Omm SKT90S - 014927

QUALITY CHANGES THE WORLD
Mining Wide-Body Dump Truck
SKT90S
Operation and Maintenance Manual

SKT90S Mining Wide-Body Dump Truck
Warning
Please read and abide by the safety precautions and operation instructions contained in this manual and on
machine labels. Otherwise, it will probably result in serious injuries, deaths, or property losses. Please preserve
this manual on the machine for easy reference.

Sany Group
Sany Heavy Equipment Co., Ltd.
No. 25, No. 16 Street, Kaifa Avenue, Economic and Technical Development Zone, Shenyang,
Liaoning, China
Postal code: 110027
http://www.sanyhe.com.cn
Tel.: 4008-808–318
Fax: 024-31808055
Due to continuous upgrade of technologies and products, the material and technical specifications are subject to
change without further notice. Copyright@2011. All copyrights are reserved by Sany Heavy Equipment Co., Ltd. .
Without the written consent from Sany Heavy Equipment Co., Ltd. it’s prohibited to duplicate, spread, sell, or
modify this manual.

Division of Responsibilities
Special Statements
Mining Wide-Body Dump Truck is a transportation equipment for transfer of materials, and it has been
extensively applied in surface mines and water conservancy & hydropower construction sites.
Sany will not be liable for any adverse consequence arising from the following conditions:
● Aftermaths resulting from failure in operating Mining Wide-Body Dump Truck correctly according to this
manual.
● Aftermaths resulting from unauthorized retrofitting or modification to the Mining Wide-Body Dump Truck.
● Damages or accidents of the machine arising from the failure to use Sany genuine parts or untested or
unauthorized parts or tools.
● Sany will not be liable for any machine malfunction or damage arising from the force majeure, including
natural disasters (earthquake and typhoon) and war.
It is impossible for SANY to foresee all dangers that might take place at the operation site, thus Mining
Wide-Body Dump Truck operators and customers shall attach great importance to safety problems.
In respect of Mining Wide-Body Dump Truck operation, different regions and local government departments
might have formulated stricter safety regulations. In case that this manual conflicts with these safety regulations,
the strictest safety regulations shall be observed.
Manufacturer Responsibilities of Sany
● Mining Wide-Body Dump Truck supplied is eligible in quality, and the accompanying documents are correct.
● Fulfill the after-service commitments and document all maintenance and repair woks conducted by the
after-service personnel.
● Train the operation and maintenance personnel of the machine on demand.
Responsibilities of Customer and Other Authorized Personnel
● Only after relevant personnel have received systematic training and fully understood contents of Mining
Wide-Body Dump Truck parts catalogue and operation & maintenance manual, can they operate and
maintain Mining Wide-Body Dump Truck.
● Make sure that personnel in charge of Mining Wide-Body Dump Truck operation and maintenance are
qualified for this work, and that they know their respective responsibilities.
● Periodically check the safety awareness of related personnel during the working.
● In case of any fault that influences the safety, stop operating Mining Wide-Body Dump Truck in no time.
● SANY service workers have the right to perform safety inspection to Mining Wide-Body Dump Truck if
necessary.
● Aside from those inspections provided by SANY, perform inspection to Mining Wide-Body Dump Truck
according to relevant laws and regulations of the countries and regions where the Mining Wide-Body Dump
Truck is applied.
● Make sure that Mining Wide-Body Dump Truck is maintained and repaired in time.
● Do well the Mining Wide-Body Dump Truck application planning meticulously and spontaneously.

Responsibilities of Working Staff
● In case of any exceptional situation that might lead to Mining Wide-Body Dump Truck’s abnormal operation
or potential dangers, make a report to the supervisor in time. If possible, correct the exceptional situation in
time.
● All personnel around Mining Wide-Body Dump Truck shall observe all warning signals and keep a wary eye
on safety.
● All working members shall understand the contents and procedure of the operation task.
● Pay attention to observe the presence of dangers and timely report the dangers to the operation personnel and
signaling personnel, including high voltage power lines, irrelevant personnel, and rough ground.
Responsibilities of Management Personnel
● Ensure that the operation personnel are well trained, fully understand the contents of the Operation and
Maintenance Manual provided by Sany, and are good in health, otherwise they are disallowed for operations
of the Mining Wide-Body Dump Truck.
● Ensure that the operators have good judgment capability, cooperation awareness, and mentality. Otherwise,
it’s prohibited to operate or maintain the Mining Wide-Body Dump Truck.
● Ensure that the signalers embody the good visual and aural judgment capability, master the standard
instruction signals, and issue the clear and correct signals. In addition, they shall be well experienced to judge
the danger factors and inform the operators for timely avoidance.
● Ensure that the assistance personnel can correctly determine the model and working condition of the vehicle
and select appropriate Mining Wide-Body Dump Truck.
● Designate corresponding safety responsibility to each operation member and demand the operation members
to report unsafe factors to the supervisor.

SKT90S Mining Wide-Body Dump Truck Contents
Contents
1. Foreword ....................................................................................................................................................... 1-3
1.1 Overview ............................................................................................................................................. 1-3
1.2 Safety Information............................................................................................................................... 1-5
1.3 Page description .................................................................................................................................. 1-8
1.4 Operation Regulation .......................................................................................................................... 1-8
1.5 Run-in of New Machine ...................................................................................................................... 1-9
1.6 Product Information ............................................................................................................................ 1-9
1.6.1 ........................................................................................................................................................ 1-9
1.6.2 Machine Serial Number Nameplate ........................................................................................ 1-9
1.6.3 Engine Serial Number Nameplate ........................................................................................ 1-11
1.6.4 Location of Display Screen................................................................................................... 1-12
1.6.4 Machine Serial Number and Dealer ...................................................................................... 1-12
2. Safety.............................................................................................................................................................. 2-5
2.1 Safety Labels ....................................................................................................................................... 2-5
2.1.2 Locations of Safety Labels...................................................................................................... 2-6
2.1.3 Safety Labels .......................................................................................................................... 2-7
2.2 General Precautions........................................................................................................................... 2-11
2.2.1 Safety Rules .......................................................................................................................... 2-11
2.2.2 Upon Detection of Abnormality............................................................................................ 2-11
2.2.3 Working Clothing and Protective Articles for Operation Personnel ..................................... 2-11
2.2.4 Fire Extinguisher and First-Aid Kit ...................................................................................... 2-13
2.2.5 Safety Equipment .................................................................................................................. 2-13
2.2.6 Keeping Machine Clean........................................................................................................ 2-13
2.2.7 Keeping Cab Clean ............................................................................................................... 2-14
2.2.8 Locking before Leaving Driver Seat..................................................................................... 2-14
2.2.9 Handrails and Ladder ............................................................................................................ 2-14
2.2.10 Guard against Scalding ......................................................................................................... 2-15
2.2.10.1 Hot Coolant ......................................................................................................................... 2-15
2.2.10.2 Hot Oil ................................................................................................................................. 2-15
2.2.11 Fire and Explosion Prevention .............................................................................................. 2-16
2.2.11.1 Fire caused by fuel or oil ..................................................................................................... 2-16
2.2.11.2 Fire caused by accumulated inflammables .......................................................................... 2-17
2.2.11.3 Fire caused by electric wires ............................................................................................... 2-17
2.2.11.4 Fire caused by hydraulic pipeline ........................................................................................ 2-17
2.2.11.5 Fire caused by lighting device ............................................................................................. 2-17
2.2.12 Action in event of Fire .......................................................................................................... 2-18
2.2.13 Windscreen Washing Fluid ................................................................................................... 2-18
Operation and Maintenance Manual I

Contents SKT90S Mining Wide-Body Dump Truck
2.2.14 Precautions for Installation of Accessories and Optional Parts............................................. 2-18

2.2.15 Cab Window Glasses ............................................................................................................ 2-18
2.2.16 Non-Authorized Modifications ............................................................................................. 2-18
2.2.17 Safety of Working Site .......................................................................................................... 2-19
2.2.18 Working on Soft Ground ....................................................................................................... 2-19
2.2.19 Keeping Away from High Voltage Cables ............................................................................ 2-20
2.2.20 Precautions for Ventilation of Exhaust Gas .......................................................................... 2-21
2.2.21 Emergency Exit of Cab ......................................................................................................... 2-21
2.2.22 Guarantee of Good Visibility ................................................................................................ 2-22
2.2.23 Guard against Harms of Asbestos Dust................................................................................. 2-22
2.3 Operation Precautions ....................................................................................................................... 2-23
2.3.1 Start of Engine ...................................................................................................................... 2-23
2.3.1.1 Get-on/Get-off safety........................................................................................................... 2-23
2.3.1.2 Adjustment of seat ............................................................................................................... 2-23
2.3.1.3 Fastening of seat belt ........................................................................................................... 2-24
2.3.1.4 Checking before start of engine ........................................................................................... 2-24
2.3.1.5 Precautions for start of engine ............................................................................................. 2-25
2.3.1.6 Start of engine in cold regions ............................................................................................. 2-25
2.3.1.7 Start of engine by auxiliary cable ........................................................................................ 2-26
2.3.1.8 After start of engine ............................................................................................................. 2-27
2.3.2 Operations ............................................................................................................................. 2-27
2.3.2.1 Checking before operations ................................................................................................. 2-27
2.3.2.2 Precautions before operations.............................................................................................. 2-27
2.3.2.3 Precautions during driving................................................................................................... 2-28
2.3.2.4 Precautions for driving on slopes ........................................................................................ 2-29
2.3.2.5 Precautions when operating lifting bucket .......................................................................... 2-29
2.3.2.6 Precautions on snowy/icy ground ........................................................................................ 2-30
2.3.2.7 Parking of machine .............................................................................................................. 2-30
2.3.2.8 Stop of machine ................................................................................................................... 2-31
2.3.3 Transport ............................................................................................................................... 2-32
2.3.3.1 ............................................................................................................................................. 2-32
2.3.3.2 Starting transportation ......................................................................................................... 2-32
2.3.3.3 Elevating transportation....................................................................................................... 2-33
2.3.4 Battery................................................................................................................................... 2-33
2.3.5 Towing .................................................................................................................................. 2-34
2.4 Maintenance Precautions................................................................................................................... 2-35
2.4.1 Warning Label....................................................................................................................... 2-35
2.4.2 Preparations of Working Field .............................................................................................. 2-35
2.4.3 Precautions before Maintenances ......................................................................................... 2-36
2.4.4 Self-Preparations................................................................................................................... 2-37
2.4.5 Stop of Engine before Maintenances .................................................................................... 2-38
2.4.6 Maintenance during Running of Engine ............................................................................... 2-38
2.4.7 Appropriate Tools ................................................................................................................. 2-39
2.4.8 Handling of Suspension Cylinder ......................................................................................... 2-39
II Operation and Maintenance Manual

2.4.9 Working beneath Machine .................................................................................................... 2-39

2.4.10 Working in Noisy Environment ............................................................................................ 2-39
2.4.11 Precautions for Use of Compressed Air ................................................................................ 2-40
2.4.12 Precautions for Use of Hammer ............................................................................................ 2-40
2.4.13 Welding Operation ................................................................................................................ 2-40
2.4.14 Precautions for High Pressure Oil......................................................................................... 2-41
2.4.15 Operation Safety of High Pressure Hoses ............................................................................. 2-42
2.4.16 Guard against Hot Cooling System....................................................................................... 2-42
2.4.17 Maintenances of A/C ............................................................................................................ 2-43
2.4.18 Precautions for High Voltage ................................................................................................ 2-43
2.4.19 Accumulator ......................................................................................................................... 2-44
2.4.20 Guard against Fire and Explosion Dangers........................................................................... 2-44
2.4.21 Periodical Replacement of Critical Safety Parts ................................................................... 2-45
2.4.22 Maintenances ........................................................................................................................ 2-45
2.4.23 Correct Disposal of Wastes ................................................................................................... 2-46
2.5 Precautions for Tires.......................................................................................................................... 2-47
2.5.1 Handling of Tires .................................................................................................................. 2-47
2.5.2 Precautions for Storage of Tires............................................................................................ 2-48
2.6 Conclusion......................................................................................................................................... 2-49
3 System Functions .......................................................................................................................................... 3-5
3.1 General Diagram of Machine .............................................................................................................. 3-5
3.2 Control Devices ................................................................................................................................... 3-6
3.3 Indicator Lamps................................................................................................................................... 3-7
3.4 Instruments ........................................................................................................................................ 3-12
3.5 Display Screen................................................................................................................................... 3-14
3.6 Switches ............................................................................................................................................ 3-16
3.6.1 ...................................................................................................................................................... 3-16
3.6.2 Key switch ............................................................................................................................ 3-17
3.7.2 Combination Switch ............................................................................................................. 3-17
3.6.4 Warning Lamp Switch .......................................................................................................... 3-18
3.6.5 Electrical-air horn switch ...................................................................................................... 3-18
3.6.6 Rear Lamp Switch ................................................................................................................ 3-19
3.6.7 Front Fog Lamp Switch ........................................................................................................ 3-19
3.6.8 Headlamp switch................................................................................................................... 3-19
3.6.9 Exhaust brake switch ............................................................................................................ 3-19
3.6.10 Fan emergency switch........................................................................................................... 3-20
3.6.11 Inter-axle discrepancy switch ............................................................................................... 3-20
3.6.12 Fault diagnosis switch ........................................................................................................... 3-20
3.6.13 Side wiper switch .................................................................................................................. 3-20
3.6.14 Elevating switch.................................................................................................................... 3-21
3.6.15 Elevating control handle switch ............................................................................................ 3-21
3.6.16 Holding switch ...................................................................................................................... 3-21
3.6.17 Forced landing switch ........................................................................................................... 3-21
3.7 Control Levers and Pedals................................................................................................................. 3-22
Operation and Maintenance Manual III

3.7.1 ...................................................................................................................................................... 3-22

3.7.2 Gearshift Lever ..................................................................................................................... 3-23
3.7.3 Accelerator Pedal .................................................................................................................. 3-24
3.7.4 Clutch pedal .......................................................................................................................... 3-24
3.7.5 Service Brake Pedal .............................................................................................................. 3-24
3.8 Cigarette Lighter ............................................................................................................................... 3-25
3.9 Horn................................................................................................................................................... 3-25
3.10 Steering Wheel .................................................................................................................................. 3-25
3.11 Fuses .................................................................................................................................................. 3-27
3.12 Central control screen........................................................................................................................ 3-29
3.12.1 Central control screen ........................................................................................................... 3-29
3.12.2 Operation instructions ........................................................................................................... 3-29
3.13 A/C System ....................................................................................................................................... 3-35
3.13.1 A/C Control Panel................................................................................................................. 3-35
3.13.2 Operation Instructions........................................................................................................... 3-35
3.13.3 Precautions for Use of A/C ................................................................................................... 3-36
3.14 Cab Door Windows ........................................................................................................................... 3-37
3.14.1 Opening of Cab Door Windows ............................................................................................ 3-37
3.14.2 Closing of Cab Door Windows ............................................................................................. 3-37
3.15 Cab Emergency Exit .......................................................................................................................... 3-37
3.16 Door Locks ........................................................................................................................................ 3-38
3.17 Cup Holder ........................................................................................................................................ 3-38
3.18 Safety support.................................................................................................................................... 3-38
4 Operations ..................................................................................................................................................... 4-4
4.1 Before Start of Engine ......................................................................................................................... 4-4
4.1.1 Walk-around Checking ........................................................................................................... 4-4
4.1.2 Checking before Start ............................................................................................................. 4-6
4.1.2.1 ............................................................................................................................................... 4-6
4.1.2.2 Checking of coolant level and adding of coolant .................................................................. 4-6
4.1.2.3 Checking of differential pressure indicator warning lamp .................................................... 4-7
4.1.2.4 Checking of oil level in engine oil and adding of oil............................................................. 4-8
4.1.2.5 Checking of transmission oil level and adding and drainage of oil ....................................... 4-9
4.1.2.6 Inspection of oil level on drive axle and refueling ................................................................ 4-9
4.1.2.7 Checking of hydraulic oil tank level and adding of oil........................................................ 4-10
4.1.2.8 Checking of fuel tank level, adding of fuel, and water drainage of fuel-water separator .... 4-10
4.1.2.9 Checking of indicator lamps, warning lamps, switches, and instruments ........................... 4-12
4.1.2.10 Checking of braking performance ....................................................................................... 4-12
4.1.2.11 Checking of accumulator nitrogen pressure ........................................................................ 4-12
4.1.2.12 Checking of hydraulic system leakage and hose wear ........................................................ 4-13
4.1.2.13 Checking of reversing alarm................................................................................................ 4-13
4.1.2.14 Checking of wires ................................................................................................................ 4-13
4.1.2.15 Checking and tightening of wheel rim nuts ......................................................................... 4-13
4.1.2.16 Checking of tire inflation pressure ...................................................................................... 4-13
4.1.3 Adjustment of seat belt ......................................................................................................... 4-14
IV Operation and Maintenance Manual

4.1.3.1 Adjustment of driver seat .................................................................................................... 4-14

4.1.3.2 Adjustment of seat belt ......................................................................................................... 4-14
4.1.3.3 Adjustment of steering wheel inclination ............................................................................ 4-15
4.1.3.4 Adjustment of mirrors ......................................................................................................... 4-16
4.1.4 Operations before Start of Engine......................................................................................... 4-17
4.2 Start of Engine................................................................................................................................... 4-18
4.2.1 Warm-up Operation .............................................................................................................. 4-18
4.2.2 Normal Start.......................................................................................................................... 4-19
4.2.3 Start of Engine in Winter ...................................................................................................... 4-20
4.3 Stop of Engine ................................................................................................................................... 4-22
4.4 Checking after Stop of Engine .......................................................................................................... 4-22
4.5 Operations of Machine ...................................................................................................................... 4-23
4.5.1 Forward Movement of Machine ........................................................................................... 4-23
4.5.2 Backward Movement of Machine ......................................................................................... 4-24
4.5.3 Stop of Machine .................................................................................................................... 4-25
4.5.3.1 Normal stop ......................................................................................................................... 4-25
4.5.3.2 Emergency stop ................................................................................................................... 4-25
4.6 Operation of gear position selection and shift ................................................................................... 4-26
4.7 Clutch ................................................................................................................................................ 4-26
4.8 Retarder Mode Operations ................................................................................................................ 4-27
4.8.1 ...................................................................................................................................................... 4-27
4.8.1 Retarder Operations .............................................................................................................. 4-27
4.8.3 Main brake operation ............................................................................................................ 4-28
4.9 Steering of Machine .......................................................................................................................... 4-28
4.10 Loading operation ............................................................................................................................. 4-28
4.11 Dumping operation............................................................................................................................ 4-29
4.13 Parking of Machine ........................................................................................................................... 4-31
4.14 Checking of Machine after Daily Operations .................................................................................... 4-32
4.15 Use of the tire .................................................................................................................................... 4-33
4.15.1 Precautions for Handling of Tires ......................................................................................... 4-33
4.15.2 Rated Ton-Kilometer/Hour (T.K.P.H.) .................................................................................. 4-33
4.15.3 Precautions for Long Distance Driving ................................................................................ 4-34
4.16 Determination and Maintenance of Driving Roads ........................................................................... 4-34
4.16.1 .................................................................................................................................................... 4-34
4.16.2 Determination of Driving Roads........................................................................................... 4-35
4.16.2 Maintenances of Driving Roads............................................................................................ 4-35
4.17 Transport ........................................................................................................................................... 4-36
4.17.1 Precautions for Transport ...................................................................................................... 4-36
4.17.2 Transport Procedure .............................................................................................................. 4-36
4.18 Operations in Winter ......................................................................................................................... 4-37
4.18.1 Low Temperature Precautions .............................................................................................. 4-37
4.18.1.1 ............................................................................................................................................. 4-37
4.18.1.2 Fuel and lubricating oils ...................................................................................................... 4-37
Operation and Maintenance Manual V

4.18.1.3 Coolant ................................................................................................................................ 4-37

4.18.1.4 Battery ................................................................................................................................. 4-37
4.18.2 Precautions at Completion of Operations ............................................................................. 4-39
4.18.3 After Winter .......................................................................................................................... 4-39
4.19 Long-Term Storage............................................................................................................................ 4-40
4.19.1 Before Storage ...................................................................................................................... 4-40
4.19.2 During Storage ...................................................................................................................... 4-40
4.19.3 After Storage......................................................................................................................... 4-41
4.19.4 Precautions after Long-Term Storage and before Driving .................................................... 4-41
5 Maintenances ................................................................................................................................................ 5-5
5.1 Safety Instructions ............................................................................................................................... 5-5
5.1.1 Overview................................................................................................................................. 5-5
5.1.2 Maintenance Personnel ........................................................................................................... 5-5
5.1.3 Risks during Maintenances ..................................................................................................... 5-5
5.1.4 Precautions before Maintenances ........................................................................................... 5-7
5.1.5 Precautions during Maintenances ........................................................................................... 5-7
5.2 Maintenances....................................................................................................................................... 5-9
5.2.1 Maintenance Overview ........................................................................................................... 5-9
5.2.2 Handling of Oil, Fuel, and Coolant and Analysis of Oil Quality ............................................ 5-9
5.2.2.1 Oils ........................................................................................................................................ 5-9
5.2.2.2 Hydraulic oil ........................................................................................................................ 5-10
5.2.2.3 Fuel ...................................................................................................................................... 5-12
5.2.2.4 Coolant in cooling system ................................................................................................... 5-12
5.2.2.5 Lubricating grease ............................................................................................................... 5-13
5.2.2.6 Storage of engine oil and fuel .............................................................................................. 5-14
5.2.2.7 Filter elements ..................................................................................................................... 5-14
5.2.2.8 Maintenances of electric system .......................................................................................... 5-15
5.3 Lubrication ........................................................................................................................................ 5-16
5.3.1 Lubricating point bitmap ...................................................................................................... 5-16
5.3.2 Lubricant ............................................................................................................................... 5-16
5.4 Wearing Parts .................................................................................................................................... 5-17
5.4.1 Table of Wearing Parts .......................................................................................................... 5-17
5.5 Recommended Fuel, Coolant, and Oils ............................................................................................. 5-18
5.5.1 ...................................................................................................................................................... 5-18
5.5.2 Selection of Lubricating Oil/Grease Materials ..................................................................... 5-20
5.5.3 Maintenance Capacity Table ................................................................................................. 5-21
5.6 Technical Specification of Tightening Torques ................................................................................. 5-23
5.7 Critical Safety Parts ........................................................................................................................... 5-29
5.8 Maintenance Procedures.................................................................................................................... 5-30
5.8.1 Maintenance of initial 2000km & 200h ................................................................................ 5-30
5.8.2 When Necessary ................................................................................................................... 5-34
5.8.2.1 Internal cleaning of cooling system ..................................................................................... 5-34
5.8.2.2 Checking of front suspension cylinder length and oil level................................................. 5-35
5.8.3 Checking before Start ........................................................................................................... 5-37
VI Operation and Maintenance Manual

5.8.4 Checking and Maintenances at Interval of 10h (Daily) ........................................................ 5-40

5.8.4.1 Inspection of engine ............................................................................................................ 5-40
5.8.4.2 Inspection of fuel system ..................................................................................................... 5-41
5.8.4.3 Inspection of cooling system ............................................................................................... 5-41
5.8.4.4 Inspection of air inlet system ............................................................................................... 5-42
5.8.4.5 Inspection of exhaust system ............................................................................................... 5-44
5.8.4.6 Inspection of drive system ................................................................................................... 5-44
5.8.4.7 Inspection of hydraulic system ............................................................................................ 5-45
5.8.4.8 Inspection of brake system .................................................................................................. 5-45
5.8.4.9 Inspection of suspension system.......................................................................................... 5-47
5.8.5 Maintenance of every 2500km&250h .................................................................................. 5-47
5.8.6 Maintenances at Interval of 500h.......................................................................................... 5-48
5.8.6.1 Replacement of engine oil and engine oil filter ................................................................... 5-48
5.8.6.2 Replacement of fuel filter and fuel-water separator filter element ...................................... 5-49
5.8.6.3 Maintenance of oil-gas separator ......................................................................................... 5-51
5.8.6.4 Maintenance of air filter ...................................................................................................... 5-51
5.8.7 Maintenance of every 10000km&1000h .............................................................................. 5-51
5.8.7.1 Checking of hydraulic system ............................................................................................. 5-51
5.8.8 Maintenance of every 20000km & 2000h............................................................................. 5-53
5.8.8.1 Cleaning of fuel tank ........................................................................................................... 5-53
5.8.9.1 Replacement of hydraulic oil ............................................................................................... 5-59
5.8.10 Maintenances at Interval of 4,000h....................................................................................... 5-60
5.8.10.1 Cleaning of radiator ............................................................................................................. 5-60
5.8.10.3 Inspection of abrasion of brake drum .................................................................................. 5-60
5.8.10.4 Change of hydraulic oil for elevation of driving cab ........................................................... 5-61
6 Malfunction Diagnosis .................................................................................................................................. 6-5
6.1 Preparations before Malfunction Diagnosis ........................................................................................ 6-5
6.1.1 Precautions for Malfunction Diagnosis .................................................................................. 6-5
6.1.2 Checking before Malfunction Diagnosis ................................................................................ 6-5
6.1.3 Working Procedure during Malfunction Diagnosis ................................................................ 6-8
6.1.4 Precautions for Malfunction Diagnosis of Electric Circuits ................................................. 6-10
6.1.5 Precautions for Handling of Hydraulic Parts ........................................................................ 6-10
6.2 Engine Malfunctions ......................................................................................................................... 6-12
6.2.1 Engine Malfunction Diagnosis Table.................................................................................... 6-12
6.2.1.1 ............................................................................................................................................. 6-12
6.2.1.2 Engine Start Failure ............................................................................................................. 6-12
6.2.1.3 Low Power .......................................................................................................................... 6-12
Operation and Maintenance Manual VII

6.2.1.4 Stop of Engine Shortly after Start........................................................................................ 6-13

6.2.1.5 High Fuel Consumption ...................................................................................................... 6-13
6.2.1.6 Black Exhaust Gas............................................................................................................... 6-14
6.2.1.7 White or Blue Exhaust Gas ................................................................................................. 6-14
6.2.1.8 Deposit of Engine Oil at Air Inlet Port and Air Inlet Pipe of Turbocharger ........................ 6-15
6.2.1.9 Unstable Speed .................................................................................................................... 6-15
6.2.1.10 Low Engine Oil Pressure ..................................................................................................... 6-15
6.2.1.11 High Water Temperature ...................................................................................................... 6-16
6.2.1.12 Fast Wear of Parts ................................................................................................................ 6-16
6.2.1.13 Excessive Noise ................................................................................................................... 6-17
6.2.1.14 Working Failure of Starter Motor ........................................................................................ 6-17
6.2.1.15 Weak Starter Motor ............................................................................................................. 6-17
6.2.1.16 Complete Power Generation Failure of Alternator .............................................................. 6-18
6.2.1.17 Insufficient charging of alternator ....................................................................................... 6-18
6.2.1.18 Unstable Charging Current .................................................................................................. 6-18
6.2.1.19 Excessive Charging of Alternator ........................................................................................ 6-19
6.2.1.20 Abnormal Sound of Alternator ............................................................................................ 6-19
6.2.2 High Water Temperature ....................................................................................................... 6-20
6.3 Malfunctions of Electric System ....................................................................................................... 6-21
6.3.1 Malfunction Diagnosis of Electric System ........................................................................... 6-21
6.3.2 Monitoring Display ............................................................................................................... 6-22
6.3.2.2 Engine trouble code ............................................................................................................. 6-22
6.3.2.3 Transmission trouble code ................................................................................................... 6-30
6.3.3 Battery................................................................................................................................... 6-34
6.3.3.1 ............................................................................................................................................. 6-34
6.3.3.2 Disassembling and installation of battery ............................................................................ 6-34
6.3.3.3 Charging of battery .............................................................................................................. 6-35
6.3.4 Start of Engine by Auxiliary Cable ....................................................................................... 6-36
6.3.4.1 Connection and disconnection of auxiliary cable ................................................................ 6-36
6.3.4.2 Connection of auxiliary cables ............................................................................................ 6-37
6.3.4.3 Start of engine...................................................................................................................... 6-37
6.3.4.4 Disconnection of auxiliary cables........................................................................................ 6-37
6.4 Malfunctions of Hydraulic System.................................................................................................... 6-38
6.4.1 Malfunction Diagnosis of Hydraulic System ........................................................................ 6-38
6.4.2 List of lifting system faults ................................................................................................... 6-39
6.4.3 Brake system malfunction table ............................................................................................ 6-40
6.5 Other Common Malfunctions ............................................................................................................ 6-42
7 Technical Specification ................................................................................................................................. 7-3
7.1 Technical Specification ....................................................................................................................... 7-3
8. Maintenance .................................................................................................................................................. 8-5
8.1 Suspension........................................................................................................................................... 8-5
8.1.1 Front suspension assembly ..................................................................................................... 8-5
8.1.1.1 ............................................................................................................................................... 8-5
8.1.1.2 Front suspension cylinder ...................................................................................................... 8-7
VIII Operation and Maintenance Manual

8.1.1.3 Thrust Bars .......................................................................................................................... 8-13

8.1.2 Rear suspension assembly .................................................................................................... 8-19
8.1.2.1 Rear suspension assembl ..................................................................................................... 8-19
8.1.2.2 Leaf Spring Assembly ......................................................................................................... 8-22
8.1.2.3 Balance Shaft Assembly ...................................................................................................... 8-23
8.1.3 Repairs and Maintenances .................................................................................................... 8-24
8.1.3.1 Tightening torque ................................................................................................................ 8-24
8.1.3.2 Run-in of New Vehicle ........................................................................................................ 8-25
8.1.3.3 Malfunction Diagnosis ........................................................................................................ 8-25
8.2 Cab accessories ................................................................................................................................. 8-27
8.2.1 ...................................................................................................................................................... 8-27
8.2.2 Disassembling and Installation ............................................................................................. 8-28
8.2.3 Air conditioning pipeline installation ................................................................................... 8-30
8.2.4 SKT90 Marking Layout ........................................................................................................ 8-41
8.3 Vehicle frame..................................................................................................................................... 8-43
8.4 Cargo Compartment and Installation................................................................................................. 8-46
8.5 Hydraulic System .............................................................................................................................. 8-50
8.5.1 Replace hydraulic oil ............................................................................................................ 8-50
8.5.2 Replacement of Steering Filter Element ............................................................................... 8-51
8.5.3 Replacement of Lifting Oil Return Filter Element ............................................................... 8-51
8.5.4 Replacement of Ventilation Valve Filter Element ................................................................. 8-52
8.5.5 Checking of Hydraulic System Pressure............................................................................... 8-52
8.5.6 Drainage of Water from Air Reservoir .................................................................................. 8-52
8.5.7 Replacement of Dryer Core .................................................................................................. 8-53
8.5.8 Checking of Pedal Free Travel.............................................................................................. 8-53
8.5.9 Checking of Brake Slave Cylinder ....................................................................................... 8-53
8.6 Power system..................................................................................................................................... 8-54
8.6.1 Engine and Installation ......................................................................................................... 8-54
8.6.2 Radiator and Pipeline Installation ......................................................................................... 8-59
8.6.2.1 Radiator Assembly Installation............................................................................................ 8-59
8.6.2.2 Expansion Tank Assembly Installation ................................................................................ 8-62
8.6.3 Air Filter and Pipeline Installation........................................................................................ 8-64
8.6.4 Exhaust System ..................................................................................................................... 8-68
8.6.5 Fuel tank and pipe installation .............................................................................................. 8-71
8.6.5.1 Fuel tank and pipe installation ............................................................................................. 8-71
8.6.5.2 Fuel Pipeline Installation ..................................................................................................... 8-73
8.7 Electric System .................................................................................................................................. 8-75
8.8 Drive system ...................................................................................................................................... 8-76
8.8.1 ...................................................................................................................................................... 8-76
8.8.2 Clutch Installation Assembly ................................................................................................ 8-77
8.8.3 Transmission Assembly Installation ..................................................................................... 8-84
8.8.3.1 ............................................................................................................................................. 8-84
8.8.3.2 Transmission ........................................................................................................................ 8-86
8.8.3.3 Transmission Rear Suspension ............................................................................................ 8-89
Operation and Maintenance Manual IX

8.8.3.4 Gear Selector/Gearshift Control Mechanism....................................................................... 8-91

8.8.4 Front Axle Installation Assembly.......................................................................................... 8-93
8.8.5 Intermediate Axle Installation Assembly .............................................................................. 8-95
8.8.6 Rear Axle Installation Assembly........................................................................................... 8-97
X Operation and Maintenance Manual

Foreword SKT90S Mining Wide-Body Dump Truck
Foreword
1. Foreword ....................................................................................................................................................... 1-3
1.1 Overview ............................................................................................................................................. 1-3
1.2 Safety Information............................................................................................................................... 1-5
1.3 Page description .................................................................................................................................. 1-8
1.4 Operation Regulation .......................................................................................................................... 1-8
1.5 Run-in of New Machine ...................................................................................................................... 1-9
1.6 Product Information ............................................................................................................................ 1-9
1.6.1 ........................................................................................................................................................ 1-9
1.6.2 Machine Serial Number Nameplate ........................................................................................ 1-9
1.6.3 Engine Serial Number Nameplate ........................................................................................ 1-11
1.6.4 Location of Display Screen................................................................................................... 1-12
1.6.4 Machine Serial Number and Dealer ...................................................................................... 1-12
Operation and Maintenance Manual 1-1

SKT90S Mining Wide-Body Dump Truck Foreword
Warning
1-2 Operation and Maintenance Manual

Safety SKT90S Mining Wide-Body Dump Truck
1. Foreword
1.1 Overview
This manual describes the operation details and
checking and maintenance methods to be followed for
this machine, in order to ensure the operation safety of
the machine. Many accidents are caused by the failure
to abide by the basic operation and maintenance safety
regulations.
Only the qualified and experienced operation personnel
with official certificate (depending on local laws) are
allowed to operate this machine.
Always operate the machine as per the relevant
national, provincial, and municipal laws and
regulations. The operation safety information and
instructions contained in this manual are merely
recommendations and warnings. Before the operations
and maintenances, read, understand, and abide by all
precautions and warnings contained in this manual and
on the machine. The failure to do so will result in
serious injuries or deaths.
It’s impossible for Sany to forecast all conditions
probably related to potential dangers during the
operations of machine. Therefore, the safety
information contained in this manual and on the
machine can’t include all possible safety precautions.
During the operations, checking, or maintenances under
the condition not covered by this manual, you are
responsible for taking necessary measures to ensure
safety. The uses or operations prohibited by this manual
are strictly prohibited. The improper operations and
maintenances of the machine are really dangerous and
will result in serious injuries or deaths.
At the resale of this machine, ensure to hand over this
manual to the new user along the machine, in order to
ease the reference of the relevant personnel.
If this manual is lost or damaged, please immediately
contact a Sany dealer and notify the model name and
series number of machine to ease the arrangement of
replacement.
The instructions, values, and figures contained in this
manual are prepared based on the latest data available

at the time of publication. The continuous design

improvements of this machine will reflect some
changes not included in this manual. For the latest
information of your machine or the questions related to
the information in this manual, please contact Sany or
Sany’s dealer.
● The numbers in the figures correspond to the
numbers in the ( ) in the main body.
● (for instance:) 1 →⑴
The machine supplied by Sany conforms to all

application specifications and standards of your
country. The machine purchased from another country
may lack of some safety devices and technical
requirements required for the operations in your
country. If you have any question whether the machine
conforms to the operation standards and specifications
of your country, please contact Sany or Sany’s dealer
before use of machine.

1.2 Safety Information

To help your safe operations of machine, this manual
describes the safety warnings and labels fixed on the
machine, in order to provide the descriptions related to
potential dangers and the methods for avoidance of
such dangers.
Before the operations and maintenances of the
machine, the user and after-service personnel must get
familiar with all warning signs on the machine, strictly
abide by the safety rules and recommendations in this
manual, and take safety precaution and handling
measures to minimize the risks of personal injury,
machine damage due to improper repairs, and the risks
due to unsafe factors.
1) Signal language
It’s used to notify you of the potential
dangers that may result in personal injury
or damage. It combines with symbol
characters to indicate the potential level of
danger.
It means that the violation will

Danger
lead to the consequence of death
or serious injuries.
It means that the violation may
Warning
lead to the potential
consequence of death or serious
injuries.
It means that the violation may
Caution
lead to the potential
consequence of low or medium
level injuries. It can also be
used to guard against the
relevant unsafe operation
applications that will robably
result in personal injury,
machine damage, and
environment harms.
2) Safety information cases for use of signal

language

Warning
No overload! The overload or brutal loading will
seriously impair t e lives of parts and vehicle.
3) Other signal language

In addition to above-mentioned signal language, the
following signal languages are used to describe the
items to be followed for protection of machine or
provide the usable information to you.
Note It’s used to indicate the measures that must be
taken to prevent reducing the life of machine.
Remarks It provides very useful information.
4) Safety nameplates
The safety nameplates are fixed on the machine to
notify the field operator and maintenance personnel of
the potential dangers during the operations and
maintenances of the machine.
The “text safety nameplate” and “graphic safety
nameplate” are used on this machine to indicate the
safety measures.
a. Example of text safety nameplate
Figure 1.2-1
b. Graphic safety nameplate
The graphic safety nameplate uses graphics to indicate
the danger level equivalent to the signal language, in
order for the operator or maintenance personnel to
understand the type and level of the dangers at any
time.
Figure 1.2-2

It’s impossible for Sany Heavy Equipment Co., Ltd. to

forecast all kinds of potential dangers probably present
during operations and maintenances. Therefore, the
safety information contained in this manual and on the
machine can’t include all safety measures that will
probably occur.
While using any method or action not explicitly
recommended or allowed by this manual, you are liable
to taking necessary measures to ensure safety.
In all cases, this machine can’t be used for the
application or operation prohibited by this manual.

1.3 Page description

The page numbers in this manual are of relative page
numbers.
Example: 2-10
Page 10 in Chapter 2
Chapter 2
1.4 Operation Regulation

Machine application
Mining Wide-Body Dump Truck’s main applications:
Loaded transport
Vehicle orientation
Front
In this manual, the vehicle orientation (front, rear, left, Right
and right) is determined on the basis of top view of

Left
vehicle by taking the forward traveling direction of Up
vehicle as front. Rear
Driver position
Down
Figure 1-3

1.5 Run-in of New Machine

Note: The machine supplied by Sany Heavy Equipment
Co., Ltd. passed the comprehensive adjustment and
testing before the delivery from the plant. However,
operating the machine under full-load before the run-in
of machine will seriously impair the performance and
shorten the life of machine.
Ensure to run in the machine within the first 100 hours
(based on the indication of the hourmeter).
Ensure to fully understand the contents of this manual
and notice the following items during the run-in of
machine:
● Idle the engine for 3~5min after start. During the
idling, do not shift gears or operate the accelerator
pedal. Then, increase the engine speed to
1,500rpm and operate slowly, till the coolant
temperature reaches approximately 60ºC.
● Avoid the high-speed operations under heavy
load.
● After the start of engine, avoid the sudden start,
sudden acceleration, and unnecessary sudden stop
and direction change.
1.6 Product Information

1.6.1
When the maintenance or ordering of replacement
parts is required, please notify Sany Heavy Equipment
Co., Ltd. of the following information.
1.6.2 Machine Serial Number Nameplate

It’s located on the right front of the frame.

Right front of the frame
Figure 1-4

1.6.3 Engine Serial Number Nameplate
Figure 1-5

1.6.4 Location of Display Screen

The location of display screen is shown in figure below.
Figure 1-6
1.6.4 Machine Serial Number and Dealer
Machine serial number
Engine serial number
Dealer name
Address
Service personnel
Tel./fax

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Safety
2. Safety.............................................................................................................................................................. 2-5
2.1 Safety Labels ....................................................................................................................................... 2-5
2.1.2 Locations of Safety Labels...................................................................................................... 2-6
2.1.3 Safety Labels .......................................................................................................................... 2-7
2.2 General Precautions........................................................................................................................... 2-11
2.2.1 Safety Rules .......................................................................................................................... 2-11
2.2.2 Upon Detection of Abnormality............................................................................................ 2-11
2.2.3 Working Clothing and Protective Articles for Operation Personnel ..................................... 2-11
2.2.4 Fire Extinguisher and First-Aid Kit ...................................................................................... 2-13
2.2.5 Safety Equipment .................................................................................................................. 2-13
2.2.6 Keeping Machine Clean........................................................................................................ 2-13
2.2.7 Keeping Cab Clean ............................................................................................................... 2-14
2.2.8 Locking before Leaving Driver Seat..................................................................................... 2-14
2.2.9 Handrails and Ladder ............................................................................................................ 2-14
2.2.10 Guard against Scalding ......................................................................................................... 2-15
2.2.10.1 Hot Coolant ......................................................................................................................... 2-15
2.2.10.2 Hot Oil ................................................................................................................................. 2-15
2.2.11 Fire and Explosion Prevention .............................................................................................. 2-16
2.2.11.1 Fire caused by fuel or oil ..................................................................................................... 2-16
2.2.11.2 Fire caused by accumulated inflammables .......................................................................... 2-17
2.2.11.3 Fire caused by electric wires ............................................................................................... 2-17
2.2.11.4 Fire caused by hydraulic pipeline ........................................................................................ 2-17
2.2.11.5 Fire caused by lighting device ............................................................................................. 2-17
2.2.12 Action in event of Fire .......................................................................................................... 2-18
2.2.13 Windscreen Washing Fluid ................................................................................................... 2-18
2.2.14 Precautions for Installation of Accessories and Optional Parts............................................. 2-18
2.2.15 Cab Window Glasses ............................................................................................................ 2-18
2.2.16 Non-Authorized Modifications ............................................................................................. 2-18
2.2.17 Safety of Working Site .......................................................................................................... 2-19
2.2.18 Working on Soft Ground ....................................................................................................... 2-19
2.2.19 Keeping Away from High Voltage Cables ............................................................................ 2-20
2.2.20 Precautions for Ventilation of Exhaust Gas .......................................................................... 2-21
2.2.21 Emergency Exit of Cab ......................................................................................................... 2-21
2.2.22 Guarantee of Good Visibility ................................................................................................ 2-22
2.2.23 Guard against Harms of Asbestos Dust................................................................................. 2-22

2.3.1 Start of Engine ...................................................................................................................... 2-23

2.3.1.1 Get-on/Get-off safety........................................................................................................... 2-23
2.3.1.2 Adjustment of seat ............................................................................................................... 2-23
2.3.1.3 Fastening of seat belt ........................................................................................................... 2-24
2.3.1.4 Checking before start of engine ........................................................................................... 2-24
2.3.1.5 Precautions for start of engine ............................................................................................. 2-25
2.3.1.6 Start of engine in cold regions ............................................................................................. 2-25
2.3.1.7 Start of engine by auxiliary cable ........................................................................................ 2-26
2.3.1.8 After start of engine ............................................................................................................. 2-27
2.3.2 Operations ............................................................................................................................. 2-27
2.3.2.1 Checking before operations ................................................................................................. 2-27
2.3.2.2 Precautions before operations.............................................................................................. 2-27
2.3.2.3 Precautions during driving................................................................................................... 2-28
2.3.2.4 Precautions for driving on slopes ........................................................................................ 2-29
2.3.2.5 Precautions when operating lifting bucket .......................................................................... 2-29
2.3.2.6 Precautions on snowy/icy ground ........................................................................................ 2-30
2.3.2.7 Parking of machine .............................................................................................................. 2-30
2.3.2.8 Stop of machine ................................................................................................................... 2-31
2.3.3 Transport ............................................................................................................................... 2-32
2.3.3.1 ............................................................................................................................................. 2-32
2.3.3.2 Starting transportation ......................................................................................................... 2-32
2.3.3.3 Elevating transportation....................................................................................................... 2-33
2.3.4 Battery................................................................................................................................... 2-33
2.3.5 Towing .................................................................................................................................. 2-34
2.4 Maintenance Precautions................................................................................................................... 2-35
2.4.1 Warning Label....................................................................................................................... 2-35
2.4.2 Preparations of Working Field .............................................................................................. 2-35
2.4.3 Precautions before Maintenances ......................................................................................... 2-36
2.4.4 Self-Preparations................................................................................................................... 2-37
2.4.5 Stop of Engine before Maintenances .................................................................................... 2-38
2.4.6 Maintenance during Running of Engine ............................................................................... 2-38
2.4.7 Appropriate Tools ................................................................................................................. 2-39
2.4.8 Handling of Suspension Cylinder ......................................................................................... 2-39
2.4.9 Working beneath Machine .................................................................................................... 2-39
2.4.10 Working in Noisy Environment ............................................................................................ 2-39
2.4.11 Precautions for Use of Compressed Air ................................................................................ 2-40
2.4.12 Precautions for Use of Hammer ............................................................................................ 2-40
2.4.13 Welding Operation ................................................................................................................ 2-40
2.4.14 Precautions for High Pressure Oil......................................................................................... 2-41
2.4.15 Operation Safety of High Pressure Hoses ............................................................................. 2-42
2.4.16 Guard against Hot Cooling System....................................................................................... 2-42
2.4.17 Maintenances of A/C ............................................................................................................ 2-43
2.4.18 Precautions for High Voltage ................................................................................................ 2-43
2.4.19 Accumulator ......................................................................................................................... 2-44

2.4.20 Guard against Fire and Explosion Dangers........................................................................... 2-44

2.4.21 Periodical Replacement of Critical Safety Parts ................................................................... 2-45
2.4.22 Maintenances ........................................................................................................................ 2-45
2.4.23 Correct Disposal of Wastes ................................................................................................... 2-46
2.5 Precautions for Tires.......................................................................................................................... 2-47
2.5.1 Handling of Tires .................................................................................................................. 2-47
2.5.2 Precautions for Storage of Tires............................................................................................ 2-48
2.6 Conclusion......................................................................................................................................... 2-49

SKT90S Mining Wide-Body Dump Truck Safety
Warning

2. Safety
2.1 Safety Labels

2.1.1
The following warning signs and safety labels are used
on this machine.
● Ensure to completely understand the correct
locations and contents of the labels.
● To guarantee the legible contents of the labels,
ensure the correct locations of labels and
frequently keep clean. Do not clean the labels by
any organic solvent or gasoline, otherwise the
labels or paint will fall off.
● There are also other labels besides warning signs
and safety labels. Treat these labels in same way.
● Any damaged, lost, or illegible label must be
replaced with new one.

2.1.2 Locations of Safety Labels
Battery compartment Tilter and Tire Front suspension cylinder
Cab Accumulator Left fender
Hydraulic oil tank Oil tank
Figure 2-1

2.1.3 Safety Labels
(1) Battery cable warning label

● This label is located on the top of battery box.
● As a strong current is generated during
welding, the electric units on the vehicle will
be damaged. Therefore, ensure to operate
strictly as per the warning label and repair
manual before welding.
Figure 2-2
(2) Alternator warning label
● This label is located on the battery box.
During the operations of vehicle, strictly
follow the contents of the warning and the
manual.
Figure 2-3
(3) Grounding label
● This label is located on the top of battery box.
● It indicates that the battery assembly has a
negative grounding system.
Figure 2-4

(4) Tire warning label

● For the safety of personnel and equipment,
please carefully read the repair manual before
inflation/deflation and repair of tires.
Figure 2-5
(5) Warning labels of tilter support
● The labels shall be located on left and right
sides of the tilter respectively.
● The vehicle shall be supported for safety
purpose during maintenance and inspection.
Figure 2-6
(6) Suspension cylinder warning label
● This label is located on the barrel walls of
front and rear suspension cylinders.
● For the safety of personnel and equipment,
please strictly follow the contents of the
warning and repair manual during repairs and
maintenances.
Figure 2-7

(7) Cargo compartment warning sticker

● The labels shall be located next to the right
door of driving cab, hydraulic oil tank and fuel
tank respectively. When the Cargo
compartment tilt angle decreases to zero,
personnel nearby shall be cautious and avoid
crush injury.
Figure 2-8
(8) No standing warning label
● This label is located on the right door of cab.
● During the traveling and movement of vehicle,
no person is allowed to stand outside of the
cab. Squat and hold the handrails to keep
balance, in order to prevent falloff due to
strong vibration.
Figure 2-9
(9) Accumulator warning label
● The label shall be located on the barrel wall of
energy accumulator.
● Before removing the valve and joint, please
ensure the internal pressure of the cylinder
shall be released, otherwise the sudden release
may cause casualties to working personnel and
damages to equipments. Please refer to the
Maintenance Manual for detailed instructions
of pressure release and nitrogen injection.
Figure 2-10

(10) Warning label of elevation of driving cab

● The label shall be located on the left fender.
● Please operate in accordance with warning
instructions to ensure the safety of working
personnel.
Figure 2-11
(11) Hydraulic oil description label
● This label is located on the hydraulic oil tank.
● To check the engine running status and the
accumulator oil level, the hydraulic oil can be
observed via the hydraulic oil level gauge.
Otherwise, stop the engine, rotate the steering
wheel of vehicle to return the accumulator oil
to the oil tank, and check the oil level from the
upper portion of hydraulic oil level gauge.
Figure 2-12
(12) Warning label of fuel tank
● The label shall be located on the fuel tank.
● No trampling on the fuel tank.
Figure 2-13

2.2 General Precautions

2.2.1 Safety Rules
● Only the trained or designated personnel are
allowed for operations and maintenances of
machine.
● During the operations and maintenances of
machine, abide by all safety rules, precautions,
and operation instructions.
● Drinking or taking medicine will seriously impair
or weaken the operation or repair capability of
machine and endanger yourself and other
personnel in the working site.
● During the operations along with another operator
or the traffic commander of working site, ensure
that all personnel understand all gesture signals in
use.
2.2.2 Upon Detection of Abnormality

● Upon detection of any abnormality (noise,
vibration, smell, incorrect instrument indication,
smoke, oil leakage, or any abnormal indication on
warning device or monitoring unit) during
operations or maintenances, report to the
supervisor and take necessary measures. Do not
operate the machine before the malfunction is
solved.
2.2.3 Working Clothing and Protective

Articles for Operation Personnel
Wear the tights or working clothing and safety articles
required for the working condition, which probably
include:
● Safety helmet
● Safety boots (shoes)
● Protective goggles
● Protective mask
● Protection gloves
● Protective clothing with reflecting layer
● Protective earshield
● Dust mask. Figure 2-14

Wear the necessary safety protective articles and the

safety protective articles required by the owner, public
utility administration, government, and laws and
regulations. Do not take your chance, in order to
prevent unnecessary risks.
Caution
● It’s prohibited to wear loose clothing or
Incorrect
accessories. There is a danger that they will
Correct
hook to a control level or other protrusion part.
● There is a danger of being entangled into the
machine if your hair is too long and protrudes
from the safety helmet. Therefore, tie up your
hair and guard your hair against being entangled
by the machine.
● Always wear safety helmet and safety shoes.
During the operations or maintenance of
machine, if required by the work, wear safety Figure 2-15
goggles, mask, gloves, earplugs, and safety belt.
● Before use, check all protection devices for
normal functioning.
● Do not listen to radio or wear music headset
during operations.

2.2.4 Fire Extinguisher and First-Aid Kit

To prevent injuries and fire, ensure to abide by the
following precautions:
● Prepare first-aid kit and fire extinguisher nearby.
● Carefully read and understand the instructions
affixed on the fire extinguisher and use the fire
extinguisher correctly.
● Perform periodical checking and maintenance to
keep the fire extinguisher under ready status.
● Periodically check the first-aid kit and when
necessary add medicines.
● Establish the countermeasures against fire and
accidents.
Figure 2-16
2.2.5 Safety Equipment
To protect yourself and surrounding personnel, you
should know the safety equipment equipped on your
vehicle. Please ensure that all safety equipment are
fixed properly and are under working status:
Example:
● Falling object protection structure (FOPS)
● Seat belt
● Lamps
● Horn
● Mudguard
● Sun visor
Figure 2-17
● Reversing alarm
● Retro-reflector
● Fire extinguisher
2.2.6 Keeping Machine Clean
● There is a danger of slip, falling, or ingress of dirt
into eyes when checking and maintaining the
machine contaminated by mud or oil dirt. Always
keep the machine clean.
● In event of water ingress into electric system, do
not start the engine, otherwise it will result in
machine malfunction or operation danger. Do not
flush the electric system (including sensors and
connectors) by water or steam.

2.2.7 Keeping Cab Clean

● Before entering the cab, remove the mud and oil
from the bottom of your shoes. Otherwise, it will
probably result in serious accident due to slip
during the operations of pedal.
● Store the scattered objects in the toolbox, instead
of placing them in the cab.
● Do not use your mobile phone during the
operations or driving of machine.
● Do not carry any dangerous object, such as
inflammable and explosive, into the cab.
2.2.8 Locking before Leaving Driver Seat
● Before adjusting or standing from the driver seat,
shift the gearshift lever to neutral gear, press the
parking brake switch to apply the parking brake,
and then stop the engine.
● The accidental touch of the gearshift lever will
result in the danger of sudden movement of
machine and cause serious injuries or property
losses.
● Before leaving the machine, shift the gearshift
lever to neutral gear and press the parking brake
switch to apply the parking brake.
2.2.9 Handrails and Ladder
To prevent the slip or falling of personnel from the
machine, generally operate as per the following
requirements:
● While getting on or off the machine, use the
handrails and ladder shown by arrows in the figure
below.
Figure 2-18

● To ensure safety, always face towards the

machine, keep three-point contact (two feet + one
hand or two hands + one foot), and use handrails
and ladder to support yourself.
● It’s prohibited to get on or off the vehicle during
the traveling of vehicle.
● Do not climb up the engine hood or cover without
anti-slip cloth.
● Check the handrails and ladder before getting on
or off the machine. The oil, lubricating grease, or Figure 2-19
sludge on the handrails or ladder must be removed
away immediately. Frequently keep these parts
clean, timely repair any damaged part, and tighten
any loose bolt.
● Do not get on or off the machine with tools in your
hands.
2.2.10 Guard against Scalding

2.2.10.1 Hot Coolant
● While checking or draining the coolant, to prevent
hot coolant or steam from spraying out to cause
scalding, wait for the coolant to cool down
completely before operations.
● Do not open the radiator cap before the engine is
cooled down. Even if the coolant is already cooled
down, before disassembling the radiator cap,
slowly loosen the cap to relieve the internal
pressure of radiator and avoid serious scalding.
Figure 2-20
2.2.10.2 Hot Oil
● While checking or draining the oil, to prevent the
hot oil from spraying out to cause scalding, wait
for the oil to completely cool down before
operations. Even if the oil is already cooled down,
before disassembling the cap or screw plug,
slowly loosen the cap or screw plug to relieve the
internal pressure.
Figure 2-21

Figure 2-22
2.2.11 Fire and Explosion Prevention

2.2.11.1 Fire caused by fuel or oil
The fuel, oil, antifreeze, and silicon sealant are all
special inflammables. To prevent fire, abide by the
following regulations:
● Store the oil or fuel in designated locations. Keep
away all non-authorized personnel.
● Do not smoke or use open fire near the fuel or oil.
● Check the pipeline fixing clamps for missing and
Figure 2-23
looseness, check hoses for presence of kink, check
for mutual friction between hoses/pipelines, check
oil cooler for damage, and check oil cooler flange
bolts for looseness to prevent oil leakage. Tighten,
repair, or replace any missing, loose, or damaged
fixing clamp, pipeline, hose, or oil cooler and its
flange bolts.
● Fill and store fuel in a well-ventilated place.
● Stop the engine before refueling.
● Do not leave the machine while adding fuel or oil.
● Do not overflow fuel to any overheated surface or
Figure 2-24
electric system part.
● After adding fuel or oil, wipe away overflown fuel
or oil.
● Place oil contaminated rag or other inflammables
in a safe container to ensure safety of working site.
● Securely tighten the fuel tank cap and oil tank cap.
● While flushing parts by oil, use non-inflammable
oil. The diesel and gasoline are easily inflammable
substances. It’s recommended to use them with
caution.
● Before starting the grinding or welding operation,
move all inflammables to a safe place.

● Do not weld or cut by cutting tool any pipeline

containing inflammable liquid.
Danger
Figure 2-25
2.2.11.2 Fire caused by accumulated inflammables
● Remove the dry leaves, wood chips, paper
chipping, dusts, and other inflammables piled or
adhered on engine, exhaust pipe, muffler, battery,
engine hood, and inside of frame at all times, in
order to prevent fire.
2.2.11.3 Fire caused by electric wires
● The short-circuit of electric system will lead to
fire.
● Keep wire connectors clean and securely
tightened.
● Daily check the cables and wires for looseness and
damage and check the wiring end caps for missing
and damage.
● Upon detection of any loose or damage cable or
wire, tighten the loose connector or wire clamp
and repair or replace damaged wire.
2.2.11.4 Fire caused by hydraulic pipeline
● Check all hoses, pipe clamps, guard plates, and
gaskets for proper tightening.
● Any loose one will cause vibration and friction
with other parts during running to cause damage
of hose and splash of high pressure oil and result
in fire danger and personal injuries.
2.2.11.5 Fire caused by lighting device

● While checking fuel, oil, battery electrolyte or
coolant, use an explosion-proof lighting device.
The failure to use an explosion-proof lighting

device will bring about explosion danger to cause

serious injuries.
● When the power supply of the machine is used for
lighting purpose, abide by the regulations in this
manual.
2.2.12 Action in event of Fire

In event of fire, rapidly leave the machine as per the
following requirements.
● Rotate the key switch to OFF to stop the engine.
● Use handrails and ladder to leave the machine.
2.2.13 Windscreen Washing Fluid

● Please use an ethanol-based washing fluid. Do not
use a methanol-based washing fluid, as it’s
irritative to your eyes.
2.2.14 Precautions for Installation of
Accessories and Optional Parts
● The installation of optional parts or accessories is
involved with safety or legal restraint issues.
Therefore, please contact Sany or its authorized
dealer in advance.
● Sany will not be liable for any injury, accident, or
product malfunction arising from the use of
non-authorized attachment or part.
● While installing and using optional attachment,
please read the general descriptions of attachments
in the attachment manual.
2.2.15 Cab Window Glasses

● If the cab glass near the working device is
damaged or broken, there is a contact danger
between the working device and the operator body.
Immediately stop the operations and replace glass.
2.2.16 Non-Authorized Modifications

The modifications to the machine without the approval
of Sany will probably result in safety problems and
personal injuries. The modification will seriously
impair the strength and view field of the machine.
Before any modification, please contact Sany or its
authorized dealer. Sany will not be liable for any
accident, malfunction, or damage arising from the
modifications not approved by Sany.

2.2.17 Safety of Working Site

Before starting operations, understand and get familiar
with the conditions of working site in advance:
● Transport road conditions
● Transport road orientation
● Culverts, obstacles, sewage, and ice (if any)
● Traffic condition
● Dense dust, smoke, and fog (If any)
● Check the rock stratum and conditions around the
working site to determine the safest operation
method. Do not operate in any region with
collapse or falling rock danger.
● To prevent the entry of non-authorized personnel
Figure 2-26
into the working zone, perform the necessary
checking.
● Before passing through shallow water or working Danger
in shallow water or soft ground, check the shape
and conditions of rock bottom and the depth and
flow rate of water.
● Design and pave the road on the working site to
ensure the safe pass-through of machine.
● If the vehicle must drive through a bar material
pile, properly select an angle, drive through one
wheel, and then pass through slowly.
● While driving the vehicle into a building,
Figure 2-27
understand the pass-through space size of the
vehicle, in order to prevent the vehicle from
damaging or crashing the door top, gateway, or
corridor during the entry of vehicle and understand
the carrying limits of ground and slope on which
the vehicle is about to drive through.
2.2.18 Working on Soft Ground
● Avoid operating the machine in a soft ground or
too close to any protrusion near the cliff edge or
any ditch. With low carrying capacity, these places
will probably collapse under the action of machine
weight and vibration to result collapse and rollover
danger of machine. Bear in mind that the soil in
such places will soften after heavy rain, blasting,
or earthquake.
● While operating the machine near an embankment

or dug ditch, the soil will soften under the action

of machine weight and vibration to cause collapse
danger. Before starting operations, verify the soil
safety step by step to prevent the rollover or
falling of machine.
2.2.19 Keeping Away from High Voltage

Cables
Do not drive or operate the machine near cables,
otherwise there is a danger of electric shock to cause
machine damage and injury accident. Operate as below
in the working site likely to close to cables:
● Before starting operations in a working site with
cables, notify the local electric power company of
the operations and consult with local electric
power company for related operation safety
measures.
● The machine is really vulnerable to electric shock
to result in serious burning or even death if the
machine is too close to the cables. Ensure to Figure 2-28
maintain a safety distance between machine and
cables (Refer to right table). Cable voltage Safety distance
● If the machine is too close to the cables, assign a 100V - 200V >2m(7 ft.)
signaler for commanding. 6,600V >2m(7 ft.)
● While operating the machine near high voltage 22,000V >3m(10 ft.)
cables, keep all personnel away from the machine. 66,000V >4m(14 ft.)
● If the machine is too close to or comes into contact 154,000V >5m(17 ft.)
with cables, to prevent electric shock, the driver 187,000V >6m(20 ft.)
shall not leave the cab till the power outage is 275,000V >7m(23 ft.)
confirmed. In addition, keep all personnel away 500,000V >11m(36 ft.)
from the machine.
● To prevent accidents, wear rubber shoes and
rubber gloves for operations. Pave a layer of
rubber matt on the seat and keep your exposed
body parts away from contact with lower body.

2.2.20 Precautions for Ventilation of

Exhaust Gas
● The exhaust gas of the engine has a lethal danger.
If it’s necessary to start the engine or handle fuel,
washing oil, or paint in an enclosed space, to
prevent gas intoxication, open doors and windows
to ensure sufficient ventilation.
Figure 2-29
Danger
Figure 2-30
2.2.21 Emergency Exit of Cab
● If the cab doors can’t be opened due to certain
cause, break the glasses by safety hammer as an
emergency exit.
● During escape, firstly remove the broken glass
pieces from window frame and guard yourself
against being scratched by glass. In addition, take
cautions not to slip by the broken glass pieces on
the ground.

2.2.22 Guarantee of Good Visibility

This machine is installed with rearview mirrors to
improve view field. However, even if the rearview
mirrors are installed, there are still non-visible areas
from the seat. Please notice this during operations.
During the operations in a place with poor visibility, if
the conditions of the working site or the obstacles
around the machine can’t be determined, it will
probably cause damage to the machine or serious
injuries to the operation personnel. During the
operations in a place with poor visibility, ensure to
strictly abide by the following precautions:
● Before starting the operations each day, check the
rearview mirrors. Remove the dirt and adjust
rearview mirrors to ensure good visibility.
● While working in a dark place, open the working
lamp and front lamp of the machine and when
necessary, set up auxiliary lamps in the working
site.
● If the visibility can’t be guaranteed (such as misty,
snowy, rainy, or sandstorm weather), stop the
operations and park the vehicle roadside.
● Set up signals on roads or soft ground. Under the
condition of poor view field, when necessary
assign a signaler. The operator shall pay special
attention to the signals and follow the instructions
of the signaler.
● Only one signaler is allowed to send the signals.
● Before starting operations, ensure all operation
personnel understand all signals and gestures.
2.2.23 Guard against Harms of Asbestos

Warning
Dust No asbestos is used on this machine. However, the
The asbestos dusts contained in the air have a fake parts probably contain asbestos. The inhalation
cancerigenic danger. There is a danger of asbestos of a mount of estos will probably result in lung
inhalation during the demolition operation in the injury or death. Therefore, ensure to use gen ine
working site or during the handling of industrial wastes. parts of Sany Heavy Equipment Co., Ltd. .
Ensure to abide by the following rules.
● During cleaning, spray water for dust fall and do
not clean by compressed air.
● If the air contains asbestos dusts, ensure to operate
the machine in upwind direction and use qualified
dust filtration mask for all personnel.

● During operations, keep all other personnel away

from the machine.
● Always abide by the laws and regulations of
working site and the environmental standards.
2.3 Operation Precautions

2.3.1 Start of Engine
2.3.1.1 Get-on/Get-off safety
To get on or off the machine:
● Always face towards the machine and maintain
three-point contact (One hand + two feet or one
foot + two hands).
● It’s prohibited to jump on or off the machine or
climb onto the machine during the traveling.
● It’s prohibited to use any control mechanism as
handrail.
● Keep clean the inside of cab, vehicle ladder, and
handrail rods. The oil, lubricating grease, ice, or Figure 2-31
snow on these places will probably result in slip
and falloff of the driver. The driver shall remove
the mud from safety boots before getting on the
machine.
2.3.1.2 Adjustment of seat
● The inappropriate seat position will easily result in
operator’s fatigue and mis-operation. At the
change of machine operator, re-adjust the seat
position. The operator leaning against the seat
backrest shall be capable of depressing the pedals
to the end and operating the control levers
correctly. Otherwise, move the seat longitudinally
for re-adjustment.
Figure 2-32

2.3.1.3 Fastening of seat belt

● In event of rollover accident, the operation
personnel will probably be injured or thrown out
of the cab or probably be squeezed by the machine
to cause serious injury accidents. Before operating
the machine, carefully check the seat belt, belt
buckle, and anchorages. Upon detection of any
damage or wear, replace the seat belt or its parts
before operating the machine.
● Ensure to sit on the operator seat and fasten the Figure 2-33
seat belt while the machine is running, in order to
prevent accidents.
● It’s better to replace the seat belt once every three
years, regardless of its working status.
2.3.1.4 Checking before start of engine
During the daily operations, check as below before the
start of engine:
Danger
● Remove the dusts from window glasses to ensure
good visibility.
● Remove the dusts from surfaces of front lamp and
working lamp and check working lamp for normal
functioning.
● Check the coolant level, fuel level, and engine oil
level.
● Check air filter for blockage and check wires for
damage.
● Check for accumulation of sludge or dirt around Figure 2-34
the moving parts of accelerator pedal or brake
pedal and check pedals for appropriate working.
● Adjust the seat to a position easy for operations
and check the seat belt and fixing clamps for
damage and wear.
● Check instruments for normal functioning, check
the height of retro-reflector, and ensure that the
gearshift lever is in neutral gear.
● Adjust the rearview mirrors in such manner that
the rearward area of the machine can be clearly
seen from the driver seat.
● Check the areas above, below, and surrounding the
machine for presence of person and obstacle. If
any, issue a warning to ensure that they are
evacuated to a safety zone.
● Check whether the parking brake switch is at
PARKING position.

2.3.1.5 Precautions for start of engine

● Before starting the engine, ensure there is no
Correct
person above, beneath, or surrounding the
machine and sound the horn to alert all personnel
around the machine to keep away from the
machine.
● Start or operate the machine only by sitting in the
seat.
● If another person is allowed to stay on the
machine, such person can only sit in the front
passenger seat.
● Do not start the engine by short circuiting the
starter motor circuit, otherwise it will not only Figure 2-35
bring about potential safety problem, but also
damage the equipment.
● As for the machine equipped with reversing alarm
device, check if the warning device works
normally.
2.3.1.6 Start of engine in cold regions

● Thoroughly warm up the engine. Before operating
the machine, if the engine is not thoroughly
warmed up, it will result in slow reactions to cause
accidents.
● If the battery electrolyte is frozen, do not charge
the battery or start the engine by other power
supply. It will result in the fire danger and
explosion of the battery.
● Before charging the battery or starting the engine
by other power supply, unfreeze the battery
electrolyte and check the battery for freezing and
leakage.

2.3.1.7 Start of engine by auxiliary cable

To start the engine by auxiliary cable method, ensure to
operate as per the instructions of the operation manual.
The incorrect operations will result in explosion of
battery or out-of-control of machine to cause personal
injuries.
It’s prohibited to start the engine by auxiliary cable
without permission. When necessary, please contact
Sany Heavy Equipment Co., Ltd. or its authorized
dealer.
● Starting the engine by auxiliary cable requires the
cooperation of two operators (One operator sits in
the driver seat and another operator operates the Figure 2-36
battery).
● Before starting the engine by auxiliary cable,
ensure to wear protective goggles and rubber
gloves.
● While connecting a normal machine to the
malfunctioned machine by auxiliary cable, the
battery voltage of the normal machine shall be
same with that of the malfunctioned machine. In
addition, take cautions to prevent the contact
between two machines.
● While connecting the auxiliary cable, rotate the
key switches of both normal machine and
malfunctioned machine to OFF. Otherwise, once
being powered on, the machine will move to cause
danger.
● While connecting the auxiliary cable, ensure to
firstly connect the positive pole (+).
● While disconnecting the auxiliary cable, firstly
disconnect the ground or negative (-) cable
(ground side).
● While disassembling the auxiliary cable, take
cautions to prevent the contact between auxiliary Figure 2-37
cable clamps and between cable clamp and
machine.
● The ether cold start fluid is a highly inflammable
and explosive substance. Please read the operation
instructions on the ether container before use.
● If the engine is equipped with spark plug type
preheater or other type preheater, do not use the
ether.

2.3.1.8 After start of engine

● After the start of engine, idle the engine for
3~5min and observe the pressure gauge,
instruments, and warning lamps to ensure they
function normally and all readings are within
normal ranges.
2.3.2 Operations
2.3.2.1 Checking before operations
Caution
● During the checking, move the machine to an open
Observe and carefully listen the machine for internal
space without obstacles, operate slowly, and keep
noise. Upon detection of malfun t on or
all personnel away from the machine.
abnormality, immediately stop the engine, solve the
● Always fasten the seat belt.
malfunction, and report to superior before further
● Check the equipment and instruments for normal
operations.
functioning and check the steering and brake
systems for normal functioning.
● Check the machine for abnormal sound, vibration,
heating, smell, and instrument and check for
leakage of oil or leakage.
● Upon detection of any abnormality, repair
immediately and do not continue the operations of
machine.
2.3.2.2 Precautions before operations
To prevent serious injury or death accident, notice the
following items before moving the machine:
● Before driving, re-check the surrounding area for
presence of person and obstacle.
● Sound the horn before driving to alert the
surrounding personnel.
● Operate the machine only by sitting in the driver
seat. Figure 2-38
● If another person is allowed to ride on the
machine, such person can only sit in the front
passenger seat.
● Check reversing alarm for normal functioning.
● Close the cab doors and windows and check and
ensure the lock of door locks.
● Please assign a signaler in the place with poor
visibility.

2.3.2.3 Precautions during driving

● Dump bucket’s load shall not exceed the
Correct
maximum payload.
● It’s prohibited to rotate the key switch to OFF
position. Stopping the engine during driving of
machine will make the steering heavy, which is
really dangerous.
● Lay down dump bucket and press floating action
button switch to drive.
● At the entry/exit and on rugged roads, the
unloaded vehicles must give way to the heavily Figure 2-39
loaded vehicles.
● To prevent the accidents due to collision with
other objects, operate the machine within the safe
operation speed, especially in places with limited
space such as gateway and place with other
machines.
● While driving the machine on rugged roads, drive
at low speed and avoid the change of direction.
● Unless otherwise approved, do not drive the
vehicle through any non-authorized road. When
the approval is granted, get sufficiently prepared to
take the safety measures. Before the entry of
vehicle, ensure that the roads ahead are free of Figure 2-40
obstacles.
● During the driving or operations of machine, keep
a safety distance from personnel, buildings, and
other machines to prevent collision.
Danger
● While driving through a bridge or driving into a
building, firstly check whether the building is
strong enough to support the weight of machine.
● There is a height restriction while operating in a
tunnel or building, under a bridge, or in other
similar place. Operate slowly and take special
caution to keep the machine or mixing drum away
from collision with any object. Figure 2-41
● Driving the vehicle at high speed continuously for
a long time will lead to tire overheating and
abnormally increased inflation pressure of tires to
cause tire burst. The tire burst is a destructive
danger that will result in serious injury or death.
● Before the long-time continuous driving, please
contact Sany or its authorized dealer.

2.3.2.4 Precautions for driving on slopes

To prevent the rollover or one-sided slide of the
machine, always operate as below.
● Slow down the vehicle by brake during downslope
driving. Do not rotate the steering wheel suddenly.
● Drive at low speed on grassland and wet/slip
roads. There is a slip danger of machine, even on a
tiny slope.
● To stop the machine on a slope, fully depress the
brake pedal, stop the machine in combination with
the parking brake, and then stop the engine.
● During the downslope driving, do not shift gears
or shift to neutral gear.
2.3.2.5 Precautions when operating lifting bucket
● Before performing the lifting operation, make sure
that there is no personnel or obstacle behind the
machine.
● Park the machine at correct position, and perform
inspection again to make sure there is no
personnel or obstacle behind the machine.
● Send the specified signal, and then operate dump
bucket slowly.
● If necessary, block the wheel with a stop dog, or
arrange another signalman. Figure 2-42
● Do not perform dumping operation on the slope
for the machine stability is poor on the slope and it
might roll over.
● Do not drive the machine when lifting the cargo
compartment.
● Do not leave or get back to the driver’s seat at the
time of loading operation.

2.3.2.6 Precautions on snowy/icy ground

● A snow-covered or frozen surface is really
slippery. Take special cautions during the driving Danger
and operations of the machine. Do not operate any
control lever suddenly. The machine will slip,
even on a tiny slope. Therefore, take special
cautions during operations on slopes.
● A frozen surface will soften following the
increasing of temperature, which will lead to
rollover of machine.
● Driving the machine into deep snow will probably
result in rollover or entrapment in snow. Take Figure 2-43
cautions not to leave the machine from road
shoulder, otherwise the machine will be entrapped
in snow.
● Install tire chains while driving on snow-covered
roads.
● While driving on snow-covered roads, do not stop
the vehicle suddenly by service brake. Instead,
shift to a low gear to utilize the engine brake and
stop the vehicle by double brake (depressing the
brake pedal for several times).
● If materials in the dump bucket are frozen, do not
perform dumping operation for the machine might
roll over
2.3.2.7 Parking of machine

Selection of parking lot
● Park the machine on a solid and level ground.
● Park the machine in a place without falling rock or
collapse danger. In a low terrain, park the machine
in a place without flooding danger.
● Do not park the machine on a construction road. If
it’s really necessary, ensure to abide by the local
rules and use flags (at daytime) or signal lamps (at
nighttime) to alert other personnel and vehicles. Figure 2-44

● If it's necessary to park the machine on a slope,

place blocks beneath the wheels to prevent the
movement of machine.
Figure 2-45
2.3.2.8 Stop of machine
Refer to operation and maintenance manual for the
detailed procedure for stop of machine. The general
stop procedure is as below:
● Place the parking switch at “Parking” position.
● Shift the transmission to neutral gear.
● Idle the engine for 3~5min to cool down the
engine.
● Rotate the steering wheel leftward and rightward
to relieve the pressure of accumulator.
● Rotate the key switch to LOCK to stop the engine.
● Withdraw the key.
● Close windows and cab doors.
● Lock all access panels and compartments.
● While leaving the machine, face towards the
machine and keep three-point contact with the
machine. Do not jump off the machine.
● While leaving the machine, notice the wet/slip
passages and ladder.

2.3.3 Transport
2.3.3.1
This machine shall be broken down for transport.
During transport, please contact Sany or its authorized
dealer.
2.3.3.2 Starting transportation
During loading and unloading, the incorrect operations
will result in rollover and falloff of the machine.
Therefore, notice the following items:
● Perform the loading and unloading operations only
on a solid and level ground. Keep a safety distance
from the edges of roads and cliff.
● Keep all bystanders away.
● Ensure to use ramps of sufficient strength and
ensure that the width, length, and thickness of the
ramps are sufficient to provide a safe unloading Ramp spacing 15º maximum gradient
Cushion block
gradient (≤15°).
● Ensure that the ramp surfaces are clean without
grease, oil, water, and bulk material and remove
the dirt from machine passages. Notice the
wet/slip surface of ramps during loading and Figure 2-46
unloading under rainy/snowy weathers.
● Run the engine and drive the machine at low speed
and operate slowly.
● At the connection between ramps and transport
truck, the gravity center of the machine will
change suddenly to lose balance of machine easily.
Drive the machine slowly to drive through this
area.
● Do not correct the driving direction on ramps. If
necessary, drive the machine off the ramps, correct
the driving direction, and then drive into the
ramps.
● While loading/unloading the machine on an
embankment or platform, ensure that the
embankment or platform has sufficient width,
strength, and gradient.
● After loading the machine onto the transport truck,
lock the cab doors. Otherwise, the doors will
probably open suddenly during the transport.
● Fix the machine by chains and cushion blocks.

2.3.3.3 Elevating transportation

During the transport of machine by a transport truck,
notice the following items:
● Understand the overall length, width, and height of
transport truck and machine to prevent collision
with any obstacle at heights or in narrow passages.
● Before passing through a bridge or building of
special port, firstly check whether the building is
strong enough to support the carrying weight.
While driving on roads, please abide by the traffic
laws and regulations and follow the instructions of
traffic police.
2.3.4 Battery
Guard against danger of battery
The battery electrolyte contains sulfur acid and can
generate inflammable and explosive hydrogen. The
incorrect operations will result in personal injury or
fire. Therefore, ensure to abide by the following
precautions:
● It’s prohibited to smoke or use open fire near the
battery.
● Before operating the battery, rotate the key switch
to OFF position.
● While operating the battery, always wear safety
goggles and rubber gloves.
● The battery electrolyte is a strongly corrosive
Figure 2-47
substance. In event of splash of electrolyte onto
your clothing and skin, flush immediately by a
great amount of water. In event of splash of
electrolyte into your eyes, there is a danger of
blindness. Immediately flush by a great amount of
water and seek for medical treatment.
To prevent battery explosion, abide by the following

precautions during operations:
● Never contact two battery terminals by any tool or
other metal object and never place any tool or
other metal object near the battery.
● Stop the engine before operating the battery.
● To disconnect the battery, firstly disconnect the
negative (-) terminal (Ground side) and then
disconnect the positive (+) terminal. To connect
the battery, firstly connect the positive (+) terminal

and then connect the negative (-) terminal

(Ground). Ensure the secure connection for all
terminals.
● If the battery temperature exceeds 45ºC during the
charging, stop the charging, wait for the battery
temperature to drop to room temperature, and then
halve the charging current to continue charging.
● Upon detection of electrolyte spray from the vent
port of battery during the charging, immediately
stop the charging.
● Eliminate the smoking and prevent the spark
source during charging.
● If the battery charge indicator is green, it indicates
that the battery is sufficiently charged. Stop the
charging.
2.3.5 Towing
Safety rule for towing
While towing a malfunctioned machine, the incorrect
operation method or the use of disqualified wire rope
will result in serious accident.
● It’s prohibited to tow the machine on slopes.
● When the wire ropes are used, wear protective
gloves and safety helmet.
● Check and ensure that the wire rope is strong
enough to carry the weight of machine being
towed.
● Do not use a wire rope with broken strand (A),
contracted diameter (B), or distortion (C), as such
wire rope has a danger of breakage during towing.
● Do not standard between the towing vehicle and Figure 2-48
the towed machine during the towing.
● Operate the machine slowly and notice not to
apply the load suddenly to the wire rope.

2.4 Maintenance Precautions

2.4.1 Warning Label
● Before the maintenances of machine, hang a label
“No operation” or similar warning label to the
gearshift lever in the cab, in order to alert other
personnel that the machine is under maintenance.
● When necessary, affix additional warning labels
around the machine.
● During the maintenances, the start of engine or the
touch or operation of retarder handle by other
person will result in serious accidents.
Figure 2-49
Danger
No operation!
When it’s not in use, please preserve this label in the
toolbox.
If no toolbox is provided, preserve it in the bag of
operation and maintenance manual.
2.4.2 Preparations of Working Field

● Choose a spacious, well illuminated, well
ventilated, and clean and level area for
maintenance works.
● Clean the working ground, wipe away the fuel,
lubricating oil, and water, and pave sands or other
absorbing material on slip ground.
● Do not leave a hammer or other tool in the
working field.
● If the working field is not kept dry and clean, there
is a danger of tripping, slip, or falloff, which will
lead to personal injury.

2.4.3 Precautions before Maintenances

To prevent accidents:
● Understand the maintenance specification before
the working.
● Keep clean and dry the working area.
● Do not spray water or steam into the cab.
● It’s prohibited to add lubricating oil or perform
other maintenance works while the machine is
moving.
● Keep your hands, feet, and clothing away from
rotating parts.

2.4.4 Self-Preparations
Only the authorized personnel are allowed for
maintenances or repairs of machine.
If necessary, a supervisor can be assigned.
● Wear the protective clothing required for the
works and wear the safety shoes.
● Before coming in contact with any corrosive
material, please wear the rubber skirt and rubber
gloves. Wear safety protective gloves while
handling wooden material, wire rope, or metal
with sharp edges.
Figure 2-50
● Please wear a face mask while disassembling a
spring or elastic part or adding electrolyte to the
battery. Wear safety helmet and goggles during
welding or cutting by a welding gun.
● Do not perform grinding, flame cutting, or
welding if the respirator and ventilation equipment
are unavailable. If it’s necessary to perform
welding on this machine, please refer to relevant
manual to understand the correct operation
procedure.
Figure 2-51
Figure 2-52

2.4.5 Stop of Engine before Maintenances

● Stop the machine on a solid and level ground.
● Choose a place with danger of falling rock,
collapse, or flooding in low terrain.
● Stop the engine after confirming no elevation of
the tilter.
● Place the parking brake switch at (Parking)
position and block the wheels to prevent
movement of machine.
Figure 2-53
2.4.6 Maintenance during Running of

Engine
To prevent injuries, do not perform any maintenance
work during the running of the engine. If it’s necessary
to perform the maintenances with the engine running,
operate by at least two operators and abide by the
following rules:
● Ensure that one operator is always sitting in the
driver seat and is ready to stop the engine and all
operators keep close contact.
● Switch the parking handle on parking position.
● There is a danger of being entangled during the
operations near fan, fan belt, or other rotating part.
Pay special attention.
● Never drop or insert any tool or other object into
the fan or fan belt, otherwise such part will be
broken or thrown out.
● Do not touch any control lever or button. If it’s
necessary to operate any control lever or button,
send a signal to other personnel and alert them to
keep away in a safe place.
Figure 2-54

2.4.7 Appropriate Tools

Only use appropriate tools correctly. The use of
damaged, low quality, defective, or temporary tool or
the incorrect use of tool will result in serious accidents.
Figure 2-55
2.4.8 Handling of Suspension Cylinder
The suspension cylinder and air reservoir are filled with
high pressure nitrogen. The incorrect handling will
result in serious injuries. To prevent such danger, abide
by the following rules.
● Do not move or dissemble the cylinders.
● Do not bring such parts near or in the fire.
● Do not drill, weld, or use cutter on such parts.
● Do not hammer or roll such parts.
● Please consult with Sany Mining Machinery or its
authorized dealer for the charging and discharging
of cylinders.
2.4.9 Working beneath Machine

● If it’s necessary to work beneath the machine,
securely support the machine by cushion blocks or
brackets strong enough to support the weight of
machine.
● Unfold the safety support device during the
inspection of elevated dump tilter.
Figure 2.4.9-1
2.4.10 Working in Noisy Environment
If working in noise for a long time during the
maintenance of engine, wear earshields or earplugs.
The excessive noise of machine will lead to temporary
or permanent hearing problem.

2.4.11 Precautions for Use of Compressed

Air
● While cleaning by air compressor, the thrown
particles will probably cause material damage and
personal injury.
● While cleaning parts or radiator by air compressor,
ensure to wear safety protective goggles, dust
mask, gloves, and other protective articles.
2.4.12 Precautions for Use of Hammer
● While hammering hard metal parts (such as pin,
edge, and bearing) by a hammer, the part and
metal chippings will be thrown to cause personal
injury. Therefore, ensure to wear protective
goggles and gloves and keep all personnel away
from surrounding area.
Figure 2-57
2.4.13 Welding Operation
● There is a danger of fire, toxic gas, and electric
shock during welding. Therefore, ensure to
perform the welding operations by qualified
welders and provide the appropriate equipment.
The disqualified personnel are prohibited for
welding operations.

2.4.14 Precautions for High Pressure Oil

The inside of hydraulic system is always under high
pressure. Before checking or replacing any pipeline,
check and ensure that the pressure in the hydraulic oil
pipeline is already relieved. It will result in serious
accident if the oil pipeline still contains pressure.
Therefore, abide by the following rules:
● Relieve the system pressure before the
maintenances of hydraulic system:
1. Unscrew the butterfly nut of ventilation valve and
press the air bleeding button to relieve the internal
pressure of hydraulic oil tank.
Figure 2-58
2. To relieve the pressure of accumulator after the
stop of engine, rotate the steering wheel leftward
and rightward for several times to relieve the
pressure of steering accumulator and depress the
brake pedal for several times to relieve the
pressure of brake accumulator.
● Keep away all open fire from the area surrounding
the hydraulic system and timely wipe away any
splashed hydraulic oil.
● Pressurized diesel and hydraulic oil can penetrate
your skin or eyes to cause serious injury,
blindness, or death. It’s difficult to detect the
leakage of pressurized hydraulic oil with naked
eyes. Use a paper board or wood plate to check for
leakage and do not directly touch the leaking fluid.
Wear mask or safety goggles to protect your eyes.
In event of permeation of fluid into your skin,
flush by clean water and seek for medical
treatment as soon as possible.
● The fuel pipeline contains internal high pressure
while the engine is running. Before checking or
maintaining the fuel pipeline system, wait for at
least 30s after the stop of engine for the internal
pressure to drop.

2.4.15 Operation Safety of High Pressure

Hoses
The leakage of high pressure hoses will result in
operation malfunctions and possibly even fire. Upon
detection of any loose bolt on hoses, stop the operations
and tighten the bolts to specified torque. Upon
detection of any damage on hoses, immediately stop the
operations and contact Sany Mining Machinery or its
authorized dealer.
Immediately replace hose upon detection of following
problems:
● Damage or leakage of hydraulic pipe connector.
● Wear-out or breakage of external layer or exposure
of reinforcement layer wire.
● Partial expansion of external layer.
● Impurities in external layer.
● Distortion or crushing damage of movable
segment.
2.4.16 Guard against Hot Cooling System
● The pressure of cooling system will increase when
the engine becomes hot. Before disassembling the
radiator cap, stop the engine to cool down the
engine. Disassemble the radiator cap only after the
coolant cools down.
Figure 2-59
Warning
Contact with hot high pressure coolant will result in
serious injuries.

2.4.17 Maintenances of A/C

Keep away from fire source during repairs and
maintenances of A/C system.
● During the maintenances of A/C system, use the
refrigerant correctly with reference to the
instructions on the refrigerant container. The
refrigerant R134a is used. Do not use any other
refrigerant, otherwise the A/C system will be
damaged.
● The ingress of A/C refrigerant into eyes will
probably cause blindness and the splash onto skin
Figure 2-60
will result in cold injury.
● Use recovery and recycling system. It’s prohibited
to directly drain refrigerant into open air.
Warning
Refrigerant R134a is a non-toxic gas under
no m l temperature. However, it will turn to
strongly toxic g s once being exposed to fire source.
2.4.18 Precautions for High Voltage

● When the engine is just running or is just stopped,
a high voltage is generated at the fuel injection
terminals and in the engine ECU so that there is a
danger of electric shock. Do not contact fuel
injector or inside of engine ECU.
● If it’s necessary to contact terminals of fuel
injector or inside of engine ECU, please contact
Sany Mining Machinery or its authorized dealer.
Figure 2-61

2.4.19 Accumulator
The accumulators are filled with high pressure
nitrogen. The improper operations of accumulator will
probably result in explosion to cause serious accidents.
Therefore, ensure to abide by the following
precautions:
● Do not break down accumulators.
● Keep accumulators away from fire source and
flame.
● Do not drill, weld, or use gas cutter on the
accumulators.
● Do not collide or roll the accumulator or apply
Figure 2-62
impact of any form onto the accumulators.
● Ensure to deflate during the handling of
accumulator. Please contact Sany Mining
Machinery or its authorized dealer for such
operations.
2.4.20 Guard against Fire and Explosion
Dangers Danger
● Ensure to stop the engine and turn off electric Do not smoke during the handling of fuel and
devices before refueling the fuel tank. Take special maintenance of fuel system, as the fuel gas in the
cautions during the refueling for a hot engine and empty fuel tank is an explosive gas. Do not cut or
eliminate fire sparks around the grounding fuel weld on fuel pipe, fuel tank, or fuel container,
nozzle. otherwise it will result in fire, explosion, and
● Please handle all solvents and dry chemicals under personal injuries.
a well-ventilated environment as per the
procedures indicated on the containers.
● Remove all dusts and residues from the machine
and do not place any oily rag or other inflammable
on the machine.
● While cleaning the parts, please use
non-inflammable solvent and do not use gasoline,
diesel, or other inflammable liquid.
● Store the inflammable liquids and materials in
appropriate containers as per the safety
regulations.
● Check the readiness of fire extinguisher, fire
extinguishing system, and fire detector (If
equipped).

2.4.21 Periodical Replacement of Critical

Safety Parts
To the long-time safe operations of machine, ensure to
periodically replace the safety related hoses, seat belts,
and other parts.
● The materials of the parts will probably deteriorate
at the expiration of specified period. The excessive
use will result in wear and damage. As it’s difficult
to judge by external checking or touch how long
these parts can be further used, the excessive use
will result in malfunction or serious harms.
Therefore, periodically replace such parts.
● Upon detection of any defect on any safety part,
replace or repair the safety part, even if the
specified period is not reached.
2.4.22 Maintenances
● During the repairs, check all parts and replace
worn, broken, and damaged parts. The excessively
worn or damaged parts will fail during the use of
machine to cause injuries and deaths. Replace
damaged or non-legible signal markings.
● Tighten all fasteners and connectors to specified
torques.
● After repairs and maintenances, install all guard
plates, cover plates, and shields. Replace or repair
damaged protective plates. Refill the system with
hydraulic oil approved or recommended by Sany
Mining Machinery only.
● Start the engine and check for leakage (check
hydraulic system). Operate all control devices to
determine the normal functions of machine.
Perform the test if necessary. After test, power off
the machine and check all your works (for any
missing split pin, washer, and nut). Before
operating the machine, recheck all hydraulic oil
levels.

2.4.23 Correct Disposal of Wastes

The improper disposal of wastes will harm the
environment and ecology. Please consult with the local
environmental-protection recycling center or Sany for
waste recycling or disposal method.
● The potentially harmful wastes in the equipment
of Sany include hydraulic oil, fuel, coolant,
refrigerant, filters, and battery.
● While draining the fluid, use the leakage-proof
container. Do not use food or beverage container,
as it will probably lead to mistaken drinking.
Figure 2-63
● Do not pour the waste fluid onto ground or into
sewage or any water source.
● The leakage of A/C refrigerant will damage the
atmosphere. Abide by the relevant laws and
regulations for recovery or recycling of A/C
refrigerant.
Figure 2-64

2.5 Precautions for Tires

2.5.1 Handling of Tires
The burst or separation of tire and/or rim will result in
serious personal injury accidents. To ensure the safety,
Incorrect Consequence
abide by the following rules:
● Thoroughly deflate the tires before the repairs of
tire and rim. Use special equipment and
technology for the maintenance, disassembling,
repair, and assembling of tires and rims.
● It’s prohibited to weld or ignite standing near tires.
● During the hoisting or handling of tires, avoid
damaging the beads of tires, in order to prevent
tire leakage.
Figure 2-65
● Never drop, throw, or roll the wheel rims, in order
to prevent deformation or damage of rims.
● It’s prohibited to mix the parts of one rim
manufacturer with those of another rim
manufacturer.
● Inflate the tire by special tire inflator to specified
pressure in a place far away from the busy
working field.
● Place the tires in a safety cage before inflation. If
no tire cage is available or the tires are installed on
vehicle, tie up the tire and rim assembly by safety
chain or wire rope.
Figure 2-66

● Do not stand on the front of any installed tire

during the inflation of tires. Stand on the side of
tire and use a long hose with clamp to inflate tires.
To prevent excessive inflation, during the pressure
buildup of air pump, measure the pressure by a
pressure gauge repeatedly.
Figure 2-67
● Keep away from the heated tires, as shown by
hatched area in the figure. At least 15m At least 460m
● The abnormal pressure drop of any tire indicates

the leakage of tire. Ensure to repair the tire.
● The increased tire pressure during the driving of
vehicle is a normal symptom and no pressure
reduction measure is required. In such case, slow
down the vehicle or stop the vehicle to cool down
the tires.
● Ensure that the tightening torque for wheel
pressure nuts meet the recommended value
specified in the manufacturer's manual. Figure 2-68
2.5.2 Precautions for Storage of Tires

● The tires for construction machinery are really
heavy. Keep away and do not attempt to stop an
overturning tire. Ensure that the hoisting
equipment is sufficient to carry the weight of tires Stop block
during hoisting.
● Generally, the tires shall be stored in a warehouse
inaccessible without permission. If the outdoor
storage is necessary, cover the tires by canvas to
guard against sunlight and rainwater.
● Keep tires away from heat source and from oils,
Figure 2-69
inflammables, and corrosive chemicals.
● Erect the tires vertically on a horizontal ground
and block the tires securely. The measure shall be
taken to prevent rolling and overturning if the tires
may be touched by any person.
● Do not lay down the tires on the side face,
otherwise it will result in deformation and damage
of tires.

2.6 Conclusion
This manual is prepared only for off-road dump truck.
You have read the safety part of this manual for the
vehicle you drive. The contents of this part can’t cover
all dangerous situations you may encounter, however
the safety protection measures and safety rules you
learnt will help you make positive judgment in event of
any danger.
Bear in mind the first element -

Safety First
Safety is your career and responsibility. Wish you
happiness in work.

System Functions SKT90S Mining Wide-Body Dump Truck
System Functions
3 System Functions .......................................................................................................................................... 3-5
3.1 General Diagram of Machine .............................................................................................................. 3-5
3.2 Control Devices ................................................................................................................................... 3-6
3.3 Indicator Lamps................................................................................................................................... 3-7
3.4 Instruments ........................................................................................................................................ 3-12
3.5 Display Screen................................................................................................................................... 3-14
3.6 Switches ............................................................................................................................................ 3-16
3.6.1 ...................................................................................................................................................... 3-16
3.6.2 Key switch ............................................................................................................................ 3-17
3.7.2 Combination Switch ............................................................................................................. 3-17
3.6.4 Warning Lamp Switch .......................................................................................................... 3-18
3.6.5 Electrical-air horn switch ...................................................................................................... 3-18
3.6.6 Rear Lamp Switch ................................................................................................................ 3-19
3.6.7 Front Fog Lamp Switch ........................................................................................................ 3-19
3.6.8 Headlamp switch................................................................................................................... 3-19
3.6.9 Exhaust brake switch ............................................................................................................ 3-19
3.6.10 Fan emergency switch........................................................................................................... 3-20
3.6.11 Inter-axle discrepancy switch ............................................................................................... 3-20
3.6.12 Fault diagnosis switch ........................................................................................................... 3-20
3.6.13 Side wiper switch .................................................................................................................. 3-20
3.6.14 Elevating switch.................................................................................................................... 3-21
3.6.15 Elevating control handle switch ............................................................................................ 3-21
3.6.16 Holding switch ...................................................................................................................... 3-21
3.6.17 Forced landing switch ........................................................................................................... 3-21
3.7 Control Levers and Pedals................................................................................................................. 3-22
3.7.1 ...................................................................................................................................................... 3-22
3.7.2 Gearshift Lever ..................................................................................................................... 3-23
3.7.3 Accelerator Pedal .................................................................................................................. 3-24
3.7.4 Clutch pedal .......................................................................................................................... 3-24
3.7.5 Service Brake Pedal .............................................................................................................. 3-24
3.8 Cigarette Lighter ............................................................................................................................... 3-25
3.9 Horn................................................................................................................................................... 3-25
3.10 Steering Wheel .................................................................................................................................. 3-25
3.11 Fuses .................................................................................................................................................. 3-27
3.12 Central control screen........................................................................................................................ 3-29
3.12.1 Central control screen ........................................................................................................... 3-29
3.12.2 Operation instructions ........................................................................................................... 3-29

SKT90S Mining Wide-Body Dump Truck System Functions
3.13 A/C System ....................................................................................................................................... 3-35

3.13.1 A/C Control Panel................................................................................................................. 3-35
3.13.2 Operation Instructions........................................................................................................... 3-35
3.13.3 Precautions for Use of A/C ................................................................................................... 3-36
3.14 Cab Door Windows ........................................................................................................................... 3-37
3.14.1 Opening of Cab Door Windows ............................................................................................ 3-37
3.14.2 Closing of Cab Door Windows ............................................................................................. 3-37
3.15 Cab Emergency Exit .......................................................................................................................... 3-37
3.16 Door Locks ........................................................................................................................................ 3-38
3.17 Cup Holder ........................................................................................................................................ 3-38
3.18 Safety support.................................................................................................................................... 3-38

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Warning

3 System Functions
3.1 General Diagram of Machine
1. Dump tilter 4. Headlamp

2. Rear wheel 5. Turn signal lamp
3. Front wheel
Figure 3-1

3.2 Control Devices
1. A/C control panel 9. Ignition key switch 17. Retarder pedal

2. Radio/MP3 player 10. Rocker switch 18. Traversing mechanism
assem y
3. A/C air vent 11. Lifting button switch 19. Combined switch
4. Combination instrument 12. Floating action button switch
5. Reversing monitor 13. Drop button switch
6. Gearshift lever 14. Emergency brake switch
7. Buzzer 15. Accelerator pedal
8. Cigarette lighter 16. Service brake pedal
1.A/C air vent 7. Cigarette lighter 13.Brake pedal

2. Instrument assembly 8. Gear position control handle 14. Steering wheel
3. Central control screen 9. Parking brake handle 15. Clutch pedal
4. Rocker switch 10. Air conditioner control knob 16. Combined switch
5. A/C air vent 11. Accelerator pedal 17. Elevating handle
6. A/C air vent 12. Retarder control switch
Note: The vehicle without retarder is not configured with No. 12 handle.
Figure 3-2

3.3 Indicator Lamps
Figure 3-3
1. Preheating indicator lamp - The light shall be on

when inlet heating is automatically operated under low
temperature. Note: During the inlet heating operation,
the starting engine shall not be in operation to protect
the storage battery, otherwise the inlet heating will be
terminated.
Figure 3-4
2. OBD indicator lamp - to indicate that the

troubleshooting is needed for the engine is faulty.
Figure 3-5
3. Oil-water separation indicator lamp - The light
shall be on when the water proportion reaches a certain
degree in the oil.

Figure 3-6
4. Air filter block indicator lamp - The light shall be

on when the air filter is blocked.
Figure 3-7
5. High beam indicator lamp - This lamp turns on

when the high beams are working.
Figure 3-8
6. Low beam indicator lamp - This lamp turns on

when the low beams are working.
Figure 3-9
7. Door indicator lamp - The light shall be on when
the vehicle door is open.
Figure 3-10
8. Charging indicator lamp - It indicates the charging

status of battery by the alternator. This lamp turns on
when the battery is insufficiently charged.
Figure 3-11
9. Low air pressure alarm light - The light shall be

on when the tank pressure is excessive low.
Figure 3-12

10. Parking indicator lamp - This lamp turns on when

the parking brake is applied.
Figure 3-13
11. Reversing indicator lamp - The light shall be on

when the reversing light is in operation.
Figure 3-14
12. Inter-axle discrepancy indicator lamp - The light

shall be on when the inter-axle discrepancy switch is
pressed on.
Figure 3-15
13. Right engine fault indicator lamp - The light shall

be on when the fault diagnosis rocker switch is pressed
in case the engine is faulty.
Figure 3-16
14. Engine oil pressure indicator lamp - The light shall

be on when the engine oil pressure is in abnormal
condition.
Figure 3-17
15. Neutral position indicator lamp - The light shall be

on when the gear is in neutral position.
Figure 3-18
16. Side work indicator lamp - The light shall be on
when the side work light is in operation.
Figure 3-19

17. Exhaust brake indicator lamp - The light shall be

on when the exhaust brake is in operation.
Figure 3-20
18. Fuel oil alarm light - The light shall be on when
the fuel oil level is excessive low.
Figure 3-21
19. Water temperature alarm light - The light shall be

on when the engine water temperature is in abnormal
condition.
Figure 3-22
20. Elevation indicator lamp - The light shall be on

when the tilter is separated from the frame; The vehicle
shall be moved when the light is turned off.
Figure 3-23
21. Left turn signal indicator lamp - This lamp flashes

when the left turn signal lamp is working.
Figure 3-24
22. Right turn signal indicator lamp - This lamp

flashes when the right turn signal lamp is working.
Figure 3-25

23. Hydraulic retarder indicator lamp - The light shall

be flashing when the hydraulic retarder is in operation.
Figure 3-26
24. Foglight indicator lamp - The light shall be

flashing when the foglight is in operation.
Figure 3-27

3.4 Instruments
Figure 3-28
1. Engine tachometer
Driven by CAN bus, the pointer indicates the engine
speed. When the pointer is within white zone, it
indicates that the engine speed is normal. If the
pointer is within red zone, it indicates that the engine
speed is too high and needs to be reduced.
Figure 3-29
2. Speedometer
Driven by CAN bus, the pointer indicates the current
driving speed of the vehicle. The data is given by the
controller.
When the pointer is within white zone, it indicates
that the vehicle speed is normal. If the pointer is
within red zone, it indicates that the vehicle speed is
too high and needs to be reduced.
Figure 3-30

3. Fuel level gauge

The pointer indicates the percentage of fuel level
against the capacity of fuel tank and is connected to
the fuel level sensor. When the pointer is within white
zone, it indicates that the fuel level is normal. If the
pointer is within red zone, it indicates that the fuel
level is too low. At this time, the buzzer acts, and it
will be atomically turned off after the buzzing sound
lasts for 10 seconds. In the case of no power Figure 3-31
interruption, the identical fault buzzer works only one
time.
4. Engine water temperature gauge
Driven by CAN bus, the pointer indicates the engine
coolant temperature. When the pointer is within white
zone, it indicates that the engine coolant temperature
is normal. If the pointer is within red zone, it indicates
that the engine coolant temperature is too high. At this
time, the buzzer acts, and it will be atomically turned
off after the buzzing sound lasts for 10 seconds. In the
case of no power interruption, the identical fault Figure 3-32
buzzer works only one time.
5. Rear axle tank air pressure gauge
It is to show the air pressure of rear axle tank with
warning areas including 0～ 0.55MPa in red scale,
0.55 ～ 0.91MPa in green scale and 0.91 ～
1.2MPa in white scale. In case the air pressure is
under the alarm limit value, the alarm symbol will be
light with the alarm sound of buzzer and interval of
0.25s.
Figure 3-33
6. Front axle tank air pressure gauge
It is to show the air pressure of front axle tank with
warning areas including 0～ 0.55MPa in red scale,
0.55 ～ 0.91MPa in green scale and 0.91 ～
1.2MPa in white scale. In case the air pressure is
under the alarm limit value, the alarm symbol will be
light with the alarm sound of buzzer and interval of
0.25s.
Figure 3-34

3.5 Display Screen

The central display is a 5” TFT color display screen in
resolution of 640x480 pixels and can normally display
the engine status, transmission status, and working
status of vehicle monitoring system.
1. Power on the machine and rotate the key switch
to “I” position. The central display displays the
“Sany” start interface and the signal indicator
lamps turn on for lamp examination. After 3s, the
central display displays the main interface and at
the same time the signal indicator lamps turn off Figure 3-35
to complete the lamp examination.
2. Press “F2” button to switch over between main
interface and system function interface. The
default interface upon power-on is the main
15:10:25, Tuesday, August 15, 2012
interface.
Sany Mining Machinery
Engine status
Transmission status
Vehicle monitoring system
Total mileage Engine hours
Figure 3-36
3. Under the system function interface, “F1” button

is the return button, “F2” button is the OK
button, “F3” button is the up button, and “F4” System Functions
Sany Mining
button is the down button. Machinery
Engine information inquiry Instrument parameter inquiry

Under system function interface, pressure F3 and F4
Vehicle monitoring system inquiry Instrument parameter setting
buttons to move the cursor to the desired function and Controller I/O monitoring Restore factory password
press F2 button to enter. System time setting Backlight brightness adjustment
Buzzer time setting Chinese - English

The section below describes the operation method by
taking the system time setting for an instance.
F1: Return F2: OK
Under the system time setting interface:
a. Press F3 and F4 buttons to select the time digit to
be changed.
Figure 3-37

b. After change, press F2 button to confirm the

change. The cursor automatically moves to the
System time setting
next digit. Sany Mining
Machinery
August 13, 2012

12:30:25
F1: Return F2: OK
Figure 3-38
c. When the cursor is moved to the last digit

(namely the single digit of second), press OK
button to confirm the current change. Press OK System time setting
button again. A “square green symbol” is shown Sany Mining
Machinery
to indicate that the current change of timing

setting is completed. August 13, 2012
12:30:25
d. Press return button to return to system function
interface.
F1: Return F2: OK
Figure 3-39

3.6 Switches
3.6.1
1. Key switch 6.Front fog lamp 11. Fault diagnosis switch

2. Combination switch 7. Headlight switch 12. Side wiper switch
3. Warning lamp switch 8. Exhaust brake switch 13. Elevating switch
4. Electrical horn switch 9. Fan emergency switch
5. Rear Lamp Switch 10. Inter-axle discrepancy switch
Figure 3-40

3.6.2 Key switch

The key switch is used to start and stop the engine.
“LOCK” position:
● The key can be inserted and rotated at this
position. When the key switch is rotated to this
position, all electric circuits are powered off and
the engine is stopped.
“ON” position:
Figure 3-41
● The power circuits of whole vehicle are powered
on when the key is at this position.
● The key switch is also at this position after the
start of engine.
“START” position:
● This position is used to start the engine. Hold the
key at this position to start the engine. Release the
key switch upon start of engine. In such case, the
key switch will return to “ON”.
3.7.2 Combination Switch

Horn
Press the left handle button 1 to sound the horn.
Light illumination
Left handle
0: Stop light illumination
Ⅰ: Start clearance light
Ⅱ: Start headlight
Cleaning pump
Figure 3-42
Press the right handle button 3 so that the washing
pump sprays washing fluid.
Wiper
Warning
Right handle
To run the wiper under non-rainy weathers, ensure to
J: Reserved
spray the washing flui befor sta ting the wiper
0: Off and reset position of wiper
motor. The wiping under dry status is pro ibited.
I: Low speed mode of wiper
II: High speed mode of wiper
Hydraulic retarder handle
Right handle 2 with four gear positions. Toggle forward
to achieve four-position hydraulic retardance.

3. Turn signal lamps

A: Initial position of turn signal lamp
B: Push forward horizontally the handle to turn on right
turn signal lamp.
C: Pull backward horizontally the handle to turn on left
turn signal lamp.
Figure 3-43
4. Headlamp
A: Normal working position of switch handle
B: When the handle is rotated to the headlight switch
and toggled from position A to position B, the full beam
and dipped beam lights shall be switched over while the
full beam light shall be flash once, then it will be
restored from position B to position A.
C: When the handle is rotated to the headlight switch
and toggled from position A to position C and
maintained, the full beam light is in operation. Figure 3-44
3.6.4 Warning Lamp Switch

Danger alarm
Press the lower portion of switch to flash external turn
signal lamps simultaneously.
Press the upper portion of switch to turn off the
warning lamp.
A: Turn off the warning lamp.
B: Turn on the warning lamp.
Figure 3-45
3.6.5 Electrical-air horn switch
Press the lower part of the switch to change to air horn.
Press the upper part of the switch to change to electrical
horn.
A: Switch to electrical horn.
B: Switch to air horn.
Figure 3-46

3.6.6 Rear Lamp Switch

Press the lower portion of switch to turn on rear lamp
and press the upper portion of switch to turn off rear
lamp.
A: Turn off rear lamp.
B: Turn on rear lamp.
Figure 3-47
3.6.7 Front Fog Lamp Switch
Press the lower portion of switch to turn on rear fog
lamp. Press the upper portion of switch to turn off rear
fog lamp.
A: Turn off front fog lamp.
B: Turn on front fog lamp.
Figure 3-48
3.6.8 Headlamp switch
Press the lower portion of rocker switch to power on
the headlamp (low beam/high beam). The high/low
beam of the combination switch is functional only
when this witch is turned on.
A: The high/low beam position of the combination
switch is non-functional.
B: The high/low beam position of the combination
switch is functional.
Figure 3-49
3.6.9 Exhaust brake switch
Press the lower part of the switch to operate the exhaust
brake; Press the upper part of the switch to stop the
exhaust brake.
A: Stop exhaust brake.
B: Start exhaust brake.
Figure 3-50

3.6.10 Fan emergency switch

Press the lower part of the switch to start the fan for
heat dissipation; Press the upper part of the switch to
stop the fan.
A: Stop the fan.
B: Start the fan for heat dissipation.
Figure 3-51
3.6.11 Inter-axle discrepancy switch
Press the lower part of the switch to start inter-axle
discrepancy; Press the upper part of the switch to stop
inter-axle discrepancy.
A: Stop inter-axle discrepancy.
B: Start inter-axle discrepancy.
Figure 3-52
3.6.12 Fault diagnosis switch
The fault diagnosis switch is installed on the control
panel. Press the lower part of the switch to start the
function; Press the upper part of the switch to stop the
function.
A: Stop fault diagnosis function.
B: Start fault diagnosis function.
Figure 3-53
3.6.13 Side wiper switch
Press the lower part of the switch to start the operation
of side wiper; Press the upper part of the switch to stop
the operation of side wiper.
A: Stop side wiper function.
B: Start side wiper function.
Figure 3-54

3.6.14 Elevating switch

Press the lower part of the switch to start the elevating
function and operate the elevating handle; Press the
upper part of the switch to stop the elevating function.
A: Stop elevating function.
B: Start elevating function.
Figure 3-55
3.6.15 Elevating control handle switch
The elevating control handle is installed on the left side
of the driver seat.
Pull back the handle to elevate the tilter; push the
handle to middle position to stop elevation.
Figure 3-56
3.6.16 Holding switch

of the driver seat.
Push the handle to middle position to maintain the tilter
staying on current position.
The elevating handle shall be pushed to this position
during normal driving.
Figure 3-57
3.6.17 Forced landing switch

of the driver seat.
Push forward the handle to achieve forced landing by
the dead weight of the tilter.
Figure 3-58

3.7 Control Levers and Pedals

3.7.1
1. Gear position control handle 3. Accelerator pedal

2. Retarder control handle 4. Brake pedal
Figure 3-59

3.7.2 Gearshift Lever

The vehicle is configured with manual gearbox, use
position shift handle to select proper gear position for
normal operation. The operation handle is located on
the right side of the driver.
Figure 3-60
Driving direction of the vehicle

Figure 3-61
Please refer to following table for maximum gradeability and speed of each gear position.
Gears Max. gradeability (%) Maximum driving speed (Km/h)
st
1 gear 31.5 4.39
nd
2 gear 21.63 5.99
rd
3 gear 16.02 8.28
th
4 gear 10.45 11.15
th
5 gear 7.11 15.15
th
6 gear 3.46 24.93
7th gear 1.28 40.14

3.7.3 Accelerator Pedal

The accelerator pedal provides engine fuel system
with an electrical signal that is proportional to the
pedal pressing angle.
Note: Before the engine temperature rises to normal
operating temperature, electrically controlled engine
has no response to the accelerator pedal’s location.
Before starting the engine, make sure that the feet
are off the accelerator pedal.
Figure 3-62
3.7.4 Clutch pedal
When the clutch pedal is stepped on, the push rod of
drive cylinder will move forward the piston to push
the brake fluid to move along the oil tube and enter
into the hydraulic control chamber of clutch booster
cylinder. The brake fluid will be used as the
working pressure on the piston, as well as the
control pressure to adjust the pressure in air
Figure 3-63
chamber of the booster cylinder. When the
compressed air enters into the air chamber of
booster cylinder and generates air power, it will
push the piston to move forward the push rod of
booster cylinder, rotate the release rocker arm, then
the release fork will drive the release bearing move
backward in order to separate the clutch.
3.7.5 Service Brake Pedal
Based on the driving speed and load of vehicle and
the conditions of road, depress the foot brake pedal
on the cab baseplate by right foot to slow down or
stop the vehicle. After slow-down, release the pedal.
If the stop is required, depress and hold the pedal,
till the vehicle is stopped steadily. Do not depress
the pedal repeatedly.
Figure 3-64

3.8 Cigarette Lighter

The cigarette lighter is used to light cigarettes.
Push down the cigarette lighter. After several
seconds, the cigarette lighter will pop up to original
position. Unplug the cigarette lighter to light
cigarettes.
The socket of cigarette lighter can also be used to
power on electric devices of no more than
240W(24V×10A).
Note: The cigarette lighter is in voltage of 24V.
Figure 3-65
3.9 Horn
Press the left button of handle horn to make the
sound.
Horn
Figure 3-66
3.10 Steering Wheel

To ease the operations, the position of steering
wheel can be adjusted as required. During
adjustment, pull out the adjustment lock, tilt up or
down the steering wheel, and after adjustment push
back the adjustment lock.
The steering system’s hydraulic power arises from
two piston pumps in continuous operation.
Figure 3-67
Rotate the steering based on the steering direction
and steering radius to steer the front wheels. The
steering speed of the front wheels is proportional to
the rotation speed of steering wheel. When the
rotation of steering wheel is stopped, the front

wheels shall stop rotation and hold in position.

Rotating the steering wheel in opposite direction
can return or continuously rotate in opposite
direction the front wheels.
Figure 3-68

3.11 Fuses
The fuses are functioned to protect electric equipment
and guard the wires against burnout.
If a fuse is corroded or the housing of a fuse shows
black, replace the fuse.
Capacities and function names of fuses

Fuse case
Fuse capacity Circuit name
10A Right full beam lamp
10A Left full beam lamp
10A Excitation
10A Control switch Figure 3-69

10A Dryer
Caution: Cut off the power supply (Rotate the key
15A Wiper
switch to OFF) before replacing a fuse. Replace the fuse
5A ECUON
with new one of same capacity and model only.
10A Air conditioner
10A Instrument indication
5A Instrument constant power
10A Reversing lamp
15A Rear working lamp
5A Flashing lamp
15A Standby
15A Ignition lock

Figure 3-70
25A ECU
15A Air condition compressor
25A Fan 1
10A Right dipped beam lamp
10A Left dipped beam lamp
10A Toplight radio
10A Flahser
10A Front working lamp
10A GPS
5A Light illumination
5A Retarder
10A Foglamp

25A Fan 2
10A Control
7.5A YS brake
10A Cigarette lighter
15A Air conditioner
25A Oil heater/filter
10A Horn
5A Brake
10A Small lamp
Relay
No. Name
A Wiper high speed relay
B Wiper low speed relay
C Wiper intermittent relay
E Rear working lamp relay
F Air conditionner relay
G Fan 1 relay
H YS brake relay
Figure 3-71
I Exhaust linkage relay
J Wiper spraying relay
K Flasher relay
L Exhaust brake relay
M Front working lamp relay
N Fan 2 relay
O Oil heater/filter relay
P Small lamp relay
Q Foglamp relay
R Horn relay
S Dipped beam lamp relay
T Full beam lamp relay
U Ignition ON relay
V Brake lamp relay

3.12 Central control screen

3.12.1 Central control screen
Basic operation: The identified gestures mainly
includes multiple types of short press, long press, drag,
slide, etc. Same function will have different results
when using different gestures, which can be operated
by user through the touchscreen.
Home: Home is the default main menu interface after

starting-up, including shortcuts of common functions
of configurations. Long click on the blank area will
call out wallpaper setting button, for the user
customized layout adjustment.
Application interface: Click menu button to enter into

the application interface, in which all the applications
installed in the vehicle software will be displayed. The
user can drag any shortcuts of common functions to
Home for convenient operations.
Delete application icon: Long click any one application

icon or widget on Home can call out the delete button.
Drag any one application icon or widget onto the
delete button, it will be changed to the deletion status
in red color, when the user can release the hand to
recycle the shortcuts of application icon or widget.
Radio: The radio can receive multiple different

broadcasting signals, the user can collect six favorite
channels to P1-P6 at most, which allows fast access to
favorite programs without channel scanning.
3.12.2 Operation instructions

Vehicle setting - sound setting: In sound setting, the
sound output effect can be set through options of
equalizer, amplifier switch, etc. which will provide
actual operation experience to users.
General setting: It will allow the users to access to
basic parameters setting and function configurations of
the machine according to personal habits.

1. Any key to start: Click any key on the touchscreen to

start the machine.
2. Brake setting: The video display is controlled by
manual brake.
3. Auto entering navigation: It will enter into
navigation function after starting up.
4. Reversing image: The reversing image will be
displayed in the mode of mirror imaging.
5. Reversing mute: All other sound outputs will be
shielded during reversing.
6. Default volume switch: It will control the default
volume of starting up.
7. Starting up default volume: It will setup the default
volume of starting up.
8. GPS sound mixing: It will control the background
sound output of navigation voice broadcast.
9. Sound mixing proportion: It will control the
background volume of navigation voice broadcast.
10. Reversing volume down: It will control the
background volume after reversing.
11. Navigation application setting: It will setup the
called navigation map.
12. Driver door location: It will be set according to
actual conditions.
Vehicle setting - GPS information: It will indicate basic

GPS locating information, and can be display in dual
modules of BD and GPS. The automatic
synchronization switch will ensure that the machine
time and locating micro time are synchronized when
the vehicle is positioned.
Vehicle setting - Factory setting: It will setup the
function configurations of the machine with access
password, not recommended to change the settings
unless the non-exceptional conditions occur to ensure
normal operation of the machine.
Bluetooth - Bluetooth telephone: The bluetooth
telephone functions can be used only when the mobile
phone is connected to the vehicle through bluetooth.
1. Open bluetooth functions of the mobile phone and
the machine respectively, and set the mobile phone as
discoverable to all.
2. Use the mobile phone to search bluetooth devices,
then select and input normal pairing password of 0000

to connect. Bluetooth - Setting: It will display the name

and pairing password of machine bluetooth, which can
be changed by the user. The automatic answering
function means any phone call will be automatically
answered. Click the bluetooth reset button to restore
the factory default settings.
Setting - System setting: It will allow to change system

settings including display time, language, etc. The user
may click the setting icons to access. Any changes to
setting without permission are not recommended to
ensure normal operations.
WLAN setting: Click the WI-FI control switch button

to activate WI-FI function. Select and click to connect
the available WIFI sources listed on the right.
Setting - Device display: It will allow the user to setup
screen brightness, wallpaper, font size and automatic
access to black screen.
Application: It will allow the user to check and mange

the memory and internal storage. The user is able to
find and click the application icon, then click the
fictional button in pop-up operation interface to delete
or stop the installed external applications.
Location information: It allows the user to setup GPS

satellite positioning to get your current location
information. The GPS satellite positioning function
shall be always on to ensure the normal navigation
functions.
Safety: It allows the use to setup restrictions to

installation of external applications. Any third party
application shall be installed after the setting of
unknown source status.
Date and time: It is to setup system time. The time

pattern is automatically acquired from network in
general.
About the vehicle machine: It is to show the basic

information of the machine including internal

applications, system and other softwares.
File manager: It will allow the user to check and

operate all files in the machine, the file directory is on
the left side of the page for selection. In case you need
to copy or move a certain file, just select the file to be
operated. A row of operating buttons will appear under
the selected file. The user can select the directory and
click the corresponding button to complete the
operation.
Touchscreen assistant - Display button: The floating

button of touchscreen assistant has many shortcuts, by
which the user can change functions conveniently. If
the user needs to show the floating button, click the
touchscreen assistant to enter the page and setup the
display button options.
Touchscreen assistant - Starting up: After the floating
button is set to be displayed, it will be displayed every
time on starting up. For interfaces of video, navigation,
etc. which need to hide the floating button, the user can
setup to hide the function when using relevant
applications.
Touchscreen - Button size adjustment: During the

operation, the user can customize the size of floating
button according to personal habits.
Touchscreen - Button transparency adjustment: During

the operation, the floating button may not be clearly
displayed due to backgrounds in different colors, to
which the user can adjust the transparency of the
button for better display.
Music player - Playlist: Click the icon on home or

application interface to enter into the main interface of
music player. The playlist will pop-up if there is no
playing history.
Music player - Introduction of play interface: Select

the song to be played in the list and click to enter the
playing interface. It will display some basic
information and common control buttons of the current
playing song, the user can click on relevant button to

achieve corresponding effect, and meanwhile the user

can drag the progress bar to realize fast forward or fast
backward. In song track display area, slide to switch to
lyrics and spectrum of current playing song. The lyrics
can be displayed by clicking on the display area to
activate the network search or lyrics file. It will
provide the user with joyful stereo music effects.
Video player - Video playing: The video player can

identify all the internal and external video resources,
supporting multiple video formats including MP4, avi,
wmv, rmvb, flv, mkv, mov, ts, etc.
Unique and simple operating interface with strong

decoding capacity and HD video playing.
Video player - Video list: In video list, the user can

select storage device type on the left to check the
corresponding video list.
Video player - Video playing interface: Select the

video from the list, click to enter into video playing
interface. It will display information such as the tile
and progress, etc., drag the progress bar to realize fast
forward and fast backward.The touchscreen operating
interface will be automatically hidden or appear for a
better watching experience.
Video player - PIP (picture in picture): Click the PIP

function, the video player will be downsized and
overlaid on the interfaces of other applications, and
click the zoom and fullscreen on the top right corner
for corresponding functions. The PIP function will help
the user to watch videos while operating other
applications.
Vehicle setting - Equalizer setting: Click the sound

effect button to enter into the page, the use can preset
sound effect or adjust the sliding bar to set the sound
effect. Click sound field button to enter the page, the
user can preset sound field mode or drag the ball to
adjust internal sound output, i.e. in case the ball is near
the driving position, then the sound effect at driving

position will be stronger than that of any other

positions inside the vehicle.
Help - FAQ:
1. The mobile phone bluetooth and vehicle bluetooth
are not paired and connected?
Please turn off the bluetooth on mobile phone, then
turn on to search and connect again. If it still does not
work, click bluetooth reset and connect again after a
few seconds.
2. Bluetooth music has no sound?

Please confirm the paired mobile phone has volume
output.
3. Click to download the phone book but no

response?
After the bluetooth is connected and clicking to
download the phone book, the mobile phone will
receive the request to download contacts, confirm and
allow to download.
4. No update after setting up the name of bluetooth?

After setting up the name of bluetooth, in case it is not
updated immediately, please disconnect bluetooth and
click pairing to connect again.
5. No data update of music player after inserting SD

card or USB?
After inserting the storage device, the music player
will detect and scan data. It will take time (1s to 1min)
to update if the quantity of data is large. If it still does
not work, please confirm the storage device is firmly
inserted.
6. The name of song track file is displayed as messy

code?
The name of song is not the name of the file. If the
song is encoded neither in general format nor in the
mode conforming to native language, then it will be
displayed as messy code.

3.13 A/C System

3.13.1 A/C Control Panel
The descriptions for the buttons of control panel are shown in follow figure
Figure 3-72
3.13.2 Operation Instructions
1. Temperature button
Rotate the knob to red area to gradually increase the
temperature and blue area to gradually decrease the
temperature.
Figure 3-73
2. Air volume key
The air volume key is to adjust the blowing capacity,
rotate the button to select proper air volume.
Figure 3-74
3. Air direction key
Rotate the knob to adjust air direction, including to
head, to head and feet, to feet, to feet and windscreen
as well as to windscreen only.
Figure 3-75
4. Refrigeration switch
Press the refrigeration switch and the air conditioner
will start cooling.
Figure 3-76

3.13.3 Precautions for Use of A/C

Ventilation
 During long-time running of A/C, shift the
“internal/external recirculation mode” to
“external recirculation mode” at interval of 1h for
ventilation purpose.
 Smoking with A/C running will harm your eyes
by smoke. Therefore, shift the “internal/external
recirculation mode” to “external recirculation
mode” to ease the removal of smoke under
continuous A/C mode.
Temperature control
 Under the A/C mode, set up the temperature in
such level that you can feel slightly cool at the
entry into the cab (lower by 5~6ºC (9~10.8ºF)
than the outside temperature). This temperature
difference is considered most appropriate to your
health. Therefore, ensure to notice the correct
adjustment of temperature.
Requirements for non-use of A/C

 To lubricate all compressor parts and operate the
A/C and dehumidification, warm up at low idling
speed for 3~5min once a month. In addition,
check the volume of refrigerant gas twice a year.
Remarks
 The A/C probably can’t work if the cab interior
temperature is low. In such case, warm up the cab
by circulating air and then rotate the A/C switch
to ON. The A/C will work.

3.14 Cab Door Windows

3.14.1 Opening of Cab Door Windows
1. Press the lock catch before opening the windows
of cab doors.
2. Slide backward the front window and/or slide
forward the rear window.
Door window lock catch
Figure 3-77
3.14.2 Closing of Cab Door Windows
1. Slide forward the front window and/or slide
backward the rear window.
2. After closing the door windows, ensure that the
lock catch is completely locked.
3.15 Cab Emergency Exit

If the doors can’t be opened in event of emergency,
hold the safety hammer to break the front windscreen
for escape.
Do not use the safety hammer in any other case.
Figure 3-78
Guard yourself against being scratched while

breaki g the glass. Take cautions during escape
to guard against harms by broken glass.

3.16 Door Locks

● Before unlocking the door locks, stop the
machine on a level ground.
● Do not unlock the door locks on a slope. The
doors will probably close suddenly to cause
harms.
● Before unlocking the door locks, do not extend
your body or hands beyond the machine or place
hands onto door frame. The doors will probably
close suddenly to cause harms.
● To close doors, push the cab doors to lock on the
cylinders.
Figure 3-79
3.17 Cup Holder

The brackets for water cup and walkie-talkie are
located on the central control console of the driving Cup Holder
cab.
Walkie-talkie
Figure 3-80
3.18 Safety support
• The safety support is located on the rear left side
of the frame.
• The safety support shall be folded in flat status
when the tilter is not elevated (not in operation).
• During the inspection or maintenance of the

Figure 3-81
elevated tilter, the safety support is to fully lift
the tilter to ensure the elevating switch is at
holding position and protect the tilter from
falling down (Rotate the safety support to the
angle shown in the figure, which is in the normal
operating status).

• Ensure the safety support is not in use after the
completion of inspection or maintenance and in

normal operation, to prevent the vehicle from
abnormal operation or even damages to the
machine.
 In case the tilter is elevated for inspection or
maintenance, please ensure the elevating switch
is at holding position and the safety support is in
normal operation.

Maintenances SKT90S Mining Wide-Body Dump Truck
Maintenances
5 Maintenances ................................................................................................................................................ 5-5
5.1 Safety Instructions ............................................................................................................................... 5-5
5.1.1 Overview................................................................................................................................. 5-5
5.1.2 Maintenance Personnel ........................................................................................................... 5-5
5.1.3 Risks during Maintenances ..................................................................................................... 5-5
5.1.4 Precautions before Maintenances ........................................................................................... 5-7
5.1.5 Precautions during Maintenances ........................................................................................... 5-7
5.2 Maintenances....................................................................................................................................... 5-9
5.2.1 Maintenance Overview ........................................................................................................... 5-9
5.2.2 Handling of Oil, Fuel, and Coolant and Analysis of Oil Quality ............................................ 5-9
5.2.2.1 Oils ........................................................................................................................................ 5-9
5.2.2.2 Hydraulic oil ........................................................................................................................ 5-10
5.2.2.3 Fuel ...................................................................................................................................... 5-12
5.2.2.4 Coolant in cooling system ................................................................................................... 5-12
5.2.2.5 Lubricating grease ............................................................................................................... 5-13
5.2.2.6 Storage of engine oil and fuel .............................................................................................. 5-14
5.2.2.7 Filter elements ..................................................................................................................... 5-14
5.2.2.8 Maintenances of electric system .......................................................................................... 5-15
5.3 Lubrication ........................................................................................................................................ 5-16
5.3.1 Lubricating point bitmap ...................................................................................................... 5-16
5.3.2 Lubricant ............................................................................................................................... 5-16
5.4 Wearing Parts .................................................................................................................................... 5-17
5.4.1 Table of Wearing Parts .......................................................................................................... 5-17
5.5 Recommended Fuel, Coolant, and Oils ............................................................................................. 5-18
5.5.1 ...................................................................................................................................................... 5-18
5.5.2 Selection of Lubricating Oil/Grease Materials ..................................................................... 5-20
5.5.3 Maintenance Capacity Table ................................................................................................. 5-21
5.6 Technical Specification of Tightening Torques ................................................................................. 5-23
5.7 Critical Safety Parts ........................................................................................................................... 5-29
5.8 Maintenance Procedures.................................................................................................................... 5-30
5.8.1 Maintenance of initial 2000km & 200h ................................................................................ 5-30
5.8.2 When Necessary ................................................................................................................... 5-34
5.8.2.2 Checking of front suspension cylinder length and oil level................................................. 5-35
5.8.3 Checking before Start ........................................................................................................... 5-37
5.8.4 Checking and Maintenances at Interval of 10h (Daily) ........................................................ 5-40
5.8.4.1 Inspection of engine ............................................................................................................ 5-40

SKT90S Mining Wide-Body Dump Truck Maintenances
5.8.4.2 Inspection of fuel system ..................................................................................................... 5-41

5.8.4.3 Inspection of cooling system ............................................................................................... 5-41
5.8.4.4 Inspection of air inlet system ............................................................................................... 5-42
5.8.4.5 Inspection of exhaust system ............................................................................................... 5-44
5.8.5 Maintenance of every 2500km&250h .................................................................................. 5-47
5.8.6 Maintenances at Interval of 500h.......................................................................................... 5-48
5.8.6.1 Replacement of engine oil and engine oil filter ................................................................... 5-48
5.8.6.2 Replacement of fuel filter and fuel-water separator filter element ...................................... 5-49
5.8.6.3 Maintenance of oil-gas separator ......................................................................................... 5-51
5.8.6.4 Maintenance of air filter ...................................................................................................... 5-51
5.8.7 Maintenance of every 10000km&1000h .............................................................................. 5-51
5.8.7.1 Checking of hydraulic system ............................................................................................. 5-51
5.8.8.1 Cleaning of fuel tank ........................................................................................................... 5-53
5.8.9.1 Replacement of hydraulic oil ............................................................................................... 5-59
5.8.10 Maintenances at Interval of 4,000h....................................................................................... 5-60
5.8.10.1 Cleaning of radiator ............................................................................................................. 5-60
5.8.10.3 Inspection of abrasion of brake drum .................................................................................. 5-60
5.8.10.4 Change of hydraulic oil for elevation of driving cab ........................................................... 5-61

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Warning

5 Maintenances
5.1 Safety Instructions

5.1.1 Overview
Many accidents occurred during the operations,
maintenances, and repairs of the machine are caused by
the failure to abide by the basic safety regulations or
precautions. These accidents often can be avoided if
diversified potential dangers are realized. The operation
personnel must be warned of all potential dangers. The
operation personnel must be trained to master the
necessary skills and use tools correctly.
The incorrect operations, lubrications, maintenances,
and repairs of the machine are dangerous and will result
in personal injury or death.
Ensure to read and understand the operation,
lubrication, maintenance, and repair information of
machine before starting these works.
5.1.2 Maintenance Personnel

● Only the trained and designated personnel are
allowed for operations and maintenances of
machine.
5.1.3 Risks during Maintenances

● High pressure cylinder
Before relieving the pressure of high pressure
cylinder, do not disassemble any valve, hydraulic
connector or valve cover or any part.
● Compressed air
The compressed air will result in personal injuries.
While using compressed air for cleaning purpose,
wear protective mask, protective clothing, and
protective shoes.
● Liquid penetrating power
Ensure to use a thin board or paper board to check
for leakage. The liquid sprayed out under high
pressure, even from a pinhole, will penetrate
human organs to cause serious injury or even
death. In event of skin penetration by liquid,
ensure to seek for medical treatment immediately.
● Asbestos material

While handling the parts containing asbestos

fibers, take special cautions to prevent the
inhalation of possibly generated powders. The
inhalation of such powders will be harmful to your
health.
● Guard against crushing and cuts
Unless otherwise specified, do not operate any
adjustment work during the working of machine or
running of engine. The machine must be securely
supported before operations beneath the machine.
Do not support merely by hydraulic cylinders.
Keep a certain distance from rotating parts.
● Guard against scalding
Under working temperature, the engine coolant is
hot and pressurized. The radiator and all pipelines
to the heater and engine contain hot water and
steam. The accidental contact will result in serious
scalding. The hot oil and engine parts will
probably cause personal injuries. Keep your skin
away from them.
● Guard against fire and explosion
All fuels, most lubricating oils, and some coolant
mixtures are inflammables. It will result in fire if
such inflammables are leaked or splashed onto hot
surfaces or electric units. Do not smoke during
refueling or in refueling zone.

5.1.4 Precautions before Maintenances

● Before the maintenances and repairs of machine,
hang a “No operation” or similar warning label
onto the key switch or handle.
● Unless otherwise specified, ensure to apply the
parking brake, shift transmission to neutral gear,
stop the engine, and withdraw the key.
● Depending on the working conditions, wear safety
helmet, protective goggles, and other protective
appliances.
● Do not wear loose clothing or jewelry, otherwise
they will probably be hooked to handle or other
machine parts.
● Ensure there is no impurity, oil, tool, or other
external object on the machine, especially the
ladder, platform, and walkway.
● Properly fix all loose objects, such as lunch box,
tools, and other external objects.
● Understand the gesture signals and the signaler.
Only take the signals from one signaler.
● Do not store maintenance liquid in a glass
container.
● Report all items that must be repaired.
● All non-authorized personnel are prohibited to get
on the machine.
5.1.5 Precautions during Maintenances

● Get on and off the machine only by ladder and
handrails.
● Before getting on and off the machine, check the
ladder and handrails and when necessary clean and
repair.
● To get on or off the machine, face towards the
machine and keep three-point contact with
footplates and handrails (Two feet + one hand or
two hands + one foot).
● It’s prohibited to get on or off the machine or jump
off the machine during the traveling of machine.
● While carrying any tool or object, do not attempt
to get on or off the machine. Hoist the objects onto
the platform by a rope.
● Before starting the engine or starting up the
machine, ensure there is no person working above,

below, or around the machine and there is no

person around the machine.
● If a “No operation” label or similar label is hung
on the key switch or control handle, do not start
the engine or move any control handle.

5.2 Maintenances
5.2.1 Maintenance Overview
● For replacement parts, lubricating grease, and
oil, ensure to use genuine parts of Sany.
● While replacing oil or adding oil, do not mix
with oil of different type. To replace with oil of
different type, ensure to fully drain the used oil,
completely add new oil, and replace the oil filter.
(The mixing of some residual oil contained in
the pipeline will not cause any influence).
5.2.2 Handling of Oil, Fuel, and Coolant
and Analysis of Oil Quality
5.2.2.1 Oils
● The oils contained in the engine and hydraulic
device continuously deteriorate during use under
severe working conditions (high temperature and
high pressure).
● Ensure to use the oils conforming to the
recommended grade of Operation and
Maintenance Manual and compatible with
minimum and maximum environment
temperatures.
● Replace the oils as per specified replacement
interval, even if the oils are not dirty.
● The lubricating oils are similar to the blood in
human body. Handle the oils with caution to
prevent the ingress of impurities (Such as water,
metal particles, and dusts).
● Most malfunctions of the machine are caused by
the ingress of impurities.
● Pay special attention to guard against the ingress
of impurities during storage and adding of oil.
● Add oil to the specified volume, otherwise it will
result in abnormality.
● Do not mix the oils of different grades or
trademarks.
● If the oil in the working device is dirty, contains
water, or there is air content in oil pipeline,
please contact an authorized dealer of Sany.
● To check the status of machine, it’s
recommended to perform oil quality analysis
periodically. If such service is required, please

contact an authorized dealer of Sany

● During the replacement of oil, ensure to replace
the related filter element. In addition, while
replacing the engine oil filter element, add the
specified clean oil into new filter element before
installation.
● Please use oil recommended by Sany
● The use of non-recommended hydraulic oil will
probably result in blockage of filter element. Do
not use such non-recommended oil.
● While replacing hydraulic oil, please drain the
residual oil from pipeline and cylinder as
complete as possible. However, the mixing of
some oils is also allowed.
5.2.2.2 Hydraulic oil
As an important constituent part of hydraulic system,
the hydraulic oil is functioned to realize the
transmission, conversion, and control of energy. In
addition, it also plays the lubrication, anti-rusting,
anti-corrosion, and cooling roles for the system.
The cleanliness of hydraulic oil not only influences
the working performance of hydraulic system and
lives of hydraulic units, but also directly relates to the
normal working of hydraulic system.
During the use of vehicle, the oil cleanliness shall not
be higher than grade NAS9. If higher, replace the
hydraulic oil.
The requirements of hydraulic oil for hydraulic
system of machine are as below:
Temperature Hydraulic oil

t＜-15ºC L-HV32 (Recommended)
-15ºC＜t＜40ºC L-HV46
t＞40ºC L-HV68 (Recommended)
The original hydraulic oil for the mining trucks is

Caltex HDZ46.
The hydraulic oil is exposed to external
contamination during transport and storage. Though
seemingly clean, the newly purchased hydraulic oil is
really “dirty”. Ensure to condition it stationary for
several days and filter it before adding into the
hydraulic system for use. The oil leaking from the

system is prohibited to return to the oil tank without
filtration.
Please fill the hydraulic oil strictly as per the
specification. Otherwise, all consequences arising
from the use of disqualified hydraulic oil or the
failure for timely replacement of hydraulic oil will be
solely borne by the user. The use of Caltex, Mobil, or
Shell hydraulic oil is recommended. To use
lubricating oil of other brand, please consult with
Sany.
To judge the contamination level of hydraulic oil, the
common judgment method is to compare the oil to be
judged with clean new oil and observe for color
difference and presence of turbidness, dust, and
sediment. The simple evaluation method for the field
use is described below.
Field visual observation method for judgment of oil
contamination status:
Appearance and color Odor Contamination status Treatment measure

Transparent, without
Normal No contamination Continue to use.
change
Continue to use, if the viscosity is
Faded transparent Normal Mixing with other oil
qualified.
Mixing with metal
Transparent, with flickers Normal Filter or replace oil.
chippings
Transparent, with black
Normal Mixing with impurities Filter or replace oil.
spots
Dark brown Frowzy Oxidized impurities Completely replace oil.
Milk white Normal Mixing with air or water Separate water or replace oil.
Replace the hydraulic oil after first 200 hours and

afterwards replace oil once every 3,000h.
Please use an oiling machine or filtering trolley to fill
the hydraulic oil. The direct filling of hydraulic oil is
prohibited.

5.2.2.3 Fuel
● To prevent the formation of water content in the
fuel tank due to condensation of moisture in the
air, ensure to fully fill the fuel tank after the
daily operation.
● The fuel injection pump is a high precision part.
If the fuel in use contains water or dirt, the fuel
injection pump can’t work normally.
● Before starting the engine or 10min after
refueling, drain the sediment and water from the
fuel tank.
● Upon detection of any impurity in fuel tank,
flush the fuel tank and fuel system.
● If the engine fuel is used up or the filter element
is replaced, ensure to bleed the air fuel from the
fuel pipeline.
● Ensure to use the fuel specified by Operation and
Maintenance Manual.
● The fuel will freeze when being used below the
specified temperature (Especially under the
temperature of below -15ºC (5ºF)).
● When the fuel is used above specified
temperature, the fuel viscosity will drop to result
in reduced output power.
● Take special caution to prevent ingress of
impurities during storage or filling of fuel.
5.2.2.4 Coolant in cooling system
● The coolant plays the significant anti-corrosion
and anti-freezing functions.
● The use of antifreeze is really necessary, even in
the regions requiring no anti-freezing measure.
● Sany machines are filled with L-35 antifreeze.
The L-35 antifreeze features excellent
anti-corrosion, anti-freezing, and cooling
characteristics.
● As a basic principle, the use of any coolant other
than L-35 antifreeze is not recommended. The
use of other coolant will probably result in
serious problems (such as corrosion) of engine
and cooling system parts with use of light metals
(such as aluminum).
● While thinning the antifreeze, use distilled water
or running water (soft water).
● The natural water, such as river and well water

(hard water), contain a large amount of mineral
substances (such as calcium and magnesium),
which will easily result in scaling in engine and
radiator. Once formed, the scale within engine or
radiator is difficult to remove. In addition, the
poor heat exchange will also result in
overheating. To thin the coolant, the use of water
with total harness below 10PPM is
recommended.
● While using the antifreeze, ensure to abide by
the precautions specified in this manual.
● The pure antifreeze is an inflammable substance.
Keep it away from open fire.
● If the engine is overheated, wait for the engine to
cool down before adding coolant.
● The under-low coolant level will result in
overheating. In addition, the air content in the
coolant can result in corrosion problem.
5.2.2.5 Lubricating grease

● The lubricating grease is functioned to prevent
distortion and noise at connections.
● The lubricating grease plays a role to lubricate
the sliding surfaces and prevent the ingress of
powders and water.
● If any part becomes inflexible or generates noise
after long-time use, add the lubricating grease.
● Ensure to use recommended lubricating grease
and select lubricating grease as per the
replacement periods and environmental
environments recommended by this manual.
● While filling grease, remove the used lubricating
grease being squeezed out.
● Ensure to remove the used lubricating grease
contaminated by sand and dirt, otherwise it will
result in wear of rotating parts.

5.2.2.6 Storage of engine oil and fuel

● Store indoors to guard against the ingress of
water, dusts, and other impurities.
● For long-time storage of oil drums, place the oil
drums with side down and place the oil filler
port of drums on the side (to prevent ingress of
moisture).
● If it’s necessary to store oil drums outdoors,
cover the oil drums by waterproof cloth or take
other protective measures.
● To prevent oil deterioration due to long-term
storage, ensure to follow the principle of first-in
and first-out (The lubricating oil or fuel with
longest storage time shall be used firstly).
5.2.2.7 Filter elements

● The filter elements are important safety parts to
prevent the ingress of impurities of oil pipeline
and air pipeline into important devices from
causing malfunctions.
● Periodically replace all filter elements. Refer to
related section of this manual for details.
● During operations under severe conditions,
replace the filter elements within shorter periods
based on the sulfur contents of lubricating oils
and fuel.
● Do not use any cleaned filter element (for filter
element type filters). Replace with new ones.
● While replacing filter elements, check for
presence of metal particles adhered on the used
filter element. Upon detection of metal particles,
please contact Sany or its authorized dealer.
● Unpack the spare filter element only
immediately before use.
● Use genuine filter elements of Sany.

5.2.2.8 Maintenances of electric system
● The moisture of electric equipment or the
damaged covering of wires will result in electric
short-circuit and machine malfunction. Do not
flush the inside of cab by water. While flushing
the machine, take cautions to guard against the
ingress of water into electric parts.
● Do not install any electric part other than those
specified by Sany.
● The external electromagnetic interference will
result in malfunction of control system
controllers. While installing radio receiver or
other wireless device, please contact Sany or its
authorized dealer.
● While installing electric devices, connect them
to the special power connectors.
● Do not connect any power supply to fuse, starter
switch, or battery relay.

5.3 Lubrication
5.3.1 Lubricating point bitmap
Figure 5-1
5.3.2 Lubricant
Figure 5-2

5.4 Wearing Parts

The wearing parts, such as oil filter element and
air filter element, shall be replace within the
maintenance period or before the wear limit is
reached.
To operate the machine more economically,
replace the wearing parts correctly.
For replacement parts, use high quality genuine
parts of Sany.
Please refer to the numbers of Parts Catalog while
ordering the parts.
5.4.1 Table of Wearing Parts
Item Part number Quantity Replacement period

Engine oil filter element 160605020019 2
Fine fuel filter element 160604020022 1 500 hours
Coarse fuel filter element 160604020023 1 (250 hours for first time)
Fuel-water separator filter element 160603020013 1
Steering system pressure oil filter element 60345316 1
1000 hours
Elevating tank breather valve 60319757 1
(250 hours for first time)
Elevating tank oil return filter element 60336511 1
The main filter element of air filter (160602020020A)

shall be checked and cleaned irregularly according to
the working conditions, in case the safety filter element
(160602030016A) is polluted, change the complete
main filter element and safety filter element.

5.5 Recommended Fuel, Coolant, and
Oils
5.5.1
● To maintain the long-term best status for your
machine, it’s really necessary to follow the
fuel/oil/grease/coolant operation and
maintenance instructions of this manual.
Otherwise, it will result in excessive wear of
engine, drive system, cooling system, and other
parts and shorten their lives.
● The lubricating oil additives available in the
market are probably helpful or harmful to your
machine. The use of lubricating oil additives is
not recommended by Sany.
● The specified volume refers to the total oil
volume in the oil tank and pipelines and the
refilling volume is the refilled volume required
during checking and maintenance.
● To start the engine under the <0ºC(32ºF)
temperature, ensure to use the recommended
multi-grade oil, even if the environment
temperature is high at daytime.
● Use recommended oils based on the environment
temperature listed in the table below.
● Replace the oil as per the maintenance periods
specified by this manual if the sulfur content of
fuel is less than 0.5%. If the sulfur content of
fuel is higher than 0.5%, replace the oil as per
the table below:
Sulfur content of fuel Oil replacement period for engine oil sump
0.5-1.0% 1/2 of standard period
>1.0% 1/4 of standard period
The fuel oil shall be complied with GB20891 and

selected in accordance with local environment
temperature and GB252, refer to following for details:
• No. 5 automobile diesel oil shall be used in
regions with risk ratio of 10% and minimum

temperature of more than 8℃.


temperature of more than 4℃.

temperature of more than -5℃.



The freezing point of normal cooling liquid contains

specifications of -25℃, -35℃, -40℃, etc. Please select
cooling liquid with different freezing points according
to local environment temperature in the principle that
the freezing point shall be around 10 degrees lower
than local minimum temperature.
Attention:
1. The cooling liquid shall be checked on regular
basis to avoid corrosion damages and shall be
changed in time according to actual conditions.
2. Do not use water or low quality cooling liquid for
the engine.

5.5.2 Selection of Lubricating Oil/Grease Materials

Use/application Environmental Trademark/viscosity Quality standard
Material name
location temperature grade grade
-20～40℃ SAE15W/40
Diesel engine
Diesel engine oil -25～30℃ SAE10W/30 API CH-4, CI-4
oil sump
-30～30℃ SAE5W/30
>8C 5#
>-4ºC 0#
>-5ºC -10# No more than GB252
Engine Fuel tank Common diesel 0.5% in sulfate
>-14ºC -20# content GB20891
>-29ºC -35#
>-44ºC -50#
>-15ºC -25#
Engine water Antifreeze, mixed
Antifreeze >-25ºC -35#
tank with soft water
>-30ºC -40#
Transmission <+40℃ SAE85W/140
Differential
Gear oil -25℃～+40℃ SAE80W/90 APIGL-5
Main reducer
Wheel reducer <-25℃ SAE75W/90
-5℃～+35℃ SAE10W
ATF C-4
Suspension cylinders Drive oil +10℃～+50℃ SAE30
CAT T0-4
<-20℃ SAE10W
Hydraulic oil tank Anti-wear hydraulic oil -10℃～+40℃ HDZ46 ISO11158 HV
Multifunctional <-40℃ ISO VG460 NLGI 1
extreme pressure
lithium-based
lubricating grease
Front wheel hub bearing
(Without molybdenum
and steering column
content), with melting <-30℃ NLGI 2
drive shaft yoke bearing
point at 190ºC.
(Composite
lithium-based synthetic
lubricating grease)
Multifunctional With or without
<25℃ NLGI 1
extreme pressure molybdenum
lithium-based
Other lubrication With or without
lubricating grease -20℃～ 25℃ NLGI 000 ～ 0
locations molybdenum
(Composite
lithium-based With or without Consult with local
lubricating grease) <-20℃
molybdenum oil/grease supplier.

Temperature conversion table
Celsius (ºC) -32 -30 -27 -25 -20 -18 -15 -10 0 10 15 25 32 35 38 45 93 190
Fahrenheit (ºF) -26 -22 -17 -13 -4 0 5 14 32 50 59 77 90 95 100 113 200 374
Note 1: If the environment temperature is continuously

higher or lower than the listed environment
temperature, please consult lubricating oil/grease
manufacturer for the correct oil/grease viscosity.
Note 2: The Benz engine manufacturer only
recommends the engine oils conforming to API grade
specification and no others. Benz recommends only the
multi-grade viscosity oils listed under diversified
environment temperatures.
Note 3: Operating under the listed minimum
temperature without correct preheating or heating will
reduce the life of transmission. If the auxiliary oil
heater is provided, preheat the oil to the minimum
temperature limit. If no auxiliary heater is provided,
operate the engine accelerator to certain level to heat up
the oil to certain temperature in neutral gear of the
transmission.
5.5.3 Maintenance Capacity Table

Maintenance capacity
No. Name
L
1 Engine crankcase and filter 28
2 Transmission 23
3 Cooling system 55
4 Fuel tank 530
5 Steering hydraulic system（including oil tank） 22
6 Retarder (not applicable for vehicle without retarder) 6.5
7 Clutch assistance oil 0.7
8 Intermediate axle main reducer 24
9 Intermediate axle wheel edge reducer 12
10 Rear axle main reducer 20
11 Rear axle wheel edge reducer 12

12 Inter-axle differential mechanism 2
13 Front suspension cylinder (total) 3.5
14 Elevating system (including fuel tank) 145

5.6 Technical Specification of
Tightening Torques
The bolted connection is a really important and
extensively applied mechanical connection. The
tightening is required for most threaded connections
during assembling, in order to enhance the connection
stiffness, compactness, and locking capacity. The
threaded connection is significantly important for main
locations and must be tightened to the specified torque.
This is because that these threaded fasteners probably
influence the reliability, working performance, and
safety of the related parts or even the entire system. If
any loose fastener is detected or the replacement of
fastener is required due to damage during use, ensure to
tighten to the specified torque.
For the fasteners, such as bolts, nuts, and studs, used on
this machine, the table below is established to prevent
the overload damage due to excessive force application
during assembling and to specify a unified standard for
safe tightening of these fasteners.
Table 1 Maximum Tightening Torques for Threaded Fasteners (Metric)
Thread Performance grade

specification 8.8 9.8 10.9 12.9
(Nominal
diameter × Tightening torque
pitch) Newton.meter Pound.footNewton.meter Pound.footNewton.meterPound.footNewton.meterPound.foot
M1.6 – – 0.20 0.15 – – 0.20 0.15
M2.0 – – 0.25 0.20 – – 0.45 0.30
M2.5 – – 1 0.75 – – 1 0.75
M3.0 – – 1 0.75 – – 2 1.5
M3.5 – – 2 1.5 – – 3 2
M4.0 – – 3 2 – – 4 3
M5.0 – – 5 4 – – 8 6
M6.0 – – 9 6 – – 13 10
M8.0×1.25 – – 21 15 27 20 32 23
M8.0×1.00 – – 23 17 29 21 34 25
M10.0×1.50 – – 42 31 54 39 63 46
M10.0×1.25 – – 45 32 57 41 67 48
M12.0×1.75 – – 74 53 94 68 110 80

M12.0×1.25 – – 81 58 103 74 121 87

M14.0×2.00 – – 118 85 151 109 176 127
M14.0×1.50 – – 128 92 163 118 190 137
M16.0×2.00 169 122 – – 234 169 274 197
M16.0×1.50 181 130 – – 250 180 292 211
M18.0×2.50 234 169 – – 323 234 378 273
M18.0×1.50 263 190 – – 363 262 425 307
M20.0×2.50 330 239 – – 457 330 531 386
M20.0×1.50 367 265 – – 507 366 593 423
M22.0×2.50 451 325 – – 623 450 728 526
M22.0×1.50 495 357 – – 684 494 800 577
M24.0×3.00 571 412 – – 790 570 923 667
M24.0×2.00 623 450 – – 861 622 1007 727
M27.0×3.00 837 605 – – 1158 836 1354 977
M27.0×2.00 903 652 – – 1250 902 1461 1055
M30.0×3.00 1135 820 – – 1570 1134 1835 1325
M30.0×2.00 1258 908 – – 1740 1256 2034 1468
M30.0×1.50 1300 939 – – 1799 1299 2102 1516
M36.0×4.00 1985 1433 – – 2745 1982 3208 2317
M36.0×3.00 2102 1517 – – 2907 2099 3398 2453
Note:
1. The maximum tightening torques for the standard
bolts (nuts) in this table are approximately 75% of
the yield limit of bolt (nut) material.
2. All tightening torques listed in this table are
applicable for the lubricated threads. The
“lubricated” here means the use of thread lubricant
or cadmium plating or the use of quenched washer.
3. The torques listed in the table are recommended
values for the use of common fasteners and the
±10% variation for tightening torques is allowed.

Table 2 Maximum Tightening Torques for Threaded Fasteners (British)

Thread Performance grade
specificati Steel GM260-M Steel GM280-M Steel GM290-M Steel GM300-M
on 12-point cap screw
Grade SAE2 Grade SAE5 Grade SAE7 Grade SAE8
(Nominal
diameter - Tightening torque
number of Newton.me Pound.f Newton.me Pound.f Newton.me Pound.f Newton.me Pound.f Newton.me Pound.f
teeth) ter oot ter oot ter oot ter oot ter oot
0.25-20 5 4 8 6 11 8 12 9 14 10
0.25-28 7 5 10 7 12 9 14 10 15 11
0.31-18 11 8 18 13 22 16 24 18 27 20
0.31-24 12 9 19 14 24 18 27 20 30 22
0.38-16 20 15 31 23 38 28 43 32 49 36
0.38-24 23 17 34 25 43 32 49 36 56 41
0.44-14 33 24 47 35 59 43 68 50 75 55
0.44-20 37 27 54 40 68 50 79 58 87 64
0.50-13 50 37 75 55 94 69 106 78 119 88
0.50-20 56 41 88 65 106 78 122 90 134 99
0.56-12 75 55 108 80 136 100 156 115 171 126
0.56-18 81 60 122 90 149 110 176 130 191 141
0.62-11 102 75 149 110 190 140 217 160 237 175
0.62-18 115 85 169 125 210 155 244 180 270 199
0.75-10 176 130 271 200 332 245 380 280 420 310
0.75-16 203 150 298 220 366 270 420 310 472 348
0.88-9 169 125 434 320 536 395 610 450 679 501
0.88-14 190 140 488 360 590 435 678 500 751 554
1.00-8 258 190 651 480 800 590 915 675 1021 753
1.00-12 285 210 719 530 881 650 1003 740 1119 825
1.00-14 285 210 732 540 902 665 1030 760 1148 847
1.12-7 366 270 800 590 1132 835 1302 960 1447 1067
1.12-12- 407 300 902 665 1274 940 1451 1075 1624 1198
1.25-7 515 380 1132 835 1600 1180 1830 1350 2043 1507
1.25-12 569 420 1254 925 1776 1310 2034 1500 2267 1672
1.38-6 664 490 1478 1090 2095 1545 2400 1770 2676 1974
1.38-12 759 560 1688 1245 2393 1765 2739 2020 3056 2254
1.50-6 881 650 1966 1450 2786 2055 3186 2350 3556 2623
1.50-8 936 690 2088 1540 2962 2185 3390 2500 3781 2789
1.50-12 990 730 2217 1635 3145 2320 3593 2650 4010 2958
1.75-5 – – – – 4393 3240 5016 3700 5604 4133
1.75-12 – – – – 5091 3755 5830 4300 6497 4792
1.88-8 – – – – 6006 4430 6874 5070 7664 5653
1.88-12 – – – – 6304 4650 7213 5320 8048 5936
2.00-4.5 – – – – 6623 4885 7565 5580 8448 6231
2.00-8 – – – – 7342 5415 8406 6200 9367 6909
2.00-12 – – – – 7687 5670 8786 6480 9811 7236

2.25-4.5 – – – – 9701 7155 11090 8180 12377 9129

2.25-8 – – – – 10629 7840 12148 8960 13566 10006
2.25-12 – – – – 11050 8150 12636 9320 14102 10401
2.5-12 – – – – 15280 11270 17463 12880 19500 14383
Note:
1. The maximum tightening torques for the standard
bolts (nuts) in this table are approximately 75% of
the yield limit of bolt (nut) material.
2. For thread specification “0.25-20”, “0.25” denotes
that the nominal diameter of thread is 0.25in and
“20” denotes 20 teeth per inch (namely the pitch).
Converted to metric size, it means that the pitch is
25.4mm/20=1.27mm.
3. All tightening torques listed in this table are
applicable for the lubricated threads. The
“lubricated” here means the use of thread lubricant
or cadmium plating or the use of quenched washer.
4. The torques listed in the table are recommended
values for the use of common fasteners and the
±10% variation for tightening torques is allowed.
5. The tightening torques listed in the table are
applicable for the materials specified by GM
standard. For the materials other than those
specified by GM standard, look up the Table 3 to
convert to GM standard materials and look for the
tightening torque.
Table 3 Correspondence between Non-GM Standard Materials and GM Standard Materials
Non-GM standard materials Hardness GM standard materials
Common low carbon SAE1018

Rockwell “B” 85~100 GM260-M
steel SAE1020
SAE1035
Common medium
SAE1038 Rockwell “C” 19~30 GM280-M
carbon steel
SAE1045
Rockwell “C” 28~34 GM290-M
SAE4140
Rockwell “C” 32~38 GM300-M
Medium carbon alloy Rockwell “C” 28~34 GM290-M

SAE8642
steel Rockwell “C” 32~38 GM300-M

Precautions:
1. It’s prohibited to use any inappropriate
screwdriver or wrench to tighten any bolt or nut.
While tightening the nuts of bolt subassemblies,
tighten uniformly by steps (generally 2~3 steps) as
per specified sequence based on the shapes of
connected parts and the distribution of bolts or
nuts, in order to ensure uniform tightening torque
for all screws and bolts. While tightening the
rectangularly distributed bolt subassemblies,
tighten from the center gradually two sides in
symmetric manner. While tightening circularly or
squarely distributed bolt or nut subassemblies,
ensure to tighten symmetrically. If the locating
pins are provided, start the tightening from the
ones near locating pins.
2. If the lock safety wires are used for the heads of
bolts, insert and secure the wires along the rotation
direction of thread. For double nuts without lock
sealant, firstly install the thin nut and tighten to
approximately 80% tightening torque and then
tighten the thick nut to 100% torque.
3. If the replacement fastener is required, the model
shall be same with that of original one or the one
with equivalent performance shall be used. It’s
disallowed to use any replacement fastener with
inferior quality or different design, in order to
prevent causing unnecessary losses, such as
machine damage or personal injuries.
Self-locking fasteners
When a self-locking fastener is disassembled and
reinstalled to original fitting part, it can generate a
measurable engagement action or torque to provide the
re-locking performance. However, the locking function
of a self-locking nut deteriorates to certain degree
following every use. To guarantee the reliability of
self-locking fasteners, it’s specified that the self-locking
fasteners used on this vehicle can only be used for up to
5 times as per the technical requirements. Ensure to add
a marking to the head of self-locking fastener once
being disassembled, in order to ensure that the
assembling operators can understand the number of
uses for this self-locking fastener. Once a fastener has

been used for 5 times, ensure to replace with new one.

The table below lists the minimum torque required for
disassembling after the first use of self-locking
fasteners. The self-locking fasteners that can be
loosened by a torque less than the minimum torque
listed in the table are prohibited for reuse, no matter
they are used for 5 times or not.
Table 4 Minimum Common Disassembling Torque for Self-Locking Fasteners

Self-locking screw Self-locking nut
Performance grade
Thread
specification Grade SAE5, SAE8, and ASTM Grade SAE5 Grade SAE8
A-574
Newton.meter Pound.foot Newton.meter Pound.foot Newton.meter Pound.foot
0.25-20 0.3 3 0.4 3.5 0.5 4.5
0.25-28 0.3 3 0.4 3.5 0.5 4.5
0.31-18 0.6 5 0.6 5.5 0.9 7.5
0.31-24 0.6 5 0.6 5.5 0.9 7.5
0.38-16 1.0 9 1.0 8.5 1.3 11.5
0.38-24 1.0 9 1.0 8.5 1.3 11.5
0.44-14 1.4 12 1.4 12 1.8 16
0.44-20 1.4 12 1.4 12 1.8 16
0.50-13 1.8 16 1.7 15 2.3 20
0.50-20 1.8 16 1.7 15 2.3 20
0.56-12 2.5 22 2.4 21 3.2 28
0.56-18 2.5 22 2.4 21 3.2 28
0.62-11 3.4 30 3.1 27 4.1 36
0.62-18 3.4 30 3.1 27 4.1 36
0.75-10 5.1 45 4.6 41 6.1 54
0.75-16 5.1 45 4.6 41 6.1 54
0.88-9 7.3 65 7.0 62 9.3 82
0.88-14 7.3 65 7.0 62 9.3 82
1.00-8 9.6 85 9.5 84 12.7 112
1.00-12 9.6 85 9.5 84 12.7 112
1.00-14 – – 9.5 84 12.7 112

5.7 Critical Safety Parts

During the operations or driving of machine, to ensure
safety continuously, the user must fulfill the periodical
maintenances for the machine. In addition, to further
improve the safety, the user shall periodically replace
the parts listed in the table. These parts are closely
related to the safety and fireproof.
As the materials of the critical safety parts will turn
along with the time vulnerable to wear and
deterioration and it’s difficult to completely judge the
status of parts via periodical maintenances, replace
these parts at the expiration of the specified periods,
regardless of their status, in order to effectively
guarantee the functions of these parts.
If any critical safety part is abnormal prior to the
expiration of the replacement period, ensure to replace
or repair immediately.
If any hose clamp is deteriorated, such as deformation
and cracking, replace the hose clamps along with the
replacement of hose.
Replace the O-ring, sealing gasket, and other similar
parts as well during the replacement of hoses.
Please consult with Sany or its authorized dealer for
replacement of critical safety parts.
Table of Critical Safety Parts
No. Periodical Replacement of Critical Safety Parts Replacement period Remarks
1 Fuel hose (Fuel tank - fuel filter)
2 Fuel hose (Fuel filter - fuel pump)
3 Fuel hose (Engine - fuel tank) Replace once every 2
Replace
years or 4,000 hours,
4 Rubber hoses in cooling system assembly.
whichever comes first
5 High pressure hoses in steering system
6 High-pressure hose in lifting system
Replace once every 3
7 Seat belt Replace.
years.

5.8 Maintenance Procedures

5.8.1 Maintenance of initial 2000km &
200h
1. Replace engine oil
2. Replace engine oil filter.
3. Check and tighten the engine belt.
4. Check and tighten the engine accessories and
fasteners of relevant systems including bolts,
clamps, hoops, etc.
5. Inspection of rim and rim bolt
Check the rim nut (1), tighten if it is loose.
Tightening torque: 750N.m-1000N.m
(76.5kgf•m-101.5kgf•m,553lbft-737lbft).
After changing the tires, tighten the nuts, and re-tighten
the nuts after driving for 5-6km.
Check if there are cracks on the rim, if yes, the rim
shall be changed immediately.
6. Inspection and adjustment of vehicle brake
clearance
After the run-in period, the normal brake clearance
shall be adjusted. Use the wrench to adjust worm shaft
hexagonal head on the whole arm. First rotate
clockwise to adjust the clearance to zero, then rotate in
reverse direction until you hear two drops of steel balls,
when the clearance is 0.4-0.8mm. Attention: Please Figure 5-3
refer to the maintenance manual of axle manufacturer
for detailed instructions.
7. Inspection of bolt torque of transmission shaft
Tighten the transmission shaft assembly and inter-axle
transmission bolt.
During the assembly of disassembled transmission
shaft, clean the grease inside transmission shaft and the
threaded hole of flange fork in prior to installation.
Spot check the bolt torque of transmission shaft in
initial operation period. Re-check after the operation
for 150 hours.

8. Inspection and change of lubricating oil for
gearbox
The lubricating oil of gearbox shall be changed after

run-in period, please refer to details as follows:
1) Locate the vehicle on flat working area when the

front brake is in driving status for the removal of front
axle hub and brake. The wheels shall be blocked to
ensure the vehicle is not able to move, otherwise
please ensure the vehicle is in parking mode with the
Figure 5-4
engine turned off.
2) Rotate the steering wheel for few rounds Ventilation plug
clockwise and anti clockwise to release the steering

system pressure. Block the wheels and turn off the
main switch of storage battery.
3) Remove the drain plug (1) of the gearbox,

discharge the gear oil into proper container and clean
the impurities (i.e. iron dust) absorbed on drain plug
magnet, then tighten the drain plug (1) onto original
Figure 5-5
position after oil discharge.
4) Remove the refueling bolt (3) and oil level

observation hole bolt (2) of the gearbox, fill oil into
the gearbox until the oil overflows from the
observation hole, then tighten the refueling bolt (3)
and oil level observation hole bolt (2) onto original
positions.
9. Inspection and change of lubricating oil for drive

axle
The lubricating oil of drive axle shall be changed after

1) Locate the vehicle on flat working area when the

front brake is in driving status for the removal of front
axle hub and brake. The wheels shall be blocked to
ensure the vehicle is not able to move, otherwise
please ensure the vehicle is in parking mode with the
engine turned off.
2) Rotate the steering wheel for few rounds clockwise

and anti clockwise to release the steering system
pressure. Block the wheels and turn off the main
switch of storage battery.
Figure 5-6

3) Remove the drain plug (1) of left wheel edge

reducer, discharge the gear oil into proper container
and clean the impurities (i.e. iron dust) absorbed on
drain plug magnet, then tighten the drain plug (1) onto
original position after oil discharge.
4) Drive the vehicle until the drain plug (1) of right

Figure 5-7
wheel edge reducer is at the very bottom.
5) Remove the drain plug (1) of right wheel edge

reducer, discharge the gear oil into proper container
and clean the impurities (i.e. iron dust) absorbed on
drain plug magnet, then tighten the drain plug (1) onto
original position after oil discharge.
6) Remove the drain plug (3) of axle housing,

discharge the gear oil into proper container and clean
the impurities (i.e. iron dust) absorbed on drain plug
magnet, then tighten the drain plug (3) onto original
position after oil discharge.
7) Remove the refueling plug (4) of axle housing, fill

oil into the axle housing until the oil overflows from
the refueling inlet, then tighten the refueling plug (4)
onto original position.

wheel edge reducer is at the very bottom. Remove the
refueling plug (2), fill oil into wheel edge reducer until
the oil overflows from the refueling inlet, then tighten
the refueling plug (2) onto original position.

wheel edge reducer is at the very bottom. Remove the
refueling plug (2) of left wheel edge reducer, fill oil
into wheel edge reducer until the oil overflows from
the refueling inlet, then tighten the refueling plug (2)
onto original position.
10. Replacement of hydraulic oil
Please use refueling machine or oil filter cart to fill in

Warning
hydraulic oil, do not pour directly, otherwise please
Please operate after the vehicle is parked for a
inject through elevating and oil return filter element of
certain period of time and the oil tank is exhausted to
hydraulic oil tank.
prevent the scald to skin by high temperature oil.
1) The vehicle shall be fully stopped and parked and
confirm the hydraulic pressure is fully released, then

clean the operating surface.
2) Remove the cover plate (1) of elevating and oil

return filter of oil tank.
3) Put into the oil output tube of hand pump or use

clean small oil bucket to fill the oil into the filter
element, ensure the filter element is not loose. Stop
filling until the oil overflows the filter element due to
fast filling, refilling when the oil flows into the tank
through filter element until the quantity of oil is
sufficient.
4) Install the O ring and observe, change in case it is

Figure 5-8
damaged. Use special tools or bar wrench to tighten
the cap. Refer to 8.8.1 for other instructions.
11. Change of pressure oil filter element for steering

system
The detailed procedures are as follows:
Remove the filter chamber (1).
Change the filter element (2) and the seal ring (3) in
the meantime, then install the filter chamber (1).
Start the vehicle, check if there is any oil leakage and

if the steering function is in normal operation.
12. Change of breather valve and oil return filter

element for elevating tank
1) Open the cap of breather valve (2).
2) Change new filter element.
3) Close the cap. Please refer to the maintenance and

inspection instructions of 500 hours, 1000 hours, 2000
hours and 3000 hours for detailed procedures to
change the oil return filter element of the elevating
tank.

5.8.2 When Necessary

5.8.2.1 Internal cleaning of cooling system
Warning
The coolant is under high temperature and the
radiator is internally under high pressure
immediately after the stop of engine.
In such case, there is a danger of scalding to
disassemble the cap and drain the coolant. Wait for
the temperature to drop before disassembling the cap
and then slowly rotate the cap to relieve the pressure.
Start the engine and flush the system. Before
standing up or leaving the driver seat, the driver shall
shift the gearshift lever to neutral gear (N) and apply
the parking brake.
If there is a danger of fan contact during the
operations, the operations are prohibited while the
engine is running.
● To clean or replace the coolant, park the machine

on a level ground.
● The coolant plays the significant anti-corrosion
and anti-freezing functions.
● It’s necessary to use antifreeze coolant, even in
the non-freezing regions.
● Use coolant recommended by Sany.
● Prepare a container with capacity exceeding
prescribed coolant volume to hold the discharged
coolant.
● Prepare one hose.
Warning
The pure antifreeze is an inflammable substance.
Therefore, preserve it in a place far away from fire.
The ntifreeze is a toxic substance. In event of
splash into your eyes, flush with a great amount
of water and i mediately seek for medical
treatment.
Figure 5-9
1. Stop the engine and wait for the engine to cool
down before opening the expansion tank cap (1).
2. Open the drainage valve (2) beneath the radiator

3. After draining the water, close the drainage
valve (2).
4. Fill the radiator with urban tap water. When the
radiator is full, cover the water tank cap (1).
5. Start the engine and run the engine at low idling
speed for 10min.
6. Stop the engine and repeat steps 1~3.
7. After draining the water, clean the radiator and
inside of expansion tank by detergent.
8. After cleaning, open the drainage valve (2) to
fully drain the water.
9. Close the drainage valve (2).
10. Filling of cooling liquid to 2/3 position of the
total volume of expansion tank
11. To completely bleed air from coolant, run the
engine at low idling speed for 5min and then run
the engine at high idling speed for 5min. (Before
this operation, disassemble the water filler cap). Figure 5-10
12. Observe the coolant level approximately 3min
after the stop of engine. If the coolant level is
low, add coolant. (Refer to the section 4.1.2.1
“Checking of Coolant Level and Adding of
Coolant")
5.8.2.2 Checking of front suspension cylinder
length and oil level
The impact arising from the rugged roads during
driving is directly transmitted to the chassis
(Abnormal bump of vehicle or telescoping of cylinder
to impact with limit block). Check the extension
length of suspension cylinder as described below.
Park the vehicle without load on flat ground, check
the extension length A of piston rod (the distance
between the center of suspension cylinder axis pin
and the upper surface of guide sleeve), which shall be
218mm. In case any abnormal conditions are
discovered, please contact the distributor for repair
and further inspection and adjustment according to
the requirements of filling suspension cylinder
specified in the manual.
1. Plug (oil filling inlet) 2. Nitrogen filling valve
Note: A stands for the extension length of piston rod,
which is the distance between the center of suspension
cylinder rod installation hole and lower surface of the
cylinder.

The unloading dimension of vehicle A = 218mm.

Figure 5-11

5.8.3 Checking before Start

● Checking of coolant level and adding of coolant
● Check if the pressure difference indicator of air
filter is in normal operation.
● Check the oil level of fuel tank, refuel, drain
water from oil-water separator and fuel rough
filter.
Attention: In case the lower water collectors of
oil-water separator and fuel rough filter are filled with
water or the spinning filter has been replaced, the
collected water shall be discharged as per the
following procedures:
(1) Open the water drain valve (2) on the bottom of
water collector (1) to fully discharge the water.
(2) Tighten the water drain valve (2) again.
Figure 5-12
4. Check if there is any leakage of oil, water or gas.
5. Check if the external parts and accessories are in
good and tight connections.
6. Check if the fans and belts are excessive tight or
loose..
7. Check the hydraulic pipelines and oil tank level.
Check if all the hoses, steel pipes, pipe clamps,
guard plates and cushions are fastened in
position, of which any loose connections in
vibration and friction during operation may
cause damages to hoses and splashing of high
pressure oil. Check the oil tank level, the oil
leveler is located on the side of oil tank, refill the
oil in case no oil can be observed through the oil
leveler viewing hole.
Figure 5-13

8. Drain the water from air cylinder.
Pull down the pulling ring of water drain valve (1),

release the ring to original position when the water is
fully discharged. Please operate the same procedure
to five (5) air cylinders one by one for water draining
of every set of vehicle.
Figure 5-14
9. Checking of service brake performance
Warning
Before checking the brake function, ensure that the
field around the vehicle is free of per onnel and
obstacles. Upon detection of vehicle movement
during checking, stop the vehicle, apply the
parking brake, and drive the vehicle only after the
malfunction is solved.
Check the service brake performance as per
procedure below:
1. Stop the machine on a level ground and depress Figure 5-15

the service brake pedal (1).
2. Shift the gearshift lever (3) to gear D.
3. Release the parking brake (4).
4. Depress the accelerator pedal (2).
5. Slowly increase the engine speed and observe
whether the machine remains stationary when
the engine speed reaches 1,350r/min. It’s normal
if the machine remains stationary.
After checking, operate as per procedure below:
1. Reduce engine speed.

2. Return the gearshift lever (3) to neutral gear (N).
3. Apply the parking brake (4).
4. Release the service brake pedal (1).
Upon detection of any abnormality, please contact

Sany for repairs.
10. Checking of parking brake performance

Warning
field around the vehicle is free of personnel and
obstacles.
Upon detection of vehicle movement during
checking, stop the vehicle, apply the parking brake,
and drive the vehicle only after the malfunction is
solved.
Check the parking brake performance as per

procedure below:
1. Stop the machine on a level ground and depress

7. Then, reduce the engine speed and return the
gearshift lever (3) to neutral gear (N).
Sany for repairs.

5.8.4 Checking and Maintenances at

Interval of 10h (Daily)
5.8.4.1 Inspection of engine
Check the engine oil level, refuel in case the oil level
is low. The engine shall not be started in case the oil
level is below the lower scale line or above the upper
scale line of the oil level indicator. Check the oil level
at least 5 min after the stop of engine to ensure there
is sufficient time for the oil to flow back to the pan.
Check if there is any leakage of water, gas and oil. Figure 5-16
Check if the engine fan and belt are damaged or in
loose connection. Visual check if there is any
damages, cracks, gaps, etc. to the engine belt, if yes,
the belt shall be replaced. Put 110N force on the belt
between the pulleys, if the deflection exceeds the
thickness of the belt within the range of 0.3m, then
please contact SANY after sales service personnel or
engine maintenance personnel for the adjustment to
the tension force of the belt.
Figure 5-17

1. Note:
Check if there is any breakage or abrasion of belt
pulley groove.
In case any abnormal conditions are discovered,
please contact SANY after sales dept. or the agent of
engines to replace the belt.
The belt shall be replaced in case it is too long to be
adjusted or there are any cutting marks or cracks
discovered.
 Check the readings of oil temperature and
pressure gauge.
 Check the water temperature of engine.
 Check if the sound of the engine is normal.
 Check if the speed and vibration of the engine
are normal
Figure 5-18
5.8.4.2 Inspection of fuel system
 Check fuel system for leakage.
 Check if the ventilation valve of fuel tank is
blocked.
 Check the oil gauge level of fuel tank, fully
refuel into the tank after work everyday.
Figure 5-19
5.8.4.3 Inspection of cooling system
 Check the cooling liquid level, refill in case it is
low. If the cooling liquid level is observed below
the lower scale line of the expansion tank, open
the cap of expansion tank and fill in more
cooling liquid, please refer to Chapter 4.1.2.1
Inspection of cooling liquid level and refilling
for detailed instructions.

Warning
To check the coolant, ensure to wait for the engine
to cool down before checking the expansion water
tank.
The coolant is under high temperature and the
radiator system contains a high pressure
immediately after the stop of engine. There is a
scalding danger to disassemble the expansion
water tank cap for checking of coolant. Ensure to
wait for the temperature to drop before opening the
water tank cap and then slowly rotate the cap to
relieve the pressure.
 Remove the cap of expansion tank, observe if
there is any oil stain on the surface of cooling
liquid.
Note: In case any abnormal conditions are discovered,
use reagent and test paper to check if there is any
cooling liquid mixed into hydraulic oil and gearbox
transmission oil, and contact SANY service engineers
for more technical supports.
 Check hoses and parts for leakage.
5.8.4.4 Inspection of air inlet system
Safety filter element

Warning
Do not clean the filter element unless the alarm is Main filter element
given by the pressure difference indicator of the air
filter, as frequent cleaning may lower the
efficiency of the filter and reduce the service life of
the engine.
 Check the sealing tightness of air inlet system.
 Check if the inlet hose is aged with cracks and Figure 5-20
the hoop is loose or not. If necessary, fasten or
replace components to ensure good tightness of
the air inlet system.
 Check vacuum dust collection valve for normal
functioning.
 Check if there is any alarm given by the pressure
difference indicator, if yes, please clean or
change the air filter element.

The maximum air inlet resistance shall be inspected
only when the engine is operating at rated speed with
High pressure air tube
full load. When the air inlet resistance reaches the
maximum limit (the pressure difference indicator will
give an alarm), the filter element shall be replaced in
accordance with following instructions:
1. The main filter element of air filter must be
replaced after cleaning for six (6) times.
Cleaning procedures of main filter element: Remove
the main filter element from the air filter, pat the end
face to make the dust falling down, or blow in reverse
direction with compressed air (from inside to Figure 5-21
outside).
Attention: Do not damage the filter paper, do not
clean filter paper with water or oil, do not pat or strike
the filter element hard.
2. The safety filter element is not required to be
cleaned, in case the there is any dust or dirt, the
safety filter element and main filter element shall
be repacked in the meantime.
3. Do not use the engine without the air filter,
otherwise the dust and impurities may enter into
the engine causing early abrasion.
Inspection of engine oil in oil basin of air filter.
1. The engine oil shall be injected into air filter oil
basin of which the type of oil shall be the same
as that used for the engine, or the viscosity is
similar to that of the engine in the meantime.
Figure 5-22
2. The level of oil injected shall be lower than the
specified scale (markings on the outside of the
basin, and lower than oil baffle plate), of which
the volume shall be around 5L.
Figure 5-23

3. The connecting tightness of steel wire clamp

between the shell and basin shall be checked
everyday.
Figure 5-24
4. In case the engine oil does not flow easily when
shaking the basin, the rough filter element
assembly shall be cleaned and the engine oil
shall be replaced;
It can be operated for continuous 80 - 120 hours in
normal conditions;
The engine oil shall be inspected, cleaned and
replaced in severe operating conditions.
5. For cleaning the rough filter element assembly,
remove the basin first, then remove the disc nuts
on the bottom of rough filter element assembly
in proper order.
Figure 5-25
5.8.4.5 Inspection of exhaust system
 Check if the exhaust color is normal or not.
 The normal exhaust color is light gray,
troubleshooting shall be done if there is any
change in the color.
Figure 5-26
5.8.4.6 Inspection of drive system
 Check the ventilation plug of gearbox, clean all
the dirt and dust around the ventilation plug.
 Check the ventilation plug of drive axle, clean
all the dirt and dust around the ventilation plug.
 Check if the tires are damaged and if the tire

pressure is complied with specifications.
5.8.4.7 Inspection of hydraulic system
 Check all hydraulic pipelines and oil tank level.
 Check the hydraulic pipelines and oil tank level.
Check if all the hoses, steel pipes, pipe clamps,
guard plates and cushions are fastened in
position, of which any loose connections in
vibration and friction during operation may
cause damages to hoses and splashing of high
pressure oil.
 Check the oil tank level, the oil leveler is located
on the side of oil tank, refill the oil in case no oil
can be observed through the oil leveler viewing
hole.
Figure 5-27
5.8.4.8 Inspection of brake system
 Drain the water from air cylinder.
Pull down the pulling ring of water drain valve (1),
release the ring to original position when the water is
fully discharged. Please operate the same procedure
to five (5) air cylinders one by one for water draining
of every set of vehicle.
 Checking of service brake performance
Warning
Before checking the brake function, ensure that the Figure 5-28
obstacles. Upon detection of vehicle movement
during checking, stop the vehicle, apply the
parking brake, and drive the vehicle only after the
malfunction is solved.

Check the service brake performance as per

procedure below:
5. Slowly increase the engine speed and observe
whether the machine remains stationary when
the engine speed reaches 1,350r/min. It’s normal
if the machine remains stationary.
Figure 5-29
After checking, operate as per procedure below:
1. Reduce engine speed.
2. Return the gearshift lever (3) to neutral gear (N).
4.
Release the service brake pedal (1).

Sany for repairs.
 Checking of parking brake performance
Warning
obstacles.
Upon detection of vehicle movement during
checking, stop the vehicle, apply the parking brake,
and drive the vehicle only after the malfunction is
solved.
Check the parking brake performance as per
procedure below: Figure 5-30
7. Then, reduce the engine speed and return the
gearshift lever (3) to neutral gear (N).

Sany for repairs.
5.8.4.9 Inspection of suspension system

 Check if the plate spring is loose, deformed or
damaged.
 Check if there is any broken or wrong plate
spring.
 Check if the retainer ring of traction bar is
separated.
 Check if the end cap bolt of balance shaft
housing is loose.
 Check if the rubber bearing in balance shaft
assembly is aged and damaged.
5.8.5 Maintenance of every
2500km&250h
5.8.5.1 Inspection of hydraulic system
 Checking of hydraulic system pressure
Lifting system Warning
Check elevating system pressure on the test point of The relevant descriptions of steering hydraulic
elevating hydraulic distribution valve. system pressure are contained in the repair manual.
Steering system If the measurement differs from the required value of
Check steering system pressure on the test point of technical specification, check, repair, or replace the
steering valve group (no less than 16MPa), before related parts to ensure the normal working condition
which the pressure of pre-charging nitrogen shall be of the system. Ensure that the air is emptied before
checked in advance. (Refer to Chapter 4.1.2.10 for checking the pressure of steering accumulator.
details) If the test result is not complied with
standard, the relevant parts or components shall be
checked, fixed or replaced to ensure normal operation
of the system.
Brake system
Observe pneumatic system pressure in real-time
through the air pressure gauge on the instrument desk
of driving cab.
5.8.5.2 Inspection of brake system
 Check the ilding stroke of pedal. Pull the pedal
upward and downward to check if there is any
idling stroke, if yes, adjust the limit screw.
 Check the push rod stroke of brake cylinder and
centering condition of push rod and gap adjuster.
In case the stroke becomes larger, please adjust the
brake connecting rod.
In case the centering of push rod is not in good
condition, or with clamping stagnation, please reface

the brake cylinder.

5.8.6 Maintenances at Interval of 500h
5.8.6.1 Replacement of engine oil and engine oil
filter
Warning
The parts and engine oil are under high
temperature after the operations of engine, which
can probably result in combustion. Wait for the
engine oil to cool down before replacement.
 Replacement of engine oil
1. Remove the drain plug (1) on the bottom of oil
pan, fully discharge the engine oil, put waste
engine oil into a proper container.
2. Check the drained engine oil. Upon detection of
excessive metal particles or external material,
please contact Sany after-service personnel.
3. Tighten the drain plug (1) after fully discharging
the engine oil.
4. Open the cap (2) of engine oil inlet, fill in oil
into the inlet (3), observe the oil level scale,
tighten the cap (2) until it meets the requirement.
Figure 5-31
 Replacement of engine oil filter element
1. Remove the old engine oil filter element (1).
2. Clean the filter base, inject clean engine oil into
the new filter element.
3. Apply engine oil on the rubber cushion before
the installation of new engine oil filter element.
4. Install the rubber cushion onto the base, tighten
for 3/4 to one circle for better sealing.
5. Operate the engine at idling speed for a short
period of time, check if there is any oil leakage,
stop the engine and check the oil level, please
refer to 4.1.2.3 Inspection of engine oil level and
refueling. Figure 5-32

5.8.6.2 Replacement of fuel filter and fuel-water
separator filter element
Warning
All parts are under high temperature immediately
after the stop of engine. Therefore, do not
immediately replace the diesel filter. Before
starting the operations, wait for the engine to cool
down. Keep flame and fire spark away.
Caution
The engine is composed of parts of higher
precision than fuel injection pump and nozzles so
that the ingress of dirt will result in malfunction.
Upon detection of any adhered dirt on fuel
pipeline, thoroughly clean by fuel.
Replace with fuel filter and filter element
recommended by Sany Heavy Equipment Co., Ltd.
The injection system will be malfunctioned due to
use of non-recommended fuel filter. Never use any
substitute part.
Use standard filter wrench to remove the fuel fine
filter element (1), fuel rough filter element (2) and
oil-water separator filter element (3) in sequence. The
water collectors (undamaged) on fuel rough filter and
oil-water separator is reusable, which can be removed
if necessary.
1. Place a proper container for the fuel oil under the
fuel fine filter element (1).
2. Clean the filter base with fuel oil and lubricate
the seal.
3. Fully fill the new fuel filter by clean fuel via the
surrounding orifices in the fuel filter.
4. Tighten the filter element by hand until the seal
is integrated with the interface.
5. Use filter wrench to tighten the filter element for
around 3/4 circle until the filter element is firmly
installed. (Tighten it to specified angle. If the
fuel filter is excessively tightened, the seal will
be damaged to cause fuel leakage. If the fuel
filter is insufficiently tightened, the fuel will leak
via the seal.) Figure 5-33
6. Place a proper container for fuel oil under the

fuel rough filter element (2).

7. Operate as per the steps 2-5.
8. Install the water collector, refer to following
instructions of replacement of water collector.
9. Place a proper container for the fuel oil under the
oil-water separator filter element (3).
10. Operate as per the steps 2-5.
11. Install the water collector, refer to following
instructions of replacement of water collector.
12. Turn ON the start key to connect to the power,
do not start the engine until the electronic fuel
pump of oil-water separator operates for more
than 1 min to discharge the gas from fuel
pipelines. (After the start of the engine, the fuel
oil may still have gas inside, therefore, the initial
operation will be unstable, which does not mean
the engine is faulty and can be solved by the
running at low idling speed until the engine is
running at stable speed.)
13. Ensure no fuel is leaking via fuel filter seal.
Upon detection of fuel leakage, check the
tightening status of fuel filter and fuel-water
separator housing.
 Replacement of water collector.
1. Turn off the engine.
2. Discharge water from the collector.
3. If possible, remove the screw (1) from the water
collector by hand; Use tools of the new water
collector if the screw is excessive tight.
4. Lubricate the seal ring (2) of the new water
collector with a few drops of engine oil.
5. Install the screw by hand and tighten the screw
by tools.
6. Check if the water collector is damaged in case it
will be reused on a new spinning filter.
7. Use torque wrench to install with torque of
20N•m.
Attention: In case the water is full or the spinning
filter has been replaced, the collected water shall be Figure 5-34
discharged.

5.8.6.3 Maintenance of oil-gas separator
1. Open the upper cap of oil-gas separator, remove Upper cap of oil-gas separator
the filter element.

2. Check the glue on both ends of filter element, if Oil-water separator filter element
any cracks are discovered, please change the
filter element.
3. Clean the surface of filter with light diesel oil or
gasoline.
4. Check the seal ring of filter element and upper
cap, change the seal ring if it becomes aged and
hard.
5. Press the filter element into the housing and Seal ring
tighten the upper cap.
Figure 5-35
5.8.6.4 Maintenance of air filter
 Replacement of air filter element.
Replace the main filter element and safety filter
element of air filter, refer to relevant content of
5.8.6.4 Inspection of air inlet system.
 Change the engine oil of air filter oil basin, clean
the rough filter assembly.
Change the engine oil of air filter oil basin, clean the
rough filter assembly, refer to relevant content of
5.8.6.4 Inspection of air inlet system.
Attention: Clean or replace air filter element, replace
engine oil and clean rough filter element in
accordance with actual needs.
In case the air filter element is changed 100 hours
before scheduled time, then no operation is required.
5.8.7 Maintenance of every
10000km&1000h
5.8.7.1 Checking of hydraulic system

 Change of pressure oil filter element for steering

system
Remove the filter chamber (1).
Change the filter element (2) and the seal ring (3) in
the meantime, then install the filter chamber (1).
Start the vehicle, check if there is any oil leakage and
if the steering function is in normal operation.
Figure 5-36
 Change of breather valve and oil return filter
element for elevating tank
1. Open the cap of breather valve (2).
2. Change new filter element.
3. Close the cap and change the oil return filter
element of the elevating tank.
Please refer to details as follows

1. Open the oil return filter cap (1), replace the O
ring in case it is aged and damaged.
2. Remove the old filter element.
3. Clean the surroundings of the filter and avoid
falling, then replace the new filter element.
4. Use special tools or bar wrench to tighten the
cap.
Figure 5-37

 Inspection and adjustment of vehicle brake
clearance
After the run-in period, the normal brake clearance
shall be adjusted. Use the wrench to adjust worm
shaft hexagonal head on the whole arm. First rotate
clockwise to adjust the clearance to zero, then rotate
in reverse direction until you hear two drops of steel
balls, when the clearance is 0.4-0.8mm.
Attention: Please refer to the maintenance manual of
axle manufacturer for detailed instructions.
Every 1200 hours
 Check if the shock absorber of rear suspension
frame is damaged, replace the shock absorber in
case the deformation exceeds 2/3.
 Check the bolt torque of transmission shaft.
Tighten the transmission shaft assembly and
inter-axle transmission bolt.
During the assembly of disassembled transmission
shaft, clean the grease inside transmission shaft and
the threaded hole of flange fork in prior to
installation. Spot check the bolt torque of
transmission shaft in initial operation period.
Re-check after the operation for 150 hours.
5.8.7.3 Inspection of suspension system
 Re-tighten all connecting bolts of push rod.
 Re-tighten the connecting bolt of suspension
casting part.
 Re-tighten the connecting bolt of balance shaft
assembly.
 Re-tighten the end cap bolt of balance shaft.
5.8.8 Maintenance of every 20000km &
2000h
5.8.8.1 Cleaning of fuel tank
Caution
The cleaning of fuel tank shall be conducted by
SANY after sales personnel or professional
maintenance personnel.

Warning
As potential dangers including oil fog, static
electricity, etc. may occur during the cleaning of
fuel tank, please execute in accordance with
protection specifications for special operations.
1. Stop the engine, disconnect all cables from the
fuel tank.
2. Place an appropriate container beneath the fuel
tank (1).
3. Open the drainage plug (2) on the bottom of fuel
tank to fully drain the fuel from fuel tank.
4. Install and tighten the drain plug (2), open the
cap, remove the filter screen.
5. Inject clean fuel oil of certain volume into the
tank (as cleaning oil).
6. The professional personnel shall use special air
pump and tube for the internal cleaning of fuel
tank.
7. Open the drain plug (2) on the bottom of fuel
tank, fully discharge the fuel oil. Figure 5-38
8. Repeat steps 5-7 until clean fuel oil flows out,
then install and tighten the drain plug (2)
9. Install the filter screen, fill up with fuel oil,
tighten the cap go fuel tank.

 Inspection and change of lubricating oil of
gearbox.
The lubricating oil of gearbox shall be changed after
1. Locate the vehicle on flat working area when the
front brake is in driving status for the removal of
front axle hub and brake. The wheels shall be
blocked to ensure the vehicle is not able to
move, otherwise please ensure the vehicle is in
parking mode with the engine turned off.
2. Rotate the steering wheel for few rounds clockwise Figure 5-39
and anti clockwise to release the steering system
pressure. Block the wheels and turn off the main Ventilation plug
switch of storage battery.

3. Remove the drain plug (1) of the gearbox,
discharge the gear oil into proper container and
clean the impurities (i.e. iron dust) absorbed on
drain plug magnet, then tighten the drain plug
(1) onto original position after oil discharge.
4. Remove the refueling bolt (3) and oil level
observation hole bolt (2) of the gearbox, fill oil
into the gearbox until the oil overflows from the Figure 5-40
observation hole, then tighten the refueling bolt
(3) and oil level observation hole bolt (2) onto
original positions.
 Inspection and change of lubricating oil for drive

axle
The lubricating oil of drive axle shall be changed
after run-in period, please refer to details as follows:

1. Locate the vehicle on flat working area when the

front brake is in driving status for the removal of
front axle hub and brake. The wheels shall be
blocked to ensure the vehicle is not able to
move, otherwise please ensure the vehicle is in
parking mode with the engine turned off.
2. Rotate the steering wheel for few rounds
clockwise and anti clockwise to release the
steering system pressure. Block the wheels and
turn off the main switch of storage battery.
3. Disassemble the oil drainage plug (1) of left
wheel reducer to drain gear oil into an
appropriate container and remove the absorbed
impurities (such as steel chippings) from the
magnet of oil drainage plug. After the oil
drainage, tighten the oil drainage plug (1) to Figure 5-41
original position.
4. Drive the vehicle till the oil drainage plug (1) of
right wheel reducer is at the bottommost Ventilation plug
position.
5. Disassemble the right oil drainage plug (1) to
drain gear oil into an appropriate container and
remove the absorbed impurities (such as steel
chippings) from the magnet of oil drainage plug. Figure 5-42
After the oil drainage, tighten the oil drainage
plug (1) to original position.
6. Disassemble the oil drainage plug (3) on the rear
axle housing to drain gear oil into an appropriate
container, remove the absorbed impurities (such
as steel chippings) from the magnet of oil
drainage plug, and then tighten the oil drainage
plug (3) to original position.
7. Disassemble the oil filler plug (4) on rear axle
housing, add oil into the rear axle housing, till
the oil overflows via the oil filler port, and then
tighten the oil filler plug (4) to original position.
8. Drive the vehicle until the drain plug (1) of right
Disassemble the oil filler plug (2) on right wheel
reducer, add oil into the wheel reducer, till the oil
overflows via the oil filler port, and then tighten
the oil filler plug (2) to original position.
9. Drive the vehicle until the drain plug (1) of right

Disassemble the oil filler plug (2) on left wheel
reducer, add oil into the left wheel reducer, till
the oil overflows via the oil filler port, and then
tighten the oil filler plug (2) to original position.
 Inspection on abrasion of brake friction plate
To ensure safety driving, the abrasion of brake
friction plate shall be checked at regular basis. The
brake friction plate shall be replaced in case the brake
friction plate is worn, or the distance between friction
plate and rivet end is less than 0.5mm, or there are oil
stains on the surface of friction plate, or there are any
corrosion or hardening phenomenon.
Please pay attention to following problems during the
change of brake friction plate:
1. The brake shoe shall be cleaned before the
riveting of new friction plate. Check the rivet
hole on brake shoe, which shall be re-punched
after repair in case it is deformed by abrasion.
2. The brake friction plates on the same vehicle
shall be made by the same manufacturer, or at
least the friction plates of two wheels on the
same axle shall be made by the same
manufacturer, in order to guarantee the same
friction coefficient and good braking efficiency
to prevent failures of braking deviation.
3. The friction plate and the shoe shall be fitted
during riveting to prevent breakage in operation
and ensure good heat dissipation. The curvature
of brake friction plate shall be the same as that of
the shoe. Use hand vise to firmly fix the friction
plate with shoe, and rivet from middle to sides in
sequence.
4. After the completion of riveting, chamfer both
sides of the brake friction plate without any
deviation and loosening. The clearance between
brake friction plate and the shoe shall be
0.12mm.
5. The surface of brake friction plate shall be kept
clean, flat and not rough, as the rough bulge part
may be worn as powder lubricant to lower the
braking efficiency.
6. After the brake friction plate is riveted, the
fitness inspection shall be conducted to adapt the
motion characteristics of brake shoe and ensure

that the brake friction plate and brake drum have

a large contact area during braking operation.
Attention:
Fitness inspection: Apply white powder on the inner
surface of brake drum (or use chalk to paint), put the
brake shoe with new riveted friction plate onto the
operating surface of brake drum and rotate back and
forth, then remove the brake shoe, observe the
working track of the plate, which shall be heavy on
both ends, light in the middle, and the contact mark
shall be no less than 50% of the friction plate. It is to
adapt the motion characteristics of brake shoe and
ensure that the brake friction plate and brake drum
have a large contact area during braking operation for
high braking efficiency.
7. Use cooper rivet for brake friction plate, of
which the standard dimension is Ф10×22mm.
Do not use aluminum rivet as it has low
intensity, easy to cut off. Cooper rivets shall be
annealed before riveting.

5.8.9 Maintenance of every 30000km &

3000h
5.8.9.1 Replacement of hydraulic oil
1. Please use an oiling machine or filtering trolley
to fill the hydraulic oil. The direct filling of
hydraulic oil is prohibited. If no oiling machine
or filtering trolley is available, ensure to fill the
oil as per following method: Please inject
through elevating and oil return filter element of
hydraulic oil tank.
2. Park the vehicle stably, ensure that the hydraulic
system pressure is completely relieved, and then
clean the surfaces of working face and keep
working face clean.
Figure 5-43
Warning
Wait for a while after parking of vehicle and
relieve the pressure of oil tank before operations, in
order to prevent high oil temperature from scalding
your skin.
3. Remove the cover plate (1) of elevating and oil

return filter of oil tank.
4. Place the oil output pipe of manual pump or use
a small clean oil drum to fill oil into the filter
element cartridge and notice not to loosen the
filter element. The oil will flood the filter
element if the oil filling speed is too fast. In such
case, stop filling the oil, till oil completely flows
into the oil tank via filter element, and then fill
the oil again, till the required oil volume is
reached.
5. Install the O ring and observe, change in case it
is damaged. Use special tools or bar wrench to
tighten the cap. Refer to 8.8.1 for other
instructions.

5.8.10 Maintenances at Interval of 4,000h

5.8.10.1 Cleaning of radiator
1. Stop the engine.
2. Open the front grille (1) of the driving cab.
3. Clean the radiator (2) along the arrow direction
shown in the figure by compressed air or water
pipe of cleaning machine.
Note: The radiator shall be cleaned in time in severe
operating conditions.
Figure 5-44
5.8.10.2 Internal cleaning of cooling system
Refer to 5.8.2.1 The internal cleaning for cooling
system.
5.8.10.3 Inspection of abrasion of brake drum
The inner diameter of brake drum may be increased
due to abrasion, and the non-concentricity with wheel
hub may be caused by out-of-round and conical
degree. In case the conical degree of brake drum inner
surface is excessive high, it will reduce the contact
area of friction plate and brake drum and lower the
braking efficiency. In case the brake drum is
out-of-round and the hub is not concentrated, the
contact of brake shoe and drum will be unstable and
vibrated during braking and lower the braking
efficiency.


5.8.10.4 Change of hydraulic oil for elevation of
driving cab
Change the hydraulic oil for elevation of the driving
cab.

Malfunction Diagnosis SKT90S Mining Wide-Body Dump Truck
Malfunction Diagnosis
6 Malfunction Diagnosis .................................................................................................................................. 5-5
6.1 Preparations before Malfunction Diagnosis ........................................................................................ 5-5
6.1.1 Precautions for Malfunction Diagnosis .................................................................................. 5-5
6.1.2 Checking before Malfunction Diagnosis ................................................................................ 5-5
6.1.3 Working Procedure during Malfunction Diagnosis ................................................................ 5-8
6.1.4 Precautions for Malfunction Diagnosis of Electric Circuits ................................................. 5-10
6.1.5 Precautions for Handling of Hydraulic Parts ........................................................................ 5-10
6.2 Engine Malfunctions ......................................................................................................................... 5-12
6.2.1 Engine Malfunction Diagnosis Table.................................................................................... 5-12
6.2.1.1 ............................................................................................................................................. 5-12
6.2.1.2 Engine Start Failure ............................................................................................................. 5-12
6.2.1.3 Low Power .......................................................................................................................... 5-12
6.2.1.4 Stop of Engine Shortly after Start........................................................................................ 5-13
6.2.1.5 High Fuel Consumption ...................................................................................................... 5-13
6.2.1.6 Black Exhaust Gas............................................................................................................... 5-14
6.2.1.7 White or Blue Exhaust Gas ................................................................................................. 5-14
6.2.1.8 Deposit of Engine Oil at Air Inlet Port and Air Inlet Pipe of Turbocharger ........................ 5-15
6.2.1.9 Unstable Speed .................................................................................................................... 5-15
6.2.1.10 Low Engine Oil Pressure ..................................................................................................... 5-15
6.2.1.11 High Water Temperature ...................................................................................................... 5-16
6.2.1.12 Fast Wear of Parts ................................................................................................................ 5-16
6.2.1.13 Excessive Noise ................................................................................................................... 5-17
6.2.1.14 Working Failure of Starter Motor ........................................................................................ 5-17
6.2.1.15 Weak Starter Motor ............................................................................................................. 5-17
6.2.1.16 Complete Power Generation Failure of Alternator .............................................................. 5-18
6.2.1.17 Insufficient charging of alternator ....................................................................................... 5-18
6.2.1.18 Unstable Charging Current .................................................................................................. 5-18
6.2.1.19 Excessive Charging of Alternator ........................................................................................ 5-19
6.2.1.20 Abnormal Sound of Alternator ............................................................................................ 5-19
6.2.2 High Water Temperature ....................................................................................................... 5-20
6.3 Malfunctions of Electric System ....................................................................................................... 5-21
6.3.1 Malfunction Diagnosis of Electric System ........................................................................... 5-21
6.3.2 Monitoring Display ............................................................................................................... 5-22
6.3.2.2 Engine trouble code ............................................................................................................. 5-22
6.3.2.3 Transmission trouble code ................................................................................................... 5-30
6.3.3 Battery................................................................................................................................... 5-34
6.3.3.1 34

SKT90S Mining Wide-Body Dump Truck Malfunction Diagnosis
6.3.3.2 Disassembling and installation of battery ............................................................................ 5-34

6.3.3.3 Charging of battery .............................................................................................................. 5-35
6.3.4 Start of Engine by Auxiliary Cable ....................................................................................... 5-36
6.3.4.1 Connection and disconnection of auxiliary cable ................................................................ 5-36
6.3.4.2 Connection of auxiliary cables ............................................................................................ 5-37
6.3.4.3 Start of engine...................................................................................................................... 5-37
6.3.4.4 Disconnection of auxiliary cables........................................................................................ 5-37
6.4 Malfunctions of Hydraulic System.................................................................................................... 5-38
6.4.1 Malfunction Diagnosis of Hydraulic System ........................................................................ 5-38
6.4.2 List of lifting system faults ................................................................................................... 5-39
6.4.3 Brake system malfunction table ............................................................................................ 5-40
6.5 Other Common Malfunctions ............................................................................................................ 5-42

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SRT33C2A-C Mining Truck Chassis Malfunction Diagnosis
Warning

6 Malfunction Diagnosis
6.1 Preparations before Malfunction
Diagnosis
6.1.1 Precautions for Malfunction
Diagnosis
● Park the machine on level ground and ensure
that the key switch is at OFF position and the
handbrake handle is at “Parking” position.
● When two or more persons conduct the
maintenance together, the persons shall agree the
maintenance procedure before the start of the
works and shall notify the companions before
conducting any operation.
● Opening the expansion water tank cap before the
cooling of engine will result in spray-out of hot
coolant to cause scalding. Therefore, ensure to
wait for the engine to cool down before starting
checking.
● Ensure to take special cautions not to touch any
hot part or grasp any rotating part.
● Before disassembling any internal plug or cap
for oil pressure, water pressure or air pressure
mechanism, ensure to relieve the internal
pressure. Ensure the correct connections while
installing testing devices.
● If the disconnection of any electric circuit is
required, firstly turn off the power master
switch.
6.1.2 Checking before Malfunction

Diagnosis
The malfunction diagnosis is intended to accurately
determine the root cause of malfunction, repair
rapidly, and prevent the reoccurrence of malfunction.
During the malfunction diagnosis, the key is to
understand the structure and function of equipment.
For effective malfunction diagnosis, it’s a shortcut to
understand the information from the operator, in order

to preliminarily determine the possible cause of the

malfunction.
1. During the malfunction diagnosis, do not haste
to disassembly parts. The immediately
disassembling of parts will probably result in
that the disassembled parts are not related to the
malfunction or the unnecessary parts are
disassembled, which will probably damage the
parts. Therefore, during the malfunction
diagnosis, ensure to check in advance and
perform the malfunction diagnosis as per
specified procedure.
2. The repair personnel shall inquire the operation
personnel of the following issues:
1) Is there any other problem?
2) Is there any abnormality of machine prior to
occurrence of malfunction?
3) Is the malfunction occurred suddenly or does the
machine already have problem prior to the
4) Under which condition this malfunction occurs?
5) Is any repair work taken prior to occurrence of
malfunction? When is the repair work taken?
6) Is there any similar malfunction in the past?
3. Other checking items:
1) Check hydraulic oil level.
2) Check hydraulic system for oil leakage.
3) Check the control handles for correct motions.
4) Check for normal lubrication of vehicle.
5) Other daily maintenance items that can be
fulfilled from the exterior of machine.
4. Determination of malfunction
Narrow the malfunction cause scope as per
above-mentioned checking procedure and test
results and then determine the malfunction
location as per 6.5.1 Malfunction Diagnosis
Table of this chapter.
Tip: While operating the machine to reproduce
the malfunction in the field, do not take any
checking or measurement action that will make
the problem worse.
5. Troubleshooting
Even after the malfunction is solved, if the
malfunction cause is not solved, the same

malfunction will still occur. Therefore, ensure to

find out and solve the malfunction cause. After
the troubleshooting, the malfunction cause and
the measure to prevent similar malfunctions shall
be introduced to the operation personnel.

6.1.3 Working Procedure during Malfunction Diagnosis
Office Working site

Step 1
Checking and determination of symptom

1) Upon receipt of a customer’s request for repair,
please firstly inquire the following issues:
• Customer name
• Model and serial number of machine.
• Details of working site
2) Master the summary of problem by inquiry.
• Malfunction status Step 8 Occurrence malfunction!
• Working status at occurrence of malfunction

• Working environment Repair in working site
• Historic repairs and maintenances
Step 2 Step 7
Determination of possible cause location • • Determination of
malfunction cause and repair plan
1) Read the section Malfunction Diagnosis in this
manual to find out the possible location of 1) Before malfunction diagnosis,
malfunction cause. determine and repair the simple
Step 8 malfunction location.
• Checking items before start
Repair in workshop • Other checking items
2) With reference to the section Malfunction Diagnosis
in this manual and based on the machine symptom,
Malfunction diagnosis select he malfunction diagnosis procedure and check
and repair.
Step 3 Step 6
Preparation of malfunction diagnosis tools Reproduction of malfunction
1) Prepare necessary tools. • Start and operate the machine, verify the machine
• T-connector malfunction, and determine the existence of
• Hydraulic instruments. malfunction.
2) Look up Parts Catalog
and prepare necessary
replacement parts.

Step 4 Step 5
Departure to working site Understand detailed malfunction information from
operation personnel.
• Is there any abnormality of machine prior to
• Is the malfunction occurred suddenly?
• Is there any repair work taken
prior to occurrence of
malfunction?

6.1.4 Precautions for Malfunction

Diagnosis of Electric Circuits
1. Ensure to turn off power supply before
disconnecting or connecting any connector.
2. Before malfunction diagnosis, check and ensure
all related connectors are correctly inserted.
● Disconnect and connect the related connectors
for several times to check.
3. Ensure to connect all disconnected connectors
before the next operation.
● If the power supply is turned on with connectors
disconnected, it will bring about unnecessary
abnormal indications.
4. During the malfunction diagnosis of electric
circuits (measurement of voltage, resistance,
continuity, or current), move the related electric
wires and connectors for several times and check
the instruments for reading variation.
● Upon detection of reading variation, there is
probably a contact malfunction in electric
circuits.
6.1.5 Precautions for Handling of
Hydraulic Parts
Due to increasing of pressure and increased precision
of hydraulic parts, the most common malfunction
cause is the blockage of hydraulic oil pipeline by oil
sludge. Ensure to take special cautions while filling
hydraulic oil and breaking down or assembling
hydraulic parts.
1. Operation environment
Avoid filling hydraulic oil, replacing filter, or
repairing machine in the rain or in windy or
dusty place.
2. Breakdown and maintenance operations in
working site
There is a danger of dust ingress into parts
during the breakdown and maintenance
operations of hydraulic parts in the working site. Figure 6-1
It's difficult to check the performance after
repairs. Therefore, it’s better to replace the
assemblies. The breakdown and maintenance of
hydraulic parts shall be performed in a special

dustproof workshop and the performance shall

be checked by special testers.
3. Filling of hydraulic oil
While filling the hydraulic oil, guard against the
ingress of oil sludge and dusts. Ensure to keep
clean the filter element and its surrounding area
and use clean pump and oil container. The use of
oil cleaning machine can probably filter out the
oil sludge accumulated during storage.
Therefore, it’s a more effective method. Figure 6-2
4. Replacement of hydraulic oil under high
temperature
The hydraulic oil or other oil can flow easily
under warm status. In addition, the sediments Flushing oil
can be drained easily along with oil from the oil
pipeline. Therefore, it’s better to replace oil
under warm status. During the replacement of
oil, drain the used hydraulic oil as complete as
possible. (Drain the oil from the hydraulic oil
tank and drain the oil from the filter and oil
pipeline drainage plug.) If any used oil is not
drained, the impurities and sediments contained Figure 6-3
therein will mix with new oil to shorten the life
of hydraulic oil.
5. Flushing operations
During the breakdown and assembling of
machine or replacement of oil, use flushing oil to
remove impurities and sediments and the used
oil from hydraulic oil pipeline. Generally, flush
the system by two steps, namely use flushing oil
for main flushing and use specified hydraulic oil
for secondary flushing.
6. Cleaning operations
It’s necessary to remove the sediments and
impurities from hydraulic oil pipeline after the
repair of hydraulic parts (Such as pumps and
control valves) or during the running of
machine. An oil cleaning machine can remove
the tiny particles and can be used to effectively
clean the oil pipeline without disassembling the
built-in filter in hydraulic parts.
Figure 6-4

6.2 Engine Malfunctions

6.2.1 Engine Malfunction Diagnosis Table
6.2.1.1
In event of malfunction, check as per the table below
and contact Sany its authorized dealer for repairs.
6.2.1.2 Engine Start Failure
Malfunction cause Troubleshooting

1. Air content in fuel system Bleed the air, check sealing performance of connectors, and repair.
2. Malfunction of fuel injection Check plunger and fuel outlet valve and repair or replace damaged parts.
pump
3. Malfunction of fuel injector Check atomization state of fuel injector.
4. Damage and leakage of valve Check and adjust.
mechanism or fuel supply pipe
5. Damage and leakage of high Repair and replace.
pressure fuel pipes
6. Insufficient cylinder Check sealing performance of valves and cylinder gasket, check wear of
compression pressure piston rings, and repair or replace.
7. Low air temperature Take the auxiliary starter measure.
6.2.1.3 Low Power

1. Intake blockage (Blockage of
Check air filter and intake pipe and clean or replace filter element.
air filter)
Check valve timing, check exhaust pipeline for blockage, and adjust and
2. Over-high exhaust backpressure
repair.
3. Insufficient pressure of
Check and solve leaks at pipeline connections.
turbocharger system
4. Abnormal working of
Replace assembly.
turbocharger
4.1 Blockage of air compressor or
Clean or replace.
turbine passage by dirt
4.2 Failure of floating bearings Replace.
4.3 Carbon deposit and oil sludge
at back gap of turbine and Clean.
compressor
Check sealing performance of fuel pipes and connectors, check the
5. Leakage or blockage of fuel
contamination degree of filter, repair the fuel pipeline or dredge the blockage
pipeline
dirt, and replace filter element.
6. Low fuel quality Clean fuel tank, filtration parts and fuel pipes, and replace fuel.
7. Excessive wear of fuel injection Repair or replace.

pump or speed regulator

8. Poor atomization of fuel Check fuel injection pressure and carbon deposit of fuel injector nozzle and
injector nozzle adjust and repair
9. Incorrect valve or fuel supply
Check and adjust.
timing
10. Under-low high-speed
Check speed regulation characteristic and adjust accordingly.
adjustment of speed regulator
11. Over-high oil level of oil sump Check oil dipstick and drain excessive engine oil.
Check compression pressure during hot state and replace damaged cylinder
12. Air leakage of cylinder gasket
gasket.
13. Wear and breakage of piston
rings and excessive gap of Replace worn parts or overhaul the engine.
bushings
14. Wear or scuffing of cylinder
Replace worn parts or overhaul the engine.
sleeve or piston
6.2.1.4 Stop of Engine Shortly after Start

Disassemble the filter body, remove internal contaminant and water, and
1. Blockage of fuel filter
when necessary replace filter element.
Check the sealing performance of fuel pipes and connectors, check and
2. Air content in fuel system
ensure the tightening of bleeding screw, and bleed the remaining air.
3. Low quality and high water content
Clean filter and replace fuel.
of fuel
4. Low regulated idling speed Re-adjust.
6.2.1.5 High Fuel Consumption

1. Blockage of intake pipe Check the air filter and intake pipeline and clean.
2.Over-high exhaust backpressure Check exhaust pipeline and brake valve and clean.
3. Low fuel quality Replace with specified fuel.
4. Blockage of fuel pipeline Check and repair.
5. Leakage of fuel pipeline Check and repair.
6. Poor atomization of fuel injector Check and adjust or repair.
7. Incorrect valve or fuel supply
Adjust valve clearance and fuel supply advance angle as per specification
timing
8. Air leakage of cylinder gasket Check compression pressure.
9. Excessive bushing clearance,
Check and overhaul.
requiring engine overhaul
10. Expanding of piston Replace cylinder sleeve, piston, and piston rings.

11. Insufficient pressure of

turbocharger system
12. Abnormal working of
Check and replace.
turbocharger
6.2.1.6 Black Exhaust Gas

1. Blockage of intake pipe or excessive
Clean.
exhaust backpressure
2. Low fuel quality Clean and replace.
3. Incorrect valve or fuel supply timing Adjust as per specification.
4. Poor atomization of fuel injector
Check and repair or replace.
nozzle
5. Excessive fuel volume of fuel
Check and adjust.
injection pump
6. Insufficient pressure of turbocharger
system
7. Abnormal working of turbocharger Check and replace assembly.
6.2.1.7 White or Blue Exhaust Gas

1. Low quality and high water content of fuel Replace fuel.
Check working temperature of thermostat and replace when
2. Under-low coolant temperature
necessary.
3. Incorrect valve or fuel supply timing Check and adjust.
4. Poor atomization of fuel injector nozzle Check and repair.
5. Low compression pressure, incomplete Check piston rings, cylinder sleeve, and cylinder gasket and
combustion, and piston expanding repair.
6. Improper run-in of piston rings and cylinder
Continue run-in.
sleeves
7. Non-staggered openings of piston rings Adjust and reassemble.
8. Failure of piston oil rings Replace.
9. Large fit clearance between piston and
Repair and replace.
cylinder sleeve
10. Wear of turbocharger seal rings Check and replace.
11. Wear of turbocharger thrust bearings Check and replace.
12. Blockage of turbocharger oil return pipe Clean or repair.

6.2.1.8 Deposit of Engine Oil at Air Inlet Port and Air Inlet Pipe of Turbocharger

1. Turbocharger sealing failure Repair or replace turbocharger.
2. Failure of fuel-air separator Replace.
3. Over-high oil sump level and excessively Check and drain engine oil as appropriate to meet the required
filled engine oil level.
6.2.1.9 Unstable Speed

1. Low fuel quality, with water or paraffin
Replace fuel.
content
Check sealing performance of fuel pipes and connectors and bleed
2. Air ingress in fuel suction pipe
air.
3. Abnormal working of speed regulator
counterweight and speed regulation Check and adjust (by professional shop).
spring
4. Non-uniform fuel supply Check and adjust (by professional shop).
5. Unstable atomization of fuel injector
Check and repair.
nozzle
Check and clean air compressor runner, dredge blockage, and remove
6. Surge of turbocharger
carbon deposit from exhaust passage.
7. Damage of turbocharger bearing Replace.
6.2.1.10 Low Engine Oil Pressure

1. Under-low oil sump level or oil shortage Check oil level and oil leaks, repair, and add oil.
2. Malfunction of main oil-way pressure regulator
Check valves and clean and repair.
valve
3. Blockage or cracking of strainer, engine oil Check and clean air compressor runner, dredge blockage,
pipeline, and connector gaskets and remove carbon deposit from exhaust passage.
Replace with engine oil as per specification and choose an
4. Inappropriate engine oil trademark
appropriate oil trademark.
5. Leakage of engine oil pump inlet pipe Check oil pipes and connectors and repair or replace.
6. Over-high water temperature of cooling system
Check working status of cooling system and correct.
and over-high engine oil temperature
7. Excessive resistance of engine oil filter Replace with new filter element.
8. Blockage of engine oil cooler Check and clean.
9. Blockage of main oil-way Check and clean.
10. Excessive bushing clearance or damage of Repair and replace.

bushing
11. Excessive wear of parts, requiring overhaul Check the working hours of engine and overhaul.
6.2.1.11 High Water Temperature

Table 6-1
1. Under-low level in water tank Check for water leaks and add water.
2. Blockage of water tank Check water tank and clean or repair.
3. Loose water pump belt Adjust tension as per specification.
4. Damage of water pump gasket and
wear of water pump impeller
5. Malfunction of thermostat Replace.
6. Damage of water pipe and ingress
Check water pipes, connectors, and gaskets and replace damaged parts.
of air
7. Under-low oil sump level or oil
Check oil level and oil leaks, repair, and add oil.
shortage
6.2.1.12 Fast Wear of Parts

1. Disqualified or damaged air filter
Check and replace with qualified filter element.
element
Check intake pipe, gasket, and connecting pipe sleeve and repair or
2. Short-circuit of intake system.
replace.
3. Under-low oil sump level or oil
Check oil level and oil leaks, repair, and add oil.
shortage
4. Blockage of oil-way Clean oil-way.
5. Inappropriate engine oil trademark Replace with specified oil.
6. Breakage or wear of piston rings Replace damaged parts.
7. Wear or scuffing of cylinder sleeve or Disassemble and check piston and cylinder sleeve and repair or
piston replace.
9. Failure to timely replace engine oil
Replace as per specification.
filter element
9. Excessive wear of parts, requiring
Check current mileage and determine overhaul.
overhaul
10. Non-concentricity between crankshaft
Check mounting bracket and repair.
and driven part
11. Use of disqualified engine oil Use a qualified oil of specified trademark.

6.2.1.13 Excessive Noise

1. Low fuel quality Replace fuel.
2. Under-low coolant temperature Check thermostat and replace when necessary.
3. Incorrect valve or fuel supply timing Check, repair, and adjust.
4. Poor atomization of fuel injector
Check, repair, and adjust.
nozzle
5. Excessive fuel volume of fuel
Check and adjust (by professional shop).
injection pump
Check for damage, check state of connecting bolts, and replace
6. Wear of shock absorbers
damaged parts.
7. Air leakage or improper adjustment
Disassemble and check valves and adjust.
of valve
8. Excessive backlash or broken teeth of
Check and replace damaged parts.
gears
9. Wear or scuffing of cylinder sleeve or
piston
10. Bending or breakage of push rod Replace.
11. Breakage or wear of piston rings Check and replace damaged parts.
6.2.1.14 Working Failure of Starter Motor

1. Insufficiently charged battery Check and charge or replace battery.
2. Poor contact of connecting
Clean circuits and tighten wiring posts.
wires
3. Burnt fuse Replace fuse.
4. Poor contact of electric brush Clean electric brush surfaces or replace electric brush.
5. Short-circuit of starter motor Check and repair motor or replace assembly
6.2.1.15 Weak Starter Motor

1. Insufficiently charged battery Charge or replace battery.
2. Wear of bearing bushing Replace assembly.
3. Poor contact of electric brush Clean electric brush surfaces or replace electric brush.
4. Dirty or burnt commutator Remove oil dirt and polish by sand paper or replace assembly.
5. Loose weld of wire ends Re-weld.
6. Poor contact of switch Check and repair switch.

7. Slip of friction clutch Adjust working moment of clutch or replace assembly.
6.2.1.16 Complete Power Generation Failure of Alternator

1. Open-circuit or short-circuit of circuits or loose
Check wiring between alternator and ammeter and repair.
connectors
2. Open-circuit, short-circuit, or ground of stator or
Repair or replace assembly.
rotor coil
3. Damage of rectifier tube Replace assembly.
4. Damage of post insulation and open-circuit of
Repair.
wires
5. Low regulation voltage of regulator Repair.
6. Burnout of regulator contact Repair or replace assembly.
6.2.1.17 Insufficient charging of alternator

1. Open-circuit or short-circuit of circuits or loose
Repair.
connectors
2. Open-circuit, short-circuit, or ground of stator or
Repair or replace assembly.
rotor coil
3. Loose alternator belt Check and adjust belt tension.
4. Damage of alternator rectifier tube and poor
Repair.
contact of battery
5. Low regulated voltage of regulator Adjust.
6. Open-circuit of regulator magnetic coil or
Repair or replace.
resistor
7. Insufficient battery electrolyte or obsolete battery Add electrolyte or replace battery.
6.2.1.18 Unstable Charging Current

1. Immediate short-circuit or open-circuit of stator
Repair or replace.
or rotor coil
2. Poor contact of electric brush Repair.
3. Loose wiring posts and poor contact Repair.
4. Damage of voltage regulator Repair.
5. Improper adjustment of voltage Check and adjust

6.2.1.19 Excessive Charging of Alternator

1. Internal short-circuit of battery Repair or replace.
2. High voltage of regulator Repair and adjust.
3. Poor ground of regulator Repair.
4. Failure or contamination of regulator contacts or
Repair or replace.
open-circuit of voltage coil or resistance wiring
6.2.1.20 Abnormal Sound of Alternator

1. Improper installation of alternator Repair.
2. Damage of bearings Replace bearings.
3. Contact between rotating part and fixed part Repair or replace.
4. Short-circuit of rectifier Replace.
5. Short-circuit of stator coil Repair or replace.

6.2.2 High Water Temperature
Warning
Do not open the water tank cap when the coolant is
under high temperature. There is a danger of
scalding, as the boiling water or steam will spray
out if the cap is opened forcibly. After t e coola t
temperature drops, place a thick cloth onto the cap
and open the cap slowly.
Caution
Do not immediately stop the engine. Otherwise the
engine parts will be damaged due to sharp
increasing of water temperature.
Do not add cold antifreeze under hot status of
engine, in order to prevent damaging alternator
parts.
If the pointer of water temperature gauge exceeds

100ºC or the alternator alarms high water
temperature, it indicates that the radiator water
temperature is beyond limit. Please stop the running
of machine and operate as below:
1. Spot check the radiator hoses for coolant

leakage.
2. Spot check fan belt for breakage and normal
tension.
3. Spot check coolant level.
4. Spot check the surfaces of radiator, engine, and
transmission for presence of sludge.
5. Check for dirty engine oil or transmission oil.
6. Check whether the thermostat is opened.
7. Check engine water pump for normal
functioning.

6.3 Malfunctions of Electric System

6.3.1 Malfunction Diagnosis of Electric System
In event of malfunction, check as per the table below and contact Sany or its authorized dealer for repairs.
Malfunction description Malfunction analysis Measure
• Open-circuit of wire harness Check and repair.
Irregular engine speed, • Internal malfunction of sensor Replace.

with fluctuation • Wire short-circuit (Grounding malfunction) Check and repair.
• Controller internal malfunction Replace.
Power-off failure of
• Battery relay malfunction Replace.
vehicle
Working failure of all • Wire short-circuit malfunction (Grounding
Check and repair.
devices malfunction)
• Fuse malfunction Replace.
Blank screen of • Wire open-circuit malfunction Check and repair.

combination instrument • Wire short-circuit (Grounding malfunction) Check and repair.
• Display screen malfunction Replace.
• Resistor malfunction Replace.
No display of • Wire open-circuit malfunction Check and repair.

combination instrument • Wire short-circuit (Grounding malfunction) Check and repair.
• Malfunction of display screen or controller Replace.
• Coolant temperature sensor malfunction Replace.
Inaccurate indication of • Wire open-circuit malfunction Check and repair.

engine water temperature • Wire short-circuit (Grounding malfunction) Check and repair.
• Wire short-circuit to 24V Check and repair.

• Fuel level sensor malfunction Replace.
Inaccurate indication of • Wire open-circuit malfunction Check and repair.

fuel level • Wire short-circuit (Grounding malfunction) Check and repair.
• Wire short-circuit to 24V Check and repair.
• Internal malfunction of wiper motor Repair or replace.
Working failure of wiper • Wire open-circuit malfunction Check and repair.
• Wire short-circuit (Grounding malfunction) Check and repair.

6.3.2 Monitoring Display

6.3.2.1 Monitoring Display
In the main interface of central display screen, if
the symbol of engine status, transmission status, or
15:10:25, Tuesday, August 15, 2012
vehicle monitoring system turns from green to red,
it indicates that there is a warning in this system.
Press “F2” button to switch over the main interface, Engine status
Transmission status
system function interface to enter the malfunction
Vehicle monitoring system
inquiry interface and inquire the trouble code for
Total mileage Engine hours
malfunction analysis.
Figure 6-4
6.3.2.2 Engine trouble code
See right figure for engine fault code query
interface. “0” in the front part of the code is Current fault of the engine
insignificant digit, for example, 000111-1 means

the SPN code is 111 and the FMI code is 1. No. Trouble code
The detailed descriptions for the trouble codes are

listed in table below:
F1: Return F2: OK
Figure 6-5

Malfunction description SPN FMI Blink Code

Unreliable accelerator and brake signals 91 7 225
Intake heater normally-opened malfunction 2898 7 322
Unreliable doubled signal relationship between
520252 2 221
accelerator pedal 1 and accelerator pedal 2
Accelerator pedal 1 voltage beyond upper threshold 91 3 221
Accelerator pedal 1 voltage below lower threshold 91 4 221
Accelerator pedal 2 voltage beyond upper threshold 29 3 221
Accelerator pedal 2 voltage below lower threshold 29 4 221
Unreliable barometric pressure sensor signal 102 2 231
Barometric pressure sensor voltage above upper
108 3 232
threshold
Barometric pressure sensor voltage below lower
108 4 232
threshold
Intake heater open-circuit 2898 5 321
Intake heater short-circuit to power supply 2898 3 321
Intake heater short-circuit to ground 2898 4 321
Original battery voltage below lower threshold 168 4 124
Original battery voltage above upper threshold 168 3 124
Intake pressure sensor voltage above upper
102 3 231
threshold
Intake pressure sensor voltage below lower
102 4 231
threshold
Unreliable braking signal 597 2 223
Failure of coolant temperature rise rate to reach
110 18 242
minimum value within a certain time
Failure to raise coolant temperature to minimum
110 17 242
value within a certain time
Unreliable clutch status signal 598 2 222
OBD torque restraint activation error 520198 11 511
Cold start indicator lamp open-circuit 626 5 332
Cold start indicator lamp short-circuit to power
626 3 332
supply
Cold start indicator lamp short-circuit to ground 626 4 332
Unreliable coolant temperature and engine oil
110 2 241
temperature signals
Water temperature beyond threshold during normal
110 15 242
running of water temperature sensor

Water temperature sensor voltage above upper

110 3 241
threshold
Water temperature sensor voltage below lower
110 4 241
threshold
Blocked off-board start/stop button 520203 5 343
Missing camshaft signal 4201 12 123
Camshaft cycle error 4201 2 123
Camshaft synchronization error 4201 11 123
Camshaft and crankshaft synchronization error 4201 13 123
Missing crankshaft signal 4203 12 122
Crankshaft synchronization error 4203 3 122
Crankshaft tooth number error 4203 4 122
Crankshaft tooth cycle error 4203 2 122
Crankshaft and camshaft signal deviation beyond
4201 14 123
threshold
Engine over-speed 1769 11 513
Exhaust brake butterfly valve open-circuit 520208 5 311
Exhaust brake butterfly valve short-circuit to power
520208 3 311
supply
Exhaust brake butterfly valve short-circuit to ground 520208 4 311
Fan actuator (PWM wave) open-circuit 4815 7 312
Fan actuator (PWM valve) short-circuit to power
4815 9 312
supply
Fan actuator (PWM valve) short-circuit to ground 4815 10 312
Fan actuator (Digital signal) open-circuit 4815 5 312
Fan actuator (Digital signal) short-circuit to power
4815 3 312
supply
Fan actuator (Digital signal) short-circuit to ground 4815 4 312
Cooling fan speed above upper threshold 1639 3 316
Cooling fan speed below lower threshold 1639 4 316
Detection of water in fuel by water-in-fuel sensor 520264 11 211
Bus received accelerator signal beyond limit 522064 19 426
CAN received frame CM1 data size error 522056 14 561
CAN received frame CM1 timeout error 522056 19 562
CAN received frame DashDspl data size error 522052 14 561
CAN received frame DashDspl timeout error 522052 19 562
CAN received frame DEC1 data size error 522062 14 561
DEC1 message receiving timeout 522062 19 437

CAN received frame EBC1 data length error 522013 14 228

CAN received frame EBC1 timeout error 522013 19 413
Timeout error 52201 19 413
CAN received frame EGF1 data size error 522053 14 561
CAN received frame EGF1 timeout error and GF1
522053 19 562
timeout error
CAN received frame EngTemp2 data size error 522020 14 561
CAN received frame EngTemp2 timeout error 522020 19 562
CAN received frame ERC1DR data size error 522021 14 561
CAN received frame ERC1DR timeout error 522021 19 562
ETC1 message data length error 522022 14 425
Message ETC1 receiving timeout 522022 19 425
CAN received frame ETC2 data size error 522023 14 425
CAN received frame ETC2 timeout error 522023 19 425
CAN received frame ETC7 data size error 522063 14 561
ETC7 message data length error 522063 19 425
CAN received frame HRVD data size error 522051 14 561
CAN received frame HRVD timeout error 522051 19 562
Bus received remote accelerator signal beyond limit 522065 19 427
RxCCVS message data length error 522030 14 478
RxCCVS message data length error 522030 19 460
CAN received frame TRF1 data size error 520217 14 561
CAN received frame TRF1 timeout error 520217 19 562
CAN received frame TSC1AE data size error 522035 14 414
CAN received frame TSC1AE timeout error 522035 19 414
CAN received frame TSC1AR data size error 522036 14 414
CAN received frame TSC1AR timeout error 522036 19 414
CAN received frame TTSC1DE data size error 522037 14 415
CAN received frame TSC1DE timeout error 522037 19 415
CAN received frame TSC1DR data size error 522038 14 415
CAN received frame TSC1DR timeout error 522038 19 415
CANTOTSC1PE data size error 522039 14 416
CANTOTSC1PE communication error 522039 19 416
CANTOTSC1TE data size error 522040 14 417
CANTOTSC1TE timeout error 522040 19 417

CANTOTSC1TR data size error 522041 14 417

CANTOTSC1TR timeout error 522041 19 417
CANTOTSC1VE data size error 522042 14 418
CANTOTSC1VE timeout error 522042 19 418
CANTOTSC1VR data size error 522043 14 418
CANTOTSC1VR timeout error 522043 19 418
Over-long upshift gap-time 520221 2 227
(Water-in-fuel indicator lamp) Indicator lamp
624 12 334
open-circuit
624 3 334
short-circuit to power supply
624 4 334
short-circuit to ground
High voltage test error 520223 20 522
EEPROM read error 2802 14 117
EEPROM write error 2802 12 117
Intake temperature sensor voltage above upper
105 3 233
threshold
Intake temperature sensor voltage below lower
105 4 233
threshold
INJdriverIC initialization version number error 507 11 147
INJdriverIC initialization error after power-on 507 11 147
INJdriverIC re-power-on error 507 11 147
Fuel injector 1 high-end short-circuit to power
1413 15 141
supply
Fuel injector 1 low-end short-circuit to power
1413 16 141
supply
Fuel injector 1 open-circuit 1413 5 141
st
1 cylinder fuel injector error 1413 11 141
1st cylinder within same Bank open-circuit to other
cylinder or short-circuit to low-voltage power 1413 6 141
supply
1st cylinder fuel injector short-circuit to ground 1413 7 141
Fuel injector 1 high-end/low-end short-circuit 1413 4 141
1414 15 142
supply
1414 16 142
supply
nd

2nd cylinder within same Bank open-circuit to other

supply
2nd cylinder fuel injector short-circuit to ground 1414 7 142
1415 15 143
supply
1415 16 143
supply
3rd cylinder fuel injector error 1415 11 143
rd
3 cylinder within same Bank open-circuit to other
supply
3rd cylinder fuel injector short-circuit to ground 1415 7 143
1416 15 144
supply
1416 16 144
supply
4th cylinder fuel injector error 1416 11 144
th
4 cylinder within same Bank open-circuit to other
supply
4th cylinder fuel injector short-circuit to ground 1416 7 144
1417 15 145
supply
1417 16 145
supply
5th cylinder fuel injector error 1417 11 145
5th cylinder within same Bank open-circuit to other
supply
1418 15 146
supply


1418 16 146
supply
th
6th cylinder within same Bank open-circuit to other
supply
Fuel meter open-circuit 1442 7 133
Fuel meter short-circuit to power supply 1442 9 133
Fuel meter short-circuit to ground 1442 10 133
Unreliable cruise control signal (Invalid switch
596 2 341
combination)
OBD lamp open-circuit 520219 5 331
OBD lamp short-circuit to power supply 520219 3 331
OBD lamp short-circuit to ground 520219 4 331
Unreliable multi-state switch signal 976 19 345
Multi-state switch voltage above upper limit 976 3 345
Multi-state switch voltage below lower limit 976 4 345
Under-low engine oil pressure 100 17 243
Over-high engine oil pressure or unreliable engine
100 15 243
oil temperature signal
Engine oil pressure sensor voltage above upper limit 100 16 243
Engine oil pressure sensor voltage below lower limit 100 18 243
Unreliable engine oil temperature sensor signal 175 15 244
Engine oil temperature sensor voltage above upper
175 3 244
threshold
Engine oil temperature sensor voltage below lower
175 4 244
threshold
Common rail relief valve open count beyond
520241 11 134
maximum technical number
Opened common rail relief valve 520241 14 135
Pressure-limiting valve opening time beyond limit 520241 0 136
Rail pressure sensor voltage above upper threshold 157 3 131
Interruption acquisition rail pressure sensor voltage
157 3 131
above upper threshold
Rail pressure sensor voltage below lower threshold 157 4 131

Interruption acquisition rail pressure sensor voltage

157 4 131
below lower threshold
Fuel volume in fuel meter beyond threshold 520243 7 252
Rail pressure deviation beyond upper threshold and
520243 0 251
fuel injection volume above limit
Rail pressure deviation below lower threshold and
520243 1 255
fuel injection volume below threshold
Rail peak pressure below lower threshold 52024 20 256
Rail peak pressure above upper threshold 520243 21 271
Unreliable fuel meter setting under over-speed mode 520243 23 273
Fuel meter monitor error under low idling speed 520243 24 274
Manual accelerator pedal 1 output voltage above
520277 3 229
upper limit
Manual accelerator pedal 1 output voltage below
520277 4 229
lower limit
Manual accelerator pedal 2 output voltage above
520278 3 229
upper limit
Manual accelerator pedal 2 output voltage below
520278 4 229
lower limit
Sensor power supply 1 voltage above upper
3509 3 112
threshold
Sensor power supply 1 voltage below lower
3509 4 112
threshold
3510 3 112
threshold
3510 4 112
threshold
3511 3 112
threshold
3511 4 112
threshold
Vehicle locked and locking mode 1 executed 522014 1 412
Vehicle locked and locking mode 2 executed 522014 2 413
Starter motor relay low-end short-circuit to power
1675 3 121
supply
Starter motor relay low-end short-circuit to ground 1675 4 121
Starter motor relay open-circuit 1675 5 121
T50 turn-on time over-limit 520253 11 345
ECU temperature sensor voltage below lower
1136 4 119
threshold

ECU temperature sensor voltage above upper

1136 3 119
threshold
Vehicle speed 1 above maximum threshold 84 0 224
Unreliable vehicle speed 1, fuel injection volume,
84 2 224
and engine speed
Warning lamp open-circuit 520250 5 333
Warning lamp short-circuit to power supply 520250 3 333
Warning lamp short-circuit to ground 520250 4 333
Original water-in-fuel sensor voltage above upper
520264 3 214
threshold
Original water-in-fuel sensor voltage below lower
520264 4 214
threshold
CAN communication error 522000 12 411
Unreliable manual accelerator 2x relationship 520252 2 229
Manual accelerator and brake reliability check 520277 7 226
key message malfunction 520218 14 561
key message timeout 520218 19 562
DEC1 message T50 signal receiving error 522065 0 234
6.3.2.3 Transmission trouble code

The trouble codes are displayed in the instrument.
The detailed descriptions of the trouble codes are
listed in table below:
Figure 6-6
Transmission
No. SPN J1939-FMI Diagnosis
indicator lamp
1 91 19 Accelerator pedal data error ON
2 91 9 Accelerator pedal abnormal upload rate ON
Over-high transmission filter differential
3 126 3 ON
voltage
4 158 2 Unstable key switch ON
Abnormal transmission input shaft speed signal
5 161 8 ON
frequency
6 168 3 Over-high ECU voltage ON
7 168 4 Under-low ECU voltage ON

8 177 16 High transmission oil temperature ON

9 177 3 High transmission oil temperature voltage ON
10 177 4 Low transmission oil temperature voltage ON
11 190 8 Abnormal engine speed signal frequency ON
12 191 14 Mismatched transmission output shaft speed ON
Abnormal transmission output shaft speed
13 191 8 ON
signal frequency
14 513 19 Engine torque data error ON
15 513 9 Abnormal engine torque update rate ON
16 625 9 Abnormal special data chain update rate ON
17 639 9 Abnormal J1939 network #1 update rate ON
18 639 14 J1939 network special instruction ON
High transmission gear range clutch C1
19 734 6 ON
solenoid valve current
Low transmission gear range clutch C1
20 734 5 ON
21 734 3 ON
solenoid valve voltage
22 735 6 ON
23 735 5 ON
24 735 3 ON
25 736 6 ON
26 736 5 ON
27 736 3 ON
28 737 6 ON
29 737 5 ON
30 737 3 ON
31 738 6 ON
32 738 5 ON


33 738 3 ON
34 739 6 ON
35 739 5 ON
36 739 3 ON
High transmission locking clutch actuator
37 740 6 ON
current
Low transmission locking clutch actuator
38 740 5 ON
current
High transmission locking clutch actuator
39 740 3 ON
voltage
40 744 6 High retarder regulator solenoid valve current ON
41 744 5 Low retarder regulator solenoid valve current ON
42 744 3 High retarder regulator solenoid valve voltage ON
43 973 9 Abnormal engine retarder update rate ON
Abnormal non-engine retarder update rate,
44 1716 8 ON
pulse width, or cycle
45 1716 9 Abnormal non-engine retarder update rate ON
46 1716 19 Non-engine retarder data error ON
47 1716 13 Non-engine retarder beyond calibration range ON
48 3027 3 High transmission oil level voltage ON
49 3027 4 Low oil level voltage ON
Engagement status (Unstable, intermittent, or
50 3463 2 ON
incorrect transfer case output shaft PTO)
51 3509 3 High sensor battery #1 voltage ON
52 3509 4 Low sensor battery #1 voltage ON
Low torque converter oil outlet temperature
53 3823 4 ON
voltage
High torque converter oil outlet temperature
54 3823 3 ON
voltage
55 3823 16 High torque converter oil outlet temperature ON
Abnormal transmission request gear update
56 525 9 ON
rate
57 3824 6 High transmission gear locking actuator current ON
58 3824 5 Low transmission gear locking actuator current ON
High transmission gear locking actuator
59 3824 3 ON
voltage

60 3824 14 Transmission gear locking special instruction ON

Abnormal transmission output shaft #2 signal
61 3825 8 ON
frequency

6.3.3 Battery
6.3.3.1
Warning
It’s dangerous to charge the battery while the
battery is still installed on the machine. Ensure to
disassemble the battery before charging.
While checking or handling the battery, stop the
engine and rotate the key switch to OFF position.
While handling the battery, ensure to wear
goggles and rubber gloves. While disassembling
the battery, firstly disconnect the grounding cable
(Negative (-) terminal). During installation, firstly
connect the positive (+) terminal. There is a
danger of spark generation if a tool touches the
positive terminal and chassis. Therefore, special
caution shall be paid.
A loose terminal will generate spark due to poor
contact to cause danger of explosion.
While disassembling or installing the terminals,
ensure to distinguish the positive (+) terminal
from negative (-) terminal.
Figure 6-7
6.3.3.2 Disassembling and installation of
battery
● Before disassembling the battery, disassemble
the grounding cable (Generally it's connected to
the negative (-) terminal).
● There is a danger of spark generation if there is
a contact between positive terminal and chassis
by a tool.
● While replacing the battery, fix the battery by
battery clamping plates.
● Connection sequence of battery cables:
Connect positive cable of battery before
connecting the negative cable of battery.
● Disconnection sequence of battery cables:
Disconnect the negative cable of battery before
disconnecting the positive cable of battery.

6.3.3.3 Charging of battery

While charging the battery, the improper handling
will result in the danger of battery explosion. Ensure
to abide by the instructions of battery and charger
and the following instructions:
● Adjust the voltage of the charger to be
compatible with the voltage of the battery to be
charged. The incorrect selection of voltage will
lead to overheating and explosion of charger.
● Connect the positive (+) cable clamp of charger
to the positive (+) terminal of battery and
connect the negative (-) cable clamp of charger
to the negative (-) terminal of battery. Ensure to
secure the cable clamps.
● While adjusting the charging current to the
rated battery capacity for rapid charging, adjust
the charging current to be less than the battery Figure 6-8
capacity. If the charging current is too high, the
electrolyte will be probably vaporized to result
in fire or explosion of battery.
● If the battery electrolyte is frozen, do not
charge the battery or start the engine by other
power supply. Otherwise it will ignite the
electrolyte and cause battery explosion.

6.3.4 Start of Engine by Auxiliary Cable

6.3.4.1 Connection and disconnection of
auxiliary cable
Warning
While connecting the cables, keep the positive (+)
and negative (-) terminals away from contact with
each other.
Take caution to keep normal machine and
malfunctioned machine away from contact with
each other. Prevent the generation of spark in the
vicinity of battery from igniting the hydrogen
relieved by the battery.
Take caution to eliminate errors while connecting
auxiliary cable. It will generate spark during the
final connection (with upper frame). Therefore, Figure 6-9
connect the cable to a place as far as away from
the battery. (However, prevent connecting to the
working device, as it’s not a good conductor).
While disassembling the auxiliary cable, take
special cautions to keep the cable clamps away
from contact with each other or with the chassis.
Note:
● This machine’s staring system adopts 24V
voltage. In normal operation of machine, adopt
four 12V battery (2 batteries in series
connection and then two groups in parallel
connection) for power supply.
● The specifications of the auxiliary cable and
the cable clamps shall be compatible with the
battery specification.
● The battery capacity of the normal machine
must be same with the engine to be started.
● Check the cables and cable clamps for presence
of damage or corrosion.
● Ensure the secure connections of cables and
cable clamps.
● Check and ensure that the gearshift levers of
both machines are in neutral gear and the
parking switches are at OFF position.
● Make sure that two machines’ cargo
compartments are all dropped onto the frames.

6.3.4.2 Connection of auxiliary cables

Keep the key switches of normal machine and
malfunctioned machine in OFF positions.
Connect the auxiliary cable as per the numeric
sequence shown in the figure and as per the
following procedure.
1. Connect one cable clamp of auxiliary cable (A)
to the positive (+) terminal of battery (C) on the
malfunctioned machine.
2. Connect another cable clamp of auxiliary cable
(A) to the positive (+) terminal of battery (D) Figure 6-10
on the normal machine.
3. Connect one cable clamp of auxiliary cable (B)
to the negative (-) terminal of battery (D) on
the normal machine.
4. Connect another cable clamp of auxiliary cable
(B) to the frame (E) of the malfunctioned
machine.
6.3.4.3 Start of engine
1. Ensure that the cable clamps are securely
connected to the battery terminals.
2. Start the engine of normal machine and run at Caution
high idling speed. For both normal machine and malfunctioned
3. Rotate the key switch of the malfunctioned machine, check the machines and ensure that the
machine to “START” position to start the parking switches are at “OFF” position and all
engine. control handles are in “Hold” or neutral positions.
If the engine fails to start in the first time, wait
for 2min before retry.
6.3.4.4 Disconnection of auxiliary cables
After the start of engine, disconnect the auxiliary
cables in reverse sequence of the connection
procedure.
1. Disconnect the cable clamp of auxiliary cable
(B) from the frame (E) of the malfunctioned
machine.
(B) from the negative (-) terminal of battery Figure 6-11
(D) on the normal machine.
(A) from the positive (+) terminal of battery
(D) on the normal machine.
(A) from the positive (+) terminal of battery

(C) on the malfunctioned machine.
6.4 Malfunctions of Hydraulic System

6.4.1 Malfunction Diagnosis of Hydraulic System
Malfunction
symptom
Blockage and obstructed oil suction of oil
Replace filter element and clean pipeline.
tank filter element or suction pipeline
Air leakage of pump oil suction port Tighten the oil suction port flange.
High noise of plunger Add oil into oil tank till the correct level is
pump Low oil level
reached.
Check pump drive shaft bearings and PTO
Misplacement of drive shaft drive shaft bearings and when necessary
replace.
Add oil into oil tank till the correct level is
Low oil level
reached.
Blockage of oil suction port due to falloff or
Reinstall the filter element.
No oil delivery of overturning of oil suction filter element
plunger pump
Disassemble and break down the pump,
check pump shaft and rotating subassembly
Breakage of pump shaft
for damage, and repair or replace pump as
required.
Under-low regulated pressure of pump
Fix the setting of load-sensing valve and
load-sensing valve or constant pressure
adjust constant pressure valve to 18MPa.
valve
Blockage of pump constant pressure valve
Clean or replace constant pressure valve.
core at “Open” position
Under-low pressure
Under-low regulated pressure of steering
of steering system Adjust relief valve to 21MPa.
valve block relief valve
Wear of pump internal parts Replace with spare parts.
Blockage of hydraulically controlled
Clean or replace hydraulically controlled
reversing valve core of steering valve block
reversing valve.
at “Open” position
Noise of steering Opened relief valve of steering valve block
Adjust relief valve to 21MPa.
valve block due to under-low regulated pressure
Failure of emergency Repair or replace steering accumulator and
Blockage of steering accumulator piston
steering filter oil.
Solve malfunction as per above-mentioned
No oil delivery of plunger pump
method.
Heavy rotation of Solve malfunction as per above-mentioned
Under-low pressure of steering system
steering wheel method.
Internal leakage of steering valve block and Check one by one and repair or replace
brake valve block with new part.
Stagnation of steering Non-coaxiality between steering gear and Loosen fastening bolts of steering gear and
wheel adapter spline shaft adjust position of steering gear.

Automatic rotation of Non-coaxiality between steering gear and Loosen fastening bolts of steering gear and
steering wheel adapter spline shaft adjust position of steering gear.
Automatic steering of
steering wheels with
Incomplete return of steering gear valve core Repair or replace steering gear.
steering wheel held
still
6.4.2 List of lifting system faults

Malfunction symptom Malfunction cause Troubleshooting
Oil tank filter element or oil suction
pipeline is clogged, leading to Replace filter element and clean the pipeline
inefficient suction
Gear pump noise, Pump suction port in air leakage Fasten the suction port flange
overmuch Add oil into the oil tank till the oil level reaches
Oil level, low
the correct position
Inspect pump drive shaft bearing and drive gear
Drive shaft in malposition
bearing. If necessary, perform replacement
Add oil into the oil tank till the oil level reaches
Oil level, low
the correct position
Blockage of oil suction port Clean oil suction pipeline.
Gear pump does not
convey oil Take down and disassemble the pump, inspect the
pump shaft and rotary components’ damage.
Pump shaft fracture
Repair or replace the pump according to
requirements.
Start engine till the air pressure reaches
Under-low air pressure
minimum 7bar.
Inspect pump drive shaft bearing and drive gear
Non-engaged drive shaft
bearing. If necessary, perform replacement
No lifting of cylinder
No hydraulic oil in oil tank or
with lifting joystick Add hydraulic oil and check oil suction pipeline.
blocked oil suction pipeline
at “Lifting” position
Incorrect connections of hydraulic
Restore correct connections.
pipeline
Incorrect connections of pneumatic
Restore correct connections.
pipeline
Working failure of
hydraulic distributor Clean and repair and when necessary replace
Malfunction of distributor valve
valve under normal with new one.
air pressure
Under-low air pressure Check air pressure (Minimum 7bar).
Slow lifting of
Serious wear or malfunction of gear
cylinder Repair or replace with new gear pump.
pump
Incorrect lowering Clean and repair and when necessary replace
Malfunction of distributor valve
(Too slow or fast) of distributor valve.

cylinder Malfunction of pneumatic control Clean and repair and when necessary replace
valve pneumatic control valve.
Over-high or under-low hydraulic
Replace with appropriate hydraulic oil.
oil viscosity
Low hydraulic oil level Add oil till the oil level reaches standard level.
Incomplete lifting of
Place the material uniformly or unload some
cylinder Overload
material.
Disorder of cylinders Deformation of cylinder barrel Contact your local Sany service engineer.
during lifting or
lowering of cylinders
(Extending/retracting Damage of internal parts (Such as
Contact your local Sany service engineer.
sequence error of guide rings)
primary and
secondary cylinders)
Sudden failure of
pneumatic control Damage or blockage of air pipes Check the pipeline.
valve
Lifting of cylinder
Reverse connection of air pipes on
with pneumatic
distributor valve or pneumatic Check the pipeline.
control valve at
control valve
“Lowering” position
Offset load
Oil permeation of Scratch of cylinder internal fitting
Contact your local Sany service engineer.
cylinder surfaces
Damage of oil seals
Drain oil, do cleaning, and add the oil anew, and
Lifting cylinder fault System pollution
replace filter element
6.4.3 Brake system malfunction table

Malfunction
symptom
Air leakage of brake air chamber Replace connector seal rings.
Check sealing performance of air compressor,
Low brake air pressure
Insufficient braking control valve, air reservoir, and pipeline.
force Damage of brake air chamber spring Replace air chamber spring.
Serious wear of brake drum wearing
Replace brake pad.
material
Incorrect position of brake valve stem,
leading to blockage of piston rod and Re-adjust or replace return spring.
Release failure of failure or damage of return spring
brake
Poor functioning of brake air chamber Check the brake air chamber.
Return failure of brake drum Check or replace return spring.
Rapid drop of air Blockage by dirt or damage of foot Apply the braking for several times and blow
reservoir pressure brake valve air inlet valve away the dirt or replace valve.

after stop of engine Loose pipe connector or rupture of

(>0.1MPa pressure Tighten connector or replace brake pipeline.
pipeline
drop in 30min) Failure or damage of dryer pressure Check for cause and when necessary replace
regulator valve timely.
Loose pipe connector Tighten the pipe connectors.
Abnormal working of air compressor Check working status of air compressor.
Slow rise of Check and clean 4-circuit protection valve
pressure reading in Damage of 4-circuit protective valve or
and find out and solve the cause of sealing
brake air pressure failure of seals
failure.
gauge Blockage of pressure control valve Clean bleeding port and check and solve the
bleeding port or leakage of check valve cause of sealing failure of check valve and
or diaphragm diaphragm.

6.5 Other Common Malfunctions

Check oil level and add correct
Insufficient or incorrect lubrication
lubricating oil.
Noise
Scratched or roughed wheel bearings Replace bearings.
Damage of wheel reducer gear Replace gear.
Over-high lubricating oil level Check oil level and drain excessive oil.
Excessive bubbles in lubricating oil Add lubricating oil correctly.
Loss of Wear or damage of oil seal Replace oil seal.
lubricating oil
Clean ventilator to keep
Rear axle Blockage of ventilator
non-obstructed.
Loose seal compression bolts or nuts Retighten bolts or nuts.
Clean ventilator to keep
Increased Blockage of ventilator
non-obstructed.
lubricating oil
Failure of brake dynamic seal Check brake dynamic seal.
High Check oil level and add correct
Insufficient or incorrect lubrication
temperature lubricating oil.
of planetary
mechanism Blockage of bearings Replace bearings.
Collision of gears Replace damaged gear.
Vibration Excessive wear of drive spiral bevel gear or
Repair or replace worn parts.
main reducer and differential housing
Continuous Excessive wear of bearings Replace.

noise Excessive wear or damage of gear Replace worn or damaged gear.
Over-tight adjustment of spiral bevel gear
Drive noise Readjust.
Main pair
reducer
Damage of bearing Replace bearings.
and
differential Sliding noise Loose adjustment of spiral bevel gear pair Readjust.
assembly
Excessive end play of drive bevel gear Readjust.
Wear of planetary gear or half shaft gear Replace gear.
Rotation noise
Damage or wear of crossing shaft bearing Replace bearings.
Damage of oil seal Replace oil seal.
Loss of
Loose nut Tighten to correct torque.
lubricating oil
Cracking of axle housing Repair or replace axle housing.
Ingress of soil or sand due to damage of dust
Replace dust ring and U-seal.
Hard suspension ring and air leakage due to damage of U-seal
Air leakage from valve core Replace valve core.


1. Water content in system, leading
Replace fluid reservoir and
to freezing blockage of expansion
re-vacuumize.
valve
Abnormal turn-on or Add refrigerant.
2. Maladjustment of thermostat
turn-off of A/C system Check and repair.
3. Poor grounding wire
Check and repair.
4. Poor contact of control switch
Check and repair.
5. Poor contact of relay
1. Loose belt Adjust or replace.
2. Loose compressor bracket Adjust.
Abnormal system sound 3. Loose evaporator fan impellor Adjust.
4. Clutch slip Repair or replace.
5. Internal wear of compressor Repair or replace.
1. Valve not opened Open valve.
2. Blockage of pipeline Repair.
Cool hot air
3. Low heating medium temperature Turn on after temperature rises.
4. Leakage of pipeline Repair or replace.
1. Compressor clutch
a) Open-circuit or short-circuit of Replace.
coil Repair or replace.
A/C b) Clutch slip Check and reconnect.
Normal functioning of 2. Wire fallout Replace.
evaporator fan and 3. Belt breakage
working failure of
compressor 4. Activation of pressure switch Find out leaks and add refrigerant.
a) Excessive leakage of refrigerant Drain as appropriate.
b) Excessive filling of refrigerant Replace damaged parts.
c) Damage of switch Replace damaged parts.
5. Damage of thermostat.
Normal functioning of 1. Excessive leakage of refrigerant Find out leaks and add refrigerant.
evaporator fan and 2. Excessive filling of refrigerant Drain as appropriate.
compressor 3. Damage of compressor Repair or replace.
Malfunction of input power supply
No rotation of evaporator a) Poor contact of grounding wire Check and repair.
fan and working failure of Check and replace.
compressor b) Burnt fuse
Check and replace.
c) Damage of power switch
1. Damage of fan
Replace.
No rotation of evaporator 2. Burnt fuse
Replace.
fan and normal working of 3. Damage of fan speed switch
compressor Replace.
4. Damage of speed regulation
Replace.
resistor

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Technical Specification SKT90S Mining Wide-Body Dump Truck
Technical Specification
7 Technical Specification ................................................................................................................................. 7-3
7.1 Technical Specification ....................................................................................................................... 7-3

SKT90S Mining Wide-Body Dump Truck Technical Specification
Warning

Technical Specification SKT90S Mining Wide-Body Dump Truck
7 Technical Specification
7.1 Technical Specification

Item Unit SKT90S
Gross weight of vehicle kg 90000
Dead weight of vehicle kg 30000
Maximum load capacity kg 60000
Cargo compartment Flat loading m³ 31

Capacity Pile loading m³ 35
Lifting/dropping time s 35/29
Engine model - WP12G460E310
Maximum torque N.m 2000
A Overall length of vehicle mm 8960
B Overall height of vehicle mm 4320
C Total height after lifting mm 8313
D Overall width of vehicle mm 3460
E Minimum ground clearance mm 325
Minimum turning radius mm 11000
1st gear km/h 4.39
nd
2 gear km/h 5.99
3rd gear km/h 8.28
Maximum vehicle Drive gears 4th gear km/h 11.15

speed 5th gear km/h 15.15
6th gear km/h 24.93
th
7 gear km/h 40.14
Reverse gear km/h 4.72

SKT90S Mining Wide-Body Dump Truck Technical Specification
Figure 7-1

SKT90S Mining Wide-Body Dump Truck Maintenance
Maintenance
8. Maintenance .................................................................................................................................................. 8-5
8.1 Suspension........................................................................................................................................... 8-5
8.1.1 Front suspension assembly ..................................................................................................... 8-5
8.1.1.1 ............................................................................................................................................... 8-5
8.1.1.2 Front suspension cylinder ...................................................................................................... 8-7
8.1.1.3 Thrust Bars .......................................................................................................................... 8-13
8.1.2 Rear suspension assembly .................................................................................................... 8-19
8.1.2.1 Rear suspension assembl ..................................................................................................... 8-19
8.1.2.2 Leaf Spring Assembly ......................................................................................................... 8-22
8.1.2.3 Balance Shaft Assembly ...................................................................................................... 8-23
8.1.3 Repairs and Maintenances .................................................................................................... 8-24
8.1.3.1 Tightening torque ................................................................................................................ 8-24
8.1.3.2 Run-in of New Vehicle ........................................................................................................ 8-25
8.1.3.3 Malfunction Diagnosis ........................................................................................................ 8-25
8.2 Cab accessories ................................................................................................................................. 8-27
8.2.1 ...................................................................................................................................................... 8-27
8.2.2 Disassembling and Installation ............................................................................................. 8-28
8.2.3 Air conditioning pipeline installation ................................................................................... 8-30
8.2.4 SKT90 Marking Layout ........................................................................................................ 8-41
8.3 Vehicle frame..................................................................................................................................... 8-43
8.4 Cargo Compartment and Installation................................................................................................. 8-46
8.5 Hydraulic System .............................................................................................................................. 8-50
8.5.1 Replace hydraulic oil ............................................................................................................ 8-50
8.5.2 Replacement of Steering Filter Element ............................................................................... 8-51
8.5.3 Replacement of Lifting Oil Return Filter Element ............................................................... 8-51
8.5.4 Replacement of Ventilation Valve Filter Element ................................................................. 8-52
8.5.5 Checking of Hydraulic System Pressure............................................................................... 8-52
8.5.6 Drainage of Water from Air Reservoir .................................................................................. 8-52
8.5.7 Replacement of Dryer Core .................................................................................................. 8-53
8.5.8 Checking of Pedal Free Travel.............................................................................................. 8-53
8.5.9 Checking of Brake Slave Cylinder ....................................................................................... 8-53
8.6 Power system..................................................................................................................................... 8-54
8.6.1 Engine and Installation ......................................................................................................... 8-54
8.6.2 Radiator and Pipeline Installation ......................................................................................... 8-59
8.6.2.1 Radiator Assembly Installation............................................................................................ 8-59
Operation and Maintenance Manual 8- 1

Maintenance SKT90S Mining Wide-Body Dump Truck
8.6.2.2 Expansion Tank Assembly Installation ................................................................................ 8-62
8.6.3 Air Filter and Pipeline Installation........................................................................................ 8-64
8.6.4 Exhaust System ..................................................................................................................... 8-68
8.6.5 Fuel tank and pipe installation .............................................................................................. 8-71
8.6.5.1 Fuel tank and pipe installation ............................................................................................. 8-71
8.6.5.2 Fuel Pipeline Installation ..................................................................................................... 8-73
8.7 Electric System .................................................................................................................................. 8-75
8.8 Drive system ...................................................................................................................................... 8-76
8.8.1 ...................................................................................................................................................... 8-76
8.8.2 Clutch Installation Assembly ................................................................................................ 8-77
8.8.3 Transmission Assembly Installation ..................................................................................... 8-84
8.8.3.1 ............................................................................................................................................. 8-84
8.8.3.2 Transmission ........................................................................................................................ 8-86
8.8.3.3 Transmission Rear Suspension ............................................................................................ 8-89
8.8.3.4 Gear Selector/Gearshift Control Mechanism....................................................................... 8-91
8.8.4 Front Axle Installation Assembly.......................................................................................... 8-93
8.8.5 Intermediate Axle Installation Assembly .............................................................................. 8-95
8.8.6 Rear Axle Installation Assembly........................................................................................... 8-97

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Warning

8. Maintenance
8.1 Suspension
8.1.1 Front suspension assembly
8.1.1.1
1. Hydro-pneumatic spring
9. Nut M16 17. Bolt M16×80 25. Bolt M20×140
upper bracket
2. Bolt M18×90 10. Bolt M14×40 18. Bolt M18×70 26. Bolt M18×80
11. Lateral thrust crossbeam 27. Front suspension crossbeam
3. Bracket 19. Thrust bar pin assembly
assembly assembly
12. Front suspension lateral 20. Front suspension
4. Bracket 28. Locating pin
thrust bar longitudinal thrust bar
5. Lateral thrust crossbeam
13. Front suspension cylinder 21. Bolt M20×170 29. Bolt M18×55
bracket assembly
6. Bolt M18×100 14. Bolt M16×70 22. Spiralock nut M20
23. Front suspension thrust bar
7. Clearance adjustment shim 15. Bracket
bracket
8. Hydro-pneumatic spring pin
16. Spiralock nut M18 24. Bolt M20×265
assembly
Figure 1 Installation of front suspension

Overview and Working Principle

WARNING!
As an important load-carrying part on the front of
vehicle, the front suspension is connected to the frame To prevent personal injuries and property losses,
by axle. Two ends of the front axle are installed with ensure that the wheel blocks and the hoisting
wheels. It’s mainly functioned to transmit all forces and appliance have sufficient capacity and are correctly
moments applied between wheels and frame, mitigate fixed to ensure safety.
the impact load transmitted from road to the frame (or
vehicle body), attenuate the vibration of the
load-carrying system arising thereof, guarantee the
driving smoothness of the vehicle, and ensure the ideal
motion characteristics of wheels and control stability of
vehicle on rough roads and in event of load change.
Disassembling
Refer to the Figure 1 for the numbers in parentheses.
1. Park the vehicle on a level working area, apply the
parking brake, stop the engine, elevate the front
end of frame by tooling, allow the free droop of
wheels onto the ground, and fix them.
2. Rotate the steering wheel in both directions for
several turns to relieve the pressure of steering
system. Block the wheels and place the battery
master switch at “OFF” position.
3. With reference to the “Relief of Suspension
Cylinder Pressure” in this chapter, relieve the
nitrogen pressure from the left and right front
suspension cylinders (13).
4. Disassembling of front suspension cylinder:
Disassemble the connecting pin (8) of front
suspension cylinder to complete the disassembling
of front suspension cylinder. Disassemble it by
appropriate tools and move it to a level place.
5. Disassembling of front suspension lateral thrust
bar: Disassemble the connecting pins (8) from two
ends of front suspension lateral thrust bar (12) to
complete the disassembling of thrust bar.
Disassemble it by appropriate tools and place it in
a level place.
6. Disassembling of front suspension longitudinal
thrust bar: Disassemble the front connecting bolts
(21) and (24) and the rear pin (8) of left and right
front suspension longitudinal thrust bars (20) to
complete the disassembling of thrust bars.
Disassemble them by appropriate tools and place
them in a level place.
7. In such case, the axle and the frame are
completely separated.
Disassembling and installation sequence: Front
suspension cylinder → Lateral thrust bar →
Longitudinal thrust bars

Checking
Thoroughly clean all connectors and mounting holes by
appropriate solvent and blow dry by compressed air.
Check the pinhole bearings for normal rotation and
check spacer rings and hinge pins for wear. Upon
detection of wear, replace with new one.
Installation
1. Remove the dirt (Such as dusts) from pins and pin
mounting holes and clean them thoroughly. Lift or
forklift the front axle in place.
2. Assemble as per specified tightening torques and
apply thread sealants onto the bolts (10).
Disassembling and installation sequence:
Longitudinal thrust bars → Lateral thrust bar →
Front suspension cylinder
3. Fill oil and charge air as per the requirements of
“Air Inflation of Front Suspension” in this chapter
to extend the front suspension to appropriate
length.
4. Adjust the toe-in of front axle as per requirements
of “Adjustment of Steering Linkages” in this
chapter.
Note: Disassemble and install other castings and
welded parts as per Table of Tightening Torques for
Suspensions.
8.1.1.2 Front suspension cylinder
Figure 2 front suspension cylinder
Filling Suspension
Relief of Suspension Cylinder Pressure

Refer to Figure 4 for the numbers in parentheses, unless
otherwise specified.
Note: Before relieving the pressure of suspension
cylinder, ensure to unload the vehicle and park the
vehicle on a level ground.
1. Support the frame near the front suspension
cylinder by a jack or wood support of sufficient
capacity.
2. Disassemble the cap from the air inflation valve
(2, Figure 3) on the top of suspension cylinder
piston rod, rotate the hexagon nut on the air
inflation valve counter-clockwise for 1/4~1/2 turn,
and push down the valve core. If no air is vented,
rotate the nut for further 1/4 turn. Repeat this
operation till the nitrogen is vented when the valve
core is pushed down.
3. Remove the sleepers or relieve the pressures of
hydraulic jacks to apply the vehicle weight
completely onto the suspension cylinders.
4. Push down the inflation valve core to ensure that
the pressure is completely relieved. Note: Draining
the nitrogen from the suspension cylinder will
commonly carry away oil. This is caused by the oil
bubbles in the suspension cylinder, as the nitrogen
dissolved in the oil under high pressure expands
under normal pressure to generate bubbles. Ensure
to refill the oil for the oil loss in this process
during the filling of air. After completely draining
the air from the suspension cylinder, the longer the
oil stays in the normal pressure, the easier the air
bubbles in the suspension cylinder can be
eliminated during the filling of air.
Filling Instruction
WARNING!
Refer to Figure 2 for the numbers in parentheses, unless
otherwise specified. High pressure suspension cylinders. Ensure to
Note 1: Fill the nitrogen only after the suspension is relieve the pressure as per the requirements of
installed on the mining truck. Relieve the nitrogen “Relief of Suspension Cylinder Pressure” before
pressure of suspension cylinder before disassembling it opening any valve or connector. The accidenta
from the mining truck. pressure relief will result in personal injuries and
property losses.
Note 2: To guarantee the same inflation pressure and
same working height for two suspension cylinders,
inflate them simultaneously. In addition, while inflating
the front suspension cylinders, the extending heights of WARNING!
two rear suspension cylinders shall be same, which can
be achieved by placing the cushion blocks of same
thickness between the rear axle and frame stop block. While relieving the suspension cylinder pressure,
While installing the cushion blocks, it's necessary to ensure to push down and hold the valve core, till the
slightly elevate the frame. However, ensure to remove air is completely drained, otherwise it will result in
the cushion blocks after the completion of air inflation. personal injuries and property losses.
Note 3: Note: The air pressure varies along with the

temperature so that a tiny change of temperature around
the suspension cylinders can result in the change of

nitrogen filled volume and thus the change of

suspension cylinder working height.
Filling of Hydraulic Oil (First Filling or Refilling
after Repair)
Note: In event of oil loss of suspension cylinder due to
some causes other than surface leakage, it’s
recommended to fill oil by this method. In event of
surface leakage, disassemble and replace the
suspension. Return the suspension to the manufacturer
for repairs, otherwise the repairs without permission
will probably impair the quality warranty.
The oil level of the suspension installed on a mining
truck can be checked and adjusted as per following
procedure:
Note 1: To check the oil level correctly, ensure to
completely drain the nitrogen from the cylinder body.
This operation can be completed by vacuumizing the
air end of the suspension or supporting the frame
appropriately by skids to keep inflation valve opened
for >24 hours. This operation is required only in event
of surface leakage or excessive no-load deviation.
Note 2: This procedure must be performed after the
suspension is installed on a mining truck. If not, place
the suspension cylinder by appropriate support mode
and fixing method before operating this procedure.
1. Park the vehicle in a safe place on a level ground
and ensure to park the vehicle stably without
applying the friction brake system of mining truck.
2. Jack up the vehicle till the suspension extends 1. Oil plug (oil filler port) 2. Nitrogen inflation valve
completely and fix the mining truck at this Note: A is the extending length of piston rod, namely
position by skids. In such case, A=258mm (See the distance from center of suspension cylinder
figure 3). upper mounting bore to top plane of guide sleeve.
Figure 3 “A” = 218mm under no-load condition of
3. Remove the protective cap from the inflation valve vehicle.
and carefully push down the inflation valve core to
drain the filled air.
4. Connect a vacuum pump to the inflation valve to
vacuumize the cylinder.
5. Start the vacuumizing and monitor this process till
the air is completely drained. It indicates that the
vacuumizing is completed when the oil in the
suspension turns dark.
Note: It’s prohibited to extract oil from the suspension.
6. Stop the vacuumizing.
7. Disassemble the cushion blocks and slowly lower WARNING!
the mining truck frame to the required position. In
such case, A=118mm (Figure 3). High pressure suspension cylinders. Ensure to
8. Completely relieve the residual pressure from the relieve the pressure as per the requirements of
suspension as per above-mentioned procedure. “Relief of Suspension Cylinder Pressure” before
opening any valve or connector. Otherwise, the

9. Unscrew the oil plug and observe for out-flow of residual air pressure will result in personal injuries
oil from the connector outlet. If not, fill oil as per and property losses. Ensure to use a high pressure
the requirements below when the oil level is low. regulator in the suspension cylinder filling device,
otherwise it will result in personal injuries and
10. Disassemble the plug (1, Figure 3) and inflation equipment damages.
valve (2, Figure 3) from the top of piston rod and
connect oil filling subassembly to oil plug port.
11. Connect the oil filling pump pipeline to a clean
and high-quality Caltex heavy-duty power drive
oil 414 supply station. The required initial oil
filling volume for every suspension is
approximately 18L.
Note: In cold regions, it’s recommended to use a
synthetic fluid (Conoco/Philips synthetic R&O or
equivalent product) as substitute product, which
features the following characteristics: ISO viscosity
grade at 46; solidifying point at -70°F(-55 ℃); PAO
synthetic agent, applicable for common insulation
devices.
12. When the piston rod is extended to "A”=118mm,
fill oil into the suspension cylinders, till the oil
overflown from the inflation valve (2, Figure 3)
port is free of air bubble. Disassemble the oil
filling device and reinstall plug (1, Figure 3) and
nitrogen inflation valve (2, Figure 3) on the piston
rod.
Note: If the cylinder is not vacuumized during the
filling of oil, to bleed the air from the auxiliary oil
chamber, lift the frame by lifting sling or elevate the
frame by cushion blocks, maintain the cylinder
extension at A=118mm, disassemble the plug (1, Figure
3) and inflation valve (2, Figure 3), and fill oil through
the mounting hole of plug (1, Figure 3), till the oil
overflown from the inflation valve (2, Figure 3) port is
free of air bubble. Disassemble the oil filling device
and reinstall plug (1, Figure 3) and inflation valve (2,
Figure 2) on the piston rod.
Fill nitrogen into suspension cylinder as per the
following procedure. WARNING!
Air (Nitrogen) Filling Method for Suspensions While filling air the suspension cylinders, use
If it's necessary to inflate two suspension cylinders nitrogen and never use oxygen. The filled oxygen
simultaneously, use a T-connector, two hoses (1, Figure will come into contact with oil or grease to cause
4), clamping connectors (2, Figure 4), and inflation explosion and result in personal injuries and vehicle
connector (3, Figure 4). This tool assembly is described damages.
in the Special Tools.
1. Unscrew the sealing nut (8, Figure 4) and connect
air filling tool to a nitrogen cylinder.
2. As described below, install valve clamping
connector (2, Figure 3) on the nitrogen inflation
valve (2, Figure 3).
a. Rotate counter-clockwise the T-handle of the
clamping connector (2, Figure 4) of valve, till it

can’t be rotated further.

b. Tighten the nut of nitrogen inflation valve (2,
Figure 3) securely.
c. Rotate counter-clockwise the small hexagon nut of
nitrogen inflation valve (2, Figure 3) for 2~3 turns
to move the internal valve away from valve seat.
d. Rotate clockwise the T-handle, till it can’t be
rotated further, and open the check valve of
nitrogen inflation valve (2, Figure 3).
3. While checking the pressure of nitrogen cylinder,
close the inflation valve (4, Figure 4), open the air
inlet valve (6, Figure 4), slowly open the valve on
the nitrogen cylinder, and notice to observe the
reading on pressure gauge (5, Figure 4). The
pressure in the nitrogen cylinder must be higher
than 3MPa.
4. Close the air inlet valve (6, Figure 4) and open the
inflation valve (4, Figure 4), till two cylinders are
filled with air to the height “A” shown in Figure 2.
Slowly open and intermittently close the inflation
valve (6, Figure 4) during air filling. While
checking the cylinder pressure, close the air inlet
valve (6, Figure 4) and observe the reading of
pressure gauge (5, Figure 4).
Note: If the extending height is different between two
suspension cylinders, check the left and right 1. Hose 6. Air inlet valve
suspension cylinders on the rear axle for equal 2. Valve clamping 7. Connector
extending length (The suspension cylinders can retract connector 8. Nut
completely) and also check whether the vehicle is 3. Inflation connector 9. Nitrogen cylinder
parked on a level and even road and is unloaded. 4. Inflation valve connector
5. Air pressure gauge 10. Relief valve
Note: Inflate two cylinders to the height shown in
Figure 3, namely A=218mm (The permissible error
Figure 4 Nitrogen Filling Tool Assembly
range is 10mm). Do not fill excessive air, otherwise it
will result in excessive extension of cylinder body and
damage of fastening bolts on piston.
Note: The air filling pressure listed in Table 1 is only
for reference. Fill the air till the height specified in
Figure 3.
Table 1
Filling Standard of Suspension Cylinder (No-load)
Oil-filled height A=118mm

Total filled height A=218mm
Note: During the air filling, after the frame is elevated,
support the frame by appropriate cushion blocks or WARNING!
hydraulic jack.
This vehicle is installed with nitrogen prefilled
5. After the height “A” (Figure 3) is achieved, close cylinders with pressure in excess of 1.8MPa. The
the valve on nitrogen cylinder and air inlet valve special permission must be obtained to transport this
(6, Figure 4) and rotate clockwise the hexagon nut vehicle or nitrogen filled cylinder by any means.
on the nitrogen inflation valve (4, Figure 4) to

close the internal valve. Rotate counter-clockwise Contact the relevant authorities for the ship
the T-handle the of clamping connector (2, Figure transport. Please consult with dealer to obtain the
4) of valve, till it can’t be rotated further. detailed permission information.
6. Open the inflation valve (4, Figure 4), close the air
inlet valve (6, Figure 4), relieve the pressure from
pressure gauge (5, Figure 4) and hose (1, Figure 4)
via relief valve (10, Figure 4), loosen the rotary
nut, and disassemble the clamping connector valve
(2, Figure 3) and hose (2, Figure 4) of nitrogen
inflation valve (1, Figure 4).
Note: For a new or repaired suspension cylinder, the
seal ring and dust ring will make the piston rod tight so
that it's difficult to achieve the filling height of
suspension cylinder shown in Figure 4. In such case,
fill air into the suspension cylinder to the pressure as
accurate as possible, operate the vehicle for several
days, and re-check the height of suspension cylinder as
per table below.
7. Check the nitrogen inflation valve (2, Figure 3) for
leakage by soapy water. Upon detection of leakage
in above-mentioned valve, rapidly push down the
valve core once or twice to reset again. If the
leakage is still present, replace valve core. Tighten
the lock nut of inflation valve and replace valve
cover. Tighten the valve cover, till it can’t be
tightened further by hand. If the leakage is still
present, replace valve core, tighten the lock nut of
inflation valve (to 50N.m), and replace the valve
cover. Tighten the inflation valve protective cover
to 4.5~5.5N.m
8. If the suspension cylinders are filled to the correct
height and the vehicle is free of overload, but the
pistons in the suspension cylinders touch the end,
the oil level is probably incorrect. Relieve the
suspension cylinders, fill oil, and then re-inflate
the nitrogen as per above-mentioned method.
Daily check the height of suspension cylinders
(Figure 3, Table 1) and lubricate as per the
lubricating oils and maintenance intervals
specified by section “Lubrications and
Maintenances".
Special Tools
Refer to “Repair Tools” for the part number of filling
tool assembly shown in Figure 4 and other parts and
common repair tools required for the air filling. These
parts and tools are available from the dealers. In
addition, while filling air to the suspension cylinders,
adjust the filling tools as per the methods below:
a. Disconnect the hose assembly (1) from the
inflation valve (4) and install a three-way
connector on the inflation valve (4).
b. Connect and tighten the hose assembly (1) to one
branch port of the three-way connector.

c. While fabricating the second hose assembly,
install the valve clamping connector and inflation
connector to one end of the hose.
d. Connect and tighten the second hose assembly to
another branch port of three-way connector.
Table 2 Special Tightening Torque Table

Drawing
No. Name Torque /Nm
number
1&6 4 Plug 65
1&6 5 Inflation valve 50
1&6 25 Plug 65
1&6 10 Screw 79
1&6 22&26&2-8 Screw 136
1&6 29 Screw 333
1&6 33 Screw 65
5 1 Screw 277
5 4 Screw 541
8.1.1.3 Thrust Bars

The structural principle and the function of the thrust
bars for front and rear suspensions are the same, though
their shapes are different. Therefore, the thrust bars for
front and rear suspensions are described together.
The thrust bars are mainly functioned to connect the
frame and axles and play a guide role.
Disassembling and Installation
1. The disassembling and installation of the
longitudinal thrust bars for front suspension are shown
in Figure 1. Disassembling: Before disassembling and
installation, support the frame by tooling, allow the free
droop of wheels onto the ground, and fix them.
Disassemble the bolt (5) by tool, unplug the pin (4),
disassemble the bolt (1) and nut (2), and move out the
longitudinal thrust bars (3) of front suspension by a
hoist to complete the disassembling.
1. Bolt 4. Hinge pin
Installation: Connect the longitudinal thrust bars (3) of 2. Nut 5.Bolt
front suspension and the castings by bolt (1) and nut 3. Front suspension
(2), swing the thrust bars (3) to an appropriate angle to longitudinal thrust bar
align with the front axle connecting slots, insert the pin Figure 1 Disassembling and Installation of
(4), and tighten the bolt (5) to complete the installation. Longitudinal Thrust Bars for Front Suspension
Note: During installation, ensure that the tightening
torques for bolt (1) and nut (2) meet the requirements
of Table of Tightening Torques for Suspensions. The
application of thread sealant is required during the

tightening of bolt (5).
2. The disassembling and installation of the lateral
thrust bar for front suspension are shown in Figure 2.
Disassembling: Before disassembling and installation,
support the frame by tooling, allow the free droop of
wheels onto the ground, and fix them. Disassemble the
bolt (3) by tool and unplug the pin (2). Perform same
operation on the other end. Disassemble the lateral
thrust bar (1) of front suspension by a hoist to complete
the disassembling.
Installation: Align the pin hole of lateral thrust bar (1)
of front suspension with that of front suspension
crossbeam, insert the pin (2), and tighten the bolt (3).
Swing the other end to an appropriate angle and
perform the same operation to complete the installation.
Note: The application of thread sealant is required
during the tightening of bolt (3).
1.Bolt 4. Balance shaft assembly
2.Nut 5. Rear suspension lower
3.Bolt thrust bar
Figure 3 Disassembling and Installation of Rear

Suspension Thrust Bar
3. The disassembling and installation of the lower
thrust bar for rear suspension are shown in Figure 3.
bolt (3) and (2) by tool, disassemble the connecting nut
(2) from the bolt (1) on the balance shaft assembly side,
and disassemble the rear suspension lower thrust bar by
a hoist to complete the disassembling.
Installation: Connect the rear suspension lower thrust
bar (5) to balance shaft assembly (4) by bolt (1) and nut
(2), swing the other end to an appropriate angle to align
the thrust bar with axle bolt hole, and connect by bolt
(3) and nut (2) to complete the installation.
Note: Tighten the bolts (1) and (3) and the nut (2) to the
torques specified by the Table of Tightening Torques
for Suspensions.

4. The disassembling and installation of the upper

nut (6) and bolt (5) to separate the rear suspension
upper thrust bar from rear axle. Disassemble the nut
(1), cover plate (2), and bolt (3) to separate the thrust
bar from frame and complete the disassembling.
Installation: Insert the bolt (3) through rear suspension
upper thrust bar (4) cover plate (2) and rear suspension
upper thrust bracket, tighten it to the nut (1), swing the
thrust bar to an appropriate angle, and connect it to axle
by bolt (5) and nut (6) to complete the installation.
Note: Tighten the bolts (3) and (5) and the nuts (1) and
(6) to the torques specified by the Table of Tightening
Torques for Suspensions.
5. The disassembling and installation of the lateral
Disassembling: Disassemble the nut (1) and bolt (5) to
separate the rear suspension lateral thrust bar (7) from
axle and disassemble the nut (1) and bolt (9) to separate
the thrust bar from frame lateral thrust bar support (8)
to complete the disassembling.
Installation: Insert the bolt (9) through frame, rear
1.Nut 6.Nut
suspension lateral thrust bar support (8), and rear
suspension lateral thrust bar (7) and then tighten it to 2.Cover plate 7. Rear suspension lateral
3.Bolt thrust bar
nut (1). Swing the thrust bar to an appropriate angle to
4. Rear suspension upper 8. Rear suspension lateral
align with the axle mounting hole, insert the bolt (5)
thrust bar thrust support
and nut (1), and tighten them to connect the thrust bar
5.Bolt 9.Bolt
to the axle and complete the installation.
Figure 4 Disassembling and Installation of Upper
Note: Tighten the bolts (5) and (9) and the nut (1) to the and Lateral Thrust Bars for Rear Suspension
for Suspensions.

Structure of Thrust Bars
Front suspension longitudinal thrust bar
The structure of front suspension longitudinal thrust bar
is shown in Figure 5.
The parts are not supplied separately. The
malfunctioned parts can be repaired or replaced at
service stations. If required, please purchase service
package separately.
1. Front suspension 4. Hole circlip 98×5

longitudinal thrust bar 5. Seal ring
body
6. Knuckle ball pin
2. Seal ring 98 assembly (With pin)
3. Knuckle ball pin
assembly
Figure 5 Structure of Front Suspension
Longitudinal Thrust Bar
Front suspension lateral thrust bar
The structure of front suspension lateral thrust bar is
shown in Figure 6.
package separately.
1. Front suspension 3. Hole circlip 98×5

longitudinal thrust bar 4. Seal ring
body
2. Knuckle ball pin
assembly (With pin)
Figure 6 Structure of Front Suspension Lateral
Thrust Bar

Rear suspension lower thrust bar

The structure of rear suspension lower thrust bar is
shown in Figure 7.
package separately.
1. Rear suspension lower 3. Knuckle ball pin

thrust bar body assembly
2.Seal ring 108 4. Hole circlip 108×5
Figure 7 Structure of Rear Suspension Lower
Thrust Bar
Rear suspension upper thrust bar
The structure of rear suspension upper thrust bar is
shown in Figure 8.
package separately.
1. Rear suspension lower 3. Knuckle ball pin

Figure 8 Structure of Rear Suspension Upper
Thrust Bar
Rear suspension lateral thrust bar
The structure of rear suspension lateral thrust bar is
shown in Figure 9.
package separately.
1. Rear suspension lateral 3. Knuckle ball pin

Figure 9 Structure of Rear Suspension Lateral

Thrust Bar

8.1.2 Rear suspension assembly

8.1.2.1 Rear suspension assembl
1. Guide plate 8. Bolt M18×80 15. Thrust bar connecting bolt 22. Bolt M24×120
2. Leaf spring assembly 9. Rear suspension lateral 16. Rear suspension lower
23. Spiralock nut M24
27×15 thrust bar thrust bar
10. Rear suspension upper 24. Rear suspension upper thrust
3. Locating pin 17. Anti-rotating shim
thrust bar bracket
4. Spiralock nut M30 11. Spiralock nut M27 18. Leaf spring long bolt 25. Bolt M18×110
5. Leaf spring pressure
12. Stud bolt 19. Bolt M27×130 26. Bolt M24×420
block
6. Rear suspension upper
13. Spiralock nut M18 20. Bolt M1 ×1.5×60
thrust pressure plate
7. Rear suspension lateral
14. Balance shaft assembly 21. Bolt M24×240
thrust bracket
Figure 1 Rear suspension assembl

WARNING!
The blocking materials shall be fixed reliably and the
The rear suspension functions as an important carrying hoisting device shall have a hoisting capacity of >1t
part on the front of the vehicle and connects the frame to ensure operation safety.
to the axle. It’s mainly functioned to transmit all forces
and torques applied between axle and frame, mitigate
the impact load transmitted from road to frame (or
body), attenuate the vibration of carrying system
arising thereof, and guarantee the driving smoothness

of vehicle, the ideal motion characteristic of wheels
under rough road and varying load condition, and the
maneuver stability of vehicle. It’s mainly composed of
leaf spring (2), balance shaft assembly (13), and thrust
bars (9), (10), and (16). The leaf spring is functioned to
carry the forces between axle and frame and absorb and
attenuate the impact and vibration. The balance shaft
assembly is mainly functioned to balance the applied
forces of intermediate and rear axles and maintain the
uniform force application on intermediate and rear
axles on rugged roads. The thrust bars play a guide role
for the inclination status of whole axle.
Disassembling of leaf spring
To disassemble the leaf spring, it’s necessary to firstly
disassemble the intermediate and rear axles. As per
Disassembling of Thrust Bars in 8.1.1, disassemble the
lower thrust bar and lateral thrust bar of rear suspension
and then disassemble the intermediate and rear axles by
a hoist. Re-check the secure fixing of frame. Before
disassembling the leaf spring, ensure the secure fixing
of vehicle. Disassemble the nut (5) by special tool and
then pull out the leaf spring long bolt (2). Disassemble
the leaf spring pressure block (3), disassemble the leaf
spring assembly (1) by a hoist, and place it in a level
place to complete the disassembling of leaf spring 1. Leaf spring assembly 4. Balance shaft assembly
assembly. 2. Leaf spring long bolt 5. Spiralock lock nut
3. Leaf spring pressure
block
Figure 2 Disassembling and Installation of Leaf
Spring
Installation of leaf spring
Ensure the secure fixing of vehicle.
Lower the leaf spring assembly onto the balance shaft
assembly (4) by a hoist and insert the head of central
bolt beneath the leaf spring assembly (1) into the
locating hole of balance shaft housing. Hoist the leaf
spring pressure block (3) above the leaf spring
assembly (1) and fit the central bolt with the locating
hole of leaf spring pressure block (3). Insert the leaf
spring long bolt (2) through balance shaft assembly (4),
leaf spring assembly (1), and leaf spring pressure block
(3) and secure by lock nut (5) to complete the
installation of leaf spring assembly.
Note: Tighten the bolt (2) and the nut (5) to the torques
specified by the Table of Tightening Torques for
Suspensions.

Disassembling of balance shaft assembly

Before disassembling the balance shaft assembly,
complete the disassembling of thrust bars and leaf
spring. Re-check the fixing status of vehicle to ensure
the secure support of vehicle.
Loosen the lock nuts (3) by tool (If some nuts can’t be
disassembled by tool, it’s necessary to loosen the end
cap of balance shaft housing and then rotate the balance
shaft housing), vertically move and disconnect the
balance shaft assembly (2) from frame by a hoist, place 1. Stud bolt 3. Spiralock lock nut
it gently to a level place, and disconnect the studs (1) 2. Balance shaft assembly
from the frame to complete the disassembling of
Figure 3 Disassembling and Installation of Balance
balance shaft assembly.
Shaft Assembly
Installation of balance shaft assembly
WARNING!
The blocking materials shall be fixed reliably and the
Before disassembling of balance shaft assembly (2), hoisting device shall have a hoisting capacity of >1t
recheck the fixing status of vehicle to ensure the secure to ensure operation safety.
support of vehicle.
Tighten studs (1) to the frame threaded holes by tool.
Slowly move the balance shaft assembly (2) by a hoist
to an appropriate position to align the balance shaft
housing holes with studs (1) and move the hoist to
connect it. Ensure the stability of vehicle, screw the
lock nuts (3), and tighten the nuts uniformly to
complete the installation of balance shaft assembly (2).
Note: Apply thread sealant while screwing the studs (1)
into frame threaded holes. Tighten the nuts (3) to the
for Suspensions.

8.1.2.2 Leaf Spring Assembly
1. Leaf spring 1st plate 1850 5. Leaf spring 7th plate 1280 9. Leaf spring 11th plate 880 13. Leaf spring 15th plate 480
2. Leaf spring 2nd ~ 4th plates 6. Leaf spring 8th plate 1180 10. Leaf spring 12th plate 780 14. Nut M16
1850
3. Leaf spring 5th plate 1850 7. Leaf spring 9th plate 1080 11. Leaf spring 13th plate 680 15. Leaf spring bolt 425
th th th
4. Leaf spring 6 plate 1380 8. Leaf spring 10 plate 980 12. Leaf spring 14 plate 580
Figure 1 Leaf Spring Assembly
The leaf spring totally has 15 plates, including 5 main

plates, and is an enhanced longitudinal semi-elliptic WARNING!
leaf spring. The configuration of all leaf spring plates All plates of leaf spring assembly passed stringent
already passed the stringent vehicle performance vehicle performance verification and it’s prohibited to
verification and the change without permission will
change without permission, otherwise it will probably
probably result in damage of leaf spring and cause
serious malfunctions and losses. In event of any broken cause damage of leaf spring and result in serious
plate, it’s recommended to replace by a service station. malfunctions and losses.
Alternatively, purchase special leaf spring plate from a
designated service station and replace by self.

8.1.2.3 Balance Shaft Assembly
1. Hexagon head bolt 3. Lock plate 5. Rubber bearing 7. Spacer sleeve 9. Locating pin
2. Heavy-duty spring 4. Bearing pressure 6. Balance shaft housing 8. Balance shaft bracket 10. Balance shaft
washer plate
Figure 2 Balance shaft assembly
The balance suspension installed on SKT90S is a

maintenance-free suspension, requiring no oil filling. WARNING!
The rubber bearings (5) for this balance suspension are In event of breakage or looseness of balance shaft
swollen under the pressure of bearing pressure plate (4) assembly bolts, please repair immediately by a
to fully fill the balance shaft housing (6). During the local service station, otherwise it will accelerate
working, the balance shaft housing (6) achieves the the damage of this assembly and cause serious
rotation around the balance shaft (10) via the torsional malfunctions and losses.
deformation of rubber bearings (5), with the torsional
angle generally at ±15°.
In event of breakage of end cap bolts, aging of rubber
bearings, or cracking of balance shaft housing, please
repair timely by a local service station. This assembly is
a heavy-duty carrying component and the non-timely
replacement will result in accelerated damage of
balance shaft assembly and cause serious malfunctions
and losses.
It’s recommended to repair the malfunction of this
assembly by a local service station. The self-repair or
improper installation of rubber bearings will impair the
performance of this assembly or even accelerate the
damage of balance shaft assembly.

8.1.3 Repairs and Maintenances

8.1.3.1 Tightening torque
Table of Tightening Torques for High-Strength Bolts
and Nuts of Suspension System
Table of Tightening Torques for Suspensions
Thread Tightening torque (N·m)

specification 10.9 12.9
M18 365 430
M 0 515 600
M24 890 1040
M27 1380 1690
M30 1950 2300
Tightening torque for end cap bolts of balance shaft
assembly: 540-600N•m. WARNING!
To prevent personal injuries and property losses, the
The fasteners for the suspension system are of
high-strength lock bolts and nuts. The suspension blocking materials and hoisting appliance shall be
connectors are critical portions related to the safety and secure and reliable and the hoisting device shall have
functionality. During the repairs and assembling, use sufficient capacity to ensure the operation safety.
the process measures, including more accurate
tightening tool, secondary tightening, and reduced
tightening speed, to reduce the torque deviation.

8.1.3.2 Run-in of New Vehicle

1 Before the use of new vehicle, check the
connection and fastening status of suspension system
parts.
2 Run-in period of new vehicle
(1) At the first 200km mileage of vehicle, under
full-load condition, check and tighten the long bolts and
nuts of leaf spring once as per specified torque.
(2) At the first 500km mileage of vehicle, check as
described above and tighten the long bolts of leaf
spring.
3 Run-in of new vehicle
(1) After the run-in and before the use of new vehicle
or after the replacement or reassembling of leaf spring
assembly, under full-load condition, check and tighten
long bolts and nuts of leaf spring once as per specified
torques.
(2) During use, under full-load condition, check and
tighten the long bolts and nuts of leaf spring for three
times, once every 200~300km.
4 Check and tighten the exposed bolts and nuts of
suspension system as per specified torques once every
1,500~2,000km of vehicle. Note: Check and tighten the
long bolts and nuts of leaf spring under full-load
condition of vehicle. If the rubber of any rubber bearing
is damaged, replace the rubber bearing timely.
8.1.3.3 Malfunction Diagnosis WARNING!

The suspension system malfunctions are related to To prevent personal injuries and property losses,
multiple systems, including the steering mechanism,
the blocking materials and hoisting appliance
axles, and tires. Upon detection of abnormality during
driving, including noise, off-tracking, vibration, and shall be secure and reliable and the hoisting
abnormal damage, check thoroughly and correct any device shall have sufficient capacity to ensure the
related situation, including: operation safety.
(1) Check tires for normal pressure.

(2) Check tires for non-uniform wear.
(3) Check tires for unbalance and damage.
(4) Check bracket connectors for looseness.
(5) Check steering parts (Including hydraulic steering
rod ball joint) for wear and looseness.
(6) Check suspensions for damage and looseness. For
instance, check thrust bar ball pins for serious wear and
check connections for looseness.
(7) Check suspension cylinders for leakage of oil and
air.
(8) Check leaf spring for misplaced or broken plate.

(9) Check for lubrication failure.
(10) Check leaf spring long bolts for deformation and
breakage.
(11) Check limit blocks for falloff.
The suspension is an important component of vehicle
carrying system. Upon detection of any damaged part,
timely repair or replace by a service station, otherwise
it will result in accelerated damage of other
non-damaged parts or even serious vehicle accident.
1. To prevent the frequently occurred problem during
the malfunction diagnosis, frequently check the bolts of
critical portions for looseness, including long bolts of
leaf spring and connecting bolts of thrust bars.
2. It's recommended to re-tighten the connecting
bolts of thrust bars once every 5,000km and the bolts of
leaf spring once every 2,000km, in order to prevent the
looseness of bolts from causing breakage of bolts or
even the damage of other suspension system parts.
Check all bolts of balance suspension system during the
first 5,000km maintenance of vehicle and afterwards
check as well once every 5,000km. Under severe road
condition, shorten the interval mileage accordingly, in
order to always maintain the vehicle under good
working status.
3. Frequently check the end cap bolts of balance
shaft for looseness.
4. Apply lubricating grease to the area around the
leaf spring and sliding plate once every
8,000~10,000km, in order to reduce the wear of sliding
plate seat. The normal wear life is half year for guide
plate and sliding plate seat. Upon detection of serious
wear, replace immediately. Note: The guide plate is of
split type. If its thickness is worn to 3mm or the motion
of leaf spring is impaired, ensure to replace.

8.2 Cab accessories

8.2.1
1. Cab assembly 2. Cab lifting installation 3. A/C installation

4. Fender installation assembly 5. Cab suspension assembly 6. Platform installation assembly
Figure 1 Cab accessories

8.2.2 Disassembling and Installation

Disassembling
Refer to the Figure (1) for the numbers in parentheses. Air filter
Note: Make mark to identify all disassembled cables,

wiring harness, pipes and pipe joints for the Platform
convenience of installation. For removed air installation
assembly
conditioning pipe interfaces, seal them with plug
immediately to avoid impurities from pollution to
system. Platform
a. Park the vehicle in a level working area, lift the

cargo compartment, and install the cargo
compartment safety pins. Refer to Cargo
Compartment and Installation.
b. Apply the parking brake, and stop the engine. Figure 8-1 Brake Oil Cooler Installation
c. Rotate the steering wheel leftward and rightward
for several times to relieve the pressure of steering
system and continuously depress the foot valve to
relieve the pressure of brake accumulator.
Continuously operate the lifting joystick to relieve
the pressure of accumulator and block the wheels.
1. Disassemble the platform installation assembly
(Figure 1-1).
1.1 Disassemble the air filter assembly from the right
platform of cab.
1.2 Disconnect the condenser pipeline.
1.3 Disassemble the cab right platform from the
platform installation assembly (6) and hoist it out.
2. Disconnect the electric circuits and pipelines.
2.1 Disconnect the cable connections between cab and
frame.
2.2 Disconnect the electric parts, including fog lamp,
turn signal lamp, and headlamp.
2.3 Disconnect the A/C pipes from cab.
2.4 Disconnect the air pipes of pneumatic control
valve.
2.5 Disconnect the drive shaft universal joint from
steering gear.
2.7 Disconnect the brake valve.
2.8 Disconnect the air pipes of pneumatic control
valve.
2.9 Disconnect the gearshift hose.
3. Disconnect the tilting cylinder and front tilting
support from cab, unlock the rear suspension
locking mechanism, and disassemble the cab.
Note:During dismantling the cab assembly, use a
special spreader and a lever with pad to prevent

excessive stress on the hook, chain, and steel cable at
the lifting point of the cab. Carefully lift the cab
assembly to the appropriate workbench.
1. Installation
Front tilting support Rear suspension
Refer to the Figure (1) for the numbers in parentheses.
Note: Tighten all fasteners according to "Standard Bolt
and Nut Torque Technical Conditions" in the manual.
Note: Tighten the pipe with "O" ring end face seal
interface, and replace the "O" ring by adherence to the
"Brake System Schematic Diagram" in the manual.
1 Install the cab suspension assembly (5) and Figure 8-2 Cab Suspension Assembly
platform installation assembly (6) on the frame.
2 Fix the cab right platform onto the platform
installation assembly (6). Before tightening the
bolts, ensure that the gap between the stand and
the cab is 20mm.
3 Fix the cab onto the front tilting support (Figure
1-2) and connect it to the locking mechanism of
rear suspension.
4 Connect the cab lifting mechanism (2) to the cab.
5 Connect the drive shaft universal joint to the
steering gear. Before connecting the universal
joint, ensure to return the tires.
6 Connect electric circuits and pipelines.

8.2.3 Air conditioning pipeline installation
1. Condenser 2. Reservoir and dryer 3. Condenser bracket 4. Condenser-reservoir 5. Compressor air vent
pipe pipe
6. Evaporator 7. Heater hose 8. Compressor 9. Reservoir-evaporator 10. Compressor air
pipe suction pipe
Figure 2-1 A/C Pipeline Installation Diagram
Disassembling
Refer to the Figure (2-1) for the numbers in
parentheses.
1. Stop the vehicle in the horizontal work area, press
the parking brake, turn off the engine, and turn the
steering wheel to the left and right for a few laps
to release the pressure of steering system.
2. Block out the wheel, and turn the battery master
switch to the "off" position.
3. After the complete vacuumizing of system, mark
the condenser-reservoir pipe (4), compressor air
vent pipe (5), heater water pipe (7),
reservoir-evaporator pipe (9), and compressor air
suction pipe (10) to ease the installation.
4. Carefully disassemble the marked pipelines and
various parts from the corresponding system
respectively and plug the connectors and
corresponding fittings to guard against ingress of
foreign materials into system.

Installation of air conditioning system

Refer to the Figure (1) for the numbers in parentheses.
1. Connect all pipelines to corresponding ports. The
hoses shall be installed without distortion, mutual
friction, or pre-stress. Ensure a certain gap
between high and low pressure pipelines. When
necessary, isolate the high and low pressure
pipelines by rubber sleeves. Place the O-rings to
the pipeline connections. Before installation, apply
some refrigerant oil.
2. Installation of compressor. While installing the
compressor, the lateral inclination shall not exceed
30° and the longitudinal inclination shall not
exceed 10°. If the inclination exceeds the specified
value, it will result in the obstructed working or
abnormal working of lubricating oil system within
compressor and thus the blockage of compressor
due to insufficient lubrication. The working
environment of the compressor shall have a large
space and well ventilation and heat dissipation,
with the environmental temperature no higher than
120℃.
3. Installation of condenser and evaporator. During
installation, place the devices to a place of low
vibration, in order to attenuate the damages of
devices. Select an installation location of
appropriate ventilation area. The over-sized or the
under-sized ventilation area will result in
obstructed air inlet, over-high high pressure, and
poor condensing performance.
4. Installation of reservoir and dryer. During the
installation, ensure that the sightglass is within the
accessible line of sight.
Environmental protection
Environmental studies have shown that the earth's
protective ozone layer in the outer stratosphere is
weakening year by year. Chlorofluorocarbons (CFC's),
such as R-12 refrigerant (Freon), which are widely used
in air conditioning system for mobile equipment, have
been proved as a possible cause of ozone depletion.
Therefore, the legislative bodies of more than 130
countries expressly stipulate to terminate the
production and distribution of R-12 refrigerant after
1995. Thus, most of current motorized air conditioning
systems use a more environmentally friendly
hydrofluorocarbon (HFC).
HFC refrigerant is commonly referred to as HFC-134a
or R-134a. For this purpose, it is forbidden to discharge
refrigerant into the atmosphere during the filling or
refilling process.
Air conditioning for off-highway vehicles

Mining and construction vehicles are characterized by
vibration, sudden load surge, operator change and
climatic conditions, which pose different problems for
the design and installation of air conditioning system.
In general, off-highway equipment is very unique and
able to undertake a variety of different operations,
which is incomparable to ordinary motor vehicles or
road engineering vehicles.
Refrigeration principles of air conditioning system
Refrigeration-cooling
 In fact, air conditioning system cooling is a

process of removing heat, not a process of making
air.
 Heat is always transferred towards cooler
temperature. This principle is the basis for
operation of the refrigeration unit. Heat transfer
occurs as long as the temperature of one object is
lower than that of the other.
 Temperature is the intensity of heat measured in
degrees. The most commonly used measuring
device is thermometer.
 All liquids have a vaporized point. Water boiling is
the most common example of heating to form
steam. Boiling is a form of rapid evaporation.
Steam is much hotter than boiling water. Once
boiling is reached, water temperature will not rise
any more. Thermal energy is utilized during the
vaporization process. The boiling point of a liquid
is directly affected by the pressure. By changing
the pressure, we can control the boiling point and
the temperature at which the vapor condenses.
When a liquid is heated and vaporized, the gas
will absorb heat without change of the pressure.
 In turn, when heat is removed from the water
vapor, gas will return to the liquid state. The heat
in the air moves toward a colder object. Normally,
the moisture in the cooling air will condense on
the cooler objects.
 Refrigerant - R134a can only be used in new
automotive systems specially designed for the
refrigerant.
Refrigeration cycle
 In an air conditioning system, the refrigerant

circulates under pressure through five main
components in a closed circuit. At these points in
the system, the refrigerant undergoes the

predetermined change of pressure and

temperature.
 The compressor sucks the low-pressure
heat-carrying refrigerant gas through the suction
valve (low pressure side), compresses the
heat-carrying refrigerant and forces it to pass
through the discharge valve (high pressure side) to
go to the condenser. The ambient air passing
through the condenser carries away the heat of the
circulating refrigerant, further causing the
refrigerant to convert from gas to liquid.
 The liquid refrigerant continues to move to the
reservoir where the impurities are filtered and the
moisture is removed. This part is also used for
temporary storage of a part of liquid refrigerant.
 Then, the liquid refrigerant under high pressure
flows out of the expansion valve, which valve
meters the amount of refrigerant entering the
evaporator. As the refrigerant flows through the
valve, it becomes a low temperature, low pressure
liquid and saturated steam. This causes the
refrigerant to cool.
 The remaining low-pressure liquid immediately
begins to boil and vaporize as it approaches the
evaporator, which increases refrigeration. The hot
and humid air in the cab is extracted by the
evaporator fan through the evaporator. Since the
temperature of the refrigerant is lower than the
temperature of the air, it absorbs heat from the air
and generates cold air that is pushed back into the
cab. The moisture in the air is condensed as soon
as it enters the evaporator and then is discharged
from the cab through the drain pipe of the
evaporator.
 When the heated low-pressure gas is again sucked
and compressed through the suction side (low
pressure side) of the compressor, the cycle ends.
Air conditioning system components
Compressor
The compressor is a device that converts the low
pressure side of the system to the high pressure side. It
collects the refrigerant returning from the evaporator to
produce high pressure and temperature considerably
higher than outside air temperature. The large

temperature difference between the refrigerant and the
outside air is the driving force necessary to assist in the
rapid heat flow between the hot refrigerant gas in the
condenser and the much cooler outside air.
To generate high pressure concentration, the
compressor absorbs refrigerant from the evaporator
through the low pressure side and forces it into the
condenser through the high pressure side during the
compression stroke. Under the pressure generated by
the action of the compressor, the refrigerant moves to
the expansion valve through the condenser, the
accumulator and the connecting hose.
The compressor is driven by the engine through a belt
which drives an electric clutch mounted on the
compressor drive shaft.
Condenser
The condenser receives the high pressure and high

temperature refrigerant gas from the compressor and
condenses it into a high pressure hot liquid.
The condenser is designed to allow thermal movement
from hot refrigerant gas to colder outside air. The
cooling of the refrigerant turns the gas into liquid. Heat
exchange is accomplished by the colder air flowing
through the condenser. The cooling of the condenser is
carried out by the flow of the ram air generated by the
movement of the radiator fan and the vehicle.
Therefore, the condenser is usually mounted in front of
the radiator.
The refrigerant's condensing refrigerant is changed
from gaseous state to liquid state, which is affected by
the refrigerant pressure and the flow of gas through the
condenser. The condensing pressure in an air
conditioning system is the control pressure of the
refrigerant, which affects the temperature at which it
condenses into liquid. During the process, a large
amount of heat is dissipated. The condensation point is
high enough to create a large temperature difference
between the hot refrigerant gas and the air passing
through the condenser cooling fins and tubes. The
temperature difference allows rapid heat transfer from
the refrigerant to the ambient air.
Liquid reservoir

The liquid reservoir is a very important part of the air

conditioning system. The dryer receives the liquid
refrigerant from the condenser and removes any
moisture and foreign matter that may enter the system.
The storage port of the reservoir is designed to store the
additional refrigerant that is not needed by the
evaporator. Such storage is temporary and depends on
the needs of the expansion valve.
Desiccant is a solid substance that removes moisture
from gases, liquids, or solids. It is held in place
between the two screens in the liquid reservoir. The two
screens also serve as filter screen.
The liquid reservoir is also equipped with an
observation window and a moisture indicator. The
observation hole gives a good indication of the system
filling. If the observation window is not clear, it shows
the system's refrigerant is low.
The moisture indicator is a device that informs the
maintenance personnel of full water in the dryer and the
necessary replacement of the dryer. The indicator is
blue when there is no moisture in the part. When the
indicator changes to light brown or dark blown, the
dryer must be replaced.
Evaporator
The evaporator cools and dehumidifies the air before it

enters the cab. The wide area of refrigeration require a
large amount of air to flow through the evaporator for
heat exchange. Therefore, the evaporator fan becomes a
key component of the evaporator assembly. It not only
draws the hot air into the evaporator, but also forces the
air through the evaporator cooling fins, where the heat
is absorbed by the refrigerant. The evaporator fan
forces the cooled air to flow out of the evaporator and
go to the cab.
Circuit
The circuit of the air conditioner is powered by an
auxiliary circuit.
The evaporator fan is controlled by a switch that
provides a fast to slow control panel. When the
evaporator fan switch is turned on, a current is present
at the compressor clutch. Once the fan is turned on, the
fan speed can be changed without influence on the
thermostat sensing level.

The thermostat reacts according to the temperature that
causes the electrical contacts to open and close. The
thermostat has a capillary that extends into the
evaporator to sense temperature.
When the contacts are closed, the current flows to the
clutch magnetic field and activates the clutch to rotate
the swash plate within the compressor, thereby starting
the refrigerating cycle. When the temperature sensing
temperature in the evaporator drops to a predetermined
value, the contacts are opened, the clutch is disengaged,
and the compressor stops operation.
When the compressor stops working, the evaporator fan
is still operating at the set speed. After the temperature
in the evaporator increases to or slightly above the set
value, the contacts in the thermostat are closed, the
compressor starts to work, and the refrigeration cycle
restarts.
Air conditioning system commissioning
For this A/C system, no fresh air function is provided

and the default mode is internal recirculation mode.
Note:
1. The air conditioning system condenser needs to be
cleaned regularly to ensure that it reaches the
normal heat dissipation function;
2. The air conditioning compressor installation bolts
should be inspected every 500h to ensure no
looseness;
3. The compressor installation belt is inspected every
500h: if the belt is pressed by finger in the middle
between the drive wheel and the compressor
pulley, it is suitable to have the deformation of
5~8mm (force is about 10kg (98N));
4. The air conditioning or compressor cannot be used
for a long time (more than 3 months). It should be
turned on regularly (at least once a month) for
more than 10 minutes to prevent the air
conditioning compressor from being stuck due to
oil shortage.
Vacuuming operation
To install an air-conditioning unit, the most important

thing to note: do not mix moisture in the air
conditioning system. The refrigerant (R134a) used in
the air conditioning system is extremely soluble in
water. If there is a small amount of water remaining in
the air conditioning system, it is easy to cause the small
hole of the expansion valve to freeze in the air

conditioning system, and get the compressor valve rust,
etc. Before the refrigerant is injected, the moisture in
the air conditioning system should be removed as much
as possible. To achieve the lowest moisture residue in
the air conditioning system, the air conditioning system
must be vacuumed before filling.
Vacuuming process:
Vacuuming steps
☆ Connection of manifold pressure gauge (refer
to figure 2-2).
1. Turn off the high pressure valve (HI) and low
pressure valve (LO) of the manifold pressure
gauge;
2. Connect the air tube (red, blue) to the
compressor auxiliary valve;
Red hose connected to high pressure side
(mark D)
Blue hose connected to the low pressure side
(mark S)
3. Connect the gas tube (green) in middle of
manifold pressure gauge to the vacuum
pump. Figure 8-3
Note: The side of the L-bending front end of the
gas tube is mounted to the compressor auxiliary
valve. In the event of opposite connection, the
valve inside the compressor cannot be opened. In
addition, do not reverse the high voltage and low
voltage parts.

☆ Vacuuming (refer to figure 2-3)
1. Open the high pressure valve (HI) and low
pressure valve (LO) of the manifold pressure
gauge;
2. Turn on the vacuum pump switch and
perform vacuuming operation (about 15
minutes);
3. When the pressure gauge negative pressure
scale (i.e. vacuum degree) reaches 750mmHg
or more, turn off the vacuum pump switch
and close the high pressure valve and low
pressure valve of manifold pressure gauge.
Figure 8-4
☆ Seal inspection
1. Place the high pressure valve and low
pressure valve of the manifold pressure gauge
for more than 5 minutes in the off status, and
confirm that there the pressure gauge reading
is the same as that before the pressure is
maintained;
2. If the pointer of the pressure gauge returns to
0 around, it indicates that leakage exits
somewhere in the air conditioning system, so
the air conditioning pipe connection needs to
be inspected and the vacuuming operation is
carried out again until no leakage exists.
Replacement of refrigerant tank
1. Close the high pressure and low pressure
valves of the manifold pressure gauge.
2. Lift the needle and disc of refrigerant tank
valve and disassemble the empty tank.
3. Install new refrigerant tank to the refrigerant
tank valve.
4. Bleed the air from the air inflation hose by
following method:
1) Tighten the refrigerant tank valve and then
loosen slightly.
2) Open the low pressure valve of manifold
pressure gauge slightly.
3) Open the air bleeding valve. Once the
refrigerant drains, immediately close the
refrigerant tank valve and low pressure valve
of manifold pressure gauge. Figure 8-5
5. Rotate the handle of the refrigerant tank
valve, open the refrigerant tank, and continue
to fill until the operation is completed.

Routine maintenance for air conditioning

system
1. Check and clean the air conditioning
condenser. It is required to clean the heat sink
without obstruction. Cold water or
compressed air instead of hot water and hot
air, should be used for cleaning.
2. Check the refrigeration system cooling dose,
that is, observe the reservoir observation
window. Under normal circumstances, there
is no bubble in the observation window, and
there are a few bubbles when the engine
speed changes.
3. Check the tension of compressor drive belt.
4. Check if the hose has good appearance and if
the connectors are secure. Figure 8-6
5. Check if the cooling system power
connection is reliable without open circuit or
short circuit.

List of Common Faults of Air Conditioning System
Malfunction Phenomenon Cause Measure

1. The system has moisture, causing Replace the reservoir and
ice blockage of the expansion valve re-vacuum
Refrigeration The cooling system is not 2. The thermostat is out of order Fill the refrigerant
intermittent opened or stopped
3. Bad wiring Check and repair
work normally.
4. Poor control switch contact Check and repair
5. Poor relay contact Check and repair
1. Belt looseness Adjustment or replacement
2. Compressor bracket looseness Adjustment
The system has an
Increased noise 3. Evaporating fan blade looseness Adjustment
abnormal sound.
4. Clutch slip Repair or replacement
5. Compressor internal wear Repair or replacement
1. The valve is not opened Open the valve
2. Pipeline is blocked Repair
Insufficient
Hot air is not hot. 3. Heating medium temperature is not Open it after temperature
heating
high rises
4. Pipeline leaks Repair or replacement
1. Compressor clutch Replacement
a. The coil is broken or short circuit Repair or replacement
b. Clutch slips Inspection and connection
The evaporator fan is 2. The thread is disengaged Replacement
normal and the 3. Belt is broken
compressor does not 4. Pressure switch action Check leakage, and make
work. a. The refrigerant leaks too much replenishing
b. The refrigerant is filled too much Release properly
c. The switch is damaged Replace the damaged parts
5. The thermostat is damaged Replace the damaged parts
Check leakage, and make
Not cooling The evaporator fan is 1. The refrigerant leaks too much
replenishing
normal and the 2. Refrigerant is charged too much
Release properly
compressor works. 3. Compressor is damaged
Repair or replacement
The evaporator fan does 1. Line power failure
Check and repair.
not rotate, and the a. Poor ground line contact
Check and replacement
compressor does not b. Fuse blown
work. Check and replacement
c. Power switch failure
1. Fan damage Replace.
The evaporator fan does
2. Fuse blown Replace.
not rotate, and the
compressor works. 3. Windshield switch failure Replace.
4. Speed resistance failure Replace.

8.2.4
Cargo compartment (Front view)

Battery compartment Cargo compartment and tires Cargo compartment (Left view)
SKT90 Marking Layout
Figure 3-1
Front suspension cylinder
Cab Accumulator Cargo compartment (Right view)

Fuel tank
Hydraulic Oil Tank Frame Left fender sheet
8- 41
Maintenance
1. Battery cable warning patch 12. “Do not stand” warning patch
2. Alternator warning label 13. Accumulator warning patch
3. Grounding signage TLBP.027 14. Right cargo compartment film
4. Tire warning patch 15. Suspension cylinder warning patch
5. Support warning label 16. Hydraulic oil description patch
6. Left cargo compartment film 17. No treading label
7. Lubrication and maintenance diagram 18. Nameplate
8. Logo 19. Rivet 3×10GB827
9. Front cargo compartment film 20. Operation warning label
10. Cab film
11. Cargo compartment warning label
Label layout diagram

8.3 Vehicle frame

1. Bolt 14. Bracket 27. Washer 40. Bumper connecting base
2. Nut 15. Pin 28. Connecting plate 41. Bolt
3. Lifting cylinder support 16. Towing hook pin 29. Bolt 42. Adjustment shim
4. Mounting base 17. Bolt 30. Bracket 43. Bolt
5. 2nd crossbeam 18. Rear towing hook bracket 31. Bolt 44. Bracket
6. Adjustment shim 19. Rear lamp holder 32. Bent plate 45. Bracket
7. Adjustment shim 20. Bolt 33. Bracket 46. Washer
8. Mounting plate 21. Bolt 34. Bolt 47. Washer
9. Nut 22. Nut 35. Nut 48. Front towing hook
10. Washer 23. Mounting base 36. Connecting plate 49. Frame
11. Bolt 24. Round tube 37. Washer
12. Nut 25. Bolt 38. Front grille
13. Bolt 26. Hinge pin 39. Bolt
Figure 1 Frame and installation
1. Disassembling
WARNING!
When removing components as shown in the figure,
observe the following steps: To prevent personal injury and property damage,
make sure vehicle is parked, and the lifting
1. Stop the vehicle in a flat place, press the parking equipment has sufficient strength and lifting
brake, turn off the engine, and turn the steering capacity, and is well fixed to ensure safe work.
wheel for a few laps to release the pressure of the
steering system.。
2. Cover the wheels and turn the battery master
switch to the "OFF" position.
3. Lift the parts with a suitable lifting device, remove
the fasteners, and remove the parts from the
vehicle.
Installation
Caution: Tighten all fasteners as per “Technical
Condition of Standard Tightening Torques for Bolts and
Nuts”.
Align the parts with the appropriate lifting equipment,
and then mount and fasten them to the chassis with the
fasteners removed during disassembly.
Repair
Checking
Check the frame and accessories at the interval of not
more than 250 hours. Check for welding bead crack,
and frame deformation distortion. In case of any
problem found, make maintenance timely.
Painting
Check the paint condition twice a year and re-paint the
chassis if necessary. If the vehicle frame needs painting,
thoroughly clean the position to be painted, firstly
apply one coat of oxidation rust primer, and then one

coat of synthetic porcelain finish. In order to minimize

rust and corrosion, it is necessary to regularly make
painting on the metal area and the wear area exposed
on the frame.
Special Tools
In the procedures described in this chapter, no special
tools are required. The general maintenance tools are
listed in the chapter "Service tools", which are available
from the factory agent.

8.4 Cargo Compartment and Installation
1. Cargo compartment body 13. Bolt 25. Tilting beam 37. Hinge pin
2. Washer 14. Cover plate 26. Nut 38. Locking plate
3. Bolt 15. Bolt 27. Bolt 39. Nut
4. Air vent connecting base 16. Washer 28. Left locking base 40. Bolt
5. Nut 17. Nut 29. Connecting fork 41. Nut
6. Washer 18. Grease nozzle 30. Bolt 42. Bolt
7. Bolt 19. Cargo compartment tilting 31. Connecting chain 43. Bolt
base
8. Pressure plate 20. Adjustment shim 32. Nut 44. Bolt
9. Mudguard 21. Adjustment shim 33. Rear support 45. Grease nozzle
10. Mudguard bushing 22. Washer 34. Left locking base
11. Mudguard bushing 23. Bolt 35. Pin
12. Bushing 24. Rear support 36. Washer
Figure 1 Cargo Compartment Installation

Overview
The baseplate of the cargo compartment (1) is made
of integral steel sheet, with five lateral and eight
longitudinal beams. The hull type cargo compartment
ensures high stiffness. A rear gate is installed to
increase the capacity of cargo compartment.
The cargo compartment is connected to the frame by
connecting base and cargo body tilting base (19) and
is lifted by one four-stage lifting cylinder.
Disassembling
Note: The whole cargo compartment is
approximately 10,362kg in weight.
1. Park the vehicle on a level working area, apply
the parking brake, and block the wheels.
2. Disassemble the connecting bolts between cargo
compartment (1) and lifting cylinder base and
properly fix the lifting cylinder.
3. Disassemble the fender sheets (10 and 11) from
cargo compartment. Figure 8-7
4. Disassemble the connecting bolts (40) between

locking plate (38) and connecting chain (31).
5. Disassemble the connecting bolts (15) between
cargo compartment (1) and cargo compartment
tilting base (19). Lift the cargo compartment (1)
out of the frame by an appropriate hoist (Refer
to attached Figure 2 for the lifting positions).
Installation
WARNING!
To prevent personal injuries and property losses,
Note: Tighten all fasteners according to "Technical ensure to securely block the wheels. The blocking
Conditions for Standard Bolt and Nut Tightening materials and the hoisting device shall be properly
Torque ". fixed and have sufficient strength and hoisting
1. Before installation, clean the disassembled pins capacity to ensure the operation safety.
and adjustment shim and wipe clean. In
addition, prepare an appropriate amount of
engine oil and necessary assembling tools and
fulfill the pre-installation preparations.
2. Fix the replacement cargo compartment on a
level and solid ground.
3. Install the bushing (12) to the cargo
compartment tilting mechanism (19).
4. Install the cargo compartment tilting base (19)
to the frame mounting shaft. Before installation,
ensure the flexible rotation of cargo
compartment tilting base (19).
5. Lift the cargo compartment body (1) to the

frame. Adjust the position of cargo
compartment, align the bolt holes of cargo
compartment connecting base and cargo
compartment tilting base (19), and fix the tail of
the cargo compartment to the cargo
compartment tilting base (19). After installation,
ensure that the gap within 0.5m is 0 at the front
and tail and no more than 5mm at other
positions of fit surface between cargo
compartment (1) and frame.
6. Add the adjustment shims (20 and 21) to ensure
that the gap between cargo compartment
connecting base and cargo compartment tilting
base (19) is <0.5mm and tighten the bolts (15)
and nuts (17).
7. Assemble the end cap (14) to the tilting base
(19).
8. Assemble the oil cup (18) to the oil filler port
on the cargo compartment tilting base (19) and
fill lithium-base lubricating grease to the oil cup
(18). After filling the lithium-base lubricating
grease, remove the surrounding lubricating
grease by detergent and then wipe clean by
clean tissue.
9. Assemble the cylinder brackets to the lifting
cylinders and cargo compartment and assemble
the grease nozzles to the cylinder brackets.
Apply thread sealant to the bolts and fill
lithium-base lubricating grease into the grease
nozzles. Adjust the positions of cylinder
brackets by the long slots on the cylinder
brackets and ensure that the unilateral gap
between cylinder bracket and lifting cylinder is
≤1mm. After filling the lubricating grease,
remove the surrounding lubricating grease by
detergent and then wipe clean by clean tissue.
10. Assemble the locking plate (38) to the tail of
cargo compartment by pins (37), washers (36),
and split pins (35) and then connect the locking
plate (38) to the connecting chain (31) by bolt
(40) and nut (39).
11. Install the connecting yoke (29) to the locking
bases (28 and 34) by nuts (17). Install one nut
(17) on its upper end and install two nuts (17)
on its lower end. Connect the connecting chain
(31) and connecting yoke (29) by bolt (30) and
nut (32) and tighten the bolt. Tension the
connecting chain (31) by adjustment nut (17).
After tensioning the connecting chain, tighten
the nut (17).
Precautions during repairs of cargo compartment
1. The incorrect disassembling or assembling will
probably cause personal injuries or damage the

machine.
2. Take cautions during the disassembling and
assembling of cargo compartment. Do not
operate brutally or collide any mounting or
fitting surface.
3. The rated lifting capacity of the lifting
equipment shall be higher than the weight of
cargo compartment. All personnel are prohibited
to access the area beneath the cargo
compartment being lifted. Ensure that the lifting
ropes are securely fixed before the lifting.
4. While starting the machine to connect with the
replacement cargo compartment, ensure the
uniform commanding and safe operations. The
driver shall guarantee the safe space for the
assembling personnel.
5. Properly preserve the disassembled fender
sheets (11 and 10), fender (9), pressure plate (8),
bolts, nuts, and shims to prevent loss.
Maintenance
1. Fulfill the daily checking for the pins and
fasteners to prevent no looseness and falloff.
2. Fulfill the daily checking for the vent holes of
cargo compartment to guard the vent holes
against blockage.
3. Fill grease to the connecting pins of rear gate
once every 100 hours.

8.5 Hydraulic System

8.5.1 Replace hydraulic oil
1. Operation environment
Avoid filling hydraulic oil, replacing filter, or
repairing machine in the rain or in windy or dusty
place.
2. Breakdown and maintenance operations in
working site
There is a danger of dust ingress into parts during the
breakdown and maintenance operations of hydraulic
parts in the working site. It's difficult to check the
performance after repairs. Therefore, it’s better to
replace the assemblies. The breakdown and
maintenance of hydraulic parts shall be performed in
a special dustproof workshop and the performance
shall be checked by special testers.
Figure 8-8
3. Filling of hydraulic oil
While filling the hydraulic oil, guard against the
ingress of oil sludge and dusts. Ensure to keep clean
the filter element and its surrounding area and use
clean pump and oil container. The use of oil cleaning
machine can probably filter out the oil sludge
accumulated during storage. Therefore, it’s a more
effective method.
Figure 8-9
4. Replacement of hydraulic oil under high
temperature
The hydraulic oil or other oil can flow easily under
warm status. In addition, the sediments can be
drained easily along with oil from the oil pipeline.
Flushing oil
Therefore, it’s better to replace oil under warm
status. During the replacement of oil, drain the used
hydraulic oil as complete as possible. (Drain the oil
from the hydraulic oil tank and drain the oil from the
filter and oil pipeline drainage plug.) If any used oil
is not drained, the impurities and sediments
contained therein will mix with new oil to shorten
the life of hydraulic oil.
5. Flushing operations
During the breakdown and assembling of machine or
replacement of oil, use flushing oil to remove Figure 8-10
impurities and sediments and the used oil from
hydraulic oil pipeline. Generally, flush the system by
two steps, namely use flushing oil for main flushing
and use specified hydraulic oil for secondary
flushing.
6. Cleaning operations
It’s necessary to remove the sediments and impurities
from hydraulic oil pipeline after the repair of
hydraulic parts (Such as pumps and control valves)
or during the running of machine. An oil cleaning
machine can remove the tiny particles and can be
used to effectively clean the oil pipeline without
disassembling the built-in filter in hydraulic parts.
8.5.2 Replacement of Steering Filter

Element
The maintenances of filter element and hydraulic oil
directly influence the health of hydraulic system.
Therefore, ensure to replace strictly as per the
specified maintenance schedule.
The detailed replacement procedure is as below:
Disassemble the filter chamber (1).
Replace the seal ring (3) along with the replacement
of filter element (2).
Install the filter chamber (1).
Start the vehicle and check for oil leakage and
normal steering function.
Figure 8-11
8.5.3 Replacement of Lifting Oil Return

Filter Element
1. Disassemble the oil return filter cap and check
the O-ring for aging and damage. If yes,
replace.
2. Unplug the used filter element.
3. Thoroughly remove the dirt around the filter to
prevent falloff and replace with new filter
element.
4. Install the cap and tighten it by special tool or
bar wrench.

8.5.4 Replacement of Ventilation Valve WARNING!

Filter Element The descriptions for the checking of lifting, steering,
and braking hydraulic system pressures are contained
1. Open the ventilation valve cap (2).
in the Repair Manual. If the measurements differ from
2. Replace with new ventilation valve filter element. the requirements of technical conditions, check and
3. Install the cap. repair or replace the parts of corresponding system to
ensure the normal working status of the system. Ensure
that the corresponding system is emptied before
checking the pressure of steering and braking
accumulator.
8.5.5 Checking of Hydraulic System
Pressure
Lifting System
Check the lifting system pressure at the test point of
lifting hydraulic distributor valve.
Steering system
Check the steering system pressure at the test point
of steering valve group. (≥16MPa) Before checking
the steering system pressure, check the pre-inflated
nitrogen pressure of accumulator. (Refer to section
4.1.2.10) If the measurements differ from the
standard values, check and repair or replace the parts
of corresponding system to ensure the normal
working status of the system. Figure 8-12
8.5.6 Drainage of Water from Air

Reservoir
Pull down the pull-tab (1) of water drainage valve
beneath the air reservoir. After the full drainage of
water, release the pull-tab to restore it to original
position. To drain the water from air reservoirs for
every vehicle, operate 5 air reservoirs in turn as per
above method.
Figure 8-13

8.5.7 Replacement of Dryer Core

Replace the dryer once a year or when the water
adsorbability is deteriorated remarkably.
The detailed replacement method is as below:
1. Disassemble all connecting pipelines and
connectors from the dryer with 4-circuit
protection valve.
2. Disassemble 3 rear mounting screws.
3. Replace the dryer and tighten mounting screws.
4. Restore the connecting pipelines and
connectors.
Figure 8-14
8.5.8 Checking of Pedal Free Travel

Operate vertically the pedal and check pedal for
presence of free travel. If yes, adjust the limit screw.
8.5.9 Checking of Brake Slave Cylinder

Check the travel of brake slave cylinder push rod and
check the alignment between push rod and brake
clearance adjuster. Upon detection of increased
travel, adjust the brake connecting rod. Upon
detection of deteriorated alignment or stagnation of
push rod, please replace the brake slave cylinder.

8.6 Power system

8.6.1 Engine and Installation
1. Bolt 6. Bolt 11. Washer 16. Engine assembly

2. Washer 7. Bolt 12. Bolt 17. Bolt
3. Nut 8. Washer 13. Left rear bracket 18. Right rear bracket
9. Front suspension shock 14. Rear suspension shock
4. Left front bracket 19. Right front bracket
absorber absorber
5. Washer 10. Bolt 15. Bracket
Figure1 Engine and Installation
1. Overview
Refer to Figure 1 for the numbers in parentheses.
For the engine manufacturer, model, and technical
specification, refer to the “Technical Specification”
in Foreword. For the detailed operations,
maintenances, and repairs of engine, please refer to
the Operation, Maintenance, and Service Manual of
engine manufacturer. The engine adopts 4-point
support mode. The engine (16) is installed onto the
frame by left front bracket (4), right front bracket
(19), left rear bracket (13), right rear bracket (18),

bracket (15), front suspension shock absorber (9),

and rear suspension shock absorber (14). The front
suspension shock absorber (9) and rear suspension
shock absorber (14) are installed between engine and
frame to provide sufficient flexibility and absorb the
vibration and torsional load of engine.
Disassembling
Note: Add markings to all cables, wires, circuits, and
pipes during disassembling to ease the installation.
1. Park the vehicle in an even working zone, ensure
that the cargo compartment is completely lowered,
apply the parking brake, and stop the engine.
2. Rotate the steering wheel in leftward and
rightward directions for several turns to relieve the
pressure of steering system and block all wheels.
3. Before disassembling, disconnect the battery
cables from the wiring terminals. Disconnect the
grounding cable before disconnecting the wiring
terminals of battery cables.
4. Ensure to wait for the engine to completely cool
down before the following operations.
5. Place an appropriate container beneath the
drainage port of engine and disassemble the drainage
plug to drain the oil. After full drainage, reinstall and
tighten the drainage plug of the engine oil sump.
6. If the vehicle is equipped with A/C system,
vacuumize the refrigerant from the system and
disassemble various pipelines from the
compressor.Refer to A/C Pipelines and Installation.
7. Prepare an appropriate container and drain the
coolant from the water drainage valve of radiator
assembly. While draining the coolant, open the
expansion tank cap. After the full drainage, close the
water drainage valve.
8. To ease the installations, add markings to all
cooling pipelines, place an appropriate container
beneath, and disconnect all cooling pipelines from
the engine (16). Plug all disconnected pipelines and
connectors.
9. Carefully disassemble the transmission assembly
from the vehicle as per the disassembling instructions
of transmission. Refer to section Transmission
Installation.
10. Disconnect and disassemble the connecting air
inlet pipeline from the air inlet port of engine
turbocharger and plug the disconnected pipelines and
ports.
11. Disconnect and disassemble the connecting air

outlet pipeline and air outlet butterfly valve from the
air outlet ports of engine turbocharger and plug the
disconnected pipelines and ports.
12. Disconnect the fuel pipelines from the fuel inlet
and outlet ports of engine (16). To ease the
reinstallation, add markings to the fuel pipelines.
Place an appropriate container at an appropriate
position, disconnect fuel pipelines from engine, and
plug the disconnected pipelines and connectors.
13. To ease the reinstallation, add markings to all
connected harnesses and cables of engine, and
disconnect the related connections.
14. Disconnect the connecting brake pipeline from
engine (16) air compressor and plug the disconnected
pipelines and connectors.
15. Connect an appropriate hosting device to the
lifting eyes of engine and lift the sling to straighten
the sling.
16. Disassemble the front suspension shock absorber
(9), rear suspension shock absorber (14), and the
connecting bolts (1 and 10) and washers (2 and 5)
from engine brackets.
17. Before lifting the engine (16), ensure that all
pipelines and cables are already disconnected.
18. Carefully lift the engine (16), detach the engine
from the frame, place the engine in an appropriate
working area, and ensure to place it steadily on the
workbench.
Breakdown
1. If required, disassemble the bolts (12) and washers
(11) of left rear bracket (13) and right rear bracket
(18) and disassemble the left rear bracket (13) and
right rear bracket (18) from the engine (16).
2. Refer to the Engine Repair and Maintenance
Manual for detailed disassembling, installation, and
repairs of engine accessories, including fan, starter
motor, and alternator, and detailed adjustment of fan
belt tension.
Checking
1. Check the front suspension shock absorber (9) and
rear suspension shock absorber (14) for damage and
replace damaged one.
2. Check the left front bracket (4), right front bracket
(19), left rear bracket (13), right rear bracket (18),
and bracket (15) for breakage and damage. Upon
detection of damage or cracking, replace and repair.

3. Replace the filter and check the tension and wear

status of drive belt as per the descriptions of the
section Maintenances.
4. Disassemble, assemble, repair, and adjust the
engine with reference to the Operation and
Maintenance Manual of the engine.
Assembling
Note: Tighten the fasteners to the torques specified in
“Technical Condition of Standard Tightening Torques
for Bolts and Nuts”, unless otherwise specified.
1. If required, disassemble the engine filter and
install new filter to the engine (16) as per the section
Maintenances.
2. If required, disassemble, install, and repair the
engine accessories, including the fan, starter motor,
and alternator, and adjust the belt tension, with
reference to the Engine Repair and Maintenance
Manual.
3. If required, fix the left rear bracket (13) and right
rear bracket (18) onto the engine (16) by bolts (12)
and washers (11). (The required tightening torque for
bolts (12) is 200N.m.)
Installation
Note: Tighten the fasteners as per “Technical
Condition of Standard Tightening Torques for Bolts
and Nuts”.
1. Lift the engine (16) by an appropriate sling and
carefully place the engine to the front frame
assembly.
2. Fix the engine (16) to the front suspension shock
absorber (9) and rear suspension shock absorber (14)
by bolts (1 and 10) and washers (2 and 5) and then
fix it onto the frame.
3. Fix the transmission onto the engine (16) as per
the installation instructions of the transmission. Refer
to section Transmission Installation for details.
4. Remove the plugs of cooling pipelines and connect
the cooling pipelines and clamps as per the markings.
5. Remove the plug of air inlet pipeline, connect the
air inlet pipeline to the air inlet port of engine (16)
turbocharger, and tighten the related pipe clamp.
6. Remove the plug of air outlet pipeline, connect the
air outlet pipe and air outlet butterfly valve to the air
outlet port of engine (16) turbocharger, and tighten
the related nut and pipe clamp.

7. Remove the plugs of fuel pipelines and connectors
and connect the fuel pipes to the engine (16) as per
the markings.
8. Remove the plugs of brake pipelines and
connectors and connect the brake pipes to the engine
(16) air compressor as per the markings.
9. Connect all harnesses and cables to the engine as
per the markings (Except the battery).
10. If the vehicle is equipped with A/C, connect the
pipeline to the compressor. Refer to section
Compressor Installation.
11. Connect the battery positive cable to the battery
wiring post and connect the battery grounding cable
to the battery wiring post.
12. Ensure that all pipelines, harnesses, and cables
are properly fixed by clamps. Ensure that all
pipelines are away from sharp corners and
overheated areas and the plugs and valves are
securely installed.
13. Fill the coolant with reference to section
“Radiator and Pipelines”.
14. Fill engine oil, with reference to the section
Maintenances.
15. Start the engine, warm up the engine to the
working temperature, and check all pipelines and
connectors for presence of leakage and tighten if
required.
16. Ensure to apply the parking brake, and remove all
wooden blocks from wheels.

8.6.2 Radiator and Pipeline Installation

8.6.2.1 Radiator Assembly Installation
1. Bolt 5. Radiator assembly 9. Bolt 13. Shock-absorbing pull rod
2. Cushion plate 6. Radiator shock absorber 10. Washer 14. Screw
3. Radiator shock absorber 7. Nut 11. Bracket 15. Pipe clamp
4. Radiator shock absorber 8. Nut 12. Bolt

bushing
Figure 1 Radiator Assembly Installation
Overview
Refer to Figure 1 for the numbers in parentheses,
unless otherwise specified.
Installed on the frame in front of the engine cooling
fan, the radiator assembly (5) mainly includes
radiator subassembly, intercooler subassembly, wind
scooper subassembly, upper cover plate subassembly,
lower lateral plate subassembly, left side plate
subassembly, and right side plate subassembly. The
radiator assembly is a combination radiator and the
intercooler and water radiator adopt tandem
structure.
Disassembling

1. Stop the vehicle in a flat place, press the parking
brake, turn off the engine, and turn the steering wheel
for a few laps to release the pressure of the steering
system.
2. After the coolant cools down, place a container of
appropriate capacity beneath the water drainage
valve of radiator assembly (5), open the water
drainage valve to empty the coolant, and then close
the water drainage valve. (Open the expansion tank
cap while draining the coolant. )
3. Disconnect all connecting pipelines of radiator
assembly (5), add markings, and protect the ports.
4. Disassemble the screw (14) and pipe clamp (15)
and take out the engine oil dipstick.
5. Disassemble the nut (8) and bolt (12), disconnect
the shock-absorbing pull rod (13) from front
suspension assembly, disassemble the bolt (9) and
washer (10), and take out the shock-absorbing pull
rod (13) and bracket (11).
6. If other parts around the radiator assembly (5) are
not disassembled, namely the disassembling space of
radiator is limited, firstly disassemble but do not take
out the wind scooper from the radiator assembly and
fix it to a position that will not hinder the lifting of
radiator assembly.
7. Disassemble the bolt (1) and nut (7) and
disconnect the radiator assembly (5) from the frame.
Take out the baseplate (2), radiator shock absorber
(3), and radiator shock absorber bushing (4), place
the radiator assembly (5) to an appropriate working
area by a hoist, and take out the radiator shock
absorber (6).
Installation
1. Place the radiator shock absorber (6) to
corresponding position of frame.
2. Place the radiator assembly (5) onto the frame by
an appropriate hoist and fix it by bolt (1), baseplate
(2), radiator shock absorber (3), radiator shock
absorber bushing (4), and nut (7). If the wind scooper
is already disassembled, after the installation of
radiator assembly, install and fix the wind scooper
thereon, adjust the wind scooper guard ring and fan
to coaxiality or near coaxiality and ensure
the >15mm minimum spacing between fan blades
and guard ring, and tighten the fastening bolts of
wind scooper.
3. Install the bracket (11) onto the radiator assembly
(5) and fix by bolt (9) and washer (10), but do not
tighten the bolt.
4. Install the shock-absorbing pull rod (13) to the

corresponding position of bracket (11) and front

suspension assembly, adjust the installation angle of
shock-absorbing pull rod (13) and bracket to ensure
no shear force during installation, and tighten the bolt
(12), nut (8), and bolt (9).
5. Install the connecting pipelines of radiator
assembly (5) as per the markings.

8.6.2.2 Expansion Tank Assembly Installation
1. Nut 3. Bolt 5. Water refilling pipe
2. Bolt 4. Expansion tank assembly 6. Air bleeding pipe
Figure 1 Expansion tank assembly installation
Overview
The expansion tank assembly (4) is installed on the
air filter bracket assembly.
Disassembling
1. Park the vehicle on a level place, apply the parking
brake, stop the engine, and wait for the engine
coolant to cool down before operations.
2. Open the expansion tank cap, drain the coolant via
water drainage valve of radiator assembly till the
coolant in the expansion tank is emptied, and then
close the water drainage valve.
3. Disassemble the bolts (2 and 3) and nut (1) and
disconnect the expansion water tank assembly (4)

from air filter bracket assembly.

4. To disassemble the water refilling pipe (5), loosen
the hoop at the connection between water refilling
pipe and expansion tank assembly (4) and then take
out the water refilling pipe.
5. To disassemble the air bleeding pipe (6), loosen
the hoop at the connection between air bleeding pipe
and expansion tank assembly (4) and then take out
the air bleeding pipe.
Installation
1. Install the expansion tank assembly (4) to the air
filter bracket assembly and tighten the bolts (2 and 3)
and nut (1).
2. Remove the plugs from water refilling pipe (5) and
port, connect the water refilling pipe to the port on
the bottom of expansion tank assembly (4), and
tighten the hoop.
3. Remove the plugs from air bleeding pipe (6) and
port, connect the air bleeding pipe to the port on the
top of expansion tank assembly (4), and tighten the
hoop.
4. Fill coolant, with reference to section Checking of
Coolant Level and Filling of Coolant.

8.6.3 Air Filter and Pipeline Installation
19. Main filter element of air

1. Air filter assembly 7. Bolt 13. Oil pan
filter
20. End cap of air filter
2. T-hoop 8. Air inlet hose 14. Oil guard plate
element
3. Intake hose 9. T-hoop 15. Filter coarse element assembly 21. Hose clamp
4. T-hoop 10. Bolt 16. Air filter housing 22. Intake pipe
5. Connecting pipe 11. Washer 17. Intake pipe assembly
6. Nut 12. Air filter bracket assembly 18. Safety filter element of air filter
Figure 1 Air Filter and Pipeline Installation
1. Overview
An oil bath type air filter assembly (1) is installed on
the right platform of the cab.
The air filter can filter out the impurities, dusts, and
water contents from the air supplied into the engine
to prolong the life of engine. The dusts and
impurities will turn the engine oil to a strongly
wearing substance, which can damage the engine
within a short period.
Adjust the installation angle of air filter core end cap
(20) to place downward the opening of rubber
vacuum valve thereon and drain the impurities, dusts,
and water during running of engine. The vacuum
valve can reduce the daily maintenance time. While
the engine is running, the vacuum valve is commonly
under low vacuum pressure status and the opening is

closed. When the engine is stopped, the vacuum
valve opens to drain the accumulated impurities,
dusts, and water.
Ensure that the vacuum valve is not damaged or
blocked. If the vacuum valve is lost or damaged,
replace it to protect the pre-filtration performance
and guarantee normal filter element life.
Check the T-clamps (2, 4, and 9) and air inlet hoses
(3 and 8) and tighten other fasteners.
The air filter element includes one air filter main
element (19) and one air filter safety element (18).
When the differential pressure indicator alarms, clean
or replace the filter element as per following
procedure:
Disassemble the main element from the air filter and
flap lightly the end face to fall off the dusts or blow
backward (from inside to outside) by compressed air.
The air filter main element must be replaced after
being cleaned for 6 times. It's prohibited to clean the
safety element. Upon detection of dusts or dirt,
ensure to replace both air filter safety element and
main element.
If the engine oil is difficult to flow when the oil pan
(13) is shaken, ensure the clean the coarse filter
element assembly (15) and replace the engine oil. Fill
the oil pan with the engine oil of same trademark
with or equivalent viscosity to that used in the
engine. The oil level shall not be higher than the
specified level (Marking on outer side of oil pan. The
oil level shall not be higher than the oil guard plate.).
The oil volume is approximately 5L.
Disassembling
1. Loosen the T-clamps (2, 4, and 9) and take out the
air inlet hoses (3 and 8) respectively.
2. Loosen the hoop (21) and take out the air inlet pipe
(22).
3. To disassemble the connecting pipe (5), firstly
loosen the clamp at the connecting elbow, disconnect
the air supply pipe of air compressor, disassemble the
nut (6) and bolt (7), and take out the connecting pipe.
4. If it's unnecessary to disassemble the air filter
bracket assembly (12), disassemble the fastening
bolts between air filter bracket assembly (12) and air
filter housing (16) and air inlet pipe assembly (17)
and take out the air filter body from the bracket by an
appropriate hoist.

5. If it's necessary to disassemble the air filter
assembly (1) (Including air filter bracket assembly
(12)), disassemble expansion tank and air bleeding
pipe clamp from the air filter bracket assembly (12).
Properly fix the expansion tank and pipeline or fully
drain the internal coolant and take measures in
advance to prevent the collision and scratch or
coolant leakage during the lifting of air filter
assembly.
6. Disassemble the nut (6), bolt (10), and washer (11)
beneath the air filter bracket assembly (12) and place
the air filter assembly (1) to an appropriate working
area by an appropriate hoist.
Breakdown
The air filter assembly (1) mainly includes air filter
bracket assembly (12), oil pan (13), oil guard plate
(14), coarse filter element assembly (15), air filter
housing (16), air inlet pipe assembly (17), air filter
safety element (18), air filter main element (19), and
air filter element end cap (20).
If required:
1. Disassemble the fastening bolts between air filter
bracket assembly (12) and air filter housing (16) and
air inlet pipe assembly (17) and take out the air filter
body from the bracket by an appropriate hoist.
2. Loosen the locking clamp between oil pan (13)
and air filter housing (16) and take out the oil pan
(13).
Notice: The oil pan contains engine oil. Guard
against the outflow of engine oil during the
disassembling and installation of oil pan.
3. Take out the oil guard plate (14) from the oil pan
(13).
4. Disassemble the butterfly nut and disassemble the
coarse filter element assembly (15).
5. Loosen the fixing clamp and disassemble the air
inlet pipe assembly (17).
6. Loosen the locking clamp between air filter
element end cap (20) and air filter housing (16), take
out the air filter element housing, and take out the air
filter main element (19) and air filter safety element
(18) in turn.
Assembling
1. Install the coarse filter element assembly (15) to
the air filter housing (16) and tighten the butterfly
nut.
2. Place the oil guard plate (14) to the oil pan (13),

fill oil as per specification, install the oil pan (13) on

the air filter housing (16), and fix the locking clamp
thereon.
3. Install the air filter safety element (18), air filter
main element (19), and air filter element end cap (20)
in turn and fix the locking clamp thereon.
4. Install the air inlet pipe assembly (17) and tighten
the clamp.
5. Lift and fix the air filter body to the air filter
bracket assembly (12) and install and tighten the
bolts between air filter bracket assembly and air filter
housing (16) and air inlet pipe assembly (17).
Installation
1. Lift the air filter assembly (1) to the corresponding
position on the right platform of cab and fix the nut
(6), bolt (10), and washer (11) beneath the air filter
bracket assembly (12).
2. Install the expansion tank and air bleeding pipe
clamp on the side face of air filter bracket assembly
(12). (If the filling of coolant is required, fill coolant
into the expansion tank as per specification.)
3. If required, install the connecting pipe (5) behind
the right platform of cab and install and tighten the
nut (6) and bolt (7) thereon.
4. Install the air inlet hoses (3 and 8) and tighten the
T-clamps (2, 4, and 9) to specified torque.
5. Install the air inlet pipe (22) and tighten the hoop
(21) to specified torque.

8.6.4 Exhaust System
1. Nut 7. Asbestos gasket 13. Bolt 19. Bracket

2. Washer 8. Exhaust pipe 14. Washer 20. Gasket
3. Exhaust pipe weldment 9. U-bolt 15. Nut 21. Nut
subassembly
4. Stud 10. Exhaust pipe 16. Support bracket 22. Exhaust butterfly valve
5. Exhaust pipe weldment 11. Exhaust pipe baseplate 17. Bolt
subassembly
6. Type V hoop 12. Support plate 18. Converter case
Figure 1 Exhaust System
Disassembling
1. Park the vehicle in an even working zone, ensure
that the cargo compartment is completely lowered,
apply the parking brake, and stop the engine.
2. Rotate the steering wheel in leftward and
rightward directions for several turns to relieve the
pressure of steering system and block all wheels.
Notice: Ensure to wait for the engine and exhaust
system related parts to completely cool down before
disassembling.
Mark the pipelines and fasteners during

disassembling.
3. Loosen the V-clamp (6) and take out the exhaust
pipe (8) and asbestos pad (7).
4. Unscrew the air pipe connector from exhaust
butterfly valve (22). After taking out the air pipe,
disassemble the stud (4), nut (1), and washer (2) and
then take out the exhaust pipe weldment subassembly
(5) and exhaust butterfly valve (22). (During the
disassembling, take cautions to guard the exhaust
pipe weldment subassembly (5) and exhaust butterfly
valve (22) against accidental falloff.)
5. Disassemble the nut (21) and take out the exhaust
pipe weldment subassembly (3) and shim (20).
6. Disassemble the nut (15), washer (14), and U-bolt
(9) and take out the exhaust pipe (10) and exhaust
pipe baseplate (11).
7. The support plate (12), support bracket (16), and
bracket (19) are installed on the frame. Disassemble
the fastening bolts (13) and nuts (1) thereon.
8. Disassemble the bolt (17), nut (1), and washer (2)
and take out the bracket (19) from the converter case
(18).
Installation
1. Install and fix the shim (20) and exhaust pipe
weldment subassembly (3) to the exhaust port of
engine by nut (21) as per the marked angles.
2. Place the exhaust butterfly valve (22) between the
exhaust weldment subassemblies (3 and 5) and
tighten the stud (4) by nut (1) and washer (2) to fix
the exhaust butterfly valve. Install the brake air pipe
to corresponding position of the exhaust butterfly
valve. Requirement: The air valve of the exhaust
butterfly valve is located on the top. Ensure the close
fit of mounting spherical surface.
3. Fix the support plate (12), support bracket (16),
and bracket (19) to corresponding positions of frame
as per markings.
4. Install the exhaust pipe (10) and exhaust pipe
baseplate (11) by nut (15), washer (14), and U-bolt
(9). The exhaust pipe baseplate is located beneath the
exhaust pipe.
5. Disassemble the exhaust connecting base between
converter case (18) and cargo compartment body,
install the converter case, and pre-tighten the bolt
(17).
6. Install the exhaust pipe (8) by V-clamp (6). Place
asbestos pad (7) within V-clamp and between two
flange faces.
7. After adjusting the exhaust pipe (8) to best

position, tighten the mounting bolt (17) and nut (1) of
converter case.
8. Install the exhaust connecting base, adjust to
coaxiality between conical port of exhaust
connecting base and pressure disc of converter case,
and then tighten the bolts.
Operation instructions of converter case (18):
Realization of downward exhaust function:
Adjust the handle to position shown in Figure 2,
pre-tighten the bolt for orientation, and then tighten
the nut.
Figure 8-15
Realization of upward exhaust function:
Adjust the handle to position shown in Figure 3 and
tighten the bolt and the nut.
Notice: The upward exhaust can realize the heating
function of cargo compartment. In such case, do not
transport any material with combustion or explosion
risk.
Figure 8-16

8.6.5 Fuel tank and pipe installation

8.6.5.1 Fuel tank and pipe installation
1. Fuel tank assembly 3. Bolt 5. Nut
2. Bolt 4. Nut
Figure 1 Fuel tank assembly installation
Overview
The fuel tank assembly (1) is installed on the frame.
Disassembling
1. Stop the vehicle in a horizontal pavement, press
the parking brake, turn off the engine, and then turn
the steering wheel to the left and right for a few laps
to release the pressure of the steering system.
Disconnect the battery cables and disconnect all
connecting harnesses from fuel tank.
2. Wait for the fuel to cool down, place a container of
appropriate capacity beneath the drainage plug of
fuel tank assembly (1), open the drainage plug to
fully drain the fuel, and then tighten the drainage
plug.
3. Disassemble connecting fuel pipelines from fuel
tank assembly (1). (Notice to guard the pipelines
against fuel leakage and protect the pipeline ports. )

4. Disassemble the nut (4), take out the fuel tank
straps, pins, and rubber pads, and add markings.
5. Place the fuel tank body to an appropriate working
area by an appropriate hoist.
6. Fix the fuel tank support by a hoist, disassemble
the bolts (2 and 3) and nut (5), and then disassemble
the fuel tank support from the frame.
Installation
1. Install the fuel tank support onto the frame by a
hoist and tighten the bolts (2 and 3) and nut (5).
2. Install the fuel tank body onto the support by an
appropriate hoist, place rubber pads between support
and fuel tank, and ensure the consistent position of
fuel tank with the original position before
disassembling.
3. Install the fuel tank straps, pins, and rubber pads
and tighten the fastening nuts (4).
4. Install the connecting fuel pipelines and electric
harness of fuel tank assembly (1).
5. Fill coolant, with reference to Checking of Fuel
Tank Level, Refueling, and Water Drainage of
Fuel-Water Separator.

8.6.5.2 Fuel Pipeline Installation
1. Fuel-water separator 6. Pipe clamp 11. Washer 16. Screw
2. Nut 7. Screw 12. Nut 17. Oil return pipe
3. Bolt 8. Hoop 13. Oil inlet pipe
4. Washer 9. Screw 14. Oil inlet pipe
5. Bolt 10. Base 15. Screw
Figure 1 Fuel Pipeline Installation
Overview
1. Install two ends of fuel inlet pipe (14) to the fuel
suction port of fuel tank and fuel inlet port of
fuel-water separator (1) by hoops (8) and fix the
middle portion to the frame and right fender
connecting pipe by pipe clamps (6).
2. Install two ends of fuel inlet pipe (13) to fuel outlet
port of fuel-water separator (1) and fuel inlet port of
engine by hoops (8) and fix the middle portion to the
frame and front suspension system bracket by pipe

clamps (6).
3. Install two ends of fuel return pipe (17) to fuel
return port of fuel tank and fuel return port of engine
by hoops (8) and fix the middle portion to the frame
by pipe clamp (2).
4. Install the fuel-water separator (1) onto the right
fender assembly.
Disassembling
1. Stop the vehicle in a horizontal pavement, press
the parking brake, turn off the engine, and then turn
the steering wheel to the left and right for a few laps
to release the pressure of the steering system.
Disconnect the battery cables and disconnect all
connecting harnesses from fuel tank.
2. Wait for the fuel to cool down before the
disassembling of fuel pipes. (The fuel will flow out
from pipes during disassembling. Collect the flown
fuel by a container of appropriate capacity and do not
splash the fuel onto other parts. )
3. Mark the disassembled fuel pipes and accessories
and protect their ports.
4. Loosen the hoops (8) on two ends of fuel inlet pipe
(14), disassemble the screw (9), base (10), washer
(11), and nut (12), and then take out the pipe clamp
(6) and fuel inlet pipe (14).
5. Loosen the hoops (8) on two ends of fuel inlet pipe
(13), disassemble the screws (15 and16), washer (11),
and nut (12), and then take out the pipe clamp (6) and
fuel inlet pipe (13).
6. Loosen the hoops (8) on two ends of fuel return
pipe (17), disassemble the screw (15), washer (11),
and nut (12), and then take out the pipe clamp (6) and
fuel return pipe.
7. If it’s necessary to disassemble the fuel-water
separator (1), disassemble the nut (2), washer (4),
and bolts (3 and 5), disconnect the fuel-water
separator from right fender assembly, and take out
the fuel-water separator.
Installation
1. If required, fix the fuel-water separator (1) to the
right fender assembly by bolts (3 and 5), washer (4),
and nut (2).
2. Install the fuel pipes and accessories as per the
markings.
3. Remove the plugs of fuel inlet pipe (14), connect
two ends of fuel inlet pipe (14) to the fuel suction
port of fuel tank and fuel inlet port of fuel-water

separator (1) respectively, and tighten the ports on

two ends by hoops (8). Then, fix the fuel inlet pipe
(14) to the frame and right fender connecting pipe by
pipe clamp (6), screw (9), base (10), washer (11), and
nut (12).
4. Remove the plugs of fuel inlet pipe (13), connect
two ends of fuel inlet pipe (13) to the fuel inlet ports
of fuel-water separator (1) and engine respectively,
and tighten the ports on two ends by hoops (8). Then,
fix the fuel inlet pipe (13) to the frame by pipe clamp
(6), screws (9, 15, and 16), base (10), washer (11),
and nut (12). Fix the fuel inlet pipe (13) to the front
suspension assembly bracket by nut (12) and screw
(7).
5. Remove the plugs of fuel return pipe (17), connect
two ends of fuel return pipe to the fuel return ports of
fuel tank and engine respectively, and tighten the
ports on two ends by hoops (8). Then, fix the fuel
return pipe to the frame by pipe clamp (6), screws
(15 and 16), washer (11), and nut (12).
Note: The fuel pipes shall be arranged naturally and
smoothly, without interference or wear risk.
8.7 Electric System

Overview
The moisture of electric equipment or the damaged
covering of wires will result in electric short-circuit
and machine malfunction. Do not flush the inside of
cab by water. While flushing the machine, take
cautions to guard against the ingress of water into
electric parts.
Do not install any electric part other than those
specified by Sany. The external electromagnetic
interference will result in malfunction of control
system controllers. While installing radio receiver or
other wireless device, please contact Sany or its
authorized dealer.
While installing electric devices, connect them to the
special power connectors. Do not connect any power
supply to fuse, starter switch, or battery relay.
Frequently check the engine and battery negative
ground bolts for looseness.

8.8 Drive system

8.8.1
1. Front axle installation assembly 3. Transmission installation assembly 5. Intermediate installation assembly
2. Clutch installation assembly 4. Drive shaft installation assembly 6. Rear axle installation assembly
Figure 1 Drive system
Overview
The drive system for SKT90S non-road wide-body
dump truck is composed of clutch, transmission,
drive shaft, retarder, and drive axle.

8.8.2 Clutch Installation Assembly
1. Oil reservoir 4. Pressure plate 7. Clutch booster
2. Clutch master cylinder 5. Release bearing 8. Bolt
3. Driven plate 6. Connector body 9. Washer
Figure 1 Clutch Installation Assembly
Overview
The clutch installed on the SKT90S non-road
wide-body dump truck is a 430 pull diaphragm
spring clutch in hydraulically operated and
pneumatically assisted structure. The control system
of the clutch is shown above.
Working parameters
1. Working medium: Compressed air and brake fluid.
2. Maximum working pressure: 4MPa for brake fluid
and 0.85MPa for compressed air.
3. Working temperature: -40℃~+80℃.
4. Brake fluid: DOT3 and DOT4 compliant.
5. Pedal travel: ≤175mm maximum travel.
6. Pedal force: ≤190N, with air assisted.
Working Principle
When the clutch pedal is depressed, the drive
cylinder push rod moves forward the piston to drive
the brake fluid into the clutch booster cylinder
hydraulic control chamber via the oil pipe. The brake

fluid acts onto the piston as the working pressure on
one hand and also functions as control pressure to
regulate the air pressure of the booster cylinder air
chamber on the other hand. The compressed air flows
into the booster cylinder air chamber to generate air
boosting force and jointly drive the movement of
booster cylinder push rod and the rotation of release
rocker so that the release fork drives the backward
movement of release bearing to disengage the clutch.
The clutch drive cylinder, clutch fluid reservoir, and
clutch pedal assembly are arranged on the front wall
of cab. The drive cylinder is connected to the clutch
booster cylinder installed on the chassis via high
pressure hoses and the clutch control mechanism and
the brake control mechanism share one bracket. The
fluid reservoir is directly installed on the clutch drive
cylinder. The brake fluid can be filled from outside of
cab after the radiator grille is opened.
Disassembling and Installation
Disassembling of clutch master cylinder
1. Park the vehicle in a level working area, apply the
parking brake, and stop the engine.
2. Disconnect the connecting pipes and connectors
from clutch master cylinder. Note: Properly preserve
the disassembled connectors and pipes and take
dustproof measure.
3. Disassemble the connecting pins between clutch
master cylinder and clutch pedal. Note: This portion
is located beneath the cab dashboard.
4. Disassemble the fastening bolts between clutch
master cylinder and front panel.
5. Take out the clutch master cylinder.
Disassembling of clutch booster
1. Park the vehicle in a level working area, apply the
parking brake, and stop the engine.
2. Disconnect the connecting oil and air pipes and
connectors from clutch booster.
Note: Properly preserve the disassembled connectors
and air and oil pipes and take dustproof measure.
3. Disassemble the connecting bolts between clutch
booster and transmission housing.
4. Take out the clutch booster.
Disassembling of clutch
1. Park the vehicle in a level working area. To ease
the disassembling of front axle wheel hubs and
brakes, place the front brake drums of vehicle under
driving status. The wheels must be blocked to
prevent sliding of vehicle. If the sliding of the vehicle
can’t be eliminated, place the vehicle under parking

status and stop the engine.

several turns to relieve the pressure of steering
system. Block the wheels and place the battery
master switch at “OFF” position.
3. Disassemble the clutch booster. Refer to
Disassembling of Clutch Booster for the
disassembling method.
4. Disassemble the transmission release fork
subassembly.
5. Disconnect the connecting harness connectors of
odometer sensor, reverse gear sensor, and neutral
gear switch from the transmission.
6. Disconnect the connecting air pipes from the
transmission PTO.
7. Disassemble the mounting subassemblies,
including transmission rear suspension.
8. Disassemble the connecting nuts between
transmission clutch housing and flywheel housing.
9. Disassemble the transmission assembly.
10. Disassemble connecting bolts between clutch
cover assembly and flywheel and take out the cover
assembly and driven disc.
11. Open the circlip of cover assembly.
12. Apply a certain pressure onto the release bearing
axially and complete the separation of release
bearing and cover assembly by compression spring
of release bearing. Take out the release bearing.
Checking of clutch
1. Check the diaphragm spring of cover assembly for
breakage malfunction.
2. Check the release claw of diaphragm spring for
presence of wear.
3. Check the driven disc for presence of oil dirt or
grease.
4. Check the clutch return spring (drive plate) for
presence of damage, inclination, or incomplete fit
that leads to gap between pressure disc and
diaphragm spring.
5. Check the cover assembly for presence of damage
and ablation.
6. Check the release bearing for presence of
abnormal wear.
7. Check the release fork for sufficient lubrication
and for abnormal wear. Upon detection of

above-mentioned problems, replace the clutch related
parts to prevent more serious losses.
Installation of clutch
1. Check and verify all parts for intactness without
collision and check the contact surfaces of driven
disc and cover assembly for presence of impurities
such as oil stain and grease.
2. Install the engine studs to the flywheel in 180°
diagonal manner to play the role of locating pins.
3. Install the driven disc and cover assembly to the
flywheel by special tooling. Note: (1) Ensure to use
special tooling to guarantee the coaxiality among
driven disc, cover assembly, and flywheel. (2) Ensure
that the opening of circlip faces downward. Tighten
the mounting bolts as per shown sequence. Note: a.
After the installation of new cover assembly, remove
the U-shim of cover assembly. b. Shake the circlip to
ensure that it can move freely within the release disc.
4. It's prohibited to impact the circlip, in order to
prevent deformation.
5. Install the release bearing to the 1st shaft of
transmission. Note: Adjust the release fork to the
correct position of release bearing.
6. Install the transmission to the engine and tighten
the mounting bolts.
7. Apply a backward pulling force (Alternatively,
attach a soft rope to the upper end of release fork and
pull backward.) to the release fork at the mounting
opening of booster cylinder by special tooling to
assemble the clutch cover assembly and release
bearing in place (Clamp the circlip to the release
bearing.).
8. Assemble the clutch booster. Note: (1) During
installation, ensure that the clutch booster push rod is
correctly installed in the slot of release fork. (2)
During installation, ensure to face downward the
clutch booster muffler.
9. Connect the oil pipes and connectors between
clutch booster and clutch master cylinder.
Adjustment of clutch
1. Check and adjust the clearance between drive
cylinder push rod and piston: During adjustment,
push the pedal lightly by hand to feel that the drive
cylinder push rod pushes against the drive cylinder
piston, adjust the height of limit bolt to ensure
0.5mm~1mm gap between push rod and piston, and
then tighten the nut. The gap between push rod and
piston shall not exceed 1mm, otherwise the effective
travel of the drive cylinder will be reduced.
Fully bleed air from hydraulic system: If the

hydraulic system of the clutch contains air, the

effective travel of the booster cylinder push rod will
be reduced to cause incomplete clutch disengagement
and difficult gearshift. While filling new brake fluid,
release the booster cylinder air bleeding valve, fill
the brake fluid of designated trademark into the fluid
reservoir while depressing the clutch pedal, till the
brake fluid overflows from air bleeding valve, and
then tighten the air bleeding valve. Then, depress the
clutch pedal rapidly for several times and then
depress and hold the pedal. Loosen the air bleeding
valve of booster cylinder, till no air overflows, and
then tighten the air bleeding valve. Repeat the above
procedure for 2~3 times to fully bleed the air from
the hydraulic system.
Precautions:
1. During the air bleeding of the system, notice to
tighten the air bleeding valve before releasing the
pedal, in order to prevent the inhalation of air. While
releasing the pedal, release the pedal to the highest
position, in order to fill the brake fluid from the
reservoir into the hydraulic chamber of the drive
cylinder.
2. The working medium of hydraulic system must
use DOT3 or DOT4 compliant brake fluid.
3. While replacing the brake fluid, ensure to fully
drain the residual fluid from the hydraulic system and
replace with the brake fluid of same trademark and
same batch. Never mix different brake fluids for use.
4. The brake fluid is a corrosive substance. While
bleeding the air, avoid splashing brake fluid onto
personal body or vehicle paint surface whenever
possible.
Analysis of Common Malfunctions

Malfunction symptom Malfunction description Malfunction cause Precaution

Driving failure of clutch, Worn damage of spline and 1. The transmission weight 1. Standardize the clutch
with high noise, after probable falloff of one or is completely hung on the installation process and
driving for several more shock-absorbing driven disc hub. The ensure that the
hundreds of kilometers springs damage is caused due to transmission 1st shaft or
distortion after short-time transmission is not hung on
use. the driven disc.
2. Poor driving habits and 2. Standardize the driver’s
fierce depressing and driving habits.
release habits or towing of
heavy trailer.
Slip of clutch under good Oil dirt on clutch driven Oil permeation from Carefully check the oil
status and correct disc transmission or engine seals of engine and
adjustment of control transmission. Upon
system detection of oil in clutch
housing, replace oil seals.
Jitter of clutch during Grease on driven disc Excessive lubricating Only use an appropriate
initial torque transmission grease on 1st shaft spline amount of lubricating
stage grease. Warning: The
lubricating grease is
diluted under high
temperature and is radiated
outward under the action
of centrifugal force.
Difficult gearshift or Broken diaphragm spring Startup for towing under Do not use 1st gear under
gearshift failure after of clutch cover assembly rugged startup condition or rugged road or during
one-period use of clutch in inappropriate gear or towing. Use higher gear
incompatible clutch over such as 3rd gear and 4th
assembly to whole vehicle gear.
Difficult gearshift or Damage, inclination, or Distortion of return spring Notice to prevent the
gearshift failure after incomplete fit of clutch due to collision of clutch collision of cover assembly
replacement of clutch return spring (drive plate), cover assembly or damage during assembling. The
leading to gap between of spring (scratched drive collided cover assembly
pressure disc and plate) by tools during shall be authenticated by
diaphragm spring and low assembling the manufacturer before
sound of cover assembly separate use.
during light knocking of 2. Carefully check the
return spring return spring before
assembling. Warning:
While the engine is
running, do not attempt to
insert any tool into the
drive plate to stop the
running of engine.
Jitter of pedal during Release claws not within Interference between During installation,
disengagement one same plane or transmission input shaft accurately guide the clutch
damaged release claws and release claws during into the transmission shaft
installation to prevent assembling
interference.
Difficult depressing of Wear of diaphragm spring Under-low or no preload of Thoroughly check all
pedal, with stiffness release claw end by release release bearing. Improper related connections during
increased along with time bearing and seemingly installation of preload installation of clutch.
good status of bearing spring or failure of Ensure that the clutch
cable is free and smooth
self-adjuster. during whole working

process of clutch. Check
the self-adjuster. Ensure
that the preload is within
50~80N.
Presence of engine related Wear trace of diaphragm Incorrect adjustment of Systematically check
noise with pedal depressed spring release claws at clutch or failure of booster push rod, related
to the end contact area with release self-adjuster connections, and
bearing self-adjuster.
High stiffness, Damage of release bearing Wear of release bearing Check fork and when
transmission noise, clutch bushing and wear of guide sleeve and necessary replace. Upon
jitter, and pedal jitter at diaphragm spring release deformation of fork detection of wear trace,
certain point of pedal claws replace release bearing
travel guide sleeve. Ensure that
the parts are well
lubricated.
Clutch noise and soft pedal Damaged locating parts of Blockage of release Systematically check
release bearing bearing or presence of clutch related connections,
noise at very start. fork, bearing, preload
Combustion of grease due spring, and self-adjuster.
to incorrect preload and
overheating of release
bearing.
Continuously high noise Serious damage of release Failure of release bearing Periodically check the
claws and blockage of due to improper adjuster of clutch.
release bearing adjustment
Jitter of clutch due to slip Burning trace of cover Always rest of driver’s Ensure the correct
assembly foot on the pedal. adjustment of clutch.
Incorrect adjustment of Train the driver.
clutch.
Clutch slip and gearshift Damage in several places Non-standardized clutch Standardize the driver’s
failure of cover assembly operations. Always rest of driving habits.
driver’s foot on the pedal.
Breakage of pressure disc
due to excessive slip and
overheating of all parts.
Clutch slip Burn-off of friction Excessively frequent use Systematically check the
material and burning of clutch. Always rest of release bearing bushing.
blueness of cover assembly driver’s foot on pedal. Standardize the driving
and flywheel Seizure between release habits.
bearing and 1st shaft
bushing.

8.8.3 Transmission Assembly Installation

8.8.3.1
1. Transmission rear suspension 2. Transmission 3. Gear selector/gearshift control

mechanism
Figure 1 Transmission assembly Installation
Overview
Please refer to “Technical Specification” for the
manufacturer, mode, and technical specification of the
transmission. Please refer to the repair manual of the
transmission manufacturer for the repairs of
transmission. The transmission is installed within the

frame and directly connected to the engine and is
supported and fixed by transmission rear auxiliary
support (1). The transmission (2) is integrated with a
hydraulic retarder. The operations of the transmission
are controlled by the gearshift system (3).

8.8.3.2 Transmission
1. 1st shaft 3. Clutch housing 5. Retarder 7. Power takeoff
2. Release fork 4. Control mechanism 6. Output flange 8. Ventilation plug
Figure 1 Transmission
Note: The vehicles without retarder contain no 5# part.
1 1st shaft
The 1st shaft is the transmission power input shaft. The
power generated by the engine is transmitted via
flywheel to the clutch driven disc. The driven disc and
the 1st shaft are connected by spline. During normal
working, the power generated by the engine is
transmitted to the 1st shaft and, after speed change by
the transmission, is transmitted backward.
2 Release fork
The clutch control mechanism drives the release
bearing by release fork to finally maintain the clutch
under disengaged status.
3 Clutch housing
It’s used to accommodate the clutch assembly and is
also connected to the engine flywheel housing.
4 Control mechanism
This transmission adopts the remote control mode and
is fitted with interlocking mechanism and self-locking
mechanism. Thanks to the multiple gears of this
transmission, the difference of speed ratio among
various gears is relatively low and the speed difference
among various gears during working is also low so that
the transmission features handy operations, simple

gearshift mechanism structure, low manufacturing cost,
and high reliability.
5 Retarder
This machine is installed with a retarder with hydraulic
retarding function. Please refer to the Repair Manual of
the transmission manufacturer for the repairs and
maintenances of the retarder.
6 Output flange
The end face teeth of output flange for this transmission
are compatible with ISO12667: 1993 (E) engaging end
face teeth. The detailed specification is φ180 end face
teeth, with 4×φ15 holes arranged by 70° in φ150mm
reference circle.
7 Power takeoff
SKT90 is equipped with standard QH70 series power
takeoff to power the lifting of cargo compartment.
8 Ventilation plug
Frequently check the ventilation plug. Upon detection
of blocking dirt, remove timely.
Disassembling
1. Park the vehicle in a level working area. To ease the
disassembling of front axle wheel hubs and brakes,
place the front brake drums of vehicle under driving
status. The wheels must be blocked to prevent sliding
of vehicle. If the sliding of the vehicle can’t be
eliminated, place the vehicle under parking status and
stop the engine.
several turns to relieve the pressure of steering system.
Block the wheels and place the battery master switch at
“OFF” position.
3. Disassemble the clutch booster. Refer to
Disassembling of Clutch Booster for the disassembling
method.
4. Disassemble the transmission release fork
subassembly.
5. Disconnect the connecting harness connectors of
odometer sensor, reverse gear sensor, and neutral gear
switch from the transmission.
6. Disconnect the connecting air pipes from the
transmission PTO.
7. Disassemble the mounting subassemblies, including
transmission rear suspension.
8. Disassemble the connecting nuts between
transmission clutch housing and flywheel housing.

9. Disassemble the transmission assembly.
10. Open the circlip of cover assembly.
11. Apply a certain pressure onto the release bearing
axially and complete the separation of release bearing
and cover assembly by compression spring of release
bearing. Take out the release bearing.
Note: During the working of transmission, the
continuous rotation of gears on the countershaft and
2nd shaft is required to supply sufficient lubricating oil
to the transmission. However, when the vehicle is being
towed with rear wheels on the ground and the drive
system connected, the above-mentioned gears are not
rotating and the 2nd shaft is driven by rear wheels for
high-speed rotation, a friction will be surly generated
between the spline shims on the 2nd shaft to seriously
damage the transmission due to very high speed
difference and insufficient lubrication. It will also result
in adverse consequences to the vehicle during the
coasting in neutral gear.
To prevent such symptom, pay attention to the
following items:
① Never coast the vehicle in neutral gear with the
engine stopped.
② Never depress the clutch pedal to coast the vehicle in
neutral gear.
③ When the vehicle is to be towed, disengage the drive
shaft or tow the vehicle with the drive wheels off the
ground.

8.8.3.3 Transmission Rear Suspension
1. Bolt 7. Crossbeam assembly 13. Bolt 19. Washer
2. Nut 8. Washer 14. Adjustment shim 20. Washer
3. Bolt 9. Spiralock nut 15. Adjustment shim 21. Nut
4. Rear bracket 10. Bolt 16. Adjustment shim
5. Rubber bearing 11. Bearing lower block 17. Rubber bearing
6. Washer 12. Washer 18. Bearing cap
Figure 1 Transmission Rear Suspension
Overview
To prevent the damage malfunction of engine flywheel
housing or transmission clutch housing due to
excessive bending moment, SKT90S wide-body dump
truck is installed with transmission rear suspension
mechanism. This mechanism contains two-stage
shock-absorbing mechanism, namely rubber bearing
(17) and transmission shock absorber (5), to effectively
absorb the vibration due to rugged road and also help
reduce the additional bending moment of engine

flywheel housing or transmission clutch housing.
Installation
Complete the installation of transmission rear
suspension as per the sequence shown in the diagram.
Notice: To reduce the additional bending moment of
engine flywheel housing or transmission clutch
housing, while installing the transmission rear
suspension, tighten the related parts, including bearing
lower block (11) and bolt (1), as per shown location,
adjust the gap between bearing cap (18) and bearing
lower block (11) to ≤1mm by adjustment shims (14),
(15), and (16), and then tighten the bolt (10).
Checking
1. Check the gaps between rubber bearing (17) and
shock absorber (5) and the fitting surfaces and when
necessary replace.

8.8.3.4 Gear Selector/Gearshift Control Mechanism
1. Gearshift flexible shaft 8. Gearshift bracket 15. Washer 22. Bolt
2. Gear selector flexible shaft 9. Bolt 16. Bolt 23. Joystick
3. Bolt 10. Gear selector rocker 17. Bolt 24. Joystick handle
4. Washer 11. Washer 18. Sealing plate 25. Gear marking
5. Washer 12. Bolt 19. Compression ring
6. Nut 13. Controller 20. Self-tapping screw
7. Gear selector bracket 14. Nut 21. Dust cover
Figure 1 Gear Selector/Gearshift Control Mechanism
Overview
The gear selector/gearshift control mechanism for
SKT90S wide-body dump truck adopts manual control
structure. The control mechanism is in
maintenance-free flexible shaft cable structure. When
the driver operates the joystick, the transmission
control mechanism is controlled by flexible shaft cable
to realize the gearshifts of transmission. The gear
sequence in the cab is shown in the diagram.
Installation

Complete the installation of gear selector/gearshift
mechanism as per the shown sequence.
Notice: Ensure that the mounting spacing on the
transmission end of gear selector/gearshift flexible
shafts is 255±3mm.
Checking
1. Periodically check the gear selector/gearshift flexible
shafts for presence of abnormal wear, burr, and
stagnation and when necessary replace.
2. Periodically check the wear status of controller
bushing and fork and adjust the mounting spacing of
flexible shaft depending on the wear status to eliminate
the increased free travel. Upon detection of excessive
wear status, replace the controller.
Figure 8-17

8.8.4 Front Axle Installation Assembly
1. Tire assembly 5. Bolt 9. Retainer ring 13. Bolt

2. Front axle assembly 6. Steering cylinder 10. Hinge pin assembly
3. Steering cylinder mounting
7. Locating sleeve 11. Washer
base
4. Washer 8. Radial knuckle bearing 12. Washer
Figure 1 Front Axle Installation Assembly
Overview
As an important load-carrying part on the front of
vehicle, the front axle is connected to the frame by
front suspension cylinder. Two ends of the front axle
are installed with wheels. It’s mainly functioned to
transmit all forces and moments applied between
wheels and frame, mitigate the impact load transmitted
from road to the frame (or vehicle body), attenuate the
vibration of the load-carrying system arising thereof,
guarantee the driving smoothness of the vehicle, and
ensure the ideal motion characteristics of wheels and
control stability of vehicle on rough roads and in event
of load change. In addition, the steering mechanism is
utilized to deflect the wheels by a certain angle to
realize the steering of vehicle.
Disassembling

1. Park the vehicle in a level working area. To ease the
disassembling of front axle wheel hubs and brakes,
place the front brake drums of vehicle under driving
status. The wheels must be blocked to prevent sliding
of vehicle. If the sliding of the vehicle can’t be
eliminated, place the vehicle under parking status and
stop the engine.
“OFF” position.
3. Relieve the nitrogen pressure from the left and right
front axle suspension cylinders.
4. Reliably fix the frame by a safe and reliable hoist or
crane.
5. Move away the front axle by a forklift or overhead
traveling crane.
6. Disassemble the wheel assemblies (1).
7. Disassemble the steering booster cylinder mounting
base (3).
8. Disassemble the pins (10) on two ends of steering
booster cylinder and disassemble the steering booster
cylinder (6).
9. Disassemble the inner circlip (9) of steering lower
knuckle arm by circlip pliers and knock the knuckle
bearing (8) and locating sleeve (7) out of the bore.
Checking
Thoroughly clean all connectors and mounting holes by
appropriate solvent and blow dry by compressed air.
Check the pinhole bearings for normal rotation and
check spacer rings and hinge pins for wear. Upon
detection of wear, replace with new one.
Installation
Complete the installation of front axle in reverse
sequence of the disassembling procedure.
Maintenances
Please refer to the manufacturer’s attached data for the
maintenances of front axle assembly.

8.8.5 Intermediate Axle Installation Assembly
1. Intermediate axle assembly 4. Bolt 7. Nut 10. Tire assembly
2. Limit block 5. Washer 8. Bolt
3. Intermediate axle limit bracket 6. Washer 9. Washer
Figure 1 Intermediate Axle Installation Assembly
Overview
As an important load-carrying part of vehicle, the
intermediate axle is connected to the frame by leaf
spring and pull rod. Two ends of the intermediate axle
are installed with wheels. It’s mainly functioned to
transmit all forces and torques applied between wheels
and frame and the torque outputted by the transmission,
in order to guarantee the startup and braking of vehicle.
Disassembling
1. Park the vehicle in a level working area. The wheels
must be blocked to prevent sliding of vehicle. If the
sliding of the vehicle can’t be eliminated, place the
vehicle under parking status and stop the engine.
“OFF” position.

crane.
4. Disconnect the connecting bolts between
intermediate axle and reaction rods.
6. Move away the intermediate axle by a forklift or
overhead traveling crane.
Installation
Complete the installation of intermediate axle in
reverse sequence of the disassembling procedure.
Maintenances
maintenances of intermediate axle.

8.8.6 Rear Axle Installation Assembly
1. Rear axle assembly 4. Bolt 7. Nut 10. Tire assembly
2. Limit block 5. Washer 8. Bolt
3. Rear axle limit bracket 6. Washer 9. Washer
Figure 1 Rear Axle Installation Assembly
Overview
As an important load-carrying part of vehicle, the rear
axle is connected to the frame by leaf spring and pull
rod. Two ends of the intermediate axle are installed
with wheels. It’s mainly functioned to transmit all
forces and torques applied between wheels and frame
and the torque outputted by the transmission, in order
to guarantee the startup and braking of vehicle.
Disassembling
1. Park the vehicle in a level working area. The wheels
must be blocked to prevent sliding of vehicle. If the
sliding of the vehicle can’t be eliminated, place the
vehicle under parking status and stop the engine.
“OFF” position.

crane.
4. Disconnect the connecting bolts between rear axle
and reaction rods.
6. Move away the rear axle by a forklift or overhead
traveling crane.
Installation
Complete the installation of rear axle in reverse
sequence of the disassembling procedure.
Maintenances
maintenances of rear axle assembly.

www.sanyzz.com
Sany Heavy Equipment Co., Ltd.

Economic and Technical Development Zone, Shenyang, Liaoning, China
Postal code: 110027
E-mail: tousu31@163.com
Service hotline: 4008–808–318

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QUALITY CHANGES THE WORLD

Mining Wide-Body Dump Truck

Operation and Maintenance Manual

SKT90S Mining Wide-Body Dump Truck

Operation and Maintenance Manual

Operation and Maintenance Manual

Operation and Maintenance Manual

Manufacturer Responsibilities of Sany

Responsibilities of Customer and Other Authorized Personnel

Operation and Maintenance Manual

Responsibilities of Management Personnel

Operation and Maintenance Manual

Operation and Maintenance Manual I

2.2.14 Precautions for Installation of Accessories and Optional Parts............................................. 2-18

II Operation and Maintenance Manual

2.4.9 Working beneath Machine .................................................................................................... 2-39

Operation and Maintenance Manual III

3.7.1 ...................................................................................................................................................... 3-22

IV Operation and Maintenance Manual

4.1.3.1 Adjustment of driver seat .................................................................................................... 4-14

Operation and Maintenance Manual V

4.18.1.3 Coolant ................................................................................................................................ 4-37

VI Operation and Maintenance Manual

5.8.4 Checking and Maintenances at Interval of 10h (Daily) ........................................................ 5-40

Operation and Maintenance Manual VII

6.2.1.4 Stop of Engine Shortly after Start........................................................................................ 6-13

VIII Operation and Maintenance Manual

8.1.1.3 Thrust Bars .......................................................................................................................... 8-13

Operation and Maintenance Manual IX

8.8.3.4 Gear Selector/Gearshift Control Mechanism....................................................................... 8-91

X Operation and Maintenance Manual

Operation and Maintenance Manual 1-1

1-2 Operation and Maintenance Manual

Operation and Maintenance Manual 1-3

at the time of publication. The continuous design

The machine supplied by Sany conforms to all

1-4 Operation and Maintenance Manual

1.2 Safety Information

It means that the violation will

2) Safety information cases for use of signal

Operation and Maintenance Manual 1-5

3) Other signal language

a. Example of text safety nameplate

1-6 Operation and Maintenance Manual

It’s impossible for Sany Heavy Equipment Co., Ltd. to

Operation and Maintenance Manual 1-7

1.3 Page description

1.4 Operation Regulation

and right) is determined on the basis of top view of

vehicle as front. Rear

1-8 Operation and Maintenance Manual

1.5 Run-in of New Machine

1.6 Product Information

1.6.2 Machine Serial Number Nameplate

Operation and Maintenance Manual 1-9

Right front of the frame

1-10 Operation and Maintenance Manual

1.6.3 Engine Serial Number Nameplate

Operation and Maintenance Manual 1-11