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SANY SRT45 Off-Highway Truck. Safety,Operation and Maintenance Manual (2014) - page 1

Foreword

2)An example alert wording and alert text

WARNING

To prevent personal injury and

property damage, be sure lifting

equipment is of adequate capacity and

properly secured to do the job safely.

3)Other alert words

In addition to the safety-related alert

words above, the following words are used in

this manual to provide additional information

to which extra attention must be paid.

Note:

It is followed by information on how to avoid

reduction of machine service life.

Remark:

It is followed by very useful information.

4)Safety decals

WARNING

Safety decals on the machine are used to

alert operator or maintenance personnel that

HIGH PRESSURE

potential hazards might be involved when the

Do not remove valves or fittings until pressure is

all released.

machine is being operated or serviced.

ACCUMULATOR

We use textual and graphical (or

Use Only Nitrogen Gas,Charging Pressure:

5.7 MPa,Ensure nitrogen precharge for

combined) decals to indicate a hazardous

proper operation of steering system.

situation and how to avoid such situation.

a.Textual safety decals

Fig. 1.2-1 is an example of textual safety

Fig. 1.2-1

decals.

b.Graphical safety decals

Graphical safety decals use images or

symbols to indicate a hazardous situation and

how to avoid it.

Fig. 1.2-2 is an example of graphical

safety decals.

Fig. 1.2-2

1-4

Foreword

1.4 Page Numbers

The pages in this manual are numbered

as the following:

2-10

Page 10 of Chapter 2

Chapter 2

1.5 Regulation of Use

1.5.1 Machine applications

Sany Mining Trucks are designed to be

Front

Right

used mainly for the following work:

Traveling with a load

Left

Rear

Top

1.5.2 Directions of machine

In this manual, the directions of the

Down

machine (front, rear, and left, right) are

determined according to the view from the

Operator 's seat

operator’s seat in the direction of travel (front)

of the machine.

Fig. 1.5-1

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 break-in period:

● Let the machine preheat prior to any

operation.

● Avoid engaging gear or operating the

pedal.

● Avoid sudden starts or fast movements or

1-6

Foreword

stops.

● Always let the system cool down at the end of the working day.

1.7 Visibility from Operator's Seat

The visibility standards (ISO 5006) for this machine require a view shown in the diagram

below.

Visibility in 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.

A

A

1000

1000

A

A

1743

1743

Fig. 1.7-1

1-7

Foreword

24-M radius visibility

The visibility at a radius 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

1-8

Foreword

1.8 Machine Information

The serial numbers and model numbers

on the components are the only numbers 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.

left front end of the frame

Fig. 1.8-1

1-9

Foreword

1.8.2 Engine identification plate

The engine identification plate is on the

right front of engine cylinder head.

Engie No.

37256546

Displacement

30.5/1860 L:in³

Valve Lash Cold

( mm/in)

Warrty Start Date

o

IMPORTANT ENGINE INFORMATION

Family D57

Static Injection Timing

0.5

BTDC

Intake

0.432/0.017

In the U.S. this engine is soley for

export and is therefore exempt under

Model QST30

Fuel Rate @ Advertised Power

270

mm3/stroke

Exhaust

0.813/0.032

40 CFR 1068.240 from U.S.

S.O. No. so10727

Advertised Power 783 /1050

kW:HP at

2100

RPM

emssions standards and

related requirements. Outside the U.S.

WARNING: Injury may result and warranty is volded

this engine may be subject to other

Ref. No.WZU2-SY-SRT95-Q30-1

Peak Torque

4629 /3414 Nm:ft-lb at

1300

RPM

emissions regulations.

if fuel rate, speed or altitude exceeds published

Engie No.37256546

maximum values for this modeland application.

Assembled by Cummins Engine Co.,Inc. U.S.A.

4295379

Fig. 1.8-2

1-10

Foreword

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

1-11

Safety

2 SAFETY

2.1 Safety Labels

The following warning signs and safety are used on this machine.

● Be sure that you fully understand the correct position and content of labels.

● To ensure that the content of labels can be read properly, be sure the they are in the correct

place and always keep them 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

2

3

4

2

5

6

7

Hydraulic oil tank

Cab(Right side outer shell)

Cab(Left side outer shell)

9

10

11

12

8

8

Battery box assembly

Accumulator

Frame rear part(left)

13

14

1

Rear tail seat

Fig. 2.1-1

2-5

Safety

2.1.2 Safety labels

(1)Lifting control label

● This label is located at the left hand side

of the cab driver seat.

● This location of lifting handle means the

carriage dip angle increases and unload.

Fig. 2.1-2

● This location of lifting handle means the

carriage dip angle remain unchanged.

Fig. 2.1-3

● 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.

Fig. 2.1-4

● This location of lifting handle means the

carriage dip angle decreases,and the

carriage will be downward to locate on the

frame.

Fig. 2.1-5

2-6

Safety

(2) Carriage warning labels

● This label are located at right cab gate of

cab, hydraulic oil tank and fuel tank. When

the carriage dip angle decrease until

located on the frame, neighboring people

should be careful to prevent be hurt.

Fig. 2.1-6

(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.

Fig. 2.1-7

(4)Hydraulic oil position

● This label is located on the hydraulic oil

tank.

● It means the hydraulic oil position, oil

should be visible in sight gauge.

Fig. 2.1-8

2-7

Safety

(5)Cab welding warning label

● This label is located at the right cab gate

side.

● Do not weld or burn CAB components

unless acoustical foam is removed.

Fig. 2.1-9

(6)No standing warning label

● This label is located 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.

Fig. 2.1-10

(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.

192.52in

Be care when the machine pass through

193.70in

cave or bridge.

Fig. 2.1-11

2-8

Safety

(8)Accumulator warning label

● This label is located on the barrel wall of

WARNING

accumulator.

● To prevent personal injury and equipment

HIGH PRESSURE

Do not remove valves or fittings until pressure is

damage, be sure pressure in the

all released.

accumulator is relieved completely before

ACCUMULATOR

Use Only Nitrogen Gas,Charging Pressure:

disassembling valves and connects.

5.7 MPa,Ensure nitrogen precharge for

proper operation of steering system.

Fig. 2.1-12

(9)Tyre warning label

● To prevent personal injury and equipment

damage, please read service manual

carefully before tyre aeration or

maintenance.

Fig. 2.1-13

(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.

Fig. 2.1-14

2-9

Safety

(11)Alternator warning label

● This label is located on the battery box.

Please do as the warning label and

handbook when operating machine.

Fig. 2.1-15

(12)Grounding label

● This label is located on the top battery

box.

● It means there is a negative electrode

grounding system in battery assembly.

Fig. 2.1-16

(13)Cliver label

● There are four cliver position, two borrow

joint hole between rear tail seat and

carriage, two located below bumper.

Fig. 2.1-17

2-10

Safety

(14)Suspension warning label

● This label 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.

Fig. 2.1-18

(15) Open water cap warning label

● This label is located on the distance water

box.

●

To prevent personal injury ,never remove

WARNING

hot radiator cap.

Never remove hot rediator cap

Fig. 2.1-19

2-11

Safety

2.2 General Precautions

2.2.1 Safety rules

● Only trained personnel are allowed to

operate and service the machine.

● All safety rules, precautions and

instructions must be followed when

operating and servicing the machine.

● Taking alcohol or drug could seriously

impair one's ability in operating or

repairing the machine, and it is hazardous

for you and other persons.

● When working with another operator or

job site traffic signalman, be sure to make

all people understand all 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 (PPE) suitable for the

environment of the job site. You may need:

● Hard hat

● Safety shoes

● Safety glasses, goggles or face shield

● Reflective protective clothing

● Hearing protection

● Dust mask

Wear all necessary PPEs as well as other

equipment required by your employer, local

Fig. 2.2-1

government, and local laws and regulations.

2-12

Safety

Never take a risk.

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 goggles, face masks,

gloves, hearing protection and safety belt if

necessary.

Make sure all PPEs are in good condition

before use.

Fig. 2.2-2

Never listen to radio or music with ear plugs

on during operation.

2.2.4 Fire extinguisher and first aid kit

To prevent injury or fire, observe the following

precautions:

● First aid kit and fire extinguisher should be

available nearby.

● Read and understand the instruction

attached to fire extinguisher. Use fire

extinguisher properly.

● Regular inspection and maintenance shall

be done to ensure proper functioning of

fire extinguisher at any time.

● Check the first aid kit regularly and

replenish it when necessary.

● Make emergency scheme to deal with fire

and accidents.

Fig. 2.2-3

2-13

Safety

2.2.5 Safety equipment

To protect you and others around you, your

machine may be equipped with the following

safety equipment. Make sure that they are

secured in place and in good condition.

● Falling Object Protection (Body pivot pin)

● Rollover Protection

● Sealt belt

● Lamps

● Horn

● Guards

● Backup alarm

Fig. 2.2-4

● Mirrors

● Fire extinguisher

CAUTION

● Make sure all covers and caps are in

proper place. Repair or replace any of them

immediately once found damaged.

● Know how to use these facilities and use

them correctly.

● Never remove the guard rail of the operator

cab (unless necessary) .

2.2.6 Cleaning your machine

● Clean the windshields, mirrors and lights.

Make sure that the operating 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

Fig. 2.2-5

(including sensors, connectors, etc.) with

water or steam.

2-14

Safety

2.2.7 Keeping the cab clean

● Clean the mud and oil on your soles when

getting into the cab. Mud or oil under

your shoes can cause your foot to slip on

the pedal during operation, and serious

accident could result.

● Remove all loose personal items or other

objects from the operator's area. Secure

these items in the tool box or remove

them from the machine.

● Never use cellular phone when operating

or driving the machine.

● 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

1

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 (1) at Neutral, set parking

brake switch to PARKING, set the dump

● control lever to HOLD, then stop the

engine.

● Remove the key from the starting switch.

Fig. 2.2-6

● Lock all the doors of the operator’s

compartment.Take the key with you and

leave it in the specified place.

2-15

Safety

2.2.9 Handholds and steps

To avoid risk of injury when getting on or

off the machine.

●

Always face the machine and maintain at

least three-point contact (both feet and

one hand, or both hands and one foot)

with the handrail and steps to ensure that

A

you support yourself.

B

●

Always check the handrails and steps

A

for oil, grease, or mud. Wipe them clean

before using.

A

●

Repair any damage and tighten any loose

B

bolts.

A

●

Never get on or off the machine while

B

holding tools in your hand.

Fig. 2.2-7

●

Never climb onto the engine hood, covers,

or other places where there are no anti-

slip pads.

●

When entering the operator’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 bone or suffer

other serious injury when landing.

Fig. 2.2-8

●

Never get on or off a moving machine.

You may be unable to support yourself

with the handrail or steps, and fall from

the machine, suffering injury. Even if the

machine starts off with no operator on it,

do not jump on the machine and try to

stop it.

2-16

Safety

2.2.10 Preventing burns

2.2.10.1 Hot coolant

● To prevent burns caused by hot coolant or

steam when checking or discharging the

coolant, wait until the engine coolant is

cool enough before proceeding.

● Never open 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.

Fig. 2.2-9

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 to

relieve internal pressure.

Fig. 2.2-10

Fig. 2.2-11

2-17

Safety

2.2.11 Preventing fire and explosion

2.2.11.1 Fire caused by fuel or oils

● Engine oil and fuel must be stored in

designated place, where unauthorized

persons cannot enter.

● Never smoke or 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

Fig. 2.2-12

oil leakage.

● Tighten, repair or replace any

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. 2.2-13

Fig. 2.2-14

2-18

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