindle
3. Bolt 10. Wheel driver
4. Shim pack 11. O Ring
5. Plate 12. Bolt
6. Bearing 13. Washer
7. Bearing
Description
Each drive wheel is mounted on its spindle
with two tapered roller bearings. All the
weight of the truck resting on the drive axle is
supported by the wheels and bearings; none
of the weight is supported by, or transmitted
through, the axle shafts. This type of
construction is known as 'Full Floating'.
The wheel itself is a large cylindrical casting
with the bearing bores and other finished
Service Manual 3-25

surfaces machined after the wheel is cast.
Removal and disassembly

warning
job safely.

one to be raised. Lift up the truck so that its
weight isnt sustained by axle. Main switch of
battery is in the OFF position.
3. Release parking brake.
4. Deflate both tyres completely, and remove
the tyre and rim assembly from the wheel.
Follow instructions under 'Removing Tyre and
Rim Assembly'. Refer to Section 4.1 'REAR
WHEEL ASSEMBLY'.
5. Drain differential and planetary gear
lubricant and remove planetary gear assembly
from the wheel. Refer to Section 3.1.1, 'TWO
STAGE PLANETARY ASSEMBLY AND AXLE
HALF'.
warning
3-26 Service Manual

6. Remove lockwire, bolts (3), plate (5) and

shim pack (4) from spindle (9). Retain shim
pack (4).
7. Pull ring gear carrier (2) from end of spindle
(9).
8. With suitable lifting device, pull wheel (1) off
of spindle (9), being careful that outer bearing
(6) cone does not fall.
9. Remove and discard 'O' ring (11) from
wheel operator (10).
Note: The wheel operator (10) portion of the
disc brake assembly is bolted to inner face
of wheel (1), when the wheel is removed, the
attached disc brake wheel operator (10) will
also be removed. Refer to Section 3.1.3, Rear
Brake Assembly and Installation, if necessary
to remove wheel operator.
Note: Bearing cups and cones must always be
replaced as a matched set, never separately.
10. Remove inner bearing (7) cone from
spindle (9).
11. If required, remove bearing (6 & 7) cups
from wheel (1).
Inspection
1. Thoroughly clean all metal components,
except bearing cones, in a suitable solvent.
Dry with compressed air and coat all threaded
components with light oil to facilitate assembly.
2. Clean bearings in volatile mineral spirits
and wipe dry with a lint free cloth. Lubricate
lightly with light oil and spin by hand, to check
for wear and roughness. Replace with new
bearings if excessively worn, or if operation is
rough or noisy.
3. Inspect all machined surfaces of all parts
for scoring, pitting, corrosion and burring.
Resurface or replace with new parts as
necessary.
4. Inspect all threaded components, and repair
or replace as necessary.
Service Manual 3-27

warning
job safely.
1. If removed, install bearing (6 & 7) cups

in their respective wheel (1) bearing bores
with care to avoid damaging their raceways.
Installation by press fit at ambient temperature
is best. Note that cups must seat fully against
shoulders of cup bores in the wheel hub to
assure retention of bearing adjustment. If
carbon dioxide, or dry ice, freezing of the cup
is used, remember to permit the cup and hub
to warm to ambient temperature after insertion
and then to tap them with a soft steel drift and
hammer to seat.
2. Lubricate inner bearing (7) cone
with lubricant specified in Section 38.1,
LUBRICATION SYSTEM. Install inner bearing
(7) cone onto spindle (9).
3. If removed, install wheel operator (10) on
wheel (1). Refer to Section 3.1.3, Rear Brake
Assembly and Installation.
4. Install new 'O' ring (11) on wheel operator
(10). Refer to Section 3.1.3, Rear Brake
Assembly and Installation.
5. With suitable lifting device slide wheel (1)
assembly onto spindle (9), carefully mating
splines of wheel operator (10) with splines
of disc brake disc operator. Refer to Section
3.1.3, Rear Brake Assembly and Installation.
6. Lubricate outer bearing (6) cone
LUBRICATION SYSTEM. Install outer bearing
(6) cone on spindle (9) and seat in outer
bearing cup (8).
7. Install ring gear carrier (2) on end of spindle
3-28 Service Manual

(9).
Note: Ensure all dirt, grease and oil is
completely removed from plate (5), shim pack
(4) and end of spindle (9) to allow accurate
setting of the bearing pre-load.
8. Install plate (5), without shim pack (4) on
end of spindle (9), and secure with eight bolts
(3). Tighten bolts (3) evenly in equal increments
to 'Gauging Bolt Torque', as specified in
'Bearing Adjustment Table', while rotating and
bumping wheel (1) assembly.
9. Remove bolts (3) and tap the wheel (1)
assembly to free bearings.
10. Reassemble plate (5) without shim pack
(4) and using only two bolts (3) located 180
apart, adjacent to gauging holes in plate (5).
Tighten bolts (3) evenly in equal increments to
'Gauging Bolt Torque' (ref. 'Bearing Adjustment
Table'), while rotating and bumping wheel (1)
assembly.
11. Determine gap between plate (5) and
end of spindle (9) at both gauging holes. To
determine gap, use a depth micrometer in both
gauging holes to measure distance from outer
face of plate (5) to end of spindle (9). Measure
thickness of plate (5) with a micrometer.
Subtract plate thickness reading from depth
gauge readings.
12. Average the two readings, obtained at
Step 11, in increments of 0.03 mm (0.001 in)
and round off to the next higher 0.03 mm (0.001
in). This is the average gap. The required shim
pack (4) thickness is equal to the average gap
plus the tabulated constant as shown in the
'Bearing Adjustment Table'.
13. Install required shim pack (4), plate (5) and
bolts (3) on end of spindle (9). Tighten bolts
(3) evenly in equal increments to 'Final Bolt
Torque' (ref. 'Bearing Adjustment Table'), while
rotating and bumping wheel (1) assembly.
Secure bolts (3) with lockwire.
14. Install planetary gear assembly and
fill planetary and differential assemblies
Service Manual 3-29

LUBRICATION SYSTEM. Install tyre and rim

assembly as described under 'Mounting Tyre
and Rim Assembly on Wheel'.
Table of special torque
Initial seating bolt torque Gauging bolt Shim pack thickness Final bolt torque
No. of No. of No. of

N. M N. M mm in N. M
Bolts Bolts Bolts
Ave. Gap Ave. Gap
8 200 2 200 8 940
+0.18 +0.007
3-30 Service Manual

3.1.3 Main reducer and differential

assembly
37
34
36
24 35 20
19
25 33 29
32
30 22 23
31
32 20
31
18
17 30
28
16
15
14 27
13
12
26
25
9 24
11
10
8
5 6 7
4
Fig.1 Main reducer and differential assembly
1. Lockwire 14. Bearing 27. Driven spiral bevel gear

2. Bolt 15. Shim 28. Nut
3. Plate 16. Main reducer housing 29. Bolt
4. Yoke 17. Screw 30. Thrust washer
5. Sleeve 18. Screw 31. Dowel pin
6. Dust shelter 19. Bushing 32. Axle shaft bevel gear
7. Screw 20. Bearing cap 33. Spider
8. Bearing seat 21. Bolt 34. Planetary bevel gear
9. Bolt 22. Lock 35. Bearing
Service Manual 3-31

10. Shim 23. Bolt 36. Left differential housing

11. Oil seal 24. Bearing Adjuster 37. Bolt
12. Bearing 25. Bearing
13. Drive spiral bevel gear 26. Right differential housing
Shim thickness: 0.10, 0.15 and 0.50mm
Overview and operation

The main reducer and differential have three
functions:
1. It multiplies torque delivered by the driveline
and change the torque direction;
2. It transmits this torque to the axle shafts;
3. It allows the drive wheels to rotate at
different speeds. When the truck is making
a turn, one drive wheel must travel a greater
distance than the other. If the wheels were
connected by a single axle shaft, the wheel
turning the larger radius of the turn circle
would have to override the wheel making the
shorter turn. Thus, one wheel would have to
skip or hop causing tire scuffing and strain on
the power train. Fig.2 Differential
The Main reducer and differential assembly
eliminates wheel skip by allowing separate
axle shafts inserted into axle shaft gears 32
(32) to rotate at different speeds as the drive 33

34
wheels rotate. spider (33) and planetary
bevel gears (34) are meshed with axle shaft
36 26
bevel gears (32), as shown in Fig.2&3. This
assembly is enclosed in Left differential
housing (36) and Right differential housing
(26)which are bolted to driven spiral bevel
gear(27). Thus, Driven spiral bevel gear(27),
Left differential housing (36) and Right
differential housing (26) rotate as an assembly
when driven by input drive spiral bevel gear
(13). However, axle shaft bevel gears (32),
into which each axle shaft is inserted, are
free to rotate independently about planetary
Fig.3 Differential assembly
bevel gears (34) with which they are meshed.
Therefore, as each drive wheel travels through Note: See Fig.1 for the serial numbers in
a different arc as the truck makes a turn, axle brackets.
3-32 Service Manual

shaft bevel gears (32) rotate about planetary

bevel gears (34) to provide the required
differential action.
Removal
raise the body and install the body prop pins.
Refer to Section 23 'BODY AND MOUNTING'.
warning
damage, be sure wheel chocks, blocking
materials and lifting equipment are
properly secured and of adequate capacity
to do the job safely. A come-a-long or chain
fall with a minimum capacity of one ton is
required for removal and installation of a
main reducer and differential assembly.
2. Apply the parking brake and switch off

the engine. Turn the steering wheel in both
directions several times to relieve pressure in
the steering system. Block all road wheels.
3. Ensure the battery switch turned to the
'OFF' position.
4. With suitable containers in position, drain
the
lubricant from the banjo housing and wheel
planetary assemblies.
5. Remove the driving flange cover from each
wheel and pull the axle shaft and sun pinion
gear assembly of each driving wheel at least
150 mm (6 in) out of the wheel housing to
disengage the inner axle shaft splines from the
splines of axle shaft bevel gears (32).
6.Identify the relationship of yoke (4) flange
with that of the driveline companion flange
using punch marks. Remove rear driveline
connecting Main reducer an differential
assembly and transmission. Refer to Section
19. Rear driveline.
7. Remove set screw (18) from main reducer
Service Manual 3-33

housing(16) housing and replace it with a

lifting eye.
8.Install chain fall or come-a-long to the loop
placed on the body just behind the hoist
brackets. Attach the other end of the lifting
device to eye previously installed in the main
reducer housing.
9. Support the weight of the main reducer and
differential assembly with the lifting device.
10. Remove the self locking nuts which secure
the main reducer and differential assembly
to the axle banjo housing. These nuts can be
used for several times.
11. Turn the four screws(17) in to break the
seal between the main reducer housing(16)
and banjo housing. If this does not move the
main reducer and differential assembly out
enough, either remove the screws(17) and
insert longer bolts in the four holes, or use a
suitable bar to pry the differential assembly
away from the banjo housing and studs. If a
bar is used, caution should be exercised to
prevent damaging the mounting surfaces.
12. Pull the main reducer and differential
assembly away from the banjo until it clears
the studs of the axle banjo housing, then
carefully lower the differential assembly.
13. Move main reducer and differential assem-
bly to a clean work area for disassembly.
Disassembly
Driven spiral bevel gear component

Before the disassembly, make marks between
the joint surfaces of some assembly parts to
facilitate reinstallation:
Make identifying punch marks on both the
bearing caps (20) and main reducer housing
(16), so that the bearing caps can be returned
to their original position in assembly.
Scribe an identifying line on bearing adjusters
(24) and main reducer housing (16) bores
which these adjusters screw into. If the
3-34 Service Manual

main reducer and differential assembly is

disassembled for inspection purposes only,
this line will be of assistance when readjusting
the preload on the side bearing(25) cups and
cones. If the main reducer and differential
assembly is disassembled and parts replaced,
do not rely on this line for determining the
preload on the side bearings.
Scribe an identifying line on the right
differential housing (26) and left differential
housing (36) and the end of spider (33) to
show their relationship for assembly purposes.
1. Cut and remove lockwires (1), then remove
bolts (23) and locks (22).
2. Use a proper tool to clamp securely the
driven spiral bevel gear (27) to prevent the
driven spiral bevel gear (27) from rotating.
Then loosen the nut (28) on the bolt (29), but
do not remove them.
3. Cut and remove lockwires (1), loosen and
remove the bolt(21). Then remove bearing
caps (20) from main reducer housing (16).
Salvage dowel bushings (19) that are seated
in the bolt holes between the bearing caps and
the main reducer housing. The bushing can be
reused.
4. Unscrew and remove bearing adjusters (24).
5. Lift the differential assembly from main
reducer housing (16) and Position it on a clean
workbench or a spacial support.
6.Inspect whether the bearing(25) cups and
cones on both sides of differential assembly
are damaged, remove cones of bearing (25)
from differential assembly just only if they are
damaged and have to be replaced. Bearing
assembly is replaceable as an assembly only.
If any component is defective, the complete
assembly must be replaced. When bearing
need not be replaced, wire the bearing(25)
cup and parts which removed from the same
side (include busing and Bearing Cap, etc.)
for mating in assembly and marks should be
made to prevent the parts from being mixed
during reassembly.
Service Manual 3-35

Note:If the cone of bearing(25) should be

removed, in conjunction with the bearing
puller, use a round steel disc, approximately
95 mm (3.75 in) diameter and 10 mm (0.38 in)
thick. This will serve as a centre for the puller
screw to push against. Puller arms must not
exert a force on the bearing roller separator
cage.
7. Loosen and remove the bolts (29) and
nuts(28) holding the driven spiral bevel
gear(27) and the right differential housing(26)
together. Position the differential assembly
vertically on a bench(could be lifted) with the
driven spiral bevel gear's tooth(27) facing
downwards. Place thick wood bar under the
gear(27) and then separate driven spiral bevel
gear(27) from right differential housing(26) by
tapping the edge of the gear(27) with a soft-
faced hammer or a copper stick.
8 . L o o s e n b o l t s ( 3 7 ) r i g h t d i ff e r e n t i a l
housing(26) and left differential housing(36)
together. Then lift right differential housing(26)
off left differential housing(36).
9. Remove one thrust washer (30) and axle
shaft bevel gear (32), then lift spider (33)
and planetary bevel gears (34) out of right
differential housing(26).
10.Inspect whether it is necessary to
replace the spider (33), bearing (35) and
four planetary bevel gears (34). Do further
disassembling only when the gear or bearing
has been excessively worn or damaged and
replacement is required.
11. Remove the axle shaft bevel gear (32) and
thrust washer (30) from the right differential
housing (26). Remove the dowel pin (31)
from the left differential housing (36) and
right differential housing (26) only when it is
necessary to replace the damaged parts in
them.
Drive spiral bevel gear component

1. Remove bolts (2) and plate (3). Pull yoke
(4) assembly from drive spiral bevel gear (13)
3-36 Service Manual

shaft with care so as not to damage or distort

the yoke flange or sleeve surface.
2. Unscrew bolts (9) attaching bearing seat (8)

and shims (10) to the main reducer housing
(16).
3. Remove set screws (7) and screw in two
bolts(M16-80) in the tapped holes of bearing
seat (8) , using these bolts as pullers to
remove bearing seat (8) assembly.
Note: If the above bearing seat assembly
removal procedure is not feasible, the
following method may be used: Invert main
reducer housing (16), as shown in Fig.4, then
use a copper bar to knock on the drive spiral
bevel gear(13) shaft to drive bearing seat (8) Fig.4 Driving Out bearing seat assembly
out of the housing. During this operation, be
careful not to obliterate the etched dimension
on the bottom of drive spiral bevel gear(13)
shaft.
4. Remove shims (10) and wire them together
to aid in assembly.
5. Remove the oil seal (11) from bearing seat
assembly and discard it.
6.Inspect the cups and cones of bearing(12,14)
matched with the drive spiral bevel gear(13)
damaged or not. If yes, using a bearing puller
remove cone of bearing(12,14) from drive
spiral gear (13) shaft. Remove the cups of
bearing(12,14) and shim pack(15) from the
bearing seat(8) and main reducer housing(16)
just when the bearing(12,14) damaged and
need to be replaced.
Note: If the bearing seat are still serviceable,
wire the cups and corresponding cones
together for mating in assembly. Bearing (12
, 14) is replaceable as an assembly only. If
any component is defective, the complete
assembly must be replaced.
Inspection
The importance of careful and thorough
inspection cannot be over stressed. Thorough
Service Manual 3-37

inspection and necessary replacement of

parts now, may eliminate costly and avoidable
trouble later.
1. Clean all parts in a suitable solvent.
2. Immediately after cleaning, dry all parts,
except bearings, with compressed air, or lint-
free cloth. Bearings are better left to air dry,
then inspected and oiled thoroughly with gear
lubricant for protection from corrosion.
3. With the parts cleaned, coat parts
immediately with light oil to prevent corrosion.
If parts are not to be assembled immediately,
treat them with a good rust preventative and
wrap them with treated paper or other suitable
material designed to prevent corrosion.
4. Replace all gaskets, 'O' rings and seals with
new parts.
5. Before installing the main reducer and
differential assembly to the banjo, clean the
inside and outside of the banjo housing to
remove any foreign material.
6. Oil seal (11) rides on a special sleeve (5),
which is on yoke (4) to provide a smooth
contact surface. If the sleeve is rough or worn,
pull it from the yoke and install a new one.
Heat the new sleeve to 177 - 205o C (350 -
400 F) in oil to expand it for installation. If oil
heating equipment is not available, heat the
bushing evenly to 205o C (400o F). This takes
about 1 minute using a torch with a heating tip.
Use a Tempilstik or other temperature gauge
to make sure sleeve (5) is hot enough. Slide
heated sleeve on the yoke and tap lightly with
a hammer to seat it. When install the sleeve,
make sure the chamfer outwards, which is
specially used for oil seal's installation.
7. Examine bearing cap bushings (19) for
wear or damage. Replace as necessary.
8. Inspect all gears and splines for cracked
or broken teeth, excessive wear, and pitted
or scored surfaces. Repair or replace as
necessary.
Note: If either driven spiral bevel gear (27)
or drive spiral bevel gear (13) is defective,
3-38 Service Manual

both gears must be replaced, because they

are serviced only as a matched set. This set
is identified by a serial number on the OD
of driven spiral bevel gear (27) and outer
face of drive spiral bevel gear (13). It is also
advisable to replace axle shaft bevel gears
(32) or planetary bevel gears (34) in matched
sets only, because a newer gear installed to
operate in conjunction with an older, worn gear
tends to carry an uneven portion of the load.
This creates an excessive amount of stress on
the new gear.
Check for pitted, scored or worn thrust
surfaces of differential housing halves, spider
trunnions and thrust washers. It is also
advisable to replace thrust washers(30) in
sets, as the use of a combination of old and
new washers may cause premature failure.
9. Inspect main reducer housing (16), driven
spiral bevel gear (27), right differential
housing(26) and bearing seat(8) for bore
damage, cracks and wear. Replace as
necessary.
10. Check the amount of run-out on the
machined surfaces of bearing seat (8). The
outer machined surface matched with the main
reducer housing(16) on the hub of the bearing
cage must be concentric with the bearing cup
bore within 0.05 mm (0.002 in) total indicator
reading (T.I. R.).
11. The outer machined surface (OD) on
bearing seat (8) must be concentric within
0.05 mm (0.002 in) T.I. R. with the surface into
which oil seal (11) fits.
12. The threads and bores of bearing caps
(20) and main reducer housing (16) must be
concentric within 0.27 mm (0.005 in) T.I. R.
and must be square with the drive spiral bevel
gear bore within 0.08 mm (0.003 in) when
checked at points 254 mm (10 in) from the
centre line of the drive spiral bevel gear bore.
Note: Bearing caps (20) and main reducer
housing (16) can only be replaced as an
assembly.
Service Manual 3-39

13. The machined mating surfaces of right

differential housing (26) and left differential
housing (36) must be square with the axis of
the housing within 0.075 mm (0.003 in) T.I. R..
The mating diameters of the cases must also
be concentric within 0.075 mm (0.003 in) T.I.
R..
Assembly
warning
A

damage, be sure lifting equipment is
Drive spiral bevel gear component

Note: During assembly and installation, make
sure that mated, punch-marked or otherwise
identified parts are returned to their original
positions, if still serviceable.
1. Determine the required shim pack (15)
Fig.5 Measuring dimension A
thickness so as to give the proper gauging
distance within 0.075 mm (0.003 in) etched on
drive spiral bevel gear (13) tail shaft (see Fig.5
and Fig.6) as follows:
Note: The OD of a bearing(14) cup can be
ground to 189.5- 190mm to provide a slip
fit special tool as an aid in determining the
required thickness of shims (15).
a. Install a shim pack (15) of approximately 1.5
mm(0.060 in), measure and record the actual
thickness as Dimension 'X', and the loosely
fitting bearing cup (14) (see previous note) in
the drive spiral bevel gear shaft bore of main
reducer housing (16).
b. Install bearing(12) cone and bearing(14)
cone on drive spiral bevel gear (13). Install
bearing(12) cup into bearing seat (8) until it
bottoms against the bearing seat shoulder.
Install drive spiral bevel gear assembly (12, 13 Fig.6 Method for measuring the dimension A
3-40 Service Manual

& 14) and bearing seat (8) into main reducer

housing (16). Secure bearing seat (8) with
eight bolts (9) equally spaced.
c. Rotate the drive spiral bevel gear (13) and
tighten bolts (9) until the gear(13) cannot be
rotated by hand to seat the bearing rollers
firmly.
d. Place a flat plate approximately 450 mm
long and 300mm wide across the two bearing
cap (20) mounting surfaces in main reducer
housing (16) as shown in Fig.5. The plate
must lie perfectly flat between the bearing cap
mounting surfaces and must be clean and free
of burrs.
e. Measure the distance from the end of drive
spiral bevel gear (13) shaft to the plate (axle
centre line). See Fig.6.
Record this distance as Dimension 'A'.
f. Record the dimension etched on the end of
drive spiral bevel gear (13) as Dimension 'B'.
g. The correct thickness of shims (15) to
be used is: Dimension 'X' + Dimension 'B' -
Dimension 'A'.
2. Determine shim pack (10) thickness so as
to allow the pair of bearing(12,14) on the drive
spiral bevel gear (13) 0.02 - 0.05mm (0.0007 -
0.002 in) axial end play as follows:
a. With drive spiral bevel gear (13) installed as
previously described in Steps 1-a through 1-f,
rotate drive spiral bevel gear (13) and tighten
the eight bolts (9) evenly spaced, to 110 Nm
(80 lbfft) torque to seat the bearing rollers
firmly.
b. Remove bolts (9) and reinstall two of them
180 apart. Tighten the two bolts alternately in
30 Nm (20 lbfft) increments to a final torque
of 275 Nm(200 lbfft).
c. Measure the gap between bearing seat (8)
and main reducer housing (16) adjacent to
the two installed bolts and record the average
measurement as Dimension 'C'.
d. The correct thickness of shim pack (10) is:
Dimension 'C'(Step 2-c) +Dimension 'B' (Step
1f) - Dimension 'A' (Step 1-c)-0.04mm. This
Service Manual 3-41

shim pack thickness should provide 0.02mm-

0.05 mm (0.007-0.002 in) axial end play of
bearing(12,14)on the drive spiral bevel gear
(13).
3. Remove bolts (9) and remove bearing seat
(8) from main reducer housing (16). Adjust
shim pack (15) to the required thickness
as calculated in Step 1-g and replace the
ground bearing(14) cup with bearing cup to be
installed permanently.
4. Install drive spiral bevel gear assembly
(12, 13 & 14) in main reducer housing (16) as
previously described in Steps1 and 2.
Note: Due to reasons such as measurement
error, incompletely compacted shims during
the measurement, the thickness of shim
pack(15) and shim pack (10) measured and
determined in the above-mentioned steps
cannot be used as the final assembling
thickness. It just provides a good starting point
or reference to determine the final thickness.
The final determining for the thickness of
shim pack(15) is that make sure the value A = Etched mounting distance 0.75
deviation is less than 0.075 mm (0.003 in) (see
Fig.7), which between the actual adjustment
distance measured as the bearing(14) pressed
tightly with the clearance disappears and the
dimension etched on the end of drive spiral
bevel gear (13) .
The final judgment for determining the Fig.7 Allowable offset distance for initial
thickness of shims (10) is that position a dial adjustment of drive bevel gear
indicator on the surface of bearing seat(8). the
dial indicator should vertically to the bolt (2)
head. With the bearing seat as the pivot, use a
crowbar to act on the plate. The runout should
be in range of 0.02 - 0.05 mm.
5. Install oil seal (11) into bearing seat (8)
flush with the bearing seat shoulder at the seal
bore.
6. Install measured shim pack (10) as
calculated in Step 2-d on bearing seat (8)
and install the assembly on main reducer
housing (16). Align slot in bearing seat (8) with
the lubrication holes in shims (10) and main
3-42 Service Manual

reducer housing(16) and install bearing seat

assembly in main reducer housing.
7. Install bolts (9) connecting bearing seat
(8) to main reducer housing (16) and tighten
to a torque of 270 Nm(198 lbfft). Install set
screws (7) in bearing seat (8).
8. Lubricate the lip of sleeve (5) and spline
of drive spiral bevel gear (13) with grease
Lubricant.
9. Install yoke (4) assembly to operator spiral
bevel gear (13) spline until it contacts bearing
cone (12).
Note:DO not pound on yoke flange.
10. Install plate (3) and secure to drive spiral
bevel gear (13) with bolts (2). Tighten bolts (2)
to a torque of 270 Nm (198 lbfft) and secure
with lockwire (1).
Driven spiral bevel gear assembly

1. Press thrust washer dowel pins (31) into
holes in left differential housing(36) and left
differential housing(38), if removed.
2. Install bolts (29) and nuts (28) and tighten
to a torque of 900 Nm (663 lbfft).
Spider and component parts assembly

1. If the dowel pin (31) of half shaft bevel
gear gasket (30) is removed, press it into the
locating holes of left differential housing (36)
and right differential housing (26).
2. Lubricate inner walls of left differential
housing (36) and right differential housing (26)
and all component parts with gear lubricant.
3. Position one thrust washer (30), grooved
side facing towards axle shaft bevel gear in
bore of right differential housing (26).
4. Install the first axle shaft bevel gear (32)
machined surface against thrust washer (30)
Dimension
in right differential housing (26). A=114.3250+0.10
5. Install bearings (35) in planetary bevel gears
Dimension
(34) and install bearings and planetary bevel B=228.650+0.20
gears assembly on spider(35), if removed.
Control the dimensions A and B as shown in Fig.8 Installation of spider, bearing and
Fig.8. planetary gear
Service Manual 3-43

6. Lay complete spider assembly in planetary

bevel gear grooves in face of right differential
housing (26).
7. Install other axle shaft bevel gear (32)
and thrust washer (30), with grooved side of
washer mating with machined surface of axle
shaft bevel gear, in left differential housing (36).
8. Assemble left differential housing (36) to
the driven spiral bevel gear (27) and right
differential housing (26) assembly, making
certain that thrust washers (30) do not slip off
dowel pins (31). Turn left differential housing
(36) until the mating mark made during
disassembly lines up with the mark made on
right differential housing (26).
9. Apply retaining compound to bolts (37) and
install four bolts (37) equally spaced. Tighten
bolts (37) to a torque of 580 Nm (428 lbfft).
10. Check assembly for free gear rotation and
correct if necessary. Install remaining bolts (37)
and tighten to a torque of 580 Nm (428 lbfft).
11. Press side bearing (25) cones squarely
and firmly over machined cylinders of left
differential housing (36) and right differential
housing (38).
D riven spiral bevel gear compon e n t

assembly to main reducer housing
Bearing adjusters(24) have two basic
functions:
Pre-loading cups and cones of bearing(25);
and positioning driven spiral bevel gear(27) to
obtain the correct backlash between the driven
spiral bevel gear(27) and drive spiral bevel
gear(13). The bearing adjuster (24) located on
the same side of drive spiral bevel gear (13)
as driven spiral bevel gear(27), pushes the
driven spiral bevel gear toward the drive spiral
bevel gear. Bearing adjuster (24), located on
the opposite side of drive spiral bevel gear
(13) than the driven spiral bevel gear, pushes
the driven spiral bevel gear away from the
drive spiral bevel gear. The driven spiral bevel
gear assembly must be installed onto main
3-44 Service Manual

reducer housing(16) so that cups and cones

of bearing(25)are properly pre-loaded; correct
backlash exists between driven spiral bevel
gear (27) and drive spiral bevel gear (13),
and satisfactory tooth pattern is established
between driven spiral bevel gear (27) and
drive spiral bevel gear (13).
These conditions can be obtained by using the
following procedures:
1. Mount driven spiral bevel gear (27) and
differential assembly on main reducer housing
(16). Make sure that side bearing(25) cups
are properly positioned on side bearing(25)
cones. Install bearing caps (20) over cups and
cones of bearing(25), then secure bearing
caps to the main reducer housing with four
dowel bushings (19) and bolts (21). Secure
bolts snugly, but do not tighten them to torque
specifications at this time. Fig.9 Checking Driven spiral bevel Gear
Note: Each bearing cap (20) is mated to Runout
main reducer housing (16), therefore, they
must be returned to their original positions by
aligning the identification marks made during
disassembly.
2. Install a dial indicator to check the back
side of driven spiral bevel gear (27) for true
running. Rotate the assembly with an easy
motion and note the back face run-out. The
run-out is not to exceed 0.075 mm (0.003
in) with the dial indicator position as shown in
Fig.9.
3. Using a micrometer, take a measurement
diagonally across bearing cap (20) lock pads
and record it for reference later.
4. Install bearing adjusters (24) in their
respective bearing caps (20).
5. Place a dial indicator in the position shown
in Fig.10, to check driven spiral bevel gear
backlash. The dial indicator pointer must be
perpendicular to the tooth surface. Tighten The gauge pointer must be perpendicular to the tooth
bearing adjuster (24) on the driven spiral bevel face, and the clearance value is 0.41~0.56mm.
gear side until the backlash between driven
Fig.10 Checking Driven Spiral Bevel Gear
spiral bevel gear (27) and drive spiral bevel
Backlash
gear (13) reads 0.41mm-0.56mm (0.016-0.022
Service Manual 3-45

in) on the dial indicator.

6. Tighten the opposite bearing adjuster (24)
until another measurement across bearing
cap (22) lock pads indicates a 0.05 - 0.13 mm
(0.002 - 0.005 in) expansion when compared
to the measurement recorded in Step 3. At
the same time, rotate the driven spiral bevel
gear(27) until the rotate torque is 9.5Nm-
19Nm. Then the corresponding preload of the
pair of bearing(25) is correct. This preload can
be measured with a spring scale by pulling
the bolt(29) in the tangential direction making
the driven spiral bevel gear just rotating as the
force is 53N-104N.
7. Recheck the backlash tolerance between
driven spiral bevel gear (27) and drive spiral
bevel gear (13) which should be 0.41 - 0.56
mm(0.016-0.022 in). If this tolerance has
not been obtained at this point, it can be
accomplished without changing the bearing
preload by backing off one adjuster a certain
number of notches and tightening up the
opposite adjuster an equal number of notches.
8. When a satisfactory backlash tolerance has
been established, check the gear tooth pattern
as described under the heading 'Adjustments'.
9. If gear tooth pattern is not correct, some
correction can be made by systematically
loosening and tightening the bearing adjusters
(24), as previously described, but in every
instance re-check the backlash tolerance.
If a favourable gear tooth pattern cannot be
established within the backlash tolerance,
it will be necessary to alter, add or remove,
shims(15) between bearing(14) cup and main
reducer housing(16) and alter shims (10) by
the same amount.
10. When altering these shims as described
in ' drive Spiral Bevel Gear Group ', disregard
all procedures given for comparing the
micrometer (measured) dimension and etched
dimension on drive Spiral Bevel Gear (13) tail
shaft end.
11. The procedures for keeping differential
3-46 Service Manual

side bearing preload, backlash and favourable

gear tooth pattern within specifications is
strictly a ' try, check, and try again ' method.
12. After a satisfactory preload, backlash and
gear tooth pattern is obtained, make certain
that the bolts (9) are tightened to a torque of
270Nm (198 lbfft). Again check backlash
tolerance and gear tooth pattern.
13. Tighten bearing cap bolts (21) to a torque
of 900 Nm (663 lbfft) and tie with lockwire
(1). The lockwire passes over the top of
bearing cap (20) and through the heads of the
respective bolts. The same procedure is to be
followed for both bearing caps.
14. A final measurement across bearing
cap (20) pilot pads must indicate a 0.05 mm
(0.002 in) to 0.13 mm(0.005 in) expansion,
after ten driven spiral bevel gear revolutions
under a light load, when compared to the
original measurement recorded in Step 3. This
ensures that the side bearings have the proper
preload.
15. Install adjuster locks (22) and secure with
bolts (23). Tighten bolts (23) to a torque of 74
Nm (54 lbfft) and tie with lockwire (1).
Adjustment
When adjusting a noisy main reducer and
differential assembly that has been in service
for some time, more harm than good can
result. Changes in adjustment will frequently
concentrate the bearing area on a small
portion of the teeth which often results in
failure. Therefore, it is advisable to know
exactly what the end result will be before
adjustments are made in an old differential.
Note: A rebuilt main reducer and differential
assembly or one that has not worn excessively
may be adjusted as previously described.
The following suggestions are offered to make
gear tooth pattern analysis and identification
easier.
1. Paint twelve teeth of driven spiral bevel
gear with Prussian Blue, oiled red lead, or
Service Manual 3-47

some other easily removed paint or dye. When

the drive spiral bevel gear is rotated, the paint
is squeezed away by the contact of the teeth,
leaving bare areas the exact size, shape and
location of the contacts.
2. Make this check by rotating the driven
spiral bevel gear at least ten revolutions under
light drive load. Another method for checking
contact pattern is to turn the driven spiral bevel
gear clockwise and anticlockwise several
times. For sharper impressions apply a drag
on the driven spiral bevel gear by forcing a
wooden block against the edge of the driven
spiral bevel gear gear while it is being turned.
3. Gear tooth patterns can be interpreted by
referring to Figs. 11- 16.
a. If a contact pattern similar to that shown in Fig.11 Proper Tooth Contact
Fig.11 is obtained, the adjustment is correct.
b. If the contact area is on the inner side of the

driven spiral bevel gear(27) teeth, see Fig.12,
move driven spiral bevel(27) away from
drive spiral bevel gear(13) by turning bearing
adjusters equal amounts until the proper
bearing pattern is obtained.
Fig.12 Insufficient Backlash
3-48 Service Manual

c. If the contact area is on the outer part of

the driven spiral bevel gear teeth, see Fig.13,
move driven spiral bevel gear toward pinion by
turning bearing adjuster.
Fig.13 Excessive Backlash
d. If the contact area is along the root of the

driven spiral bevel gear teeth, see Fig.14,
move the drive spiral bevel gear out by adding
shims.
Fig.14 Drive spiral bevel gear in Too Far - Add

Shims
Service Manual 3-49

e. If the contact area is along the top edge

of the driven spiral bevel gear teeth, see
Fig.15, move the drive spiral bevel gear in by
removing shims.
Installation
1. Be sure truck wheels are chocked securely.
2. If the body is not already raised, raise body
and install body prop pins. Refer to Section
23, BODY AND MOUNTING.
3. Clean mating surfaces of the banjo and
main reducer and differential assembly with
a hydrocarbon solvent to remove dirt, oil,
grease, or other foreign matter. Wipe cleaned
surfaces dry. Apply the sealant cord as follows:
The adhesive side of the cord is applied to Fig.15 Drive spiral bevel gears out Too Far -
the banjo face, starting at the top, looping Remove Shims
once around the first stud, then to the second
stud, etc., ensuring not to overstretch the cord
and that the loop between the studs will be
on the inside of any of the main reducer and
differential assembly extraction holes. Working
all the way round finishing with an overlap at Moving the driven spiral bevel
gear outwards to correct the
the top. situation in Figure 12
4. Set screw (18) should already have been

removed from the top of the differential Moving the drive spiral bevel
Moving the drive spiral bevel
gear outwards to correct the

gear inwards to correct the
housing and replaced with a lifting eye during

removal. If not, remove set screw (18) from
situation in Figure 14
situation in Figure 15
main reducer housing and replace it with a

lifting eye.
5. Position the main reducer and differential
assembly under the truck in front of the banjo
housing.
6. Install chain fall or come-a-long to the loop
on the body just behind the hoist brackets.
Attach the other end of the lifting device to the
eye previously installed in the main reducer Move the driven spiral bevel
gear inwards to correct the
and differential assembly. situation in Figure 13
7. Lift the main reducer and differential
Fig.16 Correct movement for adjustment
assembly and carefully position it on the studs
of the banjo housing.
8. Secure the main reducer and differential
assembly to the banjo with the self locking
3-50 Service Manual

nuts removed at removal. Tighten the nuts

evenly in increments of 90 Nm (66 lbfft) to a
final torque of 541 Nm (399 lbfft).
9. Replace the rear driveline, aligning marks
made during disassembly. Refer to Section 19,
Rear driveline.
10. Install the axle shafts, then replace and
secure the driving flange cover to the wheels.
Refer to Section 3.1, Planetary assembly.
11. Fill the drive axle, planetary reservoirs
and main reducer anddifferential assembly
with the proper grade and quantity of lubricant
specified in Section 38.1, lubrication system.
Maintenance
Periodic inspection
Inspect regularly the flange yoke mounting
bolts, drive spiral bevel gear shaft nut,
bearing seat and bearing seat bolts and main
reducer and differential assembly stud nuts
for tightness. Tighten the stud nuts and flange
bolts weekly until they 'set' or show that they
no longer need tightening. Keep the nuts tight
to reduce the possibility of main reducer and
differential assembly or driveline failure due
to excessive vibration or wear. Replace any
mounting studs which have become stripped
or broken.
Jack up the drive axle to 'test run' the main
reducer and differential assembly and listen
for noises which may indicate the need for
adjustment or replacement of worn parts.
When doing this, lift BOTH wheels off the
ground. Both wheel brakes should be free to
allow both wheels to rotate at approximately
the same speed.
Note: Do not operate with only one wheel
jacked up. Excessive operation in this manner
will overheat the differential spider and cause
galling or shearing of the spider trunnions and
bearings.
If the main reducer and differential assembly is
excessively noisy, it should be removed from
Service Manual 3-51

the banjo and disassembled for inspection.
Lubrication
The main reducer and differential assembly
is splash lubricated with an extreme pressure
lubricant. The fill level plug is located in the
centre rear of the banjo housing.
The main reducer and differential assembly
should be checked and periodically drained
and filled to the bottom of the fill-level hole,
or to no more than 13 mm (0.5 in) below the
fill level, with new lubricant as recommended.
Refer to Section 38.1, lubrication system.
When the lubricant is drained, remove any
chips of steel particles that may be attached to
the magnetic drain plug located in the bottom
of the banjo housing. After draining and
refilling an axle, the planetary gearing should
be checked after 10 hours of operation.
1. Check the level in planetaries at oil level
plug. If the oil level is low, add oil. This check
point is a minimum check point only. If the oil
level is above the check point, do not drain off
oil.
2. Add oil if needed. The oil level is correct
when oil flows from the lube level check plug
in the banjo. These checks should be made
every 10 hours until oil level in the differential
is maintained.
SPECIAL TORQUE SPECIFICATIONS

Torque
FIG. NO. ITEM NO. ITEM NAME
Nm lbfft
1 2 Bolt 270 198
1 9 Bolt 270 198
1 21 Bolt 900 663
1 23 Bolt 74 54
1 28 Nut 900 663
1 29 Bolt 900 663
1 37 Bolt 580 428
3-52 Service Manual

Table of fault diagnosis

Condition Reason Remedy
Broken gear teeth. Replace the damaged gear.
Vibration The drive spiral bevel gear or bearing seat Disassemble, correct or replace
are excessively worn. faulty part.
Bearing worn. Replace worn parts.

Continuous noise
Gears damaged or worn. Replace gears.
The drive and driven gears adjustment
Noise on drive. Adjust.
tight.
Bearing damaged. Replace the bearing.
Loose the drive and driven spiral bevel
Readjust it.
Noise on coast. gear adjustment.
Excessive drive spiral bevel gear end play.
Readjust it.
Worn axle shaft bevel gears or planetary

Replace the gear.
Noise on turns. bevel gears.
Worn or damaged spider bushings. Replace the bearing.
Oil seals worn. Replace seal.
Loss of lubricant. Loose nuts. Tighten nuts to correct torque.
Cracked housing. Repair or replace housing.
Service Manual 3-53

3.1.4 Rear axle housing assembly
Fig.1 Rear axle housing assembly
1. Thread gasket 10. Snap ring 19. oscillation Stop

2. A-frame assembly 11. Bearing 20. Link nut
3. Bearing 12. Link 21. Washer
4. Gasket 13. Shaft 22. stud
5. Bolt 14. Washer 23. Breather
6. Steel wire 15. Washer 24. Screw plug
7. Washer 16. Bolt 25. Washer
8. Bolt 17. Bolt 26. Screw plug
9. Spacer 18. Washer 27. Axle housing component
3-54 Service Manual

Description and operation

The rear axle assembly consists of axle
housing assembly(27) , A-frame (2) and
Link(12). The axle housing assembly provides
the housing for the differential and axle shafts
which drive the wheels, and spindles to which
the wheels are mounted. The axle housing
assembly also connects the rear wheels to the
chassis through A-frame (2), Link(12), and the
rear ride cylinders.

See Fig.1 for the numbers in the brackets.
warning
dequate capacity and properly secured to
dothe job safely.
1. Remove the bolt (5) from A-frame assembly

(2), take down the gasket (4) and thread
gasket (1). Then remove the bearing (3). If
necessary, the grease fitting can be removed
from the A-frame assembly (2).
2. Remove the A-frame assembly (2) from the
axle housing assembly (27) by Disassembly
bolt (8) and washer (7). Before Disassembly,
use the proper hoist device to lift up A-frame.
3. Remove the bolt (17), Washer (18) and take
down the oscillation stop (19).
4. Remove the bolt(16), washer(15), (14)
and shaft(13). Take down the spacer (9) and
link(12).
5. Remove the Snap ring (10) and bearing (11)
from the link (12).
6. Remove the breather (23) from the axle
housing assembly (27).
Inspection
Service Manual 3-55


parts.
4. Check the bush, bearing and snap ring for
wearing or deformation. Replace the defective
parts and components.
5. Replace the used gasket.

in Section 38.2 'Standard bolt and nut torque
specifications', unless it is otherwise noted.
Note: If heating of axle housing is required
to assemble spindles and axle housing, axle
housing interference areas must cool to 66 C
(150 F) maximum before welding. For welding
spindles to axle housing preheat spindles and
axle housing to 150 C (300 F) minimum in
weld area and maintain during welding.
1. Install the washer (25), Screw plug (24)
and Screw plug (26) onto the axle housing
assembly (27).
2. Install the breather (23) onto the axle
housing assembly (27).
3. Install the bearing (11) onto the link (12) and
use the Snap ring (10) for fixing. Then, install
the assembled link components onto the axle
housing component (27) and install the spacer
(9) and the articulated shaft (13). Then use the
washer (14) , (15) and bolt (16) to fix the link
(12) onto the axle housing components (27).
4. Use the bolt (17) and washer (18) to fix the
oscillation Stop (19) onto the axle housing
component (27).
3-56 Service Manual

5. Install the bearing (11) onto the A-frame

assembly (2), and install the thread gasket
(1) and gasket (4). Use the bolt (5) to fix them
onto the A-frame assembly (2) and use steel
wire (6) to lock the bolt (5).
6. Use a proper hoist device to install the
A-frame assembly (2) onto the axle housing
components (27) and use the bolt (8) and
washer (7) for fixation. The tightening moment
of bolt (8) is 3640 Nm.
warning
do the job safely.
Service Manual 3-57

3.1.5 Rear brake and installation
Fig.1 General view of brake
3-58 Service Manual

1. O-ring 20. Bolt 38. Friction disc

2. Driving wheel 21. washer 39. Friction plate
3. Hardened washer 22. Spring housing 40. Service brake piston
4. Bolt 23. Socket head screw 41. Bolt
5. O-ring 24. O-ring 42. Mounting plate
6. Lockwire 25. OG seal ring 43. Spring
7. Bolt 26. Guiding belt 44. Pin
8. washer 27. Spring 45. Return pin
9. Outer seal housing 28. Spring 46. D-ring
10. O-ring 29. Pin 47. D-ring
11. Seal ring 30. Parking brake piston 48. Service brake piston housing
12. Dynamic seal assembly 31. OD seal ring 49. Bleeder screw
13. O-ring 32. Guiding belt 50. Dust boot
15. Inner seal housing 33. Pin 51. Plug
16. O-ring 34. Housing 53. Stud
17. O-ring 35. O-ring 54. Locknut
18. Seal ring 36. Driving disc
19. Dynamic seal assembly 37. damper plate
Service Manual 3-59

port A
port C
port D
port B
port D
port C
Fig.2 Structure of brake
13. O-ring 43. Spring 47. D-ring

24. O-ring 44. Pin 49. Bleeder screw
33. Pin 45. Return pin 51. Plug
42. Mounting plate 46. D-ring 52. Plug
3-60 Service Manual

Fig.3 Exploded view of brake assembly(Refer to Fig.1 and Fig.2 for the part names corresponding
to the numbers)
Service Manual 3-61

Operation overview
Refer to Fig.1 and Fig.2 for numbers in
brackets.
Service brake
Note: The service brakes are of 'Upright
Design', i. E. requiring pressure to hold the
brakes on.
The rear service brake utilizes hydraulic force
to slow or stop the driving wheel. When the
pedal of foot brake in the cab is pressed down
or the retarder control lever on the central
operating console is operated and the retarder
selector switch (if equipped) is turned into the
position of rear disc brake, the hydraulic oil
will be transmitted to the port C on the rear
disc brake, referring to Fig.2. The hydraulic
oil entering into the port C forces the service
brake piston (40) against the brake disc pack
consisting of the damper plate (37), friction
disc (38) and friction plate (39).
The friction plate is clamped between the
friction disc (38) and it is driven by the wheel via
the driving wheel (2) and driving disc (36). To
decelerate or stop the driving wheel, pressing
force applied onto the brake disc component
directly depends on the pressed level of brake
pedal.
When the service brake pedal or retarder
control lever is released, the pressure asainst
the service brake piston (40) is immediately
relieved. The force of brake return spring (43)
tightly against the head of the return pin (45)
makes the return pin pull the piston (40) back
to the original position, and consequently
the pressure against the brake disc pack is
released.
Parking brake
Note: The parking brake is of 'Inverted
Design', i. E. requiring pressure to hold the
brakes off.
This brake is operated with the parking/
emergency brake control button mounted on
3-62 Service Manual

the instrument panel. It is applied with spring

force and released with hydraulic force. When
the control button is released, the hydraulic
oil enters into the port D, referring to Fig.2.
And it flows into the oil passage in front of the
parking brake piston (30) via the guide groove
inside the brake disc housing (34). At the
moment, the hydraulic oil will push the piston
(30) to overcome the tension of springs (27
and 28) and to remove pressure on the baffle
(37). Consequently, the release of the brake
disc component is maintained. If the control
button is pressed, the oil pressure at the port
D and that tightly against the parking piston
(30) will be immediately released. The tention
of springs (27, 28) recovers and forces against
the damper plate (37) and disc pack consisting
of friction disc(38)and friction plate(39). At the
moment, the rotating friction plates clamped
between friction discs are immediately pressed
tightly, thus keeping the wheels from rotating.
Removal
brackets.
Note: Before the disc brake assembly is
removed and disassembled, the wear extent of
friction plates and baffles should be recorded
referring to the specifications on measuring
procedure and maximum allowed wear limit
described in the 'Measuring procedure for disc
brake assembly wear' under 'Inspection' in this
section.
Service Manual 3-63

warning
To prevent personal injury and equipment
loss, it should be ensured that the hoist
equipment has sufficient carrying capacity
and the wheels are reliably fixed and
chocked to enable safe operation.
After the engine is shut down, the hydraulic
oil still remains in the brake system. Before
the brake system is operated, the pedal
valve should be continuously operated
until the pressure is completely released,
so that severe personal injuries can be
avoided.
Use extreme caution when removing
wheels. Specific operation procedure must
be complied with as describedi in 'tyre and
rim assembly'.
1. Place the truck in a flat place, apply parking

brake, turn off the engine, turn the steering
wheel in the two directions for several times,
and release the pressure of the steering
system.
2. Continuously press down the brake pedal to
release the brake system pressure. Chock the
wheels and set the main switch of battery into
the OFF position.
3. Remove the plug (51). Drain the cooling oil
inside the disc brake assembly into a clean
container and then reinstall the plug.
4. Remove the bleeder screw (49) at the
bottom. Drain the brake hydraulic oil into a
clean container. Then reinstall the bleeder
screw.
Note: To reduce the loss of hydraulic oil during
removing of oil pipe from the brake assembly,
the air breather on steering and brake control
oil tank can be removed in advance and the
port can be connected to the vacuum pump to
evacuate the air in the tank to vacuum of 0.5 -
0.7 bar.
5. Remove the brake cooling pipe from the
3-64 Service Manual

ports 'A' and 'B' of the service brake piston

housing (48) and marks properly, referring
to Fig.2. Plug the pipes and ports to prevent
contamination and keep oil in the pipes and
housing.
6. Remove the service brake pipe from the
port 'C'of the service brake piston housing (48)
and mark properly, referring to Fig.2. Plug the
pipes and ports to prevent contamination and
keep oil in the pipes.
7. Remove the parking brake pipe from the
port 'D' of the service brake piston housing (48)
and mark properly, referring to Fig.2. Plug the
pipes and ports to prevent contamination and
keep oil in the pipes.
8. Remove the wheel assembly from the truck
as described in Chapter 4 'REAR WHEEL
ASSEMBLY'.
9. Orient the driving wheel (2) upwards and
place the wheel assembly in a horizontal
position. Remove and discard the O-ring (5)
from the outer diameter of driving wheel (2).
10. Remove the bolt (4) and hardened washer
(3) securing the driving wheel (2) to the wheel
and use a proper lifting device to remove the
driving wheel from wheel.
11. Remove the O-ring (1) from the wheel and
discard it.
12. Remove the inner seal housing (15).
Remove and discard the O-ring (16).
13. Remove the dynamic seal assembly (19)
from the inner seal housing (15) and driving
disc (36), and discard the 'O'rings. The
reserved metal seal elements are put aside for
inspection.
14. Remove one bolt (20) and hardened
washer (21) from the spring housing (22)
and the service brake piston housing (48)
respectively. The two bolts removed should
be located as close to 12 o'clock as possible.
Then intall a lifting eye in each bolt hole.
15. Connect a proper lifting device to the lifting
eyes installed on the disc brake assembly in
Step 14 and tension it upwards. Then remove
Service Manual 3-65

the nut (54). Use lifting device to carefully

remove the disc brake assembly from the
spindle. Place it in a clean flat area with the
spring housing (22) oriented upwards.
16. Repeat Steps 3-15 to remove the opposite
disc brake assembly.
Disassembly
Refer to Fig.3 for numbers in the brackets.
warning
1. Remove the lockwire (6) on the bolt (7), and

remove the bolt (7) and washer (8) securing
the outer seal housing (9) to the driving disc
(36). Then remove the outer seal housing.
2. Remove and discard the O-ring (35) from
the outer diameter of driving disc (36).
3. Remove the dynamic seal assembly (12)
from the driving disc (36) and discard its O-ring.
The reserved metal elements should have no
scratch or damage.
4. Use a proper lifting device to carefully lift
the driving disc (36) out of the disc brake
assembly. Use a lifting device to turn over
the disc brake assembly to orient the service
brake piston housing (48) upwards.
5. Remove and discard the O-ring (5) from the
service brake piston housing (48). If necessary,
the bleeder screw (49) can be removed from
the service brake piston housing.
6. Remove the plug (51) and the O-ring (5)
on the service brake piston housing (48) and
discard the O-ring.
7. If necessary, remove the stud (53) from the
service brake piston housing (48).
8. Remove the bolt (20) and washer (21) from
3-66 Service Manual

the service brake piston housing (48).

9. Remove the socket head screw (23)
and hardened washer (21) with great care.
Alternately unscrew each screw by one turn
every time to prevent the service brake piston
housing (48) pressed by the springs (27 and
28) from being ejected.
warning
damage, take great care to remove the
socket head bolt (23) and hardened washer
(21) , for the spring housing (22) is under
the pressure from the springs (27, 28).
10. Use a proper lifting device to remove the

service brake piston housing (48) from the
brake housing(34) , and place it in a flat area
with service brake piston (40) side oriented
upwards.
11. Remove and discard the 'O'rings (24 and
Fig.4 Spring compression tool
13) from the service brake piston housing(48).
12. Use the tool shown in Fig.4 (Note: The tool
can be fabricated as shown in Fig.20). Screw
the T handle of the tool into the threaded hole
in the end of a return pin (45). Place the base
of this tool on the flat surface of service brake
piston (40). Press down the handle of the tool
to raise the return pin (45) and compression
spring (36) until the pin (44) is pulled out of
the return pin. Then remove the tool. Refer to
Fig.5.
13. Repeat Step 12 to remove the pin (44) on
each return pin (45).
Fig.5 Schematic diagram for operation of
spring compression tool
Service Manual 3-67

14. Install three M12 bolts in three threaded

holes on the service brake piston (40) for
pulling. Alternately screw in the bolts to
gradually pull the service brake piston (40) out
of the service brake piston housing (48). Then
remove the three pulling bolts and remove the
service brake piston. Refer to Fig.6.
15. Remove and discard D-rings (46, 47) from
the service brake piston housing (48). Fig.6 Schematic diagram for service piston
removing
16. As the spring (43) is under the mounting

plate (42), the mounting plate (42) and bolt (41)
for fixing the spring (43) should be removed
from the service brake piston housing (48)
with great care. Refer to Fig.7. spring
17. Remove the return pin (45) and return
spring (43) from the service brake piston
housing (48). Refer to Fig.7.
Fig.7 Schematic diagram for returen pin and

spring removing
18. Remove the damper plate (37) in one side

of the brake disc housing (34). Subsequently,
remove all friction plates (39) and friction discs
(38) alternately until the baffle (28) in the other
side is removed. Refer to Fig.8.
19. If necessary, remove the pin (33) from the
brake disc housing (34).
20. Use a lifting device to turn over the brake
disc housing (34) to orient the spring housing
(22) side upwards. Remove the bolt (20) and
hardened washer (21) from the spring housing
(22).
Fig.8 Schematic diagram for friction pack
removing
3-68 Service Manual

warning
For the spring housing is under the
pressure from spring (27, 28), to prevent
personal injury and equipment damage,
take great care to remove the socket head
bolt (23) and hardened washer (21) from
the spring housing (22).
21. Alternately unscrew socket head screws

Fig.9 Schematic diagram for spring housing
(23) by one turn every time, and remove
removing
them along with the hardened washers (21).
Then use a lifting device to remove the spring
housing (22) from the brake disc housing (34).
Refer to Fig.9.
22. Remove and discard the O-ring (24) from
the spring housing (22). Remove the springs
(27, 28) from the parking piston (30).
23. Use the lifting tool shown in Fig.10 to
lift and remove the parking piston (30), and
the lifting tool can be fabricated according
to Fig.23. Place legs of the tool on the edge
of brake disc housing to make the tool over
parking piston. Align the three holes of the
tool with three threaded holes in the parking
piston. Then insert three M12 bolts through
Fig.10 Hoist tool
the three holes into the three threaded holes
in the parking piston. When screw the bolts
downwards, the parking piston will move
upwards until out of the brake disc housing
due to the support of lifting tool. Then lift out
the parking piston. Refer to Fig.11.
24. Remove and discard the OG seal ring (25)
and Guiding belt (26) from the parking piston
(30).
25. If necessary, the pin (29) can be removed
from the parking piston (30).
26. Remove and discard the OD seal ring (31)
on the brake disc housing (34). Then remove
the Guiding belt (32).
27. If necessary, remove the pin (33) from the Fig.11 Schematic diagram for parking piston
brake disc housing (34). removing
Service Manual 3-69

Inspection
Detection procedure for the wearing of

brake disc assembly
Note: This detection should be performed
before the removing and disassembling of disc
brake assembly so that the wearing extent of
brake disc components can be determined.
1. Pull out the parking/emergency brake
control button. Pressure should be generated
in the parking brake cavity and the parking
brake springs (27, 28; Fig.1) should be
compressed.
2. Press down the service brake pedal or
turn the retarder selection mode switch (if
equipped) to the disc brake position, and
place the retarder control lever in the applied
position. Pressure should be generated in the
service brake piston cavity.
3. Carefully remove the plug (52) from the
4. Insert a depth micrometer into the plug hole
and measure distance from end of return pin
(45) to machined surface on the service brake
piston housing (48). This is dimension 'A'.
Record this dimension.
5. Record the dimension that is stamped on
the service brake piston housing (48). Subtract
the stamped dimension from dimension 'A'
( referring to Step 4). The difference is the
amount of brake wear. Refer to 'Wear limit of
disc brake' table for allowable wear limits.
Wear limits for new and worn brake disc
Thickness of friction plate:

New plate:....................5.080.13 mm
(0.2000.005 in)
Minimum allowable dimension of worn pla
te:.......................................4.57 mm (0.180 in)
Thickness of friction disc:
New disc:........................2.4130.064 mm
(0.0950.0025 in)
3-70 Service Manual

Minimum allowable dimension of worn disc:

.....................................2.29 mm (0.090
in)
Thickness of damper plate:
New plate:....................6.90.051 mm
(0.2700.020 in)
Compression state after use:..........5.84 mm
(0.230 in)
If the worn areas
If the worn areas
are distributed in
Wear limit of disc brake are concentrically
a non-concentric
distributed in the
Thickness (mm) form or near inner
Quantity relatively outer side
New Old side of seal ring,
of seal ring, then it
then it will be
Friction plate 13 66.04 59.41 will be allowed to
disallowed to be
Friction disc 12 28.96 27.48 be used further.
used further.
damper plate 2 13.8 11.68
Stack
Fig.12 Schematic diagram for the wearing
108.8 98.57 inspection of dynamic seal
thickness
Maximum
10.23
allowed limit
Disassembled parts
Refer to Fig.3 for the numbers in the brackets.
1. Use a proper solvent to clean all parts.
2. After cleaning, immediately dry all parts with
compressed air.
3. After cleaning and drying, coat all parts with
light oil to prevent corrosion.
4. The sealing face of dynamic seal
assemblies (3 and 11) metal rings must be
carefully inspected to determine if reuse is
possible. The sealing band, which is a highly
polished surface on the sealing face of each
metallic ring, must be within the outer half of
the total seal area, be concentric with the seal
face diameters, of uniform width and free from
wear marking. Refer to Fig.12.
Note: The metal sealing elements between
brake assemblies are not allowed to be
interchanged. Otherwise, poor assembling
will be caused in the seal housing (9) and
correct sealing contact between metals will be
Service Manual 3-71

influenced.
Note: When the metal ring which has already
conformed to inspection requirements is used
for assembling, a slight 'overlap' condition,
related to the original orientation of the seal
faces, could occur and cause initial light
leakage which will stop immediately when the
assembly starts.
5. Before installing the disc brake assembly,
clean all exterior surfaces to remove any
foreign material.
6. Inspect all splines for cracked or broken
teeth, excessive wear and pitted or scored
surfaces. Repair or replace as requirements.
7. Check for pitted, scored or worn mating
surfaces of housings.
8. Check all threaded holes and threaded
parts for dirt or damaged threads. Repair or
replace as requirement.
9. Check seal surfaces of service brake piston
(40) for pitting, scoring or wear. Repair or
replace as requriements.
10. Check springs (27, 28 , 43) for cracks or
other damage and for spring tension.
11. Check all friction plates (38) and friction
discs (39) contact surfaces for nicks, pits or
corrosion. Check teeth of friction plates and
friction discs for wear and damage.
12. Check finished surfaces of all other parts
for scored or worn surfaces. Repair or replace
if necessary.
Assembly
Refer to Fig.3 for the numbers in the brackets.
warning
damage, it must be ensured that the hoist
equipment is reliably connected and
has sufficient carrying capacity for safe
operation.
3-72 Service Manual

Note: All 'O'rings, seal rings and contacting

surfaces must be clean and lubricated at
assembling.
1. Use a lifting device to place the brake disc
housing (34) in a clean level place with the
side installed with the spring housing (22)
oriented upwards.
2. Install the removed pin (33) into the brake
disc housing (34).
3. Stretch new seal ring (31) slightly. Lubricate
seal groove in disc housing (34) and seal
ring (31) with 'Wynns S. T. P.' to aid seal ring
installation. Install seal ring (24). Fig.13 Schematic diagram for the installation
4. Lubricate guiding belt (32) with 'Wynns S. T. of driving disc
P' and install in disc housing (25) as shown in
Fig.13.
5. Install the pin (29) on the parking piston (30).
6. Use 'Wynns S. T. P.' special grease to
lubricate the new seal ring (25) and the groove
in the outer diameter of parking piston (30).
Then install the seal ring (25).
7. Use 'Wynns S. T. P.' special grease
to lubricate the guiding belt (26) and its
surrounding area, and then install it into the
parking piston (30) as shown in Fig.13.
8. Use 'Wvnns S. T. P.' to lubricate the seal
ring (31) and its surrounding area, and then
install the parking piston (30) into the brake
housing (34).
9. Place the spring housing (22) on the parking
piston (30) to align with the pin (29). Rotate
the spring housing (22) to align the pin (33) in
the brake disc housing (34) with the hole in it
so that it can be positioned. Then use six bolts
(20) to seat the parking piston (30) into the
brake disc housing (25). During the operation,
take care to avoid damage to the seal rings
(25, 31). Then remove the bolt (20) and spring
housing (22).
10. Install the springs (27, 28) in bores in
parking piston (30), as is shown in Fig.9.
Install new O-ring (24) in the groove of the
spring housing (22).
11. Use a lifting device to carefully place the
Service Manual 3-73

spring housing (22) over the springs (27,

28) in the brake disc housing (25). Then Position of O-ring
align the springs with the spring bores in the
spring housing and align the pins (29) with
dowel holes in the spring housing to facilitate
installation.
12. Install five socket head bolts (23) and
hardened washers (21) into the holes under
Fig.14 Schematic diagram for installation of
protruding ears on the spring housing (22).
O-ring
Alternately tighten the socket head bolts
(23) by one turn every time. Haul the spring
housing (22) to overcome the resilience of
springs (27, 28) and press down to the brake
disc housing (34). Then tighten the socket
head screws (23) to the torque of 260~280Nm
(190~210 lbfft) torque.
13. Install the bolts (20) and hardened
washers (21) in the remaining connecting
holes of spring housing (22) and brake disc
housing (34), and tighten the bolts to the
torque of 260~280Nm (190~210 lbfft).
14. Use a lifting device to turn over the brake
disc housing (34) and place it on a clean flat
surface with the side equiped with the spring
housing (22) oriented downwards, as is shown
in Fig.14. Install the removed pin (33) in the
brake disc housing (34).
15. Use a lifting device to install the driving
disc (36) with its large end oriented upwards
in the brake disc housing (34), and use the
50x100mm (2x4in) blocks to block it up. Refer
to Fig.13.
16. Align the teeth on the damper plate (37)
with the inner teeth of brake disc housing (34).
Ensure that the outer end face is oriented
downwards to the parking piston (30).
Note: Before the friction disc (38) is installed,
the friction plate should be coated with the
same type oil used in the system.
17. Align the inner teeth of friction plate (39)
with the spline groove on the driving disc (36)
and thread and mount it onto the driving disc.
18. Install the friction disc (38) onto the friction
plate (39). Alternately install both of them until
3-74 Service Manual

it is completed.
19. Install the other damper plate (37) onto
the last piece of friction plate (39). During
assembling, it should be noticed to orient the
cork side of the baffle upwards, and toward
the service brake piston (40).
20. Install three new 'O'rings(13) into the
counterbore in three holes in mounting face of
the brake disc housing(34).
21. Install the removed stud (53) in the service
brake piston housing (48).
22. Use a lifting device to place the service
brake piston housing (48) on a clean flat
surface with its inner face oriented upwards.
Install the return pin (45) and spring (43) into
the corresponding hole of service brake piston
housing (48).
23. Install the mounting plate (42) over the
return pins (45) and springs (43) and fix it with
the bolts (41). Slightly stretch a new D seal
ring (46) and install it along with the new D
seal ring (47) in the inner and outer grooves in
service brake piston housing (48) respectively.
Caution: Ensure that the D seal rings are
installed in position. Their twisting and
inclination will lead to oil leakage of the service
brake cavity.
24. Install the service brake piston (40) with
its flat surface oriented upwards in the service
brake piston housing (48). Ensured that three
13 mm holes in the service brake piston are
aligned with three M12 threaded holes in the
piston housing. During assembling, take care
to prevent the two D seal rings in the piston
housing assembly from being damaged.
Then, insert three M12 bolts with flat washers
through the service brake piston and screw
them in the piston housing. Alternately screw
the bolts by one turn every time to haul the
piston downwards in positon.
25. Use the spring compression tool which
is shown in Fig.4 and can be fabricated
according to Fig.20. As is shown in Fig.5,
screw the threaded end of T handle on the tool
Service Manual 3-75

into the threaded hole of a return pin (45).

26. Then, place the base of the tool on the
flat surface of service brake piston (40) and
press down the handle of tool to pull the return
pin (45) up far enough to insert the pin (44)
into the hole in the end of return pin (45),
as is shown in Fig.5. Release pressure on
tool handle, making sure pin (44) is inserted
far enough into return pin (45) to clear both
sides of return pin hole in service piston (31). Fig.15 Dynamic seal installation tool seal
Remove the spring compression tool. sleeve
27. Repeat Step 26 and install the pin (44) in
each return pin (45).
28. Remove three M12 bolts and flat washers.
29. Install the new O-ring (24) on the service
brake piston housing (48) as shown in Fig.15.
30. Use a lifting device to turn over the service
brake piston housing (48) with service brake
piston (40) downwards.
31. Install the bleeder screw (49) in the service
brake piston housing (48).
32. Replace the O-ring in the plug (51) with
new one. Then install them together in the
33. Using a proper lifting device to hang the
service brake piston housing (48) on the brake
disc housing (34), making sure the pin holes
in housing are aligned with pins (33) on disc
housing. Gradually lower piston housing onto
disc housing.
34. Install five socket head screws (23), with
hardened washers (21), in the holes under
protruding ears on service brake piston
housing (48). Tighten socket head screws (45)
alternately, one turn at a time, to draw piston
housing assembly down on disc housing (34).
Tighten socket head screws (23) to a torque of
260 - 280 Nm (190 - 210 lbfft).
35. Install the bolt (20) and hardened washer
(21) in the service brake piston housing(48).
Tighten the bolt (20) to a torque of 260-280
Nm.
Note: The disc brake assembly should be
turned over with care to prevent the driving
3-76 Service Manual

disc (36) from sliding out of the brake disc

housing (25).
36. Place the brake assembly in a vertical
position and keep the bleeder screw (49)
located at the 12 oclock position, referring to
Fig.2. Connect a portable hand pump to the
port C and inject clean brake hydraulic oil
into the port to pressurize service brake piston
cavity to 52 bars. While injecting oil to the port
C to pressurize, slightly open the bleeder
screw (49, Fig.2) to release the residual air
in the cavity until clean oil flows from bleeder
screw. Then close the bleeder screw and
pressurize the piston cavity to 52 bars. Repeat
applying and releasing pressure for 10 times.
After the piston seal ring is set in position,
shut down the hand oil pump and maintain
the 52 bar pressure. After it is maintained
for 15 minutes, if the pressure drop in the
service brake piston cavity does not exceed
3.5 bars, this service brake piston assembly is
acceptable.
37. Disconnect the pump hose from the port
C, and connect it to the port D ( Fig.2) to
set the parking piston seal ring in position and
carry out pressure test. Start to pressurize
the parking brake piston cavity, and open
the bleeder screw (49, Fig.2) slightly until all
residual air in the cavity is released and clean
oil flows out, then close the bleeder screw
and pressurize to 83 bars. Repeat applying
and releasing pressure for 10 times. After
the parking piston seal ring is set in position,
shut down the hand oil pump and maintain
the 83 bar pressure in the piston cavity. If
the pressure drop in the parking brake piston
cavity does not exceed 7 bars after the
pressure is maintained for 15 minutes, this
parking brake piston assembly is acceptable.
Installation
brackets.
Service Manual 3-77

warning
1. Install new O-ring (5) in the counterbore

on the mounting surface of the service brake
piston housing (48).
2. Remove one bolt (20) and hardened washer
(21) from the spring housing (22) and service
brake piston seat ring (48) respectively. In
addition, the two bolts removed should be
located as close to 12 o'clock as possible.
Then install a lifting eyes in each bolt hole.
3. Connect a lifting device to the lifting eyes
on the disc brake assembly. Then lift the brake
assembly on the spindle.
Caution: When installing the right brake
assembly, its INLET port is located on the
top. When installing the left brake assembly,
its INLET port is located at the bottom.
Align and install the studs (57) on the brake
assembly with the holes in the spindle flange.
During installation, it should be ensured that
the O ring (5) is maintained in the counterbore
on the piston housing assembly.
4. Install the locknuts (58) on the studs (57)
and tighten to a torque of 1166 -1193 Nm.
Note: Prior to installing the dynamic seal
assembly (12), clean O ring and metal ring in
the trichloroethane liquid.
Note: The seal installation tool (refer to the
special tools) consists of seal sleeve, seal
driver and a spring.
5. Insert the seal sleeve tool shown in Fig.15,
into the spring housing until it is in as far as it
can go.
6. Insert seal installation kit spring on one
metal seal ring of dynamic seal assembly (12).
The spring prevents the metal ring from riding
3-78 Service Manual

up the ramp of the groove hence leading to

easier installation.
7. Install one half of dynamic seal assembly
with O-ring and spring fitted into the spring
housing (22) through the bore of the seal
sleeve. It should be ensured that a clearance
from the rope connected to the spring is
present so that the spring can be easily pulled
out after the installation of dynamic seal
assembly.
8. Use the seal driver as shown in Fig.16
to press the dynamic seal assembly (12) in
position until the inside face of seal driver Fig.16 Dynamic seal installation tool- seal
is flush with the outside face of seal sleeve. driver
Refer to Fig.17.
9. Remove the seal driver, and slowly remove
the seal sleeve out of the spring housing (22).
Subsequently, pull out the spring from the
dynamic seal assembly (12). Then apply a thin
film of lubricating oil to the metal contacting
surface of dynamic seal assembly.
Driving
10. Install the O ring on the other half dynamic disc
seal assembly (12) and install in the seal Seal
Seal driver ring
housing (9) with the O ring side oriented Dynamic seal
downwards. Press the seal assembly into the Seal sleeve O-ring
housing.
Spring
11. Coat the O-ring (35) with grease and Spring housing
install it in the driving disc (36). In addition,
apply a thin film of lubricating oil on the metal
contacting face of dynamic seal assembly Fig.17 Schematic diagram for installation of
(12). Install the seal housing (9) with half seal dynamic seal assembly
assembly on the driving disc (36) and use the
bolt (7) and washer (8) for fixing. Then use the
lockwire (6) to lock the bolt (7).
Note: Ensured that the lockwire (6) will not
interfere with the O ring (8) on the driving
wheel when driving wheel is installed on the
disc brake assembly.
Note: Prior to installing the dynamic seal
assembly (3), clean the dynamic seal
assembly (3) in trichlorethane liquid. Apply a
thin film of oil to the metal contacting surfaces
of the dynamic seal assembly.
12. Use the installation tool to install half of the
Service Manual 3-79

new dynamic seal assembly (19) with the O

ring side oriented inwards over spindle. Using
seal installation tool, press dynamic seal
assembly into disc driver (27) by tapping the
tool with a soft hammer. Then remove the tool.
13. Use the tool to press and install the other
half of new dynamic seal assembly (19) with
its O ring side oriented inwards into the inner
seal seat ring (15). Then remove the tool.
14. Coat the O ring (16) with grease and install
it in the seal groove. Install the other half
dynamic seal assembly (19) in the inner seal
housing (15). Then install the inner housing
(15) in the brake assembly.
15. Install new O ring (1) in groove on the
groove.
16. Install the driving wheel (2) on the wheel
and use the bolt (4) and hardened washer (3)
for fixing. During installation, ensured that the
O ring stays in the groove on the wheel. Then
tighten the bolt (4) to a torque of 1166 -1193
Nm.
17. Install new O ring (5) on the driving wheel
(2).
18. Refer to the requirements described in
Chapter 1 'Tyre and Rim Assembly' and install
the wheel on the spindle. When the driving
wheel (2) is inserted into the driving disc (36),
the splines on the driving wheel (2) and driving
disc (36) should be aligned carefully, and it
should be noticed not to damage the O-ring (5).
19. Add 11 litres (3 US gallons) clean hydraulic
oil of the same type used in the brake cooling
circuit into the service brake pack. Block the
port A (outlet) on the brake assembly on the
opposite and pressurize the brake assembly
with 2 bar air pressure through the port B
(inlet). Refer to Fig.2.
Note: Refer to Fig.18. For brake pressure
testing, the flange plates for port A and B
can be fabricated according to Fig.20 and
Fig.21.
While rotating the wheel, observe for air
pressure loss on the air supply hose gauge.
3-80 Service Manual

Less than 0.14 bar (2 lbf/in2) air pressure loss

in 15 minutes is satisfactory. If the air pressure
loss is greater than 0.14 bar (2 lbf/in2) in 15
minutes, rotate the wheel additionally to reseat
all seals and pressurise the brake assembly
to 2 bar (30 lbf/in2). If the brake assembly
again leaks more than 0.14 bar (2 lbf/in2)
air pressure in 15 minutes, loosen the wheel
retainer bolts, rotate the wheel to reseat the
seals, and tighten the bolts. Repeat the air
pressure test to be sure the seals are properly
seated, to prevent oil leaks.
Fig.18 Schematic diagram for pressure test of brake
1. Adaptor 5. Pressure gauge

2. Pressure regulator 6. Hose assembly
3. Tee piece 7. Flange plate (For B)
4. Switch valve 8. Flange plate (For A)
Note: Be sure to open and install only one

hydraulic line at a time to prevent loss of oil
from brake hydraulic oil tank. The vacuum
pump, installed during removal, cannot retain
oil in tank if more than one line is uncapped at
a time.
20. Remove the plugs and connect the
hydraulic pipe of service brake to the port C
according to the mark made during removing.
Refer to Fig.2.
21. Similarly, connect the pipeline of parking
Service Manual 3-81

brake to the port D. See Fig.2.

22. Similarly, connect cooling pipe to the ports
A and B. Refer to Fig.2.
23. Remove the vacuum pump required to be
installed on the hydraulic oil tank for removing
the pipes. Then reinstall the ari breather into
the breathing port of oil tank.
24. Refer to the requirements in the section of
LUBRICATION AND MAINTENANCE , and fill
the steering and brake control oil tank.
Note: If brake discs, service and/or parking
pistons, piston housing, or the complete
brake assembly have been replaced, a new
brake disc stack height measurement should
be taken as described under 'Disc Assembly
We a r M e a s u r e m e n t P r o c e d u r e ' , u n d e r
'Inspection' in this section. This dimension H'
should be measured for future reference.
Bleeding
Refer to Fig.1 for numbers in brackets.
To achieve satisfactory braking, the service
brake and parking brake hydraulic system
must be bled to elimite any air in hydraulic
pipes and system.
1. Ensure that the steering and brake control
tank is filled with oil specified in the section of
lubrication and maintenance.
2. Start engine, build up oil pressure in
accumulators until accumulator pressure
warning lights are extinguished, then shut
down engine.
3. Chock all road wheels. Pull out parking/
emergency brake control to release the
brakes.
4. Securely connect a clean bleeder hose to
upper bleeder screw (49) and place loose end
of hose in a clean container.
5. Press down the service brake pedal and
gradually open bleeder screw (49). Bleeder
screw should remain open until oil that flows
out is free of air bubbles. Close bleeder screw
and release brake pedal.
Note: Pressurize the system again when
3-82 Service Manual

necessary by repeating Step 2.

6. Repeat the above full process on the brake
assembly in the opposite side.
Note: A correct oil level in the steering
and brake control oil tank must be always
maintained and the selected oil should
conform to the specifications recommended
in the section of lubrication and maintenance.
For the correct oil level, refer to the section of
hydraulic oil tank assembly.
Note: The full bleeding procedure should be
repeated on the brake assembly after repair
and maintenance to ensure that all air in the
brake assembly is completely eliminated.
Special tools
The hoist tool for parking piston can be
manufactured according to the structure and
dimensions shown in Fig.22.

Torque
No. Description
lbfft
4 Bolt 1166~1193 860~880
20 Bolt 260~280 260~280
23 Screw 260~280 260~280
53 Nut 1166~1193 860~880
Service Manual 3-83

9 5
2
7
6
3
4
Fig.19 -1 Fabrication of spring compression tool
1. Welding base 6. Bolt

2. T handle 7. Rotating shaft
3. Washer 8. Damper
4. Nut 9. Shaft
5. Handle
3-84 Service Manual

25.5
C1.5
3.2
6
3.2
25
13
3.2
50
101
+0.05
6 +0.02
6.3
12.5
25
10 50
Detail drawing of Item 1
Service Manual 3-85

51
133
76
M50.5
3-86 Service Manual

508
3.2
3.2
43 65
4M49.5 152
R13
19
140 knurling
3
25
3.2
6
25
19
4.5
12
3.2 R1 C1.5
13
16
25 20.5
79
12.5
R3
9.5
3.2
6
3.2 +0.05
6 +0.02
6
25
13
6.5 12
6.5
25.5
3.2
6.5
13
5.5 Through hole
3.2
Service Manual 3-87

4.5 3 3
24.5
25
16
6.3
3-88 Service Manual

117
77.8
414
12.5
57
A A
42.9
R15
R51.6
1/2NPT
6.3
16
3.2
3.2
R 0.6
6.3
4.450.13
7.10.13 R 0.2
66.70.25
A-A
3.2
Fig.20 Fabrication for flange plate of port A
Service Manual 3-89

R51.6
414
R15
12.5
28.4
A A
42.9
42.9
77.8
108
6.3 1/2NPT
16
3.2
3.2
7.10.13 6.3 R 0.6

4.450.13
66.70.25 R 0.2
3.2
A-A
Fig.21 Fabrication for flange plate of port B
3-90 Service Manual

(73.53)
314
84
R16
50
R63.5
50
R238
30 30
667
70
R403
50
25
50
12
Fig.22 Fabrication for parking brake piston lifting tool
Service Manual 3-91

3.2 Rear Axle Mounting Part
Fig.1 Rear axle mounting part
1. Steel wire 7. Spacer

2. Bolt 8. Shaft
3. Plate 9. Washer
4. Bush 10. Washer
5. Spacer 11. Bolt
6. Tapered pin

The rear axle mounting part consists of the
tapered pin (6), Spacer (5), bush (4), plate
(3), bolt (2), steel wire (1), spacer (7), shaft
(8), washers (9) and bolt (11). The rear axle
mounting parts are the assembly to connect
3-92 Service Manual

rear axle assembly to frame via A-frame and

link.
Remove and disassembly

warning
do the job safely.
1. Use the hoist equipment to lift up the rear

axle assembly. Remove the bolt (11) and
washers (10) and (9). Then take down the
shaft (8) and spacer (7) in turn.
2. Remove the steel wire (1) and bolt (2). Then
take down the pressure plate (3), bush (4),
Spacer (5) and tapered pin (6) from the hole of
A-frame in turn.
Inspection
parts.
4. Check the bush and spacer ring for wearing
or deformation. Replace the defective parts
and components.
5. Replace the old washers with new ones.

Service Manual 3-93

warning
do the job safely.

torques specified to standard torques listed in
Section38.2
Standard bolt and nut torque specifications.
1. Use the hoist equipment to lift up the rear
axle assembly. Place this assembly under
the truck and align it with the frame. Use a
hydraulic jack with proper carrying capacity
to slowly lift up the axle body assembly to the
installation position on the truck.
2. Install the tapered pin (6), Spacer (5), bush
(4) and plate (3) in turn. Then tighten the bolt
(2) at the specified moment and use the steel
wire (1) to lock it.
3. Install the shaft (8) and spacer (7) in turn
onto the link; apply the mucilage onto the bolt
(11). Then install the washers (9) and (10) and
bolt (11) in turn. Finally, tighten the bolt (11) at
the specified moment.
3-94 Service Manual

SRT95C Off-Highway Truck Rear Wheel Assembly
4 REAR WHEEL ASSEMBLY

4.1 Rear Wheel Assembly
6
3 4 5 7 10 11 2
39
2 5 8
6
1 1
1
1
Fig.1 Sectional View of Dual Wheel Rim Assembly
1. Flange 7. Spacer sand

2. Rim 8. Wedge band
3. Bead seat band 9. Stud
4. Wheel 10. Clamp
5. O Ring 11. Nut
6. Lock Ring
Overview
The rear wheel assembly consists of two tyre
and rim assemblies, spacer band, wedge
band, rim clamp and nut.
The tyre and rim assembly is designed to be
replaced with a pre-assembled tyre and rim.
Preparation for Servicing
warning
Before loosening rim clamps or performing
any service on the tyre or rim components,
to prevent personal injury and property
Service Manual 4-1

Rear Wheel Assembly SRT95C Off-Highway Truck

warning
Gases that build up inside an air inflated
tyre mounted on a rim during welding or
heating of rim components can ignite,
causing an explosion of the tyre and rim
components. This warning also applies
to Nitrogen gas inflated tyres. Ignition will
not occur in a Nitrogen gas atmosphere;
but the pressure build up from the applied
heat may be sufficient to cause a blowout
severe enough to injure or kill. Never
weld or otherwise apply heat on rim
components with the tyre mounted on the
rim, whether the tyre is inflated or deflated,
to prevent injury or property damage
from the potential tyre explosion! Do not
attempt to repair rims or rim components
by welding or heating, even if the tyre is
not mounted on the rim. It is recommended
to scrap questionable rim parts unless
specific permission and repair procedures
are obtained in writing either from the
company or the rim manufacturer.
Removing Tyre and Rim Assembly

If the tyre and rim assembly is to be replaced
with a pre-assembled tyre and rim assembly,
it is not necessary to remove the tyre from
the rim on the truck. The tyre and rim may be
removed from the truck as an assembly, and
transported to a more desirable location for
removing the tyre from the rim.
4-2 Service Manual

warning
properly secured and of sufficient capacity

one to be raised. Use wooden blocks 100 mm
x 100 mm (4 in x 4 in) or larger.
3. Support the truck with jack for removal of
tyre, but do not jack up the truck.
4. Completely deflate tyre by removing valve
cap and core. Check valve stem by running a
piece of wire through the stem to make sure it is
not plugged. See warning under 'Preparation
for servicing' .
5. Loosen the nut (11) on the wheel hub. But 4
B
do not remove from the stud (9). 2 3 C
6. Jack the truck up only as high as necessary
1
to remove wheel from truck, and place safety 5
blocks under the frame.
7. Support the tyre with a chain or rope of A
sufficient strength attached to a suitable lifting
device. Remove the nut(11) and clamp(10)
from the wheel stud (9). Remove wedge band
(8) and lift tyre and rim assembly clear.
8. If inner tyre and rim assembly is being
removed, remove spacer band (7), attach a
lifting device to tyre and rim assembly, and
remove from truck.
Dismounting tyre from rim Fig.2 Rim assembly

1. Outer flange 4. Rim
Note: The following instructions are applicable 2. Bead Seat Band 5. Inner flange
to use of hand tools. For procedures and 3. Lock ring
tooling required to dismount the tyre from the
Service Manual 4-3

rim, using hydraulic tools, contact the tyre

manufacturer.
warning Fig.3 Pry Bar
When lifting tyre from rim, be sure the


servicing' . Tape valve threads to protect from
damage, leaving valve end open to avoid any
2. As shown in Fig.3, break outer tyre bead
loose by placing the flat hooked end of a pry
bar, into one of the breaking slots (C) between
the bead seat band (2) and outer flange (1). A
length of pipe slipped over straight end of bar
will increase leverage. Twist straight end of
bar around toward tyre to break this portion of
bead. Another person may now insert another
pry bar of the same type into the slot between
the bead seat band (2) and outer flange (1),
and with the same twisting action, hold the
space gained with the first pry bar. Move first
pry bar all the way around the wheel, twisting
and following up with second pry bar, until
inner tyre bead is loose.
3. Start bead seat band (2) in away from lock
ring (3) by placing hooked end of pry bar in
groove of rim (4), between ends of lock ring,
and prying up with bar. Using two tools, as in
Step 2, work completely around wheel.
4. Pry lock ring (3) out in same manner by
starting at prying notch (B) in wheel, and work
all the way around wheel with the two pry
bars.
5. Remove and discard the O-ring (5, see
Fig.1).
6. After removing lock ring (3), pry out and
remove bead seat band (2). Outer flange (1)
can be removed now.
4-4 Service Manual

7. Similar breaking slots are provided on the

inside of rims. The inner bead on the back
side of the tyre may be broken by using the
same method as in Step 2, for the outer bead.
If the wheel assembly is still on the truck,
another method which can be used is to place
a small jack between the inner flange and
some solid part of the frame. By extending the
jack, pressure is exerted, which forces the tyre
bead off the rim seat. Work around the wheel
until the bead is broken at all points.
8. Use a proper lifting device to lift tyre away
from rim. The dismantling of tyre is completed
in such a way. Fig.4 Breaking Typical Tyre Bead Loose
Note: If tyre and rim is on truck, and no lifting
device is available, the tyre can be separated
off the rim as follows: force bottom of tyre
outward as far as possible; lower jack enough
to allow weight of tyre to rest on ground; force
top of tyre out as far as possible; raise jack to
original height and repeat the above until tyre
is off rim.
Inspection
Tyre
Check interior surface of the tyre to determine
its condition. Inspect for cuts or fabric breaks
that have penetrated the tyre body. Inspect
closely for any sharp, pointed objects that may
have penetrated the tyre body but is invisible
from the outside. All dust, dirt, water or other
foreign matter should be cleaned from the
inside of the tyre.
Replace valve core assembly if condition is
questionable.
Rim assembly
Overload, improper tyre inflation, rough terrain,
high speed, accidents, dirt accumulation and
corrosion will reduce service life of rims and
rim components. It is recommended that
rims be inspected, as below, not less than at
every tyre change and, as the warranty limit
approaches, consideration be given to rim
Service Manual 4-5

replacement.
warning
Never mix components of one
manufacturer's rims with those of another.
Using the rim base of one manufacturer
with the lock ring of another or vice
versa is dangerous. The lock ring of one
may not fully engage with the lock ring
groove of the other. Always consult the
rim manufacturer for proper matching and
assembly instructions.
Also, use of damaged, worn out, or
improperly rim assemblies is a very
dangerous practice. Failure to comply
with the above warnings could result in
explosions from tyre pressure causing
serious personal injury and property
damage.
1. Clean all rust and dirt from rim parts.

2. Coat parts with primer paint, allow thorough
drying before assembling.
3. Inspect rim assemblies (Fig.2) for bent,
cracked, distorted, battered, and rusted
parts which may have resulted from abusive
practices outlined above. Replace any
damaged parts with new parts.
4. Discard 'O' ring and replace with a new one.
Note: Handle 'O' rings carefully, as damage
will prevent an airtight seal for tyre inflation.
Mounting tyre on rim

warning
When lifting tyre onto rim, be sure the
4-6 Service Manual

1. If tubeless tyre valve assembly was

1 2 A
removed from rim, install this assembly in the
rim valve hole and tighten securely.
2. Whether the rim (4) is on or off the truck,
tyre installations are performed in basically the
same manner. For off-truck installations, lay
the rim on blocks with 'O' ring groove up. The
rim should be just off the floor enough so the
tyre rests on the rim and does not touch the
floor. The blocks should not extend more than
13 mm (0.5 in) beyond the rim base, so they
wont interfere with inner flange (5).
Fig.5 Installation of Lock Ring
3. Install the inner flange (5) onto the rim (4).
4. Before assembly of tyre to rim, lubricate
both tyre beads and new 'O' ring (5, Fig.1)
with a thin solution of vegetable base soap
and water. Make sure tyre valve assembly is
securely in place. Lower the tyre onto the rim,
seating tyre firmly against inner flange (5).
5. Install outer flange (1) on rim (4).
6. Install bead seat band (2) on rim (4).
7. Install lock ring (3) in groove of rim (4).
Use pry bar for this operation, as illustrated in
Fig.5.
8. Force bead seat band (2) past 'O' ring
groove in rim (4) by prying, or with lift truck
forks. Use blocking between the forks and tyre
to prevent tyre damage. Lubricate area of rim
adjacent to 'O' ring groove with a thin solution
of soap and water or another approved
lubricant which is not harmful to rubber. Avoid
using an excessive amount of lubricant. Insert
a new 'O' ring (5, Fig.1) in the groove of the
rim behind the lock ring.
9. Lift tyre upwards to effect a seal between
bead seat band (2) and 'O' ring (5, Fig.1). In
some cases the tyre will automatically spring
out, if this step is neglected,
Mounting tyre and rim assembly on wheel

Service Manual 4-7

warning
Be sure lifting equipment is of sufficient
capacity and properly secured to do the
job safely.
1. Support inner tyre and rim assembly with a

chain or rope sling attached to an overhead
lifting device and slide onto wheel (4) of the
truck. Side with lock ring (6) and bead seat
band (3) should be facing outward.
2. Install outer tyre and rim assembly in the
same manner, except with bead seat band (3)
and lock ring (6) facing inward, toward spacer
band (7). Install wedge band (8).
3. Install clamps (10) and nuts (11) on studs (9).
Gradually tighten wheel nuts opposite each
other, until all nuts are snug, torque tighten
wheel nuts (11) to 1000 N. M-1300 N. M.
Re-tighten nuts after a few hours operation.
Note: The fastener torque should be checked
regularly, particularly on new truck or newly-
installed wheels, to maintain the required
wheel rim-clamp load. A newly installed wheel
or a new truck should be checked at 30 day
intervals until rim fasteners show no significant
torque loss from the previous check. After
that, a 90 day torque check interval should be
adequate.
Tyre inflation
warning
damage, the tyre and rim assembly should
be placed in a safety cage before inflating.
If no safety cage is available or tyre is on
the truck, the tyre and rim assembly should
be wrapped with safety chains or with
cables before inflating.
Even with these precautions remember
that air-blast is a potential hazard. Tyre
4-8 Service Manual

inflation should be carried out away from

busy working areas.
damage, never stand or sit in front of a
mounted tyre during tyre inflation. Use
a clip-on air chuck with a long hose and
stand to one side while the tyre is being
inflated.
damage, always prevent flammable vapours
that could produce tyre explosions, from
being pumped into tyres during inflation,
by observing the following precautions:
1. Use an air compressor and reservoir
located inside a heated building, when
available, so that alcohol, methanol, or
other flammable antifreeze liquids are not
needed in the air tanks to prevent moisture
freezing in the tank and lines in subfreezing
temperatures.
2. Make sure that paints, lacquers, paint
thinners, or similar materials that produce
volatile, flammable vapours are not used or
stored near the air intake of the compressor
that supplies the air for inflating tyres. The
compressor should be isolated from all
such sources of flammable vapours.
3. Be sure to thoroughly flush and blow off
all flammable solvents used for cleaning
the air compressor inlet screen before
using the compressor for tyre inflation, or
any other purpose.
4. Do not charge batteries, near the air
inlet of a compressor used for inflating
tyres. Charging batteries produces highly
explosive hydrogen gas which can be
readily drawn into a nearby compressor
inlet and pumped into the tyre.
5. Never exceed the specified concentration
of alcohol when adjusting the alcohol
vaporiser, or adding alcohol to the auxiliary
air tank, used on machine air systems to
prevent freezing or moisture condensate
in below-freezing temperatures. Excessive
Service Manual 4-9

alcohol, added to the air tanks can produce

flammable vapours that will be pumped
into a tyre when this air supply is used for
tyre inflation if the tyre inflation kit is not
equipped with a moisture filter.
6. Another source of hazardous flammable
vapours in tyres is the tyre bead lubricant.
Always use bead lubricants that do not
introduce flammable vapours into the tyre.
Inflation
Note: To prevent moisture corrosion of internal
rim parts, use tyre inflation equipment with an
air filter that removes moisture from the air
supply, when available, Fig.6 Tyre Inflation Safety Cage
1. If the tyre is off the truck, it should be placed
in a safety cage before inflating. See Fig.6.
2. Inflate all tyres with ratings of 16-ply and
above to 0.52 Mpa to seat beads and seal
'O' ring, then adjust to the recommended
pressure.
3. For recommended operating air pressure,
refer to the chart 'Tyre Inflation Pressures'.
Nitrogen tyre inflation

Note: All Warnings and procedures under
'Tyre Inflation' will apply, except for differences
covered by this passage.
In certain environments it is recommended
that tyres be inflated with dry nitrogen gas,
and that the resulting oxygen content of the
inflation does not exceed 5%. All machines
whose tyres are factory inflated with dry
nitrogen gas will be identified by a decal on
the body or frame.
Nitrogen gas improves tyre pressure retention,
increases tyre life by reducing carcass
oxidation from within, minimizes rim rust
Fig.7 Nitrogen Tyre Inflation Kit
and has no detrimental effects on the tyre. It
also reduces the potential of a tyre explosion
because it is an inert gas and will not support
combustion inside the tyre.
The same tyre inflation pressure used for air
4-10 Service Manual

inflation should be used for nitrogen inflation.

Tyre valves formerly used with air inflation are
entirely satisfactory for use with nitrogen gas.
Nitrogen tyre inflation kit
warning
DO not use charging assembly for tyre
inflation because this assembly does not
include a pressure regulator, safety relief
valve, and adequate pressure gauging
which is mandatory for tyre inflation. Tyre
volume is as much as 90 times greater than
the average accumulator volume and it
takes very much longer to inflate a tyre - up
to 40 minutes or more for very large tyres.
Nitrogen gas cylinders used to inflate tyres
are generally charged to approximately
15.2Mpa. A tyre blowout or rim failure could
occur if inflation equipment is not properly
used. Proper nitrogen charging equipment
and personnel training can avoid over
inflation.
1. A nitrogen tyre inflation kit is available from

your dealer and consists of the following.
Refer to Fig.7.
a. Pressure regulator, 0 1.3 Mpa, with two
dual pressure gauges.
b. Safety relief valve, 0.86 Mpa, that will
assure an upper limit to the pressure available
for tyre inflation.
c. A 15 length of flexible hose with
interconnecting fittings. On the tyre end of the
hose is a large bore quick connect.
2. The pressure regulator is connected to a
nitrogen compressed gas cylinder available
from local suppliers.
3. The usual procedure for using this type of
equipment is as follows:
a. Connect nitrogen tyre inflation kit to nitrogen
compressed gas supply. DO not connect quick
Service Manual 4-11

connect to the tyre valve at this time.

b. Open valve on nitrogen supply.
c. With flexible hose and quick connect
connected to nitrogen tyre inflation kit
assembly but not connected to the tyre, adjust
pressure regulator so that its output pressure
is not more than 0.14Mpa higher than the
desired tyre inflation pressure.
d. Connect quick connect to the tyre valve.
The tyre will now inflate. Tyre pressure can
be monitored by observing the gauge at the
pressure regulator.
e. When desired inflation pressure has been
achieved, back off the regulator or close the
valve on the compressed gas cylinder.
f. Remove the quick connect and adjust the
tyre pressure with the tyre gauge in the usual
manner.
Re-inflation of a mounted tyre

To re-inflate a tyre with dry nitrogen gas which
is now inflated with air, proceed as follows:
1. Deflate the tyre until the air in tyre reaches
the atmospheric pressure.
2. Re-inflate the tyre using only dry nitrogen
gas to 0.41Mpa gauge as a minimum, or to
bead-seating pressure as a maximum.
3. Adjust to the service inflation pressure
required:
a. If the required service inflation pressure is
less than 0.41Mpa remove the quick connect
and adjust the pressure with the tyre gauge in
the usual manner.
b. If the required service inflation pressure is
greater than 0.41Mpa, continue inflating with
dry nitrogen gas only, to the pressure level
required. Then remove the quick connect and
adjust the pressure with the tyre gauge in the
usual manner.
New tyre mounts and remounts

To newly mount or remount a tyre to rim,
use only dry nitrogen gas; this includes the
pressure required to seat the beads. After
4-12 Service Manual

seating the tyre beads, remove the quick

connect and adjust the pressure with the tyre
gauge in the usual manner.
Note: Although a little more nitrogen gas
is used to seat beads than that used for
reinflation of a mounted tyre, its cost is
generally negligible in comparison to the
time and labour saving and, longer tyre life
achievable with the reduced oxygen content
which results.
Hydraulic bead breaking tool

The hydraulic bead breaking tool illustrated
in Fig.8 is specifically designed to break tyre Fig.8 Typical Hydraulic Bead Breaking Tool
beads on rusted rims, and is available from
your dealer. Refer to Special Tools. It can
be used on rims having pry bar slots. The
recommended procedure for using this tool is
described below.
1. Prepare for dismantling tyres according to
the necessary steps in the Preparation for
servicing and Dismantling tyre from Rim.
servicing'. Tape valve threads to protect from
damage, leaving valve end open to avoid the
3. Place the lip of the hydraulic tool in one of
four breaking slots between the flange and the
bead seat band.
4. Adjust locking screw to a position which will
hold the tool in a line perpendicular to the face
of the rim.
5. Close valve on the hydraulic pump and
apply pressure to take up the slack in the
tool and rim parts. This will cause the tool to
tilt slightly downward. Release pressure and
adjust the screw again so that the tool will be
perpendicular to the rim when under pressure.
6. Apply enough pressure to move the flange
back approximately 13 mm (0.5 in) and hold
this distance by dropping a nut, or similar
object, in the space between the flange and
the bead seat band.
Service Manual 4-13

7. Release pressure and move the tool around

the rim in either direction. Insert lip of tool At least 15m At least 360m
between bead seat band and flange. Repeat
cycle until 3/4 of the rim circumference has
been covered. Apply pressure at this point
until bead breaks loose.
8. Remove lock ring, bead seat band and
flange as described under 'Dismounting tyre
from rim'.
9. After lock ring, bead seat band and rim
flange have been removed, inner bead must
be broken loose according to Steps 3-7 for Fig.9 Do Not Approach Tyre in Shaded Area
breaking outer bead.
warning
Whenever a tyre is exposed to excessive
heat such as a truck fire or overheated
brakes the hazard of a subsequent violent
tyre explosion must be recognized. All
persons must avoid approaching the truck
so as not to be physically endangered in
the event of an explosion of the tyre and
rim parts. The truck should be moved to
a remote area, but only when this can be
done with complete safety to the operator
operating or towing the truck. All other
persons should stay clear of the truck.
The fire or overheated brakes, wheel, etc.
should be extinguished or cooled from a
safe distance. Do not attempt to extinguish
the fire or cool the machine by use of hand-
held fire extinguishers.
If it is absolutely necessary to approach a
truck with a suspect tyre, approach only
from the front or the back. Stay at least
15 m (50 ft) from the tread area. Keep
observers out of the area and at least 460
m (1 500 ft) from the tyre sidewall. Refer to
Fig.9. The tyre should be allowed at least
8 hours cooling time after the machine is
shut down or the fire extinguished before
approaching closer.
There is always a possibility of a tyre
4-14 Service Manual

explosion whenever the smell of burning

rubber or excessively hot brakes is
detected. The danger is also present when
a fire on the truck reaches the tyre and
wheel area. Under such conditions, all
personnel must avoid approaching the
truck in a manner that could result in injury
should an explosion actually occur. Move
the truck to a remote area only if it can be
done without endangering the operator or
other personnel in the area.
DO not weld on or heat rim components.
For several years the company and tyre
and rim manufacturers have warned
users never to weld rim components with
the tyre mounted on the rim. The gases
that build up inside the tyre during arc
welding or heating on rim components can
ignite, resulting in one of these explosive-
like failures of the tyre and rim. It is
recommended to scrap the part if heat is
necessary to repair any rim component.
Tyre maintenance
Tyre repairs
Prompt repair of tyre injuries will prevent small
injuries from enlarging and causing tyre failure.
Use the best tyre repair facilities available.
If good repair facilities are not available,
have the nearest dealer make the necessary
repairs.
Minor cuts, snags, or punctures should be
repaired upon discovery. Skive with a sharp
pointed knife around any cut in the tyre tread
area that is of sufficient depth or shape to
hold pebbles or dirt. The angle of the skive
should be no more than sufficient to expel all
foreign material and should extend no deeper
than the breaker. The skive should go to the
bottom of the hole. Tyres with shallow cuts, if
treated promptly, may be allowed to continue
in service. If the cut extends deeper into the
tyre carcass, the tyre should be removed for
Service Manual 4-15

repair. Ordinary tubeless tyre punctures can

be repaired without removing the tyre from
the rim. Use tyre repair plugs and follow the
directions given by the manufacturer.
The tyre must be removed from the rim to
repair larger punctures or cuts. Irregular
shaped punctures or cuts less than 13 mm in
size can be repaired with a plug and hot patch.
Insert a repair plug into the hole to keep out
moisture and to back up the hot patch. Trim
the plug off flush with the inside of the casing,
buff, and apply the hot patch according to
the instructions supplied with the hot-patch
equipment.
Punctures 13 mm or larger, large cuts, or
bruise breaks require sectional or reinforced
vulcanized repair. Cover the repair patch with
a layer of cushion gum after application to the
tubeless tyre to ensure an airtight repair. Any
cords of the inside ply that are exposed in
bugging and are not covered with repair patch
must be coated with cushion gum to prevent
air leakage into the carcass plies on tubeless
tyres.
Recapping and retreading

There are two general methods employed in
restoring the tread surface of off-the-highway
tyres: recapping and retreading.
A recapped tyre has a new tread cured right
over the old tread surface.
A retreaded tyre has the old tread removed
entirely and a new tread cured directly onto
the body of the tyre. A tyre can be recapped
or retreaded if the cord body is free of cuts,
bruises and separation, and is thoroughly
sound, including previous repairs.
Tyre Care
To obtain maximum service from off-the-
highway tyres, a few common-sense
precautions should be followed.
4-16 Service Manual

Maintain correct inflation

Most tyre damage are caused by improper
inflation. Both over-inflation and under-inflation
are detrimental to tyre life. Tyre pressure
should be checked daily, preferably before
the truck is placed in operation, see the
instructions in 'Tyre Inflation Pressures'.
The valve cores should be checked for leaks.
Keep in mind that valve cores are delicate
mechanisms that wear out in service; therefore,
they should be replaced when they become
worn. Each tyre should be equipped with a
valve cap to prevent dirt from damaging the
valve core and causing air leakage.
Maintain good haul roads

Because haul roads are considered temporary
roads, they are frequently neglected. The
better the haul road, the longer the tyre and
machine life of off-the-highway equipment.
Note: Although it takes time and effort to
maintain good haul roads, delay and cost of
tyre and machine breakdowns caused by poor
haul roads is many times greater.
Inspect tyres regularly

A systematic plan for tyre inspection will
more than pay for itself in lowered tyre costs
per hour of operation. All tyres should be
checked regularly for cuts, bruises, fabric
breaks, excessive or uneven wear, embedded
foreign matter, and any other damage which
can be repaired. A considerable increase in
tyre service can be realized if tyre injuries
are repaired before they have progressed to
the irreparable stage. The rim mounting nuts
should be checked periodically and tightened
to the recommended torque.
Prevent overloading
Mining dump trucks are designed to carry a
maximum allowable payload.
Note: Excessive loading will overstress both
the machine and tyres and shorten the life of
Service Manual 4-17

both.
Prevent tyre contact with oil

Prevent tyre contact with petroleum products.
Rubber that is exposed to oil, petrol, or grease
becomes soft and spongy and deteriorates
rapidly. Always avoid driving truck equipped
with rubber tyres through a puddle of petrol,
fuel oil, lubricating oil, or grease. Never let a
tyre stand in an oil or grease spot overnight.
Store tyres properly

The best of care given to tyres in service by
operators and maintenance personnel can
be completely nullified by careless storage.
Time is not the only contributing factor to the
deterioration of rubber products. Therefore,
tyres that are to be stored must be protected
from light, heat, oils, dirt, moisture and ozone.
Stored tyres should be carefully covered with a
tarpaulin or some other suitable material, such
as opaque plastic sheets, to prevent contact
with the contaminants listed.
Proper handling of tubeless tyres and rims

Tubeless tyres should be stored vertically.
Horizontal stacking may compress the tyre
walls making inflation difficult. If tyres are
stored in racks, the lower supporting members
should provide as broad a surface as possible
to the tyre tread to avoid a concentration of
load.
The beads of tubeless tyres must be protected
from damage or a faulty air seal will result. Do
not use hooks, cables, or chains in contact
with the tyre beads when lifting these tyres.
If forklift trucks are used for handling, they
should be equipped with broad, well rounded
arms to distribute the load and prevent
damage to the tyre bead. When handle tyres
with the fork truck, do not scrape the fork
across the bead.
Tubeless tyre rims perform an important
function as part of the assembly air seal.
4-18 Service Manual

Proper care therefore must be taken not to

distort or mutilate the rim parts, because they
must mate properly to form part of the basic air
chamber. Since the rim base, bead seat band,
and flange are endless, distortion may prevent
easy assembly as well as possibly resulting in
no seal.
Never drop, tumble, or roll rim parts.
If rim parts are stored outdoors they should be
given a protective coat of a good commercial
primer.
Similar parts should be stacked neatly to
prevent distortion.
Babbitt or lead hammers, not sledge hammers,
should be used in assembling rims.
'O' rings are seals and should be carefully
stored in a cool, dry place where they will not
be damaged.
Valve cores also should be stored in a cool,
dry and clean place.
Special Tools
Refer to Section 38.3, SERVICE TOOLS, for
part numbers of special tools outlined in this
section and general service tools required.
These tools are available from your dealer.
Tyre Inflation Pressures

stop after each 80 km (50 miles) or 2 hours
stop after each 32 km (20 miles) or 1 hour of
Normal inflation pressure of bias tyres
(27.00-49 48PR) is 0.575 Mpa. Specific job
conditions, terrain, haul road maintenance
and length, maximum and workday average
Service Manual 4-19

speed, job t-km/h (ton-mile/h) required and

tyre t-km/h (ton-mile/h) capacity, etc., may
require an increase in inflation pressure. It is
recommended that for tyres both listed and
unlisted the user consult the tyre manufacturer
and evaluate all job conditions in order to
make the proper selection.
Fig. Item Item Torque

NO. No. Name Nm lbfft
1 11 Nut 1000~1300 740~960
Tubeless Tyre Leak Diagnosis

Occasionally a tubeless off highway tyre/rim assembly may leak in field service. To determine cause
of leakage, the entire assembly including valve hardware, multi-piece rim assembly, 'O' ring and
tyre should be checked using a soap solution.
This table lists various causes of air loss and possible remedy.
Causes Remedy
Tighten parts. Replace defective parts. Use

Defective valve
valve caps.
Replace defective parts
Cracked rim or weld Warning

Do not attempt repair of wheel components.
Twisted or damaged 'O' ring Replace 'O' ring (lubricate)
Tyre cuts and snags Repair tyre damage
Bead area awl holes Repair inner liner (preferred)
4-20 Service Manual

With tyre removed from rim:

Clean tyre beads in rim contact area
Clean rim with wire brush
Inspect 5 tapered bead seat band and the rim
base in the bead seating area to determine if the
transverse weld trims are flat or concave.
Leakage between tyre bead trim Replace defective part.
Weld trim should follow rim contour.
Mount tyre using a lubricant such as Murphy's

Tyre and tube Mounting Compound, or
equivalent, on tyre beads and rim bead seat
area.
Service Manual 4-21

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LA
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4-22 Service Manual

SRT95C Off-Highway Truck Installation of Engine
5 INSTALLATION OF ENGINE
5.1 Engine and Mounting
Fig.1 Engine and Mounting
1. Engine 11. Bolt 21. Nut

2. Engine - power takeoff 12. Washer 22. Bolt
3. Fan 13. Bolt 23. Washer
4. Double-gear pump 14. Bolt 24. Nut
5. Gear pump 15. Washer 25. Bolt
6. Rear mount 16. Bolt 26. Washer
7. Washer 17. Snubbing washer 27. Compressor
8. Washer 18. Shock mount 28. Crossmember
9. Bolt 19. Snubbing washer 29. Front support
10. Washer 20. Washer
Overview
For engine make, model and specification,
Service Manual 5-1

Installation of Engine SRT95C Off-Highway Truck
refer to Section 36.4, Specifications

o f S RT 9 5 C M i n i n g Tr u c k . F o r e n g i n e
servicing and repair data refer to the engine
manufacturers service manual. The engine
is mounted to the frame at three points by a
mounting assembly (28 and 29) at the front of
engine (1) and two rear mounts (6). Rubber
Shock Mount (18) through engine mounts
provide sufficient flexibility to absorb varying
engine vibration and torsional loads. There
are four full-flow oil filters, two fuel filters and
two coolant filters mounted on the engine (1).
There are a alternator at the front right hand
side of engine, and two starting motors at the
rear left hand side of engine.
Removal
warning
to do the job safely. High electrical current
can cause sparks and personal injury from
burns. Turn ignition key switch to the 'Off'
position before removing any components.
Remove battery ground cable first, and
reconnect last, to avoid damaging electrical
components.
Note: Tag all cables, harnesses, lines and

pipes disconnected during removal to aid in
installation.
ensure the body is fully lowered, apply the
2. Turn steering wheel several times to relieve
pressure in the steering circuit. Block all road
wheels.
3. Disconnect battery cables from battery
5-2 Service Manual

terminal ports before starting re m o v a l

procedures. Disconnect ground cable first.
The connectors of electric components should
be disconnected in the following order:
a. Disconnect the ground cable of battery
compensator
b. Disconnect battery cables from battery
terminal ports (Disconnect ground cable first)
c. Disconnect the positive cable of battery
compensator
d. Disconnect the connector of ECU
4. Remove mounting hardware securing the
hood on the vehicle. Remove hood assembly
from the vehicle.
5. Disconnect electrical connections from the
radiator guard and remove mounting hardware
securing the radiator guard on the vehicle.
Remove radiator guard from the vehicle.
6. Place a suitable container under the engine
drain port, remove drain plug and drain the oil.
After draining, reinstall drain plug in the engine
sump and tighten securely.
warning
Harmful gas. Before disconnecting any air
conditioner lines refer to Refrigerant
will rapidly freeze all objects with which
it comes into contact, and it can cause
serious damage to the skin and eyes.
7. If the truck is equipped with an air

conditioning system, evacuate refrigerant
from the system and disconnect lines at the
compressor. Refer to Section 5.2, Compressor
Installation.
8. With suitable containers in position, open
drain cocks and drain coolant from the radiator
and engine (1) assembly. Close all drain cocks
after draining.
9. Identify cooling lines for ease of installation
and with suitable containers in position,
disconnect cooling lines from engine (1). Cap
Service Manual 5-3

open line ends and fittings.

10. Using suitable lifting equipment, carefully
remove the radiator assembly from the
vehicle. Refer to Chapter 32, RADIATOR AND
MOUNTING.
11. Disconnect and remove air cleaner intake
pipe from the engine turbocharger and air
cleaner.
12. Disconnect and remove exhaust tube from
the engine turbocharger.
13. Disconnect the throttle cable from the
engine (1).
14. Identify heater lines for ease of installation
and, with a suitable container in position,
disconnect heater lines from engine (1). Cap
15. Close fuel shutoff valve at filter head,
identify fuel lines for ease of installation
and, with a suitable container in position,
disconnect fuel lines from engine (1). Cap
warning
Heavy assembly. To prevent personal injury
and property damage, be sure lifting device
is of adequate capacity and properly
16.Identify all electrical harnesses and cables

attached to engine (1) for ease of installation
and disconnect from engine (1).
17. Disconnect driveline from engine coupling
and secure clear of engine (1). Refer to
Chapter 19, Transmission Shaft Installation.
18. Remove the bolts (9) and the washers (7
and 8). Remove the double-gear pump (4) and
gear pump (5) from the engine power takeoff
(2) .
Note: The hydraulic lines can be left attached
to the double-gear pump (4) and gear pump
(5).
19. Remove bolts (16), Snubbing washers
5-4 Service Manual

(17,19), Shock Mounts(18), washers (20) and

nuts(21) securing Crossmember (28) to front
mounting (29). Remove bolts (16), Snubbing
Washers(17,19), Shock Mounts (18), washers
(20) and nuts(21) securing rear mounting
brackets (6) to the frame.
20. Remove the disc brake oil cooler and
gearbox oil cooler from the Crossmember (28).
21. After the oil coolers are removed, remove
the bolt (22), washer (23) and nut (24). Remove
the Crossmember (28) from the frame.
22. Identify all electrical harnesses and cables
attached to engine (1) for ease of installation
and disconnect from engine (1).
23. Check to make certain that all necessary
line and electrical disconnections have been
made before lifting engine (1).
24. Carefully lift engine (1) assembly clear
of the frame and move to a clean work area.
Securely mount engine (1) assembly to a work
stand.
Disassembly
(15) securing front mount (29) to engine (1).
Remove front mount (29) .
(12) securing rear mounts (6) to engine (1).
Remove rear mounts (6).
3. If required, remove bolts (25) and
washers (26) fixing the compressor (27),
loosen compressor drive belt, Remove the
compressor (27) from the engine (1). Refer to
Section 5.2, Compressor Installation.
4. Remove bolts (11) and washers (10)
securing fan to engine (1) then remove fan.
5. Loosen the fan hub mounting bolts and
turn the adjusting rod anticlockwise enough to
allow slack in poly 'V' belts. Remove poly 'V'
belts.
6. If necessary, the shaft coupling can be
removed from the flywheel after the power
takeoff assembly is removed. Refer to section
Service Manual 5-5

5.1.1, Engine POWER TAKEOFF AND

INSTALLATION.
7. Take down the bolt and washer from the
removed PTO. Remove the shaft coupling
from the engine (1).
8. When removing the filters, plug the ports to
avoid grit and dust enter engine, as described
under 'Maintenance'.
9. If necessary, Refer to the Engine Service
Manual.
Inspection
1. Inspect shock mounts (18) for damage and
replace if damaged.
2. Check all mounting components for cracks
and excessive wear. Repair or replace as
required.
3. Inspect shaft coupling, joint for wear or
damage and replace if necessary.
4. Replace all filters. Check all drive belts
for tension and wear, as described under
'Maintenance'.
5. Refer to the Engine Service Manual for
additional engine disassembly/assembly,
repair, adjustment and tune-up procedures.
Assembly
in Section 38.2, STANDARD BOLT AND NUT
TORQUE SPECIFICATIONS.
1. Remove the caps and Position the new
filters, as described under 'Maintenance'.
2. If the oil filling pipe has already been
removed, Position the oil filling tube and filter
assembly to the engine and fix them with the
grip. And the secure the bolts, washers and
nuts.
3. Position the shaft coupling and power take-
off(2) to engine (1) , secure the bolts and
washers.
4. Install 'V' belts in the grooves of alternator
5-6 Service Manual

(56) and accessory drive pulley.

Note: Alternator belt tension adjustment is
made after installation of engine (1) and the
radiator assembly.
5.Install poly 'V' belts to the fan pulley and
crankshaft pulley.
6.. Adjust poly 'V' belts by turning the adjusting
screw clockwise until the correct tension is
obtained. Refer to 'Drive Belt Adjustments'.
When correct tension is obtained tighten fan
hub mounting bolts to a torque of 101 - 126
Nm (75 - 93 lbfft).
7. Position fan to fan pulley on engine (1)
and secure with bolts (11) and washers (10).
Tighten bolts 11) in a star shaped pattern to a
torque of 34 Nm (25 lbfft).
8. Position the compressor assembly (27) on
the engine (1) and secure with bolts (25) and
washers (26).
9. Position the front support (29) on the engine
(1), and secure with bolts (14) and washers
(15).
10. Position the rear mounts (6)) on the engine
(1), and secure with bolts (13) and washers
(12).
Installation
warning
damage, be sure lifting device is properly
secured and of adequate capacity to do the
job safely.

in Section 38.2, STANDARD BOLT AND NUT
1. Install the crossmember (28) on the chassis
mounts and secure with bolts (10), washers
(23) and nuts (23).
Service Manual 5-7

2. Attach suitable lifting equipment to engine

(1) lifting brackets and carefully position
engine (1) assembly in the frame.
3. Secure crossmember (28) assembly and
rear mounts (6) to engine (1) with bolts (16),
Snubbing Washers (17), Shock Mounts (18),
Snubbing Washers (19), washers (20) and
nuts (21)). Install the disc brake oil cooler and
gearbox oil cooler to the crossmember (28).
4. Connect driveline to the engine coupling.
Refer to Chapter 19, FRONT DRIVELINES.
5. Install the double gear pump (4 and 5) to
the engine power take-off (2).
6. Install tandem pump on power takeoff
assembly and secure with mounting hardware.
Refer to Chapter 32, RADIATOR AND
MOUNTING.
7. Remove caps from all cooling lines and
connect lines to the radiator assembly and
engine (1) assembly as identified at removal.
8. Install air cleaner intake pipe and exhaust
piping to engine turbocharger. Tighten
mounting clamps securely.
9. Remove caps from heater lines and fittings
and connect heater lines to engine (1) as
identified at removal.
10. Remove caps from fuel lines and fittings
and connect fuel lines to engine (1) as
identified at removal.
11. Connect all electrical harnesses and
cables to engine (1) (with the exception of
battery connections) as identified at removal.
12. If the vehicle is equipped with air
conditioning, connect the lines at the
compressor as identified at removal. On
completion of engine installation the air
conditioning system will require to be charged.
Refer to Section 5.2, Compressor Installation.
13. Connect all electrical harnesses and
cables to engine (1) assembly as identified at
removal. Do not connect battery and battery
equalizer connections at this time.
14. Connect throttle control linkage to engine
(1) assembly.
5-8 Service Manual

15. Connect electrical connections as follows:

a. Connect electrical connections at the ECU.
b. Connect battery equalizer positive cables.
c. Connect battery cables to terminal posts
(ground cables last).
d. Connect battery equalizer ground cables.
16. Check that all electrical connections and
cables, all lines and components removed or
disconnected at removal have been reinstalled
correctly. Ensure all drain plugs and drain
cocks are tightly secured.
17. Fill engine (1) with lube oil specified in
Section Section 36.1, LUBRICATION AND
MAINTENANCE. Check oil level as described
under 'Maintenance
18. Start the engine and bring the engine oil to
operating temperature. Check all lines and
fittings for leaks and tighten as required.
Switch off the engine.
19. Using suitable lifting equipment, install
hood assembly into position on the vehicle.
Secure hood assembly with mounting
hardware removed at removal.
20. Install hood side assembly on the vehicle
and secure with mounting hardware removed
at removal.
21. Connect battery positive connections to
battery terminal posts. Connect battery earth
connections to battery terminal posts.
22. Ensure all lines, harnesses and cables are
secured with clips and clamps as removed
during removal. Ensure no lines are chaffing
on sharp edges or resting against areas where
heat will be evident. Ensure all drain plugs and
cocks are secured tightly.
23. Fill the cooling system with coolant
specified in Chapter 34, Radiator Mounting
Check the coolant level as described in
Chapter 34, Radiator Mounting.
24. Fill the engine with lube oil specified in
'Maintenance'. Check oil level as described
under 'Maintenance'.
25. Start up the engine and bring the engine
oil to operating temperature. Check all lines
Service Manual 5-9

and fittings for leaks and tighten as required.

26. Ensure parking brake is applied and
remove wheel blocks from all road wheels.
Maintenance
Every 10 Hours (Daily)

Engine (1): Visually check engine for damage,
loose or frayed belts and listen for any unusual
noises. Check the turbocharger for leaks.
Engine (1) Oil Level: Check engine oil level
and add oil if low. To allow checking before
starting as well as immediately after shutting
down the engine, the dipstick is provided with
two types of marks:
1. Dot Marks - Before starting up after a major
shut down period the oil level should be up to
the top dot mark (cold level).
2. Dash Marks - Upon shutting down the
engine at low idling (wait 1 to 2 minutes) the
oil level should be up to, but not over, the top
dash mark (hot level).
Every 250 Hours

Engine (1): Drain engine oil and refill.
Refer to Section 36.1, LUBRICATION AND
MAINTENANCE. Engine Water Pump:
Inspect water pump drain hole and clean if
required.
Engine Oil Filters : Replace oil filters as
follows:
1. Using filter wrench, remove and discard
both oil filters from engine (1). Inspect the
sealing surface of the filter to ensure that the
seal ring stayed with the filter. If not, remove it
from the filter adaptor.
2. Clean the filter adaptor with a clean, lint free
cloth.
3. Lightly coat new oil filter seal with clean
engine oil Refer to Chapter 29, Lubrication
System.
4. Start a new oil filter on the filter adaptor and
tighten it by hand until the seal touches the
5-10 Service Manual

adaptor filter head. Tighten an additional 2/3 of

a turn after contact.
Note: Mechanical tightening of oil filters is not
necessary and will distort or crack the adaptor.
Tighten oil filters by hand only.
5. Repeat steps 3 and 4 for second oil filter.
6. Start and run the engine for a short period
and check for oil leaks. If any leaks are noted,
have them corrected.
7. After the engine has been stopped long
enough (approximately 20 minutes for the oil
from various parts of engine (1) to drain back
to the crankcase, check oil level and add oil
to bring it to the proper level on the dipstick.
Refer to Section 36.1, LUBRICATION AND
MAINTENANCE.
Fuel Filters: Replace primary and secondary
fuel filters as follows:
Note: There is a fuel system shut off valve
on the discharge side of secondary fuel filter.
Closing this valve will prevent loss of fuel
prime at time of filter replacement.
1. Close shut off valve at secondary fuel filter
and, using filter wrench, remove and discard
both fuel filters from engine (1).
2. Fill the replacement filters and coat the
gaskets slightly with clean fuel oil as specified
i n S e c t i o n 3 6 . 1 , L U B R I C AT I O N A N D
MAINTENANCE.
3. Start a new fuel filter on the filter adaptor
and tighten it by hand until the gasket contacts
the adaptor fully with no side movement of the
filter evident. Tighten an additional 1/2 of a
turn.
Note: Mechanical tightening of fuel filters is
not recommended, and may result in seal and/
or cartridge damage. Tighten fuel filters by
hand only.
4. Repeat step 3 for second fuel filter.
5. Start the engine and check for leaks. If any
leaks are noted, have them corrected.
Coolant Filter: Check condition of coolant
inhibitor as described in Chapter 32,
RADIATOR AND MOUNTING.
Service Manual 5-11

Note: There is a shut off valve at the coolant

inlet and outlet lines of coolant filter. Closing
these valves will enable coolant filter to be
replaced without an excessive loss of coolant.
1. Close shut off valves at coolant filter inlet
and outlet lines and, using filter wrench,
remove and discard coolant filter from engine
(1).
2. Clean the filter adaptor with a clean, lint free
cloth.
3. Lightly coat new coolant filter seal with
clean engine oil as specified in Section 36.1,
4. Start coolant filter on the filter adaptor and
tighten it by hand until the seal touches the
adaptor filter head. Tighten an additional 2/3 of
a turn after contact.
Note: Mechanical tightening of coolant filter
is not necessary and will distort or crack the
adaptor. Tighten oil filters by hand only.
5. Open shut off valves at coolant filter inlet
and outlet lines.
6. Start the engine and check for leaks. If any
leaks are noted, have them corrected. Add
coolant as required. Refer to Chapter 32,
RADIATOR AND MOUNTING.
Drive belt adjustments

Every 50 Hours: Check all drive belt tensions
and adjust if required. If vehicle is equipped
with air conditioning, compressor belts should
be checked and adjusted as described in
Section 5.2, Compressor Installation.
Every 2000 Hours: Replace all drive belts.
Note: Replace all belts in a set when one is
worn. Single belts of similar size should not
be used as a substitute for a matched belt set
as premature belt wear can result due to belt
length variation. All belts in a matched belt set
are within 0.81 mm (0.032 in) of their specified
centre distances.
Using belt tension gauge, adjust the belt
tension to the following values:
Fan - Poly 'V' Belt
5-12 Service Manual

Belt Tension 'New' - 3 340 N (750 lbf)

Belt Tension 'Used' - 2 450 - 3 340 N (550 -
750 lbf)
Alternator - 'V' Belt
Belt Tension 'New' - 556 N (125 lbf)
Belt Tension 'Used' - 445 N (100 lbf)
Note: A belt is considered 'Used' if it has been
in service for 10 minutes or longer. If the used
belt tension is less than the minimum value,
tighten the belt to the maximum value.
Belts should be neither too tight nor too
loose. Belts that are too tight impose excess
loads on the crankshaft, fan and alternator
bearings, shortening both belt and bearing life.
Excessively overtightened belts can result in
crankshaft breakage. A loose belt will slip and
may cause damage to accessory components.
Special tools
Refer to Section 36.3 'MAINTENANCE
TOOLS', for part numbers of tools referenced
in this section, general service tools required,
and service tools which should be used in
conjunction with procedures outlined in the
engine manufacturers service manual. These
tools are available from your dealer.
Special torque requirement

Torque
Drawing
No. Description Nm lbfft
No.
1 7 Bolt 150 110
1 22 Bolt 34 25
1 50 Bolt 81-95 60-70
1 61 Bolt 81-95 60-70
Fan
mounting 101-126 75-93
nut
Service Manual 5-13

5.1.1 Engine - power takeoff
22
21
20
13 19
1 2 3 23
4 7 26
14 15 18 24
25 28
5 6 12 17 29
27
8 9 10 11 16
31
26
32 30
35 34 33
45

40 41 43 44 (Oil feeding screw plug)
42
(Oil level plug 45
36 37
38
39
45
(Drain plug)
Fig.2 - Exploded View of Engine - Power Takeoff
1. Outer ring, aluminum 13. Transitional disc 25. Drive gear 37. Shell cover
2. Washer 14. Washer 26. Driven gear 38. Plug
3. Screw 15. Bolt 27. Drive shaft 39. Pin
4. Elastic body 16. Oil Seal 28. Bearing 40. Ring, retainer
5. Bolt 17. Shell seat 29. Bearing 41. Oil Seal
6. Washer 18. Rubber adaptor 30. Bolt 42. Yoke
7. Inner ring, aluminum 19. Breathing tube 31. Bolt 43. Washer
8. Screw 20. Pipe connector 32. Washer 44. Nut
9. Pressure cover 21. Pipe connector 33. Ring, retainer 45. Plug
10. Bolt 22. Breather 34. Bolt
11. Pressure cover 23. Throat collar 35. Washer
12. Sleeve, shaft 24. Pipe connector 36. Gasket
5-14 Service Manual

Description operation
The function of the power takeoff (PTO), as
the name implies, is to provide the means of
mounting and driving auxiliary components.
The hydraulic pump on the shell cover (37)
and its input shaft is meshed with the internal
spline in the hub of driven gear (26).
The major components of the PTO assembly
are: Shell seat (17), shell cover (37), drive
shaft (27), drive gear (24) and driven gear (26).
As drive shaft (27) is driven by the engine
crankcase, drive gear (25) turns to drive driven
gears (26). The hydraulic pump drive shafts,
meshed in the hub of driven gears (26), turn
with driven gears (26) to operate the hydraulic
pump which, in turn, supplies hydraulic oil to
the body hoist system and steering system
and disc brake assemblies.
Removal
warning

engine.
several times to relieve pressure in
accumulator and steering system. Block all
road wheels.
3. Disconnect driveline from yoke (42) at PTO
assembly.
4. Drain oil from power takeoff housing by
removing drain plug (45) from shell seat (17).
Service Manual 5-15

Reinstall drain plug (45) securely.

5. Match mark main hydraulic pump and
combination gear pump mounting flange
and shell cover (37) so that the pump can be
installed in the same position at installation.
6. With suitable blocking or lifting equipment,
support the hydraulic pump and combination
gear pump before loosening attaching bolts.
Remove Bolts and lock washers from main
hydraulic pump and combination gear pump
clear of PTO assembly.
7. Match mark engine flywheel housing and
shell seat (17) so that PTO assembly can be
installed in the same position at installation.
8. Attach a suitable lifting device to PTO
assembly and remove bolts (30 & 31) and lock
washers (32) securing PTO assembly to the
engine flywheel housing. Remove the rubber
adaptor (18). Carefully lower PTO assembly
from the flywheel housing and move to a clean
work area for disassembly.
the engine flywheel. Carefully remove the
transitional disc (13).
the aluminum outer ring (1) of engine flywheel.
Carefully remove the aluminum outer ring (1).
Disassembly
1. Remove the locknut (44) and washer (43)
from drive shaft (27). Pull yoke (42) from drive
shaft (27).
2. Remove the pins (39) from the shell cover
(37).
3. Place shell cover (37) yoke side up on a
work bench. Pry oil seal (41) from shell cover
(37) and discard.
4. Turn over PTO assembly. Remove the bolts
(5) and washers (6) from the aluminum Inner
ring (7). Pull aluminum Inner ring (7) from
shaft sleeve (12).
5. Remove the screw (8) from the drive shaft
5-16 Service Manual

(27). Pull pressure cover (9) from drive shaft

(27). Remove the bolt (10) from the shaft
sleeve (12). Pull pressure cover (11) and shaft
Sleeve (12) from drive shaft (27).
6. Remove the bolts (34) and washers (35)
from the shell cover (37). Pull shell cover
(37) and gasket (36) from the shell seat (17).
Discard gasket (36).
7. Remove snap rings (33 & 40) from pump
and drive shaft bores. Drive bearings (28 & 29)
from shell cover (37) with a sleeve or soft steel
drift. Drive on the outer race of bearings (28
&29) taking care not to damage the bearings.
8. Slide drive gear (25) from drive shaft (27),
and pull driven gears (26) from shell seat (17).
9. Pull drive shaft (27) from shell seat (17). Pry
oil seal (16) from shell seat (17) and discard.
10. Pull bearings (28 & 29) from shell seat (17)
with a suitable bearing puller.
Inspection
1. Wash all parts thoroughly in a suitable
solvent and dry all but bearings (28 & 29) with
compressed air. Dry bearings (28 & 29) with a
clean lint free cloth.
2. Check the condition of splines and teeth on
gears (25 & 26), drive shaft (27) and yoke (42)
for burrs or signs of wear.
3. Lubricate bearings (28 & 29) with oil and
check operation by spinning bearings by hand.
Do not spin bearings with compressed air.
Inspect bearing bores for out of roundness.
Replace bearings, if required.
4. Inspect shell seat (17) and shell cover (37)
for cracks. If either shell seat (17) or shell
cover (37) are damaged, both parts must be
replaced as an assembly.
5. Visually check oil seal lip contact surfaces
on drive shaft (27) and yoke (42) for nicks,
dents, scratches, wear, or corrosion. Replace
as necessary.
6. Inspect aluminum outer ring (1) and
Service Manual 5-17

aluminum inner ring (7) and shaft sleeve (12)

of shaft coupling for cracks. If either aluminum
outer ring (1) or aluminum inner ring (7) or
shaft sleeve (12) are damaged, the parts must
be replaced as an assembly. At the same
time, check the elastic body (4) and bolt (5 &
10) and screw (3 & 8) and pressure cover (9 &
11).
Assembly
Note: Prior to assembly, lubricate all seal lips
and surfaces with lubricant specified in Section
36.1, LUBRICATION SYSTEM.
torques specified to standard torques listed,
S TA N D A R D B O LT A N D N U T TO R Q U E
SPECIFICATIONS.
warning
damage, be sure lifting device is properly
job safely.
1. Press bearings (28 & 29) into their bores in

shell seat (17).
2. Install driven gears (26) and drive shaft (27)
into shell seat (17). Slide drive gear (25) over
drive shaft (27) to its proper location.
3. Install the new gasket (36) on the shell seat
(17). Install the shell cover (37) onto the shell
seat (17). Install the pins (39) into the shell
cover (37) and the shell seat (17).
4. Press bearings (28 & 29) into their respective
bores in shell cover (37). Install rings (33 & 40)
into the shell cover (37).
5. Use the bolt (34) and washer (35) to fix the
shell cover (37) onto the shell seat (17).
6. Install new oil seal (41) into centre bore in
the shell cover (37) so that it is flush with shell
5-18 Service Manual

cover (37) face.

7. Turn over PTO assembly. Install new oil
seal (16) in the shell seat (17) so that it is flush
with shell seat (17) face.
Note: When installing new oil seals, install them
with the oil lip (larger of the two lips with the
spring behind it) facing inward. Care should
be taken to prevent damage to seal lips during
assembly.
8. Install yoke (42) on drive shaft (27) end and
secure with hardened washer (43) and locknut
(44). Tighten locknut (44) to fasten it after the
paste is applied to it. The torque is 850 - 1050
Nm.
9. Install the pressure cover (11) of shaft
coupling onto the shaft sleeve (12). Use the
bolt (10) to fasten it after the paste is applied
to it. The torque of bolt (10) is 104Nm.Install
the shaft sleeve (12) of shaft coupling onto
the input end of drive shaft (27). Then install
the pressure cover (9) onto the drive shaft
(27). Use the set screw (8 to fasten it after the
paste is applied to it. The torque of set screw
(8) is 60Nm. Then install the aluminum inner
ring (7) of shaft coupling onto the shaft sleeve
(12). Use the bolt (5) and washer (6) to fasten
it after the paste is applied to it. The torque of
connecting bolt (5) is 350Nm.
10. Install the aluminum outer ring (1) of
shaft coupling onto the flywheel disc and use
the shaft coupling fastening screw (3) and
washer (2) to fix it. The torque of connecting
screw (3) for the aluminum outer ring (1) and
flywheel disc of shaft coupling is 170Nm. The
thread anti-loosing paste should be applied for
tightening.
11. Install the elastic body (4) in aluminum
inner ring (7). Attach a suitable rope to fix the
elastic body (4).
Installation
Note:When reassembling PTO assembly.
Service Manual 5-19

to the engine flywheel housing, and main

hydraulic and tandem pumps to PTO
assembly. be sure to align match marks
inscribed during disassembly.
Note: Tighten all fasteners to standard torques
listed, STANDARD BOLT AND NUT TORQUE
SPECIFICATIONS.
1. Install the transitional disc (13) onto the
flywheel housing and use the Bolt (15) and
washer (14) to fix it. Use suitable lifting
equipment, position Power take-off assembly
into the aluminum outer ring (1) of shaft
coupling. Remove the rope of elastic body (4).
Secure PTO assembly to the transitional disc
(13) with bolts (30 & 31) and washers (32).
2. Using suitable lifting equipment, position
hydraulic pump over its mounting studs and
secure with bolts removed during removal.
3. Reconnect driveline to yoke (42). Install
rubber adaptor (18) into shell seat (17).
4. Remove oil level plug and drain plug (45)
from the front shell cover (37) and the shell
seat (17) respectively. Add the lubricating oil
into the PTO assembly from the drain plug (45),
until the oil reliefs from the opening of oil level
plug (45). Then install and fasten the oil level
plug and drain plug (45) respectively.
5. Start the engine and bring oil to correct
operating temperature. Check for leaks and
correct as necessary.
6. Remove wheel blocks from all road wheels.
Maintenance
Note: Refer to Section 36.1, LUBRICATION
SYSTEM for recommended check and drain
intervals and lubricant specifications.
Oil level check
Remove oil level plug (45) from front part of
shell cover (37), if oil is not showing in oil level
plug (45), add lubricant until oil is to oil level
plug (45). Reinstall oil level plug (45) and
tighten securely.
5-20 Service Manual

Draining and refilling

To drain: Remove drain plug (45) from
shell seat (17) and drain oil into a suitable
container. Reinstall drain plug (45) securely
when draining is complete.
To refill: Remove oil level plug (45) from the
front of shell cover (37) and fill PTO assembly.
until oil flows from the oil level port. Install oil
level plug (44) in shell cover (36) and tighten
securely.
Service Manual 5-21

5.2 Installation of Compressor
1 2 3 4
11
10
9
6
7
Fig.1 Assembly drawing of compressor
1. Nut 7. V-belt
2. Washer 8. Nut
3. Washer 9. Adjusting screw rod
4. Screw 10. Adjusting gasket
5. Compressor 11. Compressor support
6.Bolt
Disassembly of compressor
1. Disconnect the electrical connection from
the clutch of compressor (5).
2. Loosen the nut and washer on the adjusting
screw rod (9) and release the tension of V-belt
(7).
3. Loosen the nut (1), bolt (6) and washers (2
3). Regulate the adjusting screw rod (9). The
V-belt (7) should be able to freely slip from the
groove of compressor (5).
4. Remove the nut (1), screw (4) and washers
(23) from the compressor (5). Detach the
adjusting screw rod (9) from the compressor.
5. Support the compressor (5). Remove
the adjusting gasket (10), washers (23)
and nut (1) fixing the compressor (5) onto
5-22 Service Manual

the compressor support (11). Remove the

compressor (5) from the compressor support
(11).
6. Remove the compressor support (11) from
the engine.
Note: If it isnt required to replace the V-belt (7),
then it will be unnecessary to remove it from
the engine.
Installation of compressor
1. Install the compressor support (11) onto the
engine and use the removed fasteners to fix it
properly.
2. Install the compressor (5) onto the
compressor support (11) and use the removed
fasteners to fasten it. They cant be completely
tightened in this step.
3. Install the V-belt (7) onto the rear groove of
engine fan pulley and then install it onto the
rear groove of compressor (5).
4. Insert the upper part of adjusting screw rod
(9) through the mounting hole of compressor
(5). Insert the screw (4) through the mounting
hole of compressor. Use the washers (23)
and nut (1) to fasten the adjusting screw rod (9)
and compressor (5). They cant be completely
fastened in this step.
5. Insert the lower part of adjusting screw rod
(9) through the mounting hole of base seat.
Insert the Screw(4) through the mounting hole
of compressor support (11). Use the washers
(23) and nut (1) to fasten the adjusting
screw rod (9) and compressor support (11).
They cant be completely fastened in this step.
6. Fix the compressor (5). Fasten the washers
(23) and nuts (1) in Step 4 and 5.
7. Adjust the V-belt (7) of compressor with the
adjusting screw rod (9), until a deflection of
about 10mm appears when the center part
of V-belt (7) is pressed by thumb. Tighten all
fasteners.
8. Connect the electric circuit of the clutch of
compressor (5).
Service Manual 5-23

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E
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G
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PA
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K
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N
........................................................................................................................................
LA
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B
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5-24 Service Manual

SRT95C Off-Highway Truck Transmission And Mounting
6 TRANSMISSION AND
MOUNTING
6.1 Transmission Mounting
2
9
7 8
26
5 10
6 11
12
13
14
4
1 11
3 15
2 17
18 16
19
20
25 20
24 21
23
18
22
Fig.1 Transmission and Mounting
1. Filler hose 10. Bolt 19. Plate

2. Flange nut 11. Washer 20. Shock mount
3. Retainer plate 12. Plate 21. Ringer
4. Output flange 13. Shock mount 22. Nut
5. Transmission 14. Ringer 23. Bolt
6. Ring 15. Nut 24. Washer
7. Trunnion 16. Power take-off assembly 25. Bracket
8. Input flange 17. Bolt 2 6 . Tr a n s m i s s i o n
9. Retainer plate 18. Washer retarder control
Service Manual 6-1

Transmission And Mounting SRT95C Off-Highway Truck
Description
For transmission make, model and
specification, refer to GeneralL information.
For transmission switches, sensors and
instruments, refer to Section 8.1.7, 'Switches
and sensors'.
For transmission servicing and repair data,
refer to the transmission manufacturers
service manual.
The transmission is remote mounted in
the frame and is supported by trunnion (7)
assembly at the front and two mounting
b r a c k e t s ( 2 5 ) a t t h e r e a r. I n t e g r a l w i t h
transmission (5) assembly are torque converter
and planetary gearing. There are six forward
gears and one reverse gear with automatic
lockup in all speed ranges. Operation of the
transmission is by the Commercial Electronic
Control (CEC) Shift System. A brief description
and operation of the main transmission
components are as follows:
Torque converter
The torque converter consists of three
elements -pump, turbine, and stator. The pump
is the input element and is driven directly by
the engine. The turbine is the output element
and is hydraulically driven by the pump. The
stator is the reaction (torque multiplying)
element. When the pump turns faster than
the turbine, the torque converter is multiplying
torque. When the turbine approaches the
speed of the pump the stator starts to rotate
with the pump and turbine. When this occurs,
torque multiplication stops and the torque
converter functions as a fluid coupling.
Lockup clutch
The lockup clutch is located inside the torque
converter and consists of three elements -
piston, clutch plate, and backplate. The piston
and backplate are driven by the engine and
the clutch plate, located between the piston
6-2 Service Manual

and backplate, is splined to the converter

turbine. The lockup clutch is hydraulically
engaged and released in response to electrical
signals from the ECU. It engages when the
vehicle reaches a predetermined speed.
Engagement of the lockup clutch provides a
direct drive from the engine to the transmission
gearing. This eliminates converter slippage
to provide maximum fuel economy. The
lockup clutch releases at lower speeds (and
momentarily during shifts). When the lockup
clutch is released, drive from the engine is
transmitted hydraulically through the converter
to the transmission gearing. The lockup clutch
also releases when the ECU detects certain
undesirable conditions.
Planetary gears and clutches

A series of planetary gears and shafts provide
the gear ratios and directions of travel for the
vehicle. Power flow through the planetaries
is controlled by multiple clutch packs. The
clutches are applied and released hydraulically
in response to electrical signals from the ECU.
Hydraulic retarder
A vaned rotor and two vaned stators are the
basic components of the retarder. Application
of the retarder control valve fills the cavity
around the rotor with oil when the vehicle
must be slowed on steep downgrades. When
the cavity is emptied, the rotor is free of drag.
Maximum retarder effect occurs in the lowest
gear range with foot off of the accelerator
pedal. Long continuous use of the retarder
will raise transmission oil temperature. Short
periods of full release, to interrupt continuous
application, will help prevent overheating.
During normal operation the dash mounted
transmission oil temperature gauge should
read in the green zone. However, during
transmission retarder operation oil temperature
can enter the yellow 'Retarder On' zone but
should not enter the red zone.
Service Manual 6-3

Transmission oil cooler

The transmission oil is cooled by a separate
oil cooler mounted between the radiator and
transmission to maintain transmission oil within
its required operating temperature range.
Refer to Section 33,'oil cooler assembly'.
Transmission oil filter

The transmission oil filter is mounted at the left
hand side of the transmission. It is installed in
the transmission oil lines to remove dirt and
other contaminants from the transmission oil to
minimise wear and provide maximum service
life for the transmission. Refer to Section 30,
'transmission oil filter'.
Removal
warning
High electrical current can cause sparks
and personal injury from burns. Switch
circuit breakers to the 'Off' position before
removing any electrical components.
Remove battery ground cable first, and
reconnect last, to prevent damaging
electrical components.
Any time the battery equalizer is
disconnected from the batteries, remove
ground cable first, and reconnect last, to
prevent damaging the component.

raise the body and secure in place with the
body safety pins. Refer to Section 23,'Body
and Installation'.
2. Apply the parking brake and switch off
6-4 Service Manual

the engine. Turn steering wheel in both

directions several times to relieve pressure
in the steering system. Operate the treadle
valve continuously to discharge the brake
accumulators.
3. Block all road wheels.
Note: It is important that the electrical
connections are removed in the order listed
in step 4 to prevent damage to the electrical
components.
4. Disconnect battery equalizer ground
connection from the batteries. Disconnect
battery cables from terminal posts (ground
cable first). Disconnect battery equalizer
positive connection. Disconnect electrical
connections at the ECU.
5. Using suitable lifting equipment, support
transmission guard and remove mounting
hardware securing the guard to the frame.
Remove transmission guard.
6. Disconnect driveline from input flange (8) at
the front of transmission (5). Refer to Section
19, 'Driveline Installation'.
7. Disconnect driveline from output flange
(4) at the rear of transmission (1). Refer to
Section 19, 'Driveline Installation'.
8. Drain the oil from transmission (5).
9. Disconnect the transmission retarder cables
at transmission (5).
10. Disconnect transmission oil cooler lines
and oil filter lines from transmission (1). Cap
all open lines and fittings to prevent entry of
dirt.
11. Disconnect all remaining hydraulic lines
attached to transmission (5). Cap all open
lines and fittings to prevent entry of dirt.
12. Disconnect all electrical connections and
cables attached to the transmission.
13. Disconnect filler hose(1) attached to the
transmission(5).
14. Install suitable lifting eyes into the holes
provided at the top of transmission (5) housing
and secure a suitable lifting device to the eyes.
1 5 . R e m o v e b o l t s ( 1 0 ) , w a s h e r s ( 11 ) ,
Service Manual 6-5

Plates(12)and nuts(15) securing trunnion (7)

to the frame.
16. Remove bolts (17), washers(18),
Plates(19)and nuts(22) securing brackets(25)
to the frame.
17. Check to make certain that all hydraulic
lines and electrical connections fitted to
transmission (5) have been disconnected
before moving transmission (5).
18. Carefully manoeuvre transmission (5)
out of the frame mounting and lower onto a
suitable dolly or pallet.
19. Move transmission (5) assembly to a
suitable work area or onto a work stand for
further disassembly, if necessary.
Disassembly
Note: Refer to the transmission manufacturers
Service Manual if transmission service or
repair is required.
1. Remove flange nut (2) and retainer plate (9)
securing input flange (8) on transmission (5).
Pull input flange (8) from transmission (1).
2. Pull trunnion (7) from transmission (5) and
remove ring (6) and shock mounts (13) from
trunnion (7), if required.
3. Remove flange nut (2) and retainer plate (3)
securing output flange (4) on transmission (5).
Pull output flange (4) from transmission (5).
4. Remove bolts (23) and washers(24)
securing brackets (25) on transmission (5) and
remove brackets (25).
5. If required, remove shock mounts (20) from
mounting brackets (25).
Assembly
1.If removed, fit shock mounts(13) and ring (6)
to trunnion (7). Install trunnion (7) to
transmission (5).
2.If removed, fit shock mounts (20) to brackets
(25). Install brackets (25) on transmission
(5) and loosely secure with bolts (23) and
6-6 Service Manual

washers (24).
3. Ensure transmission output shaft is in
the most outward position and the bearing
between the shaft shoulder and the flange is
tight against the shaft shoulder.
4. Coat splines of input shaft with EP, NLGI
molybdenum grease and fit input flange (33)
on input shaft.
5. Install input flange (8) on transmission
(1) securing with flange nut (2) and retainer
plate(9). Tighten flange nut (2) to a torque of
1300 Nm.
6. Coat splines of output shaft with EP, NLGI
molybdenum grease and fit output flange (4)
on output shaft.
7. Install output flange (4) on transmission (5)
securing with flange nut (2) and retainer
plate(3). Tighten flange nut (2) to a torque of
1300 Nm.
Installation
warning
1. Position transmission (5) assembly under

the truck and attach a suitable lifting device to
the eye bolts on top of transmission (5).
2. Carefully lift transmission (5) into its
mounting position and secure trunnion (7)
to the frame with bolts (10), washers(11),
plates(12) and nuts (15). Tighten bolts (10) to
a torque of 507 Nm-557Nm.
3. secure brackets (25) to the frame with
bolts (17), washers(18), plates(19) and nuts
(22). Tighten bolts (17) to a torque of 790Nm-
860Nm.
4. Remove lifting device and lifting eye bolts
Service Manual 6-7

from top of transmission (5).

5. Install filler hose (1) to transmission(5).
6. Connect all electrical connections and
cables to transmission (1) as tagged at
removal.
7. Connect transmission oil cooler lines
to transmission (1) and oil filter lines to
transmission oil filter as tagged at removal.
8. Connect any remaining hydraulic lines
which were removed during removal. Ensure
all hydraulic lines are securely tightened.
9. Connect transmission retarder cables at
transmission (1).
10. Install rear driveline to output flange (4) at
the rear of transmission (5) and secure with
mounting hardware removed during removal.
Refer to Section 19, 'Driveline Installation'.
11. Install front driveline to input flange (8) at
the front of transmission (5) and secure with
mounting hardware removed during removal.
Refer to Section 19, 'Driveline Installation'.
12. Using suitable lifting equipment, support
transmission guard and secure guard to the
frame with mounting hardware removed during
removal.
13. Fill transmission (5) with oil specified
i n S e c t i o n 3 6 . 1 , ' L U B R I C AT I O N A N D
MAINTENANCE', and check the oil level as
described under 'Oil Level Check'.
connections are made in the order listed in
step 14 to prevent damage to the electrical
components.
14. Connect electrical connections at the ECU.
Connect battery equalizer positive connection.
Connect battery cables to battery terminal
posts (ground cable last). Connect battery
equalizer ground connection.
15. Start the engine and make an operational
check of all lines and components
disconnected during removal. Check all
hydraulic lines and fittings for leaks and tighten
as required.
16. Ensure parking brake is applied, remove
6-8 Service Manual

the body safety pins and lower the body.

Remove wheel blocks from all road wheels.
Refer to Section 24,'Body and Installation'.
warning
When checking the oil level, be sure that
the parking brake is applied and all road
wheels are securely blocked.
Maintenance
Periodic inspections
For easier inspection, the transmission should
be kept clean. Make periodic checks for loose
bolts and leaking oil lines. Check the condition
of electrical harnesses and connections
regularly.
The transmission breather should be checked
regularly and as frequently as necessary,
depending on the operating conditions of the
vehicle. A badly corroded or plugged breather
restricts proper breathing and causes a
buildup of condensation and subsequent oil
deterioration.
Oil level check

Check the transmission oil level and add oil if
low, every 10 hours/daily. Use only oil of the
type specified in Section 36.1, 'LUBRICATION
AND MAINTENANCE'. Because the
transmission oil cools, lubricates and transmits
Invisible red line
hydraulic power it is important that the proper (Over-filling)
oil level be maintained at all times. If the oil
Red line
level is too low, the converter and clutches
will not receive an adequate supply of oil. If Full liquid level and
safe operating
the oil level is too high, the oil will aerate and chamber
the transmission will overheat. It is absolutely Invisible red line;
oil level too low
necessary that the oil put into the transmission
be clean. Oil must be handled in clean
containers to prevent
foreign material from entering the system. Fig.2 Visual Level Indicator
Note: Containers or fillers that have been
Service Manual 6-9

used for antifreeze or engine coolant solution

must not be used for transmission oil.
Visual level indicator

A visual level indicator is mounted on the lower
left side of the transmission main housing and
provides a method of checking the oil level.
Refer to Fig.2.
Cold oil level check

Before starting the engine, check the visual
level indicator or remove the ADD (lower)
plug. If oil is present in the indicator or if oil
flows from the plug opening, the transmission
has sufficient oil to permit safe starting of the
engine. If no oil is present, add sufficient oil to
bring the level within the indicator or to cause
a flow from the plug opening. Replace the
plug.
Hot oil level check

Note: Observe the condition of the oil in the
visual level indicator or the type of flow from
the plug opening. Foaming or spurting may
indicate a false level.
A hot oil level check is made to determine
if there is sufficient oil for working operation
o f the transmission. Select neutral o n
the transmission range selector and start
the engine. Operate the vehicle until the
transmission reaches a normal operating
temperature of 82 C - 103 C (180 F - 220
F). Idle the engine, apply the parking brake
and block all road wheels. Check the visual
level indicator or remove the FULL (upper) oil
level check plug. The oil should be within the
indicator limits shown in Fig.2 or at or near the
level of the plug opening. Add or drain oil as
necessary to bring the oil level within these
limits.
Note: The transmission may be operated
safely as long as the oil level is above the
ADD (lower) plug.
6-10 Service Manual

warning
Be sure to apply the parking brake, switch
off the engine and block all road wheels
before troubleshooting the vehicle. If
it is necessary to run the engine, it is
imperative that an operator be present in
the cab at all times, even at idle.
Oil and filter change

After the first 200 hours of operating a new or
rebuilt transmission, the transmission oil and
filters should be changed. The transmission oil
and filters should be changed at the intervals
specified in Section 36.1, 'LUBRICATION
AND MAINTENANCE', or sooner, depending
on operating conditions. Also, the oil must be
changed whenever there are traces of dirt
or evidence of high temperature indicated
by discoloration or strong odour. The screen
and magnet assembly in the sump should
be removed and cleaned with mineral spirits
at each oil change. Metal particles in the
oil (except for the minute particles normally
trapped in the oil filters) indicate damage has
occurred in the transmission. When these
particles are found in the filters, the cause
must be established and rectified immediately
to prevent damage to the transmission. At
each oil change, examine the used oil for
evidence of dirt or water. A normal amount
of condensation will emulsify in the oil during
operation of the transmission. However, if
there is evidence of water or engine coolant
in the oil, the cause must be established and
rectified immediately to prevent damage to the
transmission.
Welding on vehicles equipped with CEC

When frame or other welding is required, the
following precautions are to be taken to protect
Service Manual 6-11

the electrical components.

a. Disconnect battery equalizer ground
connection from the batteries. Disconnect
battery cables from terminal posts (ground
cable first). Disconnect battery equalizer
positive connection. Disconnect electrical
connections at the ECU.
warning
The ECU can be damaged by improper
welding procedures. Any time the battery
equalizer is disconnected from the
batteries, remove ground cable first, and
reconnect last, to prevent damaging the
component.
b. If additional system ground wires are

connected to the frame, they must be
disconnected also.
c. Cover electrical components and wiring to
protect from damage.
d. Do not connect welding cables to electrical
components. Do not weld on electrical
components. If welding is to be done close to
electrical components, the components should
be removed prior to the welding process.
e. On completion of all welding reconnect
electrical connections in the reverse order to
step a.
Troubleshooting
Converter stall test
A stall test should be conducted when the
power package (engine and transmission)
is not performing satisfactorily. The purpose
of the test is to determine the engine power
output and establish if the transmission is the
malfunctioning component.
warning
When conducting a stall test, the vehicle
6-12 Service Manual

must be positively prevented from moving.

The parking brake must be applied and
the vehicle should be blocked to prevent
movement forward or reverse. Keep people
safely away from the vehicle path. Do not
maintain the stalled condition longer than
30 seconds due to rapid heating of the
transmission oil. With the transmission
in neutral, run the engine at 1200 - 1500 r/
min for two minutes to cool the oil between
tests. Do not allow the converter-out
temperature to exceed 135 C (275 F).
Keep a close check to prevent overheating
of the engine cooling system.
1. Position the vehicle on a level area with

room for movement all round.
2. Apply the parking brake and block all road
wheels. Turn the manual mode key switch
to the 'On' position and the mode selection
switch to the 'Power' mode.
3. Apply the service brake, release the parking
brake and select fifth gear on the transmission
shift selector. The transmission will shift to fifth
gear and deactivate the lockup clutch. Apply
the parking brake and release the foot pedal.
4. Accelerate the engine to full throttle and,
using a tachometer of known accuracy, note
the maximum rev/min the engine will attain.
Converter-out pressure should be 2 bar (30
lbf/in).
Note: The stall speed of each vehicle is noted
on the final inspection records prior to the
vehicle leaving the factory. This can be used
as a guide when checking the stall speed. It
is recommended to keep a record of the stall
speed after each major service and use the
previous recorded value as a guide.
5. When the stall check is complete, return the
accelerator to the idle position and move the
shift selector to the neutral position.
Note: Engine power will decrease with an
increase in elevation (altitude), becoming more
Service Manual 6-13

pronounced at greater elevation. This will

result in a lower engine speed under converter
stall conditions.
6. During the stall check the transmission oil
temperature should rise while the engine is
under load and drop when the transmission is
returned to neutral. Should the temperature
fail to drop it indicates that there is a problem
with the converter.
7. After making allowances for elevation, a low
engine speed may indicate the engine is not
delivering full power. Refer to engine service
manual for engine repair information.
Electrical troubleshooting
Refer to troubleshooting manual TS3353 for
commercial electronic controls 2(CEC2) of
Allison transmission.
Mechanical troubleshooting
It is recommended to follow the procedures
laid down for mechanical troubleshooting, as
outlined in the 'Mechanical Trouble Shooting'
charts.
Special tools
There are no special tools required for the
Section 38.3, 'Service tools' for part numbers
of service tools which should be used in
conjunction with procedures outlined in the
transmission manufacturers service manual,
and, general service tools and adhesives
required.
6-14 Service Manual

Problem Cause Remedy

High or low oil level Restore proper oil level
Aerated (foaming) oil Refer to condition 'B'
Truck overloaded Reduce load
Engine coolant overheated Correct engine overheating
Transmission oil cooler or Clean or replace oil cooler or lines
Low coolant level Add coolant, check for leaks
Oil leaking Check transmission and lines for leaks
A - Transmission overheats
Low main pressure Refer to condition 'V'
Low converter-out pressure Refer to condition 'U'
Truck brakes dragging Check parking and service brakes
To r q u e c o n v e r t e r s t a t o r Check for low top speed of vehicle.
locked Check torque converter components.
Overhaul transmission. Replace worn
Clutch slipping
piston seal rings or clutch plates.
Change oil. Use only oil specified

Incorrect type of oil used in Section 36.1, Lubrication and
Maintenance.
B - Oil is aerated (foaming) High or low oil level Restore proper oil level
Air entering suction side of
Check oil pump bolts and gasket
oil pump
Water in oil Check for source, clean system
Completely disassemble, clean and
C - Heavy metal debris found
Transmission internal failure repair in oil transmission. Replace filters
in oil
and clean lines and oil cooler.
Completely disassemble and thoroughly

clean transmission. Replace all friction
Tr a n s m i s s i o n o i l c o o l e r
D - Coolant found in oil faced clutch plates. Repair or replace oil
leaking
cooler. Replace filters and clean external
lines.
Loss of electrical power Refer to Electrical Troubleshooting

E - Transmission will not
Internal mechanical failure Overhaul transmission
operate in any range
Driveline failure Check transmission input and output
regardless of selector
Low oil level Restore proper oil level
position
Service Manual 6-15
F - Transmission continues
in the same forward gear
Loss of electrical power Refer to Electrical Troubleshooting
regardless of selector
position
G - Shifting is erratic Refer to Electrical Troubleshooting
H - Transmission operates
only in first, neutral and Refer to Electrical Troubleshooting
reverse
I I - Tr a n s m i s s i o n s h i f t s
to neutral during reverse
Refer to Electrical Troubleshooting
operation, but will operate
normally in all other ranges
J - Ve h i c l e o p e r a t e s
in reverse and moves
J - Vehicle operates in reverse and
backwards in neutral when
moves backwards in neutral when
engine is accelerated, but Reverse clutch has failed
engine is accelerated, but stalls in all
s ta lls in a ll ot h e r g e a rs (won't release)
other gears when engine is accelerated
when engine is accelerated
- Electrical Troubleshooting OK
- Electrical Troubleshooting
OK
K - Ve h i c l e o p e r a t e s i n
first and second gears and
moves forward in neutral
when engine is accelerated, First and second gear
Overhaul transmission
but stalls in all other gears clutch failed (won't release)
OK
6-16 Service Manual

L - Ve h i c l e o p e r a t e s i n
third and fourth gears and
when engine is accelerated, Third and fourth gear clutch
but stalls in all other gears failed (won't release)
OK
M - Vehicle operates in
fifth and sixth gears and
when engine is accelerated, Fifth and sixth gear clutch
but stalls in all other gears failed (won't release)
OK
N - No power is transmitted Overhaul transmission. Check for worn

Range clutch failed (won't
in any one range - Electrical piston seals, broken piston housing, or
apply, slipping)
Troubleshooting OK worn clutch plates in that range.
O - Vehicle will operate in

Splitter-overdrive clutch
second, fourth, sixth and
won't release or splitter-
reverse gears but will not Overhaul transmission. Check splitter
direct clutch won't apply,
operate in all other gears clutches for worn components.
slipping
-Electrical Troubleshooting
OK
P - Vehicle will operate in

Splitter-direct clutch won't
first, third and fifth gears Overhaul transmission. Check splitter
release or splitter-overdrive
but will not operate in all clutches for worn components.
clutch won't apply, slipping
other gears -Electrical
Troubleshooting OK
Low oil level Add oil to proper level

Foaming oil Refer to condition 'B'
Q - Slow clutch engagement
Worn piston seals Overhaul transmission
Service Manual 6-17

Engine malfunction Check engine. Refer to engine service

manual.
Aerated oil Refer to condition 'B'
Low engine speed at
Refer to condition 'T'
converter stall
R - Vehicle lacks power and High engine speed at
Refer to condition 'S'
acceleration converter stall
Hydraulic retarder partially
Check retarder linkage
applied
Truck brakes dragging Check parking and service brakes
Stator freewheel clutch
failed
Low converter-out pressure Refer to condition 'U'
High oil temperature
S - High engine speed at Refer to condition 'A'
(above 135 C; 275 F)
converter stall
Clutch slipping, main Overhaul transmission. Replace clutch
pressure normal piston seal rings or clutch plates.
Low engine output torque Tune engine and check output
T - Low engine speed at Converter element Check for noise at stall; overhaul
converter stall interference converter if necessary
Transmission oil not up to Warm up transmission to 82 C -
operating temperature 103 C (180 F - 220 F)
Oil line leakage (oil cooler
Check for leaks, correct as required
or filter)
U - Low converter-out
Plugged oil strainer Clean oil strainer
pressure
Defective oil pump Rebuild/replace oil pump assembly
High oil temperature Refer to condition 'A'
6-18 Service Manual


Check all external points for leaks;
Leaks in hydraulic system check each range for localizing internal
leaks
Failure in pressure
Overhaul valve assembly
V - Low main pressure regulator
Worn input oil pump
Rebuild/replace pump assembly
assembly
Clogged oil strainer Clean oil strainer
Air leaks at suction side of
Check input pump, correct as required
input pump
W - Downshift of
transmission is permitted Refer to Electrical Troubleshooting
during lockup operation
X - Shift quadrant not

Failed light bulb Replace the light bulb
illuminated
Y - Reverse signal not
Refer to Electrical Troubleshooting
energized
Special torque specifications for transmission

and mounting
Torque
FIG. NO. No. Name
Ib. Ft
1 10 Bolt 507~557 373~410
1 17 Bolt 790~860 582~633
1 23 Bolt 217~240 160~177
Flange
1 2 1300 958
Nut
Service Manual 6-19

6.2 Transmission retarder control
2 3
4 5
6 3
7
8 9 10
11
12 13
14
Fig.1 Transmission retarder control
1. Linear actuator 8. Washer

2. Nut 9. Plate
3. Washer 10. Nut
4. Washer 11. Bolt
5. Bolt 12. Washer
6. Bolt 13. Washer
7. Bolt 14. Fixed plate
6-20 Service Manual

Overview
Retarder control is the term used for applying
a continuous braking force to hold the truck
to a safe steady speed when descending
grades. The truck fitted with disc brake and
transmission retarders, introduce transmission
retarder in this section.
Transmission retarder control is compose of
linear actuator (1), fixed plate (14) and plate
(9). Retarder control switch is installed on the
centre console of the operator.
If operating retarder brake during truck
operation, pushing the control switch. The
linear actuator (1) will drive plate (9) and
transmission retarder pole upwards, open
transmission retarder for hydraulic retarder.
Removal
WARNING
The retarder may be used anytime to slow
down. If additional braking is required
apply the service brakes. The retarder is
not meant for bringing the truck to a halt,
or for sudden deceleration - the service
br a k e s s hould be e m ploy e d f o r t h i s
purpose. Retarder control can not last for
more 3 minutes.

engine.
2. Block all road wheels. Set the battery in the
' off ' position.
3. Disconnect wiring harness attached to linear
actuator(1).
4. Remove bolt (6, 7), washer (3, 8), nut (2,10)
and remove plate (9).
5. Remove bolt (5), washer (3, 4), nut (2)
securing linear actuator (1) to fixed plate (14),
remove linear actuator (1).
Service Manual 6-21

6. Remove bolt (11) and washer (12,13)

securing fixed plate (14) to transmission,
remove fixed plate (14).
Installation
Note:Tighten all fasteners without special
torques specified to standard torques.
WARNING
damage, be sure wheel blocks are properly
job safely.
1. Secure fixed plate (14) to transmission with

bolts (11) and washers (12,13).
2. Secure linear actuator (1) to fixed plate (14)
with bolts (5), washers (3,4) and nuts (2).
3. Secure plate (9) to fixed plate (14) and
transmission retarder pole with bolts (6,7) ,
washers (3,8) and nuts (2,10).
4. Connect wiring harness attached to linear
actuator(1).
5. Set the battery in the 'on' position. Start
the engine and make an operational check of
retarder.
6. Ensure parking brake is applied. Remove
wheel blocks from all road wheels.
Special tools
Section 38.3, ' Service Tools '.
6-22 Service Manual

SRT95C Off-Highway Truck Fender And Platform Mounting
7 FENDER AND PLATFORM

MOUNTING
7.1 Installation of Fender And
Platform
17 16 15
18
14
13
4
2
12
8
7
5 11
9
6
10
Fig.1 Fender and platform mounting
1.Right-hand mudguard assembly 7.Fire extinguisher and bracket 13.Down tail mirror and bracket
2.Rubber plate 8.Front handrail assembly 14.Rear view mirror and bracket
3.Right-hand handrail assembly 9.Armrest assembly 15.Left-hand guardrail assembly
4.Rear view mirror and bracket 10.Step assembly 16.Rubber plate
5.Platform assembly 11.Armrest assembly 17.Left-hand mudguard assembly
6.Ladder assembly 12.Walkway assembly 18.Battery box assembly
Service Manual 7-1

Fender And Platform Mounting SRT95C Off-Highway Truck
Overview
The covering parts are installed on the left and
right front support, bumper, ring beam and
extension beam of frame. The cab is above
them. Wherein, the platform is regarded as
a component. It is the protective fence for
individual components of hydraulic system and
electrical system and protects the components
from being contaminated and damaged during
transportation. The platform and guardrails
provide the passage and safety protection for
the persons.
Removal
To remove any of the components shown in
Fig.1&Fig.2 the following procedures should
be carried out.
engine.
steering circuit.
3. Remove the body or lift up the body to the
highest position and correctly fix it.
4. Attach a suitable lifting device to the
component and remove mounting hardware.
Remove the component from the vehicle.
warning
7-2 Service Manual

SRT95C Off-Highway Truck Fender And Platform Mounting
Installation
Using a suitable lifting device, align the
component to be installed in position on the
frame. Secure the component securely to the
removal.
warning
Inspection and maintenance

1. The vibration of mudguard support is
relatively high. It requires frequent inspection.
Observe the position of mounting hole for the
cracks.
2. When the rear mirror and down view mirror
are installed, the operator should sit inside the
cab and command the installation persons to
operate so that the correct mounting angle can
be ensured. The components should be gently
handled and placed to prevent the collision
and breakage.
3. As the truck body has the relativy high width
and height, the operator should observe the
situations of rear mirror and down view mirror
at first before driving the truck every time in
order to prevent accidents.
4. The mounting bolts of handrail should be
frequently inspected for their tightening to
ensure personal safety.
5. Check all components for abrasion. If
necessary, repair or replace them in time.
Installation instructions and notices for the

gas spring in the platform assembly
1. The piston rod of gas spring must be
installed in the downward position and no
reverse installation is allowed, so that it can
Service Manual 7-3

Fender And Platform Mounting SRT95C Off-Highway Truck
reduce the friction and ensure the optimal

damping quality and buffering performance.
2. The gas spring should not be subject to the
force in the lateral direction or be used as the
armrest.
3. To ensure the reliability of seal, dont
damage the surface of piston rod. It is
prohibited to apply the paint, chemical
substance and etc. onto the piston rod. It is
prohibited to spray and apply the paint after
the gas spring is installed in the desired
position in advance.
4. The gas spring is a high-pressure product.
It is prohibited to dissect, bake and knock it at
random.
5. It is prohibited to turn the piston rod of gas
spring to the left. If it is required to adjust the
orientation of joint, it can be turned to the right
only.
6. The junction point should allow the flexible
rotation and have no seizure phenomenon.
7. The selected dimension should be
reasonable. The value of force should be
proper. The stroke dimension of piston rod
should have the margin of 10mm.
7-4 Service Manual

SRT95C Off-Highway Truck Cab Accessories
8. CAB ACCESSORIES
11 12 13 14 15

10

9
2
8
7 3
4
5 4
4
3
4
6
Fig.1 Cab accessories
1. Fixing of cab accessories 6. Bolt 11. Handle gear shifter

2. Bolt 7. Cushion 12. Nut
3.Cushion 8. Washer 13. Washer
4.Absorber 9. Washer 14. Washer
5. Washer 10. Bolt 15. Bolt
Service Manual 8-1

Cab Accessories SRT95C Off-Highway Truck
Overview
Number in parentheses refer to Fig.1.
Install the damper on the fixed seat of
drivers cab symmetrically from top to bottom;
then fasten the absorber (4), fixing of cab
accessories (1) and the fixed seat of drivers
cab with high-strength bolts(6) into a whole.
Disassembly
See Fig1 for the numbers in brackets.
Note: Mark and identify all removed cables,
wire harnesses, pipelines and tubes to
facilitate the installation, adopt dustproof
measure to protect tie-in.
1. Park the truck in a flat work area, lift up
the body and install the body safety pin. See
chapter Body and Installation.
2. Apply parking braking and shut down
engine.
3. Rotate steering wheel to the two directions
for several turns and release steering system
pressure. Press foot valve continuously
to release pressure of brake accumulator.
Continuously operate the lift control handle to
release pressure of accumulator and chock
wheels properly.
4. Disconnect electric cables in the following
order so as to prevent electric components
from being damaged.
a. Disconnect the grounding cable of battery
compensator.
b. Disconnect battery cable from terminal
posts (grounding cable firstly).
c. Disconnect anode battery cable
compensator.
d. Disconnect electric contacts of ECU.
5. Disconnect the remaining electric contacts
connected to drivers cab assembly.
6. Carefully loosen brake pipelines on two
brake accumulator seats to check whether the
brake pressure is released; re-tighten brake
pipelines.
7. Make sure to mark all steering and brake
pipelines connected to the drivers cab so as
8-2 Service Manual

to facilitate installation; collect leaking oil with

proper vessels, disconnect all pipelines and
plug all opened pipelines and connectors.
8. If an air conditioner is equipped, evacuate
the system before disconnecting air
conditioning pipelines, and plug all opened
pipelines and connectors. See Chapter AIR
CONDITIONING PIPELINE INSTALLATION.
9. Make sure to mark heater pipelines; collect
leakage with proper vessels, disconnect
heater pipelines and plug all opened pipelines
and connectors.
10. Make sure to mark body lifting control
handle so as to facilitate installation; collect
leakage with proper vessels, disconnect hoses
on the multi-way board of drivers cab bottom
board and plug all opened pipelines and
connectors.
11 . M a k e s u r e t h a t a l l t h e c o n n e c t o r s
connected to driver s cab assembly are
removed before disassembly.
12. Suspend driver s cab assembly with
proper lifting device and straighten loosened
parts; remove absorber (4), cushion (3)
washer (5) and bolt (26) of supporting beam
of drivers cab assembly.
Note: For disassembly of drivers cab
assembly, special lifting device and lever
with pad should be used to prevent over-
concentrated stress of hook, chain and wire
rope at hook-on points of drivers cab.
13. Carefully lift drivers cab assembly to a
proper working platform.
14. Loosen the bolt (10), washer (89), take
off the cushion (7).
15. Loosen the bolt (15), washer (1314) and
nut (12), take off the handle gear shifter (11).
Installation
Note: Tighten all fasteners according to
Section TECHNICAL CONDITIONS FOR
TIGHTENING TORQUES OF STANDARD
BOLTS AND NUTS in the manual.
Note: According to the descriptions of
Service Manual 8-3

Schematic diagram of brake in the manual,

tighten all of the hydraulic pipelines equipped
with the O-ring end face seal port and replace
the O-rings.
1. Install the handle gear shifter (11), tighten
the bolt (15), washer (1314) and nut (12).
2. Install the cushion (7), tighten the bolt (10),
washer (89).
3. Check whether the rubber pad is damaged.
If it is damaged, replace it. To install the new
rubber pad, use the water or proper lubricant
to lubricate it and then install it onto the
driver's cab assembly. Use the screwdriver to
get the rubber pad completely in position.
4. Use a proper hoisting device to place the
driver's cab assembly onto the drivers cab
supporting beam. Care must be taken to
prevent the pipelines and components from
interfering with the lower side of driver's cab
assembly.
5. Use absorber (4), cushion (3) washer
(5) and bolt (26) to fix parts assembly of
Cab(1) on the supporting beam of drivers cab
assembly.
6. Remove plug from lifting control handle
pipeline; connect pipeline according to signs
made upon removal and fix all pipelines
properly.
7. Remove the plug from brake steering
pipeline; connect pipeline according to signs
made upon removal and fix all pipelines
properly.
8. Except for battery cable, battery
compensator cable and EUC connector,
connect all electric connectors according to
signs made upon removal.
9. Remove plug from heating pipeline and
connector; connect pipeline according to
signs made upon removal and tighten heating
pipelines properly.
10. If an air conditioner is equipped on the
truck, connect pipeline to evaporator and refill
system.
11. Connect electric connectors in the
8-4 Service Manual

following order:
a. Connect electric connectors removed from
ECU.
b. Connect anode battery cable compensator.
c. Connect battery cable to the terminal posts
(priority is given to anode cable).
d. Connect the grounding cable of battery
compensator.
12. Check drivers cab assembly to ensure
that all pipelines and cable harnesses have
been reconnected after being removed.
13. Refill the two hydraulic oil tanks with
oil according to stipulations in section
LUBRICATION AND MAINTENANCE. Check
the coolant level in the overhead water tank of
radiator. If it is low, then add the coolant. See
section LUBRICATION AND MAINTENANCE.
14. Start engine, check for leakage,
tighten pipeline and joints according to
the requirements, heat truck up to normal
operation temperature and check all
connections for leakage.
15. Check whether all instruments and control
elements operate normally. Remove the body
safety pin and lower down the body.
Service Manual 8-5

8.1 Parts Assembly of Cab
10
9
7
6
5
3
2
Fig.2 Cab assembly
1. Steering column mounting 6. Washer

2. Throttle controller assembly 7. Bolt
3. Cab harness 8. Seat mounting assembly
4. Evaporator assembly 9. Switch and meter
5. Washer 10. Control panel of air conditioning
8-6 Service Manual

Overview
Parts assembly of cab complies with safety
rules as stipulated in ISO/SAE FOPS (falling
object protective structure) and ROPS (rollover
protective structures). Parts assembly of cab
is accessible from two sides of the truck, with
light-colored glass and a good view. The air
conditioner is installed as standard on the
driver's cab assembly. See Chapter AIR
CONDITIONING PIPELINE INSTALLATION.
Disassembly
Note: Mark and identify all removed cables,
wire harnesses, pipelines and tubes to
facilitate the installation.
1. Ensure parts assembly of cab is placed on
a proper working platform which is stable and
free of vibration.
2. Use a proper tool to dismantle the driver's
seat and co-driver's seat as well as the base.
See the installation of seat base.
3. Use the wrench to remove the flat washer
(5), washer (6) and bolt (7) fixing the
evaporator. Disconnect the cables and wire
harnesses connected to the evaporator, and
classify and place them into the storage box.
4. Disconnect the pipelines and p i p e s
connected to the evaporator,
and synchronously make the marks properly.
Plug all open pipelines and joints.
5. Place all removed objects in a visible place
to facilitate the succeeding installation.
Installation
Note:Tighten all fasteners to standard
torques listed in Section 36.2, TECHNICAL
CONDITIONS FOR BOLTS AND NUTS.
1. Use a proper tool to install the driver's seat
and co-driver's seat as well as the base. See
the installation of seat base.
2. Use the wrench to tighten the flat washer
(5), spring washer (6) and bolt (7) fixing the
evaporator. Connect the cables and wire
Service Manual 8-7

harnesses correctly according to the marks.

3. Connect all pipelines and tubes to
evaporator in the order as marked.
8-8 Service Manual

8.1.1 Body of cab
Fig.3 Body of cab
1. Body of cab welding 3. Door assembly

2. Rear window glass 4. Front windshield glass
Service Manual 8-9

Door assembly
Descriptions
The door assembly has the welded steel plate
structure and the hinge connection in its rear
part. The window glass is divided into the
front and rear parts. Door limiter can prevent
excessive swing of door. The door assembly
can be removed as an assembly from inside
the drivers cab. But the lock, handle, glass
and etc. can be separately removed when the
door is connected onto the cab.
Disassembly and installation

1. Open the door assembly and use a proper
hoisting device to hoist it. Remove the cover
and splint pin from the hinge. Use a proper
screw driver to remove the pin from the hinge.
Remove the door assembly from the driver's
cab assembly.
2. Install the new plug-pin onto the hinge.
3. Use the proper hoisting device to hoist the
door assembly. Align the door assembly with
the hinge of drivers cab. To install the pin,
perform the alignment with the hole and use
the splint pin for the fixation.
4. Check whether the door assembly (3)
is installed correctly and whether the lock
function is normal.
Replace front windshield glass

AttentionBefore replacing the broken glass,
must be sure the glass accord with rule of low,
replace front windshield glass as following
method.
AttentionBefore eliminate glass glue, front
windshield glass must be fixed.
1. Fixed front windshield glass with magnet,
eliminate glass glue by cutter, disassemble
front windshield glass.
2. Lay on the special glue on the edge of glass
and window frame.
8-10 Service Manual

3. Defend the edge of window frame by paper

tape.
4. Lay on the glass glue on the window frame.
5. Adjust the clearance of glass and double
side of window framefix up the glass.
6. Scrape glass glue between glass and frame
averagely.
7. Fill in the clearance between glass and the
double side of window frame with glass glue.
8. Eliminate the dirty glass glue.
AttentionThe thickness of glass glue should
exceed 8~10mm. In winterthe glass glue
must be roasted to 35~40 which the time
of calefaction is 6~8 hours, when replaced the
glass, the car must be stayed over 24 hours.
Replace rear window glass

must be sure the glass accord with rule of
low, replace rear window glass as following
method.
AttentionBefore eliminate glass glue, rear
window glass must be fixed.
must be sure the glass accord with rule of
low, replace rear window glass as following
method.
AttentionBefore eliminate glass glue, rear
window glass must be fixed.
1. Fixed rear window glass with magnet,
eliminate glass glue by cutter, disassemble
front windshield glass.
2. Lay on the special glue on the edge of glass
and window frame.
3. Defend the edge of window frame by paper
tape.
4. Lay on the glass glue on the window frame.
5. Adjust the clearance of glass and double
side of window framefix up the glass.
6. Scrape glass glue between glass and frame
averagely.
7. Fill in the clearance between glass and the
double side of window frame with glass glue.
Service Manual 8-11

8. Eliminate the dirty glass glue.
Detection of water leakage

It is required make detection over water
leakage after glass is mounted. Spray water
onto the sealing position from outside drivers
cab. An assistant should mark where leakage
occurs inside drivers cab. Apply sealant from
outside and start from the leakage outwards.
Spread sealant on the surrounding area of
leakage.
8-12 Service Manual

8.1.2 Seat mounting assembly
10
1
3
4
4
3
8
5
9 7 4
6
3
Fig.4 Seat Mounting Assembly
1. Mechanic suspension seat 6. Bolt

2. Nut 7. Right connecting board
3.Washer 8. Bolt
4. Washer 9. Bolt
5. Left connecting board 10. Passenger seat
Service Manual 8-13

Overview
Fix drivers seat onto the cabs bottom board
with bolt (8), washer (34) and nut (2). The
seat assembly is mounted onto the seat
support with a resilient cushion and back
cushion; and the seat frame is mounted onto
the bracket of drivers seat in an air-borne
manner. One adjustable 2-point type safety
belt is configured and it is fixed onto the seat
assembly.
Caution: This seat can automatically adjust
the rigidity of suspension mechanism in
accordance with the weight of driver through
the sensor on the seat so as to adapt seat to
the weight of driver.
1. The caster angle of seat back is controlled
through the backrest adjusting handle and can
be adjusted at the drivers will.
2. The seat can be raised by 30mm when you
hear a "click" sound, and another 30mm at
the second "click". Move the backrest to an
optimum position at where operation can be
easily conducted, and release the handle.
3. Pull up the seat can adjust height, there are
three levels(lowmiddlehigh), when the
seat is on high level, if pull up the seat, it will
return low level.
4. To move the seat forwards and backwards,
pull the front and back adjusting handles
to move seat to the required position. The
drivers seat is not equipped with a suspension
mechanism, so its height cannot be adjusted.
However, the front and back positions as well
as the angle of backrest can be adjusted in the
same way as drivers seat.

1. Park the truck in a flat working area, apply
parking brake and shut down the engine.
2. Rotate the steering wheel left and right for
several turns respectively and release the
pressure in the steering system. Chock all
wheels properly.
8-14 Service Manual

3. Use the proper lifting equipment. Properly

tie the seat. Take down the flat washer (1),
spring (2) and bolt (4) fixed on the drivers cab
bottom board. Move the whole seat assembly
out of the truck.
4. Loosen all bolts and locking gaskets with
fixed safety belts and take off the safety belts.
5. If necessary, remove the rubber cover to
expose the seat suspension frame assembly
and height adjuster.
Inspection
Check all brackets and frame for cracks and/
or damage. Repair or replace as necessary.

torques specified to torques listed in Section
36.2, STANDARD BOLT AND NUT TORQUE
SPECIFICATIONS.
1. In case the protective cover has been
removed, first install it onto the bottom of
seat so as to make it cover suspension frame
assembly and height adjuster completely.
2. Connect the drivers seat, co-drivers seat
and seat bracket with bolts and gaskets
removed during disassembly.
3. Fasten the safety belt onto the seat with
bolt and locking gasket in the same way as
disassembly.
4. Place the seat on the floor of drivers cab
with a proper lifting device and fixed it with bolt
and gasket.
Maintenance
Add a bit lubricant onto such moving
components as suspension frame assembly
and height adjuster at regular intervals.
The driver should inspect the safety belt on
schedule. If the mounting parts get worn or
broken, belt get notched or abraded, lock fails,
the connector gets loosened, or the safety belt
gets aged, they should be replaced timely.
Service Manual 8-15

Note: Due to aging, the safety belt should be

replaced at least once three years regardless
of external appearance.
8-16 Service Manual

8.1.3 Steering column mounting

assembly
Fig.5 Steering column mounting assembly
1. Steering Gear B. Steering column body

2. Screw C. Lower rubber sheath
3. Washer D. Steering spline shaft assembly
4. Washer E. Mounting bracket
5. Nut F. Combination switch
6. Bolt G. Height adjusting knob of Steering column
A.Steering wheel H. Tilt angle adjusting knob of Steering column
Service Manual 8-17

Overview
The steering column (1) is fixed onto the
drivers cab bottom board by using the bolt (6),
washer (3) and lockwasher(4). The steering
column (1) consists of the steering wheel
(A), steering column body (B), lower rubber
sheath (C), steering spline shaft assembly
(D), mounting support (E), combined switch
(F), steering column height adjusting knob(G),
steering column tilt angle adjusting knob (H)
and the connecting pieces.
Caution: The driver can adjust height and
tilt angle of the steering column by the two
buttons.
1. The driver can adjust the height of steering
column by 50mm via the height adjusting
button of steering column.
2. With the steering column tilt angle adjusting
button, the driver can perform the 14 tilting
adjustment on the steering column.

1. Park the truck in a proper way.
2. Remove the bolt (6), washer (3) and
lockwasher (4) fixing the steering column base
seat.
3. Unscrew all of the bolt (6), washer (3),
spring lockwasher (4) and nut (5) fixing the
base seat.
4. Remove the line plug connectors of steering
column, and remove the steering column
assembly from the bottom board of drivers
cab.
5. Loosen all fastening screws and gaskets of
lower rubber sheath (C) and steering spline
shaft assembly (D). Remove the clamping bolt
inside lower rubber sheath connecting to the
lower universal joint and steering spline shaft
assembly. Take out the lower rubber sheath.
6. If necessary, the lower rubber sheath
(C) can also be dismantled to expose the
8-18 Service Manual

telescopic link of steering column so as to

facilitate further disassembly.
Inspection
Check whether all connections are reliable
and whether any damage occurs to lines, shell
protective cover and lower rubber sheath.
Repair or replace it timely if any.

Caution: Tighten all fasteners to reach the

standard torque according to sectionTechnical
Conditions for Tightening Torques of Standard
Bolts and Nuts in the manual.
1. If the lower rubber sheath (C) has been
removed, then install the lower rubber sheath
onto the steering column body (B) at first.
2. Use the bolt and washer removed during
the dismantling to properly connect the lower
universal joint and the steering spline shaft
assembly (D).
3. Properly connect the upper end of lower
rubber sheath (C) and the steering column
body (B). Then install all screws and washers
for fixing the lower rubber sheath (C) and the
steering spline shaft assembly (D). It is the
same as the removing process.
4. Properly connect the steering spline shaft
assembly and the steering column. Tighten the
bolt (6), washer (2) and lockwasher (3) so that
the steering gear is fixed inside the drivers
cab.
5. Install and tighten the bolt (6), washer (3),
lockwasher (4) and nut (5).
Maintenance
Add lubricant onto the butter mouth of
universal joint at regular interval.
Service Manual 8-19

8.1.4 Accelerograph controller

mounting assembly
Overview
The accelerator pedal is secured to the cab
floor with bolts(2), washers(3), lockwashers(4)
and nuts (5). When the operator operates, the
following points should be noticed:
1. Function of accelerograph: Changing both
the rotational speed and the output power and
torque of engine synchronously. Accelerator
pedal is the operating device of the engine
oil supply system. The rotational speed of
the engine may be altered when the pedal is
1
pressed down and released.
2. The SRT95C mining dump truck adopts
the electronic accelerator control system
which mostly consists of the accelerator 2
pedal, pedal displacement sensor (sliding
rheostat), ECM (electronic control module), 3
data bus, servo motor and air throttle actuator.
The displacement sensor is installed inside 4
the accelerator pedal and it monitors the
position of accelerator pedal at any time. 5
When it is monitored that the height position of Fig.6 Accelerograph controller assembly
accelerator pedal is changed, this information
will be transmitted instantaneously to ECM. 1. Accelerograph controller 4. Lockwasher
ECM will perform the operation processing
2. Bolt 5. Nut
on this information and the data information
3. Washer
transmitted from other systems and work out a
control signal. This signal will be transmitted to
the servo motor relay via the circuit. The servo
motor will drive the air throttle actuator. The
data bus is responsible for the communication
between the system ECM and the other ECU
(electronic control unit).
3. For the fuel addition, if it is felt that the
accelerograph doesnt make a reaction as fast
as its usual performance or that the engine
lacks the power, check the spark cover, fuel
injection nozzle and air throttle to see whether
it is necessary to replace the spark cover or
clean the air throttle and fuel injection nozzle.
4. In the case that the accelerograph doesnt
8-20 Service Manual

work when it is pressed down during the

traveling, then it is normal all the time after the
truck is stopped and filled with the fuel, and
the above-mentioned fault occurs again after
the truck runs for a period, the following points
of fault causes may exist: the pressure of fuel
pump is insufficient and the air lock occurs
after the truck warms up, or the filter element
is dirty and it leads to insufficient fuel supply;
or the ignition energy is insufficient after the
coil is heated; the measurement signal of
valve sensor or air intake pressure sensor
is incorrect and it leads to the abnormal fuel
injection pulse; the fuel filter is dirty and it
leads to insufficient fuel injection or no fuel
injection during the fuel supply.

ensure the body is fully lowered, apply the
2. Remove mounting bolts (2), washers(3),
lockwashers(4) and nuts(5) securing
accelerograph controller base.
3. Disconnect wiring harness from the
accelerator pedal. Remove accelerator pedal
from cab floor.
Inspection
Check all brackets and frame for cracks and/
or damage. Repair or replace as necessary.

torques specified to torques listed in Section
36.2, STANDARD BOLT AND NUT TORQUE
SPECIFICATIONS.
1. Connect wiring harness.
2. Position pedal assembly on cab floor and
secure with bolts (2), washers(3) lockwashers
(4) and nuts(5).
Service Manual 8-21

8.1.5 Evaporator assembly
3
4
Fig.6 Evaporator assembly
1. Evaporator assembly 3. Washer

2. Bolt 4. Washer
8-22 Service Manual

Overview
Evaporator serves to make gas-liquid two-
phase coolant after reducing pressure by
regulating flow evaporate and gasify into
coolant vapor through absorbing the heat of
air which flows over the surface of evaporator,
so as to reduce the temperature of the air and
thus realize the goal of cooling.
Caution:
1. After the evaporator assembly is installed,
the barrier is present at the air intake and
return ports, and the unsmooth air intake and
return lead to the low air flow and insufficient
refrigeration.
2. Evaporator assembly is not installed firmly
and thus shakes in the later period, further
leading to leakage of air and condensate
water.
3. Evaporator assembly is not properly
grounded and the system does not operate.
4 . Tw i s t i n g o r b l o c k a g e o c c u r s t o t h e
blast pipeline connected to the air port of
evaporator, and this results in low air volume
and insufficient refrigeration.

Park the truck in a proper way.
Before dismantling evaporator assembly,
make sure that the water valve at the water
inlet tube of evaporator assembly is closed.
Remove all line plug connectors of evaporator
assembly and mark them successively.
Remove the throat collars at all air outlets of
evaporator assembly, and mark all removed air
ducts. Remove the throat collars for two water
pipes of evaporator assembly. After these two
water pipes are marked respectively, separate
these two water pipes from the evaporator
assembly. Caution: a small amount of engine
coolant will flow from the heating core of
evaporator during this process.
Generally, it isnt recommended to dismantle
the storage-rubber pipe components and
Service Manual 8-23

steam-pressure rubber pipe components

connected to the evaporator assembly.
Otherwise, cold coal inside air conditioning
system will leak out. If storage-rubber pipe
components and steam-pressure rubber
pipe components need to be disassembled,
they should be marked properly. Two rubber
pipes should be plugged promptly with choke
plug after dismantling so as to prevent air
conditioning system from contamination.
Completely remove the bolt (2) and washers
(34) fixing the evaporator assembly onto
the drivers cab bottom. Meanwhile, remove
two flow hoses on the bottom of evaporator
assembly. If necessary, evaporator can be
further disassembled.
Detection
Check whether all connections are reliable
and whether any damage occurs to lines and
pipelines. Repair or replace it timely if any.

Caution:Tighten all the fasteners to the
standard torque according to section
'TECHNICAL CONDITIONS FOR
TIGHTENING TORQUES OF STANDARD
BOLTS AND NUTS' of the manual.
Install two removed flow hoses onto
c o rresponding positions of evapora t o r
assembly and fasten them with throat collar.
Fix the evaporator assembly onto the
corresponding positions of the bottom of the
drivers cab with bolt (2) and gaskets (3, 4).
Install and restore all line plug connectors
disassembled to the designated positions
according to signs made during disassembly.
Install the two disassembled water pipes to
corresponding connectors according to signs
and fasten them with throat collar.
Install all disassembled blast pipes to
corresponding air port according to signs and
fasten them with throat collar.
8-24 Service Manual

In case the storage-rubber pipe components

and steam-pressure rubber pipe components
are both disassembled, install them to the
corresponding connectors according to signs
and fill cold coal according to stipulations after
evaporator assembly is installed completely.
Maintenance
Harnesses of evaporator assembly, blast
pipe throat collar, water intake tube and water
return tube throat collar as well as mounting
bolts of evaporator assembly should be
checked for looseness at regular intervals.
Service Manual 8-25

8.1.6 Harness of cab
Descriptions
The harness of cab refers to the wiring
components of individual electrical
components and control cabinets in the cab.
It consists of the insulation shields, terminals,
wire, and insulation wrapping material. To
facilitate the installation and maintenance and
ensure the operation of electrical equipments
in the worst conditions, integrate the wire with
different specifications and colors used by
individual electrical equipments in the whole
truck by properly arranging them, and use
the insulation material to bundle the wire to
the harness. In such a way, it achieves the
integrity and reliability. The rear part of cab
harness is connected to the control board via
the 31-pin and 32-pin electrical connections
and its front part is connected to various
electrical components in the cab via various
connectors.
Removal and Installation

The harness of cab is installed on the bottom
of cab. It enters the cab via the front and
rear wear wallboards. It is fixed and installed
by using the wire clamps and cable ties. To
dismantle the harness of cab, remove the 31-
pin and 32-pin connectors connected to the
control cabinet in the rear part of harness at
first. Then remove the connectors connected
to various electrical components in the front
part. Subsequently, remove the front and rear
wear wallboards, wire clamps and cable ties.
Then, the harness of cab can be removed at
the moment.
Installing new cab harness type should be
consistent with the original model. The wire
terminal and the wire should be reliably
connected. Individual connectors and the can
be gently pulled by hands to check them for
looseness and disengaging. Compare the
new harness with the original harness. For
8-26 Service Manual

example, the dimension, connectors, wire

marking and etc. of wire harnesses should be
consistent. Any suspicious point can be tested
with the multimeter. The replacement can be
performed only after it is confirmed that the
harness is intact. The connectors, covers and
sockets of individual electrical equipments
should correspond to the sockets and covers
on the harness. After the individual wires
are connected to the electrical components,
a certain margin should be reserved, not
tensioned or slackened.
For the inspection and connection test
of circuits, after the harness is replaced
completely, check whether the connectors and
electrical components are connected correctly
at first.
Service Manual 8-27

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........................................................................................................................................
E
........................................................................................................................................
G
........................................................................................................................................
PA
........................................................................................................................................
........................................................................................................................................
........................................................................................................................................
........................................................................................................................................
K
........................................................................................................................................
N
........................................................................................................................................
LA
........................................................................................................................................
........................................................................................................................................
........................................................................................................................................
B
........................................................................................................................................
........................................................................................................................................
........................................................................................................................................
........................................................................................................................................
........................................................................................................................................
........................................................................................................................................
........................................................................................................................................
........................................................................................................................................
........................................................................................................................................
8-28 Service Manual
8.1.7 Switches and instruments
Operating equipment and control panel
cab coping lamp
9 10
22 23 24 25 26 27 28 29
11 12 13
8
14 15 16 17 18
MP3 Radio
7 19 20
6
5
4
3 Gear shift lever
2
1 Ignition switch
21
Air conditioner control Colum switch
Fig.1
1. Combination instrument 12. Screw 23. Rocker switch

2. Cigar lighter 13. Plug 35-core 24. Rocker switch
3. Botton of solenoid valve for body stably control 14. Rocker switch frame 25. Rocker switch
4. Emergency stop switch 15. Rocker switch 26. Rocker switch
5. Monitor 16. Switch cover plate 27. Rocker switch
6. Control box 17. Retarder lever 28. Rocker switch
7. 20-meter signal-line 18. Buzzer 29. Rocker switch
8. Through-wallplate assembly 19. Nut middle frame
9. Control plate install 20. Nut
10. Central distribution case 21. Body control lever
11. GPS 22. Rocker switch
Service Manual 8-29

1 2 3 4 5 6 7 8 9 10 11 12 13
17 16 15 14
Fig.2
Indicator
1. Left steering Indicator (Green) - Flashes
when the left indicator lights are operating.
2. Parking Brake (Red)-Illuminates when the
parking brake is applied.
3. Body up (Yellow) - Illuminates to indicate
that the body is NOT resting on the chassis.
Never move the machine until this light goes
OUT.
4. Retarder Indicator (Yellow) - Illuminates
when the retarder is applied.
5. Side marker lamp (Yellow) - Such lamp will
be on when side marker lamp starts to work.
6. Dipped beam Indicator (Green)-Illuminates
when dipped beam head lamps start to work.
7 High beam Indicator (Blue)-Illuminates when
high beam head lamps start to work.
8. Fog Indicator (Yellow) - Such lamp will be
on when fog lamps start to work.
9.Rear Indicator (white)-
10. Engine Stop Indicator Red) - When the
'Stop' light comes on, the computer has
detected a major malfunction in the engine
8-30 Service Manual

that requires immediate attention.

Stop the machine when this light illuminates
and do not operate until the fault is corrected.
11. Engine Maintenance Indicator ( White)
- Indicates that the engine needs to be
maintained. See Cummins Manual for details
about specific maintenance items.
12. Engine Warning Indicator (Yellow) - When
the 'Warning' light comes on, the computer has
detected a fault in the engine which may result
in a power loss. The fault should be diagnosed
and corrected at the earliest opportunity.
13. Right steering Indicator(Green) - Flashes
when the right indicator lights are operating.
14. Alternator Charging (Red) - Illuminates to
indicate when the alternator is not charging.
15. Transmission Over speed Indicator (red)
- Illuminates when the transmission ECU
senses transmission speed above 2350 rev/
min.
16. In-converter Indicator (Green)- Illuminates
when the transmission is in Torque Converter
drive. It goes OUT when Lockup is engaged.
17. Check Trans Indicator (Red) - Illuminates
to alert of a fault in the transmission shift
system or abnormal transmission temperature.
The light will illuminate when the ignition key
switch is turned to position '1' to provide a bulb
and system check and should go off a few
seconds after the engine is started.
1 2
7 6 5 4 3
Fig.3
Service Manual 8-31

Instrument
1. Tachometer
Driven by CAN bus; it indicates engine speed
in revolutions per minute. When the pointer
is located in white area said speed is normal,
and once the pointer is located in red area
that speed is too high, should reduce speed
immediately.
2. Speedometer SANY MINING EQUIPMENT
Driven by CAN bus; it indicates vehicle
running speed. When the pointer is located in
white area said speed is normal, and once the
Fig.3-1
pointer is located in red area that speed is too
high, should reduce speed immediately.
3. Transmission Oil Temperature Gauge
The pointer indicates transmission oil
temperature value. Such meter is directly
connected to transmission temperature
08-25-2012 15:10:25 Wed
sensor. When the pointer is located in white
area said transmission oil temperature is
SANY Mining Equipment
normal, and once the pointer is located in red Engine
area that transmission oil temperature is too Transmission
high, movement, the buzzer for 10 seconds, Monitor
then shut down automatically. In the electric VEH DIST ENG HRS
XXXXXXkm XXXXX.Xh
power the same fault buzzer action only once.
4. Fuel level gauge
The pointer indicates percent of full tank
a actual fuel level. Such meter is directly Fig.3-2
connected to fuel level sensor. When the
pointer is located in white area said fuel level
is normal, and once the pointer is located in
red area that fuel level is too low, movement,
the buzzer for 10 seconds, then shut down
System Function
automatically. In the electric power the same SANYI
fault buzzer action only once. Engine information Parameters query
5. Display
Parameters setting
Monitoring system
Restore password
1. Turn on power supply, start the key switch Controller I/O
Backlight adjust
System time setting
to, the display shows 'sany' boot screen(see Buzzer time setting Chinese English
Fig.3-1), and all of the signal indicators are

applied, 3 seconds after the display shows F1:ESC F2:Enter F3: F4:
work interface, the lights go out at the same
time.
2. Click F2 key to change from work interface
Fig.3-3
to system function interface, and the work
8-32 Service Manual

interface is default (see Fig.3-2).

3. Enter the system function interface, F1 key
to return, F2 key for confirmation key, the F3 System Time Setting
SANYI
key to move up, and F4 for down key(see

Fig.3-3). 2012Y08M13D
4. Under the system function interface, click 12H30M25S
the F3 key or F4 key to choose the function
and click F2 key to confirm.
Take the case of setting system time to
F1: ESC F2: Enter F3: F4:
demonstrate operation method:
Under the system function interface:
a. Click F3 key or F4 key to choose the
Fig.3-4
number of the time;
b. Click F2 key to confirm, then the cursor will
automatically move to the next number(see
Fig.3-4);
c. When the cursor to the last digit (the second
single digits), click F2 key to confirm the System Time Setting
SANYI
current changes, and then click F2 key again
to end the modify Settings until appear a
square green claim(see Fig.3-5), 2012Y08M13D
12H30M25S
d. Click F1 key to return to the system function
interface.
6. Engine Water Temperature Gauge
Driven by CAN bus; it indicates engine coolant F1: ESC F2: Enter F3: F4:
temperature value. When the pointer is located

in white area said engine coolant temperature
is normal, and once the pointer is located in Fig.3-5
red area that engine coolant temperature is too
high, movement, the buzzer for 10 seconds,
then shut down automatically. In the electric
power the same fault buzzer action only once.
7. Engine Oil Pressure Gauge
Driven by CAN bus; it indicates engine oil
pressure value. When the pointer is located in
white area said engine oil pressure is normal,
and once the pointer is located in red area that
engine oil pressure is too high, movement,
the buzzer for 10 seconds, then shut down
automatically. In the electric power the same
fault buzzer action only once.
Service Manual 8-33

8-34
-01F8
Cab Accessories
60A -01F7
60A
-01F6 30
Fig.4 Switch and Meter

60A B
B6 0114
0108 0112 30A6 30A2 30A3

0104 0111

30A1 -01K3 -01K4
-01S1 1
30A4 30A5
0109 -01K8 0,1 -01K1
87
87
0113
2 3 4
30
30
-01M1 -01M2
S S
B1+ B1+
0116
0132
08.3C
B+ B+ 2023 0115 0106
M M -01KM1
-01H1 337
GND GND
-01F1 Engine lubrication DO_01 -01KM1
XM1.11 -01K5
system
120A 0103 DI_02
307 XM1.5
Service Manual
0101 0102 -01Q1 30
0127
2023
2A -01F9 0125 08.3C
BAT
0105
G -01F3 0140a 0140b
-01G1 GND 2A 20A -01F5
-01F10 2A
-01G2 -01G4 15A -01F4
0118 -01K5
15
0126 -01K4 -01K8
-01K3 0129
-01K1 -01G3 -01G5 5 9
0128
-01S2
-01E1
31A8 1 0
PE
31A4 7 10
PE
31A5
31A11 31A7
X
15A
31A1
10
AX
15
PE 31A6
02.2H
31
31A9
01G1- AC generator 01K1- Generator relay 01KM1- X power contactor

01G2- Battery 01K8- Starter signal relay 01M1- Starter motor
01G3- Battery 01K3- Starter motor relay 1 01M2- Starter motor
01G4- Battery 01K4- Starter motor relay 2 01H1- Room lamp
01G5- Battery 01K5-Body power contactor 01S1- Ignition key switch
01S2- Small lamp switch
Display
Control
box
Camera
11.3F
Terminal
0401
box
31D1
0409
-04F6
10A
-04A1
Fig.5 Circuit Diagram of Video Monitoring System
04A1Vedio monitor system

04F6Vedio monitor system fuse
Service Manual 8-35

XD1
0402b
31D2
-04F1
10A
-04E1
0402a
-04X1
Fig.6 Cigar Lighter Circuit Diagram
04E1Cigar lighter 04F1Cigar lighter fuse0405 04X1Socket
-04H2
15D2
0403
10A
-04F2
31D3
-04A2
0404
-04H1
Fig.7 MP3 & Radio Circuit Diagram
04A2MP3 & radio 04H1Tweeter

04H2Woofer 04F2MP3 & radio fuse
8-36 Service Manual

air conditioning system

0406
XD2
-04F3
15A
31D4
-04E2
10
Fig.8 Circuit Diagram of Air Conditioning System
04F3Fuse 04E2Air conditioner system
Service Manual 8-37

8-38
30 30
02.12B 06.2B
15 15
04.10B
10 10
03.12B 06.2B
06.7C
Cab Accessories
CANH CANH
08.3E
07.11D
CANL CANL 07.11D
08.3D
A30 A30 06.8C
10E1 -05F3
3A
A30 A30
30E1
0503
-05F1 -05F2 -05P2

5A 5A
0505 0501 3 4 5 6 7 8 9 27 23 24 25 1 2 7 8 12 14 15
Parking Rear lamp Transmission Inside CAN Power Power Regular Regular Engine In-converter
brake indicator overspeed illuminate shield supply supply power power maintenance indicator
indicator indicator Dipped beam supply supply indicator
indicator
Side Transmission Engine
marker overspeed High beam warming
indicator indicator indicator indicator
-05P7 Blue 32 core plug Green 32 core plug

J1_PIN35 J1_PIN5
Service Manual
J1_PIN24
J1_PIN12
J1_PIN9 Body up
Fuel level Brake Engine stop Right steering
sensor accumulator indicator indicator indicator
J1_PIN16 Retarder
signal sensor signal 5V 12V
Steering indicator power Alternator power
GPS Trasmission oil Check
Sensor accumulator temperature Alarm supply charging supply
earth transmission Left steering
sensor signal sensor signal Earth Earth output output indicator output
indicator indicator
J1_PIN11TX 13/26 14 15 16 21 29 30 31 32 10 11 9 10 17 25 26 27

J1_PIN23(RX)

J1_PIN31
0504 0506
Q -05S1 T -05S2
31E1 31
31
06.2H
Fig.9 GPS
05F1GPS fuse 05P2Combination instrument

05F2GPS fuse 05S1Fuel level sensor
05F3Combination instrument fuse 05S2Transmission oil temperature sensor
05P7 GPS
120
shield L H
2 1
D QST30 ECM
C
S13
CEC2 ECU S29
S12
XM4.7
2023 PLC XM4.8
XM4.3
23
Combination
24
instrument
25
J1_PIN35
GPS J1_PIN12
C
Engine 9 core
diagnostic D
interface
E
2 1
120
PE
Fig.10 CAN
Service Manual 8-39

List of Damageable Elements
Relay and type

1 60190151 DC relay JCC400/1C24 48A
2 60190150 DC relay JCC200/1C24 48A
Lights and Models
Dipped beam lamp

1 A241100000648 Headlight assembly A-1
90W,high beam lamp 100W
Combined front side marker & direction
2 A241100000649 5W
light assembly A-4- LED
Combined night direction light
3 A241100000650 5W
assembly A-5- LED
4 A241100000645 Reverse lamp assembly A-2 70W
5 A241100000647 Retarder light assembly A-6 21W
6 A241100000646 Fog light A-3 35W
7 60006212 Fog light WE-1 35W
5 A241100000647 Retarder light assembly A-6 21W
6 A241100000646 Fog light A-3 35W
7 60006212 Fog light WE-1 35W
Fuse and Models
Names Names in
Ampere Installation in central small central Power supply
Fuse Name
(A) location distribution distribution terminal
box box
Battery anode
01F1 Alternator fuse 120 Battery box
switch
Ignition key switch Central
01F2 10A F17 30
fuse distribution box
Central
01F3 Room lamp fuse 2A F19 125
distribution box
Small central
01F4 AX power supply fuse 15A F19 X
distribution box
A15 power supply Central
01F5 20 F24 15
Battery anode
01F6 30 power supply fuse 60 Battery box
switch
8-40 Service Manual

Battery anode
01F7 15 power supply fuse 60 Battery box
switch
Battery anode
01F8 X power supply fuse 60 Battery box F4
switch
Central
02F1 Wiper fuse 10 F18 30
distribution box
Central
02F3 Dipped beam 1 fuse 20 F12 X
distribution box
Central
02F4 High beam 1 fuse 20 F14 X
distribution box
Central
02F5 Washer pump fuse 10 F3 30
distribution box
Central
02F7 Horn fuse 10 F13 30
distribution box
Central
02F6 Wiper reset fuse 10 F18 30
distribution box
Central
03F1 Fog lamp fuse 15 F6 X
distribution box
Central
03F2 Rear lamp fuse 15 F4 X
distribution box
Small central
04F6 Monitor fuse 10 F5 15
distribution box
Central
04F1 Cigar lighter fuse 10 F10 X
distribution box
Small central
04F2 MP3/radio fuse 10 F8 15
distribution box
Small central
04F3 Air conditioner fuse 15 F20 X
distribution box
Small central
04F4 Actuator 10 F8 15
distribution box
Small central
05F1 GPS fuse 5 F6 15
distribution box
Central
05F2 GPS fuse 5 F20 30
distribution box
Combination Central
05F3 3 F27 15
instrument fuse distribution box
ECM power supply Central
07F1 10 F21 30
Service Manual 8-41

Central
08F2 5V power supply fuse 2 F1 5
distribution box
12V power supply Central
08F3 2 F28 12
17V power supply Small central
09F1 10 F9 15
ECM reverse and Small central
11F1 10 F5 15
neutral position fuse distribution box
Float solenoid valve Central
14F1 5 F16 X
Stop solenoid valve Small central
14F2 5 F14 X
Parking solenoid valve Small central
14F3 5 F13 X
Reverse lamp and Central
15F1 10 F8 15
buzzer fuse distribution box
Central
15F2 Brake lamp fuse 10 F9 15
distribution box
Retarder linear Central
15F3 10 F11 15
actuator fuse distribution box
Central
15F4 Retarder lamp fuse 5 F5 15
distribution box
Central
distribution box
Central
distribution box
Central
distribution box
Central
distribution box
Hoist proportional Small central
14F4 5 F1 2023
solenoid valve fuse distribution box
Drop proportional Small central
14F5 5 F2 2023
solenoid valve fuse distribution box
Retarder solenoid Small central
14F6 5 F3 2023
valve fuse distribution box
8-42 Service Manual

Fuse and Models

F1 08F2 5V power supply fuse 2A
F3 02F5 Washer pump relay fuse 10A
F4 02F2 Front fog lamp relay fuse 15A
F5 15F4 Retarder lamp relay fuse 15A
F6 03F1 Back fog lamp relay 15A
F8 15F1 Reverse lamp fuse 10A
F10 04F1 Cigar lighter fuse 10A
F11 15F3 Retarder linear actuator fuse 10A
F12 02F3 Dipped beam 1 fuse 20A
F13 02F7 Horn fuse 10A
F14 02F4 High beam 1 fuse 20A
F16 14F1 Float solenoid valve fuse 10A
F17 01F2 Ignition key switch fuse 10A
F18 02F1 Wiper fuse 10A
F19 01F3 Room lamp fuse 10A
F20 05F1 GPS fuse 5A
F21 07F1 ECM power supply fuse 15A
F22 02F2 30 power supply fuse 20A
F27 05F2 Combination instrument fuse 3A
F7 04F5 Rear lamp relay fuse 15A
F9 15F2 Brake lamp fuse 10A
Service Manual 8-43

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8-44 Service Manual

SRT95C Off-Highway Truck Hydraulic Steering Pipeline Of Operators Cab
9 HYDRAULIC STEERING
PIPELINE OF OPERATORS
CAB
9.1 Steering Control Unit
Overview
The steering control unit is connected to the
the steering valve and it controls the hydraulic 1
flow direction of steering system.
There are four ports on the unit:
P - In pressure form accumulator
T - Hydraulic oil that goes through this port 2
back to tank
R - Hydraulic control oil that goes through this
port to the cylinder which drives machine turn
right
L - Hydraulic control oil that goes through this
port to the cylinder which drives machine turn
left Fig.9.1-1 Assembly drawing
The action of steering wheel is transmitted
to the bush and driving shaft via the steering 1. Screw 2. Steering control unit
shaft. In addition, the driving shaft is fixed and
connected onto the bush by the mid-position
pin. The rotation of driving shaft leads to the R L
rotation of gear in the housing.
When the gear rotates, the oil is pressurized
to flow to the port of steering cylinder via the
spool and the bush.
There is a way to the bush from spool. It
rotates inside the bush and provides the oil
direction control.
The rated flow of steering control unit at 7MPa
(1000psi) is 1.0L/S.
T P
Operation
When the operator operates the steering Fig.9.1-2 Hydraulic schematic diagram of
wheel to left or right by a certain angle, the Steering control unit
steering action is transmitted to the spool via
the steering column. When it is rotated by the
minimum angle of 2.5 degrees, the port of
valve spool starts to be aligned with the port of
bush. When the steering wheel is rotated by
the maximum angle of 10 degrees, the ports
are completely aligned to allow the maximum
Service Manual 9-1

Hydraulic Steering Pipeline Of Operators Cab SRT95C Off-Highway Truck
flow to pass. After the 10-degree rotation is

performed in any direction, the valve spool
and bush connected via the mid-position pin
rotates as one assembly.
The pressure oil via P port to the bushing and
spool to drives steering control unit works and
provides pressure oil to the R port for makes
truck turn right. If hydraulic oil through L port
to the cylinder, then the truck will turn left.
hydraulic oil will go back to tank via T port of
the steering control unit when the cylinder
moves.
The spool will goes back to the home position
by tension of mid-spring after the steering
force is released. In such a way, the oil port is
disengaged from the original alignment state
so that the oil liquid of pump doesnt flow into
the steering cylinder any more. The truck
wont make the steering any more and it will
keep the current turning radius until the spool
is rotated for its limit of minimum 2.5-degree
angle.
For the left steering, as the steering column
rotates, the oil flow from the accumulator save
block (See the steering valve group in this
chapter) is input into the steering control unit
meter via the bushing and the valve spool and
it enters into the piston cavity of right steering
cylinder and the piston cavity of left steering
cylinder from the port L of Steering control
unit. The discharged oil flows into the port R
of Steering control unit from the other end of
steering cylinder and it is discharged into the
oil tank from the port T.
For the right steering: As the steering column
rotates, the oil flow from the accumulator
save block (See the steering valve group in
this chapter) is input into the steering control
unit meter via the bush and valve spool and it
flows out of the port R of Steering control unit
and enters into the piston cavity of left steering
cylinder and the piston cavity of right steering
cylinder. The discharged oil flows out via the
port L of steering valve from the other end
9-2 Service Manual

of steering cylinder and flows into the oil tank

from the port T.
During the manual steering operation, if the
engine and the pump are faulty, the steering
valve will be automatically switched over to the
manual steering system. When the steering
wheel is rotated, the oil liquid meter becomes
the rotating manual pump and the pressure oil
directly flows to the steering cylinder via the
corresponding port.
In the case that the steering control unit is
operated in the mid-position: In the mid-
position or non-steering position, the valve
spool and the bush are kept in a proper
position due to the mid-position spring. The
spring maintains the relatively small preload
so that the valve is just kept in the mid-position
and it can be within its limit and be released
at any time. In such a way, when the truck
temporarily stops with the power steering
system in the loading state, the system can be
protected against overheating.
Service Manual 9-3

Disassemble
See Fig.9.1-1 for the numbers in brackets.
WARNING
loss, rotate the steering wheel in two
directions for several turns and release the
system pressure.
Prevent personal injury and property loss,
and ensure that the wheels are chocked
properly and the chock and the hoist
device have sufficient capacity and work
safely.
1. Place the truck in a flat working area, lower

down the body completely, apply the parking
2. Rotate the steering wheel in two directions
for several turns and release the pressure of
accumulator and steering system. Chock the
wheels, and set the main switch of battery into
the OFF position.
3. Before the steering control unit is removed,
clean the valve block and cover pipeline in its
surrounding to prevent ingress of dust.
4. Ensure that the hydraulic pipelines
connected to the steering control unit are
properly marked to facilitate the installation.
Place a proper container in the position of
oil liquid leakage. Disconnect the hydraulic
pipelines and block all hydraulic pipelines to
prevent ingress of dust.
5. Support the steering control unit (2) and
remove the screw (1).
6. Carefully remove the steering control unit
until the spline shaft is disengaged from the
steering column and the cab firewall. Move the
steering control unit to a clean working area
to facilitate disassembly.
Installation
9-4 Service Manual

Section 36.2, Technical Conditions for

Tightening Torques of Standard Bolts and
Nuts.
Note: Tighten all hydraulic pipelines with the
O-ring end face seal and replace all 'O'rings.
WARNING
loss, ensure that the wheels are chocked
properly. The chock and hoisting device
should have sufficient capacity and be well
fixed to work safely.
1. Ensure the installation area is clean.

2. Carefully lift up the steering control unit
until the spline shaft of steering column goes
through the cab firewall and connects with the
steering column.
3. Through the steering column, use the bolts
to fix the steering control unit onto the cab
firewall.
4. Remove all of covers from the valve ports of
the steering control unit. Connect the pipelines
to the steering control unit according to the
signs made during disassembly.
5. Inspect hydraulic tank level which provides
oil to steering or brake system.
6. Remove the chock under the wheels,
set the main switch of battery into the ON
position, start up the engine, operate the
steering system, check the hydraulic pipeline
for leakage, and tighten the pipeline and joint
if necessary.
7. Inspect hydraulic oil tank level again. Refill
oil if necessary.
Service Manual 9-5

Filling and draining the steering system
WARNING
Don' start up the truck. It can be started
up only after the air in the oil is completely
vented out.
1. Fill the steering and brake system oil tank to

the maximum liquid level. Start up the engine
and prepare to refill oil. The oil level isnt
allowed to fall down to below the oil suction
pipe of pump to prevent the air from entering
the system.
2. Start up the engine at the idle speed. Fill
oil to the tank of steering and brake system
according to requirement immediately. If no
more oil is required and the oil becomes
clear, perform the operation according to the
following steps:
a. Rotate the steering wheel to the left and the
right to release the gas in the steering cylinder
and pipeline.
Note: Rapidly move the valve spool, and refill
oil to the steering and brake control oil tank
to make up for the oil liquid circulating in the
system.
b. If the oil in the oil tank becomes clear
(without turbidity or emulsion), it will indicate
that the air in the system is completed
removed.
Note: The slight creeping movement or
hysteresis of steering wheel is normal.
c. Fill the steering and brake system oil tank to
the specified oil level.
Special tools
No requirement for special tools is present
in the steps described in this chapter. These
tools can be purchased from the agent.
9-6 Service Manual

9.2 Steering Valve Group

Overview
The steering valve group consists of
three valves as follows: a check valve,
an accumulator save block and a system
2
pressure protection valve.
The accumulator save block is installed in
the middle part of valve block. The hydraulic 1
pump keeps pressure of the accumulator
normally, as shown in Fig.2; pressure oil will
goes back to the tank of steering and brake
control system via the block and the whole
process about 3-5 minutes when the pump is
turned off. Fig.9.2-1 Assembly drawing of steering valve
The safety valve is installed in the bottom of group
valve block. Its setting pressure is 21MPa
(3050psi). If any fault occurs to the pressure- 1. Screw 2. Steering valve group
compensated valve of steering pump, this
valve can be used as the auxiliary protection.
If the pressure-compensated valve makes the
steering system pressure exceed the setting
Steering system accumulator
pressure of safety valve, the safety valve will
Pressure mea-
be opened to depressurize the oil liquid and PS7
suring port
allow it to flow back to the oil tank. E G2 G3
C Port T of st-
Operating principle eering gear
The oil from the steering pump enters into Gearbox lubri- D
cation system
the steering valve group from the port A and Slewing and Port P of st-
the pressure is generated to open the check automatic sy- T
B
eering gear
stem oil tank
valve. The oil flows to the steering control unit 21MPa
via the port B and then it is supplied to the
A G1
accumulator via the port E. Pipeline filter Port P of automatic
valve group
The pressure oil runs to the pressure switch
via the port G2 and reaches the fault
detection point via the tee fitting of port G2.
See Fig.2.
In the truck running process, the transmission
pilot pressure runs through the hole D and
keeps the save block closed. Consequently,
the oil leakage from the accumulator is cut
off. The return oil of steering valve enters into
the port C and then flows into the oil tank via
the port R. The port G1 is blocked. If the
Service Manual 9-7

pressure in the oil circuit exceeds the preset

pressure in the safety valve, the valve will be
opened to allow the oil to be discharged back
to the oil tank via the port T. After the engine
stops, the pilot pressure of transmission
disappears and the spring switches over the
save block to the open position, so that the oil
in the accumulator is allowed to flow into the
internal passage via the port E and then be
discharged from the port T to the steering and
brake system oil tank via the piston.
Disassembly
WARNING
The pressure is dangerous. Before the
operation, the steering wheel should be
rotated back and forth for several times
to release the pressure in the system. If
the pressure isnt released, it will lead to
personal injury and property loss.
Prevent personal injury and property loss,
properly and the chock and the hoist
device have sufficient capacity and work
safely.
1. Park the truck in a horizontal working area,

and apply the parking brake. Shut down the
engine.
steering system and accumulator. Chock all
wheels and set the main switch of battery in
the OFF position.
3. Clean up the steering valve group and its
surrounding area and make the corresponding
marks on the hydraulic pipelines installed on
individual ports of this valve.
4. Remove all hydraulic pipelines from the
steering valve group and drain oil into a proper
container. Cover all hydraulic pipelines and
9-8 Service Manual

steering valve group port to prevent ingress of

dust.
5. Remove the steering valve group from the
truck. Use a proper solvent to clean the outer
surface of multi-way safety valve assembly.
Then move it to a clean area to facilitate
disassembling.
Installation
Note: Perform the tightening according to the
specified value in Section 38.2, Technical
Conditions for Tightening Torques of Standard
Bolts and Nuts.
Note: Tighten the hydraulic pipeline equipped
with the O-ring seal and replace the O-ring.
1. Install the steering valve group assembly
onto its fixing support. Use the fasteners
removed during disassembly to fix it.
2. According to the signs made during
disassembly, connect all oil pipes to the
steering valve group and fasten them.
3. According to the stipulations in Chapter 15,
Hydraulic Oil Tank Assembly, check the oil
level of oil tank. Add the oil to the proper oil
level according to the stipulations.
4. Remove the chock, set the main switch
of battery into the ON position, start up the
engine and operate the steering system.
Check the steering system for leakage. If
necessary, tighten the connecting piece and
recheck the oil level.
Maintenance
The maintenance of steering valve group is
limited to the replacement parts only.
Special tools
No requirement for special tools is present
tools can be purchased from the agent.
Service Manual 9-9

Operators Cab Brake Pipeline And Joint SRT95C Off-Highway Truck
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9-10 Service Manual

SRT95C Off-Highway Truck Operators Cab Brake Pipeline And Joint
10 OPERATORS CAB BRAKE

PIPELINE AND JOINT
10.1 Foot Valve
Overview
The foot valve is a mid-position cut-off valve. 2
It controls the hydraulic oil pressure value of
front and rear brakes as well as the maximum
1
brake pressure applied into these pipelines.
Such valve is controlled by the foot pedal
inside cab. It operates along with the engine
and the brake valve group can automatically
apply brake.
The different maximum operation pressures
Fig.1 Assembly drawing of foot valve
required by the front and rear brakes can be
provided by the foot valve. These pressures
1. Foot valve 2. Screw
can be adjusted according to test and
regulation. When being actuated by the foot
valve, the pressure switch of stop light will
send a signal to rear brake light to turn on the
brake light.
Operation
Apply the traveling brake
PX P1
See Fig.2.
When the foot valve is pressed down by the PS5
operator, the slide valve will move downward
B1
to push the regulating spring, which will then
push the regulating spool downward. When
the regulating spool moves downwards, the P2
current limiting groove will move away the oil PS6
groove and shut down the exits of 'B1', 'B2'
to port 'T'. The regulating spool will move T P2
downward continuously till the current limiting
Fig.2 Hydraulic principle of foot valve
groove completely aligns with the pressure
inlet. Such action opens ports 'P1', 'P2' and
exits 'B1', 'B2'.
After the pressure of hydraulic oil in the brake
is built up, the oil flow enters the cavity under
the spool via the small orifice of adjusting
spool. When the pressure in the brake rises
up, the pressure in the cavity under the
spool correspondingly increases to move the
Service Manual 10-1

adjusting spool upwards to close the outlet of

interfaces B1 and B2. The regulating spool
keeps balance between brake pressure and
regulating spring pressure. Such pressure is
produced when the operator presses down
the foot pedal. If the footplate is not pressed
down, the adjusting valve will close the inlet,
outlet and oil tank interface. The spool will be
kept in this position. If the operator continues
pressing down the footplate, the adjusting
valve will move downwards to build up the
higher pressure in the brake until it balances
the action of footplate.
Releasing normal traveling brake

See Fig.2. When the operator releases
the footplate, the adjusting spool loses the
balance. It moves upwards, and the outlet
of interfaces B1 and B2 connected to the
interface T of oil tank is opened. The oil in the
pipeline of B1 and B2 is released into the oil
tank via the interface T of oil tank. The brake
is released.
Applying/releasing emergency brake

See Fig.2. Press the emergency brake
switch to de-energize the brake multi-way
electromagnetic valve. It makes all pressure
enter the interface PX on the foot valve. It is
equivalent to the complete and rapid pressing
down of foot valve. For example, push the
adjusting spool downwards and apply the
maximum brake.
See Fig.2. Release the emergency brake
to switch on the multi-way electromagnetic
brake valve and enable the pressurized oil in
'PX' pipeline to return to the oil tank and the
pressure will drop accordingly. Exits 'B1', 'B2'
will be connected to oil tank port 'T' to return
the oil in pipelines 'B1', 'B2' to the oil tank and
release the brake.
Note: The output pressure generated at the
outlet of B1 and B2 when the emergency
brake is applied (in the pipeline of PX) is
10-2 Service Manual

higher than the one generated when the

footplate brake is applied by 5%.
Maintenance standard
Frequently check the valve for leakage or
damage. Check whether the excessive cam
swing occurs to the footplate. If necessary,
replace the component.
If the following phenomena occ u r, t h e
component should be repaired or replaced in
time:
1. External leakage occurs.
Note: Check all hydraulic pipelines and joints
and ensure no leakage.
2. The foot pedal can not restore to the original
position.
3. The footplate is kept in the pressure state
during the idle speed operation.
4. When the footplate is completely pressed
down, the pressure output varies very quickly.
5. The output pressure of pipeline should be
kept constant: 0.52MPa (75psi).
Disassembly
WARNING
damage, the wheels should be chocked
properly and the hoist device should be
fixed firmly and should have sufficient
capacity for safe work. After the engine is
shut down, the pressure of hydraulic oil
will remain in the system. The operation
can be performed on the brake system
only after the foot brake is continuously
pressed down until the pressure is
released. Otherwise, it will result in severe
personal injuries.

apply the emergency parking brake, shut
Service Manual 10-3

down the engine, continuously operate the

foot valve and release the pressure of brake
accumulator.
2. Block the wheels. Turn the accumulator
main switch to 'off' position.
3. Use proper solvent to clean the foot valve
and the surrounding area. Dismantle all of the
hydraulic pipelines connected to the foot valve
and mark them to facilitate the installation. Use
a proper container to catch the leakage oil,
and cover all open pipelines and the foot valve
interface to prevent contamination of dirt.
4. Remove and mark the electrical connector
connected to the parking light pressure switch.
5. Remove the installation parts fastening
the foot valve to cab floor. Move the foot
valve assembly to a clean working area for
performing the maintenance operations.
Installation
Note: Tighten all the fasteners according to
'Tightening Moment Technical Conditions of
Standard Bolt and Nut' in 38.2.
Note: Tighten all the hydraulic pipelines
equipped with the end face seal. Replace all
'O'rings.
1. Place the foot valve assembly onto the
floor of cab. Use the installation parts to fix it.
Remove the covers.
2. Remove the covers. Connect the hydraulic
pipelines to the foot valve assembly according
to the signs made during disassembly.
3. Connect the electrical connector to the
parking light pressure switch according to the
disassembly signs.
4. Check the oil level of steering and brake
control oil tank. Refill oil conforming to the
stipulations to reach the correct oil level
specified in the Steering and brake control oil
tank.
5. Set the main switch of accumulator into the
'on' position, remove the chock, start up the
engine and warm up the hydraulic oil to normal
10-4 Service Manual

6. Apply the brake. Check for oil leakage.

Tighten the pipelines and joints.
Note: To operate Step 7, ensure the applying
and releasing of emergency brake.
7. Press down the footplate and the
emergency brake system. Check the
conditions of brake operation.
Parking light pressure switch

The parking light pressure switch is a normally
open switch. When a testing instrument is
connected to the terminal of parking light
pressure switch, the system will be opened.
When the brake pressure is 0.27MPa or
higher, the system will be closed to signal
the brake indicator lamp to flash; when the
pressure falls down to 0.27MPa, the system
will be opened and the brake light will be off.
Maintenance
General maintenance
Check foot valve hydraulic pipelines and joints
for oil leakage and damage, tighten or replace
if necessary.
Every 1,000 hours

Check the front and rear brake pressure in the
detection points. If the pressure is not in the
specified range, inspect the valve and take
the corresponding measures (adjusting the
pressure; disassembly, repairing or replacing
the valve).
Special tools
No special tool requirement is present in the
steps described in this chapter.
Service Manual 10-5

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10-6 Service Manual

SRT95C Off-Highway Truck Air Conditioning Pipeline Installation
11 AIR CONDITIONING PIPELINE INSTALLATION

11.1 Air Conditioning Pipeline Installation
2
3
1
5
10
4
4
11
13 4 4
12
6
7 7
4
9
4 8
Fig.1 Air conditioning pipeline installation
1. Blast pipe 6. Condensation-storage rubber hose 11.Flow hose
2. Blast pipe 7. Warm water rubber hose 12.Stream-pressure rubber hose
3.Blast pipe 8.Hot water adaptor 13.Storage-steam rubber hose
4.Thimble 9.Hot water adaptor
5. Thimble 10.Pressure-condensation rubber hose
Service Manual 11-1

Air Conditioning Pipeline Installation SRT95C Off-Highway Truck
Air conditioning system pipeline dis-

assembly
See Fig1 for the number in the bracket.
1. Place the truck in a flat working area. Apply
the parking brake. Shut down the engine. Turn
the steering wheel for a few rounds to release
the pressure of the steering system.
2. Chock the truck wheel. Put the main switch
of the battery at the position of close.
3. If necessary, disassemble installation
accessories on the protective cover of the
truck.
4. After the system is completely discharged,
respectively mark flow hose (11), defrosting
blast pipe (1), blast pipe in front of drivers
seat for face blowing (2), blast pipe in front
of co-drivers seat for face blowing (3), warm
water rubber hose (7), stream-pressure
rubber hose component (12), condensation-
storage rubber hose component (6), storage-
steam rubber hose component (13), pressure-
condensation rubber hose component (10) for
the convenience of installation.
5. Carefully disassemble the marked flow hose
(11), defrosting blast pipe (1), blast pipe in front
of drivers seat for face blowing (2), blast pipe
in front of co-drivers seat for face blowing (3),
warm water rubber hose (7), stream-pressure
rubber hose component (12), condensation-
storage rubber hose component (6), storage-
steam rubber hose component (13), pressure-
condensation rubber hose component (10)
respectively from corresponding systems, plug
joint parts and corresponding pipe fittings to
prevent the entry of foreign substances into
the system.
Air conditioning system pipeline

installation
Numbers in parentheses refer to Fig.11.1-1
Note: Tighten all the fasteners according to
section 38.2 'technical conditions of tightening
moment for standard bolts and nuts'.
1. Remove plugs from end of storage-steam
11-2 Service Manual

SRT95C Off-Highway Truck Air Conditioning Pipeline Installation
rubber hose component (15) end, receiver

drier (12) and evaporator (6) port; connect
rubber hoses according to signs made at
disassembly.
2. Remove plugs from end of condensation-
storage rubber hose component (13),
condenser assembly (11) and receiver drie (12)
port; connect rubber hoses according to signs
made at disassembly.
3. Remove plugs from end of stream-pressure
rubber hose component (9) end, compressor
(14) and evaporator (6) port; connect
rubber hoses according to signs made at
disassembly.
4. Remove plugs from end of pressure-
condensation rubber hose component (10),
compressor (14) and condenser (11) port;
connect rubber hoses according to signs.
5. Remove plugs from end of warm water
rubber hose (8), evaporator (6) and engine
port, connect rubber hoses according to signs
made at disassembly.
6. Remove plugs from end of flow hose (7),
blast pipe for feet blowing (4), defrosting blast
pipe (3), blast pipe in front of operators seat
for face blowing (2), blast pipe in front of co-
operators seat for face blowing (1), evaporator
(6) and corresponding port in operator s
cab, connect according to signs made at
disassembly.
Service Manual 11-3

Air Conditioning Pipeline Installation SRT95C Off-Highway Truck
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11-4 Service Manual

SRT95C Off-Highway Truck Fuel Tank And Mounting
12 FUEL TANK AND MOUNTING

12.1 Fuel Tank and Mounting
1
2
3
8 7 56
54
5 78
2
2 12
4 5 13
6 14
10 15
9 2
17
18
16 19 14
18 28
20 27
11 21 26
23
24
29 23 25
22
Fig.1 Oil tank assembly and pipeline installation
1.Connector 16.Fuel supply line

2.Clamp 17.Connector
3.Fuel supply line 18.Washer
4.Bolt 19.Fuel control valve assembly
5.Washer 20.Connector
6.Articulating body 21.Connector
7.Connector 22.Bolt
8.Washer 23.Washer
9.Bolt 24.Damper
10.Washer 25.Fuel tank
11.Primary filter 26.Washer
12.Washer 27.Washer
13.Connector 28.Nut
14.Clamp 29.Core,filter,separator,oil-water
15.Fuel return line
Service Manual 12-1

Fuel Tank And Mounting SRT95C Off-Highway Truck
Overview
See Fig.1 for the numbers in brackets, unless
Note: fuel tank capacity and oil technical
specifications are detailed in section 36.1
'LUBRICATION AND MAINTENANCE'.
Disassembly
WARNING
damage, be sure wheel chocks and lifting
equipment are properly secured and of
adequate capacity to do the job safely.
Remove the parts and components as

following:
raise the body and install the body safety pins.
2. Apply the parking brake and switch off the
engine.
several times to relieve any pressure in the
steering system.
Block all road wheels.
4. Close fuel shut off valve at the fuel filters to
prevent loss of fuel prime at the engine.
5. Disconnect fuel liquid level sensor joint.
6. With a suitable container in position, remove
drain plug (12,Fig2) and drain fuel from fuel
tank (25). Reinstall drain plug when fuel tank
is completely drained.
7. Identify and tag fuel lines connected to
fuel tank (25) and engine, with a suitable
container available to catch leakage, loosen
the clamp(2,14)disconnect fuel lines(3.15.16)
from fuel tank (25) and engine. Cap open line
ends to prevent entry of dirt.
8. Remove bolts (9) , washers (10) , bolt (4),
Connector (7), washers (5,8) and articulating
12-2 Service Manual

body (6), and remove Primary filter (11) from

engine.
9. Using a suitable lifting device, support fuel
tank (25)and take up any slack. Remove
Bolts (22),washers(23),damper(24),wash
ers(26 27) and nuts(28), Remove bolts
and nuts, securing fuel tank (25) to chassis
mounting brackets.Remove fuel tank (25).
Fuel tank assembly

2 15
1.Remove the cover (15) and bolt securing
1
air cleaner (2) to fuel tank. Check condition of
3
gasket and replace if required.
2. Remove bolt securing level gauge (3) to fuel
tank (14) and remove level gauge (3). Check
condition of washer on level gauge (3) and
replace if required. 14
4 56 7
3. Remove bolts (7), washers (6), cover
plate(5) and O-ring (4) from fuel tank (14).
Discard O-ring (4). 8
13
9
4. Remove bolts (11), washers (10), cover 10
11
plate(9) and O-ring (8) from fuel tank (14), 12
discard O-ring (8).
Cleaning Fig.2 Fuel tank assembly disassembly

1. Remove all dirt particles from fuel strainer 1.Plug 9.Cover plate
and clean fuel strainer with clean diesel fuel. 2.Air cleaner 10.Washer
2. Cover plate (9) port in fuel tank (14) can 3.Level gauge 11.Bolt
be used as an opening to remove dirt and 4.O-ring 12.Drain plug
sludge from the bottom of fuel tank (14) with 5.Cover plate 13.Screw plug
6.Washer 14.Fuel tank
a clean dry cloth. Remove drain plug (12) and
7.Bolt welding assembly
fush fuel tank (14) with clean diesel fuel to
remove any remaining dirt particles. Reinstall 8.O-ring 15.Cover
drain plug(12) and tighten securely.
Assembly
1. Install O-ring (4) in groove of fuel tank
(14) boss and secure cover plate (5) with
washers (6) and bolts (7).
2. Install O-ring (8) in groove of fuel tank (14)
boss and secure cover plate (9) with washers
Service Manual 12-3

(10) and bolts (11),and secure plug (12).

3. Ensure gasket is located on level gauge (3)
and position level gauge (3) in fuel tank (14).
Secure level gauge (3) with bolt.
4. Install fuel strainer in fuel tank (14). If
removed install new gaskets in filter cap and
install filter cap assembly loosely to prevent
entry of dirt.
5. Ensure that drain plug and bolts are
securely tightened in fuel tank.
Installation
WARNING
damage, be sure lifting equipment is
Note: Tighten all fasteners to standard

torques listed in 'Tightening Moment Technical
Conditions of Standard Bolt and Nut' in 36.2.
1.Using suitable lifting equipment, position fuel
tank (25) on the chassis mounting brackets
and Secure with damper (24), washers (23),
nuts(28), washers (2627) and bolts (22).
2. Install articulating bolt(4), connector(7),
washers(5,8)and articulating body(6)to primary
Filter (11). Secure Primary Filter (11) to frame
with bolt(9)and washer(10).
3. Connect fuel supply lines(3)between
articulating body (6) and Connector (1), secure
with clamps(2).
4. Connect fuel supply lines (16) between
articulating body (6) and Connector (17),
secure with clamps (2).
5. Connect fuel return lines(15) between fuel
tank (25) and Connector (13), secure with
12-4 Service Manual

clamps(14).
6. Remove fller cap assembly from fller neck
on fuel tank (25) and fill fuel tank (25) with fuel
specified in Section 36.1, LUBRICATION
SYSTEM. Ensure vent hole in fller cap is clear
and install filler cap assembly on filler neck.
Tighten fller cap securely.
7. Open fuel shut off valve at the fuel filters.
8. Start the engine and run for a few minutes
to ensure fuel is being supplied to the engine.
Check for leaks at fuel lines and tighten if
required.
9. Remove body safety pins and lower the
body. Remove wheel chocks from all road
wheels.
Maintenance
Prior to starting the vehicle check the fuel
level. Fuel tank should be filled at the end
of each shift to prevent condensation from
gathering in the tank.Ensure vent hole in fller
cap is clear to prevent a vacuum from building
up in fuel tank. Check condition of all fuel lines.
When filling fuel tank check that there is
no buildup of dirt and sludge at fuel strainer.
Remove and clean fuel strainer and fller cap
as required. From time to time make a
visual check on the electrical connections at
fuel level sender.The condition of fuel tank (25)
mounting should be checked carefully. Check
washers (23) and dampers (24) for any sign
of wear or damage and repair or replace as
required. Check that nut (28), washer(26
27) and bolt (22) are securely tightened and
that no wear on mounting holes is evident.
tighten nuts and bolts as required.
Primary filter separator maintenance

Daily maintenance: Loosen the drainage at the
bottom of catchment cup, empty the collected
water.
Maintain the primary Filter separator every
Service Manual 12-5

19000km or 500 hours, or the engine power is

insufficient.
1. Remove the strainer and catchment with
special tools. Identify strainer and catchment
gasket.
2. Remove all dirt particles from strainer.
Replace the same model strainer if seriously
blocked.
3. Clean catchment and gasket with clean
diesel fuel. Check the gasket and replace if it
is damage.
4. After cleaning, ensure gasket is located on
catchment and position catchment in strainer.
5. Supply diesel fuel around the strainer
except the hole in middle.
6. Clean strainer and gasket with clean diesel
fuel. Check gasket and replace if required.
7. After cleaning, ensure gasket is located on
strainer and position strainer with special tool.
12-6 Service Manual

SRT95C Off-Highway Truck Steering Pipeline And Joint
13 STEERING PIPELINE AND

JOINT
13.1 Piston Pump
Overview
The steering pump is an axial piston variable-
displacement (adjustable) pump with the high-
pressure operating capability. It is installed on
the power take-off (PTO) of engine. It supplies
pressure oil for steering and brake system
and it could control of the output in any given
time for demand of system. The set value of
pressure compensator is 18MPa.
The steering pump rotates counterclockwise
in the view from the input shaft end of pump.
Caution: Do not drive the pump in the reverse Fig.13.1-1 Piston pump
direction. Otherwise, the pump will be seized.
The pump is mainly composed of: a pressure
compensator valve, a pump housing, a driving
shaft, a valve plate, a rotating assembly.
The variable-displacement unit includes the
mechanism which can adjust the angle of
swash plate. When the cylinder body assembly
and the driving shaft rotate, the swash plate
can control the stroke of each piston. The
valve block is also used as the rear end cover
of the whole component and includes the oil
inlet and outlet; the bearing on the valve block
and the one on the pump body are utilized to
support the driving shaft.
Operating principle
Fig.13.1-2 is the operating hydraulic schematic
diagram of steering pump. The driving shaft
of rotating pump can rotate the cylinder body,
retainer plate and piston. The piston shoe
abuts the swash plate through retainer plate.
The angle of swash plate surface can cause
the repeated movement of each piston in the
cylinder body. The input and output ports are
connected to the slotted hole of port plate.
When the piston moves towards the outside
of cylinder body, vacuum is generated. The Fig.13.1-2 Operating schematic diagram of
oil is pressed into the cavity under the action steering pump
Service Manual 13-1

Steering Pipeline And Joint SRT95C Off-Highway Truck
of atmospheric pressure. The oil flows in the

cylinder body, passes through the oil inlet
slotted hole of port plate and reaches the oil
outlet slotted hole of port plate. When the
piston moves in the reverse direction, oil is
forced out of the cylinder body and enters into
the oil discharge outlet.
The oil liquid flows from the oil discharge
outlet to the steering valve group and provides
the pressure to the steering oil circuit. The
pressure oil is split to the brake valve group
via the port 'G1' of steering valve group and
provides the pressure to the brake control oil
circuit.
The internal discharge of pump returns to
the oil tank through the oil drainage pipe of
steering pump.
Variable displacement
The displacement can be changed by
changing the included angle between the
return plate and the driving shaft. During the
period when the operating load of pump or the
pressure of system is continuously fed back
to the slide valve cavity of differential piston
and pressure-compensated valve, when the
pressure of system reaches the spring setting
value of pressure-compensated valve, the
valve spool moves and the oil flow to the
control slide valve is metered.
When the force generated by the control slide
valve overcomes the spring force of differential
piston, the angle of return plate will move
to the minimum displacement position. The
angular displacement of return plate (i. E. the
change in the displacement) depends on the
desired flow and pressure of system.
When the displacement meets the system
requirement, the balance will be established
again.
13-2 Service Manual

13.2 Cushion Valve Block

Overview
Cushion valve block is installed to the fixing
support under cab.
It is situated in the steering pipeline of Steering
control unit and steering cylinder. There are
four ports in total. Ports 'A', 'B' are connected
to the steering control unit. Ports 'A1', 'B1' are
connected to the cylinder.
Operating principle
See Fig.13.2-2 for schematic diagram.
Port 'A' is connected to port 'A1'. When the
pressure is larger than 20.7MPa (3000 psi), Fig.13.2-1 Cushion valve block
some hydraulic oil will flow back to the oil tank
through relief valve or flow back to port 'B' and
'B1', so as to buffer the braking.
Disassembly A1 B1
1. Park the truck at a horizontal working place
and apply the parking brake. Shut down the
engine.
steering system and accumulator. Chock all A B
wheels and set the main switch of accumulator
into the 'off' position. Fig.2 Hydraulic principle of cushion valve block
3. Clean the cushion valve block and the
surrounding area, mark the hydraulic pipeline
mounted to each port of such valve.
4. Remove all the hydraulic pipelines from
the cushion valve block, drain the oil into a
proper vessel, cover all the hydraulic pipelines
and cushion valve block ports to prevent the
ingress of dust.
5. Remove the cushion valve block from truck,
use proper solvent to clean the surface of
cushion valve block, and then move to a clean
area for disassembly.
Installation
Note: Tighten the hydraulic pipeline equipped
with the O-ring end face seal and replace the
'O'ring.
Service Manual 13-3

WARNING
The pressure is dangerous. Before the
operation, the steering wheel should be
rotated back and forth for several times
to release the pressure in the system. If
the pressure is not released, it will lead to
personal injury and property loss.
well and the chock and the hoist device
have sufficient capability and can work
safely.
1. Install the cushion valve block onto its fixing

support. Use the fasteners removed during
disassembly to fix it.
2. According to the signs made during
disassembly, connect all oil pipes to the
cushion valve block and fasten them.
3. According to the stipulations in the Hydraulic
Oil Tank Assembly, check the oil level of oil
tank. Refill oil to the proper oil level according
to the stipulations.
4. Remove the chock, set the main switch
of accumulator into the 'on' position, start up
the engine and operate the steering system.
Check the steering system for leakage. If
necessary, tighten the connecting piece and
recheck the oil level.
Maintenance
The maintenance of cushion valve block is
only limited to the replaceable part.
Special tools
No special tool is required in steps described
in this chapter. These tools can be purchased
from the agents.
13-4 Service Manual

13.3 Oil Filter

Overview
The oil filter is installed inside the left
longitudinal beam and under the left and
right longitudinal beams under the frame. It is
located in the steering pipeline between the
steering valve group and the steering pump
and in the pipeline connecting the cooling
system to the rear brake.
Operation principle
The hydraulic oil from the piston pump enters 2
to filter, flows into the annular region of filter 1
bowl and reaches the exit through filter. 3
The pressure of filter drops to the minimum

Fig.1 Oil Filter Diagram
during filter cleaning. When the hydraulic oil
passes through the oil filter, the dirt in the oil is
deposited on the filter. The more the dirt is, the 1.Screw 2.washer 3.Pressure Oil Filter
higher the pressure drop of filter becomes, so
must change filter at once..
Maintenance
Replace for every 1,000 hours of operation.
Replacing the filter

Note: Tighten all hydraulic pipelines equipped
with the O-ring end face seal joint and replace
the 'O'ring.
WARNING
Pressure is dangerous. Rotate the steering
wheel in each direction and release the
system pressure. If the pressure is not
released according to the stipulation, it will
lead to personal injury and property loss.
well and the chock and the hoist device
have sufficient capability and can work
safely.
1. Place the truck in a flat working area, apply
Service Manual 13-5

the parking brake and shut down the engine.

for several times, release the pressure in the
accumulator and the steering system, and
chock the wheels properly.
3. Remove the hydraulic pipelines of inlet and
outlet and drain oil into a proper container.
4.Revolve the filter up-monoblock and make
the down-monoblock separate oneself from
up-monoblock.
5.Discharge the oil of the down-monoblock
into a proper container.
6.Replace new O-ring for the oil filter.and
tighten zhe up-monoblock.
13-6 Service Manual

SRT95C Off-Highway Truck Hoist Pipeline And Joint
14 HOSIT PIPELINE AND

JOINT
14.1 Hoist Pump
Overview
The hoist pump is a gear pump installed to
engine PTO. It supplies oil to hoist system
independently.
Operation
See Fig.14.1-2 for the principle of hoist pump.
When the drive gear rotates, the driven gear Fig.14.1-1 Hoist pump outside diagram
rotates in the reverse direction. The tooth
socket between the teeth of gear will bring the
hydraulic oil from the gear pump case inlet
to the outlet. When the teeth of gears are
engaged again, the hydraulic is forced out of
the outlet. The delivery capacity of hoist pump
is determined by the width of its corresponding
gear set and the rotating speed of drive gear.
The hoist pump delivers oil to hoist control
valve. According to the movement of valve
spool, the oil flows to body hoist circuit, or
if the valve spool is at 'float' position, the oil
flows through the confluence block behind the
hoist control valve to supply the disc brake Fig.14.1-2 Hydraulic schematic diagram of
cooling system. hoist pump
Service Manual 14-1

Hoist Pipeline And Joint SRT95C Off-Highway Truck
14.2 Hoist Valve

Overview
See Fig.14.2-1 for the numbers in brackets.
2
The hoist valve is installed inside the
longitudinal beam of left frame. It is used to
guide the hydraulic oil to the hoist cylinder for
hoist or lowering the body. Depending on the
position of valve spool, the oil for disc brake
cooling system is supplied via the confluence 1
block.
The hydraulic oil is pumped into hoist valve (1)
by the double-gear pump installed to engine
PTO. The hoist valve consists of one three-
position valve spool and relief valve. It is
fastened to the inside of left longitudinal beam
Fig.14.2-1 Assembly drawing of hoist valve
by screw (2). The three positions of valve
spool are: 'hoist', 'maintaining and floating' and
1. Hoist valve 2. Screw
'lowering' (with power lowering). The valve
spool kept at 'maintaining and floating' position
will compress the internal and external
springs, which will change the valve spool
to 'maintaining' position from 'hoist' position.
The action of valve spool is controlled by the
pilot pressurized oil provided by the pilot oil
source valve group. When the hoist handle
valve on the control board on the right of seat
is operated by the operator, the pilot oil source
valve group will provide 3.5MPa (507psi)
pressure to actuate the action of hoist valve
spool. A C T
The relief valve assembly is installed to
port 'P/P1'. If the pressure exceeds 18MPa B
(2610psi), the relief valve will open to allow
the oil to return to the tank. The relief pressure a b
can be measured at the pressure check port
'G' behind the tank.
Operation
Body at 'maintaining and floating' position
See Fig.14.2-2 for the hydraulic schematic P
diagram of hoist valve operating in the
'maintaining and floating' position. Fig.14.2-2 Hydraulic schematic diagram of
When the hoist lever valve and valve spool hoist valve
14-2 Service Manual

are kept at 'maintaining and floating' position,

i. E., the valve spool is kept at the neutral
position, the oil will enter port 'P/P1' of control
valve block, flow through the valve and flow
out of port 'T', enter the confluence block of
disc brake cooling system and supply the
disc brake cooling system. The valve spool
obstructs oil from entering and leaving the
body hoist cylinder and keeps the piston of
cylinder body at the original position.
Body at the 'hoist' position

See Fig.14.2-2 for the hydraulic schematic
diagram of hoist valve operating in the 'hoist'
position.
When the hoist control handle is moved to
'hoist' position, i. E., the valve spool is at the
hoist position, the hydraulic oil will enter port
'P/P1' of control valve block. The pilot oil
pressure opens the valve spool for the oil to
flow through the valve spool, port 'B', 'hoist
port' and enter the hoist cylinder. The returned
oil from the hoist cylinder returns to the hoist
and disc brake cooling oil tank through port 'A'
of balanced valve, port 'A' of hoist valve, valve
spool passageway and port 'T1'.
Body at the 'lowering' (power lowering)

position
See Fig.14.2-2 for the hydraulic schematic
diagram of hoist valve operating in the
'lowering' position.
When moving the hoist control handle to the
'lowering' position, the valve spool in valve
block will be located at the right position shown
on Fig.2, through which the hydraulic oil can
enter port 'P/P1' of control valve block. The
pilot oil pressure opens the valve spool for oil
to reach the balanced valve group through the
open passageway of valve spool and port 'B'.
The oil liquid flows through the balanced valve
and reaches the 'forced landing port' of hoist
cylinder. The returned oil from hoist cylinder
of body enters port 'B' of control valve block,
Service Manual 14-3

flows through the open passageway of valve

spool, flows out of port 'T1' and returns to the
tank of hoist and disc brake cooling system.
14-4 Service Manual

14.3 Balanced Valve Group

Overview
The balanced valve group is installed on the
support behind the transmission. The balanced
valve group in the hydraulic hoist system can
be used to prevent the formation of vacuum in
the hoist cylinder due to the imbalanced body
during unloading. In addition, it also used to
leading oil back to the tank of hoist and brake
system via the way of the hoist control valve.
Operation
See Fig.14.3-2. When hoist the body, the Fig.14.3-1 Assembly drawing of balanced
returned oil in the hoist cylinder enters the valve group
balanced valve group from ports 'A1', 'A2'.
When lowering the body with control valve,
the pressurized oil will be delivered to ports Forced landing port of lifting valve Lifting port of lifting valve
'A1', 'A2' of the balanced valve. The spool

will moves and pressure oil flow out of part A
to lower the body down at the pressure is 17
Mpa ( 2465 psi ). return oil goes through hoist
valve back to thank of hoist, brake and cooling
system.
Disassembly
1. Ensure that the body is completely lowered,
or fix the body with the safety pin when the
body is in the hoist position. Apply the parking
brake, shut down the engine and chock all
wheels properly.
Port A of lifting valve Port B of lifting valve
2. Use a proper solvent to clean the balanced
valve group and make a sign on the hydraulic Fig.14.3-2 Schematic diagram of balanced
rubber hose to facilitate correct installation. valve
3. Remove the hydraulic pipe from the
balanced valve and drain the oil into a proper
container. To prevent ingress of dirt, cover all
pipe openings and each port of the balanced
valve group.
4. Remove the fasteners which fix the
balanced valve onto the support. Take down
the balanced valve and place it in a clean
working area to facilitate disassembly.
Service Manual 14-5

Installation
Note: Tighten all the fasteners according
to section 38.2 'Technical Conditions for
Tightening Moment of Standard Bolts and
Nuts'.
Note: Tighten all hydraulic pipelines with the
end face O-ring seal and replace all 'O'rings.
WARNING
Prevent personal injury and property loss
firmly. The chock and the hoist device
should have sufficient capacity. They
should be fixed firmly and can work safely.
1. The spacer (if used) should be placed

together with the balanced valve group on
the installation support and be fastened with
fasteners.
2. Connect the hose according to the sign
made during disassembly.
3. Lift up the body. Check the hose and
balanced valve group for leakage.
4. Connect pressure gauge with check point
'G'. In case that the engine reaches the
maximum rotating speed, the second stage of
hoist cylinder is completed extended and the
leading pipeline is removed, check whether
the pressure of balanced valve is 17MPa (2465
psi).
5. Check the oil level according to chapter 15
'Hydraulic Oil Tank Assembly'. If the oil level
is relatively low, then refill oil. . The oil used
must conform to section 36.1 'LUBRICATION
AND MAINTENANCE'.
Maintenance
Regularly check the balanced valve group for
leakage and check the pressure according to
above 'installation' requirements.
Special tools
14-6 Service Manual

No requirement for specialized tools is present

in this chapter. These tools can be purchased
from the agent.
Service Manual 14-7

14.4 Power Supply of Pilot Valve

Group 2
Overview
The Power supply of pilot valve group is
set on the support in the middle of the right
longitudinal beam and on the hydraulic
pipeline between the steering pump and the 1
body hoist control handle. See Fig.2 for the
schematic diagram. Fig.14.4-1 Assembly drawing of power supply
The leading supply valve is a pressure control of pilot valve group
valve, which will reduce pressure for 21 Mpa (
3045 psi ) to 3.5 Mpa (500 psi) from steering 1. Power supply of pilot valve group
system and it is erected with accumulator 2. Screw
which pre-charged nitrogen pressure is 1.5
Mpa (217.5 psi ).
Maintenance
The pilot valve is a non-maintenance valve.
If it is damaged, it should be replaced as a
Port P Brake valve
whole. The steps are shown as follow (See
Fig.1 for the number in brackets.):
Note: Tighten all the fasteners according
Port a of Port b of
to section 38.2 'Technical Conditions for lifting valve lifting valve
Tightening Moment of Standard Bolts and
Nuts'. Fig.14.4-2 Schematic diagram of power supply
Note: Replace all 'O'rings and tighten the of pilot valve group
threads of all hydraulic pipelines.
WARNING
After the engine is shut down, the fluid
pressure will still remain in the system.
Operate the hoist control handle in the left
and right directions for about 15 times. Any
work can performed in the hoist control
system only after it is ensured the pressure
is discharged from the accumulator.
Otherwise, it may result in severe injuries
and deaths.
damage, ensure that the wheels are
chocked properly and the hoist device has
sufficient capacity and can work safely.
14-8 Service Manual


ensure that the body is completely lowered
down, apply the parking brake and shut down
the engine.
2. Continuously operate the hoist lever valve,
release accumulator and chock all wheels
properly.
3. Make the signs on all of the hydraulic
pipelines connected to the power supply of
pilot valve group (1) to facilitate the installation.
Use a proper container to catch the leakage
oil. Remove the hydraulic pipeline and cover
all the ports of pipelines.
4. Remove the screw (2) and valve group (1)
from the mounting support.
5. Mark the positions of joints installed to the
valve, so that they can be used on the new
valve after they are removed from valve group
(1).
6. Install individual joints at the interfaces of
new pilot valve group (1).
7. Use the screw (2) to fix the pilot valve group
(1) onto the mounting support.
8. Remove the cover from the hydraulic
pipeline, and install the pipeline onto the valve
group (1) according to the signs made during
disassembly.
9. Check the oil level of the tank of hoist and
disc brake cooling system. If it is relatively low,
it will require filling of oil.
10. Remove the wheel chocks, start up the
engine .
11. Operate the valve control lever, check the
hydraulic pipeline joint for leakage and tighten
according to requirements.
Special tools
No requirement for specialized tools is
described in this section. These tools can be
purchased from the agent.
Service Manual 14-9

14.5 Hoisting Cylinder and

Installation
There are two hoisting cylinders between the
longitudinal beams of frame. The cylinder
through the bearing connected to the body.
The piston rod via the bearing too connected
to the frame. The hoisting cylinder is a two
acting cylinder, the power which drives the
body lower by the second acting of the
cylinder.
Removal
1. Park the truck in a horizontal area, raised Fig.1 Hoisting Cylinder Outside Diagram
body, install the safety pin in the rear part of
truck, apply the parking brake, shut down the
engine and chock individual wheels.
2. Use a proper lifting device to bind the oil
cylinder firmly, and connect it to the lifting
equipment.
3. Place a clean container under the cylinder.
Set the hoisting lever moves on 'FLOAT'
position. Disconnect the hydraulic pipeline and
drain the oil. Makes the signs in the position
of individual oil interfaces, and block them to
prevent invasion of dirt.
4. Remove the screw, washer and upper pin
shaft from the cylinder.
5. Compress the cylinder and use the steel
wire to wrap it to prevent it from extending
during the removal.
6. Move the cylinder to a clean site for
disassembly.
Disassembly
1. Carefully disassemble for further inspects
the internal component of the cylinder.
Inspection
1. Use a proper solvent to completely clean
all parts and use dry soft linen to wipe
them. Carefully clean all grooves so that all
contaminants can be removed.
2. Use compressed air to blow and clean the
14-10 Service Manual

oil passage of individual cylinder tubes and

pistons to remove the contaminants.
3. Under good lighting condition, check
individual cylinder bodies for the presence of
the damages such as welding seam breakage
or obvious scratch and etc.
4. Use a hone to smoothen pushing burr, gap
and scratch. Replace all irreparable parts.
5. Check the threads of all screws and nuts for
damages. If necessary, replace them with new
parts.
6. Check whether all bushes and wearing rings
are excessively worn. If necessary, replace
them with new parts.
7. Replace all sealing elements, O-rings and
dust rings.
Assembly
1. Carefully assemble the oil cylinder. During
the assembly, be careful do not damage the
sealing elements.
warning
Prevent personal injury and property loss
firmly. The chock and the hoist device
should have sufficient capacity. They
should be fixed firmly and can work safely.
Installation
1. Wrap the cylinder with a proper lifting
device. Lift the cylinder onto the truck and
ensure that the lubricating oil port on the
piston rod support abutment of oil cylinder is
oriented to the in front part of truck.
2. Install the upper pins shaft on the piston rod
support abutment of oil cylinder at first, and
use the washer and screw for fixation.
3. Remove the plug. Connect the hydraulic
pipeline to the corresponding oil cylinder
interface according to the signs made during
disassembly.
Service Manual 14-11

4. Start up the engine. Push out the cylinder

tube until the mounting hole in its supper end
is aligned with the hole on the body lifting
support. Install the pin shaft, and use the
washer and screw for fixation.
5. Check the oil level of tank according to
the oil level requirement specified in Chapter
15, 'Hydraulic Tank Mounting'. Remove the
body safety pin and operate the body. Check
individual oil cylinder pipelines for the leakage.
If necessary, tighten the joints to prevent
leakage.

SRT95C Off-Highway Truck Hydraulic Oil Tank Assembly
15 HYDRAULIC OIL TANK ASSEMBLY

15.1 Hydraulic Oil Tank Assembly
1
2
16
17
15
18 14
13
12
11
10
9
5
7
8
3
2
1 2 3 4
1
6 6
Fig.1 Hydraulic oil tank assembly
1.Bolt 10.O-ring
2.Washer 11.Spacer flange
3.Cover Plate 12.Screw
4.O-ring 13.O-ring
5.Oil suction filter element 14.Breather valve
6.Plug 15.Screw
7.Oil suction filter element 16.Cover plate
8.Oil indicator 17.O-ring
9.Box body welding assembly 18.Oil return filter element
Service Manual 15-1

Hydraulic Oil Tank Assembly SRT95C Off-Highway Truck
Overview
The hydraulic oil tank assembly is shown in
Fig.1. The internal structure of hydraulic oil
tank assembly is shown in Fig.2.
The hydraulic oil tank assembly is composed
of cabinet welding assembly (9), oil suction
filter (5 , 6), oil return filter (18), breather valve
(14), oil sign (8), check valve (11), seal ring
and fastener, two flanged cover plates (3).
The oil tank is internally isolated by three
clapboards. Clapboard I divides the oil tank
into two parts as are shown in Fig.2; the left
side is steering and brake system oil tank and
Partition
the right side is the tank of hoist and cooling
system; clapboard II divides the oil suction
Partition Partition
area and oil return area of tank of steering
and brake system; clapboard III divides the oil Fig.2 Hydraulic oil tank partition structure
suction area and oil return area of the tank of
hoist and cooling system.
Operating principle
The clapboard structure of hydraulic oil tank
is seen in Fig.2. The operating principle of
hydraulic oil tank is seen in Fig.3. The port A B
position of hydraulic oil tank is seen in Fig.4;
the digits in Fig.(1-4) are corresponding to
letters.
The hydraulic oil tank assembly is divided into
two parts by clapboard I in Fig.2 such as the
steering and brake system oil tank and the Q C
hoist and cooling system oil tank.
The function of each port of the hydraulic oil D
tank: E
F
Port A: Connect the breather valve of the
G
hoist and cooling system tank H
Port B: Connect the breather valve of the I
steering and brake system tank J
Port C: Connect the port T of the steering

valve group P O N M L K
Port D: Connect the prot T of the braking valve
group Fig.4 Diagram of hydraulic oil tank interface
Port E: Connect the prot T1 of the braking
valve group
15-2 Service Manual

Port F: Connect the port T of the Leading oil

14 8
sources valve group
Port G: Connect the prot T of the foot-operated
B R
valve
5
Port H: Connect the pressure switch
Steering and brake oil tank

J
Port I: Connect the temperauture switch
Port J: Connect steering pump inlet K
18
Port K: Connect steering pump outlet C Steering pump
Port L: Connect the cooling check valve
Port M:Connect cooling pump inlet D
Port N: Connect cooling pump inlet E
Port O: Connect hoist pump inlet F
Port P: Connect cooling system confluence G

H
block return opening
I
Port Q: Connect hoist pump outlet
Port S: Connect the oil sign of the steering Lifting pump
and brake system tank . Lifting and cooling oil tank 7 M
Port T: Connect the oil sign of the hoist and
cooling system tank
7 N
The oil in the steering and brake system is
pumped by the steering pump installed on 7 O
transmission PTO through oil suction filter (5) Cooling pump
Q
port J; the oil is pumped into the steering valve
18
group of steering system and the brake valve
group of brake system. The internally leaked L
oil of pump returns to the steering and brake
P
oil tank from the outlet of steering pump and
through port K. The returned oil of the steering A S
system returns to the steering and brake oil
tank from the steering valve group port T and
14 8
through port C indicated on Fig.3 and through
oil return filter (18).
The oil hoist system is pumped by the gear
Fig.3 Functional diagram of hydraulic oil tank
pump installed to engine PTO through oil
suction filter (7) and port O; the oil is pumped
into the hoist valve of hoist system. If the
valve spool of hoist valve is located at the
hoist or forced landing position, the hydraulic
oil will enter the hoist system. The returned
oil will flow to the balanced valve group port T
through the hoist valve port T and then flow to
the tank of hoist and cooling system through
port Q indicated on Fig.3 and oil return filter
(18); when the hoist valve spool is located at
Service Manual 15-3

the neutral position, the hydraulic oil will enter

the confluence block and disc brake cooling
system; the other end of confluence block
is installed with a check valve with settling
pressure of 0.4MPa; when the cooling oil
pressure is higher than the settling pressure,
some oil will directly flow to the tank of hoist
and cooling system through the confluence
block, check valve 11 and port M indicated
on Fig.3. Oil return filter (18) are installed
with bypass valves, which will open when the
oil pressure increases to 3.4 bar due to the
blocking of filter. The oil will directly flow back
to the oil tank through check valve.
The pressure oil of disc brake cooling system
is pumped by the double-gear pump installed
to engine PTO through oil suction filter (7),
port M, N, and into the confluence block and
the disc brake cooling system; the returned oil
gathers at another confluence block and flows
to the hoist and cooling oil tank through port Q.
(14) indicates breathe valve respectively
installed to port A, port B of two oil tanks; (8)
indicates oil pointers respectively installed
to port P, port Q of two oil tanks; liquid level
sensors are respectively installed to port D,
port A of two oil tanks; when the liquid level
drops under a safe level, a signal will be sent
to light the alarm indicator on the instrument
panel. Meanwhile, the monitor will display
different fault codes; in addition, the two oil
tanks are installed with oil drainage cover (6)
respectively for maintenance.
The flange at port H of the steering and brake
oil tank is installed with an oil temperature
switch and an oil pressure switch; if the oil
temperature reaches 95C or the oil pressure
reaches 0.17MPa, the alarm indicator on the
instrument panel in cab will light. Meanwhile,
the monitor will display different fault codes.
Check the oil level

Cold check
Unless otherwise specified, the number in
15-4 Service Manual

bracket is detailed in Fig.1.

The tank of steering and brake system:
Stop the engine, turn the steering wheel left
and right, release the steering accumulator
pressure; continuously operate the foot
valve to release brake accumulator pressure
till the oil level reaches in the middle of oil
indicator(8). Refuel the tank of steering and
brake system as required with the hydraulic oil
specified in section 36.1 'LUBRICATION AND
MAINTENANCE' till the oil level reaches the
middle of oil indicator(8), and then mounts the
cover plate (5)back.
The tank of hoist and cooling system: Shut
down the engine, completely lower down the
body; the oil level should be kept in the middle
of oil indicator (8). Refuel the hoist and cooling
oil tank in accordance with the hydraulic oil
specified in section 36.1 'LUBRICATION AND
MAINTENANCE' till the oil level reaches the
middle of oil indicator (8), mounts the cover
plate (5)back.
Note:
1. Park the truck at a flat area when checking
the oil level.
2. The normal oil level should be fully indicated
by oil indicator (8) if the oil is at working
temperature.
In order to prevent the blowby between the
tank of steering and brake system and the
tank of cooling system which results the
leakage of oil from vent filter and hydraulic
pump damage, a 10mm through-hole of
200mm away from the tank top is arranged
on clapboard I between two oil tanks. The
blowby usually happens under the following
two conditions: 1) Hoist valve blowby: The
hoist valve cavity oil with the pressure of
18MPa comes from tank of hoist and cooling
system; the hoist valve control cavity oil with
the pressure of 3MPa comes from the steering
and brake oil tank; When the valve spool is
working, the oil will leak from high pressure
cavity to low pressure cavity, that is, the oil
Service Manual 15-5

blows by from the tank of hoist and cooling

system to the tank of steering and brake
system; such blowby is usually regarded as
rational leakage; 2) Brake blowby: The parking
brake oil comes from the stank of steering and
brake system with the pressure of 8.3MPa;
the travelling brake oil comes from the tank of
steering and brake system with the pressure
of 5.3MPa; the brake cooling oil comes from
the hoist and cooling oil tank with the pressure
smaller than 0.4MPa; if the brake seal is
damaged, the hydraulic oil will leak from high
pressure cavity to low pressure cavity, that is,
the oil blows by from the steering and brake oil
tank to the tank of hoist and cooling system; in
such case, the truck must be parked for repair.
Replacing the hydraulic oil

Unless otherwise specified, see Fig.1 for the
number in bracket
Tank body welding assembly (9) should be
emptied and cleaned before replacing the
hydraulic oil. Refuel clean and specified
hydraulic oil according to section 36.1
'LUBRICATION AND MAINTENANCE'.
Replacing the filter element

number in bracket.
Replace oil suction filter element (5), (13),
and oil return filter element (18) according
t o s e c t i o n 3 6 . 1 ' L U B R I C AT I O N A N D
MAINTENANCE'.
WARNING
loss, ensure that wheel chocking material
is fixed properly and it has sufficient
capacity and works safely.
1. Place the truck in a flat working area,

15-6 Service Manual


the engine.
2. Rotate the steering wheel for several rounds
to release steering accumulator pressure;
continuously press the foot valve down to
release brake accumulator pressure; chock
the wheels, and set the accumulator main
switch to 'off' position.
3. Place a proper container, remove the end
cover from tank body welding assembly (4),
discharge the hydraulic oil, reinstall the end
cover and tighten again.
4. Remove bolt (1), washer (2) from tank body
welding assembly (9) and take down oil tank
cover plate(3).
5. Remove and discard oil suction filter
element (5), (7) and oil return filter element (18)
from tank body welding assembly (9).
6. Install new oil suction filter element (5),
(7)and oil return filter element (18) to tank
body welding assembly (5) and tighten with a
special tool.
7. Replace O-ring (4), install cover plate (3),
bolt (1), washer (2) again onto tank body
welding assembly (9) and tighten bolts with a
torque spanner.
8. Refuel the oil tank to correct liquid level
according to section 36.1'LUBRICATION AND
MAINTENANCE', then mounts the breath
valve.
9. Remove wheel chocks, start the engine, fill
the system pipeline and check the liquid level
according to 'Oil Level Inspection'.
Oil tank assembly

Disassembly
number in bracket.
WARNING
In order to prevent personal casualty and
equipment damage, make sure the wheels
Service Manual 15-7

are securely chocked and the hoist device

is capable of working safely.
1. Place the truck in a horizontal working area,

the engine.
2. Chock all the wheels.
3. Remove two end covers (6) from the
hydraulic oil tank assembly, discharge the
hydraulic oil into a proper container, reinstall
the end cover and tighten it.
4. Mark all the pipelines connected to the oil
tank, use a proper container to collect the
leaked oil, remove all the steep pipes and
rubber hoses connected to the oil tank, and
cover up the pipe ends with covers or end
covers.
5. Lift the oil tank assembly with a proper hoist
device.
6. Remove the bolts, nuts and washers on
the two sides of oil tank assembly used for
fastening.
7. Move the hydraulic oil tank assembly to a
proper site for disassembly.
Disassembly
number in bracket.
Remove all the parts from the hydraulic oil
tank assembly.
WARNING
The oil tank is heavy. In order to prevent
personal injury and equipment damage,
make sure the hoist device has sufficient
bearing capacity and is fastened correctly.
Inspection
number in bracket.
15-8 Service Manual

WARNING
Please wear appropriate protective cover
when blowing the oil tank and part with
compressed air, in order to prevent liquid
splashing.
1. Clean the hydraulic oil tank assembly and

its parts with kerosene and blow dry with
compressed air.
2. Check the oil tank welding seam and
internal welding pieces for crack and leakage.
3. Check oil suction filter element (5), (7) and
oil return filter element (18) for damage, and if
necessary, replace with new parts.
4. Check breath valve (14) for damage, and if
necessary, replace with a new one.
5. Check 'O'ring (4) for damage, and if
necessary, replace with a new one.
Assembly
number in bracket.
Install all the parts of the hydraulic oil tank
assembly indicated on diagram.
Installation
number in bracket.
Note: Tighten all the hydraulic pipelines with
O-ring end seal.
WARNING
In order to prevent personal injury and
equipment damage, make sure the wheels
are chocked, the chocking materials
and hoist device have sufficient bearing
capacity and are connected reliably.
1. Lift the hydraulic oil tank assembly to
Service Manual 15-9

installation screw hole with an appropriate

hoist device and fasten the hydraulic oil tank
with bolts, washers and nuts.
2. Remove the end covers and install
all the hydraulic pipelines to the oil tank
assembly according to the signs made during
disassembly.
3. Refuel hydraulic oil to the oil tank
according to section 36.1'LUBRICATION AND
MAINTENANCE' and mounts the cover plate
(5)back..
4. Start the engine, fill the pipeline of hydraulic
system with oil, stop the engine, and check
the oil level of oil tank according to 'Oil Level
Inspection'.
5. Check all the pipelines and joints for
leakage, tighten according to requirements,
and remove the materials for chocking wheels.

SRT95C Off-Highway Truck 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 Fig.1Brake system accumulator
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.
Service Manual 16-1

Brake Pipeline And Joint SRT95C Off-Highway Truck
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
8
inner side of left longitudinal beam of frame. 1
4 6
The major components are: Filter(1), Pressure
3
reducing valve(2), Relief valve(3), Pilot to shift
9 12
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 2
pump, to the pedal valve, front and rear 10 5 7 11
brake circuit accumulators and parking brake
at the rear wheels. The valve also provides
appropriate returns to the steering and brake Fig.1
control tank for the hydraulic oil.
1. Filter
Operating principle 2. Pressure reducing valve
See Fig.2. 3. Relief valve
The hydraulic oil enters the port 'P' of brake 4. Pilot to shift valve
valve group from the steering pump. The oil
5. Solenoid valve
pressure pushes the check valve and allow the
6. Pressure reducing valve
oil flow to the front brake accumulator via the
port 'ACC1' and to the rear brake accumulator 7. Solenoid valve
via the port 'ACC2'.The hydraulic oil flows out 8. Proportional pressure reduce valve
of the brake valve group via the port 'B1' and 9. Shuttle valve
flows to the port 'P1' of pedal valve. It flows to 10. Shuttle valve
the port 'P2' of pedal valve via the port 'B2' of 11. Check valve
brake valve group. 12. Check valve
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.
16-2 Service Manual

Pressure switch
The pressure switch in the position of port
'PS1' and 'PS2' signals the instrument alarm
FB2 G6 RB1 G7 G8 FB1 G9 G10
indicator, when the pressure drops below RB2 RB3
13.1MPa. The instrument alarm indicator will YV2
flash. P3 0.4
PS3 G14
Parking brake pressure switch 'PS3' sends 8.3MPa
T1
G13
T
a signal to illuminate the parking brake light.
G12
When the pressure in the parking brake circuit B3
1
YV3 3
1
A
drops below 6.5MPa. The instrument alarm G11 2 3

2 4
P2 YV1
indicator will flash. T2
B1 ACC1
B2 ACC2
Disassembly
G5
1. Park the truck in a horizontal working G3 G1
PS2
P P1 G4 G2
PS1
area, apply the parking brake, shut down the
engine, continuously operate the pedal valve
and release the pressure of brake power Fig.2
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.
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
Service Manual 16-3

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
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
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
16-4 Service Manual

lower down the port.
Maintenance
Frequently check the brake valve group for
the presence of leakage or damage. Repair or
replace it if necessary.
Note: The brake valve group allows only the
replacement of components.
Specialized tools
No requirement for specialized tools is present
tools and glue can be purchased from the
agent.
Service Manual 16-5

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........................................................................................................................................
E
........................................................................................................................................
G
........................................................................................................................................
PA
........................................................................................................................................
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........................................................................................................................................
........................................................................................................................................
K
........................................................................................................................................
N
........................................................................................................................................
LA
........................................................................................................................................
........................................................................................................................................
........................................................................................................................................
B
........................................................................................................................................
........................................................................................................................................
........................................................................................................................................
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16-6 Service Manual

SRT95C Off-Highway Truck Frame And Installation
1 7 F R A M E A N D
INSTALLATION
17.1 Frame and Installation
7
5 6 8
1 2 3
14 10 9
15
11
12
13
Fig.1-Exploded View of Frame Assembly
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
Service Manual 17-1

Frame And Installation SRT95C Off-Highway Truck
Remove
The following steps provided should be
followed for disassembly of the components
as illustrated in the figure:
WARNING

engine.
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
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
removal.
17-2 Service Manual

SRT95C Off-Highway Truck 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
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
Service Manual 17-3

Frame And Installation SRT95C Off-Highway Truck
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.
17-4 Service Manual

SRT95C Off-Highway Truck Driveline Installation
18 DRIVELINE INSTALLATION
18.1 Front Driveline Assembly
1 2 3
2
4
3
2 2
5
Fig.1 Front Driveline Installation
1. Output flange 4. Driveline assembly

2. Bolt 5. Input flange
3. Universal joint
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
Service Manual 18-1

Driveline Installation SRT95C Off-Highway Truck
vibration and excessive wear during any

operation.
Removal
WARNING
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.

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.
the parking brake and switch off the engine.
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
18-2 Service Manual

components with a soft faced hammer.

Note: Access to driveline assembly can be
obtained from underneath the truck.
Disassembly
joints(3) to driveline assembly(4), remove
universal joints(3).
Apply pressure Maximum allowable
here clearance 0.2mm
Inspection
Spirit level
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, Keep the
ground clean
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 Fig.2 - Checking Parallelism
universal joints mate against for parallelism.
Refer to Fig.2.
5. Check the condition of mounting bolts and
replace if required.
Assembly
Universal Joint
1. Use bolts (2) securing universal joints(3) to
driveline assembly(4). Tighten bolts (2) to a
torque of 280Nm (207lb-ft).
Installation
WARNING
Service Manual 18-3


running.

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.
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 280Nm (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.
18-4 Service Manual

Special tools
Special torque specification

Torque
Fig. No. No. Name
Nm lbft
1 2 Bolt 280 207
Service Manual 18-5

18.2 Rear Driveline Assembly
1
2 3 2
4
2 3 5
2
Fig.3 Rear Driveline Installation
1. Output flange 4. Driveline Assembly

2. Bolt 5. Input flange
3. Universal joint
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.
handling the driveline since chips, dents, burrs
or deformity on any rotating mass creates
vibration and excessive wear during any
operation.
18-6 Service Manual

Removal
WARNING
running.

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.
the parking brake and switch off the engine.
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).
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.
Service Manual 18-7

Disassembly
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
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
WARNING
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.
18-8 Service Manual


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.
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 Nm (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
Service Manual 18-9

Special torque specification

Torque
Fig. No. No. Name
Nm lbft
3 2 Bolt 470 348

SRT95C Off-Highway Truck Air Cleaner And Mounting
19 AIR CLEANER AND MOUNTING

19.1 Air Cleaner and Mounting
5
4
2 6
3
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
Service Manual 19-1

Air Cleaner And Mounting SRT95C Off-Highway Truck
Overviev
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. STOP
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 Fig.2 Air Cleaner Restriction Indicator Light
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 cleaners 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).
19-2 Service Manual

5
6 13
16 8 16 7 15
13 9 14
15 13
15
14 17 14
13 16
10
15 11
17
14 4
16
15
13 3
16
2
16
1
1
12
16
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
Service Manual 19-3

Maintenance
WARNING
A lways shutdown the engine bef o r e
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

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).
19-4 Service Manual

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
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).
Service Manual 19-5

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,
19-6 Service Manual

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
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
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
Service Manual 19-7

hand for replacement to prevent unnecessary

downtime of the vehicle.
Measuring air restriction

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.
19-8 Service Manual

c. If the restriction exceeds the levels

indicated, engine performance will be affected.
Primary filter element should be cleaned or
replaced.
Special tools
Refer to Section 36.3 'MAINTENANCE
TOOLS' for part numbers of service tools
referenced in this section and general service
tools required. These tools are available from
your dealer.
Service Manual 19-9

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SRT95C Off-Highway Truck Exhaust System Assembly
20 EXHAUST SYSTEM ASSEMBLY

20.1 Exhaust System Assembly
15
13
16 10 13 13
10 14
6 9 6 17
6 9 6
10 9
10 10
6 12 10
9
10 2
11 1
15 2
69 5 7
11 1 8 6 6 9 10
6
7 5
6
5 4
18 7 3
2 2
10
10 1
10
10
9 1
9 6
6
19
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
Service Manual 20-1

Exhaust System Assembly SRT95C Off-Highway Truck
Removal
WARNING
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:
apply the parking brake and shutdown the
engine.
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 frameremove
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.
tube3) 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 tube3) from
the truck.
tube (4) and remove washer (6, 9),nut(10)
and U-bolt(19) securing exhaust tube(4)
20-2 Service Manual

SRT95C Off-Highway Truck Exhaust System Assembly
to support(18).Remove connector(1)
gasket(2)securing exhaust tube(4)to
turbocharger,remove exhaust tube4) 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

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).
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).
tube (14) and tighten bolt(16),washer (6, 9),nut
(10)and U-bolt(15) securing exhaust tube(14)
to the platform.
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.
Service Manual 20-3

Exhaust System Assembly SRT95C Off-Highway Truck
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20-4 Service Manual

SRT95C Off-Highway Truck Rear Suspension System
21 REAR SUSPENSION SYSTEM

21.1 Rear Suspension System
Fig.1 Cutaway View of Typical Rear Suspension Cylinder
1.Snap ring 10.Seal 19.plug

2.Bearing 11.Wear ring 20.Guide sleeve
3.Oil fitting 12.Retainer ring 21.Buffer seal
4.Plug 13.O ring 22.Seal-wiper
5.Charge valve 14.Ball 23.Retainer ring
6.Dust boot 15.Bolt 24.Bolt
7.Bolt 16.Cylinder tube assy. 25.Clamp
8.Plate 17.Piston 26.Piston rod
9.Retainer ring 18.Wear ring
OVERVIEW
Oil/gas (nitrogen) rear suspension cylinder is
an elastic device suspending to the rear part
of mining car. It is installed to the rear part
of each longitudinal beam of frame, under
the body and above rear drive axle. The rear
suspension cylinders are used to absorb road
shocks, when the truck hits a bump on the
ground.
Service Manual 21-1

Rear Suspension System SRT95C Off-Highway Truck
OPEARATION
Numbers in parentheses refer toFig.1.
The rear suspension cylinder is composed
of two assembly. Piston rod assembly (26) is
installed to the frame through pin. Cylinder
tube assembly (16) is connected to the rear
axle. The cylinder is charged with oil and
compressed nitrogen. The rear suspension
cylinder works as the elastic elements and
absorber. The piston rod performs advance
and return movement in the cylinder tube to
compress nitrogen and functions as a spring;
the function of absorber can be realized
through oil flow in internal and external
oil chambers in control rear suspension
cylinder. When the truck is kept static, the
compressed nitrogen in internal cavity may
produce sufficient force to support the truck.
If the wheels suffer impact from the ground,
the piston rod will be driven into the external
cylinder barrel and thus to compress the
nitrogen and absorb energy. Meanwhile,
the oil will drive ball (14) to move and open
check valve channel. The oil quickly flows into
circular cavity (cyclic annular volume formed
by piston rod external diameter and cylinder
tube internal diameter) from the main oil
chamber and through the hole on piston rod
wall and valve hole. After the impact force is
absorbed, the increased air pressure will drive
piston rod (26) to move upward to return to the
original position. Meanwhile, the oil in annular
cavity will flow back to the main oil cavity. The
oil pressure will force ball (14) to move and
close check valve channel. The oil only flows
back to the main oil cavity through hole, so as
to restrict the flow in such direction, reduce the
speed of piston rod in returning to the original
position and conduct damp and spring back
control based on flow feature difference of oil.
21-2 Service Manual

6 2,3,4 6
2,3,4
8 8
A
7 7
1 1
5 2,3,4 2,3,4 5
Fig.2 Removal and Installation of Suspension Ride Cylinder
1. Rear ride cylinder 5. Pin Assembly

2. Bolt 6. Pin Assembly
3. Lock washer 7. Dust boot
4. Washer 8. Oil fitting
REMOVAL
WARNING
damage.
Service Manual 21-3

do the job safely.

the parking brake and switch off the
engine.
3. Lift the rear end of the mining car, keep the
distance A between the upper pin and end cap
of guide sleeve is 517mm, and keep the tyres
away from the ground. Fasten the rear axle
assembly with proper cushion block at this
position, then lower the truck slowly to remove
the load of the suspension cylinder, and fix the
frame with cushion block at this position.
4. Release the nitrogen pressure of rear
suspension cylinders according to 'Release
suspension cylinder pressure' in this section.
5. Support the suspension with sufficient force
before remove the pin. single suspension
cylinder weighs for more than 435kg; 19.5L oil
will be charged.
Attach a suitable lifting device or 'come-along'
to suspension cylinder (1). If a 'come-along'
is used, place a bar or heavy pipe through
both body prop pin holes in the frame. Attach
the 'come-along' to the bar or pipe. Place a
suitable strap or chain around suspension
cylinder (1) and take up the slack.
Note: Lower end of suspension cylinder (1)
must be disconnected before upper end.
6. Remove bolt (2), lock washer (3) and
washer (4) used for fastening the suspension
cylinder and rear axle housing, pull out pin
assembly (5); the suspension cylinder may
apply certain pressure to pin when removing
the pin assembly.
7. Remove bolt (2), lock washer (3) and
washer(4) used for fastening the upper end of
suspension cylinder and frame, then pull out
pin assembly (6).
8. Remove the rear suspension cylinder, move
21-4 Service Manual

it to a clean working area for removal; repeat

steps 5-8 to remove another suspension
cylinder if necessary.
18
17
8 19
18
17
16
15
13
12
11
4 9 10
3
2
7
1 6
5
14
2
20 1
1 20
24
21
23 1
25 22
26
Fig.3 Exploded View of Rear Suspension Cylinder
1. Snap ring 14. Bolt

2. Oil fitting 15. Guide sleeve
3. Charge valve 16. Buffer seal
4. Plug 17. Retainer ring
5. Piston rod 18. O-ring
6. Clamp 19. Wear ring
7. Dust boot 20. Bearing
8. Bolt 21. Ball
9. Plate 22. Plug
10. Retainer ring 23. Cylinder tube assy.
11. Wiper-seal 24. Bolt
12. Back-up seal 25. Piston
13. Seal 26. Wear ring
Service Manual 21-5

Disassembly
Numbers in parentheses refer to Fig. 3.
1. Remove clamp(6)used for securing dust
boot (7) to piston rod (5), remove bolt (8)used
for securing dust boot (7) to guide sleeve(15),
then remove dust boot(7).
2. Remove charge valve (3) and plug(4,22)
from cylinder. Drain oil from suspension
cylinder into a suitable container. Do not
disassemble charge valve (3) unless required.
3. Turn over the suspension with a crane and
proper device and fasten cylinder tube assy.
(23) to a proper position for disassembly.
Remove bolts (14) securing guide sleeve (15)
on cylinder tube assy. (23).
4. Install a lifting eye in the top of piston rod
Slide piston rod (5) ,piston (25) and guide
sleeve(15) as an assembly out from top
of cylinder tube assy. (23). Be careful not
to damage the surface of any component.
Place these parts on a clean workbench for
disassembly if necessary. Remove bolt (24)
securing piston(25)to piston rod (5), knock
piston (25) assembly away from the end of
piston rod (5) with a soft hammer, remove
wear ring(26) from piston (25).
WARNING
Flying metal chips. Use a soft drift and
drive to remove piston (25). Flying chips
from a hard metal drift can cause serious
personal injury.
5. Take out the ball (6) from the hole of piston

rod (5).
Note: Take care not to misplace ball (21).
6.Place piston rod (5) assembly securely into
position in a press bed with piston rod eye
down. Press piston rod (5) out of guide sleeve
(15).Be careful not to damage the surface of
parts.
21-6 Service Manual

7.Inspect, remove and discard retainer

ring(17) and O-ring (18) of guide sleeve(15)
outer groove.
8.Inspect, remove and discard steel wire
retainer ring (10), wiper-seal (11), seal(12) and
wear ring(19) in the internal groove of guide
sleeve(15).
9.Remove retainer ring(1) and push out
bearing (20) from piston rod (5) and cylinder
tube(23).
Inspection
1.Wash all parts thoroughly in a suitable
solvent. Dry all parts with compressed air.
Check all inner and outer grooves in guide
sleeve (15) for cleanliness.
2.Inspect cylinder tube assy. (23), piston rod
(5) and piston (25) for scores, scuffing or small
ridges in the walls. Use a fine stone to smooth
out any defective areas. If damage is too
extensive, replace with a new part.
3.Check all cylinder assembly components for
signs of unusual distortion or excessive wear.
Replace defective components.
4.Inspect all plugs (4) and charging valve (3).
Check their seating positions in piston rod
(5) and cylinder tube assy. (23). If threads
in any of these parts are damaged, restore
the threads. If threads are not repairable, the
defective part must be replaced.
5.Inspect both cylinder eye surfaces for
scratches or signs of excessive wear. Check
bearings (20) and snap rings (1) for wear or
warped condition. Replace defective parts.
6.Inspect wear ring (19,26) for excessive wear
or damage. Replace if damaged.
Note: The maintenance standard of bearings
(20) and wear ring (19,26) refer to Fig.1 and
Tab.1.
Service Manual 21-7

Tab.1 Maintenance standard
No. Check item Criteria Remedy
Standard Tolerance Standard

Clearance limit
Clearance size clearance
Shaft Hole
between race Replace
J1
and ball of bearing
bearing 146 0.13- 0.23 0.876
Clearance
between
-0.043 +0.272 Replace
J2 piston rod 200 0.043-0.368 0.4
-0.096 +0 bearing
and wear
ring
Clearance
between -0.05 +0.072 Replace wear
J3 280 0.05-0.368 0.8
cylinder and -0.296 0 ring
wear ring
Assembly
1.Apply a light coating of clean hydraulic
oil to all components to facilitate assembly
procedure. Make certain that all work is
carried out in a clean area so no dirt or other
contaminants can get into the oil.
2.If removed, install snap ring (1) into cylinder
tube assy.(23) eye. Use a hand press to
position bearing (2)against snap ring (1) in eye
of cylinder tube assy.(23). Retain bearing(2)
with snap ring (1). Use similar procedure to
install bearing(2) and snap rings (1) in piston
rod (5) eye end.
3.Install new snap ring (1), seal-wiper (11),
Back-up seal(12), seal(13) and wear ring(19)
into the corresponding groove of guide sleeve
(15). Before seal-wiper is installed, waterproof
glue should be applied onto the external
surface of frame.
4.Install new retainer ring (17) and O-ring (18)
into the corresponding groove on the external
surface of guide sleeve (15).
21-8 Service Manual

5.Use a proper seal expander or similar tool

to prevent the seal ring from damage. Install
the guide sleeve (15) onto the piston rod (5)
carefully.
6.Install ball (21) into the valve seat of cylinder
piston rod(5).
Note: Fix these balls temporarily with a little
clean grease in the rest assembly procedure.
7.Install wear ring (26) on piston (25) and
press piston assembly into position on end of
piston rod (5). Secure piston (25) assembly to
piston rod (5) with bolts (24). Tighten bolts (24)
evenly to a torque of 136 Nm.
8.Install a lifting eye in the top of piston rod
Insert piston rod (5) ,piston (25 ) and guide
sleeve(15) as an assembly through the top of
cylinder tube assy.(23). Pushing piston rod in
until piston (25) bottoms inside the cylinder
tube. Be careful not to damage the surface of
any component.
9.Use a seal shrinker or similar product to
prevent the seal from damage. Align with each
bolt holes and install the guide sleeve (15) into
the cylinder tube assembly carefully.
Note: Because of close tolerances, care will
have to be taken when assembling piston rod
(5) and piston(25) assembly into cylinder tube
(24).
10.Secure guide sleeve (15) to cylinder tube
assy. (23) with bolts (24). Tighten bolts to
torque of 333 Nm.
11.Install dust boot(7) on piston rod(4). Use
clamp(6) , bolt(8) and plate(9) to secure it to
piston rod (5) and guide sleeve (15).
12.Install charge valve (3) and plug(4) on
piston rod. The tighten torque of charge valve
is 50Nm, the tighten torque of charge valve
core is 0.35 - 0.45Nm, the tighten torque of
charge valve protecting cover is 4.5 - 5.5Nm.
Before installation, inspect the seal of charge
valve and plug for signs of damage, replace
them in time if they are damaged.
13.Install suspension cylinder in operation
Service Manual 21-9

position and charge oil and gas into suspension

cylinder according to the requirements of the
charging procedure.
Installation
WARNING
damage, be sure blocking or lifting
equipment
1.Clean all parts surface of suspension

cylinder and frame to make them smooth.
2. Lift rear suspension cylinder with proper
lifting equipment or chain and make sure
the charge valve is outside the cylinder. The
weight of cylinder is 435kg; the oil capacity is
19.5L.
Note: Lower end of suspension cylinder (1)
must be attached first.
3. Apply anti-seeze lubricant to pin assembly
(5).
4. Insert pin (5) through the rear axle housing
and the pin hole of suspension cylinder, push
it to specified position, and fasten it to the rear
axle housing with washer (4), lock washer (3)
and bolt (2).
5. Install upside of suspension cylinder to
frame, insert pin (5) through the frame and
the pin hole of suspension cylinder, push it to
specified position, and fasten it to the frame
housing with washer (4), lock washer (3) and
bolt (2).
6. Remove the lifting equipment or chain from
the rear suspension cylinder.
7.If the opposite suspension cylinder (1) was
removed, follow Steps 1 through 6 to install
the cylinder.
8. Charge the suspension cylinder according
to charging procedure. Check the operation of
suspension cylinder according to the contents

indicated in maintenance and adjustment

section.
Frame B
2
3
Stop block
Cylinder liner
upper end face
A
4
Rear suspension cylinder
Axle housing assembly
Fig.4 Check Length of the Rear Suspension Cylinder
A: Distance between centre of pin and the end cap of guide sleeve
Note: Dimension A =455mm with the truck empty
Dimension A =366mm with the truck loaded
1. Oil fitting 3. Plug(oil fill port)

2. Nitrogen Charging Valve 4. Plug(air exhaust port)

21 2 1
A 3 A
3
4 4
Cut-off valve
Only one side is
controlled when
charging one
5 6 7
The user provides the nitrogen cylinder,

pressure regulator and instruments.
Fig.5 Nitrogen inflation drawing

A: Distance between the center of pin and cap of guide sleeve.
1. Charge valve 3. Nitrogen joint 5. Nitrogen cylinder
2. Plug 4. Cut-off valve 6. Pressure regulator
7. Pressure gauge

Maintenance and adjustment
Periodic maintenance includes the following

steps:
1. Clean the device. Check the signs of wear,
damage or oil-gas leakage. Pay special
attention to the exposed part of piston rod
and inflation valve. Repair or replace them as
required.
Note: The dust boot is equipped with zipper
which can be replaced without remove
suspension cylinder or pin.
2. Check all parts for signs of wear or
looseness. In case of any looseness, repair or
replace them if necessary.
3. Inspect the exterior of suspension cylinder
for signs of oil leakage. Repair or replace
according to the requirements and add oil
again according to the method described in
the instructions.
Note: Refer to following procedure in this part
for detailed instructions of oil level inspections.
4. Check the relevant operating conditions of
suspension cylinder according to the following
method:
1)Run the truck and make that two suspension
cylinder can achieve a balance at the normal
2) Position the empty truck on a flat ground.
Measure the distance A between the center
of pin and the end cap of guide sleeve as
shown in Fig.8. The value obtained should
be approximately 455mm (with the error
not exceeding 10mm; refer to Fig. 8). If the
distance is not in this range, check and
adjust the nitrogen pressure according to the
procedure below this part. The following signs
indicate that it is necessary to maintain the
interior of suspension:
a. There is sign of oil leakage in the
surrounding of suspension cylinder.
b. The gas column height changes frequently.
It is required to charge nitrogen.
Note 1: The reduction in the gas column

height is usually accompanied by the loss of

gas.
Note 2: At the circumstance of normal gas
column height, the offset of gas height
indicates that the oil is losing.
Note 3: The traveling or excessive elasticity
of gas will lead to repeated operation of
3) After the suspension cylinder is inflated
to the correct height, apply the rated load,
park the truck on a flat ground, the distance
A between the center of pin and the end cap
of guide sleeve should be equal to 366mm
or higher. (If A is less than 366mm, check the
truck is overloaded or not. If not, deflate and
add oil, inflate gas again ).
Note 4: The unsmooth traveling or excessive
elasticity of gas column will lead to repeated
operation of suspension at its travel terminal.
Charging rear suspension cylinder
WARNING
Lifting heavy parts or machines. To prevent
personal injury and property damage, be
sure blocking or lifting equipment is of
do the job safely.
WARNING
damage.


do the job safely.
Relieving Cylinder Pressure
Note:Truck must be unload and on a level

surface prior to relieving suspension cylinder
pressure.
1.Support the frame near the suspension with
blocking and/or a hydraulic jack with adequate
capacity.
2.Place a 35mm cushion block between the
frame and oscillation stopper to facilitate
charging procedure.
3.Remove the cap from nitrogen charging
out on the valve 1/4 to 1/2 turn counter-
clockwise and depress the valve core. If no
gas escapes, continue to turn the hex nut in
1/4 turn increments until the nitrogen releases
as the valve core is depressed.
4.Remove blocking or release pressure on the
hydraulic jack and allow the trucks weight to
fully retract the suspension cylinder rod.
5.Depress nitrogen charging valve core again
to be sure all pressure has been relieved.
Note:Nitrogen leaving the cylinder will often
carry oil with it. This results form foaming
of the oil in the cylinder. The foaming takes
place as nitrogen which was dissolved in the
oil at high pressure expands at atmospheric
pressure. The oil lost in this operation must be
replaced in the charging operation. The longer
the oil is allowed to stand at atmospheric
pressure after discharging cylinder, the easier
it will be to purge cylinder of bubbles in the oil
when recharging.

WARNING
Pressurized cylinders. Keep valve core
depressed until all gas is bled from
cylinder. Failure to release air pressure
may result in personal injury or property
damage.
Charging Instructions
Note1: This procedure should be performed
Note2:To ensure that both suspension
cylinders will be equally charged to the
required height specifications and equal
pressures, both cylinders should be charged
simultaneously. Also when front suspension
cylinders are being charged, both rear
suspension cylinders should be extended
equally. This can be accomplished by placing
equal thickness blocks between axle and
frame at the bump stops. It may be necessary
to raise frame slightly to install spacers. Be
sure to remove spacers when charging is
complete.
Note3:The pressure of a confined gas varies
directly with its temperature. Hence, extreme
changes in suspension cylinder ambient
temperature will change its nitrogen charge
volume and,consequently, its operating height.
It might be necessary, therefore, to add or
remove nitrogen to maintain proper cylinder
height as ambient temperature changes.
WARNING
Pressure', before removing valves or


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
1. Position the truck in a level work area. The

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 ).
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
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 chapter36.1LUBRICATION
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

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: -70C (-55C); 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 .
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
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 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.

otherwise specified. 5
3 47 6
Please use the tool assembly including tee
fitting(4, Fig.6), hose (8, Fig.6), cutoff valve (5,
1
Fig.6) and charging joint(9, Fig.6) for charging 8
the left and right suspension cylinder. Tool
assembly is detailed in Fig.6 nitrogen charging 2 6
7
tool. 5
Note: Use the gas pressure regulator installed
9
on the nitrogen cylinder to protect the
pressure gauge (The nitrogen cylinder is not 10 8
supplied with the nitrogen charging assembly). The user should provides the nitrogen
An accurate and reliable pressure gauge cylinder and pressure regulator.
is very critical to the correct adjustment of

Fig.6 Nitrogen inflation tool
suspension.
Note: When the charge valve protecting 1. Elbow 6. Pipe joint
cover is removed, no residual gas pressure 2. Bleeder valve 7. Pipe joint
is allowed. If any, the protecting cover can 3. Pressure gauge 8. Line
4. Tee piece 9. Nitrogen charging joint
be removed after the pressure is completely
5. Cut-off valve 10. Pipe joint
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.

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

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 isnt 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 - 0.45Nm.
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 - 5.5Nm.

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
Cylinder pressure
'A'
Truck
A=455mm 1.5MPa
empty
Truck
A=366mm 10MPa
loaded
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

Torque
Fig. No. Item No. Name
(Nm)
3 14 Bolt 333
3 24 Bolt 136

........................................................................................................................................
........................................................................................................................................
........................................................................................................................................
........................................................................................................................................
........................................................................................................................................
........................................................................................................................................
........................................................................................................................................
E
........................................................................................................................................
G
........................................................................................................................................
PA
........................................................................................................................................
........................................................................................................................................
........................................................................................................................................
........................................................................................................................................
K
........................................................................................................................................
N
........................................................................................................................................
LA
........................................................................................................................................
........................................................................................................................................
........................................................................................................................................
B
........................................................................................................................................
........................................................................................................................................
........................................................................................................................................
........................................................................................................................................
........................................................................................................................................
........................................................................................................................................
........................................................................................................................................
........................................................................................................................................

SRT95C Off-Highway Truck Radiator Guard
22 RADIATOR GUARD
22.1 Radiator Guard
1 4
2 5
3 6
5
13
12 7
11
13
10
9 14
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
Service Manual 22-1

Radiator Protective Cover SRT95C Off-Highway Truck
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
otherwise specied.
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
otherwise specied.
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
removal.
22-2 Service Manual

SRT95C Off-Highway Truck Body And Mounting
23 BODY AND MOUNTING

23.1 Body and Mounting
42
40
39
38
41
37
36
35
34
32
33
31
29
30
28
3
27
5
26
23 21 25
24
22
20 21
1
17 18
10
19
2
14
15
16
13
12
3
4
5
11
10
9
8
5
7
4
36
Fig.1 - Exploded View of Body and Mounting
Service Manual 23-1

Body And Mounting SRT95C Off-Highway Truck
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
23-2 Service Manual

Overview
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
Service Manual 23-3

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
Note: Approximate weight of body (1) is
13,631kg.
WARNING

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).
23-4 Service Manual

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 (121314 15) to body (1).
Remove and discard damping pads (16) and
shims (121314 15).
Note: Do not remove damping pads (16) and
shims (12131415) unless damping
pads (16) are being replaced.
Installation
WARNING

torques in 36.2, STANDARD BOLT AND NUT
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
Service Manual 23-5

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 (121314 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
(12131415 ) 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

torques in 36.2, STANDARD BOLT AND NUT
23-6 Service Manual

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(12131415) 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 (12131415 ) 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
(12131415) 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
Service Manual 23-7

(9&10), and bolts (11).

7. Lift or lower body (1) to check correctness
of brace piece axial pins(28) clearance.
Note: Operation should be performed
according to steps specified in
'REMOVAL','INSTALLATION' as well as
Chapter 14.5 'HOISTING CYLINDER'.
Cleaning heated body

Note: Optional exhaust heating of the body
is available for dumping of sticky or frozen
materials.
It is necessary to periodically clean out the
carbon deposits in the body heating passages
which restrict the flow of exhaust gases. This
reduces the engine efficiency and prevents the
body from being heated.
Occasionally the carbon deposits are ignited
by spontaneous combustion or by heat from
the exhaust gases. The resulting fire in the
heating passages is helpful in that it burns
away some of the carbon and helps keep the
body passages open. However, the fire should
be allowed to burn itself out and should not be
encouraged by pouring fuel into the passages.
If excessive exhaust back pressure develops,
another method of cleaning out the body
passages is to remove the heat channel
plates and scrape the carbon from the heating
passages. To remove the heat channel plates,
burn out the weld around them and lift out
from the body assembly with suitable lifting
equipment.
Note: Prior to welding on the truck, follow the
procedures outlined for 'Welding' in Chapter
17, 'FRAME AND INSTALLATION'.
After the heating passages are thoroughly
cleaned, replace the heat channel plates
and weld to sides and bottom of the body
assembly.
Maintenance
Lubricate body brace piece axial pins at the
intervals stated and with lubricant specified
23-8 Service Manual

MAINTENANCE'.
Check the fasteners on plates of brace piece
axial pin everyday to ensure no looseness and
dropping.
Check the drainage holes of body to keep it
unblocked.
After each 250 hours of operation, check
whether damping pad can fit frame.
Adjustment should be performed if necessary.
Damping pad should be replaced in case of
damage or wearing.
Service Manual 23-9

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SRT95C Off-Highway Truck Illuminating Lamp And Installation
24 ILLUMINATION LAMP AND INSTALLATION

24.1 Illumination Lamp and Installation
9
1
3 8
4
3 3 5
6
Fig.1 Front illumination lamp and installation
1. Work Lamp 6. Nut

2. Front combination signal lamp 7. Tail light system
3. Headlamp 8. Fog light
4. Washer 9. Bulb
5. Washer
Service Manual 24-1

Illuminating Lamp And Installation SRT95C Off-Highway Truck
3 4
9
8
4
15
5 14
6
7
10
11
12
13
Fig.2 Tail Light System
1. Retarder lamp 9. Bolt

2. Camera 10. Washer
3. Rear combination signal lamp 11. Washer
4. Fog lamp 12. Nut
5. Washer 13. Alarm
6. Washer 14. Reverse lamp
7. Nut 15. Frame
8. Bolt
24-2 Service Manual

Illumination system
The illumination system of SRT45 off high-way

truck is divided into the headlamp system and
the tail light system. The headlamp system
includes: headlamp (high beam, dipped
beam), side marker lamp F, L and R, steering
lamp F, L and R; the tail lamp system includes:
fog lamp B, L and R, side marker lamp B, L
and R, brake lamp B, L and R, steering lamp
B, L and R, retarder lamp, reverse lamp and
alarm.
1. The side marker lamp is used to indicate
the length and width of the truck in the night;
2. The fog lamp helps to improve visibility in
foggy day The high beam is used while the
truck is running normally. When the trucks
is passing by, switch to dipped beam. When
passing through a road junction or overtaking
another truck, a prompt should be provided by
switching between high and dipped beams.
4. The steering lamp is flashing intermittently
when the truck is changing its direction.
5. The brake lamp is turned on when the
operator is going to stop the truck.
6. The reverse lamp is turned on when the
operator is going to reverse the truck.
7. The retarder lamp is turned on when the
transmission retarder or disc retarder is acted.
Service Manual 24-3

Maintenance
No. Fault Troubleshooting

check the wiring whether loose
check X power supply whether exist
check output signal from headlamp rocker switch
1 No headlamp whether exist
check the bulb if one light failsthen check the
fuse in central distribution box whether broke.

check flasher power supply and output in central
distribution box whether exist
2 No steering lamp
check output signal from combination switch
whether exist.

check output signal from side marker lamp rocker
3 No side marker lamp
switch whether exist.

check output signal from fog lamp rocker switch
4 No fog lamp whether exist
check the fuse in central distribution box whether
broke.

check output signal from 2023 whether exist
5 No brake lamp
broke
check output signal from brake press sensor
whether exist.
check output signal from brake press sensor whether
continue exist, if yes to change the sensor.
6 Brake lamps can't be turned off
24-4 Service Manual


check output signal from 2023 whether exist
check input signal from retarder switch or linear
7 No retarder lamp
actuator whether exist
check output signal from transmission retarder
rocker switch whether exist.
8 No reverse lamp or alarm
broke
check input and output signals from 2023 whether
exist.
Cautions on use of lamps

1. Do not turn on/off frequently.
2. If there is any crack , the lamp is prohibited
from being turned on and should be replaced
timely. Cut off the power before replace the
lamp or bulb.
Refer to the following circuit diagram for
specific circuits and components.
Service Manual 24-5

24-6
AX AX
-02F2 A30 A30
30 20A 30
X X 03.2B
01.12G
10 10
AX 10B1 A30 XB2 XB3 30B5 30B6

30B2 30B2 30B2 10B2
5 9
-02S3
-02F3 -02F4 -02F5 -02F7
-02F1
10A -02K4 20A 15A 10A 10A
1 0
1 10
0224 0225 0226
G
31 -02K5
0201 0211
0201a
0205 -02K1 -02K2 -02K3 -02K4
0211a
PE
0220

Illuminating Lamp And Installation
-02S1 S E L D V A
II 0219
J
I 0
G F U N K J C M B 5 6 9
-02S2

1 0
1 7 2 8 10
0208 -02H4
0202 0203 0206 0207
Service Manual
0204

M

-02K1 -02K7 -02K9 -02K2 -02M1
Fig.3 Circuit diagram of light illumination system (1)

-02K8 -02K10 0215 0214 0218
0209
-02K3 0216a 0216b 0216c 0217a 0217b 0217c
-02F6
10A
+
31B19 31B20 31B20 31B2 31B18 31B18 30B3 -02E2 -02E3 M

-02H2 -02H1 -02M2 DC
-02E1 -02E4 -02H3
03.4C
03.5C
-02E2
-
31B5 31B6

31B4
31B10
31
31B7 31B8 31B9 31B11 31B12 31B12 31B13 31B14 31B15 31B16 31B17 31
01.12H 03.2G
AX AX
A15 A15
02.12B X X 04.2B
10 10
10C3
AX XC2 A15 A15 XC2 AX 10C4
10C1
-03F1 -03F2

-03S1 5 15A 15A
6 9 -03S2 5 6 9 -03S3 5 6 9
0311
1 0 1 0 1 0
7 1 8 2 10 1 7 2 8 10 1 7 2 8 10
-03K1 -03K3
31C2 31C12 31C21
PE
PE
PE
Service Manual
0308
0303a 0303b 0304a 0304b 0305a 0305b 0306a 0306b 0306c
0301

0308a 0308b 0309
-03H1 -03H2 -03H3 -03H7
0302a 0302b 0302c -03H5 -03H6 -03H8 -03H9
-03K1 -03K3 -03K2
-03R1 -03R2 -03H4
-03E1 -03E2 -03H10 -03E5 -03E6
31C1 31C2 31C6 31C7 31C8 31C9 31C10 31C11 31C13 31C14 31C15
31
31C3 31C4 31C5 31C18 31C19 31
02.12H 04.2H
25-1
25-2
X X AX AX
13.11H
XQ1 XQ2 XQ3

AX
08.3C 08.3C 08.3C 08.3C
2023 2023 2023 2023 -15F2

-15F3
10A
10A
-15F1 -15F4
DO_03 DO_04 DO_06 DO_07 10Q1
5A 5A 1507
XM2.2 XM2.3 XM1.18 XM1.19

-15K2
1502
1501
-15S2 1 7 2 8 9
1503
1505 XQ1
1 0
-15K3 5 6 10
-15K1

-15K1 1509
1506a 1506b 1509a

1510
1509b
-15K3 -15K2
Service Manual
1511
1504a 1504b

-15H6 -15H7
X3
178 M
20
-15H1 -15H2
-15H3 -15M1
XM2.12
DI_11

31Q1 31Q2 31Q3
2023
31Q8 31Q8 31Q9
08.3C
31Q4 31Q4
31
14.11H
Names of standard components

02E1Dipped beam lamp L1 03H1Steering lamp F, L
02E2Dipped beam lamp R1 03H2Steering lamp B, L
02E3High beam lamp L1 03H3Steering lamp F, R
02E4High beam lamp R1 03H4Steering lamp B, R
02F1Wiper fuse 03H5Side marker lamp F,L
02F3Dipped beam lamp fuse 03H6Side marker lamp F,R
02F4High beam lamp fuse 03H7Side marker lamp B,L
02F5Washer pump fuse 03H8Side marker lamp B,R
02F6Wiper fuse 03H9Side marker indicator
02F7Horn fuse 03F1Fog lamp B fuse
02H1steering indicator R 03H1Steering lamp F, L
02H2steering indicator L 03H10Fog indicator
02H3High beam indicator 03K1Fog lamp relay
02H4Horn 03S1Fog lamp switch
02K1Dipped beam lamp relay 03S2Side marker lamp switch
02K2High beam lamp relay 15F1Reverse lamp and buzzer fuse
02K3Washer pump relay 15F2Brake lamp fuse
02K4Horn relay 15H1buzzer
02K5flasher 15H2Reverse signal lamp
02M1Wiper motor 15H3Retarder lamp
02M2Washer pump 15H6Brake lamp
02S1Combination switch 15H7Brake lamp
02S2Caution lamp switch 15K1Reverse Signal lamp relay
02S3High/dipped beam lamp switch 15K2Brake lamp relay
03E1Fog lamp B, L 15K3Retarder lamp relay
03E2Fog lamp B, R 15S2Transmission case retarder switch
03F1Fog lamp B fuse 15M1Retarder linear actuator motor
Service Manual 25-3

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25-4 Service Manual

SYSTEM
15 15
05.12B 07.3B
30 30
04.11B 07.3B
10 10
04.11B 07.3B
A15 A15
05.12B
15F3
A15F4 10F1 10F2 15F5 15F6

A15
Fig.1 CEC2 ECU wiring diagram

01.7B
85
-06K1 -06S3 -06S4 B6
5 9 5 9
31F2 -06K1
86
08.3C
0 0
2023 7 1 7 1
05.12C
05.12C
31 31
0601
0602a DO_10 357
-06H2 0604
25 VEHICLE DETECTING
PE
PE
CANL
CANH
XM1.22
CAN
0605 0606 0607
XM2.13 177
-06H1 0602
DI_12
XM1.10
Service Manual
PI_01
2023
08.3C
2023
312CM 336A 336C 346 357 08.3C
312NO 177 115 183 184 182 118 126 143
CEC2 ECU VIM

119 186 137 161 178 188
343A 343C
186 178 188

31F1
10F2
31F5
31F4
15.9F
31 31
05.11G 07.3H
25-5
Vehicle Detecting System
Vehicle Detecting System SRT95C Off-Highway Truck
Names of Standard Components

06H1Transmission fault indicator 06K1transmission case fault relay
06H2Over speed indicator 06S4Economic/power mode switch
06S3Stall detection switch CAN1HCAN communication interface
CAN1LCAN communication interface
25.1 Transmission
Refer to Fig.23-1 for specific circuit and
components.
warning
Sliding of truck in neutral position is
strictly prohibited because it will lead to
serious damage to the transmission.
Electronic Control Unit (ECU) - Contains an

electronic microcomputer. The ECU receives
and processes information defining: shift
selector position, throttle position, sump
temperature, input speed, turbine speed and
transmission output speed. The ECU, uses
this information to control the transmission
solenoids and valves, supply system status
V
and provide diagnostic information.
The ECU is programmed to take corrective
action to prevent damage to the transmission T
if a failure occurs in the CEC2 system and
S
has diagnostic capabilities which allow the
serviceman to quickly find and repair or
replace a failed component. The ECU has 3 Fig.2 ECU
connectors; Blue -Transmission Connector (T),
Gray -Vehicle Connector (V), Black - Shifter
Connector (S).
Power Module - The Power Module is located
on the side of the battery box. The Power
Module contains ignition run fuses and relays,
and a timer relay for the switch off function
of the ECU. The ignition fuses and relays
open power to the ECU. On power shut
down the timer relay remains open for a 30
25-6 Service Manual

SRT95C Off-Highway Truck Vehicle Detecting System
second period to allow the ECU to down load

information and close down properly.
CEC2 Interface Box - Provides the electrical
link between the vehicle harnesses and the
CEC2 harnesses. The interface box contains
an ignition signal fuse and function relays.
Operations of Quantum Electronic fuel

control system of engine
If the 'Stop' indicator on the dash panel
is on, it indicates that a major fault of the
engine has been detected. This should be
paid attention to immediately at this time.
The driver should shut down the engine
immediately to avoid serious damages. The
truck should be equipped with the engine
protection system which records the fault code
in case of an engine accident. In case of an
engine accident, the 'detection' indicator will
be on. Based on severity of the accident, the
engine speed and power will drop by different
degrees. If the accident deteriorates, then the
'detection' indicator will flash. At this point, the
driver should shut down the engine to avoid
serious damages.
F o r t h e s h u t - o ff e n g i n e w h o s e e n g i n e
protection system is activated, it can be
started only after the fault is diagnosed clearly
and solved.
Under the following conditions, if the yellow
'troubleshooting' indicator is on, it indicates
that the coolant level is low and therefore, the
coolant temperature increases. Verify if idle
validation and throttle pedal switch mismatch,
the intake manifold temperature is on the
high side, the oil pressure is too low, and the
fuel rail pressure is too high. When 'Stop',
'Warning' and 'troubleshooting' indicators
are on, the electronic fuel control system will
detect the fault and store information into the
memory. If there is any fault interruption, the
computer will determine the change of engine
states and the indicator will be on and off.
A special diagnostic data reader (INSITE)
Service Manual 25-7

can be used to connect the engine and the

memory so as to extract the information
related to the reason leading to the fault. After
the fault is eliminated, the electronic fuel control
system will return to the state that makes the
engine work normally. This data reader can
also identify the real time code from the code
(non-real-time code) stored in the historical
data memory. The non-real-time code can only
be displayed with the data reader. The fault
code recorded in the ECM memory will always Fig.3 Bed Hoist Interlock (body-up switch)
be kept unless it is erased by maintenance
personnel.
The operator can check for active faults by
turning the ignition key switch to the 'OFF'
position, switching the diagnostic switch
'ON' and then turning the ignition key switch
to position '1'. If no active fault codes are
recorded, all three ('Stop','Warning' & 'Fluid')
indicators will come on and stay on. If active
codes are recorded, all three indicators will
come on momentarily. The yellow ('Warning')
and red ('Stop') indicators will begin to flash
the code of the recorded fault. The fault
codes flash in the following sequence: the
yellow indicator flashes once, then there is a
pause where both indicators are off. Then the
numbers of the recorded fault code flash in
red. There is a pause between each number.
When the number is done, the yellow indicator
flashes again. e. G. yellow flashes once -
pause - red flashes twice - pause - red flashes
three times - pause- red flashes five times -
pause - yellow flashes once, indicates fault
code 235. The number will repeat in the same
sequence until the system is advanced to
the next active fault code or the diagnostic
switch is switched to the 'OFF' position. Refer
to 'Electronic Fuel System Diagnostic Codes'
table for fault code descriptions.
25-8 Service Manual

SRT95C Off-Highway Truck Vehicle Detecting System
Table 2 Electronic Fuel System Diagnostic Codes

Error Fault
Description
Code Lamp
111 ECM Hardware Internal Failure - Mission disabling Red
112 Timing Actuator - Mechanically stuck Red
113 Timing Actuator - Component shorted high Yellow
114 Timing Actuator - Component shorted low Yellow
115 Engine Speed Sensor - Both signals lost Red
116 Fuel Timing Pressure Sensor - Component shorted high Red
117 Fuel Timing Pressure Sensor - Component shorted low Red
118 Fuel Pump Pressure Sensor - Component shorted high Yellow
119 Fuel Pump Pressure Sensor - Component shorted low Yellow
121 Engine Speed Sensor - One signal lost Yellow
122 Boost Pressure Sensor - Component shorted high Yellow
123 Boost Pressure Sensor - Component shorted low Yellow
131 Throttle Position Sensor - Component shorted high Red
132 Throttle Position Sensor - Component shorted low Red
135 Oil Pressure Sensor - Component shorted high Yellow
141 Oil Pressure Sensor - Component shorted low Yellow
143 Oil Pressure Sensor - Data below normal range Yellow
144 Engine Coolant Temperature Sensor - Component shorted high Yellow
145 Engine Coolant Temperature Sensor - Component shorted low Yellow
151 Engine Coolant Temperature Sensor - Data above normal range Yellow
153 Intake Manifold Temperature Sensor - Component shorted high Yellow
154 Intake Manifold Temperature Sensor - Component shorted low Yellow
155 Intake Manifold Temperature Sensor - Data above normal range Yellow
221 Ambient Air Pressure Sensor - Component shorted high Yellow
222 Ambient Air Pressure Sensor - Component shorted low Yellow
231 Coolant Pressure Sensor - Component shorted high Yellow
232 Coolant Pressure Sensor - Component shorted low Yellow
233 Coolant Pressure, Engine Protection - Low coolant pressure Yellow
234 Engine Speed - Data above normal range Red
235 Engine Coolant Level - Data below normal range Yellow
254 Fuel Shutoff Value - Component shorted low Red
259 Fuel Shutoff Solenoid - Fuel shutoff valve stuck open Red
261 Fuel Temperature, Engine Protection - Fuel temperature high Yellow
263 Fuel Temperature Sensor - Component shorted high Yellow
265 Fuel Temperature Sensor - Component shorted low Yellow
Service Manual 25-9

316 Fuel Pump Actuator - Component shorted high or low Yellow

318 Fuel Pump Flow - Mismatch between estimated and desired pressures Yellow
342 ECM Not Calibrated - ECM software mission disabling failure Red
343 ECM Hardware Failure - Warning non mission disabling Yellow
346 ECM Software - Read/write, checksum error - Non mission disabling Yellow
415 Oil Pressure Sensor - Data indicates very low oil pressure Yellow
422 Engine Coolant Level Sensor Signals - Data invalid Yellow
423 Fuel Timing Pressure Sensor - In-range failure Yellow
431 Throttle Position Idle Validation Switch - Invalid Yellow
432 Throttle Position Idle Validation Switch - Switch position & throttle percent mismatch Yellow
441 Battery Voltage, Unswitched - Data below normal engine range Yellow
442 Battery Voltage, Unswitched - Data above normal engine range Yellow
451 Fuel Pressure Sensor - Component shorted high Red
452 Fuel Pressure Sensor - Component shorted low Red
455 Fuel Control Valve - Component shorted high or open Red
467 Timing Fuelling Flow - Mismatch between estimated and desired timing Yellow
468 Fuelling Rail Flow - Mismatch between estimated and desired rail pressure Yellow
511 Fuel Control Valve - Component shorted low Red
514 Fuel Control Valve - Actuator mechanically stuck open Red
524 Alternate Droop Switch Fault Yellow
551 Idle Validation Circuit - No voltage detected on both off-idle and idle pins Red
553 Engine Fuelling Pressure Exceeded - Data above normal range Red
554 Fuel Pressure Sensor - In-range failure Yellow
555 Blowby Pressure, Engine Protection - Blowby pressure high Yellow
719 Blowby Pressure Sensor - Component shorted high Yellow
729 Blowby Pressure Sensor - Component shorted low Yellow

10 10
06.12B 10.2B
15 15
06.12B 08.2B
01.5D
0717
15A2
B6 (
15G1 10G1 10G2

B C D E F G A
-07F1 -07S1 2 5 10 -07S2 2 9 -07F2 -07F3
5A 10A 10A
102 1 0 50
31G9
1 3 4 6 9 1 10
CAN
31G2 31G3
0704a 0704b CANL 05.12C
0704c 0705a 0705b
0701 0702 0703
CANH
05.12C
ECM QSX15 24() 14() 10 44 07 08 17 28 18 46 37 36 26 27
50 31
Service Manual
05 38 16 06 48(+5V) 47 49(0 29 30 39 40 50 07(+5) 05(H) 06(L) 19(0V)
0706 0708 0709 0710 0711 0712

0713 0714 0715 0716
-07H1 -07H2
-07H3
C D A
-07S3
3
0707a 0707b 0707c 0707d 31G5 31G6 31G7 31G8 31G9
5 4
-07R3 B
31 31
06.12H 08.2H
25-11
Vehicle Detecting System
Names of standard mounting components

07F1- Indicator fuse 07H1- Engine maintenance indicator ( White)
07F2- ECM power supply fuse 07H2- Engine warning indicator (Yellow)
07F3- ECM power supply fuse 07H3- Engine stop indicator (Red)
07S1- Idle speed adjustment rocker switch 07S3- Coolant sensor
07S2- Diagnostic rocker switch 07R3- Accelerator pedal

Fig.28.1
1 2
1
5
4 6
3 7
A
A

Hydraulic Tank Accumulator RH Cab LH Cab
8 9 11 11 13

SANY MINING EQUIPMENT CO.,LTD

Off-Highway Truck
12 12
Service Manual
10
14

Operation Panel Rear Tail Seat Rear Ride Cylinder Front Frame (Left)
11 11
1
12
A

Front Ride Cylinder Cross Beam of Frame
Fuel Tank
26-1
Arrangement Plan Of SRT95C
26-2
Fig.28.2
15 15

Rear of Carriage (Left Side) Rear of Carriage (Right Side)
Service Manual
15 15

Fender and Platform (Right Side) Fender and Platform (Leftt Side)
Fig.28.3
16 16
SRT95C SRT95C
17 18

Carriage (Right view) Carriage (left view)
Service Manual
19
21 22 23
20

Front Side of Carriage Remote Water Tank Battery box assembly
26-3
Arrangement Plan Of SRT95C SRT95C Off-Highway Truck
26 ARRANGEMENT PLAN OF SRT95C
1.Decal--body warning 13.Truck nameplate

2.Decal--hydraulic illumination 14.Rivet
3.Decal--hydraulic level 15.Decal--tyre warning
4.Decal--accumulator warning 16.Decal--body
5.Decal--cab welding warning 17.Decal--right body
6.Decal--stand forbidden 18.Decal--left body
7.Decal--driving height warning 19.Decal--front body
8.Decal--hydraulic control 20.Decal--water tank open warning
9.Decal--transmission retarding control 21.Decal--battery cable warning
10.Decal--brake retarding control 22.Decal--alternator warning
11.Decal--lifting point 23.Decal--battery earth
12.Decal--ride cylinder press warning
Fig1-Fig3 Decal
26-4 Service Manual

SRT95C Off-Highway Truck Centralized Lubrication System
5
1
6
7
8

3
2

10
11

12

9
3
1
2

Fig.1 Distribution diagram of centralized lubrication trucks
Service Manual 27-1

Centralized Lubrication System SRT95C Off-Highway Truck
Lubrication position corresponding to each serial number of Fig.1:
1.Oil fitting 7.Straight joint core

2.Screw 8.Adaptor outer cover
3.Pipe Clamp 9.liquid pipe
4.Rear distributor 10.Bent joint
5.Bolt 11.Pipe Clamp
6.Straight joint 12.Bent joint core
27 CENTRALIZED LUBRICATION SYSTEM

27.1 Manual Operation-
Centralized Lubrication System
Overview and operating principle:
This system is a manual operation centralized
lubrication system. Fill the butter to a relatively
low position through the pipeline for the limited
height lubrication point which human can
reach.
Disassembly
1. Dismantle the pipe clamp and the protecting
jacket of the lubrication pipe , loosen the
straight joint core(6) or the cap of bend
joint(10), remove the pipe.
2.Fixed the joint jacket(8) with a wrench, Fig.2
contrarotate the striaght joint core(7) or the
bent joint core(12) with other wrench, dismantle
the core.
3. Rolled the tube (9), grasp it in hand.
unscrew the joint jacket clockwise.
4. Finally, remove the lubricating pump, grease
oil filter, step type master oil distributor and
sub-distributor from corresponding mounting Take a little grease
seats.
Installation
Reinstall the all parts of the whole lubrication
system according to a four steps how does to
remove them out from the whole unit before Fig.3
after repairing and cleaning, replace new ones
if it is required. Take a little grease when install
27-2 Service Manual

the joint core.
System commissioning
Oil pipe joint
1.Oiling
Implement oiling according to the instructions
Clamp sleeve
on oil supplement for maintenance and
servicing.
Note: The type of grease used: lithium grease
(calcium grease is prohibited).
Maintenance and servicing

Fig.4
1.Grease supplement
(1).Supplementation method: Refill the grease
to the lubricating points. (Finish this step
slowly. Insure that there are not any leakage
or damages to the pipeline of the system).
(2).Insure cleanliness of grease entering into
the system.
Fig 3. Take a little grease
2.Daily inspection
Regularly observe all of pipeline and joints of
lubrication system at every day to inspects
there are any leakages or damages of the
pipeline or joints of the system, replace them if
required.
Service Manual 27-3

27.2 Automatic Centralized

Lubrication System (optional
configuration)
15
7 18 11
3 5 13
29
23
LINCOLN
24 31
22 21
26 25
20 19
28 27

30
2
4
6
12 178

16
10
14
Fig.1 Arrangement diagram of automatic centralized lubrication system
27-4 Service Manual

Fig.1 Arrangement diagram of centralized lubrication system
29
30
27
28
25
26
23
24
22
21
31
19
20
16
17
18
12
11
13 15
14
3
4
10
8
7
5
9
6
1
Fig.2 Distribution diagram of centralized lubrication trucks
Service Manual 27-5

Lubrication position corresponding to each serial number of Fig.1&Fig.2:
1.Right suspension cylinder-up 17.Right steering coupling bar-inside

2.Left suspension cylinder-up 18.Left steering coupling bar-inside
3.Right suspension cylinder-up 19.Right hoist cylinder-up
4.Left suspension cylinder- down 20. Left hoist cylinder up
5.Right A-shaped arm-front 21.Right hoist cylinder-down
6. Left A-shaped arm-front 22.Left hoist cylinder-down
7.Right A-shaped arm-rear 23.Bridge horizontal stabilizing coupling bar-up
8. Left A-shaped arm-rear 24.Bridge horizontal stabilizing coupling bar-down
9. Double crank-up 25.Right rear suspension-up
10.Double crank-down 26.Left rear suspension-up
11.Right steering cylinder-inside 27.Right rear suspension-down
12. Left steering cylinder-outside 28.Left rear suspension-down
13. Left steering cylinder-outside 29.Right body rollover
14. Left steering cylinder-outside 30.Left body rollover
15. Right steering coupling bar outside 31. A-shaped frame
16. Left steering coupling bar outside
Overview and operating principle:

1. Oiling
This system is a progressive system source of
the centralized lubrication system. The system
mainly consist of electric lubrication pump,
three sub-distributors, pipeline accessories
and control components. The system has
31 lubricating points. When it running, the
pistons does reciprocating motions insider of
the distributor to distributing grease to various
wiring points one by one.
Disassembly
1.Take wiring off from the electric lubrication
pump.
2.Dismantle the pipe clamp and loosen the
winding strap. Dismantle the branch joints from
the lubrication system and remove the master
pipeline between pump, master distributor and
sub-distributor.
27-6 Service Manual

3.Finally, remove the lubricating pump and

sub-distributor from corresponding mounting
seats.
Installation
Reinstall the all parts of the whole lubrication
system according to a four steps how does to
remove them out from the whole unit before
after repairing and cleaning, replace new ones
if it is required.
System commissioning
1.Oiling
Implement oiling according to the instructions
on oil supplement for maintenance and
servicing.
Note: the type of grease used: lithium grease
(calcium grease is prohibited).
Scope of grease use: NLG1 000#~1#
Selections in winter: NLG1 000#~0#
Selections in summer: NLG1 0#~1#
Grease for initial system commissioning:
NLG1 0# Fig.3 Control plate of lubrication pump
2.Setting of program controller

(1).Standard application setting of program
controller is working 6 minutes each 6
hours. initial setting and replacement of new
pipelines, the interval should be set to be 2
hours, working time should be set to be 30
minutes so as to enable grease to fill pipelines.
(The interval do not set to be 0).
(2).Time setting
This system operation modes is time mode
which can be set and adjusted on the program
controller. Open the protect cover from the
pump body. (Fig 4)
Notice: Restore the protect cover after finish
time setting.
Fig.4 Opening the protect cover
Service Manual 27-7

a.Setting the interval time (Blue Button P), Fig

.5
Knob
1 2 3 4 5 6 7 8
position
Hours 1 2 3 4 5 6 7 8
Knob
9 A B C D E F
position
Hours 9 10 11 12 13 14 15
Fig.5 Setting the interval time

b.Setting the working time (Red Button I),
Fig.6
Knob
1 2 3 4 5 6 7 8
position
Hours 2 4 6 8 10 12 14 16
Knob
9 A B C D E F
position
Hours 18 20 22 24 26 28 30
c.Manual button , Fig.7

Starting up the button 5 (which add-ons
lubricating) can run the compel lubricating and
testing whether the system is working order. Fig.6 Setting the working time
Maintenance and servicing:

1.Grease supplement
(1)Supple mentation method: Refill the grease
to the oil tank of lubrication system via grease
gun or other (keep the grease sealed in the
whole process).
( 2 )Ob se rve th e o i l l e ve l re g u l arl y: t h e
lubrication pump equipped with a invisible
tank to the system demand and oil level to
supplement via regularly inspection.
2.Daily inspection:
Regularly observe all of pipeline and joints of
lubrication system at every day to inspects
Fig.7 Manual button
there are an leakages or damages of the
pipeline or joints of the system, replace them if
required.
27-8 Service Manual

Serial No. Fault type Phenomenon Solution for fault

Electric pump does not work a. Check pump circuit
Electric pump does (press the manual lubricating b. The interval do not set to be 0
1
not work button, the pump do not have c. the circuit board of the pump
any action.) has be damaged.
The output pressure The pressure of oil outlet of Because the outlet piston of oil
2 of electric pump is too electric pump is too low (it can pump is clogged, replace the oil
low be blocked with fingers) pump piston.
The electric pump operates
The pipeline from electric pump
normally but no oil goes
to distributor is clogged, so check
out from the oil inlet of the
pipeline to correct the fault.
distributor.
normally and there is oil at the Corresponding distributor
The electric pump oil inlet of distributor. However, is clogged, so replace the
operates normally but there is no oil out at the oil distributor.
no oil goes out from outlet of the distributor.
3
a certain injection The electric pump operates
point of an individual normally and there is oil at the The pipeline from lubricating
system. oil outlet of the distributor, but points to distributor is clogged, so
there is not oil at one of the check pipeline to correct the fault.
lubricating points.
A certain distributor or pipeline of
the system is clogged, so inspect
normally, but oil leaks at the
the distributors or pipelines one
relief valve of electric pump.
by one to correct the fault.
Abnormal noise occurs to the
Insufficient oil supply Increase the operation time of
4 lock pin but each refueling
of the system pump as required by the system.
pipeline works normally.
Oil relief occurs to lock pin
Excessive oil supply of Decrease the operation time of
5 sleeve of some lubrication
the system pump as required by the system.
points
Leakage occurs to some
6 Leakage of pipeline Eliminate leakage
injection pipelines
Service Manual 27-9

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SRT95C Off-Highway Truck Transmission Oil Filter Assembly
28 TRANSMISSION OIL FILTER ASSEMBLY
4
3 2
3
2
1
9
1
3 8
3 1
2 7
6
12 5
11
10
1
Fig.1 Transmission Oil Filter Assembly
1. 'O' ring 7. Filter assembly

2. Elbow 8. Adaptor
3. 'O' ring 9. Hose assembly 2
4. Hose assembly 1 10. Connector
5. Bolt 11. Adaptor
6. Washer 12. Adaptor
Service Manual 28-1

Transmission Oil Filter Assembly SRT95C Off-Highway Truck
Overview
The transmission oil filter assembly is installed 4
on the frame to remove dirt, metals and other 1
contaminants from the transmission oil to
reduce wear and provide maximum service life 3
for the transmission. 2
A bypass valve in filter head (1) ensures an
adequate flow of oil to the transmission if
element (2) becomes clogged and cannot pass
oil through quickly enough to satisfy demand.
Pressure switch (4, Fig.2) is located in the
main filter assembly valve block. When the
filter is blocked to a certain degree, Installed
in filter head (1) is pressure switch (4) which
sends a signal to a filter restriction indicator Fig.2 Main filter assembly
warning light (mounted on the dash panel) to
warn the operator when element (2) becomes 1. Filter head 4. Pressure switch
sufficiently clogged to restrict oil flow. This 2. Element 5. Housing
indicates that element (2) should be changed.
3. 'O' ring
Oil flows from the transmission to the inlet side
of filter head (1) where the oil will then take
one of two paths:
a. If the oil is cold and thick, or element (2) is
clogged, oil pressure increases and opens the
bypass valve allowing the oil to bypass the
filter and flow through filter head (1) and exit at
the outlet port to the transmission.
b. If the oil is not thick and element (2) is
not clogged, oil will flow through element (2)
before returning to the transmission.
Removal
WARNING
job safely.
28-2 Service Manual


body safety pins. Apply the parking brake and
switch off the engine. Turn steering wheel
in both directions several times to relieve
pressure in the steering system.
2. Operate the treadle valve continuously
to discharge the brake accumulators. Block
all road wheels. Set the battery in the ' off '
position.
3. Tag filter hose assembly 1 (4) and hose
assembly 2 (9) to aid in installation and
disconnect from adaptor (8) and elbow (2) in
filter assembly (10). remove 'O' ring (3) . Cap
open line ends and fittings to prevent entry of
dirt.
4. Support filter assembly (7) and remove
bolts (5) and washers (6). Then remove filter
assembly (7) and drain oil from assembly into
a suitable container.
5. If filter assembly (7) is being replaced,
remove adaptors (8) and elbow (2) . If filter
element (2, Fig.2) is only being replaced,
disassemble filter assembly (7) and replace
element (2, Fig.2) as described under
changing filter element.
6. If required, remove filter hose assembly 1
(4) and hose assembly 2 (9) from adaptors (2)
in the transmission. Cap open line ends and
fittings to prevent entry of dirt.
Installation
1. If new filter assembly (7) is being fitted,
install adaptors (8) and elbow (2) in filter head
(1, Fig.2).
2. Position filter assembly (7) to frame and
secure with bolts (5) and washers (6).
3. If filter hose assembly 1 (4) and hose
assembly 2 (9) were removed, remove
blanking caps, fit 'O' ring (3) and install lines
on elbow(2) in the transmission, as tagged
during removal.
Service Manual 28-3

4. Remove blanking caps, fit 'O' ring (3) and

connect filter hose assembly 1 (4) and hose
assembly 2 (9) to adaptor (8) and elbow (2) in
filter assembly (7), as tagged during removal.
5. Set the battery in the ' on ' position. Start
the engine and check for leaks.
6. Check transmission oil level and add oil if
required.
Refer to chapter 6, ' Transmission And
Mounting ' for correct fill level and Section
36.1, ' LUBRICATION AND MAINTENANCE '
for oil specification.
7. Ensure parking brake is applied, remove the
body safety pins and lower the body. Remove
wheel blocks from all road wheels.
Changing filter element
WARNING
job safely.

Change filter element (2) at intervals specified
MAINTENANCE '. Element (2) should also be
changed whenever a transmission overhaul is
performed, or other internal servicing is carried
out.
body safety pins. Apply the parking brake and
switch off the engine. Turn steering wheel
in both directions several times to relieve
pressure in the steering system.
2. Operate the treadle valve continuously
to discharge the brake accumulators. Block
all road wheels. Set the battery in the ' off '
position.
28-4 Service Manual

3. With a suitable container under the filter

assembly(7, fig.1) to catch draining oil,
unscrew locking collar on housing (5) and
remove housing (5) and element (2). Discard
element (2).
4. Remove and discard 'O' ring (3) from filter
head (1).
5. Clean housing (5) with clean fuel oil and dry
with a clean lint free cloth. Lubricate new 'O'
ring (3) and install on filter head (1).
6. Install new element (2) on filter head (1),
making sure plastic insert in element centre
contacts spiral snap ring on filter head (1).
7. Install housing (5) over element (2) and
secure tightly with locking collar.
8. Set the battery in the ' on ' position. Start
the engine and check for leaks. Tighten lines,
fittings and filter locking collar as required.
9. Check transmission oil level and add oil if
required. Refer to chapter 6, ' Transmission
And Mounting ' for correct fill level and Section
36.1, ' LUBRICATION AND MAINTENANCE '
for oil specification.
10. Ensure parking brake is applied, remove
the body safety pins and lower the body.
Remove wheel blocks from all road wheels.
Special tools
Section 36.3, ' SERVICE TOOLS '.
Service Manual 28-5

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28-6 Service Manual

SRT95C Off-Highway Truck Disc Brake Cooling System Pipeline And Joint
29 DISC BRAKE COOLING SYSTEM PIPELINE AND JOINT

Overview
The double-gear pump II installed to the
transmission PTO supplies oil to the disc
brake cooling system.
The double-gear pump II is a composite gear
pump assembly consisting of two independent
parts. The front part includes: driving shaft and
gear, driven gear and transmission. The rear
part includes: driving gear, driven gear and
transmission. The rear part is connected to
the driving shaft and gear through connecting
shaft. Fig.1 Outline drawing of double-gear pump II
Operation
See Fig.2 for the principle of double-gear
pump II.
When the drive gear rotates, the driven gear
rotates in the reverse direction. The tooth
socket between the teeth of gear will bring the
hydraulic oil from the gear pump case inlet
to the outlet. When the teeth of gears are
engaged again, the hydraulic is forced out of
the outlet. The delivery capacity of gear pump
is determined by the width of its corresponding
gear set and the rotating speed of drive gear.
The double-gear pump II pumps oil from the Fig.2 Outline drawing of double-gear pump II
the tank of hoist and disc brake system and
send it to the disc brake cooling circuit.
Service Manual 29-1

Disc Brake Cooling System Pipeline And Joint SRT95C Off-Highway Truck
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29-2 Service Manual

SRT95C Off-Highway Truck Brake Oil Cooler And Installation
30 BRAKE OIL COOLER AND INSTALLATION
OIL INLET
LINES
7 COOLANT
8 INLET
PIPE 12
9
10 OIL
C OUTLET
LINES 13
A 11
COOLANT
D
OUTLET
PIPE
4 14
5
6 2
3 B
23
15
16
21
22 20 18
19 17
Fig.1 Disc brake oil cooler
1. Disc brake oil cooler 13. Nut

2. Washer 14. Gasket
3. Bolt 15. Washer
4. Sleeve 16. Bolt
5. Clamp 17. Bolt
6. Coolant outlet pipe 18. Washer
7. Bolt 19. Drain plug
8. Oil Inlet lines 20. Cooler flanges
9. Split flange 21. Gasket
10. 'O' Ring 22. Drain plug
11. Oil out lines 23. Heat exchanger
12. Coolant inlet pipe
Service Manual 30-1

Brake Oil Cooler And Installation SRT95C Off-Highway Truck
Overview and operation

Numbers and letters in parentheses refer to
Fig.1
The disc brake oil cooler is connected in the
cooling system between the transmission oil
cooler and engine oil cooler. The disc brake
oil cooler is connected in the hydraulic system
between disc brake filters and disc brake
assemblies, and is used to cool disc brake
cooling oil.
The disc brake oil cooler consists mainly of
heat exchanger (23) and two cooler flanges
(20), and is mounted at the engine front
crossmember.
Coolant enters disc brake oil cooler (1) at
port 'B' from the engine water pump. The
coolant circulates through cooler tubes in
heat exchanger (23) and exits at port 'A' to
the transmission oil cooler. Disc brake cooling
oil enters through ports 'C' from disc brake oil
filters, circulates around cooler tubes in heat
exchanger (23) and exits from ports 'D' to rear
disc brakes.
Note: Oil flow must always flow in the opposite
direction to coolant flow through the disc brake
oil cooler.
Removal
WARNING
damage, be sure wheel blocks and lifting

engine. Turn the steering wheel in both
the steering system.
2. Block all road wheels, set the switch of
30-2 Service Manual

accumulator into the off position.

3. Remove filler cap from the hydraulic oil tank
to relieve pressure. With a suitable container
in position, remove drain plug from the bottom
of the hydraulic oil tank and drain the oil.
4. Using a suitable lifting device, support
engine pan guard and remove mounting
hardware. Remove engine pan guard from
truck. Open drain cocks and drain cooling
system. Refer to Section 32.1 RADIATOR
AND MOUNTING.
5. Remove drain plugs (22) from the disc
brake oil cooler (1) and drain oil into a suitable
container. Remove bolt (7) and split flange
(9) securing oil inlet lines (8) to ports 'C', and
oil outlet line (11) to port D. Drain oil from oil
inlet and outlet lines (8 & 11) into a suitable
container and discard 'O' rings (10). Cap oil
inlet and outlet lines (8 & 11) and ports 'C',D
to prevent ingress of dirt.
6. Remove drain plugs (19) from cooler
flanges (20) and drain coolant into a suitable
container. Remove clamp (5) securing sleeve
(4) to ports A.
7. Support disc brake oil cooler (1) with a
suitable lifting device and remove bolts (3)
and washers (2) securing disc brake oil
cooler (1) to mounting bracket at engine front
crossmember. Lower disc brake oil cooler
(1) and remove to a clean work area for
disassembly.
Cleaning and Disassembly

Note: In the event of a major mechanical
failure, transmission oil cooler assembly
should be cleaned thoroughly or replaced.
Do not attempt to clean cooler cores, after a
transmission failure in which metal particles
from worn or broken parts are released into
the oil. Replace the cooler cores.
In many areas, raw water is extremely
corrosive or scale forming and should
be treated to prevent damage to the disc
Service Manual 30-3

brake oil cooler (1). A properly maintained

cooling system will significantly reduce
cleaning intervals. Refer to Section 36.1,
Cleaning oil side
WARNING
Dangerous fumes. To prevent personal
injury, use trichloroethylene only in the
open or in a well ventilated room.
1. Clean disc brake oil cooler (1) before

sludge hardens. After disc brake oil cooler
(1) is completely drained, circulate a solution
of trichloroethylene through the passages
surrounding the cooler tubes in heat
exchanger (23) to remove sludge.
2. If cooler tubes are badly clogged, circulate
an alkaline solution through the heat exchanger
(23). Solution should be circulated through the
heat exchanger (23), in the reverse direction
to normal flow, for approximately 15 minutes,
after soaking for 10 minutes. The duration of
circulation depends on how badly clogged the
cooler tubes are. Flush thoroughly with clean
hot water.
Cleaning water side

1. Match mark cooler flanges (20) and heat
exchanger (23) to aid in assembly.
2. Remove washers (18), bolts (17) securing
cooler flanges (20) to heat exchanger (23).
Discard gaskets (21).
3. Make up a solution composed of 1/3
muriatic acid and 2/3 water. To each 9.5 litres
(2.5 gal) of solution, add 225 g (0.5 lb) of
oxalic acid.
4. Immerse heat exchanger (23) in the
cleaning solution. Cleaning action is noticeable
by bubbling and foaming. The process must
be carefully observed and when bubbling
30-4 Service Manual

stops, usually between 30 - 60 sec, remove

heat exchanger (23) from cleaning solution
and flush thoroughly with clean, hot water.
After cleaning, dip disc brake oil cooler in light
oil.
Note: Severely fouled cooler tubes can be
cleaned by use of a rotary brush if normal
cleaning is not sufficient.
Assembly
Section 36.2, TECHNICAL CONDITIONS FOR
BOLTS AND NUTS.
1. Install new gaskets (21) to cooler flanges
(20) and secure cooler flanges (20) to heat
exchanger (23) with bolts (17), washers (18).
Tighten bolts securing cooler flanges (20)
alternately to give an even seal around cooler
flange area.
2. Install drain plugs (19 & 22) in underside of
disc brake oil cooler (1).
Installation
Numbers and letters in parentheses refer to
Fig.1
Section 36.2, TECHNICAL CONDITIONS FOR
BOLTS AND NUTS.
WARNING

disc brake oil cooler (1) to mounting bracket
at engine front crossmember and secure with
bolts (3) and washers (2).
Service Manual 30-5

2. Install sleeve (4) on coolant outlet pipe (6)

and secure sleeve (4) to port 'A' with clamps
(5).
3. Install new gasket (14) on coolant inlet pipe
(12) and secure coolant inlet pipe (12) to port
'B' with bolts (16) and nuts (13).
4. Install new 'O' rings (10) on oil inlet lines (8)
and oil outlet lines (11). Secure oil inlet lines (8)
to ports 'C' and oil outlet lines (11) to ports 'D'
with split flanges (9), and bolts (7).
5. Fill the hydraulic oil tank with hydraulic
oil specified in Section 36.1, LUBRICATION
AND MAINTENANCE. Refer to Section 15,
'HYDRAULIC OIL TANK ASSEMBLY' for
correct fill level. Install filler cap.
6. Ensure all drain cocks on the cooling
system are securely locked and fill cooling
system with coolant specified in Section 32.1
'RADIATOR AND MOUNTING'.
7. Using suitable lifting equipment, install
engine pan guard on the truck. Secure engine
pan guard to the truck with mounting hardware
removed during removal.
8. Start the engine and check for leaks.
Tighten lines and fittings as required.
Special tools
Section 36.3, MAINTENANCE TOOLS, for
part numbers of general service tools required.
30-6 Service Manual

SRT95C Off-Highway Truck Transmission Cooling Piping Mounting
31 TRANSMISSION COOLING PIPING MOUNTING
10 10
12
11 10
9
8
6 7 6 5
5 8 13
14 7 8
1 2 3 5
4 5
19 7
16
6
17 21
20 25
15 14 8 8 76
22 24
29 2 7 22 8 5
3 6 7 10 7 22
18
23 22
8 7
34 8 76 23
26 27 28
31
14 5 10
30 14
27 28
32
5
5
33
7
18
Fig.1 Transmission cooling piping mounting
1.Bolt 18.Bolt
2.Washer 19.Oil outlet pipe assembly
3.Washer 20.Steel tube assembly
4.Nut 21.Fixed plate
5.' O 'ring 22.Washer
6.Flange 23.Nut
7.Washer 24.Fixed plate
8.Bolt 25.Rubber pad
9.Oil inlet pipe assembly 26.Steel tube assembly
10.Clamp 27.Bolt
11.Rubber pad 28.Lockwasher
12.Rubber pad 29.Bolt
13.Steel tube assembly 30.Hose silicone
14.Clamp 31.Oil cooler
15.Hose silicone 32.Gasket
16.Gasket 33.Water inlet tube assembly
17.Water outlet tube assembly 34.Oil outlet pipe assembly
Service Manual 31-1

Transmission Cooling Piping Mounting SRT95C Off-Highway Truck
Overview
The transmission oil cooler is connected
between the radiator and transmission to
maintain transmission oil within its required
operating temperature range. Coolant enters
port ' D ' from disc brake oil cooler, circulates
through cores in transmission oil cooler (31),
and exits at port ' A ' to the engine water pump.
Oil to be cooled enters port ' B ' from the
transmission convertor outlet port, circulates
around cores in transmission oil cooler (31),
and exits at port ' C ' to the transmission
convertor inlet port.
Note: Oil flow must always flow in the opposite
direction to coolant flow through transmission
oil cooler.
Removal
WARNING
damage, be sure wheel blocks and lifting

the steering system.
2. Block all road wheels. Set the battery in the
' off ' position.
3. Open drain cocks and drain the cooling
system. Refer to chapter 32, ' RADIATOR AND
MOUNTING ', for procedure.
4. Remove drain plugs from oil cooler (31) and
drain transmission oil into a suitable container.
5. Remove bolts (8), washers (7) , flange(6)
and ' O ' ring (5) securing oil inlet pipe
assembly (9) to ports 'B' of oil cooler (31).
6. Drain oil into a suitable container. Cap
31-2 Service Manual

oil inlet pipe assembly (9) and port ' B ' to

prevent ingress of dirt.
7. Remove the oil outlet pipe assembly (34)
from oil cooler (31) in same method as step 5.
Cap oil outlet pipe assembly (34) and port ' C
' to prevent ingress of dirt.
8. Slacken clamps (14), drain coolant into
a suitable container. Remove bolts (18) ,
washers (7) and gasket (32)securing water
inlet tube assembly (33) to port ' D '. Cap
water inlet tube assembly (33) and port ' D ' to
prevent ingress of dirt.
9. Slacken clamps (14), drain coolant into
a suitable container. Remove bolts (18) ,
washers (7) and gasket (16) securing water
outlet tube assembly (17) to port ' A '. Cap
water outlet tube assembly (17) and port ' A '
to prevent ingress of dirt.
10. Support transmission oil cooler (31) with
a suitable lifting device and remove nut (4)
, bolts (1,29) and washers (9,10). Lower
transmission oil cooler (31) and remove to a
clean work area.
Cleaning and inspection

Note: In the event of a major mechanical
failure, transmission oil cooler (31) should
be cleaned thoroughly or replaced. Do
not attempt to clean cooler cores, after a
transmission failure in which metal particles
from worn or broken parts are released into
the oil. Replace the cooler cores. In many
areas, raw water is extremely corrosive
or scale forming and should be treated to
prevent damage to transmission oil cooler
(31). A properly maintained cooling system will
significantly reduce cleaning intervals. Refer to
chapter 32, ' RADIATOR AND MOUNTING ',
for procedure.
Service Manual 31-3

Clean oil side
WARNING
Dangerous fumes. To prevent personal
injury, use trichloroethylene only in the
open or in a well ventilated room. Avoid
direct contact with eyes or skin as irritation
can occur.
1. Clean oil cooler (31) before hardening

deposits, the oil passages in oil cooler (31)
by circulating a solution of trichloroethylene
through the passages, remove all deposits.
2.If the passages are badly clogged, circulate
an alkaline solution through the oil cooler (31).
After 10 minutes, circulate reversely for 15
minutes. Flush thoroughly with hot water.
Clean water side

1. Solution is made as follows: add 227 g (0.5
lb) of oxalic acid to each 9.5 litres (2.5 gal) of
solution composed of 1/3 muriatic acid and 2/3
water.
2. Clean the oil cooler (31) by immersing in
the solution, cleaning action is noticeable by
bubbling and foaming. The process must be
carefully observed and when bubbling stops,
usually between 30 - 60 seconds, remove
oil cooler (31) from cleaning solution and
flush thoroughly with clean, hot water. After
cleaning, dip oil cooler (31) in light oil.
Caution: If the ordinary cleaning mode is not
effective, use the rotary brush to remove the
excessive deposits.
Assembly
1. Install new gasket on oil cooler flange and
position oil cooler flange onto oil cooler (31).
Tighten the bolt.
2.Install the drain plugs onto oil cooler (31).
31-4 Service Manual

Installation
WARNING
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.
Special tools
36.3,' SERVICE TOOLS '.
Service Manual 31-5

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E
........................................................................................................................................
G
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PA
........................................................................................................................................
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........................................................................................................................................
........................................................................................................................................
K
........................................................................................................................................
N
........................................................................................................................................
LA
........................................................................................................................................
........................................................................................................................................
........................................................................................................................................
B
........................................................................................................................................
........................................................................................................................................
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31-6 Service Manual

SRT95C Off-Highway Truck Radiator And Mounting
12 27
13 26
21
3 19 16
1619
15
15 25
5
4
16 15
2 2 22
24 23
16 22 23
15
2
21
6
2
20
7 19
8 18
2 2 2 17
2 16
2 15
9 13
10 14
10 11 12
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
Service Manual 32-1

Radiator And Mounting SRT95C Off-Highway Truck
32 RADIATOR AND MOUNTING
32.1 Radiator and Mounting

Overview
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
Remove the components as following:
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
32-2 Service Manual
(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
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
Service Manual 32-3

assembly (1) and secure with clamps (2).

9. Install successively the disassembled hose
connected to the remote water tank to radiator
assembly (1).
32-4 Service Manual

32.2 Condenser Assembly
10
7 8 9
12
11
12
9
8
13
4 14
6
3
5 2
1
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
Service Manual 32-5

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 (89) and nut
(12), take off the liquid reservoir support (11)
from the pinboard (14).
(12), take off the liquid reservoir assembly(10)
from the liquid reservoir support (11).
(4), take off the condenser (5) from the bracket
(6).
Installation
1. Fasten the condenser (5) in the bracket (6)
by the bolt (1), washer (23) and nut (4).
2. Fasten the liquid reservoir assembly(10) in
the liquid reservoir support (11) by the bolt (7),
washer (89) and nut (12).
3. Fasten the liquid reservoir support (11) in
the pinboard (14) by the bolt (7), washer (89)
and nut (12).
4 . Ta k e o ff t h e p l u g s a n d c o n n e c t t h e
refrigerant hoses.
32-6 Service Manual

32.3 Liquid Accumulator Assembly
1
2
3 5
6
2
3
1 6
2
3
2
3
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
Service Manual 32-7

Installation of liquid accumulator

1. Install liquid accumulator assembly (4) to
the middle of liquid accumulator support (5)
clip.
2. Tighten the upper and lower two clips of
liquid accumulator support (5) with bolt (1),
spring washer (2), washer (3) to ensure that
liquid accumulator assembly (4) is fastened
firmly inside the clips.
3. Install liquid accumulator support (5) to the
corresponding position of condenser support.
32-8 Service Manual

SRT95C Off-Highway Truck Water Tank Mounting And Lines
33 WATER TANK MOUNTING AND LINES
9
9
9 8
9 9 10
9 10
10
9 11
4 11
7 11 11
5 9
5 8
10
6 10 9
9
9 9
132 9
9
12
1
13 9
14
14
15 1
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
Service Manual 33-1

Water Tank Mounting And Lines SRT95C Off-Highway Truck
Removal
WARNING
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
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),
33-2 Service Manual

SRT95C Off-Highway Truck 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/m 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/m 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/m, or
Service Manual 33-3

Water Tank Mounting And Lines SRT95C Off-Highway Truck
compressed air at 500 - 700 kN/m 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/m, or compressed air at 500 - 700 kN/m
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/m, or compressed air at 500 - 700 kN/
m 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
procedures outlined in this section. Refer
to Section 38.2, SERVICE TOOLS, for part
numbers of general service tools required.
33-4 Service Manual

SRT95C Off-Highway Truck Battery And Installation
34 BATTERY AND INSTALLATION
4 6
3 8
2 5
9
7 9
1
10
11
13 12
14 15
16
17
18
19
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
Service Manual 34-1

Battery And Installation SRT95C Off-Highway Truck
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 5-25C 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
34-2 Service Manual
SRT95C Off-Highway Truck Battery And Installation
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 35C, 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
Service Manual 34-3

Battery And Installation SRT95C Off-Highway Truck
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
1 60125384 Battery switch

2 A242200000057 Battery 31750T
34-4 Service Manual

/3 /2
/2 /3
Connector to Connector to Connector to Connector to
dipped /high dipped /high
Fig.1 Harness Of Front Lamp

dipped /high dipped /high beam light R3 beam light R2
beam light L2 beam light L3
/1 /1
Connector to
Connector to dipped /high
dipped /high Connector beam light R1
beam light L1 to horn
Fog lamp Fog lamp
F,L F,LR
Earth
35 CABLES AND HARNESSES
Service Manual
/
/
Connector to
Connector to direction /side
direction /side marker lamp
marker lamp F,L
F,L
AMP3
3-core Plug
AMP8SX1
8-core Plug SX1
35-1
Cables And Harnesses
35-2

Earth
Fig.2 Harness Of Rear Lamp

Hoist limit switch
AMP8SX2
8-core Plug SX2
Service Manual

AMP3
Connector to fog
3-core Plug lamp B,L

//
Connector to //
Connector to side retarder lamp
marker/brake/Indicator
lamp B,L Connector to
fog lamp B,L Connector to side
marker/brake/Indicatorlamp B,R
/
Reversing lamp/
reversing alarm
AMP8
SX1 31
8-pin Socket SX1 AMP3 SX3-B
3-pin Socket 31-pin plug SX3-B

Connector to brake 29
proximity switch SX4-B
Connector
to right rear light 29-pin plug SX4-B Connector to
hoist joystick
Fig.3 Harness Of Truck Body

Lower to
proximity Connector
switch to fuel level sensor
Steering accumulator
pressure sensor Buzzer
AMP3
Connector Connector to retarder joystick
to left rear 3-pin Socket
31 light Transmission retader rocker switch
SX3-A
31-pin plug SX3-A

29 Hoist proportional
soleniod valve Connector to AMP8SX2
SX4-A transmision
29-pin plug SX4-A pressure 8-pin Socket SX2
sensor Connector to float
soleniod valve
Service Manual

Lower proportional soleniod valve
Connector
to retarder
pushrod Connector to
transmision
Connector to transmission fuel level
temperature sensor sensor
Hydraulic retarder 1
proportional Connector to disc brakecooling oil
switch Connector to returning temperature sensor1
brake
Connector Connector accumulator
to stop to park pressure
solenoid soleniod sensor B Connector to steering Connector tosteering
valve valve oil returning
temperature sensor oil return pressure switch
Connector to brake accumulator pressure sensor F
Connector to
park pressure
sensor
35-3
Cables And Harnesses SRT95C Off-Highway Truck
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
35-4 Service Manual

SRT95C Off-Highway Truck 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
Service Manual 35-5

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
35-6 Service Manual

SRT95C Off-Highway Truck Cables And Harnesses
away from the battery vapor (inflammable and

explosive gas -- hydrogen), so accident is not
likely to happen even though there are sparks.
warning
It is not allowed to start the truck by
connecting the cables with the power
supply from electric arc welding equipment
because there is not any safe and reliable
method that can reduce the dangerous
high voltage and the strong current.
Service Manual 35-7

........................................................................................................................................
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........................................................................................................................................
........................................................................................................................................
E
........................................................................................................................................
G
........................................................................................................................................
PA
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........................................................................................................................................
........................................................................................................................................
........................................................................................................................................
K
........................................................................................................................................
N
........................................................................................................................................
LA
........................................................................................................................................
........................................................................................................................................
........................................................................................................................................
B
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35-8 Service Manual

SRT95C Off-Highway Truck 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.
Service Manual 36-1

Others SRT95C Off-Highway Truck
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.
7 1 20 16 21 10 26 10 11 21 19 22 25 13 18 9 14
29
31
5
30
6
31
27 1 23 27 20 8 26 10 28 28 4 2 3 12 15 21 17 13
Fig.38-1 Lubrication and maintenance points
36-2 Service Manual

Lubrication and Service Chart
Interval Ref. No. of

Identification Service Instructions Lubricant Service/Quantities
hours Points Points
Check oil level. Add if
1 Engine 1 EO As Required
low.
2 Transmission 1 HTF As Required
low.
Hydraulic Tank(Hoist/ Check oil level. Add if
3 1 HO As Required
Cool) low.
Hydraulic Tank(Steer/ Check oil level. Add if
4 1 HO As Required
Brake) low.
see page chapter 35

5 Remote water tank 1 Antifreeze "Remote water tank
low.
and pipe installation"
6 Filter(Steer/Brake) - 1 - -
Visually inspect for
7 Cooling Fan 1 - -
debris and damage.
Visually inspect all
_ Drive Belts _ _ Ref Engine Manual
belts.
10
Front and Rear Ride Visually inspect Ref "Ride cylinder" and
8&9 _ _
Cylinders heights. "Rear ride system"
Air Cleaner Restriction Check. Replace Refer to Air Cleaner
- 3 _
W/Light element if reqd. Service
Air Cleaner Vacuator Check for proper
- 3 _ -
Valve(s) operation.
Fuel Filter/Water Drain water and
- 1 _ -
Separator sediment.
Check condition. Ref " Front wheel

- Tyres Check pressures 6 _ assembly" and "Rear
when tyres are cold. wheel assembly"
Controls, Instruments Check for proper

- _ _ -
and W/Lights operation.
Check for leaks and
worn/damaged parts.
- General Inspection _ _ -
Repair/replace as
required.
Service Manual 36-3

9 Rear Ride Cylinders Lube 4 EP,NLGI

Steering Cylinder
10 Lube 4 EP,NLGI
Bushings
11 Low Pressure Filter Lube 4 EP,NLGI
A-Frame Nose
12 Lube 1 EP,NLGI
Spherical Bushing
Banjo Stabilizer
50 13 Lube 2 EP,NLGI -
Spherical Bushings
14 Body Hinge Pins Lube 2 EP,NLGI
15 Body Hoist Bushings Lube 4 EP,NLGI
29 A-sharp Arm Lube 6 EP,NLGI
8 Front Ride Cylinders Lube 2 EP,NLGI
30 Crank pin Lube 2 EP,NLGI
21 Cross shaft Lube 6 EP,NLGI
1 Engine Drain and refill. 1 EO -
_ Engine Oil Filters Replace filters. 4 _ Ref Engine Manual
_ Engine Fuel Filters Replace filters. 2 _ Ref Engine Manual
Check DCA
Engine Coolant
_ concentration and _ DCA4 Ref Engine Manual
Additive
replenish.
Engine Coolant Replace filter(s) if

_ 2 _ -
Filter(s) required.
Engine Crankcase
_ Clean 1 _ Ref Engine Manual
Breather
7 Engine Cooling Fan Check condition. 1 _ -
16 Engine Power Takeoff 1 EPL -
250 low.
18 Wheel Planetaries 2 EPL -
low.
_ Differential Breather Clean. 1 EPL -
_ Transmission Breather Clean. 1 _ -
Check belt tension.
_ Alternator Drive Belt 1 _ Ref Engine Manual
Adjust if required.
Accessory Drive Belts Check belt tension.
_ 2 _ Ref Engine Manual
(if fitted) Adjust if required.
Clean the primary
- Air Cleaner 3 - -
cleaner
Check wear. Replace
_ Front Brake Pads 4 _ -
as required.
36-4 Service Manual

Return filter of
- Replace filter 1 - -
hoisting system
Return filter of
steering system
Filter of steering
pipeline
Filter of cooling
1000 - Replace filter 2 - -
pipeline
- Filter of brake van Replace filter 1 - -
Breath valve of Replace breath

- 1 - -
steering valve
Breath valve of Replace breath
- 1 - -
hoisting valve
2 Transmission Drain and refill. 1 HTF -
_ Transmission Oil Filter Replace element. 1 - -
1200 - Engine PTO Drain,clean and refill 1 - -
- Differential Drain,clean and refill 1 - -
- Wheel Planetaries Drain and refill 2 - -
19 Fuel Tank Drain and refill 1 Diesel -

2000
25 Rear Brake Packs Drain and refill 2 HO -
Hydraulic Tank(steer/ Change,clean and

4 1 HO -
brake) refill
Hydraulic Tank(hoist/ Change,clean and
3 1 HO -
cool) refill
Suction filter of
3000 - Replace filter - - -
hoisting system
Suction filter of
- Replace filter - - -
steering system
Suction filter of
- Replace filter - - -
cooling system
27 Cooling System Drain, flush and refill 1 Antifreeze -
Inspect , readjust
4000
gap,replace the
26 Front Wheel Bearing 2 *EP NLGI -
grease as the case
may be.
Service Manual 36-5

*The refilling amount is half of wheel hub

cavity.
Note The lubricant should be refilled slowly
until it reliefs.
EOEngine lubricant, please refer to
'Recommended Lubricants'.
EPLEP gear oil, meeting the requirements
of MIL-L-2105C standard.
HTFAllison C-4 hydraulic transmission oil,
please refer to 'Recommended Lubricants'.
HOhydraulic oil, please refer to
EP, NLGI2 EP lithium base grease, please
refer to 'Recommended Lubricants'.
E P, N L G I 2 E P l i t h i u m b a s e g r e a s e
(molybdenum free), please refer to
PAG OIL-Polyalkene Glycol(PAG) compressor
lubricant-The number of low viscosity (ISO46).
Numbers in the figure represents the points
entailing lubrication and maintenance at
regular intervals according to requirements
in Table of Lubrication and Maintenance.
The numbers of figure are corresponding
to the 'Serial Numbers' in Lubrication and
Maintenance.
Note: For each specified maintenance interval,
prior examination should be performed apart
from the prescribed checks.
36-6 Service Manual

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 Nm (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
Service Manual 36-7

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.

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
36-8 Service Manual

Installation' of the Maintenance Manual to

adjust the tension of a new belt or recycled
belt.
Front brake-check and replace the worn brake
pads and brake disc.
Caution: Such maintenance interval is
applicable for normal working conditions.
The maintenance should be conducted more
frequently under poor working conditions. The
friction material of brake pads can not be worn
less than 3 mm (0.12 in.).

Inspection of the pressure of hydraulic system
- Check the pressures of all steering, hoist and
braking systems.
Caution: The procedure and positions
of inspection points are detailed in the
Maintenance Manual. Repair or replace the
elements of related system if the detected
pressure does not match with the set value, so
as to make sure the system can work normally.
Moreover, the safety regulations described in
related chapters must be strictly followed.
Main hydraulic oil tank filter-clean the filter
housing and replace the filter.
Rear disc brake cooling oil filter-Replace the
filter if the indicator has exceeded the limit or
worked for 1,000 hours.

Steering hydraulic oil filter-Clean the filter
housing and replace the filter when the
instrument indiciates blocking or has worked
for 2,000 hours.
Engine and transmission

The data included in the 'Table of Lubrication
and Maintenance' is cited from the 'Usage
and Maintenance Manual' provided by the
manufacturer and it is effective during the
issuance period. The data obtained by the
user from this figure should be consistent with
the 'Usage and Maintenance Manual' provided
Service Manual 36-9

by the manufacturer. If not, the engine and

transmission data provided with the machine
should prevail. Our company will regularly
contact the manufacturer for updates of the
'Usage and Maintenance Manual'.

Working capacity
Maintenance volume
Maintenance volume
Serial No. Description lubricant
L U. S. gallon
1 Engine crankcase and filter EO 134 35.4
2 Transmission and filter HTF 100 26.0
3 Hoist cooling oil tank HO 300 79.2
4 Hoist system and brake cooling system HO 560 148.0
5 Steering brake oil tank HO 62 16.4
6 Steering brake system (total) HO 65 17.2
7 Cooling system Cooling liquid 304 80.3
8 Fuel tank Diesel 1030 272.1
9 Front suspension cylinder (per piece) HO 30 8.0
10 Rear suspension cylinder (per piece) HO 21 5.6
11 Power output device EPL 4 1.1
12 Differential EPL 61 16.1
13 Hub reducer (total) EPL 57 15.1
14 Air-conditioning compressor PAG Oil 0.125 0.033
Note: The refuel amount given is not precise. Oil gauge, liquidometer or liquid level cover should
be combined with 'Recommended Lubricants'.
Temperature conversion table

-32 -30 -27 -25 -20 -18 -15 -10 0 10 15 25 32 35 38 45 93 190
-26 -22 -17 -13 -4 0 5 14 32 50 59 77 90 95 100 113 200 375

Selection of lubricants
36-12
Others
Application and Name of Ambient Grade/Level of Recom-

Quality Grade Recommended Material
lubrication Material Temperature Viscosity mended
Above -10C SAE 15W/40 Standard: API Mobil Delvac MX 15W/40
Oil sump Mobil
Diesel engine CF4SG, cG-4/SH
of diesel -25C-(-10C) SAE 10W/30 Housing
oil Senior: API CH-4, cI-4
engine
-40Cto-25C SAE 5W/30 Cummins CES20078 Mobil DeIvac No. 1 5W/30
Above 0C 0# The
content
Above -10C -10# Kunlun
of sulfate
Cummins GB 252 DIN EN590 Great
Fuel tank Light diesel oil Above -20C -20# is no
engine ASTM 23379001 wall
more
Above -35C -35#
than
Above -50C -50# 0.5%
Above -62C 40% water BS6580:1992, Mobil
Service Manual
Engine Anti-freezing ASTM D3306 Housing Mobil anti-freezing fluid (-45C);
Above -38C 40% water
water tank fluid antifreeze, to be mixed TEEC TEEC anti-freezing fluid L-35
Above -24C 40% water with soft water
Below -35C SAE 0W/30
Other -30C--35C SAE 0W/20

Mobil
Trans- Truck ATF C-4 Mobil transmission oil HD 10W
-20C- +10C SAE 10W Housing
Transmission mission type CAT T0-4 Housing Donax TC10W
oil 0C - +35C SAE 30 Mobil transmission oil HD 30
+10C-+50C SAE 50 Mobil transmission oil HD 50
SRT33 Above -35C TranSynd RD TES-295 Allison Allison TranSynd RD

Main hydraulic oil tank Mobil transmission oil HD 10W
-5C-+35C SAE 10W
steering oil tank Mobil Housing Donax TC10W
Transmission ATF C-4
+10C-+50C SAE 30 Housing Mobil transmission oil HD 30
oil CAT T0-4
Mobil transmission oil HD 10W
Suspension cylinder Above -20C SAE 10W
Housing Donax TC10W
H oist oil
tank ste-
Drump Anti-abrasive
er ing oil -10C-+40C 46 Housing Anti-abrasive hydraulic oil VG46

brake hydraulic oil
tank (all-
owed)
Above +40C SAE 85-W/140
Mobil automotive gear oil HD

Differential Hub reducer Mobil 80W/90
-25C-+40C SAE 80-W/90
PTO Gear oil API GL-5 Housing Housing hypoid gear oil GL-5
80W/90
Service Manual
Mobilube 1 SHC 75W/90
Below -25C SAE 75-W/90 Mobil Delvac MX synthetic gear
oil 75W/90
Mobilith
Multifunctional Above -40C ISO VG-460 NLGI 1.5 SHC 460
lithium base
grease
Front wheel hub bearing
(molybdenum
Steering column Mobil
free), melting
Yo k e b e a r i n g o f Housing
point being
transmission shaft
190C(compo- Above -30C NLGI 2 Lithium base grease 2#
und lithium
base synthetic
grease)
36-13
Others
Multi- With or without
Above 25C NLGI 2 Lithium base grease 2#
36-14
functional molybdenum Mobil
Others
lithium base Housing

The parts for centralized grease and other With or without Kunlun Mobil grease XHP321Mine
NLGI 1
lubrication and (molybdenum lubrication molybdenum Great Mobil grease XHP221Mine
free), wall
With or without Consult local grease
(compound Below -20C
molybdenum suppliers
lithium
Service Manual
Note1: When the ambient temperature remains

higher or lower than the specified ambient
temperature, consult the grease manufacturer
for the correct viscosity.
Note 2: Cummins Engine Company Limited
only recommends such engine oil as complies
with API grade but not other oil brands.
Cummins recommends that only oil with
multi-grade viscosities under various ambient
temperatures listed above be applied.
Note 3: Operation at the lowest temperature
listed above without correct pre-heating or
heating may result in reducing the service
life of transmission. If an auxiliary heater is
provided for oil, pre-heat oil to the minimum
temperature limit. In case of no auxiliary
heater, operate the accelerator of engine
to a certain degree and heat oil to a certain
temperature with the transmission remaining
in the neutral position.
Hydraulic oil of transmission should meet
the requirements of Allision C-4. Consult the
lubricant manufacturer for verification.
Other lubricant manufacturers may also
provide similar products, so please consult
them for verification.
Note 4: If the rear axle with antiskid differential
adopts SAE90 standard oil, great noises
and wheel clamping will occur upon sudden
turn and slow drive. EP oil with anti-skidding
additive should be applied.

36.2 Technical Conditions for

Bolts and Nuts
Threaded connection is a very important
and it is a type of widely-used mechanical
connection. Most threaded connections
need to be tightened for installation so as to
enhance rigidity, tightness and anti-looseness
capacity of connection. It is particularly true
for the threaded connection at an important
position, where the corresponding tightening
torque must be reached. These threaded
fasteners may affect related components and
even the reliability, performance and security
of the entire system. In case that any fastener
get loosened or damaged and it is required
to make replacement during operation, the
fastener must be tightened in accordance with
designated tightening torque values.
We have prepared the following tables for
all fasteners used in the truck such as bolts,
nuts, double-screw bolts as so as to prevent
overload damage resulting from overexertion
during assembly and meanwhile to establish a
unified standard for tightening these fasteners
in a secure manner.

Table 1 Maximum tightening torques of threaded fasteners (metric)

Thread Performance Level
specification 8.8 9.8 10.9 12.9
(Nominal Tightening torque
DiameterScrew
Pitch) Nm Lb/ft Nm Lb/ft Nm Lb/ft Nm Lb/ft
M1.6 0.20 0.15 0.20 0.15

M2.0 0.25 0.20 0.45 0.30
M2.5 1 0.75 1 0.75
M3.0 1 0.75 2 1.5
M3.5 2 1.5 3 2
M4.0 3 2 4 3
M5.0 5 4 8 6
M6.0 9 6 13 10
M8.01.25 21 15 27 20 32 23
M8.01.00 23 17 29 21 34 25
M10.01.50 42 31 54 39 63 46
M10.01.25 45 32 57 41 67 48
M12.01.75 74 53 94 68 110 80
M12.01.25 81 58 103 74 121 87
M14.02.00 118 85 151 109 176 127
M14.01.50 128 92 163 118 190 137
M16.02.00 169 122 234 169 274 197
M16.01.50 181 130 250 180 292 211
M18.02.50 234 169 323 234 378 273
M18.01.50 263 190 363 262 425 307
M20.02.50 330 239 457 330 531 386
M20.01.50 367 265 507 366 593 423
M22.02.50 451 325 623 450 728 526
M22.01.50 495 357 684 494 800 577
M24.03.00 571 412 790 570 923 667
M24.02.00 623 450 861 622 1007 727
M27.03.00 837 605 1158 836 1354 977
M27.02.00 903 652 1250 902 1461 1055
M30.03.00 1135 820 1570 1134 1835 1325
M30.02.00 1258 908 1740 1256 2034 1468
M30.01.50 1300 939 1799 1299 2102 1516
M36.04.00 1985 1433 2745 1982 3208 2317
M36.03.00 2102 1517 2907 2099 3398 2453

Note:
1. The maximum tightening torque value of standard bolt (nut) in this table is approximately 75%
of the yielding limit of bolt (nut) materials.
2. All the torque values in the table 'Lubrication' defined here includes the usage of threaded
lubricant, cadmium plating or quenching gasket.
3. The torque values in the table is the recommended ones for general fasteners and a variation
of 10% is allowed for tightening torque in practice.
Table 2 Maximum Tightening Torque of Threaded Fastener (British)
Thread Performance Level

Specifications GM 260-M steel GM 280-M steel GM 290-M steel GM 300-M steel With 12 cap
(Nominal SAE 2 SAE 5 SAE 7 SAE 8 screws
Diameter -
Tightening moment
Number of
teeth) Nm Lb/ft Nm Lb/ft Nm Lb/ft Nm Lb/ft Nm Lb/ft
0.25-20 5 4 8 6 11 8 12 9 14 10
0.25-28 7 5 10 7 12 9 14 10 15 11
0.31-18 11 8 18 13 22 16 24 18 27 20
0.31-24 12 9 19 14 24 18 27 20 30 22
0.38-16 20 15 31 23 38 28 43 32 49 36
0.38-24 23 17 34 25 43 32 49 36 56 41
0.44-14 33 24 47 35 59 43 68 50 75 55
0.44-20 37 27 54 40 68 50 79 58 87 64
0.50-13 50 37 75 55 94 69 106 78 119 88
0.50-20 56 41 88 65 106 78 122 90 134 99
0.56-12 75 55 108 80 136 100 156 115 171 126
0.56-18 81 60 122 90 149 110 176 130 191 141
0.62-11 102 75 149 110 190 140 217 160 237 175
0.62-18 115 85 169 125 210 155 244 180 270 199
0.75-10 176 130 271 200 332 245 380 280 420 310
0.75-16 203 150 298 220 366 270 420 310 472 348
0.88-9 169 125 434 320 536 395 610 450 679 501
0.88-14 190 140 488 360 590 435 678 500 751 554
1.00-8 258 190 651 480 800 590 915 675 1021 753
1.00-12 285 210 719 530 881 650 1003 740 1119 825
1.00-14 285 210 732 540 902 665 1030 760 1148 847
1.12-7 366 270 800 590 1132 835 1302 960 1447 1067
1.12-12- 407 300 902 665 1274 940 1451 1075 1624 1198

1.25-7 515 380 1132 835 1600 1180 1830 1350 2043 1507
1.25-12 569 420 1254 925 1776 1310 2034 1500 2267 1672
1.38-6 664 490 1478 1090 2095 1545 2400 1770 2676 1974
1.38-12 759 560 1688 1245 2393 1765 2739 2020 3056 2254
1.50-6 881 650 1966 1450 2786 2055 3186 2350 3556 2623
1.50-8 936 690 2088 1540 2962 2185 3390 2500 3781 2789
1.50-12 990 730 2217 1635 3145 2320 3593 2650 4010 2958
1.75-5 4393 3240 5016 3700 5604 4133
1.75-12 5091 3755 5830 4300 6497 4792
1.88-8 6006 4430 6874 5070 7664 5653
1.88-12 6304 4650 7213 5320 8048 5936
2.00-4.5 6623 4885 7565 5580 8448 6231
2.00-8 7342 5415 8406 6200 9367 6909
2.00-12 7687 5670 8786 6480 9811 7236
2.25-4.5 9701 7155 11090 8180 12377 9129
2.25-8 10629 7840 12148 8960 13566 10006
2.25-12 11050 8150 12636 9320 14102 10401
2.5-12 15280 11270 17463 12880 19500 14383
Note:
1. The maximum tightening torque value of standard bolt (nut) in this table is approximately 75 %
of the yielding limit of bolt (nut) materials.
2. Thread specification '0.25-20': 0.25 indicates that thread nominal diameter is 0.25in and 20 that
screw pitch is 20 teeth per foot (screw pitch), which is 25.4mm/20=1.27mm after conversion into
metric system, i. E. screw pitch is 1.27mm.
3. All the torque values in the table 'Lubrication' defined here includes the usage of threaded
lubricant, cadmium plating or quenching gasket.
4. The tightening torque values in the table is the recommended ones for general fasteners and a
variation of 10% is allowed for tightening torque in practice.
5. The tightening values in the table correspond to the materials as specified by GM standard. As
for materials beyond GM standard, refer to Table 3 for converting the materials into GM standard
materials and then search for torque values.

Table 3 Correspondence between Non-GM standard materials and GM standard materials
Non-GM Standard Material Hardness Non-GM Standard Material
Common low- SAE1018

ROCKWELL 'B'85-100 GM 260-M
carbon steel SAE1020
SAE1035
Common medium-
SAE1038 ROCKWELL 'C'19-30 GM 280-M
carbon steel
SAE1045
ROCKWELL 'C'28-34 GM 290-M
SAE4140
ROCKWELL 'C'32-38 GM 300-M
Medium-carbon ROCKWELL 'C'28-34 GM 290-M
SAE8642
alloy steel ROCKWELL 'C'32-38 GM3 00-M
Caution:
1. Inappropriate turning tools and wrenches are strictly forbidden for tightening of bolts and nuts.
For tightening of the bolts and nuts in group, they should be uniformly tightened in a certain order
gradually (generally 2~3 times) according to the shapes of adapted pieces and distribution of
bolts or nuts so as to ensure identical pre-tightening force for all bolts or screws. For tightening
groups of bolts arranged in a rectangle, start from the middle and then expand to two sides
symmetrically. For tightening groups of bolts or nuts arranged in a circle or square, it must be
done symmetrically. If there is a locating pin, start tightening from the bolt or screw adjacent to
the locating pin.
2. If anti-loosing safety iron wire applies to bolt head, thread and secure them in the turning
direction of thread. If double nuts are used without anti-loosing bonder, the thin nut should be
installed first and tightened to approximately 80% of the tightening torque. Then apply 100%
tightening torque to tighten the thick nut.
3. If fasteners need to be replaced, the new ones of the same type or substitutes with equivalent
performance as the original fasteners should be used. Substitutes with inferior quality or different
design may not be used so as to avoid unnecessary damages including equipment damages or
personal injuries.
Self-locking fasteners
After being disassembly and reinstalled onto the original fitting pieces, self-locking fasteners
can generate a kind of measurable engagement or torque for re-locking. However, the locking
function of a self-locking nut will degenerate to a certain degree after each use. To ensure the
reliability of self-locking fasteners, the self-locking fasteners specified for the truck can be used 5
times to the maximum according to technical requirements. A mark should be made on the head
of a self-locking fastener each time it is dismantled so as to inform the assembly operators of the
times that this self-locking fastener has been used. If it has been used for 5 times, it should be
replaced with new self-locking fastener.

The table below gives out the minimum torque of a self-locking fastener for disassembly after
initial use. If the self-locking fastener whose torque fail to reach the minimum torque value as
provided in the table can not be reused regardless of whether it has not been used for 5 times.
Table 4 Minimum disassembly torque of self-locking fastener

Self-locking screw Self-locking nut
Performance Level
Thread
SAE Grade 5, SAE Grade 8
specification SAE Grade 5 SAE Grade 8
and ASTM A-574
Nm Lb/ft Nm Lb/ft Nm Lb/ft
0.25-20 0.3 3 0.4 3.5 0.5 4.5
0.25-28 0.3 3 0.4 3.5 0.5 4.5
0.31-18 0.6 5 0.6 5.5 0.9 7.5
0.31-24 0.6 5 0.6 5.5 0.9 7.5
0.38-16 1.0 9 1.0 8.5 1.3 11.5
0.38-24 1.0 9 1.0 8.5 1.3 11.5
0.44-14 1.4 12 1.4 12 1.8 16
0.44-20 1.4 12 1.4 12 1.8 16
0.50-13 1.8 16 1.7 15 2.3 20
0.50-20 1.8 16 1.7 15 2.3 20
0.56-12 2.5 22 2.4 21 3.2 28
0.56-18 2.5 22 2.4 21 3.2 28
0.62-11 3.4 30 3.1 27 4.1 36
0.62-18 3.4 30 3.1 27 4.1 36
0.75-10 5.1 45 4.6 41 6.1 54
0.75-16 5.1 45 4.6 41 6.1 54
0.88-9 7.3 65 7.0 62 9.3 82
0.88-14 7.3 65 7.0 62 9.3 82
1.00-8 9.6 85 9.5 84 12.7 112
1.00-12 9.6 85 9.5 84 12.7 112
1.00-14 9.5 84 12.7 112

36.3 Maintenance Tools

IntroductionThis chapter involves
recommended tools or devices for repair,
maintenance, and troubleshooting, to some
of which both the metric system and British
unit system are applicable. These tools can
be purchased from manufacturers or relevant
agents.
Note: The company reserves the right of
designing and manufacturing tools and
devices, and such tools and equipment sold
previously can be modified free of restraint.
Note: One tool may consist of one piece or
many pieces.

General tools
Material code Name of Material

21082029 Preset torque wrench
21082357 AC-type torque wrench
21082140 Torque wrench
B260401090201 Manual torque wrench
21082597 Industrial torque wrench
B260401090200 Torque spanner
21085392 1 Torque spanner
A260401090255 Open torque spanner
21085398 6 torque wrench with changeable head
A260401090198 Manual torque wrench
21084144 Ratchet wrench
21085383 Pneumatic wrench
21085384 Pneumatic inner hexagon socket
21085386 Pneumatic inner hexagon socket
21085387 Pneumatic socket
21085388 Pneumatic socket
B260401010153 Pneumatic socket
B260401010154 Pneumatic socket
B260401090213 Pneumatic wrench
B260401090170 Pneumatic impact wrench
B260401090167 Pneumatic impact wrench
23000385 Heavy socket wrench
A260401030089 Socket wrench
21006035 Socket drawbar
21082977 Cross screwoperator
A260402020020 Cross screwoperator (wooden handle)
21005839 Cross screwoperator (wooden handle)
A260404000064 Bench vice (fixed)
21083138 Digital multimeter
21084296 Slotted screwoperator
A260402010022 Slotted screwoperator (plastic handle)
21006722 Flared tip screwoperator

A260404000002 Cutting pliers

A260404000001 Cutting pliers
21004526 Diagonal pliers
21083797 Diagonal pliers
B260404000083 Diagonal pliers
B260404000080 Crimping pliers
B260404000081 Wire strippers
21080200 Sharp-nose pliers
21080201 Sharp-nose pliers
A260404000010 Sharp-nose pliers
B260404000082 Sharp-nose pliers
21018648 Electric iron bracket (including rosin and sponge)
A260409000679 Adjustable thermostatic electric iron
21018647 Directly-heated electric iron
21022552 Grease gun
21005407 Double offset ring wrench
21005904 BSW double offset ring wrench
21083801 Open-end wrench
21083762 Pistol drill
21083802 Electric hand drill
A260299000010 Angle grinder
23004510 Sledge hammer
A239900001247 Quakeproof rubber mallet
A239900001248 Quakeproof rubber mallet
21000589 Cabinet file
21084054 Round file
A290000002775 Hoist jack
21008017 Utility knife
A260302040006 Steel tape
A260302040000 Steel tape
A290000002810 Charging flashlight
21008415 Manual riveting gun
A249900001088 Wiring board
21085444 Inner jump ring tongs
B260404000002 Inner jump ring tongs
B260404000005 Outer jump ring tongs

21085079 Flat hanging strip with protection

A230200000757 Flat hanging strip with protection
A230200000767 Flat hanging strip
A230200000768 Flat hanging strip
60002297 One-leg chain sling
60002298 Dual-leg chain sling
A290000002675 Dual-leg chain sling
21003504 Monkey wrench
21084294 Monkey wrench
A260401040007 Monkey wrench
21084375 Feeler gauge
21007746 Flat spade
A260302010008 Vernier height caliper
A880305010022 Vernier depth caliper
21000872 Dial vernier caliper
23003828 Inside micrometer
A260302010012 Outside micrometer
A260301000001 Dial gage
A260309000008 Magnetic force gauge stand
21084880 Stainless steel ruler
A260302050002 Steel ruler
A260409000795 Nitrogen inflation tool
A550200000458 Dressmaker shears
21083609 Electrical grinder
A250100000296 Tension spring balance
21083602 Iron sheet shears
21005892 Digital electroprobe

21084584 (K-01) No. 1 tool kit 5

21084280 Terminal block
21014346 Mobile pump station
21026895 Multipurpose screw turning tool
21002059 Diamond file
Accumulator/inflation tool of suspension

cylinder
A260409000795 nitrogen inflation tool
The above components can be assembled

for inflating the front and rear suspension
cylinders.
Glue and sealant
A420300000032 Kesaixin 1277

36.4 List of Wearing Parts of

SRT95C Mining Truck
Serial No. Material code Name of Material Number

1 A222100000615 Filter, diesel 2
2 21083623 Filter, water 2
3 60013897 Main cartridge of air cleaner 2
4 60216402 Dowm tail mirror 3
5 B222100000595 Filter, engine oil 2
Repair kits of front suspension
6 60209392 1
cylinder
7 B222100000622 Oil-water separator filter core 1
Repair kits of rear suspension
8 60209393 1
cylinder
Combination type front steering
9 A241100000649 2
light assembly
10 60046289 High pressure filter 1
Combination type rear steering
11 A241100000650 2
light assembly
12 60149949 Oil Seal 1
13 60149950 Oil Seal 1
14 60004471 Seal component 2
15 60004470 Lining kit 2
16 60037002 Valve Stem Assy 2
17 60037003 Valve Stem Assy 2
18 60037012 Valve Extension Bar 2
19 60050650 Rearview mirror 2
20 60215480 Oil return filter element 2
21 60141948 Rearview mirror 1
22 60215915 Filter core 1
23 60186788 Filter core 2
24 B230101002023 Dynamic seal assembly 2
25 B230101002024 Dynamic seal assembly 2
26 60209904 Oil suction filter element 1
27 60209906 Oil suction filter element 3
28 60231041 Repair kit of steering cylinder 2
29 60232234 Repair kit of hoisting cylinder 2
30 60211735 Energy storage repair kit 4

Repair kit of filter of lower

31 60197257 2
pressure pipeline
32 60204007 Repair kits of steering control unit 1
33 60004579 Tyre 6
34 A241100000053 Bulb 2
35 60037011 Seal ring 4
36 60013930 Bulb 2
37 21011354 Bulb 2
38 12829446 Locating bushing 16
39 60013932 Bulb 2
40 11123586 Wearing cover sleeve 2
41 21019917 Fuse 5
42 10554209 Spacer 2
43 60014830 Fuse 5
44 12147069 Retainer ring 4
45 21019916 Fuse 5
46 12564516 Wearing cover sleeve 2
47 21019915 Fuse 5
48 12148150 Spacer 2
49 60014829 Fuse 5
50 12568820 Auti-dust cover 8
51 21019914 Fuse 5
52 A222100000615 Filter, diesel 2
53 60144045 Rear Oil Seal 1

SRT95C Off-Highway Truck Technical Parameters
5420
5100
900
12
00
0
320 680
9385
230 5464 400
7220
9825
2000
4890
4630
4350
1003
49
4215 2610 4570
10075
Unitmm
Fig.1 - Machine Dimensions
36.5 Technical parameters
Engine
Model.....................................Cummins engine
CumminsQST30-C1050
Type......................4 Cycle, water-cooled direct
injection, Turbocharged/Aftercooled
Gross power
At the rate of 2100 r/min.........................728kW
976hp

Technical Parameters SRT95C Off-Highway Truck
Net power
At the rate of 2100rpm
728kW
976hp
Note: Power ratings to SAE J1995 June 1990;
the engine emission shall comply with TIER
II USA EPA/CARB MOH 40 CFR 89 and EU
non-highway vehicle standard.
Maximum torque (1300rpm)4629Nm
(3415 Ib ft
Number of Cylinders/Configuration .........12 /V
Bore x Stroke ........................140165mm
5.51 6.49 in
Total Displacement ....................15 L (915 in3)
Transmission
Make/model...........................Allison H8610AR
Automatic electronic control with soft shift
feature.Remote mounted in the frame.
Integral TC 682 torque converter and planetary
gearing. Six speeds forward, one reverse.
Automatic converter lockup action in all speed
ranges. Downshift inhibitor. Integral hydraulic
retarder.
Forward 1st 2nd 3rd 4th 5th 6th

gear gear gear gear gear gear gear
Ratio 4.24 2.32 1.69 1.31 1 0.73
km/h 8 14.7 20.1 26 34 47
mile/h 5 9.2 12.5 16.2 21.2 36.2
Reversing gear R1
Ratio 5.75
km/h 6
mile/h 3.8
Drive axle
Heavy duty axle with single reduction spiral
bevel gear differential, full floating axle shafts,
and planetary reduction at each wheel.

Ratios:
Differential.............................................2.16 : 1
Planetary...............................................13.75:1
Total reduction.......................................29.70:1
Suspension
Front: Macpherson type independent
suspension with variable rate ,nitrongen/oil
cylinder for effective absorption of road shocks
Rear: Variable rate nitrogen/oil cylinders with
A-frame linkage,lateral stabilizer bar .
Maximum strut stroke:
Front.........................................300mm11.8in
Rear.........................................200mm6.9in
Maximum rear axle oscillation.....................7
Wheel and tyres

Wheel rim width......................................19.5in
Tyre..................................27.00-49/48PRE-4
Note: Under certain working conditions,TKPH
(ton-km/h)capabilities of standard tyres could
be exceeded.consult tyre manufactures for
optimum tyre selection.
Brakes
Service:
All hydraulic brake system control.Trans-
mission PTO mounted pressure compensating
piston pump provides hydraulic pressure
for brake and steering. Independent circuits
front and rear.Each circuit incorporates a
accumulator which stores energy to provide
instant braking response.
Front brake circuit pressure........15.5~15.9MPa
(2300 lbf/ in2)
Rear brake circuit pressure..................5.2MPa
(750 lbf/in2)
Accumulators:
Nitrogen precharge pressure................5.5MPa
(800 lbf/in2)
Front:
Type.............Dry disc with 1 calliper per wheel
Disc diameter...........................965mm38in

Pad area,total......................1960cm2304in2
Rear:
Type........................Oil cooled, multiple friction
discs,completely sealed from dirt and water.
Braking surface, total.......91000cm214105in2
Parking:
Application of rear brakes by springs in brake
disc pack.Hydraulically released.
Hold-off pressure..................................8.3MPa
(1200 lbf/in2)
Steering system
Independent hydrostatic steering with closed-
centre steering valve, accumulator and
pressure compensating piston pump.
Accumulator provides uniform steering
regardless of engine speed. In the event of
loss of engine power it provides steering of
approximately two lock-to-lock turns.
A low pressure indicator light warns of system
pressure below 11.5MPa (1660 lbf/in2).
Steering meets ISO 5010 and SAE J53.
Steering angle (left /right)..........................40
Hoist system
It is set up separately from the power hydraulic
system.Two body hoist cylinders are mounted
between the frame rails. Cylinders are two-
stage with power down in the second stage.
System pressure....................................180bar
(2610 lbf/in2)
Hoist pump:
Type..................................................Gear type
Capacity at (at 2100 r/min)................375L/min
Control valve:
Type...............Servo control, neutral gear open
Body raise time..........................................19 s
Body lower time.........................................15 s
Body
Longitudinal 'V' type floor with integral

transverse box-section stiffeners. The body is

exhaust heated and rests on resilient impact
absorption pads.
Body wear surfaces are high hardness
abrasion resistant steel.
Plate thicknesses:
Floor.........................................18 mm (0.71 in)
Side...........................................8 mm (0.31 in)
Front lower................................8 mm (0.39 in)
Deluxe operator cabin with integrated ROPS/
FOPS conform to ISO 3471 and SAE Jl040C
Fed86.
Volume:
Struck(SAE std) ..........................42m3(55yd3)
Heaped 2:1 (SAE std) .................60m3(79yd3)
Frame
Highly rigid frame with the whole box-shaped
section, which is equipped with anti-twisting
beam, is adopted. Integral front bumper and
closed-loop crossmember are equipped. Front
and rear beam, twisting drum, rear mounting
rack and bumper are made of low-carbon
steel. At the stress concentrated areas, cast
steel parts with high tenacity are used, and in
this way, the frame boasts high tenacity and
stronger impact resistance.
Maintenance service capacities
Maintenance
Description volume
L US gal
Engine crankcase and filters 134 35.4
Transmission and filters 100 26.4
Cooling system 300 79.3
Fuel tank 1030 272.1
Steering hydraulic tank 62 16.4
Steering system 170 44.9
Lifting hydraulic tank 280 74

Lifting and brake cooling system 480 126.8

Planetaries (total) 57 15.1
Differential 61 16.1
Front ride strut (each) 30 8.0
Rear ride strut (each) 21 5.5
Power takeoff 4 1.1
Typical noise levels

Operator ear (ISO 6394)..........................78dB
*Exterior sound rating (ISO 6395) ............89dB
*The above result is for the mode giving
the highest exterior sound level when
measured and operated as per the prescribed
procedures of the standard. Results shown
are for the vehicle in base configuration.
Note: Noise Level Exposure to the operator
and bystander personnel may be higher
depending upon proximity to buildings, rock
piles, machinery etc.. The actual job site
Noise Level Exposure must be measured and
applicable regulations complied with in respect
to Employee Hearing Protection.
Vehicle weights (Mass)
Vehicle weights (Mass)

kg Ib
Chassis, with hoists 52000 114000
Body, standard 13000 29000
Net weight 65000 143000
Rated loading capacity 95000 209000
Maximum gross weight* 160000 352000
Weight distribution Front Rear
axle axle
Empty 48% 52%
Loaded 32% 68%

others
Suggestion Feedback Table
Proponent Positon Contact
Manual Name Chapter Page
Issues description:
Suggestion:
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Note:
1.If you have any questions or advises during your daily job with manual, please fill this table out
with your points, we will get that perious advises via our service engineer.
2. Copy this table, if you found another issues out during your daily job with this manual

Issues description:
Suggestion:
Signature
DATE
(Service Engineer)
Note:

SRT95C Off-Highway Truck others
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SRT95C Off-Highway Truck

SANY Mining Equipment

Kunshan Economic & Technological Developement Zone

Jiangsu Province, P. R. of China 215300

http://www. Sanyhe. Com

Safety warning sign

1. Following the safety information

notes, cautions and labels of the agreement

Danger It indicates an emergent

Warning It indicates a potentially

Caution It indicates a dangerous

Preparation for operation

Notes during operation

discharge cover and liquidometer, the operator

This is a general rules. Pay greater attention

9. Transmission Feed oil into the oil sump of

Long-term storing within six months

Storing for over six months

Others storing of truck

Distribution and Timely Revision

Sign Item Description

During operation, pay

2) The wire rope must be hung between the

4) When hoisting a heavy heavy, the hoisting

they may lift 2000kg in total; when the hoisting

Convert mminto in B 1mm=0.03937in

convert mm into in 1mm=0.03937in

convert L into U. S. Gal 1L=0.2642 U. S. Gal

1L=0.21997 U.K. Gal

0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980

convert kgm into ftlb 1kgm =7.233 ftlb

convert kg/cm2 into lb/in2 1kg/cm2=14.2233lb/in2

1 FRONT WHEEL ASSEMBLY 1-1

2 FRONT AXLE ASSEMBLY 2-1

3 REAR AXLE ASSEMBLY AND INSTALLATION 3-1

4 REAR WHEEL ASSEMBLY 4-1

5 INSTALLATION OF ENGINE 5-1

6 TRANSMISSION AND MOUNTING 6-1

7 FENDER AND PLATFORM MOUNTING 7-1

8. CAB ACCESSORIES 8-1

9 HYDRAULIC STEERING PIPELINE OF OPERATORS CAB9-1

10 OPERATORS CAB BRAKE PIPELINE AND JOINT 10-1

11 AIR CONDITIONING PIPELINE INSTALLATION 11-1

12 FUEL TANK AND MOUNTING 12-1

13 STEERING PIPELINE AND JOINT  13-1

14 HOSIT PIPELINE AND JOINT  14-1

15 HYDRAULIC OIL TANK ASSEMBLY 15-1

16 BRAKE PIPELINE AND JOINT 16-1

17FRAME AND INSTALLATION 17-1

18 DRIVELINE INSTALLATION 18-1

19 AIR CLEANER AND MOUNTING 19-1

20 EXHAUST SYSTEM ASSEMBLY 20-1

21 REAR SUSPENSION SYSTEM 21-1

22 RADIATOR GUARD  22-1

23 BODY AND MOUNTING 23-1

1 FRONT WHEEL ASSEMBLY 1-1

2 FRONT AXLE ASSEMBLY 2-1

3 REAR AXLE ASSEMBLY AND INSTALLATION 3-1

4 REAR WHEEL ASSEMBLY 4-1

5 INSTALLATION OF ENGINE 5-1

6 TRANSMISSION AND MOUNTING 6-1

7 FENDER AND PLATFORM MOUNTING 7-1

8. CAB ACCESSORIES 8-1

9 HYDRAULIC STEERING PIPELINE OF OPERATORS CAB9-1

10 OPERATORS CAB BRAKE PIPELINE AND JOINT 10-1

11 AIR CONDITIONING PIPELINE INSTALLATION 11-1

12 FUEL TANK AND MOUNTING 12-1

13 STEERING PIPELINE AND JOINT 13-1

14 HOSIT PIPELINE AND JOINT 14-1

15 HYDRAULIC OIL TANK ASSEMBLY 15-1

16 BRAKE PIPELINE AND JOINT 16-1

17FRAME AND INSTALLATION 17-1

18 DRIVELINE INSTALLATION 18-1

19 AIR CLEANER AND MOUNTING 19-1

20 EXHAUST SYSTEM ASSEMBLY 20-1

21 REAR SUSPENSION SYSTEM 21-1

22 RADIATOR GUARD 22-1

23 BODY AND MOUNTING 23-1

24 ILLUMINATION LAMP AND INSTALLATION 24-1

25 VEHICLE DETECTING SYSTEM 25-5

26 ARRANGEMENT PLAN OF SRT95C 26-4

27 CENTRALIZED LUBRICATION SYSTEM 27-2

28 TRANSMISSION OIL FILTER ASSEMBLY 28-1

29 DISC BRAKE COOLING SYSTEM PIPELINE AND JOINT 29-1

30 BRAKE OIL COOLER AND INSTALLATION 30-1

31 TRANSMISSION COOLING PIPING MOUNTING 31-1

32 RADIATOR AND MOUNTING 32-2

33 WATER TANK MOUNTING AND LINES 33-1

34 BATTERY AND INSTALLATION 34-1

35 CABLES AND HARNESSES 35-1