Hitachi EH4500 Rigid Frame Truck operator’s manual

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  This is the most complete Operation and Maintenance Manual for the HITACHI EH4500 RIGID FRAME TRUCK . Operation and Maintenance Manual can come in handy especially when you have to do immediate repair to your HITACHI EH4500 RIGID FRAME TRUCK .Operation and Maintenance Manual comes with comprehensive details regarding technical data. Diagrams a complete list of HITACHI EH4500 RIGID FRAME 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. DISTRIBUTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADDRESS PHONE NO.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DLR/BRCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADDRESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PHONE NO. . . . . . . . . . . . . SERVICE PHONE NO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPARE PARTS PHONE NO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MACHINE: SERIAL NO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE TYPE/NO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HYDRAULIC TRANSM. TYPE/NO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTING KEY NO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAB KEY NO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PRINTED IN U.S.A. PUBLICATION NO. MANUAL EH4500 OPERATORS 10183 ENG. EDITION 1 401MD/402MD 12/00 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. CONTENTS 3 PRESENTATION 5 INSTRUMENT PANEL 13 OPERATORS CONTROLS 41 OPERATING INSTRUCTIONS 58 99BASIC PREVENTIVE MAINTENANCE SPECIFICATIONS 151 ALPHABETICAL INDEX 172
  • 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, Inc. 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 EUCLID--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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRIC DRIVE SYSTEM 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 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPERATING INSTRUCTIONS GENERAL OPERATING RULES 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPERATOR’S QUALIFICATIONS 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DUTIES OF THE OPERATOR 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A FEW SIMPLE SAFETY RULES BEFORE OPERATING 58. . . . . . . . . . . . . OPERATING WITH THE MACHINE NEAR OVERHEAD WIRES OR CABLES 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPERATING WITH THE MACHINE NEAR HIGH VOLTAGE OVERHEAD POWER LINES 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SIGNALLING DIAGRAM 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PROCEDURE BEFORE STARTING 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RUN IN INSTRUCTIONS 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTING ENGINE 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BEFORE OPERATING 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPERATING THE MACHINE 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PARKING MACHINE 84. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STORAGE OF EUCLID--HITACHI RIGID HAULERS 85. . . . . . . . . . . . . . . . . TRANSPORTING 95. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TOWING 96. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
  • 5. CONTENTS4 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 106. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE 107. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AIR CLEANER SYSTEM 115. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL SYSTEM 117. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COOLING SYSTEM 121. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL SYSTEM 124. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE SYSTEM 130. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WHEEL SUSPENSION AND STEERING 132. . . . . . . . . . . . . . . . . . . . . . . . . FRAME SUSPENSION AND WHEELS 136. . . . . . . . . . . . . . . . . . . . . . . . . . . CAB 141. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HYDRAULIC SYSTEM AND OTHER FUNCTIONS 144. . . . . . . . . . . . . . . . . SPECIFICATIONS RECOMMENDED LUBRICANTS 151. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SERVICE SPECIFICATIONS 154. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PERFORMANCE/RETARDER 163. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MACHINE DIMENSIONS 164. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BOLT TORQUE CHART, GENERAL 165. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ALPHABETICAL INDEX ALPHABETICAL INDEX 172. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
  • 6. 5PRESENTATION EL19644 PRESENTATION The Hitachi EH4500 is a rigid frame hauler capable of carrying a 273,063 kg (602,000 lb.) payload. The Hitachi EH4500 Hauler features an independent trailing arm and frame. Neocon suspension cylin- ders are also utilized on the rear axle. ENGINE The Hitachi EH4500 (401MD) is powered by a 65 liter (3966 cu. in.), 2014 kw (2700 HP), 16 cylinder, four cycle, turbo--charged Detroit Diesel 16V4000 engine. The Hitachi EH4500 (402MD) is powered by a 65 liter (3966 cu. in.), 2014 kw (2700 HP), 16 cylinder, four cycle, turbo--charged Cummins QSK60 engine. ELECTRIC DRIVE SYSTEM The Euclid AC drive technology uses Siemens controls and proven GTO inverter phase modules. Dynamic retarding capacity to zero speed using solid state technology. Alternator direct mounted to engine. Euclid AC drive technology, developed in conjunction with Siemens, provides superior performance with higher drive efficiency. Superior productivity is attained with higher top speed, better gradeability, and stronger retardation. Brushless operation reduces maintenance. BRAKES The machine is equipped with dual independent hydraulic circuits within the service brake system that provide fully modulated reserve braking capability. Both front dry disc and rear wet disc are automatically applied when loss of pressure is detected. Four spring on, hydraulic off armature disc brake heads provide parking capabilities. The braking system complies with SAE J/ISO 3450. Superior retardation to zero speed on grades is achieved through AC wheel motors in conjunction with the Siemens resistor grid package. A recessed grid box, located on the service deck, enhances operator visibility. Cooling for the grid package is achieved with forced airflow provided by a blower driven by a single electric motor. STEERING The machine is equipped with a flow amplified, power steering system using two double acting cylinders, pressure limit with unload piston pump, and a brake actuation/steering system reservoir. Accumulators provides supplementary steering in accordance with J/ ISO 5010. CAB The machine is equipped with a cab that has an integral ROPS standard in accordance with J/ISO 3471.The cab is fully insulated and includes a filtered air heater and pressurizing system. BODY The body is designed with a flat chute type, sloped floor, continuously exhausted heated. Extended canopy protects service deck area.
  • 7. 6 PRESENTATION INFORMATION AND WARNING PLATES EL19642 EH4500 EH4500 10 13 12 11 13 5 6 7 8 9 4 3 2 1 1 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 1 High Voltage On high voltage areas of Electrical shock/electrocution. Refer to Operators Manual machine 2 Manual Release Valve Located on the outside and Consult technical manual for service procedures the inside of the hydraulic control cabinet 3 Product Identification Number Plate Above right door 4 Propulsion Inhibit Above right side of windshield When the body is raised off the frame propulsion is inhibited 5 Pedal Location and Function Above right side of windshield 6 Warning, Read Operators Manual Above left side of windshield before starting and operating the machine 7 Hoist Control Lever Above left side of windshield 8 Retarder Operation Decal Above left side of windshield Refer to the Operators Manual 9 Crushing Hazard of Whole Body from Dump Body Located on the back of the Insert safety lock before getting in hazardous area cab 10 Warning Contents Under Pressure Located on steering Consult technical manual for service procedures accumulator 11 Rollover Protective Structure (ROPS) Above left side of cab behind operator 12 Lock Body Located next to body prop pin Refer to the Operators Manual on left--hand side of dump body 13 Lifting Locations Front and rear of machine NO. DESCRIPTION POSITION
  • 9. 8 PRESENTATION INFORMATION AND WARNING PLATES EL19643 22 15 23 22 21 24 17 20 19 18 16 20 26 14 27 26 25 28 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 14 Front Wheel Crush Area Located on each fender Stay clear of front axle 15 Jump Starting Warning Located inside battery box Electrical shock/electrocution. Refer to Operators Manual 16 Ladder Light Located on the center of radiator cowl 17 Emergency Off Located on the center of radiator cowl 18 Work Lights Located on the center of radiator cowl 19 Battery Disconnect Located on the center of radiator cowl 20 Warning Limited Visibility--Front Located on the right and left Stay a safe distance from the machine side of front fenders 21 G.M.W.(Gross Machine Weight) Located on the right side of the control panel 22 Air Cleaner Located on the front of the air References the replacement part numbers for the cleaners inner and outer filter elements 23 Burn Hazard Located on the top center of Remove radiator cap slowly after machine has cooled down. the radiator guard 24 Proposition 65 Warning Located lower left corner of California, United States of America windshield 25 Warning Limited Visibility--Rear On both sides of body Stay a safe distance from the machine 26 Tie Down On the front bumper, the rear and front frame 27 Engine Start On hydraulic tank, steer--brake Indicates where level should be with engine started sight gauge 28 Hose Location On back of hydraulic control cabinet NO. DESCRIPTION POSITION
  • 11. 10 PRESENTATION PRODUCT IDENTIFICATION NUMBER Euclid--Hitachi Construction Equipment Corporation is a worldwide company that produces the Euclid Rigid Hauler. Toaid inproduction 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, Inc. EL18484 Product Identification Number Locations 1. Product Identification Plate -- Located inside the cab above the windshield. 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 hand side 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. 11PRESENTATION MAINTENANCE AND INSPECTIONS MAINTENANCE TS40011 If the machine is to work as efficiently as possible, thorough maintenance is necessary. Recommended intervals for maintenance and lubrication are based on normal working and environmental conditions. The maintenance work described in this manual can be carried out by a trained operator. Further adjustments and repairs to the machine should be performed by an authorized EUCLID--HITACHI distributor. INSPECTIONS Delivery Inspections Before the machine left the factory it was tested and adjusted. In addition to this, your EUCLID--HITACHI distributor has carried out a further check, the “ Pre--Delivery Inspection”, before the mac
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