Hitachi EH1100 Rigid Dump Truck Service Repair Manual

HITACHI

EH1100 423LD SERVICE MANUAL EDITION 1

PUBLICATION NO. 10215ENG. DISTRIBUTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

DLR/BRCH

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

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

SERVICE PHONE NO

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SPARE PARTS PHONE NO

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

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

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

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

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

9/01

PRINTED IN U.S.A.

GROUP 0

EH1100 GENERAL SERVICE INFORMATION FORM/PUBLICATION NO. GROUP 091

9/01

TITLE Service Position and Safety Instructions

423LD SM857

PUBLICATION 10215

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”

EL19641

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 cable.

4. The wheels blocked.

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 SM857

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 cable.

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

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.

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 SM857

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.

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.

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.

Form SM857

GROUP 091 Page 4 SERVICE POSITION AND SAFETY INSTRUCTIONS

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 driveshaft 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.

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

V50389A

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.

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 SM857

GROUP 1

EH1100 SERVICE AND OPERATOR’S INDEX FORM/PUBLICATION NO. GROUP 161 161 170 179

9/01

TITLE Automatic Centralized Lubrication Centralized Lubrication Machine Specifications Special Tools

423LD SM481R2 SM756R1 SM858 SM331R6

PUBLICATION 10215

GROUP 161 Page 1

AUTOMATIC CENTRALIZED LUBRICATION SYSTEM .

ELI18618

Figure 1 - Automatic Centralized Lubrication System, Model View 1. Electric Pump Station 2. Master Valve 3. Secondary Valve #1

DESCRIPTION

4. Secondary Valve #4 5. Secondary Valve #2 6. Secondary Valve #3

OPERATION Numbers in parentheses refer to Figure 1.

Numbers in parentheses refer to Figures 1 & 1A.

The Automatic 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 master valve (2), and the secondary valves (3, 4, 5, & 6) that direct lubricant to the various components on the machine.Typical wiring of this system is shown in Figure 2. Individual details of each component are shown in Figures 5-- 10.

This system is a single line, series progressive system in which a lubricant source supplies lubricant flow through a single supply line to the system.The single supply carries the lubricant to the divider valve.The dipensing pistons of the divider valve are �in line�, that is, the source is directly connected to each piston progressively through unique, internal porting. Each piston is in turn moved by the lubricant flow and the preceding piston must move before the next piston can.

The divider valve is ported such that when all pistons have moved in one direction, lubricant flow is diverted automatically to move them progressively in the opposite direction. Refer to Figures 10 &11.

Form SM481R2

GROUP 161 Page 2 AUTOMATIC CENTRALIZED LUBRICATION SYSTEM .

EL16636

Figure 1A - Automatic Centralized Lubrication System, Schematic 1. Electric Pump Station 2. Master Valve 3. Secondary Valve #1

4. Secondary Valve #4 5. Secondary Valve #2 6. Secondary Valve #3

Form SM481R2

GROUP161 Page 3 AUTOMATIC CENTRALIZED LUBRICATION SYSTEM

Note: The timer is set to call for a lube cycle when the ignition is turned off for more than two hours. When the ignition switch is turned on after less than two hours, the timer will pick up from when the ignition switch was turned off. When the ignition switch is turned on after greater than two hours, the pump will cycle for the length of time set and then will shut off.The timer will count the length of time set as off time and will then initiate another lube cycle. ON TIME-- 6 Minutes/ OFF TIME-- 60 Minutes EL16643

Figure 2 - Typical Electrical Wiring, Centralized Lube System

OPERATION (cont’d) This progressive movement or cycling continues as long as lubricant flow is maintained.

Should a piston be unable to deliver its measured volume, the cycling of all pistons is stopped. Lubricant flow will be stopped and the lubricant pressure will increase. As long as there is no lubricant flow in the system none of the pistons will move.

This system can be described as a dividing system.

The length of stroke and diameter of each piston determines how much lubricant is displaced during each cycle of that piston. Therefore, the total lubricant flow can be divided into different values dependent on the displacements of the pistons chosen to make up the divider valve.

In a typical system, the pump supplies a quantity of lubricant to the master valve which divides the lubricant into smaller quantities in proportion to the valve sizes used. Each of these proportioned quantities is either dispensed to secondary divider valves where it is further divided into smaller proportioned quantities which are then dispensed to bearings. Performance

indicators (Figure 10, Item7) are used to signal excessive system pressure due to a blocked lube line or stalled divider valve piston.They mount into the alternate outlet port of the divider valve and will give you a ”localized” visual indication of excessive pressure.

Cycle indicator pins (Figure 10, Item 3) are an extension of the piston in the divider valve and will cycle back and forth as the piston cycles to provide a positive indication of system operation.

The ”OFF” timer begins accumulating time when the ignition switch closes. When the ”OFF” timer reaches the preset value the pump will turn on.The pump remains activated for the period of time that is preset on the ”ON” timer.

When the ignition switch opens, the ”OFF” timer will retain its accumulated time for a period of five days.

When the ignition switch closes during the five day period, the ”OFF” timer will resume timing from the accumulated time it reached prior to the ignition switch opening. If the ignition switch is not closed before the end of the five day period, the timer will begin with an ”ON” period. Remove the sealing plug (9), Figure 4, to access manual lube switch, timer adjustments or to view the system LED’s.

Form SM481R2

GROUP 161 Page 4 AUTOMATIC CENTRALIZED LUBRICATION SYSTEM

ELI

Figure 3 - Timer Settings

9

EL16637

Figure 4 - Electric Pump Station 1.

2.

3.

4.

Electric Pump Hex Capscrews, Nuts, Washers Support Bracket Reservoir

5.

6.

7.

8.

9.

Run Tee Safety Valve Union Lubricant Pressure Gauge Sealing Plug Form SM481R2

GROUP161 Page 5 AUTOMATIC CENTRALIZED LUBRICATION SYSTEM

EL16638

Figure 5 - Master Valve 1.

2.

3.

4.

5.

6.

7.

Mounting Bracket Inlet Baseplate End Baseplate Intermediate Baseplate Hex Bolt, Flat Washer,Nut Metering Valve,40T, Rt Hand Metering Valve,30S

8.

9.

10.

11.

12.

13.

14.

Metering Valve,10S 15. Bushing Closure Plug 16. Leakproof Grease Ftg. Straight Adapter,1/8NPT 17. Tie Rods 90 Degree Adapter,1/8NPT 90 Degree Adapter, 1/4NPT Reset Press.Ind.,6900kPa (1,000psi.)

Service Tee

Form SM481R2

GROUP 161 Page 6 AUTOMATIC CENTRALIZED LUBRICATION SYSTEM

EL16639

Figure 6 - Secondary Divider Valve #1 1.

2.

3.

4.

5.

6.

7.

Mounting Bracket Inlet Baseplate End Baseplate Intermediate Baseplate Hex Bolt, Flat Washer,Nut Metering Valve 20T Metering Valve 10S

8.

9.

10.

11.

12.

13.

14.

Metering Valve 25T Metering Valve 35T Closure Plug Straight Adapter,1/8NPT 45 Degree Adapter, 1/8NPT 90 Degree Adapter, 1/8NPT 90 Degree Adapter, 1/4NPT

15. Tie Rods

Form SM481R2

GROUP161 Page 7 AUTOMATIC CENTRALIZED LUBRICATION SYSTEM

2

11

11

EL16640

Figure 7 - Secondary Divider Valve #2 1.

2.

3.

4.

5.

6.

Mounting Bracket Inlet Baseplate End Baseplate Intermediate Baseplate Hex Bolt, Flat Washer,Nut Metering Valve 20T

7.

8.

9.

10.

11.

Metering Valve 30T Metering Valve 15T 90 Degree Adapter,1/4NPT Straight Adapter,1/8NPT Tie Rods

Form SM481R2

GROUP 161 Page 8 AUTOMATIC CENTRALIZED LUBRICATION SYSTEM

EL16641

Figure 8 - Secondary Divider Valve #3 1.

2.

3.

4.

5.

6.

Mounting Bracket Inlet Baseplate End Baseplate Intermediate Baseplate Hex Bolt, Flat Washer,Nut Metering Valve 10S

7.

8.

9.

10.

11.

12.

Metering Valve 35S 90 Degree Adapter,1/4NPT Closure Plug 45 Degree Adapter,1/8NPT 45 Degree Adapter,1/4NPT Tie Rods

Form SM481R2

GROUP161 Page 9 AUTOMATIC CENTRALIZED LUBRICATION SYSTEM

EL16642

Figure 9 - Secondary Divider Valve #4 1.

2.

3.

4.

5.

6.

7.

Mounting Bracket Inlet Baseplate End Baseplate Intermediate Baseplate Hex Bolt, Flat Washer,Nut Metering Valve 20T Metering Valve 10T

8.

9.

10.

11.

12.

13.

14.

Metering Valve 25T Closure Plug Metering Valve 35T Straight Adapter,1/8NPT 45 Degree Adapter, 1/8NPT 90 Degree Adapter, 1/8NPT 90 Degree Adapter, 1/4NPT

15. Tie Rods

Form SM481R2

GROUP 161 Page 10 AUTOMATIC CENTRALIZED LUBRICATION SYSTEM

7

EL16644

Figure 10 - Exploded View of Divider Valve 1.

2.

3.

4.

5.

6.

7.

Tie Rod Nut End Baseplate Cycle Indicator Tie Rod Inlet Baseplate Intermediate Baseplate Performance Indicator

8.

9.

10.

11.

12.

13.

14.

Divider Valve Piston Divider Valve O-- ring Divider Valve Piston Bore Plug Alternate Outlet Bore Plug O-- ring Mounting Screw

A. Lubricant Inlet B. Lubricant Outlet C. Alternate Outlet Port

Form SM481R2

GROUP161 Page 11 AUTOMATIC CENTRALIZED LUBRICATION SYSTEM

The inlet passageway is connected to all piston chambers at all times with only one piston free to move at any one time.With all pistons at the far right, lubricant from the inlet flows against the right end of piston 1.

Lubricant flow shifts piston 1 from right to left, dispensing lube through connecting passages to outlet 1.The shifting of piston 1 directs the lubricant flow against right side of piston 2.

Lubricant flow shifts piston 2 from right to left, dispensing lube through valve ports of piston 1 and through outlet 2.

Piston 2 shift directs lubricant flow against right side of piston 3.

Lubricant flow shifts piston 3 from right to left, dispensing lube through valve ports of piston 2 and through outlet 3.

Piston 3 shifts and directs lubricant through connecting passage to the left side of piston 1.

Lubricant flow against left side of piston 1 begins the second half cycle which shifts pistons from left to right, dispensing lubricant through outlets 4,5, and 6 of the divider valve.

EL16645

Figure 11 - Cutaway of Divider Valve Form SM481R2

GROUP 161 Page 12 AUTOMATIC CENTRALIZED LUBRICATION SYSTEM

TROUBLESHOOTING BLOCKAGE If blockage has occured anywhere in the system, the system will cease to operate. If the pump continues to provide lubricant, the pressure will start to increase and the excessive pressure will first be evident at the pressure gauge, the performance indicators will be exceeded next, and last the pressure relief valve.

If the blockage has created pressure to exceed a performance indicator on the master valve, that indicates the blockage is in the portion of the system supplied by the outlet monitored by that performance indicator.Proceed to the secondary divider valve which is downstream from that outlet port and remove each alternate outlet port which is common to a discharge port. Cycle the pump. If lubricant flows freely from each alternate outlet port, then the blockage is not in the secondary valve, but in one of the supply lines downstream from it. Install the alternate outlet plugs and cycle the pump to build pressure in the system.When sufficient pressure is achieved, stop the pump.

Loosen each outlet hose connection in turn. When the fitting of the blocked line is loosened, lubricant will flow under pressure from that fitting. If the line is in good condition, then the blockage is in the bearing inlet or fitting.

If the open alternate outlet ports of the secondary valve did not discharge lubricant when the pump cycled, then the blockage is in the secondary divider valve itself. The secondary divider valve must be disassembled and cleaned.

Make sure that all pistons are replaced in their original bores and that all the metering valves are located in their same position on the secondary valve. ( It is recommmended that you make a detailed drawing of the position of all components before any work is carried out on the divider valve).

After the entire divider valve has been cleaned and assembled, test the operation with a manual lubricant pump.

When lubricant is pumped into the inlet of the divider valve it will be discharged out the discharge ports alternating progressively from one to the next.

If the master divider valve is not equipped with performance indicators, remove each alternate outlet port which is common to a discharge port. Cycle the pump. If lubricant flows feely from each alternate port, then blockage is downstream of the master valve. Replace the alternate outlet port plugs and cycle the pump to build pressure in the system. When sufficient pressure is achieved, stop the pump. Loosen each outlet hose connection in turn. When you loosen the fitting of the hose feeding the blocked portion of the system, lubricant will flow under pressure from it.

Proceed to the secondary valve on the downstream side of that fitting.

If lubricant did not flow from the open alternate ports of the master valve, then the blockage is in the master valve itself. It must be cleaned, rebuilt and tested.

Any new lines or rebuilt divider valves must be filled with lubricant before they are returned to the system. They can be charged with either a manual or an air driven greaser.

When the internal components of the metering valves are cleaned, any scoring or physical damage to the components will require that they be replaced.

All servicing should be carried out under the cleanest possible conditions.

Form SM481R2

GROUP161 Page 13 AUTOMATIC 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.

Pressure relief exceeded.

Performance indicators exceeded.

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.

Blocked divider valve.

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.

Leakage at divider valve.

Check for loose screws or tie rod nuts. Check for damaged gasket plates and replace if necessary.

Form SM481R2

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