Hitachi EH 5000AC-3 User manual

TTQHA-EN-00EH5000AC-3 RIGID DUMP TRUCK TECHNICAL MANUAL TROUBLESHOOTING
Service Manual consists of the following separate Part No.
Technical Manual (Operational Principle) : Vol. No.TOQHA-EN
Technical Manual (Troubleshooting) : Vol. No.TTQHA-EN
Workshop Manual : Vol. No.WQHA-EN
TTQHA-EN-00
PART NO.
Rigid Dump Truck
Technical Manual
Troubleshooting
5000AC-3
EH
PRINTED IN JAPAN (E) 2013, 02
URL:http://www.hitachi-c-m.com

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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.
yBe 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.
yInformation 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:
yTechnical Manual: T 1-3-5
T Technical Manual
1 Section Number
3 Group Number
5 Consecutive Page Number for Each Group
yIf 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.):
xPublications Marketing & Product Support Hitachi
Construction Machinery Co. Ltd.
xTEL: 81-29-832-7084
xFAX: 81-29-831-1162
xE-mail: [email protected]
yInformation 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.
yInformation 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.
yWorkshop 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.
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Recognize Safety Information
yThese are the SAFETY ALERT SYMBOLS.
xWhen you see these symbols on your machine or in this
manual, be alert to the potential for personal injury.
xFollow recommended precautions and safe operating
practices.
Understand Signal Words
yOn machine safety signs, signal words designating the
degree or level of hazard - DANGER, WARNING, or CAUTION
- are used with the safety alert symbol.
xDANGER indicates an imminently hazardous situation
which, if not avoided, will result in death or serious injury.
xWARNING indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury.
xCAUTION indicates a potentially hazardous situation
which, if not avoided, may result in minor or moderate
injury.
xDANGER or WARNING safety signs are located near
specific hazards. General precautions are listed on
CAUTION safety signs.
xSome safety signs do not use any of the designated signal
words above after the safety alert symbol are occasionally
used on this machine.
yCAUTION also calls attention to safety message in this
manual.
yTo avoid confusing machine protection with personal safety
messages, a signal word IMPORTANT indicates a situation
which, if not avoided, could result in damage to the
machine.
y
fNOTE indicates an additional explanation for an
element of information.
SA-1
SAFETY
SA-688
SA-1223
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Follow Safety Instructions
yCarefully read and follow all safety signs on the machine
and all safety messages in this manual.
ySafety signs should be installed, maintained and replaced
when necessary.
xIf a safety sign or this manual is damaged or missing,
order a replacement from your authorized dealer in the
same way you order other replacement parts (be sure to
state machine model and serial number when ordering).
yLearn how to operate the machine and its controls correctly
and safely.
yAllow only trained, qualified, authorized personnel to
operate the machine.
yKeep your machine in proper working condition.
xUnauthorized modifications of the machine may impair
its function and/or safety and affect machine life.
yThe safety messages in this SAFETY chapter are intended
to illustrate basic safety procedures of machines. However
it is impossible for these safety messages to cover every
hazardous situation you may encounter. If you have any
questions, you should first consult your supervisor and/
or your authorized dealer before operating or performing
maintenance work on the machine.
SAFETY
SA-2
SA-003
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Prepare for Emergencies
yBe prepared if a fire starts or if an accident occurs.
xKeep a first aid kit and fire extinguisher on hand.
xThoroughly read and understand the label attached on
the fire extinguisher to use it properly.
xTo ensure that a fire-extinguisher can be always used
when necessary, check and service the fire-extinguisher
at the recommended intervals as specified in the fire-
extinguisher manual.
xEstablish emergency procedure guidelines to cope with
fires and accidents.
xKeep emergency numbers for doctors, ambulance
service, hospital, and fire department posted near your
telephone.
Wear Protective Clothing
yWear close fitting clothing and safety equipment
appropriate to the job.
You may need:
A hard hat
Safety shoes
Safety glasses, goggles, or face shield
Heavy gloves
Hearing protection
Reflective clothing
Wet weather gear
Respirator or filter mask.
Be sure to wear the correct equipment and clothing for the
job. Do not take any chances.
xAvoid wearing loose clothing, jewelry, or other items that
can catch on control levers or other parts of the machine.
yOperating equipment safely requires the full attention of
the operator. Do not wear radio or music headphones while
operating the machine.
SA-437
SAFETY
SA-3
SA-438
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Protect Against Noise
yProlonged exposure to loud noise can cause impairment or
loss of hearing.
xWear a suitable hearing protective device such as
earmuffs or earplugs to protect against objectionable or
uncomfortably loud noises.
Inspect Machine
yInspect your machine carefully each day or shift by walking
around it before you start it to avoid personal injury.
xIn the walk-around inspection, be sure to cover all points
described in the “Inspect Machine Daily Before Starting”
section in the operator’s manual.
SAFETY
SA-4
SA-434
SA-435
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General Precautions for Cab
xBefore entering the cab, thoroughly remove all dirt and/or
oil such as mud, grease, soil or stones that may mess up
the cab from the soles of your work boots. If any controls
such as a pedal is operated while with dirt and/or oil on
the soles of the operator’s work boots, the operator’s foot
may slip off the pedal, possibly resulting in a personal
accident.
xDo not mess up around the operator’s seat with parts,
tools, soil, stones, obstacles that may fold up or turn
over, cans or lunch box. The pedals become inoperable if
obstacle jams in operation stroke of the accelerator pedal,
electric brake pedal or service brake pedal, which may
result in serious injury or death.
xDo not leave parts and/or tools lying around the
operator’s seat. Store them in their specified locations.
xAvoid storing transparent bottles in the cab. Do not
attach any transparent type window decorations on
the windowpanes as they may focus sunlight, possibly
starting a fire.
xRefrain from listening to the radio, or using music
headphones or mobile telephones in the cab while
operating the machine.
xKeep all flammable objects and/or explosives away from
the machine.
xAfter using the ashtray, always cover it to extinguish the
match and/or tobacco.
xDo not leave cigarette lighters in the cab. When the
temperature in the cab increases, the lighter may
explode.
xUse proper floor mat dedicated to the machine. If another
floor mat is used, it may be displaced and contact with
the accelerator pedal, electric brake pedal or service
brake pedal during operation, resulting in serious injury
or death.
yWhen operator drives the machine with decreased
attentiveness, resulting in serious injury or death.
xNever operate the machine in the state with drinking
alcohol or drug.
SAFETY
SA-5
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Use Handholds and Steps
yFalling is one of the major causes of personal injury.
xWhen you get on and off the machine, always face the
machine and maintain a three-point contact with the
steps and handrails.
xDo not use any controls as handholds.
xNever jump on or off the machine. Never mount or
dismount a moving machine.
xBe careful of slippery conditions on platforms, steps, and
handrails when leaving the machine.
xDo not step or climb on surfaces, which are not intended
for walking. Step only on the areas provided with the slip
resistant surfaces.
SA-439
SAFETY
SA-6
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Operator’s Visibility
yThis machine is equipped with mirrors and cameras to
see around the machine. Adjust the view mirrors and
cameras position so that the best visibility is obtained from
the operator’s seat. If the mirrors and cameras are dirty,
immediately clean them. Also see carefully around the
machine while moving your viewpoint as need arises.
xThe view mirrors and cameras position should be
adjusted whenever changing the operator for the
machine. Always take extra attention for surrounded area
during operating.
xWhen the machine is modified or fitted with equipment
that influences visibility, it is necessary to check again the
operator’s visibility according to the ISO 5006. Contact
your authorized dealer before modifying the machine.
yThis machine has the blind area created because of parts of
the base machine and/or its equipment from the operator’s
seat by direct.
yOperate the machine safely with sufficient recognition this
machine has blind area from the operator’s seat by direct.
yThe operator’s visibility according to the ISO 5006 of this
machine with standard mirrors and cameras is as follows.
Operator’s visibility on a rectangular 1 m boundary
close around the machine
Operator can see the entire circumference of the height
1.5 m located at 1 m distance from the outside rectangular
boundary of the machine as illustrated.
Operator’s visibility on a 12 m visibility test circle
Operator can see the entire circumference located the circle
with 12 m radius located on the ground reference plane
with its center vertically below the operator’s eye point as
illustrated.
TM: test machine
RB: rectangular 1 m boundary
VTC: visibility test circle with 12 m radius
OEP: operator’s eye point
SAFETY
SA-7
VTC
ΤΜ
OEP
12 m
1 m
TM
OEP
1 m
RB
SS-3231
SS-3232

Adjust Operator’s Seat
yA poorly adjusted seat for either the operator or the
work at hand may quickly fatigue the operator leading to
misoperations.
xThe seat should be adjusted whenever changing the
operator for the machine.
xThe operator should be able to fully depress the pedals
and to correctly operate the steering wheel with his back
against the seat back.
xIf not, move the seat forward or backward, and check
again.
xAdjust the mirror position so that the best rear visibility is
obtained from the operator’s seat. If the mirror is broken,
immediately replace it with a new one.
Fasten Your Seat Belt
yIf the machine should overturn, the operator may become
injured and/or thrown from the cab. Additionally the
operator may be crushed by the overturning machine,
resulting in serious injury or death.
xPrior to operating the machine, thoroughly examine
webbing, buckle and attaching hardware. If any item is
damaged or worn, replace the seat belt or component
before operating the machine.
xBe sure to remain seated with the seat belt securely
fastened at all times when the machine is in operation to
minimize the chance of injury from an accident.
xWe recommend that the seat belts are replaced every
three years regardless of its apparent condition.
SAFETY
SA-8
SA-462
SA-237

Move and Operate Machine Safely
yBystanders can be run over.
xTake extra care not to run over bystanders. Confirm the
location of bystanders before moving, or operating the
machine.
xAlways keep the backup alarm and horn in working
condition (if equipped). It warns people when the
machine starts to move.
xUse a signal person when moving, or operating the
machine in congested areas. Coordinate hand signals
before starting the machine.
xUse appropriate illumination. Check that all lights are
operable before operating the machine. If any faulty
illumination is present, immediately repair it.
xAlways keep the cab door closed while operating the
machine.
xCheck the mirrors and the monitors in the CAB for
problems. If there are problems, replace the problem
parts or clean the mirrors, cameras and monitors.
Refer to Camera Monitor section on the cleaning of the
camera and monitor.
Handle Starting Aids Safely
Starting fluid:
yStarting fluid is highly flammable.
xKeep all sparks and flame away when using it.
xKeep starting fluid well away from batteries and cables.
xRemove container from machine if engine does not need
starting fluid.
xTo prevent accidental discharge when storing a
pressurized container, keep the cap on the container, and
store it in a cool, well-protected location.
xDo not incinerate or puncture a starting fluid container.
SAFETY
SA-9
SA-1598
SA-293

Operate Only from Operator’s Seat
yInappropriate engine starting procedures may cause the
machine to runaway, possibly resulting in serious injury or
death.
xStart the engine only when seated in the operator’s seat.
xNEVER start the engine while standing on the platform.
xDo not start engine by shorting across starter terminals.
xCheck that the parking brake switch is turned ON.
xBefore starting the engine, confirm that shift lever is in
the NEUTRAL position.
xBefore starting the engine, confirm the safety around the
machine and sound the horn to alert bystanders.
Jump Starting
yBattery gas can explode, resulting in serious injury.
xIf the engine must be jump started, be sure to follow the
instructions shown in the “OPERATING ENGINE” chapter in
the operator’s manual.
xThe operator must be in the operator’s seat so that the
machine will be under control when the engine starts.
Jump starting is a two-person operation.
xNever use a frozen battery.
xFailure to follow correct jump starting procedures could
result in a battery explosion or a runaway machine.
SAFETY
SA-10
SA-1599
SA-032

Avoid Injury Caused by High Tension Electric
Shock
yNever attempt to open any electrical component covers
displaying a decal with the words “HIGH VOLTAGE.”You may
receive an electric shock, possibly resulting in personal
injury or death.
yNever attempt to touch or grab any high tension electrical
components or the power cable with wet hands. You may
receive an electric shock, possibly resulting in personal
injury or death.
Investigate Job Site Beforehand
yWhen working on a road shoulder, the machine could tip
over, possibly resulting in serious injury or death.
xInvestigate the configuration and ground conditions of
the job site beforehand to prevent the machine from
falling and to prevent the ground, stockpiles, or banks
from collapsing.
xMake a work plan. Use machines appropriate to the work
and job site.
xReinforce ground, edges, and road shoulders as
necessary. Keep the machine well back from the edges of
excavations and road shoulders.
xWhen working on an incline or on a road shoulder,
employ a signal person as required.
xWhen the footing is weak, reinforce the ground before
starting work.
xWhen working on frozen ground, be extremely alert. As
ambient temperatures rise, footing becomes loose and
slippery.
xBeware the possibility of fire when operating the machine
near flammable objects such as dry grass.
xDriver should try to travel the road once to understand
potential danger.
Provide Signals for Jobs Involving Multiple
Machines
yFor jobs involving multiple machines, provide signals
commonly known by all personnel involved. Also, appoint
a signal person to coordinate the job site. Make sure that all
personnel obey the signal person’s directions.
SA-1601
SAFETY
SA-11
SA-112
SA-481

SAFETY
SA-12
Drive Machine Safely
yBefore driving the machine, always confirm that the shift
lever direction corresponds to the direction you wish to
drive.
xBe sure to detour around any obstructions.
xAvoid traveling over obstructions. Soil, fragments of rocks,
and/or metal pieces may scatter around the machine. Do
not allow personnel to stay around the machine while
traveling.
xIf the engine stops while driving, the steering function
becomes inoperative. Immediately stop the machine by
applying the service brake to prevent personal accident.
xDo not inertia run with the shift lever in Neutral position.
Because engine speed is in the slow idling state, the
cooling capability of the rear wet disk brake reduces.
The brake unit may be seriously damaged if the machine
continues to drive with the shift lever in Neutral position.
yDriving on a slope may cause the machine to slip or
overturn, possibly resulting in serious injury or death.
xDriving across the face of a slope or steering on a
slope may cause the machine to skid or overturn. If
the direction must be changed, move the machine to
level ground, then, change the direction to ensure safe
operation.
yThe “Electric Brake Performance Decal” is provided in the
cab as a general guideline for proper downgrade operation
of the loaded machine. Warning, understand downhill
speed operation thoroughly before operation. Machine
road speed is reduced during downhill operation. When
electric brake operation with overloaded machine on
the steep downgrade continues for more than 2 minutes
continuously, grid box resistance will be electrical overload.
Pay attention that electric brake torque reduces.
xOverloaded machine reduces the electric brake
performance. Observe strictly the Hitachi loading policy
while driving.
xBefore descending on a slope, decelerate the machine
sufficiently using electric brake.
xWhen descending on a slope, drive the machine slowly
using electric brake.
yDriving on a rough road may cause the machine to slip or
overturn, possibly resulting in serious injury or death.
xWhen driving on a rough road or soft ground, reduce
speed sufficiently.
xDriving on a wet road may cause the machine to slip,
possibly resulting in serious injury or death. Avoid
applying the electric brake for quick stops.
SA-1602
WRONG
SA-1603
SSYA00018311

SAFETY
SA-13
Wheel Maintenance
yMishandling of a tire and rim parts can cause serious injury
or death.
xInspect tires and wheels daily. Do not operate with low
pressure, cuts, bubbles, damaged rims, or missing lug
bolts and nuts.
xWhen inflating tires, use a clip-on chuck and extension
hose long enough to allow you to stand to one side and
not in front of or over the tire assembly. Use a safety cage
if available.
xDo not attempt to inflate or mount a tire unless you have
the proper equipment and experience to perform the
job. Have it done by your authorized dealer or a qualified
repair service.
xAlways maintain the correct tire pressure. DO NOT inflate
tire above the recommended pressure.
xExplosions of air inflated tires have resulted from heat-
induced gas combustion inside the tires. Explosions
can be caused by heat that is generated by welding, by
heating rim components, by external fire, or by excessive
use of brakes. Explosions differ from punctures or tire
bursts because the destructive force is extremely large.
This could result in tire explosion which could propel
projectiles in excess of 500 m (1640 ft) from the machine.
Both the force of the explosion and the flying debris can
cause property damage, personal injury, or death. If tire
overheating is suspected or noticed, do not approach the
tire within any area included in the shaded area (15 m in
radius) in the illustration and restrict access underneath
the truck, until the tire has cooled down sufficiently.
yStore tires safely.
xStore tires in the place where tires are not exposed to the
direct sunlight, rain, water and oil. Avoid near external
heat source or electric sparks hazard.
xStand tire on level ground, and block it securely so that it
cannot roll or fall over.
xStore the tires in a warehouse in which unauthorized
persons cannot enter. If the tires are stored outside,
always erect a fence around the tires and put up“No
Entry” and other warning signs that even young children
can understand.
SA-249
SA-034
SA-2298
15 m 500 m

SAFETY
SA-14
Drive on Snow Safely
yBeware of the possibility of slipping or overturning the
machine when traveling on frozen snow surfaces.
xThe machine may slip more easily than expected on
frozen snow surfaces even if the inclination is small.
Reduce speed when driving. Avoid fast starts, stops and
quick turns.
xRoad shoulder and/or set-up utilities covered with snow
are difficult to locate. Be sure where they are before
removing snow.
xAvoid applying the brake for quick stops on snow.
Avoid Injury from Rollaway Accidents
yDeath or serious injury may result if you attempt to mount
or stop a moving machine.
To avoid rollaways:
1. Select level ground when possible to park the machine.
2. Do not park the machine on a grade.
3. Lower the dump body to the frame rail.
4. Place the shift lever in the Neutral position and switch
the parking brake switch ON.
5. Run the engine at slow idle speed without load for 5
minutes to cool down the engine.
6. Stop the engine and remove the key from the key switch.
7. Chock the wheels if you must park on a grade.
8. Position the machine to prevent rolling.
9. Park at a reasonable distance from other machines.
SA-1579
SA-1580
SA-1578

SAFETY
SA-15
Avoid Injury from Back-Over Accidents
yIf any person is present near the machine when backing
the machine, the machine may hit or run over that person,
resulting in serious injury or death.
To avoid back-over accidents:
xAlways look around BEFORE YOU BACK UP THE MACHINE.
BE SURE THAT ALL BYSTANDERS ARE CLEAR.
xKeep the backup alarm in working condition.
ALWAYS BE ALERT FOR BYSTANDERS MOVING INTO THE
WORK AREA. USE THE HORN OR OTHER SIGNAL TO WARN
BYSTANDERS BEFORE MOVING MACHINE.
xUSE A SIGNAL PERSON WHEN BACKING UP IF YOUR VIEW
IS OBSTRUCTED. ALWAYS KEEP THE SIGNAL PERSON IN
VIEW.
xUse hand signals, which conform to your local regulations,
when work conditions require a signal person.
xNo machine motions shall be made unless signals are
clearly understood by both signal person and operator.
xLearn the meanings of all flags, signs, and markings used
on the job and confirm who has the responsibility for
signaling.
xKeep windows, mirrors, and lights clean and in good
condition.
xDust, heavy rain, fog, etc., can reduce visibility. As visibility
decreases, reduce speed and use proper lighting.
xRead and understand all operating instructions in the
operator’s manual.
Keep Person Clear from Working Area
yA person may be hit severely by the machine and/or may be
crushed against another object, resulting in serious injury or
death.
xKeep all persons clear from the area of operation and
machine movement.
xBefore operating the machine, set up barriers to the sides
and rear area of the working area to prevent anyone from
entering the work area.
SA-1583
SA-1582
SA-1581

SAFETY
SA-16
Avoid Tipping
DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING MACHINE ---
SERIOUS OR FATAL CRUSHING INJURIES WILL RESULT
MACHINE WILL TIP OVER FASTER THAN YOU CAN JUMP
FREE
THEREFORE, HOLD FIRMLY ONTO THE STEERING WHEEL IF
THE MACHINE SHOULD TIP OR ROLL OVER. DO NOT JUMP.
FASTEN YOUR SEAT BELT
yThe cab, cab mounting structure and frame are designed
for the protection of the operator and it meets the
requirements for Roll-Over Protection Structures (ROPS)
according to the adopted standard for this machine.
IMPORTANT:
yNever make any unauthorized modifications or
alterations to the Roll-Over Protective Structures
(ROPS) such as; welding on fire extinguisher
brackets, CB antenna brackets, or fire suppression
systems. Such unauthorized modifications will affect
the structural limits of the ROPS and will void the
certification and could result in loss of protection to
the operator.
Contact your authorized dealer for modification or
repair of ROPS.
yDo not convert Hauler into Water Truck. (This cab has
not been certified to meet specified requirements
according to ISO 3471 Tractor.)
The Roll-Over Protective Structures (ROPS) has been certified
to meet specified requirements according to ISO 3471 Hauler.
yThe danger of tipping is always present when operating on
a grade, possibly resulting in serious injury or death.
To avoid tipping:
yBe extra careful before operating on a grade.
xKeep the machine at a safe distance from the edge of
cliffs and slide areas.
xReduce operating speeds to avoid tipping or slipping.
xAvoid changing direction when driving on grades.
xUse the seat belt during operation.
xWhen operating the machine, both doors should be
closed at all times.
yBe careful when working on frozen ground.
xTemperature increases will cause the ground to become
soft and make ground travel unstable.
SA-1584