Hitachi EH 5000AC-3 User manual

ENMQHA-1-1EH5000AC-3 RIGID DUMP TRUCK OPERATOR’S MANUAL
Serial No 010002 and up
Rigid Dump Truck
PRINTED IN JAPAN (E) 2012, 07
This book is printed on recycled paper.
ENMQHA-1-1
PART NO.
Operator’s Manual
URL:http://www.hitachi-c-m.com
EH5000AC-3

INTRODUCTION
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.
©2012 Hitachi Construction Machinery Co., Ltd.
All rights reserved.
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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
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
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
Cylinder ......................................................................................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
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........................................1-14
Driving Related Warning Indicators.......................................1-17
Hydraulic Related Warning Indicators .................................. 1-21
Light Indicators .............................................................................1-24
Miscellaneous Indicators...........................................................1-25
Alarm Occurrence Screen..........................................................1-27
Clock Setting..................................................................................1-28
Head Lights/Front Combination Lights/Horns..................1-30
Side Lights.......................................................................................1-31
Rear Lights ......................................................................................1-32
Maintenance Lights.....................................................................1-33
Steering Wheel..............................................................................1-34
Horn Switch....................................................................................1-34
Turn Signal/High Beam Lever Switch.................................... 1-34
Hazard Warning Lamp Switch..................................................1-35
Tilt/Telescope Steering Wheel .................................................1-35
Accelerator Pedal..........................................................................1-35
Service Brake Pedal......................................................................1-36
Electric Brake Pedal......................................................................1-37
Parking Brake.................................................................................1-37
Center Console..............................................................................1-38
Hoist Lever......................................................................................1-40
Console Panel ................................................................................1-42
Rear Console ..................................................................................1-49
Dome Light Switch ......................................................................1-50
Sun Visor..........................................................................................1-50
Air Conditioner..............................................................................1-51
Designations and Functions of the Control Panel............1-52
Cooling............................................................................................. 1-53
Heating.............................................................................................1-54
Dehumidifying and Heating.....................................................1-54
Defrosting .......................................................................................1-54
Blower Operation Without Cooling or Heating.................1-55
Ventilation of the Cab.................................................................1-55
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CONTENTS
AM/FM Radio Operation............................................................ 1-56
Digital Clock Setting Procedure..............................................1-57
Camera Monitor............................................................................1-58
Adjusting Operator’s Seat .........................................................1-59
Adjusting Trainer’s Seat..............................................................1-62
Seat Belt...........................................................................................1-63
Cab Door Lock...............................................................................1-64
Opening/Closing Cab Left Door .............................................1-64
Electrical Equipment Box (Behind Cab)................................1-65
Relay Box .........................................................................................1-67
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 Engine 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
Electric Brake.....................................................................................4-6
Auto Retard........................................................................................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 Dump Body Prop Cable.............................................7-5
Removal and Storage of Dump Body Prop Cable................7-6
Installing Dump Body Prop Pins ................................................7-7
Removal and Storage of Dump Body Prop Pins...................7-8
Inspection/Maintenance Lights.................................................7-9
Main Part/Component Location Diagram...........................7-11
Periodic Replacement of Parts.................................................7-12
Hydraulic System..........................................................................7-13
Maintenance Guide .....................................................................7-15
A. Greasing......................................................................................7-20
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 Air Breather.........................................7-30
Clean Oil Cooler Core ............................................................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 Element .......................................7-36
Replace Line Filter Element.................................................7-37
Change Hydraulic Oil.............................................................7-38
Replace Suction Filter............................................................7-38
Check Hoses and Lines .........................................................7-41
Service Recommendations for Hydraulic Fittings.......7-44
Replace Hydraulic Oil Tank Breather................................7-47
E. Fuel System................................................................................7-48
Drain Fuel Tank Sump............................................................7-50
Drain Fuel Filter........................................................................7-50
Replace Fuel Filter Element................................................. 7-51
Replace Fuel Filter...................................................................7-52
Check Fuel Hoses .................................................................... 7-53
Clean and Replace Fuel Tank Breather ............................7-54
F. Air Cleaner...................................................................................7-55
Clean Air Cleaner Outer Element ......................................7-55
Replace Air Cleaner Outer and Inner Elements............7-55
Clean Air Cleaner Dust Cups............................................... 7-57
Check Vacuator Valve.............................................................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
Check Tightening Torque.....................................................7-77
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CONTENTS
Seasonal Maintenance..........................................................7-78
I. Electrical System........................................................................ 7-79
Batteries .....................................................................................7-80
Replacing Fuses.......................................................................7-85
Check Fusible Link..................................................................7-87
Check Electrical Cables and Wire Harnesses.................7-88
Check Emergency Engine Stop Switch...........................7-90
Check Lights .............................................................................7-91
Check Horn and Backup Alarm Buzzer............................7-91
Check Suspension Pressure Sensor..................................7-92
J. Brakes & Steering System ......................................................7-94
Check Brake Operation.........................................................7-94
Check Service Brake...............................................................7-95
Check Parking Brake ..............................................................7-96
Check Accumulator................................................................ 7-97
Check Front Brake Lining .....................................................7-99
Check Front Brake Disk .........................................................7-99
Check Rear Brake Cooling Oil Level................................7-100
Drain Rear Brake Cooling Oil Tank Sump......................7-101
Change Rear Brake Cooling Oil........................................7-102
Replace Suction Filter..........................................................7-102
Replace Line Filter Element...............................................7-104
Clean Brake Cooling Oil Cooler........................................7-105
K. Suspension, Wheels & Tires................................................7-106
Check Suspension.................................................................7-107
Check Wheels .........................................................................7-108
Check Front Axle ...................................................................7-109
Check Front Wheel Lubricant ...........................................7-109
Change Front Wheel Lubricant........................................7-109
Check Tire Inflation Pressure.............................................7-110
Check Tire Condition ...........................................................7-111
Check Wheel Alignment.....................................................7-111
L. Miscellaneous..........................................................................7-112
Check, Clean and Replace Alternator
Carbon Brush ....................................................................7-112
Check and Change Coolant
in the Control Cabinet ...................................................7-115
Clean and Replace Pressurized
Control Cabinet Filter.....................................................7-116
Clean Rear Axle Inside.........................................................7-117
Check and Replace Seat Belt.............................................7-117
Check Windshield Washer Tank .......................................7-117
Check Play Amount in Steering Wheel Stroke............7-118
Check Auto-Lubrication System......................................7-119
Check Tightening Torque of Bolts and Nuts................7-121
Check Dump Body Prop Cable.........................................7-132
MAINTENANCE UNDER SPECIAL
ENVIRONMENTAL CONDITIONS.............................................9-1
STORAGE
Storing Machine............................................................................10-1
Removing Machine from Storage ..........................................10-2
TROUBLESHOOTING
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......................................................11-11
Steering Pump.............................................................................11-12
Steering Control Valve..............................................................11-13
Front Axle......................................................................................11-14
Rear Axle........................................................................................11-15
Hoist Pump Driveline................................................................11-15
Rear Axle Planetary....................................................................11-16
Parking Brake...............................................................................11-16
Alternator......................................................................................11-17
Wheel Motor ................................................................................11-17
Blower Motor ...............................................................................11-18
SPECIFICATIONS
Specifications.................................................................................12-1
Hitachi Loading Policy................................................................12-2
INDEX...............................................................................................14-1
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CONTENTS
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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:
*HCMQHA00A00010001*
Marks to indicate the start
and end of the PIN
PRODUCT IDENTIFICATION
NUMBER (PIN)
M8R7-03-001
MACHINE NUMBERS
Machine ROPS Cab
View A
Rollover Protective Structure Cab Name Plate
MODEL/TYPE:
ROPS
MODEL
NUMBER:
MAX
MACHINE
MASS, M-kg:
A
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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
MQHA-00-002
M8R8-00-027
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