This manual provides technical information for maintaining and repairing a rigid dump truck. It contains instructions for maintenance, repair, and disassembly/reassembly of components. Safety symbols are explained, including warnings regarding hazardous situations that could result in injury or death. Operators must be properly trained and qualified according to national regulations to operate the truck safely.

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

2. 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:
Operators Manual
Parts Catalog
Operation Manual of the Engine
Operation Manual of the Transmission
o 5000-9000 Series Transmissions Commer-
cial Electronic Controls 2 (CEC2) Manual
o Allison Transmission 5610-6610 Series Ser-
vice Manual
Hitachi 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

3. 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.

4. 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 0.03937
Length
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 0.10197
Force
N lbf 0.2248
N m kgf m 1.0197
Torque
N m lbf ft 0.7375
Quantity
To Convert
From Into Multiply by
MPa kgf/cm² 10.197
Pressure
MPa psi 145.0
kW PS 1.360
Power
kW HP 1.341
Temperature C F C 1.8 32
Velocity km/h mph 0.6214
L/min US gpm 0.2642
Flow Rate
mL/rev cc/rev 1.0

5. TITLE / Introduction
IN-04
MEMO
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6. SERVICE AND MAINTENANCE / Safety
SA-1
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. 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
On 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.
These signal words also call attention to safety
messages in this manual.
To 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

7. SERVICE AND MAINTENANCE / Safety
SA-2
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.
Operator must be licensed if required by National
Rules and Regulations.
Before 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.
Know the work area and the company rules and
regulations
Never operate the rigid dump truck while under the
influence of alcohol, medicine or other drugs.
INSPECT RIGID DUMP TRUCK
Inspect 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

8. SERVICE AND MAINTENANCE / Safety
SA-3
FOLLOW SAFETY INSTRUCTIONS
Carefully read and follow all safety signs on the rigid
dump truck 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 Hitachi
dealer in the same way you order other replacement
parts (be sure to state rigid dump truck model and
serial number when ordering).
Learn how to operate the rigid dump truck and its
controls correctly and safely.
Allow only trained qualified, authorized personnel to
operate the rigid dump truck.
Keep 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.
The 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
Be 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

9. SERVICE AND MAINTENANCE / Safety
SA-4
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.
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
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. May be necessary
when working outside of the cab, during the Daily
Walk Around Inspection, for example.
SA-434
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.
SA-432

10. 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.

11. SERVICE AND MAINTENANCE / Safety
SA-6
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.
• When you get on and off the rigid dump truck, always
face the rigid dump truck and maintain a three-point
grip with the steps and handrails. (i.e., Two hands and
one foot or one hand and two feet.)
• DO NOT JUMP on or off the rigid dump truck. Never
mount or dismount a moving rigid dump truck.
• Do not step or climb on surfaces, which are not
intended for walking. Step only on the areas provided
with the slip resistant surfaces.
• Be careful of slippery conditions on platforms, steps,
and handrails when leaving the rigid dump truck.
• All steps, ladders, stairways, handholds, platforms,
walkways, and guardrails must be free of dirt, snow,
and ice.
• All steps, ladders, stairways, platforms, walkways,
and non-skid deck strips must be replaced if
damaged.
• The use of a rope is recommended to hoist up to the
deck or cab lunch box, tools, etc so as to maintain a
three-point grip when entering or leaving the rigid
dump truck.
SA-439
EL20273
ADJUST THE OPERATOR’S SEAT
A poorly adjusted seat for either the operator or for the
work at hand may quickly fatigue the operator leading to
miss-operations.
• The seat should be adjusted whenever changing the
operator for the rigid dump truck.
• The operator should be able to fully depress the
pedals and to correctly operate the control levers with
his back against the seat back.
• If not, move the seat forward or backward to adjust,
and check again.
SA-378

12. SERVICE AND MAINTENANCE / Safety
SA-7
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.
• Prior to operating the rigid dump truck, thoroughly
examine webbing, buckle and attaching hardware. If
any item is damaged or worn, replace the seat belt or
component immediately before operating the rigid
dump truck.
• Be sure to remain seated with the seat belt securely
fastened at all times when the rigid dump truck is in
operation to minimize the chance of injury from an
accident.
• Recommend that the seat belt be replaced every
three years regardless of its apparent condition.
SA-237
OPERATE ONLY FROM OPERATOR’S SEAT
Inappropriate engine starting procedures may cause the
rigid dump truck to runaway, possibly resulting in serious
injury or death.
• Start the engine only from the operator’s seat.
• NEVER start the engine while standing on the ground.
• Do not start engine by shorting across starter
terminals.
Before starting the engine, confirm that all control levers
are in neutral and the park brake switch is in the applied
position.
EL20368

13. SERVICE AND MAINTENANCE / Safety
SA-8
JUMP STARTING
Battery gas can explode, resulting in serious injury.
• If the engine must be jump-started, be sure to follow
the instructions shown under Using Booster
Batteries in the OPERATING THE ENGINE section
of the Operator’s Manual.
• The operator must be in the operator’s seat so that
the rigid dump truck will be under control when the
engine starts. Jump-starting is a two-person
operation.
• Never use a frozen battery.
• Failure to follow correct jump starting procedures
could result in a battery explosion, a runaway rigid
dump truck or damage to electronic equipment on the
rigid dump truck.
SA-032
KEEP RIDERS OFF RIGID DUMP TRUCK
Riders on rigid dump truck are subject to injury
such as being struck by foreign objects and being
thrown off the rigid dump truck.
• Do not allow riders other than on the
passenger's seat. Riders must also have their
seat belt fastened.
• Riders also obstruct the operator’s view,
resulting in the rigid dump truck being operated
in an unsafe manner.
EL20369

14. SERVICE AND MAINTENANCE / Safety
SA-9
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.
• Close cab windows while the rigid dump truck is being
loaded.
EL20380-1
PROVIDE SIGNALS FOR JOBS INVOLVING
MULTIPLE NUMBERS OF VEHICLES
For jobs involving multiple numbers of vehicles, 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-481

15. SERVICE AND MAINTENANCE / Safety
SA-10
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. Stay away from people, the
edge of cliffs; slide areas, other machines and vehicles,
etc.
While traveling on the haul road, maintain a sufficient
distance behind the rigid dump truck ahead (depending
on roads, speeds, and haul road conditions). This
practice should always be followed to allow sufficient
safe maneuvering and stopping room.
During all operations, the rigid dump truck may vibrate
or shake to some extent. Therefore, operate the rigid
dump truck in such a way that your body is exposed to
as little vibrations as possible.
Have the operator’s seat properly adjusted and
wear the seat belt.
Pick the smoothest and safest path for the rigid
dump truck.
Adjust the speed of the rigid dump truck to the
terrain.
EL14019

16. SERVICE AND MAINTENANCE / Safety
SA-11
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. If any person is present in the area between the
chassis and the front wheel, the person could be
crushed when the front wheels are turned.
To avoid these situations:
• Always look around BEFORE YOU MOVE THE
RIGID DUMP TRUCK. BE SURE THAT ALL
BYSTANDERS ARE CLEAR.
• Keep the back-up 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 RIGID DUMP TRUCK.
• USE A SIGNAL PERSON IF YOUR VIEW IS
OBSTRUCTED. ALWAYS KEEP THE SIGNAL
PERSON IN VIEW.
• No rigid dump truck motions shall be made unless
signals are clearly understood by both signalman and
operator.
• Learn the meanings of all flags, signs, and markings
used on the job and confirm who has the
responsibility for signaling.
• Keep windows, mirrors, and lights clean and in good
condition.
• Dust, heavy rain, fog, etc., can reduce visibility. As
visibility decreases, reduce speed and use proper
lighting.
• Read and understand all operating instructions in the
operator’s manual.
EL20370
EL20371
EL20372

17. SERVICE AND MAINTENANCE / Safety
SA-12
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.
The cab is for the protection of the operator and it meets
the requirements for rollover protective structures (ROPS)
according to the adopted standard for this rigid dump truck.
DO NOT ATTEMPT TO JUMP CLEAR OF A TIPPING
RIGID DUMP TRUCK --- SERIOUS OR FATAL CRUSHING
INJURIES WILL RESULT.
RIGID DUMP TRUCK WILL TIP OVER FASTER THAN
YOU CAN JUMP FREE.
THEREFORE, HOLD FIRMLY ONTO THE STEERING
WHEEL IF THE RIGID DUMP TRUCK SHOULD TIP OR
ROLL OVER. DO NOT JUMP.
IMPORTANT: Never make any unauthorized
modifications or alterations to the Rollover
Protective Structure (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.
The Rollover Protective Structure (ROPS) has been certified
to meet specified requirements according to SAE J1040C,
SAE J231, ISO 3471 and ISO 3449.
Any planned modification or change must be reviewed in
advance by our Engineering Department to determine if the
modification or change can be made within the limits of the
certified tests.
IMPORTANT: Each person in your organization, including
management should be made aware of
these rules involving the Rollover
Protective Structure (ROPS). Whenever
anyone sees a rigid dump truck’s ROPS
with unauthorized modifications or
changes both the customer and
manufacturer should be notified in writing.
EL20373

18. SERVICE AND MAINTENANCE / Safety
SA-13
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.
• Do not park the rigid dump truck on a grade.
• Reference: PARK RIGID DUMP TRUCK SAFELY in this
section.
• Chock the wheels if you must park on a grade.
• Position the rigid dump truck to prevent rolling.
• Park a reasonable distance from other vehicles.
EL20374

19. SERVICE AND MAINTENANCE / Safety
SA-14
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. This
includes overhead wires, cables and power lines.
• Traveling with a raised body places greater stress to the
body pivot pins, hydraulic cylinders and the frame.
• Never “jump dump” by bouncing the rear wheels against
a stop rail or by jerking the body control lever.
EL20375
EL20376

20. SERVICE AND MAINTENANCE / Safety
SA-15
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.
• The rigid dump truck operator must be given clear
information about this. Make sure that all relevant and
practical measures to help detect such lines are taken.
• Local authorities and/or communication and power
companies should be contacted for guidance and advice.
• Overhead wires and cables must be protected against
damage in a suitable way. The electricity should be
turned off when practical.
OPERATING WITH THE RIGID DUMP TRUCK
NEAR HIGH VOLTAGE, OVERHEAD POWER
LINES
A power line is a single conductor suspended on or from
poles or other supports as well as accessories such as
insulators, hooks, and bars.
Serious injury or death can result if the rigid dump truck is
not kept a safe distance from electric lines.
• When operating near an electric line, NEVER move any
part of the rigid dump truck or load closer than 3 m (10 ft.)
plus twice the line insulator length.
• Never operate the rigid dump truck with the body in the
raised position.
• Check and comply with any local regulations that may
apply.
• If the rigid dump truck comes into contact with a high
voltage line, the operator must remain in the operator’s
seat and not leave the cab; if the line is live and the
operator tries to reach the ground his or her life is in
danger. Call for help by signaling in some way, sounding
the horn or mobile telephone, so that the power can be
turned off.
• Wet ground will expand the area that could cause any
person on it to be affected by electric shock. Keep all
bystanders or co-workers away from the wet ground.
• If the rigid dump truck is used in potentially dangerous
environments, e.g. explosive atmosphere, areas with dust
including asbestos, special safety regulations must be
followed and the rigid dump truck must be equipped for
such operations.
EL20377

21. SERVICE AND MAINTENANCE / Safety
SA-16
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.
• Apply the parking brake and release the service brakes
to insure that the parking brake is holding the rigid dump
truck.
• Let the engine run at low idle for three to five minutes for
cool down.
• Make sure the body hoist control lever is in the Float
position.
• Check that all switches and controls are in the OFF
position.
• Turn the Key Switch to the OFF position.
• Turn the Battery Disconnect Switch to the OFF position.
• Place wheel chocks both ahead and behind tires of axle.
Chocks must contact tire tread surface when installed
correctly.
NOTE: Running out of fuel with the engine running,
especially under load, is very detrimental to engine
life and requires a time consuming restart
procedure.
• Perform a walk around inspection and fill out the required
Preventative Maintenance form or other required operator
report forms. Be sure to report any adjustments of service
required to those responsible for maintenance.
• When leaving the rigid dump truck unattended, remove
the key. Lock the doors and any vandalism guards to
prevent theft or damage.
EL20378

22. SERVICE AND MAINTENANCE / Safety
SA-17
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.
• Use an inflation cage, safety cables, or chains when
inflating tires.
• Never use air from a compressed air system, to inflate a
tire if alcohol has been used as antifreeze.
Inspect all rims, wheels and components.
• Replace any worn or damaged rims, wheels and
components.
Do not remove any wheel nuts; rim clamps or dagger
clamps until the tire is deflated.
• No personnel should be touching the rim, rim clamp, or
tire when dislodging the rim clamps or dagger clamps.
• Never stand in front of rim clamps or dagger clamps
during removal.
• Trained and certified personnel should only do the
dismounting and mounting of tires. It is recommended
that a certified tire repair service be hired to perform the
dismounting and mounting of tires from rims.
DISCHARGE ACCUMULATORS
Before removing and disassembling brake or steering
accumulators, they must be discharged to prevent serious
injury. Refer to the appropriate Workshop Manual section
for BRAKE ACCUMULATOR and STEERING
ACCUMULATOR.
EL20379
EL20560

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