Quality Changes the World

Off-Highway Truck

Safety,Operation and Maintenance Manual

[Link]

SANY MINING EQUIPMENT CO.,LTD

ADD: Sany Industry Town,Dongcheng Avenue,Economic and Technological Development
Zone,Kunshan,Jiangsu.

Tel:0086-10-60738666 Fax: 0086-10-60738831

E-mail:crd@[Link]
SRT45 Off-Highway Truck

SRT45 Off-Highway Truck

Safety,Operation and Maintenance Manual

WARNING
Read and follow the safety precautions and instructions in this manual and on the mac-
hine decals. Failure to do can cause serious injury, death or property damage. Keep this
manual with the machine for reading and future reference.

Safety, Operation and Maintenance Manual

 SRT45Off-Highway Truck

Sany Group

SANY Mining Equipment CO.,LTD

Sany Industry Town,Dongcheng Avenue,Economic and

Technological Development Zone,Kunshan,Jiangsu, P.R. of
China 215300

[Link]

Tel: 0086-10-60738666

Fax: 0086-10-60738831

© 2014 by Sany Group. All right reserved. No part of this publication may be
reproduced,used, distributed or disclosed except during normal operation of the machine
as described herein. All information included within this publication was accurate at the
time of publication. Product improvements ,revisions, etc., may result in differences
between your machine and what is presented here. Sany Group assumes no liability. For
more information, Contact Sany Group.

Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck

Exemption Clauses
SPECIFIC DECLARATION

Mining truck is a critical earth/rock moving machine with high traffic ability,which is mainly
distributed to coal, iron ore, limestone, quarry,hydropower...
Sany assumes no responsibility for consequences caused by the following factors:
● Misuse of the truck due to failure to observe the information provided hereunder in this
manual;
● Unauthorized restructuring or modification to the truck;
● Use of non-genuine parts, or untested or unapproved parts or tools.
● Machine failure or damage resulted from natural disasters (such as earthquake,
typhoon,etc.), wars and other force majeure.
● Sany cannot anticipate all potential hazards that may occur on work site. Therefore, dump
truck operator and owner shall attach great importance to the issue of safety.
● Local government may impose higher standards for use of a dump truck. If local regulations
have 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 personnel who fully understand the Parts Book and the Safety, Operation and
Maintenance Manual are allowed to operate and service the dump truck.
● Make sure that the truck operator and service person are qualified for this job and know their
responsibilities.
● Regularly inspect the safety awareness of related persons at work.
● Should any fault threatening safety occurs, shut down the truck immediately.
● Sany service personnel have the right to carry out safety inspection to the truck when
required.
● Besides the checks specified by Sany, local laws and regulations on truck shall also be
observed.
● Ensure timely maintenance and repair of the dump truck.
● Make a detailed plan for proper use of the dump truck.

Safety, Operation and Maintenance Manual

 SRT45Off-Highway Truck

Obligations of all operating personnel

● Any abnormalities that could bring improper operation of the dump truck or potential hazards
should be reported to your supervisor. The abnormalities should be corrected timely if
possible.
● All workers around the dump truck must know and obey all warning signals, and be alert to
safety of oneself and others.
● All operators must know the operating items and procedures.
● Be alert to any hazardous situation and immediately inform operator and signalman of the
hazards such as high voltage cables, irrelevant people and worse ground condition.

Obligations of manager

● The operator must have been trained and fully understand the provision of the Safety,
Operation
● and Maintenance Manual. The operator must be healthy and licensed. Otherwise he/she is
not allowed to operate the dump truck.
● Make sure that the operator has good sense, cooperation awareness and psychological
quality, or he/she is not allowed to operate or service the dump truck.
● Make sure that the signal person has good visibility and hearing ability, knows standard
command signals and can give signals clearly and correctly. The signal person shall also
have enough experience to recognize hazardous factors and timely tell the operator to avoid
the hazards.
● Make sure that the assistant person can positively identify the model and working condition
of dump truck and choose a suitable dump truck.
● Each operating personnel of a project shall bear certain safety responsibilities and is required
to timely report unsafe factors to the supervisor.

Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Table of Contents

Table of Contents

1 Foreword
1.1 Overview ����������������������������������������������������������������������������������������������������������������� 1-1
1.2 Safety Information  �������������������������������������������������������������������������������������������������� 1-3
1.3 Page Numbers �������������������������������������������������������������������������������������������������������� 1-5
1.4 Regulation of Use ���������������������������������������������������������������������������������������������������� 1-5
1.4.1 Machine applications �������������������������������������������������������������������������������������� 1-5
1.4.2 Directions of machine ������������������������������������������������������������������������������������� 1-5
1.5 Breaking in a New Machine ������������������������������������������������������������������������������������� 1-6
1.6 Visibility from Operator's Seat ��������������������������������������������������������������������������������� 1-7
1.7 Machine Information ������������������������������������������������������������������������������������������������ 1-9
1.7.1 Product identification plate ���������������������������������������������������������������������������� 1-9
1.7.2 Engine identification plate ���������������������������������������������������������������������������� 1-10
1.7.3 Display screen �����������������������������������������������������������������������������������������������1-11
1.7.4Table for serial number and distributor information ����������������������������������������1-11

2 Safety
2.1 Safety Labels ........................................................................................................... 2-5
2.1.1 Position for attaching safety labels ��������������������������������������������������������������� 2-5
2.1.2 Safety labels ��������������������������������������������������������������������������������������������������� 2-6
2.2 General Precautions .............................................................................................. 2-12
2.2.1 Safety rules �������������������������������������������������������������������������������������������������� 2-12
2.2.2 Abnormalities ������������������������������������������������������������������������������������������������ 2-12
2.2.3 Personal protective equipment �������������������������������������������������������������������� 2-12
2.2.4 Fire extinguisher and first aid kit ������������������������������������������������������������������ 2-13
2.2.5 Safety equipment ����������������������������������������������������������������������������������������� 2-14
2.2.6 Cleaning your machine �������������������������������������������������������������������������������� 2-14
2.2.7 Keeping the cab clean ��������������������������������������������������������������������������������� 2-15
2.2.8 Precautions when leaving the machine ������������������������������������������������������� 2-15
2.2.9 Handholds and steps ����������������������������������������������������������������������������������� 2-16
2.2.10 Preventing burns ���������������������������������������������������������������������������������������� 2-17
[Link] Hot coolant  .......................................................................................... 2-17
[Link] Hot oil .................................................................................................. 2-17

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Table of Contents SRT45 Off-Highway Truck

2.2.11 Preventing fire and explosion  ..................................................................... 2-18

[Link] Fire caused by fuel or oils �������������������������������������������������������������������� 2-18
[Link] Fire caused by flammable materials ���������������������������������������������������� 2-19
[Link] Fire caused by electric lines ���������������������������������������������������������������� 2-19
[Link] Fire caused by hydraulic lines ������������������������������������������������������������ 2-19
[Link] Fire caused by illumination equipment  ............................................... 2-20
2.2.12 In the event of fire �������������������������������������������������������������������������������������� 2-20
2.2.13 Windshield cleaning detergent ������������������������������������������������������������������� 2-20
2.2.14 Precautions when using ROPS(Roll over protective structure) ����������������� 2-21
2.2.15 Attachment installation ������������������������������������������������������������������������������� 2-21
2.2.16 Cab windows glasses ��������������������������������������������������������������������������������� 2-22
2.2.17 Unauthorized modification �������������������������������������������������������������������������� 2-22
2.2.18 Examination and confirmation of worksite  ������������������������������������������������ 2-22
2.2.19 Operation on soft ground ��������������������������������������������������������������������������� 2-23
2.2.20 Overhead power cables ����������������������������������������������������������������������������� 2-24
2.2.21 Alternate exit ���������������������������������������������������������������������������������������������� 2-25
2.2.22 Ensure good visibilty ���������������������������������������������������������������������������������� 2-25
2.2.23 Asbestos hazard ����������������������������������������������������������������������������������������� 2-26
2.3 Safe Operation Precautions ���������������������������������������������������������������������������������� 2-27
2.3.1 Safe starting ������������������������������������������������������������������������������������������������� 2-27
[Link] Safe mounting ��������������������������������������������������������������������������������������� 2-27
[Link] Seat adjustment ������������������������������������������������������������������������������������ 2-27
[Link] Seat belt ������������������������������������������������������������������������������������������������ 2-28
[Link] Before starting the engine ��������������������������������������������������������������������� 2-28
[Link] Engine starting rules ����������������������������������������������������������������������������� 2-29
[Link] Starting engine in cold season �������������������������������������������������������������� 2-29
[Link] Engine starting aid �������������������������������������������������������������������������������� 2-30
[Link] After starting the engine  ........................................................................ 2-31
2.3.2 Operation ����������������������������������������������������������������������������������������������������� 2-31
[Link] Inspection before operation ������������������������������������������������������������������� 2-31
[Link] Prior-operation precautions ������������������������������������������������������������������� 2-31
[Link] Precautions when traveling ������������������������������������������������������������������� 2-32
[Link] Precautions when traveling on slopes ��������������������������������������������������� 2-34
[Link] Precautions when operating ������������������������������������������������������������������ 2-34
[Link] Precautions for accumulated snow, and ice ������������������������������������������ 2-34
[Link] Parking the machine ����������������������������������������������������������������������������� 2-35
[Link] Preparing the machine  .......................................................................... 2-36

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SRT45 Off-Highway Truck Table of Contents

2.3.3 Transportation ���������������������������������������������������������������������������������������������� 2-37

[Link] Loading and unloading the machine ����������������������������������������������������� 2-37
[Link] Transporting the machine  ...................................................................... 2-38
2.3.4 Battery ��������������������������������������������������������������������������������������������������������� 2-39
2.3.5 Towing ���������������������������������������������������������������������������������������������������������� 2-41
2.4 Precautions for Maintenance ��������������������������������������������������������������������������������� 2-42
2.4.1 Lock-out and tag-out ������������������������������������������������������������������������������������ 2-42
2.4.2 Select a working area ���������������������������������������������������������������������������������� 2-42
2.4.3 Prior-maintenance precautions �������������������������������������������������������������������� 2-42
2.4.4 Preparing yourself ��������������������������������������������������������������������������������������� 2-43
2.4.5 Stop engine before carrying out maintenance ��������������������������������������������� 2-44
2.4.6 Maintenance with engine running ���������������������������������������������������������������� 2-45
2.4.7 Using proper tools ��������������������������������������������������������������������������������������� 2-46
2.4.8 Handling suspension cylinder ���������������������������������������������������������������������� 2-46
2.4.9 Working under the machine ������������������������������������������������������������������������� 2-46
2.4.10 Work in loud noise ������������������������������������������������������������������������������������� 2-47
2.4.11 Use compressed air ����������������������������������������������������������������������������������� 2-47
2.4.12 Use a hammer ������������������������������������������������������������������������������������������� 2-47
2.4.13 Welding operation �������������������������������������������������������������������������������������� 2-47
2.4.14 Precautions with high-pressure oil ������������������������������������������������������������� 2-48
2.4.15 High-pressure hoses ��������������������������������������������������������������������������������� 2-49
2.4.16 Hot cooling system ������������������������������������������������������������������������������������ 2-49
2.4.17 Air-conditioning system ������������������������������������������������������������������������������ 2-50
2.4.18 High voltage precautions ��������������������������������������������������������������������������� 2-50
2.4.19 Accumulator ����������������������������������������������������������������������������������������������� 2-51
2.4.20 Avoiding fire and explosion ������������������������������������������������������������������������ 2-51
2.4.21 Regular replacement of safetyrelated parts ����������������������������������������������� 2-52
2.4.22 Maintenance operation ������������������������������������������������������������������������������ 2-52
2.4.23 Proper disposal of wastes ������������������������������������������������������������������������� 2-53
2.5 Precautions With Tires ������������������������������������������������������������������������������������������ 2-54
2.5.1 Handling tires ����������������������������������������������������������������������������������������������� 2-54
2.5.2 Precautions when storing tire ���������������������������������������������������������������������� 2-55

3 CONTROLS AND OPERATING  3-1

3.1 Controls and Instruments ���������������������������������������������������������������������������������������� 3-1
3.2 Indicator ������������������������������������������������������������������������������������������������������������������� 3-2

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3.3 Instruments �������������������������������������������������������������������������������������������������������������� 3-4

3.4 Reversing monitor system ��������������������������������������������������������������������������������������� 3-6
3.5 Switches ������������������������������������������������������������������������������������������������������������������ 3-7
3.6 Combined switch ����������������������������������������������������������������������������������������������������� 3-8
3.7 Air Conditioner Control Panel ���������������������������������������������������������������������������������� 3-9
3.8 Driver Seat �������������������������������������������������������������������������������������������������������������3-11
3.9 Seat Belt �����������������������������������������������������������������������������������������������������������������3-11
3.10 Truck Controls ����������������������������������������������������������������������������������������������������� 3-12
3.10.1 Braking ������������������������������������������������������������������������������������������������������ 3-12
3.10.2 Service brake ��������������������������������������������������������������������������������������������� 3-12
3.10.3 Parking brake �������������������������������������������������������������������������������������������� 3-13
3.10.4 Emergency brake  ������������������������������������������������������������������������������������� 3-13
3.10.5 Retarder ����������������������������������������������������������������������������������������������������� 3-13
3.11 Engine ������������������������������������������������������������������������������������������������������������� 3-15
3.11.1 Accelerator pedal ��������������������������������������������������������������������������������������� 3-15
3.11.2 QUANTUM electronic fuel system ������������������������������������������������������������� 3-15
3.11.3 Quantum electronic fuel system - description �������������������������������������������� 3-17
3.11.4 QUANTUM electronic fuel system - operation  ������������������������������������������ 3-18
3.11.5 Electronic fuel system diagnostic codes ���������������������������������������������������� 3-20
3.12 Steering ���������������������������������������������������������������������������������������������������������� 3-24
3.13 Transmission ������������������������������������������������������������������������������������������������ 3-25
3.13.1 CEC2 Shift System ������������������������������������������������������������������������������������ 3-25
3.13.2 Introduction and operation ������������������������������������������������������������������������� 3-28
3.13.3 General Transmission Operation ��������������������������������������������������������������� 3-32
3.13.4 Retrieving Diagnostic Codes ��������������������������������������������������������������������� 3-33
3.13.5 Clearing Diagnostic Codes ������������������������������������������������������������������������ 3-33
3.14 Body Control �������������������������������������������������������������������������������������������������������� 3-38
3.15 The common fault code of vehicle monitor system ��������������������������������������������� 3-40

4 OPERATING THE TRUCK  4-1

4.1 Pre-Starting Inspection ����������������������������������������������������������������������������������������� 4-1
4.2 Check of each component ������������������������������������������������������������������������������������ 4-3
4.3 Engine Operation �������������������������������������������������������������������������������������������������� 4-6
4.4 Start the Engine ����������������������������������������������������������������������������������������������������� 4-8
4.5 Starting the Engine with Jumper Cables ���������������������������������������������������������� 4-10
4.6 Pre-Operating Checks ������������������������������������������������������������������������������������������4-11

IV Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Table of Contents

4.7 Braking Function Check ������������������������������������������������������������������������������������� 4-12

4.8 Service Brake Performance Check �������������������������������������������������������������������� 4-12
4.9 Emergency Brake Performance Check ������������������������������������������������������������� 4-13
4.10 Driving and Stopping ���������������������������������������������������������������������������������������� 4-13
4.11 Stopping the Engine ������������������������������������������������������������������������������������������ 4-14
4.12 Parking ��������������������������������������������������������������������������������������������������������������� 4-16
4.13 Prolonged 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 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 150hrs  ����������������������������������������������� 8-21
8.6.3 Maintenance inspection form for 250hrs  ����������������������������������������������� 8-23
8.6.4 Maintenance inspection form for 300hrs ������������������������������������������������ 8-25
8.6.5 Maintenance inspection form for 450hrs ������������������������������������������������ 8-27
8.6.6 Maintenance inspection form for 500hrs ������������������������������������������������ 8-29
8.6.7 Maintenance inspection form for 600hrs ������������������������������������������������ 8-33

Safety, Operation and Maintenance Manual V

Table of Contents SRT45 Off-Highway Truck

8.6.8 Maintenance inspection form for 750hrs ������������������������������������������������ 8-35

8.6.9 Maintenance inspection form for 900hrs ������������������������������������������������ 8-37
8.6.10 Maintenance inspection form for 1000hrs �������������������������������������������� 8-39
8.6.11 Maintenance inspection form for 1050hrs ��������������������������������������������� 8-43
8.6.12 Maintenance inspection form for 1200hrs �������������������������������������������� 8-45
8.6.13 Maintenance inspection form for 1250hrs �������������������������������������������� 8-47
8.6.14 Maintenance inspection form for 1350hrs �������������������������������������������� 8-49
8.6.15 Maintenance inspection form for 1500hrs �������������������������������������������� 8-51
8.6.16 Maintenance inspection form for 1650hrs �������������������������������������������� 8-55
8.6.17 Maintenance inspection form for 1750hrs �������������������������������������������� 8-57
8.6.18 Maintenance inspection form for 1800hrs �������������������������������������������� 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 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 3150hrs �������������������������������������������� 8-91
8.6.31 Maintenance inspection form for 3250hrs �������������������������������������������� 8-93
8.6.32 Maintenance inspection form for 3300hrs �������������������������������������������� 8-95
8.6.33 Maintenance inspection form for 3450hrs �������������������������������������������� 8-97
8.6.34 Maintenance inspection form for 3550hrs �������������������������������������������� 8-99
8.6.35 Maintenance inspection form for 3600hrs ������������������������������������������ 8-101
8.6.36 Maintenance inspection form for 3750hrs ������������������������������������������ 8-103
8.6.37 Maintenance inspection form for 3900hrs ������������������������������������������ 8-107
8.6.38 Maintenance inspection form for 4000hrs ������������������������������������������ 8-109
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

VI Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Foreword

9 TECHNICAL DATA  9-1

Safety, Operation and Maintenance Manual VII

Foreword SRT45 Off-Highway Truck

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VIII Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Foreword

1 FOREWORD
1.1 Overview
The explanations, values, and illustrations
in this manual have been prepared based on
the latest information available as of the date
of its publication. Continuing improvements
in the design of this machine may lead to
additional changes that are not reflected in
this manual. Consult SANY or your SANY
distributor for the latest available information
concerning your machine or with questions
regarding information contained in this manual.
This manual gives details of the operation
and methods of inspection and maintenance
for this machine that must be obeyed in order
to use the machine safely. Most accidents are
caused by the failure to follow 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 manual and on the
machine may not include all possible safety
precautions.
If you carry out any operation, inspection,
or maintenance under conditions that are not
described in this manual, understand that it
is your responsibility to take the necessary
precautions to ensure safety. In no event
should you or others engage in the prohibited
uses or actions described in this manual. If the
machine is operated mistakenly when carrying
out inspection and maintenance, there is
danger that it may lead to serious injury or
death.

Safety, Operation and Maintenance Manual 1-1

Foreword SRT45 Off-Highway Truck

If you sell the machine, be sure to give

this manual to the new owner together with the
machine, so that all relevant personnel can
read it at any time.
If this manual is lost or damaged, contact
your distributor immediately to arrange for
its replacement. To ensure that the correct
manual is sent, check the serial number of the
machine and inform your SANY distributor.
The explanations, values, and illustrations
in this manual have been prepared based on
the latest information available as of the date
of its publication. Continuing improvements
in the design of this machine may lead to
additional changes that are not reflected 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→⑴)
The letters in the illustrations correspond
to the letters in ○ in the text.
(For example: A→ )
SANY delivers machines that comply with
all applicable regulations and standards of
the country to which it has been shipped. If
this machine has been purchased in another
country, it may lack certain safety devices
and specifications that are necessary for
use in your country. If there is any question
about whether your product complies with the
applicable standards and regulations of your
country, consult SANY Mining Equipment Co.
or your SANY distributor before operating the
machine.

1-2 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Foreword

1.2 Safety Information

Hazard alert words are used in this
manual and on some machine decals to inform
the operator of imminent or potential hazards
that lead to death, personal injury or property
damage.

1)Alert words

● The sign is used for warning you the

CAUTION
potential danger of human injuries,
when it is used together with notes such
as “DANGER, WARING, CAUTION”, it
indicate the degree of hazard.
● It indicates an imminently
DANGER
hazardous situation
which, if not avoided, will
result in death or serious
injury.

● It indicates a potentially
WARNING
hazardous situation
which, if not avoided,
could result in death or
serious injury.

● It indicates a potentially
CAUTION
hazardous situation
which, if not avoided,
may result in minor or
moderate injury. It can
also be used to alert
unsafe operation as which
may cause property loss.

Safety, Operation and Maintenance Manual 1-3

Foreword SRT45 Off-Highway Truck

2)An example alert wording and alert text

WARNING
To p r e v e n t p e r s o n a l i n j u r y a n d
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.

[Link] safety decals

Fig. 1.2-1 is an example of textual safety
Fig. 1.2-1
decals.

[Link] 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 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Foreword

1.3 Your Documentation Package

The documentation for this machine
includes the following items:
● Safety, Operation & Maintenance Manual
(SOMM) — This manual is in the operator
cab seat pocket.
● Parts Book — This publication consists
of parts lists and matching drawings for
ordering spare parts as-needed. If it was
not already shipped with your machine,
the parts book for your machine is
available directly from Sany.

1.3.1 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).
● Insert Sany replacement pages
mmediately into the appropriate book;
destroy old versions of those pages.

1.3.2 Documentation storage

● Always keep the operator manual and
load charts with the machine in the
operator cab.
● The parts book is best left either shelved
in the workshop area or office. It should
always be available to the maintenance
and service personnel as required.

Safety, Operation and Maintenance Manual 1-5

Foreword SRT45 Off-Highway Truck

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

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 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck 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.
750

1000

1200
A

1000
3900

A
1000

1000
1000

A A

1743 1743

Fig. 1.7-1

Safety, Operation and Maintenance Manual 1-7

Foreword SRT45 Off-Highway Truck

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 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck 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

Safety, Operation and Maintenance Manual 1-9

Foreword SRT45 Off-Highway Truck

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)
in
s Warrty Start Date
o m IMPORTANT ENGINE INFORMATION
Family D57 Static Injection Timing 0.5 BTDC Intake 0.432/0.017 um In the U.S. this engine is soley for
C export and is therefore exempt under
Model QST30 Fuel Rate @ Advertised Power 270 mm 3/stroke Exhaust 0.813/0.032 40 CFR 1068.240 from U.S.
emssions standards and
S.O. No. so10727 Advertised Power 783 /1050 kW:HP at 2100 RPM related requirements. Outside the U.S.
this engine may be subject to other
Ref. No.WZU2-SY-SRT95-Q30-1 WARNING: Injury may result and warranty is volded 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 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Foreword

1.8.3 Display screen

The position of display screen is shown as
follows:

！ ！

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

Safety, Operation and Maintenance Manual 1-11

Foreword SRT45 Off-Highway Truck

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1-12 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Safety

Safety

2 Safety 2-5

2.1 Safety Labels ........................................................................................................... 2-5

2.1.1 Position for attaching safety labels ................................................................ 2-5
2.1.2 Safety labels ................................................................................................... 2-6

2.2 General Precautions .............................................................................................. 2-12

2.2.1 Safety rules �������������������������������������������������������������������������������������������������� 2-12
2.2.2 Abnormalities ������������������������������������������������������������������������������������������������ 2-12
2.2.3 Personal protective equipment �������������������������������������������������������������������� 2-12
2.2.4 Fire extinguisher and first aid kit ������������������������������������������������������������������ 2-13
2.2.5 Safety equipment ����������������������������������������������������������������������������������������� 2-14
2.2.6 Cleaning your machine �������������������������������������������������������������������������������� 2-14
2.2.7 Keeping the cab clean ��������������������������������������������������������������������������������� 2-15
2.2.8 Precautions when leaving the machine ������������������������������������������������������� 2-15
2.2.9 Handholds and steps ����������������������������������������������������������������������������������� 2-16
2.2.10 Preventing burns  ........................................................................................ 2-17
[Link] Hot coolant ........................................................................................ 2-17
[Link] Hot oil ................................................................................................ 2-17
2.2.11 Preventing fire and explosion  ..................................................................... 2-18
[Link] Fire caused by fuel or oils ����������������������������������������������������������������� 2-18
[Link] Fire caused by flammable materials ������������������������������������������������� 2-19
[Link] Fire caused by electric lines �������������������������������������������������������������� 2-19
[Link] Fire caused by hydraulic lines ���������������������������������������������������������� 2-19
[Link] Fire caused by illumination equipment ............................................. 2-20

Safety, Operation and Maintenance Manual 2-1

Safety SRT45 Off-Highway Truck

2.2.12 In the event of fire �������������������������������������������������������������������������������������� 2-20

2.2.13 Windshield cleaning detergent ������������������������������������������������������������������� 2-20
2.2.14 Precautions when using ROPS(Roll over protective structure) ����������������� 2-21
2.2.15 Attachment installation ������������������������������������������������������������������������������� 2-21
2.2.16 Cab windows glasses ��������������������������������������������������������������������������������� 2-22
2.2.17 Unauthorized modification �������������������������������������������������������������������������� 2-22
2.2.18 Examination and confirmation of worksite  ������������������������������������������������ 2-22
2.2.19 Operation on soft ground ��������������������������������������������������������������������������� 2-23
2.2.20 Overhead power cables ����������������������������������������������������������������������������� 2-24
2.2.21 Alternate exit ���������������������������������������������������������������������������������������������� 2-25
2.2.22 Ensure good visibilty ���������������������������������������������������������������������������������� 2-25
2.2.23 Asbestos hazard ......................................................................................... 2-26

2.3 Safe Operation Precautions .................................................................................. 2-27

2.3.1 Safe starting  ................................................................................................. 2-27
[Link] Safe mounting ������������������������������������������������������������������������������������� 2-27
[Link] Seat adjustment ���������������������������������������������������������������������������������� 2-27
[Link] Seat belt ���������������������������������������������������������������������������������������������� 2-28
[Link] Before starting the engine ������������������������������������������������������������������� 2-28
[Link] Engine starting rules ��������������������������������������������������������������������������� 2-29
[Link] Starting engine in cold season ������������������������������������������������������������ 2-29
[Link] Engine starting aid ������������������������������������������������������������������������������ 2-30
[Link] After starting the engine  ...................................................................... 2-31
2.3.2 Operation  ..................................................................................................... 2-31
[Link] Inspection before operation ���������������������������������������������������������������� 2-31
[Link] Prior-operation precautions ���������������������������������������������������������������� 2-31
[Link] Precautions when traveling ����������������������������������������������������������������� 2-32
[Link] Precautions when traveling on slopes ������������������������������������������������ 2-34
[Link] Precautions when operating ��������������������������������������������������������������� 2-34
[Link] Precautions for accumulated snow, and ice ��������������������������������������� 2-34
[Link] Parking the machine ��������������������������������������������������������������������������� 2-35
[Link] Preparing the machine ........................................................................ 2-36
2.3.3 Transportation  .............................................................................................. 2-37
[Link] Loading and unloading the machine ��������������������������������������������������� 2-37
[Link] Transporting the machine  ................................................................... 2-38
2.3.4 Battery ���������������������������������������������������������������������������������������������������������� 2-39
2.3.5 Towing  .......................................................................................................... 2-41

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SRT45 Off-Highway Truck Safety

2.4 Precautions for Maintenance ................................................................................. 2-42

2.4.1 Lock-out and tag-out ������������������������������������������������������������������������������������ 2-42
2.4.2 Select a working area ����������������������������������������������������������������������������������� 2-42
2.4.3 Prior-maintenance precautions �������������������������������������������������������������������� 2-42
2.4.4 Preparing yourself ���������������������������������������������������������������������������������������� 2-43
2.4.5 Stop engine before carrying out maintenance ��������������������������������������������� 2-44
2.4.6 Maintenance with engine running ���������������������������������������������������������������� 2-45
2.4.7 Using proper tools ���������������������������������������������������������������������������������������� 2-46
2.4.8 Handling suspension cylinder ���������������������������������������������������������������������� 2-46
2.4.9 Working under the machine ������������������������������������������������������������������������� 2-46
2.4.10 Work in loud noise �������������������������������������������������������������������������������������� 2-47
2.4.11 Use compressed air ����������������������������������������������������������������������������������� 2-47
2.4.12 Use a hammer �������������������������������������������������������������������������������������������� 2-47
2.4.13 Welding operation �������������������������������������������������������������������������������������� 2-47
2.4.14 Precautions with high-pressure oil ............................................................. 2-48
2.4.15 High-pressure hoses  .................................................................................. 2-49
2.4.16 Hot cooling system ..................................................................................... 2-49
2.4.17 Air-conditioning system .............................................................................. 2-50
2.4.18 High voltage precautions ............................................................................ 2-50
2.4.19 Accumulator ............................................................................................... 2-51
2.4.20 Avoiding fire and explosion  ........................................................................ 2-51
2.4.21 Regular replacement of safetyrelated parts ............................................... 2-52
2.4.22 Maintenance operation ............................................................................... 2-52
2.4.23 Proper disposal of wastes .......................................................................... 2-53

2.5 Precautions With Tires ........................................................................................... 2-54

2.5.1 Handling tires ............................................................................................... 2-54
2.5.2 Precautions when storing tire ....................................................................... 2-55

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Safety SRT45 Off-Highway Truck

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SRT45 Off-Highway Truck 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
A

Hydraulic oil tank Cab(Right side outer shell) Cab(Left side outer shell)

9
10 11 12

Battery box assembly Accumulator

Frame rear part(left)

13

14

Rear tail seat

Rear suspension cylinder Distance water box
Fig. 2.1-1

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Safety SRT45 Off-Highway Truck

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

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SRT45 Off-Highway Truck 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

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Safety SRT45 Off-Highway Truck

(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

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SRT45 Off-Highway Truck Safety

(8)Accumulator warning label

● This label is located on the barrel wall of WARNING
accumulator.
● To prevent personal injury and equipment HIGH PRESSURE
damage, be sure pressure in the Do not remove valves or fittings until pressure is
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

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Safety SRT45 Off-Highway Truck

(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

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SRT45 Off-Highway Truck 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

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Safety SRT45 Off-Highway Truck

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.

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SRT45 Off-Highway Truck Safety

Never take a risk.

CAUTION

ong
Wr
Never wear slack clothing and jewelry,which
t
Correc
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

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Safety SRT45 Off-Highway Truck

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.

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SRT45 Off-Highway Truck 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
[Link] the key with you and
leave it in the specified place.

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Safety SRT45 Off-Highway Truck

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
you support yourself. A
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.
● Never climb onto the engine hood, covers, Fig. 2.2-7
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.

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SRT45 Off-Highway Truck Safety

2.2.10 Preventing burns

[Link] 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

[Link] 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

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Safety SRT45 Off-Highway Truck

2.2.11 Preventing fire and explosion

[Link] 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

er
Dang

Fig. 2.2-14

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SRT45 Off-Highway Truck Safety

[Link] Fire caused by flammable materials

● Remove at any time dry leaves, wood

chips, paper pieces, dirt and other
flammable materials built up or stuck
on engine, exhaust manifold, battery or
interior of engine hood to prevent fire.

[Link] Fire caused by electric lines

● Short circuit of electrical system can

cause fire.
● Keep electric terminals clean and
fastened.
● Check power cables 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.

[Link] Fire caused by hydraulic lines

● Check the clamps, guards and gaskets of

all hoses and pipes to see whether they
are tightened in position.
● In case of loosening, their vibration in
operation may lead to friction against
other components, resulting damage
of hose, ejection of high-pressure oil,
disastrous fire or serious injury.

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Safety SRT45 Off-Highway Truck

[Link] Fire caused by illumination

equipment

● Anti-blast illumination equipment shall

be used to avoid explosion when fuel,
oil,electrolyte, window cleaning detergent
or cooling fluid is being checked.
● 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 use

methanol based detergent as it irritates
eyes.

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SRT45 Off-Highway Truck Safety

2.2.14 Precautions when using

ROPS(Roll over protective structure)

● The operator’s cab has a ROPS structure.

In addition to supporting of the load if the
machine tips over, it also absorbs the
impact energy and protects the operator.
If the function of ROPS is reduced, it
cannot protect the operator and he may
be injured.
● Always do the following. Do not weld, drill
holes, or make any other modification to
the operator’s cab structure.
Repair or replace the operator’s cab if it Fig. 2.2-15
●
is deformed by falling objects or when the
machine tips over. For details of repair,
please consult your SANY distributor.

Fig. 2.2-16

2.2.15 Attachment installation

● Installation of optional parts or

attachments may involve safety issues or
be limited by the law. In this case, contact
your Sany distributor in advance.
● Sany assumes no responsibility for the
injury,accidents and product failure caused
by the use of unauthorized attachments
and parts.
● Before installing and using machine
attachments,read related instructions
regarding the attachment and general
precautions on attachment in this manual.

Safety, Operation and Maintenance Manual 2-21

Safety SRT45 Off-Highway Truck

2.2.16 Cab windows glasses

● Broken cab windows at the side of the

work equipment may expose the operator
in direct contact with the work equipment.
In this case, stop operation immediately
and replace the glasses.
● Broken or damaged window provides
no protection to the operator. When
the roof window is damaged, replace it
immediately with a new one.

2.2.17 Unauthorized modification

Any modification unauthorized by Sany

may lead to safety problems, personal injury
or death. Improper modification can affect
machine's strength and operator'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 over, or the ground may collapse, or rocks
may fall,causing injury to the operator. Always:
● Check the terrain and condition of the
ground at the worksite, and determine
the safest method of operation. Do
not operate where there is a hazard of
landslides or falling rocks.
● Prevent any unauthorized person from
entering the operating area.
Before operating in shallow water or on Fig. 2.2-17
●

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SRT45 Off-Highway Truck Safety

soft ground, check the depth of the water,

speed of the current, and the firmness r
Dange
and shape of the ground. Avoid any area
where there is any obstruction to travel
operations.
● Maintain the travel path on the jobsite
so that there is no obstruction to travel
operations.

Fig. 2.2-18

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
operation, take protective measures to
prevent your machine from tipping over or
falling.

Safety, Operation and Maintenance Manual 2-23

Safety SRT45 Off-Highway Truck

2.2.20 Overhead power cables

Never drive or operate your machine near

power cables, which may bring electrocution
hazard and cause machine damage, personal
injury or death. The following steps are to be
followed while working at where power cables
could be nearby.
● Before operation in the vicinity of power
cables, inform local power company of the
coming operation and ask them to take
necessary measures.
● If your machine is too close to power
cable, electrocution is most likely to occur Fig. 2.2-19
and cause burns or death. A safe distance
must be kept between machine and power
cable (See Table 1-1). Before operation,
communicate with local power company Cable Voltage Safe Distance
regarding safety measures. 100V - 200V 2 m ( 7 ft) or above
● A signalman is to be designated to give 6，600V 2 m ( 7 ft) or above
signals if your machine is too close to 22，000V 3m（10 ft）or above
power cables.
66，000V 4m（14 ft）or above
● Nobody is allowed to approach the
154，000V 5m（17 ft）or above
machine when it is operated near high-
voltage cables. 187，000V 6m（20 ft）or above
● If your machine is too close to the 275，000V 7m（23 ft）or above
cable or touches the cable, to prevent 500，000V 11m（36 ft）or above
electrocution, operator shall not leave Table 1-1
the cab until machine power is surely
cut off. In addition, Nobody is allowed to
approach the machine.
● To prevent accidents, wear rubber shoes
and rubber gloves during operation. Cover
the operator’s seat with rubber sheet and
pay attention to exposed part of body
that should not touch the lower part of
machine.

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SRT45 Off-Highway Truck Safety

2.2.21 Alternate exit

● If you are unable to open the cab door

in case of emergency, use the safety
hammer to break the rear window to
escape.
● Remove the pieces of glass from the
window frame before escaping. Be
careful not to be cut by broken glass.
Pay attention to the broken glass on the
ground, which may cause you to slip and
fall.
Fig. 2.2-20

2.2.22 Ensure good visibilty

This machine is equipped with mirrors to er

Dang
improve the visibility, but even with mirrors,
there are places, which cannot be seen from
the operator’s seat, so always be careful when
operating.
When operating 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
Fig. 2.2-21
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 sufficiently
assured, position a flagman if necessary.
The operator should pay careful attention
to the signs and follow the instructions of
the flagman.
● The signals should be given only by one
flagman.
● When working in dark places, turn on
the working lamps and front lamps of
the machine, and if necessary, set up
additional lighting in the area.
● Stop operations if there is poor visibility,

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Safety SRT45 Off-Highway Truck

such as in fog, snow, rain, or sand storms.

● Check the mirrors on the machine before
starting operations every day. Clean off
any dirt and adjust the view to ensure
good visibility.
● In areas where it is impossible to confirm
the area behind the machine and
observation cameras have been set
● up, clean off any dirt from the lens and
make sure that the camera gives a clear
view of the rear.

2.2.23 Asbestos hazard

Inhalation of asbestos dust can cause

lung cancer. It is possible to inhale asbestos WARNING
dust when performing tear-down operation
No asbestos is used in this machine.
or handling industrial wastes at job site. The
But aftermarket parts could contain
following rules must be followed.
asbestos. Therefore,use only the parts
● Use water, instead of compressed air, to
and components supplied by Sany.
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 approach the
machine during operation.
● The regulations, rules and environment
criterion at job site shall be observed.

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2.3 Safe Operation Precautions

2.3.1 Safe starting

[Link] Safe mounting

When you mount or dismount the

machine:
● Always face the machine and maintain
a three-point contact (one hand and two
feet or two hands and one foot).
● Never jump on/off the machine. Never
mount a moving machine.
● Never use any control lever as handhold.
Remove the mud, oil dirt and water from
the pedals, handholds and your soles at Fig. 2.3-1
all times.
● The cab must be aligned with the
undercarriage centerline before you enter
or exit the cab.

[Link] 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 push the pedal to its limit with his foot,
and operate the control lever properly.
Otherwise, the seat should be readjusted
by moving it forward or backward.

Fig. 2.3-2

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Safety SRT45 Off-Highway Truck

[Link] Seat belt

● The operator may get seriously injured or

killed when the machine tips over. Before
operating the machine, check carefully
your seat belt, the buckles and the anchor
point. Replace the seat belt if damage or
excessive wear is observed. When the
machine is being operated, keep your
seat belt buckled up.
● The seat belt must be replaced every
three years regardless of its condition.
Fig. 2.3-3

[Link] Before starting the engine

Before starting your daily work, the

following items must be observed before
er
Dang
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 Fig. 2.3-4
accumulated around the movable parts of
the accelerator pedal or brake pedal, and
check that the pedals work properly.
● Adjust the operator’s seat so that it is
easy to see to the front, and check that
there is no damage or wear to the seatbelt
or seatbelt mounts.
● Check that the instruments and gauges
are working properly, that the gear shift
lever is at the Neutral position, and that
the dump control lever is at the FLOAT
position.

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● Adjust the mirrors so that the rear of the

machine can be seen clearly from the
operator’s seat.
● Check that there are no persons or
obstacles above, below, or in the area
around the machine.
● Check that the parking brake switch is in
the PARKING position.

[Link] Engine starting rules

● Before starting the machine, make

sure nobody is on, under or around the t
Correc
machine. Sound the horn to warn people
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.

Fig. 2.3-5

[Link] Starting engine in cold season

● Sufficient warm-up operation is necessary.

Incomplete warming up may result in slow
reaction and accidents.
● Before starting, check the battery
[Link] case of frozen electrolyte,
never charge the battery or use alternative
power source to start the engine; instead,
melt the electrolyte first. Otherwise, fire
may break out on the battery.

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Safety SRT45 Off-Highway Truck

[Link] Engine starting aid

Follow procedures in the Operation

sectionwhen using jumper cables to start the
engine. Improper handling may cause battery
explosion or loss of machine control, resulting
in personal injury and death. Never use jumper
cables to start the engine unless necessary.
Contact your Sany distributor before such an
attempt.
● Using jumper cables to start the engine
needs two persons working together with
one seated in the operator seat and the
other handling the battery.
● Wear goggles and rubber gloves before Fig. 2.3-6
starting the engine with jumper cables.
● When connecting a normal machine 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 negative terminal when
disconnecting the jump cable.
● When disconnecting the jumper cable,
take care not to allow the clips of jumper
cable to contact with each other or with
the machine.
● Ether is a liquid used for cold start, which
is extremely flammable and explosive. Fig. 2.3-7
Read the instructions on the ether
container before application.
● Never use ether if the engine is equipped
with spark-plug preheater or other forms
of preheater.

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[Link] After starting the engine

● Run the engine at low idle for 3 to 5

minutes after engine startup, and check
the running parameters and make sure
they are normal and all readings are
within normal working range.

2.3.2 Operation

[Link] Inspection before operation

● When conducting inspection, move the

machine to a spacious area without
barriers and operate slowly. Any other
person is not allowed to approach the
machine.
● Be sure to buckle the seat belt. Check
the gauges and machine 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.
● I n c a s e o f a n y a b n o r m a l i t y, s t o p
operation and take corrective measures
immediately.

[Link] Prior-operation precautions

To prevent serious injury or death, follow

the items below before moving the machine.
● It is dangerous to stay in the working
range during machine operation. Sound
the horn to warn people within the working
range before operating your machine.
● Nobody is allowed to stay on and near the
machine, or within the working range.
● To improve the visibility in the travel Fig. 2.3-8
direction, you may turn the cab if
necessary.

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Safety SRT45 Off-Highway Truck

● Assign a signalman at where visibility is

poor.

[Link] Precautions when traveling

● Do not load the dump body above the
maximum payload. The brakes will lose
their effect.
● Never turn the starting switch key to
the OFF position when the machine is
traveling. If the engine stops when the
Fig. 2.3-9
machine is traveling, the steering will corre
ct

become heavy. There is danger that

this may cause mistaken operation of
the steering wheel and lead to serious
personal injury. 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
distance when traveling.
● When traveling on rough ground, travel
at low speed and avoid sudden changes
in direction to prevent the machine from
turning over.
● When operating in tunnels, inside
buildings, or under bridges or electric
wires, or other places where the height is
Fig. 2.3-10

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limited, operate slowly and be extremely

careful not to let the machine or dump
body contact anything.

● Continuous long time traveling at high

speed may cause tires to heat up, r
Dange
abnormally increasing the inflation
pressure inside the tires, and to blow
up. The explosion of the tire is very
destructive, and it can lead to serious
injury or death.
● Contact with SANY before doing long
continuous traveling.
Do not move the gear shift lever to the N Fig. 2.3-11
●
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 danger that it will
overheat or that the actuation of the brake
will be poor.
● There may also be damage to the
transmission or other parts of the power
train, and there is danger of unexpected
accidents.

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Safety SRT45 Off-Highway Truck

[Link] Precautions when traveling on

slopes

To prevent the machine from tipping over

or slipping to the side, always do as follows.
● When traveling downhill, use the retarder
brake to reduce speed. Do not turn the
steering wheel suddenly.
● Travel on grass, fallen leaves, or wet steel
plates with low speed. Even with slight
slopes there is a hazard that the machine
may slip.
● If the engine should stop on a slope, apply
the brakes fully and apply the parking
brake also to stop the machine.

[Link] Precautions when 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 [Link] necessary, use blocks for
the wheels or position a flagman.
● Do not carry out dumping operations on
slopes. The machine stability will become
poor and there is the danger that it could
tip over.
Fig. 2.3-12
● Do not travel with the body raised.
● Do not leave or return to the operator’s
seat during loading work.

[Link] Precautions for accumulated snow,

and ice

● When traveling on snow-covered or icy

roads, there is danger that the machine
may slip when traveling and tip over or

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fall off the road. This may lead to serious

personal injury and damage. Always do as
follows.
● Fit tire chains.
● Do not apply the brake suddenly on Danger
slopes. Reduce the speed and use the
braking force of the engine together with
the foot brake (depress the foot brake
repeatedly; do not keep it depressed) to
stop the machine.
● Do not enter areas where the snow is
deep. There is danger of driving off the
road.
Fig. 2.3-13

[Link] 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 Fig. 2.3-14
park your machine in such a place, flags
are to be used on daytime and signal
lamps at night to warn other people or
vehicles according to local regulations.
● Chock the wheels to prevent unexpected
movement.

Fig. 2.3-15

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Safety SRT45 Off-Highway Truck

[Link] Preparing the machine

Before maintaining the machine:

● Place the parking switch to "Pa r k"
position.
● Move the transmission to Neutral position.
● Raise the hand lever to "Float" position.
● Run the engine at idle 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 slippery aisle and ladder
when dismounting the machine.

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2.3.3 Transportation

This machine must be disassembled

for transportation. When transporting the
machine, please consult your Sany distributor.

[Link] Loading and unloading the machine

Improper loading and unloading of the

machine may cause it to fall or tip over. Follow
the procedures below:
● Load or unload the machine only on
a solid and flat [Link] it a safe
distance away from road sides or a cliff.
Space Max. Angle15°
● Keep on-lookers away. Blocks
● Use an access ramp with enough
[Link] sure that the width, length
and thickness of the access ramp is
capable of providing a safe loading/
Fig. 2.3-16
unloading 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. Travel slowly when the
machine is on the joint area.
● Never reposition the machine on the
access ramp. If necessary, drive it off the
ramp, reposition, and get on the ramp
again.
● When loading or unloading the machine
on a platform, make sure the platform has
adequate width, strength and a proper
grade.
● Once the machine is loaded, lock the cab
door. Otherwise, it may swing open during
transportation.

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Safety SRT45 Off-Highway Truck

● Secure the machine with chains and

chocks.

[Link] Transporting the machine

Observe the 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.

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2.3.4 Battery

Electrolyte contains sulfuric acid, which gives

off flammable and explosive gases. Improper
handling may cause personal injury or fire. Observe
the instructions below when handling battery:
● Never smoke or use fire near a battery.
● Turn the engine ignition key to the OFF
position before working on the battery.
● Wear safety glasses and rubber gloves
when handling battery.
● Electrolyte is a strong acid. If electrolyte
contacts your clothing or skin, flush Fig. 2.3-17
i m m e d i a t e l y w i t h p l e n t y o f w a t e r.
Electrolyte may cause blindness if it
contacts your eyes. Flush immediately
with plenty of clean water under such
circumstances 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, and then
connect the negative (-) terminal. Ensure
all terminals are securely connected.
● Battery temperature rises when it is being
charged. When battery temperature
exceeds 45°C, stop charging and wait till
it is at ambient temperature. Reduce the
charging current by half and continue the
charging process.
● A battery being charged may give off
flammable gases. Before charging a
battery, remove it from the undercarriage,
put it in well-ventilated area and remove
the cap.

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Safety SRT45 Off-Highway Truck

● A battery being charged may give off

flammable gases. Before charging a
battery, remove it from the undercarriage,
put it in 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.

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2.3.5 Towing

● When towing a damaged machine, improper

operation or use of unacceptable wire cable
could lead to serious accident:
● Never tow the machine on a slope.
● Wear protective gloves and a had hat when A
using wire ropes.
● Check the strength of wire cable and make B
sure it could bear the weight of machine.
● Never use ropes with broken wires (A), C
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. Fig. 2.3-18

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Safety SRT45 Off-Highway Truck

2.4 Precautions for Maintenance

2.4.1 Lock-out and tag-out

● Before maintenance, attach a Never

1
OPERATE tag or similar sign to the cab's
retarder lever to warn others that this
machine is under maintenance.
● Attach other warning tags around the
machine if necessary.
● When maintenance is underway, starting
the engine or moving the control levers or
pedals could lead to serious accident. Fig. 2.4-1

DANGEROUS
Never OPERATE ！
When this tag is not being used keep it in the
2.4.2 Select a working area storage [Link] more,when there
is no storage compartment,keep it in the
● For maintenance work, select a clean flat operation manual case.
area with plenty of space, ample sunlight
and good ventilation.
● 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
before operation.
● Keep a clean and dry working area.
● Never spray water or steam in the cab.
● Never add lubricant and carry out other
maintenance work when your machine is

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SRT45 Off-Highway Truck Safety

moving.
● Keep your hands, feet and clothing away
from rotating parts.

2.4.4 Preparing yourself

Only approved personnel can maintain

or repair the machine. An observer may be
assigned if necessary.
● Wear protective clothing and shoes
necessary for the job. Fig. 2.4-2
● 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 aspirator and
ventilation equipment.

Fig. 2.4-3

Fig. 2.4-4

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Safety SRT45 Off-Highway Truck

2.4.5 Stop engine before carrying out

maintenance

● Park the machine on solid and flat ground.

● Lower the bucket to the ground. P

！ ！

● Lower the dump body, set dump control

lever (1) to the HOLD position, lock the
dump control lever , then stop the engine.
3
2
4

1 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

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SRT45 Off-Highway Truck 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 P

！ ！

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
3
2
4
engine at any time. All the workers
involved shall keep in touch.
set dump control lever (1) to the HOLD 1 2
● 1
position,then set parking brake switch (2)
to the PARKING position.

Fig. 2.4-7

Fig. 2.4-8

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Safety SRT45 Off-Highway Truck

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.

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2.4.10 Work in loud noise

● Wearing ear covers or ear plugs if you

have to work in loud noise for a long time.
● Loud noise may impair your hearing
permanent or temporary.

2.4.11 Use compressed air

● When compressed air is used for

cleaning, flying particles may cause
personal injury. 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.

Fig. 2.4-11

2.4.13 Welding operation

● Welding operation may lead to fire or

[Link] qualified welders are
allowed to conduct welding operation
using proper equipment.

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Safety SRT45 Off-Highway Truck

2.4.14 Precautions with high-pressure

oil

The hydraulic system is always under

[Link] 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 [Link] 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. W h e n
checking or servicing the fuel system,
shut down the engine and wait for 30
seconds till internal pressure drops before
operation.

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2.4.15 High-pressure hoses

If oil leaks from high-pressure hose, fault or

even fire may occur. If any bolt on hose is
loose, stop operation and tighten it to specified
torque. In case of hose damage, stop
operation immediately and contact Sany HM
authorized dealer.
Replace the hose immediately in case of the
following problems:
● 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 cool down. The
radiator cover could only be removed after
the coolant in it has cooled down.

WARNING

Touching hot high-pressure coolant may

cause serious injury. Fig. 2.4-13

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Safety SRT45 Off-Highway Truck

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

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SRT45 Off-Highway Truck Safety

2.4.19 Accumulator

Accumulator contains highly pressurized

[Link] 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
o f t h e a c c u m u l a t o r. C o n t a c t S a n y
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.

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Safety SRT45 Off-Highway Truck

● Clean the machine of all dust and

residuals. Never place greasy rag or other
flammable materials on machine.
● When cleaning the parts and components,
use nonflammable solvents instead of
gasoline, diesel oil or other flammable
fluids.
● Store flammable liquids and materials
in suitable vessels as required by safety
laws and regulations.
● Check fire extinguishers, fire-fighting
system and fire detectors (if equipment)
and make sure they are ready for use.

2.4.21 Regular replacement of

safetyrelated parts

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 parts could
serve. Therefore, regular replacement is
necessary.
● Repair or replace any safety parts once
found defective regardless of its service
time.

2.4.22 Maintenance operation

● Check all parts and replace the worn,

broken and damaged parts during
repairing operation. Over-worn and over-
damaged parts may fail in operation and
cause injury and death. Replace damaged

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SRT45 Off-Highway Truck 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,
fuel, cooling liquid, refrigerant, filter and Fig. 2.4-17
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

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Safety SRT45 Off-Highway Truck

2.5 Precautions With Tires

2.5.1 Handling tires

Explosive separation of a tire and/or rim parts

can cause serious injury or [Link] 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.

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SRT45 Off-Highway Truck 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
挡块
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.

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Safety SRT45 Off-Highway Truck

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N

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LA

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SRT45 Off-Highway Truck

TABLE OF CONTENTS

3 CONTROLS AND OPERATING  3-1

3.1 Controls and Instruments ���������������������������������������������������������������������������������������� 3-1
3.2 Indicator ������������������������������������������������������������������������������������������������������������������� 3-2
3.3 Instruments �������������������������������������������������������������������������������������������������������������� 3-4
3.4 Reversing monitor system ��������������������������������������������������������������������������������������� 3-6
3.5 Switches ������������������������������������������������������������������������������������������������������������������ 3-7
3.6 Combined switch ����������������������������������������������������������������������������������������������������� 3-8
3.7 Air Conditioner Control Panel ���������������������������������������������������������������������������������� 3-9
3.8 Driver Seat ������������������������������������������������������������������������������������������������������������ 3-11
3.9 Seat Belt ���������������������������������������������������������������������������������������������������������������� 3-11
3.10 Truck Controls ����������������������������������������������������������������������������������������������������� 3-12
3.10.1 Braking ������������������������������������������������������������������������������������������������������ 3-12
3.10.2 Service brake ��������������������������������������������������������������������������������������������� 3-12
3.10.3 Parking brake �������������������������������������������������������������������������������������������� 3-13
3.10.4 Emergency brake  ������������������������������������������������������������������������������������� 3-13
3.10.5 Retarder ����������������������������������������������������������������������������������������������������� 3-13
3.11 Engine ������������������������������������������������������������������������������������������������������������� 3-15
3.11.1 Accelerator pedal ��������������������������������������������������������������������������������������� 3-15
3.11.2 QUANTUM electronic fuel system ������������������������������������������������������������� 3-15
3.11.3 Quantum electronic fuel system - description �������������������������������������������� 3-17
3.11.4 QUANTUM electronic fuel system - operation  ������������������������������������������ 3-18
3.11.5 Electronic fuel system diagnostic codes ���������������������������������������������������� 3-20
3.12 Steering ���������������������������������������������������������������������������������������������������������� 3-24
3.13 Transmission ������������������������������������������������������������������������������������������������ 3-25
3.13.1 CEC2 Shift System ������������������������������������������������������������������������������������ 3-25
3.13.2 Introduction and operation ������������������������������������������������������������������������� 3-28
3.13.3 General Transmission Operation ��������������������������������������������������������������� 3-32
3.13.4 Retrieving Diagnostic Codes ��������������������������������������������������������������������� 3-33
3.13.5 Clearing Diagnostic Codes ������������������������������������������������������������������������ 3-33
3.14 Body Control �������������������������������������������������������������������������������������������������������� 3-38
3.15 The common fault code of vehicle monitor system ��������������������������������������������� 3-40

4 OPERATING THE TRUCK  4-1

4.1 Pre-Starting Inspection ����������������������������������������������������������������������������������������� 4-1

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 SRT45 Off-Highway Truck

4.2 Check of each component ������������������������������������������������������������������������������������ 4-3

4.3 Engine Operation �������������������������������������������������������������������������������������������������� 4-6
4.4 Start the Engine ����������������������������������������������������������������������������������������������������� 4-8
4.5 Starting the Engine with Jumper Cables ���������������������������������������������������������� 4-10
4.6 Pre-Operating Checks ������������������������������������������������������������������������������������������4-11
4.7 Braking Function Check ������������������������������������������������������������������������������������� 4-12
4.8 Service Brake Performance Check �������������������������������������������������������������������� 4-12
4.9 Emergency Brake Performance Check ������������������������������������������������������������� 4-13
4.10 Driving and Stopping ���������������������������������������������������������������������������������������� 4-13
4.11 Stopping the Engine ������������������������������������������������������������������������������������������ 4-14
4.12 Parking ��������������������������������������������������������������������������������������������������������������� 4-16
4.13 Prolonged 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 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 150hrs  ����������������������������������������������� 8-21

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SRT45 Off-Highway Truck

8.6.3 Maintenance inspection form for 250hrs  ����������������������������������������������� 8-23

8.6.4 Maintenance inspection form for 300hrs ������������������������������������������������ 8-25
8.6.5 Maintenance inspection form for 450hrs ������������������������������������������������ 8-27
8.6.6 Maintenance inspection form for 500hrs ������������������������������������������������ 8-29
8.6.7 Maintenance inspection form for 600hrs ������������������������������������������������ 8-33
8.6.8 Maintenance inspection form for 750hrs ������������������������������������������������ 8-35
8.6.9 Maintenance inspection form for 900hrs ������������������������������������������������ 8-37
8.6.10 Maintenance inspection form for 1000hrs �������������������������������������������� 8-39
8.6.11 Maintenance inspection form for 1050hrs ��������������������������������������������� 8-43
8.6.12 Maintenance inspection form for 1200hrs �������������������������������������������� 8-45
8.6.13 Maintenance inspection form for 1250hrs �������������������������������������������� 8-47
8.6.14 Maintenance inspection form for 1350hrs �������������������������������������������� 8-49
8.6.15 Maintenance inspection form for 1500hrs �������������������������������������������� 8-51
8.6.16 Maintenance inspection form for 1650hrs �������������������������������������������� 8-55
8.6.17 Maintenance inspection form for 1750hrs �������������������������������������������� 8-57
8.6.18 Maintenance inspection form for 1800hrs �������������������������������������������� 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 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 3150hrs �������������������������������������������� 8-91
8.6.31 Maintenance inspection form for 3250hrs �������������������������������������������� 8-93
8.6.32 Maintenance inspection form for 3300hrs �������������������������������������������� 8-95
8.6.33 Maintenance inspection form for 3450hrs �������������������������������������������� 8-97
8.6.34 Maintenance inspection form for 3550hrs �������������������������������������������� 8-99
8.6.35 Maintenance inspection form for 3600hrs ������������������������������������������ 8-101
8.6.36 Maintenance inspection form for 3750hrs ������������������������������������������ 8-103
8.6.37 Maintenance inspection form for 3900hrs ������������������������������������������ 8-107
8.6.38 Maintenance inspection form for 4000hrs ������������������������������������������ 8-109
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 SRT45 Off-Highway Truck

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

D Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Controls and Operating

3 CONTROLS AND OPERATING

3.1 Controls and Instruments
1 2 3 4

5
P ！
！

10 9
6
20
8
19 7
18
17 11

12
16 15
13
21
14

Fig 3-1

1. Air outlet 8. Emergency brake button 15. Service brake pedal

[Link] of solenoid valve
2. Combination instrument 16. Ignition key switch
for body stably control
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

Safety, Operation and Maintenance Manual 3-1

Controls and Operating SRT45 Off-Highway Truck

1 2 3 4 5 6 7 8 9 10 11 12 13

P ！
！

17 16 15 14

P ！
！

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 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 lamps start to work.

3-2 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Controls and Operating

9. Engine stop indicator (red)- Illuminates

when rear lamps start to work.
10. Engine Stop Indicator Red) - When the
'Stop' indicator comes on, the computer has
detected a major malfunction in the engine
that requires immediate attention.
Stop the machine when this light illuminates
and do not operate until the fault is removed.
11. Engine maintenance indicator (white)-
Indicates that the engine needs to be
maintained. See Cummins Manual for details
about specific maintenance items.
12. Engine warning indicator (yellow) -
When the 'Warning' indicator comes on, the
computer has detected a fault in the engine
which may result 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 over speed indicator-
Illuminates when the transmission is in Torque
Converter drive. It goes OUT when Lockup is
engaged.
17. Check trans indicator (red) - Illuminates to
alert of a fault in the transmission shift system
or abnormal transmission temperature. The
light will illuminate when the ignition key switch
is turned to position '1' to provide a bulb and
system check and should go off a few seconds
after the engine is started.

Safety, Operation and Maintenance Manual 3-3

Controls and Operating SRT45 Off-Highway Truck

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
SANY MINING EQUIPMENT
immediately.

2. Speedometer
Driven by CAN bus; it indicates vehicle Fig 3-3.1
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

3-4 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Controls and Operating

high, movement, the buzzer for 10 seconds,

then shut down automatically. In the electric
power the same fault buzzer action only once.
08-25-2012 [Link] Wed

4. Fuel level gauge

SANY Mining Equipment

The pointer indicates percent of full tank Engine

a actual fuel level. Such meter is directly Transmission

connected to fuel level sensor. When the Monitor

pointer is located in white area said fuel level VEH DIST ENG HRS

XXXXXXkm [Link]
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 Fig 3-3.2
fault buzzer action only once.

5. Display
1. Turn on power supply, start the key switch
toΙ, the display shows "sany " boot screen(see System Function
SANYI
fig3-3.1), and all of the signal indicators are
applied, 3 seconds after the display shows
Engine information Parameters query
Parameters setting
Monitoring system
work interface, the lights go out at the same Controller I/O
Restore password

time. System time setting

Backlight adjust

Buzzer time setting

2. Click F2 key to change from work interface
Chinese English

to system function interface, and the work

interface is default(see fig3-3.2). F1:ESC F2:Enter F3: F4:

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- Fig 3-3.3
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 SANYI
System Time Setting
demonstrate operation method.
Under the system function interface:
2012Y08M13D
a. click F3 key or F4 key to choose the number 12H30M25S
of the time;
b. click F2 key to confirm, then the cursor will
automatically move to the next number(see
F1: ESC F2: Enter F3: F4:
fig3-3.4);
c. When the cursor to the last digit (the second
single digits) , click F2 key to confirm the
current changes, and then click F2 key again Fig 3-3.4
to end the modify Settings until appear a

Safety, Operation and Maintenance Manual 3-5

Controls and Operating SRT45 Off-Highway Truck

square green claim(see fig3-3.5),

d. Click F1 key to return to the system function
interface.

6. Engine Water Temperature Gauge

System Time Setting
Driven by CAN bus; it indicates engine coolant SANYI

temperature value. When the pointer is located

in white area said engine coolant temperature 2012Y08M13D
is normal, and once the pointer is located in 12H30M25S
red area that engine coolant temperature is too
high, movement, the buzzer for 10 seconds,
then shut down automatically. In the electric
F1: ESC F2: Enter F3: F4:
power the same fault buzzer action only once.

7. Engine Oil Pressure Gauge

Fig 3-3.5
Driven by CAN bus; it indicates engine oil
pressure value. When the pointer is located in
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,
the buzzer for 10 seconds, then shut down
automatically. In the electric power the same
fault buzzer action only once.

3.4 Reversing monitor system Power Supply

Indicator
The monitor (see Fig 3-4) on instrument panel Power
Supply
is mainly used for monitoring the reversing
Menu
truck as well as watching the situation behind （+）
truck. The matching camera is at the rear part （-）

of truck. Mirror
/Normal
Operation instructions: Light
[Link] 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
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.
[Link] control

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SRT45 Off-Highway Truck Controls and Operating

Press the MENU key until contrast appears

on the screen, then press “+” or “-” key to
increase or decrease image contrast.
[Link] control
Press the MENU key until brightness appears
on the screen, then press “+” or “-” key to
increase or decrease image brightness.
[Link] control
Press the MENU key until volume appears
on the screen, then press “+” or “-” key to
increase or decrease volume.
[Link]/ 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

1 2 3 4 5 6 7 8 9 10

Fig 3-5

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. Parking brake switch
The driver can perform rear braking
independently. Such brake can be used for
load parking or stopping.
3. Hazard warning lamp switch
Press bottom of switch to make four steering

Safety, Operation and Maintenance Manual 3-7

Controls and Operating SRT45 Off-Highway Truck

lamp flash simultaneous; press the top of the

switch to turn them off.
4. Headlamp switch
Press the bottom of the switch to electrify
the headlamp ( dipped beam/high beam);
the dipped beam/high beam of the combined
switch will be effective; otherwise, they will be
ineffective.
5. Fog lamp switch
Press switch bottom to turn on the rear fog
lamp. Press the upper part of switch to turn off
the rear fog lamp.
6. Clearance lamp switch
Press switch bottom to turn on the front and
rear clearance 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 sounds.
2. Washer
Ring Pushed = Windscreen wash 1

3. Windscreen Wiper
Position J = Not used 2

Position 0 = Stop, reset wiper

Position I = Wiper slow speed 3 4
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

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SRT45 Off-Highway Truck Controls and Operating

3.7 Air Conditioner Control Panel

Set up C

Fig 3.7
1. Panel display instructions

Set up C Set up C Set up C

Set up C Set up C

Refrigeration mode Heat mode Circulating mode Defrosting mode Blower mode

Fig 3.7.1

2. Panel key-press instructions

ON/OFF Auto/ Manual Refrigeration/ Heat

key-press key-press key-press

Defrosting Blower mode

Air circulating key-press
key-press key-press
Wind speed Temperature adjusting
key-press key-press

Fig 3.7.2
3. Operation instructions
a. Open
Press power supply key to turn on the
machine; the controller will automatically
select the working mode according to the air
conditioning system inside truck; then press
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,

Safety, Operation and Maintenance Manual 3-9

Controls and Operating SRT45 Off-Highway Truck

ventilating).
c. Refrigeration
Forced refrigerating function:
1. On blower mode, press Refrigeration/ Heat
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℃ (larger than 30℃ ) under
refrigerating mode. On refrigeration statues,
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).
d. Heating mode
Forced heating function: HI will be displayed
to activate forced heating mode when the
temperature is set larger than 30 ℃ (smaller
than 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 will turn on if the temperature of
defrosting sensor is smaller than 4℃ .On other
status it will enter core defrosting.
f. Press circulation key, i.e., fresh air function;
the external circulation is used for blowing
fresh air and the internal circulation for
stopping fresh air intake.

CAUTION

Air conditioner uses the manual

v a l v e t o c o n t r o l w a r m w a t e r, i n
summer, must de sure the valve is
shut when refrigerate; in winter, must
be sure the valve is on when heat.

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SRT45 Off-Highway Truck Controls and Operating

3.8 Driver Seat

1. The travel of suspension device is 100mm.
2. Body weight and height adjustment. Pull
up the seat can adjust height, there are three
levels(low、middle、high), when the seat is
on high level, if pull up the seat, it will return
low level. The adjusting handle (1) on seat can
adjust the rigidity of suspension mechanism, 2
(the green indication belt on body weight 3
adjustment indication strip is at a visible
position). 1
3. Front/rear adjustment. Pull handle (2) on
the right side to slide seat to a proper position.
The maximum front and rear adjustment
distance is 210mm.
4. Back angle adjustment. This is used to Fig 3.8
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 moving.
Loss of control may result. Stop the
machine; apply the brakes;then adjust.

3.9 Seat Belt 1

Adjust the seat to the best height which does

2
not affect the driving. Completely release the
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 Fig 3.9
3-9).

Safety, Operation and Maintenance Manual 3-11

Controls and Operating SRT45 Off-Highway Truck

3.10 Truck Controls

P ！
！

Parking brake
Emergency
brake button

Service brake 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
e m e r g e n c y b r a k e i n a n e m e r g e n c y. 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 Fig 3-10).

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SRT45 Off-Highway Truck Controls and Operating

3.10.3 Parking brake

Pushing the switch in will apply the spring
operated parking brakes within the rear brake
assemblies and the service brakes at all
wheels. The parking brake indicator on the
combination instrument will illuminate when
the control is pushed in. Push the switch at top
to release the brakes.

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
Fig 3.11
meant for bringing the machine to a halt, or
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
indicator at the rear of the truck will illuminate
to warn following trucks.

Safety, Operation and Maintenance Manual 3-13

Controls and Operating SRT45 Off-Highway Truck

The retarder is off when the lever is fully

forward and is applied as the lever is pulled
back. Rear disc brake retarder can obtain
different retardation by shifting handle from
front to rear. Maximum retardation is obtained
when the lever is in the fully back position.
(1) Retarder operation
Before the machine crests the top of a grade
and starts down, the operator should slow the
machine with the service brakes and downshift
to the gear range which would be used to
ascend the grade. The retarder should be
applied before starting the descent. Machine
downgrade speed (with the retarder applied
as required) in the gear range selected should
be high enough to keep the engine operating
at governed speed with the throttle closed
(operator's foot off the accelerator pedal).
This will ensure maximum oil circulation and
cooling. 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 is strongly recommended that just one
of them is used and the transmission retarder
is prior. Only when maximum transmission
retardation is obtained and additional
retardation is required, the rear disk brake
retarder be used.
Note: In order to obtain the maximum
retardation and cooling effect during
retardation, the engine speed should be
maintained as high as possible without
exceeding the maximum recommendation.
(2) Oil temperature - rear disc brake
The disc brake hydraulic temperature warning
indicator on the instrument panel will illuminate
and an electric horn will sound if the oil flowing
through the disc brake assemblies overheats.

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SRT45 Off-Highway Truck Controls and Operating

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 white z-
one, should not enter the red zone. Otherwise,
reduce downgrade travel speed immediately 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 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 pedal.

3.11.2 QUANTUM electronic fuel system Fig 3.12

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.

Safety, Operation and Maintenance Manual 3-15

Controls and Operating SRT45 Off-Highway Truck

2 1 4

3 5 6 7

P ！
！

Fig 3.13

[Link] control module (ECM) 5. Stop indicator

2&3. Harness connector (50 and 31pin RHS) 6. Maintenance indicator
4. Accelerator pedal 7. Warning indicator

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
(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.

3-16 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Controls and Operating

3.11.3 Quantum electronic fuel system -

description

1. Electronic Control Module (ECM)

Receives electronic inputs from the driver as
well as from mounted sensors that provide
information electronically, such as oil pressure
and temperature and intake manifold pressure.
This information is used to control both the
quantity of fuel injected and injection timing.
2. Programmable Read Only Memory
Located in the ECM and encoded with the
operating software. Additional information
is programmed into the EEPROM. This
information controls the horsepower rating,
torque curve, maximum engine speed and
engine protection devices. The ECM processes
this information and sends electronic signals
to the Electronic Fuel System Injectors where
the precise amount of fuel is injected into the
engine.
[Link] 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 injector performs four functions:
a - Creates the high fuel pressure required for
efficient injection.
b - Meters and injects the exact amount of fuel
required to handle the load.
c - Atomizes the fuel for mixing with the air in
the combustion chamber.
d - Permits continuous fuel flow for component
cooling.
Electronic fuel system injectors are self
compensating and virtually eliminate engine
tune-ups.
Note: Never apply 12V or 24V directly to
terminals on the injector as it will burn out.
Before removing injectors.

Safety, Operation and Maintenance Manual 3-17

Controls and Operating SRT45 Off-Highway Truck

3.11.4 QUANTUM electronic fuel system

- operation

When the 'Stop' indicator on the dash panel

illuminates, the computer has detected a
major malfunction in the engine that requires
immediate attention. It is the operators
responsibility to shut down the engine to avoid
serious damage.
The machine is equipped with an engine
protection derate system, which records fault
codes when an out-of-range conditions is
found. The Maintenance indicator illuminates
when the engine protection derate system
is initiated. The engine power and speed
will be gradually reduced depending on the
level of severity of the out-of-range condition.
The Maintenance indicator will start to flash
if the out-of-range condition continues to get
worse. The operator MUST shut down 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 temperature, Low oil pressure
and High fuel rail pressure.
Whenever the 'Stop', 'Warning' or Maintenance
indicator comes on, the Electronic Fuel
System computer will determine where the
problem is and will store this information in
its memory. If the malfunction is intermittent,
the indicators will come on and go off as
the computer senses the changing engine
condition.
A special diagnostic data reader (INSITE) is
available that can be plugged into the engine
computer memory to extract information
related to the cause of the problem. Once
the malfunction has been corrected, the

3-18 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Controls and Operating

Electronic Fuel System will return the engine

to normal operation. The data reader can now
distinguish between active codes and those
stored in the historic code memory (inactive
codes). Inactive codes can only be viewed
using the data reader. The fault code recorded
in the ECM memory will remain until it is
erased by a technician.
The operator can check for active faults by
turning the ignition key switch to the 'OFF'
position, switching the diagnostic switch
'ON' and then turning the ignition key switch
to position '1'. If no active fault codes are
recorded, all three ('Stop', 'Warning' &
Maintenance) indicators will come on and
stay on. If active 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 number is done, the
yellow indicator flashes again. e.g. yellow
flashes once - pause - red flashes twice -
pause - red flashes three times - pause - red
flashes five times - pause - yellow flashes
once, indicates fault code 235. The number
will repeat in the same sequence until the
system is advanced to the next active fault
code or the diagnostic switch is switched to
the 'OFF' position.
Refer to 'Electronic Fuel System Diagnostic
Codes' table for fault code descriptions.

Safety, Operation and Maintenance Manual 3-19

Controls and Operating SRT45 Off-Highway Truck

3.11.5 Electronic fuel system diagnostic codes

Detection Codes of Electronically Controlled Fuel System

Error Code Description Fault lamp
111 Engine Control Module – Critical internal failure Red
Engine Speed/Position Sensor Circuit - lost both of two signals from the magnetic
115 Red
pickup sensor
Engine Speed/Position Sensor Circuit - lost one of two signals from the magnetic
121 Yellow
pickup sensor
122 Intake Manifold Pressure Sensor #1 Circuit - shorted high Yellow
123 Intake Manifold Pressure Sensor #1 Circuit - shorted low Yellow
131 Accelerator Pedal Position Sensor Circuit - shorted high Red
132 Accelerator Pedal Position Sensor Circuit - shorted low Red
133 Remote Accelerator Pedal Position Sensor Circuit - shorted high Red
134 Remote Accelerator Pedal Position Sensor Circuit - shorted low Red
135 Engine Oil Pressure Sensor Circuit - shorted high Yellow
141 Engine Oil Pressure Sensor Circuit - shorted low Yellow
143 Engine Oil Pressure Low – Warning Yellow
144 Engine Coolant Temperature 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 - shorted low Yellow
155 Intake Manifold Temperature #1 High -Critical Red
187 Sensor Supply Voltage #2 Circuit -shorted low Yellow
Additional OEM/Vehicle Diagnostic Codes have been logged. Check other ECM's
211 None
for DTC's.
212 Engine Oil Temperature Sensor Circuit - shorted high Yellow
213 Engine Oil Temperature Sensor Circuit - shorted low Yellow
214 Engine Oil Temperature High - Critical Red
219 Low Oil Level in the Centinel makeup oil tank Maint.
221 Ambient Air Pressure Sensor Circuit – shorted high Yellow
222 Ambient Air Pressure Sensor Circuit – shorted low Yellow
223 Engine Oil Burn Valve Solenoid Circuit – shorted low Yellow
227 Sensor Supply Voltage #2 Circuit - shorted high Yellow
234 Engine Speed High – Critical Red

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SRT45 Off-Highway Truck Controls and Operating

235 Engine Coolant Level Low - Critical Red

241 Vehicle Speed Sensor Circuit – data incorrect Yellow
242 Vehicle Speed Sensor Circuit - tampering has been detected Yellow
245 Fan Clutch Circuit - shorted low Yellow
254 Fuel Shutoff Valve Circuit - shorted low Red
255 Fuel Shutoff Valve Circuit - shorted high Yellow
259 Fuel Shutoff Valve - stuck open Red
Engine Speed/Position Sensor #1 (Crankshaft) Supply Voltage Circuit - shorted
284 Yellow
low
285 SAE J1939 Multiplexing PGN Timeout Error Yellow
286 SAE J1939 Multiplexing Configuration Error Yellow
287 SAE J1939 Multiplexing Accelerator Pedal Sensor System Error Red
288 SAE J1939 Multiplexing Remote Throttle Data Error Red
293 Auxiliary Temperature Sensor Input # 1 Circuit – shorted high Yellow

294 Auxiliary Temperature Sensor Input # 1 Circuit – shorted low Yellow

295 Ambient Air Pressure Sensor Circuit - data incorrect Yellow

297 Auxiliary Pressure Sensor Input # 2 Circuit – shorted high Yellow
298 Auxiliary Pressure 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 Valve Cylinder #2 Circuit – grounded circuit Yellow
319 Real Time Clock - Power Interrupt Maint.
341 Engine Control Module – data lost Yellow
343 Engine Control Module – Warning internal hardware failure Yellow
346 Engine Control Module – Warning Software error Yellow
349 Transmission Output Shaft (Tailshaft) Speed High – Warning Yellow
352 Sensor Supply Voltage #1 Circuit - shorted low Yellow
378 Fueling Actuator #1 Circuit - open circuit Yellow
379 Fueling Actuator #1 Circuit – grounded circuit Yellow
386 Sensor Supply Voltage #1 Circuit - shorted high Yellow
387 Accelerator Pedal Position Sensor Supply Voltage Circuit - shorted high Yellow
394 Timing Actuator #1 Circuit - open circuit Yellow
395 Timing Actuator #1 Circuit – grounded circuit Yellow
396 Fueling Actuator #2 Circuit - open circuit Yellow

Safety, Operation and Maintenance Manual 3-21

Controls and Operating SRT45 Off-Highway Truck

397 Fueling Actuator #2 Circuit – grounded circuit Yellow

398 Timing Actuator #2 Circuit - open circuit Yellow
399 Timing Actuator #2 Circuit – grounded circuit Yellow
415 Engine Oil Pressure Low – Critical Red
WIF /
418 Water in Fuel Indicator High –Maintenance
Maint.
422 Engine Coolant Level Sensor Circuit - data incorrect Yellow
426 SAE J1939 datalink - cannot transmit None
428 Water in Fuel Sensor Circuit – shorted high Yellow
429 Water in Fuel Sensor Circuit – shorted low Yellow
431 Accelerator Pedal Idle Validation Circuit - data incorrect Yellow
432 Accelerator Pedal Idle Validation Circuit - out of calibration Red
433 Intake Manifold Pressure Sensor Circuit - data incorrect Yellow
434 Power Lost without Ignition Off Yellow
435 Engine Oil Pressure Sensor Circuit - data incorrect Yellow
441 Battery #1 Voltage Low - Warning Yellow
442 Battery #1 Voltage High - Warning Yellow
443 Accelerator Pedal Position Sensor Supply Voltage Circuit - shorted low Yellow
449 Fuel Pressure High - Warning Yellow
451 Injector 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 Metering Rail #2 Pressure High - Warning Yellow
486 Injector Metering Rail #2 Pressure Low - Warning Yellow
489 Transmission Output Shaft (Tailshaft) Speed Low – Warning Yellow
496 Engine Speed/Position Sensor #2 (Camshaft) Supply Voltage Yellow
527 Auxiliary Input/Output #2 Circuit - shorted high Yellow
528 OEM Alternate torque validation switch - data incorrect Yellow
529 Auxiliary Input/Output #3 Circuit - shorted high Yellow
546 Fuel Delivery Pressure Sensor Circuit - shorted high Yellow
547 Fuel Delivery Pressure Sensor Circuitshorted low Yellow
551 Accelerator Pedal Idle Validation Circuit - shorted low Yellow
553 Injector Metering Rail #1 Pressure High - warning level Yellow
581 Fuel Supply Pump Inlet Pressure Sensor Circuit - shorted high Yellow
582 Fuel Supply Pump Inlet Pressure Sensor Circuit – shorted low Yellow

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SRT45 Off-Highway Truck Controls and Operating

583 Fuel Supply Pump Inlet Pressure Low - warning level Yellow
595 Turbocharger #1 Speed High – warning level Yellow
596 Electrical Charging System Voltage High - warning 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

Safety, Operation and Maintenance Manual 3-23

Controls and Operating SRT45 Off-Highway Truck

3.12 Steering
The steering wheel position can be adjusted
as required for the most convenient operating
position. To adjust, pull out adjustment lock
and tilt steering wheel up or down as desired;
release lever to lock adjustment.
The steering system provides full-time Adjusting rotary Adjusting rotary
hydraulic power with a continuous-running knob of high-low knob of front-rear
pump and a pressurized accumulator. The
accumulator helps maintain a constant flow
of hydraulic power to operate the steering Fig 3.14
cylinders (Fig 3-14, 3-15).
To steer the front wheels, rotate the steering
wheel in the desired direction to the required
radius of turn. The front wheels will turn only
as the steering wheel is turned and at a rate of
turning directly proportional to steering wheel
Trun left Trun right
speed. The front wheels will stop and 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 Fig 3.15
accumulator provides a maximum
of two lock to lock turns of the front
wheels. A red warning indicator on
the instrument panel illuminates and a
buzzer sounds when steering pressure
falls below 11.5MPa (1660 pound/in2).
If this warning indicator illuminates,
indicating a loss of steering power, the
machine must be stopped immediately
and no further operation attempted
until the fault is corrected. The
accumulator slowly bleeds down after
engine shut-off to prevent accidental
s t e e r i n g . H o w e v e r, a c c u m u l a t o r
pressure should be dissipate after
engine shut-off by turning the steering

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SRT45 Off-Highway Truck Controls and Operating

wheel in both directions to avoid

accidental steering during bleed down.
Improper steering control unit repair or
hose connections can cause sudden
and forceful steering wheel movement
when engine is [Link] hands off
steering wheel when starting engine.

3.13 Transmission

3.13.1 CEC2 Shift System

The transmission of the truck adopts the
CEC2 (2nd generation commercial electronic
control) shift system. CEC2 is a well designed
computer-controlled automatic shift system,
which integrates functions including automatic
gear-shift, misoperation screening, diagnostic
capabilities, etc., so as to effectively reduce
the fatigue of the driver and make the driver
work safely, easily and simply by focusing on
the road conditions.
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.
Reverse Inhibit: Prevents gear selection if
engine is operating at more than 20% throttle.
Hoist interlock pressure switch - The ECU will
shift the transmission from Reverse to Neutral
if the body control lever is moved to the 'Raise'
[Link] the body is held in the 'Raise'
position,will prevent to engage reverse gear.
Body Up Interlock: When the body is raised, the
CEC2 system will only allow the transmission
to operate in first gear. This feature is only
operational in the normal automatic driving
mode, either power or economy. It is not

Safety, Operation and Maintenance Manual 3-25

Controls and Operating SRT45 Off-Highway Truck

activated during the manual mode.

Parking Brake Interlock: If the parking brake
is applied while the transmission is in neutral,
the CEC2 system will prevent a shift out of
neutral to protect the brake components. If the
parking brake is applied while the transmission
is in gear, the parking brake interlock will not
function and normal shifts will occur.
Lock-in-gear: The lock-in-gear feature is
designed to protect the transmission from
damage should wheel spinning or lockup occur
due to poor traction or panic braking. The ECU
will delay making a shift for several seconds
and then, if the condition fails to correct itself,
locks in gear and prevents any further shifting.
The transmission fault indicator will come on.
If 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 transmission" and
"inhibit gear shift" warning indicator should go
off.
Cold Weather Starts: During cold weather
starts, if the transmission temperature is
below -24℃ (-10°F), The "check transmission"
and "forbid gear shifting" warning indicator
will come on, and the ECU will keep the
transmission at neutral gear. Between -24° C
(-10°F) and -7℃ (19°F) ,the warning indicator
will go out and the ECU will only permit
operation in First or Reverse gears. Above
-7℃ (19°F), normal operation will be permitted.

WARNING

Before any welding is done on a

machine equipped with a CEC shift

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SRT45 Off-Highway Truck Controls and Operating

system, disconnect battery equalizer

ground cables, battery cables from
terminal posts (ground cable first),
battery equalizer positive cables
and electrical connections at the
ECU to avoid damage to electrical
components. Turn off ignition key
switch to isolate the batteries before
disconnecting any components.
The standard procedure for raising the
body must still be adhered to.

P ！
！

3 P
8
7
6
5 2
4
idle/diag
1 P ！
！
2H 2G 2F 2E 1H 1G 1F 1E 12H 12G 12F 12E 11H 11G 11F 11E
0801 0203 0404 0501 0405 0402 0401 17
R14-86 R14-87 F15 F14 R5-86 F12 F11 F10 F27 F26 F25 F24 F23 F22 F2 F1
R9-86 R9-87 R14-30 R14-87a R4-86 R4-87 R7-86 R7-87 R11-86 R11-87 R12-86 R12-87 F21 F20 F2 F1
0308 0302 0219 0202 1506 1505 0702 0701 15
2A 2B 2C 2D 1A 1B 1C 1D 12A 12B 12C 12D 11A 11B 11C 11D
B068-7034-F B068-7034-B B068-7034-H B068-7034-C
RED GREY BROWN GREEN
YELLOW

X X X X X X X X
BLACK

B068-7034-E
B068-7034-A

R12-GND R1-86 R1-87

R5-87 R13-30 R13-87

10B
0106
0220
3F

F15 F14 F12 F11 F10 F27 F26 F25 F24 F23 F22 F2 F1
R12-PWR R12-LOAD

R14
R14-85 R13-86

10C

10F
15F1

0110
3G

3B

10D

10E
15F2
3H

3A

R9 R7 R5 R11 R10 F21 F20 R1

R13
R2-87 R2-86
R3-87 R3-86
R13-87a R13-85

●
R8-87 R8-86 R6-87 R6-86

0204

0205
1403

ORANGE
0601

9H

R4 F13
9A
4E

4D

R8 R6 R3 R2
B068-7034-D
BLUE
B068-7034-G

0221

0216
9B
1401

9G
4F
115

4C

R12
F28 F8 F7 F6 F5 F4 F3 F19 F18 F17 F16 F9
0101
F16
F18
0209
F28

0306

9C
4G

4B

9F

9
F17
F19
0201
F28

0403

10
9D
0301

9E
4H

4A

B151-7155-12 B151-7155-11
B068-7073-11 B068-7073-11

5S 6S 7S 8S

BAT '31-' BAT 'X+' BAT '15+' BAT '30+'

Fig 3.16

[Link] control unit (ECU) 6. Diagnosis switch

[Link] box [Link] detection switch
[Link] shift selector [Link] adjustment switch
[Link] selection switch 9. Transmission overspeed indicator
[Link] switch [Link] fault indicator

Safety, Operation and Maintenance Manual 3-27

Controls and Operating SRT45 Off-Highway Truck

3.13.2 Introduction and operation

(1) Electronic Control Unit (ECU) – The ECU
contains an electronic [Link]
receives information in the form of electronic
signals from switches and sensors, processes
the information, and sends electronic signals
to the appropriate solenoids which control the
transmission.
(2) Control box -- contains VIM and ECU.
(3) Gear shift selector -- the shift selector is
a remote mounted lever type. The gear shift
selector is connected to the ECU by a wiring
harness. The shift lever has 6 forward ranges
and 1 reverse ranges, as well as a neutral
position.
The shift selector has a single digit LED
display, which during normal operation R
N
will display the gear selected. Diagnostic
MODE

D
information can be displayed on the single 5
R 4
digit LED display by pressing the diagnostic 3
display button. There is a hold override button 2
1
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 Fig 3.17
the number ranges without pressing the hold
override button. (Refer to fig.3-17)

WARNING

Do not allow the vehicle to coast in

Neutral. This practice can result in
severe transmission damage.

The transmission upshifts and downshifts

automatically between first range and the
highest range selected on the range selector
in direct response to throttle position, engine
speed and transmission output speed.
When Reverse is selected the reverse alarm
sounds and the reverse indicator illuminates
at the rear of the vehicle. This feature warns
personnel to the immediate rear of the vehicle

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SRT45 Off-Highway Truck Controls and Operating

that the operator has shifted to reverse.

When drive 'D' is selected, the transmission
automatically upshifts and downshifts through
all six forward ranges as required by loads and
travel speeds. Selecting a lower range (4th,
3rd etc.) limits the highest range to which the
transmission will automatically upshift.
If a lower range is selected while moving
forward, the transmission automatically
downshifts sequential to the selected lower
range at maximum controlled engine speeds.
Downshifts will not occur until vehicle is
slowed by use of the service brakes and/or
retarder.
When shifting from neutral to start from a
standstill, or to reverse direction, decelerate
the engine to idle speed. To move forward,
select drive 'D' and accelerate the engine to
the vehicle load and speed requirements. 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 is required,
the transmission will upshift to the next higher
range at less than maximum rated engine
speed.
Upgrades or soft spots might slow travel
speed, even at full throttle, requiring
transmission downshifts to maintain maximum
powertrain performance. When this occurs,
the transmission downshifts automatically.
Shift the transmission to the next lowest range
if transmission 'Hunting' or 'Shift Cycling'
occurs.
When temporarily stopped, such as for
yielding the right-of-way to a loaded vehicle,
the transmission can be left in the selected
range and the vehicle held stationary with the
service brakes.

Safety, Operation and Maintenance Manual 3-29

Controls and Operating SRT45 Off-Highway Truck

However, when stopped for a more extended

period with the engine left running, shift the
transmission to neutral to avoid unnecessary
heat buildup and apply the parking brake.

WARNING

Always select Neutral and apply the

parking brake before leaving the
operator’s seat.

(4) Mode selection switch - Gives the option

to select between transmission 'POWER' and
'ECONOMY' shift schedules.
Note: The transmission must be in neutral
before the switch will function; otherwise,this
practice can result in transmission damage.
The transmission torque converter is equipped
with a lockup clutch which, when engaged
by the ECU, locks the converter pump and
turbine together as a single unit and allows
power to be transmitted 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
received by the throttle position sensor (giving
engine speed as a percent of throttle), the
transmission output shaft speed sensor,
and range selector. The ECU may delay
application of the lockup clutch and allow
torque multiplication by the torque converter to
take place until a balance is achieved between
engine speed and transmission output shaft
speed before activating the lockup clutch.
Power versus Economy Mode
The POWER mode is designed for
applications involving heavy loads and hilly

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SRT45 Off-Highway Truck Controls and Operating

duty cycles where performance rather than

fuel economy is of prime importance.
The ECONOMY mode is designed for
applications involving lighter loads and level
duty cycles or where fuel economy is more
important than performance.
In the ECONOMY mode, the ECU controls
operation of the lockup clutch with a timed,
preprogrammed schedule where in second
through sixth gears the lockup clutch is
disengaged only long enough to allow the
torque converter’s fluid coupling to absorb
shift shock. Otherwise, the lockup clutch is
engaged and no torque multiplication takes
place in Second through Sixth gears.
(5)Reversing switch-This switch is provided for
reversing function,Operator can use.
(6)Diagnosis switch -- This switch is provided
for the professional service technician of the
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 switch-This switch is
provided for idling adjustment function,
operator can use to increase or decrease
idling.
(9)Transmission over speed indicator (Red)
-- Illuminates when the transmission ECU
senses engine speed above 2350 r/min.
(10) Transmission fault indicator(Red) --
Illuminates to alert of a minor fault in the
transmission shift system or abnormal
transmission temperature. The warning
indicator will come 'On' when the ignition key
switch is turned to position '1' to provide a bulb
and system check and should go 'Off' a few
seconds after the engine is started and the
transmission oil pressure rises.

Safety, Operation and Maintenance Manual 3-31

Controls and Operating SRT45 Off-Highway Truck

The transmission fault indicator will come

'On' during operation if the ECU has detected
a minor fault in an electrical component or
abnormal transmission oil temperature. If
transmission oil temperature is too high, stop
the machine, select Neutral (N), and increase
engine speed to allow a greater flow of oil
to the oil cooler until oil temperature drops
to normal operating range. In most cases, a
minor fault triggering the transmission fault
indicator will not prevent normal operation
from continuing but, depending on the nature
of the problem, the ECU could take action to
protect the transmission from damage, such
as preventing operation in high gear ranges. If
the ' check trans ' warning indicator 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 truck operation. If
the transmission oil 4
temperature gauge, on vehicles which do not R
3 MODE
N
have a transmission retarder fitted, shows D
5
oil temperature consistently rising above the R
2 4
green zone (65°C - 135°C; 149°F - 275°F) 3
2
under normal operating conditions; check for 1 1
external causes. If none are evident shift to
Neutral (N) and operate the engine at 1200 -
1500 r/min. If the transmission oil temperature
does not decrease into the green zone within Fig 3.18
2 or 3 minutes, the cause of the overheating

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SRT45 Off-Highway Truck Controls and Operating

should be corrected before the machine is

operated further. Watch the oil temperature
gauge when operating on upgrades, also. If
the oil temperature goes into the red zone
(135°C -165°C; 275°F- 392°F), select the
range which will limit upshifts to the highest
range in which the transmission will operate
within the normal temperature range. If
upshifting must be consistently limited to
ranges lower than normal for the loads and the
grades encountered to prevent overheating
the transmission oil, the causes should be
determined and corrected.

3.13.4 Retrieving Diagnostic Codes

Diagnostic fault codes can be retrieved from
the CEC2 system using the gear shift 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 the two digit main code, then
the two digit subcode.
※ To advance to the next code, press the
mode button (3). Up to five codes can be
stored.
※Active codes are indicated by illumination of
the mode light (4).

3.13.5 Clearing Diagnostic Codes

To clear active codes, press and hold mode
button (4) for 3 to 5 seconds.
To clear inactive codes, press and hold mode
button (4) for 8 to 10 seconds.
To exit diagnostic mode, press diagnostic
button (6). Refer to table for diagnostic code
description.

Safety, Operation and Maintenance Manual 3-33

Controls and Operating SRT45 Off-Highway Truck

........................................................................................................................................

........................................................................................................................................

........................................................................................................................................

........................................................................................................................................

........................................................................................................................................

........................................................................................................................................

........................................................................................................................................

E
........................................................................................................................................

G
........................................................................................................................................

PA
........................................................................................................................................

........................................................................................................................................

........................................................................................................................................

........................................................................................................................................
K

........................................................................................................................................
N

........................................................................................................................................
LA

........................................................................................................................................

........................................................................................................................................

........................................................................................................................................
B

........................................................................................................................................

........................................................................................................................................

........................................................................................................................................

........................................................................................................................................

........................................................................................................................................

........................................................................................................................................

........................................................................................................................................

........................................................................................................................................

3-34 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Controls and Operating

3.13.6 Diagnostic Codes

Check
M a i n Sub Inhibited Operation
Description Trans
code Code Description
Light
12 ECU input voltage, low Yes DNS
13
23 ECU input voltage, high Yes DNS
12 Throttle position sensor, failed low Yes Use throttle default values
21
23 Throttle position sensor, failed high Yes Use throttle default values
Engine speed sensor reasonableness
14 Yes Use default engine speed
test
Turbine speed sensor reasonableness
22 15 Yes DNS, lock in current range
test
Output speed sensor reasonableness
16 Yes DNS, lock in current range
test
Hold in last valid direction. May
12 Primary shift selector or RSI link fault Yes
cause “cateye” display
13 Primary shift selector mode function fault No Mode change not permitted
Secondary shift selector or RSI link Hold in last valid direction. May
23 14 Yes
fault cause “cateye” display
Secondary shift selector mode
15 No Mode change not permitted
function fault
16 Shift Selector display line fault Yes None. May cause “cateye” display
12 Sump fluid temperature, cold Yes DNS, lock-to-range
24 No upshifts above a calibration
23 Sump fluid temperature, hot Yes
range
Output speed sensor, detected at 0 output
11 Yes DNS, lock in current range (1st)
rpm, 1st
Output speed sensor, detected at 0 output
22 Yes DNS, lock in current range (2nd)
rpm, 2nd
Output speed sensor, detected at 0 output
25 33 Yes DNS, lock in current range (3rd)
rpm, 3rd
Output speed sensor, detected at 0 output
44 Yes DNS, lock in current range (4th)
rpm, 4th
Output speed sensor, detected at 0 output
55 Yes DNS, lock in current range (5th)
rpm, 5th

Safety, Operation and Maintenance Manual 3-35

Controls and Operating SRT45 Off-Highway Truck

Output speed sensor, detected at 0 output

66 Yes DNS, lock in current range (6th)
rpm, 6th
Output speed sensor, detected at 0 output
25 77 Yes DNS, lock in current range (7th)
rpm, 7th
Output speed sensor, detected at 0 output
88 Yes DNS, lock in current range (8th)
rpm, 8th
26 00 Throttle source not detected No Use throttle default values
12 Sump fluid temperature sensor failed low Yes Use default value of 93°C (200°F)
33
23 Sump fluid temperature sensor failed high Yes Use default value of 93°C (200°F)
Factory calibration compatibility number
12 Yes DNS, SOL OFF
wrong
13 Factory calibration fault Yes DNS, SOL OFF
Use previous location, or factory
14 Power off fault Yes
34 calibration
Use previous location, or clear
15 Diagnostic queue fault Yes
diagnostic queue
16 Real time fault Yes DNS, SOL OFF
17 Customer modifiable constants fault Yes DNS, SOL OFF
Power interruption (code set after power None (hydraulic default during
00 No
35 restored) interruption)
16 Real time write interruption Yes DNS, SOL OFF
36 00 Hardware/software not compatible Yes DNS, SOL OFF
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 Yes DNS
45 21 General solenoid failure - H/J Yes Turn off trim boost J, DNS H
22 General solenoid failure – A Yes No action taken
23 General solenoid failure – D Yes DNS
24 General solenoid failure - I Yes No action taken
26 General solenoid failure - C Yes DNS
21 Hi side overcurrent, H/J solenoid Yes Turn off H/J solenoid, DNS
26 Hi side overcurrent, C, D, E solenoid circuit Yes Turn off C, D, E solenoids
46
DNS. Turn off A, B, F, G, I, K
27 Hi side overcurrent, A, B, F, G, I, K Yes
solenoids
11 Range verification ratio test, 1st Yes DNS
22 Range verification ratio test, 2nd Yes DNS
56
33 Range verification ratio test, 3rd Yes DNS
44 Range verification ratio test, 4th Yes DNS

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SRT45 Off-Highway Truck Controls and Operating

55 Range verification ratio test, 5th Yes DNS

66 Range verification ratio test, 6th On DNS
56
77 Range verification ratio test, 7th or R1 Yes DNS
88 Range verification ratio test, 8th or R2 Yes DNS
65 00 Engine rating too high Yes DNS, Lock-in-neutral
66 00 Serial communications interface fault No Use default throttle values
27 ECU, inoperative 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

Reset ECU, shutdown ECU on 2nd

ECU, Computer Operating Properly (COP) occurrence (power loss; hydraulic
33 Yes
fault defaults). May cause “cateye”
69 display or all segments blank display

34 ECU, EEPROM, fault Yes DNS, SOL OFF

35 ECU, EEPROM, fault Yes Reset ECU
39 Communication chip addressing error Yes Use defaults for J1939 data
GPO 1–8 and reverse warning
42 SPI output failure No
inoperable
43 SPI input failure Yes DNS, lock-in-range

Safety, Operation and Maintenance Manual 3-37

Controls and Operating SRT45 Off-Highway Truck

3.14 Body Control

Operate the hoist lever(see Fig 3-19) the left
of operator’s seat to raise or lower body. The
four operating positions of the lever from front
to rear are as follows :
Raise -this position directs oil to extend the
body hoists and raise the body.
When released, the lever will be spring-
returned to the 'HOLD' position.
HOLD - Lever to this position while the body
is being raised and lowered to stop movement
and hold the body to the expected height.
The lever will be locked and kept at “ HOLD”
position during releasing.
FLOAT – While the body drops via gravity, the
lever will be moved to and kept at this position
until the body will be operated again. The lever Fig 3.19
shall be kept at “float” position during the truck
is in motion .
Lower -This position provides hydraulic force
to power-down the body. The body raised to HOIST
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 HOLD

a certain height, it will drop via gravity. Then,

release lever and the lever will be moved to
FLOAT
the float position via spring which inside of the
valve (see Fig 3-20).
1. Hoist LOWER
Preparation:
(1) Run the engine in idling speed;
(2) Make sure the rear wheels are on the firm Fig 3.20
level ground;
(3)Shift the transmission to Neutral and hold
the machine stationary by applying the brakes
with the Parking-Emergency brake control.
Hoisting:
(1) Pull the lever backward to the “Raise”
position, hold the lever and accelerate engine
to raise body;
(2) Moves the raise lever to "hold" position
when the body is required to stay at a certain
height;

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SRT45 Off-Highway Truck Controls and Operating

(3) Decelerate the engine when the last stages

of the body hoists begin to extend to slow the
raising speed as the hoists approach their
maximum extensions;
(4) Pull the lever to “HOLD” position when the
body is raised to the desired height.

WARNING

Drain the pressure form the pilot valve

before while repairing the raise system and
its control system .
Method: Turn off the engine, operate the
RAISE lever for about 15 times in two
directions, to drain the 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 and power
the body downward until it begins lowering
by gravity. Then move the lever to 'FLOAT'
position in the specially situation.
Caution : Make sure that the body is
completely lowered and the control lever is
in 'FLOAT' before releasing the brakes and
moving the machine.

Safety, Operation and Maintenance Manual 3-39

Controls and Operating SRT45 Off-Highway Truck

3.15 The common fault code of

vehicle monitor system
There is an indicator of vehicle monitor system
state in display. The indicator is green when
the vehicle is normal, and turns red when any
one or more of the following fault accruing.

Fault code Description Operation Instruction

Disc brake cooling oil returning

2685 Must check
Temperature high
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 check
2700 Water in fuel indicator Need check
2701 Parking pressure low Must check
2705 Over speed Reduce speed
2706 Hoist oil returning filter block Must check

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SRT45 Off-Highway Truck Operating the Truck

4 OPERATING THE TRUCK

4.1 Pre-Starting Inspection
※ Before the engine is started ensure the
machine is ready for operation.
※ The machine should be in a level position to
permit accurate checking 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 following
pages.

Safety, Operation and Maintenance Manual 4-1

Operating the Truck SRT45 Off-Highway Truck

Rear lamp assembly Check for leakage

REAR RIDE CYLINDERS and normal working
WHEELS AND TYRES Check condition, Check for debris leaks and
inflation, nuts and for damaged rims damage. Check height DIFFERENTIAL Check for leaks

DISC BRAKE ASSEMBLIES Check for leaks

BODY CYLINDERS Check for debris,

leaks and damage. Check lines for
FUEL TANK Check fuel level.
wear and leaks.
Ensure fuel tank is full.
Check that tank is securely mounted.

TRANSMISSION Check oil level.

Check for leaks
Hydraulic oil tank Check oil level.
Check for leaks
STEERING CYLINDERS Check for
debris, leaks and damage.
Check lines for wear and leaks FRONT RIDE CYLINDERS
Check for debris, leaks and
damage. Check height

BRAKE ACCUMULATORS
Check for leaks.

ENGINE Check oil level.

Check liquid level of expan- Check for leaks
sion water tank and leakage

Front lamp assembly Check

for damage and normal working
CAB, PLATFORM AND STEPS Check
for cleanliness. Check seat belts.

Fig 4.1

4-2 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Operating the Truck

4.2 Check of each component

1. Engine
With the engine off, check oil level. The oil
level should be between the lower and upper
marks on the dipstick. Add oil if low (see Fig
4-2).

Fig 4.2

2. Fuel filters
Drain sediment and water from sump until fuel
runs clear (see Fig 4-3).

Fig 4.3

[Link] 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 Fig 4.4
completely. Fill to bottom of filler neck.

Safety, Operation and Maintenance Manual 4-3

Operating the Truck SRT45 Off-Highway Truck

4. Air Cleaner vacuator valve(s)

Check for proper operation. Clean if Required
(see Fig 4-5).

Fig 4.5

5. Tyres
Carefully 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).

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).

Fuel gauge

Fig 4.7

4-4 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Operating the Truck

7. Body and disc brake cooling tank - cold

oil level
The bottom sight gauge should show full. Add
fluid, if low (see Fig 4-8)

8. Steering and braking tank - cold oil level

With the engine off, 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).

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 (see Fig 4-9).

Oil level

Fig 4.9

Safety, Operation and Maintenance Manual 4-5

Operating the Truck SRT45 Off-Highway Truck

10. Seat and seat belts

Adjust the seat position and lap belt as
required to allow complete machine control at
all times with minimum fatigue. Make sure the
seat belt does not restrict movement for proper
safety belt
machine operation (see Fig 4-10 and 4-11).

Fig 4.10

safety belt

Fig 4.11

4.3 Engine Operation

Note: The electronic 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.
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.
Operate engine at top rated speed when
maximum power is needed for the load.

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SRT45 Off-Highway Truck Operating the Truck

NEVER idle the engine more than 5 minutes

at a time; shut it off.
If any gauge operates outwith its normal
operating range or a warning indicator
illuminates, shut engine down immediately and
report to service or maintenance personnel.
Turn off the engine if the “stop”, “warning”,
and “maintenance” indicators are lighted
simultaneously when the engine is working,
and the engine state indicator in display is red
at the same [Link] 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 speed can cause severe engine
damage. The engine speed must
not exceed 2400 rev/min under any
circumstances. When descending
a steep grade, use a combination
of transmission gears, retarder and
service brakes to control the vehicle
and engine speed.

Safety, Operation and Maintenance Manual 4-7

Operating the Truck SRT45 Off-Highway Truck

4.4 Start the Engine

Attention to the warning indicators and P

instruments when starting the engine, and

！
！

operating, will help the operator monitor the

machine systems and components.
1. Make sure the parking brake switch is in the P

'PARK' position.(see Fig 4-12).

parking brake switch

Fig 4.12

[Link] sure the body control lever is in the

'FLOAT' position.(see Fig 4-13).

Fig 4.13

3. Make sure the transmission shift selector is

in the 'NEUTRAL' position.(see Fig 4-14).

R
MODE
N
D
5
N 4
3
2
1

Fig 4.14

4. Insert Ignition key and turn clockwise to

position 'I'.(see Fig 4-15).

Fig 4.15
4-8 Safety, Operation and Maintenance Manual
SRT45 Off-Highway Truck Operating the Truck

5. Check the instrument panel; the engine

“maintenance”, “warning”, and “stop” indicators 1 2 3
shall flash for several seconds and then P ！

extinguish; the “Alternator Charging” and ！

“transmission fault” indicators shall be 4 5

constantly on; “transmission state” indicator
show red, “engine state” and “vehicle monitor
system state” indicators show green, no Fig 4.16
buzzer alarm (see Fig4-16).

[Link] stop indicator

[Link] maintenance indicator
[Link] warning indicator
[Link] fault indicator
[Link] charging indicator
Horn contorl

6. Press horn control to sound horn. (see Fig

4-17).
Caution:Always sound horn before starting Fig 4.17
engine or operating anycontrol.

7. Turn key further clockwise against spring

pressure 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). Fig 4.18

[Link] the engine oil pressure gauge. Within

10 to 15 seconds at engine idle,the gauge
needle should rise into the white zone. If the
P

needle does not rise within 15 seconds, shut

off the engine and do not operate until the fault
is identified and corrected. (see Fig 4-19).
Engine pressure
gauge
9. Observe the engine water temperature
gauge. After a few minutes running time at
moderate load and varying speed, the gauge
Engine water temperature gauge
needle should be in the white zone. If the
needle moves into the red zone, the engine
is over heated and should be shut down Fig 4.19

Safety, Operation and Maintenance Manual 4-9

Operating the Truck SRT45 Off-Highway Truck

immediately.(see Fig 4-19).

4 . 5 S t a r t i n g t h e E n g i n e wit h
Jumper Cables
Caution: Be sure machines are not touching
each other. Use cables that are equal to cable
size on the machine.
If jumper cables are used to start an engine,
be sure to follow this procedure:
Connect one end of a jumper cable, usually
coloured red, to the discharged battery
'POSITIVE' (+) post. Connect the other end of
the same cable to the 'POSITIVE' (+) post on
the booster or charged battery.
Connect one end of the second cable, usually
coloured black, to the 'NEGATIVE' (-) post of
the booster battery. Connect the other end of
the 'NEGATIVE' (-) cable to machine frame.

WARNING

Hazardous hydrogen gas and

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 explosion/fire. Keep
all sources of ignition away from
batteries. Do not lean over batteries,
and wear eye protection at all times to
prevent personal injury.
Do not jump start a vehicle by using
arc welding equipment. Currents and
voltages are dangerously high and
cannot be sufficiently reduced to make
the method safe.

4-10 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Operating the Truck

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 Oil level
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 Fig 4.20
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.

Safety, Operation and Maintenance Manual 4-11

Operating the Truck SRT45 Off-Highway 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 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck 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 indicators. All instruments should
operate in their normal range and all warning
indicators should be out except possibly the
Direction Indicator and Headlight Main Beam
warning indicators.
Make sure the area around the machine is
clear of personnel and obstructions before
driving off.
In the first few minutes of travel, check
carefully for the required steering, braking,
engine and transmission power response for

Safety, Operation and Maintenance Manual 4-13

Operating the Truck SRT45 Off-Highway Truck

maximum operating safety.

1. Make sure the body is fully down and body
control lever is in the 'FLOAT' position.(see
Figure 4-21)
2. Apply the service brake and release the
parking brake.
3. Select the driving direction and the required Fig 4.21
range.(see Figure 4-22)
4. Sound horn; two blasts for forward and
three blasts for reverse.
5. Release the service brake, apply the
accelerator and move off.
6. To stop the machine release the accelerator MODE
R
N
and depress the service brake pedal. Release D
5
the service brake as the machine slows until, 3 4
3
when stopped, the pedal is depressed just 2
1
enough to hold the machine stationary. The
retarder brake is recommended to decelerate
the truck unless the truck must be stopped
immediately. Fig 4.22
7. When the machine has stopped, shift the
transmission to Neutral, apply the parking
brake and release the service brake.
[Link] the service brake does not stop the
machine. Apply the emergency brake. This P

！
！

should only be applied to stop the machine in

an emergency.

4.11 Stopping the Engine

P

parking brake switch

1. Make sure the rocker switch is in the 'PARK'
position. (see Fig4-23). Fig 4.23

R
2. Make sure the transmission is in MODE
N
D
'NEUTRAL'.(see Fig 4-24). 5
N 4
3. Allow the engine to idle 3 - 5 minutes after 3
a full load operation before shutting it off. 2
1
This allows the engine to cool gradually and
uniformly.

Fig 4.24

4-14 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Operating the Truck

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
P ！
！

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

Safety, Operation and Maintenance Manual 4-15

Operating the Truck SRT45 Off-Highway 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 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Working the Truck

5 WORKING THE TRUCK

5.1 Working the Truck
Mining Dump 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 Keep the dump
into four phases; loading, hauling, dumping truck static
and the empty return.
Note: After coming to a stop for loading or
unloading the truck, the Parking-Emergency
Brake control can be pushed in to hold the
brakes in the applied position as though the Fig 5.1
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. 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 5.2
period of time and the quicker the truck can be
loaded.

Fig 5.3

Safety, Operation and Maintenance Manual 5-1

Working the Truck SRT45 Off-Highway Truck

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 Dump truck space
method eliminates all backing. Waiting is the length of two
machines should stay about two truck lengths dump trucks
behind the one being loaded to avoid any Fig 5.4
spillage from the loading machine bucket or
truck body. The operator of the waiting truck is
also better able to judge the best spot for his
truck when it is his turn to be loaded(refer to
fig.5-4).
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
position on the opposite side of the loader
and the loading machine can swing over to
Two-side loading
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 Fig 5.5
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 face of the
bank or stockpile. This minimizes loader travel
time, particularly with a raised, full bucket.
Where possible, the truck should also locate
downwind of the loader when dusty-type
material is being loaded on a windy day. This
practice improves both working conditions and
visibility for the loader operator(refer to fig.5- Fig 5.6
6).
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

5-2 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Working the Truck

when entering the loading area to avoid

congestion, and for maximum safety(fig.5-7).
The following precautions should be observed
when approaching the loading area and while
being loaded.
Avoid rocks and other shovel spillage that
can needlessly damage tyres or other truck
components. Allow the cleanup machine Take care of other
sufficient time to clear up such debris. trucks
Do not move the truck into loading position Fig 5.7
with the shovel bucket swinging overhead.
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
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 Fig 5.8

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
required for ascending is also correct for
descending a grade(refer to fig.5-9).
Always remain a safe distance behind the
machine ahead, particularly on downgrades.
Fig 5.9
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

Safety, Operation and Maintenance Manual 5-3

Working the Truck SRT45 Off-Highway Truck

normal operating conditions. Under adverse

conditions, allow more room for safe operation. ast
at le
On jobs on which minimum distance between gth
k len
-truc
machines is specified for the haul road, be Two
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).
Safety first
Pay attention to haul road conditions to
avoid rocks, holes, or other obstacles. Such
obstacles not only present hazards to safe Fig 5.10
operation, but can needlessly damage tyres
and rides if not avoided(refer to fig.5-11).
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.

5.4 Dumping
The dumping operation usually depends upon Fig 5.11
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
this size. While backing to dump, the operator
must watch the 'SPOTTER' at all times and Fig 5.12
follow his direction. Under no circumstances
should the operator leave his seat to gain
better visibility while backing(refer to fig.5-12).
Always remain seated to maintain maximum
machine control(refer to fig.5-13).
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
hitting the protecting rail at the hopper. If a
DRIVEOVER HOPPER is used, the operator Fig 5.13

5-4 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Working the Truck

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
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.5-14). 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 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 control to hold the
machine stationary(refer to fig.5-15).
Push the body control lever back into the
'RAISE' position and accelerate the engine.
Fig 5.15
Decelerate the engine to slow the raising
speed as the hoists approach their maximum
extension. 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

Safety, Operation and Maintenance Manual 5-5

Working the Truck SRT45 Off-Highway Truck

relivalve operation.
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,
extensive stresses. (refer to fig.5-16)
Fig 5.16
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.
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.
Fig 5.17
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
the truck, there can be severe danger
from contacting overhead electric
cables, trees, or bridges over the haul
route.

5-6 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck 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.

6.2 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

Safety, Operation and Maintenance Manual 6-1

Roading SRT45 Off-Highway Truck

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.
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.

6-2 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Roading

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.

Safety, Operation and Maintenance Manual 6-3

Roading SRT45 Off-Highway Truck

........................................................................................................................................

........................................................................................................................................

........................................................................................................................................

........................................................................................................................................

........................................................................................................................................

........................................................................................................................................

........................................................................................................................................

E
........................................................................................................................................

G
........................................................................................................................................

PA
........................................................................................................................................

........................................................................................................................................

........................................................................................................................................

........................................................................................................................................
K

........................................................................................................................................
N

........................................................................................................................................
LA

........................................................................................................................................

........................................................................................................................................

........................................................................................................................................
B

........................................................................................................................................

........................................................................................................................................

........................................................................................................................................

........................................................................................................................................

........................................................................................................................................

........................................................................................................................................

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6-4 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck 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
unexpected machine movement. When

Safety, Operation and Maintenance Manual 7-1

Moving Disabled Truck SRT45 Off-Highway Truck

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 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.
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 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Lubrication and Servicing

8 L U B R I C AT I O N A N D
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.

Safety, Operation and Maintenance Manual 8-1

Lubrication and Servicing SRT45 Off-Highway Truck

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 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Lubrication and Servicing

7 20 21 10 25 8 10 11 21 19 22 24 13 18 9 14

27

27 27

26
5
26
28

1 23 20 8 25 10 11 11 4 2 3 12 15 21 17 13
Fig 8.1

Safety, Operation and Maintenance Manual 8-3

Lubrication and Servicing SRT45 Off-Highway Truck

Lubrication and Service Chart

Interval Ref. No. of
Identification Service Instructions Lubricant Service/Quantities
hours Points Points
Check oil level. Add
10 1 Engine 1 EO As Required
if low.
Check oil level. Add
2 Transmission 1 HTF As Required
if low.
Hoisting/Cooling Check oil level. Add
3 - HO As Required
hydraulic tank if low.
Steering/Braking Check oil level. Add
4 - HO As Required
hydraulic tank if low.

Check coolant level. Refer to 'Remote Water

5 Expansion tank 1 Antifreeze
Add if low. Tank'

Cooling fan of the Visually inspect for

7 1 - -
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

Mechanical air Check. Replace
- 1 - 'Requirements for Air
resistance indicator element if reqd.
Filter Maintenance'

Air cleaner vacuator Check for proper

- 1 - -
valve operation
Oil-water separator for
- Discharge water 1 - -
engine fuel

Refer to 'Front Wheel

Check condition.
Assembly' and 'Rear
- Tyre Check pressures 6 -
Wheel Assembly' in the
when tyres are cold.
Maintenance Manual

Controls, instruments Check for proper

- - - -
and warning indicators operation.

Check for leaks

and worn/damaged
- General Inspection parts. - - -
Repair/replace as
required.

8-4 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Lubrication and Servicing

Check. Replace
30 Steering oil return filter - - -
element if reqd.
10
Check. Replace
35 Steering pipeline filter - - -
element if reqd.
Front suspension
8 Lubrication 2 EP,NLGI
cylinder bearing
Rear suspension
9 Lubrication 4 EP,NLGI
cylinder bearing
Steering cylinder
10 Lubrication 4 EP,NLGI
bearing
Steering tie rod
11 Lubrication 4 EP,NLGI
bearing
A frame spherical
12 Lubrication 1 EP,NLGI
50 bearing
Transverse stabilizer
13 Lubrication 2 EP,NLGI
spherical bearing
14 Body hinge pin Lubrication 2 EP,NLGI
Hoisting cylinder
15 Lubrication 4 EP,NLGI
bearing
Front and rear drive
21 Lubrication 6 EP,NLGI
shaft/ spider
27 A arm bearing Lubrication 6 EP,NLGI
28 Steering crank pin Lubrication 2 EP,NLGI
1 Engine Drain and refill 1 EO -
Refer to the Engine
- Engine oil flters Replace filters 2 -
Manual
Refer to the Engine
- Engine fuel filters Replace filters 2 -
Manual

Check DCA
Refer to the Engine
250 - Engine fuel filters concentration and - DCA4
Manual
replenish

Replace filters if
- Engine coolant filters 1 - -
required
Engine crankcase Refer to the Engine
- Clean 1 -
breather Manual
7 Engine cooling fan Check condition 1 - -

Safety, Operation and Maintenance Manual 8-5

Lubrication and Servicing SRT45 Off-Highway Truck

Engine Power Takeoff

16 Check condition 1 EPL -
(PTO)
Check oil level. Add
18 Wheel planetaries 2 EPL -
if low.
- Rear axle breather Clean 1 EPL -
- Transmission breather Clean 1 - -
Air conditioning Check belt tension. Refer to the Engine
- 1 -
compressor belt Adjust if required. Manual
250
Accessory drive belts Check belt tension. Refer to the Engine
- 2 -
(if fitted) Adjust if [Link] Manual

- Engine fuel filter Replace filter 1 -

Clean primary tubes
- Air cleaner - - -
and inlet screens

- Front brake disk Replace 4 - -

Hydraulic Tank
6 Replace breather - - -
Breather
Clean filler neck
19 Fuel Tank - - -
screen and cap.
Check nitrogen
500 20 Accumulators - - -
pressures.
Steering Column
23 Lube. 2 *EP,NLGI See note
Universal Joints
S t e e r i n g Ta n k
37 Replace breather - - -
Breather
2 Transmission Discharge and refill 1 HTF -
Replace filter
- Transmission cleaner 1 - -
element
Replace filter
30 Steering oil return filter - - -
element
1000 Hydraulic system Check pressures at
- - - -
pressure checks check points
Replace filter
33 Hoisting oil return filter - - -
element
Replace filter
34 Cooling oil return filter - - -
element

8-6 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Lubrication and Servicing

Replace filter
35 Steering pipeline filter - - -
element
1000
Replace filter
36 Cooling pipeline filter - - -
element
Engine crankcase Clean/replace filter
- 1 - -
filter element
Drain, clean and
16 Engine PTO 1 EPL -
1200 refill
Main reducer and Drain, clean and
17 2 EPL -
differential assembly refill
18 Wheel planetaries Drain and refill 1 EPL -
Hoisting/Cooling Wash,clean and
3 - - -
hydraulic tank refill
Steering/braking Wash,clean and
4 - - -
hydraulic tank refill
Wash,clean and
19 Fuel tank 1 Diesel -
refill
24 Rear brake packs Drain and refill 2 HO -
25 Front wheel bearing Repack 2 *EP NLGI -
2000
Drain, flush and
26 Cooling system - Antifreeze -
refill
Replace the filter
29 Steering in-line filter - - -
element

31 Hoisting in-line filter Wash and replace - - -

32 Cooling in-line filter Wash and replace - - -

Air conditioning Drain, flush and

4000 - 1 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,

Safety, Operation and Maintenance Manual 8-7

Lubrication and Servicing SRT45 Off-Highway Truck

refer to 'Recommended Lubricants'.

HO—hydraulic transmission oil, refer to
'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'.
PA G O I L - P o l y a l k l e n e G l y c o l ( PA G )
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

8-8 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Lubrication and Servicing

noises.
Engine Air Cleaners - Check air cleaner
piping, hoses and clamps. Change or clean
air cleaner element only when the color of
mechanical air resistance indicator turns
blue to red. 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 [Link]
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 indicator 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 indicator illuminates,
the filter element should be replaced.
Replace the filter element,If the warning
indicator illuminates.
Fuel pre-filter - Discharge water and impurities.
Refer to Chapter 14 'Installation of Fuel Tank
and Pipeline'，in the Maintenance Manual.

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

Safety, Operation and Maintenance Manual 8-9

Lubrication and Servicing SRT45 Off-Highway Truck

Every 250 hours of operation

Coolant Additive - Check and replenish DCA4
concentration as [Link] 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 [Link]
to Chapter 15 'Remote Water Tank'，in the
Maintenance Manual.
Cooling 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
[Link] 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 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 14 'Installation of
Fuel Tank and Pipeline'，in the Maintenance
Manual.

Every 1000 hours of operation

Hydraulic System Pressure Checks - Check all
steering, body and braking system pressures.
Note: Instructions for checking pressure, and

8-10 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Lubrication and Servicing

locations of pressure check points, are

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 [Link] should ensure that
information contained in this chart reflects
the information shown in the relevant
manufacturers 'Operation and Maintenance
Manual' supplied with the Truck.

Safety, Operation and Maintenance Manual 8-11

Lubrication and Servicing SRT45 Off-Highway Truck

8.4 Service Capacity

Ref. Service Capacities
Identification Lubricant
Points Iiters US gal
1 Engine Crankcase and Filters EO 55 14.6
2 Transmission and Filters HTF 85 22.5
3 Hoisting cooling tank HO 158 41.8
4 Hoisting system and 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 Conditioning Compressor PAG Oil 0.125 0.033

8-12 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Lubrication and Servicing

8.5 Recommended Lubricants

Component Lubricant Viscosity (see note 1)

Engine oil with 1.00% sulphated ash Ambient temper- Recommendation

is recommended. Sulphated ash must ature
Engine not exceed 1.85% limit. API code CH-4, -10℃ and above SAE 15W-40
ACEA-E5. See Note 2* -25℃ to 20℃ SAE 10W-30
-40℃ to20℃ SAE 5W-30

Ambient temper- Recommendation

ature
-30℃ to 25℃ SAE 0W-20 (cold)
Engine oil, API code CH-4, ACEA-E5. -27℃ to 25℃
DERON- Ⅲ
Transmission Preheat is required below minimum
-20℃ to 15℃ SAE 10W
temperatures shown. See Note 3.
-15℃ to 45℃ SAE15W-40
0℃ to 35℃ SAE 30
10℃ to 45℃ SAE 40

Heavy Duty Coolant. Refer to Section

Cooling System " R e m o t e w a t e r t a n k " , C O O L I N G Mobil antifreeze
SYSTEM, in the Service Manual.
Diesel Fuel Oil with maximum sulphur
Fuel Tank 0#GB252
0.5%.
Differential Multipurpose Extreme Pressure type gear
SAE GL-5 80W-90 at ambient
Planetary Gears oil meeting MIL-L-2105C Specifications
temperatures of -25℃～ 40℃
Power Takeoff (No Zinc Additive). See Note 4.

Multipurpose Extreme Pressure Lithium

Grease (which may or may not contain
Grease Fittings No. 2 Consistency
'Molybdenum'), with a melting point of
190℃ .typical

Transmission shaft/cross Multi-functional extreme-pressure Li-

shaft Steering column based grease (including or excluding No. 2 viscosity
Wheel hub bearing “Mo”); typical melting point is 190℃ .

SAE 10W
Ride Cylinder Oil comply with HD10WATFC-4 standard The applicable ambient temperature
is -18℃～ 32℃

SAE 10W at ambient temperatures of

Hydraulic oil complies with Caltex 414 -18℃～ 32℃
Hydraulic System
transmission oil standard SAE 30W at ambient temperatures of
above 32℃

Safety, Operation and Maintenance Manual 8-13

Lubrication and Servicing SRT45 Off-Highway Truck

Note 1 - Consult your lubricant supplier for

the correct viscosity of lubricant to use when
ambient temperatures are consistently above
or below those listed.
Note 2 - Cummins Engine Co., does not
recommend any specific brand of engine oil
but the use of oils that meet API categories.
Cummins recommends use of only the multi-
graded viscosity oils shown for the various
ambient temperatures listed.
Note 3-Operation below the minimum
temperatures listed for the oil used without
proper preheat or warm-up results in greatly
reduced transmission life. If 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 [Link]
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 very
loud noise and jerking of the wheels when
driving slowly round sharp corners and an EP
oil with limited slip additives should be used.
Other lubricant suppliers may have
comparable products and should be consulted
for confirmation.

Temperature conversion
℃ -32 -30 -27 -25 -20 -18 -15 -10 0 10 15 25 32 35 38 45 93 190
℉ -26 -22 -17 -13 -4 0 5 14 32 50 59 77 90 95 100 113 200 375

8-14 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Lubrication and Servicing

8.6 Maintenance Procedures

8.6.1 Daily (10hrs) maintenance inspection form

For regular inspection and duty, fills this form out each 10 hrs. This form should be used with
other forms in this manual.
[Link] normally checking
Check all operation devices by driving……………................................................……………
[Link]
Check and ensure of all lubrication points work well.……...........................................………
3. Electronic system
Check all of indicator lamps, caution lamps, gauges and assistant devices..….....................
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 air cleaner Restriction W/Light..……………………….………………........................…
Check air cleaner vacuator valve(S)………………….…….........................................……..…
Check leakages and cracks for filter.………….………..............................................…………
5. Transmission
Check leakages………………………………………………..........………………………………
Check liquid level, refill as required……………………......………………………………………
Check oil temperatures and pressures……………………........................................…………

Checker Date

Remarks

Safety, Operation and Maintenance Manual 8-15

Lubrication and Servicing SRT45 Off-Highway Truck

Repair and Maintenance Record Table

Repair and main-

Date Cost Time required Unused time Remarks
tenance performed

8-16 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Lubrication and Servicing

Daily (10hrs) maintenance inspection form (supplement)

For regular inspection and duty, fills this form out each 10 hrs. This form should be used with
other forms in this manual.
6. Suspension system
Check for altitude of front and rear ride cylinder according to service manual.…………....…
Check leakages.……………..........................................................................…………………
7. Wheels
Check status and pressures……………………...................................…………………………
8. Rims
Check fasteners by torque.....……………………………………...................………………..…
9. Hydraulic system
Hoisting and cooling hydraulic system
Check hoisting system oil level, , refill if required.........................................................………
Replace the breather valve for the steering hydraulic tank in period.............................………
Note: replace new filter for the system if it working time over 500hrs.
Replace 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(The first replace at 1000
hrs).
Replace the oil suction filter of cooling 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 cooling system in period..............................................………
Note: replace new filter for the system if it working time over 500hrs.
Check leakages for hydraulic system and its components , check worn and damaged for hoses.
…....................................................................................................................................……

Checker Date

Remarks

Safety, Operation and Maintenance Manual 8-17

Lubrication and Servicing SRT45 Off-Highway Truck

Repair and Maintenance Record Table

Repair and main-

Date Cost Time required Unused time Remarks
tenance performed

8-18 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Lubrication and Servicing

Daily (10hrs) maintenance inspection form (supplement)

For regular inspection and duty, fills this form out each 10 hrs. This form should be used with
other forms in this manual.
Steering and braking hydraulic system
Check status for steering control unit………….........................…….…..………………………
Shutdown the engine and rotate the wheel to check the ability of steering system in emergency co
ndition…………………………………………………………………………………………………
Check status for foot brake system and parking brake system.…….…….……………………
Check steering system oil level, refill if required.……………………....................................…
Replace the oil suction filter of steering system in period.………......………….……..…..……
Note: replace new filter for the system if it working time over 500hrs.
Replace 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 system if it working time over 500hrs.
Change oil for the tank and clean the whole tank and accessories....................................….
Check the pressure for the system………………………………………….……………..………
Check the pressure for the steering system……………………………….……………..………
Check the pressure for the front breaking system………………..……….……………..………
Caution: Replace all of o–rings for hoist steering, brake and cooling system if maximum
adjustments as required for ensure systems with high performance and safety above.

Checker Date

Remarks

Safety, Operation and Maintenance Manual 8-19

Lubrication and Servicing SRT45 Off-Highway Truck

Repair and Maintenance Record Table

Repair and main-

Date Cost Time required Unused time Remarks
tenance performed

8-20 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Lubrication and Servicing

8.6.2 Maintenance inspection form for 150hrs

Except daily (10hrs) inspection projects, the following projects also have to finish after running
150hrs.
1. For normally checking
Check leakages, loosened and damaged parts for truck.……….........…………………………
Observe the cracks and welder seam for frame……………................................................…
2. Cummins engine
Check the fasteners for engine………………………………………...........................…………
Check PTO liquid level, refill as required……………………..…………..............………………
3. Transmission
Drain, replace filter and refill (first time after 150hrs, next time after each 1200hrs).….......…
Remark: drain, replace filter and refill after 150hrs, if transmission has been fixed.
Clean the breather valve for transmission and lubricates again.……...........…......…..………
Check status about block caution lamp for filter.……………………................................…….
4. Main reducer and differential assembly,Planetary assemblyand 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.
Check the driveline bolts torque(first time after 150hrs, next time after each 1200hrs)….…..
Tightening torque Check torque
Bolt code Use of the site
(N·m) (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.
5. Lubrication
Front, rear transmissions cross shafts…………….......................…………..................……..4 points
Front, rear transmission shafts………………………….......………………….................…….2 points
[Link] up the dust on the pin shaft of foot-operated valve,and add the lubricating oil…...…

Checker Date

Remarks

Safety, Operation and Maintenance Manual 8-21

Lubrication and Servicing SRT45 Off-Highway Truck

Repair and Maintenance Record Table

Repair and main-

Date Cost Time required Unused time Remarks
tenance performed

8-22 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Lubrication and Servicing

8.6.3 Maintenance inspection form for 250hrs

Except daily (10hrs) inspection projects, the following projects also have to finish after running
250hrs.
1. Cummins engine
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
[Link] system
Check the pressure for the system.....................................................................................….
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 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 breaking system
note:
a . The instruction about how to make a inspection for the hoisting , steering and breaking system
are contained in manual book
Check and replace old components with new one to ensure of the system work well if the
inspection result are different with requirement
b. Make sure the pressure drain out of the accumulator before checks the pre-charge for the
accumulator

Checker Date

Remarks

Safety, Operation and Maintenance Manual 8-23

Lubrication and Servicing SRT45 Off-Highway Truck

Repair and Maintenance Record Table

Repair and main-

Date Cost Time required Unused time Remarks
tenance performed

8-24 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Lubrication and Servicing

8.6.4 Maintenance inspection form for 300hrs

Except daily (10hrs) inspection projects, the following projects also have to finish after running
300hrs.
1. For normally checking
Check leakages, loosened and damaged parts for truck.……….........…………………………
Observe the cracks and welder seam for frame……………................................................…
2. Cummins engine
Check the fasteners for engine………………………………………...........................…………
Check PTO liquid level, refill as required……………………..…………..............………………
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.
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 breather valve for PTO……………………….............…………...…
Remark: change oil when replace new one or after fixed.
5. Lubrication
Front, rear transmissions cross shafts…………….......................…………..................……..4 points
Front, rear transmission shafts………………………….......………………….................…….2 points
[Link] up the dust on the pin shaft of foot-operated valve,and add the lubricating oil…...…

Checker Date

Remarks

Safety, Operation and Maintenance Manual 8-25

Lubrication and Servicing SRT45 Off-Highway Truck

Repair and Maintenance Record Table

Repair and main-

Date Cost Time required Unused time Remarks
tenance performed

8-26 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Lubrication and Servicing

8.6.5 Maintenance inspection form for 450hrs

Except daily (10hrs) inspection projects, the following projects also have to finish after running
450hrs.
1. For normally checking
Check leakages, loosened and damaged parts for truck.……….........…………………………
Observe the cracks and welder seam for frame……………................................................…
2. Cummins engine
Check the fasteners for engine………………………………………...........................…………
Check PTO liquid level, refill as required……………………..…………..............………………
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.
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 breather valve for PTO……………………….............…………...…
Remark: change oil when replace new one or after fixed.
5. Lubrication
Front, rear transmissions cross shafts…………….......................…………..................……..4 points
Front, rear transmission shafts………………………….......………………….................…….2 points
[Link] up the dust on the pin shaft of foot-operated valve,and add the lubricating oil…...…

Checker Date

Remarks

Safety, Operation and Maintenance Manual 8-27

Lubrication and Servicing SRT45 Off-Highway Truck

Repair and Maintenance Record Table

Repair and main-

Date Cost Time required Unused time Remarks
tenance performed

8-28 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Lubrication and Servicing

8.6.6 Maintenance inspection form for 500hrs

Except daily (10hrs) inspection projects, the following projects also have to finish after running
500hrs.
1. Cummins engine
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. Front, rear transmissions cross shafts
Refill enough grease………….……………………………………………………………..………
4. Lubrication
Front, rear transmissions cross shafts………………….……......................…..................…..4 points
Front, rear transmission 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 filter which mounted inside of the rear braking valve group……………..………
Replace new filter for the suction filter of the steering system…………………………..………
Replace new filter for the suction filter of the hoisting system……………………..……...……
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………………………….…..………

Checker Date

Remarks

Safety, Operation and Maintenance Manual 8-29

Lubrication and Servicing SRT45 Off-Highway Truck

Repair and Maintenance Record Table

Repair and main-

Date Cost Time required Unused time Remarks
tenance performed

8-30 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Lubrication and Servicing

Maintenance inspection form for 500hrs(supplement)

Except daily (10hrs) inspection projects, the following projects also have to finish after running
500hrs.
[Link]
Check screw between steering arm and front suspension cylinder. If loosed or damaged ,tighten or
replace new screw.……..................………………………………………………………..………
7. 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………..………
8. 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 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 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.
.…....................................................................................................................................…

Checker Date

Remarks

Safety, Operation and Maintenance Manual 8-31

Lubrication and Servicing SRT45 Off-Highway Truck

Repair and Maintenance Record Table

Repair and main-

Date Cost Time required Unused time Remarks
tenance performed

8-32 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Lubrication and Servicing

8.6.7 Maintenance inspection form for 600hrs

Except daily (10hrs) inspection projects, the following projects also have to finish after running
600hrs.
1. For normally checking
Check leakages, loosened and damaged parts for truck.……….........…………………………
Observe the cracks and welder seam for frame……………................................................…
Check displacement and worn for transmission shaft by lever.……….....................…….……
[Link]
Check and ensure of all lubrication points work well………….....................…….....…………
3. Electrical system
Check harnesses status.………………………………..................………………………………
Check status 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
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 reducer and differential assembly and Planetary assembly
for checking and analysis ...................................................................................................…
Check liquid level, refill as required…………………………………………......…………………
Check and clean the breather valve for differential.………………..............…………….......…
Check and clean the breather valve for PTO……………………….............…………..........…
Remark: change oil when replace new one or after fixed.
[Link] up the dust on the pin shaft of foot-operated valve,and add the lubricating oil…...…

Checker Date

Remarks

Safety, Operation and Maintenance Manual 8-33

Lubrication and Servicing SRT45 Off-Highway Truck

Repair and Maintenance Record Table

Repair and main-

Date Cost Time required Unused time Remarks
tenance performed

8-34 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Lubrication and Servicing

8.6.8 Maintenance inspection form for 750hrs

Except daily (10hrs) inspection projects, the following projects also have to finish after running
750hrs.
1. For normally checking
Check leakages, loosened and damaged parts for truck.……….........…………………………
Observe the cracks and welder seam for frame……………................................................…
2. Cummins engine
Check the fasteners for engine………………………………………...........................…………
Check 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…………….….......................................................….
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.
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.…....................................................................................................................................…
Check liquid level, refill as required…………………………………………......…………………
Check and clean the breather valve for differential.………………..............………………
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 points
[Link] up the dust on the pin shaft of foot-operated valve,and add the lubricating oil…...…

Checker Date

Remarks

Safety, Operation and Maintenance Manual 8-35

Lubrication and Servicing SRT45 Off-Highway Truck

Repair and Maintenance Record Table

Repair and main-

Date Cost Time required Unused time Remarks
tenance performed

8-36 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Lubrication and Servicing

8.6.9 Maintenance inspection form for 900hrs

Except daily (10hrs) inspection projects, the following projects also have to finish after running
900hrs.
1. For normally checking
Check leakages, loosened and damaged parts for truck.……….........…………………………
Observe the cracks and welder seam for frame……………................................................…
2. Cummins engine
Check the fasteners for engine………………………………………...........................…………
Check PTO liquid level, refill as required……………………..…………..............………………
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.
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 breather valve for PTO……………………….............…………...…
Remark: change oil when replace new one or after fixed.
[Link] up the dust on the pin shaft of foot-operated valve,and add the lubricating oil…...…

Checker Date

Remarks

Safety, Operation and Maintenance Manual 8-37

Lubrication and Servicing SRT45 Off-Highway Truck

Repair and Maintenance Record Table

Repair and main-

Date Cost Time required Unused time Remarks
tenance performed

8-38 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Lubrication and Servicing

8.6.10 Maintenance inspection form for 1000hrs

Except daily (10hrs) inspection projects, the following projects also have to finish after running 1000hrs.
1. Cummins engine
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
[Link] 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.…........
Replace new filter which mounted inside of the rear braking valve group...........................….
Replace new filter for the suction filter of the steering system............................................….
Replace new filter for the suction filter of the hoisting system............................................….
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................................................….

Checker Date

Remarks

Safety, Operation and Maintenance Manual 8-39

Lubrication and Servicing SRT45 Off-Highway Truck

Repair and Maintenance Record Table

Repair and main-

Date Cost Time required Unused time Remarks
tenance performed

8-40 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Lubrication and Servicing

Maintenance inspection form for 1000hrs(supplement)

Except daily (10hrs) inspection projects, the following projects also have to finish after running 1000hrs.
5. 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………..………
[Link]
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 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 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 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 continue to use it
……………………………………………………………………………………………...…………
[Link]
Check screw between steering arm and front suspension cylinder. If loosed or damaged ,tighten or
replace new screw.……..................………………………………………………………..………

Checker Date

Remarks

Safety, Operation and Maintenance Manual 8-41

Lubrication and Servicing SRT45 Off-Highway Truck

Repair and Maintenance Record Table

Repair and main-

Date Cost Time required Unused time Remarks
tenance performed

8-42 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Lubrication and Servicing

8.6.11 Maintenance inspection form for 1050hrs

Except daily (10hrs) inspection projects, the following projects also have to finish after running
1050hrs.
1. For normally checking
Check leakages, loosened and damaged parts for truck.……….........…………………………
Observe the cracks and welder seam for frame……………................................................…
2. Cummins engine
Check the fasteners for engine………………………………………...........................…………
Check PTO liquid level, refill as required……………………..…………..............………………
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.
[Link] 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 breather valve for PTO……………………….............…………...…
Remark: change oil when replace new one or after fixed.
[Link] up the dust on the pin shaft of foot-operated valve,and add the lubricating oil…...…

Checker Date

Remarks

Safety, Operation and Maintenance Manual 8-43

Lubrication and Servicing SRT45 Off-Highway Truck

Repair and Maintenance Record Table

Repair and main-

Date Cost Time required Unused time Remarks
tenance performed

8-44 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Lubrication and Servicing

8.6.12 Maintenance inspection form for 1200hrs

Except daily (10hrs) inspection projects, the following projects also have to finish after running
1200hrs.
1. For normally checking
Check leakages, loosened and damaged parts for truck.……….........…………………………
Observe the cracks and welder seam for frame……………................................................…
Check displacement and worn for transmission shaft by lever.……….....................…….……
[Link]
Checking and ensure of all lubrication points work wel..........................................................
3. Electrical system
Check harnesses status.………………………………..................………………………………
Check status 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
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 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 breather valve for PTO……………………….............…………...…
Remark: change oil when replace new one or after fixed.
[Link] up the dust on the pin shaft of foot-operated valve,and add the lubricating oil…...…

Checker Date

Remarks

Safety, Operation and Maintenance Manual 8-45

Lubrication and Servicing SRT45 Off-Highway Truck

Repair and Maintenance Record Table

Repair and main-

Date Cost Time required Unused time Remarks
tenance performed

8-46 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Lubrication and Servicing

8.6.13 Maintenance inspection form for 1250hrs

Except daily (10hrs) inspection projects, the following projects also have to finish after running
1250hrs.
1. Cummins engine
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

Safety, Operation and Maintenance Manual 8-47

Lubrication and Servicing SRT45 Off-Highway Truck

Repair and Maintenance Record Table

Repair and main-

Date Cost Time required Unused time Remarks
tenance performed

8-48 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Lubrication and Servicing

8.6.14 Maintenance inspection form for 1350hrs

Except daily (10hrs) inspection projects, the following projects also have to finish after running
1350hrs.
1. For normally checking
Check leakages, loosened and damaged parts for truck.……….........…………………………
Observe the cracks and welder seam for frame……………................................................…
2. Cummins engine
Check the fasteners for engine………………………………………...........................…………
Check PTO liquid level, refill as required……………………..…………..............………………
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)….…..
Tightening torque Check torque
Bolt code Use of the site
(N·m) (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 and differential assembly,Planetary assembly 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.
[Link] up the dust on the pin shaft of foot-operated valve,and add the lubricating oil…...…

Checker Date

Remarks

Safety, Operation and Maintenance Manual 8-49

Lubrication and Servicing SRT45 Off-Highway Truck

Repair and Maintenance Record Table

Repair and main-

Date Cost Time required Unused time Remarks
tenance performed

8-50 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Lubrication and Servicing

8.6.15 Maintenance inspection form for 1500hrs

Except daily (10hrs) inspection projects, the following projects also have to finish after running
1500hrs.
1. For normally checking
Check leakages, loosened and damaged parts for truck.……….........…………………………
Observe the cracks and welder seam for frame……………................................................…
2. Cummins engine
Check the fasteners for engine………………………………………...........................…………
Check 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…………….….......................................................….
3. Transmission
Check the status of the pin of injector, tighten it if required.…….........................……..………
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.
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 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 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 points
[Link] up the dust on the pin shaft of foot-operated valve,and add the lubricating oil…...…

Checker Date

Remarks

Safety, Operation and Maintenance Manual 8-51

Lubrication and Servicing SRT45 Off-Highway Truck

Repair and Maintenance Record Table

Repair and main-

Date Cost Time required Unused time Remarks
tenance performed

8-52 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Lubrication and Servicing

Maintenance inspection form for 1500hrs (supplement)

Except daily (10hrs) inspection projects, the following projects also have to finish after running
1500hrs.

[Link] 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.……….
Replace the 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……………….............………....…
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………..………
[Link]
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 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 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.
.…....................................................................................................................................…
[Link]
Check screw between steering arm and front suspension cylinder. If loosed or damaged ,tighten or
replace new screw.……..................………………………………………………………..………

Checker Date

Remarks

Safety, Operation and Maintenance Manual 8-53

Lubrication and Servicing SRT45 Off-Highway Truck

Repair and Maintenance Record Table

Repair and main-

Date Cost Time required Unused time Remarks
tenance performed

8-54 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Lubrication and Servicing

8.6.16 Maintenance inspection form for 1650hrs

Except daily (10hrs) inspection projects, the following projects also have to finish after running
1650hrs.
1. For normally checking
Check leakages, loosened and damaged parts for truck.……….........…………………………
Observe the cracks and welder seam for frame……………................................................…
2. Cummins engine
Check the fasteners for engine………………………………………...........................…………
Check PTO liquid level, refill as required……………………..…………..............………………
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.
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 breather valve for PTO……………………….............…………...…
Remark: change oil when replace new one or after fixed.
[Link] up the dust on the pin shaft of foot-operated valve,and add the lubricating oil…...…

Checker Date

Remarks

Safety, Operation and Maintenance Manual 8-55

Lubrication and Servicing SRT45 Off-Highway Truck

Repair and Maintenance Record Table

Repair and main-

Date Cost Time required Unused time Remarks
tenance performed

8-56 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Lubrication and Servicing

8.6.17 Maintenance inspection form for 1750hrs

Except daily (10hrs) inspection projects, the following projects also have to finish after running
1750hrs.
1. Cummins engine
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

Safety, Operation and Maintenance Manual 8-57

Lubrication and Servicing SRT45 Off-Highway Truck

Repair and Maintenance Record Table

Repair and main-

Date Cost Time required Unused time Remarks
tenance performed

8-58 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Lubrication and Servicing

8.6.18 Maintenance inspection form for 1800hrs

Except daily (10hrs) inspection projects, the following projects also have to finish after running
1800hrs.
1. For normally checking
Check leakages, loosened and damaged parts for truck.……….........…………………………
Observe the cracks and welder seam for frame……………................................................…
Check displacement and worn for transmission shaft by lever.……….....................…….……
[Link]
Check and ensure of all lubrication points work well………….....................………….………
3. Electrical system
Check harnesses status.………………………………..................………………………………
Check status 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
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 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 breather valve for PTO……………………….............…………...…
Remark: change oil when replace new one or after fixed.
7. Fuel tank
Drain, clean and refill………………………………………..........................................…………
[Link] up the dust on the pin shaft of foot-operated valve,and add the lubricating oil…...…

Checker Date

Remarks

Safety, Operation and Maintenance Manual 8-59

Lubrication and Servicing SRT45 Off-Highway Truck

Repair and Maintenance Record Table

Repair and main-

Date Cost Time required Unused time Remarks
tenance performed

8-60 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Lubrication and Servicing

8.6.19 Maintenance inspection form for 1950hrs

Except daily (10hrs) inspection projects, the following projects also have to finish after running
1950hrs.
1. For normally checking
Check leakages, loosened and damaged parts for truck.……….........…………………………
Observe the cracks and welder seam for frame……………................................................…
2. Cummins engine
Check the fasteners for engine………………………………………...........................…………
Check PTO liquid level, refill as required……………………..…………..............………………
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.
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 breather valve for PTO……………………….............…………...…
Remark: change oil when replace new one or after fixed.
[Link] up the dust on the pin shaft of foot-operated valve,and add the lubricating oil…...…

Checker Date

Remarks

Safety, Operation and Maintenance Manual 8-61

Lubrication and Servicing SRT45 Off-Highway Truck

Repair and Maintenance Record Table

Repair and main-

Date Cost Time required Unused time Remarks
tenance performed

8-62 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Lubrication and Servicing

8.6.20 Maintenance inspection form for 2000hrs

Except daily (10hrs) inspection projects, the following projects also have to finish after running
2000hrs.
1. Cummins engine
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.……....……………………
[Link] brake system
Check and record the worn status about rear brake disc unit............................................….
[Link]-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................................................................................….
[Link]
Front, rear transmissions cross shafts………………….……......................…..................…..4 points
Front, rear transmission shafts…………………………………………......…….................…..2 points
6. 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………..………
[Link]
Check screw between steering arm and front suspension cylinder. If loosed or damaged ,tighten or
replace new screw.……..................………………………………………………………..………

Checker Date

Remarks

Safety, Operation and Maintenance Manual 8-63

Lubrication and Servicing SRT45 Off-Highway Truck

Repair and Maintenance Record Table

Repair and main-

Date Cost Time required Unused time Remarks
tenance performed

8-64 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Lubrication and Servicing

Maintenance inspection form for 2000hrs (supplement)

Except daily (10hrs) inspection projects, the following projects also have to finish after running
2000hrs.
[Link] 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........….
Replace new filter which mounted inside of the rear braking valve group..........................….
Replace new filter for the suction filter of the steering system...........................................….
Replace new filter for the suction filter of the hoisting system............................................….
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………………..……….………..……..………
[Link]
Replace new bearings for steering drag link......................................................................….
Replace new bearings for A-shape arm.............................................................................….
Replace new bearings for 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 continue to use it
.…....................................................................................................................................…

Checker Date

Remarks

Safety, Operation and Maintenance Manual 8-65

Lubrication and Servicing SRT45 Off-Highway Truck

Repair and Maintenance Record Table

Repair and main-

Date Cost Time required Unused time Remarks
tenance performed

8-66 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Lubrication and Servicing

8.6.21 Maintenance inspection form for 2100hrs

Except daily (10hrs) inspection projects, the following projects also have to finish after running
2100hrs.
1. For normally checking
Check leakages, loosened and damaged parts for truck.……….........…………………………
Observe the cracks and welder seam for frame……………................................................…
2. Cummins engine
Check the fasteners for engine………………………………………...........................…………
Check PTO liquid level, refill as required……………………..…………..............………………
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.
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 breather valve for PTO……………………….............…………...…
Remark: change oil when replace new one or after fixed.
[Link] up the dust on the pin shaft of foot-operated valve,and add the lubricating oil…...…

Checker Date

Remarks

Safety, Operation and Maintenance Manual 8-67

Lubrication and Servicing SRT45 Off-Highway Truck

Repair and Maintenance Record Table

Repair and main-

Date Cost Time required Unused time Remarks
tenance performed

8-68 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Lubrication and Servicing

8.6.22 Maintenance inspection form for 2250hrs

Except daily (10hrs) inspection projects, the following projects also have to finish after running
2250hrs.
1. For normally checking
Check leakages, loosened and damaged parts for truck.……….........…………………………
Observe the cracks and welder seam for frame……………................................................…
2. Cummins engine
Check the fasteners for engine………………………………………...........................…………
Check 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…………….….......................................................….
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.
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.…....................................................................................................................................…
Check liquid level, refill as required…………………………………………......…………………
Check and clean the breather valve for differential.………………..............………………
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 points
[Link] up the dust on the pin shaft of foot-operated valve,and add the lubricating oil…...…

Checker Date

Remarks

Safety, Operation and Maintenance Manual 8-69

Lubrication and Servicing SRT45 Off-Highway Truck

Repair and Maintenance Record Table

Repair and main-

Date Cost Time required Unused time Remarks
tenance performed

8-70 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Lubrication and Servicing

8.6.23 Maintenance inspection form for 2400hrs

Except daily (10hrs) inspection projects, the following projects also have to finish after running
2400hrs.
1. For normally checking
Check leakages, loosened and damaged parts for truck.……….........…………………………
Observe the cracks and welder seam for frame……………................................................…
Check displacement and worn for transmission shaft by lever.……….....................…….……
[Link]
Check and ensure of all lubrication points work well………….....................……….…………
3. Electrical system
Check harnesses status.………………………………..................………………………………
Check status about cables for storage battery……………………………………………………
Tighten for alternator and generator.…..................………………………………………………
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
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.
[Link] 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 breather valve for PTO……………………….............…………...…
Remark: change oil when replace new one or after fixed.
[Link] up the dust on the pin shaft of foot-operated valve,and add the lubricating oil…...…

Checker Date

Remarks

Safety, Operation and Maintenance Manual 8-71

Lubrication and Servicing SRT45 Off-Highway Truck

Repair and Maintenance Record Table

Repair and main-

Date Cost Time required Unused time Remarks
tenance performed

8-72 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Lubrication and Servicing

8.6.24 Maintenance inspection form for 2500hrs

Except daily (10hrs) inspection projects, the following projects also have to finish after running
2500hrs.
1. Cummins engine
Drain, replace filter and refill………………………………..................………………………..…
Check breather valve for crankcase………………………................….......……………………
Fuel system
Replace fuel filter…………………………………………………………………….………………
Cooling system
Reassemble 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
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.......….
Replace new filter which mounted inside of the braking valve group.................................….
Replace the breather valve for the steering hydraulic tank................................................….
Replace the breather valve for the hoisting hydraulic tank................................................….
[Link]
Check screw between steering arm and front suspension cylinder. If loosed or damaged ,tighten or
replace new screw.……..................………………………………………………………..………

Checker Date

Remarks

Safety, Operation and Maintenance Manual 8-73

Lubrication and Servicing SRT45 Off-Highway Truck

Repair and Maintenance Record Table

Repair and main-

Date Cost Time required Unused time Remarks
tenance performed

8-74 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Lubrication and Servicing

Maintenance inspection form for 2500hrs(supplement)

Except daily (10hrs) inspection projects, the following projects also have to finish after running
2500hrs.

6. Bearing
Check the wearing status for oscillating bearings of steering drag link , 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 A-shape arm , 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 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
.…....................................................................................................................................…
7. 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
.…....................................................................................................................................…

Checker Date

Remarks

Safety, Operation and Maintenance Manual 8-75

Lubrication and Servicing SRT45 Off-Highway Truck

Repair and Maintenance Record Table

Repair and main-

Date Cost Time required Unused time Remarks
tenance performed

8-76 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Lubrication and Servicing

8.6.25 Maintenance inspection form for 2550hrs

Except daily (10hrs) inspection projects, the following projects also have to finish after running
2550hrs.
1. For normally checking
Check leakages, loosened and damaged parts for truck.……….........…………………………
Observe the cracks and welder seam for frame……………................................................…
2. Cummins engine
Check the fasteners for engine………………………………………...........................…………
Check PTO liquid level, refill as required……………………..…………..............………………
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)….…..
Tightening torque Check torque
Bolt code Use of the site
(N·m) (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 and differential assembly,Planetary assembly 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.
[Link] up the dust on the pin shaft of foot-operated valve,and add the lubricating oil…...…

Checker Date

Remarks

Safety, Operation and Maintenance Manual 8-77

Lubrication and Servicing SRT45 Off-Highway Truck

Repair and Maintenance Record Table

Repair and main-

Date Cost Time required Unused time Remarks
tenance performed

8-78 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Lubrication and Servicing

8.6.26 Maintenance inspection form for 2700hrs

Except daily (10hrs) inspection projects, the following projects also have to finish after running
2700hrs.
1. For normally checking
Check leakages, loosened and damaged parts for truck.……….........…………………………
Observe the cracks and welder seam for frame……………................................................…
2. Cummins engine
Check the fasteners for engine………………………………………...........................…………
Check PTO liquid level, refill as required……………………..…………..............………………
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.
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 breather valve for PTO……………………….............…………...…
Remark: change oil when replace new one or after fixed.
[Link] up the dust on the pin shaft of foot-operated valve,and add the lubricating oil…...…

Checker Date

Remarks

Safety, Operation and Maintenance Manual 8-79

Lubrication and Servicing SRT45 Off-Highway Truck

Repair and Maintenance Record Table

Repair and main-

Date Cost Time required Unused time Remarks
tenance performed

8-80 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Lubrication and Servicing

8.6.27 Maintenance inspection form for 2750hrs

Except daily (10hrs) inspection projects, the following projects also have to finish after running
2750hrs.
1. Cummins engine
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

Safety, Operation and Maintenance Manual 8-81

Lubrication and Servicing SRT45 Off-Highway Truck

Repair and Maintenance Record Table

Repair and main-

Date Cost Time required Unused time Remarks
tenance performed

8-82 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Lubrication and Servicing

8.6.28 Maintenance inspection form for 2850hrs

Except daily (10hrs) inspection projects, the following projects also have to finish after running
2850hrs.
1. For normally checking
Check leakages, loosened and damaged parts for truck.……….........…………………………
Observe the cracks and welder seam for frame……………................................................…
2. Cummins engine
Check the fasteners for engine………………………………………...........................…………
Check PTO liquid level, refill as required……………………..…………..............………………
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.
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 breather valve for PTO……………………….............…………...…
Remark: change oil when replace new one or after fixed.
[Link] up the dust on the pin shaft of foot-operated valve,and add the lubricating oil…...…

Checker Date

Remarks

Safety, Operation and Maintenance Manual 8-83

Lubrication and Servicing SRT45 Off-Highway Truck

Repair and Maintenance Record Table

Repair and main-

Date Cost Time required Unused time Remarks
tenance performed

8-84 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Lubrication and Servicing

8.6.29 Maintenance inspection form for 3000hrs

Except daily (10hrs) inspection projects, the following projects also have to finish after running
3000hrs.
1. For normally checking
Check leakages, loosened and damaged parts for truck.……….........…………………………
Observe the cracks and welder seam for frame……………................................................…
Check displacement and worn for transmission shaft by lever.……….....................…….……
2. Lubrication
Front, rear transmissions cross shafts………………….……......................…..................…..4 points
Front, rear transmission shafts…………………………………………......…….................…..2 points
Checking and ensure of all lubrication 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 cleaner
Clean pipeline and filter for air cleaner.…………….…........................................................….
[Link]
Check screw between steering arm and front suspension cylinder. If loosed or damaged ,tighten or
replace new screw.……..................………………………………………………………..………
[Link] up the dust on the pin shaft of foot-operated valve,and add the lubricating oil…...…

Checker Date

Remarks

Safety, Operation and Maintenance Manual 8-85

Lubrication and Servicing SRT45 Off-Highway Truck

Repair and Maintenance Record Table

Repair and main-

Date Cost Time required Unused time Remarks
tenance performed

8-86 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Lubrication and Servicing

Maintenance inspection form for 3000hrs (supplement)

Except daily (10hrs) inspection projects, the following projects also have to finish after running
3000hrs.
7. Transmission
Check the status of the pin of injector, tighten it if required.…….........................……..………
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.
8. 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 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 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 the rear braking valve group…………..…………
Replace the breather valve for the steering hydraulic tank………………………………….….
Replace the breather valve for the hoisting hydraulic tank………………………………………

Checker Date

Remarks

Safety, Operation and Maintenance Manual 8-87

Lubrication and Servicing SRT45 Off-Highway Truck

Repair and Maintenance Record Table

Repair and main-

Date Cost Time required Unused time Remarks
tenance performed

8-88 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Lubrication and Servicing

Maintenance inspection form for 3000hrs (supplement)

Except daily (10hrs) inspection projects, the following projects also have to finish after running
3000hrs.
11. Bearing
Check the wearing status for oscillating bearings of steering drag link , 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 A-shape arm , 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 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
.…....................................................................................................................................…
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 the clearance of the
bearing S≥ 0.63mm .Conversely, you could continue to use it
.…....................................................................................................................................…
Check the wearing status for oscillating bearings of A-shape , replace new one if the clearance of
the bearing S≥ 0.84mm .Conversely, you could continue to use it
.…....................................................................................................................................…
12. 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
.…....................................................................................................................................…

Checker Date

Remarks

Safety, Operation and Maintenance Manual 8-89

Lubrication and Servicing SRT45 Off-Highway Truck

Repair and Maintenance Record Table

Repair and main-

Date Cost Time required Unused time Remarks
tenance performed

8-90 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Lubrication and Servicing

8.6.30 Maintenance inspection form for 3150hrs

Except daily (10hrs) inspection projects, the following projects also have to finish after running
3150hrs.
1. For normally checking
Check leakages, loosened and damaged parts for truck.……….........…………………………
Observe the cracks and welder seam for frame……………................................................…
2. Cummins engine
Check the fasteners for engine………………………………………...........................…………
Check PTO liquid level, refill as required……………………..…………..............………………
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.
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 breather valve for PTO……………………….............…………...…
Remark: change oil when replace new one or after fixed.
[Link] up the dust on the pin shaft of foot-operated valve,and add the lubricating oil…...…

Checker Date

Remarks

Safety, Operation and Maintenance Manual 8-91

Lubrication and Servicing SRT45 Off-Highway Truck

Repair and Maintenance Record Table

Repair and main-

Date Cost Time required Unused time Remarks
tenance performed

8-92 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Lubrication and Servicing

8.6.31 Maintenance inspection form for 3250hrs

Except daily (10hrs) inspection projects, the following projects also have to finish after running
3250hrs.
1. Cummins engine
Check the fasteners for engine………………………………………...........................…………
Check 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

Checker Date

Remarks

Safety, Operation and Maintenance Manual 8-93

Lubrication and Servicing SRT45 Off-Highway Truck

Repair and Maintenance Record Table

Repair and main-

Date Cost Time required Unused time Remarks
tenance performed

8-94 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Lubrication and Servicing

8.6.32 Maintenance inspection form for 3300hrs

Except daily (10hrs) inspection projects, the following projects also have to finish after running
3300hrs.
1. For normally checking
Check leakages, loosened and damaged parts for truck.……….........…………………………
Observe the cracks and welder seam for frame……………................................................…
2. Cummins engine
Check the fasteners for engine………………………………………...........................…………
Check PTO liquid level, refill as required……………………..…………..............………………
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.
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 breather valve for PTO……………………….............…………...…
Remark: change oil when replace new one or after fixed.
[Link] up the dust on the pin shaft of foot-operated valve,and add the lubricating oil…...…

Checker Date

Remarks

Safety, Operation and Maintenance Manual 8-95

Lubrication and Servicing SRT45 Off-Highway Truck

Repair and Maintenance Record Table

Repair and main-

Date Cost Time required Unused time Remarks
tenance performed

8-96 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Lubrication and Servicing

8.6.33 Maintenance inspection form for 3450hrs

Except daily (10hrs) inspection projects, the following projects also have to finish after running
3450hrs.
1. For normally checking
Check leakages, loosened and damaged parts for truck.……….........…………………………
Observe the cracks and welder seam for frame……………................................................…
2. Cummins engine
Check the fasteners for engine………………………………………...........................…………
Check PTO liquid level, refill as required……………………..…………..............………………
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.
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 breather valve for PTO……………………….............…………...…
Remark: change oil when replace new one or after fixed.
[Link]
Check screw between steering arm and front suspension cylinder. If loosed or damaged ,tighten or
replace new screw.……..................………………………………………………………..………
[Link] up the dust on the pin shaft of foot-operated valve,and add the lubricating oil…...…

Checker Date

Remarks

Safety, Operation and Maintenance Manual 8-97

Lubrication and Servicing SRT45 Off-Highway Truck

Repair and Maintenance Record Table

Repair and main-

Date Cost Time required Unused time Remarks
tenance performed

8-98 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Lubrication and Servicing

8.6.34 Maintenance inspection form for 3550hrs

Except daily (10hrs) inspection projects, the following projects also have to finish after running
3550hrs.
1. 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.....……
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
Replace coolant filter………………………………………………………………………..………
Check and supplement DCA to coolant…………….….......................................................….
3. Front brake system
Check status about disc worn to determinate replace it if required.……....……………………
4. Lubrication
Front, rear transmissions cross shafts………………….……......................…..................…..4 points
Front, rear transmission shafts…………………………………………......…….................…..2 points

Checker Date

Remarks

Safety, Operation and Maintenance Manual 8-99

Lubrication and Servicing SRT45 Off-Highway Truck

Repair and Maintenance Record Table

Repair and main-

Date Cost Time required Unused time Remarks
tenance performed

8-100 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Lubrication and Servicing

8.6.35 Maintenance inspection form for 3600hrs

Except daily (10hrs) inspection projects, the following projects also have to finish after running
3600hrs.
1. For normally checking
Check leakages, loosened and damaged parts for truck.……….........…………………………
Observe the cracks and welder seam for frame……………................................................…
Check displacement and worn for transmission shaft by lever.……….....................…….……
2. Lubrication
Front, rear transmissions cross shafts………………….……......................…..................…..4 points
Front, rear transmission shafts…………………………………………......…….................…..2 points
Checking and ensure of all lubrication points work well……...............................................…
3. Electrical system
Check harnesses status.………………………………..................………………………………
Check status about cables for storage battery……………………………………………………
Tighten for alternator and generator……………................………………………………………
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
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 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 breather valve for PTO……………………….............…………...…
Remark: change oil when replace new one or after fixed.
7. Fuel tank
Rain ,clean it and refilling…………...…......................................……….............…………...…
[Link] up the dust on the pin shaft of foot-operated valve,and add the lubricating oil…...…

Checker Date

Remarks

Safety, Operation and Maintenance Manual 8-101

Lubrication and Servicing SRT45 Off-Highway Truck

Repair and Maintenance Record Table

Repair and main-

Date Cost Time required Unused time Remarks
tenance performed

8-102 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Lubrication and Servicing

8.6.36 Maintenance inspection form for 3750hrs

Except daily (10hrs) inspection projects, the following projects also have to finish after running
3750hrs.
1. For normally checking
Check leakages, loosened and damaged parts for truck.……….........…………………………
Observe the cracks and welder seam for frame……………................................................…
2. Cummins engine
Check the fasteners for engine………………………………………...........................…………
Check 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…………….….......................................................….
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)….…..
Tightening torque Check torque
Bolt code Use of the site
(N·m) (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.

Checker Date

Remarks

Safety, Operation and Maintenance Manual 8-103

Lubrication and Servicing SRT45 Off-Highway Truck

Repair and Maintenance Record Table

Repair and main-

Date Cost Time required Unused time Remarks
tenance performed

8-104 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Lubrication and Servicing

Maintenance inspection form for 3750hrs(supplement)

Except daily (10hrs) inspection projects, the following projects also have to finish after running
3750hrs.
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)
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 points
[Link] up the dust on the pin shaft of foot-operated valve,and add the lubricating oil…...…

Checker Date

Remarks

Safety, Operation and Maintenance Manual 8-105

Lubrication and Servicing SRT45 Off-Highway Truck

Repair and Maintenance Record Table

Repair and main-

Date Cost Time required Unused time Remarks
tenance performed

8-106 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Lubrication and Servicing

8.6.37 Maintenance inspection form for 3900hrs

Except daily (10hrs) inspection projects, the following projects also have to finish after running
3900hrs.
1. For normally checking
Check leakages, loosened and damaged parts for truck.……….........…………………………
Observe the cracks and welder seam for frame……………................................................…
2. Cummins engine
Check the fasteners for engine………………………………………...........................…………
Check PTO liquid level, refill as required……………………..…………..............………………
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.
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 breather valve for PTO……………………….............…………...…
Remark: change oil when replace new one or after fixed.
[Link] up the dust on the pin shaft of foot-operated valve,and add the lubricating oil…...…

Checker Date

Remarks

Safety, Operation and Maintenance Manual 8-107

Lubrication and Servicing SRT45 Off-Highway Truck

Repair and Maintenance Record Table

Repair and main-

Date Cost Time required Unused time Remarks
tenance performed

8-108 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Lubrication and Servicing

8.6.38 Maintenance inspection form for 4000hrs

Except daily (10hrs) inspection projects, the following projects also have to finish after running
4000hrs.
1. Cummins engine
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.……....……………………
[Link] brake system
Check and record the worn status about rear brake disc unit............................................….
[Link]-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................................................................................….
[Link]
Front, rear transmissions cross shafts………………….……......................…..................…..4 points
Front, rear transmission shafts…………………………………………......…….................…..2 points
[Link] 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........….
Replace new filter which mounted inside of the rear braking valve group.........................….

Checker Date

Remarks

Safety, Operation and Maintenance Manual 8-109

Lubrication and Servicing SRT45 Off-Highway Truck

Repair and Maintenance Record Table

Repair and main-

Date Cost Time required Unused time Remarks
tenance performed

8-110 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Lubrication and Servicing

Maintenance inspection form for 4000hrs (supplement)

Except daily (10hrs) inspection projects, the following projects also have to finish after running
4000hrs.
[Link] system pressure checking
Replace new filter for the suction filter of the steering system...........................................….
Replace new filter for the suction filter of the hoisting system............................................….
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 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 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 .

Checker Date

Remarks

Safety, Operation and Maintenance Manual 8-111

Lubrication and Servicing SRT45 Off-Highway Truck

Repair and Maintenance Record Table

Repair and main-

Date Cost Time required Unused time Remarks
tenance performed

8-112 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Lubrication and Servicing

Maintenance inspection form for 4000hrs (supplement)

Except daily (10hrs) inspection projects, the following projects also have to finish after running
4000hrs.
[Link]
Replace new bearings for steering drag link......................................................................….
Replace new bearings for A-shape arm.............................................................................….
Replace new bearings for 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 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. Tyres
Front Wheel
Inspect the bearings, readjust the gap,replace the grease as the case may be.....................
Rear Wheel
Inspect the bearings, readjust the gap....................................................................................
[Link]
Check screw between steering arm and front suspension cylinder. If loosed or damaged ,tighten or
replace new screw.……..................………………………………………………………..………

Checker Date

Remarks

Safety, Operation and Maintenance Manual 8-113

Lubrication and Servicing SRT45 Off-Highway Truck

Repair and Maintenance Record Table

Repair and main-

Date Cost Time required Unused time Remarks
tenance performed

8-114 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Lubrication and Servicing

8.6.39 Maintenance inspection form for 4050hrs

Except daily (10hrs) inspection projects, the following projects also have to finish after running
4050hrs.
1. For normally checking
Check leakages, loosened and damaged parts for truck.……….........…………………………
Observe the cracks and welder seam for frame……………................................................…
2. Cummins engine
Check the fasteners for engine………………………………………...........................…………
Check PTO liquid level, refill as required……………………..…………..............………………
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.
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 breather valve for PTO……………………….............…………...…
Remark: change oil when replace new one or after fixed.
[Link] up the dust on the pin shaft of foot-operated valve,and add the lubricating oil…...…

Checker Date

Remarks

Safety, Operation and Maintenance Manual 8-115

Lubrication and Servicing SRT45 Off-Highway Truck

Repair and Maintenance Record Table

Repair and main-

Date Cost Time required Unused time Remarks
tenance performed

8-116 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Lubrication and Servicing

8.6.40 Maintenance inspection form for 4200hrs

Except daily (10hrs) inspection projects, the following projects also have to finish after running
4200hrs.
1. For normally checking
Check leakages, loosened and damaged parts for truck and Clean whole truck by vapour ….........
...............................................................................................................................................
Observe frame for cracks and weld seam opening.…….........................................…….……
Check displacement and worn for transmission shaft by lever.……........................…….……
Check status for body lining plate.……....…….................................................................……
Check hoist guide rail, electroplate it again as required.……..................................…….……
Check status for all hoses; replace all worn, leaked and damaged ones.……….....…….……
2. Lubrication
Front, rear transmissions cross shafts………………….……......................…..................…..4 points
Front, rear transmission shafts…………………………………………......…….................…..2 points
Checking and ensure of all lubrication points work well.........................................................
3. Electrical system
Check harnesses status.………………………………..................………………………………
Check status 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 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 reducer and differential assembly and Planetary assembly
for checking and analysis....................................................................................................…
Check liquid level, refill as required…………………………………………......…………………
Check and clean the breather valve for differential.………………..............………………
Check and clean the breather valve for PTO……………………….............…………...…
Remark: change oil when replace new one or after fixed.
[Link] up the dust on the pin shaft of foot-operated valve,and add the lubricating oil…...…

Checker Date

Remarks

Safety, Operation and Maintenance Manual 8-117

Lubrication and Servicing SRT45 Off-Highway Truck

Repair and Maintenance Record Table

Repair and main-

Date Cost Time required Unused time Remarks
tenance performed

8-118 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Lubrication and Servicing

8.6.41 Maintenance inspection form for 6000hrs

Except daily (10hrs) inspection projects, the following projects also have to finish after running
6000hrs.
1. Engine PTO
Disassemble, inspect and fix or replace some parts if required which parts has been worn.………
………............................................................................................................................…….
Check Pin Spindle and Bush ,replace them as required…………………........................…….
2. Hoist 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…………………........................…….
3. Front, 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 bearings or replace damaged parts for the cylinder if reqiured...............
6. Oil cooling unit
Disassembly, fixing and reassembly…………...………………………………………………….
7. Radiator
Disassembly, fixing and reassembly………………...…………………………………………….
[Link] shaft
Check and fix or replace some parts if required which parts has been worn.………….
Check balance.……………………………………………………………………..........………….

Checker Date

Remarks

Safety, Operation and Maintenance Manual 8-119

Lubrication and Servicing SRT45 Off-Highway Truck

Repair and Maintenance Record Table

Repair and main-

Date Cost Time required Unused time Remarks
tenance performed

8-120 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Lubrication and Servicing

Maintenance inspection form for 6000hrs(supplement)

Except daily (10hrs) inspection projects, the following projects also have to finish after running
6000hrs.
9. Body
Replace lining plate as required.............................................……………………………….….
Replace Pin Spindle and Bush as required…........................……………………………….….
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...................….
[Link] Axle
Replace a frame, drag link and bush…...........................................………………………...…
[Link]
Check fasteners for spray equipment, fasten as required ..................…………………………
Check the driveline bolts torque(first time after 150hrs, next time after each 1200hrs)….…..
Tightening torque Check torque
Bolt code Use of the site
(N·m) (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.
[Link]
Check screw between steering arm and front suspension cylinder. If loosed or damaged ,tighten or
replace new screw.……..................………………………………………………………..………
[Link] 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.......….
Replace new filter which mounted inside of the rear braking valve group.........................….
Replace new filter for the suction filter of the steering system...........................................….
Replace new filter for the suction filter of the hoisting system............................................….

Checker Date

Remarks

Safety, Operation and Maintenance Manual 8-121

Lubrication and Servicing SRT45 Off-Highway Truck

Repair and Maintenance Record Table

Repair and main-

Date Cost Time required Unused time Remarks
tenance performed

8-122 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Lubrication and Servicing

Maintenance inspection form for 6000hrs (supplement)

Except daily (10hrs) inspection projects, the following projects also have to finish after running
6000hrs.
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...................................….
Hydraulic system pressure checking
Check system pressure of steering system........................................................................….
Check pressure of front brake system................................................................................….
Check pressure of rear brake system.................................................................................….
Check pressure of parking system.....................................................................................….
Steering system: Check pre-charge pressure for accumulator 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 .
[Link]
Replace new bearings for steering drag link......................................................................….
Replace new bearings for A-shape arm.............................................................................….
Replace new bearings for ends of the A-shape arm..........................................................….
Replace new bearings for steering cylinder........................................................................….
Replace new bearings for front suspension cylinder.....…………......................…………
Replace new bearings for rear suspension cylinder…………….................................……
Replace new bearings for A-shape.....................................................................................….
Replace new bearings for link............................................................................................….
[Link] up the dust on the pin shaft of foot-operated valve,and add the lubricating oil……

Checker Date

Remarks

Safety, Operation and Maintenance Manual 8-123

Lubrication and Servicing SRT45 Off-Highway Truck

Repair and Maintenance Record Table

Repair and main-

Date Cost Time required Unused time Remarks
tenance performed

8-124 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Lubrication and Servicing

8.6.42 Maintenance inspection form for 10000hrs

Except daily (10hrs) inspection projects, the following projects also have to finish after running
10000hrs.
According to the sample of the oil to determinate whether replace components or not.
1. Engine
Contacting with manufacturer for further information..............................………………………
2. Transmission
Disassemble, inspect and fix or replace some parts if required which parts has been worn.............
............................................................................................................................................…
Remark: drain, replace filter and refill after 150hrs, if transmission has been fixed.
3. Main reducer and differential assembly,Planetary assembly
Disassemble, inspect and fix or replace some parts if required which parts has been worn.…........
........................................................................................................................................……
4. Bearing
Replace new bearings for steering drag link......................................................................….
Replace new bearings for A-shape arm.............................................................................….
Replace new bearings for 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 continue to use it
.….......................................................................................................................................…
Check the wearing status for oscillating bearings of link , replace new one if the clearance of the
bearing S≥ 0.63mm .Conversely, you could continue to use it
.….......................................................................................................................................…
Check the wearing status for oscillating bearings of A-shape , replace new one if the clearance of
the bearing S≥ 0.84mm .Conversely, you could continue to use it
.….......................................................................................................................................…
[Link]
Check screw between steering arm and front suspension cylinder. If loosed or damaged ,tighten or
replace new screw.……..................…………………………………………………...………..…
[Link] up the dust on the pin shaft of foot-operated valve,and add the lubricating oil…...…

Checker Date

Remarks

Safety, Operation and Maintenance Manual 8-125

Lubrication and Servicing SRT45 Off-Highway Truck

........................................................................................................................................

........................................................................................................................................

........................................................................................................................................

........................................................................................................................................

........................................................................................................................................

........................................................................................................................................

........................................................................................................................................

E
........................................................................................................................................

G
........................................................................................................................................

PA
........................................................................................................................................

........................................................................................................................................

........................................................................................................................................

........................................................................................................................................
K

........................................................................................................................................
N

........................................................................................................................................
LA

........................................................................................................................................

........................................................................................................................................

........................................................................................................................................
B

........................................................................................................................................

........................................................................................................................................

........................................................................................................................................

........................................................................................................................................

........................................................................................................................................

........................................................................................................................................

........................................................................................................................................

........................................................................................................................................

8-126 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Technical Data

9 TECHNICAL DATA
4580
4450

3900
4180
2805
3440
4075

8175
6085

°
60
4115
560

685
1515
2135 4100
2865 8615
4215
Unit:mm
Fig 9.1

Engine
Model ............... Cummins engine QSX15-
C525-C525
Type......................4 Cycle, water-cooled direct
injection, 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

Safety, Operation and Maintenance Manual 9-1

Technical Data SRT45 Off-Highway Truck

II USA EPA/CARB MOH 40 CFR 89 and EU

non-highway vehicle standard.
Maximum torque (1400 r/min)..........2440 N• m
(1800 lb ft)
Number of Cylinders/Configuration ............ 6V
Bore x Stroke ...............................137×169mm
(5.33×6.65 in)
Total Displacement ....................15 L (915 in3)

Transmission
Make/model...........................Allison H5620AR
Automatic electronic control with soft shift
[Link] mounted in the frame.
Integral TC 682 torque converter and planetary
gearing. Six speeds forward, two reverse.
Automatic converter lockup action in all speed
ranges. Downshift inhibitor. Integral hydraulic
retarder.

Forward 1st 2nd 3rd 4th 5th 6th

gear gear gear gear gear gear 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 duty axle with single reduction spiral
bevel gear differential, full floating axle shafts,
and planetary reduction at each wheel.

Ratios:
Differential.............................................3.73 : 1
Planetary...............................................5.80 : 1
Total reduction....................................21.63 : 1

Suspension

9-2 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Technical Data

Front: Macpherson type independent

suspension with variable rate ,nitrongen/oil
cylinder for effective absorption of road shocks
Rear: Variable rate nitrogen/oil cylinders with
A-frame linkage,lateral stabilizer bar .
Maximum strut stroke:
Front......................................300 mm (11.8 in)
Rear.........................................186 mm (7.3 in)
Maximum rear axle oscillation...................±6.5°

Wheel and tyres

Wheel rim width.........................................15in
Tyre..................................21.00-35/(36PR)E-4
Note: Under certain working conditions,TKPH
(ton-km/h)capabilities of standard tyres could
be [Link] tyre manufactures for
optimum tyre selection.

Brakes
Service:
All hydraulic brake system [Link]-
mission PTO mounted pressure compensating
piston pump provides hydraulic pressure
for brake and steering. Independent circuits
front and [Link] 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)
Accumulators:
Nitrogen precharge pressure................5.5MPa
(800 lbf/in2)
Front:
Type.............Dry disc with 1 calliper per wheel
Disc diameter...........................710 mm (28 in)
Pad area,total......................1400 cm2 (217 in2)
Rear:
Type........................Oil cooled, multiple friction
discs,completely sealed from dirt and water.
Braking surface, total.......49000 cm2 (7595 in2)
Parking:
Application of rear brakes by springs in brake

Safety, Operation and Maintenance Manual 9-3

Technical Data SRT45 Off-Highway Truck

disc [Link] released.

Hold-off pressure..................................8.3MPa
(1200 lbf/in2)

Steering system
Independent hydrostatic steering with closed-
centre steering valve, accumulator and
pressure compensating piston pump.
Accumulator provides uniform steering
regardless of engine speed. In the event of
loss of engine power it provides steering of
approximately two lock-to-lock turns.
A low pressure indicator light warns of system
pressure below 11.5MPa (1660 lbf/in2).
Steering meets ISO 5010 and SAE J53.
Steering angle (left /right)..........................±40°
Minimun turning radius(SAE)..............9400mm

Hoist system
It is set up separately from the power hydraulic
[Link] 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 gear open
Body raise time..........................................13 s
Body lower time.........................................11 s

Body
Longitudinal 'V' type floor with integral
transverse box-section stiffeners. The body is
exhaust heated and rests on resilient impact
absorption pads.
Body wear surfaces are high hardness
abrasion resistant steel.
Plate thicknesses:
Floor.........................................18 mm (0.70 in)
Side..........................................10 mm (0.39 in)

9-4 Safety, Operation and Maintenance Manual

SRT45 Off-Highway Truck Technical Data

Front lower...............................10 mm (0.39 in)

Deluxe operator cabin with integrated ROPS/
FOPS conform to ISO 3471 and SAE Jl040C
Fed86.

Volume:
Struck(SAE std) ........................22m3(28.8yd3)
Heaped 2:1 (SAE std) ............29.5m3(38.6yd3)

Frame
Highly rigid frame with the whole box-shaped
section, which is equipped with anti-twisting
beam, is adopted. Integral front bumper and
closed-loop crossmember are equipped. Front
and rear beam, twisting drum, rear mounting
rack and bumper are made of low-carbon
steel. At the stress concentrated 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 with doors and windows closed.

Maintenance service capacities

Maintenance
Description volume
L US gal
Engine crankcase and filters 55 14.6
Transmission and filters 85 22.5
Cooling system 130 34.4
Fuel tank 470 124.4
Steering hydraulic tank 63 16.7
Steering system 71 18.8
Lifting hydraulic tank 158 41.8

Safety, Operation and Maintenance Manual 9-5

Technical Data SRT45 Off-Highway Truck

Lifting and brake cooling system 237 67.2

Planetaries (total) 43 11.4
Differential 52 13.7
Front ride strut (each) 19 5.0
Rear ride strut (each) 16.0 4.2
Power takeoff 4 1.1

Typical noise levels

Operator ear (ISO 6394)..........................78dB
*Exterior sound rating (ISO 6395) ............89dB
*The above result is for the mode giving
the highest exterior sound level when
measured and operated as per the prescribed
procedures of the standard. Results shown
are for the vehicle in base configuration.
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 28200 61858
Body, standard 8600 18865
Net weight 36800 80723
Rated loading capacity 45000 98710
Maximum gross weight* 81800 179432
*Maximum total weight of truck includes alternative
device, all the accessories and full fuel tank and
load.

Weight distribution Front Rear

axle axle
Empty 49% 51%
Loaded 33% 67%

9-6 Safety, Operation and Maintenance Manual