SKT90S Product Present - C

SANY HEAVY EQUIPMENT CO., LTD.
品质改变世界 Quality Changes the World
Product Training on SKT Series

Wide-body Truck (Service)
SANY HEAVY EQUIPMENT CO., LTD. 品质改变世界 Quality Changes the World
SANY HEAVY EQUIPMENT CO., LTD.

Oct, 2019
1
SANY
SANY HEAVY EQUIPMENT CO.,
HEAVY EQUIPMENT CO., LTD.
LTD. 品质改变世界 Quality Changes
Qualit y Changes t he the World
World
Product basic information of

01 wide-body truck
02 System principle of wide-body truck
Content
03 Operation and maintenance
04 Analysis of typical failures
2
SANY HEAVY
三一 EQUIPMENT
重型装备有CO.,
限 LTD.
公司品质改变世界 Quality Changes
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01 Product basic information

1.1 Competitive products
1.2 Product composition
3
SANY
SANY HEAVY
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EQUIPMENT CO.,CO.,
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1.1 Competitive products

Currently, the transportation vehicles for open mines include rigid truck, wide-body truck and road dump truck. Featuring good cost
performance and comprehensive benefits, the wide-body truck has been recognized by domestic customers with its increasing sales
reference year by year.
Category Rigid truck (mechanical wheel) Wide-body truck Road dump truck
1. Larger capacity, higher efficiency

1. Low purchasing cost
1. Large capacity, high efficiency 2. Good cost performance
2. Low purchasing cost of accessories
Advantages 2. High reliability 3. Industrial scale has been formed
3. Low requirement to associated
3. High safety specializing in transportation vehicles for
equipment, obvious cost advantage
open mining industry
1. Lower reliability and safety compared 1. Low reliability with service life of 1-2
1. High purchasing cost
with rigid truck, few specifications not years
2. High cost of operation and
conforming to the safety requirement of 2. Small capacity, low efficiency
Disadvantages maintenance
mines 3. Required more vehicles and personnel
3. High requirement to associated
2. Higher cost of special parts compared with management difficulties on condition
equipment
with heavy truck of same mining quantity
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1.1 Marketing research
Rated loading capacity

No. Manufacturer Main models Sales in 2017 Market shares
45T 60T
1 LGMG MT86(H)/MT95 2438 28.4% 5% 95%
2 SNTONGLY TL875(B) 2080 24.23% 45% 55%

3 SINOTRUK HOWO 70 1355 15.78% 15% 85%
4 SENTA Tank 90 1000 11.65% 36% 64%
5 SXTONGLI TONGLI 90 320 3.73% 40% 60%
6 PENGXIANG PX90 330 3.84% 20% 80%
7 XCMG XG90 434 5.06% 40% 60%
8 Shaanxi Express Express 90 236 2.75% 30% 70%
9 GUERTE / 106 1.23% 100% 0
10 Yutong YTK89 86 1.02% 60% 40%
Total 8385
The models of rated loading capacity of 60t (73.5%) is the main share and 45t is the secondary share of the market sales volume.
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Pain points of wide-body truck industry include high failures, low

1.1 Marketing research attendance, low safety, non-comfort, outdated control
• Frame cracking
• Plate spring breakage
• U-shape bolt breakage
• Steering difficulties
• Braking abrasion
• Poor sealing of driving cab
• Serious vibration of
machine
• Frequent electrical failures
• Outdated control system
• ……
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1.2 Product composition Model SANY SKT90S
Curb weight (kg) 30000
Total weight (kg) 90000

Tilter capacity m³ 31
Max. speed (km/h) 40
Engine WEICHAI WP12.460
Gearbox FAST 7DS200 (hydraulic retardar)
Axle (T) 19+35+35
Steering type (mm) Full hydraulic + emergency steering
Suspension structure Front hydro-pneumatic suspension + Rear

plate spring suspension
Driving cab Innovation
Electrical system 2-in-1 electrical control system
Frame assembly 450mm high riveted frame
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No. Critical components LGMG MT86 SNTONGLY TL875B SKT90S Note
Main frame (380mm) Main frame (380mm) No subframe to prevent

1 Frame Frame + subframe + subframe Main frame (450mm) cracking of the main
frame
Preventing from
2 Front suspension Plate spring + rubber Main spate spring + Hydro-pneumatic breakage of front plate
auxiliary spring auxiliary spring suspension
Suspension spring
system Balance suspension +
3 Rear suspension plate spring + direct Balance suspension + Balance suspension +
push plate spring + V-push plate spring + tie rod
4 Engine WP12G430E310 WP12G430E310 WP12G460E310
5 Air filter Donaldson filter Three-level oil filter Three-level oil filter
Power
system
6 Fuel tank 530L aluminum alloy 500L iron 530L aluminum alloy
7 Exhaust Exhaust switching box Silencer Exhaust switching box Optional silencer
8 Gearbox 7DS200K 7DS180 7DS200 (after the speed Xi’an FC automatic

optimization) gearbox
Curved axle 19T Curved axle 18T
9 Drive system Front axle (HANDE) (HANDE) 19T (PENGXIANG)
10 Rear axle 35T+35T (HANDE) 35T+35T (HANDE) 35T+35T (PENGXIANG) 8

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No. Critical components LGMG MT86 SNTONGLY TL875B SKT90S Note
11 Drive Tyre 14.00-25 (36PR) 14.00-25 (36PR) 14.00-25 (36PR) 14.00R25 optional
system
12 Driving cab 3.3m wide-body driving 3.3m wide-body driving SKT90S driving cab New appearance,
cab cab comfortable
Driving cab
13 Seat Air seat (Hills) Mechanical seat Mechanical seat Reliable
(Huatai) (Huatai)
14 Steering Normal full hydraulic Dual steering engine Classic full hydraulic Safe and comfortable
Hydarulic steering steering
system
15 Elevation Deppkaler 196 HYVA 179 WEIFU 196 Reliable
16 Main brake Pneumatic drum brake Pneumatic drum brake Pneumatic drum brake
Braking
system Optional eddy current Optional eddy current
17 Auxiliary brake retarder retarder Hydraulic retarder
Electrical Compatible with

18 system Electrical Relay Relay Automatic controller intelligent management
system
19 Air Applicable for 50℃
conditioner Air conditioner Standard HKAC Standard HKAC Standard HKAC environment
20 Tilter Tilter Baffle tilter 29.5m³ Baffle tilter 30m³ Baffle tilter 31m³ 9
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Optional modules
No. System Module Working
conditions
1 Power WP12G430E310 Flat pavement
Applicable for
2 Drive Automatic box demanding market
of comfortable
operation
3 Hydraulic retarder
Braking Rampway on
heavy load
4 Braking spraying
5 E-4 steel wire tyre Gravel road

Tyre
6 Stone deflector Gravel condition
1 7 Tilter Back-lifting tilter Rock

2 3 4 5 6 diameter≥500mm
10
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02 System principle
2.1 Power system
2.2 Drive system
2.3 Suspension system
2.4 Hydraulic system
2.5 Braking system
2.6 Electrical system
2.7 Driving cab
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2.1 Power system
In-line arrangement V-arrangement Horizontal arrangement Opposed arrangement
Top dead center
Top dead center
Bottom dead
center Bottom dead
center
Displacement = area x stroke

x No. of cylinders
Compression
ratio 12
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2.1 Power system
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2.1 Power system
Lubrication system
Engine body assembly Suspension system
Crank connecting rod

Cooling system
mechanism assembly
Cylinder head assembly Fuel system
Valve mechanism assembly Air inlet system
Gear system assembly Exhaust system

Electrical system
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2.1.1 Suspension system
Horizontal and vertical surface pressure Horizontal and vertical surface pressure
of shock condition in latest proposal of shock condition in previous proposal
• Vibration decoupling+model analysis+intensity • Double-stage oil pump with large

analysis, increasing fatigue life, improving comfort inclination
Rear suspension level and reducing noise • Axial flow fan with low failure rate of
shock absorber • Four-point suspension, good stability, high shock bearing
resistance • Medium and low speed and large torque,
• Uniform thickness processing of rear support baseplate applicable for heavy loading and climbing
Front suspension to minimize the tolerance of tilt • High speed and high power, quick response
and high efficiency
shock absorber 15
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2.1.2 Cooling system
Retarder water return inlet Heater water intake Engine water outlet
ø50 ø20 ø60
Thermostat
Flowing cylinder
head
Flowing water pipe

inner cavity
Flowing cylinder Low-temperature

sleeve starting water intake
NPT3/4
Water pump
Retarder intake impeller
ø50
Flowing engine oil Heater water return

Dual-cylinder water cooler
inlet
cooling air Low-temperature ø20
compressor starting water return
inlet
M26X1.5 Engine water inlet
ø75
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2.1.2 Cooling system

The fan shall be
To radiator
started under
To radiator
Spring Thermostat Full-meshing of clutch

82℃, operated at
Spring Thermostat
medium speed
Valve Valve Opening of side outlet to
radiator Thermostat under 85℃ and
Electrical silicone oil fan
fully started
Turning off of fan
Plunger Plunger separating from under 92℃.
thermostat
Self-
Thermal
sensor
Self-
motivated
Thermal
sensor
motivated
engine The thermostat shall be started 72℃, and
engine
body
body
fully started under 82℃.
Opening of side outlet to water
pump
In case of high-temperature of
cooling water
In case of low-temperature of
To water cooling water
To water pump
pump
■The thermostat has internal thremo-sensitive element
(paraffin with thermal expansion and contraction) which
will vertically move as per the change of temperature
■In case of cold cooling liquid, the paraffin will be
contracted, the water-way to radiator will be closed
while the water-way to water pump will be opened.
■In case the water temperature reaches certain level, the
paraffin will be expanded, the water-way to radiator will
be opened while the water-way to water pump will be
closed. 17
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2.1.3 Fuel system
Refined High pressure Oil outlet

filter oil rail Oil
absorption
Outlet valve
Nozzle
Limiting
High pressure Check valve
Fuel injector valve
oil pump
Plunger
ECU cooler Tappet

Gear pump
Camshaft
Rough filter
Fuel tank ✓ 5530L aluminum alloy fuel tank with four

chambers including oil inlet port, oil return
port, oil level sensor, vent valve independent
chamber)
✓ Three-level full filter element, remote oil
heater/filter (oil-water separator), rough and
refined filters installed in engine for easy
maintenance
✓ Optional fuel radiator for high temperature
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areas and regions
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2.1.4 Air inlet system

Rated
Recommended Optional desert filter
power/revolvin Engine air inlet SKT90S air
Model air filter flow
g speed (m3/h) filter flow (m3/h)
kg/h(m3/h)
(kw/rpm)
WP12G340E310 250/2100 1816
WP12G380E310 280/2100 1875
2043
WP12G430E310 316/2100 1949
WP12G460E310 338/2100 1992 2600
WP13G480E310 353/2100 2184
WP13G500E310 368/2100 2218 2344
WP13G530E310 390/2100 2285
Turbine
Oxygen
molecule
Oxygen
molecule
No Turbocharger
Impeller turbocharger installed Electronic differential pressure indicator,
instrument with warning indication 19
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2.1.5 Exhaust system

Tighten the bolt then nut
box (Patent)
Exhaust switching
Tighten the nut then bolt
✓ The exhaust piping is designed as sectional with flange installation, the bellows section
is straight piping
✓ Configured with matching exhaust butterfly valve to improve braking capacity and
safety performance
✓ Innovative exhaust switching box in compact design and good internal space
utilization with good sealing performance and noise elimination 20
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02 System principle
2.1 Power system
2.2 Drive system
2.5 Braking system
2.7 Driving cab
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2.2 Drive system
The drive system of wide-boy truck includes clutch (no auto gear-shifting), gearbox (retarder), drive shaft, axles
(front, middle and rear) and wheels.
Engine Tyre
Rear shaft
Gearbox Drive shaft
Clutch Drive shaft

Middle axle
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2.2 Drive system

Description Model Technical specifications Industrial specifications Manufacturer
1. Allowable input torque: 1. Allowable input torque: 2000N.m; 2.
Gearbox 7DS200+FHB400 2000N.m; 2.Allowable input power: Allowable input power: 355Kw; 2. FAST
355Kw; 2. Speed ratio: Speed ratio: 9.14;6.7;4.85;3.6;2.65;1.61;1
9.14;6.7;4.85;3.6;2.65;1.61;1 R:8.51 R:8.51
Clutch Ø430 1. Transmitted torque: 2100N.m; 2. Pressing 1. Transmitted torque: 2100N.m; 2. Valeo
force: 35000N Pressing force: 35000N
1. Pedal travel: ≤138mm; 2. Pedal effort: 1. Pedal travel: ≤138mm; 2. Pedal effort:
Control of
clutch Integral ≤155N; 3. Hydraulic pressure: ≤1.1MPa; 4. ≤155N; 3.
≤1.1MPa; 4.
Hydraulic pressure:
Pneumatic pressure: Keli
Pneumatic pressure: ≤0.85MPa ≤0.86MPa
1. Gear-selecting travel: ≤176mm; 2. Gear- 1. Gear-selecting travel: ≤205mm; 2.
Gear-selecting Dual sealing selecting effort: 7.8-62N; 3. Gear-shifting Gear-selecting effort: ≤50N (average); 3. NINGBO
operation travel:≤100mm; 4. Gear-shifting effort:18- Gear-shifting travel: ≤120mm; 4. Gear- GAOFA
60N; shifting effort: ≤50N (average);
Front axle 1. Rated loading capacity: 19000Kg 2. Single 1. Rated loading capacity: 19000Kg 2.
axle braking torque: 90000N.m Single axle braking torque: 90000N.m
Axle PENGXIANG/H
1. Rate loading capacity: 35000Kg; 2. Drive 1. Rated loading capacity: 35000Kg; 2. ANDE
Middle and rear axle reduction ratio: 12.82; 3. Single axle braking Drive reduction ratio: 12.82; 3. Single
torque: 90000N.m axle braking torque: 90000N.m
Drive shaft Light weight 1. Cross shaft diameter:Φ68mm; 2. Shaft 1. Cross shaft diameter: Φ68mm; 2. Shaft YODON
tube: Φ140×7mm tube: Φ140×5mm
Rim 10.00-25 1. Section width 254mm; 2. Rim inner offset: 1. Section width 254mm; 2. Rim inner SEM
204mm; 3. Plate thickness: 16mm offset: 204; 3. Plate thickness: 16mm
14.00-25 Aeolus/Guizhou
Tyre
Tyre
14.00R25 TECHKING/Gui
zhou Tyre
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2.2 Drive system
2.2.1 Clutch and control
Oil can
Schematic diagram of control
Release bearing Master pump of clutch

The pedal effort
will be amplified
by actuator and
mechanism
Mechanical
applied on release force
bearing Shifting fork
Mechanical
force
Hydraulic
pressure
Air cylinder
Pedal mechanism
Clutch booster
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2.2 Drive system

Pedal
Manual control
Master pump
Oil pipe
Master
Booster
pump
Pedal
Separating effort High pressure oil
force
Hydraulic
Air High
pressure Booster
cylinder gas
Push rod
Gearbox Release
Air supply shifting fork bearing
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2.2 Drive system

Structure of master pump Sealing ring Piston Oil inlet Sealing ring
Return spring Retainer

ring
Pressure generation oil

chamber
Dust cover
Oil outlet
Push rod
Spring base
Constant pressure oil

chamber
Valve
Cylinder body
Valve limit rod
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2.2 Drive system

Structure of booster Valve spring Air inlet Air chamber
Air bleed screw Pneumatic valve

Air piston
Balance piston spring

Piston Y-shape ring
Balance piston
Return spring
Oil inlet
Plunger
Pressure generation oil

chamber
Valve body
Oil chamber sealing ring
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2.2 Drive system

Pressing plate of clutch
No. Description / Function No. Description / Function No. Description / Function
1 Fixing ring/To fix the separating pull ring with 6 Spacer bushing/To position and fix the driving blade 11 Cover rivet/To rivet the cover with driving blade
diaphragm spring and pressing plate
2 Separating pull ring/To support the separating end of 7 Cover/To provide space for configuration of parts 12 Diaphragm spring/To apply pressing force to
diaphragm spring and components pressing plate
Pressing plate/To transfer the pressing force to
3 Clamp/To fix the bearing and axis 8 Balance rivet/Dynamic balance weight 13 friction plate
4 Screw/To fix the driving blade and pressing plate 9 Support ring/To support the diaphragm spring
Driving blade/To connect the cover and pressing
5 Spring washer/To tighten the screws 10 plate, to apply restoring force to pressing plate for
separation
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2.2 Drive system

Driven plate of clutch
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2.2 Drive system

Releasing bearing
No. Description No. Description

1 Sleeve assembly 7 Semi-retainer
2 Outer cover 8 Rivet
3 Wave spring 9 Inner ring
4 Sealing ring 10 Outer ring
5 Sealing ring 11 Coil pressure spring
6 Steel ball
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2.2 Drive system

2.2.2 Gearbox and operation
Gearbox
Rated
Torque Input power
Model revolving
N.m Kw
speed rpm
7DS200 2000 355 2600
Speed 1 2 3 4 5 6 7 R
ratio 9.14 6.7 4.85 3.6 2.65 1.61 1 8.51
• All gears and shafts are design with intensity, low speed ratio compared
with low gear positions of 7DS200K gearbox used by competitors and
high adaptability for different working conditions;
• No synchronizer and auxiliary box, simple structure and high reliability;
• Built-in forced lubrication system to ensure good lubrication of gearbox
for all types of working conditions
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2.2 Drive system

Gearbox
• Schematic diagram
• Numbering principle of power
transmission
×10 = Nominal input torque (Nm)

Dual intermediate shaft structure
Single box (no auxiliary box)
Number of forward gears
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2.2 Drive system

Retarder of gearbox
Standard retarder comparison
Item Hydraulic retarder Note

(FHB400)
Weight (Kg) 70
Max. cruise inclination (%) 13.50%

Cruise speed under 10% inclination
12.8
(Km/h)
Non-load loss ＜2Kw
• Standard FHB400 hydraulic retarder with max. cruise inclination up

to 12% and better performance than FHB320 which is commonly used
in the industry.
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2.2 Drive system Braking principle of retarder
2.2.2 Gearbox and operation When the retarder is filled with oil, the rotor with output shaft
will apply an angular momentum to drive the oil to rotate with
Retarder of gearbox
the shaft; The oil will rotate in circle along the blade and will
be applied onto guide wheel. Meanwhile, the fixed guide
4 Power takeoff wheel blade will also apply a reversed angular momentum
connector
3 Flange output
onto the oil. From the guide wheel to rotor, the oil will create
21 Gear drive device

a resisting moment onto the rotor to block the rotor then to
reduce the speed of the vehicle.
90 INTARDER
electronic controller
The hydraulic reduction will be achieved by the reactive

24 Idling reduction
device
22 Stator
force onto the impeller rotor generated by full utilization of oil
30 Oil/cooling liquid
23 Rotor heat exchanger
by the fixed stator, of which the moment of reaction is

essentially the oil damping effect with constant and smooth
action. Meanwhile, the moment of deceleration will be
applied onto the output shaft of gearbox to ensure the brake
not to be locked. 34
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2.2 Drive system

2.2.2 Gearbox and operation Oil-way
Air-way
Water-way
Retarder of gearbox Control current
1. Rotor 2. Stator 3. Oil temperature sensor 4. Water temperature sensor 5. Heat exchanger 6. Air
pressure sensor 7. Proportional valve 8. Silencer 1(air exhaust of oil pool casing)
9. Silencer 2 (air exhaust of working chamber) 10. Floating valve 11. Lubrication pump
A. Compressed air source of machine B. Control current C. Gas control of exhaust passage
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D. Exhaust passage E. Oil pool F. Oil inlet passage
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2.2 Drive system

SKT90S wide-body dump truck is configured with manual

gear-shifting mechanism which is maintenance-free flexible
shaft guy wire structure. The operator can operate the lever
to control the gearbox through flexible shaft guy wire then to
achieve gear-shifting operations.
1. Gear-shifting flexible shaft 8. Gear-shifting support 15. Washer 22. Bolt

2. Gear-selecting flexible shaft 9. Bolt 16. Bolt 23. Control lever
3. Bolt 10. Gear-selecting rocker arm 17. Bolt 24. Control handle
4. Washer 11. Washer 18. Sealing plate 25. Gears markings
5. Washer 12. Bolt 19. Pressing ring
6. Nut 13. Controller 20. Self-tapping screw
7. Gear-selecting support 14. Nut 21. Dust cover
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2.2 Drive system

2.2.3 Axle
Installation of front axle
1. Tyre assembly 5. Bolt 9. Retainer ring 13. Bolt

2. Front axle assembly 6. Steering cylinder 10. Pin shaft assembly
3. Installation base of steering cylinder 7. Positioning sleeve 11. Washer
4. Washer 8. Centripetal oscillating bearing 12. Washer
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2.2 Drive system

2.2.3 Axle
Installation of middle axle
1. Middle axle assembly 4. Bolt 7. Nut 10. Tyre assembly

2. Limit block 5. Washer 8. Bolt
3. Middle axle limit support 6. Washer 9. Washer 38
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2.2 Drive system

2.2.3 Axle
Installation of rear axle
1. Rear axle assembly 4. Bolt 7. Nut 10. Tyre assembly

2. Limit block 5. Washer 8. Bolt
3. Middle axle limit support 6. Washer 9. Washer 39
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02 System principle
2.1 Power system
2.2 Drive system
2.5 Braking system
2.7 Driving cab
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2.3.1 Front suspension Non-load capacity Non-load height Full-load capacity Full-load height
Full-load axle
inclination
Front suspension 9.86t 365mm 17.89t 325mm Back-tilting of 2.5°
Front suspension cylinder Front suspension horizontal push rod
Horizontal push beam assembly

Hydro-pneumatic spring upper support
Front suspension push rod support
Hydro-pneumatic spring pin shaft assembly
Front suspension vertical push rod

Push rod pin shaft assembly
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2.3.2 Rear suspension
The rear suspension frame is using the classic structure of heavy load truck: maintenance-free balance shaft
assembly+enhanced plate spring
Structural features: The balance shaft assembly will, especially in severe pavement of mines, ensure the constant and
balanced load bearing of the middle and rear axles, which will prevent the supporting part from being damaged due
to overloading onto single axle.
We are using the balance shaft assembly of rubber bearing for classic structure of rear suspension frame, featuring
maintenance-free without frequency refilling to prevent from oil leakage of balance shaft casing.
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2.3.2 Rear suspension

Non-load capacity Non-load height Full-load capacity Full-load height Full-load axle inclination
Middle axle back-tilting of 3°, rear axle

Rear suspension 20.14t 365mm 71.96t 335mm
back-tilting of 7.5°
Plate spring pressing DTFLOCK lock nut

block
Plate spring assembly
Rear suspension
vertical push rod
Rear suspension horizontal push rod support
Rear suspension lower

push rod assembly
Rear suspension horizontal push rod
Guide plate Balance shaft assembly 43

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2.3.3 Hydro-pneumatic spring
The front suspension cylinder is self-adaptive hydro-

pneumatic suspension cylinder, of which the rigidity
will be increased in nonlinearity with the increase of
loading bearing. The comfort of rigid-variable elastic
components is better than that of rigid-equal elastic
components i.e. plate spring.
● Elastic medium - Gas (inactive gas - nitrogen)
● Force-transmitting medium - Oil
The rigid and damping characteristics will be achieved
by oil compressed gas and flow control of oil.
Hydro-pneumatic travel: 160mm
Change in length: 600mm-760mm
Oil filling level: 20mm
Non-load air inflation: 100mm
Change in non-load and full-load: 40.4mm
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2.3.4 Push rod

There are five types of push rods configured for SKT90S,
including:
• Front suspension vertical push rod
• Front suspension horizontal push rod
• Rear suspension lower push rod
• Rear suspension upper push rod
• Rear suspension horizontal push rod
The pull rod is for the guidance of axles and the
transmission of vertical and horizontal tension and pressure.
Front suspension vertical push rod

Front suspension horizontal push rod
Rear suspension horizontal push rod Rear suspension upper push rod Rear suspension lower push rod
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2.3.4 Push rod

• Most of manufacturers are using vulcanization of rubber for ball head of
push rod, moving the ball pin inside the push rod body by compressional
Straight ball support rod deformation.
PU
• Advantage: Cost performance of complete vehicle
• Disadvantage: Limited service life, the vulcanized rubber will be damaged
in severe working conditions of long-term and high intensity
• Our push rod is using articulated ball pin structure, of which the ball pin
can be freely rotated inside the rod body, applicable for the complexity of
Piping dia. 40mm and vulcanization
different working conditions.
• Advantage: The ball pin can be rotated freely in accordance with different
forces to prevent the rubber parts from being aged and improve the
durability
• Disadvantage: Higher price than vulcanization structure
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2.3.4 Push rod
Compare with the real axle push rod structure, the frame
connection is using side cylindrical ball pin connection.
The problem of breakage of ball pin on the push rod of rear
axle has always been an important matter in the development
and exploration of wide-body trucks.
Most of products are using ordinary ball bolt connection
structure in the market, while we are using cylindrical ball to
connect the ball head with the frame, to increase the root
section and intensity of ball head and minimize the risk to
break the root of ball head.
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2.3.5 Plate spring assembly
Main specifications Length/piece • Verified by the market, the rear plate spring will using
Full-load(Kg) 35000 1850
thicker and less leaves. We are using 27mm×15 five-
Curb load (Kg) 10000 1850
Free static deflection (mm) 53 1850 leaf plate spring structure with maximum length of
Clamping static deflection (mm) 43 1850 1850mm, width of 120mm and loading capacity of 35T.
Clamping static load camber height (mm) 10 1850
It is modified and improved from the plate spring of
Free camber height (mm) 53 1380
Assembly thickness (mm) 405 1280 competitions, applicable for the complicated working
Assembly width (mm) 120 1180 conditions of mines.
Material dimension (mm) 27*120 1080
• The specifications of plate spring manufacturer can meet
Number of springs 15 980
the requirement of full-loading and overloading
Number of main pieces 5 880
Operating distance (mm) 1500 780 performance of suspension frame. The offset frequency
U-bolt span 210 680 of construction machinery vehicles can meet the comfort
Material 51CrV4 580
requirement of the operator.
Installation mode Inverted 480
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2.3.6 Maintenance-free balance shaft assembly
The balance shaft assembly is applied for the balance of

load bearing and to ensure the constant load on middle
and rear axles.
Currently, most of competitors are using balance shaft
assembly with lubricating oil refilled inside the casing,
refer to left Figure.
Problems:
• Waste of manpower and material resources for
necessary maintenance of refilling of engine oil
• Frequency damage of oil seal causing oil leakage
from balance shaft
• Illegal refilling of engine oil may increase the failure
rate of balance shaft.
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2.3.6 Maintenance-free balance shaft assembly
We are using the maintenance-free balance shaft assembly with no need of

refilling of engine oil.
In the balance shaft assembly, pressed by the bearing pressing plate (4),
the rubber bearing (5) will be over-expanded to fill the balance shaft
1 Hexagonal bolt 5 Rubber bearing 9 Positioning pin
Heavy duty spring Balance shaft casing (6). In case of driving on uneven road, the balance shaft (10) will
2 6 10 Balance shaft
washer casing
rotate due to the torsional deformation of ±15° of the rubber bearing (5).
3 Locking plate 7 Spacer sleeve
Balance shaft
4 Bearing pressing plate 8
support
Product features of rubber bearing: The rotation of balance shaft is caused
by the torsional deformation of rubber bearing, maintenance-free,
conservation of manpower and materials, preventing from any risks of oil
leakage and damage due to improper maintenance.
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02 System principle
2.1 Power system
2.2 Drive system
2.4 Hydarulic system
2.5 Braking system
2.7 Driving cab
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2.4 Steering system
➢ The steering system is consisted of components including plunger pump, filter, steering valve group, steering gear,
energy accumulator, steering cylinder, etc.
➢ The pressure oil supplied by plunger pump will flow through steering valve group and steering gear, apply on steering
cylinder to achieve the steering of wheels through the action of steering mechanism driven by the extension of oil
cylinder.
Energy
accumulator
Pump Filter Steering

valve group
Steering Steering
gear cylinder 52
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2.4 Steering system
1- Plunger pump
2- Filter
3- Steering valve group
4- Steering gear
5- Steering cylinder
6- Steering energy accumulator
7- Air filter
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2.4 Steering system
4 3 1
1. Plunger pump
2. Filter
3. Steering valve group
4. Steering gear
5. Steering cylinder
6. Energy accumulator
6
➢ The plunger pump is directly connected with PTO of the engine.

5 ➢ Two energy accumulators are located under the driving cab on left
side of the frame. 54
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2.4 Steering system
Component and function - Plunger pump

Oil intake (From: fuel tank)
Oil outlet (TO: filter)
Oil discharge (TO: fuel tank)
➢ The elevating pump is installed on PTO.

➢ The elevating pump is plunger pump.
➢ Rated pressure is 28MPa.
➢ Nominal displacement is 28ml/r.
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2.4 Steering system

Component and function - Filter
➢ The filter is not configured with bypass valve,

opening pressure is 0.6MPa.
➢ Pressure difference communication device, in case
Communicator
the pressure difference is 0.5MPa due to the filter is
polluted and blocked, that the opening signal will be
transmitted, the filter element shall be replaced to
ensure the safety of the system.
➢ Nominal pressure is 32MPa.
➢ Filter accuracy is 10μm
➢ Recommended initial replacing time is 250hrs,
replace every 1000hrs in the future.
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2.4 Steering system

Component and function - Steering valve group
➢ Steering valve group is located on the bottom of driving cab
on the outer side of the frame, consisted of check valve,
overflow valve and hydraulic reversing valve.
Overflow pressure ➢ Function: To supply the oil from of plunger pump to energy
adjusting screw accumulator and steering gear, and protect the complete
Pressure
testing point steering system.
G1/4 Oil intake (From: filter A)
Oil outlet (TO: energy accumulator E)
Oil outlet (TO: steering gear B)
Oil outlet (TO: pressure oil tank T)
Oil intake (From: steering gear C)

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Auxiliary valve block of steering gear

2.4 Steering system Inlet check valve: It will be opened when the oil is flowing into the steering gear, to prevent the
steering wheel from shaking due to the reversing of high pressure oil caused by external shock
Component and function - during low speed driving.
Steering gear Two-way overload valve: In case the oil pressure reaches the limit pressure due to the increase of
pressure caused by external shock, the overload valve will open to discharge the oil and protect
the steering cylinder from being overloaded.
Oil supplementary valve: In case the overload valve is opened and in order to prevent from
cavitation, the oil supplementary valve will open the oil return port to absorb the oil then supply
the left or right chamber of steering cylinder with pressure oil immediately.
The steering gear is closed-core and non-response, installed on the bottom of the driving
cab.
P－Oil inlet to steering gear T－Return to fuel tank
R－Oil supply of cylinder during right steering L－ Oil supply of cylinder during left
steering
Oil intake (From: steering valve group P)
Oil outlet (TO: steering cylinder)
Oil outlet (TO: steering cylinder)
Oil outlet (To: steering valve group T) 58

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2.4 Steering system

Component and function - Steering cylinder
Steering cylinder
The steering cylinder is single-stage dual functional cylinder, installed on the

truck by oscillating bearing.
Horizontal In case the left steering cylinder has rod chamber, the connected steering
cylinder has no rod chamber, and vice versa. When one cylinder is extended by
pressure oil, the other one cylinder is retracted, which will drive the steering
mechanism. When the left (right) cylinder is extended, the tyres will be turned
right (left).
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2.4 Steering system

Component and function - Energy accumulator
It is located under the driving cab on the front side of the frame, with dual-4.5L parallel configuration.
Operating principle of energy accumulator: The energy accumulator will be filled with nitrogen through the top charging valve, and
the piston will move to the bottom. When the engine is started, the pressure oil of steering pump will push the piston and compress
nitrogen. In case the pressure of steering system is decreased, the compressed nitrogen will push the piston to discharge the pressure
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oil.
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2.5 Elevating system
1. Elevating tank (self-innovation)

2. Hydraulic distribution valve
3. Limit valve
4. Elevating lever
5. Elevating cylinder
6. Elevating gear pump
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1. The elevating tank is located on the

outside of the extension beam of the frame,
behind the driving cab
2. The elevating cylinder is middle roof
3. The elevating gear pump is connected
with the drive shaft of the engine
Air-way
Oil-way
Instructions:
1. Fuel tank 2. Gear pump 3. Pneumatic valve 4. Distribution valve 5. Oil cylinder 6. Limit valve
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Component and function - Fuel tank
Air filter (2)

p Operating capacity of tank: 140L
p Oil return filter: 25μ (It is

Oil return filter
recommended to replace the filter
element twice every year, and four
Maintenance times every year under severe
window
conditions.)
p Air filter: 10μ (It is recommended to

replace the filter element twice every
year, and four time every year under
Stop valve severe conditions.)
Check valve
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Component and function - Distribution valve (PT valve)
Manual valve Pressure testing
Manual valve declination interface G1/8”
elevation interface
interface
The selected hydraulic distribution valve is
configured with mechanical adjusting screw of
slow declination, that when the oil cylinder is
lowering too slow, remove the sealing nut,
loosen out the adjusting screw; Otherwise,
when the oil cylinder is lowering too fast,
remove the sealing nut, tighten in the adjusting
screw. The sealing nut shall be tightened after
the adjustment.
Travel adjusting bolt 64

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Component and function - limit valve
Air inlet
Exhaust pipe
Working principle
P- Air inlet (connected to pneumatic
valve)
A- Air outlet (connected to elevating
valve)
O- Exhaust
It is used to adjust the elevation of the

tilter, the bolt is adjustable.
Air outlet
Limit valve support 65
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Component and function - Elevating hand lever valve
It is installed on the support located on the left side of the

driving seat, featuring functions including elevation, declination
and medium stop.
Pull back the lever to elevate the tiler。
Push forward the lever to lower the tilter.
Regulate the pressing angle of the lever to change the elevating

speed of the tilter.
66
Connected to air inlet of limit valve
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02 System principle
2.1 Power system
2.2 Drive system
2.5 Braking system
2.7 Driving cab
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2.6 Braking system

➢ The braking system is applied for the brake of the vehicle, SKT90S is using air brake, including serve brake and parking brake.
Service braking pedal

Parking braking lever
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2.6 Braking system

General
introduction - 1
Components layout
9
3 7
6 4 8
6 1- Air compressor
2- Dryer
5 3- Air cylinder (5)
4- Relay valve (3)
2 5- Two-position three-way
electro-pneumatic valve (3)
5 6- Braking pump (6)

7- Foot braking valve (service
brake)
6 8- Manual braking valve
(parking brake)
9- Air pressure gauge 69
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2.6 Braking system - Principle of service brake

Step down the braking valve pedal, the port 22 of foot pedal will enter into port 4 of relay Cylinder 5
valve to reverse the valve element, that the compressed air will flow into braking pump
Cylinder 4
through relay valve to achieve the service brake of middle and rear axles. When the port 12
of foot pedal enters into the braking pump of front axle, it will achieve the service brake of Cylinder 3
front axle.
Pipe ø12
Pipe ø12
Relay valve Relay valve

Pipe ø8 Pipe ø8
Foot valve- Cylinder 1

service
brake Cylinder 2
Pipe ø12 Pipe ø12 Pipe ø12

Pipe ø12 Pipe ø12
Pipe ø8 Pipe ø8 Front Middle Rear
Pipe ø12 Pipe ø12
axle axle Pipe ø12 axle
Braking pump
35L-cylinder 50L-cylinder 50L-cylinder
3 1 2
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2.6 Braking system - Principle of parking brake

Parking Pull back manual braking valve Air bleed of braking pumps (422) Parking by braking pumps Cylinder 5
process:
Release Cylinder 4
Push forward manual braking valve Air supply to braking pumps (122) Release parking by braking pumps
process:
Parking release
Braking pump Cylinder 1 Cylinder 2
Pipe ø12
Parking
Manual
brake/parking Relay valve
Pipe ø8
Pipe ø12 Pipe ø12 Pipe ø12

Pipe ø12 Pipe ø12
Pipe ø12 Front Middle Rear
Pipe ø12 Pipe ø12
Pipe ø8 axle axle Pipe ø12 axle
Pipe ø12
35L-cylinder
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2.6 Braking system

Component and function -
Air compressor
Air inlet (From: air filter)
Air outlet (TO: dryer)
Dual cylinder piston water Left side of engine flywheel

Type Position
cooling, gear drive casing end
Rated operating pressure
Rated displacement (L/min) 570 1.0MPa
(MPa)
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2.6 Braking system

Component and function - Dryer
Configured with four-loop Schematic diagram
protection valve
Air inlet (From: air compressor)
Air outlet (TO: air cylinder)

Control interface connected
Pressure specifications of four-loop interface
to decompression of air
Interface
compressor Item
Opening pressure (bar)
Sustaining pressure of
effective pipings (Interface 73
1 sustaining gas 8bar)
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2.6 Braking system

Cylinder 5 (35L)
Component and
function - Air
Cylinder 4 (35L)
cylinder
Cylinder 3(35L)
Water draining valve
Cylinder 1 (50L)
1. Every air cylinder is configured with lower water

2 Cylinder (50L)
draining valve.
Cylinder 1: Front axle brake 2. The water shall be discharge once every half a
Cylinder 2 and 3: Series connection, middle and rear axle brake month.
Cylinder 4: Parking brake 3. Pull the metal ring to either side to open the water
draining valve. No vertical pulling is allowed.
Cylinder 5: Auxiliary air supply 74
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2.6 Braking system

Component and function - Air compressor 4
2
2
Parking brake relay valve 1
3 Service brake relay valve
Interface 1: Air inlet
Interface 2: Air outlet
Interface 3: Exhaust
Interface 4: Control
Three relay valves in total, located inside the right vertical beam.
Function: To ensure the braking air chamber can be supplied with pressure by air cylinder, to reduce the response time and braking
75
release time of the air-way, in order for acceleration and fast discharge in the braking process.
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2.6 Braking system

Component and function - Two-position three-way electro-pneumatic valve
Air outlet
Air inlet
Exhaust
Air inlet (From: Air cylinder)
Air outlet (TO: Auxiliary air supply)
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2.6 Braking system

Component and function - Manual brake valve
Hand lever
1st pressure
point (Push locked on
Parking
point) parking released
Automatic position
Service position
position
Parking
Parking
released
1: Air inlet
Parking 2: Air outlet
3: Exhaust
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2.6 Braking system

Component and function - Pipings and connectors
Nylon tube
Nut Bushing Sleeve Piping

connector
There are three types of nylon tubes configured for SKT90S air braking system, including 6mm, 8mm and 12mm. 78
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02 System principle
2.1 Power system
2.2 Drive system
2.5 Braking system
2.7 Driving cab
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2.6.1 Electrical components 120 ohms
Monitoring
Storage battery system
group
Radio
GPS
Temperature sensor Horn

Switching Illumination
group handle lever Headlight
Pressure sensor assembly
Liquid level sensor Rear light

assembly
Revolving speed sensor

Wiper
Central power
Temperature sensor distribution box
Pressure sensor
Air conditioner
Pressure sensor
120 ohms
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2.6.1.1 Combination
instrument
a. The range of speedometer: 0-140 km/h, all scales are in white color.
b. The speed signal shall be collected from the sensor, the supply voltage to the sensor is 12V.
c. The default setting is 25125 pulse/km, the range of pulses (k) is 2700～60000 pulse/km.
d. Speed alarm output: speed V ≤5km/h with low level output; Speed V＞5km/h with high level output.
e. The instrument also has odometer signal output interface in two modes i.e. direct connection (hard-wired) and CAN bus. The output speed signal
ID of engine is 0CFE6CEE, Byte 7 and 8, resolution is 1/256km/h/Bit.
f. In case the driving speed exceeds the alarm limit (default is 45km/h), the buzzer will give a sound alarm for 10s with interval of 0.5s.
a. The range of water thermometer is 40～120℃.

b. The warning areas including yellow scale area for 40～60℃, green scale area for 60～100℃ and red scale area for 100～120℃.
c. The water temperature signal collection is CAN bus, ID: 18FEEE00, Byte 1, resolution: 1°/bit -40.
d. In case the engine water temperature exceeds the alarm limit (100℃), the corresponding symbol will be constantly lighting for alarm.
In case the temperature increases to specified limit, the indication light will be on, the alarm will be stopped when the temperature is lower than -3℃.
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2.6.1.1 Combination instrument
Fuel level 0 1/16 Alarm 1/8 1/4 1/2 3/4 1
Resistance Ω 240 220 190 150 100 60 30
Tolerance Ω ±2 ±2 ±3 ±3 ±3 ±4 ±7
a. Configuration of dual mechanical pressure gauge, 1.5MPa bourdon tube, M12×1.25 screw
connection, the pointers of two gauges shall be consistent.
b. Operating range: 0～1.2MPa.
c. φ6 quick inserting tube (modified and lengthened).
d. The warning areas of pressure gauge include red scale for 0～0.55MPa, green scale for 0.55～
0.91MPa and white scale for 0.91～1.2MPa.
e. When the air pressure is lower than the alarm limit, the alarm symbol will be lighting
constantly, the buzzer will give a constant sound alarm with interval of 0.25s.
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2.6.1.2 Rocker switch
Alarm light Horn Rear light Front fog Headlight

light
Exhaust brake
PTO
Fan Inter-axle Diagnosis
Side wiper
emergency differential switch
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2.6.1.3 Air conditioner panel
Temperature Air volume switch Air direction switch

Rotate the knob to Rotate the knot to regulate Rotate the knob to regulate
gradually increase the the air volume to a proper the air direction including
temperature (red area) or value. head, head and feet, feet,
decrease the temperature feet and windscreen or
(blue area). windscreen only.
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2.6.1.4 Gearbox sensor
Neutral switch Reversing switch
Mileage sensor
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Fuse capacity Relay

2.6.1.5 Power distribution box Fuse capacity Lines No. Description
10A Right full beam light
A Wiper high speed relay
10A Left full beam light
10A Excitation B Wiper low speed relay
10A Control switch C Wiper intermittent relay
10A Dryer
E Rear working light relay
15A Wiper
5A ECU ON F Air conditioner relay
10A Air conditionner
G Fan 1 relay
10A Instrument indication
5A Instrument constant H YS brake relay
power
I Exhaust linkage relay
10A Reversing light
15A Rear working light J Wiper spraying relay
5A Flashing light
K Flasher relay
15A Standby
L Exhaust brake relay
25A ECU
15A Air conditioning M Front working light relay
compressor
25A Fan 1 N Fan 2 relay
10A Right dipped beam light O Oil heater/filter relay
10A Left dipped beam light
P Small light relay
10A Toplight radio
10A Flasher Q Foglight relay
10A Front working light
R Horn relay
10A GPS
5A Light illumination S Dipped beam light relay
5A Retarder T Full beam light relay

10A Foglight
U Ignition ON relay
25A Fan 2
10A Control V Brake light relay
7.5A YS brake
10A Cigarette lighter
15A Air conditioner
25A Oil heater/filter
10A Horm
5A Brake
10A Small light
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2.6.1.6 Combination switch
Headlight
Small light
Light illumination tap

Wiper tap positions
Overtaking positions
(auto reset)
Press for auto

reset of horn Dipped beam Press for auto reset of washing
light
Full beam light
Gear 4 retarding
Gear 3 retarding
Right steering Gear 2 retarding
Gear 1 retarding
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Left steering
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2.6.1.7 Chassis wiring

interface
35-core sheath for chassis (Male for large terminals, female for small terminals)
2nd version, 2018 35-core sheath for chassis (Male for large terminals, female for small terminals)
Hole Wire Function Hole Wire Function Hole Wire Function Hole Wire Function
position marking position marking position marking position marking
A X224 ECU output power supply e X108 Electronic accelerator A B Main power supply 1 e 19 Proximity switch power
1 signal 2 supply
B X274 ECU output power supply f X127 Electronic accelerator B 58 Rear working light f 20 Low pressure alarm
2 negative electrode 2 signal
C X142 Data CAN-H g X153 Clutch switching signal C E Negative electrode g 31 Axle lock
electromagnetic valve
D 189 Hydraulic fan 1 h 34 Dryer
D X143 Data CAN-L h X154 Neutral switching signal
E B+ Main power supply 2 j 35 Small light
E X158 Ignition switch ON j X160 Diagnosis switch
F X159 Ignition switch ON power k X165 Exhaust brake switch F 190 Hydraulic fan 2 K 49 (D+)Engine charging
supply light (D+)
G 56 Oil heater/filter power L 50 Braking light

G l X120 Exhaust brake low level supply
trigger
35-hole socket H E Negative electrode M 80 Odometer sensor12V+
H X101 ECU power supply m X138 YS brake low level
35-hole socket trigger
Sheath for chassis (Schlemmer) J 112 Air conditioning n 81 Odometer sensor signal
Sheath for chassis (Schlemmer) J n 918 Retarder oil temperature compressor
K p 919 Retarder oil temperature
Material description Material model K p 82 Odometer sensor
Material description Material model negative electrode
L X145 Diagnosis CAN-H r 920 Retarder water
Body 7812226 L r 85 PTO electromagnetic
Body 7812226
temperature valve
Converting part 78077341 M s 101 Generator excitation
M X146 Diagnosis CAN-L s 921 Retarder water
Converting part 78077341
temperature
N t 115 Exhaust brake
N t 922 Retarder valve body 90-degree elbow 7807408
electromagnetic valve
90-degree elbow 7807408
P u 923 Retarder valve body Black screw cap 9801138
P u 128 Reversing light power
Black screw cap 9801138
supply
a X124 Electronic accelerator v 924 Retarder valve body a 8 Reversing light v 134 Elevating switch signal
Grey screw cap 9800905
power 1 (reversing image)
Grey screw cap 9800905
b 11 Left steering light w
b X107 Electronic accelerator w 925 Retarder pressure Sealing ring 8117225
Sealing ring 8117225 signal 1
c 12 Right steering light x 93 YS brake
c X125 Electronic accelerator x 926 Retarder pressure Large terminal 7814039/7814048 electromagnetic valve
Large terminal 7814048
negative electrode 1 (female)
(female) d X128 Electronic accelerator d 16 Fuel sensor
power 2 Small terminal 7814045
(male)
Small terminal 7815045
(male)
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2.6.1.8 Liquid level sensor

Technical specifications (Test after the elevation to top and declination of floating ball)
K-direction
Oil level (H) Gear position Resistance
Yellow: Signal Full tank

GND: Black
Sealing
washer
Level position Hole
Rubber rear 空箱
molding
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2.6.1.9 Engine ECM Plug
Sliding plate shall be placed to

the inner side
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2.6.1.10 RC-Box
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2.6.2 Electrical Principle
Ignition
2 6
switch
Clutch switch
5
Neutral switch Connected to
elevating proximity
switch
Oil-water sensor
Connected to
generator D+
Instrument
illumination
Odometer
Connected to
4 Air pressure gauge 1
1 instrument
charging
Air pressure gauge 2
3 Fuel gauge
Water thermometer CAN
Electronic Oil pressure gauge CAN

Diagnosis interface
accelerator pedal OBD
Revolution meterCAN
Generator Starter Pre-heating Engine ECU system Instrument system

device
92
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2.6.2.1 Storage battery group
The storage battery group is 24V of series connection of two groups of batteries, supplying power for the starting circuit and
control circuit fo the vehicle.
Connected to
Start
instrument
charging
2.6.2.2 Power switch

Excitation
Turn off the main power switch to power down the

complete vehicle.
Generator Starter
93
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2.6.2.3 Key switch
• The common terminal of key switch will be connected to common

power through a 15A fuse, which will be powered on when turning
Ignition
on the main power switch. switch
• There are three positions of the key switch:

① ACC - central control screen power supply
② ON - key power supply
③ STA - Starting ignition
2.6.2.4 Generator
Connected to
• L: Charging instrument
charging
indication light
Excitation
• 15: Excitation
Generator 94
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2.6.2.5 Neutral position switch

• Power pin: X2-24
• Signal pin: X1-54 Clutch switch Neutral switch
• Function: The switch will be turned on when the gearbox is in

neutral position.
Please make sure the gearbox is in neutral position before start to
prevent from dangerous accidents.
2.6.2.6 Combination instrument

• The engine revolution meter, speedometer and water thermometer is driven
by the bus
• The fuel level gauge is driven by hard-wire
• The air pressure gauge is connected through air tube to indicate the
pressure of air cylinder, the warning areas includes:
0 ～ 0.55MPa in red scale area (the alarm limit of air cylinder is 0.52MPa)
0.55 ～ 0.91MPa in green scale area
0.91 ～ 1.2MPa in white scale area
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Signal to
10
instrument
Electronic
flasher
Backlight
illumination
11
Horn button
7 8
Reversing
switch
Interior light switch
9
Door light
switch
Cigarette Dryer Headlight Rear light Interior Central Reversing light Steering light Oil heater/filter Air horn Electric horn 96
lighter light entertainment
screen 4
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2.6.2.7 Headlight 2.6.2.8 Rear light
Rear
Headlight
Press the rocker light Press the rocker
switch of front switch of rear
headlight to light to electrify
electrify the relay the relay J19 and
J5 and close the close the normal
normal open open contact to
contact to turn on turn on the rear
the front light.
headlight.
Generator
Headlight Rear light 97
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2.6.2.9 Door light switch 2.6.2.10 Alarm light
When the door is Operate the steering

opened, the door light switch or alarm
light switch will light rocker switch of
be closed to turn combination switch
Interior light
switch
on the top light of to close the circuit of
the driving cab. left and right steering
lights, then the
steering indication
Door light
switch lights on instrument
panel and vehicle
body will be flashing
in the meantime.
Interior light
Steering light
98
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2.6.2.11 Electrical/pneumatic horn change-over switch
Horn
Signal to
instruments Press the horn button of
combination switch to electrify
the relay J1 and close the
normal open contact, the horn
Horn button starts to operate. Press the
electrical/pneumatic switching
button then press the horn
button to start the pneumatic
horn.
99
Pneumatic horn Electrical horn 4
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13
Pressure switch
12
Wiper intermittence
Compressor
Air Foglight Small Left/right full Left/right Side wiper

Wiper system
conditioner light beam light dipped beam system
(Positive) 100
light (Positive)
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2.6.2.12 Foglight switch 2.6.2.13 Combination switch + Side wiper switch
When the door is

opened, the door
light switch will
Interior light be closed to turn
switch
on the top light of
the driving cab. Wiper intermittence
Door light
switch
Interior light Small

Left/right full Left/right Side wiper
beam light dipped beam Wiper system
light system
light (Positive)
(Positive) 101
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14 Braking
15 16
switch
Connected to exhaust
linkage
18
19
Oil
temperatur
e
Water
17
temperatur
e
Valve
body
Pressure
Hydraulic
cooling
fan 1
FAST retarder system Braking light Hydraulic cooling Axle lock PTO Controller Elevating Flashing
fan proximity light
switch 102
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2.6.2.14 Hydraulic retarder (optional) 2.6.2.15 Inter-axle differential
Press the inter-axle

There are four differential rocker
positions of switch to open the
hydraulic retarder electro-pneumatic
lever, push valve with
forward for four- corresponding
position indication light
deceleration with turned on.
the corresponding
indication light
turned on.
Axle lock
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2.6.2.16 Power takeoff (PTO) 2.6.2.17 Proximity switch
Press the PTO When the tilter is

rocker switch to elevated, the
open the PTO to signal line 134 of
activate elevation elevating
function, operate the proximity switch
elevating lever for Elevating is powered off
proximity
relevant actions. switch
with elevation
indication light
turn on.
PTO Controller
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2.6.2.18 Flashing light (optional) 2.6.2.19 GPS
Press the alarm light GPS terminal has a 8-

rocker switch to turn pin plug, of which
on the top flashing PIN5 will be connected
light on the driving to power cable 30
cab. through 10A fuse.
PIN1 to GND
PIN3 to CANH
PIN7 to CANL
Flashing light
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02 System principle
2.1 Power system
2.2 Drive system
2.5 Braking system
2.7 Driving cab
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2.7 Driving cab
General overview of driving cab

• The driving cab is featuring latest industrial design and proper
interior arrangement with good appearance, functions and
comfortable operations.
• Large cambered windscreen to minimize the dead zone for better
vision of the operator
• All new interior decoration and arrangement and operation of
instrument panel, featuring ergonomic structure design.
• Dual-sealing door for quiet operation space for the driver.
• The vehicle body is featuring the structure of section bars (square-
welded framework) and metal plate (impact molded covering).
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Structure of driving cab
No. Description
1 Driving cab assembly
2 Driving cab elevation
3 Air conditioner
4 Fender assembly
5 Platform installation assembly
6 Anti-flipping device
7 Driving cab suspension assembly
8 Markings layout drawing
9 Elevating rod
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Technical specifications of driving cab

The driving cab is consisted of the cab, right platform and bumper
Weight: 1.1t
Turnover angle: 50°
Glass: Front 6mm laminated glass, others are 5mm tempered glass
Illumination: Combination light, side steering light, interior top light,
front foglight, driving cab toplight, clearance light and back light of
the cab, etc.
Accessories: Sun-shading curtain, extinguisher, emergency hammer,
etc.
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3 4 5
Interior configuration
No. Description No. Description
2 1 Seat 6 Rest seat
2 Steering wheel 7 15-functional rocker switch

1 3 Instrument platform 8 Central control screen
4 Console 9 Combination instrument
10 9 8 7 6 5 Auxiliary console 10 Combination switch
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Auxiliary Console
Description Advantages
Storage box For storage
Walkie-talkie Including a big one and a small one for different
box dimensions
Mobile phone
To store the mobile phone
box
Cigarette lighter To light the cigarette
Water cup Including a big one and a small one for different sizes of
support water cups
111
Mechanical suspension seat

• High adjustment
Seat adjusting height: 60mm
• Body weight adjustment
Regulate on digital disc to adjust the data to be consistent with
the weight of operator.
• Horizontal adjustment: 190mm
Fully pull the lever to adjust the seat forward or backward.
• Backrest adjustment
Pull the lever and lean on the seat to adjust to required
position.
• Headrest adjustment
Press the lever to adjust the headrest to proper position.
• Front and rear end inclination adjustment
• Three-point safety belt
112
Elevating Manual hydraulic Elevation of driving cab

Oil tube
cylinder pump • During the elevation of the driving cab, the gravity
center of the cab shall be not going across the safety line;
During the elevation of the driving cab, unlock the guy
wire which is to prevent the cylinder from falling and
shall be properly installed.
• It is recommended to replace the pressure oil once every
half a year, and the recommended oil is No. 10 aviation
and ground hydraulic oil.
Guy wire
113
Suspension of driving cab

• The from turnover support is casted, with internal
polyurethane lining and connected with the driving cab.
• The rear suspension is using two spring shock absorbers
with rigidity of 100 and 45.
• Unlock the mechanical lock in case the driving cab is
elevated, and lock it in case the driving cab is lowered.
• The clamping force of mechanical lock is 2500KG.
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Introduction of air conditioning system

It is consisted of evaporator, condenser, compressor, dryer
and pipings, etc.
The diesel engine will convey refrigerant to the compressor
through the triangle belt for the cooling operation; And the
heating will be done by the cooling water of the diesel engine.
Engine rated speed 2100rpm System voltage24V

Electrical
Engine idling speed 600rpm power 300W
consumption
Axle power
Driving cab volume 9.1m3 2000W
consumption
System refrigerating Temperature
5200W -40℃～45℃
capacity range
System heating
5000W Air output 520m3/h
capacity
Condenser Piping Evaporator Compressor
System refrigerant R134a Noise Less than 72db
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Condenser assembly
The condenser is installed on the right platform of the driving
cab, applied to condensate the refrigerant vapor with high
temperature and pressure discharged from the compressor to
high pressure liquid through the radiation to the air.
Evaporator
The evaporator is installed on the front panel of driving cab,
applied as the heat exchanger for air cooling through the
evaporation of refrigerant.
116
Liquid storage dryer

• It is applied to filter and store the refrigerant, absorb
water vapor to prevent the generation of acid.
• The configured sight window is applied to help to judge
the filling quantity of refrigerant and relevant system
information. In case the sight window is not clear, more
refrigerant shall be refilled for the system.
117
Compressor
• The compressor is the device to change the low pressure
to high pressure of the system, which will collect the
refrigerant returned from the evaporator and generate
high pressure and excessively high temperature.
• Type: Pressing plate
• Belt wheel diameter: 140mm
• Displacement: 148mm/r
• No. of cylinders: 5
• Belt pulley groove profile: 6PK
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1 2 3
Control panel
No. Description Instructions
Blue for low

Temperature
1 temperature, red for
button
high temperature
Air volume
2 4-position regulation
button
Air direction
3 5 modes
4 5 button
Press internal
circulation button, if the
Circulation light is on, internal
4
button circulation is started,
otherwise the external
circulation is started.
Press A/C button to start
5 Cooling switch
the compressor 119
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3.1 Power system

3.2 Drive system
3.6 Air conditioning system
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3.1 Power system

3.1.1 Speed and loading limit during run-in period
When the latest wide-body truck is started to service in mines, the revolution of diesel engine shall be less than
80% 60~80 hrs

(1800r/min) of the rated speed within the initial , and the loading
capacity shall be less than 60~70% of rated capacity.
The loading capacity of new truck shall be

controlled to ensure good running-in of all
friction pairs and maximize the service life of
the engine and complete vehicle.
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3.1.2 Fuels and relevant technical standard

The fuels shall be complied with specifications of relevant national standards. The users may choose fuels of different grades as per local
temperature in accordance with GB252.
Min. temperature
Diesel grade
(Risk ratio of 10%) Warning
10 12℃ The gasoline shall not be mixed with ethyl
alcohol or diesel, otherwise it may cause
5 8℃
severe explosion.
0 4℃
-10 -5℃
Warning
-2 -14℃
It is critical that the fuels or water are maintained clean
-3 -29℃ without any pollution as the diesel injection is a system of
extreme precision, otherwise it many cause severe damage
-50 -44℃ to the fuel pump and the injector.
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3.1.3 Engine oil and relevant technical standard

• The special engine oil of SANY shall be used as it is critical to the reliability and service life of the engine.
• The engine oil of CH-4 or above shall be used for the diesel engine of wide-body dump truck in accordance with the
S: For gasoline engine
specifications of API. C: For diesel engine
SC: General for gasoline
and diesel engine
SAE viscosity Applicable environmental temperature (℃) The number after W refers to
the motion viscosity of the
0W-20 ≥-35 engine oil under 100℃, the
5W-30 ≥-30 more the value, the higher the
viscosity.
10W-30 ≥-25
For example, 40 means the
15W-40 ≥-20 motion viscosity of engine oil is
within the range of
20W-50 ≥-15
12.5~16.3mm2/s under 100℃. It
does not mean the oil can be
used under 40℃.
Rated speed 350~550
Engine oil Idling speed 130~250 • Check the oil level in prior to starting the engine
pressure • Pay attention in spite of no alarm of engine oil pressure
(kPa) Low pressure warning 100
• Do not check the oil level during the operation of the engine
High pressure warning 700
• Different models of oil from different manufacturers shall not mixed123
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3.1.4 Cooling liquid and relevant technical standard

As the freezing points of common cooling liquid (propylene glycol + distilled water + additives) include -25℃, -35℃, -40℃, etc.,
please choose proper cooling liquid in accordance with local temperature in the principle that the freezing point shall be 10 degree
lower than local temperature. It is recommended to use special cooling liquid of SANY.
Description Product category
HEC-Ⅱ-25
Heavy-load engine cooling liquid HEC-Ⅱ-35
HEC-Ⅱ-40
• The cooling liquid shall be checked on regular basis and replaced in time if necessary to prevent from any corrosion or
damages.
• Water and other cooling liquid of low quality shall not be used as the cooling liquid for the engine
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3.1.5 Maintenance items

No. Description Maintenance time
1 Check the engine oil level, refill when necessary
2 Check if there is any leakage of the engine
3 Check if the fan and belt of the engine is damaged or loose
4 Check the engine oil temperature and oil pressure gauge
5 Check the water temperature of the engine
6 Check if there is any noise of the engine
7 Check if the revolution and vibration of the engine are in normal condition
8 Check if there is any leakage of the fuel system
9 Check the oil level of fuel tank, full refill after the completion of work everyday Daily & 10h
10 Check if the vent valve is blocked of the fuel tank
11 Check the cooling liquid level, refill when necessary
12 Check if there is any leakage of hoses or parts
13 Check the tightness of air inlet system
14 Check if the vacuum dust collecting valve is in normal operation
15 Check if there is any alarm of pressure differential indicator, clean or replace the air filter
element when necessary
16 Check the engine oil in oil basin of the air filter
17 Check if the exhaust color is normal
1 ☆Replace the engine oil
2 ☆Replace the engine oil filter element
3 Replace the refined filter element of fuel oil
4 Replace the rough filter element of fuel oil Every 5000km & 500h
5 Replace the filter element of oil-water separator (oil filter/heater (Initial 2000km&200h for the items marked ☆)
6 Maintenance of oil-gas separator
7 Replace the air filter element
8 Replace the engine oil in oil basin of air filter, clean the rough filter element assembly
1 Clean the fuel tank Every 20000km & 2000h
1 Clean the radiator
Every 40000km & 4000h
2 Clean the internal parts of cooling system
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3.1.6 Inspection and refilling of cooling liquid level
Warning
Make sure the engine is fully cooled down before checking the expansion tank during the inspection of cooling liquid, as the
cooling liquid will be very hot and the pressure will be very high in cooling system upon the stop of engine. It may cause burning
injury if one will open the expansion tank to check the cooling liquid. The expansion tank shall be opened after the temperature is
getting lower, then rotate the cover slowly to release the pressure.
1. Park the truck on flat position, check the cooling liquid level in expansion tank, which
shall be in the middle of the upper and lower scales (2/3 of the total volume is optimum).
2. In case the cooling liquid level is below the lower scale of expansion tank, remove the
cover and fill in with more cooling liquid, then tighten the cover of the expansion tank.
3. In case more cooling liquid is filled, please check if there is any leakage of relevant parts
and components.
4. In case the cooling liquid level is above the upper scale of expansion tank, check if there
is any other liquid inside the tank, if no, discharge the cooling liquid until the liquid level is
within the range of 2/3 of the expansion tank.
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3.1.7 Inspection and refilling of engine oil
Warning
The engine oil level shall not be lower than mark L (low) or higher than
mark H (high), otherwise it may impact the performance or cause damages
of the engine.
1. Open the front grille of driving cab, remove and clean the oil level indicator with cloth.
2. Fully insert the oil level indicator into the pipe of oil level gauge, then remove and
observe the oil level, of which the oil level shall be within the range between mark H
and L.
• In case the oil level is below mark L, refill more engine oil into filling port.
• In case the oil level is above mark H, remove the oil draining plug on the bottom of the
casing, fully discharge the oil, then re-check the oil level.
Attention
• Check the oil level at least 15 min since the stop of the engine.
• Please ensure the machine shall be horizontally parked in prior to the inspection.
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3.1.8 Replacement of engine oil filter element
Warning
The engine oil shall be fully cooled down before changing the filter element
to prevent from burning injury due to the high temperature of parts and oil
upon the stop of engine.
1. Remove the used engine oil filter element.

2. Clean the filter support base, fully fill in the new filter element with clean oil.
3. Apply some engine oil on the support base before installing the new filter.
4. Install and tighten for 3/4～1 circle the rubber gasket onto the support base for
good sealing performance.
5. Operate the engine at idling speed for a short duration, check if there is any
leakage and the oil level after the stop of the machine.
6. Refill with more engine oil if necessary.
Please use the engine oil filter and element recommended by SANY. 128
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3.1.9 Replacement of fuel filter and oil-water separator filter element
Warning Warning
Do not replace fuel filter as all parts are very Prevent from any pollutant, otherwise it may
hot upon the stop of the engine. Operate after cause failures as the engine is consisted of
precision parts including fuel injection pump
the engine is fully cooled down. Keep off and nozzle, etc. In case there is any pollutant
from any fire sources. attached inside the fuel pipings, fully clean with
fuel oil.
1. Place a proper container under the filter element to contain the fuel.
2. Clean the fuel filter support base, lubricate and seal with fuel.
3. Fully fill in with clean fuel through surrounding holes.
4. Tighten the filter until the seal contacts with the interface.
5. Use special wrench to tighten the filter until it is firmly fixed (around 3/4 circle).
6. Turn ON the key to connect the power, do not start the engine until the electronic fuel pump
of oil-water separator has been operating for more than one min.
7. Conduct leakage test to confirm if there is any leakage from the seal of filter.
Note: The water collector (undamaged) can be re-used. Please use the fuel filter and element recommended by SANY. 129
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3.1.10 Maintenance of oil-water separator
1. Open the top cover of the oil-gas separator and remove the filter element
2. Check if there is cracking of the glue on both ends of the filter element, replace the element if
it has cracks.
3. Clean the surface of filter element in light diesel or gasoline.
4. Check the sealing ring of filter and top cover, in case of aging and hardening of the sealing
ring, replace immediately
5. Insert the filter element into the casing and tighten the top cover
Top cover of oil-gas

separator
Filter element of oil-

Sealing ring
gas separator
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Warning: Do not operate the engine without filter installed, otherwise the dust and
3.1.11 Maintenance of air filter
impurities may cause early abrasion to the engine.
Check if there is any alarm of pressure differential indicator, clean or
replace the air filter element if necessary
(Note: Check the maximum air intake resistance under the operation at rated speed and full load of
the engine, in case there is an alarm of pressure differential indicator, please clean or replace the
filter element.)
• The main element of air filter shall be replaced in case it have been cleaned for six (6)
times.
• Cleaning of main filter element: Flap the end face gently to remove the dust, or blast from
inside with compressed air
• No repeated maintenance in case the air filter element has been replaced for less than 100
hrs. (Or complied with actual working conditions)
• Adjust the end cover of filter element, place the opening of rubber vacuum valve
downward
Check the engine oil in oil basin of air filter

• The engine oil refilled into the basin shall be of the same grade with that for the engine
• The oil shall not exceed the specified level, and shall be lower than the baffle plate
(Refer to the mark outside the oil basin), the oil volume shall be around 5L.
2. Oil baffle 3. Rough filter • In case the engine oil is not easy to flow out when shaking the basin, clean the rough
1. Oil basin plate assembly 4. Air filter casing
filter assembly and replace the oil once every 80~120h or everyday under severe
5. Air inlet piping 6. Safety filter 7. Main filter 8. Filter element 131
assembly element end cover working conditions.
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3.2 Drive system
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3.2 Drive system
3.2.1 Maintenance principle

Regular maintenance will enhance the service life and improve safety of steering gear, of which use of proper lubrication oil and
maintenance of specified period will be critical and complied with following procedures:
(1) Choosing proper lubrication oil of right grade.
(2) Inspecting regularly and maintain the proper lubrication oil level.
(3) The lubrication oil shall be from qualified suppliers or as recommended.
(4) Different lubrication oils shall not be mixed in the same steering gear except from special circumstances.
(5) Replace lubrication oil in accordance with specified mileage or time interval.
(6) The wastes generated during maintenance period may cause pollution to the environment, which shall be disposed in
accordance with local laws and regulations.
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Recommended replacement period of oil for FAST transmission

Environmental Oil replacement Applicable working
No. Assembly Standard Recommendation
temperature period conditions
Non-pavement, over-
1 Transmission F91010 -20℃~45℃ Shell Ⅰ 80W-90 10000km or 500hrs
low speed
Average
Non-pavement, over-
2 Transmission F91010 temperature more Shell Ⅰ 85W-140 10000km or 500hrs
low speed
than 40℃
Selection of lubrication oil and mileage for oil replacement

It is recommended to use FAST special lubrication: SHELL I (Enhanced) special lubrication oil for manual gearbox.
Instruction: Passing strict tests of FAST, SHELL I (Enhanced) special lubrication oil for mechanical gearbox is complied
with standard F91010 featuring good protection and lubrication for mechanical parts of FAST gearbox.
The residual oil shall be fully discharged before replacing new lubrication oil.
The lubrication oil shall be replaced after the new steering gear has been operated for 2000～5000 km.
Check the lubrication oil level and leakage every 5000 km of driving, refill when necessary.
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Accurate oil level

The oil level shall be checked on regular basis, while the vehicle is parked on flat pavement. The oil level shall not
be check immediately unless it becomes stable and cooled for certain period of time as the test result may be
inaccurate due to the expansion of hot oil upon the vehicle is parked.
Oil level
Oil level Oil level
Inaccurate Inaccurate Accurate

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Maintenance and repair

The steering gear shall be repaired and maintained in case of following conditions including:
Out-of-gear of off-gear
Difficulty in gear-shifting
Loud noise
Maintenance standard
Bearing: All bearings shall have proper axial and radical clearance, all steel balls, pin rollers and ball tracks shall have no holes or
spalling.
Gear: There shall be no holes or spalling on gear surface, all gears of abrasion or with shorter meshing length due to gear-shifting shall be
replaced.
Spline: Check the abrasion on all splines, replace the spline in case the sliding gear sleeve or output flange is deviated to any side of the
spline due to abrasion.
Thrust washer: Replace the washer in case of cracking or thinning of the surface.
Gray iron part: Replace in case of any cracking or severe abrasion.
Oil seal: Check the oil seals in uniaxial bearing cover and odometer casing, replace in case of any abrasion or scratches on the cutting edge
of oil seal.
O-ring: Replace in case of any damage or deformation.
Sliding bushing: Replace in case of excessive abrasion on shifting fork and groove, overheated color-changing or abrasion on contacting
area of joint teeth.
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3.1 Power system
3.2 Drive system
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Operation instructions
Warning
1. Please make sure proper covering materials and lifting appliances are firmly installed
for safety operation to prevent from any casualties and property loss.
2. As the front suspension cylinder is filled with high pressure nitrogen, the pressure
shall be fully released from the cylinder in prior to the removal and installation of front
suspension.
3. The pressure shall be release in accordance with the instructions of pressure release
of suspension cylinder before disconnecting the valves and joints, to prevent from any
casualties and damages to equipment due to sudden pressure release.
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3.3.1 Removal of front suspension frame
1) Park the vehicle on flat area, start parking brake and turn off the engine.
2) Rotate the steering wheel for several circle clockwise and anti-clockwise to
release the pressure from steering system. Cover the wheels, turn OFF the main
switch of storage battery.
3) Release the pressure of nitrogen from two suspension cylinders before removal
as required.
4) Use the jack to lift the frame on the cross beam until the front cylinder is fully
extended.
5) Jack up the suspension until the the tyres are suspended, then fix the steering
arm.
6) Remove the front tyres and rim.
7) Remove the push rod, steering cylinder and steering tie rod.
8) Use the forklift to support the suspension and wheel assembly.
9) Remove the pin shaft of front suspension.
10) Transfer and place relevant components to proper working area, including front
suspension cylinder, push rod, steering cylinder and tie rod, etc.
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3.3.2 Installation of front suspension frame
1) Place the front suspension onto the upper support of

hydro-pneumatic spring before using the lifting appliance.
2) Connect the pin shaft with hydro-pneumatic spring and
install on the frame.
3) Use the hoister or forklift to place the axle beneath the
frame, use the push rod to connect the axle with the frame.
4) Connect the front suspension cylinder to axle with pin
shaft.
5) Connect the braking hydraulic piping to brake caliper,
and exhaust from braking system.
6) Install front tyres and rim assembly.
7) Refill the suspension as per the instructions.
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3.3.3 Removal of rear suspension frame
1) Support and fix the complete frame, middle and rear axle
respectively.
2) Remove the tyres and rim.
3) Remove all connecting bolts of push rod and axle, remove the
axle and use special lifting appliance or forklift the move the
middle and rear axle to flat area.
4) Remove the pressing block of plate spring, remove the long
bolt and move it to flat area with lifting appliance or forklift.
5) Remove all push rods.
6) Loosen the double-end stud nut connecting the balance shaft
assembly and the frame, remove the balance shaft to remove the
rear suspension.
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3.3.4 Installation of rear suspension frame

1) Support and fix the complete frame.
2) Lift the balance shaft assembly to proper position, align the bolt
hole and tighten the nut to finish the installation of balance shaft
assembly.
3) Connect all push rods with the frame.
4) Lift the plate spring above the balance shaft casing, install the plate
spring assembly and pressing plate, insert the bolt and tighten the nut
to complete installation of plate spring.
5) Use lifting appliance or forklift to move the middle and rear axle to
proper position beneath the frame, connect the push rod.
6) Install the tyres and rim to complete the installation of rear
suspension.
Note: 1. Apply thread tightening glue before tightening on the frame end of double-head stud nut connecting the
balance shaft assembly and frame.
2.Apply lubricating grease during the installation of the support of the plate spring. 142
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3.3.5 Filling of oil gas for front suspension cylinder
Oil plug (Rod end): Filling port
A
Charging valve: Nitrogen filling
Plug (Cylinder barrel): Exhaust
A - Testing point of oil gas filling, plane distance from the center of installation hole on suspension cylinder to guide sleeve. 143
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3.3.5 Filling of oil gas for front suspension cylinder - Pressure release
1) In prior to release the pressure of suspension cylinder, park the

vehicle unloaded on the flat pavement and ensure the vehicle is
firmly parked with mining braking system turned off.
2) Support the frame next to suspension cylinder with the jack or
sole timber block of sufficient bearing capacity.
Warning 3) Remove the cover of top charging valve on piston rod of
suspension cylinder, rotate the hexagonal nut on charging valve
The charging valve or oil plug of suspension cylinder shall
anti-clockwise for 1/4～1/2 circle, press down the valve element, if
not be opened unless the pressure is released, otherwise it
there is no gas discarded, rotate for 1/4 circle, and stop repeating
may case casualties and damages to equipment as the
suspension cylinder is a pressure cylinder. above actions until the nitrogen is discharged when the valve
element is pressed.
4) Remove the cushion block or release the pressure of hydraulic
jack, make sure the weight of vehicle is fully applied on the
suspension cylinder.
5) Press the charging valve element, make sure the pressure is fully
released.
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3.3.5 Filling of oil gas for front suspension cylinder - Filling of hydraulic oil (initial filling or
refilling in maintenance)
1) Park the vehicle on flat and safe pavement.

2) The nitrogen shall be fully discarded for accurate testing of
oil level. Vacuumize the air of suspension or keep the
A=258 charging valve opened for more than 24 hrs by
supporting the frame with proper cushion block to
complete the action.
3)Use the jack to lift the frame until the suspension is fully
extended, support the frame by proper cushion block of
front suspension, ensuring the mining truck is fixed by
fully extended front and rear suspension cylinder. Refer
to following figure: Front suspension cylinder
A=258mm.
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4) Remove the protective cover of charging valve, release

the filled gas as per the instructions.
5) Gently lower the frame to required position, refer to
A=118
following figure: Front suspension cylinder A=118mm.
6) Fully release the residual pressure from the suspension.
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7) Oil filling
a. Open the oil plug on cylinder to fully discharge the gas from the auxiliary oil chamber to ensure accurate filling of oil.
b. Remove the oil plug on the head of piston rod, open the plug on the cylinder, connect the oil filling component to the plug port
on piston rod to fill until the oil without bubbles is flowing out from the plug port. Check if the sealing washer is damaged before
installing the plug, then install and tighten as specified of standard tightening torque.
c. Remove the charging valve from the head of piston rod, continue to fill in oil through the plug port of piston rod head until the
oil without bubbles is flowing our from the port of charging valve.
d. Check if the sealing washer of oil plug and O-ring of charging valve are deformed or falling off, replace if necessary. If they are
in good condition, install and tighten as specified of standard tightening torque.
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3.3.5 Filling of oil gas for front suspension cylinder - Filling of nitrogen
Pressure
AIr inlet valve Connector
gauge
Charging valve to nitrogen
cylinder
Connect Nut
or
Release valve Check valve Warning
Do not open the valve or remove the connector unless the pressure
is released as required, to prevent from and casualties due to any
Inflation connector unexpected accidents. Please make sure to use a high pressure
regulator in the filling device of suspension cylinder, otherwise it
Hose
may cause casualties and damages to equipment. The pressure of
nitrogen cylinder shall be more than 5Mpa.
Nitrogen filling device
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1) Park the vehicle on safe and flat position and make sure the vehicle is firmly
parked with mining friction braking system turned off.
Suspension cylinder 2) Gently remove the protective cover of charging valve as it may have residual
charging valve
pressure.
Suspension cylinder
charging valve 3) Unscrew the sealing nut, connect the nitrogen filling device with nitrogen
cylinder.
4) Connect the filling port of nitrogen filling device to the charging valve of
suspension cylinder.
5) Gently open the valve on the cylinder and observe the readings on pressure
gauge. The in-cylinder pressure of nitrogen cylinder shall be more than 3MPa.
6) Rotate anti-clockwise the small hexagonal nut of the charing valve on suspension
Nitrogen
cylinder cylinder two or three circles to separate the internal valve from the seat.
Three-way Rotate anti-clockwise the T-shape handle of charging connector until it cannot
connector be rotated, open the check valve of charging port. Close the inlet valve, open
the charging valve, gently open and periodically close the inlet vale during the
filling of gas. Close the inlet valve and pay attention to the readings on
Nitrogen filling device
pressure gauge during the inspection of in-cylinder pressure.
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7) Two cylinder shall be filled with gas until they reach the level shown in following figure, over-inflation is not allowed,
otherwise it will cause damages to the fixing bolt on piston due to excessive extension of the cylinder.
8) The front suspension shall reach A=218mm (unloaded inflation height). Close the valves and inlet valve on nitrogen
cylinder, rotate clockwise the hexagonal nut of charging valve on suspension cylinder to close the internal valve. Then
rotate clockwise the T-shape handle of charging connector until it cannot be rotated.
A=218
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9) Open the charging valve and close the inlet valve of nitrogen filling device, release the pressure from pressure gauge and
hose through release valve, unscrew the nut, remove the charging connector on the charging valve of suspension cylinder.
10) Use soap-suds to check if there is leakage of charging valve of the suspension cylinder, if yes, press the valve element once
or twice quickly to reset. If there is still leakage, replace the valve element. Tighten the fixing nut of charging valve
(tightening torque of 50N·m), replace the protective cover of charging valve (torque of 4.5～5.5N·m).
11) Inspect the height of unloaded operation and adjust in accordance with specified standard after around twenty-four (24)
hours of operation.
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Note 1: In case any leakage discovered in the element of charging valve:

a) Check the torque of valve element, which shall be 0.35～0.45N·m.
b) If there is still leakage, check if the valve element is damages or polluted. Replace if necessary.
Note 2: The piston rod will be tight due to the sealing ring and dust ring of new or repaired suspension cylinder, therefore
the required filling height cannot be reached. Check the height of suspension cylinder again after several days of
operation and make the filling as accurate as possible.
Note 3: In case the suspension cylinder is filled to accurate height, the vehicle is not over-loaded, and the piston is reaching
the bottom of the cylinder, the oil level may be inaccurate and the suspension cylinder shall be refilled with more oil
gas.
Warning
The suspension cylinder shall be filled with dry nitrogen. Do not
use oxygen or liquid nitrogen, otherwise it will cause explosion.
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Maintenance instructions
Failure mode
The failure of suspension system is related to multiple systems, including steering mechanism, axles and tyres, etc. In case of any
abnormal conditions, noise, off-tracking, vibration and abnormal damages, complete inspection and alignment shall be done, including:
(1) Check if the tyre pressure is normal
(2) Check if there is any irregular abrasion of tyres
(3) Check if the tyres are unbalanced and damaged
(4) Check if all supports and connectors are loose
(5) Check if there is any abrasion and loose connection of steering parts, i.e. hydraulic steering rod ball head, etc.
(6) Check if the suspension frame is damaged and loose, i,e, if the abrasion is severe and connection is loose of push rod ball pin.
(7) Check if there is any oil and gas leakage of suspension cylinder.
(8) Check if there is any inaccurate or broken blade of plate spring.
(9) Lubrication failure
(10) Check if the long bolt of plate spring is deformed or broken.
(11) Check if the limit block is separated.
The suspension is one of the most critical parts of bearing system, please contact the maintenance service station to repair or replace the
damaged parts, otherwise it will accelerate the damages to other parts and even severe accidents.
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Maintenance of suspension system
Following parts shall be inspected on daily basis:

1) Check if there is any abrasion, damage or oil gas leakage of hydro-pneumatic spring, pay special attention to the
exposed part of piston rod and charging valve.
2) Check if there is any broken or inaccurate blade of plate spring, if the long bolt of plate spring is loose and if any bolt
of push rod is loose.
Repair or replace in case of any loose or damaged parts found.
3) Check if the end cover bolt of balance shaft is loose.
4) Check if the left and right suspensions are at the same level, in case they are at different levels, test the unloaded
suspension cylinders and refill more nitrogen after parking on fall pavement.
5) Check if the joints and connectors of suspension system are in normal condition.
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Maintenance of suspension system

1) In order to prevent form the common problems specified in 3.2.1, all bolts of critical parts shall be checked and confirmed if they are loose, and the bolts of
suspension system shall be re-tightened on regular basis.
• After the vehicle is delivered for running-in for one week,
All bolts and long bolts of plate spring connecting with push rod of front and rear suspension shall be re-tightened.
The support for push rod of front suspension, upper support of hydro-pneumatic spring, support for upper push of rear suspension and support for horizontal
push of rear suspension shall be relighted in accordance with actual conditions.
• Upon the initial maintenance (2000km),
• Upon the second time maintenance (5000km),
• It is recommended that all bolts and long bolts of plate spring connecting with push rod of front suspension shall be re-tightened every 5000km of
operation.
• For severe working conditions, the maintenance shall be more frequent to ensure the normal operation of the vehicle.
2) Apply lubricating grease between the plate spring and sliding plate every 8000-10000km to reduce the abrasion of sliding plate base.
The normal wearing life of guide plate and sliding plate base is half a year, replace them in case of severe abrasion occurred.
Note: The guide plate is using separated type, which shall replaced in case the abrasion reaches 3mm or it starts to impact the actions.
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Appendix: Tightening torque of high-intensity bolts and nuts of suspension system.
Suspension tightening torque
Tightening torque (N·m)

Screw thread
10.9 12.9
M18 365 430
M20 515 600
M24 890 1040

M27 1380 1690
M30 1950 2300
Tightening torque for end cap bolt of balance shaft assembly: 540-600N·m
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3.2 Drive system
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Operation instructions
• In case the elevation stops in the middle, do not step the accelerator suddenly, check if it is lack of hydraulic oil. Refill with
more oil immediately if necessary, otherwise the plunger pump may be damaged.
• In case the elevating cylinder is shaking during elevation and the bolts are loose, re-check and tighten immediately to prevent
from any danger.
• It is recommended to steer during driving and avoid pivot steering to prevent early abrasion of tyres.
• In case of difficulty in steering, drive to repair factory as soon as possible to prevent the vehicle from breaking down in
workplace.
Maintenance instructions
• Replace the filter element and hydraulic oil on regular basis.
• When replacing the pump due to damages, the filter and hydraulic oil shall be replaced even if it is not the time, the filtered
hydraulic oil can be used again.
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3.1 Power system

3.2 Drive system
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Electrical operation instructions
Removal and installation of storage battery

• Disconnect the grounding cable (connected to
negative terminal) before removing the storage
battery.
• It is very dangerous that the relevant tools are
contacted between positive terminal and chassis.
• Fix the battery with clamping plate to replace the
storage battery.
• Sequence of connection: Connect the positive cable,
then connect the negative cable of the storage battery.
• Sequence of disconnectionL Disconnect the negative
cable, then disconnect the positive cable of the storage
battery.
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Electrical operation instructions

Charging of storage battery
• Regulate the voltage of charger to the matching value of storage battery. Inaccurate voltage will cause overheating and explosion
of the charger.
• Connect the positive (+) cable clamp of charger to positive (+) terminal of storage battery, connect the negative (-) cable clamp of
charger to negative (-) terminal of storage battery. Make sure the clamps are firmly connected.
• Regulate the charging current to 1/10 of rated capacity of storage battery. For quick charge, regulate the charging current lower
than rated capacity of storage battery. High charging current will cause fire or explosion of storage battery due to the leakage and
evaporation of electrolyte.
• In case the electrolyte is frozen, do not charge the storage battery or start the engine on other different power supply, otherwise it
will cause fire of electrolyte and explosion of the storage battery.
Circuit failure diagnosis instructions
• Ensure to turn off the power in prior to disconnection and connection.
• In prior to failure diagnosis, check if all relevant connectors are in normal condition, then disconnect and connect relevant
connectors for several times for inspection.
• Make sure to connect all connectors before the following step, otherwise the power supply upon disconnections will cause
abnormal indications.
• During circuit failure diagnosis (including the measurement of voltage, resistance, connectivity or current), move relevant cable
and connectors for several time and check the readings on instruments which shall be consistent. Otherwise, it may have contact
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failures in circuit.
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Electrical maintenance instructions
• In case of dampness of electrical equipment and damage of cable covering, it will cause failures due to electrical short-
circuit. Do not wash the interior of driving cab with water. Ensure no water entering into electrical components when
cleaning the machine.
• Do not install any other electrical components other than those specified by SANY.
• The control system will be faulty due to external electromagnetic interference. Please contact SANY and authorized agents
for the installation of wireless receivers including radio receiver.
• Please connect the electrical equipment with specified power connector.
• Do not connect the optional power supply with fuses, starting switch or the relay of storage battery.
• Check frequently if the connecting bolt of engine and negative electrode of storage battery is loose.
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3.1 Power system

3.2 Drive system
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Operation instructions of air conditioner
1. No water entering into air conditioner controller

The air conditioner will not operated if it is damaged by water as the controller is electrical
assembly.
2. The air conditioner shall be started unless the engine is started
If the air conditioner is started before the engine is started, the clutch will be actuated with the
drive disc of compressor, then start the engine, when the instant torque will be excessively
large and severe friction will be generated between the clutch chuck and drive disc, which may
cause early abrasion of the clutch during such long-term operation.
3. Close the doors and windows when the air conditioner is in operation.
4. Do not close all air outlets, make to 1/3 of air outlets are opened.
5. The temperature control or defrost protection shall not be short-circuited in normal
condition (No forced cooling is allowed.).
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Maintenance instructions of air conditioner
1. Please avoid direct sunlight when parking in summer

2. Check the abrasion of belt, replace with standard belt immediately (Replace
two identical belts in the meantime.).
3. Check and clean the grid filter screen of return air and evaporator on
regular basis:
• Clean once every week. For areas of more dust pollution, the frequency can be
adjustable in accordance with actual conditions.
• The filter screen shall be cleaned once every month at least when the air
condition is not operated in relevant seasons.
Warning! The filter screen of air conditioner shall be clean as specified, otherwise
large quantity of dusts and oil pollutants entering into the core of evaporator will
impact the heat transfer efficiency of evaporator and the cooling effect of the air
conditioner!
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4. Inspection of refrigerant
Normal Insufficient
Status of refrigerant observed at sight window

The content of refrigerant is accurate in case of no obvious bubbles found. The content of refrigerant is insufficient in
case of obvious and flowing bubbles.
5. Check the cleanliness of the core of evaporator and heat transfer fin of condenser
• The core shall be cleaned once every year in following methods including:
• Use high pressure hydraulic giant with cleaning agent to clean the surface of the core of condenser and evaporator.
• Use high pressure air to blast the surface of the core of evaporator and condenser.
• Attention: The high pressure hydraulic giant and pneumatic gun shall be used with proper pressure, no beating
down of the fin. The cores and fins with too much pollutants and dusts shall be cleaned with diluted special
cleaning agent for air conditioner.
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Operation instructions on routine maintenance of operator

Description Maintenance period Condition Operation and requirement
Before and after At least 2/3 air outlets shall be opened to ensure good circulation during operation. Check if the air
Air outlet Daily
starting-up volumes of both sides are approximately same.
Air return grid filter Clean the dust filter screen of return air (sponge block) with clear water, of which the cleaning time can be
Weekly Before staring-up
screen adjustable for workplaces with more dusts.
Clean the filter screen of the core of evaporator with clear water, of which the cleaning time can be
Evaporator filter screen Monthly Before starting-up
adjustable for workplaces with more dusts.
Condensation water Check if there is any condensate water discharged after one hour of operation. The water discharge is large
Daily After starting-up
piping in regions of high humidity or rainy season including southern or coastal areas.
Weekly Before starting-up Check the tightness and abrasions the belt, adjust or replace if necessary. Apply 10kg force (about 98N) on
Driving belt the belt in the middle of two pulleys by vertically pressing by two thumbs, the deflection shall in within the
Monthly Before starting-up
range of 10m per meter from the center.
Check the oil level of compressor. Observe from the sight window the refrigerating oil level of compressor,
which shall be more than 4/5 after the air conditioner is stopped for 30 min and shall be 1∕4～3∕4 in normal
Before and after
Compressor oil volume Daily or weekly operation. In case that it cannot comply with above standard with in running-in of 250 hrs, replace with
starting-up
new felt and refill with more refrigerating oil. Replace with new shaft seal in case it exceeds running-in
period and does not comply with above standard.
Before and after Check if there is any abnormal sound of clutch bearing before powering on. Check if the electromagnetic
Electromagnetic clutch Daily
starting-up clutch can be actuated and separated without slipping after powering on.
Annually Before staring-up Check if the bolt on support of compressor is loose.

Compressor Check if the parts are in normal operation once a week when the compressor is not in operation period.
Weekly After starting-up
Start the heater and warm-up before start the air conditioner in cold weather.
Fan Annually After starting-up Check if there is any abnormal sound in normal operation.
Replace the dryer. (Note: In case the paper of sight window is not in yellow color, the cooling system is in
Dryer Annually After starting-up
normal operation and the sight window is clear, then the dryer may not be replaced.
Connectors and terminals Monthly Before staring-up Check if the cables of compressor clutch or wiring terminals of engine is loose.
Check if the main power fuse, fan fuse and plug-in fuse are in good condition. Check if the ends of fuse
Fuse Monthly Before staring-up
and fixing bolt on support base are loose.
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04 Analysis of typical failures
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4.1 Power system

• The engine cannot be started
• Insufficient power of the engine
• Abnormal noise during operation of the engine

Common failures
• Black smoke from exhaust Thinking

Simplification
• White and blue smoke from exhaust Insight
Analysis
• Abnormal pressure of engine oil
Solution
• Excessively hot water outlet
• Failure of turbocharger
• Flameout of engine
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4.1.1 The engine cannot be started
No. Possible causes Troubleshooting
Check if the joints or clamps of pinging are loose, re-tighten if necessary. Loosen the air bleed
1 Air in fuel pipings screw (on the filter) or loosen high pressure oil piping connector of injector ro remove the oil
return pipe, use manual pump to deliver fuel until the fuel without bubbles flows out.
2 Fuel pipings are blocked or damaged. Check if the oil supply piping is blocked or leaked.
3 Fuel filter is blocked. Replace the fuel filter element.
4 No supply or intermittent supply from fuel pump Check if the fuel pump is faulty.
1. Check the atomization of oil injector.

5 Small quantity injection, no injection or low-pressure injection
2. Check if the injection pump plunger and oil outlet valve are worn-out or stuck.
Failure of starting system: 1. Check if the wiring is accurate and reliable.

Inaccurate wiring or poor contact 2. Charge the storage battery.
6
Insufficient power of storage battery 3. Repair or replace the electric brush, clean the surface of commutator with wood abrasive
Poor contact of carbon brush and commentator of the starter paper and blast to clear.
The connector of fuel shut-off electromagnetic valve is loose,

7 Tighten, clean or replace.
polluted or corroded.
1. Replace the piston ring, install cylinder sleeve if necessary.

Excessive abrasion of piston ring or leakage of air valve,
8 2. Check the valve clearance, sealing performance of valve spring, guide tube and support base,
compression ignition cannot be done.
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4.1.2 Insufficient power of engine

1 Air inlet is blocked. Check the air filter and inlet piping, clean or replace air filter element.
2 The back pressure of exhaust is excessively high. Check the valve timing, adjust if necessary; Clean the exhaust piping.
3 Insufficient pressure of turbocharger system Check and solve the problems of leakage of pipings and connections.
4 Turbocharge is faulty or in poor condition. Clean or replace gas wheel casing and turbine housing; Replace the turbocharger.
5 Intercooler is damaged or leaked. Repair or replace
6 Fuel pipings are blocked or damaged. Check if the oil supply piping is blocked or leaked.
7 Fuel filter is blocked. Replace the fuel filter element.

Check the atomization of oil injector; Check if the injection pump plunger and outlet valve are
8 Small quantity injection or low-pressure injection
worn-out.
9 Cooling liquid is excessively hot. Check and repair or clean the radiator, thermostat, fan and regulate the tension of belt.
Abrasion of piston and piston ring or leakage of air valve and
10 Adjust or replace if necessary.
cylinder gasket
11 Inaccurate valve timing phase Check and adjust valve timing and clearance.
12 No proper advance angle of oil supply Check and adjust.

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13 Sensor is damaged. Check and replace.
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4.1.3 Abnormal noise during the operation of engine
Check if the timing gear is installed correctly.

1 Abnormal sound in air cylinder
Check and regulate the valve timing.
Excessive abrasion of connecting rod bearing pad and main bearing

2 Check the bearing pad, replace if necessary.
pad (The crash can be heard from the crankcase.)
3 The shock absorber is damaged and cannot operate. Check the damages of connecting bolt and shock absorber, replace if necessary.
Abrasion and excessive clearance of drive gear (The crash can be

4 Check the gear edge clearance, replace the gear if necessary.
heard from the timing gear housing.)
Excessive clearance between piston and air cylinder (The crash can Replace the piston, add cylinder for maintenance if necessary, pay attention to the clearance of
5
be heard from cylinder wall during operation.) matching cylinder.
The bearing of turbocharger is broken, rotary parts collide with the

6 Replace the turbocharger assembly.
casing.
Excessively large valve clearance, obvious sound from the cylinder

7 Adjust the valve clearance.
cover.
Clear the carbon deposition and pollutant in the channels of compressor and waste gas
8 Surge of turbocharger
Excessively high operating elevation
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4.1.4 Black smoke from exhaust
1 Blocking of air inlet Check and clean the air filter and inlet piping.
2 Insufficient pressure of turbocharger Check and solve the leakage of pipings and connections.
3 Abnormal operation of turbocharger Check and replace the assembly.
4 The intercooler is damaged and leaked. Repair or replace.
5 Poor quality of fuel Replace with specified fuel.
6 Poor atomization of oil injector Check, repair or replace.
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4.1.5 White or blue smoke from exhaust
1 Poor quality of fuel or excessive water content Replace with fuel
2 Excessive low temperature of cooling liquid Pre-heating; Check the thermostat, replace if necessary.
3 Inaccurate timing of air or oil supply Check and adjust.
4 Check the piston ring and cylinder gasket, replace.

Low compression or incomplete combustion
Inaccurate installation direction of piston ring with
5 Check and re-assemble.
inaccurate staggered joint
6 Long-term low-load operation Apply proper working revolution and load.
Abrasion of sealing ring or thrust bearing of
7 Check and replace.
turbocharger
8 The oil return piping of turbocharger is blocked. Clean and repair.
In general conditions, white smoke is caused by the water vapor in combustion, blue smoke is caused by the engine oil in combustion.
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4.1.6 Abnormal pressure of engine oil

1 Dilute or improper engine oil Choose specified engine oil.

Abrasion of engine oil rotor or excessively large
2 Replace with new engine oil pump.
clearance
Engine oil filter is blocked or pressure regulating valve
3 Replace
does not work.
4 Low pressure Damage or abrasion of engine oil pump gear Replace
5 Cracking on inlet pipe of engine oil pump Repair or replace.
6 The fixing bolt of inlet pipe of engine oil pump is loose. Tighten as specified of tightening torque.
7 Excessive large clearance between bearing pads Check and replace.

Choose specified engine oil, operate at low speed and low-load, re-check after the oil
8 Excessive low temperature, viscosity becomes higher
temperature is normal.
High pressure
9 The overflow valve or oil-gas separator is blocked. Check and clean
10 The engine oil piping is leaked. Check and repair
11 The engine is over-loaded. Reduce the load.

High loss
12 Improper engine oil is used. Choose specified engine oil.
Abrasion or lubrication system components, or loss of
13 Check the piston, piston ring, air cylinder, air valve, etc., repair or replace if necessary.
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4.1.7 Excessively hot water outlet
Check if the cooling liquid level is accurate and if there is any leakage or
1 Insufficient cooling water with small flow
blocking.
2 Check if the belt is excessively loose. Adjust the tensioning wheel or replace the belt.
3 The water pump does not work or damaged. Repair or replace immediately.
4 The thermostat does not work or damaged. Check or replace.
The instruments do not work, the water temperature

5 Check if the actual temperature is consistent with indication value.
sensor does not work.
6 Cylinder gasket is shocked. Check and replace the cylinder gasket.
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4.1.8 Failure of turbocharger
The impeller or turbine may be damaged due to abnormal articles entering into
1 Abnormal articles entering
inlet or exhaust.
Collision between the rotor of air compressor and
2 Change the assembly
housing or turbine housing
3 Poor lubrication, leakage of inlet or return piping Check and replace
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4.1.9 Flameout of engine
1 Running out of fuel Check and refill, make sure to fully discharge the air from oil-way.
The oil-way is blocked for filled with large volume of Check and clean the oil-way, fully discharge the air from the oil-way, find and
2
air solve the problem.
3 Inaccurate connection of inlet and outlet pipings It is of common circumstances after the flameout of electronic fuel pump.
If the machine is shutdown under normal temperature of water, it is of common

4 The bearing pad is burned due to poor lubrication. circumstances. Remove the bottom casing to check, repair and replace the
damaged parts and components.
Self-cooling shall be done (Do not fill or wash with cold water), then rotate the
Cylinder scoring due to overheating of the engine crank shaft, if it is not stuck, fill in cooling liquid and start. If the crank shaft
5
(It is normally caused by water shortage or overheating.) cannot be rotated, remove relevant parts to check, repair and replace the
damaged parts and components.
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4.2 Drive system

Failures Descriptions Possible causes Prevention measures
The separation fingers are not at the Interference between gearbox input shaft and separation
The foot pedal shakes during separation. Prevent from any interference by accurate installation of clutch into the gearbox.
same level or damamged. finger during installation.
The separation finger end of
Limited or no pre-loading of releasing bearing. The pre- Check all relevant connections during the installation of clutch. Make sure the gut
Difficult to step down the pedal, the diaphragm spring is worn-out by
loading spring is not well installed or the self-adjusting wire is in normal condition during the operation of clutch. Check the self-adjusting
righty will increase with time. release bearing, and the bearing
mechanism does not work. mechanism. The preload shall be in the range of 50N～80N .
seems to be in normal condition.
There is wearing crack in the contact

Noise of engine generated when the The clutch is not well adjusted or the self-adjusting Check the booster push rod, relevant connections and self-adjusting mechanism
area of diaphragm spring separation
pedal is fully stepped down. mechanism is ineffective. shall be checked through system grounding.
finger and release bearing.
High rigidity at certain point during the The sleeve of releasing bearing is Check the shifting fork, replace if necessary. In case of any abrasion, replace with
Abrasion of guide sleeve of release bearing, and
stroke of pedal, noise of gearbox, damaged, the separation finger of new guide sleeve of releasing bearing. Make sure relevant parts and components
deformation of shifting fork.
vibration of clutch, shaking of pedal. diaphragm spring is worn-out. have been lubricated.
The release bearing is stuck or has noise from the start.

The positioning part of releasing Check relevant connections, shifting fork, bearing, pre-loading spring and self-
Noise of clutch, pedal is loose. The oil grease is burins caused by overheating of release
bearing is damaged. adjusting mechanism of clutch through system grounding.
bearing due to inaccurate pre-loading.
The separation finger is badly

The release bearing is ineffective due to improper
Constant and loud noise. damaged, the release bearing is Check the adjusting mechanism of clutch on regular basis.
adjustment.
stuck.
The operator keeps stepping on the pedal. The Make sure the clutch is properly adjusted and organize training courses for the
Slipping of clutch causing shaking. The cover assembly is burned.
adjustment of clutch is not accurate. operators and drivers.
Illegal operation of clutch. The operator keeps stepping

Slipping of clutch, gear-shifting cannot Several parts are damaged of cover on the pedal during driving. The pressing plate is broken
The operators shall abide by the standard.
be operated. assembly. caused by overheating of all parts and components due
to excessive slipping.
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Common failures and troubleshooting

1. Difficulty in gear engaging
a. Check if the oil of clutch is accurate.
b. Check if the pressure is accurate.
c. Check if there is any gas in the oil pipings of clutch, check if the exhaust is in normal condition.
d. Check if there is any oil or gas leakage of all pinpoints.
e. Check if there is any stagnation of releasing bearing and release shifting fork.
f. Check if the air inlet of gearbox is leaked or bent.
g. Check if there is any abnormal abrasion or deformation of the clutch.
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Common failures and troubleshooting

2. Slipping and ablation of clutch
a. Confirm he driving habit of the operator.
b. Check the loading capacity and working condition of vehicles.
c. Check if there is any stagnation or difficulties in return of the clutch pedal.
d. Check if there is any stagnation of releasing bearing.
e. Check if the driven disc of clutch is polluted or with abnormal articles.
f. Check if the pressing plate is accurately installed. Check if the bolt is tighten to specified torque.
g. Check if the release shifting fork and fixed shifting fork are well lubricated.
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Part failure Figures Possible causes Failures Settlement
*The friction surface of Crackings Grooves 1. Oil leakage in gearbox, oil

pressing plate is rough with dirt on the surface of friction
obvious worn-out steps or plate. The supplier of clutch
grooves. Blue color due to 2. The vehicle is in the status Shaking shall not be
ablation
*The friction surface is in of semi-linkage for long Slipping responsible for the
obvious blue color with period (It is approved that the Difficulty in gear- failures caused by the
cravings and warnings. clutch may be burned for shifting operator or other
Refer to following figure for continuous semi-linkage more reasons.
the color comparison of than 1min.)
ablation. 3. Severe over-loading
1. Poor shot blasting of

The claim for compensation diaphragm spring Difficulty in gear-
Valeo shall accept the
shall be accepted in case the 2. Burrs on breakage of shifting
claim for
diaphragm spring is broken diaphragm spring. Abnormal sound
compensation.
not due to man-made causes. 3. Excessive large separation Shaking
stroke.
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Part failure Figure Possible causes Failures Settlement
Check the dimensions of

returned parts in warranty:
Qualified: Valeo shall not
Difficulty in gear- accept the claim for
1. Inaccurate rigidity of the drive
shifting compensation on problems
Breakage of drive blade blade.
Abnormal sound not due to the quality of
2. Inaccurate operation
Shaking parts.
Disqualified: Valeo shall
accept the claim for
compensation on quality
problems.
1. Excessive large air hole of

The claim for compensation shall pressing plate casting Difficulty in gear-
be accepted in case the pressing 2. The parts have been shocked by shifting Valeo shall accept the
plate is broken not due to man- large external force Abnormal sound claim for compensation.
made causes. 3.Heated stress fracture of pressing Shaking
plate
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1. The diaphragm spring is not well

Uneven condition of separation Difficulty in gear-
processed.
fingers (>1.2mm) in assembly shifting Valeo shall undertake the
2. Abnormal articles between
status, not due to man-made Abnormal sound claim for compensation.
diaphragm spring and pressing plate
causes Shaking
cover.
Check the dimensions of

returned parts in warranty:
Qualified: Valeo shall not
1. Inclined assembly of release accept the claim for
Abnormal sound
bearing compensation on problems
Breakage of snap ring cover Difficulty in gear-
2. Inaccurate dimension of snap not due to the quality of
shifting
ring cover parts.
Disqualified: Valeo shall
accept the claim for
compensation on quality
problems.
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* Recommendation: Prize the

diaphragm spring with
screwdriver to install it back
*Check the dimensions of
1. Inclined assembly of release returned parts in warranty:
Abnormal sound
bearing Qualified: Valeo shall not accept
Falling-off of snap ring cover Difficulty in gear-
2. Inaccurate dimension of snap the claim for compensation on
shifting
ring cover problems not due to the quality of
parts.
Disqualified: Valeo shall accept
the claim for compensation on
quality problems.
screwdriver to install it back
* Check the dimensions of
1. Inclined assembly of release returned parts in warranty:
Abnormal sound
Falling-off of snap ring Difficulty in gear-
shifting
parts.
quality problems. 185
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screwdriver to install it back*
Check the dimensions of returned
1. Inclined assembly of release parts in warranty:
Abnormal sound
Breakage of snap ring Difficulty in
gear-shifting
parts.
quality problems.
Manual polishing of
The claim for compensation shall
identification marking Malicious claim -
not be accepted.
information
4
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Parts failure Figures Possible causes Failures Settlement
1. Oil leakage in gearbox, oil dirt

on the surface of friction plate. Slipping
The friction plate has been 2. The vehicle is in the status of Difficulty in
The supplier of clutch shall not be
worn-out to the head of rivet, semi-linkage for long period (It gear-shifting
responsible for the failures caused
ablation or falling-off of is approved that the clutch may Abnormal sound
by the operator or other reasons.
friction plate be burned for continuous semi- Shaking
linkage more than 1min.) Heavy pedal
3. Severe over-loading
1. Oil leakage in gearbox, oil dirt

on the surface of friction plate. Slipping
2. The vehicle is in the status of Difficulty in
The supplier of clutch shall not be
semi-linkage for long period (It gear-shifting
Ablation of friction plate responsible for the failures caused
is approved that the clutch may Abnormal sound
by the operator or other reasons.
be burned for continuous semi- Shaking
linkage more than 1min.) Heavy pedal
3. Severe over-loading
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Parts failure Figures Possible causes Failures Settlement
1. Oil leakage of gearbox

2. Excessive grease applied
on input shaft will The supplier of clutch shall
Even oil pollutant accumulated on the not be responsible for the
Slipping
covering the lines on the interface of wheel hub after failures caused by other
Shaking
surface of friction plate assembly, which will be reasons excluding quality
thrown onto the friction problems.
plate under the effect of
centrifugal force.
Shaking
1. The vehicle is always The supplier of clutch shall
Abrasion of driven disc Difficulty in
under semi-linkage not be responsible for the
friction plate gear-
condition. failures caused by the
engaging
2. Severe over-loading operator.
Heavy pedal
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1. Inaccurate rigidity of the

Breakage of wheel hub
wheel hub.
2. Inaccurate dimension of
The claim for Abnormal
wheel hub.
compensation shall be sound
3. Inaccurate dimension of Valeo shall undertake the
accepted in case the Difficulty in
input shaft. claim for compensation.
wheel hub is broken not gear-engaging
4. The input shaft of
due to man-made causes. No separation
gearbox is not vertical to
the end face of flywheel.
1. In accurate rigidity of
clamping plate. Shaking
2. Inaccurate dimension of Abnormal
The external springs are
the window. sound Valeo shall undertake the
broken not due to man-
3. Inaccurate rigidity of Difficulty in claim for compensation.
made causes.
spring. gear-engaging
4. Abnormal articles stuck No separation
during operation. 189
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1. Inaccurate rigidity of Shaking

Breakage of spring clamping plate. Abnormal
window of clamping 2. Inaccurate dimension of sound Valeo shall undertake the
plate not due to man- the window. Difficulty in claim for compensation.
made causes. 3. Abnormal articles stuck gear-engaging
during operation. No separation
1.Inaccurate rigidity of
positioning pin.
Breakage of stop pin of Abnormal
2. The positioning pin is Valeo shall undertake the
driven disc not due to sound
not installed in position. claim for compensation.
man-made causes. Shaking
3. Excessively deep
riveting.
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1. The input shaft of gearbox is

not vertical to the end face of * Check the rigidity of cushioning
flywheel. plate of returned parts in warranty:
Abnormal sound
2. It is applied for vehicles of Qualified: Valeo shall not accept
Shaking
large torque. the claim for compensation on
Breakage of cushioning plate Difficulty in
3. Improper operations including problems not due to the quality of
of driven disc gear-shifting
sudden step-down accelerator, parts.
No separation
continuous and sudden release of Disqualified: Valeo shall accept
clutch pedal, etc. the claim for compensation on
4. Inaccurate rigidity of quality problems.
cushioning plate.
The cushioning plate * Check the rigidity of cushioning

becomes flat and not plate of returned parts in warranty:
No elasticity of cushioning
elastic. Qualified: Valeo shall not accept
plate of driven disc (The 1. Inaccurate rigidity of Difficulty in
distance between two friction cushioning plate. gear-shifting
problems not due to the quality of
plates of driven disc - 2. Deformation of cushioning No separation
parts.
thickness of cushioning plate plate due to high temperature. Heavy pedal
<0.6)
quality problems.
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Poor sealing performance

of release bearing, large
quantity of grease will Abnormal Valeo shall undertake the
Oil leakage of bearing
overflow from the seal sound claim for compensation.
when the bearing is
rotating.
The flange cannot rotate

Abnormal
due to the burning of Valeo shall undertake the
Bearing stuck sound
bearing. claim for compensation.
Shaking
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The bearing has fallen

Abnormal
apart including the 1. Inaccurate assembly of
sound
falling-off of inner and parts Valeo shall undertake the
Shaking
outer ring and damage of 2. Parts have been claim for compensation.
Difficulty in
sealing ring due to impacted by external force
gear-engaging
abnormal abrasion.
Valeo shall not responsible

for the problems not due to
Eccentric abrasion of 1. Inaccurate installation Abnormal quality of parts and
hanger by customer sound components including
inaccurate installation of
release bearing on the body.
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Valeo shall not responsible

for the problems not due to
Abnormal
Eccentric abrasion of 1. Misalignment of input quality of parts and
sound
release bearing sleeve shaft by customer components including the
Shaking
eccentric abrasion of the
sleeve.
194
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1. Take oil sample from

observation hole and check if
there is any iron dust.
2. If the oil contains iron dust,
1. The oil seal is damaged by
remove and check if the bearing if
iron dust due to the abrasion of
Abnormal sound worn-out and if the head locknut
bearing.
Oil leakage from wheel edge Iron dust in Needle bearing Tighten the nut, gear ring of axles is loose.
abrasion has clearance 2. The oil seal or O-ring is
of middle and rear axles lubricating oil
Oil leakage of 3. Check if the oil seal and O-ring
damaged by irregular axial
wheel edge are complete.
action of axle wheel edge due to
4. The bearing has been modified
the abrasion of bearing.
and improved by the manufacturer
in June, pay attention to the
production date for the feedback
Oi seal is Tighten the nut, the plate is Wheel edge analysis.
damaged damaged leakage
Bending of steering horizontal Insufficient 1. Check if there is any collision

1. It is caused by external force
pull rod steering on the horizontal pull rod.
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Breakage of air chamber 1. The casting part is not Insufficient 1. Check the section of
support of middle axle complied with standard. braking force casting part.
1. As the failure is new, the

service personnel shall
inspect the vehicle on
Insufficient weekly basis to investigate
Leakage of connection 1. Uneven sealing glue axle oil the failure and feedback.
between main reducer applied Abnormal 2. The manufacturer has take
housing and axle housing 2. Fixing bolt is loose sound the control on production
Gear damage technology in October, pay
attention to the production
date for the feedback
analysis.
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Cracks on upper support of hydro-pneumatic spring
• Failures of upper sport of hydro-pneumatic spring

is caused by multiple reasons including
insufficient intensity, poor quality control of
supplier, loose connection of support, etc. Check
the upper support on daily basis, replace in case of
any cracks.
• The products manufactured after August will be
configured with new-type upper support of hydro-
pneumatic spring, the machines after serial
number of KT090SY90213 are configured with
new structure.
Comparison between previous and latest structures:
• Thickness of previous support is 22.5m
• Thickness of latest support is 30mm
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Loose connection and fracture of plate spring long bolt and central bolt
• Loose connection of long bolt and center bolt of plate spring, all
breakages are cause by loose connection of long bolt.
• The long bolt of plate spring shall be re-tightened in accordance
with maintenance standard.
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Loosening of push rod bolt and breakage of push rod ball head of middle and rear axles
• Breakage of ball head on push rod of middle and

rear axle, in case that the breakages is due to the
side bolt is loose or lost, the failure is caused by
loose connection of connecting bolts.
• The bolt of push rod shall be re-tightened in
accordance with maintenance standard.
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Breakage of plate spring

• Breakage of non-batch plate spring, contact the spares
warehouse to replace with new spring.
• Please clarify the name of supplier as there are two
suppliers of plate spring.
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1. Failure analysis on oil penetration of elevating cylinder
Failure cause:
The oil cylinder is leaked caused by deviated loading due to the severe abrasion of lower support.
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1. Failure analysis on oil penetration of

elevating cylinder
Solution:
The manufacturer will replace with new cylinder and new
support base.
Cooper sleeve and

lubricating groove
Long-term solution:
• Replace with new structural support base with internal
cooper sleeve and lubricating groove.
• Apply lubricating grease as per the requirements of
maintenance.
• Enlarge the elevating cylinder sleeve.
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2. Failure analysis on oil penetration of

steering cylinder
照1
The piston rod is bent

Failure cause:
The leakage of oil cylinder is caused by the bending of piston rod through disassembly.
Apply new sleeve to prevent from more dust. 203
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3. Breakage and leakage of feedback piping

Cooling water pipe
of air compressor Operating temperature
It is analyzed that the breakage is near the engine piping and the of 85 degree
piping are becoming soft and burst caused by high temperature

according to the shape of breakage.
Breakage
Engine manifold (oil pipe)

Operating temperature of 95
Piping breakage degree, instant of more than
Breakage 100 degree
Solution: Modify and add one more section of pipe. 204
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我们先来了解常见
Common failures
的线束故障形式有 The wiring harness if critical to the quality of complete
of哪些
wiring harness
vehicle, any improper configuration will impact normal
operation of parts and components (The indication lights do
not work.) or cause severe accidents i.e. fire disaster. The
proportion of wiring failures is more than 5% of all
electrical failures.
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Failure cause: The fuse is burned due to the operating current is higher
than protective current caused by severe dust accumulation and
overloading of long-time operation of radiator fan of air conditioner.
It is complied with relevant standard (1.2-1.5 times of rated current for
electrical components) the the rated current of air conditioner is 10A
and the 15A fuse is applied for electrical design.
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Improvement measures
1) The filter screen shall be more tight for the structural modification of
external air conditioning filter element. Refer to the designs of competitors as
shown in the following figure:
2) The air conditioning evaporator shall be configured with filter screen, there
is no filter screen of internal circulation in default configuration.
3) Enhance the maintainability by modification of the installation structure of
air conditioning evaporator.
As the disassembly of air conditioning evaporator is very complicated that
almost all parts of driving cab will be removed including instrument panel,
rocker switch, combination instrument, display screen, divider, wiper motor
and spraying piping, it is recommended to re-deign the installation structure to
improve the maintainability that the evaporator can be directly removed from
the outside of the driving cab.
207
4
4.6 Driving cab

1. Difficulty in steering
◆ Failure: Difficulty in steering
◆ Working condition: Heavy-loaded climbing on uneven
and tough pavement of earth-rock mixture.
◆ Failure cause: There is clearance less than 1mm after
assembly, through which the dust may enter and block
the bearing. Refer to the position marked with red color
in the figure.
Solution 1: Add a sealing washer between steering Solution 2: Add framework oil seal on Solution 3: Add removable sealing caps on both sides
column support and chassis. steering column support. of installation base of steering column support. 208
2. No refrigeration of air conditioner
◆Failure: Hot air outlet in refrigeration mode

◆Working condition: Heavy-loaded climbing on uneven and
tough pavement of earth-rock mixture.
◆Failure cause:
◆It is because of the non-operation of fan caused by low
temperature protection due to the surface of evaporator is
polluted by the dusts during climbing of the vehicle.
Solution 1: Add filter cotton on the evaporator. SONGZ

had such failures in desert in Kuwait, which has been
solved by adding the filter cotton.
Solution 2: It is recommended that the customer shall
clean the external circulation filter screen regularly, to
prevent the evaporator from being blocked by dusts and
impacting refrigeration.
209
SANY
SANY HEAVY
HEAVY EQUIPMENT
EQUIPMENT CO.,
CO., LTD.
LTD. 品质改变世界 Quality
QualityChanges theWorld
Changes the World
THANKS
210

SKT90S Product Present - C

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SANY HEAVY EQUIPMENT CO., LTD.

品 质 改 变 世 界 Quality Changes the World

Product Training on SKT Series

SANY HEAVY EQUIPMENT CO., LTD.

Product basic information of

02 System principle of wide-body truck

04 Analysis of typical failures

01 Product basic information

1.1 Competitive products

1. Larger capacity, higher efficiency

1.1 Marketing research

Rated loading capacity

2 SNTONGLY TL875(B) 2080 24.23% 45% 55%

Pain points of wide-body truck industry include high failures, low

• Plate spring breakage

• U-shape bolt breakage

• Poor sealing of driving cab

• Frequent electrical failures

• Outdated control system

1.2 Product composition Model SANY SKT90S

Curb weight (kg) 30000

Total weight (kg) 90000

Max. speed (km/h) 40

Engine WEICHAI WP12.460

Gearbox FAST 7DS200 (hydraulic retardar)

Axle (T) 19+35+35

Steering type (mm) Full hydraulic + emergency steering

Suspension structure Front hydro-pneumatic suspension + Rear

Electrical system 2-in-1 electrical control system

Frame assembly 450mm high riveted frame

1.2 Product composition

Main frame (380mm) Main frame (380mm) No subframe to prevent

4 Engine WP12G430E310 WP12G430E310 WP12G460E310

8 Gearbox 7DS200K 7DS180 7DS200 (after the speed Xi’an FC automatic

10 Rear axle 35T+35T (HANDE) 35T+35T (HANDE) 35T+35T (PENGXIANG) 8

1.2 Product composition

Electrical Compatible with

1 Power WP12G430E310 Flat pavement

5 E-4 steel wire tyre Gravel road

1 7 Tilter Back-lifting tilter Rock

2.1 Power system

In-line arrangement V-arrangement Horizontal arrangement Opposed arrangement

Top dead center

Top dead center

Displacement = area x stroke

2.1 Power system

2.1 Power system

Crank connecting rod

Cylinder head assembly Fuel system

Valve mechanism assembly Air inlet system

Gear system assembly Exhaust system

2.1.1 Suspension system

• Vibration decoupling+model analysis+intensity • Double-stage oil pump with large

2.1.2 Cooling system

Flowing water pipe

Flowing cylinder Low-temperature

Flowing engine oil Heater water return

2.1.2 Cooling system

Spring Thermostat Full-meshing of clutch

2.1.3 Fuel system

Refined High pressure Oil outlet

ECU cooler Tappet

品质改变世界 Quality Changes the World