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Hitachi EH1100-3 Workshop Manual

Rigid dump truck
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Manual No. W8R4-E-03
WORKSHOP MANUAL
E E H1100-3
RIGID DUMP TRUCK

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Summary of Contents for Hitachi EH1100-3

  • Page 1 Manual No. W8R4-E-03 WORKSHOP MANUAL E E H1100-3 RIGID DUMP TRUCK...

  • Page 2: Manual Composition

    Parts Catalog Operation Manual of the Engine Operation Manual of the Transmission 5000-9000 Series Transmissions Commer- TS41154 cial Electronic Controls 2 (CEC2) Manual Allison Transmission 5610-6610 Series Ser- vice Manual Hitachi Weld Repair Manual KO-111-00 IN-01 Find manuals at https://best-manuals.com...
  • Page 3 TITLE / Introduction 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...

  • Page 4: Units Used

    TITLE / Introduction UNITS USED Example: 24.5 MPa (3550 psi) SI system units and English units are used in this manual. English units are in parentheses behind SI A table for conversion from SI units to other system units. units is shown below for reference purposes. To Convert Quantity From...
  • Page 5 TITLE / Introduction MEMO ............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................IN-04 Find manuals at https://best-manuals.com...

  • Page 6: Recognize Safety Information

    SERVICE AND MAINTENANCE / Safety RECOGNIZE SAFETY INFORMATION SAFETY 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.

  • Page 7: Service And Maintenance / Safety

    SERVICE AND MAINTENANCE / Safety OPERATOR’S QUALIFICATIONS Only trained personnel should operate the rigid dump truck. Operator 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.

  • Page 8: Follow Safety Instructions

    • 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).

  • Page 9: Wear Protective Clothing

    SERVICE AND MAINTENANCE / Safety WEAR PROTECTIVE CLOTHING Wear 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.
  • Page 10 SERVICE AND MAINTENANCE / Safety 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.

  • Page 11: Adjust The Operator's Seat

    SERVICE AND MAINTENANCE / Safety USE HANDHOLDS AND STEPS Falling is one of the major causes of personal injury. • When entering or leaving the rigid dump truck, always use the steps and the handrails. • Do not use any controls as handholds. •...
  • Page 12 SERVICE AND MAINTENANCE / Safety FASTEN YOUR SEAT BELT If the rigid dump truck should overturn, the operator may become injured and/or thrown from the cab if the seat belt is not securely fastened. Additionally the overturning rigid dump truck may crush the operator, resulting in serious injury or death.

  • Page 13: Jump Starting

    SERVICE AND MAINTENANCE / Safety JUMP STARTING Battery gas can explode, resulting in serious injury. • If the engine must be jump-started, be sure to follow instructions shown under Using Booster Batteries in the OPERATING THE ENGINE section of the Operator’s Manual. •...
  • Page 14 SERVICE AND MAINTENANCE / Safety PROTECT AGAINST FALLING STONES AND DEBRIS • Stay in your cab while your rigid dump 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.
  • Page 15 SERVICE AND MAINTENANCE / Safety OPERATE THE RIGID DUMP TRUCK SAFELY When pulling out of the loading area, avoid hitting debris, rocks and loading rigid dump truck overflow that can cause tire damage. Allow the clean-up dozer sufficient time to clear the loading area. Watch where you are going.
  • Page 16 SERVICE AND MAINTENANCE / Safety AVOID INJURY FROM RUNNING OVER, FRONT AND BACK, AND FRONT WHEEL CRUSH AREA If any person is present near the rigid dump truck when backing or moving forward, the rigid dump truck may hit or run over that person, resulting in serious injury or death.

  • Page 17: Avoid Tipping

    SERVICE AND MAINTENANCE / Safety AVOID TIPPING Keep the rigid dump truck a safe distance from the edge of cliffs and slide areas. There is the danger of tipping or rolling over. Avoid operating on the side of slopes. Use the seat belt during operation. When operating the rigid dump truck, both doors should be closed at all times.
  • Page 18 SERVICE AND MAINTENANCE / Safety AVOID INJURY FROM ROLLAWAY ACCIDENTS Death or serious injury may result if you attempt to mount or stop a moving rigid dump truck. To avoid rollaways: • Select level ground when possible to park rigid dump truck.
  • Page 19 SERVICE AND MAINTENANCE / Safety NEVER TRAVEL WITH THE BODY OFF THE FRAME • Make sure the body is resting on the frame prior to moving the rigid dump truck. • If the raised body contacts an overhead obstacle, both the rigid dump truck and the overhead obstacle will be damaged, and personal injury may result as well.
  • Page 20 SERVICE AND MAINTENANCE / Safety OPERATING WITH THE RIGID DUMP TRUCK NEAR OVERHEAD WIRES OR CABLES Before operating the rigid dump truck, check with employer/supervisor to find out if there are any overhead cables or wires on the work site. •...
  • Page 21 SERVICE AND MAINTENANCE / Safety PARK RIGID DUMP TRUCK SAFELY • Fill the fuel tank to minimize water condensation in the tank. • Park rigid dump truck on a level surface. • Lower the body to the frame. • Move the shift selector to the N neutral position. •...
  • Page 22 SERVICE AND MAINTENANCE / Safety SAFE HANDLING OF OFF ROAD TIRES When doing any tire service, especially tire inflation, NEVER stand in the TRAJECTORY PATH. Serious injury or death can result if an explosion should occur. • Use a self-attaching air chuck with a hose long enough to be out of the trajectory path when filling a tire with air.

  • Page 23: Handle Fluids Safely Avoid Fires

    SERVICE AND MAINTENANCE / Safety HANDLE FLUIDS SAFELY AVOID FIRES Handle fuel with care; it is highly flammable. If fuel ignites, an explosion and/or a fire may occur, possibly resulting in serious injury or death. • Do not refuel the rigid dump truck while smoking or when near open flame or sparks.
  • Page 24 SERVICE AND MAINTENANCE / Safety A FEW SIMPLE RULES WHEN SERVICING Before working on the rigid dump truck, park it on a level surface and put it in the SERVICE POSITION: 1. Engine stopped, ignition key removed (except when service requires engine operation). 2.
  • Page 25 SERVICE AND MAINTENANCE / Safety A FEW SIMPLE RULES WHEN SERVICING (continued) Be sure the rigid dump truck is in the “SERVICE POSITION" before lifting or jacking up the rigid dump truck. Always support an elevated rigid dump truck using proper blocks and/or cribbing before beginning work on it.
  • Page 26 SERVICE AND MAINTENANCE / Safety USE TOOLS PROPERLY Use tool(s) appropriate for the work to be done. • Use the correct tool(s) for the job. Repair or replace and broken or defective equipment or tool(s). • Makeshift tools, parts, and procedures can create safety hazards.

  • Page 27: Prevent Burns

    SERVICE AND MAINTENANCE / Safety PREVENT BURNS Hot spraying fluids: After operation, engine coolant is hot and stored under pressure. Hot water or steam is contained in the engine, radiator and heater lines. Skin contact with escaping hot water steam cause severe burns.

  • Page 28: Avoid High-Pressure Fluids

    SERVICE AND MAINTENANCE / 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. •...

  • Page 29: Fire Prevention Measures

    SERVICE AND MAINTENANCE / Safety FIRE PREVENTION MEASURES Fire prevention features provided manufacturer should be maintained in operational condition and should be used to supplement operator’s fire prevention efforts. In no case should the features be used or assumed as replacement for diligent operator efforts at preventing fires.
  • Page 30 SERVICE AND MAINTENANCE / Safety Hydraulic fluid is flammable. Do not weld on pipes or tubes that are filled with fluid. Be careful when welding next to filled pipes or tubes. There is always a risk of fire. Find out which type of fire extinguisher to use, where it is and how to use it.
  • Page 31 SERVICE AND MAINTENANCE / Safety EVACUATING IN CASE OF FIRE If a fire breaks out, evacuate the rigid dump truck in the following way: • Lower the body to the chassis. • Set parking brake. • Stop the engine by turning the key switch to the OFF position.
  • Page 32 SERVICE AND MAINTENANCE / Safety PRECAUTIONS FOR WELDING, CUTTING, AND GRINDING When performing any welding operation on a rigid dump truck, specific electrical components must disconnected. Refer to Electrical Disconnects before Welding in the MAINTENANCE section of this manual. Grinding on the rigid dump truck may create fire hazards.

  • Page 33: Avoid Heating Near Pressurized Fluid Lines

    SERVICE AND MAINTENANCE / Safety AVOID HEATING NEAR PRESSURIZED FLUID LINES Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders. • Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials.

  • Page 34: Prevent Battery Explosions

    SERVICE AND MAINTENANCE / Safety PREVENT BATTERY EXPLOSIONS Battery gas can explode. • Keep sparks, lighted matches, and flame away from the top of battery. • Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer. •...

  • Page 35: Handle Chemical Products Safely

    DISPOSE OF WASTE PROPERLY Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with Hitachi rigid dump trucks includes such items as oil, fuel, coolant, hydraulic fluid, used filters, and batteries. • Use leak proof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them.
  • Page 36 SECTION 7 STEERING SECTION 8 FRAME SUSPENSION & WHEEL COPYRIGHT(C) 2008 Hitachi Construction Truck SECTION 9 CAB Manufacturing Ltd. Guelph, Canada All rights reserved SECTION 10 HOIST ATTACHMENT...
  • Page 37 <BLANK>...
  • Page 38 SECTION 1 GENERAL —CONTENTS— Group 1 Precautions for Disassembling and Assembling Precautions for Disassembling and Assembling......... W1-1-1 Bleeding Air from Hydraulic System.... W1-1-2 Floating Seal Precautions (Wheel Seal) ..W1-1-3 Precautions for Using Nylon Sling ....W1-1-4 Maintenance Standard Terminology.... W1-1-6 Group 2 Tightening Torque Tightening Torque Specifications ....
  • Page 39 <BLANK> W1-0...
  • Page 40 GENERAL / Precautions for Disassembling and Assembling PRECAUTIONS DISASSEMBLING Precautions for Disassembling AND ASSEMBLING • To prevent dirt from entering, cap or plug the Precautions for Disassembling and Assembling removed pipes, hoses and ports. • Before disassembling, clean the exterior of the Clean the rigid dump truck components.
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