Hitachi EH5000ACII Rigid Frame Truck operator’s manual

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  This is the most complete Operation and Maintenance Manual for the HITACHI EH5000ACII RIGID FRAME TRUCK . Operation and Maintenance Manual can come in handy especially when you have to do immediate repair to your HITACHI EH5000ACII RIGID FRAME TRUCK .Operation and Maintenance Manual comes with comprehensive details regarding technical data. Diagrams a complete list of HITACHI EH5000ACII RIGID FRAME TRUCK parts and is a must for the will not be dissatisfied. Operation Manual Covers: Machine Numbers Safety Safety Signs Components Name Operator’s Station Break-In Operating the Rigid Dump Truck Operating Methods Transporting Maintenance Storage Troubleshooting Specifications Options Information Feedback Form 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. Manual No. EM8RA-1-3 Operator’s Manual Rigid Dump Truck Serial No. EH5000ACII 411RD: 77706 and Up EH5000ACII 8RAAA: 8RAAAN00001000 and Up
  • 2. INTRODUCTION 05/09 Manual No. EM8RA-1-3 Read this manual carefully to learn how to operate and service your rigid dump truck correctly. Failure to do so could result in personal injury and/or rigid dump truck damage. This manual should be considered a permanent part of your rigid dump truck and should remain with the rigid dump truck when you sell it. Measurements in this manual are given in both met- ric and customary U.S. unit equivalent. Use only cor- rect replacement parts and fasteners. Metric and inch fasteners may require a specific metric or inch wrench. Write product identification numbers in the Rigid dump truck Numbers section. Accurately record all the numbers to help in tracing the rigid dump truck should it be stolen. Your dealer also needs these numbers when you order parts. File a copy of the identification numbers in a secure place off the rigid dump truck. Warranty is provided as a part of Hitachi’s support program for customers who operate and maintain their equipment as described in this manual. The warranty is explained on the warranty certificate which you should have received from your dealer. This warranty provides you the assurance that Hitachi will back its products when defects occur within the warranty period. In some circumstances, Hitachi also provides field improvements, often without charge to the customer, even if the product is out of warranty. Should the equipment be abused or modified to change its performance beyond the original fac- tory specifications, the warranty will become void and field improvements may be denied. Setting fuel delivery above specifications or otherwise overpowering rigid dump trucks will result in such ac- tion. Moreover, when replacement parts are required, be sure to use genuine Hitachi parts. Failure to do so may result in voiding the warranty and/or denial of field improvements. Only qualified, experienced operators officially li- censed (according to local law) should be allowed to operate the rigid dump truck. Only officially, licensed personnel should be al- lowed to inspect/service the rigid dump truck. The Yellow Pages in this operator’s manual con- tain IMPORTANT SAFETY INFORMATION. Read these pages thoroughly and familiarize yourself with the safety standards and recom- mendations set forth in these yellow pages of the manual. Follow all safety instructions prior to and while operating the rigid dump truck. Prior to operating this rigid dump truck, it may be necessary to make modifications to it so that it com- plies with the local standards (including safety stan- dards) and requirements of your country. Please do not operate this rigid dump truck until such compli- ance has been confirmed. Please contact Hitachi Construction Truck Manufacturing Ltd. or any of our authorized dealers concerning compliance. All information, illustrations and specifications in this manual are based on the latest product information avail- able at the time of publication. The right is reserved to make changes at any time without notice.
  • 3. INTRODUCTION (Blank)
  • 4. INDEX All information, illustrations and specifications in this manual are based on the latest product information available at the time of publication. The right is reserved to make changes at any time without notice. COPYRIGHT(C) 2008 Hitachi Truck Manufacturing Ltd. Guelph, Canada All rights reserved MACHINE NUMBERS SAFETY SAFETY SIGNS COMPONENTS NAME OPERATOR’S STATION BREAK-IN OPERATING THE RIGID DUMP TRUCK OPERATING METHODS TRANSPORTING MAINTENANCE STORAGE TROUBLESHOOTING SPECIFICATIONS OPTIONS INFORMATION FEEDBACK FORM ALPHABETICAL INDEX
  • 5. CONTENTS INTRODUCTION INDEX MACHINE NUMBERS RIGID DUMP TRUCK TYPE AND SERIAL NUMBER.....................................M-1 ROLLOVER PROTECTIVE STRUCTURE NAMEPLATE ............................................M-1 FRAME PRODUCT IDENTIFICATION NUMBER ..................................................M-2 MTU DETROIT DIESEL DATA TAG..............M-2 LEFT WHEEL MOTOR DATA TAG...............M-3 RIGHT WHEEL MOTOR DATA TAG.............M-3 LEFT SPINDLE ASSEMBLY DATA TAG ......M-3 RIGHT SPINDLE ASSEMBLY DATA TAG....M-3 TRACTION ALTERNATOR DATA TAG ........M-4 TRACTION CONTROL CABINET DATA TAG .....................................................M-4 SAFETY RECOGNIZE SAFETY INFORMATION ........ S-1 UNDERSTAND SIGNAL WORD ................... 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 HANDLE STARTING AIDS SAFELY............. 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 ..... S-9 PROVIDE SIGNALS FOR JOBS ................... S-9 OPERATE THE RIGID DUMP TRUCK SAFELY..................................... S-10 AVOID INJURY FROM RUNNING OVER CRUSH AREA......................................... S-11 AVOID TIPPING........................................... S-12 AVOID INJURY FROM ROLLAWAY ........... S-13 NEVER TRAVEL WITH BODY OFF THE FRAME ........................................... S-13 OPERATING WITH THE RIGID DUMP TRUCK NEAR OVERHEAD WIRES............ S-14 OPERATING WITH THE RIGID DUMP TRUCK NEAR HIGH VOLTAGE OVERHEAD POWER LINES.................. S-14 PARK RIGID DUMP TRUCK SAFELY ........ S-15 SAFE HANDLING OF OFF ROAD TIRES... S-16 DISCHARGE ACCUMULATORS ................ S-16 HANDLE FLUIDS SAFELY AVOID FIRES.. S-17 A FEW SIMPLE RULES WHEN SERVICING ............................................ S-18 USE TOOLS PROPERLY............................ S-20 PREVENT BURNS ...................................... S-21 REPLACE RUBBER HOSES PERIODICALLY...................................... S-21 AVOID HIGH-PRESSURE FLUIDS............. S-22 FIRE PREVENTION MEASURES............... S-23 EVACUATING IN CASE OF FIRE............... S-25 BEWARE OF EXHAUST FUMES................ S-25 PRECAUTIONS FOR WELDING, CUTTING, AND GRINDING ................... S-26 REMOVE PAINT BEFORE WELDING OR CUTTING.......................................... S-26 AVOID HEATING NEAR PRESSURIZED FLUID LINES .......................................... S-27 AVOID APPLYING HEAT TO LINES CONTAINING FLAMMABLE FLUIDS..... S-27 PREVENT BATTERY EXPLOSIONS.......... S-28 SERVICE AIR CONDITIONING SYSTEM SAFELY .................................. S-38 HANDLE CHEMICAL PRODUCTS SAFELYS-29 DISPOSE OF WASTE PROPERLY ............ S-29 SAFETY SIGNS FRONT VISIBILITY...................................... SS-5 SAFETY RADIATOR ................................... SS-5 NO JUMP START........................................ SS-5 FAN BLADE ............................................... SS-5 HIGH VOLTAGE.......................................... SS-6 TIRE SIZE.................................................... SS-6 GROSS MACHINE WEIGHT....................... SS-6 RETARDER DECAL.................................... SS-6 FORWARD & REVERSE PROPULSION INHIBIT .......................... SS-7 READ & UNDERSTAND OPERATOR’S MANUAL ........................ SS-7 HIGH PRESSURE ....................................... SS-7 BODY DOWN ............................................. SS-7 REAR VISIBILITY ........................................ SS-8 BODY LOCK POSITION.............................. SS-8 FOUR POINT LIFT ...................................... SS-8 NO TOWING .............................................. SS-8 OVERHEAD LOAD...................................... SS-9 CRUSH AREA ............................................. SS-9 BATTERY DISCONNECT ........................... SS-9 EMERGENCY SHUTDOWN ....................... SS-9 PLANETARY LUBRICANT LEVEL............ SS-10 MAINTENANCE FREE BATTERY ............ SS-10 LOCK BODY.............................................. SS-10 CONTENTS UNDER PRESSURE ............ SS-10 DO NOT LIFT............................................. SS-11 FASTEN THE SEAT BELT........................ SS-11 AVOID EXHAUST FUMES........................ SS-11 PEDAL LOCATION.................................... SS-11 DISCHARGE ACCUMULATORS .............. SS-12
  • 6. CONTENTS COMPONENTS NAME COMPONENTS NAME...................................1-1 OPERATOR’S STATION DASH CONTROLS .........................................2-1 LAMP DISPLAY ............................................2-17 LCD MONITOR.............................................2-27 CONTROL, AC & HEATER ..........................2-39 STEERING COLUMN CONTROLS..............2-43 FOOT CONTROLS .......................................2-46 CENTER CONSOLE CONTROLS................2-47 OPERATOR’S SEAT ADJUSTMENT...........2-51 SEAT CONTROLS........................................2-52 CAB REAR, COMPONENT LAYOUT...........2-55 CAB OUTSIDE REAR PANEL......................2-56 REMOTE MOUNTED CONTROLS ..............2-57 HITACHI RIGID DUMP TRUCK PAYLOAD POLICY..................................2-60 HAUL CYCLE DATA.....................................2-62 BREAK-IN OBSERVE RIGID DUMP TRUCK CLOSELY........................................................3-1 OPERATING THE RIGID DUMP TRUCK INSPECT RIGID DUMP TRUCK DAILY BEFORE STARTING......................4-1 PRE-OPERATION INSPECTION ...................4-2 OIL AND WATER LEAKS ...............................4-4 CHECK INSTRUMENTS & CONTROLS BEFORE STARTING .................................4-5 COOLANT LEVEL CHECK.............................4-5 STARTING ENGINE .......................................4-6 USING BOOSTER BATTERIES.....................4-9 SUPPLEMENTAL STEER/BRAKE OPERATIONAL TEST .............................4-11 LOADING ......................................................4-12 LOAD WEIGHING.........................................4-13 HAULING ......................................................4-17 DUMPING .....................................................4-18 STOPPING....................................................4-21 ANTI-ROLL PROTECTION...........................4-21 STOPPING THE ENGINE.............................4-22 OPERATING METHODS GENERAL INFORMATION.............................5-1 COOLING A HOT ENGINE.............................5-2 SHIFTING DIRECTIONAL RANGE SELECTOR................................................5-2 ACCELERATOR PEDAL ................................5-3 STEERING......................................................5-3 CRUISE CONTROL........................................5-4 DYNAMIC RETARDER...................................5-4 RETARDER DECAL .......................................5-5 SERVICE BRAKES.........................................5-7 PARK BRAKE .................................................5-7 LOAD DUMP BRAKE SWITCH......................5-8 OPERATING THE HOIST CONTROL LEVER .......................................................5-9 RIGID DUMP TRUCK STUCK IN DEEP SAND, SNOW OR MUD..........................5-13 COLD WEATHER RESTRICTIONS.............5-13 TOWING .......................................................5-14 PARKING RIGID DUMP TRUCK..................5-16 TRANSPORTING THE RIGID DUMP TRUCK TRANSPORTING ...........................................6-1 MAINTENANCE CORRECT MAINTENANCE AND INSPECTION PROCEDURES ..................7-1 WASHING RIGID DUMP TRUCK...................7-1 SERVICE RIGID DUMP TRUCK AT SPECIFIED INTERVALS...........................7-2 RECOMMENDED LUBRICANTS...................7-3 RECOMMENDED FUEL.................................7-8 PREPARE RIGID DUMP TRUCK FOR SERVICE ...................................................7-9 INSTALLING BODY PROP PINS.................7-10 REMOVAL AND STORAGE OF BODY PROP PINS ..................................7-11 ELECTRICAL DISCONNECTS BEFORE WELDING ON THE RIGID DUMP TRUCK.....................................................7-12 MAINTENANCE INTERVAL GUIDE ............7-13 A. GREASING...............................................7-22 B. ENGINE....................................................7-26 C. POWER TRANSMISSION .......................7-31 D. HYDRAULIC STEERING/BRAKE APPLY SYSTEM......................................7-34 E. HYDRAULIC HOIST/BRAKE COOLING SYSTEM.................................7-40 F. BRAKES, SERVICE AND PARK..............7-45 G. FUEL SYSTEM ........................................7-48 H. AIR CLEANER .........................................7-51 I. COOLING SYSTEM ..................................7-56 J. ELECTRICAL SYSTEM............................7-63 K. SUSPENSION, WHEELS AND TIRES ....7-78 L. CAB...........................................................7-83 M. GENERAL................................................7-89 MAINTENANCE OF OPTIONAL SYSTEMS ...............................................7-93 STORAGE SHORT TERM STORAGE .............................8-1 MODERATE TERM STORAGE......................8-3 LONG TERM STORAGE................................8-5 RETURN TO SERVICE..................................8-6
  • 7. CONTENTS TROUBLESHOOTING ENGINE ..........................................................9-1 ENGINE COOLING.........................................9-4 STARTER AND MOUNTING ..........................9-4 AIR CLEANER ................................................9-5 ELECTRICAL SYSTEM ..................................9-6 HYDRAULIC SYSTEM....................................9-9 HYDRAULIC HOIST SYSTEM .....................9-11 HYDRAULIC STEER SYSTEM ....................9-12 STEER PUMP...............................................9-13 STEER CONTROL VALVE...........................9-14 FRONT AXLE................................................9-16 REAR AXLE .................................................9-17 HOIST PUMP DRIVELINE............................9-18 REAR AXLE PLANETARY ...........................9-18 PARK BRAKE ...............................................9-19 SPECIFICATIONS SERVICE SPECIFICATIONS EH5000ACII .............................................10-1 MACHINE DIMENSIONS..............................10-8 PERFORMANCE/RETARDER CHARTS ...10-12 OPTIONS OPTIONS......................................................11-1 INFORMATION FEEDBACK FORM INFORMATION FEEDBACK FORM.............12-1 INDEX ALPHABETICAL INDEX ...............................13-1
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