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

Operating the Truck

4.7 Braking Function Check

Determination the function of the braking

system before the working each times for

safety !

Caution:The following checks are NOT

intended to measure maximum brake holding

ability. If NEW brake pads are fitted, they

MUST be burnished as per the manufacturers

recommendations before carrying out the

checks.

WARNING

Make sure the surrounding area of

truck is free of person and barrier

before checking brake 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 machine should not move

before engine speed increased to 1350 r/min.

following sequence as below when the

checking has been finish:

1. Decelerate the engine;

2. Shift transmission to NEUTRAL brake;

3. Apply the parking brake;

4. Release the service brake pedal.

4-12

Operating the Truck

4.9 Emergency Brake

Performance Check

Following the methods and sequence at below

for checking in sequence :

1. Depress the service brake pedal;

2. Release emergency brake;

3. Select 1st gear on the transmission shift

selector;

4. Apply emergency brake;

5. Release service brake pedal;

6. Depress the accelerator pedal,

Inspection,the machine should not move

before engine speed increased to 1350 r/min.

Then, decelerate the engine and select 1st

gear on the transmission shift selector.

Caution:

1. Brake holding effort required to hold a

machine static at a specific engine speed,

can vary from machine to machine due 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 instruments and

warning lights. All instruments should operate

in their normal range and all warning lights

should be out except possibly the Direction

Indicator and Headlight Main Beam warning

lights.

Make sure the area around the machine is

clear of personnel and obstructions before

driving off.

Fig. 4.21

In the first few minutes of travel, check

carefully for the required steering, braking,

4-13

Operating the Truck

engine and transmission power response for

maximum operating safety.

1. Make sure the body is fully down and body

control lever is in the 'FLOAT' position.(see

Figure. 4-21)

MODE

2. Apply the service brake and release the

parking brake.

3. Select the driving direction and the required

range.(see Figure. 4-22)

4. Sound horn; two blasts for forward and

three blasts for reverse.

5. Release the service brake, apply the

Fig. 4-22

accelerator and move off.

6. To stop the machine release the accelerator

and depress the service brake pedal. Release

the service brake as the machine slows until,

when stopped, the pedal is depressed just

enough to 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

parking brake switch

an emergency.

Fig 4.23

4.11 Stopping the Engine

1. Make sure the parking brake control is in

the 'PARK' position. (see Fig.4-23).

MODE

2. Make sure the transmission is in

'NEUTRAL'.(see Fig.4-24).

3. Allow the engine to idle 3 - 5 minutes after

a full load operation before shutting it off.

Fig. 4-24

4-14

Operating the Truck

This allows the engine to cool gradually and

uniformly.

WARNING

There is no mechanical connection

between the engine and wheels

on machines with converter

transmissions. The parking brake must

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).

Fig 4.25

5. Make sure the body control lever is in the

'FLOAT' position. (see Fig.4-26).

Fig. 4-26

6. Turn the ignition key switch to the 'OFF'

position ('0'). (see Fig.4-27).

Fig. 4-27

4-15

Operating the Truck

4.12 Parking

When parking the machine overnight, or for

an extended period, the following procedure in

addition to that given in 'Stopping the Engine'

will help maintain it in good condition for

subsequent use:

1. Fill the fuel tank completely, to prevent

condensation. If security kit is supplied, keep it

locked.

2. Always park the machine on level ground

where possible. If the machine must be

parked on a grade, position the machine at

right angles to the grade and block the wheels

securely.

3. If below freezing temperatures are

expected, make sure 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 control to alert others if

lubricant has been drained, batteries removed

etc.

4.13 Prolonged Storage

Turn the circuit breaker beside battery to

“shutoff” position to prevent battery leakage

when removing CEC memory and radio power

supply.

Retune the radio if the circuit breaker is set

again.

Note: The code in CEC memory may be lost

after the power supply is disconnected.

4-16

Working the Truck

5 WORKING THE TRUCK

5.1 Working the Truck

Off-Highway trucks are used on a variety of

hauling jobs, from mine overburden removal

to dam building. Every truck operation,

regardless of the type of job, can be divided

into four phases; loading, hauling, dumping

and the empty return.

Note: After coming to a stop for loading or

unloading the truck, the Parking-Emergency

brake button can be pushed in to hold the

brakes in the applied position as though the

foot brake is depressed.

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. And the shorter the

distance the loading unit bucket must travel

between the cut, or stockpile and the truck

body, the more passes it can make in a given

Fig. 5-1

period of time and the quicker the truck can be

loaded.

Ideally, the hydraulic excavator or rope shovel

should require 90o or less swing to dump

into the truck body for best loading efficiency.

Required turning and backing to position the

truck for loading should be held to a minimum.

A common loading method is to have trucks

travel a semicircle in the loading area. This

method eliminates all backing. Waiting

machines should stay about two trucklengths

Fig. 5-2

behind the one being loaded to avoid any

spillage from the loading machine bucket or

truck body. The operator of the waiting truck is

5-1

Working the Truck

also better able to judge the best spot for his

truck when it is his turn to be loaded(refer to

fig.5-3).

On some jobs, the loading machine might work

most efficiently when trucks are positioned

on both sides of the loader. Thus, while one

truck is being loaded, another can move into

Stay Two Lengths

position on the opposite side of the loader

Behind

and the loading machine can swing over to

load the next truck with a minimum of lost

Fig. 5-3

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.5-4).

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 face of the

bank or stockpile. This minimizes loader travel

time, particularly with a raised, full bucket.

Where possible, the truck should also locate

Two-side loading

downwind of the loader when dusty-type

material is being loaded on a windy day. This

Fig .5-4

practice improves both working conditions and

visibility for the loader operator(refer to fig.5-

5).

A cleanup dozer or small loader is often

working in conjunction with the main loading

machine to keep the area clear of bucket

spillage for maximum efficiency of the loading

operation. The truck operator must always be

alert to the position of the cleanup machine

when entering the loading area to avoid

congestion, and for maximum safety(fig.5-6).

The following precautions should be observed

when approaching the loading area and while

being loaded.

Fig. 5-5

Avoid rocks and other shovel spillage that

can needlessly damage tyres or other truck

components. Allow the cleanup machine

sufficient time to clear up such debris.

Do not move the truck into loading position

with the shovel bucket swinging overhead.

5-2

Working the Truck

Large rocks that might fall from the bucket can

be dangerous to both the truck and operator.

Keep your head and arms inside the cab

during loading to avoid the danger of falling

rocks or other shovel spillage.

When the loader operator signals that the

truck is loaded, sound two blasts on the horn,

release the brakes and shift the transmission

Take care of other

to drive (D). Move out of the loading area

trucks

and onto the haul road with the least possible

Fig. 5-6

delay to allow any waiting truck to move into

the loading position as soon as possible(refer

to fig.5-7).

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 approaching downgrades, select

the proper transmission range and use the

retarder and service brakes as required to

maintain safe descent speed without over-

speeding the engine or gaining excess travel

speed. Generally, the transmission range

Fig. 5-7

required for ascending is also correct for

descending a grade(refer to fig.5-8).

Always remain a safe distance behind the

machine ahead, particularly on downgrades.

A good rule-of-thumb to follow is to allow two

(2) truck-lengths between machines for each

15 km/h (10 mile/h) of travel speed under

normal operating conditions. Under adverse

conditions, allow more room for safe operation.

On jobs on which minimum distance between

machines is specified for the haul road, be

sure to observe the regulations at all times.

Such regulations would be established for the

safety of everyone on the job(refer to fig.5-10).

Pay attention to haul road conditions to

Fig.5-8

avoid rocks, holes, or other obstacles. Such

obstacles not only present hazards to safe

5-3

Working the Truck

operation, but can needlessly damage tyres

and rides if not avoided(refer to fig.5-10).

Be sure to reduce speed and come to a full

stop, as required, at intersections, rail-roads,

public highways etc.. Where a 'FLAGMAN' is

stationed to direct traffic, always stay alert and

follow his directions.

Safety first

5.4 Dumping

Fig .5-9

The dumping operation usually depends upon

the type of material 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

Fig. 5.-10

this size. While backing to dump, the operator

must watch the 'SPOTTER' at all times and

follow his direction. Under no circumstances

should the operator leave his seat to gain

better visibility while backing(refer to fig.5-11).

Always remain seated to maintain maximum

machine control(refer to fig.5-12).

Mineral ores, blasted rock etc., are usually

dumped into a hopper or crusher where it is

processed before shipment. When dumping

into a hopper, the operator, in order to

avoid excess wear on the tyres, must avoid

Fig .5-11

hitting the protecting rail at the hopper. If a

DRIVEOVER HOPPER is used, the operator

must avoid rubbing the tyre inner sidewalls.

When hauling dirt or rock from a borrow pit into

a fill area such as an earth-fill dam, the load

is usually dumped in a string with other loads

and the loads smoothed out with a crawler

tractor. When dumping on a fill of this type,

the operator usually works alone and picks his

own dumping place. To save bulldozer work

and cleaning up, the load should be dumped

Fig. 5-12

5-4

Working the Truck

as close as possible to the preceding load.

The operator should pull past the preceding

load, turn in line with the string and back his

truck until it is within a few feet of the last load.

This assures that the load will fall in the right

place.

No matter what kind of job the operator is

working, there are a few things which are

common to all jobs and which the operator

should observe. When dumping over a spoil

bank 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.5-13).

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 body hinge pins, hoists

and chassis. Stop the machine, allow the

engine to slow to idle, shift the transmission

to 'NEUTRAL' and apply the brakes with the

Parking-Emergency brake button to hold the

Fig. 5-13

machine stationary(refer to fig.5-14).

Push the body control lever back into the

'RAISE' position and The engine speed should

be holds within 1000rpm for stably during the

starts and ends peroid of rasing the body.

When the body has been raised to the desired

height, release the control lever into the

'HOLD' position until the body is to be lowered.

Do not hold the lever in the 'RAISE' position

when the hoists are fully extended to prevent

unnecessary hydraulic system relief valve

operation.

Fig .5-14

NEVER 'JUMP DUMP' the machine by

bouncing the rear tyres against a stop block,

or otherwise jarring the body in its raised

position to dislodge stuck or frozen material.

The tremendous loads that this practice

develops on the body pin area, chassis

and hydraulic system can cause needless,

5-5

Working the Truck

extensive stresses. (refer to fig.5-15)

Once the load has been dumped, push the

control lever down into the 'FLOAT' position

to allow the body's weight to lower it to the

chassis. If the body does not begin to lower by

its weight, push the control lever 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.

Fig .5-15

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 transmission is shifted to the correct

range before releasing the brakes and moving

away from the dump site.(refer to fig.5-16)

Except for the above, the procedure for

returning empty to the loading area is the

same as that given earlier for 'HAULING'.

WARNING

DO NOT drive the truck with the body

up. Apart from effecting the stability of

Fig. 5-16

the truck, there can be severe danger

from contacting overhead electric

cables, trees, or bridges over the haul

route.

5-6

Roading

6 ROADING

6.1 General

‘ROADING’ (operating a truck over public

highways) requires special care and attention.

Trucks, because of their large size, are

slower and less manoeuvrable than most

other vehicles encountered on the road. Yet,

while on the road, they must be operated for

extended periods of time at or near maximum

speeds.

Before 'ROADING' a truck for an extended

distance between jobs, or between widely

scattered sections of a job, the machine must

be properly equipped and in good condition.

It is also recommended to carry a 'Warning

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.

6-1

Roading

6.2 Preparation Prior to Roading

Lubrication

Thoroughly lubricate and service all

components and systems as described under

'LUBRICATION AND SERVICING' in this

handbook and/or service manuals for this

machine.

Inspection

Perform all pre-starting and post-starting

checks described in this Handbook. Pay

particular attention to the function of all

instruments and lights, and make any repairs

necessary.

Note: Improper tyre inflation during over-

the-road operation can cause rapid tyre

deterioration by overheating. Tyre pressures

increase with heat. Always check pressures

while tyre is cold. Consult your tyre dealer

for proper pressures and tyre speed limits for

roading.

Note: Make sure the body control lever is

in the 'FLOAT' position. Failure to comply to

this caution could result in overheating the

hydraulic oil and failure of the hydraulic system

components.

Check the inflation pressures of all tyres,

while cold, with an accurate tyre pressure

gauge. Inflate tyres if necessary, while cold, to

the recommended pressure for 'ROADING'.

Inspect all tyres thoroughly and carefully for

stones or other debris embedded in the treads

or carcasses. Inspect for cuts, bruises, burned

beads, abnormal wear and damaged wheels

rims. 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.

6-2

Roading

Clean all glass and adjust the seat for proper

operation of all controls.

Check all lights and other controls for proper

operation.

Make sure the truck body is empty, fully

lowered and the body control lever is in the

'FLOAT' position.

6.3 In Case of Trouble

If trouble develops en route, move machine

off the road at the first safe parking place, and

shut off the engine. Carefully note as many

of the symptoms of the trouble as possible,

such as rough engine operation with loss

of power and overheating, or, loss of speed

and transmission clutch pressure with normal

engine operation etc..

If the area in which the trouble occurs requires

that the machine be left unattended while the

trouble is reported by phone, disconnect a

battery cable and apply security locks, if so

equipped, before leaving the parked machine.

Make sure body is completely lowered and the

parking 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 component that

develops a minor defect can be completely

destroyed in just a few extra minutes of

unnecessary operation.

6-3

Moving Disabled Truck

7 MOVING DISABLED TRUCK

7.1 Moving Disabled Truck

Any unusual power train noises noted while

operating the truck should be reported to

those responsible for maintenance. Should

the power train, hydraulic or electrical systems

fail, the machine should be stopped and shut

down immediately until suitable repairs can

be made. If the failure is in the power train

and the truck must be moved to a service

Fig. 7-1

area or workshop to make required repairs,

remove the drive flange covers from the drive

wheels and pull the axle shafts and final

drive planetary sun gears from the planetary

assemblies. This will prevent any possible

additional damage, which may be caused by

the drive wheels 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 engine

operation, repairs must be made on the site of

the breakdown, or special arrangements made

for towing the machine safely to the repair

area without steering and braking power.

WARNING

Uncontrolled machine movement

hazard. There is no mechanical

connection between the machine

wheels and the engine when the

parking brake is released. Before

releasing the parking brake, make sure

the machine wheels are secured with

chock-blocks to prevent or restrict

7-1

Moving Disabled Truck

unexpected machine movement. When

moving the machine with insufficient

hydraulic pressure and power for safe

steering and braking, use extreme

caution to ensure personnel and

property safety.

Connect a suitable towing bar to one of the

lugs on the front bumper of the disabled

machine and reverse another machine, in a

straight and in-line manoeuvre, towards the

disabled machine. Connect the opposite end

of the towing bar to the towing point on the

rear axle of the recovery machine and ensure

that it is securely locked.

Note: An alternative method of towing a

disabled machine is by connecting an A-Frame

arrangement to the lugs on the front bumper

of the disabled machine and the towing point

of the recovery machine.

To prevent possible damage to the

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.

When pulling, take up the slack slowly

to avoid jerking. A chain or cable which

fails under load can cause serious

injury. Stand clear. Do not pull through

a kinked chain or cable. Do not pull or

tow unless the operator’s compartment

is guarded against or out of reach of a

whipping chain or cable. Attach only

to the towing points. Failure to follow

these instructions could cause serious

injury or death.

7-2

Lubrication and Servicing

8 LUBRICATION AND

SERVICING

8.1 Safety Precautions

Do not allow unauthorized personnel to

service or maintain this truck. Study the

Operator’s Handbook and Maintenance

Manual before starting, operating or servicing

this truck. Always follow procedures and safety

precautions detailed in the Service Manual.

Always attach a 'DO NOT OPERATE' or

similar warning sign to ignition switch or a

control before cleaning, lubricating or servicing

the truck. Never allow anyone to work on the

truck while it is moving. Make sure no one is

on the truck before working on it. Do not work

under or near an unblocked or unsupported

body. Always use the body safety pins. Do

not work under or near any unblocked or

unsupported linkage, part 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 engine, transmission

and hydraulic systems, or removing hydraulic

lines, remember that the oil may be hot and

can cause burns to unprotected skin. When

working on or around exhaust components,

remember that the components may be hot

and can cause burns to unprotected skin.

Always deflate the tyre before attempting to

remove any embedded objects or removing

the tyre and rim assembly from the truck.

Always use a self-attaching chuck with a long

airline, and, stand to one side while the tyre

is inflating. Refer to 4.11 in the Maintenance

Manual.

8-1

Lubrication and Servicing

8.2 Lubrication and Maintenance

Lubrication

Lubrication is an essential part of preventive

maintenance. It is important that the

instructions, regarding types of lubricants and

the frequency of their application, be followed

to prolong the useful life of the truck. Periodic

lubrication of moving parts reduces to a

minimum the possibility of mechanical failures.

WARNING

These trucks s are equipped with

engine and transmission oil pans

which permit operation on longitudinal

slopes up to 30° (60%). For operation

on steeper slopes, the factory 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 suppliers.

Thoroughly clean all fittings, caps, plugs etc.,

to prevent dirt from entering any system while

carrying out servicing procedures. Lubricants

must be at operating temperature when

draining.

Note: Do not operate any system unless oil

level is within the recommended operating

levels as indicated on oil level dipstick, sight

gauge or level plug.

8-2

Lubrication and Servicing

Lubrication and Service Chart

Interval

Ref.

No. of

Identification

Service Instructions

Lubricant

Service/Quantities

hours

Points

Check oil level. Add

Engine

As Required

if low.

Check oil level. Add

Transmission

HTF

As Required

if low.

Hoisting/Cooling

Check oil level. Add

As Required

hydraulic tank

if low.

Steering/Braking

Check oil level. Add

As Required

hydraulic tank

if low.

Check coolant level.

Refer to 'Remote Water

Expansion tank

Antifreeze

Add if low.

Tank'

Cooling fan of the

Visually inspect for

engine

debris and damage

Visually inspect all

Refer to the Engine

Belt

belts

Manual

Refer to 'Front

Front & rear

Visually inspect

8&9

Suspension Cylinder' and

suspension cylinders

heights

'Rear Suspension System'

Refer to the label

Air cleaner restriction

Check. Replace

'Requirements for Air

warning light

element if reqd.

Filter Maintenance'

Air cleaner vacuator

Check for proper

valve

operation

Oil-water separator for

Discharge water

engine fuel

Refer to 'Front Wheel

Check condition.

Assembly' and 'Rear

Tyre

Check pressures

Wheel Assembly' in the

when tyres are cold.

Maintenance Manual

Controls, instruments

Check for proper

and warning lights

operation.

8-4

Lubrication and Servicing

Check for leaks

and worn/damaged

General Inspection

parts.

Repair/replace as

required.

Check. Replace

Steering oil return filter

element if reqd.

Check. Replace

Steering pipeline filter

element if reqd.

Front suspension

Lubrication

EP,NLGI

cylinder bearing

Rear suspension

Lubrication

EP,NLGI

cylinder bearing

Steering cylinder

Lubrication

EP,NLGI

bearing

Steering tie rod

Lubrication

EP,NLGI

bearing

A frame spherical

Lubrication

EP,NLGI

bearing

Transverse stabilizer

Lubrication

EP,NLGI

spherical bearing

Body hinge pin

Lubrication

EP,NLGI

Hoisting cylinder

Lubrication

EP,NLGI

bearing

Front and rear drive

Lubrication

EP,NLGI

shaft/ spider

A arm bearing

Lubrication

EP,NLGI

Steering crank pin

Lubrication

EP,NLGI

Engine

Drain and refill

Refer to the Engine

Engine oil flters

Replace filters

Manual

Refer to the Engine

Engine fuel filters

Replace filters

Manual

250

Check DCA

Refer to the Engine

Engine fuel filters

concentration and

DCA4

Manual

replenish

Replace filters if

Engine coolant filters

required

8-5

Lubrication and Servicing

Engine crankcase

Refer to the Engine

Clean

breather

Manual

Engine cooling fan

Check condition

Engine Power Takeoff

Check condition

EPL

(PTO)

Check oil level. Add

Wheel planetaries

EPL

if low.

Differential breather

Clean

EPL

250

Transmission breather

Clean

Air conditioning

Check belt tension.

Refer to the Engine

compressor belt

Adjust if required.

Manual

Accessory drive belts

Check belt tension.

Refer to the Engine

(if fitted)

Adjust if required.lt

Manual

Engine fuel filter

Replace filter

Clean primary tubes

Air cleaner

and inlet screens

Front brake disk

Replace

Hydraulic Tank

Replace breather

Breather

Clean filler neck

Fuel Tank

screen and cap.

Check nitrogen

500

Accumulators

pressures.

Steering Column

Lube.

*EP,NLGI

See note

Universal Joints

Steering Tank

Replace breather

Breather

Transmission

Discharge and refill

HTF

Replace filter

Transmission cleaner

element

Replace filter

Steering oil return filter

element

1000

Hydraulic system

Check pressures at

pressure checks

check points

Replace filter

Hoisting oil return filter

element

Replace filter

Cooling oil return filter

element

8-6

Lubrication and Servicing

Replace filter

Steering pipeline filter

element

1000

Replace filter

Cooling pipeline filter

element

Engine crankcase

Clean/replace filter

filter

element

Drain, clean and

Engine PTO

EPL

refill

1500

Drain, clean and

Differential

EPL

refill

Wheel planetaries

Drain and refill

EPL

Fan idler pivot arm

Lubrication

EP,NLGI

Refer to Note

Hoisting/Cooling

Wash,clean and

hydraulic tank

refill

Steering/braking

Wash,clean and

hydraulic tank

refill

Wash,clean and

Fuel tank

Diesel

refill

Rear brake packs

Drain and refill

2000

Front wheel bearing

Repack

*EP NLGI

Drain, flush and

Cooling system

Antifreeze

refill

Replace the filter

Steering in-line filter

element

Hoisting in-line filter

Wash and replace

Cooling in-line filter

Wash and replace

Air conditioning

Drain, flush and

4000

PAG 100

compressor

refill

Fill compartment one half full.

Note - Lubricate slowly until excess lube is

seen.

EO —Engine oil, refer to 'Recommended

Lubricants'.

EPL—Extreme Pressure Gear Lubricant

meeting

specification MIL-L-2105C

HTF—Allison C-4 hydraulic transmission oil,

refer to 'Recommended Lubricants'.

HO—hydraulic transmission oil, refer to

8-7

Lubrication and Servicing

'Recommended Lubricants'.

EP, NLGI — #2 EP lithium base grease, refer

to 'Recommended Lubricants'.

*EP, NLGI—Extreme Pressure Lithium No.

2 Grease(without 'Molybdenum')., refer to

'Recommended Lubricants'.

PAG OIL - Polyalklene Glycol (PAG)

Compressor Lubricating oil-Low Viscosity

(ISO46).

Small circles on the following illustration

represent points at which lubrication and/

or servicing must take place, at the intervals

indicated on the left hand side of the

lubrication and service chart. The numbered

circles on the illustration contain reference

numbers 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 -Inspect wiper blades

and replace if damaged. Top up washer

reservoir.

After first 10 hours of operation re-torque nuts

to1000-1300 N.m (739-961 pound-foot). Check

torque every 50 hours (weekly) thereafter.

Every 10 hours of operation

Walk around for inspection - Inspect the truck

according to instructions in Chapter 4 of the

Operation Manual.

Engine - Visually check engine for damage,

loose or frayed belts and listen for any unusual

noises.

8-8

Lubrication and Servicing

Engine Air Cleaners - Check air cleaner

piping, hoses and clamps. Change air

cleaner element only when air cleaner flow

restriction warning light illuminates. Service

vacuator valve daily. Inspect and remove any

obstructions from the vacuator valve lips.

Valve lips should be open and pliable with

engine stopped.

Note: Service air cleaners more often under

extremely dusty operating conditions.Radiator

Header Tank - Check coolant level and add if

low. Fill radiator header tank with coolant until

coolant reaches the bottom of the filler neck

and holds at that level.

Note: Any time a significant amount of coolant

is added, the DCA4 concentration MUST be

checked. If the concentration 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 light with the truck

empty,brakes released, oil at normal operating

temperature, engine operating at 1 500 r/min

and while turning the steering wheel at one

turn/sec. If the warning light illuminates, the

filter element should be replaced.

Replace the filter element,If the warning light

illuminates.

Fuel pre-filter - Discharge water and impurities.

Refer to Chapter 33 'HYDRAULIC TANK

MOUNTING'.

After first 150 hours of operating new or

rebuilt components.

Transmission - Drain oil, replace filters and

refill.

Differential - Drain oil and refill.

Planetaries - Drain oil and refill

8-9

Lubrication and Servicing

Every 250 hours of operation

Coolant Additive - Check and replenish DCA4

concentration as described.Coolant Filter(s) -

Replace coolant filter(s) if required. When

testing the DCA4 concentration, depending

on the level of DCA4, the coolant filter(s) may

not necessarily have to be changed.Refer to

Chapter 15 'WATER TANK MOUNTING AND

LINES'.

Coolin Fan - Visually check the fan for cracks,

loose rivets, and bent or loose blades. Check

fan mounting and tighten if required. Replace

any fan that is damaged.

Note: The fan belt is maintained to the correct

belt tension by a spring loaded idler arm,

therefore, there is no need to check or adjust

belt tension.

Drive Belts - Visually check the belts and

replace if they are cracked 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 7 'INSTALLATION OF

ENGINE' 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 applies to normal

driving Check more frequently under more

severe conditions. Thickness of pad friction

material should never be allowed to wear

below 3 mm (0.12 in).

Oil Can Points - Oil hinges, and other working

parts with engine oil.

Fuel pre-filter - Replace filter element of fuel

pre-filter. Refer to Chapter 33 'HYDRAULIC

TANK MOUNTING'.

Every 1000 hours of operation

Hydraulic System Pressure Checks - Check all

steering, body and braking system pressures.

Note: Instructions for checking pressure, and

locations of pressure check points, are

8-10

Lubrication and Servicing

contained in the relevant service manual

section. If the pressures are outwith the

specified settings then components in the

relevant system should be inspected, repaired

or replaced to ensure the correct operation

of the system. All safety instructions in the

relevant sections should be strictly adhered to.

Steering oil return filter-

Clean the housing for the filter , follow the

failure code from the display or working time

to replace filter if time over 1000hours.

Hoisting oil return filter - Clean the filter shell,

and install a new filter element.

Cooling oil return filter - Clean the housing for

the filter and replace new filter for it.

Steering In-line Filter - Clean the housing

for 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

install new element.

Hoisting in-line filter - Clean filter housing and

install new element.

Cooling in-line filter - Clean filter housing and

install new element.

Engine and transmission

All information contained in the 'Lubrication

and Service Chart' was extracted from the

relevant manufacturers 'Operation and

Maintenance Manual',and was correct at

time of publication.User should ensure that

information contained in this chart reflects

the information shown in the relevant

manufacturers 'Operation and Maintenance

Manual' supplied with the Truck.

8-11

Lubrication and Servicing

8.4 Service Capacity

Ref.

Service Capacities

Identification

Lubricant

Points

liters

US gal

Engine Crankcase and Filters

17.2

Transmission and Filters

HTF

22.5

Hoisting cooling tank

239

63.4

Hoisting system and brake cooling system(Total)

258

68.4

Steering Hydraulic Tank

19.3

Steering and Braking Hydraulic System

20.1

Cooling System

Coolant

166

Fuel Tank

Disel

620

164.3

Front Ride Cylinder(each)

5.0

Rear Ride Cylinder(each)

4.2

Engine Power Takeoff

EPL

1.1

Differential

EPL

13.3

Wheel Planetaries (Total)

EPL

11.9

Air Conditioning Compressor

PAG Oil

0.125

0.033

8-12

Lubrication and Servicing

8.5 Recommended Lubricants

Reco-

Application

Ambient

Grade/

Name of

Quality

mme-

and lubrication

tempe-

Level of

Material

Grade

nded

position

rature

Viscosity

Brand

Material

Mobil

Standard

Above -

Delvac

SAE 15W-40

API

10°C

CF4SG,

15W-40

Diesel

CG-4/SH

Diesel engine

-25°C-

Mobil

engine oil

SAE 10W-30

Advanced

oil

10°C

Shell

pan

API CH-4,

Mobil

CI-4

-40°C-

Delvac

SAE 5W-30

Cummins

25°C

MX No.1

CES20078

5W-30

Above

The

0°C

content

Above

GB 252

Kun-

-10#

Cum-

DIN

-10°C

Light diesel fuel

sulfate

lun

mins

Fuel tank

Above

EN590

oil

-20#

is no

Great

engine

-20°C

ASTM

Wall

Above

23379001

-35#

than

-35°C

0.5%

-50#

Above

BS6580

Mobil

40%water

-62°C

:1992,

anti-

ASTM

freez-

Above

50%water

D3306

ing

-38°C

Engine

Mobil

Antifr-

fluid

water

Antifreeze

Shell

eezeshall

(-45°C);

tank

TEEC

Above

60%water

mixed with

anti-

-24°C

soft water

freezing

for use

(-35°C)

8-13

Lubrication and Servicing

Mobil

trans-

mission

oil

HD 10W

Shell

-35°C-

Donax

SAE 10W

0°C

TC10W

ATF

4000

Caltex

Drive

SRT

Allison

Caltex

Transmission case

Mobil

shaft

55D

C-4

trans-

Shell

mission

oil 414

Mobil

trans-

mission

Above

oil

SAE 30

0°C

HD 30

Shell

Donax

TC30

Below

32#

-15°C

Caltex

Hoisting and

Rando

cooling hydraulic

-15°C-

46#

HDZ 46 /

tank/Steering and

Hydraulilc oil

40°C

Mobil

braking hydraulic

hydraulic

tank

Above

oil

40°C

68#

Caltex

Mobil

trans-

Shell

mission

oil

HD 10W/

Suspension

transmission

Above

Shell

SAE 10W

cylinder

oil

-20°C

Donax

TC10W/

Caltex

trans-

mission

oil 414

8-14

Sany SRT55D Off-Highway Truck. Safety, Operation and Maintenance Manual (2014) - page 5