Hitachi AH500-D Articulated Dump Truck Technical Manual (KM-8TJ-E) PDF DOWNLOAD

Hitachi AH500-D Articulated Dump Truck Technical Manual

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Hitachi AH500-D Articulated Dump Truck Technical Manual

Language : English
Pages : 756
Downloadable : YES
Format : PDF
Size : 26.1 MB
Manual No.:KM-8TJ-E
Vol. No. :T8TJ-E-01

DESCRIPTION:

Hitachi AH500-D Articulated Dump Truck Technical Manual

TO THE SERVICE PERSONEL:

Do not operate the machine unless you have read the Operator’s Manual and fully understand how to operate the machine properly. 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 HITACHI 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 HITACHI 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. 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. HITACHI Co. has a policy of continuous product development, improvement, and design.
• HITACHI 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, HITACHI 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 HITACHI Product Support Representative whenever you have a query on your HITACHI product or this manual.

TABLE OF CONTENTS:

Hitachi AH500-D Articulated Dump Truck Technical Manual

USER’S INFORMATINON FEEDBACK FORM 11
SAFETY 19
Specification 19
Safety Features 19
Unauthorised Modifications of the Roll Over Protective Structure (ROPS) and the Falling Objects Protective
Structure (FOPS) 20
Noise Emission Levels 20
General Safety 20
SAFETY DECALS 27
CHAPTER 1. OPERATIONAL CHECK OUT PROCEDURE 37
OPERATIONAL CHECK OUT 37
OPERATIONAL CHECKS KEY SWITCH ON, ENGINE OFF 37
OPERATIONAL CHECKS ENGINE ON 39
CHAPTER 2. ENGINE 45
SECTION 1. THEORY OF OPERATION 45
ENGINE 45
SECTION 2. DIAGNOSE ENGINE MALFUNCTIONS 49
SECTION 3. ADJUSTMENTS 53
DISPLAY MENU TACHOMETER 53
SLOW AND FAST IDLE ADJUSTMENT 53
VALVE CLEARANCE ADJUSTMENT 53
EXHAUST BRAKE ADJUSTMENT 54
SECTION 4. TESTS 57
CYLINDER COMPRESSION TEST 57
FUEL PUMP PRESSURE TEST 57
CHAPTER 3. ELECTRICAL SYSTEM 61
SECTION 1. SYSTEM INFORMATION 61
HARNESSES AND COMPONENT LOCATION 62
EXPLANATION OF WIRE MARKINGS 92
PLUGS AND CONNECTORS 117
SECTION 2. DESCRIPTION OF CIRCUITS 245
ISOLATOR SWITCH 245
IGNITION SWITCH ON 247
IGNITION SWITCH IN START POSITION 248
MENU D 270
SECTION 3. REFERENCES 273
SERVICE CODE DIAGNOSTICS AFTER MACHINE REPAIR 273
SECTION 4. TESTS 363
KEY SWITCH TEST 363
RELAYS 363
Material Safety Data Sheets (MSDS) 20
TABLE OF CONTENTS
14
CHAPTER 4. TRANSMISSION HD4560 387
SECTION 1. THEORY OF OPERATION 387
GENERAL DESCRIPTIONS 387
TRANSMISSION IDENTIFICATION 388
TORQUE CONVERTER 389
TORQUE CONVERTER OPERATION 390
LOCK UP CLUTCH OPERATION 394
PLANETARY GEARS AND POWER FLOWS 397
THE BASIC LAWS OF PLANETARY GEAR SETS 398
CLUTCHES 398
HD TRANSMISSION PLANETARY CONFIGURATION 399
HD TRANSMISSION CLUTCH CONFIGURATION 400
POWER FLOW 404
HYDRAULIC SYSTEM 413
MAIN PRESSURE CIRCUIT 413
CONTROL MAIN CIRCUIT 415
TORQUE CONVERTER CIRCUIT 415
CONVERTER IN PRESSURE CIRCUIT 416
HYDRAULICS (OPERATION) 417
SOLENOIDS 417
NORMALLY OPEN SOLENOIDS 418
NORMALLY CLOSED SOLENOIDS 419
HYDRAULIC CIRCUITS 421
TORQUE CONVERTER AND LUBE PRESSURE CIRCUITS OVERVIEW 429
CONVERTER FLOW VALVE OPERATION 429
OVERDRIVE KNOCKDOWN VALVE 429
EXHAUST BACKFILL PRESSURE 430
PRESSURE TABLE AND TEST PIONTS 431
RETARDER 433
APPLICATIONS AND CAPACITIES 433
Retarder Control Overview 434
Apply Controls 434
INPUTS AND OUTPUTS 435
RETARDER CONTROL HYDRAULICS 435
TESTING RETARDER CHARGING PRESSURE 436
Retarder Off 436
HD RETARDER HYDRAULIC SCHEMATIC RETARDER OFF 437
HD RETARDER HYDRAULIC SCHEMATIC RETARDER ON 438
ELECTRONIC CONTROL SYSTEM 439
TRANSMISSION CONTROL UNIT
(T C U) 439
PULSE WIDTH MODULATION (P W M) 439
PUSH BUTTON SHIFT SELECTOR 443
AH500 D STALL SPEEDS 396
TABLE OF CONTENTS
15
SPEED SENSORS 444
WIRING HARNESSES 444
RANGE / SHIFT TESTS 445
DO NOT SHIFT LIGHT 446
SECTION 2. DIAGNOSTIC INFORMATION 455
DIAGNOSTIC PROCEDURE 455
DIAGNOSE POWER TRAIN SYSTEM MALFUNTIONS 456
CHAPTER 5. PNEUMATIC SYSTEM 473
SECTION 1. THEORY OF OPERATION 473
PNEUMATIC SYSTEM OPERATION 473
PNEUMATIC SYSTEM SCHEMATIC 474
SECTION 2. DIAGNOSTIC INFORMATION 485
DIAGNOSTIC PROCEDURE 485
DIAGNOSE PNEUMATIC SYSTEM MALFUNCTIONS 486
SECTION 3. TESTS 495
PNEUMATIC SYSTEM MAIN PRESSURE TEST AND ADJUSTMENT 495
PARK BRAKE PRESSURE TEST 496
CHAPTER 6. HYDRAULIC SYSTEM 497
SECTION 1. THEORY OF OPERATION 497
ARTICULATED DUMP TRUCK HYDRAULIC SYSTEM OPERATION 497
SECTION 2. DIAGNOSTIC INFORMATION 535
DIAGNOSTIC PROCEDURE 535
DIAGNOSE HYDRAULIC SYSTEM MALFUNCTIONS 536
HYDRAULIC SYSTEM COMPONENT LOCATION 544
SECTION 3. TESTS 557
JT05800 DIGITAL THERMOMETER INSTALLATION 557
JT02156A DIGITAL ANALOGUE PRESSURE/TEMPERATURE ANALYZER INSTALLATION 557
HYDRAULIC SYSTEM WARM UP PROCEDURE 558
MAIN HYDRAULIC PUMP RESIDUAL AND COMPENSATOR VALVES TEST AND
PRIORITY VALVE TEST 562
ACCUMULATOR PRESSURE REDUCING VALVE TEST AND ADJUSTMENT 562
BRAKE ACCUMULATOR CHARGE VALVE TEST AND ADJUSTMENT 563
BRAKE LOW PRESSURE SWITCH AND BRAKE ACCUMULATOR TEST 564
FRONT AND REAR BRAKE ACCUMULATORS PRESSURE TEST AND CHARGE
SERVICE BRAKE VALVE TEST 565
STEERING RELIEF VALVE PRESSURE TEST AND ADJUSTMENT 566
HYDRAULIC OIL CLEANUP PROCEDURE USING PORTABLE FILTER CADDY 557
ADJUSTMENT 560
CYCLE TIME TEST 559
PROCEDURE 565
SYSTEM RELIEF VALVE AND BIN RAISE CIRCUIT RELIEF VALVE TEST 561
TABLE OF CONTENTS
16
STEERING CYLINDER LEAKAGE TEST 567
SECONDARY STEERING PUMP RESIDUAL AND COMPENSATOR VALVES TEST AND ADJUSTMENT
567
BIN LOWER CIRCUIT RELIEF VALVE TEST 568
FAN DRIVE CONTROLLER TEST AND ADJUSTMENT 569
CHAPTER 7. HEATING AND AIR CONDITIONING 573
SECTION 1. THEORY OF OPERATION 573
AIR CONDITIONING SYSTEM CYCLE OF OPERATION 573
HEATER CORE OPERATION 574
SECTION 2. DIAGNOSTIC INFORMATION 575
DIAGNOSE AIR CONDITIONING SYSTEM MALFUNCTIONS 575
DIAGNOSE HEATER SYSTEM MALFUNCTIONS 577
HEATING/AIR CONDITIONING COMPONENT LOCATION 578
SECTION 3. TESTS 581
AIR CONDITIONING OPERATIONAL CHECKS 581
R134A AIR CONDITIONING SYSTEM TEST 582
OPERATING PRESSURE DIAGNOSTIC CHART 583
A/C FREEZE CONTROL SWITCH TEST 585
A/C COMPRESSOR CLUTCH TEST 585
A/C HIGH/LOW PRESSURE SWITCH TEST 585
A/C EXPANSION VALVE TEST 586
EXPANSION VALVE BENCH TEST 587
REFRIGERANT LEAK TEST 588
CHAPTER 8. MENU DISPLAY UNIT AND ALPHA NUMERICAL DISPLAY 589
START UP DISPLAY 589
DEFAULT SCREEN 590
TO SELECT BETWEEN MENUS 590
CHAPTER 9. MAINTENANCE SCHEDULES 601
CHAPTER 10. DAILY OR 10 HOURLY SERVICE CHECKS 605
CHAPTER 11. 500 HOURS SERVICE AND CHECKS 607
SECTION 1. DRIVE TRAIN 607
INTRODUCTION 607
SERVICE INSTRUCTIONS 607
ENGINE 607
TRANSMISSION 609
BRAKES 610
AXLES 611
TRANFER CASE 612
SECTION 2. CLEAN, CHECK AND REPALCE BREATHERS 613
GENERAL CHECK DRIVELINE & SUSPENSION FASTENERS 613
REPLACE CRANKCASE BREATHER 613
TABLE OF CONTENTS
17
TRANSMISSION BREATHER (LOCATED UNDER CAB) 614
REPLACE FUEL TANK BREATHER 614
TRANSFER CASE BREATHER (LOCATED BEHIND CAB) 614
AXLE BREATHERS 614
SECTION 3. CAB AND ELECTRICAL 616
INSPECT, CLEAN AND REPLACE CAB AIR FILTER 616
CHECK BATTERIES, CLEAN AND TIGHTEN TERMINALS 617
CHECK ELECTRICAL CONNECTORS, HARNESSES AND LOOMS 617
CHECK WORK LIGHTS, REVERSE BUZZER AND HORNS 617
RECORD & DELETE FAULT CODES ON THE MDU. 617
CHECK THE OPERATOR CONTROLS AND INSTUMENTS 617
SECTION 4. LUBRICATION 619
CHECK GREASE LEVEL OF AUTO GREASING SYSTEM 619
REPLACE AUTO GREASING SYSTEM FILTER 619
HYDRAULICS 620
CHAPTER 12. 1 000 HOURS SERVICE AND CHECKS 623
SECTION 1. ENGINE 623
INTRODUCTION 623
SERVICE INSTRUCTIONS 623
REPLACE TRANSMISSION OIL FILTERS 629
Check oil level. (See Chapter 12 Check Transmission Oil Level). 629
CHANGE THE TRANSFER CASE FILTER 629
SECTION 3. HYDRAULICS AND LUBRICATION 631
REPLACE HYDRAULIC RESERVOIR BREATHER 631
SECTION 4. AXLES AND CHASSIS & SUSPENSION 633
CHANGE AXLE OIL 633
CHANGE FINAL DRIVE OIL 634
CHAPTER 13. 2 000 HOURS SERVICE AND CHECKS 635
SECTION 1. DRIVE TRAIN 635
INTRODUCTION 635
SERVICE INSTRUCTIONS 635
SECTION 2. HYDRAULICS AND LUBRICATION 637
REPLACE HYDRAULIC SYSTEM OIL RETURN FILTER 638
SECTION 3. CAB, PNEUMATICS AND ELECTRICAL 641
REPLACE PNEUMATIC SYSTEM DRYER FILTER 641
CHAPTER 14. 4 000 HOURS SERVICE AND CHECKS 643
SECTION 1. HYDRAULICS AND PNEUMATICS 643
INTRODUCTION 643
SERVICE INSTUCTIONS 643
CHAPTER 15. AS REQUIRED SERVICE 645
CHAPTER 16. MISCELLANEOUS SERVICE AND CHECKS 647
SECTION 2. TRANSMISSION AND TRANSFER CASES 629
TABLE OF CONTENTS
18
SECTION 1. ENGINE 647
INTRODUCTION 647
SERVICE INSTRUCTIONS 647
SECTION 2. ELECTRICAL 649
USING BATTERY CHARGER 649
ADJUST HEADLIGHTS 651
SECTION 3. OPERATIONAL CHECKOUT 655
OPERATIONAL CHECK OUT 655
CHAPTER 17. TROUBLE SHOOTING 665
SECTION 1. SYMPTOMS AND REMEDIES 665
INTRODUCTION 665
SECTION 2. FAULT CODES 679
Table of Error Codes For Machine and Engine 679
TRANSMISSION CONTROL UNIT ERROR CODES 693
TABLE OF ERROR CODES 694

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