Hitachi AH350-D AH400-D Articulated Dump Truck Service Manual
FILE DETAILS:
Hitachi AH350-D AH400-D Articulated Dump Truck Service Manual
Size : 22.1 MB
Language : English
Pages : 531
Downloadable : YES
Format : PDF
Serial No.001817 and up
DESCRIPTION:
Hitachi AH350-D AH400-D Articulated Dump Truck Service Manual
INTRODUCTION:
Read this manual carefully for it has been produced to assist you in the correct operation, maintenance and care of your HITACHI machine. Failure to do so could result in personnel injury or equipment damage. Right and left hand sides are determined by facing in the direction of forward travel. Warranty is provided as part of HITACHI support program for customers who operate and maintain their equipment as described in this manual.
- The warranty is explained on the warranty certificate which you should have received from your dealer. Should the equipment be abused, or modified to change its performance beyond the original factory specifications, the warranty will become void and field improvements may be denied. 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 HITACHI 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.
- HITACHI . has a policy of continuous product development, improvement, and design. HITACHI . 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. 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 AH350-D AH400-D Articulated Dump Truck Service Manual
SAFETY 13
SAFETY FEATURES 13
GENERAL SAFETY 14
SAFETY REGULATION 15
SAFETY DECALS 21
CHAPTER 1 OPERATIONAL CHECK-OUT PROCEDURE 45
OPERATIONAL CHECK-OUT 45
OPERATIONAL CHECKS – KEY SWITCH ON, ENGINE OFF 45
CHAPTER 2 ENGINE 51
SECTION 1 THEORY OF OPERATION 51
ENGINE 51
SECTION 2 DIAGNOSE ENGINE MALFUNCTIONS 55
SECTION 3 ADJUSTMENTS 57
DISPLAY MENU TACHOMETER 57
SLOW AND FAST IDLE ADJUSTMENT 57
VALVE CLEARANCE ADJUSTMENT 57
EXHAUST BRAKE ADJUSTMENT 58
SECTION 4 TESTS 61
CYLINDER COMPRESSION TEST 61
FUEL PUMP PRESSURE TEST 61
OIL PUMP PRESSURE TEST 63
CAN BUS J1939 67
WHAT EXACTLY IS A “CAN BUS” 67
CANBUS 69
TESTING THE “CANBUS” 71
CHECKING THE CABLES 71
CHECKING OPENS, SHORTS BETWEEN WIRES AND SHORTS TO GROUND ON THE CAN
HARNESS 71
MAIN “CAN” HARNESS 72
“CAN” SHORT TO GROUND 73
“CAN “OPEN CIRCUIT 74
“CAN” SHORT TO POSITIVE 0 -24 VOLTS 75
REVISION 0 35
CHAPTER 3 ELECTRICAL SYSTEM 77
SECTION 1 SYSTEM INFORMATION 77
ELECTRICAL SCHEMATIC SYMBOLS 77
CHASSIS CONTROL UNIT (CCU & OEU) 78
MDU2 (MONITOR DISPLAY UNIT) 79
MDU2 LAYOUT 80
MDU2 INPUT AND OUTPUTS 81
RELAY 83
START-UP DISPLAY 84
DEFAULT SCREEN 84
DEFAULT SCREEN 84
DEFAULT SCREEN 84
DEFAULT SCREEN 84
DEFAULT SCREEN 85
TO GO TO MAIN MENU FROM DEFAULT SCREEN 85
MAIN MENU 85
EXPLANATION OF WIRE MARKINGS 90
SECTION 2 DESCRIPTION OF CIRCUITS 123
SSM 135
MDU2 WARNING LIGHTS 146
MDU2 GAUGES 150
CCU2 OUTPUT SPECIFICATION 151
OEU OUTPUT SPECIFICATION 155
SECTION 3 REFERENCES 159
ENGINE FAULT CODES (ADM) 159
ENGINE FAULT CODES (PLD-MR) 164
SSM FAULT CODES 190
PART 2 DM1 FAULT CODES 191
SECTION 4 TESTS 209
KEY SWITCH TEST 209
RELAYS 209
Diode Test 210
Pneumatic System Solenoids, Pressure Switches, and Sensor Tests 211
Steering Column Switch Test 216
TABLE OF CONTENTS
36 REVISION 0
CHAPTER 4 TRANSMISSION HD4560 229
SECTION 1 THEORY OF OPERATION 229
GENERAL DESCRIPTIONS 229
STALL SPEEDS 236
PLANETARY GEARS AND POWER FLOWS 238
THE BASIC LAWS OF PLANETARY GEAR SETS 239
HD TRANSMISSION PLANETARY CONFIGURATION 240
HD TRANSMISSION CLUTCH CONFIGURATION 241
TRANSMISSION CROSS SECTIONAL DIAGRAM 243
POWER FLOW 245
HYDRAULIC SYSTEM 255
SOLENOIDS 259
HYDRAULIC CIRCUITS 261
TORQUE CONVERTER AND LUBE PRESSURE CIRCUITS – OVERVIEW 269
EXHAUST BACKFILL PRESSURE 270
PRESSURE TABLE AND TEST POINTS 275
RETARDER 276
APPLICATIONS AND CAPACITIES 276
INPUTS AND OUTPUTS 278
RETARDER CONTROL HYDRAULICS 278
TESTING RETARDER CHARGING PRESSURE 279
HD RETARDER HYDRAULIC SCHEMATIC RETARDER OFF 280
HD RETARDER HYDRAULIC SCHEMATIC RETARDER ON 281
ELECTRONIC CONTROL SYSTEM 282
PUSH BUTTON SHIFT SELECTOR 286
SPEED SENSORS 287
WIRING HARNESSES 287
RANGE / SHIFT TESTS 288
DO NOT SHIFT LIGHT 289
SECTION 2 DIAGNOSTIC INFORMATION 291
DIAGNOSTIC PROCEDURE 291
DIAGNOSE POWER TRAIN SYSTEM MALFUNCTIONS 292
CHECK THE TRANSMISSION FLUID LEVEL 304
TRANSMISSION CONTROL UNIT ERROR CODES 307
REVISION 0 37
TABLE OF CONTENTS
Service Code Diagnostics – How To Use Listing For Transmission Codes 308
TABLE OF ERROR CODES 309
ALLISON HD 4560R ELECTRONIC CONTROL WTEC III 315
SECTION 3 ADJUSTMENTS AND TESTS 317
TRANSMISSION WARM-UP PROCEDURE 317
TRANSMISSION OIL COOLER RESTRICTION TEST 326
CHAPTER 5 PNEUMATIC SYSTEM 327
SECTION 1 THEORY OF OPERATION 327
PNEUMATIC SYSTEM OPERATION 327
PNEUMATIC SYSTEM SCHEMATIC 328
SECTION 2 DIAGNOSTIC INFORMATION 339
DIAGNOSTIC PROCEDURE 339
DIAGNOSE PNEUMATIC SYSTEM MALFUNCTIONS 340
SECTION 3 ADJUSTMENTS AND TESTS 342
PNEUMATIC SYSTEM MAIN PRESSURE TEST AND ADJUSTMENT 342
PARK BRAKE PRESSURE TEST 343
PARK BRAKE ADJUSTMENT 344
GRAMMER SEAT FUNCTIONAL TEST 346
CHAPTER 6 HYDRAULIC SYSTEM 347
SECTION 1 THEORY OF OPERATION 347
ARTICULATED DUMP TRUCK HYDRAULIC SYSTEM OPERATION 347
SECTION 2 DIAGNOSTIC INFORMATION 381
DIAGNOSTIC PROCEDURE 381
DIAGNOSE HYDRAULIC SYSTEM MALFUNCTIONS 382
SECTION 3 TESTS 395
JT05800 DIGITAL THERMOMETER INSTALLATION 395
JT02156A DIGITAL ANALOGUE PRESSURE/TEMPERATURE ANALYSER INSTALLATION 395
HYDRAULIC OIL CLEANUP PROCEDURE USING PORTABLE FILTER CADDY 395
HYDRAULIC SYSTEM WARM-UP PROCEDURE 396
CYCLE TIME TEST 397
MAIN HYDRAULIC PUMP RESIDUAL AND COMPENSATOR VALVES TEST AND ADJUSTMENT
398
SYSTEM RELIEF VALVE AND BIN RAISE CIRCUIT RELIEF VALVE TEST 400
PRIORITY VALVE TEST 401
ACCUMULATOR PRESSURE REDUCING VALVE TEST AND ADJUSTMENT 401
BRAKE ACCUMULATOR CHARGE VALVE TEST AND ADJUSTMENT 402
38 REVISION 0
TABLE OF CONTENTS
BRAKE LOW PRESSURE SWITCH AND BRAKE ACCUMULATOR TEST 403
FRONT AND REAR BRAKE ACCUMULATORS PRESSURE TEST AND CHARGE PROCEDURE
404
SERVICE BRAKE VALVE TEST 405
STEERING RELIEF VALVE PRESSURE TEST AND ADJUSTMENT 406
STEERING CYLINDER LEAKAGE TEST 406
SECONDARY STEERING PUMP RESIDUAL AND COMPENSATOR VALVES TEST AND
ADJUSTMENT 407
BIN LOWER CIRCUIT RELIEF VALVE TEST 408
FAN DRIVE CIRCUIT PRESSURES 409
CHAPTER 7 HEATING AND AIR CONDITIONING 411
SECTION 1 THEORY OF OPERATION 411
AIR CONDITIONING SYSTEM CYCLE OF OPERATION 411
HEATER CORE OPERATION 412
SECTION 2 DIAGNOSTIC INFORMATION 413
DIAGNOSE AIR CONDITIONING SYSTEM MALFUNCTIONS 413
HEATING/AIR CONDITIONING COMPONENT LOCATION 415
SECTION 3 TESTS 417
AIR CONDITIONING OPERATIONAL CHECKS 417
R134A AIR CONDITIONING SYSTEM TEST 418
OPERATING PRESSURE DIAGNOSTIC CHART 419
A/C FREEZE CONTROL SWITCH TEST 421
A/C COMPRESSOR CLUTCH TEST 421
A/C HIGH/LOW PRESSURE SWITCH TEST 421
A/C EXPANSION VALVE TEST 422
EXPANSION VALVE BENCH TEST 423
REFRIGERANT LEAK TEST 424
CHAPTER 8 MAINTENANCE SCHEDULES 427
NOTES: 430
CHAPTER 9 DAILY OR 10 HOURLY SERVICE CHECKS 431
CHAPTER 10 150 HOURS SERVICE AND CHECKS 433
SECTION 1 DRIVE TRAIN 433
INTRODUCTION 433
SERVICE INSTRUCTIONS 433
LOWER AND RAISE THE BELLY PLATE 433
CHAPTER 11 500 HOURS SERVICE AND CHECKS 437
REVISION 0 39
TABLE OF CONTENTS
SECTION 1 DRIVE TRAIN 437
INTRODUCTION 437
SERVICE INSTRUCTIONS 437
ENGINE 437
TRANSMISSION 438
BRAKES 441
TRANSFER CASE 442
SECTION 2 CLEAN, CHECK AND REPLACE BREATHERS 443
GENERAL CHECK DRIVE LINE & SUSPENSION FASTENERS 443
TRANSFER CASE BREATHER (LOCATED UNDER THE HYDRAULIC RESERVOIR) 443
TRANSMISSION BREATHER AND AXLE BREATHERS 443
SECTION 3 CAB AND ELECTRICAL 445
INSPECT, CLEAN AND REPLACE CAB AIR FILTER 445
CHECK BATTERIES, CLEAN AND TIGHTEN TERMINALS 446
CHECK ELECTRICAL CONNECTORS, HARNESSES AND LOOMS 446
CHECK WORK LIGHTS, REVERSE BUZZER AND HORNS 446
RECORD & DELETE FAULT CODES ON THE MDU 446
CHECK THE OPERATOR CONTROLS AND INSTRUMENTS 446
SECTION 4 LUBRICATION 447
GREASE ALL GREASE POINTS 447
HYDRAULICS 448
REPLACE HYDRAULIC RESERVOIR BREATHER 448
WET DISC BRAKE COOLING OIL RESERVOIR (AH400-D) ONLY (ON TOP OF RESERVOIR) 449
CHAPTER 12 1 000 HOURS SERVICE AND CHECKS 451
SECTION 1 DRIVE TRAIN 451
INTRODUCTION 451
SERVICE INSTRUCTIONS 451
Engine 451
SECTION 2 HYDRAULICS AND LUBRICATION 455
REPLACE HYDRAULIC RESERVOIR BREATHER 455
SECTION 4 AXLES AND CHASSIS & SUSPENSION 457
CHECK AXLE OIL LEVEL 457
CHECK FINAL DRIVE OIL LEVELS 457
CHANGE AXLE OIL (AH350-D With Hitachi Wet Brakes) 457
CHECK BIN SHOCK PAD CLEARANCE 458
CHAPTER 13 2 000 HOURS SERVICE AND CHECKS 461
SECTION 1 DRIVE TRAIN 461
INTRODUCTION 461
SERVICE INSTRUCTIONS 461
ENGINE 461
40 REVISION 0
TABLE OF CONTENTS
SECTION 2 HYDRAULICS AND LUBRICATION 465
REPLACE WET DISC BRAKE COOLER OIL AND FILTER 465
SECTION 3 CAB, PNEUMATICS AND ELECTRICAL 467
REPLACE PNEUMATIC SYSTEM DRYER FILTER 467
CHAPTER 14 3 000 HOURS SERVICE AND CHECKS 469
SECTION 1 DRIVE TRAIN 469
INTRODUCTION 469
SERVICE INSTRUCTIONS 469
SECTION 2 HYDRAULICS AND PNEUMATICS 471
CHAPTER 15 4 000 HOURS SERVICE AND CHECKS 473
SECTION 1 DRIVE TRAIN 473
REPLACE FAN BELT 473
SECTION 2 HYDRAULICS AND PNEUMATICS 475
INTRODUCTION 475
SERVICE INSTRUCTIONS 475
CHAPTER 16 AS REQUIRED SERVICE 477
SECTION 1 ENGINE 477
INTRODUCTION 477
SERVICE INSTRUCTIONS 477
SECTION 2 CAB AND LUBRICATION 481
CLEAN AIR CONDITIONING FILTERS 481
GREASE HINGES 481
CHAPTER 17 MISCELLANEOUS SERVICE AND CHECKS 483
SECTION 1 DRIVE TRAIN 483
INTRODUCTION 483
SERVICE INSTRUCTIONS 483
ENGINE 483
WHEELS 483
SECTION 2 ELECTRICAL 485
USING BATTERY CHARGER 485
ADJUST HEADLIGHTS 487
SECTION 3 OPERATIONAL CHECKOUT 491
OPERATIONAL CHECK-OUT 491
REVISION 0 41
TABLE OF CONTENTS
CHAPTER 18 TROUBLE SHOOTING 499
SECTION 1 SYMPTOMS AND REMEDIES 499
INTRODUCTION 499
CHAPTER 19 APPENDIX 511
OBW Functional Description – ADT Mk IV
001-4002-00 511
HYDRAULIC FAN COOLER FUNCTIONAL DESCRIPTION – ADT MK IV
001-4003-02 514
TABLE OF CONTENTS 514
1 INTRODUCTION 514
2 CHASSIS CONTROL UNIT SOFTWARE REQUIREMENTS 514
CCU2 HEADLIGHT LOGIC AND CONTROL
001-4004-00 517
1 INTRODUCTION 517
2 HEADLIGHT LOGIC AND CONTROL 517
CCU2 WIPER CONTROL LOGIC
001-4005-00 519
1 INTRODUCTION 519
2 WIPER CONTROL LOGIC AND TIMING 519
AIR-CONDITIONING CONTROL LOGIC
001-4006-00 521
1 INTRODUCTION 521
2 INPUTS/OUTPUTS 521
BIN CONTROL LOGIC
001-4007-00 523
1 INTRODUCTION 523
2 BIN CONTROL LOGIC 523
PR001_PARK BRAKE FUNCTION 527
INTRODUCTION 527
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