Hitachi EH1700-3 Rigid Dump Truck Service Repair Manual

Manual No: W8R6-E-01

WORKSHOP MANUAL EH1700-3 8R6AA RIGID DUMP TRUCK

Service Manual consists of the following separate Part No; Workshop Manual W8R6-E-01

TITLE / Introduction TO THE READER

MANUAL COMPOSITION

This manual is written for an experienced technician to provide technical information needed to maintain and repair this rigid dump truck.

This manual consists of three portions; the Technical Manual (Operational Principle) the Technical Manual (Troubleshooting) and the Workshop Manual.

Be sure to thoroughly read this manual for correct product information and service procedures.

The Technical Manual (Operational Principle) contains the information necessary for delivery, operation and activation of all devices and systems.

If you have any questions or comments, or if you found any errors regarding the contents of this manual, please contact us using the “PLEASE TELL US” form. The form follows this INTRODUCTION section.

The Technical Manual (Troubleshooting) contains the information about operational performance tests, and troubleshooting procedures.

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

ADDITIONAL REFERENCES Please refer to the materials listed below in addition to this manual: Operators Manual Parts Catalog Operation Manual of the Engine o Detroit Diesel 16V2000 Service Manual Operation Manual of the Transmission o 8000-9000 Series Transmissions Commercial Electronic Controls 2 (CEC2) Manual o Allison Transmission 8610-9610 Series Service Manual Hitachi Weld Repair Manual KO-111-00

TS41154

IN-01

TITLE / Introduction PAGE NUMBER The Manuals have the page number located on the center lower part of the page, as well as, additional numbers on the page to help the technician locate specific information: W2-1-3 Consecutive Page Number for each group Group Number Section Number T = Technical Manual W = Workshop Manual

SAFETY ALERT SYMBOL AND HEADLINE NOTATIONS In this manual, the following safety alert symbol and signal words are used to alert the reader to the potential for personal injury or rigid dump truck damage.

This is the safety alert symbol. When you see this symbol, be alert to the potential for personal injury. Always follow the safety instructions that accompany the safety alert symbol.

The safety alert symbol is also used to draw attention to the weight of component parts.

To avoid injury and damage, be sure to use appropriate lifting techniques and equipment when lifting heavy parts.

WARNING: Indicates a potentially hazardous situation that could, if not avoided, result in personal injury or death.

NOTE: Indicates supplementary technical information or know-how.

IN-02

TITLE / Introduction UNITS USED Example: 24.5 MPa (3550 psi) SI system units and English units are used in this manual. English units are in parentheses behind SI units.

Quantity Length Volume

Weight Force Torque

Quantity Pressure Power Temperature Velocity Flow Rate

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

To Convert From mm mm L L m³ kg N N N m N m

To Convert From MPa MPa kW kW C km/h L/min mL/rev

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

Into kgf/cm² psi PS HP F mph US gpm cc/rev

IN-03

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

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

TITLE / Introduction MEMO ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................

IN-04

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

SAFETY PARK RIGID DUMP TRUCK SAFELY Park rigid dump truck on a level surface.

Lower the body to the frame.

Move the shift controller lever to the N (Neutral) position.

Apply the parking brake and release the service brakes to insure that the parking brake is holding the rigid dump truck.

Let the engine run at idle for three to five minutes for cool down.

Make sure the body hoist control lever is in the Float position.

Check that all switches and controls are in the OFF position.

Turn the Key Switch to the OFF position.

EL20378

Turn the Battery Disconnect Switch to the OFF position.

Fill the fuel tank to minimize water condensation in the tank.

NOTE: Running out of fuel with the engine running, especially under load, is very detrimental to engine life and requires a time consuming restart procedure.

Perform a walk around inspection and fill out the required Preventative Maintenance form or other required operator report forms. Be sure to report any adjustments of service required to those responsible for maintenance.

When leaving the rigid dump truck unattended, remove the key. Lock the doors and any vandalism guards to prevent theft or damage.

S-16

SAFETY SAFE HANDLING OF OFF ROAD TIRES When doing any tire service, especially tire inflation, NEVER stand in the TRAJECTORY PATH. Serious injury or death can result if an explosion should occur.

Use a self-attaching air chuck with a hose long enough to be out of the trajectory path when filling a tire with air.

Use an inflation cage, safety cables, or chains when inflating tires.

Never use air from a compressed air system, to inflate a tire if alcohol has been used as antifreeze.

Inspect all rims, wheels and components.

Replace any worn or damaged rims, wheels and components.

Do not remove any wheel nuts; rim clamps or dagger clamps until the tire is deflated.

No personnel should be touching the rim, rim clamp, or tire when dislodging the rim clamps or dagger clamps on larger dumps.

Never stand in front of rim clamps or dagger clamps during removal.

Trained and certified personnel should only do the dismounting and mounting of tires. It is recommended that a certified tire repair service be hired to perform the dismounting and mounting of tires from rims.

DISCHARGE ACCUMULATORS Before removing and disassembling brake or steering accumulators, they must be discharged to prevent serious injury. Refer to the appropriate Maintenance Manual section for BRAKE ACCUMULATOR and STEERING ACCUMULATOR.

S-17

EL20379

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