Hitachi EH 4000AC-3 Technical Manual
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Hitachi EH 4000AC-3 Technical Manual

Rigid dump truck
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URL:http://www.hitachi-c-m.com
PRINTED IN JAPAN (E) 2013, 12
PART NO.
TOQFB-EN-00
Technical Manual
Operational Principle
EH
4000AC
-3
Rigid Dump Truck
Service Manual consists of the following separate Part No.
Technical Manual (Operational Principle)
Technical Manual (Troubleshooting)
Workshop Manual
: Vol. No.TOQFB-EN
: Vol. No.TTQFB-EN
: Vol. No.WQFB-EN

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  • Page 1 PART NO. TOQFB-EN-00 Technical Manual Operational Principle 4000AC 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.TOQFB-EN Technical Manual (Troubleshooting) : Vol. No.TTQFB-EN PRINTED IN JAPAN (E) 2013, 12 Workshop Manual : Vol.
  • Page 2 Find manuals at https://best-manuals.com...
  • Page 3 Form” at the end of this manual. (Note: Do not tear off  Be sure to thoroughly read this manual for correct the form. Copy it for usage.): product information and service procedures.  Publications Marketing & Product Support Hitachi Construction Machinery Co. Ltd.  TEL: 81-29-832-7084  FAX: 81-29-831-1162 ...
  • 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 The right is reserved to make changes at any time without notice. COPYRIGHT(C)2013 Hitachi Construction Machinery Co., Ltd. Tokyo, Japan All rights reserved TOQFB-EN-00(20180620) Find manuals at https://best-manuals.com...
  • Page 6 TECHNICAL MANUAL (Troubleshooting) WORKSHOP MANUAL SECTION 4 OPERATIONAL PERFORMANCE TEST SECTION 1 GENERAL INFORMATION Group 1 Introduction Group 1 Precautions for Disassembling and Assembling Group 2 Standard Group 2 Tightening Group 3 Engine Test Group 3 Periodic Replacement of Parts Group 4 Machine Performance Test SECTION 2 BODY Group 5 Component Test...

  • Page 7: Table Of Contents

    SECTION 1 GENERAL CONTENTS Group 1 Machine Specifications Alternator ................T1-3-10 Control Cabinet ..............T1-3-11 Machine Specifications ............. T1-1-1 Pump Device ..............T1-3-13 Group 2 Component Layout Travel Device...............T1-3-14 Main Component Layout ..........T1-2-1 Brake Device ...............T1-3-16 Operator's Seat ..............T1-2-2 Steering Device ..............T1-3-17 Liquid Crystal Display (LCD) (Normal Operation Suspension Device ............T1-3-18 Screen) ................
  • Page 8 (Blank) TOQFB-EN-00(20180620) QFBT-1-2 Find manuals at https://best-manuals.com...

  • Page 9: Group 1 Machine Specifications

    Minimum Turning Diameter (ISO) 30.2 m (99 ft 1 in) Travel Speed Forward 56 Km/h (35 mile/h), Reverse 10 km/h (6.2 mile/h) Electric Drive Hitachi AC-Drive System Tires Size 40.00R57 / 46/90R57 NOTE: These specifications are subject to change without notice. TOQFB-EN-00(20180620) T1-1-1 Find manuals at https://best-manuals.com...
  • Page 10 SECTION 1 GENERAL Group 1 Machine Specifications (Blank) TOQFB-EN-00(20180620) T1-1-2 Find manuals at https://best-manuals.com...

  • Page 11: Group 2 Component Layout

    SECTION 1 GENERAL Group 2 Component Layout Main Component Layout 20, 21 TQFB-01-02-001 T8DS-03-09-061 14, 35 TQFB-01-02-002 TQFB-01-02-003 Front Axle (Right) Tire (Rear Right) Suspension Cylinder (Front Brake Valve Tire (Front Right) Wheel Motor (Right) Right, Front Left) Steering Valve Front Wheel (Right) Parking Brake (Right, Left) Hoist Cylinder (Right, Left)

  • Page 12: Operator's Seat

    SECTION 1 GENERAL Group 2 Component Layout Operator's Seat M8R7-03-003 Steering Wheel Air Conditioner Unit Accelerator Pedal Drive Control Deactivation Grid Dry Switch Shift Lever Electric Brake Pedal Switch Radio Hoist Lever Service Brake Pedal Console Panel Dump Override Switch Turn Signal/High Beam Lever Camera Monitor Load Dump Brake Switch...

  • Page 13: Liquid Crystal Display (Lcd) (Normal Operation Screen)

    SECTION 1 GENERAL Group 2 Component Layout Liquid Crystal Display (LCD) (Normal Operation Screen) TQFB-01-02-019 Engine Related Warning Driving Related Warning Fuel Gauge Engine Oil Pressure Gauge Indicator Indicator Brake/Steering Hydraulic Oil Message Display Area Speedometer (With Right Turn Signal Indicator Pressure Gauge SAE Code Display Area Odometer)

  • Page 14: Console Panel

    SECTION 1 GENERAL Group 2 Component Layout Console Panel M8R7-01-004 Cruise Control/Auto Retard Key Pad Side Deck Light Switch Buzzer Deactivation Switch Main Switch Emergency Engine Stop Manual Rear Light Switch Engine Room Work Light Cruise Control/Auto Retard Switch Entrance Light Switch Indicator Speed Setting Switch Key Switch...

  • Page 15: Engine, Driving, And Hydraulic Related Indicators

    SECTION 1 GENERAL Group 2 Component Layout Engine, Driving, and Hydraulic Related Indicators TQFB-01-02-019 Engine Related Indicator Driving Related Indicator Hydraulic Related Indicator Engine Warning Indicator Traction Warning Indicator 14- Hydraulic Oil Temperature Warning Engine Oil Pressure Warning Indicator Wheel Motor Temperature Warning Indicator Coolant Level Warning Indicator Indicator...

  • Page 16: Headlight, Front Combination Light/Horn

    SECTION 1 GENERAL Group 2 Component Layout Headlight, Front Combination Light/Horn M8R7-01-014 Front Combination Light Headlight ULO Headlight LLI (Right) Front Combination Light (Left) Headlight LRI Headlight URO Horn (Left) High Headlight LRO Headlight URI Horn (Left) Low Horn (Right) Low Headlight ULI Headlight LLO Horn (Right) High...

  • Page 17: Side Light

    SECTION 1 GENERAL Group 2 Component Layout Side Light M8R7-01-015 M8R7-01-002 Left Side Right Side Deck Mounted Manual Rear Deck Mounted Manual Rear Front Tire Light (Right) Light (Left) Light (Right) Front Tire Light (Left) TOQFB-EN-00(20180620) T1-2-7...

  • Page 18: Rear Light

    SECTION 1 GENERAL Group 2 Component Layout Rear Light TQHA-01-02-034 Rear Combination Light (Left) Rear Combination Light Reverse Light (Right) Reverse Light (Left) (Right) Backup Alarm Buzzer TOQFB-EN-00(20180620) T1-2-8...

  • Page 19: Maintenance Light

    SECTION 1 GENERAL Group 2 Component Layout Maintenance Light M8R7-01-025 M8R7-01-014 A - A M8R7-01-029 Light Mounting Position in Rear Axle Entrance Light (1) Entrance Light (3) Engine Room Work Light Engine Room Work Light (Left) Entrance Light (2) (Right) Rear Axle Work Light TOQFB-EN-00(20180620) T1-2-9...

  • Page 20: Electrical Component Box (Behind Cab)

    SECTION 1 GENERAL Group 2 Component Layout Electrical Component Box (Behind Cab) TQFB-01-02-020 Download Connector DC/DC Converter Relay Box 1 (Refer to T1-2-12.) Information Display Unit (IDU) Optional Terminal Board Relay Box 2 (Refer to T1-2-12.) Central Control Unit (CCU) Engine Fault Indicator Relay Box 3 (Refer to T1-2-12.) Data Logging Unit (DLU)

  • Page 21: Fuse Box

    SECTION 1 GENERAL Group 2 Component Layout Fuse Box Fuse Layout M8R7-01-028 Refer to the right figure for the fuse layout. A - Fuse Box 1 Fuse Box 2 C - Fuse Box 3 FU-01(MAIN SW.) FU-17(CCU POWER) FU-31(AIR CONDITIONER 1) FU-47((OPT.) OPT.

  • Page 22: Relay Box

    SECTION 1 GENERAL Group 2 Component Layout Relay Box TQFB-01-02-020 Relay Box 3(C) Relay Box 4(D) 21- RY-21(ACCESS WAY LAMP (1)) 31- RY-31(LOAD WEIGHING LAMP (G)) 22- RY-22(ACCESS WAY LAMP (2)) 32- RY-32(FUEL FULL INDICATOR LAMP) 23- RY-23(SIDE DECK WORK LAMP (LHS)) 33- RY-33(HEATED MIRROR (1)) 24- RY-24(SIDE DECK WORK LAMP (RHS)) 34- RY-34(HEATED MIRROR (2))

  • Page 23: Battery Relay Box

    SECTION 1 GENERAL Group 2 Component Layout Battery Relay Box Cummins Engine MQFB-01-003 Fusible Link FL-01 Fusible Link FL-06 11- Battery Relay (2) 16- Starter Relay 1 Fusible Link FL-02 Fusible Link FL-07 12- Battery Relay (1) 17- Relay (for Pre-lubrication) Fusible Link FL-03 Fusible Link FL-08 13- Fuse (for Pre-lubrication)

  • Page 24: Hydraulic Component

    SECTION 1 GENERAL Group 2 Component Layout Hydraulic Component Main Pump System A - A TQFB-01-02-005 TQFB-01-02-007 1, 2, 3 B - B TQFB-01-02-006 TQFB-01-02-008 Front Rear Main Pump 1 (for Hoist) Hoist Control Valve Fitter (for Rear Brake Cooling Reducing Valve (for Load / Main Pump 2 (for Steering) Line Filter...

  • Page 25: Around The Operator's Seat

    SECTION 1 GENERAL Group 2 Component Layout Around the Operator's Seat View A T8R7-01-02-005 T8R7-01-02-006 Service Brake Pedal Accumulator Mounting Part W8R7-02-09-002 Brake Valve Main Accumulators (2 Used) Front Brake Accumulator Steering Valve Rear Brake Accumulator Manual Body Down Valve TOQFB-EN-00(20180620) T1-2-15...

  • Page 26: Front Axle

    SECTION 1 GENERAL Group 2 Component Layout Front Axle T8R7-01-02-007 T8R7-01-02-008 View A Flow Amplifier To Rod Side of Right Steering To Bottom Side of Left To Bottom Side of Right To Rod Side of Left Steering Cylinder Steering Cylinder Steering Cylinder Cylinder TOQFB-EN-00(20180620)

  • Page 27: Brake

    SECTION 1 GENERAL Group 2 Component Layout Brake W8R7-02-04-073 Rear Brake Mounting Part W8R7-02-04-082 T8DS-05-11-001 Parking Brake Mounting Part Front Brake Mounting Part Rear Brake Wheel Reduction Device Disc Brake Piston Parking Brake Brake Head Wheel Motor Front Brake Wheel TOQFB-EN-00(20180620) T1-2-17...

  • Page 28: Steering Cylinder

    SECTION 1 GENERAL Group 2 Component Layout Steering Cylinder T704-06-00-002 Left Trailing Arm Left Spindle Right Steering Cylinder Left Spindle Right Trailing Arm Tie Rod Left Steering Cylinder Hoist Cylinder MQHA-07-034 Hoist Cylinder Transportation Retainer TOQFB-EN-00(20180620) T1-2-18...

  • Page 29: Suspension Cylinder

    SECTION 1 GENERAL Group 2 Component Layout Suspension Cylinder T8DS-07-26-005 Pressure Sensor Rear Suspension Cylinder Tie Rod Suspension Tube Track Rod Front Suspension Cylinder Rear Axle Housing Trailing Arm Rear Axle Housing Wheel Reduction Device Cooling System TQFB-01-02-009 TQFB-01-02-010 Wheel Reduction Device (Left) Wheel Reduction Device (Right) Cooler (2 Used)

  • Page 30: Control Cabinet (1)

    SECTION 1 GENERAL Group 2 Component Layout Control Cabinet (1) A - A TQFB-01-02-011 Forward Backward Terminal Board (TB3) Drive System Controller (DSC) 17- Line Filter (FLT306) 25- Heater (H311) Terminal Board (TBZ10) 10- Rectifier Unit 18- Line Filter (FLT304) 26- Heater (H308) Terminal Board (TBZ7) 11- Inverter Unit (Left)

  • Page 31: Control Cabinet (2)

    SECTION 1 GENERAL Group 2 Component Layout Control Cabinet (2) 10 11 12 TQFB-01-02-012 A - A Forward Backward Program Upload Interface Radiator (RAD303) 15- Main Alternator Field 20- Auxiliary Alternator Field Connector (CN1) Terminal Board (TBZ8) Regulator (MFR) Unit Regulator (AFR) Unit Connector (CN2) 10- Control Power (CS) Unit...

  • Page 32: Terminal Board (Tb3)-Output Connector

    SECTION 1 GENERAL Group 2 Component Layout Terminal Board (TB3)-Output Connector TQFB-01-02-013 TQFB-01-02-014 Control Cabinet Front View Control Cabinet Left Side View TQFB-01-02-016 Wheel Motor Blower Output Wheel Reduction Gear Cooling Grid Blower R3 Output Trolley Control Box Output Alternator Blower Output Motor Output Grid Blower L1 Output Auxiliary Alternator Field Coil...

  • Page 33: Breaker, Fuse, Relay, Others

    SECTION 1 GENERAL Group 2 Component Layout Breaker, Fuse, Relay, Others Control Cabinet Front View TQFB-01-02-014 18 17 16 15 14 TQFB-01-02-017 Breaker (CB301) Fuse (F303) Relay (RY310) Temperature Sensor (TH301) Breaker (CB302) Fuse (F304) Relay (RY309) Diode (D306) Breaker (CB305) Fuse (F305) Relay (RY308) Diode (D303)

  • Page 34: Auxiliary Alternator Field Regulator (Afr) Unit

    SECTION 1 GENERAL Group 2 Component Layout Auxiliary Alternator Field Regulator (AFR) Unit TQFB-01-02-015 TQHA-01-02-031 Control Cabinet (Rear View) Auxiliary Alternator Field Regulator (AFR) Unit A - A TQHA-01-02-032 Capacitor (C311A) Terminal Board (TB1) Capacitor (C311B) Auxiliary Alternator Field Resistor (R311) IGBT (TRS311) Rectifier (D311) Regulator Board (VPM08)

  • Page 35: Control Power (Cs) Unit

    SECTION 1 GENERAL Group 2 Component Layout Control Power (CS) Unit TQFB-01-02-015 TQHA-01-02-022 Control Cabinet (Rear View) Control Power (CS) Unit TQHA-01-02-023 Capacitor (C302A) Overvoltage Protection Diode (D301) Resistor (R302) Capacitor (C302B) Module (VAX03) Diode (D305) Terminal Board (TBZ6) Line Filter (FLT301) TOQFB-EN-00(20180620) T1-2-25...

  • Page 36: Contactor, Relay, Others

    SECTION 1 GENERAL Group 2 Component Layout Contactor, Relay, Others TQFB-01-02-015 Control Cabinet (Rear View) 4, 5 TQFB-01-02-018 Relay (RY303) Contactor (CTT305) Contactor (CTT301) 13- Contactor (CTT307) Relay (RY304) Contactor (CTT304) 10- Contactor (CTT309) Relay (RY305) Contactor (CTT303) 11- Contactor (CTT302) Surge Absorber (SA305) Contactor (CTT306) 12- Contactor (CTT308)

  • Page 37: Drive System Controller (Dsc)

    SECTION 1 GENERAL Group 2 Component Layout Drive System Controller (DSC) Control Cabinet Front View TQFB-01-02-014 T8R8-01-04-011 Drive System Controller (DSC) Interface Board (VIO13) Communication Control Board PI Case Drive Control Board (XDC01) (VDC07) Back Board (XZT38) Interface Board (VIO14) Trolley Control Box Input/ DC/DC Converter (HDR10) Interface Board (VIO15)

  • Page 38: Rectifier (Rec) Unit

    SECTION 1 GENERAL Group 2 Component Layout Rectifier (REC) Unit Machine Right Side Machine Left Side TQFB-01-02-014 TQHA-01-02-025 Control Cabinet Front View Rectifier (REC) Unit A - A' TQHA-01-02-026 Rectifier Voltage Sensor (DCPT2) Resistor (R9B) Resistor (R9D) Temperature Sensor (TH1) Current Sensor (HCT2) Resistor (R7A) Resistor (R8B)
  • Page 39 SECTION 1 GENERAL Group 2 Component Layout Inverter (INV) Unit TQHA-01-02-027 TQFB-01-02-014 Control Cabinet (Front View) Inverter (INV) Unit A – A' B - B' TQHA-01-02-028 Current Sensor (HCT11) Temperature Sensor (TH11) Diode (D11) Resistor (R12B) Current Sensor (HCT12) Temperature Sensor (TH11A) IGBT(TRS14) Resistor (R12A) Current Sensor (HCT14)

  • Page 40: Control Cabinet

    SECTION 1 GENERAL Group 2 Component Layout Fan Unit TQFB-01-02-015 T8R8-01-04-013 Control Cabinet (Rear View) Fan Unit T8R8-01-04-015 Fan (FAN303) Fan (FAN304) Connector (CN1) TOQFB-EN-00(20180620) T1-2-30...
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