*mydirectindustry

Catalogs
SANY
SRT55D

SRT55D

Product catalog summary

Overview: The SRT55D Off-Highway Truck manual provides comprehensive guidelines on safety, operation, and maintenance. It emphasizes the importance of adhering to safety precautions to prevent injury, death, or property damage. The manual should be kept with the machine for reference.

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

Obligations:

Sany Group: Provide quality trucks, adhere to after-sales commitments, and offer operator training.
Owners/Authorized Persons: Ensure only trained personnel operate the truck, conduct regular safety inspections, and maintain the truck properly.
Operating Personnel: Report abnormalities, follow safety signals, and be aware of hazards.
Managers: Ensure operators are trained, healthy, and licensed, and that signal persons are competent.

Safety Information:

Safety Labels: Proper placement and understanding of safety labels are crucial.
General Precautions: Includes rules for personal protective equipment, fire safety, and machine cleanliness.
Safe Operation Precautions: Guidelines for safe starting, operation, and transportation of the truck.
Maintenance Precautions: Emphasizes lock-out/tag-out procedures, proper tool use, and safety during maintenance tasks.

Key Sections:

Machine Information: Details on product and engine identification, and display screen usage.
Safe Operation: Instructions for safe starting, operation on slopes, and parking.
Transportation: Procedures for loading, unloading, and transporting the machine.
Battery and Towing: Safety measures for handling batteries and towing operations.
Maintenance: Includes precautions for working under the machine, handling high-pressure systems, and welding operations.

Foreword: This section provides an overview of the manual for the SRT55D 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 information available at the time of publication and advises consulting SANY or a distributor for updates.

Safety Information: The manual uses hazard alert words such as 'DANGER', 'WARNING', and 'CAUTION' to indicate the severity of potential hazards. It includes examples of alert wording and emphasizes the importance of safety decals on the machine to warn operators of potential hazards.

Your Documentation Package: This section lists the documents included with the machine, such as the Safety, Operation & Maintenance Manual and the Parts Book. It provides recommendations for using and storing these documents to ensure they remain complete and up-to-date.

Regulation of Use: The manual specifies the intended applications for Sany Mining Trucks, primarily for traveling with a load. It also defines the directions of the machine from the operator's perspective.

Breaking in a New Machine: A break-in period of 100 operating hours is recommended for new machines to ensure optimal performance and longevity. Guidelines include preheating the machine, avoiding sudden movements, and allowing the system to cool down after use.

Visibility from Operator's Seat: The manual outlines visibility standards (ISO 5006) and provides diagrams showing areas where visibility is blocked by the machine's structure, emphasizing the importance of being aware of blind spots.

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

Safety Labels:

Ensure all safety labels are understood, correctly positioned, and kept clean. Avoid using organic solvents for cleaning.
Replace damaged or unreadable labels promptly.

General Precautions:

Only trained personnel should operate the machine. Follow all safety rules and precautions.
Report any abnormalities such as noise or leaks immediately and do not operate until resolved.
Wear appropriate PPE including hard hats, safety shoes, and goggles.
Keep a fire extinguisher and first aid kit accessible and ensure they are maintained.

Safety Equipment:

Ensure safety equipment like seat belts, lamps, and alarms are in place and functional.
Clean the machine regularly, especially windshields and mirrors, to prevent accidents.

Preventing Burns and Fire:

Allow engine and oil to cool before checking or discharging to prevent burns.
Store fuel and oil safely, away from unauthorized access, and avoid smoking near them.
Regularly inspect and maintain electrical and hydraulic lines to prevent fires.

Emergency Procedures:

In case of fire, turn off the engine and evacuate using handholds and steps.
Use alcohol-based detergents for cleaning windshields to avoid irritation.

Safety and Maintenance Guidelines for SRT55D Off-Highway Truck:

1. Rollover Protective Structure (ROPS): The ROPS is crucial for operator safety during machine tip-overs. Modifications such as welding or drilling are prohibited. Deformed cabs must be repaired or replaced by a SANY distributor.

2. Attachment Installation: Installation of optional parts may involve safety issues or legal limitations. Unauthorized attachments can lead to accidents and product failure. Always consult the manual and SANY distributor before installation.

3. Cab Windows: Broken windows must be replaced immediately to ensure operator safety. Damaged windows provide no protection.

4. Unauthorized Modifications: Modifications not approved by SANY can compromise safety and machine integrity. Consult SANY before any changes.

5. Worksite Examination: Assess the jobsite for potential hazards like landslides or falling rocks. Ensure safe operation methods and restrict unauthorized access.

6. Operation on Soft Ground: Avoid operating near cliffs or trenches as soft ground can cause the machine to sink or tip over. Take precautions on dams or near ditches to prevent landslides.

7. Overhead Power Cables: Maintain a safe distance from power cables to prevent electrocution. Inform local power companies before operations near cables and designate a signalman for guidance.

8. Alternate Exit: In emergencies, use a safety hammer to break the rear window for escape. Clear glass shards carefully to avoid injury.

9. Visibility: Ensure good visibility by using mirrors and additional lighting if necessary. Stop operations in poor visibility conditions like fog or storms.

10. Asbestos Hazard: Follow safety protocols to avoid inhaling asbestos dust. Use water to suppress dust and wear appropriate masks.

11. Safe Operation Precautions:

Safe Starting: Maintain three-point contact when mounting/dismounting. Adjust seat for comfort and check seatbelt condition.
Before Starting Engine: Conduct pre-start checks including cleaning windows, checking fluid levels, and ensuring no obstructions around the machine.
Engine Starting Rules: Warn others before starting the engine and ensure no one is on or near the machine.
Cold Season Starting: Warm up the engine sufficiently and check battery electrolyte to prevent fire hazards.
Engine Starting Aid: Use jumper cables cautiously with proper safety gear and procedures.

12. Operation:

Inspection Before Operation: Conduct inspections in a barrier-free area and check for abnormalities.
Prior-operation Precautions: Warn people in the working range and ensure no one is near the machine.
Traveling Precautions: Avoid overloading, maintain safe distances, and travel at low speeds on rough ground.

Safety Precautions:
1. Avoid long high-speed travel to prevent tire overheating and potential blowouts. Contact SANY for guidance on long travels.
2. Always keep the transmission in gear when traveling; avoid using Neutral to maintain control and prevent overheating.
3. Use retarder brakes on slopes and avoid sudden steering to prevent tipping.
4. Ensure no persons or objects are behind the machine before dumping operations.
5. Avoid operating on slopes and do not travel with the dump body raised.
6. Use tire chains on snow or ice and avoid sudden braking.
7. Park on solid, flat surfaces away from hazards and use chocks.

Machine Preparation and Maintenance:
1. Follow lock-out and tag-out procedures before maintenance.
2. Select a clean, flat, and well-ventilated area for maintenance.
3. Wear appropriate protective gear and ensure tools are in good condition.
4. Stop the engine before maintenance; if necessary, have a second person ready to shut it down.
5. Use proper tools and handle high-pressure components with care.
6. Ensure safety when working under the machine and use ear protection in noisy environments.

Transportation and Towing:
1. Disassemble the machine for transport and consult SANY for guidance.
2. Load/unload on solid, flat surfaces and secure the machine with chains and chocks.
3. Follow local traffic regulations and ensure the trailer can support the machine's weight.
4. Use appropriate cables for towing and avoid towing on slopes.

Battery and Welding Safety:
1. Handle batteries with care, avoiding sparks and ensuring proper ventilation during charging.
2. Only qualified personnel should perform welding operations, using appropriate safety equipment.

Hydraulic System Maintenance:
1. Release system pressure before maintenance to prevent accidents.
2. Avoid open flames around hydraulic systems.

Hydraulic System Safety: The document emphasizes the importance of quickly removing splashed hydraulic oil and highlights the dangers of diesel oil or pressurized hydraulic oil penetrating the skin or eyes, which can cause serious injury or death. It advises using a cardboard or wooden board to check for leaks and wearing protective gear.

High-Pressure Hoses: Leaks from high-pressure hoses can lead to faults or fires. Loose bolts should be tightened to the specified torque, and damaged hoses should be replaced immediately.

Cooling System: The cooling system's pressure increases with engine temperature. The radiator cover should only be removed after the system has cooled down to avoid injury from hot coolant.

Air-Conditioning System: The document advises keeping fire sources away from the air-conditioning system and using the specified refrigerant (R134a) to avoid damage. It warns against refrigerant exposure to eyes and skin.

High Voltage Precautions: High voltage can occur in the fuel injector terminal and engine controller, posing an electrocution risk. Only authorized personnel should access these components.

Accumulator Safety: Accumulators contain highly pressurized nitrogen and should not be disassembled or exposed to fire. Proper disposal involves releasing the gas and contacting authorized personnel.

Fire and Explosion Prevention: Smoking and open flames should be avoided near fuel systems. Proper storage and handling of flammable materials are crucial, and fire-fighting equipment should be ready for use.

Regular Replacement of Safety Parts: Safety-related parts like hoses and seat belts should be replaced regularly to prevent deterioration and potential accidents.

Maintenance Operations: All parts should be checked and replaced if worn or damaged. Fasteners should be tightened to specified torque, and only approved hydraulic oil should be used.

Waste Disposal: Proper disposal of waste materials is essential to prevent environmental harm. Local regulations should be followed for recycling and waste disposal.

Tire Handling and Storage: Special tools and procedures are required for tire maintenance. Tires should be stored securely to prevent rolling or falling, and pressure should be released before removing rim components.

Controls and Indicators: The document lists various controls and indicators on the SRT55D Off-Highway Truck, including steering indicators, parking brake, body up indicator, retarder indicator, and engine maintenance indicators, among others.

Overview: The document is a section from the Safety, Operation, and Maintenance Manual for the SRT55D Off-Highway Truck. It provides detailed instructions on the controls and operating procedures of the truck, focusing on various instruments, switches, and systems.

1. Instruments:

Tachometer: Indicates engine speed in RPM. Normal speed is in the white area; high speed is in the red area.
Speedometer: Shows vehicle speed. Normal speed is in the white area; high speed is in the red area.
Transmission Oil Temperature Gauge: Displays transmission oil temperature. Normal temperature is in the white area; high temperature is in the red area.
Fuel Level Gauge: Indicates fuel level. Normal level is in the white area; low level is in the red area.
Engine Water Temperature Gauge: Shows engine coolant temperature. Normal temperature is in the white area; high temperature is in the red area.
Engine Oil Pressure Gauge: Displays engine oil pressure. Normal pressure is in the white area; high pressure is in the red area.

2. Display and System Functions:

Power on the display to show the boot screen and work interface.
Use function keys (F1-F4) to navigate and set system functions, such as system time.

3. Reversing Monitoring System:

Monitor automatically turns on when the gear is in reverse or manually via the power key.
Adjust contrast, brightness, and volume using the MENU key.
Switch between mirror and normal image display.

4. Switches:

Economical/Powerful Mode Switch: Selects between 'POWER' and 'ECONOMY' transmission schedules.
Parking Brake Switch: Engages rear braking independently for parking or stopping.
Front Brake Pressure Reduction: Reduces front brake pressure by 50% to prevent wheel lockup.
Hazard Warning Lights: Activates all direction indicators simultaneously.
Headlight and Fog Lamp Switches: Control headlights and rear fog lamps.

5. Combined Switch:

Includes controls for horn, washer, wiper speeds, and headlight functions.

6. Air Conditioner Control Panel:

Controls modes such as refrigeration, heating, and defrosting.
Adjusts temperature, wind speed, and air circulation.

7. Driver Seat Adjustments:

Adjustments for forward/backward position, backrest, height, suspension, and headrest.

8. Seat Belt:

Instructions for proper seat belt use and adjustment.

9. Truck Controls:

Braking: Includes service, parking, emergency brakes, and retarders.
Service Brake: Operated by a pedal for normal slowing or stopping.
Parking Brake: Engages rear brakes for parking.
Emergency Brake: Used in emergencies, not for regular braking.
Retarder: Provides continuous braking force for descending grades.

Gear Range and Retarders: The document advises operators to select an appropriate gear range to ensure safe descent and efficient retarder operation. It is recommended to use only one retarder at a time, prioritizing the transmission retarder. The rear disk brake retarder should only be used when additional retardation is needed. Operators should maintain high engine speed for maximum retardation and cooling effect without exceeding recommended limits.

Oil Temperature Monitoring: The manual highlights the importance of monitoring oil temperatures for both the rear disc brake and transmission. Warning systems are in place to alert operators of overheating, prompting them to reduce speed or stop the machine to prevent damage.

Engine and Electronic Foot Pedal: The electronic foot pedal sends signals to the engine's fuel control system. The engine will override pedal input until it reaches the correct operating temperature. The Quantum electronic fuel system monitors engine conditions and provides diagnostic capabilities to prevent damage.

Quantum Electronic Fuel System: This system includes an Electronic Control Module (ECM) that manages fuel injection and engine performance. It features self-compensating injectors that eliminate the need for engine tune-ups. The system also includes a derate function to protect the engine from damage by reducing power and speed when faults are detected.

Diagnostic Codes: The document provides a comprehensive list of diagnostic codes for the electronically controlled fuel system, detailing various sensor and component failures that trigger warning lights and require attention.

Steering System: The steering system is hydraulically powered with an accumulator to maintain constant flow. In case of pressure loss, the accumulator allows for limited steering control. Operators are warned to stop the machine immediately if steering power is lost.

Transmission and CEC2 Shift System: The truck uses a CEC2 automatic shift system that selects gears based on throttle position, engine speed, and truck speed. It includes features to reduce driver fatigue and enhance safety by focusing on road conditions.

Transmission Safety Features:

Reverse Inhibit: Prevents gear selection if the engine throttle exceeds 20%.
Hoist Interlock: Shifts transmission to Neutral when the body is raised, preventing Reverse gear engagement.
Body Up Interlock: Limits transmission to First gear when the body is raised, operational only in automatic mode.
Parking Brake Interlock: Prevents shifting out of Neutral if the parking brake is applied.
Lock-in-Gear: Protects transmission from damage due to wheel spinning or lockup by locking the gear and requiring ECU reset.

ECU Reset Procedure: To reset the ECU after a lock-in-gear event, stop the truck, select Neutral, apply the parking brake, shut down the engine, disconnect and reconnect the battery main switch, and restart the engine.

Cold Weather Starts: If transmission temperature is below -24°C, the ECU keeps the transmission in Neutral. Between -24°C and -7°C, only First or Reverse gears are allowed. Above -7°C, normal operation resumes.

Transmission Operation:

Electronic Control Unit (ECU): Processes signals from switches and sensors to control the transmission.
Gear Shift Selector: Allows selection of 5 forward and 2 reverse ranges, with a diagnostic display for fault codes.
Mode Selection Switch: Offers 'POWER' and 'ECONOMY' modes, affecting lockup clutch operation and fuel economy.

Warnings and Recommendations:

Avoid coasting in Neutral to prevent transmission damage.
Always select Neutral and apply the parking brake before leaving the operator’s seat.
Monitor transmission oil temperature to prevent overheating.

Diagnostic Codes: Fault codes can be retrieved using the gear shift selector or a diagnostic data reader. Active and inactive codes can be cleared by holding the mode button for specified durations.

Specifications and Fault Codes:
The document outlines various fault codes and their corresponding actions for the SRT55D Off-Highway Truck. Key issues include turbine speed sensor reasonableness, output speed sensor faults, and shift selector faults. For each fault, specific actions such as DNS (Do Not Shift), locking in current range, or using default values are recommended.

Body Control Operations:
The hoist lever has four positions: HOIST, HOLD, FLOAT, and LOWER, each controlling the movement of the truck's body. The document provides detailed instructions on how to operate the hoist lever to raise or lower the truck body safely.

Pre-Starting Inspection:
Before starting the engine, ensure the machine is on level ground, the parking brake is applied, and all lights and controls are functioning properly. A comprehensive checklist for inspecting various components such as the engine, hydraulic systems, brakes, and tyres is provided.

Component Checks:
Instructions for checking the engine oil level, draining fuel filters, checking coolant levels, and inspecting tyres are detailed. The document emphasizes ensuring proper fluid levels and tyre conditions to maintain safe operation.

Engine Operation:
The engine should not be placed under full load immediately after starting. It is crucial to allow the engine to warm up and circulate lubricant before operating at full speed.

Engine Operation and Safety Guidelines:
Operate the engine at top-rated speed for maximum power. Avoid idling for more than 5 minutes; shut off the engine if necessary. If any gauges or warning lights indicate a problem, shut down the engine immediately and report it. Never start the engine indoors without proper ventilation due to hazardous exhaust gases. Do not exceed 2400 rev/min to prevent engine damage.

Starting the Engine:
Ensure the park brake is in 'PARK', the body control lever is in 'FLOAT', and the transmission is in 'NEUTRAL'. Insert the key and turn to position 'I'. Check the instrument panel for indicator lights. Sound the horn before starting. Turn the key to position 'II' to crank the engine, releasing it once the engine starts. Monitor the oil pressure and water temperature gauges to ensure they are within normal ranges.

Using Jumper Cables:
Ensure machines are not touching and use cables equal to the machine's cable size. Connect the red cable to the positive posts and the black cable to the negative post and machine frame for grounding. Avoid ignition sources near batteries to prevent explosions.

Pre-Driving Checks:
Ensure all glass, mirrors, and lights are clean. Test controls and check transmission, body, and steering hydraulic tanks for proper oil levels. Perform braking function checks to ensure safety.

Driving and Stopping:
Observe instruments and warning lights before driving. Ensure the area is clear of obstructions. Use the service brake to stop and apply the parking brake when stationary. Use the retarder brake for deceleration unless an immediate stop is necessary.

Stopping the Engine:
Allow the engine to idle for 3-5 minutes after full load operation before shutting it off. Apply the parking brake and turn the ignition key to 'OFF'.

Parking and Storage:
Fill the fuel tank to prevent condensation and park on level ground. Check for damage and ensure sufficient antifreeze in cold conditions. For prolonged storage, turn the circuit breaker to 'shutoff' to prevent battery leakage.

Working the Truck:
Off-highway trucks are used for various hauling jobs. Loading methods include hydraulic excavators, rope shovels, and front-end loaders. Efficient loading involves minimizing truck maneuvers and loader travel time. Position trucks strategically to optimize loading efficiency and safety.

Loading Procedures:
Operators must remain vigilant of the cleanup machine's position to avoid congestion. Avoid rocks and debris to prevent tire damage. Do not position the truck under a swinging shovel bucket. Keep limbs inside the cab during loading to avoid injury from falling debris. Once loaded, signal with two horn blasts, release brakes, and proceed to the haul road promptly.

Hauling Guidelines:
Maintain a safe speed and never coast in 'NEUTRAL'. Use appropriate transmission range and brakes on downgrades. Keep a safe distance from other machines, typically two truck-lengths per 15 km/h. Adhere to specified minimum distances on haul roads for safety.

Dumping Operations:
Dumping varies by material type. Use a 'SPOTTER' for guidance due to limited rear visibility. Avoid hitting protective rails when dumping into hoppers. Ensure the truck is on firm, level ground before raising the body. Do not 'JUMP DUMP' to dislodge material as it can cause damage.

Empty Return:
Ensure the body is fully lowered and the control lever is in 'FLOAT' before moving from the dump site. Follow the same procedures as hauling when returning empty.

Roading:
Special care is required when operating on public highways. Ensure the truck is in good condition and carry a 'Warning Triangle'. Obtain necessary permits and remain alert for overhead obstacles. Perform thorough lubrication and inspection before roading.

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 noises immediately. If systems fail, stop the machine until repairs can be made. If necessary, move the truck to a service area for repairs.

Overview: This document is a technical manual for the SRT55D Off-Highway Truck, focusing on safety, operation, and maintenance procedures. It includes detailed instructions for towing a disabled truck, lubrication and servicing schedules, and safety precautions.

Towing Procedures:

Remove drive flange covers and axle shafts to prevent damage during towing.
Ensure hydraulic pressure for steering and braking; if not possible, repair on-site or arrange safe towing.
Use a towing bar or A-Frame for towing, ensuring secure connections.
Limit towing speed to 10 km/h and distance to 10 km to avoid transmission damage.
Warnings include securing wheels with chock-blocks and ensuring chains or cables are strong and properly secured.

Lubrication and Servicing:

Regular lubrication is crucial for preventing mechanical failures.
Follow specific intervals for checking and replacing lubricants and filters.
Use recommended lubricants and ensure systems are at operating temperature when draining.
Detailed lubrication and service chart provided, specifying intervals and types of lubricants for various components.

Safety Precautions:

Unauthorized personnel should not service the truck.
Always attach a 'DO NOT OPERATE' sign during maintenance.
Relieve pressure before servicing pressurized systems.
Be cautious of hot oil and exhaust components to avoid burns.
Deflate tires before removing embedded objects or the tire assembly.

Other Maintenance:

Inspect seat belts and replace every three years.
Check wiper blades and washer fluid regularly.
Perform a walk-around inspection every 10 hours of operation.
Check engine, air cleaners, and coolant levels frequently.
Specific maintenance tasks are outlined for intervals up to 4000 hours.

Maintenance and Servicing Overview for SRT55D Off-Highway Truck:

Drive Belt and Brake Maintenance: Regularly check and adjust drive belt tension. Inspect front brake pads and discs for wear, ensuring pad friction material does not wear below 3 mm. Increase inspection frequency under severe conditions.

Lubrication Points: Oil hinges and working parts with engine oil. Replace the fuel pre-filter element as per Chapter 33 instructions.

Hydraulic System Maintenance: Every 1000 hours, check pressures in steering, body, and braking systems. Clean and replace filters in steering, hoisting, and cooling systems as specified. Follow safety instructions strictly.

Service Capacities: Detailed capacities for various components such as engine crankcase, transmission, hoisting systems, and fuel tank are provided, with specific lubricant types and quantities.

Recommended Lubricants: Use specified grades and brands of lubricants for different components, considering ambient temperature conditions. Consult lubricant suppliers for appropriate viscosity.

Daily Maintenance Procedures: Conduct a daily inspection every 10 hours, checking operation devices, lubrication systems, electronic systems, engine, fuel system, cooling system, air cleaner, transmission, suspension, and wheels. Record maintenance activities in the provided table.

Hydraulic System Checks: Regularly check and refill oil levels, replace filters, and inspect for leaks and damage. Follow specified intervals for filter replacements.

Steering and Braking Hydraulic System:

Check the status of the steering control unit and ensure the steering system functions in emergency conditions by rotating the wheel with the engine off.
Inspect the foot brake and parking brake systems.
Monitor and refill the steering system oil level as needed.
Replace the oil return filter periodically, with specific intervals at 500 hours and 2000 hours (first replacement at 1000 hours).
Replace the pipeline filter and the filter inside the rear braking valve group every 500 hours.
Change the oil in the tank and clean the tank and accessories thoroughly.
Check system pressures for steering, front braking, and rear braking systems.
Replace all O-rings for hoist steering, brake, and cooling systems to maintain high performance and safety.

Lubrication and Servicing:

Regular maintenance includes checking for leaks, loose or damaged parts, and observing cracks or broken welds on the truck frame.
For the Cummins engine, check fasteners and PTO liquid levels, refilling as necessary.
Transmission maintenance involves replacing the oil-water separator filter initially at 150 hours and subsequently every 1200 hours, cleaning the breather assembly, and checking the block caution lamp for the filter.
Main reducer, differential assembly, planetary assembly, and PTO require lubrication changes and breather assembly checks.
Lubrication points include front and rear transmission cross shafts and shafts.
Driveline assembly bolts require inspection and torque checks at specified intervals.
Clean and lubricate the pin shaft of the foot-operated valve.

Maintenance Inspection Forms:

150-hour inspection includes checking for leaks, engine fasteners, PTO liquid levels, and transmission maintenance.
250-hour inspection involves engine filter replacements, fuel and coolant system checks, and brake system inspections.
300-hour inspection focuses on checking for leaks, engine fasteners, and transmission maintenance.
450-hour inspection repeats similar checks as previous intervals with additional focus on lubrication and breather assembly maintenance.
500-hour inspection includes comprehensive filter replacements in the hydraulic system and bearing wear checks.
600-hour inspection involves checking for leaks, lubrication system maintenance, and electrical system checks.

Maintenance Procedures for SRT55D Off-Highway Truck:

1. Filter and Valve Replacement:

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

2. Oil and Pressure Checks:

Change oil and clean tanks and accessories.
Check system pressures, including steering and braking systems.

3. Bearing Inspection:

Check oscillating bearings for steering drag link, A-shape arm, steering cylinder, and suspension cylinders. Replace if clearance exceeds specified limits.

4. Screw and Bolt Checks:

Inspect and tighten screws between steering arm and front suspension cylinder.
Check driveline assembly bolts for proper torque.

5. Regular Maintenance Intervals:

2100hrs: Check for leaks, cracks, and fasteners. Clean and lubricate transmission and breather assemblies.
2250hrs: Replace fuel and coolant filters, check brake disc wear, and lubricate transmission shafts.
2400hrs: Inspect electrical system, clean air cleaner, and check universal joint of steering rod.
2500hrs: Replace hydraulic system filters and inspect bearings.
2550hrs: Change lubrication for main reducer and differential assembly, and check driveline bolts torque.

6. Additional Checks:

Regularly clean dust from pin shafts and add lubricating oil.
Ensure all maintenance is recorded with details on cost, time, and remarks.

Maintenance Overview: The document provides detailed maintenance schedules and procedures for the SRT55D Off-Highway Truck, focusing on safety, operation, and maintenance. It includes specific inspection forms for various operational hours, highlighting tasks that need to be completed at each interval.

Key Sections:

General Checks: Regular inspections for leakages, loosened or damaged parts, and frame integrity are emphasized across all maintenance intervals.
Cummins Engine Maintenance: Regular checks and maintenance tasks include inspecting fasteners, checking and refilling PTO liquid levels, and replacing filters and oil as necessary.
Transmission Maintenance: Includes cleaning breather assemblies, checking caution lamps for filters, and performing oil changes after repairs or at specified intervals.
Main Reducer and Differential Assembly: Lubrication samples are extracted for analysis, and liquid levels are checked and refilled. Breather assemblies are cleaned regularly.
Brake System: Regular checks on the front brake system for disc wear and necessary replacements.
Lubrication Points: Detailed lubrication points for front and rear transmission shafts and universal joints are specified.
Hydraulic System: Regular replacement of filters in the hoisting and steering systems, and checking of breath valves.
Bearing Checks: Detailed procedures for checking the wear status of oscillating bearings, with specific clearance measurements provided for replacement decisions.

Additional Notes: The document includes tables for recording repair and maintenance activities, costs, time required, and remarks, ensuring comprehensive tracking of maintenance activities.

Maintenance Overview for SRT55D Off-Highway Truck:

General Maintenance Procedures:

Regularly check for leakages, loosened, and damaged parts.
Inspect cracks and weld seams on the frame.

Engine Maintenance:

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

Transmission Maintenance:

Clean and lubricate the breather assembly.
Monitor block caution lamp for filter status.
Drain, replace filter, and refill every 150 hours if repaired.

Hydraulic System Maintenance:

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

Brake System Maintenance:

Inspect front and rear brake discs for wear and replace if necessary.

Lubrication Points:

Lubricate front and rear transmission cross shafts and shafts.
Clean and lubricate the pin shaft of the foot-operated valve.

Electrical System Maintenance:

Check harnesses and battery cables.
Tighten alternator and generator connections.

Additional Checks:

Inspect and clean air conditioning components.
Check and adjust driveline assembly bolts torque.

Inspection Intervals:

Specific maintenance tasks are scheduled at intervals of 3450, 3500, 3550, 3600, 3750, 3900, and 4000 hours.

Transmission Maintenance:
Disassemble, inspect, and repair or replace worn parts as necessary. After repairs, drain, replace the filter, and refill the transmission fluid every 150 hours.

Main Reducer and Differential Assembly:
Disassemble, inspect, and repair or replace worn parts as necessary.

Bearing Inspection:
Check the wear status of oscillating bearings in various components. Replace bearings if the clearance exceeds specified limits:

Steering drag link: S ≥ 0.54mm
A-shape arm: S ≥ 0.55mm
Ends of A-shape arm: S ≥ 0.7mm
Steering cylinder: S ≥ 0.54mm
Front suspension cylinder: S ≥ 0.55mm
Rear suspension cylinder: S ≥ 0.63mm

Screw Inspection:
Check the screw between the steering arm and front suspension cylinder. Tighten or replace if loose or damaged.

Technical Data:
Engine:
Make/Model: Cummins QSK19-C700
Type: 4 cycle, turbocharged, low temperature aftercooled, electronic management
Gross Power: 522 kW (700 hp) at 2100 rpm
Net Power: 481 kW (645 hp) at 2100 rpm
Emissions: Meets Tier II USA EPA/CARB and EU NRMM standards.

Transmission:
Make/Model: Allison H6620AR automatic electronic control
Features: Soft shift, six speeds forward, two reverse, automatic converter lockup, downshift inhibitor, integral hydraulic retarder.

Suspension:
Front: Macpherson type independent suspension
Rear: Variable rate nitrogen/oil cylinders with A-frame linkage
Maximum Strut Stroke: Front 300 mm, Rear 186 mm

Braking Systems:
Service Brakes: All hydraulic system with independent circuits
Parking Brake: Rear brakes applied by spring-loaded piston
Retarding Brake: Controlled by two levers
Emergency Brake: Solenoid valve for service and parking brakes

Steering System:
Independent hydraulic steering with closed-center valve and accumulator
Minimum Turning Diameter: 19,080 mm

Hoist System:
Hydraulic system with two hoist cylinders
System Relief Pressure: 205 bar
Body Raise Time: 14 sec
Body Lower Time: 13 sec

Body:
Construction: Longitudinal 'V' type floor with transverse stiffeners
Volume: Struck 26 m3, Heaped 35 m3

Cab:
Features: Large windscreen, acoustic lining, suspension seat
Noise Level: Less than 78 dB(A)

Maintenance Service Capacities:
Engine Crankcase: 65 L
Transmission: 85 L
Cooling System: 166 L
Fuel Tank: 620 L
Steering Hydraulic Tank: 73 L

Noise Levels:
Operator Ear: 78 dB
Exterior Sound: 89 dB

Weight Parameters:
Chassis with Hoists: 31,000 kg
Body: 11,000 kg
Net Weight: 42,000 kg
Payload Maximum: 55,000 kg
Maximum Gross Weight: 97,000 kg
Weight Distribution: Empty - Front 48%, Rear 52%; Loaded - Front 33%, Rear 67%.

Catalog excerpts

SRT55D 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

Open the catalog to page 1

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...

Open the catalog to page 2

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.),...

Open the catalog to page 3

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...

Open the catalog to page 4

SANYI Safety, Operation and Maintenance Manual I

Open the catalog to page 5

Table of Contents SRT55D Off-Highway Truck N Safety, Operation and Maintenance Manual f^SANYi

Open the catalog to page 6

f^SANYi Safety, Operation and Maintenance Manual III

Open the catalog to page 7

IV Safety, Operation and Maintenance Manual ^SANYI

Open the catalog to page 8

7 Moving Disabled Truck SANYI Safety, Operation and Maintenance Manual V

Open the catalog to page 9

VI Safety, Operation and Maintenance Manual f^SANYi

Open the catalog to page 10

SRT55D Off-Highway Truck Foreword Safety, Operation and Maintenance Manual

Open the catalog to page 11

Safety, Operation and Maintenance Manual

Open the catalog to page 12

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...

Open the catalog to page 13

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...

Open the catalog to page 14

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,...

Open the catalog to page 15

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...

Open the catalog to page 16

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...

Open the catalog to page 17

1.4 Page Numbers The pages in this manual are numbered as the following: 2-10 Page 10 of Chapter 2 Chapter 2 1.5 Regulation of Use 1.5.1 Machine applications Sany Mining Trucks are designed to be used mainly for the following work: Traveling with a load Down Operator 's seat 1.6 Breaking in a New Machine Your machine has been thoroughly adjusted and tested before shipment. However, initial operation of the machine under severe conditions can adversely affect the performance of the machine or shorten the machine life. Therefore, Sany recommends that you allow a break-in period of 100 operating...

Open the catalog to page 18

SRT55D

SRT55D

Catalog excerpts

All SANY catalogs and technical brochures

Archived catalogs