Hitachi EH1600 Rigid Dump Truck (Haul Truck) operator’s manual

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  This is the most complete Operation and Maintenance Manual for the HITACHI EH1600 RIGID DUMP TRUCK (HAUL TRUCK) . Operation and Maintenance Manual can come in handy especially when you have to do immediate repair to your HITACHI EH1600 RIGID DUMP TRUCK (HAUL TRUCK) .Operation and Maintenance Manual comes with comprehensive details regarding technical data. Diagrams a complete list of HITACHI EH1600 RIGID DUMP TRUCK (HAUL TRUCK) parts and is a must for the will not be dissatisfied. Operation Manual Covers: Contents Presentation Instrument Panel Operators Controls Operating Instructions Basic Preventive Maintenance Specifications Alphabetical Index File Format: PDF Compatible: All Versions of Windows & Mac Language: English Requirements: Adobe PDF Reader All pages are run off what you need & take it with you into the garage or save money $$ By doing your own repairs!These manuals make it easy for any skill level with these very easy to by step instructions! Looking for some other Operation and Maintenance Manual, Please see the below link: https://www.aservicemanualpdf.com/
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  • 1. PRINTED IN U.S.A. MANUAL OPERATORS 09/01 PUBLICATION NO. 10202 ENG. EDITION 1 EH1600 360NDHITACHI DISTRIBUTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADDRESS PHONE NO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DLR/BRCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADDRESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PHONE NO . . . . . . . . . . . . . SERVICE PHONE NO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MACHINE: SERIAL NO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE TYPE NO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HYDRAULIC TRANSM. TYPE/NO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MASTER KEY SWITCH NO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAB KEY NO FUEL FILLER CAP KEY NO.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
  • 2. FOREWORD 1 KNOW THE CAPACITY AND LIMITS OF YOUR MACHINE! FOREWORD This Operators Manual is intended as a guide for the correct use and maintenance of the machine. The manual should always be kept in the vehicle. Carefully read the manual before starting and operating the machine or before carrying out any preventive maintenance. We have taken many hours in designing and producing the safest and most efficient equipment possible. All this may be wasted if you do not read the safety instructions or if you do not follow them. Make yourself familiar with all controls and instructions and keep this manual in the machine for handy reference. If the manual is lost, it should be replaced immediately. Machines rarely cause accidents, whereas people do. A safety conscious person and a well maintained machine make a safe, efficient and profitable combination. This manual has been adapted to cover all markets, thus it may contain information about equipment not necessarily fitted to the version of the machine you have purchased. We therefore ask you to disregard information which is not applicable to your machine. We are continually striving to improve our products and therefore, reserve the right to make changes and improvements to the design whenever we consider that these increase the efficiency of the product. However, this does not commit us to introduce these improvements on products which have already been delivered or are in service. We also retain the right to change data and equipment, as well as instructions for service and maintenance without prior notice. SAFETY REGULATIONS Every country (State) 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. SAFETY ALERT SYMBOL This symbol, which will appear at various points in the manual and on the machine 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 machine and that they are readable. Accidents may otherwise occur. CONTENTS 3 PRESENTATION 5 INSTRUMENT PANEL 13 OPERATORS CONTROLS 43 BASIC PREVENTIVE MAINTENANCE 127 ALPHABETICAL INDEX 207 SPECIFICATIONS 183 OPERATING INSTRUCTIONS 69
  • 3. FOREWORD2 UNAUTHORIZED MODIFICATION OF ROLLOVER PROTECTIVE STRUCTURE (ROPS) Never make any unauthorized modifications or alterations to the 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 Structures (ROPS) have been certified to meet specified test requirements according to ISO 3471 ROPS. 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 certifying tests. It is important that each person in your organization, including management, be made fully aware of these rules involving the ROPS. Whenever anyone sees a machine ROPS with unauthorized modifications or changes, both the customer and manufacturer should be notified in writing. OPERATION AND MAINTENANCE OF THE MACHINE EUCLID–HITACHI Heavy Equipment, Ltd is only responsible if: – the machine has been used in a correct manner and been maintained according to instructions in this Operator’s Manual and the Service Manuals. – the prescribed service and prescribed inspections have been carried out at the stated points in time. – the recommended lubricants according to the manual have been used. – no security seals have been broken by other than authorized persons. – all modifications and repairs have been carried out and methods been followed in the way prescribed by EUCLID–HITACHI. – only EUCLID–HITACHI genuine parts/accessories, or attachments which meet EUCLID–HITACHI requirements, have been used. Note: Any questions regarding the content of this manual should be directed to your nearest HITACHI Distributor. WARNING! A hauler operator must have sufficient knowledge and instruction before operating and servicing the machine. Untrained operators may cause severe injuries or even fatalities. Therefore, it is important that you read and follow the instructions in this Operator’s Manual. Never use a hauler if an Operator’s Manual is not available. Learn to understand the warning plates, symbols and operator instructions before you begin to operate the machine.
  • 4. CONTENTS 3 TABLE OF CONTENTS FOREWORD FOREWORD 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAFETY REGULATIONS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UNAUTHORIZED MODIFICATION OF ROLLOVER PROTECTIVE STRUCTURE (ROPS) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPERATION AND MAINTENANCE OF THE MACHINE 2. . . . . . . . . PRESENTATION PRESENTATION 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . POWER TRANSMISSION 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKES 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STEERING 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAB 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BODY 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INFORMATION AND WARNING PLATES 6. . . . . . . . . . . . . . . . . . . . . . PRODUCT IDENTIFICATION NUMBER 10. . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE AND INSPECTIONS 11. . . . . . . . . . . . . . . . . . . . . . . . . INSTRUMENT PANEL INSTRUMENT PANEL 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPERATORS CONTROLS OPERATORS CONTROLS 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPERATING INSTRUCTIONS GENERAL OPERATING RULES 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPERATOR’S QUALIFICATIONS 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . DUTIES OF THE OPERATOR 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A FEW SIMPLE SAFETY RULES BEFORE OPERATING 69. . . . . . . . OPERATING WITH THE MACHINE NEAR OVERHEAD WIRES OR CABLES 71. . . . . . . . . . . . . . . . . . . . . . . . . . OPERATING WITH THE MACHINE NEAR HIGH VOLTAGE OVERHEAD POWER LINES 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SIGNALLING DIAGRAM 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PROCEDURE BEFORE STARTING 73. . . . . . . . . . . . . . . . . . . . . . . . . . . Daily Walk Around Inspection 73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . RUN IN INSTRUCTIONS 74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTING ENGINE 75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BEFORE OPERATING 79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPERATING THE MACHINE 80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PARKING MACHINE 104. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STORAGE OF HITACHI RIGID HAULERS 105. . . . . . . . . . . . . . . . . . . . .
  • 5. CONTENTS4 OPERATING INSTRUCTIONS (continued) TRANSPORTING 112. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ROADING 121. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MACHINE STUCK IN DEEP SAND, SNOW OR MUD 122. . . . . . . . . . . TOWING 123. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BASIC PREVENTIVE MAINTENANCE SERVICE POSITION 127. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A FEW SIMPLE RULES WHEN SERVICING 128. . . . . . . . . . . . . . . . . . . FIRE PREVENTION MEASURES 130. . . . . . . . . . . . . . . . . . . . . . . . . . . . . WASTE HAZARDOUS TO THE ENVIRONMENT 131. . . . . . . . . . . . . . . BASIC PREVENTIVE MAINTENANCE INTERVAL CHART 132. . . . . . . GENERAL INFORMATION 135. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE 137. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AIR CLEANER SYSTEM 140. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL SYSTEM 144. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COOLING SYSTEM 147. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL SYSTEM 152. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . POWER TRANSMISSION 158. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE SYSTEM 164. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WHEEL SUSPENSION AND STEERING 167. . . . . . . . . . . . . . . . . . . . . . FRAME, SPRINGS, AND WHEELS 170. . . . . . . . . . . . . . . . . . . . . . . . . . . CAB 172. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HYDRAULIC SYSTEM AND OTHER FUNCTIONS 175. . . . . . . . . . . . . . CHASSIS AND DRIVESHAFT GREASE FITTING LOCATIONS 180. . . SPECIFICATIONS RECOMMENDED LUBRICANTS 183. . . . . . . . . . . . . . . . . . . . . . . . . . . . . SERVICE SPECIFICATIONS 185. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PERFORMANCE CHART 194. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RETARDER CHARTS 195. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MACHINE DIMENSIONS 196. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BOLT TORQUE CHART, GENERAL 197. . . . . . . . . . . . . . . . . . . . . . . . . . . ALPHABETICAL INDEX ALPHABETICAL INDEX 207. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
  • 6. 5PRESENTATION ELI19662/1600 PRESENTATION The HITACHI EH1600 (360ND) is a rigid frame hauler capable of carrying a 90,720 kg (200,000 lb) maximum payload, with no options. The HITACHI EH1600 Hauler features independent trailing arms for each front wheel with Neocon suspension cylinders mounted between the trailing arm and frame. Neocon suspension cylinders are also utilized on the rear axle. ENGINE The HITACHI EH1600 (360ND) is powered by a 30.5 liter (1861 cu.in), 783 kw (1050 bhp), 12 cylinder, four cycle, turbocharged Cummins QST–30 engine. POWER TRANSMISSION The HITACHI EH1600 (360ND) is equipped with the Allison DP8963 transmission. The transmission is remote mounted and has six forward speeds and one reverse speed. Allison Commercial Electronic Control I (CEC I) provides park brake interlock and hoist interlock as well as built in diagnostics. The drive axles have full floating axle shafts. Double reduction in the Euclid axle is provided by a bevel gear set in the center housing and a planetary reduction in the wheel. BRAKES The machine is equipped with an all–hydraulic actuated braking system with dual circuits. There is a circuit for the front dry disc brakes and another circuit for the rear axle wet disc brakes. The dry disc parking brake is mounted on the differential input shaft. It is controlled by a toggle switch on the instrument panel. The parking brake will automatically apply if brake hydraulic pressure is lost. The foot operated retarder valve allows the operator to control the all–hydraulic actuation of the oil–cooled wet disc brakes on the rear axle. The system provides modulated pressure to the rear brakes for constant speed control. STEERING The machine is equipped with a closed center hydraulic system with a brake actuation/steering system reservoir. The hydraulic power steering uses two double acting cylinders, an accumulator, and a piston type pump. The accumulator provides supplementary steering capability. CAB The machine is equipped with a cab that has been ROPS/FOPS tested and approved in accordance with SAE J1040 and ISO 3471.The cab is fully insulated and includes a filtered fresh air heater and pressurizing system. BODY The dump body is designed with a flat floor, a low center of gravity for maximum stability, and is continuously exhaust heated. Optional superstructures can be mounted if required. An electronically controlled hoist is standard.
  • 7. 6 PRESENTATION NAMEPLATES, WARNING, AND INFORMATION DECALS ELI19717/1600 9 17 26 32 43 59 (6) (11) (16) (20) (27) (37) 1 2 3 4 5 6 20 11 8 6 5 3 20 12 9 7 5 4 20 15 12 10 8 6 20 16 12 10 8 7 EH1600 2.86 3.15 2.86 3.15 8.00:1 146050 KG. 27X49 (36 PR) 322000 LB. 158680 KG. 27X49 (42 PR) 349830 LB. 160613 KG. 27X49 (48 PR) 354086 LB. & 27R49 RADIAL & 31/80R49 RADIAL The numbers on the illustration refer to the machine plates, warning and information decals installed on the machine. The operator of the machine must know and follow warnings and information given on decals and plates. Decals/plates which have disappeared, been damaged, painted over, or for any reason are no longer legible, must be replaced immediately. The part numbers of the respective plates/decals can be found in the Parts Catalog.
  • 8. 7PRESENTATION CHASSIS/BODY NAMEPLATES, WARNINGS AND INFORMATION DECALS NO. DESCRIPTION POSITION 10. Manual Release Valve Above the release valve Consult the technical manual for service procedures by the brake accumulators 11. Transmission Filter. Number referenced on the decal On the transmission filter is the part number for the replacement filter element 12. Made in Canada Left and right hand side of the front sheet metal 13. Warning, Contents Under Pressure On the steering and brake accumulators 14. Jump Start Warning Front of the battery box Electrical shock/electrocution. Refer to Operators Manual 15. Battery Disconnect Top of the battery box 16. Air Cleaner. Numbers referenced on the decal are the On the air cleaners part numbers for the inner and outer replacement filter elements 1. G.M.W. (Gross Machine Weight) Right side of the instrument panel 2. Propulsion Inhibit Above windshield, right side When the body is raised off the frame, reverse propulsion is inhibited 3. Pedal Location and Function Above wiindshield, right side 4. Warning. Read Operators Manual Above windshield, left side before starting and operating the machine 5. Hoist Control Lever Function Above windshield, left side 6. Retarder Operation Decal Above windshield. left side Refer to the Operators Manual 7. Product Identification Number Plate Above door, left side 8. Rollover Protective Structure (ROPS) Left side of cab, behind operator 9. Proposition 65 Warning Lower left corner of California, United States of America windshield CAB NAMEPLATES, WARNINGS AND INFORMATION DECALS NO. DESCRIPTION POSITION
  • 9. 8 PRESENTATION NAMEPLATES, WARNING, AND INFORMATION DECALS ELI19718/1600 The numbers on the illustration refer to the machine plates, warning and information decals installed on the machine. The operator of the machine must know and follow warnings and information given on decals and plates. Decals/plates which have disappeared, been damaged, painted over, or for any reason are no longer legible, must be replaced immediately. The part numbers of the respective plates/decals can be found in the Parts Catalog.
  • 10. 9PRESENTATION 17 Lock Body Rear of tailchute, above Refer to the Operator’s Manual body prop cable 18 Warning Limited Visibility – At Rear of Machine On both sides of the body Stay a safe distance from the machine. 19 NEOCON–E Located on front and rear ride (Trees indicates friendly to environment.) struts 20 Crush Hazard from Dump Body Located at the back of the Install body prop cable before getting in hazardous area. box and at the rear of the cab 21 Hydraulic Filter – Number referenced on decal is the Located on each hydraulic part number for the replacement filter element. filter housing 22 Steering Filter – Number referenced on decal is the Located on the steering part number for the replacement filter element. section of the hydraulic tank 23 Engine Start On the hydraulic tank Indicates where level should be with engine running 24 Front Wheel Crush Area Both sides of the machine Stay clear of front axle on the frame in the axle area 25 Warning Limited Visibility – At Front of Machine Both sides of the sheet metal Stay a safe distance from the machine. side member 26 Tie Down – Where chains attach to machine. For example On the front bumper, rear when transporting on a lowboy. frame lug, and left & right side of frame. 27 Lifting Locations At the front bumper. In the rear, at the frame lug. 28 Burn Hazard when machine is hot Radiator top tank (installed Remove radiator cap slowly after machine has cooled down at the radiator cap) 29 Steering Pressure Test Port Located in front of the test port, top of the accumulator CHASSIS/BODY NAMEPLATES, WARNINGS AND INFORMATION DECALS (Continued) NO. DESCRIPTION POSITION
  • 11. 10 PRESENTATION PRODUCT IDENTIFICATION NUMBER Hitachi Construction Machinery Company is a worldwide company that produces several product lines under different product names, one of which is Euclid Rigid Hauler. To aid in production scheduling, certain machine models are built in several plants and exported to meet our world market requirements. At the time of manufacture, every machine is assigned a product identification (serial) number to identify that machine from all others built by EUCLID-HITACHI Heavy Equipment, Ltd. EL19901 EL19902 European Community Market Symbol Product Identification Number Locations 1. Product Identification Plate – Located inside the cab above the passenger door. 2. Frame Serial Number – Stamped into the frame on the top of the front bumper, located next to the ladder. 3. Engine Serial Number Plate – Located on the right bank of the engine, under the turbocharger. 4. Transmission Serial Number Plate – Located on the lower–rear side of the transmission
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