Hitachi AH500-D Articulated Dump Truck Service Manual
FILE DETAILS:
Hitachi AH500-D Articulated Dump Truck Service Manual
Language : English
Pages : 533
Downloadable : YES
Format : PDF
Size : 14.7MB
Serial No.AH500-D 001954 and up
DESCRIPTION:
Hitachi AH500-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 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 Service Manual
SAFETY 13
SAFETY FEATURES 13
GENERAL SAFETY 14
SAFETY REGULATION 15
SAFETY DECALS 21
CHAPTER 1 OPERATIONAL CHECK-OUT PROCEDURE 39
OPERATIONAL CHECK-OUT 39
OPERATIONAL CHECKS – KEY SWITCH ON, ENGINE OFF 39
CHAPTER 2 ENGINE 45
SECTION 1 THEORY OF OPERATION 45
ENGINE 45
SECTION 2 DIAGNOSE ENGINE MALFUNCTIONS 49
SECTION 3 ADJUSTMENTS 51
DISPLAY MENU TACHOMETER 51
SLOW AND FAST IDLE ADJUSTMENT 51
VALVE CLEARANCE ADJUSTMENT 51
EXHAUST BRAKE ADJUSTMENT 53
SECTION 4 TESTS 55
CYLINDER COMPRESSION TEST 55
FUEL PUMP PRESSURE TEST 55
OIL PUMP PRESSURE TEST 57
CAN BUS J1939 60
WHAT EXACTLY IS A “CAN BUS” 60
CANBUS 61
TESTING THE “CANBUS” 62
CHECKING THE CABLES 62
CHECKING OPENS, SHORTS BETWEEN WIRES AND SHORTS TO GROUND ON THE CAN
HARNESS 63
MAIN “CAN” HARNESS 63
“CAN” SHORT TO GROUND 64
“CAN “OPEN CIRCUIT 65
“CAN” SHORT TO POSITIVE 0 -24 VOLTS 66
REVISION 0 27
CHAPTER 3 ELECTRICAL SYSTEM 67
SECTION 1 SYSTEM INFORMATION 67
ELECTRICAL SCHEMATIC SYMBOLS 67
CHASSIS CONTROL UNIT (CCU & OEU) 68
MDU2 (MONITOR DISPLAY UNIT) 69
MDU2 LAYOUT 70
MDU2 INPUT AND OUTPUTS 71
RELAY 73
START-UP DISPLAY 74
DEFAULT SCREEN 74
DEFAULT SCREEN 74
DEFAULT SCREEN 74
DEFAULT SCREEN 74
DEFAULT SCREEN 75
TO GO TO MAIN MENU FROM DEFAULT SCREEN 75
MAIN MENU 75
EXPLANATION OF WIRE MARKINGS 80
SECTION 2 DESCRIPTION OF CIRCUITS 113
SSM 125
MDU2 WARNING LIGHTS 136
MDU2 GAUGES 140
CCU2 OUTPUT SPECIFICATION 141
OEU OUTPUT SPECIFICATION 145
SECTION 3 REFERENCES 149
ENGINE FAULT CODES (ADM) 149
ENGINE FAULT CODES (PLD-MR) 154
SSM FAULT CODES 180
PART 2 DM1 FAULT CODES 181
SECTION 4 TESTS 199
KEY SWITCH TEST 199
RELAYS 199
Diode Test 200
Pneumatic System Solenoids, Pressure Switches, and Sensor Tests 201
Steering Column Switch Test 206
TABLE OF CONTENTS
28 REVISION 0
CHAPTER 4 TRANSMISSION 219
SECTION 1 THEORY OF OPERATION 219
GENERAL DESCRIPTIONS 219
STALL SPEEDS 226
PLANETARY GEARS AND POWER FLOWS 228
THE BASIC LAWS OF PLANETARY GEAR SETS 229
HD TRANSMISSION PLANETARY CONFIGURATION 230
HD TRANSMISSION CLUTCH CONFIGURATION 231
POWER FLOW 232
HYDRAULIC SYSTEM 241
SOLENOIDS 245
3000 and 4000 4th Generation Control Valve Body 246
HYDRAULIC CIRCUITS 248
TORQUE CONVERTER AND LUBE PRESSURE CIRCUITS – OVERVIEW 256
EXHAUST BACKFILL PRESSURE 257
PRESSURE TABLE AND TEST POINTS 262
RETARDER 263
APPLICATIONS AND CAPACITIES 263
INPUTS AND OUTPUTS 265
RETARDER CONTROL HYDRAULICS 265
TESTING RETARDER CHARGING PRESSURE 266
HD RETARDER HYDRAULIC SCHEMATIC RETARDER OFF 267
HD RETARDER HYDRAULIC SCHEMATIC RETARDER ON 268
ELECTRONIC CONTROL SYSTEM 269
PUSH BUTTON SHIFT SELECTOR 273
SPEED SENSORS 274
WIRING HARNESSES 274
RANGE / SHIFT TESTS 275
DO NOT SHIFT LIGHT 276
SECTION 2 DIAGNOSTIC INFORMATION 278
DIAGNOSTIC PROCEDURE 278
DIAGNOSE POWER TRAIN SYSTEM MALFUNCTIONS 279
CHECK THE TRANSMISSION FLUID LEVEL 290
TRANSMISSION CONTROL UNIT ERROR CODES 293
REVISION 0 29
TABLE OF CONTENTS
TABLE OF ERROR CODES 294
ALLISON HD 4560R ELECTRONIC CONTROL WTEC III 300
SECTION 3 ADJUSTMENTS AND TESTS 301
TRANSMISSION WARM-UP PROCEDURE 301
TRANSMISSION OIL COOLER RESTRICTION TEST 310
CHAPTER 5 PNEUMATIC SYSTEM 311
SECTION 1 THEORY OF OPERATION 311
PNEUMATIC SYSTEM OPERATION 311
PNEUMATIC SYSTEM SCHEMATIC 312
SECTION 2 DIAGNOSTIC INFORMATION 321
DIAGNOSTIC PROCEDURE 321
DIAGNOSE PNEUMATIC SYSTEM MALFUNCTIONS 322
SECTION 3 ADJUSTMENTS AND TESTS 324
PNEUMATIC SYSTEM MAIN PRESSURE TEST AND ADJUSTMENT 324
PARK BRAKE PRESSURE TEST 325
PARK BRAKE ADJUSTMENT 326
GRAMMER SEAT FUNCTIONAL TEST 328
CHAPTER 6 HYDRAULIC SYSTEM 329
SECTION 1 THEORY OF OPERATION 329
ARTICULATED DUMP TRUCK HYDRAULIC SYSTEM OPERATION 329
SECTION 2 DIAGNOSTIC INFORMATION 359
DIAGNOSTIC PROCEDURE 359
DIAGNOSE HYDRAULIC SYSTEM MALFUNCTIONS 360
SECTION 3 TESTS 371
JT05800 DIGITAL THERMOMETER INSTALLATION 371
JT02156A DIGITAL ANALOGUE PRESSURE/TEMPERATURE ANALYSER INSTALLATION 371
HYDRAULIC OIL CLEANUP PROCEDURE USING PORTABLE FILTER CADDY 371
HYDRAULIC SYSTEM WARM-UP PROCEDURE 372
CYCLE TIME TEST 373
MAIN HYDRAULIC PUMP RESIDUAL AND COMPENSATOR VALVES TEST AND ADJUSTMENT
374
SYSTEM RELIEF VALVE AND BIN RAISE CIRCUIT RELIEF VALVE TEST 376
PRIORITY VALVE TEST 377
ACCUMULATOR PRESSURE REDUCING VALVE TEST AND ADJUSTMENT 377
BRAKE ACCUMULATOR CHARGE VALVE TEST AND ADJUSTMENT 378
BRAKE LOW PRESSURE SWITCH AND BRAKE ACCUMULATOR TEST 379
30 REVISION 0
TABLE OF CONTENTS
FRONT AND REAR BRAKE ACCUMULATORS PRESSURE TEST AND CHARGE PROCEDURE
380
SERVICE BRAKE VALVE TEST 382
STEERING RELIEF VALVE PRESSURE TEST AND ADJUSTMENT 383
STEERING CYLINDER LEAKAGE TEST 383
SECONDARY STEERING PUMP RESIDUAL AND COMPENSATOR VALVES TEST AND
ADJUSTMENT 384
BIN LOWER CIRCUIT RELIEF VALVE TEST 385
SUSPENSION CALIBRATION PROCEDURE 386
SUSPENSION SERVICE CHECK 387
Hydraulic Pressure Setting and Fault Finding Procedure 390
CHAPTER 7 HEATING AND AIR CONDITIONING 403
SECTION 1 THEORY OF OPERATION 403
AIR CONDITIONING SYSTEM CYCLE OF OPERATION 403
HEATER CORE OPERATION 404
SECTION 2 DIAGNOSTIC INFORMATION 405
DIAGNOSE AIR CONDITIONING SYSTEM MALFUNCTIONS 405
HEATING/AIR CONDITIONING COMPONENT LOCATION 407
SECTION 3 TESTS 409
AIR CONDITIONING OPERATIONAL CHECKS 409
R134A AIR CONDITIONING SYSTEM TEST 410
OPERATING PRESSURE DIAGNOSTIC CHART 411
A/C FREEZE CONTROL SWITCH TEST 413
A/C COMPRESSOR CLUTCH TEST 413
A/C HIGH/LOW PRESSURE SWITCH TEST 413
A/C EXPANSION VALVE TEST 414
EXPANSION VALVE BENCH TEST 415
REFRIGERANT LEAK TEST 416
CHAPTER 8 MAINTENANCE SCHEDULES 419
NOTES: 421
CHAPTER 9 DAILY OR 10 HOURLY SERVICE CHECKS 423
CHAPTER 10 500 HOURS SERVICE AND CHECKS 425
SECTION 1 DRIVE TRAIN 425
INTRODUCTION 425
SERVICE INSTRUCTIONS 425
ENGINE 425
TRANSMISSION 428
BRAKES 431
REVISION 0 31
TABLE OF CONTENTS
AXLES 431
TRANSFER CASE 432
SECTION 2 CLEAN, CHECK AND REPLACE BREATHERS 433
GENERAL CHECK DRIVE LINE & SUSPENSION FASTENERS 433
TRANSMISSION BREATHER (LOCATED UNDER CAB) 433
REPLACE FUEL TANK BREATHER 433
TRANSFER CASE BREATHER (LOCATED BEHIND CAB) 433
AXLE BREATHERS 434
SECTION 3 CAB AND ELECTRICAL 435
INSPECT, CLEAN AND REPLACE CAB AIR FILTER 435
CHECK BATTERIES, CLEAN AND TIGHTEN TERMINALS 436
CHECK ELECTRICAL CONNECTORS, HARNESSES AND LOOMS 436
CHECK WORK LIGHTS, REVERSE BUZZER AND HORNS 436
RECORD & DELETE FAULT CODES ON THE MDU 436
CHECK THE OPERATOR CONTROLS AND INSTRUMENTS 436
SECTION 4 LUBRICATION 437
CHECK GREASE LEVEL OF AUTO GREASING SYSTEM 437
REPLACE AUTO GREASING SYSTEM FILTER 437
HYDRAULICS 438
CHAPTER 11 500 HOURS SERVICE AND CHECKS 441
SECTION 1 DRIVE TRAIN 441
INTRODUCTION 441
SERVICE INSTRUCTIONS 441
ENGINE 441
TRANSMISSION 442
BRAKES 445
TRANSFER CASE 445
SECTION 2 CLEAN, CHECK AND REPLACE BREATHERS 447
GENERAL CHECK DRIVE LINE & SUSPENSION FASTENERS 447
TRANSFER CASE BREATHER (LOCATED UNDER THE CAB) 447
AXLE BREATHERS 447
SECTION 3 CAB AND ELECTRICAL 449
INSPECT, CLEAN AND REPLACE CAB AIR FILTER 449
CHECK BATTERIES, CLEAN AND TIGHTEN TERMINALS 450
CHECK ELECTRICAL CONNECTORS, HARNESSES AND LOOMS 450
CHECK WORK LIGHTS, REVERSE BUZZER AND HORNS 450
RECORD & DELETE FAULT CODES ON THE MDU 450
CHECK THE OPERATOR CONTROLS AND INSTRUMENTS 450
SECTION 4 LUBRICATION 451
CHECK GREASE LEVEL OF AUTO GREASING SYSTEM 451
REPLACE AUTO GREASING SYSTEM FILTER 451
HYDRAULICS 452
32 REVISION 0
TABLE OF CONTENTS
CHAPTER 12 1 000 HOURS SERVICE AND CHECKS 455
SECTION 1 DRIVE TRAIN 455
INTRODUCTION 455
SERVICE INSTRUCTIONS 455
Engine 455
SECTION 2 HYDRAULICS AND LUBRICATION 459
REPLACE HYDRAULIC RESERVOIR BREATHER 459
SECTION 4 AXLES AND CHASSIS & SUSPENSION 461
CHECK AXLE OIL LEVEL 461
CHECK FINAL DRIVE OIL LEVELS 461
CHECK BIN SHOCK PAD CLEARANCE 461
CHAPTER 13 2 000 HOURS SERVICE AND CHECKS 463
SECTION 1 DRIVE TRAIN 463
INTRODUCTION 463
SERVICE INSTRUCTIONS 463
ENGINE 463
SECTION 2 HYDRAULICS AND LUBRICATION 467
REPLACE HYDRAULIC OIL RETURN FILTER 467
SECTION 3 CAB, PNEUMATICS AND ELECTRICAL 469
REPLACE PNEUMATIC SYSTEM DRYER FILTER 469
DRYER FILTER 469
CHAPTER 14 3 000 HOURS SERVICE AND CHECKS 471
SECTION 1 DRIVE TRAIN 471
INTRODUCTION 471
SERVICE INSTRUCTIONS 471
SECTION 2 HYDRAULICS AND PNEUMATICS 473
CHAPTER 15 4 000 HOURS SERVICE AND CHECKS 475
SECTION 1 DRIVE TRAIN 475
REPLACE FAN BELT 475
SECTION 2 HYDRAULICS AND PNEUMATICS 477
INTRODUCTION 477
SERVICE INSTRUCTIONS 477
CHAPTER 16 AS REQUIRED SERVICE 479
SECTION 1 ENGINE 479
REVISION 0 33
TABLE OF CONTENTS
INTRODUCTION 479
SERVICE INSTRUCTIONS 479
SECTION 2 CAB AND LUBRICATION 483
CLEAN AIR CONDITIONING FILTERS 483
GREASE HINGES 483
CHAPTER 17 MISCELLANEOUS SERVICE AND CHECKS 485
SECTION 1 DRIVE TRAIN 485
INTRODUCTION 485
SERVICE INSTRUCTIONS 485
ENGINE 485
WHEELS 485
SECTION 2 ELECTRICAL 487
USING BATTERY CHARGER 487
ADJUST HEADLIGHTS 489
SECTION 3 OPERATIONAL CHECKOUT 493
OPERATIONAL CHECK-OUT 493
CHAPTER 18 TROUBLE SHOOTING 501
SECTION 1 SYMPTOMS AND REMEDIES 501
INTRODUCTION 501
CHAPTER 19 APPENDIX 513
OBW Functional Description – ADT Mk IV
001-4002-00 513
HYDRAULIC FAN COOLER FUNCTIONAL DESCRIPTION – ADT MK IV
001-4003-02 516
TABLE OF CONTENTS 516
1 INTRODUCTION 516
2 CHASSIS CONTROL UNIT SOFTWARE REQUIREMENTS 516
CCU2 HEADLIGHT LOGIC AND CONTROL
001-4004-00 519
1 INTRODUCTION 519
2 HEADLIGHT LOGIC AND CONTROL 519
CCU2 WIPER CONTROL LOGIC
001-4005-00 521
1 INTRODUCTION 521
34 REVISION 0
TABLE OF CONTENTS
2 WIPER CONTROL LOGIC AND TIMING 521
AIR-CONDITIONING CONTROL LOGIC
001-4006-00 523
1 INTRODUCTION 523
2 INPUTS/OUTPUTS 523
BIN CONTROL LOGIC
001-4007-00 525
1 INTRODUCTION 525
2 BIN CONTROL LOGIC 525
PR001_PARK BRAKE FUNCTION 529
INTRODUCTION 529
REVISION 0
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