Hitachi EH3500 Rigid Frame Truck operator’s manual

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  This is the most complete Operation and Maintenance Manual for the HITACHI EH3500 RIGID FRAME TRUCK . Operation and Maintenance Manual can come in handy especially when you have to do immediate repair to your HITACHI EH3500 RIGID FRAME TRUCK .Operation and Maintenance Manual comes with comprehensive details regarding technical data. Diagrams a complete list of HITACHI EH3500 RIGID FRAME TRUCK parts and is a must for the will not be dissatisfied. Operation Manual Covers: Contents Presentation Instrument Panel Operators Controls Operation 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. EH3500 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PRINTED IN U.S.A. PUBLICATION 5/01 341SD/342SD OPERATORS MANUAL EDITION 1 NO. 10204ENG HITACHI
  • 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. PRESENTATION 5 CONTENTS 3 INSTRUMENT PANEL 13 OPERATORS CONTROLS OPERATING INSTRUCTIONS BASIC PREVENTIVE MAINTENANCE SPECIFICATIONS 153 ALPHABETICAL INDEX 43 61 99 177
  • 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 deter- mine 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 servic- ing 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 SAFETY REGULATIONS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAFETY ALERT SYMBOL 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UNAUTHORIZED MODIFICATION OF ROLLOVER PROTECTIVE STRUCTURE (ROPS) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPERATION AND MAINTENANCE OF THE MACHINE 2. . . . . . . . . . . . PRESENTATION ENGINE 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRIC DRIVE SYSTEM 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKES 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RETARDER 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STEERING 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAB 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BODY 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAMEPLATES, WARNING, AND INFORMATION DECALS 6. . . . . . . . . PRODUCT IDENTIFICATION NUMBER 10. . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE AND INSPECTIONS 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTRUMENT PANEL INSTRUMENT PANEL 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPERATORS CONTROLS OPERATORS CONTROLS 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPERATING INSTRUCTIONS GENERAL OPERATING RULES 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPERATOR’S QUALIFICATIONS 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DUTIES OF THE OPERATOR 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A FEW SIMPLE SAFETY RULES BEFORE OPERATING 61. . . . . . . . . . . OPERATING WITH THE MACHINE NEAR OVERHEAD WIRES OR CABLES 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPERATING WITH THE MACHINE NEAR HIGH VOLTAGE OVERHEAD POWER LINES 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SIGNALLING DIAGRAM 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PROCEDURE BEFORE STARTING 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RUN--IN INSTRUCTIONS 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTING ENGINE 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BEFORE OPERATING 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPERATING THE MACHINE 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PARKING MACHINE 88. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STORAGE OF HITACHI RIGID HAULERS 89. . . . . . . . . . . . . . . . . . . . . . . .
  • 5. CONTENTS4 OPERATING INSTRUCTIONS (CONTINUED) TRANSPORTING 95. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TOWING 96. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BASIC PREVENTIVE MAINTENANCE SERVICE POSITION 99. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A FEW SIMPLE RULES WHEN SERVICING 100. . . . . . . . . . . . . . . . . . . . . . FIRE PREVENTION MEASURES 102. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WASTE HAZARDOUS TO THE ENVIRONMENT 103. . . . . . . . . . . . . . . . . . BASIC PREVENTIVE MAINTENANCE INTERVAL CHART 104. . . . . . . . . . GENERAL INFORMATION 108. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CENTRALIZED SERVICE PANEL 109. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE 110. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AIR CLEANER SYSTEM 113. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL SYSTEM 116. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COOLING SYSTEM 119. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL SYSTEM 123. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE SYSTEM 131. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STEERING SYSTEM 133. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRAME, SUSPENSION AND WHEELS 137. . . . . . . . . . . . . . . . . . . . . . . . . . . CAB 141. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HYDRAULIC SYSTEM AND OTHER FUNCTIONS 144. . . . . . . . . . . . . . . . . SPECIFICATIONS RECOMMENDED LUBRICANTS 153. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAPACITIES 155. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SERVICE SPECIFICATIONS 156. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PERFORMANCE/RETARDER CHARTS 165. . . . . . . . . . . . . . . . . . . . . . . . . . MACHINE DIMENSIONS 166. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BOLT TORQUE CHART, GENERAL 167. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPLIT FLANGE CLAMP TORQUE VALUES 176. . . . . . . . . . . . . . . . . . . . . . . ALPHABETICAL INDEX ALPHABETICAL INDEX 177. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
  • 6. 5PRESENTATION EL19877 PRESENTATION The HITACHI EH3500 is a rigid hauler capable of carrying a maximum payload of 172,365 kg (380,000 lb.) The HITACHI EH3500 features independent trailing arms and frame. NEOCON struts are mounted between the trailing arms and frame. NEOCON struts also suspend the drive axle from the frame. ENGINE The HITACHI EH3500 is powered by a 12 cylinder, 4 cycle, turbocharged Detroit diesel engine. Model 12V4000 with DDEC or a 16 cylinder, 4 cycle, turbocharged Cummins diesel engine, Model K2000E with CENTRY ELECTRIC DRIVE SYSTEM The drive system consists of a General Electric alternator, Model GTA22M, direct mounted to the engine. Standard wheel motors are General Electric Model GE788. The GE788 Statex III motorized wheel is a force ventilated D.C. motor with a speed reducing transmission which converts electric power into mechanical energy through a double reduction gear train. The motorized wheel assembly is mounted on the machine’s rear axle box. The motorized wheel functions as a transmission, a current generator for retardation and traction motor BRAKES All--hydraulic actuated braking system provides braking control and quick system response. The system is pressure proportioned, front to rear, for improved slippery road control. Three calipers per front disc, one caliper per rear disc are utilized. The main valves are conveniently located on the engine compartment firewall. A primary accumulator stores oil under sufficient pressure to ensure 100% braking capacity is always available. Two independent hydraulic circuits within the service brake system provide fully modulated reserve braking capability. The system is automatically applied when loss of pressure is detected. Spring--on, hydraulic--off park brake heads provide parking capability. RETARDER Retardation on grades is achieved through D.C. wheel motors in conjunction with General Electric resistor grid package located on the cab deck. Cooling for the grid package is achieved with forced air flow provided by dual blowers driven by a single electric motor. Three--step extended range retardation package is standard. STEERING Closed--center, full--time hydrostatic steering system using two double--acting cylinders, pressure limit compensated piston pump, and a brake actuation/steering system reservoir. An accumulator provides supplementary steering. A tilt/telescopic steering wheel with 35 of tilt and 57,15 mm (2.25 in) telescopic travel is standard. CAB Integral ROPS (Rollover Protective Structure) is standard. Double wall construction of 11 gauge inner and outer steel panels produces a more structurally sound cab. Foam rubber lining material along with foam rubber--backed carpeting and multiple layered floor mat act to absorb sound and control interior temperature. A three--point rubber iso--mounted arrangement to the the deck surface minimizes vibration to the operator compartment. BODY The body has a flat floor, sloped tailchute, and is continuously exhaust--heated. Extended canopy protects the service deck area.
  • 7. 6 PRESENTATION NAMEPLATES, WARNING, AND INFORMATION DECALS EL19882A The numbers on the illustration refer to the machine plates, warning, and information decals installed on the machine. It is the responsibility of the operator to make sure that the yellow and black warning decals are readable, otherwise accidents may occur. If the decals are no longer readable, new ones should be ordered and installed.
  • 8. 7PRESENTATION CHASSIS/BODY NAMEPLATES, WARNINGS AND INFORMATION DECALS NO. DESCRIPTION POSITION 10. Engine Start Hydraulic tank, steer--brake Indicates where level should be with the engine started sight gauge 11. Manual Release Valve Rear of hydraulic tank above Consult the technical manual for service procedures valve 12 High Voltage Control cabinet and grid box Electrical shock/electrocution. Refer to Operators Manual 13. Ladder Light Service switch box 14. Work Lights Service switch box 15. Battery Disconnect Service switch box 16. Emergency Off Service switch box 1. G.M.W. (Gross Machine Weight) Right side of the instrument panel 2. Product Identification Number Plate Above right side door 3. Propulsion Inhibit Above windshield, right side When the body is raised off the frame propulsion is inhibited 4. Pedal Location and Function Above wiindshield, right side 5. Warning. Read Operators Manual Above windshield, left side before starting and operating the machine 6. Hoist Control Lever Above windshield, left side 7. Retarder Operation Decal Above windshield. left side Refer to the Operators Manual 8. Proposition 65 Warning Lower left corner of California, United States of America windshield 9. Rollover Protective Structure (ROPS) Left side of cab, behind operator CAB NAMEPLATES, WARNINGS AND INFORMATION DECALS NO. DESCRIPTION POSITION
  • 9. 8 PRESENTATION NAMEPLATES, WARNING, AND INFORMATION DECALS ELI19882B 28 The numbers on the illustration refer to the machine plates, warning, and information decals installed on the machine. It is the responsibility of the operator to make sure that the yellow and black warning decals are readable, otherwise accidents may occur. If the decals are no longer readable, new ones should be ordered and installed.
  • 10. 9PRESENTATION 17. Air Cleaner Front of the air cleaners Numbers reference the replacement part numbers for the inner and outer filter elements 18. Burn Hazard Top Center of the radiator Remove radiator cap slowly after the machine has guard cooled down 19. Jump Start Warning Inside each battery box Electrical shock/electrocution. Refer to Operators Manual 20. Crushing Hazard from Dump Body Back of the operator’s cab Insert safety lock before getting in hazardous area 21. Warning. Contents Under Pressure Steering accumulator Consult Technical Manual for service procedures 22. Lifting Locations Front of the machine and inside of frame lugs 23. Tie Down Front of the machine, inside of frame lugs, and side of frame near front axle 24. Warning Limited Visibility -- Rear Both sides of body Stay a safe distance from the machine 25. Lock Body Next to body prop cable Refer to the Operators Manual 26. Front Wheel Crush Area Frame behind front wheel Stay clear of front axle 27. Warning Limited Visibility -- Front Right and left sides of front Stay a safe distance from the machine bumper 28. Made in Canada Left and right hand side of the front sheetmetal 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 Hitachi Rigid Hauler. To aid in production schedul- ing, 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 thetop of the front bumper, located next to the ladder. 3. Engine Serial Number Plate -- Located on the left bank side of the front gear cover of the engine. The following breakdown explains the product identification (serial) numbering system. Current Production >00000 X 00000< 3. Production Sequence Number. 2. Engine Manufacturer Designation. 1. Model Designation (4 or 5 digits). Always use the complete product identification (serial) number on all Delivery & Inspection Reports, parts orders, warranty requests, correspondence, service reports and literature orders.
  • 12. 11PRE
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