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SRT95C

SRT95C

Product catalog summary

Overview: The SRT95C 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 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 experienced and capable.

Safety Information: The manual includes detailed safety labels and general precautions, such as using personal protective equipment, fire prevention, and handling hazardous situations. It also covers safe operation procedures, including starting, operating, and transporting the truck.

Maintenance Precautions: Guidelines for maintenance include lock-out/tag-out procedures, selecting a safe working area, using proper tools, and handling high-pressure oil. Maintenance should be performed with the engine off unless specified otherwise.

Foreword: The manual provides detailed information on the operation, inspection, and maintenance of the SRT95C Off-Highway Truck. It emphasizes the importance of following safety rules to prevent accidents and injuries. Users are advised to consult SANY or their distributor for the latest updates and information.

Regulation of Use: Sany Mining Trucks are primarily designed for traveling with a load. Directions are determined from the operator’s seat in the direction of travel.

Breaking in a New Machine: A break-in period of 100 operating hours is recommended to ensure optimal performance and longevity. During this period, preheat the machine before operation, avoid sudden starts or stops, and allow the system to cool down after use.

Visibility from Operator's Seat: The machine complies with ISO 5006 visibility standards. Diagrams illustrate areas where visibility is blocked by machine parts, even with standard mirrors or aids.

Machine Information: Product and engine identification plates are crucial for ordering parts and service. Their locations are specified for easy reference.

Safety Procedures and Precautions: Ensure the parking brake is set to 'PARKING', the dump control lever is on 'HOLD', and the engine is stopped. Remove the key, lock the operator's compartment, and store the key in a designated place. Maintain three-point contact when getting on or off the machine. Check and clean handrails and steps of any oil, grease, or mud. Avoid holding tools while climbing and never jump on or off the machine.

Preventing Burns: Allow engine coolant and oil to cool before checking or discharging. Loosen caps slowly to relieve internal pressure.

Fire and Explosion Prevention: Store engine oil and fuel securely, avoid smoking near them, and check for leaks or damage in pipes and hoses. Ensure good ventilation when refueling or storing oils.

Fire Safety: Remove flammable materials from the engine area. Check electrical lines for damage and ensure hydraulic lines are secure to prevent fires.

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

Windshield Cleaning: Use alcohol-based detergents, avoiding methanol-based ones.

ROPS Precautions: Do not modify the operator's cab structure. Repair or replace if damaged.

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

Cab Windows: Replace broken windows immediately to ensure operator safety.

Unauthorized Modifications: Avoid unauthorized modifications to prevent safety issues and consult Sany distributor for guidance.

Worksite Examination: Assess terrain and ground conditions before operation to avoid hazards like landslides or falling rocks.

Operation on Soft Ground: Avoid operating near cliffs or trenches to prevent sinking or tipping over.

High-Voltage Cables: Maintain a safe distance from power cables to prevent electrocution. Designate a signalman for guidance.

Engine Operation Indoors: Ensure good ventilation to avoid health hazards from exhaust gases.

Alternate Exit: Use a safety hammer to break the rear window in emergencies.

Visibility: Ensure good visibility by cleaning mirrors and using additional lighting if necessary. Stop operations in poor visibility conditions.

Asbestos Hazard: Follow safety protocols to avoid inhaling asbestos dust during operations.

Safe Operation Precautions: Maintain three-point contact when mounting or dismounting the machine. Adjust the seat for comfort and safety, and always use the seat belt. Perform pre-start checks on windows, lamps, coolant, fuel, and oil levels.

Engine Starting Rules: Before starting the machine, ensure no one is around it and sound the horn as a warning. Only the operator should be on the machine, and the engine should never be started by shorting the start motor circuit.

Cold Season Starting: Warm-up operations are crucial to prevent slow reactions and accidents. Check the battery electrolyte before starting; if frozen, do not charge or use an alternative power source until it is melted to avoid fire hazards.

Engine Starting Aid: Use jumper cables only when necessary and with caution to prevent battery explosions or loss of control. Ensure two people are involved, one in the operator seat and the other handling the battery, and wear protective gear.

After Starting the Engine: Run the engine at low idle for 3 to 5 minutes, checking that all parameters are normal.

Operation Inspection: Conduct inspections in a spacious area, ensuring the seat belt is buckled and checking for any abnormalities in gauges, noise, or leaks. Stop operation immediately if any issues are detected.

Traveling Precautions: Do not exceed the maximum payload, and avoid turning off the engine while traveling. Maintain proper distances to avoid accidents and travel slowly on rough or slippery surfaces.

Dumping Operations: Ensure no one is behind the machine before dumping, and avoid operations on slopes to prevent tipping.

Parking the Machine: Park on a solid, flat surface away from hazards, and use flags or signal lamps if parked in a construction area.

Battery Handling: Handle batteries with care, avoiding contact with terminals and ensuring proper ventilation during charging to prevent explosions.

Towing Precautions: Use appropriate wire cables and avoid towing on slopes. Operate slowly and avoid sudden loads on the cable.

Maintenance Precautions: Before maintenance, use lock-out and tag-out procedures to ensure safety.

Maintenance Safety Procedures:

Warning Signs: Place warning tags on the machine to indicate maintenance is in progress. Ensure all necessary areas are marked to prevent accidental operation.
Working Area Selection: Choose a clean, flat, and well-ventilated area for maintenance. Remove any hazardous materials and ensure the area is free of tools when not in use.
Prior-Maintenance Precautions: Understand procedures before starting. Keep the area dry and avoid using water or steam in the cab. Do not perform maintenance while the machine is moving.
Personal Preparation: Only authorized personnel should perform maintenance. Wear appropriate protective gear, including gloves, goggles, and safety hats, depending on the task.
Engine and Machine Preparation: Park on solid ground, lower all equipment, and ensure the engine is off before maintenance. Use blocks to prevent movement.
Engine Running Maintenance: If necessary, have at least two workers present, with one ready to shut down the engine. Avoid contact with rotating parts and ensure communication among workers.
Tool Usage: Use proper and undamaged tools to prevent accidents.
Handling High-Pressure Systems: Exercise caution with suspension cylinders and high-pressure hoses. Follow specific procedures to release pressure safely.
Noise and Air Safety: Use ear protection in loud environments and wear protective gear when using compressed air.
Welding and Grinding: Only qualified personnel should perform these tasks with appropriate safety equipment.
Hydraulic System Maintenance: Relieve system pressure before maintenance. Avoid open flames and handle leaks with care.
Fire and Explosion Prevention: Avoid smoking and open flames near fuel systems. Store flammable materials properly and ensure fire safety equipment is operational.
Regular Replacement of Safety Parts: Replace safety-related parts regularly to prevent deterioration and potential accidents.
Waste Disposal: Dispose of waste materials according to environmental regulations to prevent ecological harm.

Tire Safety Precautions:

Handling Tires: Use special tools and procedures for tire maintenance. Ensure proper inflation and check for defects regularly.
Storing Tires: Store tires securely to prevent unauthorized access and ensure they are stable and blocked on level ground.

Safety Instructions: Ensure the tire cannot roll or fall over if touched. Do not lay the tire on its side to prevent deformation and deterioration. If a tire falls, do not attempt to stop it; move away quickly.

System Function Overview: The document provides a detailed overview of the SRT95C Off-Highway Truck's system functions, including controls, instruments, and warning lights.

Controls and Instruments: The manual lists various controls and instruments such as the air outlet, instrument assembly, reversing monitor, emergency switch, hoist switch, and more. Each component is identified with a specific function to ensure proper operation.

Warning Lights: The document describes the function of various warning lights, including indicators for parking brake, body up, retarder, clearance lamp, dipped headlight, high beam, fog lamp, rear lighting lamp, engine stop, engine maintenance, engine warning, direction indicators, charge up, transmission overspeed, and check trans.

Instruments: Key instruments include the engine tachometer, travel speed meter, transmission oil temperature gauge, and fuel meter. Each instrument provides critical information about the truck's operation, such as engine speed, travel speed, oil temperature, and fuel level.

Additional Features: The manual also covers other features like the air conditioning system, door window glass operation, alternate exit, door catch, water cup bracket, and literature bag, ensuring comprehensive understanding and operation of the truck.

Engine Monitoring and Control: The document describes the engine water temperature and oil pressure gauges, both driven by the CAN bus. The gauges indicate normal and critical levels with a buzzer alert for high temperature or low pressure, which lasts 10 seconds and activates only once per energized condition.

Display System: The central monitor features a 5-inch color TFT display with a resolution of 640x480 pixels, showing engine, transmission, and vehicle status. The interface includes a start-up sequence and options to switch between work and system function interfaces using function keys.

Reversing Monitor System: This system includes a monitor for viewing the rear of the truck, activated automatically when the gear is in reverse or manually via a power button. It includes controls for contrast, brightness, volume, and mirror image settings.

Switches and Controls: The document details various switches including ignition, combination, economic power, parking brake, warning lamp, headlight, fog lamp, width lamp, and others. Each switch has specific functions for vehicle operation, such as starting the engine, controlling lights, and activating brakes.

Lever and Pedal Operations: The shift lever uses a CEC2 system for automatic gear shifting, with specific positions for different travel conditions. The hydraulic retarder handle provides continuous braking force, especially useful downhill. The foot pedal controls engine fuel proportionally, and the brake pedal is used for speed control.

Safety and Maintenance: The manual emphasizes the importance of proper switch usage and the need for caution when operating the vehicle's braking systems. It advises against frequent brake pedal use and highlights the role of the retarder in maintaining safe speeds.

Overview: This document is a technical manual for the SRT95C Off-Highway Truck, detailing various components and their operations, including the cigar lighter, horn, steering wheel, fuse system, safety pin, radio, and air conditioning system.

1. Cigar Lighter: The cigar lighter operates at DC 24V and is used for lighting cigars. It can also serve as a power supply for electrical equipment up to 240W (24Vx10A).

2. Horn: The horn is activated by pressing the intermediate button on the steering column.

3. Steering Wheel: The steering wheel is adjustable via a regulate lock and operates using hydraulic oil supplied by a piston pump. The direction and speed of the wheel's turn are controlled by the steering wheel's rotation.

4. Fuse System: The fuse system protects electrical equipment and prevents wire damage. It includes two fuse boxes with various fuses for different components, such as lamps, pumps, and the ignition key. Fuses should be replaced with the same capacity and model if damaged.

5. Safety Pin: Safety pins are used during truck maintenance to secure the dump body. They must be inserted on both sides during inspection and removed before lowering the body.

6. Radio: The radio includes various function buttons for power, mode selection, and station presets. It supports MP3, FM, and AUX modes, with options for adjusting sound settings and storing frequencies.

7. Air Conditioning System: The air conditioning system features an ON/OFF switch, wind speed control, temperature adjustment, and air outlet selection. It can operate in automatic or manual modes, with settings displayed on an LCD panel.

System Function Overview: This section of the manual provides detailed instructions on the operation and maintenance of the air conditioning system in the SRT95C Off-Highway Truck. It covers various modes such as heating, defrosting, and fresh air functions, along with precautions for operating the air conditioning system.

Heating Mode: In heating mode, the air conditioner can be switched from refrigeration to heating by pressing the Refrigeration/Heat key. The system enters forced heating mode when the temperature is set above 30°C or below 15°C. Wind speed can be adjusted using the wind speed key.

Defrosting Mode: The defrosting mode is activated by pressing the defrosting key. Wind speed can be adjusted, and the system has an automatic defrosting function that operates based on the temperature of the defrosting sensor.

Fresh Air Function: The system allows for external circulation to blow fresh air and internal circulation to stop fresh air intake.

A/C Operation Precautions: It is advised to start the air conditioning system with the engine running at low speed to avoid damage. The manual valve should be adjusted according to the season to control warm water flow. Regular ventilation is recommended, especially if smoking inside the cab.

Temperature Control: The recommended temperature setting is 5 or 6°C above the outdoor temperature for optimal comfort and health.

Inspection and Maintenance: Regular checks and maintenance of the air conditioning system are necessary, including running the engine at low speed monthly to lubricate components and checking refrigerant levels twice a year.

Door and Window Operations: Instructions are provided for opening and closing door window glass, using alternate exits in emergencies, and ensuring safety when operating doors on slopes.

Additional Features: The manual also describes the location and use of the water cup bracket and literature bag for storing manuals.

Operation Manual Overview: This document is a comprehensive operation, safety, and maintenance manual for the SRT95C Off-Highway Truck. It provides detailed instructions and guidelines for the safe and efficient operation of the vehicle.

1. Pre-Starting Inspection: Before starting the engine, a thorough walk-around check is necessary. This includes inspecting for loose nuts, bolts, oil, fuel, or coolant leaks, and checking the condition of the hydraulic system. Daily inspections should cover the body, frame, tires, cylinders, linkage, and hoses for any signs of wear or damage. Cleaning around the engine, battery, and radiator is also essential to prevent fire hazards.

2. Checks Before Starting: Before starting the engine each day, check the coolant level, ensuring it is at the correct level in the sight glass. The radiator cap should only be opened when the engine is cool to avoid burns. The dust indicator should be checked to ensure it does not indicate excessive pressure, which would require cleaning or replacing the air cleaner element.

3. Tire and Rim Inspection: Inspect tires for wear and damage, ensuring they are not used if tread grooves are less than 15% of a new tire or if there is significant damage. Rims should be checked for deformation, corrosion, and cracks, particularly in the side rings, lock rings, and rim flanges.

4. Oil Level Check: Check the engine oil level using the dipstick, ensuring it is between the H and L marks. If the oil level is low, add oil through the filler port. If it is too high, drain the excess oil and recheck the level.

5. Safety Warnings: Warnings are provided throughout the manual to emphasize the importance of removing flammable materials from high-temperature areas and ensuring all repairs are conducted by qualified personnel to prevent accidents and injuries.

Oil Level Checks: Ensure the oil filler cap is securely fastened. After engine operation, wait at least 15 minutes before checking the oil level. The machine should be on a horizontal surface for accurate measurement. If the oil level is low, add oil to the engine oil pan, transmission, and hydraulic oil tank as necessary.

Fuel Management: Check the fuel level using the gauge in the cab or on the fuel tank. Add fuel if necessary, ensuring no overflow occurs to prevent fire hazards. Drain water from the water separator before starting the engine.

Brake and Hydraulic Systems: Inspect the brake system and accumulator pressure. Ensure the hydraulic system has no leaks and hoses are intact. If abnormalities are found, contact a SANY distributor for repairs.

Electrical and Safety Checks: Verify the functionality of lamps, warning lights, switches, and meters. Check for damaged fuses or wires and ensure the battery area is free from flammable materials. Tighten wheel rim nuts to specified torque and check tire inflation pressure.

Driver Adjustments: Adjust the driver's seat for optimal control of the vehicle. Ensure the seatbelt is functional and properly fastened. Adjust the steering wheel and mirrors for clear visibility and comfort.

Pre-Operation Checks: Before starting the engine, ensure the parking brake is engaged, the shift lever is in neutral, and all control buttons are in the correct position. Verify that all instruments are functioning normally.

Engine Operation: Allow the engine to idle for 5 minutes after starting to warm up. Check for any operational issues such as abnormal noises or vibrations. In winter, additional precautions such as heating the engine body may be necessary.

Stopping the Engine: Set the gear shift to neutral and engage the parking brake. Allow the engine to idle for 5 minutes before turning it off to prevent damage. Conduct a post-operation check for any leaks or debris.

Operating Machine:

Move Machine Forward: Ensure no warnings on the monitor, fasten seat belt, and check the float button and parking brake. Release the parking brake and shift lever to the desired position before accelerating.
Move Machine in Reverse: Shift to 'R' and ensure the dump body is lowered. Exercise caution due to blind spots.
Stopping Machine: For normal stops, release the accelerator and apply the brake. In emergencies, use the retarder and emergency brake.

Shifting Operation:

Automatic Transmission: The machine shifts automatically based on speed. Lower the dump body for optimal performance.
Shifting Up/Down: Accelerate to shift up; release the pedal to shift down. Avoid sudden shifts to prevent shocks.

Traveling Downhill:

Use the transmission retarder to maintain a safe speed. Avoid using the brake pedal unless necessary to prevent overheating.

Retarder Operation:

Utilize the transmission and rear disk brake retarders for controlled descent. Monitor oil temperatures to avoid overheating.

Steering:

Adjust the steering wheel as needed. Reduce speed before curves to maintain control.

Loading Operations:

Load sand or soil before large rocks to cushion impact. Ensure even distribution of load.

Dump Operations:

Follow flagman signals when dumping. Avoid loading while the dump body is raised.

Operation Procedures: 1. The dump body operation is controlled by raise, float, and lower buttons. The engine speed should be maintained at 1000rpm for stability during these operations. 2. When the dump body reaches the desired position, releasing the raise button will stop it. Further raising requires pressing the raise button again. 3. To lower the dump body, set the lower button to the LOWER position. Once it reaches the second stage cylinder, pressing the float button allows it to descend under its own weight.

Precautions for Operation: 1. Exercise caution on slippery surfaces and avoid overloading the front of the dump body. 2. If the engine stops while traveling, shift to NEUTRAL and restart the engine. 3. On slippery roads, downshift to prevent wheel locking.

Parking Instructions: 1. Stop the machine using the brake pedal and shift to NEUTRAL. 2. Apply the parking brake and avoid sudden stops. 3. Park on firm, level ground and use blocks if parking on a slope. 4. Check engine coolant temperature, oil pressure, and fuel level before stopping the engine.

Tire Handling and Maintenance: 1. Replace defective tires with new ones if they show significant wear or damage. 2. Use the TKPH rating to ensure tires are not overloaded or overheated. 3. For long-distance travel, check tire inflation and avoid reducing pressure while traveling.

Travel Road Maintenance: 1. Design roads for one-way travel or provide passing places. 2. Ensure curves have large radii and are well-lit. 3. Maintain roads regularly to remove obstacles and prevent dust.

Transportation and Lifting: 1. Disassemble the machine for transport and secure it on a trailer. 2. Use appropriate lifting equipment and ensure the machine is balanced during lifting operations.

Cold Weather Operation: 1. Use low viscosity fuel and lubricants in cold temperatures. 2. Ensure the battery is fully charged to prevent freezing. 3. Remove mud and water from the machine to prevent freezing and park on dry ground.

Long-term Storage Procedures:

Before Storage: Clean and dry all parts, store indoors if possible, fill the fuel tank to prevent rust, lubricate and change oil, coat hydraulic cylinder rods with grease, disconnect battery, apply parking brake, set tire pressure, and fill coolant to prevent rust.
During Storage: Operate the machine monthly to maintain lubrication and charge the battery. Remove grease from hydraulic rods before operation.
After Storage: Consult a distributor if rust-prevention was not performed. Clean hydraulic rods, lubricate all points, check for water in oil, and verify oil and water levels before use. Start with a slow travel speed to ensure proper operation.

Maintenance Overview:

Safety Instructions: Includes an overview, personnel requirements, risks, and precautions before and during maintenance.
Handling Fluids: Guidelines for oil, hydraulic oil, fuel, coolant, and grease management, including filter and electrical system maintenance.
Lubrication: Details on manual and automatic lubrication systems, recommended greases, and lubrication procedures.
Wear Parts: Lists wear parts and provides recommendations for fuel, coolant, and lubricants.
Service Procedures: Initial service intervals at 150, 250, and 2000 hours, and tasks required when necessary, such as cleaning systems, checking fluid levels, and inspecting tires.

Hydraulic Oil: The hydraulic oil is crucial for energy transfer, lubrication, and cooling in the hydraulic system. It must be clean to ensure system performance and longevity. The recommended oil is CALTEX 414, and cleanliness should not exceed NAS9. Replace hydraulic oil every 250 hours initially, then every 2000 hours.

Fuel: To prevent condensation, fill the fuel tank after daily use. Use clean fuel to avoid pump issues. Drain sediment and water from the tank before starting the engine. Use fuel suitable for the ambient temperature to prevent congealing or viscosity issues.

Coolant: Coolant prevents corrosion and freezing. Use L-35 coolant for its superior properties. Dilute with soft water to avoid scaling. Maintain coolant levels to prevent overheating and corrosion.

Grease: Grease prevents joint seizure and noise. Use recommended grease and adhere to change intervals. Clean old grease to avoid wear from dirt.

Oil and Fuel Storage: Store indoors to prevent contamination. Use a first-in, first-out system to maintain quality.

Filters: Filters are vital for preventing impurities. Replace them regularly and use genuine SANY filters. Do not reuse filters.

Electrical System Maintenance: Prevent electrical short circuits by avoiding water exposure. Only install SANY-approved components.

Lubrication: Manual and automatic lubrication systems are used. Manual lubrication involves specific points on the truck, while automatic systems cover 31 points. Use EP NLGI 2 and EP NLGI 0 grease.

Wear Parts: Replace wear parts like filters and air cleaners periodically. Use genuine SANY parts for replacements.

Recommended Fuel, Coolant, and Lubricant: Use specified oils and lubricants based on ambient temperature. Follow guidelines for oil changes based on sulfur content in fuel.

Selection of Lubricating Grease Material: Use multipurpose extreme pressure lithium grease, considering ambient temperature and specific applications.

Oil Recommendations: Cummins engine company advises using multi-grade viscosity oil suitable for ambient temperatures, adhering to API grade specifications. Preheating is crucial in low temperatures to prevent reduced transmission service life. Transmission hydraulic oil should meet Allison C-4 requirements.

Service Capacities: The document provides a detailed table of service capacities for various components, including engine crankcase, transmission, hydraulic systems, cooling system, and fuel tank, with measurements in liters and US gallons.

Standard Tightening Torques: Proper tightening of threaded connections is essential for system reliability and safety. Tables provide recommended torque values for metric and imperial thread specifications, emphasizing the importance of lubricated threads and allowing a ±10% variation in tightening load.

Safety Critical Parts: Regular maintenance and replacement of safety-critical parts are necessary to ensure machine safety and performance. A table lists parts like fuel hoses and seat belts with specified replacement intervals.

Service Procedures: Detailed procedures for replacing filters, checking and cleaning components, and changing oils are outlined for various service intervals (e.g., every 250, 1000, 1200, and 1500 hours).

Initial and Periodic Maintenance: Specific maintenance tasks are required after the first 150 and 250 hours of operation, including checking wheel bearings and cleaning the cooling system. Safety warnings are provided for handling hot engine coolant.

Maintenance Procedures for SRT95C Off-Highway Truck:

1. Cooling System Maintenance: Clean the inside of the cooling system every 250 hours or change the antifreeze coolant, whichever comes sooner. Every 2 years or every 4000 hours, whichever comes sooner, is also recommended. Use only the recommended coolant to prevent engine corrosion and freezing. Follow a detailed procedure for draining and refilling the coolant, ensuring the removal of air from the system.
2. Window Cleaning Fluid: Regularly check and fill the window cleaning fluid, ensuring no dust contaminates the fluid. Use antifreeze cleaning fluid in freezing temperatures.
3. Condenser Cleaning: Clean the condenser weekly using compressed air to maintain air conditioner performance.
4. Coolant Level Check: Regularly check the coolant level and ensure no bubbles are present when the engine is running.
5. Dump Body Inspection: Inspect for cracks and damage, and make necessary repairs. Check suspension dimensions for both empty and loaded conditions.
6. Brake System Bleeding: Bleed both front and rear brakes to remove air from the hydraulic system, ensuring optimal braking performance.
7. Tire Selection and Inspection: Select tires based on usage conditions and machine weight. Regularly check tire inflation pressure and inspect for damage.
8. Lubrication Sample Extraction: Extract lubrication samples from the main reducer, differential assembly case, and final drive for analysis.
9. Pre-Start Checks: Conduct a series of checks before starting, including coolant, oil levels, brake system, and tire pressure.
10. Daily and Periodic Maintenance: Perform daily checks on lubrication, electric systems, engine, fuel system, cooling system, transmission, suspension, tires, hydraulic system, and body. Every 50 hours, perform lubrication tasks using a grease pump on specified components.

Maintenance Overview: This document provides detailed maintenance procedures for the SRT95C Off-Highway Truck, focusing on safety, operation, and maintenance tasks. Key maintenance activities are outlined with specific instructions and warnings to ensure safe and effective operation.

Hoist and Steering Components: Maintenance involves greasing hoist cylinder pins, front suspension, steering cylinder pins, and steering linkage. Grease should be added until it overflows the spline and bearing portions.

250-Hour Service Tasks:

Oil Checks: Check oil levels in the main reducer, differential assembly case, and final drive case. Add oil if necessary, ensuring safety precautions are followed to prevent burns from hot oil.
Rear Axle Plug: Clean and check the rear axle plug for sludge and dust.
PTO Liquid Level: Check and refill as required.
Transmission Breather: Clean the breather to remove mud and dirt.
Water Filter: Replace the water filter using a filter wrench, ensuring no leaks after installation.
Lubricating Oil: Change the oil in the oil pan and replace the lubricating oil filter cartridge.
Fuel Filter and Water Separator: Replace these components, ensuring no fuel leaks post-installation.
Air Cleaner: Check, clean, or replace the air cleaner elements based on the dust indicator reading.

Additional Maintenance Checks:

Fan and Drive Belt: Inspect for damage and ensure proper tension.
Drive Shaft: Check for looseness or play and contact a distributor for repairs if needed.
Air Conditioner: Regularly start the compressor and check the coolant level.
Frame Inspection: Wash and inspect the frame for damage, especially in colored areas.
Service Brake: Perform functional checks to ensure the service brake is operational.

Safety Warnings: Throughout the document, numerous warnings emphasize the importance of safety, such as avoiding burns from hot oil, ensuring secure footing during maintenance, and preventing dust inhalation during air cleaner maintenance.

Maintenance Procedures for SRT95C Off-Highway Truck:

1. Parking Brake Check: Ensure the area around the truck is clear. Position the truck on level ground, depress the service brake, release the parking and emergency brakes, shift to 'D', apply the parking brake, release the service brake, and accelerate to 1350 r/min. If the truck does not move, the parking brake is functional. If issues arise, contact SANYI MINING.
2. Emergency Brake Check: Similar to the parking brake check, but apply the emergency brake instead. Follow the same steps to ensure functionality.
3. Filter Element Replacement (Every 1000 Hours): Replace hoist oil return, steering oil return, steering oil pipe, braking control valve group, and breath valve filter elements. Ensure O-rings are protected and replaced if damaged. Follow torque specifications for reassembly.
4. Hydraulic System Pressure Detection: Check pressures in hoist, steering, and brake systems. Ensure accumulator pre-charge pressures are correct before testing.
5. Transmission Oil and Filter Change (Every 1200 Hours): Drain and replace transmission oil and filter. Perform cold and hot oil level checks to ensure proper levels for operation.
6. Power Take-Off (PTO) Oil Change: Drain and refill PTO oil, ensuring all plugs are securely tightened.
7. Drive Shaft Bolt Torque Check: Check and adjust torque on front and rear drive shaft bolts after initial operation and periodically thereafter.
8. Breather Assembly Cleaning: Remove and clean the breather assembly with diesel oil or detergent, then reinstall securely.
9. Main Reducer and Differential Assembly Oil Change (Every 1500 Hours): Drain and refill oil in the main reducer, differential assembly, and final drive case. Ensure oil levels are correct.
10. Fuel Tank Cleaning (Every 2000 Hours): Drain and clean the fuel tank with diesel oil, then refill with clean fuel. Ensure all components are securely reinstalled.
11. Hydraulic Oil Replacement: Use a filter oil tanker or follow specific procedures to refill hydraulic oil, ensuring no contamination occurs.
12. Hoist, Cooler, and Oil Return Filter Element Replacement: Replace these filter elements, ensuring O-rings are intact and torque specifications are followed.

Maintenance Schedule:

Every 4000 Hours Service: Inspect the water pump for leaks and the vibration damper for fluid loss or damage. Check and adjust wheel bearings, ensuring safety precautions are followed.
Every 6000 Hours Service: Replace front friction components when wear reaches 5.16mm. Ensure the truck is on level ground and brake oil temperature is below 40°C during checks.
Every 10000 Hours Service: Contact Cummins service engineer for engine maintenance and potential overhauls.

Troubleshooting Guide:

Preparation: Ensure the machine is stopped on level ground with the key switch off. Coordinate with others if working in a team and allow the engine to cool before removing the radiator cap.
Procedure: Gather information about the failure, including symptoms and conditions under which it occurred. Avoid unnecessary disassembly and follow a structured troubleshooting process.
Common Issues: Check hydraulic oil levels, system leaks, and ensure correct operation of handles. Use the common fault table to narrow down issues.

Troubleshooting Procedures:

Identify potential failure locations by consulting the troubleshooting section of the manual.
Prepare necessary tools such as a T-connector and hydraulic gauge, and refer to the Parts Book for replacement parts.
Gather information from the operator about the failure, including any abnormalities before the failure and actions taken during the failure.
Verify the existence of the failure symptom by operating the machine.
Develop a service plan, deciding whether repairs will be conducted on-site or in a workshop.

Safety Precautions:

Ensure power is off before disconnecting or connecting connectors.
Check all connectors are properly plugged in and reconnect them if necessary.
Handle electric equipment carefully, checking for changes in instrument readings that may indicate contact failure.

Hydraulic Equipment Handling:

Avoid working in dusty or adverse weather conditions to prevent contamination.
Perform disassembly and maintenance in a dustproof workshop to ensure performance post-repair.
Use clean equipment when filling hydraulic oil and change oil when warm to facilitate sludge removal.
Conduct flushing operations after maintenance to remove contaminants.

Engine Troubleshooting:

For engine start failures, check electrical components such as the battery, key switch, and wiring.
Address overheating by checking coolant levels, fan belts, and radiator cleanliness.
Low lubricating oil pressure may require adding oil, checking for leaks, or replacing filters.
For smoke issues, inspect fuel injectors and air cleaners.

Electrical System Faults:

Diagnose electrical faults by checking wire harnesses, sensors, and circuits for faults or disconnections.
Use the display monitor to identify fault codes and refer to the manual for specific code explanations.

Overview: This document is a technical manual for the SRT95C Off-Highway Truck, focusing on troubleshooting, safety, operation, and maintenance procedures. It includes detailed fault codes, descriptions, and corrective actions for various systems within the vehicle.

1. Fault Codes and Inhibited Operations:

ECU Input Voltage: Low and high voltage issues are indicated, with DNS (Do Not Shift) as a common response.
Sensor Failures: Throttle position, engine speed, and turbine speed sensor failures are addressed with default value usage or locking in current range.
Shift Selector Faults: Issues with primary and secondary shift selectors are noted, often resulting in holding the last valid direction or inhibiting mode changes.
Temperature and Speed Sensor Issues: Sump fluid temperature and output speed sensor faults are highlighted, with actions like DNS and locking in range.
Solenoid Failures: Various solenoid failures are listed, with DNS and SOL OFF (solenoid off) as typical responses.

2. Vehicle Monitoring System Fault Codes:

Includes codes for high rear brake oil temperature, transmission oil filter blockage, and low transmission oil pressure, among others. Each fault requires specific checks or actions, such as stopping the vehicle or reducing speed.

3. Battery Maintenance:

Removal and Installation: Guidelines for safely removing and installing the battery, emphasizing the order of connecting and disconnecting terminals to prevent sparks.
Charging: Instructions for charging the battery safely, including voltage and current specifications to avoid overheating or explosions.

4. Auxiliary Cable Usage:

Details on connecting and disconnecting auxiliary cables for engine starting, with warnings about avoiding sparks and ensuring correct connections.

5. Hydraulic System Troubleshooting:

Steering System: Issues like slow steering, drift, and free-wheeling are addressed with remedies such as replacing pumps or correcting oil supply problems.
Hoist System: Troubles like high noise and no system pressure are discussed, with solutions including adjusting valve pressures and replacing filters.
Brake System: Inadequate braking and non-releasing brakes are covered, with checks on system pressure and valve operations recommended.

Troubleshooting and Maintenance Overview for SRT95C Off-Highway Truck:

1. Brake System Issues:
- Parking/Emergency Brakes: Issues such as electromagnetic coil damage, solenoid valve damage, and oil leakage can prevent brakes from applying. Remedies include repairing or replacing damaged components and checking for restrictions in lines.
- Front Brake Disc Overheating: Caused by foot pedal valve lock-up or pipeline blockages. Solutions involve checking and cleaning valves or replacing them as needed.
- Rear Brakes Not Releasing: Potential causes include foot pedal valve damage and proportional pressure valve issues. Repair or replacement is recommended.
2. Rear Axle and Lubrication Issues:
- Noise and Vibration: Insufficient lubrication or damaged bearings and gears can cause noise. Solutions include checking oil levels, replacing bearings, and adjusting gear alignments.
- Lubricant Loss: Caused by worn seals or loose components. Remedies include replacing seals and tightening nuts and bolts.
3. Air Conditioning System Faults:
- Discontinuous Refrigeration: Issues such as ice-blocking, poor contact in switches, and relay problems. Solutions involve replacing components and performing system checks.
- Insufficient Heating: Caused by blocked water pipes or valve issues. Maintenance or replacement of components is necessary.
- No Refrigeration: Potential causes include compressor clutch issues and refrigerant leaks. Solutions include checking connections and replenishing refrigerants.
4. General Recommendations:
- Regular maintenance and checks are essential to prevent and address issues promptly.
- Ensure proper lubrication and component alignment to avoid mechanical failures.
- Address electrical and control system issues to maintain operational efficiency.

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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SRT95C 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 Off-Highway 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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Table of Contents SRT95C Off-Highway Truck II Safety, Operation and Maintenance Manual ^SANYI

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f^SANYi Safety, Operation and Maintenance Manual III

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IV Safety, Operation and Maintenance Manual & SANYI

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f^SANYi Safety, Operation and Maintenance Manual V

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Table of Contents SRT95C Off-Highway Truck VI Safety, Operation and Maintenance Manual & SANYI

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Safety, Operation and Maintenance Manual

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SANYI Safety, Operation and Maintenance Manual IX

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Safety, Operation and Maintenance Manual

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f^sANYi Safety, Operation and Maintenance Manual 1-1

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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. Note: 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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