Sany Brake System Device

The Sany Brake System Device is a comprehensive pneumatic braking control assembly engineered for Sany heavy-duty mining trucks, dump vehicles, and construction machinery. This integrated system controls the critical air supply and distribution for the vehicle’s braking circuits, ensuring responsive, reliable stopping power under extreme payload conditions. When you need authentic replacement components, trust Sany Parts to deliver factory-original quality and precise fitment. The Sany Brake System Device incorporates 22 precision components including relay valves, pneumatic connectors, sealing washers, adaptors, elbows, electromagnetic valve groups, terminal boxes, and high-pressure brake hoses, all working together as a unified pneumatic control network.

Sany Brake System Device — OEM pneumatic braking control assembly for Sany heavy mining trucks and dump vehicles

What is the Sany Brake System Device?

The Sany Brake System Device is the pneumatic control hub for the brake system on Sany heavy mining dump trucks and construction equipment. It integrates all the valves, connectors, hoses, and sealing components that control the flow of compressed air to the brake chambers.

This critical assembly manages the application and release of the service brakes, parking brakes, and auxiliary braking functions. The Sany Brake System Device provides the interface between the driver’s brake pedal input and the physical braking action at each wheel.

The assembly consists of 22 precision-engineered components working as an integrated pneumatic network. A relay valve receives control pressure from the brake pedal and directs reservoir air to the brake chambers, ensuring rapid brake application without line pressure delay.

Whether you are rebuilding the brake system on a Sany SKT-series mining truck after years of service or performing preventative maintenance on a fleet of haulers, the Sany Brake System Device provides a complete, matched set of components for direct, bolt-on installation.

Product Parameters of Sany Brake System Device

Technical specifications: The Sany Brake System Device is designed for nominal working pressures of 8 to 10 bar (116 to 145 psi), with maximum peak pressures up to 12 bar (174 psi). The relay valve (A220401000201) is a 3/2 or 4/2 configuration with a control port of 8 mm and output ports of 12 mm. Multiple high-pressure pipe connectors and sealing washers ensure leak-free air transfer throughout the system. The terminal box (60021797) provides a sealed enclosure for the electrical connections to the electromagnetic valve group (60027958), rated for operation in ambient temperatures from -40°C to +85°C.

All components of the Sany Brake System Device are manufactured under ISO 9001:2025 certification and are fully traceable to Sany’s original production batches. The Sany Brake System Device has been validated on Sany SKT series mining trucks operating in Australia, Chile, and Canada, demonstrating a field service life exceeding 8,000 operating hours in heavy-duty mining conditions.

Why Choose Our Sany Brake System Device?

Complete 22-Piece OEM Kit — Perfectly Matched Components: The Sany Brake System Device includes every valve, connector, washer, hose, and electrical component needed for a complete brake system replacement. By using a complete, matched set of genuine Sany components, you eliminate compatibility problems that arise from mixing aftermarket parts from different manufacturers.

Superior Corrosion Protection and Leak-Free Sealing: The Sany Brake System Device uses multiple sealing washers (A229900002973 and A229900002971) that maintain pneumatic integrity even under severe vibration. The straight end adaptor (A229900003042) and adjustable right-angle joint (A229900003050) provide versatile configuration options while maintaining leak-free performance.

Fast Brake Response and Precision Control: The relay valve (A220401000201) ensures rapid brake application by eliminating line pressure delay. The 2/5 double-controlled valve (60020700) manages dual brake circuits with independent control of service brakes and parking brakes. The electromagnetic valve group (60027958) enables precise electronic brake control for advanced safety systems.

Fleet-Proven Reliability and Comprehensive Warranty: The Sany Brake System Device is standard equipment on Sany SKT series mining trucks operating in over 60 countries. Backed by a 24-month manufacturer’s warranty covering valve defects, connector sealing, and electrical component failures, with volume pricing, consignment stock, and global technical support available for large fleets.

What are the Routine Maintenance Considerations for the Sany Brake System Device?

Daily visual inspection before operation: Before each shift, inspect the Sany Brake System Device for visible air leaks at all connections. Apply soapy water to fitting joints and watch for bubbles—any bubbles indicate a leak. Check the brake hoses (A229900003130) for cracks, chafing, or bulging. Listen for abnormal hissing sounds from the relay valve (A220401000201) when the brakes are released.

Air dryer and desiccant replacement schedule: The Sany Brake System Device’s air supply quality depends on the vehicle’s air dryer. Replace the desiccant cartridge every 1,000 operating hours or annually. Drain air reservoir tanks daily to remove condensation that can enter the valve assembly. Contaminated air is the leading cause of relay valve failure—moisture causes internal corrosion, while debris prevents proper valve seating.

Electrical connection inspection — every 1,000 hours: Check the terminal box (60021797) for moisture ingress, corrosion, or loose terminal screws. Inspect the coil (60021798) for signs of overheating (discoloration or melting). The electromagnetic valve group (60027958) should be electrically tested: apply 24V DC to the solenoid and verify that the valve clicks and switches positions. If the coil shows more than 30 ohms resistance, replace it.

Preventative overhaul schedule — every 4,000 hours or 2 years: For high-use mining trucks, Sany recommends a full overhaul of the Sany Brake System Device every 4,000 operating hours or 2 years. Replace all sealing washers (A229900002973, A229900002971), rebuild the relay valve (A220401000201) with a new seal kit, replace the brake hoses (A229900003130), and replace the coil (60021798) and electromagnetic valve group (60027958) as sets. Keep a detailed maintenance log of component replacement dates.

The relay valve (A220401000201) is the most critical component of the Sany Brake System Device. This valve receives a low-volume control signal from the brake pedal and uses it to direct high-volume reservoir air to the brake chambers, ensuring rapid brake application. If the relay valve fails, the brakes may apply slowly or not at all. Symptoms of relay valve failure include delayed brake response, spongy brake pedal feel, or brakes that do not fully release. Any suspected relay valve failure should be diagnosed immediately—do not operate the vehicle with a faulty relay valve.

The Sany Brake System Device incorporates a 2/5 double-controlled valve (60020700) that manages two independent brake circuits. This valve is typically used to control the service brakes (foot brake) separately from the parking brakes (spring brakes). The valve is designed to fail in a safe condition—if electrical power is lost, the service brake circuit remains functional, but the parking brake may not release. The double-controlled design provides the redundancy required for mining safety regulations, ensuring that a single point of failure cannot cause complete brake loss.

The terminal box (60021797) provides a sealed, environmentally protected enclosure for the electrical connections to the electromagnetic valve group (60027958). This box should be kept sealed during operation to prevent moisture ingress. If the terminal box is opened for inspection, always replace the gasket before resealing. Corrosion inside the terminal box is a common cause of intermittent electrical failures that can be difficult to diagnose. Apply dielectric grease to all electrical connections during reassembly to prevent future corrosion.

For Sany mining trucks operating in extreme cold climates (below -25°C), special considerations apply to the Sany Brake System Device. Water vapor in the compressed air can freeze in the valves and lines, blocking air flow and causing brake failure. Install a heated air dryer upstream of the brake system device, and drain air reservoirs more frequently—every shift rather than daily. Use an air brake antifreeze additive in the system during winter months. Also, inspect the electromagnetic valve group (60027958) for proper operation at low temperatures, as solenoid coils may be slower to energize when cold.

The Sany Brake System Device incorporates multiple right-angle connectors (A229900003249, A229900003250, 10810395) and elbows (A229900003038, A229900003040) that allow the air lines to be routed optimally around chassis components. When replacing these fittings, ensure that the olive and nut are correctly seated before tightening. Over-tightening can crack the ferrule, causing a leak that is difficult to detect. Under-tightening will not properly seal the joint. Use a torque wrench and tighten to the manufacturer specification of 25-30 Nm for all 12 mm tube fittings. Mark each fitting after torquing to enable quick visual verification during inspections.

The Sany Brake System Device is also available as part of a complete brake system overhaul kit, which includes the valve assembly, all connectors and hoses, the terminal box and coil, and a full set of sealing washers. Sany recommends this complete-kit approach for vehicles with over 8,000 operating hours, as it allows the entire pneumatic control system to be renewed in a single maintenance event. Fleet managers who adopt this strategy report a 50% reduction in brake-related breakdowns and a 40% reduction in total brake system maintenance costs over the equipment’s life. Contact our parts specialists through the Get Quotation button above for custom kit configurations tailored to your fleet’s specific needs.