Hitachi EH 4000AC-3 User manual

TOQFB-EN-00
EH4000AC-3 RIGID DUMP TRUCK TECHNICAL MANUAL OPERATIONAL PRINCIPLE
PRINTED IN JAPAN (E) 2013, 12
Service Manual consists of the following separate Part No.
Technical Manual (Operational Principle) : Vol. No.TOQFB-EN
Technical Manual (Troubleshooting) : Vol. No.TTQFB-EN
Workshop Manual : Vol. No.WQFB-EN
TOQFB-EN-00
PART NO.
Rigid Dump Truck
Technical Manual
Operational Principle
URL:http://www.hitachi-c-m.com
4000AC-3
EH

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INTRODUCTION
IN-01
To The Reader
Additional References
Manual Composition
Page Number
This manual is written for an experienced technician to
provide technical information needed to maintain and
repair this machine.
Be sure to thoroughly read this manual for correct
product information and service procedures.
Please refer to the other materials (operator’s manual,
parts catalog, engine technical material and Hitachi
training material etc.) in addition to this manual.
This manual consists the Technical Manual, the Workshop
Manual and the Engine Manual.
Information included in the Technical Manual:
Technical information needed for redelivery and delivery,
operation and activation of all devices and systems,
operational performance tests, and troubleshooting
procedures.
Each page has a number, located on the center lower part
of the page, and each number contains the following
information:
Example:
Technical Manual: T 1-3-5
T Technical Manual
1 Section Number
3 Group Number
5 Consecutive Page Number for Each Group
If you have any questions or comments, at if you found
any errors regarding the contents of this manual,
please contact using “Service Manual Revision Request
Form” at the end of this manual. (Note: Do not tear off
the form. Copy it for usage.):
Publications Marketing & Product Support Hitachi
Construction Machinery Co. Ltd.
TEL: [phone]
FAX: [phone]
E-mail: [email protected]
Information included in the Workshop Manual:
Technical information needed for maintenance and
repair of the machine, tools and devices needed for
maintenance and repair, maintenance standards, and
removal / installation and assemble / disassemble
procedures.
Information included in the Engine Manual:
Technical information needed for redelivery and delivery
and maintenance and repair of the machine, operation
and activation of all devices and systems, troubleshooting
and assemble / disassemble procedures.
Workshop Manual: W 1-3-2-5
W Workshop Manual
1 Section Number
3 Group Number
2 Sub Group Number
5 Consecutive Page Number for Each Sub Group
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INTRODUCTION
IN-02
Safety Alert Symbol and Headline Notations
In this manual, the following safety alert symbol and
signal words are used to alert the reader to the potential
for personal injury of machine damage.
dThis is the safety alert symbol. When you see this
symbol, be alert to the potential for personal injury.
Never fail to follow the safety instructions prescribed
along with the safety alert symbol.
The safety alert symbol is also used to draw attention to
component/part weights.
To avoid injury and damage, be sure to use appropriate
lifting techniques and equipment when lifting heavy
parts.
dCAUTION:
Indicated potentially hazardous situation which could, if
not avoided, result in personal injury or death.
IMPORTANT:
Indicates a situation which, if not conformed to the
instructions, could result in damage to the machine.
fNOTE:
Indicates supplementary technical information or know-
how.
Units Used
Quantity To Convert From Into Multiply By
Length mm in 0.03937
mm ft 0.003281
Volume L US gal 0.2642
L US qt 1.057
m3yd31.308
Weight kg lb 2.205
Force N kgf 0.10197
N lbf 0.2248
Torque N·m kgf·m 0.10197
Pressure MPa kgf/cm210.197
MPa psi 145.0
Power kW PS 1.360
kW HP 1.341
Temperature °C °F °C×1.8+32
Velocity km/h mph 0.6214
min-1 rpm 1.0
Flow rate L/min US gpm 0.2642
mL/rev cc/rev 1.0
fNOTE: The numerical value in this manual might be
different from the above-mentioned table.
SI Units (International System of Units) are used in this
manual. MKSA system units and English units are also
indicated in parentheses just behind SI units.
Example: 24.5 MPa (250 kgf/cm2, 3560 psi)
A table for conversion from SI units to other system units
is shown below for reference purposes.
TOQFB-EN-00(20180620)
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COPYRIGHT(C)2013
Hitachi Construction Machinery Co., Ltd.
Tokyo, Japan
All rights reserved
SECTION AND GROUP
CONTENTS
TECHNICAL MANUAL
(Operational Principle)
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.
SECTION 1 GENERAL
Group 1 Machine Specifications
Group 2 Component Layout
Group 3 Component Specifications
SECTION 2 SYSTEM
Group 1 Control System
Group 2 Travel System
Group 3 Hydraulic System
Group 4 Electrical System
Group 5 Other System
SECTION 3 COMPONENT OPERATION
Group 1 Engine
Group 2 Alternator
Group 3 Control Cabinet
Group 4 Pump Device
Group 5 Travel Device
Group 6 Brake Device
Group 7 Steering Device
Group 8 Suspension
Group 9 Hoist Device
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SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 1 Introduction
Group 2 Standard
Group 3 Engine Test
Group 4 Machine Performance Test
Group 5 Component Test
SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure
Group 2 Component Layout
Group 3 Troubleshooting A
Group 4 Troubleshooting B
Group 5 Troubleshooting C
Group 6 Troubleshooting D
TECHNICAL MANUAL (Troubleshooting) WORKSHOP MANUAL
SECTION 1 GENERAL INFORMATION
Group 1 Precautions for Disassembling and Assembling
Group 2 Tightening
Group 3 Periodic Replacement of Parts
SECTION 2 BODY
Group 1 Cab
Group 2 Engine / Alternator
Group 3 Pump Device
Group 4 Drive Device
Group 5 Front Axle
Group 6 Tire and Rim
Group 7 Front Brake
Group 8 Brake Valve
Group 9 Brake Accumulator
Group 10 Steering System
Group 11 Frame Suspension
SECTION 3 HOIST DEVICE
Group 1 Hoist Control Valve
Group 2 4-Unit Proportional Control Solenoid Valve
Group 3 Hoist Cylinder
Group 4 Dump Body
SECTION 4 AC DRIVE CONTROL DEVICE
Group 1 Control Cabinet
Group 2 Grid Box
Group 3 Alternator Blower
Group 4 Wheel Motor Blower
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QFBT-1-1
Group 1 Machine Specifications
Machine Specifications..................................................... T1-1-1
Group 2 Component Layout
Main Component Layout.................................................T1-2-1
Operator's Seat .................................................................... T1-2-2
Liquid Crystal Display (LCD) (Normal Operation
Screen)............................................................................... T1-2-3
Console Panel....................................................................... T1-2-4
Engine, Driving, and Hydraulic Related
Indicators.......................................................................... T1-2-5
Headlight, Front Combination Light/Horn................ T1-2-6
Side Light............................................................................... T1-2-7
Rear Light............................................................................... T1-2-8
Maintenance Light ............................................................. T1-2-9
Electrical Component Box (Behind Cab) .................T1-2-10
Fuse Box ...............................................................................T1-2-11
Relay Box..............................................................................T1-2-12
Battery Relay Box .............................................................T1-2-13
Hydraulic Component.....................................................T1-2-14
Main Pump System...........................................................T1-2-14
Around the Operator's Seat ..........................................T1-2-15
Front Axle.............................................................................T1-2-16
Brake......................................................................................T1-2-17
Steering Cylinder ..............................................................T1-2-18
Hoist Cylinder.....................................................................T1-2-18
Suspension Cylinder ........................................................T1-2-19
Rear Axle Housing ............................................................T1-2-19
Control Cabinet (1) ...........................................................T1-2-20
Control Cabinet (2) ...........................................................T1-2-21
Terminal Board (TB3)-Output Connector.................T1-2-22
Breaker, Fuse, Relay, Others...........................................T1-2-23
Auxiliary Alternator Field Regulator (AFR) Unit......T1-2-24
Control Power (CS) Unit..................................................T1-2-25
Contactor, Relay, Others .................................................T1-2-26
Drive System Controller (DSC) .....................................T1-2-27
Rectifier (REC) Unit ...........................................................T1-2-28
Inverter (INV) Unit.............................................................T1-2-29
Fan Unit ................................................................................T1-2-30
Main Alternator Field Regulator (MFR) Unit............T1-2-31
Grid Box................................................................................T1-2-32
Group 3 Component Specifications
Engine (Cummins) .............................................................. T1-3-1
Engine (MTU)........................................................................ T1-3-5
Engine Accessories............................................................. T1-3-9
Alternator.............................................................................T1-3-10
Control Cabinet .................................................................T1-3-11
Pump Device ......................................................................T1-3-13
Travel Device.......................................................................T1-3-14
Brake Device .......................................................................T1-3-16
Steering Device .................................................................T1-3-17
Suspension Device ...........................................................T1-3-18
Hoist Device........................................................................T1-3-19
Fuses and Others...............................................................T1-3-20
Relay and Others...............................................................T1-3-23
Sensors .................................................................................T1-3-26
Lights.....................................................................................T1-3-28
Filter.......................................................................................T1-3-29
Others ...................................................................................T1-3-30
SECTION 1
GENERAL
CONTENTS
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QFBT-1-2
(Blank)
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T1-1-1
SECTION 1 GENERAL
Group 1 Machine Specifications
Machine Specifications
Model EH4000AC-3
Dump Body Capacity (Heap) 154.1 m3(201.6 yd3)
Operating Weight 161000 kg (355000 lb)/163000 kg (359000 lb)
Nominal Payload With Standard Equipment 205000 kg (452000 lb)/221000 kg (487000 lb)
Target Gross Machine Operating Weight
(TGMOW) 366000 kg (807000 lb)/384000 kg (847000 lb)
Engine
Cummins QSK60
1864 KW/1900 min-1
(2500 HP/1900 rpm)
MTU 16V4000 C21
1864 KW/1900 min-1
(2500 HP/1900 rpm)
A: Overall Length 14280 mm (46 ft 10 in)
B: Overall Width 9540 mm (31 ft 4 in)
C: Overall Height 7350 mm (24 ft 1 in)
D: Wheel Base 6060 mm (19 ft 11 in)
E. E’: Tread (Front Tire/Rear Tire WT) 6050 mm (19 ft 10 in)/4960 mm (16 ft 3 in)
F. F’: Tires Overall (Front Tire/Rear Tire) 7290 mm (23 ft 11 in)/7580 mm (24 ft 10 in)
G. G’: Ground Clearance (Front Axle/Rear Axle) 990 mm (3 ft 3 in)/840 mm (2 ft 9 in)
H: Front Overhang 4240 mm (13 ft 11 in)
I. J: Body Inside (Length/Width) 9190 mm (30 ft 2 in)/7760 mm (25 ft 6 in)
K: Body Height 6070 mm (19 ft 11 in)
L. L’ Body Dump Height (Max./Min.) 13840 mm (45 ft 5 in)/1740 mm (5 ft 9 in)
M: Body Dump Angle 50.5º
Minimum Turning Diameter (ISO) 30.2 m (99 ft 1 in)
Travel Speed Forward 56 Km/h (35 mile/h), Reverse 10 km/h (6.2 mile/h)
Electric Drive Hitachi AC-Drive System
Tires Size 40.00R57 / 46/90R57
fNOTE: These specifications are subject to change without notice.
E
M
F'
E'
B
J
I
A
DH
F
G
L'
G'
K
L
C
MQFB-12-001
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Group 1 Machine Specifications
SECTION 1 GENERAL
T1-1-2
(Blank)
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