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SRT45 Off-Highway Truck

4-11

Safety, Operation and Maintenance Manual

4.6 Pre-Operating Checks

Make  sure  all  cab  glass,  mirrors  and  lights
are  clean.  Test  all  controls  to  ensure  they
are  functioning  properly.  Select  'REVERSE'
momentarily on the transmission shift selector
to make sure the reverse alarm sounds.
1. Transmission  -  Hot  Oil  Level  - The  parking
brake  must  be  applied  and  the  road  wheels
securely  blocked  while  carrying  out  this
check.  With  the  engine  idling,  transmission
in  'NEUTRAL'  and  at  normal  operating
temperature,  the  top  of  the  oil  column  should
be  visible  in  the  sight  gauge. Add  oil  if  low.  If
the top of the column is above the sight gauge,
the  transmission  is  overfull  and  oil  should  be
drained.
2.  Body  and  Rear  Brake  Cooling  Hydraulic
Tank - Hot Oil Level - Operate the body hoist
cylinders  to  their  fully-extended  positions  to
charge  all  cylinders  and  lines  then  lower  the
body. With the engine running, and body fully
lowered,  the  oil  level  should  show  in  the  top
sight gauge. Add oil if low. Under all conditions
the bottom sight gauge should show full.
3.  Steering  and  Braking  Hydraulic  Tank  -
Hot  Oil  Level  -  With  the  engine  running,  oil
at  operating  temperature  and  accumulators
charged,  oil  must  be  between  the  top  and
middle  sight  gauges.  Shut  down  the  engine
and  operate  the  steering  left  and  right  to
discharge  steering  accumulator.  Operate
treadle  valve  continuously  to  discharge
braking  accumulators.  Oil  should  show  in  the
top sight gauge.

Oil level

Fig 4.20

Operating the Truck

Courtesy of Machine.Market

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Summary of Contents for SRT45

Page 1: ...Off Highway Truck Safety Operation and Maintenance Manual Quality Changes the World Courtesy of Machine Market ...

Page 2: ...D Sany Industry Town Dongcheng Avenue Economic and Technological Development Zone Kunshan Jiangsu SANY MINING EQUIPMENT CO LTD Tel 0086 10 60738666 Fax 0086 10 60738831 E mail crd sany com cn Courtesy of Machine Market ...

Page 3: ...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 Courtesy of Machine Market ...

Page 4: ...31 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 ...

Page 5: ... regulations have conflicts 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 personne...

Page 6: ...stand 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 s...

Page 7: ...te 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 Cl...

Page 8: ... 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 c...

Page 9: ...pension 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 f...

Page 10: ...tum 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...

Page 11: ...oading 6 1 6 3 In Case of Trouble 6 2 7 MOVING DISABLED TRUCK 7 1 7 1 Moving Disabled Truck 7 1 8 LUBRICATION AND SERVICING 8 1 8 1 Safety Precautions 8 1 8 2 Lubrication and Maintenance 8 2 8 3 Other Maintenance 8 8 8 4 Service Capacity 8 12 8 5 Recommended Lubricants 8 13 8 6 Maintenance Procedures 8 15 8 6 1 Daily 10hrs maintenance inspection form 8 15 8 6 2 Maintenance inspection form for 150h...

Page 12: ... Maintenance inspection form for 2400hrs 8 71 8 6 24 Maintenance inspection form for 2500hrs 8 73 8 6 25 Maintenance inspection form for 2550hrs 8 77 8 6 26 Maintenance inspection form for 2700hrs 8 79 8 6 27 Maintenance inspection form for 2750hrs 8 81 8 6 28 Maintenance inspection form for 2850hrs 8 83 8 6 29 Maintenance inspection form for 3000hrs 8 85 8 6 30 Maintenance inspection form for 315...

Page 13: ...Foreword Safety Operation and Maintenance Manual VII SRT45 Off Highway Truck 9 TECHNICAL DATA 9 1 Courtesy of Machine Market ...

Page 14: ...Foreword Safety Operation and Maintenance Manual VIII SRT45 Off Highway Truck B L A N K P A G E Courtesy of Machine Market ...

Page 15: ... fundamental safety rules for the operation and maintenance of machines Read understand and follow all precautions and warnings in this manual and on the machine before performing operation and maintenance Failure to do so may result in serious injury or death SANY cannot predict every circumstance that might involve a potential hazard when the machine is used Therefore the safety messages in this...

Page 16: ...lected in this manual Consult SANY Mining Equipment Co Ltd or your SANY distributor for the latest available information concerning your machine or with questions regarding information contained in this manual The numbers in the illustrations correspond to the numbers in in the text For example 1 The letters in the illustrations correspond to the letters in in the text For example A SANY delivers ...

Page 17: ...ether with notes such as DANGER WARING CAUTION it indicate the degree of hazard It indicates an imminently h a z a r d o u s s i t u a t i o n which if not avoided will result in death or serious injury It indicates a potentially h a z a r d o u s s i t u a t i o n which if not avoided could result in death or serious injury It indicates a potentially h a z a r d o u s s i t u a t i o n which if n...

Page 18: ...afety decals on the machine are used to alert operator or maintenance personnel that potential hazards might be involved when the machine is being operated or serviced We use textual and graphical or combined decals to indicate a hazardous situation and how to avoid such situation a Textual safety decals Fig 1 2 1 is an example of textual safety decals b Graphical safety decals Graphical safety de...

Page 19: ...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 is always complete and up to date Keep all pages inside its binder if shipped loose leaf I n s e r t S a n y r e p l a c e m e n t p a g e s mmediately into the appropriate book destroy old versions of those pages 1 3 2 Docum...

Page 20: ... the direction of travel front of the machine 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 hours for a new machine During the...

Page 21: ... immediate area The visibility of this machine in the area 1 m from the outside surface of the machine at a height of 1 5 m is shown in the diagram below The hatched area A shows the area where the view is blocked by part of the machine when mirrors or other aids to visibility are installed as standard Please be fully aware that there are places that cannot be seen when operating the machine 1000 ...

Page 22: ...of 24 m from the machine is as shown in the diagram below The hatched areas B show the areas where the view is blocked when mirrors or other aids to visibility are installed as standard Please be fully aware that there are places that cannot be seen when operating the machine B B B B B B B B Fig 1 7 2 Courtesy of Machine Market ...

Page 23: ...that your Sany distributor will need when ordering replacement parts or requiring assistance for your equipment It is a good idea to record this information in this manual for future use Below are the locations of the data plates 1 8 1 Product identification plate It is located on the left front end of the frame Fig 1 8 1 left front end of the frame Courtesy of Machine Market ...

Page 24: ...lve Lash Cold mm in Intake 0 432 0 017 Exhaust 0 813 0 032 Advertised Power 783 1050 kW HP at 2100 RPM Peak Torque 4629 3414 Nm ft lb at 1300 RPM Assembled by Cummins Engine Co Inc U S A 4295379 C um m ins Warrty Start Date IMPORTANT ENGINE INFORMATION In the U S this engine is soley for export and is therefore exempt under 40 CFR 1068 240 from U S emssions standards and related requirements Outsi...

Page 25: ...ghway Truck 1 8 3 Display screen The position of display screen is shown as follows P Fig 1 8 3 1 8 4 Table for serial number and distributor information Machine Serial No Engine Serial No Distributor Name Address Service Personnel Phone Fax Courtesy of Machine Market ...

Page 26: ...Foreword Safety Operation and Maintenance Manual 1 12 SRT45 Off Highway Truck B L A N K P A G E Courtesy of Machine Market ...

Page 27: ...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 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 ...

Page 28: ...7 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 ...

Page 29: ...r 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 fire and explosion 2 51 2 4 21 Regular re...

Page 30: ...Safety Safety Operation and Maintenance Manual 2 4 SRT45 Off Highway Truck Courtesy of Machine Market ...

Page 31: ...m clean When cleaning them do not use organic solvents or gasoline These may cause the labels to peel off There are also other labels in addition to the warning signs and safety labels Handle those labels in the same way If labels are damaged lost or cannot be read properly replace them with new ones 2 1 1 Position for attaching safety labels Fig 2 1 1 12 3 2 2 A A 11 Cab Left side outer shell Cab...

Page 32: ...gle increases and unload This location of lifting handle means the carriage dip angle remain unchanged This location of lifting handle means the carriage is in suspension state The handle must be in this location when the machine is stopped or moving This location of lifting handle means the carriage dip angle decreases and the carriage will be downward to locate on the frame Fig 2 1 2 Fig 2 1 3 F...

Page 33: ...revent be hurt 3 Hydraulic oil instruction label This label is located on the hydraulic oil tank Check engine running and accumulator charged Oil should be visible in sight gauge If not shut off engine and turn steering wheel to discharge accumulator check it again in upper sight gauge 4 Hydraulic oil position This label is located on the hydraulic oil tank It means the hydraulic oil position oil ...

Page 34: ...ated at the right cab gate side The people is not allowed standing on the platform when the engine running and should fall down and hold up handrail to prevent tumbling 7 Machine moving high warning label This label is located at the middle side of right cab gate The machine whole high is 4 92meters unloaded and 4 89 meters full loaded Be care when the machine pass through cave or bridge 192 52in ...

Page 35: ...nt damage please read service manual carefully before tyre aeration or maintenance 10 Battery cable warning label This label is located on the top battery box Weld will produce big electric current which may damage electric elements so just do according with warning label and operator s handbook Use Only Nitrogen Gas Charging Pressure 5 7 MPa Ensure nitrogen precharge for proper operation of steer...

Page 36: ...label and handbook when operating machine 12 Grounding label This label is located on the top battery box It means there is a negative electrode grounding system in battery assembly 13 Cliver label There are four cliver position two borrow joint hole between rear tail seat and carriage two located below bumper Fig 2 1 15 Fig 2 1 16 Fig 2 1 17 Courtesy of Machine Market ...

Page 37: ... is located on the barrel wall of suspension cylinder To prevent personal injury and equipment damage please do as the warning label and service manual when maintenance 15 Open water cap warning label This label is located on the distance water box To prevent personal injury never remove hot radiator cap Fig 2 1 18 Fig 2 1 19 Courtesy of Machine Market ...

Page 38: ...ll hand signals to be used 2 2 2 Abnormalities In case of any abnormalities found during operation and maintenance such as noise vibration odor incorrect gauge display smoke or oil leakage contact your Sany distributor and take necessary measures Never operate the machine before the faults are corrected 2 2 3 Personal protective equipment Wear proper work clothes and personal protective equipment ...

Page 39: ...inguisher at any time Check the first aid kit regularly and replenish it when necessary Make emergency scheme to deal with fire and accidents CAUTION Never wear slack clothing and jewelry which may get caught by control evers or other machine parts Long hair can be caught in moving parts Tie your hair if necessary to avoid such hazard Always have your hard hat and safety shoes on Wear safety goggl...

Page 40: ...area steps and handholds are free from oil grass snow ice or mud which can cause you to slip and fall Remove the mud on your soles before getting on the machine If water has penetrated into the electrical system never rush to power on your machine and start the engine which can cause machine failure or PC board damage Never flush the electrical system including sensors connectors etc with water or...

Page 41: ... Never bring Hazardous articles such as flammable or explosive products into the cab 2 2 8 Precautions when leaving the machine If the correct procedures are not followed when stopping the machine the machine may suddenly move off with no operator on it This may lead to serious personal injury Always observe the following precautions strictly When leaving the operator s cab place gear shift lever ...

Page 42: ... onto the engine hood covers or other places where there are no anti slip pads W h e n e n t e r i n g t h e o p e r a t o r s compartment never hold the dump control lever If the dump control lever is gripped it may move Never jump onto the machine There is danger that your feet will slip and you will fall and be seriously injured Never jump off the machine There is danger that you will break a b...

Page 43: ...the cap of radiator before the engine cools down Loosen the cap of the radiator slowly before removing it Internal pressure of radiator must be relieved to avoid serious burns 2 2 10 2 Hot oil To prevent scalds caused by hot oil when checking or discharging the oil always wait for the engine oil to cool down before you proceed When the engine has cooled down loosen the cover or screw plug slowly t...

Page 44: ... use fire near fuel or engine oil Check for missing or loose pipe clamps twisted hoses hoses rubbing against pipeline damaged oil cooler and loose bolts in flange of oil cooler so as to avoid oil leakage Ti g h t e n r e p a i r o r r e p l a c e a n y missing loose or damaged pipe clamps pipelines hoses oil coolers or other flange bolts Refuel or store oils in a place with good ventilation Fig 2 ...

Page 45: ...les and electric lines for looseness entanglement hardening or break each day after operating for 8 10 hours Check the presence or damage of wiring terminal cover In case of slack or entangled power cables or electric wires tighten the connections or wire clips and repair or replace broken wires 2 2 11 4 Fire caused by hydraulic lines Check the clamps guards and gaskets of all hoses and pipes to s...

Page 46: ...ed Instructions in this manual must be followed when power outlet on the machine is used for illumination 2 2 12 In the event of fire When a fire breaks out leave the machine immediately by the following steps Turn start switch to the OFF position to shut down the engine Leave the machine with the help of hand holds and steps 2 2 13 Windshield cleaning detergent Use alcohol based detergent Never u...

Page 47: ...e Repair or replace the operator s cab if it is deformed by falling objects or when the machine tips over For details of repair please consult your SANY distributor 2 2 15 Attachment installation I n s t a l l a t i o n o f o p t i o n a l p a r t s o r attachments may involve safety issues or be limited by the law In this case contact your Sany distributor in advance Sany assumes no responsibilit...

Page 48: ...tor s view Contact your Sany distributor before making any modification Sany assumes no responsibility for the accidents failure or damage caused by unauthorized modification 2 2 18 Examination and confirmation of worksite Before starting operations check first if there is any danger on the jobsite If you do not understand the dangers of the jobsite before starting operations the machine may tip o...

Page 49: ...rations 2 2 19 Operation on soft ground Avoid traveling or operating your machine near cliffs road shoulders or trenches The soft ground plus machine weight and vibration can cause your machine to sink or tip over The ground may become even softer after heavy rain explosion or earthquake When operating on a dam or near an excavated ditch vibration and machine weight may trigger a landslide Before ...

Page 50: ...egarding safety measures A signalman is to be designated to give signals if your machine is too close to power cables Nobody is allowed to approach the machine when it is operated near high voltage cables If your machine is too close to the cable or touches the cable to prevent electrocution operator shall not leave the cab until machine power is surely cut off In addition Nobody is allowed to app...

Page 51: ...rating or traveling in places with poor visibility if it is impossible to confirm the condition of the job side or obstacle is in the area around the machine there is danger that the machine may suffer damage or the operator may suffer serious personal injury Whenoperating or traveling in places with poor visibility always observe the following items strictly If the visibility cannot be sufficient...

Page 52: ...ation of asbestos dust can cause lung cancer It is possible to inhale asbestos dust when performing tear down operation or handling industrial wastes at job site The following rules must be followed Use water instead of compressed air to remove the dust If the air contains asbestos dust operate the machine following the wind All persons shall wear acceptable filter mask Nobody is allowed to approa...

Page 53: ...move the mud oil dirt and water from the pedals handholds and your soles at all times The cab must be aligned with the undercarriage centerline before you enter or exit the cab 2 3 1 2 Seat adjustment Uncomfortable seat position can easily lead to operator fatigue and mistakes The seat position should be adjusted upon change of operator Leaning against the back of seat operator shall be able to pu...

Page 54: ...efore starting the engine Clean the windows to ensure a good visibility Clean the head lamps and work lamps and check if they are in good condition Check coolant level fuel level and engine oil level Check for blocked air filter and damaged electrical wires Check that there is no mud or dust accumulated around the movable parts of the accelerator pedal or brake pedal and check that the pedals work...

Page 55: ...ople around Always start and operate the machine from the operator seat No one is allowed to stay on the machine except the operator Never start the engine by shorting the start motor circuit which is dangerous and may cause machine damage 2 3 1 6 Starting engine in cold season Sufficient warm up operation is necessary Incomplete warming up may result in slow reaction and accidents Before starting...

Page 56: ...ne with a faulty machine with jumper cables battery voltage of the two machines shall be the same Be careful not to allow the two machines to contact with each other Turn both start switches to OFF position when connecting the two machines Otherwise the machine may move and cause danger when it is powered on Start with the positive terminal when connecting the jumper cable Start with the ground or...

Page 57: ...achine operation for abnormality check the swivel system and steering system for abnormal operation Check for abnormal noise vibration heating odor or gauge reading check oil or fuel for leakage In case of any abnormality stop operation and take corrective measures immediately 2 3 2 2 Prior operation precautions To prevent serious injury or death follow the items below before moving the machine It...

Page 58: ...ry If the engine stops depress the brake pedal immediately and stop the machine Lower the dump body setting the dump lever at FLOAT position then travel Never transport anyone riding on the body or carry out any other operation besides the main use for the machine This is dangerous To avoid accidents caused by coming in contact with people structures and other machines always maintain the proper d...

Page 59: ...ing long continuous traveling Do not move the gear shift lever to the N position when the machine is traveling or when it is traveling down a slope Always place the transmission in gear before traveling If the transmission is in Neutral the engine cannot provide any braking effect and the steering wheel will become heavier In addition there will be lack of cooling oil for the retarder so there is ...

Page 60: ... operating Before starting the dumping operation check to be sure there is no person or object behind the machine Stop the machine in the correct position and check again that there is no person or object behind the machine Give the determined signal then slowly operate the dump body If necessary use blocks for the wheels or position a flagman Do not carry out dumping operations on slopes The mach...

Page 61: ...s deep There is danger of driving off the road 2 3 2 7 Parking the machine Select a parking place Park your machine on a solid and flat surface Park the machine in an ares free of such hazards as falling stones or landslide If the terrain is low park it in a relatively higher place Never park your machine on a road undergoing construction If you have to park your machine in such a place flags are ...

Page 62: ...le speed for 3 to 5 minutes to cool the engine Move the steering wheel back and forth to release the residual pressure in the accumulator Turn the start switch to OFF position and stop the engine Close the windows and the cab door Lock all access doors boxes and chambers When leaving your machine face the machine and maintain a three point contact with it Never jump off the machine Be careful with...

Page 63: ...ading operation at an angle 15 Make sure the access ramp is free from grease oil water and debris Clean the track if necessary Be extremely careful when loading or unloading the machine in rainy or snowy weather Run the engine at low speed and operate slowly Gravity center of the machine may alter when it passes the jointing area between the ramp and the trailer The machine may tilt at this moment...

Page 64: ...following items when transporting the machine Note the dimension of the trailer and the machine especially the height Watch outfor barriers overhead and in narrow passages Check the structure and strength of a bridge before crossing it Obey local traffic regulations and traffic police directions when transporting the machine on highways Courtesy of Machine Market ...

Page 65: ... and seek medical treatment To avoid battery induced explosion observe the following precautions Never allow tools and other metal parts to contact with battery terminals Keep tools or metal parts away from batteries Stop the engine and wait for one minute before you proceed Always disconnect the grounding terminal negative first To connect battery cables always begin with the positive terminal an...

Page 66: ...n well ventilated area and remove the cap If acid squirts out of battery vent during charging stop charging immediately Never smoke and keep flames or sparks out when charging When the battery has been fully charged a green indicator will be on Stop the charging process at this time Restore the battery cover after charging Put the battery back to its original position Courtesy of Machine Market ...

Page 67: ...ar protective gloves and a had hat when using wire ropes Check the strength of wire cable and make sure it could bear the weight of machine Never use ropes with broken wires A reduced diameter B and twisting C Such ropes may break when towing Never stand between the towing machine and the towed machine during towing operation Operate the machine slowly Never add load to the wire cable suddenly A B...

Page 68: ...ation Clean the working area by removing fuel lubricant and water and covering slippery ground with sand or other absorptive materials Never leave your hammer or other tools at the working area If a clean tidy working area cannot be guaranteed there would be danger of tipping thus resulting in personal injury 2 4 3 Prior maintenance precautions To prevent accidents Understand maintenance procedure...

Page 69: ...thing and shoes necessary for the job Wear rubber apron and rubber gloves when handling corrosive materials Wear heavy gloves when handling wooden materials wire ropes or sharp edged metals Wear a face shield when removing spring or elastic parts or adding acid to battery Wear safety hat and goggles when you weld or cut with a torch Never carry out grinding flame cutting or welding without an aspi...

Page 70: ... solid and flat ground Lower the bucket to the ground Lower the dump body set dump control lever 1 to the HOLD position lock the dump control lever then stop the engine Set parking brake switch 2 to the PARKING position and put blocks under the tires to prevent the machine from moving Fig 2 4 5 Fig 2 4 6 P 1 2 3 4 1 2 Courtesy of Machine Market ...

Page 71: ...maintenance has to be done on a running engine at least two worker are needed to carry out the maintenance One of the workers shall stay in the operator seat ready to shut down the engine at any time All the workers involved shall keep in touch set dump control lever 1 to the HOLD position then set parking brake switch 2 to the PARKING position Fig 2 4 7 Fig 2 4 8 P 1 2 3 4 1 2 Courtesy of Machine...

Page 72: ...o not remove or disassemble unless necessary Do not bring it near flame or dispose of it in fire Do no make holes in it weld it or use a cutting torch Do not bear any shock by hammering rolling or similar activity Ask your Sany distributor when sealing gas into the cylinder or replacing gas from it 2 4 9 Working under the machine If the machine or work equipment has to be lifted for maintenance bl...

Page 73: ... In this case wear goggles dust preventive mask gloves and other protective gear 2 4 12 Use a hammer When using a hammer to strike hard metal parts such as pin bucket teeth cutting edge or shaft the flying of parts and metal pieces may cause bodily injury Therefore wear goggles and gloves and ensure the surrounding area is clear of any other people 2 4 13 Welding operation Welding operation may le...

Page 74: ...continuously to release pressure of brake accumulator Open fire is not allowed around the hydraulic system Remove splashed hydraulic oil as quickly as possible Diesel oil or pressurized hydraulic oil can penetrate skin or eyes causing serious injury blindness or death It is hard to find the leaking of hydraulic oil with naked eyes A cardboard or wooden board is necessary for checking for leaks Nev...

Page 75: ...roblems Damage or leak of hydraulic hose fitting Damage or break of outer cover or exposed steel wires of reinforcement layer Ballooning outer cover in some places Distortion or crushing of movable parts Impurities in outer cover 2 4 16 Hot cooling system When engine temperature rises pressure of the cooling system increases Before removing the radiator cover stop the engine and let the system coo...

Page 76: ...ite if splashed on your skin Obey local material disposal regulations Never discharge refrigerant directly into the air WARNING Refrigerant R134 a is a harmless gas under room temperature It will change into highly toxic gas when burning 2 4 18 High voltage precautions When the engine is running or has just been shut down high voltage can occur in fuel injector terminal and engine controller Since...

Page 77: ...en disposing of the accumulator Contact Sany distributor for this disposal 2 4 20 Avoiding fire and explosion DANGER Never smoke when handling the fuel or maintaining the fuel system The gases in empty fuel tank can cause explosion easily Never carry out flame cutting or welding operation on fuel pipe fuel tank or fuel vessels which can lead to fire explosion injury or death Then engine must be sh...

Page 78: ...Safety related parts such as hoses and seat belt must be replaced regularly for the consideration of operating the machine safely in a long term Materials of some parts may deteriorate naturally when exceeding specific time limit Repeated use may lead to deterioration wear and damage hence the accidents and serious injury Through merely visual inspection or feel it is hard to find out how long the...

Page 79: ...e if there are missing pins gaskets and nuts Check again all hydraulic oil levels before operation 2 4 23 Proper disposal of wastes Improper disposal of wastes harms the environment and ecology Consult local environmental protection department or Sany distributors for methods of recycling and waste disposal Potential harmful substances used in Sany products include hydraulic oil fuel cooling liqui...

Page 80: ...m becoming too high measure the pressure from time to time with an air gauge while pumping up the tire If the pressure goes down abnormally or the rim parts go not fit the tire there is a problem with the tires or rim parts Always contact your Komatsu distributor for repairs If the rim parts are not fitted properly when the tire is being pumped up there is danger that the rim parts may fly off so ...

Page 81: ...ways erect a fence and put up No Entry signs if the tires must be stored outside Stand the tire on level ground and block it securely so that it cannot roll or fall over if any person should touch it Do not lay the tire on its side This will deform the tire and cause it to deteriorate If the tire should fall over do not attempt to stop it Get out of the way quickly Block Courtesy of Machine Market...

Page 82: ...Safety Safety Operation and Maintenance Manual 2 56 SRT45 Off Highway Truck B L A N K P A G E Courtesy of Machine Market ...

Page 83: ...0 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 Transm...

Page 84: ...olonged Storage 4 16 5 WORKING THE TRUCK 5 1 5 1 Working the Truck 5 1 5 2 Loading 5 1 5 3 Hauling 5 3 5 4 Dumping 5 4 5 5 Empty Return 5 6 6 ROADING 6 1 6 1 General 6 1 6 2 Preparation Prior to Roading 6 1 6 3 In Case of Trouble 6 2 7 MOVING DISABLED TRUCK 7 1 7 1 Moving Disabled Truck 7 1 8 LUBRICATION AND SERVICING 8 1 8 1 Safety Precautions 8 1 8 2 Lubrication and Maintenance 8 2 8 3 Other Mai...

Page 85: ...rs 8 59 8 6 19 Maintenance inspection form for 1950hrs 8 61 8 6 20 Maintenance inspection form for 2000hrs 8 63 8 6 21 Maintenance inspection form for 2100hrs 8 67 8 6 22 Maintenance inspection form for 2250hrs 8 69 8 6 23 Maintenance inspection form for 2400hrs 8 71 8 6 24 Maintenance inspection form for 2500hrs 8 73 8 6 25 Maintenance inspection form for 2550hrs 8 77 8 6 26 Maintenance inspectio...

Page 86: ...ual 8 6 39 Maintenance inspection form for 4050hrs 8 115 8 6 40 Maintenance inspection form for 4200hrs 8 117 8 6 41 Maintenance inspection form for 6000hrs 8 119 8 6 42 Maintenance inspection form for 10000hrs 8 125 9 TECHNICAL DATA 9 1 Courtesy of Machine Market ...

Page 87: ... body stably control 16 Ignition key switch 3 Reversing monitor 10 Cigar lighter 17 Steering column assembly 4 Air outlet 11 Accelerator pedal 18 Horn 5 Air outlet 12 Gear shift lever 19 Combination switch 6 Switch 13 Transmission retarder switch 20 Air conditioner control 7 Radio MP3 14 Retarder lever 21 Body control lever Fig 3 1 Controls and Operating 20 12 13 11 5 3 2 1 9 8 7 6 14 15 16 17 18 ...

Page 88: ...Never move the machine until this light goes OUT 4 Retarder indicator yellow Illuminates when the retarder is applied 5 Side marker lamp yellow Such lamp will be on when side marker lamp starts to work 6 Dipped beam Indicator green Illuminates when dipped beam start to work 7 High beam indicator blue Illuminates when high beam start to work 8 Fog indicator yellow Such lamp will be on when fog lamp...

Page 89: ...lt in a power loss The fault should be diagnosed and removed at the earliest opportunity 13 Right steering indicator green Flashes when the right indicator lights are operating 14 Alternator charging red Illuminates to indicate when the alternator is not charging 15 Transmission over speed indicator red Illuminates when the transmission ECU senses engine speed above 2350 rev min 16 Transmission ov...

Page 90: ...hen the pointer is located in white area said speed is normal and once the pointer is located in red area that speed is too high should reduce speed immediately 3 Transmission oil temperature gauge The pointer indicates transmission oil temperature value Such meter is directly connected to transmission temperature sensor When the pointer is located in white area said transmission oil temperature i...

Page 91: ...the system function interface F1 key to return F2 key for confirmation key the F3 key to move up and F4 for down key see fig3 3 3 4 Under the system function interface click the F3 key or F4 key to choose the function and click F2 key to confirm Take the case of setting system time to demonstrate operation method Under the system function interface a click F3 key or F4 key to choose the number of ...

Page 92: ...he buzzer for 10 seconds then shut down automatically In the electric power the same fault buzzer action only once 3 4 Reversing monitor system The monitor see Fig 3 4 on instrument panel is mainly used for monitoring the reversing truck as well as watching the situation behind truck The matching camera is at the rear part of truck Operation instructions 1 Power supply switch There are two methods...

Page 93: ... button to set reversal effect of image Reversal image can be displayed when switch is placed at MIR position Normal image can be displayed when switch is placed at the NOR position 3 5 Switches 1 Economical Powerful mode switch Allows the operator to select between the transmission POWER and ECONOMY shift schedules Caution Move the transmission shift lever to Neutral before selecting schedule 2 P...

Page 94: ... lamp Press down the upper part of switch to turn off the lamp 7 Rear lamp switch Press switch bottom to turn on rear lamp Press down the upper part of switch to turn off rear lamp 8 Small lamp switch Press switch bottom to turn on rocker switch indicator Press down the upper part of switch to turn off indicator 9 Backup Switch 10 Backup Switch 3 6 Combined switch 1 Horn Button pushed in Horn soun...

Page 95: ...ress power supply key to turn off power supply and all the outputs b Blower mode Press mode key to set air conditioner working mode automatic refrigerating heating C C C C C Refrigeration mode Heat mode Circulating mode Defrosting mode Blower mode Set up Set up Set up Set up Set up Fig 3 7 Fig 3 7 2 Fig 3 7 1 C Set up Temperature adjusting key press Wind speed key press ON OFF key press Auto Manua...

Page 96: ... 15 under heating mode On heating statues press wind speed key press can adjust wind speed low middle and high e Defrosting mode 1 Press defrosting key press it is on defrosting statues press wind speed key press can adjust wind speed low middle and high 2 Automatic defrosting function During refrigerating the temperature of defrosting sensor is smaller than 1 5 the compressor will turn off it wil...

Page 97: ...adjustment distance is 210mm 4 Back angle adjustment This is used to make the driver lean tightly on the seat back Pull handle 3 on the left to move the back to a proper position and then put down the handle The back angle adjustment scope is larger than 90 5 Headrest height adjustment Adjustment scope of 105mm see Fig 3 8 WARNING Do not attempt to adjust the seat or seat belt while the machine is...

Page 98: ... stopping Use emergency brake in an emergency A continuous braking force to hold the truck to a safe steady speed 3 10 2 Service brake This is a floor mounted pedal operated by the right foot Depress the pedal as required by speed load and road conditions to slow or stop the machine Release the pedal as the machine slows until when stopped the pedal is depressed just enough to hold it stationary s...

Page 99: ...Fig3 11 this truck is equipped with two retarders the transmission retarder and the rear disk brake retarder The handle 2 is used to control the rear disk brake retarder The transmission retarder switch 1 is used to control the transmission retarder Retardation is the term used for applying a continuous braking force to hold the truck to a safe steady speed when descending grades The retarder may ...

Page 100: ...ling If the rate of descent is too slow the transmission should be upshifted to the next highest gear range If the rate of descent is too fast the gear range selected is too high and the operator must slow the machine by using the service brakes then downshift into a lower gear range which will allow a safe descent and efficient retarder operation The two retarders can be used at the same time it ...

Page 101: ...t 3 11 Engine 3 11 1 Accelerator pedal The accelerator pedal provides an electrical signal to the engine s fuel control system in proportion to the degree of pedal actuation see Fig3 12 Note The electronically controlled engine will override the accelerator pedal position until the engine is warmed up to the correct operating temperature The engine MUST be started with foot OFF the accelerator ped...

Page 102: ...box connector ECM interface harness connector 30 pin RHS ECM power harness connector 5 pin RHS and ECM sensor harness connector 30 pin LHS Turn off ignition key switch to isolate the batteries before disconnecting any components After welding connect all of the above in the reverse order 1 Electronic control module ECM 5 Stop indicator 2 3 Harness connector 50 and 31pin RHS 6 Maintenance indicator...

Page 103: ...e Electronic Fuel System Injectors where the precise amount of fuel is injected into the engine 3 Electronic Fuel System Injectors The injector is a lightweight compact unit that injects diesel fuel directly into the combustion chamber The amount of fuel injected and the beginning of injection timing is determined by the ECM The ECM sends a command pulse which activates the injector solenoid The i...

Page 104: ...own the engine to avoid serious damage The engine should not be restarted after it has been shut down after activation of the engine protection derate system unless the problem has been diagnosed and corrected Conditions that will cause the amber Maintenance indicator to come on are Low coolant level High coolant temperature Idle validation throttle pedal switch mismatch High intake manifold tempe...

Page 105: ...ive codes are recorded all three indicators will come on momentarily The yellow Warning and red Stop indicators will begin to flash the code of the recorded fault The fault codes flash in the following sequence the yellow indicator flashes once then there is a pause where both indicators are off Then the numbers of the recorded fault code flash in red There is a pause between each number When the ...

Page 106: ... Sensor Circuit shorted high Yellow 145 Engine Coolant Temperature Sensor Circuit shorted low Yellow 147 Accelerator Pedal Position Sensor Circuit low frequency Red 148 Accelerator Pedal Position Sensor Circuit high frequency Red 151 Engine Coolant Temperature High Critical Red 153 Intake Manifold Temperature Sensor 1 Circuit shorted high Yellow 154 Intake Manifold Temperature Sensor 1 Circuit sho...

Page 107: ...e Sensor Input 2 Circuit shorted low Yellow 299 Engine Shutdown Commanded by J1939 Yellow 311 Injector Solenoid Valve Cylinder 1 Circuit grounded circuit Yellow 312 Injector Solenoid Valve Cylinder 5 Circuit grounded circuit Yellow 313 Injector Solenoid Valve Cylinder 3 Circuit grounded circuit Yellow 314 Injector Solenoid Valve Cylinder 6 Circuit grounded circuit Yellow 315 Injector Solenoid Valv...

Page 108: ...jector Metering Rail 1 Pressure Sensor Circuit shorted high Yellow 452 Injector Metering Rail 1 Pressure Sensor Circuit shorted low Yellow 466 Turbocharger 1 Wastegate Control Circuit shorted low Yellow 482 Fuel Pressure Low Warning Yellow 483 Injector Metering Rail 2 Pressure Sensor Circuit shorted high Yellow 484 Injector Metering Rail 2 Pressure Sensor Circuit shorted low Yellow 485 Injector Me...

Page 109: ...g level Yellow 597 Electrical Charging System Voltage Low Warning Level Yellow 598 Electrical Charging System Voltage Low Critical Level Red 611 Engine Hot Shutdown None 753 Engine Speed Position 2 Cam sync error None 755 Injector Metering Rail 1 Pressure Malfunction Yellow 758 Injector Metering Rail 2 Pressure Malfunction Yellow 951 Cylinder Power Imbalance between cylinders None Controls and Ope...

Page 110: ...hold position when the steering wheel is stopped To return the front wheels to the straight ahead position or to the opposite direction turn the steering wheel in the opposite direction WARNING In the event of loss of steering pump output pressure a fully pressurize accumulator provides a maximum of two lock to lock turns of the front wheels A red warning indicator on the instrument panel illumina...

Page 111: ...ons Automatic Gear shift CEC2 can automatically select appropriate gear position according to throttle position engine speed and truck speed Do not move the gear shift handle frequently during driving The truck speed can be controlled through controlling oil supplied to throttle position by foot pedal CEC2 can select economy mode and power mode So as to meet the different requirements of customers...

Page 112: ... this occurs the ECU must be reset before normal operation may be resumed Reset procedure if the transmission has locked in gear because of wheel spinning or emergency brake stop the truck select neutral apply the parking brake and shut down the engine Turn off battery main switch wait ten seconds then reconnect the main switch and restart the engine Select reverse then neutral The check transmiss...

Page 113: ...08 0306 0301 0220 0203 0219 0202 0205 0216 0204 0221 0106 0110 F2 F1 11E 11F F1 11D R12 87 R12 86 R11 87 R11 86 F27 F26 F25 F24 F23 F22 YELLOW B068 7034 E 10B 10C R1 86 R1 87 R12 LOAD 10F 10D 10E R12 GND R12 PWR R14 85 R5 87 R13 30 R13 86 R13 87 R13 85 F28 F28 4F 4G 4H R13 87a 3A 3B 4E 3G 3H 3F B068 7034 A BLACK R12 F28 R13 R14 F2 F1 9H 9G 9F 9E 2C 2D R3 86 R3 87 F18 F19 R9 87 R9 86 F27 F26 12G 12...

Page 114: ...ation can be displayed on the single digit LED display by pressing the diagnostic display button There is a hold override button that must be pressed when shifting between R N and D The hold override button is released when desired selector position is reached The selector lever can move freely between D and the number ranges without pressing the hold override button Refer to fig 3 17 WARNING Do n...

Page 115: ...nts The transmission will automatically upshift from 1st through 6th ranges as travel speed increases With the throttle fully depressed and the mode selection switch in the Power position the transmission upshifts to the next higher range when the engine attains 2175rpm since maximum power train output is needed under this condition At lower throttle settings where minimum power train performance ...

Page 116: ...nsmitted mechanically from the engine directly to the transmission gearing on a 1 to 1 ratio When the lockup clutch is disengaged the torque converter acts as a fluid coupling multiplying torque when engine speed is significantly higher than transmission output shaft speed When the mode selection switch is in the POWER position the ECU controls operation of the lockup clutch according to signals r...

Page 117: ...e engine and is used to retrieve fault codes of the engine By default this switch is opened by pressing its bottom lower part 7 Stall check This switch is provided for the professional service technician of the transmission and is used to test the matching between the transmission and the engine output torque By default this switch is opened by pressing its top upper part 8 Idling adjustment switc...

Page 118: ...tor comes on have the problem diagnosed and corrected at the earliest opportunity WARNING Do not operate engine for more than 30 seconds at full throttle with transmission in gear and output stalled as this will result in severe overheat damage to the transmission 3 13 3 General Transmission Operation Watch for wide deviations from normal readings on the transmission oil temperature gauge during t...

Page 119: ... selector or by plugging in the diagnostic data reader DDR To obtain diagnostic codes using the gear shift selector Check transmission warning indicator on dash will illuminate when ECU detects a fault Stop truck and select Neutral Press diagnostic button 1 on gear shift selector Display 2 on gear shift selector will flash one digit at a time Display starts with code position D1 D2 etc followed by...

Page 120: ...SRT45 Off Highway Truck 3 34 Safety Operation and Maintenance Manual B L A N K P A G E Controls and Operating Courtesy of Machine Market ...

Page 121: ...y shift selector mode function fault No Mode change not permitted 14 Secondary shift selector or RSI link fault Yes Hold in last valid direction May cause cateye display 15 Secondary shift selector mode function fault No Mode change not permitted 16 Shift Selector display line fault Yes None May cause cateye display 24 12 Sump fluid temperature cold Yes DNS lock to range 23 Sump fluid temperature ...

Page 122: ...es DNS SOL OFF 35 00 Power interruption code set after power restored No None hydraulic default during interruption 16 Real time write interruption Yes DNS SOL OFF 36 00 Hardware software not compatible Yes DNS SOL OFF 45 12 General solenoid failure F Yes DNS 13 General solenoid failure K Yes DNS Inhibit lockup 14 FGeneral solenoid failure B Yes DNS Inhibit Reverse 15 General solenoid failure G Ye...

Page 123: ...ive A B F G I K solenoid Yes DNS SOL OFF 28 ECU inoperative H J solenoid Yes DNS SOL OFF 29 ECU inoperative C D E solenoid Yes DNS SOL OFF 33 ECU Computer Operating Properly COP fault Yes Reset ECU shutdown ECU on 2nd occurrence power loss hydraulic defaults May cause cateye display or all segments blank display 34 ECU EEPROM fault Yes DNS SOL OFF 35 ECU EEPROM fault Yes Reset ECU 39 Communication...

Page 124: ...position during the truck is in motion Lower This position provides hydraulic force to power down the body The body raised to the highest position needs to be dropped with hydraulic power i e the lever shall be pushed to this position when the body is dropped to a certain height it will drop via gravity Then release lever and the lever will be moved to the float position via spring which inside of...

Page 125: ...e pressure oil form the pilot valve 2 Lower Lowering the body 1 Move the handle to float position then the body will lower to the frame via gravity 2 If the body is required to stay at a certain height the handle shall be moved to HOLD position 3 If the body does not begin to lower by its own weight such as after dumping downgrade move the control lever all the way forward to the LOWER position an...

Page 126: ...ke cooling oil returning Temperature high Must check 2690 Transmission oil filter block Must check 2691 Transmission oil temperature high Must check 2693 Brake accumulator pressure F low Must check 2694 Brake accumulator pressure B low Must check 2696 Steering accumulator pressure low Must check 2697 Steering oil returning temperature high Need check 2698 Steering oil returning filter block Need c...

Page 127: ...ng of fluid quantities in the engine and other components Make sure parking brake is applied and block wheels securely to prevent accidental movement of the machine while checking component levels Test all lights warning signals controls and instruments for proper operation Walk around the machine and carry out the Inspections and Component Checks described in the drawing opposite and on the follo...

Page 128: ...ck for leaks Rear lamp assembly Check for leakage and normal working WHEELS AND TYRES Check condition inflation nuts and for damaged rims REAR RIDE CYLINDERS Check for debris leaks and damage Check height FUEL TANK Check fuel level Ensure fuel tank is full Check that tank is securely mounted TRANSMISSION Check oil level Check for leaks STEERING CYLINDERS Check for debris leaks and damage Check lin...

Page 129: ...ee Fig 4 2 2 Fuel filters Drain sediment and water from sump until fuel runs clear see Fig 4 3 3 Radiator header tank Check coolant level Add if low see Fig 4 4 In subfreezing temperatures be sure that the coolant contains sufficient antifreeze WARNING Press button in centre of cap to bleed pressure before removing cap completely Fill to bottom of filler neck Fig 4 2 Fig 4 3 Fig 4 4 Operating the ...

Page 130: ...ully inspect all tyres for cuts bruises or other damage and proper inflation for the loads to be carried Inflate all tyres to the recommended pressure while cold see Fig 4 6 6 Fuel level gauge Check fuel level Tank should be filled at end of each shift to prevent condensation see Fig 4 7 Fig 4 5 Fig 4 6 Fig 4 7 Fuel gauge Operating the Truck Courtesy of Machine Market ...

Page 131: ...f turn the steering wheel back and forth to dissipate any pressure in the steering accumulator Oil should be showing in the middle sight gauge Add fluid if low see Fig 4 8 9 Transmission cold oil level This check is made only to determine if the transmission contains sufficient oil for safe starting Make sure there is some oil showing on the sight gauge before starting the engine Add oil if low se...

Page 132: ...rolled engine will override the electronic foot pedal position until the engine is warmed up to the correct operating temperature The engine MUST be started with foot OFF the electronic foot pedal Do not place engine under FULL LOAD at FULL SPEED IMMEDIATELY after starting ALWAYS allow the engine to fully circulate lubricant and warm up gradually before operating at full speed and full load Operat...

Page 133: ... clear the fault following the Charpter 3 of this manual Operation of Electronic Control Fuel System WARNING Never start the engine indoors unless proper exhaust ventilation is provided to remove deadly exhaust gases Once the engine is running move the machine outdoors as soon as possible Exhaust gases are hazardous and can cause unconsciousness and death Operating the engine beyond high idle spee...

Page 134: ...mponents 1 Make sure the parking brake switch is in the PARK position see Fig 4 12 2 Make sure the body control lever is in the FLOAT position see Fig 4 13 3 Make sure the transmission shift selector is in the NEUTRAL position see Fig 4 14 4 Insert Ignition key and turn clockwise to position I see Fig 4 15 Fig 4 12 Fig 4 13 Fig 4 14 Fig 4 15 parking brake switch P P MODE R N D 5 4 3 2 1 N Operatin...

Page 135: ...e to position II to crank the engine Release the key as soon asthe engine starts firing Caution Never crank the engine more than 30 seconds continuously Allowstarter s at least 2 minutes cooling time between cranking periods to avoid overheating see Fig4 18 8 Check the engine oil pressure gauge Within 10 to 15 seconds at engine idle the gauge needle should rise into the white zone If the needle do...

Page 136: ...loured black to the NEGATIVE post of the booster battery Connect the other end of the NEGATIVE cable to machine frame WARNING H a z a r d o u s h y d r o g e n g a s a n d sulphuric acid Check for required voltage and polarity connections to discharged batteries Excessive booster voltage and or incorrect jumper cable connections open flame lighted cigar or other ignition source can cause battery e...

Page 137: ...ransmission is overfull and oil should be drained 2 Body and Rear Brake Cooling Hydraulic Tank Hot Oil Level Operate the body hoist cylinders to their fully extended positions to charge all cylinders and lines then lower the body With the engine running and body fully lowered the oil level should show in the top sight gauge Add oil if low Under all conditions the bottom sight gauge should show ful...

Page 138: ... function If the truck moves during these checks the operator shall stop use the parking brake and don t operate again until all of fault are corrected 4 8 Service Brake Performance Check Following the methods and sequence at below for checking 1 Depress the foot brake pedal 2 Select 1st gear on the transmission shift selector 3 Release parking brake 4 Depress the accelerator pedal Inspection the ...

Page 139: ...to differences in engine performance power train efficiency etc as well as differences in brake holding ability 2 As an indication of system deterioration the engine speed at which point the machine moved with the service or emergency brakes applied can be compared against the engine speed your machine was able to hold to on a previous check 4 10 Driving and Stopping Before driving off observe all...

Page 140: ...hold the machine stationary The retarder brake is recommended to decelerate the truck unless the truck must be stopped immediately 7 When the machine has stopped shift the transmission to Neutral apply the parking brake and release the service brake 8 If the service brake does not stop the machine Apply the emergency brake This should only be applied to stop the machine in an emergency 4 11 Stoppi...

Page 141: ...always be applied when the engine is switched off 4 Turn the steering wheel in both directions to dissipate the pressure in the steering accumulator to prevent accidental steering during bleed down see Fig 4 25 5 Make sure the body control lever is in the FLOAT position see Fig 4 26 6 Turn the ignition key switch to the OFF position 0 see Fig 4 27 Fig 4 25 Fig 4 26 Fig 4 27 P Operating the Truck C...

Page 142: ...the cooling system has sufficient antifreeze to prevent the coolant freezing If antifreeze cannot be added to the cooling system drain the cooling system completely Check all tyres hoses wiring tubing and fittings for cuts ply separation abrasion fraying or other damage or deterioration Inspect for structural damage to the cab body and chassis Attach warning signs to the steering wheel or to a con...

Page 143: ...lied position as though the foot brake is depressed see Fig 5 1 5 2 Loading The most common methods of loading trucks are with hydraulic excavators rope shovels and front end loaders For maximum material movement the truck operator must help the loading machine operator hold loading time to a minimum The fewer manoeuvres the truck must make to get into loading position the sooner loading can start...

Page 144: ...d the loading machine can swing over to load the next truck with a minimum of lost time Since the truck is usually backed into the loading position with this method the operator must be alert and careful while backing refer to fig 5 5 For fastest most accurate loading when being loaded by a front end loader the truck operator should spot his machine on the most level area and at an angle to the fa...

Page 145: ... the transmission to drive D Move out of the loading area and onto the haul road with the least possible delay to allow any waiting truck to move into the loading position as soon as possible refer to fig 5 8 5 3 Hauling While travelling the haul road always maintain a safe speed for the haul road conditions and grades Never allow the machine to move or coast with the transmission in NEUTRAL When ...

Page 146: ...al being hauled For instance overburden and other waste material is usually dumped over a spoil bank or piled into large mounds The dumping on a job of this type might be controlled by a dump SPOTTER FLAGMAN or BANKSMAN or second person who directs the truck to its dumping area The SPOTTER is needed due to the limited rear visibility the operator has with a loaded truck of this size While backing ...

Page 147: ...ank without a SPOTTER know how close the machine can safely approach the edge under all weather conditions If in doubt as to dumping safety dump the load a safe distance from the edge so that it can be pushed over the edge later refer to fig 5 14 Before raising the body make sure the rear wheels are on firm level ground If one wheel is higher than the other a twisting strain is imposed upon the bo...

Page 148: ...ver down into the LOWER position and power the body down until it begins to lower by gravity Then release the control lever into the FLOAT position Note For the truck running stably that should be operated the hoisting handle slowly while the body hoisting period and lowing period 5 5 Empty Return Make sure the body is completely lowered the body control lever is in the FLOAT position and the tran...

Page 149: ... Triangle The operator must use extra care while on the public highways and remain constantly alert especially for overhead cables and low bridges Necessary permits must be obtained from the proper authorities before the machine is ROADED on public highways 6 2 Preparation Prior to Roading Lubrication Thoroughly lubricate and service all components and systems as described under LUBRICATION AND SE...

Page 150: ...s Replace any damaged or excessively worn tyres Check all hoses drain cocks fuel level check cocks and other potential sources of leaks Make sure that all leaks are repaired and that all drain cocks are sufficiently tightened to avoid subsequent loosening Make sure that all warning flags oversize load signs etc are in place and secure Clean all glass and adjust the seat for proper operation of all...

Page 151: ...brake is applied Report the following data as soon as possible 1 Exact location 2 Destination 3 The nature of the trouble with as many details as possible and the time and conditions under which it happened 4 The telephone number at which the machine operator can be reached Note Do not attempt to restart or operate the machine unless instructed to do so An engine pump transmission or other compone...

Page 152: ...SRT45 Off Highway Truck 6 4 Safety Operation and Maintenance Manual B L A N K P A G E Roading Courtesy of Machine Market ...

Page 153: ...s turning the power train as the machine is towed Replace the covers on the drive wheels to retain lubricant and prevent entry of dirt refer to fig 7 1 If possible start the engine to provide the required hydraulic pressure for steering and braking Never allow riders on a machine being towed without sufficient hydraulic pressure for safe steering and braking If the nature of the trouble prevents e...

Page 154: ...ent to the lugs on the front bumper of the disabled machine and the towing point of the recovery machine To p r e v e n t p o s s i b l e d a m a g e t o t h e transmission the towing speed should never exceed 10 km h 6 2 mile h and the distance towed should not be longer than 10 km 6 2 miles WARNING If using a chain or cable be sure it is strong enough for the expected load and properly secured W...

Page 155: ...art or truck Always relieve pressure before servicing any pressurized system Follow the procedures and safety precautions detailed in the Maintenance Manual Always shut down the engine according to the procedure under Stopping The Engine described on page 4 11 before cleaning lubricating or servicing the truck except as called for in this Handbook or the Maintenance Manual When changing oil in the...

Page 156: ...actory should be consulted All change and service periods are recommendations based on average operating conditions Lubricants showing evidence of excessive heat oxidation or dirt should be changed more frequently to prevent these conditions Lubricant change and service periods must be established on the basis of individual job conditions utilizing oil sampling and recommendations from lubricant s...

Page 157: ... Truck 8 3 Safety Operation and Maintenance Manual Fig 8 1 7 20 21 10 25 8 10 11 21 19 22 24 13 18 9 14 1 23 20 8 25 10 11 11 4 2 3 12 15 21 17 13 26 26 27 5 28 27 27 Lubrication and Servicing Courtesy of Machine Market ...

Page 158: ... Belt Visually inspect all belts Refer to the Engine Manual 8 9 Front rear suspension cylinders Visually inspect heights Refer to Front Suspension Cylinder and Rear Suspension System Mechanical air resistance indicator Check Replace element if reqd 1 Refer to the label Requirements for Air Filter Maintenance Air cleaner vacuator valve Check for proper operation 1 Oil water separator for engine fue...

Page 159: ...cation 2 EP NLGI 14 Body hinge pin Lubrication 2 EP NLGI 15 Hoisting cylinder bearing Lubrication 4 EP NLGI 21 Front and rear drive shaft spider Lubrication 6 EP NLGI 27 A arm bearing Lubrication 6 EP NLGI 28 Steering crank pin Lubrication 2 EP NLGI 250 1 Engine Drain and refill 1 EO Engine oil flters Replace filters 2 Refer to the Engine Manual Engine fuel filters Replace filters 2 Refer to the E...

Page 160: ...ean primary tubes and inlet screens Front brake disk Replace 4 500 6 Hydraulic Tank Breather Replace breather 19 Fuel Tank Clean filler neck screen and cap 20 Accumulators Check nitrogen pressures 23 S t e e r i n g C o l u m n Universal Joints Lube 2 EP NLGI See note 37 S t e e r i n g T a n k Breather Replace breather 1000 2 Transmission Discharge and refill 1 HTF Transmission cleaner Replace fi...

Page 161: ... clean and refill 19 Fuel tank Wash clean and refill 1 Diesel 24 Rear brake packs Drain and refill 2 HO 25 Front wheel bearing Repack 2 EP NLGI 26 Cooling system Drain flush and refill Antifreeze 29 Steering in line filter Replace the filter element 31 Hoisting in line filter Wash and replace 32 Cooling in line filter Wash and replace 4000 Air conditioning compressor Drain flush and refill 1 PAG 1...

Page 162: ...which correspond to the reference numbers in the Ref Points column of the lubrication and service chart Note At each scheduled maintenance interval perform all previous checks in addition to the ones specified 8 3 Other Maintenance As required Seat belt Inspect seat belts and replace if damaged Note Replace seat belt at least once 3 years regardless of external appearance Wipers and cleaners Inspe...

Page 163: ...ration is low engine damage will result Conversely over inhibiting antifreeze solutions can cause silicate dropout Steering braking and lifting systems Check for correct operation of all systems beforeoperating the truck Steering hydraulic tank filter Check steering filter restriction warning indicator with the truck empty brakes released oil at normal operating temperature engine operating at 1 5...

Page 164: ...ked or frayed Adjust belts that have a glazed or shiny surface which indicates belt slippage Correctly installed and tensioned belts will show even pulley and belt wear Refer to Chapter 6 Installation of Engine in the Maintenance Manual for drive belt tension and adjustment of new and used drive belts Front Brakes Check pads and discs for wear and replace where necessary Note This service interval...

Page 165: ...or the filter follow the failure code from the display or working time to replace filter if time over 500 hours Cooling pipeline filter Replace with a new spin on filter element Every 2000 hours of operation Steering In line Filter Clean filter housing and install new element when indicated or after 1 000 hours of operation whichever comes first Steering in line filter Clean filter housing and ins...

Page 166: ...nd brake cooling system Total HO 237 62 7 5 Steering Hydraulic Tank HO 63 16 7 6 Steering and Braking Hydraulic System HO 71 18 8 7 Cooling System Coolant 130 34 4 8 Fuel Tank Disel 470 124 2 9 Front Ride Cylinder each HO 19 5 0 10 Rear Ride Cylinder each HO 16 4 2 11 Engine Power Takeoff EPL 4 1 1 12 Main reducer and differential assembly EPL 52 13 3 13 Wheel Planetaries Total EPL 43 11 9 14 Air ...

Page 167: ...nual Mobil antifreeze Fuel Tank Diesel Fuel Oil with maximum sulphur 0 5 0 GB252 Differential Multipurpose Extreme Pressure type gear oil meeting MIL L 2105C Specifications No Zinc Additive See Note 4 SAE GL 5 80W 90 at ambient temperatures of 25 40 Planetary Gears Power Takeoff Grease Fittings Multipurpose Extreme Pressure Lithium Grease which may or may not contain Molybdenum with a melting poin...

Page 168: ...auxiliary heating is available preheat the oil to the minimum temperature limit If not available run the engine at part throttle with the transmission in neutral to raise the fluid temperature Hydraulic Transmission Oil meeting the Allison C 4 requirements Consult your lubricant supplier for confirmation Note 4 If rear axle has limited slip differential use of standard SAE 90 oil may result in ver...

Page 169: ...ces 4 Cummins engine Check liquid level refill as required Check leakages Check damaged for fan Check the oil temperatures and oil pressures Check the driving belt tension and adjust as required Fuel system Check leakages for fuel system Check liquid level and refill after daily job Cooling system Check coolant level refill as required Check leakages for hose and other components Air cleaner Check...

Page 170: ... Truck 8 16 Safety Operation and Maintenance Manual Repair and Maintenance Record Table Date Repair and main tenance performed Cost Time required Unused time Remarks Lubrication and Servicing Courtesy of Machine Market ...

Page 171: ...lace the breather valve for the hoisting hydraulic tank in period Note replace new filter for the system if it working time over 500hrs Replace new filter for the return system in period Note replace oil return filter of hoisting system if it working time over 500hrs Replace the oil suction filter of hoisting system in period Note replace new filter for the system if it working time over 2000hrs T...

Page 172: ... Truck 8 18 Safety Operation and Maintenance Manual Date Repair and main tenance performed Cost Time required Unused time Remarks Repair and Maintenance Record Table Lubrication and Servicing Courtesy of Machine Market ...

Page 173: ...lace the oil return filter of steering system in period Note replace new filter for the system if it working time over 2000hrs The first replace at 1000 hrs Replace the Pipeline filter of steering system in period Note replace new filter for the system if it working time over 500hrs Replace the filter which mounted inside of the rear braking valve group in period Note replace new filter for the sy...

Page 174: ... Truck 8 20 Safety Operation and Maintenance Manual Date Repair and main tenance performed Cost Time required Unused time Remarks Repair and Maintenance Record Table Lubrication and Servicing Courtesy of Machine Market ...

Page 175: ...r take off PTO Change the gear oil of Main reducer and differential assembly Planetary assembly and PTO Check liquid level refill as required Check and clean the breather valve for rear axle Check and clean the breather valve for PTO Remark change oil when replace new one or after fixed Check the driveline bolts torque first time after 150hrs next time after each 1200hrs Bolt code Use of the site ...

Page 176: ... Truck 8 22 Safety Operation and Maintenance Manual Date Repair and main tenance performed Cost Time required Unused time Remarks Repair and Maintenance Record Table Lubrication and Servicing Courtesy of Machine Market ...

Page 177: ...ck the pressure for the steering system Check the pressure for the front breaking system Check the pressure for the rear breaking system Check the pressure for the parking system Steering system Check the pre charge pressure for the accumulator before the checks pressure for the steering system Breaking system check the pre charge pressure for the accumulator before the checks pressure for the bre...

Page 178: ... Truck 8 24 Safety Operation and Maintenance Manual Date Repair and main tenance performed Cost Time required Unused time Remarks Repair and Maintenance Record Table Lubrication and Servicing Courtesy of Machine Market ...

Page 179: ... for filter Remark drain replace filter and refill after 150hrs if transmission has been fixed 4 Main reducer and differential assembly Planetary assembly and power take off PTO Extract lubrication sample from Main reducer and differential assembly and Planetary assembly for checking and analysis Check liquid level refill as required Check and clean the breather valve for rear axle Check and clean...

Page 180: ... Truck 8 26 Safety Operation and Maintenance Manual Date Repair and main tenance performed Cost Time required Unused time Remarks Repair and Maintenance Record Table Lubrication and Servicing Courtesy of Machine Market ...

Page 181: ... for filter Remark drain replace filter and refill after 150hrs if transmission has been fixed 4 Main reducer and differential assembly Planetary assembly and power take off PTO Extract lubrication sample from Main reducer and differential assembly and Planetary assembly for checking and analysis Check liquid level refill as required Check and clean the breather valve for rear axle Check and clean...

Page 182: ... Truck 8 28 Safety Operation and Maintenance Manual Date Repair and main tenance performed Cost Time required Unused time Remarks Repair and Maintenance Record Table Lubrication and Servicing Courtesy of Machine Market ...

Page 183: ... shafts 2 points 5 Hydraulic system Replace new filter for the return flter of hoisting system Replace new filter for the return filter of cooling system Replace new filter for the return filter of steering system Replace new filter for the filter which mounted on the pipeline of the steering syst Replace new filter for the filter which mounted on the pipeline of the cooling system Replace new fil...

Page 184: ... Truck 8 30 Safety Operation and Maintenance Manual Date Repair and main tenance performed Cost Time required Unused time Remarks Repair and Maintenance Record Table Lubrication and Servicing Courtesy of Machine Market ...

Page 185: ...the wearing status for oscillating bearings of steering drag link replace new one if the clearance of the bearing S 0 48mm Conversely you could continue to use it Check the wearing status for oscillating bearings of A shape arm replace new one if the clearance of the bearing S 0 36mm Conversely you could continue to use it Check the wearing status for oscillating bearings of ends of the A shape ar...

Page 186: ... Truck 8 32 Safety Operation and Maintenance Manual Date Repair and main tenance performed Cost Time required Unused time Remarks Repair and Maintenance Record Table Lubrication and Servicing Courtesy of Machine Market ...

Page 187: ...ll as required Air cleaner Clean pipeline and filter for air cleaner 5 Transmission Clean the breather valve for transmission and lubricates again Check status about block caution lamp for filter Remark drain replace filter and refill after 150hrs if transmission has been fixed 6 Main reducer and differential assembly Planetary assembly and power take off PTO Extract lubrication sample from Main r...

Page 188: ... Truck 8 34 Safety Operation and Maintenance Manual Date Repair and main tenance performed Cost Time required Unused time Remarks Repair and Maintenance Record Table Lubrication and Servicing Courtesy of Machine Market ...

Page 189: ...nsmission and lubricates again Check status about block caution lamp for filter Remark drain replace filter and refill after 150hrs if transmission has been fixed 4 Front brake system Check status about disc worn to determinate replace it if required 5 Differential planetary gearing and power take off PTO Extract lubrication sample from differential and planetary gearing for checking and analy sis...

Page 190: ...afety Operation and Maintenance Manual Date Repair and main tenance performed Cost Time required Unused time Remarks Repair and Maintenance Record Table Lubrication and Servicing Lubrication and Servicing Courtesy of Machine Market ...

Page 191: ...ricates again Check status about block caution lamp for filter Remark drain replace filter and refill after 150hrs if transmission has been fixed 4 Main reducer and differential assembly Planetary assembly and power take off PTO Extract lubrication sample from Main reducer and differential assembly and Planetary assembly for checking and analysis Check liquid level refill as required Check and cle...

Page 192: ... Truck 8 38 Safety Operation and Maintenance Manual Date Repair and main tenance performed Cost Time required Unused time Remarks Repair and Maintenance Record Table Lubrication and Servicing Courtesy of Machine Market ...

Page 193: ...stem Replace new filter for the return filter of hoisting system Replace new filter for the return filter of cooling system Replace new filter for the return filter of steering system Replace new filter for the filter which mounted on the pipeline of the steering system Replace new filter for the filter which mounted on the pipeline of the cooling system Replace new filter which mounted inside of ...

Page 194: ... Truck 8 40 Safety Operation and Maintenance Manual Repair and Maintenance Record Table Date Repair and main tenance performed Cost Time required Unused time Remarks Lubrication and Servicing Courtesy of Machine Market ...

Page 195: ... could continue to use it Check the wearing status for oscillating bearings of ends of the A shape arm replace new one if the clearance of the bearing S 0 55mm Conversely you could continue to use it Check the wearing status for oscillating bearings of steering cylinder replace new one if the clearance of the bearing S 0 78mm Conversely you could continue to use it Check the wearing status for osc...

Page 196: ... Truck 8 42 Safety Operation and Maintenance Manual Date Repair and main tenance performed Cost Time required Unused time Remarks Repair and Maintenance Record Table Lubrication and Servicing Courtesy of Machine Market ...

Page 197: ...bricates again Check status about block caution lamp for filter Remark drain replace filter and refill after 150hrs if transmission has been fixed 4 Main reducer and differential assembly Planetary assembly and power take off PTO Extract lubrication sample from Main reducer and differential assembly and Planetary assembly for checking and analysis Check liquid level refill as required Check and cl...

Page 198: ... Truck 8 44 Safety Operation and Maintenance Manual Date Repair and main tenance performed Cost Time required Unused time Remarks Repair and Maintenance Record Table Lubrication and Servicing Courtesy of Machine Market ...

Page 199: ...refill as required Air cleaner Clean pipeline and filter for air cleaner 5 Transmission Clean the breather valve for transmission and lubricates again Check status about block caution lamp for filter Remark drain replace filter and refill after 150hrs if transmission has been fixed 6 Main reducer and differential assembly Planetary assembly and power take off PTO Extract lubrication sample from Ma...

Page 200: ... Truck 8 46 Safety Operation and Maintenance Manual Date Repair and main tenance performed Cost Time required Unused time Remarks Repair and Maintenance Record Table Lubrication and Servicing Courtesy of Machine Market ...

Page 201: ...e Drain replace filter and refill Check breather valve for crankcase Fuel system Replace fuel filter Cooling system Replace coolant filter Check and supplement DCA to coolant 2 Front brake system Check status about disc worn to determinate replace it if required 3 Lubrication Front rear transmissions cross shafts 4 points Front rear transmission shafts 2 points Checker Date Remarks Lubrication and...

Page 202: ... Truck 8 48 Safety Operation and Maintenance Manual Date Repair and main tenance performed Cost Time required Unused time Remarks Repair and Maintenance Record Table Lubrication and Servicing Courtesy of Machine Market ...

Page 203: ...ext time after each 1200hrs Bolt code Use of the site Tightening torque N m Check torque N m 60011099 Front driveline 145 140 60011098 Rear driveline 230 220 Caution The scene conducts the driveline assembly Upon assembly the first cleaning threaded hole oil of driveline and yoke to install At the beginning of operation three consecutive days of checking the driveline bolts torque 4 Main reducer a...

Page 204: ... Truck 8 50 Safety Operation and Maintenance Manual Date Repair and main tenance performed Cost Time required Unused time Remarks Repair and Maintenance Record Table Lubrication and Servicing Courtesy of Machine Market ...

Page 205: ... for transmission and lubricates again Check status about block caution lamp for filter Remark drain replace filter and refill after 150hrs if transmission has been fixed 4 Front brake system Check status about disc worn to determinate replace it if required 5 Main reducer and differential assembly Planetary assembly and power take off PTO Extract lubrication sample from Main reducer and different...

Page 206: ... Truck 8 52 Safety Operation and Maintenance Manual Date Repair and main tenance performed Cost Time required Unused time Remarks Repair and Maintenance Record Table Lubrication and Servicing Courtesy of Machine Market ...

Page 207: ...f brace piece axial pin seat and flange end face of frame The shims needs to be increased or replaced when the single clearance is above 1mm 9 Bearing Check the wearing status for oscillating bearings of steering drag link replace new one if the clearance of the bearing S 0 48mm Conversely you could continue to use it Check the wearing status for oscillating bearings of A shape arm replace new one...

Page 208: ... Truck 8 54 Safety Operation and Maintenance Manual Date Repair and main tenance performed Cost Time required Unused time Remarks Repair and Maintenance Record Table Lubrication and Servicing Courtesy of Machine Market ...

Page 209: ...bricates again Check status about block caution lamp for filter Remark drain replace filter and refill after 150hrs if transmission has been fixed 4 Main reducer and differential assembly Planetary assembly and power take off PTO Extract lubrication sample from Main reducer and differential assembly and Planetary assembly for checking and analysis Check liquid level refill as required Check and cl...

Page 210: ... Truck 8 56 Safety Operation and Maintenance Manual Date Repair and main tenance performed Cost Time required Unused time Remarks Repair and Maintenance Record Table Lubrication and Servicing Courtesy of Machine Market ...

Page 211: ...e Drain replace filter and refill Check breather valve for crankcase Fuel system Replace fuel filter Cooling system Replace coolant filter Check and supplement DCA to coolant 2 Front brake system Check status about disc worn to determinate replace it if required 3 Lubrication Front rear transmissions cross shafts 4 points Front rear transmission shafts 2 points Checker Date Remarks Lubrication and...

Page 212: ... Truck 8 58 Safety Operation and Maintenance Manual Date Repair and main tenance performed Cost Time required Unused time Remarks Repair and Maintenance Record Table Lubrication and Servicing Courtesy of Machine Market ...

Page 213: ...l as required Air cleaner Clean pipeline and filter for air cleaner 5 Transmission Clean the breather valve for transmission and lubricates again Check status about block caution lamp for filter Remark drain replace filter and refill after 150hrs if transmission has been fixed 6 Differential planetary gearing and power take off PTO Extract lubrication sample from Main reducer and differential asse...

Page 214: ... Truck 8 60 Safety Operation and Maintenance Manual Date Repair and main tenance performed Cost Time required Unused time Remarks Repair and Maintenance Record Table Lubrication and Servicing Courtesy of Machine Market ...

Page 215: ...bricates again Check status about block caution lamp for filter Remark drain replace filter and refill after 150hrs if transmission has been fixed 4 Main reducer and differential assembly Planetary assembly and power take off PTO Extract lubrication sample from Main reducer and differential assembly and Planetary assembly for checking and analysis Check liquid level refill as required Check and cl...

Page 216: ... Truck 8 62 Safety Operation and Maintenance Manual Date Repair and main tenance performed Cost Time required Unused time Remarks Repair and Maintenance Record Table Lubrication and Servicing Courtesy of Machine Market ...

Page 217: ... about rear brake disc unit 4 Air condition Check evaporimeter and cooling S pipe clean as required Check fasteners to replace or adjust for compressor Check status about coolant via window Check all system hoses and fittings for leakages Check working status for air condition 5 Lubrication Front rear transmissions cross shafts 4 points Front rear transmission shafts 2 points 6 Body Check the sing...

Page 218: ... Truck 8 64 Safety Operation and Maintenance Manual Date Repair and main tenance performed Cost Time required Unused time Remarks Repair and Maintenance Record Table Lubrication and Servicing Courtesy of Machine Market ...

Page 219: ...stem Replace new filter for the suction filter of the cooling system Replace the breather valve for the steering hydraulic tank Replace the breather valve for the hoisting hydraulic tank Change oil for the tank and clean the whole tank and accessories Check the pressure for the hydraulic system Check the pressure for the steering system Check the pressure for the front braking system 9 Bearing Rep...

Page 220: ... Truck 8 66 Safety Operation and Maintenance Manual Date Repair and main tenance performed Cost Time required Unused time Remarks Repair and Maintenance Record Table Lubrication and Servicing Courtesy of Machine Market ...

Page 221: ...bricates again Check status about block caution lamp for filter Remark drain replace filter and refill after 150hrs if transmission has been fixed 4 Main reducer and differential assembly Planetary assembly and power take off PTO Extract lubrication sample from Main reducer and differential assembly and Planetary assembly for checking and analysis Check liquid level refill as required Check and cl...

Page 222: ... Truck 8 68 Safety Operation and Maintenance Manual Date Repair and main tenance performed Cost Time required Unused time Remarks Repair and Maintenance Record Table Lubrication and Servicing Courtesy of Machine Market ...

Page 223: ...ansmission and lubricates again Check status about block caution lamp for filter Remark drain replace filter and refill after 150hrs if transmission has been fixed 4 Front brake system Check status about disc worn to determinate replace it if required 5 Differential planetary gearing and power take off PTO Extract lubrication sample from differential and planetary gearing for checking and analy si...

Page 224: ... Truck 8 70 Safety Operation and Maintenance Manual Date Repair and main tenance performed Cost Time required Unused time Remarks Repair and Maintenance Record Table Lubrication and Servicing Courtesy of Machine Market ...

Page 225: ... Clean pipeline and filter for air cleaner 5 Transmission Drain and refill for transmission Clean the breather valve for transmission and lubricates again Check status about block caution lamp for filter Clean and replace filters Clean filling port for transmission Remark drain replace filter and refill after 150hrs if transmission has been fixed 6 Main reducer and differential assembly Planetary ...

Page 226: ... Truck 8 72 Safety Operation and Maintenance Manual Date Repair and main tenance performed Cost Time required Unused time Remarks Repair and Maintenance Record Table Lubrication and Servicing Courtesy of Machine Market ...

Page 227: ...smission shafts 2 points 4 Hydraulic system Replace new filter for the return filter of hoisting system Replace new filter for the return filter of cooling system Replace new filter for the return filter of steering system Replace new filter for the filter which mounted on the pipeline of the steering system Replace new filter for the filter which mounted on the pipeline of the cooling system Repl...

Page 228: ... Truck 8 74 Safety Operation and Maintenance Manual Repair and Maintenance Record Table Date Repair and main tenance performed Cost Time required Unused time Remarks Lubrication and Servicing Courtesy of Machine Market ...

Page 229: ...ew one if the clearance of the bearing S 0 48mm Conversely you could continue to use it Check the wearing status for oscillating bearings of ends of the A shape arm replace new one if the clearance of the bearing S 0 55mm Conversely you could continue to use it Check the wearing status for oscillating bearings of steering cylinder replace new one if the clearance of the bearing S 0 78mm Conversely...

Page 230: ... Truck 8 76 Safety Operation and Maintenance Manual Date Repair and main tenance performed Cost Time required Unused time Remarks Repair and Maintenance Record Table Lubrication and Servicing Courtesy of Machine Market ...

Page 231: ...ext time after each 1200hrs Bolt code Use of the site Tightening torque N m Check torque N m 60011099 Front driveline 145 140 60011098 Rear driveline 230 220 Caution The scene conducts the driveline assembly Upon assembly the first cleaning threaded hole oil of driveline and yoke to install At the beginning of operation three consecutive days of checking the driveline bolts torque 4 Main reducer a...

Page 232: ... Truck 8 78 Safety Operation and Maintenance Manual Date Repair and main tenance performed Cost Time required Unused time Remarks Repair and Maintenance Record Table Lubrication and Servicing Courtesy of Machine Market ...

Page 233: ...bricates again Check status about block caution lamp for filter Remark drain replace filter and refill after 150hrs if transmission has been fixed 4 Main reducer and differential assembly Planetary assembly and power take off PTO Extract lubrication sample from Main reducer and differential assembly and Planetary assembly for checking and analysis Check liquid level refill as required Check and cl...

Page 234: ... Truck 8 80 Safety Operation and Maintenance Manual Date Repair and main tenance performed Cost Time required Unused time Remarks Repair and Maintenance Record Table Lubrication and Servicing Courtesy of Machine Market ...

Page 235: ...e Drain replace filter and refill Check breather valve for crankcase Fuel system Replace fuel filter Cooling system Replace coolant filter Check and supplement DCA to coolant 2 Front brake system Check status about disc worn to determinate replace it if required 3 Lubrication Front rear transmissions cross shafts 4 points Front rear transmission shafts 2 points Checker Date Remarks Lubrication and...

Page 236: ... Truck 8 82 Safety Operation and Maintenance Manual Date Repair and main tenance performed Cost Time required Unused time Remarks Repair and Maintenance Record Table Lubrication and Servicing Courtesy of Machine Market ...

Page 237: ...bricates again Check status about block caution lamp for filter Remark drain replace filter and refill after 150hrs if transmission has been fixed 4 Main reducer and differential assembly Planetary assembly and power take off PTO Extract lubrication sample from Main reducer and differential assembly and Planetary assembly for checking and analysis Check liquid level refill as required Check and cl...

Page 238: ... Truck 8 84 Safety Operation and Maintenance Manual Date Repair and main tenance performed Cost Time required Unused time Remarks Repair and Maintenance Record Table Lubrication and Servicing Courtesy of Machine Market ...

Page 239: ...ation points work well 3 Electrical system Check harnesses status Check status about cables for storage battery 4 Cummins engine Check fasteners for engine tighten them if required Check oil level for PTO refill as required Drain replace filter and refill Check breather valve for crankcase Fuel system Replace fuel filter Cooling system Replace coolant filter Check and supplement DCA to coolant Air...

Page 240: ... Truck 8 86 Safety Operation and Maintenance Manual Date Repair and main tenance performed Cost Time required Unused time Remarks Repair and Maintenance Record Table Lubrication and Servicing Courtesy of Machine Market ...

Page 241: ...ck liquid level refill as required Check and clean the breather valve for rear axle Check and clean the breather valve for PTO Remark change oil when replace new one or after fixed 9 Front brake system Check status about disc worn to determinate replace it if required 10 Hydraulic system Replace new filter for the return filter of hoisting system Replace new filter for the return filter of cooling...

Page 242: ... Truck 8 88 Safety Operation and Maintenance Manual Date Repair and main tenance performed Cost Time required Unused time Remarks Repair and Maintenance Record Table Lubrication and Servicing Courtesy of Machine Market ...

Page 243: ...aring S 0 55mm Conversely you could continue to use it Check the wearing status for oscillating bearings of steering cylinder replace new one if the clearance of the bearing S 0 78mm Conversely you could continue to use it Replace new bearings for front suspension cylinder Replace new bearings for rear suspension cylinder Check the wearing status for oscillating bearings of link replace new one if...

Page 244: ... Truck 8 90 Safety Operation and Maintenance Manual Date Repair and main tenance performed Cost Time required Unused time Remarks Repair and Maintenance Record Table Lubrication and Servicing Courtesy of Machine Market ...

Page 245: ...bricates again Check status about block caution lamp for filter Remark drain replace filter and refill after 150hrs if transmission has been fixed 4 Main reducer and differential assembly Planetary assembly and power take off PTO Extract lubrication sample from Main reducer and differential assembly and Planetary assembly for checking and analysis Check liquid level refill as required Check and cl...

Page 246: ... Truck 8 92 Safety Operation and Maintenance Manual Date Repair and main tenance performed Cost Time required Unused time Remarks Repair and Maintenance Record Table Lubrication and Servicing Courtesy of Machine Market ...

Page 247: ...k PTO liquid level refill as required Drain replace filter and refill Check breather valve for crankcase Fuel system Replace fuel filter Cooling system Replace coolant filter Check and supplement DCA to coolant 2 Front brake system Check status about disc worn to determinate replace it if required 3 Lubrication Front rear transmissions cross shafts 4 points Front rear transmission shafts 2 points ...

Page 248: ... Truck 8 94 Safety Operation and Maintenance Manual Date Repair and main tenance performed Cost Time required Unused time Remarks Repair and Maintenance Record Table Lubrication and Servicing Courtesy of Machine Market ...

Page 249: ...bricates again Check status about block caution lamp for filter Remark drain replace filter and refill after 150hrs if transmission has been fixed 4 Main reducer and differential assembly Planetary assembly and power take off PTO Extract lubrication sample from Main reducer and differential assembly and Planetary assembly for checking and analysis Check liquid level refill as required Check and cl...

Page 250: ... Truck 8 96 Safety Operation and Maintenance Manual Date Repair and main tenance performed Cost Time required Unused time Remarks Repair and Maintenance Record Table Lubrication and Servicing Courtesy of Machine Market ...

Page 251: ...r Remark drain replace filter and refill after 150hrs if transmission has been fixed 4 Main reducer and differential assembly Planetary assembly and power take off PTO Extract lubrication sample from Main reducer and differential assembly and Planetary assembly for checking and analysis Check liquid level refill as required Check and clean the breather valve for rear axle Check and clean the breat...

Page 252: ... Truck 8 98 Safety Operation and Maintenance Manual Date Repair and main tenance performed Cost Time required Unused time Remarks Repair and Maintenance Record Table Lubrication and Servicing Courtesy of Machine Market ...

Page 253: ... filter for the filter which mounted on the pipeline of the cooling system Replace new filter which mounted inside of the rear braking valve group Replace the breather valve for the steering hydraulic tank Replace the breather valve for the hoisting hydraulic tank 2 Cummins engine Drain replace filter and refill Check breather valve for crankcase Fuel system Replace fuel filter Cooling system Repl...

Page 254: ... Truck 8 100 Safety Operation and Maintenance Manual Repair and Maintenance Record Table Date Repair and main tenance performed Cost Time required Unused time Remarks Lubrication and Servicing Courtesy of Machine Market ...

Page 255: ...asteners for engine Check PTO liquid level refill as required Air cleaner Clean pipeline and filter for air cleaner 5 Transmission Clean the breather valve for transmission and lubricates again Check status about block caution lamp for filter Remark drain replace filter and refill after 150hrs if transmission has been fixed 6 Main reducer and differential assembly Planetary assembly and power take...

Page 256: ... Truck 8 102 Safety Operation and Maintenance Manual Date Repair and main tenance performed Cost Time required Unused time Remarks Repair and Maintenance Record Table Lubrication and Servicing Courtesy of Machine Market ...

Page 257: ...lter Check and supplement DCA to coolant 3 Transmission Clean the breather valve for transmission and lubricates again Check status about block caution lamp for filter Remark drain replace filter and refill after 150hrs if transmission has been fixed Check the driveline bolts torque first time after 150hrs next time after each 1200hrs Bolt code Use of the site Tightening torque N m Check torque N ...

Page 258: ... Truck 8 104 Safety Operation and Maintenance Manual Date Repair and main tenance performed Cost Time required Unused time Remarks Repair and Maintenance Record Table Lubrication and Servicing Courtesy of Machine Market ...

Page 259: ...ssembly and power take off PTO Change the gear oil of Main reducer and differential assembly Planetary assembly and PTO Check liquid level refill as required Check and clean the breather valve for rear axle Check and clean the breather valve for PTO Remark change oil when replace new one or after fixed 6 Lubrication Front rear transmissions cross shafts 4 points Front rear transmission shafts 2 po...

Page 260: ... Truck 8 106 Safety Operation and Maintenance Manual Date Repair and main tenance performed Cost Time required Unused time Remarks Repair and Maintenance Record Table Lubrication and Servicing Courtesy of Machine Market ...

Page 261: ...ubricates again Check status about block caution lamp for filter Remark drain replace filter and refill after 150hrs if transmission has been fixed 4 Main reducer and differential assembly Planetary assembly and power take off PTO Extract lubrication sample from Main reducer and differential assembly and Planetary assembly for checking and analysis Check liquid level refill as required Check and c...

Page 262: ... Truck 8 108 Safety Operation and Maintenance Manual Date Repair and main tenance performed Cost Time required Unused time Remarks Repair and Maintenance Record Table Lubrication and Servicing Courtesy of Machine Market ...

Page 263: ...ing S pipe clean as required Check fasteners to replace or adjust for compressor Check status about coolant via window Check all system hoses and fittings for leakages Check working status for air condition 5 Lubrication Front rear transmissions cross shafts 4 points Front rear transmission shafts 2 points 6 Hydraulic system Replace new filter for the return filter of hoisting system Replace new f...

Page 264: ... Truck 8 110 Safety Operation and Maintenance Manual Date Repair and main tenance performed Cost Time required Unused time Remarks Repair and Maintenance Record Table Lubrication and Servicing Courtesy of Machine Market ...

Page 265: ...nk Change oil for the tank and clean the whole tank and accessories Check the pressure for the steering system Check the pressure for the front breaking system Check the pressure for the rear breaking system Check the pressure for the parking system Steering system Check pre charge pressure for accumulator first then does check pressure for steering system Braking system Check pre charge pressure ...

Page 266: ... Truck 8 112 Safety Operation and Maintenance Manual Date Repair and main tenance performed Cost Time required Unused time Remarks Repair and Maintenance Record Table Lubrication and Servicing Courtesy of Machine Market ...

Page 267: ...55mm Conversely you could continue to use it Check the wearing status for oscillating bearings of rear suspension cylinder replace new one if the clearance of the bearing S 0 63mm Conversely you could continue to use it 9 Body Check the single clearance of brace piece axial pin seat and flange end face of frame The shims needs to be increased or replaced when the single clearance is above 1mm 10 T...

Page 268: ... Truck 8 114 Safety Operation and Maintenance Manual Date Repair and main tenance performed Cost Time required Unused time Remarks Repair and Maintenance Record Table Lubrication and Servicing Courtesy of Machine Market ...

Page 269: ...ubricates again Check status about block caution lamp for filter Remark drain replace filter and refill after 150hrs if transmission has been fixed 4 Main reducer and differential assembly Planetary assembly and power take off PTO Extract lubrication sample from Main reducer and differential assembly and Planetary assembly for checking and analysis Check liquid level refill as required Check and c...

Page 270: ... Truck 8 116 Safety Operation and Maintenance Manual Date Repair and main tenance performed Cost Time required Unused time Remarks Repair and Maintenance Record Table Lubrication and Servicing Courtesy of Machine Market ...

Page 271: ...tatus about cables for storage battery 4 Cummins engine Check the fasteners for engine Check PTO liquid level refill as required Air cleaner Clean pipeline and filter for air cleaner 5 Transmission Check and tighten for transmission according to requirement Clean the breather valve for transmission and lubricates again Check status about block caution lamp for filter Remark drain replace filter an...

Page 272: ... Truck 8 118 Safety Operation and Maintenance Manual Date Repair and main tenance performed Cost Time required Unused time Remarks Repair and Maintenance Record Table Lubrication and Servicing Courtesy of Machine Market ...

Page 273: ... rear ride cylinder Disassemble inspect and fix or replace some parts if required which parts has been worn Check Pin Spindle and Bush replace them as required 4 Steering connecting rod gear Check and fix or replace some parts if required which parts has been worn 5 Steering cylinder Dismounting checking and repair or replace damaged components for the cylinder if requir ed Check the pins and bear...

Page 274: ... Truck 8 120 Safety Operation and Maintenance Manual Date Repair and main tenance performed Cost Time required Unused time Remarks Repair and Maintenance Record Table Lubrication and Servicing Courtesy of Machine Market ...

Page 275: ...30 220 Caution The scene conducts the driveline assembly Upon assembly the first cleaning threaded hole oil of driveline and yoke to install At the beginning of operation three consecutive days of checking the driveline bolts torque 12 Steering Check screw between steering arm and front suspension cylinder If loosed or damaged tighten or replace new screw 13 Hydraulic system Replace new filter for...

Page 276: ... Truck 8 122 Safety Operation and Maintenance Manual Date Repair and main tenance performed Cost Time required Unused time Remarks Repair and Maintenance Record Table Lubrication and Servicing Courtesy of Machine Market ...

Page 277: ...lator first then does check pressure for steering system Braking system Check pre charge pressure for accumulator first then does check pressure for steering system Note when the data compared with maintenance manual are different the operator has to check fix problems for system to make it work well Drain all pressure oil out from the accumulator before when you decided to check pressure of it 14...

Page 278: ... Truck 8 124 Safety Operation and Maintenance Manual Date Repair and main tenance performed Cost Time required Unused time Remarks Repair and Maintenance Record Table Lubrication and Servicing Courtesy of Machine Market ...

Page 279: ...r ends of the A shape arm Replace new bearings for steering cylinder Check the wearing status for oscillating bearings of front suspension cylinder replace new one if the clearance of the bearing S 0 55mm Conversely you could continue to use it Check the wearing status for oscillating bearings of rear suspension cylinder replace new one if the clearance of the bearing S 0 63mm Conversely you could...

Page 280: ...SRT45 Off Highway Truck 8 126 Safety Operation and Maintenance Manual B L A N K P A G E Lubrication and Servicing Courtesy of Machine Market ...

Page 281: ...ction Turbocharged Aftercooled Gross power At the rate of 2100 r min 391 KW 525 hp Net power At the rate of 2100 r min 360 KW 483 hp Note Power ratings to SAE J1995 June 1990 the engine emission shall comply with TIER 560 1515 2865 4215 4075 4580 4450 3440 2805 4180 3900 4115 2135 4100 685 8615 8175 6085 6 0 Fig 9 1 Technical Data Unit mm Courtesy of Machine Market ...

Page 282: ...lanetary gearing Six speeds forward two reverse Automatic converter lockup action in all speed ranges Downshift inhibitor Integral hydraulic retarder Forward gear 1st gear 2nd gear 3rd gear 4th gear 5th gear 6th gear Ratio 4 00 2 68 2 01 1 35 1 00 0 67 km h 8 41 12 45 16 57 24 50 33 38 50 00 mile h 5 28 7 79 10 60 15 30 20 60 32 50 Reversing gear R1 Ratio 5 15 km h 6 7 mile h 4 2 Drive axle Heavy ...

Page 283: ...lection Brakes Service All hydraulic brake system control Trans mission PTO mounted pressure compensating piston pump provides hydraulic pressure for brake and steering Independent circuits front and rear Each circuit incorporates a accumulator which stores energy to provide instant braking response Front brake circuit pressure 15 9MPa 2300 lbf in2 Rear brake circuit pressure 5 2MPa 750 lbf in2 Ac...

Page 284: ...g angle left right 40 Minimun turning radius SAE 9400mm Hoist system It is set up separately from the power hydraulic system Two body hoist cylinders are mounted between the frame rails Cylinders are two stage with power down in the second stage System pressure 180bar 2610 lbf in2 Hoist pump Type Gear type Capacity at at 2100 r min 307 L min 81US gal min Control valve Type Servo control neutral ge...

Page 285: ...rated areas cast steel parts with high tenacity are used and in this way the frame boasts high tenacity and stronger impact resistance Cab Large area of windscreen gives operator an all around visibility Acoustic lining material provides quiet operator space Suspension seat reduces vibration efficiently The cab provides a sound exposure Leq equivalent sound level of less than 78 dB A when tested w...

Page 286: ... Note Noise Level Exposure to the operator and bystander personnel may be higher depending upon proximity to buildings rock piles machinery etc The actual job site Noise Level Exposure must be measured and applicable regulations complied with in respect to Employee Hearing Protection Vehicle weights Mass Vehicle weights Mass kg Ib Chassis with hoists Body standard Net weight 28200 8600 36800 61858...

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