Hitachi EH 5000AC-3 Technical Manual
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Hitachi EH 5000AC-3 Technical Manual

Hitachi EH 5000AC-3 Technical Manual

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URL:http://www.hitachi-c-m.com
PRINTED IN JAPAN (E) 2013, 02
PART NO.
TTQHA-EN-00
Technical Manual
Troubleshooting
EH
5000AC
-3
Rigid Dump Truck
Service Manual consists of the following separate Part No.
Technical Manual (Operational Principle)
Technical Manual (Troubleshooting)
Workshop Manual
: Vol. No.TOQHA-EN
: Vol. No.TTQHA-EN
: Vol. No.WQHA-EN
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  • Page 1 PART NO. TTQHA-EN-00 Technical Manual Troubleshooting 5000AC Rigid Dump Truck URL:http://www.hitachi-c-m.com Service Manual consists of the following separate Part No. Technical Manual (Operational Principle) : Vol. No.TOQHA-EN Technical Manual (Troubleshooting) : Vol. No.TTQHA-EN PRINTED IN JAPAN (E) 2013, 02 Workshop Manual...
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  • Page 3: Additional References

    FAX: 81-29-831-1162 E-mail: [email protected] Additional References Please refer to the other materials (operator’s manual, parts catalog, engine technical material and Hitachi training material etc.) in addition to this manual. Manual Composition This manual consists the Technical Manual, the Workshop Information included in the Workshop Manual: Manual and the Engine Manual.
  • Page 4 INTRODUCTION Safety Alert Symbol and Headline Notations In this manual, the following safety alert symbol and CAUTION: signal words are used to alert the reader to the potential Indicated potentially hazardous situation which could, if for personal injury of machine damage. not avoided, result in personal injury or death.

  • Page 5: Recognize Safety Information

    SAFETY Recognize Safety Information These are the SAFETY ALERT SYMBOLS. When you see these symbols on your machine or in this manual, be alert to the potential for personal injury. Follow recommended precautions and safe operating practices. SA-688 Understand Signal Words On machine safety signs, signal words designating the degree or level of hazard - DANGER, WARNING, or CAUTION - are used with the safety alert symbol.
  • Page 6 SAFETY Follow Safety Instructions Carefully read and follow all safety signs on the machine and all safety messages in this manual. Safety 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 dealer in the same way you order other replacement parts (be sure to state machine model and serial number when ordering).
  • Page 7 SAFETY Prepare for Emergencies Be prepared if a fire starts or if an accident occurs. Keep a first aid kit and fire extinguisher 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-...

  • Page 8: Inspect Machine

    SAFETY Protect Against Noise Prolonged 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. SA-434 Inspect Machine Inspect your machine carefully each day or shift by walking around it before you start it to avoid personal injury.
  • Page 9 SAFETY General Precautions for Cab Before 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.
  • Page 10 SAFETY Use Handholds and Steps Falling is one of the major causes of personal injury. When you get on and off the machine, always face the machine and maintain a three-point contact with the steps and handrails. Do not use any controls as handholds. Never jump on or off the machine.
  • Page 11 SAFETY Operator’s Visibility This 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.
  • Page 12 SAFETY Adjust Operator’s Seat A poorly adjusted seat for either the operator or the work at hand may quickly fatigue the operator leading to misoperations. The seat should be adjusted whenever changing the operator for the machine. The operator should be able to fully depress the pedals and to correctly operate the steering wheel with his back against the seat back.
  • Page 13 SAFETY Move and Operate Machine Safely Bystanders can be run over. Take extra care not to run over bystanders. Confirm the location of bystanders before moving, or operating the machine. Always keep the backup alarm and horn in working condition (if equipped). It warns people when the machine starts to move.

  • Page 14: Jump Starting

    SAFETY Operate Only from Operator’s Seat Inappropriate engine starting procedures may cause the machine to runaway, possibly resulting in serious injury or death. Start the engine only when seated in the operator’s seat. NEVER start the engine while standing on the platform. Do not start engine by shorting across starter terminals.
  • Page 15 SAFETY Avoid Injury Caused by High Tension Electric Shock Never 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. Never attempt to touch or grab any high tension electrical components or the power cable with wet hands.
  • Page 16 Pay attention that electric brake torque reduces. SSYA00018311 Overloaded machine reduces the electric brake performance. Observe strictly the Hitachi loading policy while driving. Before descending on a slope, decelerate the machine sufficiently using electric brake.

  • Page 17: Wheel Maintenance

    SAFETY Wheel Maintenance Mishandling of a tire and rim parts can cause serious injury or death. Inspect tires and wheels daily. Do not operate with low pressure, cuts, bubbles, damaged rims, or missing lug bolts and nuts. When 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.
  • Page 18 SAFETY Drive on Snow Safely Beware of the possibility of slipping or overturning the machine when traveling on frozen snow surfaces. The 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.
  • Page 19 SAFETY Avoid Injury from Back-Over Accidents If 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: Always look around BEFORE YOU BACK UP THE MACHINE. BE SURE THAT ALL BYSTANDERS ARE CLEAR.

  • Page 20: Avoid Tipping

    SAFETY 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 The cab, cab mounting structure and frame are designed for the protection of the operator and it meets the...
  • Page 21 SAFETY Protect Against Falling Stones and Debris Stay in your cab while truck is being loaded. Stepping out of the cab could result in possible injury. Do not place your head and/or arms outside of the window. NOTE: The cab is for the protection of the operator and it meets the requirements for Falling-Object Protective Structures (FOPS) according to the adopted standard for this machine.
  • Page 22 The overloading raises the center of gravity position and may cause overturning or long braking distance. It is very dangerous and serious injury or death may result. Obey the loading policy of Hitachi rigid dump truck. (Refer to the page 12-2 in the operator’s manual.) SA-1797...
  • Page 23 SAFETY Protect Against Flying Debris If 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. Keep bystanders away from any working area before striking any object.

  • Page 24: Handle Fluids Safely - Avoid Fires

    SAFETY Prevent Unintended Machine Movement Be careful not to accidentally actuate controls when co- workers are present. Lower the dump body during stopping the work. Place the shift lever in the Neutral position, then press the parking brake switch to the ON position to stop the engine before allowing anyone to approach the machine.

  • Page 25: Practice Safe Maintenance

    SAFETY Practice Safe Maintenance To avoid accidents: Understand service procedures before starting work. Keep the work area clean and dry. Do not spray water or steam inside cab. Never lubricate or service the machine while it is moving. Keep hands, feet and clothing away from power-driven parts.
  • Page 26 SAFETY Sufficiently illuminate the work site. Use a maintenance work light when working under or inside the machine. Always use a work light protected with a guard. In case the light bulb is broken, spilled fuel, oil, antifreeze fluid, or window washer fluid may catch fire.

  • Page 27: Support Machine Properly

    SAFETY Support Machine Properly Never attempt to work on the machine without securing the machine first. Always lower the dump body to the frame rail before you work on the machine. If you must work on a raised dump body, securely support the dump body by using the prop cable or pins.

  • Page 28: Prevent Burns

    SAFETY Prevent Parts From Flying Accumulators and hydraulic components are under high pressure. Failure to follow the precautions below may result in serious injury, blindness, or death. Do not attempt to remove plugs or hoses until pressure is fully relieved. As pieces may fly off, be sure to keep body and face away from accumulator and hydraulic components to avoid injury.
  • Page 29 SAFETY Replace Rubber Hoses Periodically Rubber hoses that contain flammable fluids under pressure may break due to aging, fatigue, and abrasion. It is very difficult to gauge the extent of deterioration due to aging, fatigue, and abrasion of rubber hoses by inspection alone. Periodically replace the rubber hoses.

  • Page 30: Avoid High-Pressure Fluids

    SAFETY Avoid High-Pressure Fluids Fluids such as diesel fuel or hydraulic oil under pressure can penetrate the skin or eyes causing serious injury, blindness or death. Avoid this hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard;...
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