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Sany SRT55D Off-Highway Truck. Safety, Operation and Maintenance Manual (2014) - page 3

Safety

2.4.5 Stop engine before carrying out

maintenance

● Park the machine on solid and flat ground.

● Lower the bucket to the ground.

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！

● Lower the dump body, set dump control

lever (1) to the HOLD position, lock the

dump control lever , then stop the engine.

2

1

Fig. 2.4-5

● Set parking brake switch (2) to the

PARKING position and put blocks under

the tires to prevent the machine from

moving.

Fig. 2.4-6

2-40

Safety

2.4.6 Maintenance with engine running

To prevent injury, no maintenance shall

be carried out when the engine is running.

However, if maintenance has to be done on

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！

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

2

engine at any time. All the workers

involved shall keep in touch.

● set dump control lever (1) to the HOLD

1

position,then set parking brake switch (2)

to the PARKING position.

Fig. 2.4-7

Fig. 2.4-8

2-41

Safety

2.4.7 Using proper tools

Use proper tools and use them correctly.

Using damaged, inferior, defective, temporary

tools or using the tools incorrectly could lead

to serious accidents.

Fig. 2.4-9

2.4.8 Handling suspension cylinder

The suspension cylinder and accumulator

are charged with high-pressure nitrogen gas.

If any mistake is made in handling, there is

danger that it may cause an explosion or

serious personal injury.

● Do 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, blocks

or supports that are strong enough to

support the machine or work equipment

should be used.

● When carrying out inspection with the

dump body raised, always set the dump

control lever to the HOLD position, then

Fig. 2.4-10

insert the body pivot pin.

2-42

Safety

2.4.14 Precautions with high-pressure

oil

The hydraulic system is always under

pressure.Make sure pressure in hydraulic

circuits has been relieved before checking or

replacing the lines. Residual pressure in the

circuit may cause serious accidents.

Release system pressure before

maintainingthe hydraulic system:

1) Remove thebutterfly nut of the vent

valve and pressthe venting button to release

the internalpressure of the hydraulic tank;

2) Shut down engine.Rotate steering

wheel to the two directions for several turns

and release steering system pressure. Press

foot valve continuously to release pressure of

Fig. 2.4-12

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. Never

touch leaking liquid with bare hand. Wear

face shield or safety goggles to protect

your eyes. If any liquid penetrates your

skin, flush with clean water immediately

and get medical attention as soon as

possible.

●

The fuel lines are under high pressure

when the engine is running. When

checking or servicing the fuel system,

shut down the engine and wait for 30

seconds till internal pressure drops before

operation.

2-44

Safety

2.4.17 Air-conditioning system

Keep fire source away when servicing

airconditioning system.

● In maintenance of air-conditioning

system, observe the instruction on the

refrigerant cylinder and use it correctly.

The type of refrigerant is R134a. Use of

other refrigerants may damage the air-

conditioning system.

● Refrigerant getting into eyes may cause

blindness. It may cause frostbite if

splashed on your skin.

Fig. 2.4-14

● 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 there is danger of electrocution,

never touch fuel injector or interior of

engine controller.

● Please contact Sany distributor if you

have to access fuel injector terminal or

interior of engine controller.

Fig. 2.4-15

2-46

Safety

2.4.19 Accumulator

Accumulator contains highly pressurized

nitrogen.Improper operation of accumulator

can cause explosion and serious accidents.

Therefore, the following precautions must be

observed:

● Never disassemble the accumulator.

● Never let the accumulator be near a fire

source or exposed in flame.

● Never punch, weld or flame-cut on

accumulator.

● Never strike or roll the accumulator, or let

Fig. 2.4-16

it bear any impact.

● The gas must be released when 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 shut down and

electrical equipment must be switched

off when refueling the tank. Be extremely

careful when adding fuel to a hot engine.

No sparks shall occur around the

grounding nozzle.

● Handle all solvents and dry chemicals in

a place with good ventilation according to

the steps indicated on vessel.

2-47

Safety

or illegible signs and marks.

● Tighten all fasteners and connectors to

specified torque.

● Install all guards, covers and hoods

after repair and service. Replace or

repair damaged guards. Only the type of

hydraulic oil approved or recommended

by Sany should be used to make up the

hydraulic system.

● Start the engine and check for any

leaks (check the hydraulic system), and

operate all control devices to be sure of

their proper functioning. Make road test

if necessary. Shut down the engine and

check the work you have done (see 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,

Fig. 2.4-17

fuel, cooling liquid, refrigerant, filter and

batteries etc.

● Use leak-proof vessels to hold discharged

fluids. Never use food or beverage

containers.

● Never dump waste fluids directly to the

ground, sewage or water source.

● Leaking of refrigerant from air conditioner

can spoil the atmosphere of the globe.

Related laws and regulations must be

followed to recover or regenerate the

refrigerant.

Fig. 2.4-18

2-49

Safety

2.5 Precautions With Tires

2.5.1 Handling tires

Explosive separation of a tire and/or rim parts

can cause serious injury or death.To ensure

safety, always do as follows.

●

When carrying out maintenance,

disassembly, repair, or assembly of the

tire or rim, special tools and procedures

must be used. Always ask your Komatsu

distributor to do the work.

●

Use only specified tires and inflate them

to the specified pressure.

●

When pumping up the tires, check that no

other person is standing near the tire, and

install an air chuck with a clip that can be

secured to the air valve. To prevent the

tire inflation pressure from becoming too

Fig. 2.5-1

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

set up a protective fence around the tire,

and do not stand directly in front of the

rim. Stand beside the tread when pumping

Fig. 2.5-2

up the

●

Do not adjust the tire inflation pressure

immediately after traveling at high speed

or carrying out operations under heavy

load.

●

Never carry out welding or light a fire near

the tire.

●

Always release all pressure from a single

tire, or from both tires of a dual assembly,

prior to removing any rim components.

2-50

Safety

2.5.2 Precautions when storing tire

● Store the tires in a warehouse where

unauthorized persons cannot enter.

Always erect a fence and put up "No

Entry" signs if the tires must be stored

Block

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

Fig. 2.5-3

to stop it. Get out of the way quickly.

2-51

Controls and Operating

3 CONTROLS AND OPERATING

3.1 Controls and Instruments

1

2

3

4

P ！

！

5

10

9

6

20

8

19

7

18

11

17

12

16

15

13

21

14

Fig 3-1

1. Air Outlet

11.Transmission Gear Shift Selector

2.Combination instrument

12.Retarder Control

3. Reversing Monitor

13. Hydraulic Retarder Lever

4. Air Outlet

14. Service brake pedal

5. Air Outlet

15. Ignition and Starter Key Switch

6. Switch

16. Steering Wheel

7. Radio / MP3

17. Horm control

8. Emergency brake button

18. Headlight Dipper, Direction Indicator, Wind-

screen Wiper/Washer

9. Cigar lighter

19. Air Conditioner Control

10. Accelerator Control

20. Body Control Lever

3-1

Controls and Operating

1

2

3

4

5

6

7

8

9 10 11

12 13

P

！

！

17

16

15

14

P

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！

Fig 3-2

3.2 Indicator

1. Left steering Indicator (Green) - Flashes

when the left indicator lights are operating.

2. Parking Brake (Red)-Illuminates when the

parking brake is applied.

3. Body up (Yellow) - Illuminates to indicate

that the body is NOT resting on the chassis.

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 head lamps start to work.

7 High beam Indicator (Blue)-Illuminates when

high beam head lamps start to work.

8. Fog Indicator (Yellow) - Such lamp will be

on when fog lamps start to work.

9.Rear Indicator (white)

10. Engine Stop Indicator Red) - When the

'Stop' light comes on, the computer has

3-2

Controls and Operating

1

2

P

！

！

7

6

5

4

3

Fig 3-3

3.3 Instruments

1. Tachometer

Driven by CAN bus; it indicates engine speed

in revolutions per minute. When 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.

2. Speedometer

Driven by CAN bus; it indicates vehicle

running speed. When 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 is

normal, and once the pointer is located in red

area that transmission oil temperature is too

high, movement, the buzzer for 10 seconds,

then shut down automatically. In the electric

power the same fault buzzer action only once.

3-4

Controls and Operating

4. Fuel level gauge

The pointer indicates percent of full tank

a actual fuel level. Such meter is directly

connected to fuel level sensor. When the

pointer is located in white area said fuel level

is normal, and once the pointer is located in

red area that fuel level is too low, movement,

the buzzer for 10 seconds, then shut down

automatically. In the electric power the same

fault buzzer action only once.

SANY MINING EQUIPMENT

5. Display

1. Turn on power supply, start the key switch

toΙ, the display shows "sany " boot screen(see

fig3-3.1), and all of the signal indicators are

Fig 3-3.1

applied, 3 seconds after the display shows

work interface, the lights go out at the same

time.

08-25-2012

15:10:25

Wed

SANY Mining Equipment

Engine

2. Click F2 key to change from work interface

Transmission

to system function interface, and the work

Monitor

interface is default(see fig3-3.2).

VEH DIST

ENG HRS

XXXXXX

km

XXXXX.Xh

Fig 3-3.2

3. Enter 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).

System Function

SANYI

Engine information

Parameters query

4. Under the system function interface, click

Parameters setting

Monitoring system

the F3 key or F4 key to choose the function

Restore password

Controller I/O

Backlight adjust

and click F2 key to confirm.

System time setting

Buzzer time setting

Chinese

English

Take the case of setting system time to

demonstrate operation method:

F1:ESC F2:Enter F3:

F4:

Under the system function interface:

a. click F3 key or F4 key to choose the number

of the time;

Fig 3-3.3

3-5

Controls and Operating

b. click F2 key to confirm, then the cursor will

automatically move to the next number(see

System Time Setting

fig3-3.4);

SANYI

c. When the cursor to the last digit (the second

single digits) , click F2 key to confirm the

2012Y08M13D

current changes, and then click F2 key again

12H30M25S

to end the modify Settings until appear a

square green claim(see fig3-3.5),

d. Click F1 key to return to the system function

F1: ESC F2: Enter F 3:

F4:

interface.

6. Engine Water Temperature Gauge

Driven by CAN bus; it indicates engine coolant

Fig 3-3.4

temperature value. When the pointer is located

in white area said engine coolant temperature

is normal, and once the pointer is located in

System Time Setting

red area that engine coolant temperature is too

SANYI

high, movement, the buzzer for 10 seconds,

then shut down automatically. In the electric

2012Y08M13D

power the same fault buzzer action only once.

12H30M25S

7. Engine Oil Pressure Gauge

Driven by CAN bus; it indicates engine oil

pressure value. When the pointer is located in

F1: ESC F2: Enter F 3:

F4:

white area said engine oil pressure is normal,

and once the pointer is located in red area that

engine oil pressure is too high, movement,

Fig 3-3.5

the buzzer for 10 seconds, then shut down

automatically. In the electric power the same

fault buzzer action only once.

3.4 Reversing Monitoring System

Power Supply

Indicator

The monitor (see Fig 3-4) on instrument panel

Power

is mainly used for monitoring the reversing

Supply

truck as well as watching the situation behind

Menu

č+Ď

truck. The matching camera is at the rear part

č-Ď

of truck.

Mirror

Operation instructions:

/Normal

Light

1.Power Supply Switch

Sensor

There are two methods available for turning

on the monitor: The monitor will be turned on

Fig 3-4

automatically when the transmission gear shift

selector is placed at REVERSE position; press

down the power supply key on monitor to turn

3-6

Controls and Operating

on the monitor, and press again to turn off the

monitor.

The Power Supply Indicator (Red) will be on

when the monitor is turned on and it will be off

when the monitor is turned off.

2.Contrast Control

Press the MENU key until Contrast appears

on the screen, then press “+” or “-” key to

increase or decrease image contrast.

3.Brightness Control

Press the MENU key until Brightness appears

on the screen, then press “+” or “-” key to

increase or decrease image brightness.

4.Volume Control

Press the MENU key until Volume appears

on the screen, then press “+” or “-” key to

increase or decrease volume.

5.Mirror/ Normal Selection

Press such 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

Fig 3-5

1. Economical/Powerful Mode Switch

Allows the operator to select between the

transmission 'POWER' and 'ECONOMY' shift

schedules.

3-7

Controls and Operating

3.6 Combined Switch

1. Horn

Button pushed in = Horn Sounds.

2. Washer

Ring Pushed = Windscreen wash

3. Windscreen Wiper

Position J = Not used

Position 0 = Stop, reset wiper

Position I = Wiper Slow Speed

Position Ⅱ = Wiper Fast Speed

4. Headlight Dipper and Flasher

Control downwards = Main Beam

Neutral Position = Dipped Beam

Control Upwards = Headlight Flash

Fig 3-6

3.7 Air Conditioner Control Panel

3.7.1 Air conditioner control panel

设置

C

图 3-7

Set up

C

Set up

C

Set up

C

Set up

C

Set up

C

Refrigeration mode

ḤHeat mode

Circulating mode

Defrosting mode

Blower mode

Panel display picture

3-9

ON/OFF

Refrigeration/ Heat

Auto/ Manual

key-press

key-press

key-press

Defrosting

Air circulating

Blower mode

key-press

key-press

key-press

Wind speed

Temperature adju-

key-press

sting key-press

Panel key-press picture

Operation instructions

a. Open

Press power supply key to turn on the

ON

machine; the controller will automatically

OFF

select the working mode according to the air

conditioning system inside truck; then press

图3-7.1

power supply key to turn off power supply and

all the outputs.

b. Blower mode

Press mode key to set air conditioner working

Ḥ设置

C

mode (automatic, refrigerating, heating,

ventilating).

图3-7.2

c. Refrigeration

Forced refrigerating function:

1. On blower mode, press Refrigeration/ Heat

Ḥഡᇂ

C

key-press, air conditioner is on refrigeration

statues, LO will be displayed to activate forced

refrigerating mode when the temperature is

set smaller than 15°C(larger than 30°C) under

refrigerating mode. On refrigeration statues,

图3-7.3

press wind speed key-press can adjust wind

speed(low,middle and high).

2. On refrigeration statues, wind speed is on

high (wind speed and night mode can adjust

but temperature can not).

3-10

d. Heating mode

Forced heating function: HI will be displayed

to activate forced heating mode when the

Ḥഡᇂ

C

temperature is set larger than 30°C(smaller

than 15°C) under heating mode. On heating

statues, press wind speed key-press can

adjust wind speed(low,middle and high).

图3-7.4

e. Defrosting mode

1. Press defrosting key-press, it is on defrosting

statues, press wind speed key-press can

Ḥഡᇂ

C

adjust wind speed(low,middle and high).

2. Automatic defrosting function: During

refrigerating, the temperature of defrosting

sensor is smaller than 1.5°C, the compressor

图3-7.15

will turn off; it will turn on if the temperature of

defrosting sensor is smaller than 4°C.On other

status it will enter core defrosting.

f. Fresh air function

The external circulation is used for blowing

Ḥഡᇂ

C

fresh air and the internal circulation for

stopping fresh air intake.

图3-7.13

3.8 Driver Seat

1. Forward and backward adjustment

Pull the lever (2) upward, slide the seat to

desired position, and release the lever.

Adjustment space: 210mm (10mm for each

adjustment)

2. Backrest adjustment

Lift handle (3), move the backrest to an

optimum position at where operation can be

easily conducted, and release the handle.

3. Height adjustment

3

The seat can be raised by 30 mm when you

2

hear a "click" sound, and another 30 mm at

the second "click". The seat can be lowered to

the minimum height if you continue to raise it.

1

4. Suspension adjustment (if equipped)

Fig 3.8

3-11

Controls and Operating

Turning the adjusting handle (1) clockwise will

bring you a hard suspension which is suitable

for heavy operator; turning the adjusting

handle (1) counterclockwise will bring you

a soft suspension which is suitable for light

operator.

Remark: To achieve the best adjustment,

adjust the reading (kg) on the green indication

belt to weight of operator, which is on the left

side of the adjusting handle.

Adjustment scope: 50Kg-130Kg

5. Headrest height adjustment

Adjust headrest up and down.

Adjustment scope: 105mm (see Fig 3-8)..

warning

Do not attempt to adjust the seat or

seat belt while the machine is moving.

Loss of control may result. Stop the

machine; apply the brakes;then adjust.

1

3.9 Seat Belt

2

Adjust the seat to the best height which does

not affect the driving. Completely release the

Fig 3-9

seat belt (1), sit down on the seat, pull out seat

belt (1), and buckle up lock catch (2). In order

to remove the seat belt, press the button on

lock catch (2) to pop up seat belt (1) (see Fig

3-9).

3-12

Controls and Operating

3.10 Truck Controls

！

！

Parking brake switch

Ernergency

brake switch

P

Foot pedal

Fig 3.10

3.10.1 Braking

The truck is provided with following brake

methods: Service brake, parking brake,

emergency brake, retarder, which can be

selected according to the actual condition.

Use service brake during normal operation;

Use parking brake during 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.

(see Figure 3-10).

3-13

Controls and Operating

3.10.3 Parking Brake

Pushing the control in will apply the spring

operated parking brakes within the rear brake

assemblies and the rear service brakes. The

front service brakes will not apply when the

parking brake control is operated.

warning

Always apply the parking brake before

leaving the operator's seat.

3.10.4 Emergency brake

Pushing the control switch in an emergency.

To release the brakes, turn the control

clockwise.

Note:Try to avoid using the control switch.

For normal braking the service brake pedal

should be employed.

3.10.5 Retarder

Refer to Fig3-11, this truck is equipped with

2

two retarders: the transmission retarder and

the rear disk brake retarder. The handle (2) is

used to control the rear disk brake retarder.

1

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 be used anytime

to slow down. If additional braking is required

apply the service brakes. The retarder is not

meant for bringing the machine to a halt, or

Fig.3-11

for sudden deceleration - the service brakes

should be employed for this purpose.

When the retarder is applied, the ' Retarder

Indicator Light ' on the instrument panel will

illuminate and an orange coloured warning

light at the rear of the truck will illuminate to

warn following trucks.

3-14

Controls and Operating

through the disc brake assemblies overheats.

If alarm is activated, reduce downgrade travel

speed. If the trouble persists, stop the machine

and have the fault corrected.

(3) Oil Temperature - Transmission

During normal operation the transmission oil

temperature gauge should read in the green

zone. However, during transmission retarder

operation oil temperature can enter the yellow

' RETARDER ON ' zone but should not enter

the red zone. Do not allow the temperature

to stay at or near the top of the yellow zone

for more than 3 minutes. Reduce downgrade

travel speed to avoid the oil overheating and

possible damage to the transmission.

warning

Great care should be used if applying

the retarder when road surfaces are

slippery. Retarder braking effect will

occur only at the driving axle and

could make truck control difficult.

3.11 Engine

3.11.1 Electronic Foot Pedal

The electronic foot 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 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.

Fig.3-12

3-16

Controls and Operating

3.11.2 Quantum electronic fuel system

This machine is equipped with the Quantum

Electronic Fuel System, an electronic engine

control system, which continually monitors

the engine and warns the operator when a

problem develops. The system also takes

action to prevent damage to the engine and,

provides the serviceman with diagnostic

capabilities so that problems can be corrected

quickly and easily.

2

1

4

5

6

7

3

P

！

！

Fig.3-13

1.Electronic Control Module (ECM)

5. Stop light

2&3. Harness connector (31 and 21pin RHS)

6. Maintenance indicator

4.Electronic Foot Pedal

7. Warning light

warning

Before any welding is done on a

machine equipped with the Quantum

Electronic Fuel System, disconnect the

following in this order:

Battery earth cable, battery supply

cable, alternator earth cables,

alternator supply cables, transmission

black box connector, ECM interface

harness connector (30 pin RHS), ECM

power harness connector (5 pin RHS)

and ECM sensor harness connector

3-17

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