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
o Cummins Signature, ISX,QSX Service Man-
ual
o Electronic Control System Signature and ISX
Troubleshooting and Repair Manual
o Troubleshooting and Repair Manual Signa-
ture, ISX, and QSX15
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
Manufacturers Industrial Product Catalogs that
contain specific hose assembly instruction for
hoses using reusable field installed hose end fit-
tings. Catalogs available from the following sup-
pliers.
o Aeroquip Industrial Product
o Parker Hose and Fitting
o Gates Rubber Co.
o Imperial Eastman
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
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. Never fail to follow the safety instructions pre-
scribed along with the safety alert symbol.
The safety alert symbol is also used to draw attention
to component/part weights.
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.
IN-02
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 (3560 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
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. 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
HANDLE STARTING AIDS SAFELY
Starting fluid:
Starting fluid is highly flammable.
• Keep all sparks and flame away when using it.
• Keep starting fluid well away from batteries and
cables.
• Remove container from rigid dump truck if engine
does not need starting fluid. Do not store starting fluid
canisters on rigid dump truck. Starting fluid should
never be stored inside operator cab.
• To prevent accidental discharge when storing a
pressurized container, keep the cap on the container,
and store it in a cool, well-protected location.
• Do not incinerate or puncture a starting fluid
container.
NOTE: Due to increased safety hazards and potential
for engine damage, the engine manufacturer
does NOT recommend the use of starting fluid
without metering equipment.
SA-293
13. SERVICE AND MAINTENANCE / Safety
SA-8
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.
EL20368
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 Starting with Auxiliary
Batteries in the OPERATING INSTRUCTIONS
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 or a runaway rigid
dump truck.
SA-032
14. SERVICE AND MAINTENANCE / Safety
SA-9
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
PROTECT AGAINST FALLING STONES
AND DEBRIS
• Stay in your cab while your dumper 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 hauler 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 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
engine 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 protection 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
