Hitachi EH750-3 Rigid Dump Truck operator’s manual SN8R1AB-0001001 and up

Manual No. EM8R6-1-4

Operator’s Manual

Rigid Dump Truck

Serial No. EH750-3 EH1100-3 EH1700-3 EH1700-3

8R1AB: 8R4AB: 8R6AA: 8R6BA:

8R1AB-0001001 and Up 8R4AB-0001001 and Up 8R6AA-0001001 and Up 8R6BA-0001001 and Up

INTRODUCTION Read this manual carefully to learn how to operate and service your rigid dump truck correctly. Failure to do so could result in personal injury and/or rigid dump truck damage.

This manual should be considered a permanent part of your rigid dump truck and should remain with the rigid dump truck when you sell it.

This rigid dump truck is of metric design. Measurements in this manual are metric. Use only metric hardware and tools as specified.

Write product identification numbers in the Machine Numbers section. Accurately record all the numbers to help in tracing the rigid dump truck should it be stolen. Your dealer also needs these numbers when you order parts. If this manual is kept in the rigid dump truck, also file the identification numbers in a secure place off the rigid dump truck.

Warranty is provided as a part-Hitachi’s support program for customers who operate and maintain their equipment as described in this manual. The warranty is explained on the warranty certificate which you should have received from your dealer.

This warranty provides you the assurance that Hitachi will back its products when defects occur within the warranty period. In some circumstances, Hitachi also provides field improvements, often without charge to the customer, even if the product is out of warranty.

Should the equipment be abused or modified to change its performance beyond the original fac-

tory specifications, the warranty will become void and field improvements may be denied. Setting fuel delivery above specifications or otherwise overpowering rigid dump trucks will result in such action.

Moreover, when replacement parts are required, be sure to use genuine Hitachi parts. Failure to do so may result in voiding the warranty and/or denial of field improvements.

Only qualified, experienced operators officially licensed (according to local law) should be allowed to operate the rigid dump truck.

Moreover, only officially licensed personnel should be allowed to inspect/service the rigid dump truck.

The Yellow Pages in this operator’s manual contain IMPORTANT SAFETY INFORMATION. Read these pages thoroughly and familiarize yourself with the safety standards and recommendations set forth in these yellow pages of the manual.

Follow all safety instructions prior to and while operating the rigid frame rear dumper.

Prior to operating this rigid dump truck, it may be necessary to make modifications to it so that it complies with the local standards (including safety standards) and requirements of your country. Please do not operate this rigid dump truck until such compliance has been confirmed. Please contact-Hitachi Construction Truck Manufacturing Ltd. or any of our authorized Hitachi dealers concerning compliance.

EL20110NS1100

All information, illustrations and specifications in this manual are based on the latest product information available at the time of publication. The right is reserved to make changes at any time without notice.

11/08

Manual No. EM8R6-1-4

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11/08

Manual No. EM8R6-1-4

MACHINE NUMBERS

INDEX

SAFETY SAFETY SIGNS COMPONENTS NAME OPERATOR’S STATION

All information, illustrations and specifications in this manual are based on the latest product information available at the time of publication. The right is reserved to make changes at any time without notice.

BREAK-IN OPERATING THE RIGID DUMP TRUCK OPERATING METHODS TRANSPORTING MAINTENANCE

COPYRIGHT(C) 2008 Hitachi Truck Manufacturing Ltd. Guelph, Canada All rights reserved

STORAGE TROUBLESHOOTING SPECIFICATIONS OPTIONS INFORMATION FEEDBACK FORM ALPHABETICAL INDEX

MACHINE NUMBERS The numbers asked for in this section are the individual numbers; model, product identification, serial, type and manufacturer given to each machine and major components. These numbers are requested when inquiring about replacement parts or machine service. Fill in the blank spaces in this section to immediately have them available upon request.

MACHINE TYPE, SERIAL NUMBER, AND ROLLOVER PROTECTIVE STRUCTURE NAMEPLATE MODEL: PRODUCT IDENTIFICATION NUMBER: ROPS MODEL NUMBER: MAX MACHINE MASS, M-kg:

OM21000

MACHINE NUMBERS FRAME PRODUCT IDENTIFICATIION NUMBER

OM21001

ENGINE TYPE AND SERIAL NUMBER TYPE: MFG. NO.: OM21002

OM21000EH750-3 OM21003EH1100-3

TRANSMISSION TYPE AND SERIAL NUMBER TYPE: MFG. NO.:

OM21005

OM21006

CONTENTS MACHINE NUMBERS

SAFETY SIGNS ................................... S-31

SAFETY

COMPONENTS NAME ..........................1-1

Recognize Safety Information............................. S-1 Understand Signal Words ................................... S-1 Operator’s Qualifications..................................... S-2 Duties of the Operator ....................................... S-2 Inspect Rigid Dump Truck................................... S-2 Follow Safety Instructions ................................... S-3 Prepare for Emergencies .................................... S-3 Wear Protective Clothing .................................... S-4 Protect Against Noise ......................................... S-4 Protect Against Flying Debris.............................. S-4 General Precautions for Cab .............................. S-5 Use Handholds and Steps .................................. S-6 Adjust the Operator’s Seat.................................. S-6 Fasten Your Seat Belt......................................... S-7 Operate Only from Operator’s Seat .................... S-8 Jump Starting ...................................................... S-8 Keep Riders Off Rigid Dump Truck .................... S-8 Protect Against Falling Stones and Debris ......... S-9 Provide Signals for Jobs Involving Multiple Numbers of Vehicles..................................... S-9 Operate The Rigid Dump Truck Safely............. S-10 Avoid Injury From Running Over, Front and Back, And Front Wheel Crush Area .... S-11 Avoid Tipping .................................................... S-12 Avoid Injury From Rollaway Accidents ............. S-13 Never Travel With the Body Off The Frame ..... S-14 Operating With the Rigid Dump Truck Near Overhead Wires or Cables ......................... S-15 Operating With the Rigid Dump Truck Near High Voltage, Overhead Power Lines ........ S-15 Park Rigid Dump Truck Safely.......................... S-16 Safe Handling of Off Road Tires ....................... S-17 Discharge Accumulators ................................... S-17 Handle Fluids Safely-Avoid Fires...................... S-18 A Few Simple Rules When Servicing ............... S-19 Use Tools Properly ...........................................S-21 Prevent Burns ...................................................S-22 Replace Rubber Hoses Periodically ................. S-22 Avoid High-Pressure Fluids .............................. S-23 Fire Prevention Measures................................. S-24 Evacuating in Case of Fire................................ S-26 Beware of Exhaust Fumes................................ S-26 Precautions for Welding, Cutting, and Grinding.. S-27 Remove Paint before Welding or Cutting ......... S-27 Avoid Heating Near Pressurized Fluid Lines .... S-28 Avoid Applying Heat to Lines Containing Flammable Fluids ..................... S-28 Prevent Battery Explosions............................... S-29 Service Air Conditioning System Safely ........... S-29 Handle Chemical Products Safely .................... S-30 Dispose of Waste Properly ............................... S-30

OPERATOR’S STATION Cab Features....................................................... 2-1 Instrument Monitoring Panel ......................... 2-2 Speedometer........................................... 2-3 Coolant Temperature Gauge .................. 2-3 Fuel Gauge.................................................... 2-3 Tachometer ............................................. 2-3 Engine Lights .......................................... 2-4 LCD Display Main Screen....................... 2-4 Lights, Indicator....................................... 2-4 Blank (spare)...........................................2-4 Left/Right LCD Panel Buttons ................. 2-5 Monitoring Alarm System........................ 2-6 Position and Low Beam Indicator ........... 2-7 High Beam Indicator................................ 2-7 Active Traction Control Indicator............. 2-7 Electronic Downhill Speed Control Indicator......................... 2-7 Body Up Indicator.................................... 2-8 Load Weight Yellow (Amber) Light ......... 2-8 Load Weight Red Light ........................... 2-8 Engine Oil Pressure Indicator ................. 2-8 Alternator Indicator.................................. 2-9 Central Warning Caution Indicator.......... 2-9 Central Warning Stop Indicator............... 2-9 Parking Brake Indicator (Red)............... 2-10 Filter Indicator Light...............................2-10 Low Engine Coolant Level (Red) .......... 2-10 Low Transmission Oil Pressure (Red) .. 2-10 Transmission Oil Temperature (Red) ... 2-11 Brake Oil Pressure Indicator (Red)....... 2-11 Brake Oil Temperature Indicator (Red). 2-11 Seat Belt Indicator................................. 2-11 Steering Oil Pressure Indicator (Red)... 2-12 Low Fuel Level Indicator Light .............. 2-12 High Engine Coolant Temperature Light .................. 2-12 Left/Right LCD Panel Buttons ............... 2-12 Turn/Hazard Indicator ........................... 2-13 LCD Display – Main Screen.................. 2-13 Dash Controls.............................................. 2-16 Windshield Wiper and Washer Switch........................... 2-17 Headlight Switch ................................... 2-18 Instrument Lighting Rheostat ................ 2-18 Key Switch ............................................ 2-19 Parking Brake Switch............................ 2-19 Front Brake Cut-Off Switch ................... 2-19 Heater/Air Conditioner .......................... 2-20 ECC Controls ........................................ 2-21 ECC User Display ................................. 2-21

CONTENTS Modes of Operation.......................... 2-22 Error Messages .................................... 2-23 Auxiliary Backup Light Switch............... 2-24 Fog Light Switch ................................... 2-24 Engine Idle Timer Switch ...................... 2-24 EDSC Switch ........................................ 2-25 ATC Switch ........................................... 2-25 Heated Mirrors Switch .......................... 2-25 Rear View Camera Monitor .................. 2-26 Automatic Mode............................. 2-26 Manual Mode................................. 2-26 Marker ........................................... 2-27 Display Configuration .................... 2-27 Display Adjustments...................... 2-28 Groeneveld Lube System Display ........ 2-29 MP3 CD Player ..................................... 2-31 General Operation......................... 2-32 Tuner Operation ............................ 2-34 CD Player Operation ..................... 2-35 MP3/WMA Files............................. 2-36 Engine/Fuel Heater Timer .................... 2-37 Switching Off ................................. 2-37 Engine Pre-Heating ....................... 2-37 7 Day Programming/Operating Instructions ............................. 2-38 Boost Heating ................................ 2-39 Operation with 7 Day Digital Timer ...................................... 2-39 Programmed Heater Operation ..... 2-39 Pre-Selected Starting Times ......... 2-39 Operating Time.............................. 2-39 Remaining Operating Time ........... 2-39 Setting the Digital Timer ................ 2-39 Steering Wheel ........................................... 2-40 Hazard Warning Switch ........................ 2-40 Tilt/Telescope Steering Wheel.............. 2-40 Turn Signal/High Beam Lever Switch... 2-41 Horn Switch .......................................... 2-41 Pedal Location ............................................ 2-42 Pedal Location and Function Decal...... 2-42 Retarder Pedal...................................... 2-43 Brake Pedal .......................................... 2-43 Accelerator Pedal ................................. 2-44 Hoist Lever............................................ 2-44 Transmission Shift Selector.................. 2-45 Load/Dump Brake Switch ..................... 2-45 DC 24-Volt Power Port ......................... 2-45 Operator’s Seat Adjustment........................ 2-46 Mechanical Suspension Seat ............... 2-46 Air-Ride Seat ........................................ 2-46 Semi-Active Seat .................................. 2-47 Seat Belt...................................................... 2-48 Pasenger Seat ............................................ 2-48 Dome Light.................................................. 2-49 Body Down Indicator................................... 2-49

Engine Diagnostic Connectors.................... 2-49 Mirrors ......................................................... 2-50 Manual Release Valve ................................ 2-50 Battery Disconnect Switch .......................... 2-51 LCD Panel Software Guide ............................... 2-52

BREAK-IN Observe Rigid Dump Truck Closely .................... 3-1 Engine ........................................................... 3-1 Daily or Every 10 Hours ................................ 3-1 After the First 50 Hours ................................. 3-1

OPERATING THE RIGID DUMP TRUCK Inspect Rigid Dump Truck Daily before Starting .................................... 4-1 Pre-Operation Inspection EH750-3 and EH1100-3 .............................4-2 EH1700-3.................................................... 4-4 Pre-Operation Inspection Check Sheet............... 4-3 Pre-Operation Inspection Check Sheet............... 4-5 Leaks, Oil and Water Leaks Clean and Check All Lines and Hoses ... 4-6 Check Instruments before Starting...................... 4-7 Starting the Engine.............................................. 4-8 Starting in Warm Weather............................. 4-8 Starting in Cold Weather ............................... 4-9 Measures During Cold Weather.................. 4-10 Using Booster Batteries..................................... 4-11 Check Instruments after Starting....................... 4-13 Steering and Brake Accumulator Operation Tests..................................... 4-14 Steering Accumulator Test ................................ 4-15 Brake Accumulator Test .................................... 4-15 Test Completion ................................................ 4-15 Application ......................................................... 4-16 Startup and Traveling Empty....................... 4-16 Loading........................................................ 4-17 Loading Precautions ...................................4-20 Hauling ........................................................ 4-21 Dumping ...................................................... 4-23 Dumping Precautions.................................. 4-26 Stopping and Parking .................................. 4-27 Stopping the Engine .................................... 4-27 Parking/Overnight Storage Instructions ...... 4-28

OPERATING METHODS General Information............................................. 5-1 Cooling a Hot Engine .................................... 5-2 Transmission ................................................. 5-2 Automatic Shifting ......................................... 5-3 Mode Buttons ................................................ 5-4 Malfunction .................................................... 5-5 Lock-In-Range...............................................5-5 Reset Procedure ........................................... 5-6 Downshift or Reverse Inhibitor Feature ........ 5-6

CONTENTS Transmission Cold Weather Restrictions ..... 5-6 Accelerator Pedal.......................................... 5-7 Using The Retarder............................................. 5-7 Retarder Operation Decal............................. 5-9 Steering ............................................................... 5-9 Service Brakes .................................................... 5-9 Front Brake Cut-Off Switch ............................... 5-10 Electronic Downhill Speed Control (EDSC) .... 5-11 Electronic Downhill Speed Control Switch ...... 5-12 Active Traction Control...................................... 5-12 Active Traction Control System Boost Switch... 5-13 Parking Brake.................................................... 5-14 Load/Dump Brake ............................................. 5-14 Hill Hold ............................................................. 5-15 Operating the Body with the Hoist Lever .......... 5-16 Hoist Lever Functions ................................. 5-16 Raising the Body......................................... 5-17 Lowering the Body ...................................... 5-18 Rigid Dump Truck Stuck in Deep Sand, Snow or Mud............................................... 5-19 Rocking Out ................................................ 5-19 Towing .............................................................. 5-20 With Engine Operable................................. 5-21 With Engine Inoperable .............................. 5-22

TRANSPORTING THE RIGID DUMP TRUCK Transporting - General........................................ 6-1 Transporting EH750-3......................................... 6-2 Transporting EH1100-3....................................... 6-3 Loading Body ................................................ 6-5 Transporting EH1700-3....................................... 6-6 Loading Body ................................................ 6-7 Traveling on Roadways ...................................... 6-8

MAINTENANCE Correct Maintenance and Inspection Procedures . 7-1 Service Your Rigid Dump Truck at Specified Intervals ................................... 7-2 Check the Hour Meter Regularly ........................ 7-2 Use Correct Fuels and Lubricants ...................... 7-2 Prepare Rigid Dump Truck for Service ............... 7-3 Installing Body Prop Pins for EH750-3 ......... 7-4 Removal and Storage of Body Prop Pins ..... 7-6 Installing Body Prop Cable for EH1100-3 and EH1700-3 ........................................ 7-7 Electrical Disconnects Before Welding on the Rigid Dump Truck.......... 7-8 Grille Removal ............................................ 7-10 Recommended Lubricants for EH750-3, EH1100-3 and EH1700-3........... 7-11 Recommended Fuel.................................... 7-12 Hydraulic Oil Cleanliness Specification ............ 7-14 Maintenance Interval Guide (EH750-3) ............ 7-15 Maintenance Interval Guide (EH1100-3) .......... 7-16

Maintenance Interval Guide (EH1700-3)........... 7-17 A. Greasing........................................................ 7-18 B. Engine ...........................................................7-21 Check Engine Oil Level ............................... 7-22 Change Engine Oil ...................................... 7-24 Replace Engine Oil Filter ............................ 7-24 Check/Clean Crankcase Breather Tube ....... 7-26 Valve Lash................................................... 7-27 C. Transmission ................................................ 7-28 Check Transmission Oil Level..................... 7-29 Change Transmission Oil............................ 7-30 Replace Transmission Filter........................ 7-31 Clean Transmission Sump Strainer ............ 7-32 Clean Cooling Line Strainer ........................ 7-32 CheckTransmission Breather Element ....... 7-33 Check Differential Oil Level......................... 7-34 Change Differential Oil ................................ 7-34 Check Rear Planetary Hub Oil Level .......... 7-35 Change Rear Planetary Hub Oil.................. 7-36 Check Axle Breather Element ..................... 7-36 Replace Axle Breather Element .................. 7-36 D. Hydraulic Steering/Brake Apply System....... 7-37 Check Hydraulic Fluid Level/Steering ......... 7-38 Change Hydraulic Fluid............................... 7-39 Replace Hydraulic Filter .............................. 7-40 Check Steering Accumulator....................... 7-41 Check Brake Accumulator Capacity ........... 7-42 Check Brake Pressure Release Procedure 7-44 Check Hydraulic Hoses and Lines .............. 7-44 E. Hydraulic Hoist/Brake Cooling System ......... 7-45 Check Hydraulic Fluid Level/Hoist .............. 7-46 Change Hydraulic Fluid............................... 7-47 Replace, Hoist Filter Element...................... 7-48 Check Hydraulic Tank Breather Element.... 7-49 Replace Hydraulic Tank Breather Element. 7-49 Check Hydraulic Hoses and Lines .............. 7-49 F. Brakes, Service & Parking / Steering............ 7-50 Check Brake/Retarder Operation................ 7-51 Check Parking Brake .................................. 7-52 Check Steering Operation........................... 7-52 G. Fuel System.................................................. 7-53 Drain Fuel Tank Sediment .......................... 7-54 Drain Fuel-Water Separator ........................ 7-55 Replace Fuel-Water Separator ................... 7-56 Check Fuel Tank Mounting ......................... 7-58 Check Hoses and Lines .............................. 7-59 Replace Fuel Filters .................................... 7-60 H. Air Cleaner....................................................7-61 Check Vacuator Valve................................. 7-62 Check/Clean Dust Cup................................ 7-63 Service Air Cleaner, Primary Element......... 7-64 Service Air Cleaner, Safety Element........... 7-66 Check Air Intake Lines and Clamps............ 7-68 I. Cooling System .............................................. 7-69 Check Coolant Level ................................... 7-70

CONTENTS Check SCA ................................................. 7-72 Coolant Change and Flush System............ 7-73 Replace Coolant Filter..................................... 7-74 Check Cooling Fan ..................................... 7-75 Clean Radiator ............................................ 7-75 Check Fan Belt ........................................... 7-76 J. Electrical System........................................... 7-77 Check Battery Condition ............................. 7-78 Check Battery Cables and Connections..... 7-79 Check Electrical Wiring and Connections .. 7-79 Check Fuse/Relay ...................................... 7-80 Check Neutral Start Circuit ......................... 7-83 Check Exterior Lights.................................. 7-84 Check Back-up Alarm................................. 7-85 Check Horn................................................. 7-85 Check Gauges ............................................ 7-86 Check Indicator Lights ................................ 7-86 Headlight Aiming......................................... 7-87 Check Alternator/Air Conditioning Belt ....... 7-88 K. Suspension, Wheels & Tires ........................ 7-89 Tire Inflation Chart ...................................... 7-89 Check Struts ............................................... 7-90 Check Wheels............................................. 7-91 Check Front Wheel Lubricant ..................... 7-91 Change Front Wheel Lubricant................... 7-91 Check Tire Inflation..................................... 7-92 Check Tire Condition .................................. 7-93 Check Wheel Alignment ............................. 7-93 L. Cab................................................................ 7-94 Clean/Change Air Filter .............................. 7-95 Clean/Change Air Conditioner Filters......... 7-96 Check Mounts............................................. 7-97 Check Wiper Blade Condition..................... 7-97 Check Windshield Washer Fluid Level....... 7-98 Check Seat Belt and Mounting ................... 7-99 Replace Seat Belt ....................................... 7-99 Check Air Conditioning ............................. 7-100 Check Heater and Defroster..................... 7-100 M. General ...................................................... 7-101 Check for Fluid Leaks ............................... 7-102 Check Body Prop Pins or Cable ............... 7-102 Check Main Rail, Strut and Axle Lug Welds ............................. 7-103 Check Frame Assembly ........................... 7-103 Check Tightening Torque of Bolts and Nuts .................................. 7-103 Maintenance of Optional Systems .................. 7-115 Webasto Coolant/Fuel Heater .................. 7-115 Initial Operation ................................. 7-115 Annual Preventative Maintenance .... 7-116 Troubleshooting................................. 7-117 Rear View Camera System ...................... 7-119 Troubleshooting................................. 7-119 Groeneveld Auto Lube System................. 7-124 Annual Preventative Maintenance .... 7-124

System Testing .................................. 7-124 Locating Doser Blocks that Leak ....... 7-125 Bleeding the System..........................7-125 Troubleshooting Charts ..................... 7-127 ATC/EDSC ................................................ 7-130 Error Check........................................ 7-130 System Diagnostic Procedure ........... 7-131 ATC Function Test.............................7-131 EDSC System Function Test .............7-132 Alternate Procedure.................... 7-132 System Diagnostic Procedure ........... 7-132 ATC System Function Test................ 7-134 Ansul Fire Protection System.................... 7-135 Monthly Inspection.............................7-138 Semi-Annual Examination ................. 7-139 Recharge Procedure.......................... 7-141 Haultronic Loadweigh System .................. 7-142 Calibration.......................................... 7-142 Downloading Records........................ 7-144 Lincoln Auto Lube System ........................ 7-145 Setting and Operation of Controls ..... 7-145 Maintenance ......................................7-148 Pump Troubleshooting....................... 7-149 System Troubleshooting .................... 7-150 Tightening Torques............................7-152

STORAGE Storage of Hitachi Rigid Dump Truck.................. 8-1 Short Term Storage......................................... 8-1 Moderate Term Storage..................................8-3 Long Term Storage ......................................... 8-5 Return to Service ............................................ 8-7

TROUBLESHOOTING Engine ................................................................. 9-1 Engine Coolant ....................................................9-4 Drive Coupling ..................................................... 9-4 Starter And Mounting .......................................... 9-5 Air Cleaner........................................................... 9-5 Transmission ....................................................... 9-7 Electrical System ............................................... 9-12 Hydraulic System............................................... 9-15 Hydraulic Hoist System ..................................... 9-18 Hydraulic Steering System ................................ 9-19 Steering Pump...................................................9-20 Steering Control Valve ...................................... 9-21 Front Axle .......................................................... 9-22 Rear Axle........................................................... 9-24 Front Driveshaft ................................................. 9-25 Reat Driveshaft.................................................. 9-25 Differential ......................................................... 9-26 Rear Axle Planetary .......................................... 9-27 Dry Disc Parking Brake ..................................... 9-28

CONTENTS SPECIFICATIONS Engine .............................................................. 10-1 Power Transmission ......................................... 10-1 Drive Axle.......................................................... 10-2 Planetary ................................................... 10-2 Differential ................................................. 10-2 Tires .............................................................. 10-2 Travel Speeds ................................................... 10-3 Electrical System............................................... 10-3 Batteries ...................................................... 10-3 Alternator .................................................... 10-3 Starting Motor ............................................. 10-3 Lights........................................................... 10-4 Body Capacities ................................................ 10-4 Machine Weights............................................... 10-4 Steering System................................................ 10-5 Hydraulics ......................................................... 10-5 Brakes .............................................................. 10-5 Front............................................................ 10-5 Rear ............................................................ 10-5 Parking ........................................................ 10-5 Retarder ...................................................... 10-6 ROPS/FOPS Cab.............................................. 10-6 Sound Levels .............................................. 10-6 Machine Dimensions......................................... 10-7 Retarder Charts............................................... 10-10 Performance Charts........................................ 10-17

OPTIONS Cold Weather Packege-Mild Cold......................11-1 Cold Weather Packege-Extreme Cold ...............11-1 Auxiliary Backup Lights......................................11-1 Deck Mounted Muffler On Exhaust System.......11-1 Additional Reverse Lamp...................................11-2 Sound Suppression............................................11-2 Fog Lights ..........................................................11-2 Heated Mirrors ...................................................11-3 Hill Hold..............................................................11-3 Fluid Sampling Ports ..........................................11-3 Engine Access Ladders .....................................11-3 Engine Compartment Lights ..............................11-4 Engine Ground Level Shutdown Switch ............11-4 Body ...................................................................11-4 Haultronics III .....................................................11-5 ATC with EDSC..................................................11-5 Circuit Breakers..................................................11-5 Battery Equalizer................................................11-5 Side-Mounted Rear View Camera .....................11-6 Centralized Lubrication Systems .......................11-6 Centralized Manual Lubrication ..................11-6 Lincoln Automatic Lubrication .....................11-6 Groeneveld Automatic Lubrication..............11-6 Deck Mounted Fire Extinguisher........................11-7 Manually Actuated Ansul....................................11-7 Service Center ...................................................11-7

Premium Lights.................................................. 11-7

INFORMATION FEEDBACK ................... 12-1 ALPHABETICAL INDEX...........................13-1

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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 (Jurisdiction) 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.

S-1

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

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

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

DUTIES OF THE OPERATOR Before operating the rigid dump truck, this manual must be read and understood. Contact your supervisor if you do not understand any portion of this manual. By reading and understanding the manual, you will become aware of and observe how to avoid injury and damage.

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

Due to the position of the cab and size of the rigid dump truck, the operator has limited visibility to areas close to or near the rigid dump truck. No person should enter the operating area of the rigid dump truck when it is in operation without first notifying the operator. If a person has to enter the operating area of the rigid dump truck, they should signal the operator and wait for an acknowledgement of recognition by the operator.

During rigid dump truck operation no one should be allowed to get any closer than 7m (23 ft.). Any closer will limit one’s time to react and move away from the vehicle when it starts.

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 RIGID DUMP TRUCK section in this operator’s manual.

SA-435

S-2

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 its life.

The safety messages in this SAFETY chapter are intended to illustrate basic safety procedures of the rigid dump truck. 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 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.

S-3

SA-437

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. This may be necessary when working outside of the cab, during the Pre-Operation Inspection, for example.

SA-434

PROTECT AGAINST FLYING DEBRIS If flying debris hits 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 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 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.

S-5

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 it 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 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.

EL20273

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 rigid dump truck.

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

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

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.

S-6

SA-378

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

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.

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.

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

S-7

SA-237

SAFETY 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 activated.

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 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 or a runaway 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.

EL20369

S-8

SAFETY PROTECT AGAINST FALLING STONES AND DEBRIS 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.

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

S-9

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 vehicle 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 vibration as possible.

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

Pick the smoothest path for the rigid dump truck.

Adjust the speed of the rigid dump truck to the terrain, and driving conditions.

S-10

EL14019

SAFETY AVOID INJURY FROM RUNNING OVER, FRONT AND BACK, AND FROM 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 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 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.

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

EL20371

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 rigid dump truck at safe distance from the edge of cliffs and slide areas. There is the danger of tipping or roll 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 protection structures (ROPS) according to the adopted standard for this rigid dump truck.

THE OPERATOR AND PASSENGER SHOULD NOT ATTEMPT TO JUMP CLEAR OF A TIPPING RIGID DUMP TRUCK --- SERIOUS OR FATAL CRUSHING INJURIES WILL RESULT. A 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, 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.

S-12

EL20373

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

S-13

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 hits against 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

S-14

SAFETY OPERATING 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 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 dump 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 site.

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 shall be equipped for such operations.

S-15

EL20377

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