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

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

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

Language : English
Pages : 428
Downloadable : YES
Format : PDF
Vol No.: W8TDE-00

DESCRIPTION:

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

TO THE SERVICE PERSONEL:

This manual is written for an experienced technician and are on-the-job guides containing only the vital information needed for diagnosis, analyses, testing and repair. Essential tools required in performing certain service works are identified and in this manual and are recommended for use. The safe operation of your BELL EQUIPMENT machines very important to prevent any personal injury and/ or damage.

• This manual must be read and fully understood before carrying out any tests on your BELL EQUIPMENT machine. Right and left hand sides are determined by facing in the direction of forward travel. This manual is divided into chapters. The information contained in the manual is in logical sequence, with the instructions written in step by step format.
• Effective maintenance on your BELL EQUIPMENT machine is achieved when personnel fully understand the information contained in this manual. Every effort has been made to ensure that the information contained in this manual was correct at the time of publication.
• BELL EQUIPMENT Co. has a policy of continuous product development, improvement, and design. BELL EQUIPMENT Co. reserves the right to change, amend and update the design of its product at any time without prior notice. With this policy, changes may have occurred that are not included in this manual.
• Whilst every endeavour has been made to provide accurate and reliable information, BELL EQUIPMENT Co. specifically disclaims any actual or implied warranty and under no circumstances shall be liable for any loss, damage or injury to person or property suffered, whether direct, indirect or consequential, arising from the use of this manual.
• In particular and without detracting from above, the disclaimer also applies in the event of any specification, warning, or representation contained in this manual being inadequate, inaccurate, or unintentionally misleading. The user is urged to strictly comply with the instructions and warnings that are given in the interests of general safety.
• Please do not hesitate to contact your BELL EQUIPMENT Product Support Representative whenever you have a query on your BELL EQUIPMENT product or this manual.

TABLE OF CONTENTS:

Hitachi AH250-D AH300-D Articulated Dump Truck Workshop 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
USER’S INFORMATINON FEEDBACK FORM i
CHAPTER 1. WHEELS 1
REMOVAL AND INSTALLATION OFWHEELS 1
CHAPTER 2. AXLES AND SUSPENSION SYSTEMS 3
SECTION 1. REMOVAL AND INSTALLATION 3
AXLES 3
SECTION 2. DIFFERENTIAL OR BEVEL DRIVE 9
AXLE DIFFERENTIAL FRONT AND REAR 9
AXLE DIFFERENTIAL MIDDLE AXLE 18
SECTION 3. INPUT DRIVE SHAFTS AND U JOINTS 33
DRIVE SHAFTS 33
SECTION 4. AXLE MOUNTING PARTS 39
SECTION 5. AXLE SHAFTS, BEARINGS AND REDUCTION GEARS 51
FINAL DRIVE PLANETARY 51
CHAPTER 3. TRANSMISSION 59
SECTION 1.REMOVAL AND INSTALLATION 59
SECTION 2. INPUT DRIVE SHAFTS AND U JOINTS 61
REMOVE AND INSTALL TRANSMISSION TO TRANSFER CASE DRIVE SHAFT 61
SECTION 3. GEAR, SHAFT AND POWER SHIFT CLUTCHES 63
SECTION 4. HYDRAULIC SYSTEM 155
REMOVE AND INSTALL TRANSMISSION OIL TO AIR COOLER 155
CHAPTER 4. ENGINE 157
SECTION 1. REMOVAL AND INSTALLATION 157
ENGINE 157
SECTION 2. CRANKSHAFT, MAIN BEARINGS AND FLYWHEEL 161
INSTALL ENGINE ON REPAIR STAND 161
CRANKSHAFT AND MAIN BEARING FAILURE ANALYSIS 161
FLYWHEEL 165
CRANKSHAFT 169
TABLE OF CONTENTS
2
GRINDING GUIDELINES 175
BLEED ENGINE OIL CIRCUIT AFTER MAJOR OVERHAUL 177
SECTION 3. CAMSHAFT AND TIMING GEAR TRAIN 179
SECTION 4. CYLINDER BLOCK, LINERS, PISTONS AND RODS 187
LINER, PISTON AND ROD ANALYSIS 187
SECTION 5. LUBRICATION SYSTEM 203
REMOVE, INSPECT, AND INSTALL ENGINE OIL FILTER BYPASS VALVE 204
REMOVE, INSPECT AND INSTALL PISTON COOLING ORIFICES 204
SECTION 6. CYLINDER HEAD AND VALVES 205
CYLINDER HEAD AND VALVES FAILURE ANALYSIS 205
SECTION 7. EXHAUST SYSTEM 221
SECTION 8. FUEL INJECTION SYSTEM 223
REMOVE AND INSTALL HAND PRIMER PUMP 223
REMOVE AND INSTALL FUEL SUPPLY PUMP 223
SECTION 9. AIR INTAKE MANIFOLD SYSTEM 225
SECTION 10. TURBOCHARGER 227
SECTION 11. COOLING SYSTEM 233
SECTION 12. THERMOSTATS, HOUSING ANDWATER PIPING 237
CHAPTER 5. ENGINE AUXILIARY SYSTEM 239
SECTION 1. COOLING SYSTEM 239
SECTION 2. AIR INTAKE SYSTEM 241
INTAKE SYSTEM 241
SECTION 3. EXTERNAL EXHAUST SYSTEM 243
SECTION 4. ENGINE MOUNTING 247
ENGINE AND TRANSMISSION MOUNTINGS 247
SECTION 5. EXTERNAL FUEL SUPPLY SYSTEMS 251
PRIMARY FUEL FILTER 251
SECTION 1. ELEMENTS 255
CONNECTOR DRIVE (FLEXPLATE) 255
CHAPTER 7. TRANSFER CASE (DROP BOX) 257
SECTION 1. REMOVAL AND INSTALLATION 257
TRANSFER CASE (DROP BOX) 257
SECTION 2. GEAR SHAFTS AND BEARINGS 263
TRANSFER CASE (DROP BOX) 263
CHAPTER 8. STEERING SYSTEM 283
SECTION 1. SECONDARY STEERING 283
TABLE OF CONTENTS
3
SECONDARY STEERING PUMP 283
SECTION 2. HYDRAULIC SYSTEM 287
STEERING VALVE 287
STEERING CYLINDER 290
CHAPTER 9. SERVICE BRAKES 295
SECTION 1. ACTIVE ELEMENTS 295
SERVICE BRAKES 295
SECTION 2. HYDRAULIC SYSTEM 299
BRAKE VALVE 299
CHAPTER 10. PARK BRAKE 303
SECTION 1. ACTIVE ELEMENTS 303
PARK BRAKE 303
CHAPTER 11. FRAME AND SUPPORTING STRUCTURE 307
SECTION 1. FRAME INSTALLATION 307
WELDING ON MACHINE 307
SEPARATE FRONT AND REAR FRAMES 307
CHAPTER 12. OPERATOR’s STATION 317
SECTION 1. CAB 317
CAB MOUNTINGS 317
SECTION 2. SEAT AND SEAT BELT 321
OPERATOR’S SEAT 321
SECTION 3. HEATING AND AIR CONDITIONING 323
REFRIGERANT CAUTIONS AND PROPER HANDLING 323
R134a REFRIGERANT OIL INFORMATION 324
CHAPTER 13. SHEET METAL AND STYLING 337
SECTION 1. BONNET OR ENGINE ENCLOSURE 337
BONNET 337
CHAPTER 14. MAIN HYDRAULIC SYSTEM 341
SECTION 1. HYDRAULIC SYSTEM 341
MAIN HYDRAULIC PUMP 341
SUCTION STRAINER 346
HYDRAULIC SYSTEM MANIFOLD ASSEMBLY 347
CHAPTER 15. PNEUMATIC SYSTEMS 353
SECTION 1. PUMPS AND DRIVES 353
AIR COMPRESSOR 353
SECTION 2. CONTROL VALVES 363
TABLE OF CONTENTS
4
PNEUMATIC MANIFOLD 363
SECTION 3. RESERVOIR, FILTER AND TRAP 369
AIR UNLOADER VALVEWITH INTEGRAL AIR DRYER 369
SECTION 4. CYLINDERS 373
REMOVE AND INSTALL EXHAUST BRAKE AIR CYLINDER 373
CHAPTER 16. HAULAGE DEVICE 375
SECTION 1. FRAMES 375
BIN 375
SECTION 2. HYDRAULIC SYSTEM 379
BIN TIP CYLINDER 379
CHAPTER 17. DEALER FABRICATED TOOLS 385
SECTION 1. TOOLS 385
DFT1178 LIFTING TOOL 386
DFT1233 BUSHING DRIVER 386
DFT1199 BUSHING PUSHER 388

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