SANY SRT45 Guide

Off-Highway Truck
Safety,Operation and Maintenance Manual
Quality Changes the World
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www.sanyhe.com
ADD: Sany Industry Town,Dongcheng Avenue,Economic and Technological Development
Zone,Kunshan,Jiangsu.
SANY MINING EQUIPMENT CO.,LTD
Tel:[phone] Fax: [phone]
E-mail:[e-mail]
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Safety, Operation and Maintenance Manual
SRT45 Off-Highway Truck
SRT45 Off-Highway Truck
Safety,Operation and Maintenance Manual
WARNING
Read and follow the safety precautions and instructions in this manual and on the mac-
hine decals. Failure to do can cause serious injury, death or property damage. Keep this
manual with the machine for reading and future reference.
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Safety, Operation and Maintenance Manual
SRT45Off-Highway Truck
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: [phone]
Fax: [phone]
© 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 presented here. Sany Group assumes no liability. For
more information, Contact Sany Group.
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Safety, Operation and Maintenance Manual
SRT45 Off-Highway Truck
Exemption Clauses
SPECIFIC DECLARATION
Mining truck is a critical earth/rock moving machine with high trafc 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 modication 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.), wars and other force majeure.
●Sany cannot anticipate all potential hazards that may occur on work site. Therefore, dump
truck operator and owner shall attach great importance to the issue of safety.
●Local government may impose higher standards for use of a dump truck. If local regulations
have conicts to the safety rules described herein, whichever the stricter applies.
Obligations of Sany
●Offer quality truck along with correct information.
●Abide by after-sales service commitment and keep a record for all maintenance work and
repair work.
●Provide training for truck operators and service persons as required.
Obligations of owners or authorized persons
●Only trained personnel who fully understand the Parts Book and the Safety, Operation and
Maintenance Manual are allowed to operate and service the dump truck.
●Make sure that the truck operator and service person are qualied for this job and know their
responsibilities.
●Regularly inspect the safety awareness of related persons at work.
●Should any fault threatening safety occurs, shut down the truck immediately.
●Sany service personnel have the right to carry out safety inspection to the truck when
required.
●Besides the checks specified by Sany, local laws and regulations on truck shall also be
observed.
●Ensure timely maintenance and repair of the dump truck.
●Make a detailed plan for proper use of the dump truck.
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Safety, Operation and Maintenance Manual
SRT45Off-Highway Truck
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.
Obligations of manager
●The operator must have been trained and fully understand the provision of the Safety,
Operation
●and Maintenance Manual. The operator must be healthy and licensed. Otherwise he/she is
not allowed to operate the dump truck.
●Make sure that the operator has good sense, cooperation awareness and psychological
quality, or he/she is not allowed to operate or service the dump truck.
●Make sure that the signal person has good visibility and hearing ability, knows standard
command signals and can give signals clearly and correctly. The signal person shall also
have enough experience to recognize hazardous factors and timely tell the operator to avoid
the hazards.
●Make sure that the assistant person can positively identify the model and working condition
of dump truck and choose a suitable dump truck.
●Each operating personnel of a project shall bear certain safety responsibilities and is required
to timely report unsafe factors to the supervisor.
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Table of Contents
Safety, Operation and Maintenance Manual
I
SRT45 Off-Highway Truck
Table of Contents
1 Foreword
1.1 Overview .................................................................................................................. 1-1
1.2 Safety Information .................................................................................................. 1-3
1.3 Page Numbers ......................................................................................................... 1-5
1.4 Regulation of Use .................................................................................................... 1-5
1.4.1 Machine applications ...................................................................................... 1-5
1.4.2 Directions of machine ..................................................................................... 1-5
1.5 Breaking in a New Machine ..................................................................................... 1-6
1.6 Visibility from Operator's Seat ................................................................................. 1-7
1.7 Machine Information ................................................................................................ 1-9
1.7.1 Product identification plate ............................................................................ 1-9
1.7.2 Engine identification plate ............................................................................ 1-10
1.7.3 Display screen ...............................................................................................1-11
1.7.4Table for serial number and distributor information ........................................1-11
2 Safety
2.1 Safety Labels ........................................................................................................... 2-5
2.1.1 Position for attaching safety labels ................................................................ 2-5
2.1.2 Safety labels ................................................................................................... 2-6
2.2 General Precautions .............................................................................................. 2-12
2.2.1 Safety rules .................................................................................................. 2-12
2.2.2 Abnormalities ................................................................................................ 2-12
2.2.3 Personal protective equipment ..................................................................... 2-12
2.2.4 Fire extinguisher and first aid kit .................................................................. 2-13
2.2.5 Safety equipment ......................................................................................... 2-14
2.2.6 Cleaning your machine ................................................................................ 2-14
2.2.7 Keeping the cab clean .................................................................................. 2-15
2.2.8 Precautions when leaving the machine ........................................................ 2-15
2.2.9 Handholds and steps ................................................................................... 2-16
2.2.10 Preventing burns ........................................................................................ 2-17
2.2.10.1 Hot coolant .......................................................................................... 2-17
2.2.10.2 Hot oil .................................................................................................. 2-17
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Table of Contents
Safety, Operation and Maintenance Manual
II
SRT45 Off-Highway Truck
2.2.11 Preventing fire and explosion ..................................................................... 2-18
2.2.11.1 Fire caused by fuel or oils .................................................................... 2-18
2.2.11.2 Fire caused by flammable materials .................................................... 2-19
2.2.11.3 Fire caused by electric lines ................................................................ 2-19
2.2.11.4 Fire caused by hydraulic lines ............................................................ 2-19
2.2.11.5 Fire caused by illumination equipment ............................................... 2-20
2.2.12 In the event of fire ...................................................................................... 2-20
2.2.13 Windshield cleaning detergent ................................................................... 2-20
2.2.14 Precautions when using ROPS(Roll over protective structure) .................. 2-21
2.2.15 Attachment installation ............................................................................... 2-21
2.2.16 Cab windows glasses ................................................................................. 2-22
2.2.17 Unauthorized modification .......................................................................... 2-22
2.2.18 Examination and confirmation of worksite ................................................. 2-22
2.2.19 Operation on soft ground ........................................................................... 2-23
2.2.20 Overhead power cables ............................................................................. 2-24
2.2.21 Alternate exit .............................................................................................. 2-25
2.2.22 Ensure good visibilty .................................................................................. 2-25
2.2.23 Asbestos hazard ......................................................................................... 2-26
2.3 Safe Operation Precautions .................................................................................. 2-27
2.3.1 Safe starting ................................................................................................. 2-27
2.3.1.1 Safe mounting ....................................................................................... 2-27
2.3.1.2 Seat adjustment .................................................................................... 2-27
2.3.1.3 Seat belt ................................................................................................ 2-28
2.3.1.4 Before starting the engine ..................................................................... 2-28
2.3.1.5 Engine starting rules .............................................................................. 2-29
2.3.1.6 Starting engine in cold season .............................................................. 2-29
2.3.1.7 Engine starting aid ................................................................................. 2-30
2.3.1.8 After starting the engine ........................................................................ 2-31
2.3.2 Operation ..................................................................................................... 2-31
2.3.2.1 Inspection before operation ................................................................... 2-31
2.3.2.2 Prior-operation precautions ................................................................... 2-31
2.3.2.3 Precautions when traveling ................................................................... 2-32
2.3.2.4 Precautions when traveling on slopes ................................................... 2-34
2.3.2.5 Precautions when operating .................................................................. 2-34
2.3.2.6 Precautions for accumulated snow, and ice .......................................... 2-34
2.3.2.7 Parking the machine .............................................................................. 2-35
2.3.2.8 Preparing the machine .......................................................................... 2-36
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Table of Contents
Safety, Operation and Maintenance Manual
III
SRT45 Off-Highway Truck
2.3.3 Transportation .............................................................................................. 2-37
2.3.3.1 Loading and unloading the machine ..................................................... 2-37
2.3.3.2 Transporting the machine ...................................................................... 2-38
2.3.4 Battery ......................................................................................................... 2-39
2.3.5 Towing .......................................................................................................... 2-41
2.4 Precautions for Maintenance ................................................................................. 2-42
2.4.1 Lock-out and tag-out .................................................................................... 2-42
2.4.2 Select a working area .................................................................................. 2-42
2.4.3 Prior-maintenance precautions .................................................................... 2-42
2.4.4 Preparing yourself ........................................................................................ 2-43
2.4.5 Stop engine before carrying out maintenance ............................................. 2-44
2.4.6 Maintenance with engine running ................................................................ 2-45
2.4.7 Using proper tools ........................................................................................ 2-46
2.4.8 Handling suspension cylinder ...................................................................... 2-46
2.4.9 Working under the machine ......................................................................... 2-46
2.4.10 Work in loud noise ..................................................................................... 2-47
2.4.11 Use compressed air ................................................................................... 2-47
2.4.12 Use a hammer ........................................................................................... 2-47
2.4.13 Welding operation ...................................................................................... 2-47
2.4.14 Precautions with high-pressure oil ............................................................. 2-48
2.4.15 High-pressure hoses .................................................................................. 2-49
2.4.16 Hot cooling system .................................................................................... 2-49
2.4.17 Air-conditioning system .............................................................................. 2-50
2.4.18 High voltage precautions ........................................................................... 2-50
2.4.19 Accumulator ............................................................................................... 2-51
2.4.20 Avoiding re and explosion ........................................................................ 2-51
2.4.21 Regular replacement of safetyrelated parts ............................................... 2-52
2.4.22 Maintenance operation .............................................................................. 2-52
2.4.23 Proper disposal of wastes .......................................................................... 2-53
2.5 Precautions With Tires ........................................................................................... 2-54
2.5.1 Handling tires ............................................................................................... 2-54
2.5.2 Precautions when storing tire ...................................................................... 2-55
3 CONTROLS AND OPERATING 3-1
3.1 Controls and Instruments ........................................................................................ 3-1
3.2 Indicator ................................................................................................................... 3-2
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Table of Contents
Safety, Operation and Maintenance Manual
IV
SRT45 Off-Highway Truck
3.3 Instruments .............................................................................................................. 3-4
3.4 Reversing monitor system ....................................................................................... 3-6
3.5 Switches .................................................................................................................. 3-7
3.6 Combined switch ..................................................................................................... 3-8
3.7 Air Conditioner Control Panel .................................................................................. 3-9
3.8 Driver Seat ..............................................................................................................3-11
3.9 Seat Belt .................................................................................................................3-11
3.10 Truck Controls ..................................................................................................... 3-12
3.10.1 Braking ....................................................................................................... 3-12
3.10.2 Service brake ............................................................................................. 3-12
3.10.3 Parking brake ............................................................................................. 3-13
3.10.4 Emergency brake ...................................................................................... 3-13
3.10.5 Retarder ..................................................................................................... 3-13
3.11 Engine ............................................................................................................. 3-15
3.11.1 Accelerator pedal ....................................................................................... 3-15
3.11.2 QUANTUM electronic fuel system ............................................................. 3-15
3.11.3 Quantum electronic fuel system - description ............................................ 3-17
3.11.4 QUANTUM electronic fuel system - operation .......................................... 3-18
3.11.5 Electronic fuel system diagnostic codes .................................................... 3-20
3.12 Steering .......................................................................................................... 3-24
3.13 Transmission ................................................................................................ 3-25
3.13.1 CEC2 Shift System .................................................................................... 3-25
3.13.2 Introduction and operation ......................................................................... 3-28
3.13.3 General Transmission Operation ............................................................... 3-32
3.13.4 Retrieving Diagnostic Codes ..................................................................... 3-33
3.13.5 Clearing Diagnostic Codes ........................................................................ 3-33
3.14 Body Control ........................................................................................................ 3-38
3.15 The common fault code of vehicle monitor system ............................................. 3-40
4 OPERATING THE TRUCK 4-1
4.1 Pre-Starting Inspection ......................................................................................... 4-1
4.2 Check of each component .................................................................................... 4-3
4.3 Engine Operation ................................................................................................... 4-6
4.4 Start the Engine ..................................................................................................... 4-8
4.5 Starting the Engine with Jumper Cables ........................................................... 4-10
4.6 Pre-Operating Checks ..........................................................................................4-11
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