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SRT45

Product catalog summary

Overview: The SRT45 Off-Highway Truck Safety, Operation, and Maintenance Manual provides comprehensive guidelines for the safe and efficient use of the SRT45 truck. It emphasizes the importance of adhering to safety precautions and proper maintenance procedures to prevent injury, death, or property damage.

Exemption Clauses: Sany disclaims responsibility for misuse, unauthorized modifications, use of non-genuine parts, and damage from natural disasters or force majeure. Operators and owners must prioritize safety and comply with local regulations.

Obligations:

Sany's Obligations: Provide quality trucks, accurate information, after-sales service, and operator training.
Owner's Obligations: Ensure only trained personnel operate the truck, conduct regular safety inspections, and maintain the truck properly.
Operating Personnel's Obligations: Report abnormalities, follow safety signals, and be aware of hazards.
Manager's Obligations: Ensure operators are trained, healthy, and licensed, and that signal persons are competent.

Safety Precautions:

General Precautions: Use personal protective equipment, maintain cleanliness, and prevent burns and fires.
Safe Operation: Follow safe starting procedures, inspect before operation, and take precautions when traveling or parking.
Transportation: Guidelines for loading, unloading, and transporting the machine safely.
Maintenance Precautions: Lock-out/tag-out procedures, use proper tools, and handle high-pressure systems with care.

Key Sections:

Safety Labels: Placement and importance of safety labels on the truck.
Machine Information: Identification plates and display screen details.
Safe Operation Precautions: Detailed steps for safe starting, operation, and transportation.
Maintenance Precautions: Specific guidelines for safe maintenance practices.

Foreword: This section provides an overview of the manual for the SRT45 Off-Highway Truck, emphasizing the importance of adhering to safety rules and maintenance procedures to prevent accidents. It highlights that the manual is based on the latest available information and advises consulting SANY or a distributor for updates. The foreword stresses the necessity of reading and understanding all safety precautions and warnings to avoid serious injury or death. It also mentions the responsibility of the operator to ensure safety when operating under conditions not described in the manual.

Safety Information: This section explains the use of hazard alert words such as "DANGER," "WARNING," and "CAUTION" to indicate the severity of potential hazards. It provides examples of alert wording and emphasizes the importance of using lifting equipment with adequate capacity. The section also describes the use of safety decals on the machine to alert operators and maintenance personnel of potential hazards.

Your Documentation Package: The documentation package includes the Safety, Operation & Maintenance Manual (SOMM) and a Parts Book. Recommendations are provided for using and storing the documentation, ensuring it remains complete and up-to-date.

Regulation of Use: This section outlines the intended applications of Sany Mining Trucks, primarily for traveling with a load. It defines the directions of the machine from the operator's seat perspective and advises on a 100-hour break-in period for new machines to ensure optimal performance and longevity.

Visibility from Operator's Seat: The visibility standards for the machine are described, including diagrams showing areas where the view is blocked by parts of the machine. Operators are advised to be aware of these blind spots when operating the machine.

Machine Information: This section details the locations of product and engine identification plates, which are essential for ordering replacement parts or seeking assistance. It includes a table for recording serial numbers and distributor information.

Safety Labels:

Ensure safety labels are correctly positioned and legible. Clean them without using solvents or gasoline to prevent damage.
Replace damaged or unreadable labels promptly.

General Precautions:

Only trained personnel should operate or service the machine.
Follow all safety rules and precautions strictly.
Avoid operating under the influence of alcohol or drugs.

Safe Operation Precautions:

Inspect the machine before operation and ensure all safety measures are in place.
Adjust the seat and fasten the seat belt before starting the engine.
Follow specific precautions when operating on slopes or in adverse weather conditions.

Maintenance Precautions:

Lock-out and tag-out procedures must be followed during maintenance.
Stop the engine before performing maintenance tasks.
Use appropriate tools and handle high-pressure systems with care.

Precautions with Tires:

Handle and store tires properly to prevent damage and ensure safety.

Hand Signals: Ensure all personnel understand the hand signals to be used during operations.

Abnormalities: Report any operational abnormalities such as noise, vibration, odor, incorrect gauge display, smoke, or oil leakage to your Sany distributor and do not operate the machine until issues are resolved.

Personal Protective Equipment (PPE): Wear appropriate PPE including hard hats, safety shoes, safety glasses, reflective clothing, hearing protection, and dust masks as required by the job site and regulations.

Fire Extinguisher and First Aid Kit: Ensure a first aid kit and fire extinguisher are accessible, regularly inspected, and maintained. Understand how to use them properly.

Safety Equipment: Ensure all safety equipment such as Falling Object Protection, Rollover Protection, seat belts, lamps, horns, guards, backup alarms, mirrors, and fire extinguishers are in place and functional.

Cleaning and Maintenance: Keep windshields, mirrors, and lights clean. Avoid water penetration in the electrical system. Ensure all covers and caps are intact and repair any damages immediately.

Cab Cleanliness: Keep the cab free of mud, oil, and loose items. Do not use cell phones or bring hazardous materials into the cab.

Leaving the Machine: Follow proper shutdown procedures including setting the gear to neutral, applying the parking brake, and removing the key.

Handholds and Steps: Use three-point contact when entering or exiting the machine. Keep handrails and steps clean and in good repair.

Preventing Burns: Allow engine coolant and oil to cool before checking or discharging to prevent burns.

Fire and Explosion Prevention: Store fuel and oils properly, avoid smoking near them, and regularly inspect hoses and electrical systems to prevent leaks and short circuits.

In the Event of Fire: Shut down the engine and exit the machine using handholds and steps.

Windshield Cleaning Detergent: Use alcohol-based detergents and avoid methanol-based ones.

ROPS Precautions: Do not modify the ROPS structure. Repair or replace if damaged.

Attachment Installation: Consult Sany before installing attachments to ensure safety and compliance with laws.

Cab Windows: Replace broken windows immediately to maintain operator protection.

Unauthorized Modifications: Avoid unauthorized modifications as they may compromise safety and machine integrity.

Worksite Examination: Assess the job site for hazards such as unstable ground or falling rocks before operation.

Operation on Soft Ground: Avoid operating near cliffs or trenches where the ground may be unstable.

Overhead Power Cables: Maintain a safe distance from power cables and consult the local power company for safety measures.

Alternate Exit: In emergencies, use a safety hammer to break the rear window for escape.

Ensure Good Visibility: Use mirrors and flagmen to maintain visibility and avoid obstacles during operation.

Safety and Operation Procedures:

Flagman Signals: Only one flagman should give signals. Ensure proper lighting in dark areas and stop operations in poor visibility conditions like fog or storms.
Asbestos Hazard: Inhalation of asbestos dust can cause lung cancer. Use water to remove dust, wear filter masks, and follow site regulations. Use only parts supplied by Sany to avoid asbestos exposure.
Safe Starting: Maintain a three-point contact when mounting/dismounting the machine. Adjust the seat for comfort and ensure the seat belt is in good condition. Clean windows and lamps for visibility, check fluid levels, and ensure no obstacles are around the machine before starting.
Engine Starting Rules: Ensure no one is around the machine before starting. Use jumper cables only if necessary and follow safety procedures to avoid battery explosions.
Operation Precautions: Inspect the machine in a spacious area, check for abnormalities, and ensure no one is within the working range. Assign a signalman where visibility is poor.
Traveling Precautions: Do not overload the dump body, avoid sudden stops, and maintain a safe distance from obstacles. Be cautious on slopes and in poor weather conditions.
Parking and Maintenance: Park on a solid, flat surface away from hazards. Secure the machine with chains and chocks during transportation.

Battery Safety: - Handle batteries with care due to sulfuric acid and explosive gases. - Avoid smoking or open flames near batteries. - Use protective gear like safety glasses and rubber gloves. - Follow proper procedures for connecting and disconnecting battery terminals. - Charge batteries in well-ventilated areas and monitor temperature.

Towing Guidelines: - Avoid towing on slopes and ensure the wire cable is strong enough. - Use protective gear and avoid standing between towing and towed machines. - Operate slowly and avoid sudden loads on the cable.

Maintenance Precautions: - Use lock-out and tag-out procedures to prevent accidental operation during maintenance. - Select a clean, flat, and well-ventilated area for maintenance. - Understand maintenance procedures and keep the area clean and dry. - Wear appropriate protective clothing and gear. - Stop the engine before maintenance and ensure the machine is stable.

Handling High-Pressure Systems: - Release system pressure before maintaining hydraulic systems. - Use proper tools and avoid using damaged or incorrect tools. - Handle suspension cylinders with care due to high-pressure nitrogen gas.

Fire and Explosion Prevention: - Avoid smoking and open flames near fuel systems. - Use nonflammable solvents for cleaning and store flammable materials properly. - Ensure fire extinguishers and fire-fighting systems are operational.

Regular Replacement of Safety Parts: - Regularly replace safety-related parts like hoses and seat belts. - Inspect and replace worn or damaged parts to prevent accidents.

General Safety Recommendations: - Use ear protection in loud environments. - Wear protective gear when using compressed air or hammers. - Only qualified personnel should perform welding operations. - Follow high-voltage precautions and consult professionals when necessary.

Proper Disposal of Wastes: Improper disposal of wastes can harm the environment. It is advised to consult local environmental protection departments or Sany distributors for recycling and waste disposal methods. Key substances include hydraulic oil, fuel, cooling liquid, refrigerant, filters, and batteries. Use leak-proof containers for fluids and never use food or beverage containers. Avoid dumping waste fluids on the ground or into water sources. Follow laws for refrigerant recovery to prevent atmospheric damage.

Precautions with Tires: Handling tires requires caution due to the risk of explosive separation. Use special tools and procedures, and consult a Komatsu distributor for maintenance. Use specified tires and inflate them to the correct pressure. Ensure no one is near the tire during inflation and use an air chuck with a clip. If pressure drops or rim parts do not fit, contact a distributor. Set up a protective fence during inflation and avoid welding or lighting fires near tires. Release all pressure before removing rim components.

Storing Tires: Store tires in secure areas to prevent unauthorized access. If stored outside, erect a fence and use "No Entry" signs. Stand tires on level ground and block them securely. Do not lay tires on their sides to prevent deformation. If a tire falls, do not attempt to stop it; move out of the way quickly.

Table of Contents Overview: The manual includes sections on controls and operating, operating the truck, working the truck, roading, moving disabled trucks, and lubrication and servicing. Each section provides detailed procedures and safety precautions for the SRT45 Off-Highway Truck.

Maintenance Inspection Forms: This section outlines the maintenance inspection forms required at various operational hours for the SRT45 Off-Highway Truck. The forms are scheduled at intervals ranging from 1800 hours to 10000 hours, ensuring comprehensive checks and maintenance are conducted to maintain optimal performance and safety.

Controls and Operating:

Controls and Instruments: The truck is equipped with various controls including air outlets, emergency brake button, service brake pedal, ignition key switch, and more. These controls are essential for the operation and safety of the vehicle.
Indicators: The dashboard includes indicators for steering, parking brake, body position, retarder, side marker lamps, and more. These indicators provide real-time feedback on the truck's status and alert the operator to any issues.
Instruments: Key instruments include the tachometer, speedometer, transmission oil temperature gauge, fuel level gauge, engine water temperature gauge, and engine oil pressure gauge. These instruments help monitor the truck's performance and ensure it operates within safe parameters.
Reversing Monitor System: This system aids in monitoring the truck's rear view, enhancing safety during reversing operations.
Switches: Various switches control the truck's functions, including the economical/powerful mode switch, parking brake switch, hazard warning lamp switch, and more.
Combined Switch: This includes controls for the horn, washer, windscreen wiper, and headlight dipper and flasher.
Air Conditioner Control Panel: The panel allows for control over the air conditioning system, including modes for refrigeration, heating, and defrosting.

Driver Seat Adjustments:

The suspension device allows for 100mm of travel.
Height adjustment is available in three levels: low, middle, and high. Pulling up the seat at the high level returns it to low.
Front/rear adjustment is possible with a handle on the right side, allowing a 210mm range.
Back angle adjustment is greater than 90° for optimal comfort.
Headrest height can be adjusted by 105mm.

Seat Belt Usage:

Adjust the seat to a comfortable height before fastening the seat belt.
To release, press the button on the lock catch.

Truck Controls:

Braking Systems: Includes service, parking, emergency brakes, and retarders.
Service Brake: Operated by a pedal, used for normal slowing and stopping.
Parking Brake: Engaged by a switch, applies brakes to all wheels.
Emergency Brake: Activated by a control switch, used only in emergencies.
Retarder: Two types, transmission and rear disk brake, used for maintaining speed on descents.

Engine and Fuel System:

Accelerator Pedal: Provides electrical signals to the engine's fuel control system.
Quantum Electronic Fuel System: Monitors engine performance and warns of issues.
Electronic Control Module (ECM): Manages fuel injection and engine parameters.
Diagnostic Codes: Fault codes are stored and can be read with a diagnostic tool.

Warnings and Recommendations:

Do not adjust the seat or seat belt while the vehicle is moving.
Always apply the parking brake before leaving the operator's seat.
Use the retarder cautiously on slippery surfaces.
Follow proper procedures for welding on vehicles with electronic fuel systems.

Overview: This document is a Safety, Operation, and Maintenance Manual for the SRT45 Off-Highway Truck. It includes detailed information on various systems and components, including engine diagnostics, steering, and transmission systems.

Engine Diagnostics: The manual lists numerous diagnostic codes related to engine and vehicle systems, categorized by severity (Critical Red, Warning Yellow, Maintenance). Key issues include low engine coolant levels, vehicle speed sensor circuit errors, fuel shutoff valve malfunctions, and various sensor circuit shorts and errors. Critical issues require immediate attention to prevent damage or unsafe operation.

Steering System: The steering system is hydraulic with a continuous-running pump and a pressurized accumulator. The steering wheel position is adjustable for operator comfort. In case of a loss of steering pump pressure, the accumulator allows for limited steering control. A warning system alerts the operator to low steering pressure, necessitating immediate cessation of operation until the issue is resolved.

Transmission System: The truck uses a CEC2 electronic control shift system, which automates gear shifting based on throttle position, engine speed, and truck speed. Features include automatic gear-shift, reverse inhibit, body up interlock, and parking brake interlock. The system also includes a lock-in-gear feature to prevent damage during wheel spinning or lockup. Cold weather starting procedures and warnings about potential transmission damage are provided.

Transmission Operation: The ECU processes signals from various sensors and controls the transmission solenoids. The gear shift selector allows for manual selection of gears, with automatic upshifting and downshifting based on driving conditions. Safety warnings emphasize not coasting in neutral to avoid transmission damage.

Transmission Operation and Controls: The document outlines the operation and control mechanisms of the SRT45 Off-Highway Truck's transmission system. It details the automatic upshifting and downshifting processes, emphasizing the need for manual intervention in cases of 'Hunting' or 'Shift Cycling'. When temporarily stopped, the transmission can remain in the selected range, but for extended stops, it should be shifted to neutral to prevent heat buildup.

Mode Selection: The transmission offers 'POWER' and 'ECONOMY' modes. The 'POWER' mode is suitable for heavy loads and hilly terrains, prioritizing performance over fuel economy. The 'ECONOMY' mode is designed for lighter loads and flat terrains, focusing on fuel efficiency. The lockup clutch operation varies between these modes to optimize performance and fuel consumption.

Diagnostic and Safety Features: The truck is equipped with various switches for reversing, diagnostics, stall checks, and idling adjustments. Indicators alert the operator to transmission overspeed and faults. The document warns against operating the engine at full throttle with the transmission in gear for more than 30 seconds to avoid overheating.

Transmission Temperature Management: Operators are advised to monitor the transmission oil temperature, especially during upgrades. If the temperature exceeds normal ranges, corrective actions should be taken to prevent damage.

Diagnostic Codes: The document provides a comprehensive list of diagnostic codes, detailing potential faults and their implications on transmission operation. It includes instructions for retrieving and clearing these codes using the gear shift selector or a diagnostic data reader.

Technical Document Summary:

1. Fault Codes and Troubleshooting: - ECU, EEPROM fault: Reset ECU. - Communication chip addressing error: Use defaults for J1939 data. - SPI output failure: No specific action. - SPI input failure: DNS, lock-in-range. - Common vehicle monitor system faults include high temperatures, blocked filters, low pressures, and overspeed, each requiring specific checks or actions.

2. Body Control Operations: - The hoist lever has four positions: Raise, Hold, Float, and Lower, each controlling the body movement of the truck. - Safety precautions include draining pressure from the pilot valve before repairs.

3. Pre-Starting Inspection: - Ensure the machine is on level ground, parking brake is applied, and wheels are blocked. - Check all lights, signals, controls, and instruments. - Inspect various components such as engine oil, fuel level, hydraulic systems, and brakes for leaks and proper levels.

4. Engine Operation and Starting: - Allow the engine to warm up before full load operation. - Never idle the engine for more than 5 minutes. - Follow specific steps for starting the engine, including checking indicators and using jumper cables safely if needed.

5. Pre-Operating Checks: - Ensure all glass, mirrors, and lights are clean. - Test controls and check transmission and hydraulic oil levels. - Perform a braking function check to ensure safety.

Service Brake Performance Check: To ensure proper service brake performance, follow these steps: depress the foot brake pedal, select 1st gear, release the parking brake, and depress the accelerator pedal. The machine should not move until the engine speed reaches 1350 r/min. After checking, decelerate the engine, shift to neutral, apply the parking brake, and release the service brake pedal.

Emergency Brake Performance Check: For emergency brake checks, depress the service brake pedal, release the emergency brake, select 1st gear, apply the emergency brake, release the service brake pedal, and depress the accelerator pedal. The machine should remain stationary until the engine speed reaches 1350 r/min. Caution is advised as brake holding effort can vary between machines.

Driving and Stopping: Before driving, ensure all instruments and warning indicators are functioning correctly. Check the area around the machine for obstructions. During travel, verify steering, braking, engine, and transmission responses. To stop, release the accelerator, depress the service brake, and apply the parking brake once stopped. Use the emergency brake only in emergencies.

Stopping the Engine: Ensure the rocker switch is in 'PARK', the transmission is in 'NEUTRAL', and allow the engine to idle for 3-5 minutes before shutting it off. Turn the steering wheel to dissipate pressure and ensure the body control lever is in 'FLOAT'. Turn the ignition key to 'OFF'.

Parking: When parking, fill the fuel tank to prevent condensation, park on level ground, and ensure sufficient antifreeze in the cooling system. Inspect tyres, hoses, and other components for damage. Attach warning signs if necessary.

Prolonged Storage: Turn the circuit breaker beside the battery to 'shutoff' to prevent leakage. Retune the radio if the circuit breaker is reset.

Working the Truck: Truck operations include loading, hauling, dumping, and returning. Efficient loading involves minimizing truck maneuvers and loader travel. During hauling, maintain safe speeds and distances. Dumping operations vary by material type and may require a spotter for safety. Always ensure the machine is on firm ground before raising the body.

Empty Return Procedure: Ensure the truck body is fully lowered and the control lever is in the 'FLOAT' position before moving away from the dump site. Follow the same procedure for returning empty to the loading area as outlined for 'HAULING'.
Warning: Do not drive with the truck body up to avoid stability issues and potential hazards from overhead obstacles.

Roading: General: Operating trucks on public highways requires special care due to their size and maneuverability. Ensure the truck is properly equipped and in good condition before roading. Obtain necessary permits and remain alert for overhead cables and low bridges.
Preparation: Lubricate and service all components as per the manual. Perform pre-start and post-start checks, focusing on instruments and lights. Check tyre pressures while cold and inspect for damage. Ensure all warning signs are in place and secure.
In Case of Trouble: If issues arise, move the truck off the road safely, shut off the engine, and report the problem with detailed information. Do not attempt to restart the machine unless instructed.

Moving Disabled Truck: Report any unusual power train noises. If systems fail, stop the machine immediately. For power train failures, remove drive flange covers and axle shafts to prevent damage during towing. Use a towing bar or A-Frame for towing, ensuring safety precautions are followed. Limit towing speed to 10 km/h and distance to 10 km.
Warning: Use strong, properly secured chains or cables for towing. Avoid jerking and ensure the operator's compartment is protected.

Lubrication and Servicing: Safety Precautions: Only authorized personnel should service the truck. Follow all safety procedures and attach warning signs before servicing. Relieve pressure before servicing pressurized systems and shut down the engine as per the manual.
Lubrication: Follow instructions for lubricant types and application frequency to extend truck life. Clean all fittings before servicing and ensure lubricants are at operating temperature when draining. Do not operate systems unless oil levels are within recommended limits.

Overview: This document is a comprehensive maintenance manual for the SRT45 Off-Highway Truck, detailing lubrication, servicing, and inspection procedures. It includes specifications for various components, recommended lubricants, and maintenance schedules.

Key Sections:

Inspection and Maintenance: Regular inspections are crucial for ensuring the truck's optimal performance. This includes checking the suspension systems, air resistance indicators, oil-water separators, tyre conditions, and control instruments. Specific procedures are outlined for each component, such as replacing elements or checking for proper operation.
Lubrication and Servicing: The document provides a detailed lubrication chart, specifying the type of lubricant required for each component, such as engine oil, hydraulic oil, and extreme pressure gear lubricant. It also outlines the service capacities for various parts of the truck.
Maintenance Intervals: Maintenance tasks are scheduled at different intervals, such as every 10, 250, 1000, and 2000 hours of operation. Tasks include checking and replacing filters, inspecting belts, and ensuring proper operation of steering, braking, and lifting systems.
Recommended Lubricants: The manual lists recommended lubricants for different components, considering ambient temperature ranges. It emphasizes the importance of using the correct viscosity and type of lubricant to prevent damage and ensure longevity.
Service Capacity and Procedures: Detailed service capacities are provided for various components, such as the engine crankcase, transmission, and hydraulic systems. The document also includes specific procedures for daily maintenance inspections and other routine checks.

Critical Information: The manual stresses the importance of adhering to the recommended maintenance schedules and using the specified lubricants to avoid potential damage and ensure the truck's efficient operation. It also highlights the need for regular inspections and timely replacement of worn or damaged parts.

Overview: This document is a comprehensive maintenance and inspection manual for the SRT45 Off-Highway Truck. It outlines detailed procedures for regular checks and servicing of various systems and components to ensure optimal performance and safety.

1. Lubrication: Regular checks and maintenance of lubrication points are essential. Ensure all lubrication points are functioning correctly to prevent wear and tear.

2. Electronic System: Inspect all indicator lamps, caution lamps, gauges, and assistant devices to ensure they are operational.

3. Cummins Engine: Regularly check and refill liquid levels, inspect for leakages, check fan condition, monitor oil temperatures and pressures, and adjust the driving belt tension as needed.

4. Fuel System: Inspect for leakages and ensure fuel levels are adequate after daily operations.

5. Cooling System: Maintain coolant levels and inspect hoses and components for leakages.

6. Air Cleaner: Check the air cleaner restriction light, vacuator valve, and inspect filters for leakages and cracks.

7. Transmission: Regularly check for leakages, maintain liquid levels, and monitor oil temperatures and pressures.

8. Suspension System: Inspect the altitude of ride cylinders and check for leakages.

9. Wheels and Rims: Check the status and pressure of wheels and ensure rim fasteners are properly torqued.

10. Hydraulic System: Regularly check oil levels, replace filters as per the specified hours of operation, and inspect for leakages and worn components.

11. Steering and Braking System: Inspect steering control units, brake systems, and replace filters as required. Ensure all systems are functioning correctly under emergency conditions.

12. Maintenance Schedules: The document provides detailed inspection forms for various intervals (10hrs, 150hrs, 250hrs, 300hrs, 450hrs, 500hrs) outlining specific checks and maintenance tasks to be performed.

13. Key Recommendations: Regularly replace filters and lubricants as per the specified intervals to maintain system efficiency. Ensure all components are checked for wear and damage to prevent failures.

Maintenance Overview for SRT45 Off-Highway Truck:

1. General Maintenance Procedures: Regular inspections are required at various intervals (500hrs, 600hrs, 750hrs, 900hrs, 1000hrs, and 1050hrs) to ensure the optimal performance of the SRT45 Off-Highway Truck. These inspections include checking for leakages, loosened or damaged parts, and observing cracks or weld seams on the frame.

2. Lubrication: Ensure all lubrication points are functioning correctly. Specific lubrication tasks include greasing the front and rear transmission cross shafts and shafts at designated points.

3. Hydraulic System: Regular replacement of filters is necessary for the hoisting, cooling, and steering systems. This includes both return and suction filters, as well as breather valves for hydraulic tanks.

4. Engine and Transmission: For the Cummins engine, check fasteners, PTO liquid levels, and replace air and fuel filters as needed. The transmission requires cleaning of the breather valve and checking the block caution lamp for the filter. Oil changes are recommended after repairs or at specified intervals.

5. Brake and Steering Systems: Inspect the front brake system for disc wear and replace if necessary. Check the steering system for loose or damaged screws and ensure proper clearance in oscillating bearings.

6. Bearings and Body: Inspect oscillating bearings for wear and replace if clearance exceeds specified limits. Check the body for single clearance issues and adjust shims as needed.

7. Additional Checks: Regularly clean and lubricate components such as the pin shaft of the foot-operated valve and ensure all systems are functioning correctly.

Maintenance Overview for SRT45 Off-Highway Truck:

1. General Maintenance Procedures:

Regularly check for leakages, loosened, and damaged parts.
Inspect cracks and weld seams on the frame.
Check displacement and wear on the transmission shaft using a lever.

2. Lubrication:

Ensure all lubrication points are functioning properly.
Clean and lubricate breather valves for transmission and PTO.
Regularly clean dust from pin shafts and apply lubricating oil.

3. Cummins Engine Maintenance:

Check and tighten engine fasteners.
Monitor and refill PTO liquid levels as needed.
Drain, replace filters, and refill fluids at specified intervals.

4. Transmission Maintenance:

Clean breather valves and lubricate as necessary.
Check and replace filters after 150 hours if repairs have been made.
Monitor block caution lamp for filter status.

5. Main Reducer and Differential Assembly:

Extract lubrication samples for analysis.
Check and refill liquid levels as required.
Change oil when replacing components or after repairs.

6. Electrical System:

Inspect harnesses and battery cable status.

7. Brake System:

Check front brake disc wear and replace if necessary.

8. Hydraulic System:

Replace filters for hoisting, cooling, and steering systems.
Replace breather valves for hydraulic tanks.

9. Bearing and Steering Maintenance:

Check oscillating bearings for wear and replace if clearance exceeds specified limits.
Inspect and tighten screws between steering arm and suspension cylinder.

10. Inspection Intervals:

Maintenance tasks are scheduled at intervals of 1200, 1250, 1350, 1500, 1650, 1750, and 1800 hours, with specific tasks outlined for each interval.

Transmission: Regular maintenance includes cleaning the breather valve and lubricating the transmission. The block caution lamp for the filter should be checked. It is recommended to drain, replace the filter, and refill every 150 hours if the transmission has been repaired.

Differential, Planetary Gearing, and PTO: Lubrication samples should be extracted from the main reducer, differential assembly, and planetary assembly for analysis. Check and refill liquid levels as needed. Clean the breather valves for the rear axle and PTO. Oil should be changed when new components are installed or after repairs.

Fuel Tank: The fuel tank should be drained, cleaned, and refilled regularly.

Foot-Operated Valve: Dust should be cleaned from the pin shaft, and lubricating oil should be added.

Maintenance Inspection Forms: These forms outline specific maintenance tasks required at various operational hours (1950hrs, 2000hrs, 2100hrs, 2250hrs, 2400hrs, 2500hrs). Tasks include checking for leaks, inspecting fasteners, cleaning and replacing filters, and ensuring proper lubrication across various components such as the Cummins engine, transmission, brake systems, and hydraulic systems.

Hydraulic System: Filters for various systems (hoisting, cooling, steering) should be replaced regularly. The breather valves for hydraulic tanks should also be replaced, and the entire tank and accessories should be cleaned. Pressure checks for the hydraulic, steering, and braking systems are necessary.

Bearings: Bearings for steering components and suspension cylinders should be checked for wear and replaced if necessary.

General Recommendations: Regular checks for leaks, loosened or damaged parts, and cracks in the frame are essential. Fasteners should be inspected and tightened as needed. The maintenance schedule is crucial for ensuring the longevity and safety of the SRT45 Off-Highway Truck.

Maintenance Overview for SRT45 Off-Highway Truck:

1. General Maintenance Procedures:

Regular checks for leakages, loosened, and damaged parts are essential.
Observation of cracks and welder seams on the frame is necessary.

2. Engine Maintenance:

Check and tighten fasteners for the Cummins engine as needed.
Monitor and refill the PTO liquid level.
Drain, replace filters, and refill engine fluids periodically.

3. Transmission Maintenance:

Clean and lubricate the breather valve regularly.
Check the status of block caution lamps for filters and replace them after 150 hours if necessary.
Ensure driveline bolts are torqued correctly, with specific torque values provided for front and rear drivelines.

4. Hydraulic System Maintenance:

Replace filters for hoisting, cooling, and steering systems as well as those mounted on pipelines.
Replace breather valves for steering and hoisting hydraulic tanks.

5. Brake System Maintenance:

Inspect front brake discs for wear and replace if required.

6. Lubrication:

Ensure lubrication of front and rear transmission shafts and cross shafts at specified points.

7. Bearing Maintenance:

Check oscillating bearings for wear and replace if clearance exceeds specified limits.

8. Additional Checks:

Inspect and clean the breather valve for the rear axle and PTO.
Clean the pin shaft of the foot-operated valve and apply lubricating oil.

9. Electrical System Maintenance:

Check the status of harnesses and cables for the storage battery.

10. Inspection Intervals:

Specific maintenance tasks are outlined for intervals of 2500, 2550, 2700, 2750, 2850, and 3000 hours, with additional tasks supplementing daily inspections.

Maintenance Procedures and Specifications:

1. Bearing Wear Checks: Regularly inspect oscillating bearings in various components such as the A-shape arm, steering cylinder, and link. Replace bearings if the clearance exceeds specified limits (e.g., 0.55mm for A-shape arm bearings).

2. Suspension Cylinder Bearings: Replace bearings for both front and rear suspension cylinders as part of routine maintenance.

3. Body Inspection: Check the clearance of brace piece axial pin seat and flange end face of the frame. Adjust shims if clearance exceeds 1mm.

4. Scheduled Maintenance (3150hrs to 3750hrs): Detailed inspection forms outline specific tasks to be completed at various intervals (e.g., 3150hrs, 3250hrs, etc.). Tasks include checking for leaks, inspecting fasteners, cleaning breather valves, and replacing filters.

5. Engine and Transmission Maintenance: Regular checks on Cummins engine fasteners, PTO liquid levels, and transmission components. Replace filters and lubricate as necessary.

6. Differential and PTO Maintenance: Extract lubrication samples for analysis, check liquid levels, and clean breather valves. Change oil when necessary.

7. Brake System Checks: Inspect front brake discs for wear and replace if needed.

8. Hydraulic System Maintenance: Replace filters in the hydraulic system, including those for hoisting, cooling, and steering systems.

9. Electrical System Checks: Inspect harnesses, cables, and ensure alternator and generator are secure.

10. Driveline Maintenance: Check and adjust driveline bolt torque at specified intervals. Ensure proper assembly and initial checks post-installation.

11. General Lubrication: Ensure all lubrication points are functioning correctly, including cross shafts and transmission shafts.

Maintenance Overview: This document outlines the maintenance procedures for the SRT45 Off-Highway Truck, focusing on lubrication, inspection, and servicing tasks required at various operational hours (3900hrs, 4000hrs, 4050hrs, 4200hrs, and 6000hrs).

1. Lubrication and Servicing: - Regular checks and refills of gear oil for main reducer, differential assembly, planetary assembly, and PTO. - Cleaning and maintenance of breather valves for rear axle and PTO. - Lubrication of front and rear transmission shafts and cross shafts. - Dust removal and lubrication of the pin shaft of the foot-operated valve.

2. Maintenance Inspection Forms: 3900hrs: - Check for leakages, loosened, and damaged parts. - Inspect Cummins engine fasteners and PTO liquid levels. - Clean and lubricate transmission breather valve. - Extract lubrication samples for analysis. 4000hrs: - Drain and replace filters for Cummins engine and fuel system. - Inspect front and rear brake systems. - Check air-conditioning system components. - Replace filters in hydraulic systems. 4050hrs: - Similar checks as 3900hrs with additional focus on transmission and PTO components. 4200hrs: - Comprehensive checks on truck body, transmission shafts, and electrical systems. - Ensure all lubrication points are functioning. 6000hrs: - Disassemble and inspect engine PTO, hoist cylinder, and ride cylinders. - Check and replace worn parts in steering components.

3. Key Recommendations: - Regular oil changes when replacing components or after repairs. - Ensure all breather valves are clean and functional. - Maintain a detailed record of repairs, maintenance performed, and associated costs.

4. Safety and Operational Notes: - Always compare maintenance data with the manual and address discrepancies. - Drain pressure oil from accumulators before pressure checks. - Regularly inspect and adjust bearings and suspension components.

Maintenance Procedures:

Oil Cooling Unit, Radiator, Transmission Shaft: Disassembly, fixing, and reassembly are required. Check and replace worn parts as necessary, and ensure balance is maintained.
Body and Rear Axle: Replace lining plates, pin spindles, bushes, and check clearances. Replace frame, drag link, and bush as needed.
Transmission: Check fasteners and torque of driveline bolts. Clean threaded holes before assembly and monitor torque for three days post-assembly.
Steering and Hydraulic System: Inspect screws and replace filters for various systems. Check system pressures and replace breather valves as needed.
Bearings: Replace bearings for various components, ensuring clearances are within specified limits.
General Maintenance: Clean dust from pin shafts and lubricate as necessary.

Technical Data:

Engine: Cummins QSX15-C525, 4-cycle, water-cooled, turbocharged. Gross power: 391 KW, Net power: 360 KW. Maximum torque: 2440 N•m.
Transmission: Allison H5620AR with six forward and two reverse speeds. Features include automatic electronic control and hydraulic retarder.
Drive Axle: Heavy-duty with single reduction spiral bevel gear differential and planetary reduction.
Suspension: Front Macpherson type independent suspension, rear with A-frame linkage and stabilizer bar.
Wheels and Tyres: Wheel rim width of 15 inches, tyre size 21.00-35/(36PR)E-4.
Brakes: All hydraulic brake system with independent circuits for front and rear.

Brake System: The SRT45 Off-Highway Truck features an energy-storing accumulator for instant braking response. The front brake circuit pressure is 15.9 MPa (2300 lbf/in2), while the rear brake circuit pressure is 5.2 MPa (750 lbf/in2). The nitrogen precharge pressure for accumulators is 5.5 MPa (800 lbf/in2). The front brakes are dry discs with one caliper per wheel, having a disc diameter of 710 mm (28 in) and a total pad area of 1400 cm2 (217 in2). The rear brakes are oil-cooled, multiple friction discs, sealed from dirt and water, with a total braking surface of 49000 cm2 (7595 in2). The parking brake is applied by springs and hydraulically released, with a hold-off pressure of 8.3 MPa (1200 lbf/in2).

Steering System: The truck uses an independent hydrostatic steering system with a closed-centre steering valve, accumulator, and pressure compensating piston pump. The accumulator ensures uniform steering regardless of engine speed and provides approximately two lock-to-lock turns in case of engine power loss. A low-pressure indicator warns if system pressure falls below 11.5 MPa (1660 lbf/in2). The steering system complies with ISO 5010 and SAE J53 standards, with a steering angle of ±40° and a minimum turning radius of 9400 mm.

Hoist System: The hoist system operates independently from the power hydraulic system, featuring two-stage body hoist cylinders with power down in the second stage. The system pressure is 180 bar (2610 lbf/in2), with a gear-type hoist pump delivering 307 L/min (81 US gal/min) at 2100 r/min. The control valve is servo-controlled with a neutral gear open, achieving a body raise time of 13 seconds and a body lower time of 11 seconds.

Body and Frame: The truck's body has a longitudinal 'V' type floor with transverse box-section stiffeners, exhaust heated and resting on impact absorption pads. The body is made of high hardness abrasion-resistant steel, with floor thickness of 18 mm (0.70 in) and side thickness of 10 mm (0.39 in). The frame is highly rigid with a box-shaped section and anti-twisting beam, using low-carbon steel and high tenacity cast steel parts in stress-concentrated areas.

Cab: The operator cabin features a large windscreen for all-around visibility, acoustic lining for noise reduction, and a suspension seat to minimize vibration. It provides a sound exposure level of less than 78 dB(A) with doors and windows closed, conforming to ISO 3471 and SAE J1040C standards.

Maintenance Service Capacities: The truck's maintenance volumes include 55 L (14.6 US gal) for the engine crankcase and filters, 85 L (22.5 US gal) for the transmission and filters, 130 L (34.4 US gal) for the cooling system, and 470 L (124.4 US gal) for the fuel tank, among others.

Noise Levels: The operator's ear noise level is 78 dB (ISO 6394), and the exterior sound rating is 89 dB (ISO 6395). Actual noise exposure may vary based on environmental factors.

Vehicle Weights: The chassis with hoists weighs 28200 kg (61858 lb), the standard body 8600 kg (18865 lb), and the net weight is 36800 kg (80723 lb). The rated loading capacity is 45000 kg (98710 lb), with a maximum gross weight of 81800 kg (179432 lb). Weight distribution is 49% front and 51% rear when empty, and 33% front and 67% rear when loaded.

Catalog excerpts

_ Quality Changes the World Off-Highway Truck Safety, Ope rati on and Maintenance Manual

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SANY MINING EQUIPMENT CO.,LTD ADD: Sany Industry Town,Dongcheng Avenue,Economic and Technological Development Zone,Kunshan,Jiangsu. Tel:0086-10-60738666 Fax: 0086-10-60738831 E-mail:[email protected]

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SRT45 Off-Highway Truck Safety,Operation and Maintenance Manual WARNING Read and follow the safety precautions and instructions in this manual and on the machine decals. Failure to do can cause serious injury, death or property damage. Keep this manual with the machine for reading and future reference. Safety, Operation and Maintenance Manual

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Sany Group SANY Mining Equipment CO.,LTD Sany Industry Town,Dongcheng Avenue,Economic and Technological Development Zone,Kunshan,Jiangsu, P.R. of China 215300 http://www.sanyhe.com Tel: 0086-10-60738666 Fax: 0086-10-60738831 © 2014 by Sany Group. All right reserved. No part of this publication may be reproduced,used, distributed or disclosed except during normal operation of the machine as described herein. All information included within this publication was accurate at the time of publication. Product improvements ,revisions, etc., may result in differences between your machine and what is...

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Exemption Clauses SPECIFIC DECLARATION Mining truck is a critical earth/rock moving machine with high traffic ability,which is mainly distributed to coal, iron ore, limestone, quarry,hydropower... Sany assumes no responsibility for consequences caused by the following factors: ● Misuse of the truck due to failure to observe the information provided hereunder in this manual; ● Unauthorized restructuring or modification to the truck; ● Use of non-genuine parts, or untested or unapproved parts or tools. ● Machine failure or damage resulted from natural disasters (such as earthquake, typhoon,etc.),...

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Obligations of all operating personnel ● Any abnormalities that could bring improper operation of the dump truck or potential hazards should be reported to your supervisor. The abnormalities should be corrected timely if possible. All workers around the dump truck must know and obey all warning signals, and be alert to safety of oneself and others. All operators must know the operating items and procedures. Be alert to any hazardous situation and immediately inform operator and signalman of the hazards such as high voltage cables, irrelevant people and worse ground condition. The operator must...

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SANYI Safety, Operation and Maintenance Manual I

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II Safety, Operation and Maintenance Manual Cw SANYI

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f^SANYi Safety, Operation and Maintenance Manual III

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Table of Contents SRT45 Off-Highway Truck IV Safety, Operation and Maintenance Manual CW SANYI

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7 MOVING DISABLED TRUCK 7-1 f^SANYi Safety, Operation and Maintenance Manual V

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Table of Contents SRT45 Off-Highway Truck Safety, Operation and Maintenance Manual f^SANYi

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SRT45 Off-Highway Truck Foreword Safety, Operation and Maintenance Manual

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Safety, Operation and Maintenance Manual

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1 FOREWORD 1.1 Overview The explanations, values, and illustrations in this manual have been prepared based on the latest information available as of the date of its publication. Continuing improvements in the design of this machine may lead to additional changes that are not reflected in this manual. Consult SANY or your SANY distributor for the latest available information concerning your machine or with questions regarding information contained in this manual. This manual gives details of the operation and methods of inspection and maintenance for this machine that must be obeyed in order...

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If you sell the machine, be sure to give this manual to the new owner together with the machine, so that all relevant personnel can read it at any time. If this manual is lost or damaged, contact your distributor immediately to arrange for its replacement. To ensure that the correct manual is sent, check the serial number of the machine and inform your SANY distributor. The explanations, values, and illustrations in this manual have been prepared based on the latest information available as of the date of its publication. Continuing improvements in the design of this machine may lead to additional...

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1.2 Safety Information Hazard alert words are used in this manual and on some machine decals to inform the operator of imminent or potential hazards that lead to death, personal injury or property damage. 1)Alert words ● The sign is used for warning you the CAUTION potential danger of human injuries, when it is used together with notes such as “DANGER, WARING, CAUTION”, it indicate the degree of hazard. It indicates an imminently DANGER hazardous situation which, if not avoided, will result in death or serious injury. WARNING It indicates a potentially hazardous situation which, if not avoided,...

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2)An example alert wording and alert text WARNING To p r e v e n t p e r s o n a l i n j u r y a n d property damage, be sure lifting equipment is of adequate capacity and properly secured to do the job safely. 3)Other alert words In addition to the safety-related alert words above, the following words are used in this manual to provide additional information to which extra attention must be paid. Note: It is followed by information on how to avoid reduction of machine service life. Remark: It is followed by very useful information. 4)Safety decals Safety decals on the machine are used to alert...

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1.3 Your Documentation Package The documentation for this machine includes the following items: ● Safety, Operation & Maintenance Manual (SOMM) — This manual is in the operator cab seat pocket. ● Parts Book — This publication consists of parts lists and matching drawings for ordering spare parts as-needed. If it was not already shipped with your machine, the parts book for your machine is available directly from Sany. 1.3.1 Recommendations on using the documentation ● This documentation applies only to this ● ● ● machine and should not be used with any other machines. To ensure that the documentation...

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SRT45

SRT45

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