Hitachi EH1100-3 Instruction manual

Manual No. W8R4-E-03
WORKSHOP MANUAL
E
EH1100-3
RIGID DUMP TRUCK

TITLE / Introduction
IN-01
TO THE READER
This manual is written for an experienced technician
to provide technical information needed to maintain
and repair this rigid dump truck.
Be sure to thoroughly read this manual for correct
product information and service procedures.
If you have any questions or comments, or if you
found any errors regarding the contents of this man-
ual, please contact us using the “PLEASE TELL US”
form. The form follows this INTRODUCTION section.
ADDITIONAL REFERENCES
Please refer to the materials listed below in addition
to this manual:
xOperators Manual
xParts Catalog
xOperation Manual of the Engine
xOperation Manual of the Transmission
o5000-9000 Series Transmissions Commer-
cial Electronic Controls 2 (CEC2) Manual
oAllison Transmission 5610-6610 Series Ser-
vice Manual
xHitachi Weld Repair Manual KO-111-00
MANUAL COMPOSITION
The Workshop Manual contains the information nec-
essary for maintenance and repair of the rigid dump
truck, tools and devices necessary for maintenance
and repair, maintenance standards, and re-
moval/installation and disassembly/assembly proce-
dures.
TS41154
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TITLE / Introduction
IN-02
PAGE NUMBER
The Manuals have the page number located on the
center lower part of the page, as well as, additional
numbers on the page to help the technician locate
specific information:
W2-1-3
Consecutive Page Number for each
group
Group Number
Section Number
T = Technical Manual
W = Workshop Manual
SAFETY ALERT SYMBOL AND HEAD-
LINE NOTATIONS
In this manual, the following safety alert symbol and
signal words are used to alert the reader to the po-
tential for personal injury or rigid dump truck damage.
This is the safety alert symbol. When you see
this symbol, be alert to the potential for personal
injury. Always follow the safety instructions that ac-
company the safety alert symbol.
The safety alert symbol is also used to draw attention
to the weight of component parts.
To avoid injury and damage, be sure to use appropri-
ate lifting techniques and equipment when lifting
heavy parts.
WARNING: Indicates a potentially hazardous
situation that could, if not avoided, result in per-
sonal injury or death.
NOTE: Indicates supplementary technical infor-
mation or know-how.
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TITLE / Introduction
IN-03
UNITS USED
SI system units and English units are used in this
manual. English units are in parentheses behind SI
units.
Example: 24.5 MPa (3550 psi)
A table for conversion from SI units to other system
units is shown below for reference purposes.
Quantity
To Convert
From Into Multiply by
mm in 0.03937Length
mm ft 0.003281
L US gal 0.2642
L US qt 1.057
Volume
m³ yd³ 1.308
Weight kg lb 2.205
N kgf 0.10197Force
N lbf 0.2248
N˹m kgf˹m 1.0197Torque
N˹m lbf˹ft 0.7375
Quantity
To Convert
From Into Multiply by
MPa kgf/cm² 10.197Pressure
MPa psi 145.0
kW PS 1.360Power
kW HP 1.341
Temperature qC qF qCu1.832
Velocity km/h mph 0.6214
L/min US gpm 0.2642Flow Rate
mL/rev cc/rev 1.0
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TITLE / Introduction
IN-04
MEMO
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SERVICE AND MAINTENANCE / Safety
SA-1
RECOGNIZE SAFETY INFORMATION
xSAFETY ALERT SYMBOL
This symbol, which will appear at various points in the
manual and on the rigid dump truck together with a
warning statement, means: “Warning, be alert! Your
safety is involved!” Carefully read the message that
follows. It is the obligation of the operator to make sure
that all warning decals are in place on the rigid dump
truck and that they are readable. Accidents may
otherwise occur.
•Follow recommended precautions and safe operating
practices.
•Every country (State) has its own safety regulations. It
is the obligation of the operator to know and follow
these. This also applies to local regulations covering
different types of work. Should the recommendations
in this manual deviate from those of your country
(State), your local safety regulations should be
followed.
UNDERSTAND SIGNAL WORD
xOn the rigid dump truck safety signs, signal words
designating the degree or level of hazard – DANGER,
WARNING, or CAUTION – are used with the safety alert
symbol.
•DANGER indicates an imminently hazardous situation
which, if not avoided, will result in death or serious
injury.
•WARNING indicates a potential hazardous situation
which, if not avoided, could result in death or serious
injury.
•CAUTION indicates a potentially hazardous situation
which, if not avoided, may result in minor or moderate
injury.
•DANGER or WARNING safety signs are located
near specific hazards. General precautions are listed
on CAUTION safety signs.
xThese signal words also call attention to safety
messages in this manual.
xTo avoid confusing rigid dump truck protection with
personal safety messages, a signal word IMPORTANT
indicates a situation which, if not avoided, could result in
damage to the rigid dump truck.
NOTE: indicates an additional explanation for an
element of information
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SERVICE AND MAINTENANCE / Safety
SA-2
OPERATOR’S QUALIFICATIONS
xOnly trained personnel should operate the rigid dump
truck.
xOperator should be of legal rigid dump truck operating
age according to country (State) regulations and
familiar with the operation and maintenance of the rigid
dump truck.
xOperator must be licensed if required by National
Rules and Regulations.
xBefore operating the rigid dump truck this manual must
be read and understood. By reading and
understanding the manual the operator will become
aware of and observe how to avoid injury and damage.
xKnow the work area and the company rules and
regulations
xNever operate the rigid dump truck while under the
influence of alcohol, medicine or other drugs.
INSPECT RIGID DUMP TRUCK
xInspect your rigid dump truck carefully each day or shift
by walking around it before you start it to avoid personal
injury.
•Be sure to cover all points described under “INSPECT
RIGID DUMP TRUCK DAILY BEFORE STARTING”
found in the OPERATING THE ENGINE section in the
Operator’s Manual.
SA-435
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SERVICE AND MAINTENANCE / Safety
SA-3
FOLLOW SAFETY INSTRUCTIONS
xCarefully read and follow all safety signs on the rigid
dump truck and all safety messages in this manual.
xSafety signs should be installed, maintained and
replaced when necessary.
•If a safety sign or this manual is damaged or missing,
order a replacement from your authorized Hitachi
dealer in the same way you order other replacement
parts (be sure to state rigid dump truck model and
serial number when ordering).
xLearn how to operate the rigid dump truck and its
controls correctly and safely.
xAllow only trained qualified, authorized personnel to
operate the rigid dump truck.
xKeep your rigid dump truck in proper working condition.
•Unauthorized modifications of the rigid dump truck
may impair its function and/or safety and affect rigid
dump truck life.
xThe safety messages in this SAFETY chapter are
intended to illustrate basic safety procedures of rigid
dump trucks. 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 Hitachi
dealer before operating or performing maintenance work
on the rigid dump truck.
SA-003
PREPARE FOR EMERGENCIES
xBe prepared if a fire starts or if an accident occurs.
•It is recommended that a first aid kit and fire
extinguisher be kept on hand.
•Thoroughly read and understand the label attached
on the fire extinguisher to use it properly.
•To 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.
•Establish emergency procedure guidelines to cope
with fires and accidents.
•Keep emergency numbers for doctors, ambulance
service, hospital, and fire department posted near
your telephone.
SA-437
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SERVICE AND MAINTENANCE / Safety
SA-4
WEAR PROTECTIVE CLOTHING
xWear 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.
Avoid wearing loose clothing, jewelry, or other items that
can catch on control levers or other parts of the rigid dump
truck.
Operating equipment safely requires the full attention of
the operator. Do not wear radio or music headphones
while operating the rigid dump truck.
SA-438
PROTECT AGAINST NOISE
xProlonged exposure to loud noise can cause impairment
or loss of hearing.
•Wear a suitable hearing protective device such as
earmuffs or earplugs to protect against objectionable
or uncomfortably loud noises. May be necessary
when working outside of the cab, during the Daily
Walk Around Inspection, for example.
SA-434
PROTECT AGAINST FLYING DEBRIS
xIf flying debris hit eyes or any other part of the body,
serious injury may result.
•Guard against injury from flying pieces of metal or
debris; wear goggles or safety glasses.
SA-432
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SERVICE AND MAINTENANCE / Safety
SA-5
GENERAL PRECAUTIONS FOR CAB
•Before entering the cab, thoroughly remove all dirt
and/or oil from the soles of your work boots. If any
controls such as a pedal are operated with dirt 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.
•Don’t leave parts and/or tools lying around the
operator’s seat. Store them in their specified
locations.
•Loose items should not be stored inside cab,
including personal items such as lunch box, thermos
bottle or fire extinguisher.
•Avoid storing transparent bottles in the cab. Don’t
attach any transparent type window decorations on
the windowpanes as they may focus sunlight, possibly
starting a fire.
•Refrain from listening to a radio or music with
headphones or mobile telephones in the cab while
operating the rigid dump truck.
•Keep all flammable objects and/or explosives away
from the rigid dump truck.
•After using the ashtray, always cover it to extinguish
the match and/or tobacco.
•Don’t leave cigarette lighters in the cab. When the
temperature in the cab increases, the lighter may
explode.
•When operating the rigid dump truck, both doors
should be closed at all times.
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