Hitachi EH1100-3 Rigid Dump Truck Service Repair Manual

Manual No. W8R4-E-03

WORKSHOP MANUAL

RIGID DUMP TRUCK

TITLE / Introduction TO THE READER

MANUAL COMPOSITION

This manual is written for an experienced technician to provide technical information needed to maintain and repair this rigid dump truck.

The Workshop Manual contains the information necessary for maintenance and repair of the rigid dump truck, tools and devices necessary for maintenance and repair, maintenance standards, and removal/installation and disassembly/assembly procedures.

Be sure to thoroughly read this manual for correct product information and service procedures.

If you have any questions or comments, or if you found any errors regarding the contents of this manual, please contact us using the “PLEASE TELL US” form. The form follows this INTRODUCTION section.

ADDITIONAL REFERENCES Please refer to the materials listed below in addition to this manual: Operators Manual Parts Catalog Operation Manual of the Engine Operation Manual of the Transmission o 5000-9000 Series Transmissions Commercial Electronic Controls 2 (CEC2) Manual o Allison Transmission 5610-6610 Series Service Manual Hitachi Weld Repair Manual KO-111-00

TS41154

IN-01

TITLE / Introduction PAGE NUMBER The Manuals have the page number located on the center lower part of the page, as well as, additional numbers on the page to help the technician locate specific information: W2-1-3 Consecutive Page Number for each group Group Number Section Number T = Technical Manual W = Workshop Manual

SAFETY ALERT SYMBOL AND HEADLINE NOTATIONS In this manual, the following safety alert symbol and signal words are used to alert the reader to the potential for personal injury or rigid dump truck damage.

This is the safety alert symbol. When you see this symbol, be alert to the potential for personal injury. Always follow the safety instructions that accompany the safety alert symbol.

The safety alert symbol is also used to draw attention to the weight of component parts.

To avoid injury and damage, be sure to use appropriate lifting techniques and equipment when lifting heavy parts.

WARNING: Indicates a potentially hazardous situation that could, if not avoided, result in personal injury or death.

NOTE: Indicates supplementary technical information or know-how.

IN-02

TITLE / Introduction UNITS USED Example: 24.5 MPa (3550 psi) SI system units and English units are used in this manual. English units are in parentheses behind SI units.

Quantity Length Volume

Weight Force Torque

Quantity Pressure Power Temperature Velocity Flow Rate

A table for conversion from SI units to other system units is shown below for reference purposes.

To Convert From mm mm L L m³ kg N N N m N m

To Convert From MPa MPa kW kW C km/h L/min mL/rev

Into in ft US gal US qt yd³ lb kgf lbf kgf m lbf ft

Into kgf/cm² psi PS HP F mph US gpm cc/rev

IN-03

Multiply by 0.03937 0.003281 0.2642 1.057 1.308 2.205 0.10197 0.2248 1.0197 0.7375

Multiply by 10.197 145.0 1.360 1.341 C 1.8 32 0.6214 0.2642 1.0

TITLE / Introduction MEMO ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................

IN-04

SERVICE AND MAINTENANCE / Safety RECOGNIZE SAFETY INFORMATION SAFETY ALERT SYMBOL This symbol, which will appear at various points in the manual and on the rigid dump truck together with a warning statement, means: “Warning, be alert! Your safety is involved!” Carefully read the message that follows. It is the obligation of the operator to make sure that all warning decals are in place on the rigid dump truck and that they are readable. Accidents may otherwise occur.

Follow recommended precautions and safe operating practices.

Every country (State) has its own safety regulations. It is the obligation of the operator to know and follow these. This also applies to local regulations covering different types of work. Should the recommendations in this manual deviate from those of your country (State), your local safety regulations should be followed.

UNDERSTAND SIGNAL WORD On the rigid dump truck safety signs, signal words designating the degree or level of hazard – DANGER, WARNING, or CAUTION – are used with the safety alert symbol.

DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

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

CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

DANGER or WARNING safety signs are located near specific hazards. General precautions are listed on CAUTION safety signs.

These signal words also call attention to safety messages in this manual.

To avoid confusing rigid dump truck protection with personal safety messages, a signal word IMPORTANT indicates a situation which, if not avoided, could result in damage to the rigid dump truck.

NOTE: indicates an additional explanation for an element of information

SA-1

SERVICE AND MAINTENANCE / Safety

OPERATOR’S QUALIFICATIONS Only trained personnel should operate the rigid dump truck.

Operator should be of legal rigid dump truck operating age according to country (State) regulations and familiar with the operation and maintenance of the rigid dump truck.

Operator must be licensed if required by National Rules and Regulations.

Before operating the rigid dump truck this manual must be read and understood. By reading and understanding the manual the operator will become aware of and observe how to avoid injury and damage.

Know the work area and the company rules and regulations Never operate the rigid dump truck while under the influence of alcohol, medicine or other drugs.

INSPECT RIGID DUMP TRUCK Inspect your rigid dump truck carefully each day or shift by walking around it before you start it to avoid personal injury.

Be sure to cover all points described under “INSPECT RIGID DUMP TRUCK DAILY BEFORE STARTING” found in the OPERATING THE ENGINE section in the Operator’s Manual.

SA-435

SA-2

SERVICE AND MAINTENANCE / Safety FOLLOW SAFETY INSTRUCTIONS Carefully read and follow all safety signs on the rigid dump truck and all safety messages in this manual.

Safety signs should be installed, maintained and replaced when necessary.

If a safety sign or this manual is damaged or missing, order a replacement from your authorized Hitachi dealer in the same way you order other replacement parts (be sure to state rigid dump truck model and serial number when ordering).

Learn how to operate the rigid dump truck and its controls correctly and safely.

SA-003

Allow only trained qualified, authorized personnel to operate the rigid dump truck.

Keep your rigid dump truck in proper working condition.

Unauthorized modifications of the rigid dump truck may impair its function and/or safety and affect rigid dump truck life.

The safety messages in this SAFETY chapter are intended to illustrate basic safety procedures of rigid dump trucks. However it is impossible for these safety messages to cover every hazardous situation you may encounter. If you have any questions, you should first consult your supervisor and/or your authorized Hitachi dealer before operating or performing maintenance work on the rigid dump truck.

PREPARE FOR EMERGENCIES Be prepared if a fire starts or if an accident occurs.

It is recommended that a first aid kit and fire extinguisher be kept on hand.

Thoroughly read and understand the label attached on the fire extinguisher to use it properly.

To ensure that a fire extinguisher can be always used when necessary, check and service the fire extinguisher at the recommended intervals as specified in the fire-extinguisher manual.

Establish emergency procedure guidelines to cope with fires and accidents.

Keep emergency numbers for doctors, ambulance service, hospital, and fire department posted near your telephone.

SA-3

SA-437

SERVICE AND MAINTENANCE / Safety WEAR PROTECTIVE CLOTHING Wear close fitting clothing and safety equipment appropriate to the job.

You may need: A hard hat Safety shoes Safety glasses, goggles, or face shield Heavy gloves Hearing protection Reflective clothing Wet weather gear Respirator or filter mask.

Be sure to wear the correct equipment and clothing for the job. Do not take any chances.

SA-438

Avoid wearing loose clothing, jewelry, or other items that can catch on control levers or other parts of the rigid dump truck.

Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating the rigid dump truck.

PROTECT AGAINST NOISE Prolonged exposure to loud noise can cause impairment or loss of hearing.

Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortably loud noises. May be necessary when working outside of the cab, during the Daily Walk Around Inspection, for example.

SA-434

PROTECT AGAINST FLYING DEBRIS If flying debris hit eyes or any other part of the body, serious injury may result.

Guard against injury from flying pieces of metal or debris; wear goggles or safety glasses.

SA-432

SA-4

SERVICE AND MAINTENANCE / Safety

GENERAL PRECAUTIONS FOR CAB Before entering the cab, thoroughly remove all dirt and/or oil from the soles of your work boots. If any controls such as a pedal are operated with dirt or oil on the soles of the operator’s work boots the operator’s foot may slip off the pedal, possibly resulting in a personal accident.

Don’t leave parts and/or tools lying around the operator’s seat. Store them in their specified locations.

Loose items should not be stored inside cab, including personal items such as lunch box, thermos bottle or fire extinguisher.

Avoid storing transparent bottles in the cab. Don’t attach any transparent type window decorations on the windowpanes as they may focus sunlight, possibly starting a fire.

Refrain from listening to a radio or music with headphones or mobile telephones in the cab while operating the rigid dump truck.

Keep all flammable objects and/or explosives away from the rigid dump truck.

After using the ashtray, always cover it to extinguish the match and/or tobacco.

Don’t leave cigarette lighters in the cab. When the temperature in the cab increases, the lighter may explode.

When operating the rigid dump truck, both doors should be closed at all times.

SA-5

SERVICE AND MAINTENANCE / Safety USE HANDHOLDS AND STEPS Falling is one of the major causes of personal injury.

When entering or leaving the rigid dump truck, always use the steps and the handrails.

Do not use any controls as handholds.

When you get on and off the rigid dump truck, always face the rigid dump truck and maintain a three-point grip with the steps and handrails. (i.e., Two hands and one foot or one hand and two feet.)

DO NOT JUMP on or off the rigid dump truck. Never mount or dismount a moving rigid dump truck.

SA-439

Do not step or climb on surfaces, which are not intended for walking. Step only on the areas provided with the slip resistant surfaces.

Be careful of slippery conditions on platforms, steps, and handrails when leaving the rigid dump truck.

All steps, ladders, stairways, handholds, platforms, walkways, and guardrails must be free of dirt, snow, and ice.

All steps, ladders, stairways, platforms, walkways, and non-skid deck strips must be replaced if damaged.

The use of a rope is recommended to hoist up to the deck or cab lunch box, tools, etc so as to maintain a three-point grip when entering or leaving the rigid dump truck.

EL20273

ADJUST THE OPERATOR’S SEAT A poorly adjusted seat for either the operator or for the work at hand may quickly fatigue the operator leading to miss-operations.

The seat should be adjusted whenever changing the operator for the rigid dump truck.

The operator should be able to fully depress the pedals and to correctly operate the control levers with his back against the seat back.

If not, move the seat forward or backward to adjust, and check again.

SA-6

SA-378

SERVICE AND MAINTENANCE / Safety FASTEN YOUR SEAT BELT If the rigid dump truck should overturn, the operator may become injured and/or thrown from the cab if the seat belt is not securely fastened.

Additionally the overturning rigid dump truck may crush the operator, resulting in serious injury or death.

Prior to operating the rigid dump truck, thoroughly examine webbing, buckle and attaching hardware. If any item is damaged or worn, replace the seat belt or component immediately before operating the rigid dump truck.

SA-237

Be sure to remain seated with the seat belt securely fastened at all times when the rigid dump truck is in operation to minimize the chance of injury from an accident.

Recommend that the seat belt be replaced every three years regardless of its apparent condition.

OPERATE ONLY FROM OPERATOR’S SEAT Inappropriate engine starting procedures may cause the rigid dump truck to runaway, possibly resulting in serious injury or death.

Start the engine only from the operator’s seat.

NEVER start the engine while standing on the ground.

Do not start engine by shorting across starter terminals.

Before starting the engine, confirm that all control levers are in neutral and the park brake switch is in the applied position.

EL20368

SA-7

SERVICE AND MAINTENANCE / Safety

JUMP STARTING Battery gas can explode, resulting in serious injury.

If the engine must be jump-started, be sure to follow the instructions shown under Using Booster Batteries in the OPERATING THE ENGINE section of the Operator’s Manual.

The operator must be in the operator’s seat so that the rigid dump truck will be under control when the engine starts. Jump-starting is a two-person operation.

SA-032

Never use a frozen battery.

Failure to follow correct jump starting procedures could result in a battery explosion, a runaway rigid dump truck or damage to electronic equipment on the rigid dump truck.

KEEP RIDERS OFF RIGID DUMP TRUCK Riders on rigid dump truck are subject to injury such as being struck by foreign objects and being thrown off the rigid dump truck.

Do not allow riders other than on the passenger's seat. Riders must also have their seat belt fastened.

Riders also obstruct the operator’s view, resulting in the rigid dump truck being operated in an unsafe manner.

SA-8

EL20369

SERVICE AND MAINTENANCE / Safety

PROTECT AGAINST AND DEBRIS

FALLING

STONES

Stay in your cab while your rigid dump truck is being loaded. Stepping out of the cab could result in possible injury.

Do not place your head and/or arms outside of the window.

Close cab windows while the rigid dump truck is being loaded.

EL20380-1

PROVIDE SIGNALS FOR JOBS INVOLVING MULTIPLE NUMBERS OF VEHICLES For jobs involving multiple numbers of vehicles, provide signals commonly known by all personnel involved.

Also, appoint a signal person to coordinate the job site.

Make sure that all personnel obey the signal person’s directions.

SA-481

SA-9

SERVICE AND MAINTENANCE / Safety OPERATE THE RIGID DUMP TRUCK SAFELY When pulling out of the loading area, avoid hitting debris, rocks and loading rigid dump truck overflow that can cause tire damage. Allow the clean-up dozer sufficient time to clear the loading area.

Watch where you are going. Stay away from people, the edge of cliffs; slide areas, other machines and vehicles, etc.

While traveling on the haul road, maintain a sufficient distance behind the rigid dump truck ahead (depending on roads, speeds, and haul road conditions). This practice should always be followed to allow sufficient safe maneuvering and stopping room.

During all operations, the rigid dump truck may vibrate or shake to some extent. Therefore, operate the rigid dump truck in such a way that your body is exposed to as little vibrations as possible.

Have the operator’s seat properly adjusted and wear the seat belt.

Pick the smoothest and safest path for the rigid dump truck.

Adjust the speed of the rigid dump truck to the terrain.

SA-10

EL14019

SERVICE AND MAINTENANCE / Safety AVOID INJURY FROM RUNNING OVER, FRONT AND BACK, AND FRONT WHEEL CRUSH AREA If any person is present near the rigid dump truck when backing or moving forward, the rigid dump truck may hit or run over that person, resulting in serious injury or death. If any person is present in the area between the chassis and the front wheel, the person could be crushed when the front wheels are turned.

To avoid these situations: Always look around BEFORE YOU MOVE THE RIGID DUMP TRUCK. BE SURE THAT ALL BYSTANDERS ARE CLEAR. Keep the back-up alarm in working condition.

ALWAYS BE ALERT FOR BYSTANDERS MOVING INTO THE WORK AREA. USE THE HORN OR OTHER SIGNAL TO WARN BYSTANDERS BEFORE MOVING RIGID DUMP TRUCK.

EL20370

USE A SIGNAL PERSON IF YOUR VIEW IS OBSTRUCTED. ALWAYS KEEP THE SIGNAL PERSON IN VIEW. No rigid dump truck motions shall be made unless signals are clearly understood by both signalman and operator.

Learn the meanings of all flags, signs, and markings used on the job and confirm who has the responsibility for signaling.

EL20371

Keep windows, mirrors, and lights clean and in good condition.

Dust, heavy rain, fog, etc., can reduce visibility. As visibility decreases, reduce speed and use proper lighting.

Read and understand all operating instructions in the operator’s manual.

EL20372

SA-11

SERVICE AND MAINTENANCE / Safety AVOID TIPPING Keep the rigid dump truck a safe distance from the edge of cliffs and slide areas. There is the danger of tipping or rolling over.

Avoid operating on the side of slopes.

Use the seat belt during operation.

When operating the rigid dump truck, both doors should be closed at all times.

The cab is for the protection of the operator and it meets the requirements for rollover protective structures (ROPS) according to the adopted standard for this rigid dump truck.

DO NOT ATTEMPT TO JUMP CLEAR OF A TIPPING RIGID DUMP TRUCK --- SERIOUS OR FATAL CRUSHING INJURIES WILL RESULT. RIGID DUMP TRUCK WILL TIP OVER FASTER THAN YOU CAN JUMP FREE. THEREFORE, HOLD FIRMLY ONTO THE STEERING WHEEL IF THE RIGID DUMP TRUCK SHOULD TIP OR ROLL OVER. DO NOT JUMP. IMPORTANT: Never make any unauthorized modifications or alterations to the Rollover Protective Structure (ROPS) such as; welding on fire extinguisher brackets, CB antenna brackets, or fire suppression systems. Such unauthorized modifications will affect the structural limits of the ROPS and will void the certification and could result in loss of protection to the operator.

The Rollover Protective Structure (ROPS) has been certified to meet specified requirements according to SAE J1040C, SAE J231, ISO 3471 and ISO 3449.

Any planned modification or change must be reviewed in advance by our Engineering Department to determine if the modification or change can be made within the limits of the certified tests.

IMPORTANT: Each person in your organization, including management should be made aware of these rules involving the Rollover Protective Structure (ROPS). Whenever anyone sees a rigid dump truck’s ROPS with unauthorized modifications or changes both the customer and manufacturer should be notified in writing.

SA-12

EL20373

SERVICE AND MAINTENANCE / Safety AVOID INJURY FROM ROLLAWAY ACCIDENTS Death or serious injury may result if you attempt to mount or stop a moving rigid dump truck.

To avoid rollaways: Select level ground when possible to park rigid dump truck.

Do not park the rigid dump truck on a grade.

Reference: PARK RIGID DUMP TRUCK SAFELY in this section.

Chock the wheels if you must park on a grade.

Position the rigid dump truck to prevent rolling.

Park a reasonable distance from other vehicles.

EL20374

SA-13

SERVICE AND MAINTENANCE / Safety NEVER TRAVEL WITH THE BODY OFF THE FRAME Make sure the body is resting on the frame prior to moving the rigid dump truck.

If the raised body contacts an overhead obstacle, both the rigid dump truck and the overhead obstacle will be damaged, and personal injury may result as well. This includes overhead wires, cables and power lines.

Traveling with a raised body places greater stress to the body pivot pins, hydraulic cylinders and the frame.

Never “jump dump” by bouncing the rear wheels against a stop rail or by jerking the body control lever.

EL20375

EL20376

SA-14

SERVICE AND MAINTENANCE / Safety OPERATING WITH THE RIGID DUMP TRUCK NEAR OVERHEAD WIRES OR CABLES Before operating the rigid dump truck, check with employer/supervisor to find out if there are any overhead cables or wires on the work site.

The rigid dump truck operator must be given clear information about this. Make sure that all relevant and practical measures to help detect such lines are taken.

Local authorities and/or communication and power companies should be contacted for guidance and advice.

Overhead wires and cables must be protected against damage in a suitable way. The electricity should be turned off when practical.

OPERATING WITH THE RIGID DUMP TRUCK NEAR HIGH VOLTAGE, OVERHEAD POWER LINES A power line is a single conductor suspended on or from poles or other supports as well as accessories such as insulators, hooks, and bars.

Serious injury or death can result if the rigid dump truck is not kept a safe distance from electric lines.

When operating near an electric line, NEVER move any part of the rigid dump truck or load closer than 3 m (10 ft.) plus twice the line insulator length.

Never operate the rigid dump truck with the body in the raised position.

Check and comply with any local regulations that may apply.

If the rigid dump truck comes into contact with a high voltage line, the operator must remain in the operator’s seat and not leave the cab; if the line is live and the operator tries to reach the ground his or her life is in danger. Call for help by signaling in some way, sounding the horn or mobile telephone, so that the power can be turned off.

Wet ground will expand the area that could cause any person on it to be affected by electric shock. Keep all bystanders or co-workers away from the wet ground.

If the rigid dump truck is used in potentially dangerous environments, e.g. explosive atmosphere, areas with dust including asbestos, special safety regulations must be followed and the rigid dump truck must be equipped for such operations.

SA-15

EL20377

SERVICE AND MAINTENANCE / Safety PARK RIGID DUMP TRUCK SAFELY Fill the fuel tank to minimize water condensation in the tank.

Park rigid dump truck on a level surface.

Lower the body to the frame.

Move the shift selector to the N neutral position.

Apply the parking brake and release the service brakes to insure that the parking brake is holding the rigid dump truck.

Let the engine run at low idle for three to five minutes for cool down.

Make sure the body hoist control lever is in the Float position.

Check that all switches and controls are in the OFF position.

Turn the Key Switch to the OFF position.

Turn the Battery Disconnect Switch to the OFF position.

Place wheel chocks both ahead and behind tires of axle.

Chocks must contact tire tread surface when installed correctly.

NOTE: Running out of fuel with the engine running, especially under load, is very detrimental to engine life and requires a time consuming restart procedure.

Perform a walk around inspection and fill out the required Preventative Maintenance form or other required operator report forms. Be sure to report any adjustments of service required to those responsible for maintenance.

When leaving the rigid dump truck unattended, remove the key. Lock the doors and any vandalism guards to prevent theft or damage.

SA-16

EL20378

SERVICE AND MAINTENANCE / Safety SAFE HANDLING OF OFF ROAD TIRES When doing any tire service, especially tire inflation, NEVER stand in the TRAJECTORY PATH. Serious injury or death can result if an explosion should occur.

Use a self-attaching air chuck with a hose long enough to be out of the trajectory path when filling a tire with air.

Use an inflation cage, safety cables, or chains when inflating tires.

Never use air from a compressed air system, to inflate a tire if alcohol has been used as antifreeze.

Inspect all rims, wheels and components.

Replace any worn or damaged rims, wheels and components.

Do not remove any wheel nuts; rim clamps or dagger clamps until the tire is deflated.

No personnel should be touching the rim, rim clamp, or tire when dislodging the rim clamps or dagger clamps.

Never stand in front of rim clamps or dagger clamps during removal.

Trained and certified personnel should only do the dismounting and mounting of tires. It is recommended that a certified tire repair service be hired to perform the dismounting and mounting of tires from rims.

EL20379

DISCHARGE ACCUMULATORS Before removing and disassembling brake or steering accumulators, they must be discharged to prevent serious injury. Refer to the appropriate Workshop Manual section for BRAKE ACCUMULATOR and STEERING ACCUMULATOR.

EL20560

SA-17

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