Hitachi AH250-D AH300-D Articulated Dump Truck Technical Manual PDF DOWNLOAD

Hitachi AH250-D AH300-D Articulated Dump Truck Technical Manual

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Hitachi AH250-D AH300-D Articulated Dump Truck Technical Manual

Language : English
Pages : 314
Downloadable : YES
Format : PDF
Vol No.: T8TDE-00

DESCRIPTION:

Hitachi AH250-D AH300-D Articulated Dump Truck Technical Manual 

SAMPLE PAGES FROM THE MANUAL:

OPERATIONAL CHECK-OUT:

Use this procedure to check operation of the machine. This procedure is designed so you can make a quick check of the machine operation while performing specific checks from the operator’s seat. Should you experience a problem with the machine, you will find helpful diagnostic information in this checkout that will help pinpoint the cause.

• A location will be required which is level and has adequate space to perform the check-out procedure. No tools or equipment are required to perform the check-out procedure.
• Compete the necessary visual checks (oil levels, oil condition, external leaks, loose hardware, linkages, wiring, etc.) prior to doing the operational check-out. The machine must be at operating temperature for many of the checks. Start at the top of the left column and read completely down column before performing check.
• Follow this sequence from left to right. In the far right column, if no problem is found, you will be instructed to go to next check. If a problem is indicated, you will be referred to either a chapter in this manual for specific test or the repair manual for repair procedure.

TABLE OF CONTENTS:

Hitachi AH250-D AH300-D Articulated Dump Truck Technical Manual 

SAFETY I
Specification I
Safety Features I
Material Safety Data Sheets (MSDS) II
Unauthorised Modifications of the Roll Over Protective Structure (ROPS) and the Falling Objects Protective
Structure (FOPS) II
Noise Emission Levels II
General Safety II
Safety Regulation II
Mounting and Dismounting the Machine II
AvoidWork Site Hazards III
Keep Riders Off the Machine III
Prepare for Emergencies III
Avoid Backing Over Accidents III
Handle Chemical Products And Flammable Fluids Safety III
Clean the Machine Regularly IV
Prevent Battery Explosions and Acid Burns IV
Wear Protective Equipment V
Use the Seat Belt V
Avoid High Pressure Fluids V
Stay Clear Of Moving Parts V
Beware of Toxic Fumes V
Dispose of Waste Properly VI
Start Only From Operator’s Seat VI
Operating The Machine VI
Welding Repairs VI
Tyre Information VII
Inspect and Maintain ROPS VII
Drive Metal Pins VII
USER’S INFORMATINON FEEDBACK FORM i
CHAPTER 1. OPERATIONAL CHECK OUT PROCEDURE 1
OPERATIONALCHECK OUT 1
OPERATIONAL CHECKS KEY SWITCH ON, ENGINE OFF 1
OPERATIONAL CHECKS ENGINE ON 3
CHAPTER 2. ENGINE 9
SECTION 1. THEORY OF OPERATION 9
ENGINE 9
Electronic Unit Injector Fuel System 10
Cold Start Option 12
SECTION 2. DIAGNOSE ENGINE MALFUNCTIONS 13
TABLE OF CONTENTS
b
SECTION 3. ADJUSTMENTS 17
DISPLAY MENU TACHOMETER 17
SLOWAND FAST IDLE ADJUSTMENT 17
VALVE CLEARANCE ADJUSTMENT 17
EXHAUST BRAKE ADJUSTMENT 18
SECTION 4. TESTS 19
CYLINDER COMPRESSION TEST 19
FUEL PUMP PRESSURE TEST DOWNSTREAM OF FUEL FILTER 20
Specification 20
Essential Tools 20
Service Equipment And Tools 20
Specification 21
Special Tools 21
Specification 22
Special Tools 22
Specification 23
OIL PUMP PRESSURE TEST 24
Specification 24
Essential Tools 24
Service Equipment And Tools 24
CHAPTER 3. ELECTRICAL SYSTEM 25
SECTION 1. SYSTEM INFORMATION 25
Electrical Schematic Symbols 25
HARNESSES AND COMPONENT LOCATION 26
EXPLANATION OF WIRE MARKINGS 52
Wire Colour 52
MultipleWire Colours 52
Circuit Breakers 52
SECTION 2. SYSTEMS AND SUB SYSTEMDIAGRAMS 55
SECTION 2. SYSTEMS AND SUB SYSTEM THEORY OF OPERATION AND DIAGNOSTICS
69
STARTING AND CHARGING CIRCUIT THEORY OF OPERATION 69
Starting Circuit 69
Charging Circuit 69
Flame Start Theory Of Operation 70
Electronic Unit Injector Controller Circuit Theory Of Operation 70
Temperature Sensors 71
Pressure Sensors 72
Engine Control Unit Circuit Theory Of Operation 72
Transmission Control Unit And Retarder Circuit Theory Of Operation 73
TABLE OF CONTENTS
c
Chassis Control Unit Circuit Theory Of Operation 77
Bin Control And Range Hold Circuit Theory Of Operation 79
Range Hold Circuit 80
Park Brake And Exhaust Brake Circuit Theory Of Operation 81
Turn Signal and 4 Way Flasher 85
Unloader Valve Heater Circuit Theory of Operation 91
SECTION 3. REFERENCES 93
SERVICE CODE DIAGNOSTICS AFTER MACHINE REPAIR 93
Service Code Diagnostics How Codes Are Displayed On Menu Display Unit 93
Service Code Diagnostics Engine Control Unit 94
Key Switch Test 123
Relay Test 123
Diode Test 124
Hydraulic Pressure Switches Test 127
Hydraulic Temperature Sensors Test 128
Bin Position Sensor Test 129
Retarder Voltage Regulator Test 131
Transmission Solenoids, Speed Sensors, Sump Temperature Sensor, and Retarder Resistor
Tests 132
Retarder Proportional Solenoid Test 133
Retarder Temperature Sensor Test 133
Transmission Shift Control Test 133
Remove and Install Engine Control Unit 135
Remove and Install Cold Start Module 136
Remove and Install Chassis Control Unit 136
Disconnect harness connectors (4 and 5). 136
Remove and Install Transmission Control Unit 137
Remove and Install Battery Balancer 137
Remove and Install Menu Display Unit 138
Replace Menu Display Unit Bulbs 138
Remove, Install, and Calibrate Accelerator Pedal Position Sensor 140
Replace DEUTSCH™ Rectangular or Triangular Connectors 140
Replace DEUTSCH™ Connectors 141
Install DEUTSCH™Contact 142
Replace WEATHER PACK™ Connector 143
InstallWEATHER PACK™Contact 143
Replace (Pull Type) Metri Pack™ Connectors 144
Replace (Push Type) Metri Pack™ Connectors 145
Remove Connector Body from Blade Terminals 145
CHAPTER 4. POWER TRAIN 147
SECTION 1. THEORY OF OPERATION 147
TRANSMISSION EXTERNAL COMPONENTS 147
TABLE OF CONTENTS
d
TRANSMISSION CONTROL SYSTEM 148
Retarder Operation 156
SECTION 2. DIAGNOSTIC INFORMATION 159
DIAGNOSTIC PROCEDURE 159
Know The System 159
Ask The Operator 159
Inspect The Machine 159
Perform Operational Check out. 159
Perform Troubleshooting 159
Trace And Cause 159
DIAGNOSE POWER TRAIN SYSTEM MALFUNTIONS 160
SECTION 3. TESTS 171
TRANSMISSION WARM UP PROCEDURE 171
Transmission Pressure Test 171
Torque Converter Stall Test 173
Torque Converter Stator Test 174
Transmission Oil to Air Cooler Restriction Test 174
Transmission Oil to Water Cooler Restriction Test 175
Front Suspension Strut Leakage Check 175
Park brake Test 175
Park Brake Pad Thickness Check 176
Park Brake Adjustment 176
CHAPTER 5. PNEUMATIC SYSTEM 179
SECTION 1. THEORY OF OPERATION 179
PNEUMATIC SYSTEM OPERATION 179
All pneumatic functions are supplied pressurized air by the engine driven compressor. 179
PNEUMATIC SYSTEM SCHEMATIC 180
Air Pressure Supply Circuit Operation 182
Air Dryer and Unloader Valve 183
Pneumatic Manifold 184
Pneumatic Circuit 190
CHAPTER 5. PNEUMATIC SYSTEM 193
SECTION 2. DIAGNOSTIC INFORMATION 193
DIAGNOSTIC PROCEDURE 193
DIAGNOSE PNEUMATIC SYSTEM MALFUNCTIONS 194
SECTION 3. TESTS 199
PNEUMATIC SYSTEM MAIN PRESSURE TEST AND ADJUSTMENT 199
Pneumatic System Main Specification 199
Essential Tools 199
TABLE OF CONTENTS
e
Service Equipment and Tools 199
PARK BRAKE PRESSURE TEST 200
Park Brake Pressure Specifications 200
Essential Tools 200
Service Equipment and Tools 200
CHAPTER 6. HYDRAULIC SYSTEM 201
SECTION 1. THEORY OF OPERATION 201
ARTICULATED DUMP TRUCK HYDRAULIC SYSTEM OPERATION 201
SECTION 2. DIAGNOSTIC INFORMATION 237
DIAGNOSTIC PROCEDURE 237
Know the system. 237
Ask the operator. 237
Inspect themachine. 237
Perform Operational Check out. 237
Perform troubleshooting. 237
Trace a cause. 237
DIAGNOSE HYDRAULIC SYSTEM MALFUNCTIONS 238
Hydraulic System Malfunctions 238
Service Brake System Malfuntion 242
Steering System Malfunctions 243
HYDRAULIC SYSTEM COMPONENT LOCATION 246
SECTION 3. TESTS 252
JT05800 DIGITAL THERMOMETER INSTALLATION 252
JT02156A DIGITAL PRESSURE/TEMPERATURE ANALYZER INSTALLATION 252
HYDRAULIC OIL CLEANUP PROCEDURE USING PORTABLE FILTER CADDY 252
Specifications 252
Service Equipment And Tools 252
Specification 253
HYDRAULIC SYSTEM WARM UP PROCEDURE 253
Service Equipment And Tools 253
CYCLE TIME TEST 254
Specifications 254
Service Equipment And Tools 254
MAIN HYDRAULIC PUMP RESIDUAL AND COMPENSATOR VALVES TEST AND ADJUSTMENT
255
Specifications Residual Valve 255
Compensator Valve 255
Essential Tools 255
Service Equipment And Tools 255
Residual Valve Pressure Setting 255
Compensator Valve Pressure Setting 256
TABLE OF CONTENTS
f
SYSTEM RELIEF VALVE AND BIN RAISE CIRCUIT RELIEF VALVE TEST 256
Specifications 256
Essential Tools 256
Service Equipment And Tools 256
PRIORITY VALVE TEST 257
Specifications 257
Essential Tools 257
Service Equipment And Tools 257
ACCUMULATOR PRESSURE REDUCING VALVE TEST AND ADJUSTMENT 257
Specifications 257
Essential Tools 257
Service Equipment And Tools 257
BRAKE ACCUMULATOR CHARGE VALVE TEST AND ADJUSTMENT 258
Specifications 258
Essential Tools 258
Service Equipment And Tools 258
BRAKE LOW PRESSURE SWITCH AND BRAKE ACCUMULATOR TEST 259
Specifications 259
Essential Tools 259
Service Equipment And Tools 259
FRONT AND REAR BRAKE ACCUMULATORS PRESSURE TEST AND CHARGE PROCEDURE
260
Specifications 260
Essential Tools 260
SERVICE BRAKE VALVE TEST 260
Specifications 260
Essential Tools 260
Service Equipment And Tools 260
STEERING RELIEF VALVE PRESSURE TEST AND ADJUSTMENT 261
Specifications 261
Essential Tools 261
Service Equipment And Tools 261
STEERING CYLINDER LEAKAGE TEST 262
Specifications 262
SECONDARY STEERING PUMP RESIDUAL AND COMPENSATOR VALVES TEST AND ADJUSTMENT
262
Specifications 262
Essential Tools 262
Service Equipment And Tools 262
Residual Valve Adjustment 263
Compensator Valve Adjustment 263
BIN LOWER CIRCUIT RELIEF VALVE TEST 264
Specifications 264
TABLE OF CONTENTS
g
Essential Tools 264
Service Equipment And Tools 264
CHAPTER 7. HEATING AND AIR CONDITIONING 265
SECTION 1. THEORY OF OPERATION 265
AIR CONDITIONING SYSTEM CYCLE OF OPERATION 265
HEATER CORE OPERATION 266
SECTION 2. DIAGNOSTIC INFORMATION 267
DIAGNOSE AIR CONDITIONING SYSTEM MALFUNCTIONS 267
DIAGNOSE HEATER SYSTEM MALFUNCTIONS 269
HEATING/AIR CONDITIONING COMPONENT LOCATION 270
SECTION 3. TESTS 273
AIR CONDITIONING OPERATIONAL CHECKS 273
Visual Inspection of Components 273
R134A AIR CONDITIONING SYSTEM TEST 274
Specifications 274
Service Equipment And Tools 274
OPERATING PRESSURE DIAGNOSTIC CHART 275
A/C FREEZE CONTROL SWITCH TEST 277
Specifications 277
A/C COMPRESSOR CLUTCH TEST 277
A/C HIGH/LOWPRESSURE SWITCH TEST 277
Specifications 277
Service Equipment And Tools 277
A/C EXPANSION VALVE TEST 278
Specifications 278
Essential Tools 278
Service Equipment And Tools 278
EXPANSION VALVE BENCH TEST 279
Specifications 279
Essential Tools 279
Service Equipment And Tools 279
REFRIGERANT LEAK TEST 280
Specifications 280

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