Hitachi EH3500AC II Rigid Frame Truck operator’s manual (Serial No. 010001 and up)

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  This is the most complete Operation and Maintenance Manual for the HITACHI EH3500AC II RIGID FRAME TRUCK . Operation and Maintenance Manual can come in handy especially when you have to do immediate repair to your HITACHI EH3500AC II RIGID FRAME TRUCK .Operation and Maintenance Manual comes with comprehensive details regarding technical data. Diagrams a complete list of HITACHI EH3500AC II RIGID FRAME TRUCK parts and is a must for the will not be dissatisfied. Operation Manual Covers: Machine Numbers Safety Safety Signs Components Name Getting on off Machine Emergency Exit Operator’s Station Break-In Operating Engine Driving Machine Operating Machine Maintenance Maintenance under Special Environmental Conditions Storage Troubleshooting Specifications 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. MACHINE NUMBERS The manufacturing Nos. explained in this group is the individual number (serial No.) given to each machine and hydraulic components. These numbers are requested when inquiring any information on the machine and/or components. Fill these serial Nos. in the blank spaces in this group to immediately make them available upon request. MACHINE MODEL/TYPE: PRODUCT IDENTIFICATION NUMBER: NOTE: HCM8R800A00010001 PRODUCT IDENTIFICATION NUMBER (PIN) ROLLOVER PROTECTCTIVE STRUCTURE CAB NAME PLATE MODEL/TYPE: ROPS MODEL NUMBER: MAX MACHINE MASS, M-kg: M8R8-01-105 Marks to indicate the start and end of the PIN
  • 2. MACHINE NUMBERS ENGINE TYPE: MFG. NO.: WHEEL MOTOR TYPE: MFG. NO.(LEFT): MFG. NO.(RIGHT): ALTERNATOR TYPE: MFG. NO.: M8R8-00-025 M8R8-00-028 M8R8-00-027
  • 3. MACHINE NUMBERS CONTROL CABINET TYPE: MFG. NO.: HYDRAULIC PUMP TYPE: MFG. NO.: CONTROL VALVE TYPE: MFG. NO.: M8R8-00-007 M8R8-00-029 M8R8-00-030
  • 4. MACHINE NUMBERS TRAVEL REDUCTION GEAR TYPE: MFG. NO.(LEFT): MFG. NO.(RIGHT): M8R8-00-031
  • 5. CONTENTS 1 MACHINE NUMBERS SAFETY Recognize Safety Information .............................S-1 Understand Signal Words ...................................S-1 Follow Safety Instructions ...................................S-2 Prepare for Emergencies.....................................S-2 Wear Protective Clothing.....................................S-3 Protect Against Noise..........................................S-3 Inspect Machine ..................................................S-3 General Precautions for Cab...............................S-4 Use Handholds and Steps...................................S-4 Operator’s Visibility..............................................S-5 Adjust Operator’s Seat ........................................S-6 Fasten Your Seat Belt .........................................S-6 Move and Operate Machine Safely.....................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 Avoid Injury Caused by High Tension Electric Shock................................................S-9 Investigate Job Site Beforehand .........................S-9 Provide Signals for Jobs Involving Multiple Machines .......................................................S-9 Drive Machine Safely.........................................S-10 Drive on Snow Safely ........................................S-10 Wheel Maintenance...........................................S-11 Avoid Injury from Rollaway Accidents ...............S-11 Avoid Injury from Back-Over Accidents.............S-12 Keep Person Clear from Working Area.............S-12 Avoid Tipping.....................................................S-13 Protect Against Falling Stones and Debris........S-14 Operate with Caution.........................................S-14 Avoid Power Lines.............................................S-14 Precautions for Lightning...................................S-15 Avoid Overloading ...........................................S-15 Protect Against Flying Debris ............................S-16 Park Machine Safely..........................................S-16 Prevent Unintended Machine Movement ..........S-17 Handle Fluids Safely  Avoid Fires ...................S-17 Practice Safe Maintenance ...............................S-18 Warn Others of Service Work............................S-19 Support Machine Properly.................................S-19 Stay Clear of Moving Parts................................S-19 Prevent Parts from Flying..................................S-20 Prevent Burns....................................................S-20 Replace Rubber Hoses Periodically..................S-21 Avoid High-Pressure Fluids...............................S-21 Prevent Fires .....................................................S-22 Evacuating in Case of Fire ................................S-23 Beware of Exhaust Fumes ................................S-23 Precautions for Welding and Grinding...............S-24 Avoid Heating Near Pressurized Fluid Lines.....S-24 Avoid Applying Heat to Lines Containing Flammable Fluids........................................S-24 Remove Paint Before Welding or Heating........ S-25 Beware of Asbestos Dust.................................. S-25 Prevent Battery Explosions............................... S-26 Service Air Conditioning System Safely ........... S-26 Handle Chemical Products Safely .................... S-27 Dispose of Waste Properly ............................... S-27 SAFETY SIGNS .......................................... S-28 COMPONENTS NAME............................... 1-1 GETTING ON/OFF MACHINE.................. 1-2 EMERGENCY EXIT Emergency Exit................................................... 1-3 Evacuating in Case of Fire.................................. 1-4 OPERATOR’S STATION Cab Features ...................................................... 1-6 Monitor Display ................................................... 1-7 How to Use Screens ........................................... 1-7 How to Use Key Pad........................................... 1-9 Basic Screen..................................................... 1-10 Engine Related Warning Indicators .................. 1-13 Driving Related Warning Indicators .................. 1-16 Hydraulic Related Warning Indicators .............. 1-20 Light Indicators.................................................. 1-23 Miscellaneous Indicator .................................... 1-24 Alarm Occurrence Screen................................. 1-26 Clock Setting..................................................... 1-27 Head Lights/Front Combination Lights/Horns... 1-29 Side Lights ........................................................ 1-30 Rear Lights........................................................ 1-31 Maintenance Lights........................................... 1-32 Steering Wheel ................................................. 1-33 Horn Switch....................................................... 1-33 Turn Signal/High Beam Lever Switch ............... 1-33 Tilt/Telescope Steering Wheel.......................... 1-34 Accelerator Pedal.............................................. 1-34 Service Brake Pedal ......................................... 1-35 Retarder Brake Pedal ....................................... 1-36 Parking Brake.................................................... 1-36 Center Console ................................................. 1-37 Hoist Lever........................................................ 1-39 Console Panel................................................... 1-41 Dome Light Switch ............................................ 1-47 Sun Visor........................................................... 1-47 Air Conditioner .................................................. 1-48 Designations and Functions of the Control Panel........................................................... 1-49 Cooling.............................................................. 1-50 Heating.............................................................. 1-51 Dehumidifying and Heating............................... 1-51 Defrosting.......................................................... 1-51 Blower Operation Without Cooling or Heating.. 1-52 Ventilation of the Cab........................................ 1-52
  • 6. CONTENTS 2 AM/FM Radio Operation....................................1-53 Digital Clock Setting Procedure.........................1-54 Camera Monitor.................................................1-55 Adjusting Operator’s Seat .................................1-56 Adjusting Trainer’s Seat ....................................1-59 Seat Belt ............................................................1-60 Cab Door Lock...................................................1-61 Opening/Closing Cab Left Door ........................1-61 Electrical Equipment Box (Behind Cab) ............1-62 Deck upper Relay Box.......................................1-65 BREAK-IN Observe Machine Closely ...................................2-1 Every 10 Hours or Each Shift..............................2-1 After the First 50 Hours .......................................2-1 OPERATING ENGINE Inspect Machine Daily Before Starting ................3-1 Before Starting Engine ........................................3-2 System Check .....................................................3-3 Starting Engine in Normal Temperature..............3-4 Starting in Cold Weather .....................................3-5 Check Instruments After Starting ........................3-6 Using Booster Batteries.......................................3-7 Stopping Engine ..................................................3-9 DRIVING MACHINE Drive Machine Carefully ......................................4-1 Starting ................................................................4-2 Propel Change.....................................................4-3 Acceleration.........................................................4-3 Cruise Control......................................................4-4 Deceleration ........................................................4-6 Retarder Brake ....................................................4-6 Auto Retarder ......................................................4-7 Steering ...............................................................4-9 Stopping Machine..............................................4-10 Parking Machine................................................4-11 Towing ...............................................................4-12 OPERATING MACHINE Loading................................................................5-1 Load Weighing System........................................5-2 Hauling ................................................................5-3 Dumping ..............................................................5-4 Speed Limitation Function While Dump Body is Raised....................................5-7 Deactivation of Speed Limitation Function in an Emergency ...........................................5-7 MAINTENANCE Correct Maintenance and Inspection Procedures...................................7-1 Check Hour Meter Regularly...............................7-2 Use Correct Fuels and Lubricants.......................7-2 Prepare Machine for Maintenance ......................7-3 Installing Body Prop Pins.................................... 7-5 Removal and Storage of Body Prop pins............ 7-6 Inspection/Maintenance Lights ........................... 7-7 Main Part/Component Location Diagram............ 7-9 Periodic Replacement of Parts ......................... 7-10 Hydraulic System .............................................. 7-11 Maintenance Guide........................................... 7-13 A. Greasing ....................................................... 7-18 B. Engine........................................................... 7-23 Check Engine Oil Level .............................. 7-24 Change Engine Oil...................................... 7-25 Replace Engine Oil Filters .......................... 7-25 C. Travel Reduction Gear ................................. 7-27 Check Gear Oil Level.................................. 7-28 Change Gear Oil......................................... 7-29 Replace Gear Oil Filter ............................... 7-29 Clean and Replace Breather ...................... 7-30 Clean Oil Cooler.......................................... 7-30 D. Hydraulic System ......................................... 7-31 Inspection and Maintenance of Hydraulic Equipment ............................. 7-32 Check Hydraulic Oil Level........................... 7-34 Drain Hydraulic Oil Tank Sump .................. 7-35 Replace Full-Flow Filter .............................. 7-36 Replace Line Filter...................................... 7-38 Change Hydraulic Oil.................................. 7-40 Suction Filter Cleaning................................ 7-40 Check Hoses and Lines.............................. 7-43 Service Recommendations for Hydraulic Fittings ................................... 7-46 E. Fuel System.................................................. 7-49 Drain Fuel Tank Sump................................ 7-51 Drain Fuel Filter Element ............................ 7-51 Replace Fuel Filter Element ....................... 7-52 Replace Fuel Filter...................................... 7-53 Check Fuel Hoses ...................................... 7-54 Clean Fuel Tank Breather........................... 7-55 F. Air Cleaner.................................................... 7-56 Clean Air Cleaner Outer Element ............... 7-56 Replace Air Cleaner Outer and Inner Elements ...................................... 7-56 Clean Air Cleaner Dust Cups...................... 7-58 G. Cooling System ............................................ 7-59 Check Coolant Level................................... 7-60 Check DCA4 Concentration in Coolant ...... 7-61 Replace Coolant Filter ................................ 7-69 Change Coolant.......................................... 7-70 Clean Radiator, After Cooler Interior .......... 7-70 Clean Radiator, After Cooler Core.............. 7-71 Check Fan Belt for Wear ............................ 7-71 H. Air Conditioner.............................................. 7-72 Clean and Replace Recirculation Air Filter. 7-72 Clean and Replace Ventilation Air Filter..... 7-73 Check Refrigerant Quantity ........................ 7-74 Check Compressor Belt Tension................ 7-75 Clean Condenser Core ............................... 7-76
  • 7. CONTENTS 3 Check Tightening Torque............................7-77 Seasonal Maintenance................................7-78 I. Electrical System............................................7-79 Batteries ......................................................7-79 Replacing Fuses..........................................7-84 Check Fusible Link......................................7-88 Check Electrical Cables and Wire Harnesses......................................7-89 Check Emergency Engine Stop Switch ......7-91 Check Lights ...............................................7-92 Check Horm and Backup Alarm Buzzer .....7-92 Check Suspension Pressure Sensor ..........7-93 J. Brakes & Steering System.............................7-95 Check Brake Operation...............................7-95 Check Service Brake...................................7-95 Check Parking Brake...................................7-96 Check Accumulator .....................................7-97 Check Front/Rear Brake Lining...................7-99 Check Front/Rear Brake Disk......................7-99 K. Suspension, Wheels & Tires.......................7-100 Check Suspension ....................................7-101 Check Wheels ...........................................7-102 Check Front Axle.......................................7-103 Check Front Wheel Lubricant....................7-103 Change Front Wheel Lubricant .................7-103 Check Tire Inflation ...................................7-104 Check Tire Condition.................................7-105 Check Wheel Alignment............................7-105 L. Miscellaneous..............................................7-106 Check and Replace Alternator Carbon Brush.......................................7-106 Check and Change Coolant in the Control Cabinet ..........................7-108 Clean and Replace Pressuerized Control Cabinet Filter ...........................7-109 Clean Rear Axle Inside..............................7-110 Check and Replace Seat Belt ...................7-110 Check Windshield Washer Tank ...............7-110 Check Play Amount in Steering Wheel Stroke .....................7-111 Check Tightening Torque of Bolts and Nuts..................................7-112 MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS....9-1 STORAGE Storing Machine.................................................10-1 Removing Machine From Storage.....................10-2 TROBLESHOOTING Cummins Fault Code Lamps and Diagnostic Switches ....................................11-1 Engine ...............................................................11-2 Electrical System...............................................11-6 Hydraulic System...............................................11-9 Hydraulic Hoist System................................... 11-11 Hydraulic Steering System.............................. 11-12 Steering Pump ................................................ 11-13 Steering Control Valve .................................... 11-14 Front Axle........................................................ 11-16 Rear Axle ........................................................ 11-17 Hoist Pump Driveline ...................................... 11-18 Rear Axle Planetary........................................ 11-18 Parking Brake.................................................. 11-19 Alternator......................................................... 11-20 Wheel Motor.................................................... 11-20 Blower Motor................................................... 11-21 SPECIFICATIONS Specifications.................................................... 12-1 Hitachi Loading Policy....................................... 12-2 INDEX............................................................. 14-1
  • 8. CONTENTS 4 MEMO ...................................................................................................................................................................................... ...................................................................................................................................................................................... ...................................................................................................................................................................................... ...................................................................................................................................................................................... ...................................................................................................................................................................................... ...................................................................................................................................................................................... ...................................................................................................................................................................................... ...................................................................................................................................................................................... ...................................................................................................................................................................................... ...................................................................................................................................................................................... ...................................................................................................................................................................................... ...................................................................................................................................................................................... .................................................
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