Hitachi EH4500 Rigid Frame Truck Service Repair Manual

HITACHI

EH4500 401MD/402MD SERVICE MANUAL EDITION 2

PUBLICATION NO. 10186 ENG. DISTRIBUTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADDRESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PHONE NO . . . . . . . . . . . . . . .

DLR/BRCH

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ADDRESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PHONE NO . . . . . . . . . . . . . . .

SERVICE PHONE NO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPARE PARTS PHONE NO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MACHINE: SERIAL NO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE TYPE/NO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HYDRAULIC TRANSM. TYPE/NO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STARTING KEY NO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CAB KEY NO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12/01

PRINTED IN U.S.A.

GROUP 0

EH4500 GENERAL SERVICE INFORMATION FORM/PUBLICATION NO. GROUP 091

12/01

TITLE Service Position and Safety Instructions

401MD SM799

402MD SM799

PUBLICATION 10186

GROUP 091 Page 1

SERVICE POSITION AND SAFETY INSTRUCTIONS SERVICE POSITION Before working on the machine, park it on a level surface and put it in the “SERVICE POSITION”

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1. Engine stopped, ignition key removed (except when service requires engine operation).

2. “DO NOT OPERATE” tag or red warning flag on steering wheel.

3. If body is raised, use body prop pins.

4. The wheels blocked.

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3

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5. Body electric control lever in the “FLOAT” position.

6. Parking brakes applied.

7. Allow the machine to cool down.

8. Pressure released from all lines, tanks, and accumulators.

WARNING! If work must be done on a warm machine, beware of hot fluids and components.

Form SM799

GROUP 091 Page 2 SERVICE POSITION AND SAFETY INSTRUCTIONS

A FEW SIMPLE RULES WHEN SERVICING Do not perform any work on the machine unless you are authorized to do so.

Maintenance can be dangerous unless performed properly. Be satisfied that you have the necessary skill, information, correct tools, and equipment to do the job correctly.

Standard maintenance procedures should always be observed.

Read the manufacturer’s manual or find assistance if you do not understand what you are doing.

TS41154

Read all nameplates and decals before you operate the machine. Each nameplate and decal has important information about operation or service.

Deflate tires before loosening any rim clamp bolts.

Always stop the engine before removing inspection covers. Do not let tools or parts fall into the engine compartment opening.

Stand away from the rear of the machine when the engine is running.

When running a machine indoors, be sure the building is properly ventilated.

EL13914

Do not wear loose fitting clothing or jewelry when working on a machine.

Always wear a hard hat, safety glasses, gloves, shoes, or other protective articles as the job requires.

Before you work on the machine always lower the body. If you must work on the machine with the body raised, always securely support the body using the body prop pins.

Be sure the machine is in the SERVICE POSITION before lifting the machine. Always support an elevated machine using proper blocks and/or cribbing before beginning work.

Be sure the “Body Prop Pins” are connected when working beneath a raised dump body.

When lifting or supporting components, use equipment with a weight capacity as great as or greater than the weight of the component..

Use the correct tool(s) for the job. Repair or replace any broken or defective equipment or tools.

Make sure that no tool(s) or other object(s) are left inside the machine where they may cause damage.

EL18044

Form SM799

GROUP 091 Page 3 SERVICE POSITION AND SAFETY INSTRUCTIONS

A FEW SIMPLE RULES WHEN SERVICING (cont’d) Release all system pressure slowly before working on any part of the hydraulic system.

Remove all pressure caps carefully.

Be careful of hot fluid when changing oil in the engine, hydraulic system, etc.

To find leakage, use cardboard or wood, not your hand.

Never adjust a pressure relief valve above the manufacturer’s recommendations.

Always inspect the cooling system with the engine stopped.

Check that there is no damage to electric wires and hoses.

TS21481

Check that there is no damage to hydraulic and brake hoses caused by chafing. When wires have been disconnected it is important that they are clamped so they cannot be exposed to chafing.

When performing any welding operation on a machine, turn the battery disconnect switch to the “OFF” position and disconnect the negative (--) and positive (+) wire connections at the battery.

The main breaker switch in the control cabinet must also be turned ”OFF” as well as it is necessary to disconnect all control cables at the rear of the main cabinet, to the Euclid ECU behind the buddy seat inside the cab and to the engine ECU. Refer to Group 7, Frame General for more specific instructions.

When welding and cutting, the paint must be removed up to a distance of 10 cm (4 in) from the welding or cutting point. Paint which is subject to high temperature may cause harmful gases.

The following safety instructions should be followed: Remove the paint from the area where work is to be performed through sand blasting.

If the paint cannot be removed by sand blasting, it must be removed in some other way e.g., with paint stripper.

EL13917

Note:

When using paint stripper, be sure to wear protective gloves and work in a well ventilated area.

Note:

A high speed grinding machine also heats the paint and must only be used in a well ventilated area.

Polymer materials such as rubber and certain kinds of plastics can, when heated, give off gases that may be dangerous to health and environment.

Form SM799

GROUP 091 Page 4 SERVICE POSITION AND SAFETY INSTRUCTIONS The following safety instructions should be followed: Do not weld or cut near polymer materials without first having protected them from the heat.

Never burn polymer materials when scrapping them.

FIRE PREVENTION MEASURES Fire prevention features provided by the manufacturer should be maintained in operational condition and should be used to supplement operator’s fire prevention efforts. In no case should the features be used or assumed as replacement for diligent operator efforts at preventing fires.

Keep the work place clean. Oil or water on the floor makes it slippery and dangerous in connection with electrical equipment or electrically powered tools. Oily clothes are a serious fire hazard.

Keep the machine and all equipment free of dirt and oil. This will decrease possible fire hazards and make it easier to find loose or defective parts. This is especially important when working with combustible materials.

Machines should be clean of debris particularly around the engine, exhaust, and drive shaft components. Keep the machine extra clean when working in a sensitive environment.

Note:

If a high pressure jet is used for cleaning, take great care as the insulation of electrical wires can become damaged even at moderately high pressure and temperature. Protect electrical wires in a suitable way.

Gasoline is highly flammable and should never be used as a cleaning fluid. Use an approved solvent for cleaning.

Some solvents can cause skin rashes and or fire dangers. Do not inhale solvent vapors.

V50389A

Store flammable starting aids in a cool, well ventilated location.

Smoking, open flames, etc., should not be permitted around any machine during fueling operations and/or when the fuel system is open to the atmosphere.

Prior to welding or brazing on any part of the machine, the part and the surrounding area should be cleaned and a fire extinguisher should be made readily available.

Hydraulic fluid is flammable. Do not weld on pipes or tubes that are filled with fluid. Be careful when welding next to filled pipes or tubes.

There is always a risk of fire. Find out which type of fire extinguisher to use, where it is and how to use it.

Form SM799

GROUP 091 Page 5 SERVICE POSITION AND SAFETY INSTRUCTIONS In case of fire be prepared to run for safety, but if time permits first: Lower body.

Stop the engine.

Start combating the fire and/or call for help.

Form SM799

GROUP 091 Page 6 SERVICE POSITION AND SAFETY INSTRUCTIONS

NOTES

Form SM799

GROUP 1

EH4500 SERVICE AND OPERATOR’S INDEX FORM/PUBLICATION NO. GROUP 161 170 179

12/01

TITLE Lincoln Centralized Lubrication Machine Specifications Special Tools

401MD SM754R2 SM800R1 SM672R1

402MD SM754R2 SM800R1 SM672R1

PUBLICATION 10186

GROUP 161 Page 1

LINCOLN CENTRALIZED LUBRICATION SYSTEM

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L.H. TRACK ROD L.H. LOWER REAR STRUT L.H. UPPER REAR STRUT L.H. BODY HINGE L.H. UPPER HOIST BG.

R.H. UPPER HOIST BG. R.H. BODY HINGE R.H. UPPER REAR STRUT R.H. LOWER REAR STRUT

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2

R.H. TRACK ROD

CUSTOMER SUPPLIED

7 PUMP STATION NOSE CONE L.H. LOWER HOIST BG. R.H. LOWER HOIST BG.

TIMER OR CONTROLLER

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4

L.H. OUTER TRAIL ARM L.H. INNER TRAIL ARM L.H. STEER CYL. BASE END

R.H. OUTER TRAIL ARM R.H. INNER TRAIL ARM R.H. STEER CYL. BASE END

L.H. TIE ROD L.H. LOWER KING PIN

R.H. TIE ROD R.H. LOWER KING PIN

L.H. STEER CYL. ROD END L.H. UPPER KING PIN

R.H. STEER CYL. ROD END R.H. UPPER KING PIN

L.H. LOWER STRUT L.H. UPPER STRUT

R.H. LOWER STRUT R.H. UPPER STRUT

ELI

Figure 1 --Lincoln Centralized Lubrication System 1. Pump Station 2. Timer or Controller 3. Right Front Manifold

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Left Front Manifold Left Rear Manifold Right Rear Manifold Center Manifold Form SM754R2

GROUP 161 Page 2 LINCOLN CENTRALIZED LUBRICATION SYSTEM

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*2

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3 7 5 ELI

Figure 2 -- Lincoln Centralized Lubrication System, Model View *1. Pump Station (customer supplied) *2. Timer or Controller (customer supplied) 3. Right Front Manifold

DESCRIPTION Numbers in parentheses refer to Figure 1.

The Lincoln Centralized Lubrication System provides a systematic method of lubricating a machine. While the machine is in motion, the lubricant is automatically delivered in time controlled and metered quantities to all connected lube points in the system.The major components of the system are: the electric pump station (1), the timer (2), and the injectors (3, 4, 5, 6 & 7) that direct lubricant to the various components on the machine.Typical wiring of this system is shown in Figure 3.

OPERATION Numbers in parentheses refer to Figure 1.

In a single line, parallel system, a lubricant source supplies lubricant flow through a single supply line at-

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Left Front Manifold Left Rear Manifold Right Rear Manifold Center Manifold

tached to each injector manifold. The individual injectors of the injector manifold are �in line�, that is, the source is directly connected to each injector at all times. Each injector is operated simultaneously by the lubricant flow and each injector operates independently of the others in the system. The movement or cycling of the individual injectors are therefore in parallel to one another.

As previously stated, the injectors cycle independently of one another. Should an injector be unable to cycle, the cycling of all the other injectors in the system carries on normally. Lubricant flow will be stopped only in the injector which is not cycling.

This system can be described as a measuring system. The source provides lubricant to the system and in each injector the rising pressure and the flow of lubricant causes the injector to dispense and to measure lubricant. Once this portion of the cycle takes place the injector is closed to lubricant flow; lubricant Form SM754R2

GROUP 161 Page 3 LINCOLN CENTRALIZED LUBRICATION SYSTEM flow is blocked and the system builds pressure. The system pressure rises to a preset maximum and the supply of lubricant is stopped. The length of stroke, which is adjustable, and the diameter of each measuring piston in the injector determines how much lubricant is displaced during each cycle of that injector.

Therefore the total lubricant flow from the source is not delivered beyond the injector; only the volume measured by each injector.

The injectors of the system are reset when the lubricant pressure in the supply line is relieved or vented back through the source to the reservoir. It is very important to understand that the lubricant supply side of the system has to complete a cycle; first providing lubricant and having that supplied lubricant build to a preset pressure, and then removing the lubricant supply and allowing the supply pressure to fall back to zero.

CUSTOMER SUPPLIED

TIMER OR CONTROLLER

EL LIN

Figure 3 -- Typical Electrical Wiring, Centralized Lube System

SL1 INJECTOR Each Lincoln �Centro--Matic� SL1 injector assembly contains from one to five injectors mounted on a manifold. It is designed to inject grease to bearings with an outut pressure of up to 3,500 psi.

Each manifold contains; the supply line connection ports at either end, the mounting surface for the individual injectors, flow passages to interconnect the injectors and connection ports, and the mounting holes to fix the manifold to the machine.

The injector is attached to its manifold by an adapter bolt and is sealed by copper gaskets. Individual injectors can be removed from the manifold for repair or replacement without disturbing the other injectors or the supply lines by turning out the adapter bolt and disconnecting the feed line from the injector outlet port.

The indicator stem is directly connected to the injector piston and provides a visual indication of the injector operation. When the supply system pressure increases, the indicator stem moves into the Form SM754R2

GROUP 161 Page 4 LINCOLN CENTRALIZED LUBRICATION SYSTEM injector body and when the supply side relieves pressure the indicator stem moves back out to rest against the adjusting screw.

The adjusting screw allows you to externally adjust the lubricant output of each individual injector. For the SL1 injector, the adjustment range is from .008 to 0.08 cubic inches. As stated earlier the adjustment of one injector does not affect any other injector output in the system. The injector assembly can be mounted in any position with no effect on its operating efficiency.

Under the cover cap of the fitting assembly is a grease fitting which is directly connected to the discharge

chamber of the injector. By connecting a manual or air powered grease gun you can inject grease directly into the bearing through its feed line without diturbing the lines or the functioning of the system.

If a component of the overall machine is removed and the lubrication of that component is no longer required the portion of the Centro--Matic system not used can be plugged without any effect to the other injectors of the system. If it is a single bearing point, then the output port can be plugged with a plug. If it is a leg of the supply side, then the end of the operating supply side is plugged after the unused portion is disconnected.

EL18562

Figure 4 --SL1 Injector Assembly 1.

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Manifold Mounting Hole Adapter Bolt Injector Cover Cap, Metal Indicator Stem

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Adjusting Screw Adjusting Screw Locknut Measuring Chamber Injector Piston Discharge Chamber Fitting Assembly

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Outlet Port(1/8 NPTF) Plunger Spring Slide Valve Passage Gasket

Form SM754R2

GROUP 161 Page 5 LINCOLN CENTRALIZED LUBRICATION SYSTEM

EL LIN

Figure 5 -- SL1 Injector Cutaway Form SM754R2

GROUP 161 Page 6 LINCOLN CENTRALIZED LUBRICATION SYSTEM

SYSTEM MALFUNCTIONS

MALFUNCTION

SYMPTOM

Pump does not discharge lubricant.

Little or no pressure at the gauge.

Excessive system pressure. See troubleshooting chart.

Bearing not receiving lubricant. System is operating and lubricant is being dispensed.

High pressure at gauge.

Dry bearing.

CAUSE

SOLUTION

Empty reservoir.

Fill

Loss of power to pump.

Check fuse.

Check electrical connections.

Check timer.

Air trapped within the pump element.

Disconnect the outlet line and cycle the pump to purge.

Pump damaged internally.

Replace.

Loss of hydraulic pressure

Check system pressure

Blocked injector.

Remove metering valve and clean. Check piston and bore for damage and replace if necessary.

Blocked or crushed line.

Replace.

Blocked bearing inlet.

Clean out material.

Tight bearing.

New pin and bushing may be too tight. Modify grease channel.

Broken line.

Check lines; replace where necessary.

Leakage at fitting.

Tighten loose fittings. Replace damaged fittings.

Form SM754R2

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