Hitachi EH3500ACII User manual

EM8R8-1-4EH3500AC RIGID DUMP TRUCK OPERATOR’S MANUAL
Serial No 010132 and up
Rigid Dump Truck
PRINTED IN JAPAN (E) 2012, 12
This book is printed on recycled paper.
EM8R8-1-4
PART NO.
Operator’s Manual
URL:http://www.hitachi-c-m.com
EH3500AC

INTRODUCTION
©2012 Hitachi Construction Machinery Co., Ltd.
All rights reserved.
Read this manual carefully to learn how to operate and
service your machine correctly. Failure to do so could
result in personal injury and/or machine damage.
This standard specification machine can be operated
under the following conditions without being modified.
Atmospheric Temperature: -20 to 50 °C (-4 to 122 °F)
Altitude: 0 m to 2000 m (0 ft to 6600 ft)
In case the machine is used under conditions other than
described above, consult your nearest Hitachi dealer.
This manual should be considered a permanent part of
your machine and should remain with the machine when
you sell it.
This machine is of metric design. Measurements in this
manual are metric. Use only metric hardware and tools as
specified.
• SI Units (International System of Units) are used in
this manual.
For reference MKS system units and English units are
also indicated in parentheses after the SI units.
Example : 24.5 MPa (250 kgf/cm, 3550 psi)
Right-hand and left-hand sides are determined by
facing in the direction of forward travel.
Write product identification numbers in the Machine
Numbers section. Accurately record all the numbers
to help in tracing the machine should it be stolen.
Your dealer also needs these numbers when you order
parts. If this manual is kept on the machine, also file the
identification numbers in a secure place off the machine.
Use only diesel fuel with quality specified in JIS K-2204,
EN-590 or ASTM D-975 which contents 15 ppm or lower
sulfur.
Also use fuel that complies with solid contamination level
of class 18/16/13 of ISO4406-1999 (solid contamination
includes dust). If the fuel specified above is not used,
exhaust gas that exceeds the regulation values may be
discharged, causing serious problem on the engine.
Consult your nearest Hitachi dealer.
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 factory
specifications, the warranty will become void and field
improvements may be denied.
Setting fuel delivery above specifications or otherwise
overpowering machines will result in such action.
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.
The Yellow Pages in this operator’s manual contain
IMPORTANT SAFETY INFORMATION.
Read these pages thoroughly and familiarize yourself
with the safety standards and recommendations set
forth in these yellow pages of the manual.
Follow all safety instructions prior to and while
operating this dump truck.
Only qualified, experienced operators officially licensed
(according to local law) should be allowed to operate the
machine.
Moreover, only officially licensed personnel should be
allowed to inspect and service the machine.
Prior to operating this machine, including
communication satellite system, in a country other
than a country of its intended use, it may be necessary
to make modifications to it so that it complies with
the local regulatory standards (including safety
standards) and legal requirements of that particular
country.
Please do not export or operate this machine
outside of the country of its intended use until such
compliance has been confirmed. Please contact
Hitachi Construction Machinery Co., Ltd. or any of
our authorized distributors or dealers if you have any
questions concerning compliance.
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.
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INDEX
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
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CONTENTS
MACHINE NUMBERS .......................................................................1
SAFETY ..............................................................................................S-1
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
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
Wheel Maintenance ....................................................................S-11
Drive on Snow Safely ..................................................................S-12
Avoid Injury from Rollaway Accidents.................................. S-12
Avoid Injury from Back-Over Accidents............................... S-13
Keep Person Clear from Working Area..................................S-13
Avoid Tipping.................................................................................S-14
Protect Against Falling Stones and Debris.......................... S-15
Operate with Caution .................................................................S-15
Avoid Power Lines........................................................................S-15
Precautions for Lightning..........................................................S-16
Avoid Overloading.......................................................................S-16
Protect Against Flying Debris ..................................................S-17
Park Machine Safely..................................................................... S-17
Prevent Unintended Machine Movement...........................S-18
Handle Fluids Safely − Avoid Fires ......................................... S-18
Practice Safe Maintenance........................................................ S-19
Warn Others of Service Work ...................................................S-20
Support Machine Properly........................................................ S-20
Stay Clear of Moving Parts ........................................................S-20
Prevent Parts from Flying ..........................................................S-21
Prevent Burns................................................................................. S-21
Replace Rubber Hoses Periodically........................................S-22
Avoid High-Pressure Fluids.......................................................S-22
Prevent Fires................................................................................... S-23
Evacuating in Case of Fire.......................................................... S-24
Beware of Exhaust Fumes..........................................................S-24
Precautions for Welding and Grinding .................................S-25
Avoid Heating Near Pressurized Fluid Lines.......................S-25
Avoid Applying Heat to Lines Containing Flammable
Fluids ...........................................................................................S-25
Precautions for Handling Accumulator and Gas
Damper.......................................................................................S-26
Remove Paint Before Welding or Heating...........................S-26
Beware of Asbestos and Silicon Dust and Other
Contamination......................................................................... S-26
Prevent Battery Explosions ....................................................... S-27
Service Air Conditioning System Safely ...............................S-27
Handle Chemical Products Safely........................................... S-28
Dispose of Waste Properly.........................................................S-28
Precautions for Communication Terminal........................... S-28
SAFETY SIGNS .............................................................................S-29
COMPONENTS NAME .................................................................1-1
Components Name ........................................................................1-1
GETTING ON/OFF MACHINE ....................................................1-2
Getting ON/OFF Machine.............................................................1-2
EMERGENCY EXIT .........................................................................1-3
Emergency Exit ................................................................................1-3
Evacuating in Case of Fire.............................................................1-4
OPERATOR’S STATION ................................................................1-5
Cab Features......................................................................................1-5
Monitor Display................................................................................1-6
How to Use Screens........................................................................1-6
Displaying Starting Check Screen........................................1-6
How to Use Key Pad........................................................................1-8
Basic Screen.......................................................................................1-9
Speedometer............................................................................1-10
Odometer (2)............................................................................1-10
Tachometer (3), Shift Lever Position Indicator (4).......1-10
Engine Oil Pressure Gauge ..................................................1-10
Coolant Temperature Gauge ..............................................1-11
Wheel Motor Temperature Gauge....................................1-11
Brake/Steering Oil Pressure Gauge...................................1-11
Engine Related Warning Indicators........................................1-12
Engine Warning Indicator....................................................1-13
Engine Oil Pressure Warning Indicator............................1-13
Engine Overheat Warning Indicator ................................1-13
Engine Coolant Level Warning Indicator........................1-14
Alternator Warning Indicator..............................................1-14
Air Cleaner Restriction Warning Indicator .....................1-14
Stop Valve Warning Indicator.............................................1-14
Grid Dry Warning Indicator .................................................1-14
Driving Related Warning Indicators.......................................1-15
Traction Fault Warning Indicator.......................................1-16
Drive Shut Down Warning Indicator................................1-16
Wheel Motor Temperature Warning Indicator .............1-16
Wheel Motor & Alternator Blower Fault Warning
Indicator................................................................................1-16
Electric Brake Warning Indicator.......................................1-17
Parking Brake Warning Indicator.......................................1-17
Load/Dump Brake Warning Indicator .............................1-17
Engine Stop Warning Indicator..........................................1-18
Central Warning Indicator....................................................1-18
AC Drive System Maintenance Required Warning
Indicator................................................................................1-18
Hydraulic Related Warning Indicators ..................................1-19
Hydraulic Oil Overheat Warning Indicator.....................1-20
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CONTENTS
Steering Oil Pressure Warning Indicator.........................1-20
Auto-Lubrication Warning Indicator................................1-20
Hydraulic Oil Level Warning Indicator.............................1-21
Dump Body Up Indicator.....................................................1-21
Hoist Lever Position Warning Indicator...........................1-21
Light Indicators .............................................................................1-22
Rear Light Indicator ...............................................................1-23
Front Tire Light Indicator (Optional) ................................1-23
Head Light/High Beam Indicator ......................................1-23
Miscellaneous Indicators...........................................................1-23
Turn Signal/Hazard Indicator..............................................1-23
Fuel Gauge ................................................................................1-24
Load Meter ................................................................................1-24
Hour Meter................................................................................1-24
Clock............................................................................................1-24
Alarm Occurrence Screen..........................................................1-25
Clock Setting..................................................................................1-26
Time Adjusting.........................................................................1-27
Head Lights/Front Combination Lights/Horns..................1-28
Side Lights.......................................................................................1-29
Rear Lights ......................................................................................1-30
Maintenance Lights.....................................................................1-31
Steering Wheel..............................................................................1-32
Horn Switch....................................................................................1-32
Turn Signal/High Beam Lever Switch....................................1-32
Hazard Warning Lamp Switch..................................................1-33
Tilt/Telescope Steering Wheel .................................................1-33
Accelerator Pedal..........................................................................1-33
Service Brake Pedal......................................................................1-34
Electric Brake Pedal......................................................................1-35
Parking Brake.................................................................................1-35
Center Console..............................................................................1-36
Shift Lever (1)............................................................................1-36
Dump Override Switch (2)...................................................1-36
Load/Dump Brake Switch (3)..............................................1-37
Hoist Lever......................................................................................1-38
Hoist Lever Functions............................................................1-38
Console Panel ................................................................................1-40
Cruise Control/Auto Retard Main Switch (1).................1-41
Cruise Control/Auto Retard Speed Setting
Switch (2)..............................................................................1-41
Grid Dry Switch (4)..................................................................1-41
AC Drive Shut Down Switch (5)..........................................1-41
Parking Brake Switch (6).......................................................1-42
Emergency Engine Stop Switch (10)................................1-42
Key Switch (11).........................................................................1-42
Headlight Switch (12)............................................................1-42
Front Tire Light Switch (15) (Optional)............................1-43
Rear Light Manual Switch (16) ...........................................1-43
Ladder & Deck Light Switch (17) .......................................1-43
Wiper/Washer Switch (18) ...................................................1-43
AC Drive Fault Reset Switch (19)........................................1-44
Cigar Lighter (20) ....................................................................1-44
Dimmer Switch (21) ...............................................................1-44
Buzzer Deactivation Switch (22)........................................1-44
Engine Room Maintenance Light Indicator (23)..........1-45
Rear Axle Inside Maintenance Light Indicator (24)..... 1-45
AC Drive System Maintenance Switch (25)....................1-45
Dome Light Switch ......................................................................1-46
Sun Visor..........................................................................................1-46
Air Conditioner..............................................................................1-47
Designations and Functions of the Control Panel............1-48
Cooling.............................................................................................1-49
Heating.............................................................................................1-50
Dehumidifying and Heating.....................................................1-50
Defrosting .......................................................................................1-50
Blower Operation Without Cooling or Heating.................1-51
Ventilation of the Cab.................................................................1-51
AM/FM Radio Operation ...........................................................1-52
Controls on the Radio............................................................1-52
Tuning Procedure ...................................................................1-52
Station Presetting Procedure..............................................1-52
Sound Adjustment .................................................................1-53
Digital Clock Setting Procedure..............................................1-53
Camera Monitor............................................................................1-54
How to Use Camera Monitor ..............................................1-54
Control Panel Designation and Function.......................1-54
Adjusting Operator’s Seat .........................................................1-55
Seat Incline Adjustment.......................................................1-55
Seat Fore-Aft Adjustment .................................................... 1-55
Armrest Angle Adjustment ................................................1-55
Armrest Height Adjustment................................................1-55
Seat/Backrest Fore-Aft Adjustment .................................1-56
Seat Height Adjustment.......................................................1-56
Absorber Adjusting................................................................1-56
Seat/Armrest/Backrest Fore-Aft Adjustment................1-56
Backrest Adjustment .............................................................1-57
Headrest Adjustment ............................................................1-57
Adjusting Trainer’s Seat .............................................................1-58
Weight adjustment ...............................................................1-58
Seat Belt...........................................................................................1-59
Seat Belt......................................................................................1-59
Cab Door Lock...............................................................................1-60
Opening/Closing Cab Left Door .............................................1-60
Electrical Equipment Box (Behind Cab)................................1-61
Relays ..........................................................................................1-62
Fuses............................................................................................1-63
Deck Upper Relay Box.................................................................1-64
Relays ..........................................................................................1-65
Relay Box 3 ................................................................................1-65
Relay Box Optional.................................................................1-65
Relay Box 2 ................................................................................1-65
Fuse Box 3..................................................................................1-66
BREAK-IN ..........................................................................................2-1
Observe Machine Closely.............................................................2-1
Every 10 Hours or Each Shift .......................................................2-1
After the First 50 Hours .................................................................2-1
OPERATING ENGINE ....................................................................3-1
Inspect Machine Daily Before Starting ....................................3-1
Before Starting Engine ..................................................................3-2
System Check....................................................................................3-3
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CONTENTS
Starting Engine in Normal Temperature.................................3-4
Starting Engine in Cold Weather................................................3-5
Check Instruments After Starting..............................................3-6
Using Booster Batteries.................................................................3-7
Stopping Engine..............................................................................3-9
DRIVING MACHINE ......................................................................4-1
Drive Machine Carefully................................................................4-1
Starting ...............................................................................................4-2
Propel Change..................................................................................4-3
Acceleration ......................................................................................4-3
Cruise Control...................................................................................4-4
Deceleration......................................................................................4-6
Electric Brake.....................................................................................4-6
Auto Retard........................................................................................4-7
Steering...............................................................................................4-9
Stopping Machine........................................................................4-10
Parking Machine...........................................................................4-11
Towing..............................................................................................4-12
OPERATING MACHINE ................................................................5-1
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
ΜΑΙΝΤΕΝΑΝCΕ ..............................................................................7-1
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 Dump Body Prop Pins ................................................7-5
Removal and Storage of Dump Body Prop Pins...................7-6
Installing Dump Body Prop Cable.............................................7-7
Removal and Storage of Dump Body Prop Cable................7-8
Inspection/Maintenance Lights.................................................7-9
Main Part/Component Location Diagram...........................7-11
Periodic Replacement of Parts.................................................7-13
Hydraulic System..........................................................................7-14
Maintenance Guide.....................................................................7-16
A. Greasing......................................................................................7-21
B. Engine..........................................................................................7-24
Check Engine Oil Level..........................................................7-25
Change Engine Oil..................................................................7-26
Replace Engine Oil Filters ....................................................7-26
C. Travel Reduction Gear............................................................7-28
Check Gear Oil Level..............................................................7-29
Change Gear Oil ......................................................................7-30
Replace Gear Oil Filter...........................................................7-30
Clean and Replace Air Breather.........................................7-31
Clean Oil Cooler Core ............................................................7-31
D. Hydraulic System.....................................................................7-32
Inspection and Maintenance of Hydraulic Equipment...7-33
Check Hydraulic Oil Level ....................................................7-35
Drain Hydraulic Oil Tank Sump ..........................................7-36
Replace Full-Flow Filter Element .......................................7-37
Replace Line Filter Element.................................................7-39
Change Hydraulic Oil.............................................................7-41
Replace Suction Filter............................................................7-41
Replace Tank Air Breather Element...................................7-44
Check Hoses and Lines .........................................................7-45
E. Fuel System ................................................................................7-51
Drain Fuel Tank Sump............................................................7-53
Drain Fuel Filter (Stage 1 Filter)..........................................7-53
Replace Fuel Filter Element (Stage 1 Filter)...................7-54
Replace Fuel Filter (Stage 2 Filter).....................................7-55
Check Fuel Hoses....................................................................7-56
Clean Fuel Tank Breather......................................................7-57
F. Air Cleaner...................................................................................7-58
Clean Air Cleaner Outer Element ......................................7-58
Replace Air Cleaner Outer and Inner Elements............7-58
Clean Air Cleaner Dust Cups...............................................7-60
G. Cooling System........................................................................7-61
Check Coolant Level ..............................................................7-62
Check DCA4 Concentration in Coolant...........................7-63
Replace Coolant Filter ...........................................................7-71
Change Coolant.......................................................................7-72
Clean Radiator, After Cooler Interior................................7-72
Clean Radiator, After Cooler Core .....................................7-73
Check Fan Belt for Wear........................................................7-73
H. Air Conditioner.........................................................................7-74
Clean and Replace Recirculation Air Filter.....................7-74
Clean and Replace Ventilation Air Filter..........................7-75
Check Refrigerant Quantity.................................................7-76
Check Compressor Belt Tension ........................................7-77
Clean Condenser Core ..........................................................7-78
Check Tightening Torque.....................................................7-79
Seasonal Maintenance..........................................................7-80
I. Electrical System........................................................................7-81
Batteries .....................................................................................7-82
Replacing Fuses.......................................................................7-87
Check Fusible Link..................................................................7-91
Check Electrical Cables and Wire Harnesses.................7-92
Check Emergency Engine Stop Switch...........................7-94
Check Lights .............................................................................7-95
Check Horn and Backup Alarm Buzzer............................7-95
Check Suspension Pressure Sensor..................................7-96
J. Brakes & Steering System ......................................................7-98
Check Brake Operation.........................................................7-98
Check Service Brake...............................................................7-98
Check Parking Brake ..............................................................7-99
Check Accumulator..............................................................7-100
Check Front/Rear Brake Lining.........................................7-102
Check Front/Rear Brake Disk.............................................7-102
K. Suspension, Wheels & Tires................................................7-103
Check Suspension.................................................................7-104
Check Wheels .........................................................................7-105
Check Front Axle ...................................................................7-106
Check Front Wheel Lubricant ...........................................7-106
Change Front Wheel Lubricant........................................7-106
Check Tire Inflation Pressure.............................................7-107
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CONTENTS
Check Tire Condition ...........................................................7-108
Check Wheel Alignment.....................................................7-108
L. Miscellaneous..........................................................................7-109
Check, Clean and Replace Alternator Carbon
Brush....................................................................................7-109
Check and Change Coolant in the Control
Cabinet................................................................................7-112
Clean and Replace Pressurized Control Cabinet
Filter......................................................................................7-113
Clean Rear Axle Inside.........................................................7-114
Check and Replace Seat Belt.............................................7-114
Check Windshield Washer Tank .......................................7-114
Check Play Amount in Steering Wheel Stroke............7-115
Auto-Lubrication System ...................................................7-116
Check Tightening Torque of Bolts and Nuts................7-118
Check Dump Body Prop Cable.........................................7-130
MAINTENANCE UNDER SPECIAL ENVIRONMENTAL
CONDITIONS ...................................................................................9-1
Maintenance Under Special Environmental Conditions...9-1
STORAGE .......................................................................................10-1
Storing Machine............................................................................10-1
Removing Machine from Storage ..........................................10-2
TROUBLESHOOTING ................................................................11-1
Cummins Fault Code Lamps and Diagnostic Switches ..11-1
Engine...............................................................................................11-2
Electrical System...........................................................................11-5
Hydraulic System..........................................................................11-8
Hydraulic Hoist System ............................................................11-10
Hydraulic Steering System......................................................11-10
Steering Pump.............................................................................11-11
Steering Control Valve..............................................................11-12
Front Axle......................................................................................11-13
Rear Axle........................................................................................11-14
Hoist Pump Driveline................................................................11-14
Rear Axle Planetary....................................................................11-15
Parking Brake...............................................................................11-15
Alternator......................................................................................11-16
Wheel Motor ................................................................................11-16
Blower Motor ...............................................................................11-17
SPECIFICATIONS ........................................................................12-1
Specifications.................................................................................12-1
Hitachi Loading Policy................................................................12-2
INDEX ..............................................................................................14-1
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The manufacturing Nos. explained in this group is the
individual number (serial No.) given to each machine and main
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:
fNOTE:
*HCM8R800A00010001*
Marks to indicate the start
and end of the PIN
PRODUCT IDENTIFICATION
NUMBER (PIN)
M8R8-01-105
MACHINE NUMBERS
Rollover Protective Structure Cab Name Plate
MODEL/TYPE:
ROPS
MODEL
NUMBER:
MAX
MACHINE
MASS, M-kg:
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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
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