Hitachi EH4500-2 Rigid Frame Truck Service Repair Manual

EH4500-2 411MD/412MD/413MD WORKSHOP MANUAL

PUBLICATION NO. W10249E - 02

1/08

PRINTED IN U.S.A.

INTRODUCTION TO THE READER This manual is written for an experienced technician to provide technical information needed to maintain and repair this machine.

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

MANUAL COMPOSITION This manual consists of two portions; the Technical Manual (operational principle) and the Workshop Manual.

The Technical Manual contains the information necessary for delivery and redelivery, operation, and activation of all devices and systems.

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

Page1

TS41154

INTRODUCTION PAGE NUMBER Group Number

The Technical Manual and the Workshop Manual 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: Group Number: Located in the upper right corner (on oddnumbered pages) or the upper left corner (on even-numbered pages). This number identifies the function group to which that particular component belongs. Refer to illustration.

Form SM Number: Located in the bottom right corner of the page.

This number identifies the service manual (SM) information for that particular component. Refer to illustration.

SAFETY ALERT SYMBOL AND HEADLINE NOTATIONS

Page Number

In this manual, the following safety alert symbol and signal words are used to alert the reader to the potential for personal injury or machine damage.

This is the safety alert symbol. When you see this symbol, be alert to the potential for personal injury. Never fail to follow the safety instructions prescribed along with the safety alert symbol.

The safety alert symbol is also used to draw attention to component/part weights.

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.

Page2

Form SM Number

INTRODUCTION UNITS USED

Example: 24.5 MPa (3560 psi)

SI system units and English units are used in this manual. English units are in parentheses behind SI units.

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

Quantity Length Volume

Weight Force Torque

To Convert From

Into

mm mm L L m³ kg N N N m N m

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

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

Quantity Pressure Power Temperature Velocity Flow Rate

Page3

To Convert From

Into

MPa MPa kW kW C km/h L/min mL/rev

kgf/cm² psi PS HP F mph US gpm cc/rev

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

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Page4

SAFETY RECOGNIZE SAFETY INFORMATION SAFETY ALERT SYMBOL This symbol, which will appear at various points in the manual and on the machine 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 machine 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 WORDS On the machine 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 machine protection with personal safety messages, a signal word IMPORTANT indicates a situation which, if not avoided, could result in damage to the machine.

NOTE: indicates an additional explanation for an element of information.

S-1

SAFETY OPERATOR S QUALIFICATIONS Only trained personnel should operate the machine.

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

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

Before operating the machine 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 machine while under the influence of alcohol, medicine or other drugs.

INSPECT MACHINE Inspect your machine 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 MACHINE DAILY BEFORE STARTING found in the OPERATING THE ENGINE section in this operator s manual.

SA-435

S-2

SAFETY FOLLOW SAFETY INSTRUCTIONS Carefully read and follow all safety signs on the machine 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 dealer in the same way you order other replacement parts (be sure to state machine model and serial number when ordering).

Learn how to operate the machine and its controls correctly and safely.

SA-003

Allow only trained qualified, authorized personnel to operate the machine.

Keep your machine in proper working condition.

Unauthorized modifications of the machine may impair its function and/or safety and affect machine life.

The safety messages in this SAFETY chapter are intended to illustrate basic safety procedures of machines. 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 dealer before operating or performing maintenance work on the machine.

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.

SA-437

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.

S-3

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 machine.

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

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

S-4

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 while with dirt and/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.

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 machine.

Keep all flammable objects and/or explosives away from the machine.

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 machine, both doors should be closed at all times.

S-5

SAFETY USE HANDHOLDS AND STEPS Falling is one of the major causes of personal injury.

When entering or leaving the machine, always use the steps and the handrails.

Do not use any controls as handholds.

When you get on and off the machine, always face the machine 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 machine. Never mount or dismount a moving machine.

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 machine.

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 bring up to the deck or cab lunch box, tools, etc so as to maintain a three-point grip when entering or leaving the machine.

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 machine.

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, and check again.

SA-378

S-6

SAFETY FASTEN YOUR SEAT BELT If the machine should overturn, the operator may become injured and/or thrown from the cab.

Additionally the overturning machine may crush the operator, resulting in serious injury or death.

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

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

SA-237

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

HANDLE STARTING AIDS SAFELY Starting fluid: Starting fluid is highly flammable.

Keep all sparks and flame away when using it.

Keep starting fluid well away from batteries and cables.

Remove container from machine if engine does not need starting fluid.

To prevent accidental discharge when storing a pressurized container, keep the cap on the container, and store it in a cool, well-protected location.

SA-293

Do not incinerate or puncture a starting fluid container.

NOTE: Due to increased safety hazards and potential for engine damage, the engine manufacturer does NOT recommend the use of starting fluid without metering equipment.

S-7

SAFETY OPERATE ONLY FROM OPERATOR S SEAT Inappropriate engine starting procedures may cause the machine 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.

EL20368

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 Starting with Auxiliary Batteries in the OPERATING INSTRUCTIONS section of the Operator s Manual.

The operator must be in the operator s seat so that the machine 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 or a runaway machine.

KEEP RIDERS OFF MACHINE Riders on machine are subject to injury such as being struck by foreign objects and being thrown off the machine.

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

Riders also obstruct the operator s view, resulting in the machine being operated in an unsafe manner.

EL20369

S-8

SAFETY PROTECT AGAINST FALLING STONES AND DEBRIS Stay in your cab while your dumper 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.

EL20380-1

PROVIDE SIGNALS FOR JOBS INVOLVING MULTIPLE NUMBERS OF MACHINES For jobs involving multiple numbers of machines, 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

S-9

SAFETY OPERATE THE MACHINE SAFELY When pulling out of the loading area, avoid hitting debris, rocks and loading machine 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 machine 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 machine may vibrate or shake to some extent. Therefore, operate the machine in such a way that your body is exposed to as little vibrations as possible.

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

Pick the smoothest path for the machine.

Adjust the speed of the machine to the terrain.

S-10

EL14019

SAFETY AVOID INJURY FROM RUNNING OVER, FRONT AND BACK, AND FRONT WHEEL CRUSH AREA If any person is present near the machine when backing or moving forward, the machine may hit or run over that person, resulting in serious injury or death. If any person is present in the area between the engine 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 MACHINE. 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 MACHINE.

EL20370

USE A SIGNAL PERSON IF YOUR VIEW IS OBSTRUCTED. ALWAYS KEEP THE SIGNAL PERSON IN VIEW. No machine 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

S-11

SAFETY AVOID TIPPING Keep the machine a safe distance from the edge of cliffs and slide areas. There is the danger of tipping or rolling over the machine.

Avoid operating on the side of slopes.

Use the seat belt during operation.

When operating the machine, both doors should be closed at all times.

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

DO NOT ATTEMPT TO JUMP CLEAR OF A TIPPING MACHINE --- SERIOUS OR FATAL CRUSHING INJURIES WILL RESULT. MACHINE WILL TIP OVER FASTER THAN YOU CAN JUMP FREE. THEREFORE, HOLD FIRMLY ONTO THE STEERING WHEEL IF THE MACHINE 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 machineÂ’s ROPS with unauthorized modifications or changes both the customer and manufacturer should be notified in writing.

S-12

EL20373

SAFETY AVOID INJURY FROM ROLLAWAY ACCIDENTS Death or serious injury may result if you attempt to mount or stop a moving machine.

To avoid rollaways: Select level ground when possible to park machine.

Do not park the machine on a grade.

Reference: PARK MACHINE SAFELY in this section.

Chock the wheels if you must park on a grade.

Position the machine to prevent rolling.

Park a reasonable distance from other machines.

EL20374

NEVER TRAVEL WITH THE BODY OFF THE FRAME Make sure the body is resting on the frame prior to moving the machine.

If the raised body hits against an overhead obstacle, both the machine 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.

EL20375

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

EL20376

S-13

SAFETY OPERATING WITH THE MACHINE NEAR OVERHEAD WIRES OR CABLES Before operating the machine, check with employer/supervisor to find out if there are any overhead cables or wires on the work site.

The machine 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.

EL20377

OPERATING WITH THE MACHINE 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 machine is not kept a safe distance from electric lines.

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

Never operate the machine with the dump body in the raised position.

Check and comply with any local regulations that may apply.

If the machine 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 site.

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

S-14

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