Hitachi EH1700-3 Rigid Dump Truck operator’s manual SN 8R6AA-0001001 and Up

Manual No. EM8R4-1-2

Operator’s Manual

Rigid Dump Truck

Serial No. EH750-3 EH1100-3

411TDD: 77598 and Up 441LDD: 77589 and Up

CONTENTS MACHINE NUMBERS

SAFETY SIGNS ................................... S-32

SAFETY

COMPONENTS NAME ..........................1-1 OPERATOR’S STATION

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

Cab Features....................................................... 2-1 Monitor Panel ................................................2-2 Brake/Steer Hydraulic Oil Pressure Gauge ................................ 2-3 Fuel Gauge.................................................... 2-3 Coolant Temperature Gauge .................. 2-3 Converter Oil Temperature Gauge ......... 2-4 Brake Cooling Oil Temperature Gauge .. 2-4 Hour Meter .............................................. 2-4 Speedmeter............................................. 2-4 Odometer ................................................ 2-5 Tachometer ............................................. 2-5 Engine Light ............................................2-5 Haultrinic IIITM Load Monitoring System ....................... 2-5 Load Counter .......................................... 2-5 Monitoring Alarm System........................ 2-6 Engine Stop Indicator.............................. 2-7 Caution Indicator ..................................... 2-7 Engine Oil Pressure Indicator ................. 2-8 Engine Coolant Level Indicator ............... 2-8 Engine Malfunction Indicator................... 2-8 Battery Charging System Indicator ......... 2-8 Transmission Malfunction Indicator ........ 2-8 Transmission Oil Pressure Indicator....... 2-8 Filter, Air, Steer, Hoist, Transmission Indicator....... 2-8 Steering Hydraulic Oil Temperature Indicator ........................ 2-8 Steering Hydraulic Oil Pressure Indicator ............................. 2-9 Brake Hydraulic Oil Pressure Indicator... 2-9 Parking Brake Indicator........................... 2-9 Active Traction Control Indicator............. 2-9 Electronic Downhill Speed Contol (EDSC)Indicator .......... 2-9 ATC/EDSC Error Indicator ...................... 2-9 Turn Hazard Indicator ............................. 2-9 High Beam Indicator................................ 2-9 Body Up Indicator .................................... 2-9 Instrument Panel ......................................... 2-10 WindShield Wiper and Washer Switch........................ 2-11 Headlight Switch ................................... 2-12 Instrument Lighting Rheostat ................ 2-12 Key Switch ............................................ 2-13 Front Brake Cut-Off Switch ................... 2-13 Parking Brake Switch............................ 2-13 Heater/Air Conditioner .......................... 2-14 ECC Controls ........................................ 2-15 ECC User Display ................................. 2-15

CONTENTS Modes of Operation .............................. 2-17 Steering Wheel ..................................... 2-18 Hazard Warning Switch ........................ 2-18 Tilt/Telescope Steering Wheel.............. 2-18 Turn Signal/High Beam Lever Switch... 2-19 Horn Switch .......................................... 2-19 Pedal Location ............................................ 2-20 Pedal Location and Function Decal...... 2-20 Retarder Pedal...................................... 2-21 Brake Pedal .......................................... 2-21 Accelerator Pedal ................................. 2-22 Hoist Lever............................................ 2-22 Transmission Shift Selector.................. 2-23 Load/Dump Brake Switch ..................... 2-23 DC 24-Volt Power Port ......................... 2-23 Operator’s Seat Adjustment........................ 2-24 Standard Seat ....................................... 2-24 Seat Belt...................................................... 2-25 Pasenger Seat ............................................ 2-25 Dome Light.................................................. 2-26 Body Down Indicator................................... 2-26 Engine Diagnostic Connectors ................... 2-26 Mirrors ......................................................... 2-27 Manual Release Valve................................ 2-27 Battery Disconnect Switch .......................... 2-28

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

Lock-In-Range for EH750-3&EH1100-3 ....... 5-6 Reset Procedure ........................................... 5-7 Downshift or Reverse Inhibitor Feature ........ 5-7 Using The Retarder....................................... 5-8 Retarder Operation Decal ........................... 5-10 Performance Chart ............................................ 5-11 Retarder Charts.................................................5-12 Transmission Cold Weather Restrictions.......... 5-16 Accelerator Pedal ..............................................5-16 Steering ............................................................. 5-17 Service Brakes ..................................................5-17 SupplementarySteering and Brake Operation Test ........................... 5-18 Before The Test................................................. 5-18 Steering Accumulator Test ................................ 5-19 Brake Accumulator Test .................................... 5-19 Test Completion ................................................ 5-20 Front Brake Cut-Off Switch ............................... 5-20 Electronic Downhill Speed Control (EDSC) .... 5-20 Electronic Downhill Speed Control Switch ...... 5-21 Active Traction Control ...................................... 5-22 Engine Overspeed Protection ........................... 5-23 Parking Brake ....................................................5-23 Load/Dump Brake .............................................5-23 Operating the Body with the Hoist Lever........... 5-24 Rigid Dump Truck Stuck in Deep Sand, Snow or Mud....................................................5-27 Rocking Out................................................. 5-27 Towing .............................................................. 5-28 With Engine Operable ................................. 5-29 With Engine Inoperable............................... 5-30 Parking The Rigid Dump Truck ......................... 5-31

OPERATING THE ENGINE Inspect Rigid Dump Truck Daily before Starting.................................... 4-1 Daily Walk Around Inspection ........................... 4-2 Daily Walk Around Inspection Check Sheet ....... 4-3 Leaks, Oil and Water Leaks Clean and Check All Lines and Hoses ... 4-4 Check Instruments before Starting ..................... 4-5 Starting the Engine.............................................. 4-6 Starting in Warm Weather ............................ 4-6 Starting in Cold Weather............................... 4-7 Measures During Cold Weather ................... 4-8 Check Instruments after Starting ........................ 4-9 Using Booster Batteries .................................... 4-10 Stopping the Engine.......................................... 4-12

OPERATING THE RIGID DUMP TRUCK Loading................................................................6-1 Hauling ................................................................ 6-5 Dumping .............................................................. 6-6 Dumping Precautions .......................................... 6-7 Stopping .............................................................. 6-8 Overnight Storage Instructions............................ 6-8

TRANSPORTING THE Rigid Dump Truck Transporting - General ........................................ 7-1 Transporting EH750-3 .........................................7-2 Transporting EH1100-3 .......................................7-3 Traveling on Roadways....................................... 7-5

MAINTENANCE OPERATING METHODS General Information ............................................ 5-1 Cooling a Hot Engine .................................... 5-2 Transmission................................................. 5-2 Automatic Shifting ......................................... 5-3 Mode Buttons................................................ 5-4 Status Lights ................................................. 5-5

Correct Maintenance and Inspection Procedures.. 8-1 Service Your Rigid Dump Truck at Specified Intervals ................................... 8-2 Check the Hour Meter Regularly......................... 8-2 Use Correct Fuels and Lubricants....................... 8-2 Prepare Rigid Dump Truck for Service ............... 8-3

CONTENTS Installing Body Prop Pins for EH750-3 ......... 8-4 Removal and Storage of Body Prop Pins ..... 8-6 Installing Body Prop Cable for EH1100-3..... 8-7 Electrical Disconnects Before Welding on the Rigid Dump Truck.......... 8-8 Recommended Lubricants ................................ 8-11 Recommended Fuel.................................... 8-12 Maintenance Interval Guide (EH750-3) ............ 8-13 Maintenance Interval Guide (EH1100-3) .......... 8-14 A. Greasing ............................................... 8-15/8-21 B. Engine........................................................... 8-24 Check Engine Oil Level............................... 8-25 Change Engine Oil...................................... 8-26 Replace Engine Oil Filter ............................ 8-26 Check and Clean Crankcase Breather Tube 8-28 Adjust, Valves / Injectors............................. 8-28 C. Transmission ................................................ 8-29 Check Transmission Oil Level .................... 8-30 Change Transmission Oil ........................... 8-31 Replace Transmission Filter ....................... 8-31 Clean Transmission Sump Strainer ............ 8-33 Clean Cooling Line Strainer........................ 8-33 CheckTransmission Breather ..................... 8-34 Replace Transmission Breather ................. 8-34 Check Differential Oil Level ........................ 8-35 Change Differential Oil................................ 8-35 Check Rear Planetary Hub Oil Level .......... 8-36 Change Rear Planetary Hub Oil ................. 8-36 Check Axle Breather Element..................... 8-37 Replace Axle Breather Element.................. 8-37 D. Hydraulic Steering/Brake Apply System ...... 8-38 Check Hydraulic Fluid Level/Steering......... 8-39 Change Hydraulic Fluid .............................. 8-40 Replace Hydraulic Filter.............................. 8-42 Check Steering Accumulator ...................... 8-43 Check Brake Accumulator Capacity ........... 8-44 Check Barke Pressure Release Procedure 8-45 Check Hydraulic Hoses and Lines.............. 8-45 E. Hydraulic Hoist/Brake Cooling System......... 8-46 Check Hydraulic Fluid Level/Hoist .............. 8-47 Change Hydraulic Fluid .............................. 8-48 Replace, Hoist Filter.................................... 8-50 Check Hydraulic Tank Breather Element ... 8-51 Replace Hydraulic Tank Breather Element 8-51 Check Hydraulic Hoses and Lines.............. 8-51 F. Brakes, Service & Parking / Steering ........... 8-52 Check Brake Operation .............................. 8-53 Check Parking Brake...............................................8-54 Check Steering Operation .......................... 8-54 G. Fuel System ................................................. 8-55 Drain Fuel Tank Sediment .......................... 8-56 Drain Fuel-Water Separator........................ 8-57 Replace Fuel Filter...................................... 8-58 Check Fuel Tank Mounting ....................................8-60 Check Hoses and Lines.............................. 8-60

H. Air Cleaner....................................................8-61 Check Vacuator Valve................................. 8-62 Check/Clean Dust Cup................................ 8-62 Service Air Cleaner, Primary Element......... 8-63 Service Air Cleaner, Safety Element........... 8-65 Check Air Intake Lines and Clamps............ 8-66 I. Cooling System .............................................. 8-67 Check Coolant Level ................................... 8-68 Check SCA.................................................. 8-69 Coolant Change and Flush System ............ 8-72 Replace Coolant Filter .................................... 8-73 Check Cooling Fan...................................... 8-74 Clean Radiator ............................................8-74 Check Fan Belt............................................8-75 J. Electrical System ........................................... 8-76 Check Battery Condition ............................. 8-77 Check Battery Cables and Connections ..... 8-78 Check Electrical Wiring and Connections... 8-78 Check Fuse/Relay....................................... 8-79 Check Neutral Start Circuit ......................... 8-82 Check Exterior Lights.................................. 8-82 Check Back-up Alarm ................................. 8-83 Check Horn .................................................8-83 Check Gauges ............................................8-83 Check Indicator Lights ................................ 8-83 Headlight Aiming ......................................... 8-84 Check Alternator/Air Conditioning Belt ....... 8-85 K. Suspension, Wheels & Tires......................... 8-86 Check Struts................................................ 8-87 Check Wheels ............................................. 8-88 Check Front Wheel Lubricant ..................... 8-88 Change Front Wheel Lubricant ................... 8-88 Check Tire Inflation ..................................... 8-89 Check Tire Condition .................................. 8-90 Check Wheel Alignment.............................. 8-90 L. Cab ................................................................ 8-91 Clean/Change Air Filter............................... 8-92 Clean/Change Air Conditioner Filters ......... 8-93 Check Mounts .............................................8-94 Check Wiper Blade Condition ..................... 8-94 Check Windshield Washer Fluid Level ....... 8-94 Check Seat Belt and Mounting ................... 8-95 Check Air Conditioning ............................... 8-96 Check Heater and Defroster ....................... 8-96 M. General.........................................................8-97 Check for Fluid Leaks ................................. 8-98 Check Body Prop Pins or Cable ................. 8-98 Check Main Rail, Strut and Axle Lug Welds............................... 8-99 Check Frame Assembly.............................. 8-99 Check Tightening Torque of Bolts and Nuts ................................... 8-99 Torque Values ...................................8-104 to 8-127

CONTENTS STORAGE Storage of Hitachi Rigid Dump Truck ................. 9-1 Short Term Storage ....................................... 9-1 Moderate Term Storage ................................ 9-3 Long Term Storage........................................ 9-5 Return to Service........................................... 9-7

TROUBLESHOOTING Engine ............................................................... 10-1 Engine Coolant.................................................. 10-4 Drive Coupling................................................... 10-4 Starter And Mounting ........................................ 10-5 Air Cleaner ........................................................ 10-5 Transmission..................................................... 10-7 Electrical System............................................. 10-12 Hydraulic Sysem ............................................. 10-15 Hydraulic Hoist System................................... 10-18 Hydraulic Steering System.............................. 10-19 Steering Pump ................................................ 10-20 Steering Control Valve .................................... 10-21 Front Axle........................................................ 10-22 Rear Axle ........................................................ 10-24 Front Driveshaft............................................... 10-25 Reat Driveshaft ............................................... 10-25 Differential ....................................................... 10-26 Rear Axle Planetary ........................................ 10-27 Dry Disc Parking Brake................................... 10-28

SPECIFICATIONS Service Specifications ........................................11-1 Machine Weights ....................................... 11-1 Capacities .................................................. 11-1 Engine........................................................ 11-2 Electrical System ....................................... 11-2 Power Transmission .................................. 11-3 Travel Speeds ........................................... 11-3 Planetary ................................................... 11-3 Differential ................................................. 11-3 Brake System.................................................... 11-4 Steering System................................................ 11-5 Wheels .............................................................. 11-6 Cab .............................................................. 11-7 Hoist System ..................................................... 11-8 Machine Truck Dimensions............................... 11-9

OPTIONS Cold Weather Packege-Mild Cold..................... 12-1 Auxiliary Backup Lights..................................... 12-1 Muffler On Exhaust System .............................. 12-1 Additional reverse Lamp ................................... 12-2 Sound Suppression........................................... 12-2 Fog Lights ......................................................... 12-2 Air-Ride Seat..................................................... 12-3 Semi-Active Seat............................................... 12-4

INFORMATION FEED BACK .................. 13-1 ALPHABETICAL INDEX...........................14-1

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.

02/07

Manual No. EM8R4-1-2

MACHINE NUMBERS

INDEX

SAFETY SAFETY SIGNS COMPONENTS NAME OPERATOR’S STATION BREAK-IN OPERATING THE ENGINE OPERATING METHODS OPERATING THE RIGID DUMP TRUCK TRANSPORTING MAINTENANCE 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

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 ENGINE 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 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 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

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