Hitachi EH1700-3 Rigid Dump Truck operator’s manual SN 8R6BA-0001001 and Up

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  Manual No. EM8R4-1-2Operator’s ManualRigid Dump TruckSerial No. EH750-3 EH1100-3411TDD: 77598 and Up 441LDD: 77589 and UpCONTENTS MACHINE…
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Manual No. EM8R4-1-2Operator’s ManualRigid Dump TruckSerial No. EH750-3 EH1100-3411TDD: 77598 and Up 441LDD: 77589 and UpCONTENTS MACHINE NUMBERSSAFETY SIGNS ................................... S-32SAFETYCOMPONENTS NAME ..........................1-1 OPERATOR’S STATIONRecognize 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-30Cab 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 ................................. 2-15CONTENTS 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 .......................... 2-28BREAK-IN Observe Rigid Dump Truck Closely.................... 3-1 Engine........................................................... 3-1 Daily or Every 10 Hours ................................ 3-1 After the First 50 Hours................................. 3-1Lock-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 ......................... 5-31OPERATING 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.......................................... 4-12OPERATING THE RIGID DUMP TRUCK Loading................................................................6-1 Hauling ................................................................ 6-5 Dumping .............................................................. 6-6 Dumping Precautions .......................................... 6-7 Stopping .............................................................. 6-8 Overnight Storage Instructions............................ 6-8TRANSPORTING THE Rigid Dump Truck Transporting - General ........................................ 7-1 Transporting EH750-3 .........................................7-2 Transporting EH1100-3 .......................................7-3 Traveling on Roadways....................................... 7-5MAINTENANCE 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 ................................................. 5-5Correct 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 ............... 8-3CONTENTS 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.............................. 8-60H. 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 8-127CONTENTS 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........................................... 9-7TROUBLESHOOTING 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................................... 10-28SPECIFICATIONS Service Specifications ........................................11-1 Machine Weights ....................................... 11-1 Capacities .................................................. 11-1 Engine........................................................ 11-2 Electrical System ....................................... 11-2 Power Transmission ..
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