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 Detroit Diesel 16V2000 Service Manual
Operation Manual of the Transmission
o 8000-9000 Series Transmissions Commer-
cial Electronic Controls 2 (CEC2) Manual
o Allison Transmission 8610-9610 Series Ser-
vice Manual
Hitachi Weld Repair Manual KO-111-00
MANUAL COMPOSITION
This manual consists of three portions; the Technical
Manual (Operational Principle) the Technical Manual
(Troubleshooting) and the Workshop Manual.
The Technical Manual (Operational Principle) con-
tains the information necessary for delivery, operation
and activation of all devices and systems.
The Technical Manual (Troubleshooting) contains the
information about operational performance tests, and
troubleshooting procedures.
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.
5. 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
7. SAFETY
S-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 (Jurisdiction) 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.
8. SAFETY
S-2
OPERATOR’S QUALIFICATIONS
Only trained personnel should operate the rigid dump
truck.
Operator should be of legal operating age according
to country (Jurisdiction) regulations and familiar with
the operation and maintenance of the rigid dump
truck.
Operator must be licensed if required by National
Rules and Regulations.
DUTIES OF THE OPERATOR
Before operating the rigid dump truck, this manual
must be read and understood. Contact your
supervisor if you do not understand any portion of
this manual. By reading and understanding the
manual, you will become aware of and observe
how to avoid injury and damage.
Know the work area and the company rules and
regulations
Never operate any vehicle while under the
influence of alcohol, medicine or other drugs.
Due to the position of the cab and size of the rigid
dump truck, the operator has limited visibility to areas
close to or near the rigid dump truck. No person
should enter the operating area of the rigid dump
truck when it is in operation without first notifying the
operator. If a person has to enter the operating area
of the rigid dump truck, they should signal the
operator and wait for an acknowledgement of
recognition by the operator.
During rigid dump truck operation no one should be
allowed to get any closer than 7m (23 ft.). Any closer
will limit one’s time to react and move away from the
vehicle when it starts.
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 RIGID DUMP TRUCK
section in this operator’s manual.
SA-435
9. SAFETY
S-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 its life.
The safety messages in this SAFETY chapter are
intended to illustrate basic safety procedures of the rigid
dump truck. 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 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
10. SAFETY
S-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. This
may be necessary when working outside of the
cab, during the Pre-Operation Inspection, for
example.
SA-434
PROTECT AGAINST FLYING DEBRIS
If flying debris hits 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
11. SAFETY
S-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
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.
• Don’t leave parts and/or tools lying around the
operator’s seat. Store them in their specified
locations.
• 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.
12. SAFETY
S-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 it 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 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 bring 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.
• The seat should be adjusted whenever changing
rigid dump truck operator.
• 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, and
check again. SA-378
13. SAFETY
S-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.
• We recommend that the seat belt be replaced
every three years regardless of its apparent
condition.
SA-237
14. SAFETY
S-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, and the park brake switch is
activated.
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
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
15. SAFETY
S-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.
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
16. SAFETY
S-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 vehicle 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 vibration 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, and driving conditions.
EL14019
17. SAFETY
S-11
AVOID INJURY FROM RUNNING OVER,
FRONT AND BACK, AND FROM 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
18. SAFETY
S-12
AVOID TIPPING
Keep the rigid dump truck at safe distance from the
edge of cliffs and slide areas. There is the danger of
tipping or roll 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.
THE OPERATOR AND PASSENGER SHOULD NOT
ATTEMPT TO JUMP CLEAR OF A TIPPING RIGID
DUMP TRUCK --- SERIOUS OR FATAL CRUSHING
INJURIES WILL RESULT.
A 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, 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
19. SAFETY
S-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
20. SAFETY
S-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 hits against 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
21. SAFETY
S-15
OPERATING 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 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 dump
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
site.
• 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 shall be equipped for such
operations.
EL20377
22. SAFETY
S-16
PARK RIGID DUMP TRUCK SAFELY
• Park rigid dump truck on a level surface.
• Lower the body to the frame.
• Move the shift controller lever 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 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.
• Fill the fuel tank to minimize water condensation in
the tank.
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
23. SAFETY
S-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 on larger dumps.
• 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.
EL20379
DISCHARGE ACCUMULATORS
Before removing and disassembling brake or
steering accumulators, they must be discharged to
prevent serious injury. Refer to the appropriate
Maintenance Manual section for BRAKE
ACCUMULATOR and STEERING
ACCUMULATOR.
