Sany SRT55D Off-Highway Truck. Safety, Operation and Maintenance Manual (2014)

Lubrication and Servicing

Above

SAE 85W-140

+40°C

Mobil

auto-

motive

gear

oil HD

-25°C-

SAE 80W-90

80W--90

+40°C

Shell

hypoid

Differential

gear oil

Steering

Mobil

Wheel planetaries

API GL-5

GL-5

hydraulic tank

Shell

PTO

80W-90

Mobilube

1 SHC

75W/90

Mobil

Below

SAE 75W-90

Delvac

-25°C

synthetic

gear oil

75W-90

Above

Mobilith

ISO VG460

NLGI 1.5

Multipurpose

-40°C

SHC 460

Extreme

Pressure

Front wheel bearing

Lithium

Steering column

Mobil

Lithium

Grease (without

Drive shaft fork

Above

Shell

base

'Molybdenum'),

NLGI 2

bearing

-30°C

grease

with a typica

melting point of

190° C.

8-15

Lubrication and Servicing

Note 1 - Consult your lubricant supplier for

the correct viscosity of lubricant to use when

ambient temperatures are consistently above

or below those listed.

Note 2 - Cummins Engine Co., does not

recommend any specific brand of engine oil

but the use of oils that meet API categories.

Cummins recommends use of only the multi-

graded viscosity oils shown for the various

ambient temperatures listed.

Note 3-Operation below the minimum

temperatures listed for the oil used without

proper preheat or warm-up results in greatly

reduced transmission life. If auxiliary heating

is available, preheat the oil to the minimum

temperature limit. If not available, run the

engine at part throttle with the transmission in

neutral to raise the fluid temperature.Hydraulic

Transmission Oil meeting the Allison C-4

requirements. Consult your lubricant supplier

for confirmation.

Note 4 - If rear axle has limited slip differential,

use of standard SAE 90 oil may result in very

loud noise and jerking of the wheels when

driving slowly round sharp corners and an EP

oil with limited slip additives should be used.

Other lubricant suppliers may have

comparable products and should be consulted

for confirmation.

Temperature conversion

℃

-32

-30

-27

-25

-20

-18

-15

-10

190

℉

-26

-22

-17

-13

-4

100

113

200

375

8-17

Lubrication and Servicing

8.6 Maintenance Procedures

8.6.1 Daily (10hrs) maintenance inspection form

For regular inspection and duty, fills this form out each 10 hrs. This form should be used with

other forms in this manual.

1.For normally checking

Check all operation devices by driving……………

……………

2.Lubrication

Hands lubrication system

Check crack or leakage and damaged of the fittings, replace them if required.……

………

Check status of the lubrication point

…………………………

Check the electric pump

………………………………………

Refill oil to the lubrication system via centralization lubrication machine which mounted on the

frame and under the bearing of the rear lamps

………

3. Electronic system

Check and reads the current gauge.……………………………………..…………………..……

Check status about all of indication lamps, caution lamps, meters and assistant devices..…

4. Cummins engine

Check liquid level, refill as required.………………………………………

……………………

Check leakages.…………………………………………………………..…………………………

Check damaged for fans…………………………………………………

………

Check the oil temperatures and read pressures.………………………

………

Check tension of the driving belt and adjust as required……………………

………………

Check fuel system

Check leakages for fuel system……..…………………………………

……

Check liquid level and refill after daily job.……..…………………

………

Cooling system

Check coolant level, refill as required.……………….……………

………………

Check leakages for hoses and other components……….…………

……………………

Air cleaner

Check status for the vacuator valve..……………………………

…

Check status for filter………………………………….……

……..…

Check leakages and cracks for air-intake system.………….………

…………

5. Transmission

Check leakages………………………………………………

………………………………

Check liquid level, refill as required……………………

………………………………………

Check oil temperatures and pressures……………………

…………

6. Suspension system

Check water level for front and rear ride cylinder according to service manual.………………

Check leakages.……………

…………………

7. Wheels

Check status and pressures……………………

…………………………

8-19

Lubrication and Servicing

supplement:

8. Rims

Check fasteners by torque

……………………………………

………………..…

9. Hydraulic system

Hoisting and cooling hydraulic system

Check hoisting system oil level, , refill if required

………

Replace the breath valve for the steering hydraulic tank in period

………

Note: replace new filter for the system if it working time over 500hrs.

Replace the breath valve for the hoisting hydraulic tank in period

………

Note: replace new filter for the system if it working time over 500hrs.

Replace new filter for the return system in period…

………

Note: replace oil return filter of hoisting system if it working time over 500hrs.

Replace the oil suction filter of hoisting system in period

………

Note: replace new filter for the system if it working time over 2000hrs(The first replace at 1000

hrs).

Replace the oil suction filter of cooling system in period

………

Note: replace new filter for the system if it working time over 2000hrs(The first replace at 1000

hrs).

Replace the Pipeline filter of cooling system in period

………

Note: replace new filter for the system if it working time over 500hrs.

Check leakages for hydraulic system and its components , check worn and damaged for hoses.

…

……

Steering and braking hydraulic system

Check status for steering control unit…………

…….…..………………………

Shutdown the engine and rotate the wheel to check the ability of steering system in emergency co

ndition…………………………………………………………………………………………………

Check status for foot brake system and parking brake system.…….…….……………………

Check steering system oil level, refill if required.……………………

…

Replace the oil return filter of steering system in period.………

………….………………

Note: replace new filter for the system if it working time over 500hrs.

Replace the oil return filter of steering system in period.………

………….………………

Note: replace new filter for the system if it working time over 2000hrs(The first replace at 1000

hrs).

Replace the Pipeline filter of steering system in period.………

………….…………………

Note: replace new filter for the system if it working time over 500hrs.

Replace the filter which mounted inside of the rear braking valve group in period……………

Note: replace new filter for the system if it working time over 500hrs.

Change oil for the tank and clean the whole tank and accessories

….

Check the pressure for the system………………………………………….……………..………

Check the pressure for the steering system……………………………….……………..………

Check the pressure for the front breaking system………………..……….……………..………

Caution: Replace all of o-rings for hoist steering, brake and cooling system if maximum

adjustments as required for ensure systems with high performance and safety above.

8-21

Lubrication and Servicing

8.6.2 Maintenance inspection form for 150hrs

Except daily (10hrs) inspection projects, the following projects also have to finish after running

150hrs.

1. For normally checking

Check leakages, loosened and damaged parts for truck.………

…………………………

Observe the cracks and broken welds for frame……………

…

2. Cummins engine

Check the fasteners for engine………………………………………

…………

Check PTO liquid level, refill as required……………………..…………

………………

3. Transmission

Replace filter of the oil-water separator (first time after 150hrs, next time after each 1200hrs).…

.......…….…

…….…

Remark: drain, replace filter and refill after 150hrs, if transmission has been fixed.

Clean the breather assembly for transmission and lubricates again.……

……..………

Check status about block caution lamp for filter.……………………

…….

4. Main reducer and differential assembly,planetary assemblyand power take-off (PTO)

Change the lubrication of Main reducer and differential assembly,planetary assembly and PTO.

.…

…

Check liquid level, refill as required…………………………………………

…………………

Check and clean the breather assembly for rear shaft.………………

………………

Check and clean the breather assembly for PTO………………………

…………...…

Remark: change oil when replace new one or after fixed.

5. Lubrication

Front, rear transmissions cross shafts……………

…………

……..6 points

Front, rear transmission shafts…………………………

…………………

…….2 points

6.The scene did not conduct the driveline assembly bolts inspection requirements (The first 150

hours, After every 1200 hours)

Front driveline bolts tightening torque:145N.m……………………………………

…………

Rear driveline bolts tightening torque:260N.m……………….……………………

…………

Front driveline bolts check torque:140N.m……………………...…………………

…………

Rear driveline bolts check torque:250N.m…………………………………………

…………

7. Clean up the dust on the pin shaft of foot-operated valve,and add the lubricating oil.……

8.Check the driveline bolts torque(first time after 150hrs, next time after each 1200hrs)…...

Use of the site

Tightening torque

Check torque

Front driveline

145

140

Fear driveline

260

250

Checker

Date

Remarks

8-23

Lubrication and Servicing

8.6.3 Maintenance inspection form for 250hrs

Except daily (10hrs) inspection projects, the following projects also have to finish after running

250hrs.

1. Cummins engine

Drain, replace filter and refill………………………………

………………………..…

Check breather assembly for crankcase………………………

………………………

Fuel system

Replace fuel filter…………………………………………………………………….………………

Cooling system

Replace coolant filter………………………………………………………………………..………

Check and supplement DCA to coolant…………

…

….

2. Front brake system

Check status about disc worn to determinate replace it if required.……

……………………

3. Lubrication

Front, rear transmissions cross shafts………………….……

…

…..6 points

Front, rear transmission shafts…………………………………………

……

…..2 points

4.Hydraulic system

Check the pressure for the system

….

Check the pressure for the steering system

….

Check the pressure for the front breaking system

….

Check the pressure for the rear breaking system

….

Check the pressure for the parking system

….

Steering system: Check the pre-charge pressure for the accumulator before the checks pressure

for the steering system

Breaking system: check the pre-charge pressure for the accumulator before the checks pressure

for the breaking system

note:

a . The instruction about how to make a inspection for the hoisting , steering and breaking system

are contained in manual book

Check and replace old components with new one to ensure of the system work well if the

inspection result are different with requirement

b. Make sure the pressure drain out of the accumulator before checks the pre-charge for the

accumulator

Checker

Date

Remarks

8-25

Lubrication and Servicing

8.6.4 Maintenance inspection form for 300hrs

Except daily (10hrs) inspection projects, the following projects also have to finish after running

300hrs.

1. For normally checking

Check leakages, loosened and damaged parts for truck.………

…………………………

Observe the cracks and welder seam for frame……………

…

2. Cummins engine

Check the fasteners for engine………………………………………

…………

Check PTO liquid level, refill as required……………………..…………

………………

3. Transmission

Clean the breather assembly for transmission and lubricates again.……

……..………

Check status about block caution lamp for filter.……………………

…….

Remark: drain, replace filter and refill after 150hrs, if transmission has been fixed.

4. Main reducer and differential assembly,planetary assembly and power take-off (PTO)

Extract lubrication sample from Main reducer and differential assembly and planetary assembly

for checking and analysis

…

Check liquid level, refill as required…………………………………………

…………………

Check and clean the breather assembly for rear shaft.………………

………………

Check and clean the breather assembly for PTO………………………

…………...…

Remark: change oil when replace new one or after fixed.

5. Lubrication

Front, rear transmissions cross shafts……………

…………

……..6 points

Front, rear transmission shafts…………………………

…………………

…….2 points

6. Clean up the dust on the pin shaft of foot-operated valve,and add the lubricating oil.……

Checker

Date

Remarks

8-27

Lubrication and Servicing

8.6.5 Maintenance inspection form for 450hrs

Except daily (10hrs) inspection projects, the following projects also have to finish after running

450hrs.

1. For normally checking

Check leakages, loosened and damaged parts for truck.………

…………………………

Observe the cracks and welder seam for frame……………

…

2. Cummins engine

Check the fasteners for engine………………………………………

…………

Check PTO liquid level, refill as required……………………..…………

………………

3. Transmission

Clean the breather assembly for transmission and lubricates again.……

……..………

Check status about block caution lamp for filter.……………………

…….

Remark: drain, replace filter and refill after 150hrs, if transmission has been fixed.

4. Main reducer and differential assembly,planetary assembly and power take-off (PTO)

Extract lubrication sample from Main reducer and differential assembly and planetary assembly

for checking and analysis

…

Check liquid level, refill as required…………………………………………

…………………

Check and clean the breather assembly for rear shaft.………………

………………

Check and clean the breather assembly for PTO………………………

…………...…

Remark: change oil when replace new one or after fixed.

5. Lubrication

Front, rear transmissions cross shafts……………

…………

……..6 points

Front, rear transmission shafts…………………………

…………………

…….2 points

6. Clean up the dust on the pin shaft of foot-operated valve,and add the lubricating oil.……

Checker

Date

Remarks

8-29

Lubrication and Servicing

8.6.6 Maintenance inspection form for 500hrs

Except daily (10hrs) inspection projects, the following projects also have to finish after running

500hrs.

1. Cummins engine

Drain, replace filter and refill………………………………

………………………..…

Check breather assembly for crankcase………………………

………………………

2. Front brake system

Check status about disc worn to determinate replace it if required.……

……………………

3. Front, rear transmissions cross shafts

Refill enough grease………….……………………………………………………………..………

4. Lubrication

Front, rear transmissions cross shafts………………….……

…

…..6 points

Front, rear transmission shafts…………………………………………

……

…..2 points

5. Hydraulic system

Replace new filter for the return filter of hoisting system………………………………..………

Replace new filter for the return filter of steering system………………………………..………

Replace new filter for the filter which mounted on the pipeline of the steering syste…

Replace new filter for the filter which mounted on the pipeline of the cooling system………

Replace new filter which mounted inside of the rear braking valve group……………..………

Replace new filter for the suction filter of the steering system…………………………..………

Replace new filter for the suction filter of the hoisting system…………………………..………

Replace new filter for the suction filter of the cooling system…………………………..………

Replace the breath valve for the steering hydraulic tank……………………………..………

Replace the breath valve for the hoisting hydraulic tank………………………………..………

6. Bearing

Check the wearing status for oscillating bearings of steering drag link, replace new

one if the clearance of the bearing S≥ 0.54mm .Conversely, you could continue use it.

.…

…

Check the wearing status for oscillating bearings of A-shape arm, replace new one

if the clearance of the bearing S≥ 0.55mm .Conversely, you could continue use it.

.…

…

Check the wearing status for oscillating bearings of ends of the A-shape arm, replace

new one if the clearance of the bearing S≥ 0.7mm .Conversely, you could continue use it.

.…

…

Check the wearing status for oscillating bearings of steering cylinder , replace new

one if the clearance of the bearing S≥ 0.54mm .Conversely, you could continue use it.

.…

…

7. Check screw between steering arm and front suspension cylinder. If loosed or damaged ,tighten

or replace new screw………………………………………

………………………..…

8-31

Lubrication and Servicing

8.6.7 Maintenance inspection form for 600hrs

Except daily (10hrs) inspection projects, the following projects also have to finish after running

600hrs.

1. For normally checking

Check leakages, loosened and damaged parts for truck.………

…………………………

Observe the cracks and welder seam for frame……………

…

Check displacement and worn for transmission shaft by lever.………

…….……

2.Lubrication

Universal joint of steering rod

3 points

Hands lubrication system

Check and clean the grease filter element…………

………………………………

3. Electrical system

Check harnesses status.………………………………

………………………………

Check status about cables for storage battery……………………………………………………

4. Cummins engine

Check the fasteners for engine………………………………………

…………

Check PTO liquid level, refill as required……………………..…………

………………

Air cleaner………………………………………………………………

…………………………

Clean pipeline and filter for air cleaner

………………………………..………

5. Transmission

Clean the breather assembly for transmission and lubricates again.……

……..………

Check status about block caution lamp for filter.……………………

…….

Remark: drain, replace filter and refill after 150hrs, if transmission has been fixed.

6. Main reducer and differential assembly,planetary assembly and power take-off (PTO)

Extract lubrication sample from Main reducer and differential assembly and planetary assembly

for checking and analysis

…

Check liquid level, refill as required…………………………………………

…………………

Check and clean the breather assembly for differential.………………

………………

Check and clean the breather assembly for PTO………………………

…………...…

Remark: change oil when replace new one or after fixed.

7. Clean up the dust on the pin shaft of foot-operated valve,and add the lubricating oil.……

Checker

Date

Remarks

8-33

Lubrication and Servicing

8.6.8 Maintenance inspection form for 750hrs

Except daily (10hrs) inspection projects, the following projects also have to finish after running

750hrs.

1. For normally checking

Check leakages, loosened and damaged parts for truck.………

…………………………

Observe the cracks and welder seam for frame……………

…

2. Cummins engine

Check the fasteners for engine………………………………………

…………

Check PTO liquid level, refill as required……………………..…………

………………

Drain, replace filter and refill………………………………

………………………..…

Check breather assembly for crankcase………………………

………………………

Fuel system

Replace fuel filter…………………………………………………………………….………………

Cooling system

Replace coolant filter………………………………………………………………………..………

Check and supplement DCA to coolant…………….…

….

3. Transmission

Clean the breather assembly for transmission and lubricates again.……

……..………

Check status about block caution lamp for filter.……………………

…….

Remark: drain, replace filter and refill after 150hrs, if transmission has been fixed.

4. Front brake system

Check status about disc worn to determinate replace it if required.……

……………………

5. Differential, planetary gearing and power take-off (PTO)

Extract lubrication sample from differential and planetary gearing for checking and analy-

sis.…

…

Check liquid level, refill as required…………………………………………

…………………

Check and clean the breather assembly for differential.………………

………………

Check and clean the breather assembly for PTO………………………

…………...…

Remark: change oil when replace new one or after fixed.

6. Lubrication

Front, rear transmissions cross shafts……………

…………

……..6 points

Front, rear transmission shafts…………………………

…………………

…….2 points

7. Clean up the dust on the pin shaft of foot-operated valve,and add the lubricating oil.……

Checker

Date

Remarks

8-35

Lubrication and Servicing

8.6.9 Maintenance inspection form for 900hrs

Except daily (10hrs) inspection projects, the following projects also have to finish after running

900hrs.

1. For normally checking

Check leakages, loosened and damaged parts for truck.………

…………………………

Observe the cracks and welder seam for frame……………

…

2. Cummins engine

Check the fasteners for engine………………………………………

…………

Check PTO liquid level, refill as required……………………..…………

………………

3. Transmission

Clean the breather assembly for transmission and lubricates again.……

……..………

Check status about block caution lamp for filter.……………………

…….

Remark: drain, replace filter and refill after 150hrs, if transmission has been fixed.

4. Main reducer and differential assembly,planetary assembly and power take-off (PTO)

Extract lubrication sample from Main reducer and differential assembly and planetary assembly

for checking and analysis

…

Check liquid level, refill as required…………………………………………

…………………

Check and clean the breather assembly for rear shaft.………………

………………

Check and clean the breather assembly for PTO………………………

…………...…

Remark: change oil when replace new one or after fixed.

5. Clean up the dust on the pin shaft of foot-operated valve,and add the lubricating oil.……

Checker

Date

Remarks

8-37

Lubrication and Servicing

8.6.10 Maintenance inspection form for 1000hrs

Except daily (10hrs) inspection projects, the following projects also have to finish after running 1000hrs.

1. Cummins engine

Drain, replace filter and refill………………………………

………………………..…

Check breather assembly for crankcase………………………

………………………

Fuel system

Replace fuel filter…………………………………………………………………….………………

Cooling system

Replace coolant filter………………………………………………………………………..………

Check and supplement DCA to coolant…………….…

….

2. Front brake system

Check status about disc worn to determinate replace it if required.……

……………………

3. Lubrication

Front, rear transmissions cross shafts………………….……

…

…..6 points

Front, rear transmission shafts…………………………………………

……

…..2 points

4.Hydraulic system

Replace new filter for the return filter of hoisting system

….

Replace new filter for the return filter of steering system

….

Replace new filter for the filter which mounted on the pipeline of the steering system…

Replace new filter for the filter which mounted on the pipeline of the cooling system.…

Replace new filter which mounted inside of the rear braking valve group

….

Replace new filter for the suction filter of the steering system

….

Replace new filter for the suction filter of the hoisting system

….

Replace new filter for the suction filter of the cooling system

….

Replace the breath valve for the steering hydraulic tank

….

Replace the breath valve for the hoisting hydraulic tank

….

Checker

Date

Remarks

8-39

Lubrication and Servicing

supplement:

5.Bearing

Check the wearing status for oscillating bearings of steering drag link, replace new

one if the clearance of the bearing S≥ 0.54mm .Conversely, you could continue use it.

.…

…

Check the wearing status for oscillating bearings of A-shape arm, replace new one

if the clearance of the bearing S≥ 0.55mm .Conversely, you could continue use it.

.…

…

Check the wearing status for oscillating bearings of ends of the A-shape arm, replace

new one if the clearance of the bearing S≥ 0.7mm .Conversely, you could continue use it.

.…

…

Check the wearing status for oscillating bearings of steering cylinder , replace new

one if the clearance of the bearing S≥ 0.54mm .Conversely, you could continue use it.

.…

…

Check the wearing status for oscillating bearings of front suspension cylinder , replace new one if

the clearance of the bearing S≥ 0.55mm .Conversely, you could continue use it

….

Check the wearing status for oscillating bearings of rear suspension cylinder , replace new one if

the clearance of the bearing S≥ 0.63mm .Conversely, you could continue use it

….

7. Check screw between steering arm and front suspension cylinder. If loosed or damaged ,tighten

or replace new screw………………………………………

………………………..…

Checker

Date

Remarks

8-41

Lubrication and Servicing

8.6.11 Maintenance inspection form for 1050hrs

Except daily (10hrs) inspection projects, the following projects also have to finish after running

1050hrs.

1. For normally checking

Check leakages, loosened and damaged parts for truck.………

…………………………

Observe the cracks and welder seam for frame……………

…

2. Cummins engine

Check the fasteners for engine………………………………………

…………

Check PTO liquid level, refill as required……………………..…………

………………

3. Transmission

Clean the breather assembly for transmission and lubricates again.……

……..………

Check status about block caution lamp for filter.……………………

…….

Remark: drain, replace filter and refill after 150hrs, if transmission has been fixed.

4.Main reducer and differential assembly,planetary assembly and power take-off (PTO)

Extract lubrication sample from Main reducer and differential assembly and planetary assembly

for checking and analysis

…

Check liquid level, refill as required…………………………………………

…………………

Check and clean the breather assembly for rear shaft………………

………………

Check and clean the breather assembly for PTO………………………

…………...…

Remark: change oil when replace new one or after fixed.

5. Clean up the dust on the pin shaft of foot-operated valve,and add the lubricating oil.……

Checker

Date

Remarks

8-43

Lubrication and Servicing

8.6.12 Maintenance inspection form for 1200hrs

Except daily (10hrs) inspection projects, the following projects also have to finish after running

1200hrs.

1. For normally checking

Check leakages, loosened and damaged parts for truck.………

…………………………

Observe the cracks and welder seam for frame……………

…

Check displacement and worn for transmission shaft by lever.………

…….……

2.Lubrication

universal joint of steering rod

3 points

Hands lubrication system

Check and clean the grease filter element…………

………………………………

3. Electrical system

Check harnesses status.………………………………

………………………………

Check status about cables for storage battery……………………………………………………

4. Cummins engine

Check the fasteners for engine………………………………………

…………

Check PTO liquid level, refill as required……………………..…………

………………

Air cleaner………………………………………………………………

…………………………

Clean pipeline and filter for air cleaner

………………………………..………

5. Transmission

Clean the breather assembly for transmission and lubricates again.……

……..………

Check status about block caution lamp for filter.……………………

…….

Remark: drain, replace filter and refill after 150hrs, if transmission has been fixed.

6. Main reducer and differential assembly,planetary assembly and power take-off (PTO)

Extract lubrication sample from Main reducer and differential assembly and planetary assembly

for checking and analysis

…

Check liquid level, refill as required…………………………………………

…………………

Check and clean the breather assembly for rear shaft.………………

………………

Check and clean the breather assembly for PTO………………………

…………...…

Remark: change oil when replace new one or after fixed.

7. Clean up the dust on the pin shaft of foot-operated valve,and add the lubricating oil.……

Checker

Date

Remarks

8-45

Sany SRT55D Off-Highway Truck. Safety, Operation and Maintenance Manual (2014) - page 6