Sany SRT55D Off-Highway Truck. Safety, Operation and Maintenance Manual (2014) - page 9
Lubrication and Servicing
Repair and Maintenance Record Table
Repair and main-
Date
Cost
Time required
Unused time
Remarks
tenance performed
8-106
Lubrication and Servicing
8.6.39 Maintenance inspection form for 4000hrs
Except daily (10hrs) inspection projects, the following projects also have to finish after running
4000hrs.
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.Rear brake system
Check and record the worn status about rear brake disc unit
….
4.Air-condition
Check evaporimeter and cooling “S” pipe, clean as required
….
Check fasteners to replace or adjust for compressor
….
Check status about coolant via window
….
Check all system hoses and fittings for leakages
….
Check working status for air-condition
….
5.Lubrication
Front, rear transmissions cross shafts………………….……
…
…..6 points
Front, rear transmission shafts…………………………………………
……
…..2 points
6.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
….
Change oil for the tank and clean the whole tank and accessories
….
8-107
Lubrication and Servicing
Repair and Maintenance Record Table
Repair and main-
Date
Cost
Time required
Unused time
Remarks
tenance performed
8-108
Lubrication and Servicing
supplement:
Hydraulic system pressure checking
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 pre-charge pressure for accumulator first then does check pressure for
steering system.
Braking system: Check pre-charge pressure for accumulator first then does check pressure for
steering system.
Note: when the data compared with maintenance manual are different. the operator has to check
,fix problems for system to make it work well.
Drain all pressure oil out from the accumulator before when you decided to check pressure of it .
7.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
….
8. Check screw between steering arm and front suspension cylinder. If loosed or damaged
,tighten or replace new screw……………………………
………………………..…
Checker
Date
Remarks
8-109
Lubrication and Servicing
Repair and Maintenance Record Table
Repair and main-
Date
Cost
Time required
Unused time
Remarks
tenance performed
8-110
Lubrication and Servicing
8.6.40 Maintenance inspection form for 4050hrs
Except daily (10hrs) inspection projects, the following projects also have to finish after running
4050hrs.
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
8-111
Lubrication and Servicing
Repair and Maintenance Record Table
Repair and main-
Date
Cost
Time required
Unused time
Remarks
tenance performed
8-112
Lubrication and Servicing
8.6.41 Maintenance inspection form for 4200hrs
Except daily (10hrs) inspection projects, the following projects also have to finish after running
4200hrs.
1. For normally checking
Check leakages, loosened and damaged parts for truck and Clean whole truck by vapour …
Observe frame for cracks and weld seam opening.……
…….……
Check displacement and worn for transmission shaft by lever.……
…….……
Check status for body lining plate.……
……
……
Check hoist guide rail, electroplate it again as required.……
…….……
Check status for all hoses; replace all worn, leaked and damaged ones.………
…….……
2. Lubrication
Front, rear transmissions cross shafts………………….……
…
…..6 points
Front, rear transmission shafts…………………………………………
……
…..2 points
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
Check and tighten for transmission according to requirement……
……..………
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.
8. Clean up the dust on the pin shaft of foot-operated valve,and add the lubricating oil.……
Checker
Date
Remarks
8-113
Lubrication and Servicing
Repair and Maintenance Record Table
Repair and main-
Date
Cost
Time required
Unused time
Remarks
tenance performed
8-114
Lubrication and Servicing
8.6.42 Maintenance inspection form for 6000hrs
Except daily (10hrs) inspection projects, the following projects also have to finish after running
6000hrs.
1. Engine PTO
Disassemble, inspect and fix or replace some parts if required which parts has been worn.………
………
…….
Check Pin Spindle and Bush ,replace them as required…………………
…….
2. Hoist cylinder
Disassemble, inspect and fix or replace some parts if required which parts has been worn.………
………
…….
Check Pin Spindle and Bush ,replace them as required…………………
…….
3. Front, rear ride cylinder
Disassemble, inspect and fix or replace some parts if required which parts has been worn.………
………
…….
Check Pin Spindle and Bush ,replace them as required…………………
…….
4. Steering connecting-rod gear
Check and fix or replace some parts if required which parts has been worn
………………
5. Steering cylinder
Dismounting ,checking and repair or replace damaged components for the cylinder if requir
ed
……
……
Check the pins and bearings or replace damaged parts for the cylinder if reqiured
6. Oil cooling unit
Disassembly, fixing and reassembly…………...………………………………………………….
7. Radiator
Disassembly, fixing and reassembly………………...…………………………………………….
Transmission shaft
Check and fix or replace some parts if required which parts has been worn.………….
Check balance.……………………………………………………………………
………….
9. Body
Replace lining plate as required
……………………………….….
Replace Pin Spindle and Bush as required…
……………………………….….
10.Rear Axle
Replace a frame, drag link and bush…
………………………...…
11.Transmission
Check fasteners for spray equipment, fasten as required
…………………………
12. Clean up the dust on the pin shaft of foot-operated valve,and add the lubricating oil...…
8-115
Lubrication and Servicing
Repair and Maintenance Record Table
Repair and main-
Date
Cost
Time required
Unused time
Remarks
tenance performed
8-116
Lubrication and Servicing
supplement:
13.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
….
Change oil for the tank and clean the whole tank and accessories
….
Hydraulic system pressure checking
Check system pressure of steering system
….
Check pressure of front brake system
….
Check pressure of rear brake system
….
Check pressure of parking system
….
Steering system: Check pre-charge pressure for accumulator first then does check pressure for
steering system.
Braking system: Check pre-charge pressure for accumulator first then does check pressure for
steering system.
Note: when the data compared with maintenance manual are different. the operator has to check
,fix problems for system to make it work well.
Drain all pressure oil out from the accumulator before when you decided to check pressure of it .
14.Bearing
Replace new bearings for steering drag link
….
Replace new bearings for A-shape arm
….
Replace new bearings for ends of the A-shape arm
….
Replace new bearings for steering cylinder
….
Replace new bearings for front suspension cylinder
…………
…………
Replace new bearings for rear suspension cylinder……………
……
Replace new bearings for A-shape
….
Replace new bearings for link
….
15. Check screw between steering arm and front suspension cylinder. If loosed or damaged
,tighten or replace new screw……………………………
………………………..…
Checker
Date
Remarks
8-117
Lubrication and Servicing
Repair and Maintenance Record Table
Repair and main-
Date
Cost
Time required
Unused time
Remarks
tenance performed
8-118
Lubrication and Servicing
8.6.43 Maintenance inspection form for 10000hrs
Except daily (10hrs) inspection projects, the following projects also have to finish after running
10000hrs.
According to the sample of the oil to determinate whether replace components or not.
1. Engine
Contacting with manufacturer for further information
………………………
2. Transmission
Disassemble, inspect and fix or replace some parts if required which parts has been worn
............................................................................................................................................…
Remark: drain, replace filter and refill after 150hrs, if transmission has been fixed.
3. Main reducer and differential assembly,planetary assembly
Disassemble, inspect and fix or replace some parts if required which parts has been worn.……
........................................................................................................................................……
4. 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
….
5. Check screw between steering arm and front suspension cylinder. If loosed or damaged
,tighten or replace new screw……………………………
………….……………..…
Checker
Date
Remarks
8-119
Technical Data
9 TECHNICAL DATA
4632
2900
2226
4308
3460
4344
Unit : mm
Fig. 9-1
Engine
Make/Model…
Cummins QSK19-C700
Type…………………
4 cycle,
turbocharged/low temperature aftercooled.
electronic management
Gross power
At the rate of 2100rpm………..…522kw
(700hp)
Net power
At the rate of 2100rpm…….……481kw (645hp)
Note: Power ratings to SAE J1995 Jun 90.
Engine emission meets Tier II USA EPA/CARB
MOH 40 CFR 89 and proposed EU NRMM
(non-road mobile machinery directive).
9-1
Technical Data
Maximum torque (1500rpm)……….…3118N•m
(2300Ib ft)
Number of cylinders/configuration……6, in line
Bore x stroke…….………………...159×159mm
(6.25×6.25in)
Total displacement………………..19L (1150in3)
Transmission
Make/model………………… Allison H6620AR
automatic electronic control with soft shift
feature. Remote mounted in the frame.
Integral TC 682 torque converter and planetary
gearing. Six speeds forward, two 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
4.00
2.68
2.01
1.35
1.00
0.67
km/h
9.9
14.6
19.5
29.1
39.3
57.5
mile/h
6.1
9.1
12.1
18.1
24.4
35.7
Reverse
R1
R2
gear
Ratio
5.15
3.46
km/h
6.6
11.8
mile/h
4.1
7.3
Driving axle
Heavy duty axle with single reduction spiral
bevel gear differential, full floating axle shafts,
and planetary reduction at each wheel.
Ratios:
Differential…………………………………3.73:1
Planetary………………………….……….5.80:1
Total reduction…………………………...21.63:1
Suspension
Front: Macpherson type independent
9-2
Technical Data
suspension with variable rate, nitrogen/
oil cylinder for effective absorption of road
shocks.
Rear: Variable rate nitrogen/oil cylinders with
A-frame linkage and lateral stabilizer bar.
Maximum strut stroke:
Front
300 mm (11.8 in)
Rear
186 mm (7.3 in)
Maximum rear axle oscillation
±7°
Wheels and tyres
Wheel rim width ……….……………………17in
Tyre ……….…………...24.00-35/(36/42PR)
e-4
Under certain working conditions, TKPH(ton-
Km/h) capabilities of standard tyres could be
exceeded. Consult tyre manufacturers for
optimum tyre selection.
Braking systems
Service Brakes - All hydraulic brake system
control. Transmission PTO mounted pressure
compensating piston pump provides hydraulic
pressure for brakes and steering. Independent
circuits front and rear.Each circuit incorporates
a accumulator which stores energy to provide
instant braking response.
Front: Dry disc brake
Disc diameter
710 mm (28 in)
Pad area, total
1,400 cm2 (217 in2)
Rear: Oil-cooled, disc brake, completely
sealed from dirt and water.
Braking surface, total
49,000 cm2
(7,595in2)
Parking Brake - Rear brakes applied by
spring loaded opposing piston on disc pack,
hydraulically released.
Retarding Brake - Two levers separately
control the rear disc brakes and hydraulic
retarder in transmission.
Emergency Brake - Through solenoid valve to
provide service brakes and parking brake.
9-3
Technical Data
Steering system
Independent hydraulic steering with closed-
center steering valve, pressure compensating
piston pump and accumulator.
Accumulator provides uniform steering
regardless of engine speed. In the event of
loss of engine power, it provides emergency
power to system for steering. A low pressure
indicator light warns of system pressure below
115bar (1,660 lbf/in2).
Minimum turning diameter
19,080mm
Hoist system
Independently hydraulic system.Two hoist
cylinders are mounted between the frame rails
to keep stable of body while raises the body.
System Relief Pressure
205bar
(2,972 lbf/in2)
Body Hydraulic Pump Flow Rate @ 2,100 rpm
...........................................................307L/min
(81 USgal/min)
Body raise time
……
14 sec
Body lower time
……
13 sec
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
……
18mm (0.70in)
Side
…
…
…
…10mm (0.39in)
Front lower……………………….10mm (0.39in)
Volumes :
Struck (SAE)……………...………..26m3(34yd3)
Heaped 2:1 (SAE)……..…………..35m3(46yd3)
Frame
Box structure with variable-section provides
resistance to bending and torsion.
Mild steel used throughout bumper, front
9-4
Technical Data
and rear longitudinal beams, torque tubes,
rear mounting rack provides flexibility and
resistance to impact loads. Low alloy cast-
steel components are used in the high-stress
areas for a higher strength and greater life
frame.
Cab
Large area of windscreen gives operator an
all-around visibility. Acoustic lining material
provides quiet operator space. Suspension
seat reduces vibration efficiently.The cab
provides a sound exposure Leq (equivalent
sound level) of less than 78 dB(A) when tested
with doors and windows closed.
ROPS/FOPS meet the requirements of ISO
3471 and the interior dimensions are designed
according to ISO 3411.
Maintenance service capacities
Maintenance
Description
volume
L
US gal
Engine crankcase and filters
65
17.2
Transmission and filters
85
22.5
Cooling system
166
44
Fuel tank
620
164.3
Steering hydraulic tank
73
19.3
Steering system
76
20.1
Hoist and brake cooling tank
239
63.4
Hoist and brake cooling system
258
68.4
Planetaries (total)
45
11.9
Differential
50
13.3
Front suspension cylinder (each)
19
5.0
Rear suspension cylinder (each)
16
4.2
Power takeoff
4
1.1
9-5
Technical Data
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.
Weight parameters
Weight parameter
Description
Kg
lb
Chassis, with hoists
31,000
68,000
Body, standard
11,000
24,000
Net weight
42,000
92,000
Payload, maximum
55,000
121,000
Maximum gross weight
97,000
213,400
Note: Maximum permissible gross vehicle
weight with options, attachments, full tank and
payload.
Weight distribution
Front axle
48%
Empty
Rear axle
52%
Front axle
33%
Loaded
Rear axle
67%
9-6