HITACHI WORKSHOP MANUAL EHIIOO-3 RIGID DUMP TRUCKTITLE / Introduction TO THE READER This manual is written for an experienced technician to provide technical information needed to maintain and fepair 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 Operation Manual of the Transmission © 5000-9000 Series Transmissions Commer- cial Electronic Controls 2 (CEC2) Manual © Alison Transmission 5610-6610 Series Ser- vie Manual + Hitachi Weld Repair Manual KO-111-00 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- cures, IN-01TITLE / Introduction PAGE NUMBER The Manuals have the page number located on the center lower part of the page, 2s well as, additional numbers on the page to help the technician locate specific information: W243 Consecutive Page Number for each group Group Number ‘Section Number |-—= T= Technical Manual WE 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 A tris 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 Bi wenn: inctestes potentaly nazardous situation that could, if not avoided, resutt in per- sonal injury or death @inove: indostes supplementary technica! infor mation or know-how. IN-02TITLE / Introduction UNITS USED SI system units and English units are used in this manual. English units are in parentheses behind S| units, Example: 245 MPa (3550 psi) {A table for conversion from SI units to other system Units is shown below for reference purposes, To Convert Quantity | From Into | Muttiply by Tength mm in | 0.03937 mm ft 0.003287 Volume L US gal [0.2642 v US qt [4.057 m «P| 4.308, Weight kg lb | 2.206 Force N kgf [0.10797 N If [0.2248, Torque Nem kof-m | 1.0197, Nem bet [0.7375 To Convert Quantity From Into _|_ Multiply by Pressure MPa__|_katiom® [10.197 MPa psi | 145.0 Power KW Ps [71.360 KW HE 1.341 ‘Temperature | °C SF [x1 832 Velocit enwh moh | 0.6214 Flow Rate Umin | US gom | 02642 murev | corey | 1.0 IN-03TITLE / Introduction MEMO IN-04SERVICE AND MAINTENANCE / Safety 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 waming decals are in place on the rigid dump ‘ruck 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 @ potential hazardous situation ‘which, if not avoided, could result in death or serious i CAUTION oe which, if not avoided, may result in minor or moderate injury + DANGER or WARNING safety signs are located IMPORT. ANT rear specific hazards. General precautions are listed on CAUTION safety signs. ‘These signal words also call attention to. safety Henne go NOTE '* To avoid confusing rigid dump truck protection with personal safety messages, a signal ward IMPORTANT indicates a situation which, if not avoided, could result in, damage to the rigid dump truck @ wore: retectes an atonal explanation fran lament of vomaton SAASERVICE AND MAINTENANCE / Safety 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) regulstions 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 aleahol, 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 paints described under “INSPECT RIGID DUMP TRUCK DAILY BEFORE STARTING’ found in the OPERATING THE ENGINE section in the Operator's Manual SA2SERVICE AND MAINTENANCE / Safety FOLLOW SAFETY INSTRUCTIONS. ‘© Carefully read and follow all safety signs on the rigid ump truck and all safety messages in this manual. ‘Safety signs should be installed, maintained and replaced when necessary. + Ifa 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 conection. + 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 ump 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 andlor your authorized Hitachi dealer before operating or performing maintenance work con the rigid dump truck. PREPARE FOR EMERGENCIES ‘¢ Be prepared ifa fire starts or if an accident ocours. + It is recommended that a first ald kit and fire extinguisher be kept on hand. Thoroughly read and understand the label attached on the fire extinguisher to use it property. 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. ee SA3SERVICE AND MAINTENANCE / Safety WEAR PROTECTIVE CLOTHING ‘* Wear close iting clothing and safety equipment appropriate to the job veunay Ove & hard hat Safety shoes da Safety glasses, goggles, or face shield Heavy gloves Hearing protection Reflective clothing = Wet weather gear Respirator or fiter mask, Se A at, 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 attertion of the operator. Do not wear radio or musi headphones while operating the rigid dump truck PROTECT AGAINST NOISE ‘+ Prolonged exposure to loud noise can cause impairment or loss of hearing + Wear a suitable hearing protective device such as earmufis or earplugs to protect agsinst objectionable of uncomfortably loud noises. May be necessary when working outside of the cab, during the Daity Walk Around Inspection, for example PROTECT AGAINST FLYING DEBRIS. If fying 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 SsA4SERVICE AND MAINTENANCE / Safety 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 of the pedal, possibly resulting in a personal accident. + Don't leave parts andior 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 fre extinguisher. Avoid storing transparent bottles in the cab, Dontt 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 abjects and/or explosives away from the rigid cump truck, + After using the ashtray, aways cover it to extinguish the mateh andlor tobacco + Donit 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. SASSERVICE AND MAINTENANCE / Safety USE HANDHOLDS AND STEPS ‘+ Falling is one of the major causes of personal injury. + When entering or leaving the rigid dump truck, alvays. | use the steps and the handrails *+ Do not use any controls as hancholds, + When you get on and off the rigid dump truck, aways. face the rigid dump truck and maintain a three-point grip with the steps and handrails. (Le, Two hands and ‘ne foot or one hand and two feet } + DO NOT JUMP on oF of the rigid dump truck, Never ae mount or dismount a moving rigid dump truck. ' + Do not step of clim on surfaces, which are not | intended for walking. Step only on the areas provided withthe 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 ditt, snow, and ice. + All steps, ladders, staiways, platforms, walkways, J and non-skid deck strips must be replaced if damaged. + The use of a rope is recommended to hoist up to the a deck or cab lunch box, tools, ete so as to maintain a three-point grip when entering or leaving the rigid dump truck ADJUST THE OPERATOR'S SEAT e '* A poorly adjusted seat for either the operator or for the \wark 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, a and check again, SASSERVICE AND MAINTENANCE / Safety FASTEN YOUR SEAT BELT ‘¢ Ifthe rigid dump truck should overturn, the operator may become injured and/or thrown from the cab if the seat belt is not securely fastened. 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 fo remain seated with the seat bell 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, 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 in the applied position, a SATSERVICE AND MAINTENANCE / Safety 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 Using Booster Batteries in the OPERATING THE ENGINE 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 @ two-person operation, + Never use a frozen battery. + Failure to follow correct jump starting procedures could result in a battery explosion, a runaway rigid dump truck or damage to electronic equipment on the rigid dump truck. 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 inan unsafe manner SABSERVICE AND MAINTENANCE / Safety 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, + Close cab windows while the rigid dump truck is being loaded, PROVIDE SIGNALS FOR JOBS INVOLVING MULTIPLE NUMBERS OF VEHICLES '* For jobs invalving muttiple 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 Girections. SA9SERVICE AND MAINTENANCE / Safety OPERATE THE RIGID DUMP TRUCK SAFELY ‘¢ When pulling out of the loading area, avoid hitting ebris, rocks and loading rigid cump 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 clifs; slide areas, other machines and vehicles, etc. ‘* While traveling on the haul road, maintain a sufficient Gistance behind the rigid dump truck ahead (depending fon roads, speeds, end haul road conditions). This Practice should alvays be followed to allow sufficient safe maneuvering and stopping room. ‘* During all operations, the rigid cump truck may vibrate or shake to some extent. Therefare, aperate the rigid ‘dump truck in such @ way that your body is exposed to a litle viorations as possible * Have the operator's seat properly adjusted and ‘wear the seat belt © Pick the smoothest and safest path for the rigid dump truck. © Adjust the speed of the rigid dump truck to the terrain, SA-10SERVICE AND MAINTENANCE / Safety 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 Geath. If any person is present in the area between the chassis and the front wheel, the person could be ‘crushed when the front wheels are tured 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 Sa 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 signalmen and operator. + Learn the meanings of all flags, signs, and markings used on the job and confirm who has the responsibilty for signaling + Keep windows, mirrors, and lights clean and in good, condition, + Dust, heavy rain, fog, ete., can reduce visibility. As visibilly decreases, reduce speed and use proper lighting, + Read and understand all operating instructions in the operator's manual oy SA-11SERVICE AND MAINTENANCE / Safety AVOID TIPPING ‘+ Keep the rigid dump truck a safe distance from the edge of clifs and slide areas. There is the danger of tipping or rolling over. ‘+ Avoid operating on the side of slopes '* Use the seat bett 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 protective 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. SAA2SERVICE AND MAINTENANCE / Safety 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, / uf + Do not park the rigid dump truck on a grade. Reference: PARK RIGID DUMP TRUCK SAFELY in this section Chock the whee's if you must park on a grade. Position the rigid dump truck to prevent rolling + Park a reasonable distance from other vehicles, Fa SA-13SERVICE AND MAINTENANCE / Safety NEVER TRAVEL WITH THE BODY OFF THE FRAME + Make sure the body is resting on the frame prior to ‘moving the rigid dump truck. + ifthe raised body contacts 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 contol lever SA14SERVICE AND MAINTENANCE / Safety OPERATING WITH 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 ovethead 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 andior 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 electristy should be tumed off when practical OPERATING WITH 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 ot kept a safe distance from electric lines, + When operating near an electric line, NEVER move any part ofthe rigid dump truck or laad closer than 3 m (10 ft.) plus twice the line insulator length, + Never operate the rigid dump truck with the 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 ife is in danger, Call for help by signaling in some way, sounding the hom or mobile telephone, so that the power can be tumed 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 wet ground, + 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 must be equipped for such operations, SAA5SERVICE AND MAINTENANCE / Safety PARK RIGID DUMP TRUCK SAFELY + Fill the fuel tank to minimize water condensation in the tank Park rigid dump truck on a level surface. Lower the body to the frame. + Move the shift selector 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, ae Let the engine run at low idle for three to five minutes for coo! down, + Make sure the body hoist control lever is in the Float position, Check that all switches and controls are in the OFF position, ‘Tumn the Key Switch to the OFF position ‘Tumn the Battery Disconnect Switch to the OFF position Place wheel chocks both ahead and behind tires of axle. Chocks must contact tire tread surface when installed correctly Qiwore: Runcing out of fuel with the engine run, Capone une od, evry Geet 0 engios life and requires a time consuming restart procature + 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. SA-16SERVICE AND MAINTENANCE / Safety ‘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-atiaching air chuck with a hose long enough to be out ofthe trajectory path when fling 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 f alcohol has been used as antifreeze ‘ Inspect all rims, whee's and components + Replace any wom or damaged rims, wheels and components, '* Do not remove any wheel nuts; rim clamps or dagger ‘clamps unti the tire is deflated + No personnel should be touching the rim, rim clamp, or tire when dislodging the rim clamps or dagger clamps. + 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 @ certified tire repair service be hited to perform the dismounting and mounting of tires from rims, DISCHARGE ACCUMULATORS ‘* Before removing and disassembling brake or steering ‘acoumulators, they must be discharged to prevent serious injury. Refer to the appropriate Workshop Manual section for BRAKE ACCUMULATOR and STEERING ACCUMULATOR SAATSERVICE AND MAINTENANCE / Safety HANDLE FLUIDS SAFELY AVOID FIRES eee tena eee + Do not refuel the rigid cump truck while smoking or when near open flame or sparks. + Always stop the engine before refueling the rigid dump truck, + Fill the fuel tank outdoors, ‘ Allfuels, most lubricants, and some coolants are flammable. + Store flammable fluids well away from fire hazards, + Do not incinerate or puncture pressurized containers. + Do not store oily rags; they can ignite and burn spontaneously Discard them into @ sealed, fire resistant container, + Seourely tighten the fuel and oil filler caps. SAABSERVICE AND MAINTENANCE / Safety A FEW SIMPLE RULES WHEN SERVICING Before working on the rigid dump truck, park it on a level surface and put tin the SERVICE POSITION 41, Engine stopped, ignition key removed (except when service requires engine operation). 2. Tag the rigid dump truck following local lockout and tag procedure. Identify rigid dump truck as “Out of Service”. 3. Ifthe body is raised, use the body prop cable. 4, The wheels blocked, 5. Hoist lever in “FLOAT” position. 6. Parking brake applied 7. Allow the rigid dump truck fluid systems to cool down 8 Pressure released fromall lines, tanks, and accumulators. If work must be done on a warm rigid dump truck, beware of hot fluids end components, Do not perform any work on the rigid dump truck unless you are authorized to do so Maintenance can be dangerous unless performed properly, Be satisfied that you have the necessary Skils, information, correct tools, and personal protective «equipment to do the job correctly ‘+ Standard maintenance procedures should always be observed, Read the manufacturer's manual or find assistance if you do not understand what you are doing Feilure to perform the Basic Preventive Maintenance as outlined may void rigid dump truck warranty Deflate tires before loosening any rim clamp nuts, Always stop the engine before removing inspection covers, Do not let too's or parts fall into the opening, Before you work on the rigid dump truck always lower the body. If you must work on the rigid dump truck with the body raised, always securely support the body with the body prop cable. SAA9SERVICE AND MAINTENANCE / Safety A FEW SIMPLE RULES WHEN SERVICING (continued) oe ‘> © Be sure the rigid dump truck is in the “SERVICE POSITION" before lifting or jacking up the rigid dump truck, ‘Always support an elevated rigid dump truck using proper blocks and/or cribbing before beginning work on it. * Be sure the body prop cable is installed when working beneath a raised dump body. le. * Inspect certain parts periodically and repair or replace as necessary. Refer to the section discussing that part in this section of the manual, ‘* Keep all parts in good condition and properly installed ‘* Fix damage immediately Replace worn or broken parts, Remove any buildup of grease, oil, or debris, + Tate cate to ensue tat hands et, thing, evely and hairdo. not become entangled wen working. atound oa rosso pane Pa * Do not wear loose fitting clothing or jewelry when working on a rigid dump truck. * When cleaning parts, aways use nonfiammable detergent mixed with steam or high pressure water. Never use highly flammable fluids such as fuel oil or gasoline to clean parts of surfaces. Control wash water runoff (waste) and dispose of property following local environmental rules. * Suffciently tluminate the work site. Use @ maintenance ‘work light when working under or inside the rigid dump truck © Always use a work light protected with a guard. In case the light bulb is broken, spilled fuel, oil, antifreeze fluid, or window washer fluid may catch fire * Polymer materials such as rubber and certain kinds of plastics can, when heated, give off gases that may be dangerous to health and environment + Do not weld or cut near polymer materials without first having protected them from the heat + Never burn polymer materials when sorapping them, SA-20SERVICE AND MAINTENANCE / Safety USE TOOLS PROPERLY ‘+ Use tool(s) appropriate for the work to be done, Use the correct tool(s) for the job. Repair or replace and broken or defective equipment or tools) Makeshift tools, parts, and procedures can create safety hazards, For loosening and tightening hardware, use the correct size tool to avoid injury caused by slipping wrenches. Make sure that no tools) or other object(s) are left inside the rigid dump truck where they may cause damage, When lifting or supporting components, use equipment with @ hoist capacity rating greater then the sum total weight of the component being hoisted, plus lifting chains, slings and spreader beam or frame, SA-21SERVICE AND MAINTENANCE / Safety PREVENT BURNS Hot spraying fluids: '* After operation, engine coolant is hot and stored under pressure. Hot water or steam is contained in the engine, radiator and heater lines. Skin contact with escaping hot water or steam can cause severe bums, + To avoid possible injury from hot spraying water DO NOT remove the pressure cap from the surge tank for the cooling system until the engine is cool, When removing, depress the red button on top of the pressure cap to relieve system pressure. Then slowly tum and remove the cap, + The hydraulic oll tank is pressurized. Again, be sure to release all pressure before removing the cap, Hot fluids and surfaces: '* Engine oil, gear oll and hydraulic oll also become hot during operation, ‘The engine, hoses, lines and other parts become hot as well mil “Tl ‘+ Wait for the oil and components to cool before starting any maintenance or inspection work, REPLACE RUBBER HOSES PERIODICALLY ‘+ Rubber hoses that contain flammable fluids under ‘s pressure may break due to aging, fatigue, and abrasion. It is very dificut to gauge the extent of deterioration due to aging, fatigue, and abrasion of rubber hoses by inspection alone. + Periodically replace the rubber hoses. ane ‘Failure to periodically replace rubber hoses may cause a fire, fluid injection into skin, or the dump body to fall, which may result in severe burns, gangrene, o otherwise serious injury SA-22SERVICE AND MAINTENANCE / Safety AVOID HIGH-PRESSURE FLUIDS ‘* Fluids such as diesel fuel or hydraulic oll under Pressure can penetrate the skin or eyes causing ‘serious injury, blindness or death. + Avoid this hazard by relieving pressure before disconnecting hydraulic or other lines. + Remove all pressure caps carefully Tighten all connections before applying pressure. Never adjust 2 pressure relief valve above the manufacturer's recommendations, + Be careful of hot fluid when changing oil in the engine, hydraulic system, etc Search for leaks with @ piece of cardboard or ‘wood, not your hand. Take care to protect hands and body from high-pressure fluids. Wear a face shield or goggles for eye protection + If'an accident occurs, see a doctor familiar with this type of injury immediately. Any fluid injected into the skin must be surgcally removed within a few hours or gangrene may result SA-23SERVICE AND MAINTENANCE / Safety FIRE PREVENTION MEASURES ‘Fite prevention features provided by the manufacturer should be maintained in operational condition and should be used to supplement operator’ fire prevention efforts, In no case should the features be used or assumed 2s replacement for diligent operator efforts at preventing fires, ¢ Keep the work place clean. Oil and water on the (ff Tor makes sippey. and dangerous, scared " tlectcal equpmontorelectcaly powered tol Oy doltes area serous frehazad J ‘© Keep the rigid dump truck and all equipment free of ditt and oil. This will decrease possible fire hazards and make it easier to find loose or defective parts. This is especially important when working with combustible materials, soa ‘Rigid dump trucks should be clean of debris particularly around the engine, exhaust, and drive shaft components. Keep the rigid dump truck extra lean when working in @ sensitve environment @ nore: tr hgh presaue [eis used for cloning, take at ome ‘20 be Inutaon of electrical wires can become damaged vor a modertay hgh presse ard fempertie Proce akc mies iva ‘suitable way. ‘© Gasoline is highly flammable and should never be used as cleaning fluid, Use an approved solvent for cleaning. ‘* Some solvents can cause skin rashes and or fire dangers. Do not inhale solvent vapors. + Store flammable starting aids in a designated cool, well-ventilated location. Identify locaton to others with appropriate signage marked “Flammabie" following local regulations. ‘* Smoking, open flames, etc. should not be permitted around any rigid dump truck during fueling shel operations andar when the fuel system is open to the atmosphere, '* Prior to welding or brazing on any part of the rigid dump truck, the part and the surrounding area should be cleaned and a fire extinguisher should be made readily available SA-24SERVICE AND MAINTENANCE / Safety © Hydraulic fluid is flammable. Do not weld on pipes or tubes that are filled with fluid, Be careful when welding next to filled pipes or tubes, © There is always a risk of fire, Find out which type of fire extinguisher to use, where it is and how to use it Check for Oil Leaks: Fuel, hydraulic oll and lubricant leaks can lead to fires. + Check for oil leaks due to missing or loose clamps, kinked hoses lines or hoses that rub against each other, damage to the oil-cooler, and loose oll-cooler flange bolts, + Tighten, repair of replace any missing, loose or damaged clamps, lines, hoses, oi-cooler and oi- cooler fiange bolts + Do not bend or strike high-pressure lines. + Never install bent or damaged lines, pipes or hoses Check for Electrical Shorts: ‘Short circuits can cause fires. + Clean and tighten all electrical connections. + Check electrical wiring connections every 250 hours of operation. Check for loose, kinked, hardened or frayed electrical cables and wires, + 00 NOT OPERATE RIGID DUMP TRUCK if cable or wires are loose, kinked, etc, Clean up Fiammables: Clean and property dispose of spilled fuel, oil antifreeze fluid, window washer fluid, trash, grease, debris, accumulated coal dust, and other flammables that may cause fires. + Prevent fires by inspecting and cleaning the rigid dump truck daily, and by removing spilled or accumulated flammables immediately SA-25SERVICE AND MAINTENANCE / Safety EVACUATING IN CASE OF FIRE e «© Ifa fire breaks out, evacuate the rigid dump truck in the following way’ + Lower the body to the chassis, + Set parking brake + Stop the engine by turing the key switch to the OFF position. + Exit and get away from the rigid dump truck Take @ hand portable extinguisher along if one is ce avaliable, if you can + Activate fite suppression system, if equipped. + Califor help, + Stand by with the hand portable extinguisher and Use it if possible. BEWARE OF EXHAUST FUMES ‘* Prevent asphyxiation. Engine exhaust fumes can cause sickness or death, + Stand away from the rear exhaust area when the engine is running, + Ifyou must operate in 2 building, be sure there Is adequate ventilation. Either use an exhaust pipe extension to remove the exhaust fumes or open doors. sate and windows to bring enough outside air into the area, * Ventilation must be adequate for underground operation + Diesel engine exhaust and some of its constituents, are known to the State of California to cause cancer, birth defects and other reproductive harm, SA-26SERVICE AND MAINTENANCE / Safety PRECAUTIONS FOR WELDING, CUTTING, AND GRINDING # When performing any welding operation on 2 rigid dump truck, specific electrical components must be disconnected. Refer to Electrical Disconnects before Welding in the MAINTENANCE section of this manual Grinding on the rigid dump truck may create fire hazards, Store flammable objects in a safe place before starting gringing. QNOTE: A high speed:-grinding rigid dump truck will heat the paint and must only be used in 2 wel ventilated area © Be sure to perform welding in 2 well ventilated and prepared area, Store flammable objects in a safe place before starting welding, ‘© Only qualified personnel should perform welding. Never allow an unquaitfied person to perform welding. ‘* After completing the welding, recheck that there are no abnormalities such as the area surrounding the welded area still smoldering, REMOVE PAINT BEFORE WELDING OR CUTTING Paint must be removed up to @ distance of 10 cm (4 in) from the welding or cutting point. ‘© Remove the paint from the area work is to be performed through sand blasting, + If you sand blast or grind paint, avoid breathing the dust. Wear an approved respirator. + Work outside or in a well-ventilated area «IF the paint cannot be removed by sand blasting, it must be removed in some other way e.g. with paint stripper + Wear protective gloves and work outside or in a well. ventilated area. + Dispose of paint and solvent properly. + IF you use solvent or paint stripper, remove stripper with soap and water before welding, + Remove solvent or paint stripper containers and other flammable material from area Allow fumes to disperse at least 15 minutes before welding or cutting SA-27SERVICE AND MAINTENANCE / Safety AVOID HEATING NEAR PRESSURIZED FLUID LINES. «Flammable sprey can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders. + Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials, + Pressurized lines can be accidentally cut when heat, goes beyond the immediate flame area, Install temporary fire-resistant guards to protect hoses or a ‘other materials before engaging in welding, soldering, ete, AVOID APPLYING HEAT TO LINES CONTAINING FLAMMABLE FLUIDS + Do not weld or flame cut pipes or tubes that contain flammable fluids. + Clean them thoroughly with nonflammable solvent before welding or flame cutting them SA-28SERVICE AND MAINTENANCE / Safety PREVENT BATTERY EXPLOSIONS «Battery gas can explode. + Keep sparks, lighted matches, and flame away from the top of battery, + Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer. + Do not charge a frozen battery; it may explode. Warm. the battery to 16°C (60°F) first. + Do not continue to use or charge the battery when, electrolyte level is lower than specified. Explosion of the battery may resutt + Loose terminals may produce sparks. Securely, tighten all terminals, Battery electrolyte is poisonous. If the battery should explode battery electrolyte may be splashed into eyes, possibly resulting in blindness + Be sure to wear eye protection and personal protective equipment when checking electrolyte specific gravity ++ Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and brrth defecis or other reproductive harm. Wash hands after handling SERVICE AIR CONDITIONING SYSTEM ‘SAFELY @NOTE: Only certified technicians should be allowed to service ait conattioning systems. « If spilled onto skin refrigerant may cause @ cold contact —— bum + Refer to the Freon container for proper use and weer the required personal protective equipment when ‘servicing the air conditioning system, + Use a recovery and recycling system to avoid venting Freon into the atmosphere. + Never let the Freon stream make contact with the skin SA-29SERVICE AND MAINTENANCE / Safety HANDLE CHEMICAL PRODUCTS SAFELY © Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with your rigid dump truck include such items as lubricants, coolants, paints, and adhesives. + A Material Safety Data Sheet (MSOS) provides specific details on chemical products: physical and ya health hazards, safely procedures, and emergency J response techniques. + Check the MSDS before you start any job using @ hazardous chemical. That way you will know exactly ‘what the risks are and how to do the job safely. Then follow procedures and use recommended equipment. + To obtain a copy of a MSDS see your authorized Hitachi dealer (available only in English) for chemical products supplied with your rigid dump truck DISPOSE OF WASTE PROPERLY ‘Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with Hitachi rigid dump trucks includes such items as oil, fuel, coolant, hydraulic fluid, used filers, and batteries + Use leak proof containers when draining fluids. Do not use food or beverage containers that may mislead ‘someone into drinking from them, + Do not pour waste onto the ground, down a drain, or into any water source. * + Air conditioning refrigerant escaping into the air can damage the Ears atmosphere. Government regulations may require a certified air conditioning service center to recover and recycle used air conditioning refrigerant. + Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center. SA-30SECTION CONTENTS WORKSHOP MANUAL All. information, illustrations and specifications in this manual are based on the latest product information available at the time of publication. The right is reserved to make changes at any time without notice COPYRIGHT(C) 2008 Hitachi Construction Truck Manutacturng Lic Guelph, Canada Allrights reserved SECTION 1 GENERAL SECTION 2 SERVICE & MAINTENANCE SECTION 3 ENGINE SECTION 4 ELECTRICAL & INSTRUMENTS SECTION 5 POWER TRANSMISSION SECTION 6 BRAKE SYSTEM SECTION 7 STEERING SECTION 8 FRAME SUSPENSION & WHEEL SECTION 9 CAB SECTION 10 HOIST ATTACHMENTSECTION 1 GENERAL —CONTENTS— Group 1 Precautions for Disassembling and Assembling Precautions for Disassembling and Assembling, W1-1-1 Bleeding Alr from Hydraulic System... Wt-1-2 Floating Seal Precautions (Whee! Seal... Wi-1-3 Precautions for Using Nylon Sing Wt-t-4 Maintenance Standard Terminology. Witt Group 2 Tightening Torque Tightening Torque Specifications wea Torque Charts Wi22 Bolt Tightening Order W125 Nut and Bolt Locking wi26 Torque Formula T-FL. W126 Piping Joint Wi27 (Orting Seal Joint W128 Spit Flange Clamp Torque Values. wi29 Seal Tape Application Wt-240 Low-Pressure Hose Clamp Torque Value w1-2-40 Connecting Hose wont Periodic Replacement of Parts. WH-242 wo W1-0GENERAL / Precautions for Disassembling and Assembling PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING Precautions for Disassembling and Assembling © Clean the rigid dump truck Thoroughly wash the rigid dump truck before bringing it into the shop. Bringing a dirty rigid dump truck into the shop may cause rigid dump truck Components to be contaminated during disassembiinglassembling, resulting in damage to the components, 2s well as decreased efficiency in servicing the rigid dump truck Inspect the rigid dump truck Be eure to thoroughly understand all disassembiing/ assembling procedures beforehand, to help avoid incorrect disassembly of components as well as personal injury. Check and record the items listed below to prevent problems from occurring in the future + The rigid dump truck model, serial number, and hour meter reading + Reason for disassembly (symptoms, failed parts, and causes). + Clogging of fiters and oil, water or air leaks, if ary. + Levels and condition of lubricants. + Loose, worn of damaged parts. Prepare/Clean Tools and Disassembly Area Prepare the necessary tools to be used in the area for disassembly work, and the required personal protective equipment, ‘* Precautions for Disassembling To prevent dirt from entering, cap or plug the removed pipes, hoses and ports Before disassembling, clean the exterior of the components, Before disassembling, drain all fluids into approptiate containers for draining fluids and make available for the remainder of the disassemby. Use matching marks for easier reassembling Be sure to use the specified special tools, when instructed. If a part or component cannot be removed after removing tts securing nuts and bolts, do not attempt to remove it forcibly. Find the cause(s), then take the appropriate measures to remove it Orderly arrange disassembled parts. Mark and tag them as necessary. ‘Store common parts, such as bolts and nuts with reference to where they are to be used and in a manner that will prevent loss, Inspect the contact or sliding surfaces of disassembled parts for abnormal wear, sticking, or other damage. Measure and record the emountidegree of wear and clearances. W1-1-1GENERAL / Precautions for Disassembling and Assembling «* Precautions for Assembling + Be sure to clean alll parts and inspect them for any damage. If ary damage is found, repair or replace part + Dirt or debris on the contact or sliding surfaces ‘may shorten the service life of the component or secondary component. Take care not to Contaminate any contact or sliding surfaces. + Be sure to replace O-rings, backup rings, and oil seals with new ones once they are assembled Apply a film of grease before installing, unless otherwise stated + Be sure that liquid-gasket-applied surfaces are clean and dry + fan anti-corrosive agent has been used on anew part, be sure to thoroughly clean the part to remove the agent. + Utlize matching marks when assembling. + Be sure to use the designated tools to assemble bearings, bushings and oll seals. + Keep 2 record of the number of tools used for disassembiy/assembly. After assembling is complete, count the number of tools, so as to make sure that no forgotten tools remain in the assembled rigid dump truck. + Record new component serial numbers and hour meter reading, if required Bleeding Air from Hydraulic System When hydraulic oil is drained, the suction filter or the suction lines are replaced, or the removal and installa~ tion of the pump, or cylinder is done, bleed air from the hydraulic system in the following procedures: IMPORTANT: If the engine is started with air trapped in the hydraulic pump hous- ing, damage to the pump may result. If the hydraulic system is operated with air trapped inside major com- ponents, damage may result. If the cylinder is operated with air trapped in the cylinder tube, damage to the seal or cylinder may result. Be sure to bleed air before starting the engine. ‘* Bleeding Air from Hydraulic Pump + Loosen the inlet hose connection or bleeding plug from the top of the pump and fil the pump hous- ing with hydraulic oil Oil wil flow by gravity into pump housing. + After the pump housing is filed with hydraulic oil, temporarily tighten the plug. Check and adjust hydraulic tank oil level before engine starting. Then, start the engine and run at low idle speed. + Alter bleeding all the air, securely tighten all plugs and connections ‘* Bleeding Air from Hoist Cylinder + Remove bleed plug from top of hoist cylinder. Run engine with hoist controller in float position when ail fows from port install plug. ‘© Bleeding Air from Hydraulic Circuit + After refilling the hydraulic oil to the proper level, start the engine and cycle the hoist and steering cylinders evenly. Operate the rigid dump truck under light load for 10 to 15 minutes. Slowly start each operation and don't fully stroke the cylinders during initial operation stage. + Lower the body to the chassis rails + Stop the engine, Recheok the hydraulic oil level in both the steering and hoist ol tanks. Replenish oil as necessary to the proper levels. PinoTe: Eneur the body si tl contact withthe chassis, and the oil in the steering accu- ‘muletor has completely returned to tank W1-1-2GENERAL / Precautions for Disassembling and Assembling Floating Seal Precautions (Wheel Seals) 4. In general, replace the floating seal with a new one after disassembling. If the floating seal is to be reused, follow these procedures: (1) Keep seal rings together as a matched set with seal ring faces together. Insert a piece of clean cardboard between the contact surfaces to protect the surfaces. (2) Check the slide surface on seal ring (A) for scuffing, scoring, corrosion, deformation or uneven wear, (3) Check toric O-ring (8) for tears, breaks, deformation or hardening, 2. If incorrectly assembled, oil leakage or damage will occur. Be sure to do the following, to prevent trouble. (1) Clean the fioating seal and seal mounting bores with cleaning solvent that does not leave a residue. Use a wire brush to remove mud, rust or dirt ‘After oleaning, thoroughly dry parts with compressed air, Incoreet eS 2) inpect the flosting seal mounting bores Check te Bove srfce for scuing or Scatng Ss oe Seal bore surface machining must be smooth and uniform, (3) Check that the O-ring is not twisted, and that it is installed correcty on the seal ring. (4) Throughly wet the seal toric O-ring and seal bore immediately before installation using a aerosol brake cleaner solvent or alcohol wash After installing the floating seal, check that seal ring surface (A) is parallel with seal mating face (©) by measuring the distances (A) and (C) at point (a) and (b), as illustrated if these distances differ, correct the O-ring seating, W1-1-3GENERAL / Precautions for Disassembling and Assembling Precautions for Using Nylon Sling 1 Follow the precautions below to use nylon slings safely + Attach protectors (soft material) on the comers of the load so that the nylon sling does not di- rectly contact the corners. This will prevent the nylon sling from being damaged and the lifted load from slipping, + Lower the temperature of the lifted load to lower than 100°C (212°), If unavoidably lifting a load with a temperature of 100°C (212 °F) or more, reduce the load weight + Do not lt id or alkali chemicals. + Take care not to allow the sling to become wet Do not use wet of oil soaked slings. The load may slip. + When required to use more than one sling, use matched stings with the same width and length to keep the lifted load balanced. + When lifting a load using an eyehole, be sure to eliminate any gaps between the siing and load. The sling should grasp the load tightly in a choke hold, Reduce the load weight so that t is less than 80 % ofthe sling breaking force + Avoid using twisted, bound, connected, or hitched slings. Do not use a visually damaged sling to hoist load. + Do not hoist any object with twisted or bent slings. (Refer to the right illustration) A sling that is cut creased or kinked should not be used ‘+ When removing the slings from under the load, take care not to damage the nylon slings. Avoid contact with protrusions. + Avoid dragging slings on the ground, throwing slings or pushing slings with a metal object + When using with other types of slings (wire rope) or accessories (shackle), protect the joint s0 that the nylon sling is not damaged + Store the nylon slings indoors so they won't de- teriorate with heat, sun light, or chemicals. Correct Eyehole Lifting Method Incorrect Eyehole Lifting Method! W1-14GENERAL / Precautions for Disassembling and Assembling Damaged Appearance CAUTION: If a load is lifted with a damaged nylon sling, serious personal injury may re- sult. Be sure to visually check the nylon sling for any damage before using. 2. Before using a nylon sling, visually check the ny: lon sling for any damage carresponding ta exam- ples shown to the right. If any damage is found, cout sling apart and discard the sling. Even it no damage is found, da not use slings older than T-years, Fuzg, Broken Sewing Thread [Broken Sewing Thread Broken Sewing Thread Broken Sewing Thread Separation of wicstcvaw W1-1-6GENERAL / Precautions for Disassembling and Assembling MAINTENANCE STANDARD. TERMINOLOGY “standard” 4. Dimension for parts on a new rigid dump truck. 2. Dimension of new components or assembles ad- justed to specification, “Allowable Limit” 4. Normal rigid dump truck performance cannot be accomplished after exceeding this limit 2. Repair or adjustment is impossible after exceed. ing this limit. 3. Therefore, in consideration of operation efficiency and maintenance expense, proper maintenance shall be carried out before reaching the “Allowable Limit’ W1-1-6GENERAL / Tightening Torque TIGHTENING TORQUE SPECIFICATIONS ‘COMPONENT LOCATION. ary TORQUE Nm [lbf-ft] BRACKET TO ENGINE FRONT é 270 (199) BRACKET TO ENGINE REAR 12 270 [199] ENGINE | RUBBER MTG FRONT 4 433 [319] RUBBER MTG REAR 2 1048 [773] FANMTG 6 123 (90), BRACKET TO TRANS. REAR 8 222-260 [164-199 TRANSMISSION | RUBBER MTG FRONT 2 814 [600] STANDARD [RUBBER MTG REAR 2 814 [600] PTOTO TRANSMISSION a 52-68 [38-50] BRACKET TO TRANS, FRONT 4 433 [349] BRACKET TO TRANS. REAR 12 222-260 [164-192] TRANSMISSION [RUBBER MTG FRONT 2 812 [600] RUBBER MTG REAR 2 812 [600] PTOTO TRANSMISSION 8 57 [42] ‘COUPLER TO ENG 12 501371 pRiveuNe | FRONT DRVLN TO COUPLER 4 123 (90) HaNeuecickt FRONT ORVLN TO TRANS. IN 4 163 [120] TRANS, OUT TO REAR DRVLN é 244 [180] REAR DRVLN TO DIFF. FLANGE 8 326 [240] COUPLER TO ENG 12 50 [37] DRIVELINE | FRONT DRVLN TO COUPLER 4 87 [64] HEAVY DUTY [FRONT ORVLN TO TRANS. IN 4 163 [120] TRANSMISSION TRANS. OUT TO REAR DRVIN é 244 (180) REAR DRVLN TO DIFF. FLANGE 8 325 [240] RUBBER MTG 2 495 [365] RADIATOR | BRACKET MGT é 307 [226] BRACKETS 2 307 [226] CAB MOUNT __| CAB MOUNT 3 813-1085 [600-800] CALIPERS MTG 32 699 (515) BRAKE FRONT DISK MTG 50 699 [515] W1-2-1GENERAL / Tightening Torque ‘COMPONENT LOCATION ary TORQUE Nm [lbf-ft] SHEETMETAL | UPRIGHTS MTG 6 2084 (1544) BRAKE TO SPINDLE MTG 54 742 [547] BRAKE REAR 173 (1 BRAKE ASSY 2 31128) 28 307 [226] CYL SOCKETS 2 292-305 [215-225] STEER SOCKET NUT 2 410-495 [300-320] TRUNNION CAPS, 2084 [1544] 7 RANE NOSE CONE PLATE 4 178 1321 4 1048 [773] BEARINGS FRONT 8 Refer to Acroset Procedure WHEELS MTG [BEARINGS REAR 46 __| Refer to Acroset Procedure REAR WHEEL TO BRAKE 40 742 [547] REAR AXLE | FRAME BUSHING RETENTION PLATE 14 123-195,5 [90-100] : -70 IN-LBS} ee 2 5,65-7,91 [50- y rein 46,1-50,2 [408-444 IN-LBS] REAR 2 5,65-7,91 [50-70 IN-LBS] PLANETARY TO WHEEL MTG 30 742 [547] PLANETARY GEARS MTG 8 1048 [773] DIFFERENTIAL TO REAR AXLE 23 407-434 [300-330] FLANGE 3 237-256 [175-190] DIFFERENTIAL. | BEARING CAPS 2 983-1084 [750-800] RING GEAR NTG 18 576-712 [425-525] LOCKING TEE 4 34.38 [25-28] RETAINER 14 169-190 [125-140] BODY MTG 12 244 [180] 307 [226] PARK BRAKE | PARK BRAKE MTG 4 le) 4 307 [226] W1-2-2GENERAL / Tightening Torque ‘COMPONENT LOCATION ary, TORQUE Nim [Ibf-ft] ee 4 11,9-12,4 [100-110 IN-LBS] BRAKELINES 5,6-7,9 [50-70 IN-LBS) ACCUM, REAR 1 11,9-12,4 [100-110 IN-LBS] BRAKE, Bosna BRAKE COOLER MTG 2 244 (180) STEERING 4 92-104 [68-75] DRIVELINE ‘COLUMN 1 54-65 [40-48] TIRE RIM MTG 76 942 [695] \B NOTE: Make sure bolt and nut threads are clean ‘and lubricated with oil (or costed with Loctite, i required) before installing. Do not use ollon a bot that requires Loctite \PINoTE: The above torque specifications are crit cal fo the operation of the hauler and should be used at all times. Uso a torque wrench as opposed 1 an air gun to ensure precise torquing on critical bots. W1-2-3GENERAL / Tightening Torque TORQUE CHARTS Bolt Types Tighten nuts or bolts correctly to torque specifications, Many different types and grades of batt are employed. Make sure to employ correct bolts and tighten them ‘correctly when assembling the rigid dump truck or ‘components JA. caution: Use toots appropriate for the work to be done. Makeshift tools and procedures can create safety hazards. For loosening and tightening nuts and bolts, use correct size tools. Otherwise, tightening tools may slip, potentially causing personal injury. Use only properly calibrated torque wrenches / tools during final assembly. EA ori ea dump truck use Nylock type bolts. It is Beeline mies eond te actola a Saori cist oneness used when replacing these types of bolts, W1-24GENERAL / Tightening Torque Standard Imperial Tightening Torque Chart, Plain Finish with Oil Fastener De i Hex Head, 12 pt Flange Head, Hex Sckt Head, Hex Sckt Button Head, L9 Hex Cap scription ‘Grade? Balt TAWALLOY 1960 Series Classification | 9 Stud 1 by strength category Standard tightening al le} fe a} Js} 13 x] fe 1048 15442004 | 1737 2356 1700 2261 22et [2687 26a [028 _an09 30003980 W1-25GENERAL / Tightening Torque Standard Metric Tightening Torque Chart, Plain Finish with Oil Description Hexagon head bolt Classification by strength 48 bolt 8.8 bolt 10.9 bott category O 88 Seereer eager [usar | wet [roa style) q Standard tight- | mg 10(7) 20 (15) 30 22) fening torque by bolt size M10 20 (15) 50 67) 65 (48) Ne-m (ft.b) Miz 35 (26) 90 (66) 110 (81) M4 55 (41) 140 (103) 180 (133) Mis 80 (69) 210 (155) 270 (199) Mis 120 @9) 300 21) 400 (295) M20 170 (125) 400 (295) 550 (406) M22 220 (162) 550 (406) 750 (653) M24 280 (207) 700 616) 950 (701) M27 400 (295) 1050 (774) 1400 (1033) M30 '550 (406) 1450 (1069) 1950 (1438) M33 750 (653) 1950 (1438) 2600 (1918) M36 950 (701) 2450 (1807) 3200 (2360) W1-246