Hitachi EH4500-2 Rigid Frame Truck operator’s manual

Manual No. EM8D9-1-2

Operator’s Manual

Rigid Dump Truck

Serial No. EH4500-2 EH4500-2 EH4500-2 EH5000 EH5000 EH5000 EH5000

411MD: 413MD: 8D9AC: 401RD: 402RD: 403RD: 8DWAC:

77165 and Up 77416 and Up 8D9AC-00001000 and Up 77084 and Up 76954 and Up 77449 and Up 8DWAC-00001000 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 on the rigid dump truck, also file the identification numbers in a secure place off the rigid dump truck.

Warranty is provided as a part of 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 factory specifications, the warranty will become void and field improvements may be de-

nied. 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 dealers concerning compliance.

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.

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Manual No. EM8D9-1-2

INTRODUCTION MEMO ................................................................................................................................................................................... ................................................................................................................................................................................... ................................................................................................................................................................................... ................................................................................................................................................................................... ................................................................................................................................................................................... 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08/08

Manual No. EM8D9-1-2

INDEX

MACHINE NUMBERS SAFETY SAFETY SIGNS COMPONENTS NAME OPERATOR’S STATION BREAK-IN OPERATING THE ENGINE

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.

OPERATING METHODS OPERATING THE RIGID DUMP TRUCK TRANSPORTING MAINTENANCE

COPYRIGHT(C) 2008

STORAGE

Hitachi Truck Manufacturing Ltd. Guelph, Canada All rights reserved

TROUBLESHOOTING SPECIFICATIONS OPTIONS INFORMATION FEEDBACK FORM ALPHABETICAL INDEX

CONTENTS MACHINE NUMBERS

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

SAFETY

COMPONENTS NAME

Recognize Safety Information ............................ S-1 Understand Signal Words................................... S-1 Operators Qualifications ..................................... S-2 Inspect Machine.................................................. 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 Handle Starting Aids Safely ................................ S-7 Operate Only from Operator’s Seat.................... S-8 Jump Starting...................................................... S-8 Keep Riders Off Machine.................................... S-8 Protect Against Falling Stones and Debris......... S-9 Provide Signals for Jobs Involving Multiple Numbers of Machines................................... S-9 Operate The Machine 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-13 Operating With the Machine Near Overhead Wires or Cables ......................... S-14 Operating With the Machine Near High Voltage Overhead Power Lines.................. S-14 Park Machine Safely......................................... S-15 Safe Handling of Off Road Tires....................... S-16 Discharge Accumulators................................... S-16 Handle Fluids Safely-Avoid Fires ..................... S-17 A Few Simple Rules When Servicing ............... S-18 Use Tools Properly ........................................... S-20 Prevent Burns ................................................... S-21 Replace Rubber Hoses Periodically ................. S-21 Avoid High-Pressure Fluids .............................. S-22 Fire Prevention Measures ................................ S-23 Evacuating in Case of Fire................................ S-25 Beware of Exhaust Fumes................................ S-25 Precautions for Welding, Cutting, and Grinding . S-26 Remove Paint before Welding or Cutting ......... S-26 Avoid Heating Near Pressurized Fluid Lines.... S-27 Avoid Applying Heat to Lines Containing Flammable Fluids ..................... S-27 Prevent Battery Explosions............................... S-28 Service Air Conditioning System Safely ........... S-28 Handle Chemical Products Safely .................... S-29 Dispose of Waste Properly ............................... S-29

View of EH4500-2 / EH5000 ............................... 1-1

OPERATOR’S STATION Cab Features....................................................... 2-1 Instrument Panel ................................................. 2-2 Instrument Lighting Rheostat ........................ 2-3 Brake/Steering Oil Pressure Gauge ................. 2-3 Rear Brake Temperature Gauge .................. 2-4 Speedometer................................................. 2-4 Tachometer ................................................... 2-4 Headlight Switch ........................................... 2-5 Dome Light Switch ........................................ 2-5 Engine Coolant Temperature Gauge ............ 2-5 Wheel Motor Temperature Gauge ................ 2-6 Engine Oil Pressure Light ............................. 2-6 Central Warning Light ................................... 2-6 Blower Loss Light.......................................... 2-7 Engine Coolant Temperature Light ............... 2-7 Brake Pressure Light .................................... 2-8 Parking Brake Light....................................... 2-8 Steering Pressure Light ................................ 2-8 Traction Fault Light ....................................... 2-9 Engine Service Light ..................................... 2-9 Engine Shutdown Light ................................. 2-9 Direction Indicator Light .............................. 2-10 Hydraulic and Steering Temperature Light . 2-10 Brake Temperature Light ............................ 2-10 Alternator Light............................................ 2-10 Engine Coolant Level Light............................2-11 High Beam Indicator Light........................... 2-11 Filter Light ................................................... 2-11 Wheel Motor Temperature Light ................. 2-12 Windshield Wiper Switch ............................ 2-12 Windshield Wiper/Washer Switch ............... 2-12 Blower Knob................................................ 2-13 Mode Knob.................................................. 2-13 Temperature Control Knob ......................... 2-14 Air Conditioning Switch ............................... 2-14 Recirculating Switch.................................... 2-14 Master Key Switch ...................................... 2-14 Cruise Control Switch On/Off...................... 2-15 Body Up Light.............................................. 2-15 Reverse Light Switch (Manual Operation) .. 2-15 Fog Lamp Switch ........................................ 2-15 Stairway and Deck Light ............................. 2-16 Parking Brake Switch .................................. 2-16 Lincoln Lube Light ....................................... 2-16 Engine Diagnostic Connector ..................... 2-16 Contronic Display Service Tool Connector . 2-16 Siemens Interface Connector ..................... 2-16 Heated Mirrors Switch................................. 2-16 Engine Shutdown Timer Switch .................. 2-16

CONTENTS Traction Fault Reset Switch.........................2-17 Drive Shutdown Switch................................2-17 Cruise Control Set/Decel, Resume/Accel....2-17 Grid Dry Switch............................................2-17 Contronic Liquid Crystal Display (LCD) Unit..............................................2-18 Contronic III, Monitoring and Alarm System ......2-20 Alarm Messages..........................................2-24 Errors ...........................................................2-24 Operator’s LCD Screens .............................2-25 Haultronics III System Description.....................2-30 Hitachi Rigid Dump Truck Payload Policy .........2-32 Haultronics III – Operator Available Screens ....2-34 Haul Cycle Data – Definition of Terms ..............2-36 Operator’s Controls............................................2-37 Dome Light ..................................................2-38 Shift Controller Lever...................................2-38 Dump Override Switch.................................2-38 Load/Dump Brake Switch ............................2-39 Cigar Lighter ................................................2-39 12 Volt Power Port.......................................2-40 Ashtray.........................................................2-40 Horn .............................................................2-40 Hoist Control Lever......................................2-41 Accelerator Pedal ........................................2-41 Dynamic Retard Pedal.................................2-41 Brake Pedal .................................................2-42 Tilt Steering Wheel Adjustment Control ......2-42 Turn Signal/High Beam Lever .....................2-42 Hazard Warning...........................................2-43 Operator’s Seat Controls .............................2-43 Seat Belt ......................................................2-47 Passenger Seat ...........................................2-47 Passenger Seat Belt....................................2-47 Manual Release Valve.................................2-48 Service Switches .........................................2-48 Emergency Shutdown Switch................2-48 Battery Disconnect Switch.....................2-49 Engine Work Light Switch .....................2-49 Stairway/Deck Light Switch ...................2-49 Rear View Camera Monitor .........................2-50 Mirrors..........................................................2-53

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

OPERATING THE ENGINE Inspect Machine Daily before Starting.................4-1 Pre-Operation Inspection.....................................4-2 Pre-Operation Inspection Check Sheet...............4-3 Oil and Water Leaks ............................................4-4 Check Instruments/Controls Before Starting .......4-5 Coolant Level Check............................................4-5

Starting Engine.................................................... 4-6 Starting with Auxiliary Batteries........................... 4-9 Stopping the Engine .......................................... 4-10

OPERATING METHODS General Information ............................................ 5-1 Cooling a Hot Engine .......................................... 5-2 Shifting 5-2 Accelerator Pedal................................................ 5-3 Steering ............................................................... 5-3 Cruise Control ..................................................... 5-4 Dynamic Retarder ............................................... 5-4 Service Brakes .................................................... 5-5 Parking Brake...................................................... 5-5 Load/Dump Brake Switch.................................... 5-6 Operating the Hoist Control Lever ...................... 5-7 Hoist Control Lever Functions............................. 5-7 Supplementary Steer/Brake Operation Tests ... 5-11 Performance/Retarder Charts ........................... 5-12 Retarder Operation Decal ................................. 5-20 Rigid Dump Truck Stuck in Deep Sand, Snow, or Mud .............................................. 5-22 Rocking Out....................................................... 5-22 Cold Weather Restrictions ................................ 5-22 Towing .............................................................. 5-23 Parking the Rigid Dump Truck .......................... 5-26

OPERATING THE MACHINE Loading................................................................ 6-1 Haultronic III ........................................................ 6-2 Hauling ................................................................ 6-5 Dumping .............................................................. 6-5 Dumping Precautions.......................................... 6-6 Stopping .............................................................. 6-7

TRANSPORTING .......................................... 7-1 MAINTENANCE Correct Maintenance and Inspection Procedures.. 8-1 Service Your Machine at Specified Intervals ...... 8-2 Check the Hour Meter Regularly......................... 8-2 Use Correct Fuels and Lubricants ...................... 8-2 Recommended Lubricants ............................ 8-3 Recommended Fuel...................................... 8-8 Prepare Rigid Dump Truck for Service ............... 8-9 Installing Body Prop Pins ............................ 8-10 Removal and Storage of Body Prop Pins ... 8-11 Electrical Disconnects Before Welding on the Rigid Dump Truck ........ 8-12 Maintenance Interval Guide .............................. 8-13 A. Greasing ....................................................... 8-21 B. Engine ........................................................... 8-24 Engine Oil Level .......................................... 8-25 Change Engine Oil ...................................... 8-26 Replace Engine Oil Filter ............................ 8-27 Check and Clean Engine Spinner Filter ........ 8-28

CONTENTS Change Engine Breather .............................8-30 C. Power Transmission......................................8-31 Oil Level, Sump Tank Brake Seal ...............8-31 Oil Test, Sample Planetary .........................8-31 Check Rear Planetary Hubs Lubricant Level ......................................8-32 Change Rear Planetary Lubricant ...............8-32 Spindle Mount Bolts....................................8-33 Spindle Mount Tie Rods..............................8-33 D. Hydraulic Steering/Brake Apply System .......8-34 Check Hydraulic Fluid Level ........................8-35 Change Hydraulic Fluid ...............................8-35 Replace Hydraulic Filter ..............................8-37 Check Steering Accumulator.......................8-37 Check Brake Accumulator ...........................8-38 Check Hydraulic Hoses and Lines ..............8-38 E. Hydraulic Hoist/Brake Cooling System .........8-40 Check Hydraulic Fluid Level ........................8-41 Change Hydraulic Fluid ...............................8-42 Replace Hydraulic Filter ..............................8-43 Change Hydraulic Tank Breather Element..8-44 Check Hydraulic Hoses and Lines ..............8-44 Check Supplementary Steer/Brake .............8-45 F. Brakes, Service & Parking / Steering ............8-46 Check Brake Operation ...............................8-46 Check Service Brake ...................................8-47 Check Parking Brake...................................8-48 Check Measure Wear..................................8-48 G. Fuel System ..................................................8-49 Replace Fuel Filter ......................................8-50 Check Fuel Tank Mounting, Lines, and Fittings ............................................8-52 Drain Fuel Tank Sediment...........................8-52 Drain Fuel Water Separator.........................8-53 H. Air Cleaner ....................................................8-54 Check Primary Element...............................8-55 Check Safety Element .................................8-57 Check Tubes, Hoses and Clamps...............8-58 Check Air Cleaner Dust Cups .....................8-58 I. Cooling System...............................................8-59 Check Coolant Level ...................................8-60 Check SCA Cummins..................................8-61 Sample, Coolant Test Cummins..................8-62 Check SCA DD ............................................8-64 Sample, Coolant Test DD............................8-65 Coolant Change and Flush System.............8-65 Replace Coolant Filter .................................... 8-66 Check Cooling Fan ......................................8-67 Clean Radiator.............................................8-67 Check Fan Belt ............................................8-67 J. Electrical System ...........................................8-68 Check Battery Condition..............................8-69 Inspect Battery Charge................................8-69 Check Battery Cables and Connections......8-70 Check Electrical Wiring and Connections ...8-70 Check Fuse/Relay .......................................8-71

Check Shift Controller ................................. 8-74 Check Exterior Lights.................................. 8-75 Check Back-up Alarm ................................. 8-75 Check Horn ................................................. 8-75 Check Gauges ............................................ 8-76 Check Indicator Lights ................................ 8-76 Headlight Aiming......................................... 8-77 Check Alternator/Air Conditioning Belt ....... 8-78 Check Switch Functions ............................. 8-78 Check Pump Isolator................................... 8-78 K. Suspension, Wheels & Tires......................... 8-79 Check Struts ............................................... 8-80 Check Wheels............................................. 8-80 Check Front Axle ........................................ 8-81 Check Front Wheel Lubricant ..................... 8-81 Change Front Wheel Lubricant................... 8-81 Check Tire Inflation ..................................... 8-81 Check Tire Condition .................................. 8-82 Check Wheel Alignment ............................. 8-83 Inspect Steer Spindle.................................. 8-83 L. Cab................................................................ 8-84 Clean/Change Air Filter .............................. 8-85 Check Mounts ............................................. 8-85 Check Wiper Blade Condition..................... 8-85 Check Windshield Washer Fluid Level ....... 8-86 Check Seat Belt and Mounting ................... 8-86 Check Air Conditioning ............................... 8-87 Check Heater and Defroster ....................... 8-87 Check A/C Compressor Belt....................... 8-88 M. General......................................................... 8-89 Check for Fluid Leaks ................................. 8-90 Check Body Prop Pins ................................ 8-90 Check Frame Assembly.............................. 8-91 Check Rear Axle Assembly ........................ 8-91 Check Front Axle Assembly........................ 8-91 Check Tightening Torque of Bolts and Nuts .................................... 8-91 Check for Loose Bolts and Fittings ............. 8-91 Maintenance of Optional Systems Auto Lube System....................................... 8-92 Rear View Camera System ........................ 8-97 Ansul Fire Protection System ................... 8-102 Haultronics III ............................................ 8-109

STORAGE Short Term Storage............................................. 9-1 Moderate Term Storage ...................................... 9-3 Long Term Storage ............................................. 9-5 Return to Service................................................. 9-9

TROUBLESHOOTING Engine ............................................................... 10-1 Engine Coolant.................................................. 10-4 Starter and Mounting......................................... 10-4 Air Cleaner ........................................................ 10-5 Electrical System............................................... 10-6

CONTENTS Hydraulic System...............................................10-9 Hydraulic Hoist System....................................10-11 Hydraulic Steering System ..............................10-12 Steering Pump .................................................10-13 Steering Control Valve.....................................10-14 Front Axle.........................................................10-16 Rear Axle .........................................................10-17 Hoist Pump Driveline .......................................10-18 Rear Axle Planetary.........................................10-18 Parking Brake ..................................................10-19

MP3 Player / CD Player / Radio...................... 12-16 Cold Weather Options ..................................... 12-22 Rear Body Lamps............................................ 12-23 Deck Mounted Fire Extinguisher ..................... 12-23 Body ................................................................ 12-23 Circuit Breakers............................................... 12-24 Load Weigh L.E.D. Display(s) ......................... 12-24 Additional Load Weigh Lights.......................... 12-24 Low Fuel Software........................................... 12-25 Cab Retard Lights ........................................... 12-25 Body Liners ..................................................... 12-25

SPECIFICATIONS Service Specifications EH4500-2 ......................11-1 Capacities ....................................................11-1 Engine .........................................................11-1 Electrical......................................................11-2 Brake System ..............................................11-3 Steering System ..........................................11-4 Wheels ........................................................11-5 Suspension..................................................11-5 Cab..............................................................11-5 Hydraulic System ........................................11-6 Machine Weights.........................................11-7 Machine Dimensions...................................11-8 Service Specifications EH5000..........................11-9 Capacities ....................................................11-9 Engine .........................................................11-9 Electrical....................................................11-10 Brake System ............................................ 11-11 Steering System ........................................11-12 Wheels ......................................................11-13 Suspension................................................11-13 Cab............................................................11-13 Hydraulic System ......................................11-14 Machine Weights.......................................11-15 Machine Dimensions.................................11-16

OPTIONS CENSE...............................................................12-1 Diagnostic....................................................12-1 Stop Engine .................................................12-1 Check Engine ..............................................12-2 Engine Maintenance ...................................12-2 Operational States.......................................12-3 Engine Shut Down Switch .................................12-4 Fog Lamps .........................................................12-4 Service Center ...................................................12-4 Additional Reverse Light....................................12-5 Hydraulic Tank Shut Off Valves .........................12-5 2 Camera Video System....................................12-6 Fire Suppression................................................12-7 Keyless Start Switch ..........................................12-8 Automatic Lube System.....................................12-8 Buddy Hoist System ..........................................12-9 Buddy Steer System ........................................12-11 Trolley ..............................................................12-13

INDEX ............................................................. 13-1

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 AND SERIAL NUMBER PRODUCT MODEL NUMBER: PRODUCT IDENTIFICATION NUMBER:

EL20456

ROLLOVER PROTECTIVE STRUCTURE NAMEPLATE HITACHI MODEL TYPE: ROPS MODEL NUMBER: MAX MACHINE MASS, M-kg:

EL20475

MACHINE NUMBERS FRAME PRODUCT IDENTIFICATIION NUMBER

EL20210

00C00069

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

ELI

Detroit

TYPE: MFG. NO.:

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 operating practices.

precautions

and

safe

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 (Jurisdiction), 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 personal safety messages, a IMPORTANT indicates a situation avoided, could result in damage to truck.

protection with signal word which, if not the rigid dump

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 rigid dump truck 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 you operate 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 the rigid dump truck 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.) of the rigid dump truck. 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 rigid dump truck life.

The safety messages in this SAFETY chapter are intended to illustrate basic safety procedures of rigid dump trucks. 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 a 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 personal protective safety equipment (PPE) 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 ear muffs or ear plugs 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 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 the rigid dump truck and maintain a three-point contact with the steps and handrails. (i.e., two hands and one foot or one hand and two feet.)

SA-439

DO NOT JUMP on or off the rigid dump truck.

Never mount or dismount a moving rigid dump truck.

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 by each individual 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.

SA-293

Recommend the seat belt is replaced every three years regardless of its apparent condition.

HANDLE STARTING AIDS SAFELY Starting fluid: Starting fluid is highly flammable.

Keep all sparks and flame away when using it.

Keep starting fluid well away from batteries and cables.

Remove container from rigid dump truck if engine does not need starting fluid.

To prevent accidental discharge when storing a pressurized container, keep the cap on the container, and store it in a cool, well-protected location.

Do not incinerate or puncture a starting fluid container.

NOTE: Due to increased safety hazards and potential for engine damage, the engine manufacturer does NOT recommend the use of starting fluid without metering equipment.

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.

Sound horn to alert and warn personnel of your intention to start the engine.

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 RIGID DUMP TRUCKS For jobs involving multiple numbers of rigid dump trucks, 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 rigid dump trucks and vehicles, etc.

While traveling on the haul road, maintain a sufficient distance behind the rigid dump truck 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. Slow operation when approaching intersections or unusual traffic.

S-10

EL14019

SAFETY AVOID INJURY FROM RUNNING OVER, FRONT AND BACK, AND 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. USE A SIGNAL PERSON IF YOUR VIEW IS OBSTRUCTED. ALWAYS KEEP THE SIGNAL PERSON IN VIEW.

EL20370

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.

Dust, heavy rain, fog, etc., can reduce visibility. As visibility decreases, reduce speed and use proper lighting.

EL20371

Read and understand all operating instructions in the operator’s manual.

EL20372

S-11

SAFETY AVOID TIPPING 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.

Keep the rigid dump truck a safe distance from the edge of cliffs and slide areas. There is the danger of tipping or rolling 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 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.

EL20373

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.

S-12

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