Hitachi AH250-D AH300-D Articulated Dump Truck Service + Technical + Workshop Manual
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Hitachi AH250-D AH300-D Articulated Dump Truck Service + Technical + Workshop Manual
This Manual includes:
- Hitachi AH250-D AH300-D Articulated Dump Truck Service Manual (KM8TE-E-01)
- Hitachi AH250-D AH300-D Articulated Dump Truck TechnicalManual (KM8TE-E-01)
- Hitachi AH250-D AH300-D Articulated Dump Truck Workshop Manual (KM8TE-E-01)
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DESCRIPTION:
Hitachi AH250-D AH300-D Articulated Dump Truck Service + Technical + Workshop Manual
- 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.
- 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.
- 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 Service Manual (KM8TE-E-01)
AH250-D/300-D_KM8TE-E-00………………………………………………………. 1
TO THE SERVICE PERSONNEL………………………………………………………. 5
SAFETY SYMBOL………………………………………………………………… 6
IMPORTANT……………………………………………………………………. 8
ABBREVIATIONS………………………………………………………………… 9
AMENDMENT……………………………………………………………………. 11
INTRODUCTION…………………………………………………………………. 13
TABLE OF CONTENTS…………………………………………………………….. 39
SAFETY………………………………………………………………………. 15
SAFETY FEATURES…………………………………………………………… 15
GENERAL SAFETY……………………………………………………………. 16
SAFETY REGULATION…………………………………………………………. 17
SAFETY DECALS………………………………………………………………… 23
CHAPTER 1. OPERATIONAL CHECK-OUT PROCEDURE………………………………………. 49
OPERATIONAL CHECK-OUT……………………………………………………… 49
OPERATIONAL CHECKS – KEY SWITCH ON, ENGINE OFF……………………………….. 49
CHAPTER 2. ENGINE…………………………………………………………….. 55
SECTION 1. THEORY OF OPERATION……………………………………………… 55
ENGINE……………………………………………………………….. 55
SECTION 2. DIAGNOSE ENGINE MALFUNCTIONS……………………………………… 59
SECTION 3. ADJUSTMENTS…………………………………………………….. 61
DISPLAY MENU TACHOMETER………………………………………………… 61
SLOW AND FAST IDLE ADJUSTMENT…………………………………………… 61
VALVE CLEARANCE ADJUSTMENT……………………………………………… 61
EXHAUST BRAKE ADJUSTMENT……………………………………………….. 62
SECTION 4. TESTS………………………………………………………….. 63
CYLINDER COMPRESSION TEST………………………………………………. 63
FUEL PUMP PRESSURE TEST………………………………………………… 64
FUEL RETURN FLOW QUANTITY AT ENGINE TEST…………………………………. 65
FUEL SYSTEM LOW PRESSURE FUEL CIRCUIT LEAK TEST…………………………… 67
OIL PUMP PRESSURE TEST…………………………………………………. 68
CAN BUS J1939…………………………………………………………. 71
WHAT EXACTLY IS A “CAN BUS”…………………………………………….. 71
CANBUS……………………………………………………………….. 73
TESTING THE “CANBUS”…………………………………………………… 75
CHECKING THE CABLES……………………………………………………. 75
CHECKING OPENS, SHORTS BETWEEN WIRES AND SHORTS TO GROUND ON THE CAN HARNESS…. 76
MAIN “CAN” HARNESS…………………………………………………….. 76
“CAN” SHORT TO GROUND………………………………………………….. 77
“CAN “OPEN CIRCUIT…………………………………………………….. 78
“CAN” SHORT TO POSITIVE 0 -24 VOLTS……………………………………… 79
CHAPTER 3. ELECTRICAL SYSTEM…………………………………………………… 81
SECTION 1. SYSTEM INFORMATION………………………………………………. 81
ELECTRICAL SCHEMATIC SYMBOLS……………………………………………. 81
CHASSIS CONTROL UNIT (CCU & OEU)………………………………………… 82
MDU2 (MONITOR DISPLAY UNIT)…………………………………………….. 83
MDU2 LAYOUT…………………………………………………………… 84
MDU2 INPUT AND OUTPUTS…………………………………………………. 85
RELAY………………………………………………………………… 87
START-UP DISPLAY………………………………………………………. 88
DEFAULT SCREEN………………………………………………………… 88
DEFAULT SCREEN………………………………………………………… 88
DEFAULT SCREEN………………………………………………………… 88
DEFAULT SCREEN………………………………………………………… 88
DEFAULT SCREEN………………………………………………………… 89
TO GO TO MAIN MENU FROM DEFAULT SCREEN…………………………………… 89
MAIN MENU…………………………………………………………….. 89
EXPLANATION OF WIRE MARKINGS……………………………………………. 94
SECTION 2. DESCRIPTION OF CIRCUITS…………………………………………..127
SSM…………………………………………………………………..139
MDU2 WARNING LIGHTS…………………………………………………….150
MDU2 GAUGES……………………………………………………………154
CCU2 OUTPUT SPECIFICATION……………………………………………….155
OEU OUTPUT SPECIFICATION………………………………………………..159
SECTION 3. REFERENCES………………………………………………………163
PART 1. ENGINE FAULT CODES (ADM)…………………………………………163
PART 1: ENGINE FAULT CODES (PLD-MR)………………………………………168
PART 2. DM1 FAULT CODES…………………………………………………194
Service Code Diagnostics – Electronic Unit Injector (EUI) Controller…………211
SECTION 4. TESTS…………………………………………………………..213
KEY SWITCH TEST………………………………………………………..213
RELAYS………………………………………………………………..213
Diode Test…………………………………………………………….214
Pneumatic System Solenoids, Pressure Switches, and Sensor Tests……………..215
Steering Column Switch Test……………………………………………..220
CHAPTER 4. TRANSMISSION ZF 6 HP 592 C PLUS……………………………………….233
SECTION 1. THEORY OF OPERATION………………………………………………233
GENERAL DESCRIPTIONS……………………………………………………233
STALL SPEEDS…………………………………………………………..240
PLANETARY GEARS AND POWER FLOWS………………………………………….242
THE BASIC LAWS OF PLANETARY GEAR SETS…………………………………….243
ECOMAT TRANSMISSION PLANETARY CONFIGURATION……………………………….244
TRANSMISSION CLUTCH CONFIGURATION………………………………………..245
TRANSMISSION CROSS SECTIONAL DIAGRAM……………………………………..247
POWER FLOW…………………………………………………………….249
HYDRAULIC SYSTEM……………………………………………………….259
VALVE SCHEMATIC………………………………………………………..261
VALVE SCHEMATIC………………………………………………………..262
HYDRAULIC PRESSURES…………………………………………………….263
PRESSURE CHART…………………………………………………………264
RETARDER………………………………………………………………265
RETARDER LEVER…………………………………………………………266
ZF GEAR SHIFT CONTROL LEVER……………………………………………..267
INTERNAL SOLENOIDS……………………………………………………..273
REMOVE VALVE BODY………………………………………………………275
RENEWING SENSORS……………………………………………………….276
EXTERNSL SOLENOIDS……………………………………………………..284
DIAGNOSTIC CODES……………………………………………………….285
ELECTRONIC CONTROL SYSTEM……………………………………………….285
WIRING HARNESSES……………………………………………………….289
RANGE / SHIFT TESTS…………………………………………………….289
DO NOT SHIFT LIGHT……………………………………………………..290
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…………………………………….305
TABLE OF ERROR CODES……………………………………………………306
SECTION 3. ADJUSTMENTS AND TESTS…………………………………………….329
TRANSMISSION WARM-UP PROCEDURE…………………………………………..329
CHAPTER 5. PNEUMATIC SYSTEM…………………………………………………….333
SECTION 1. THEORY OF OPERATION………………………………………………333
PNEUMATIC SYSTEM OPERATION………………………………………………333
PNEUMATIC SYSTEM SCHEMATIC………………………………………………334
SECTION 2. DIAGNOSTIC INFORMATION……………………………………………345
DIAGNOSTIC PROCEDURE……………………………………………………345
DIAGNOSE PNEUMATIC SYSTEM MALFUNCTIONS……………………………………346
SECTION 3. ADJUSTMENTS AND TESTS…………………………………………….348
PNEUMATIC SYSTEM MAIN PRESSURE TEST AND ADJUSTMENT…………………………348
PARK BRAKE PRESSURE TEST………………………………………………..349
PARK BRAKE ADJUSTMENT…………………………………………………..350
GRAMMER SEAT FUNCTIONAL TEST…………………………………………….352
CHAPTER 6. HYDRAULIC SYSTEM…………………………………………………….353
SECTION 1. THEORY OF OPERATION………………………………………………353
ARTICULATED DUMP TRUCK HYDRAULIC SYSTEM OPERATION………………………….353
SECTION 2. DIAGNOSTIC INFORMATION……………………………………………387
DIAGNOSTIC PROCEDURE……………………………………………………387
DIAGNOSE HYDRAULIC SYSTEM MALFUNCTIONS……………………………………388
SECTION 3. TESTS…………………………………………………………..401
JT05800 DIGITAL THERMOMETER INSTALLATION………………………………….401
JT02156A DIGITAL ANALOGUE PRESSURE/TEMPERATURE ANALYSER INSTALLATION…………401
HYDRAULIC OIL CLEANUP PROCEDURE USING PORTABLE FILTER CADDY…………………401
HYDRAULIC SYSTEM WARM-UP PROCEDURE……………………………………….402
CYCLE TIME TEST………………………………………………………..403
MAIN HYDRAULIC PUMP RESIDUAL AND COMPENSATOR VALVES TEST AND ADJUSTMENT………404
SYSTEM RELIEF VALVE AND BIN RAISE CIRCUIT RELIEF VALVE TEST…………………406
PRIORITY VALVE TEST…………………………………………………….407
ACCUMULATOR PRESSURE REDUCING VALVE TEST AND ADJUSTMENT…………………….407
BRAKE ACCUMULATOR CHARGE VALVE TEST AND ADJUSTMENT…………………………408
BRAKE LOW PRESSURE SWITCH AND BRAKE ACCUMULATOR TEST……………………….409
FRONT AND REAR BRAKE ACCUMULATORS PRESSURE TEST AND CHARGE PROCEDURE…………410
SERVICE BRAKE VALVE TEST………………………………………………..411
STEERING RELIEF VALVE PRESSURE TEST AND ADJUSTMENT…………………………412
STEERING CYLINDER LEAKAGE TEST…………………………………………..412
SECONDARY STEERING PUMP RESIDUAL AND COMPENSATOR VALVES TEST AND ADJUSTMENT…..413
BIN LOWER CIRCUIT RELIEF VALVE TEST………………………………………414
CHAPTER 7. HEATING AND AIR CONDITIONING………………………………………….415
SECTION 1. THEORY OF OPERATION………………………………………………415
AIR CONDITIONING SYSTEM CYCLE OF OPERATION………………………………..415
HEATER CORE OPERATION…………………………………………………..416
SECTION 2. DIAGNOSTIC INFORMATION……………………………………………417
DIAGNOSE AIR CONDITIONING SYSTEM MALFUNCTIONS……………………………..417
HEATING/AIR CONDITIONING COMPONENT LOCATION……………………………….419
SECTION 3. TESTS…………………………………………………………..421
AIR CONDITIONING OPERATIONAL CHECKS………………………………………421
R134A AIR CONDITIONING SYSTEM TEST……………………………………….422
OPERATING PRESSURE DIAGNOSTIC CHART………………………………………423
A/C FREEZE CONTROL SWITCH TEST…………………………………………..425
A/C COMPRESSOR CLUTCH TEST………………………………………………425
A/C HIGH/LOW PRESSURE SWITCH TEST………………………………………..425
A/C EXPANSION VALVE TEST………………………………………………..426
EXPANSION VALVE BENCH TEST………………………………………………427
REFRIGERANT LEAK TEST…………………………………………………..428
CHAPTER 8. MAINTENANCE SCHEDULES………………………………………………..431
NOTES:……………………………………………………………………434
CHAPTER 9. DAILY OR 10 HOURLY SERVICE CHECKS……………………………………..435
CHAPTER 10. 150 HOURS SERVICE AND CHECKS…………………………………………437
SECTION 1. DRIVE TRAIN……………………………………………………..437
INTRODUCTION…………………………………………………………..437
SERVICE INSTRUCTIONS……………………………………………………437
LOWER AND RAISE THE BELLY PLATE………………………………………….437
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………………………………………………………….446
SECTION 2. CLEAN, CHECK AND REPLACE BREATHERS…………………………………447
GENERAL CHECK DRIVE LINE & SUSPENSION FASTENERS……………………………447
TRANSFER CASE BREATHER (LOCATED UNDER THE HYDRAULIC RESERVOIR)………………447
TRANSMISSION BREATHER AND 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
GREASE ALL GREASE POINTS………………………………………………..451
HYDRAULICS…………………………………………………………….452
REPLACE HYDRAULIC RESERVOIR BREATHER……………………………………..452
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………………………………………..469
REPLACE HYDRAULIC OIL RETURN FILTER………………………………………469
SECTION 3. CAB, PNEUMATICS AND ELECTRICAL…………………………………….471
REPLACE PNEUMATIC SYSTEM DRYER FILTER…………………………………….471
CHAPTER 14. 3 000 HOURS SERVICE AND CHECKS……………………………………….473
SECTION 1. DRIVE TRAIN……………………………………………………..473
INTRODUCTION…………………………………………………………..473
SERVICE INSTRUCTIONS……………………………………………………473
SECTION 2. HYDRAULICS AND PNEUMATICS…………………………………………475
CHAPTER 15. 4 000 HOURS SERVICE AND CHECKS……………………………………….477
SECTION 1. DRIVE TRAIN……………………………………………………..477
REPLACE FAN BELT……………………………………………………….477
SECTION 2. HYDRAULICS AND PNEUMATICS…………………………………………479
INTRODUCTION…………………………………………………………..479
SERVICE INSTRUCTIONS……………………………………………………479
CHAPTER 16. AS REQUIRED SERVICE…………………………………………………481
SECTION 1. ENGINE………………………………………………………….481
INTRODUCTION…………………………………………………………..481
SERVICE INSTRUCTIONS……………………………………………………481
SECTION 2. CAB AND LUBRICATION………………………………………………485
CLEAN AIR CONDITIONING FILTERS…………………………………………..485
GREASE HINGES………………………………………………………….485
CHAPTER 17. MISCELLANEOUS SERVICE AND CHECKS……………………………………..487
SECTION 1. DRIVE TRAIN……………………………………………………..487
INTRODUCTION…………………………………………………………..487
SERVICE INSTRUCTIONS……………………………………………………487
ENGINE………………………………………………………………..487
WHEELS………………………………………………………………..487
SECTION 2. ELECTRICAL………………………………………………………489
USING BATTERY CHARGER…………………………………………………..489
ADJUST HEADLIGHTS………………………………………………………491
SECTION 3. OPERATIONAL CHECKOUT……………………………………………..495
OPERATIONAL CHECK-OUT…………………………………………………..495
CHAPTER 18. TROUBLE SHOOTING……………………………………………………503
SECTION 1. SYMPTOMS AND REMEDIES…………………………………………….503
INTRODUCTION…………………………………………………………..503
CHAPTER 19. APPENDIX…………………………………………………………..515
OBW Functional Description – ADT Mk IV 001-4002-00…………………………….515
HYDRAULIC FAN COOLER FUNCTIONAL DESCRIPTION – ADT MK IV 001-4003-02……………..518
TABLE OF CONTENTS………………………………………………………518
1. INTRODUCTION………………………………………………………..518
2. CHASSIS CONTROL UNIT SOFTWARE REQUIREMENTS……………………………..518
CCU2 HEADLIGHT LOGIC AND CONTROL 001-4004-00………………………………….521
1. INTRODUCTION………………………………………………………..521
2. HEADLIGHT LOGIC AND CONTROL…………………………………………..521
CCU2 WIPER CONTROL LOGIC 001-4005-00…………………………………………523
1. INTRODUCTION………………………………………………………..523
2. WIPER CONTROL LOGIC AND TIMING………………………………………..523
AIR-CONDITIONING CONTROL LOGIC 001-4006-00……………………………………525
1. INTRODUCTION………………………………………………………..525
2. INPUTS/OUTPUTS………………………………………………………525
BIN CONTROL LOGIC 001-4007-00……………………………………………….527
1. INTRODUCTION………………………………………………………..527
2. BIN CONTROL LOGIC……………………………………………………527
PR001_PARK BRAKE FUNCTION…………………………………………………..531
INTRODUCTION…………………………………………………………..531
SERVICE MANUAL REVISION REQUEST FORM…………………………………………….533
Hitachi AH250-D AH300-D Articulated Dump Truck TechnicalManual (KM8TE-E-01)
INDEX_T……………………………………………………………………………………….. 1
SAFETY………………………………………………………………………………………… 5
Specification………………………………………………………………………………. 5
Safety Features…………………………………………………………………………….. 5
Material Safety Data Sheets (MSDS)……………………………………………………………. 6
Unauthorised Modifications of the Roll Over Protective Structure (ROPS) and the Falling Objects P……. 6
Noise Emission Levels……………………………………………………………………….. 6
General Safety……………………………………………………………………………… 6
USER’S INFORMATINON FEEDBACK FORM………………………………………………………………… 25
CHAPTER 1. OPERATIONAL CHECK-OUT PROCEDURE………………………………………………………… 27
OPERATIONALCHECK-OUT………………………………………………………………………… 27
OPERATIONAL CHECKS – KEY SWITCH ON, ENGINE OFF…………………………………………………. 27
OPERATIONAL CHECKS – ENGINE ON……………………………………………………………….. 29
CHAPTER 2. ENGINE………………………………………………………………………………. 35
SECTION 1. THEORY OF OPERATION……………………………………………………………….. 35
ENGINE…………………………………………………………………………………. 35
SECTION 2. DIAGNOSE ENGINE MALFUNCTIONS……………………………………………………….. 39
SECTION 3. ADJUSTMENTS………………………………………………………………………. 43
DISPLAY MENU TACHOMETER………………………………………………………………….. 43
SLOW AND FAST IDLE ADJUSTMENT…………………………………………………………….. 43
VALVE CLEARANCE ADJUSTMENT……………………………………………………………….. 43
EXHAUST BRAKE ADJUSTMENT…………………………………………………………………. 44
SECTION 4. TESTS……………………………………………………………………………. 45
CYLINDER COMPRESSION TEST………………………………………………………………… 45
FUEL PUMP PRESSURE TEST DOWNSTREAM OF FUEL FILTER…………………………………………… 46
FUEL RETURN FLOW QUANTITY AT ENGINE TEST…………………………………………………… 47
FUEL INTAKE PRESSURE UPSTREAM OF FUEL PUMP TEST…………………………………………….. 48
FUEL SYSTEM LOW PRESSURE FUEL CIRCUIT LEAK TEST…………………………………………….. 49
OIL PUMP PRESSURE TEST…………………………………………………………………… 50
CHAPTER 3. ELECTRICAL SYSTEM…………………………………………………………………….. 51
SECTION 1. SYSTEM INFORMATION………………………………………………………………… 51
HARNESSES AND COMPONENT LOCATION………………………………………………………….. 52
EXPLANATION OF WIRE MARKINGS……………………………………………………………… 78
SECTION 2. SYSTEMS AND SUB-SYSTEM THEORY OF OPERATION AND DIAGNOSTICS…………………………….. 95
STARTING AND CHARGING CIRCUIT THEORY OF OPERATION…………………………………………… 95
SECTION 3. REFERENCES………………………………………………………………………..119
SERVICE CODE DIAGNOSTICS – AFTER MACHINE REPAIR……………………………………………..119
CHAPTER 4. POWER TRAIN…………………………………………………………………………..173
SECTION 1. THEORY OF OPERATION………………………………………………………………..173
TRANSMISSION EXTERNAL COMPONENTS…………………………………………………………..173
TRANSMISSION CONTROL SYSTEM……………………………………………………………….174
SECTION 2. DIAGNOSTIC INFORMATION……………………………………………………………..185
DIAGNOSTIC PROCEDURE……………………………………………………………………..185
DIAGNOSE POWER TRAIN SYSTEM MALFUNTIONS…………………………………………………….186
SECTION 3. TESTS…………………………………………………………………………….197
TRANSMISSION WARM-UP PROCEDURE…………………………………………………………….197
CHAPTER 5. PNEUMATIC SYSTEM………………………………………………………………………205
SECTION 1. THEORY OF OPERATION………………………………………………………………..205
PNEUMATIC SYSTEM OPERATION………………………………………………………………..205
All pneumatic functions are supplied pressurized air by the engine driven compressor…………….205
PNEUMATIC SYSTEM SCHEMATIC………………………………………………………………..206
CHAPTER 5. PNEUMATIC SYSTEM………………………………………………………………………219
SECTION 2. DIAGNOSTIC INFORMATION……………………………………………………………..219
DIAGNOSTIC PROCEDURE……………………………………………………………………..219
DIAGNOSE PNEUMATIC SYSTEM MALFUNCTIONS……………………………………………………..220
SECTION 3. TESTS…………………………………………………………………………….225
PNEUMATIC SYSTEM MAIN PRESSURE TEST AND ADJUSTMENT…………………………………………..225
PARK BRAKE PRESSURE TEST………………………………………………………………….226
CHAPTER 6. HYDRAULIC SYSTEM………………………………………………………………………227
SECTION 1. THEORY OF OPERATION………………………………………………………………..227
ARTICULATED DUMP TRUCK HYDRAULIC SYSTEM OPERATION……………………………………………227
SECTION 2. DIAGNOSTIC INFORMATION……………………………………………………………..263
DIAGNOSTIC PROCEDURE……………………………………………………………………..263
DIAGNOSE HYDRAULIC SYSTEM MALFUNCTIONS……………………………………………………..264
HYDRAULIC SYSTEM COMPONENT LOCATION………………………………………………………..272
SECTION 3. TESTS…………………………………………………………………………….278
JT05800 DIGITAL THERMOMETER INSTALLATION……………………………………………………278
JT02156A DIGITAL PRESSURE/ TEMPERATURE ANALYZER INSTALLATION………………………………….278
HYDRAULIC OIL CLEANUP PROCEDURE USING PORTABLE FILTER CADDY…………………………………..278
HYDRAULIC SYSTEM WARM-UP PROCEDURE…………………………………………………………279
CYCLE TIME TEST………………………………………………………………………….280
MAIN HYDRAULIC PUMP RESIDUAL AND COMPENSATOR VALVES TEST AND ADJUSTMENT………………………..281
SYSTEM RELIEF VALVE AND BIN RAISE CIRCUIT RELIEF VALVE TEST…………………………………..282
PRIORITY VALVE TEST………………………………………………………………………283
ACCUMULATOR PRESSURE REDUCING VALVE TEST AND ADJUSTMENT………………………………………283
BRAKE ACCUMULATOR CHARGE VALVE TEST AND ADJUSTMENT…………………………………………..284
BRAKE LOW PRESSURE SWITCH AND BRAKE ACCUMULATOR TEST…………………………………………285
FRONT AND REAR BRAKE ACCUMULATORS PRESSURE TEST AND CHARGE PROCEDURE…………………………..286
SERVICE BRAKE VALVE TEST………………………………………………………………….286
STEERING RELIEF VALVE PRESSURE TEST AND ADJUSTMENT…………………………………………..287
STEERING CYLINDER LEAKAGE TEST…………………………………………………………….288
SECONDARY STEERING PUMP RESIDUAL AND COMPENSATOR VALVES TEST AND ADJUSTMENT…………………….288
BIN LOWER CIRCUIT RELIEF VALVE TEST………………………………………………………..290
CHAPTER 7. HEATING AND AIR CONDITIONING……………………………………………………………291
SECTION 1. THEORY OF OPERATION………………………………………………………………..291
AIR CONDITIONING SYSTEM CYCLE OF OPERATION………………………………………………….291
HEATER CORE OPERATION…………………………………………………………………….292
SECTION 2. DIAGNOSTIC INFORMATION……………………………………………………………..293
DIAGNOSE AIR CONDITIONING SYSTEM MALFUNCTIONS……………………………………………….293
DIAGNOSE HEATER SYSTEM MALFUNCTIONS………………………………………………………..295
HEATING/AIR CONDITIONING COMPONENT LOCATION…………………………………………………296
SECTION 3. TESTS…………………………………………………………………………….299
AIR CONDITIONING OPERATIONAL CHECKS………………………………………………………..299
R134A AIR CONDITIONING SYSTEM TEST…………………………………………………………300
OPERATING PRESSURE DIAGNOSTIC CHART………………………………………………………..301
A/C FREEZE CONTROL SWITCH TEST…………………………………………………………….303
A/C COMPRESSOR CLUTCH TEST………………………………………………………………..303
A/C HIGH/LOW PRESSURE SWITCH TEST………………………………………………………….303
A/C EXPANSION VALVE TEST………………………………………………………………….304
EXPANSION VALVE BENCH TEST………………………………………………………………..305
REFRIGERANT LEAK TEST…………………………………………………………………….306
Hitachi AH250-D AH300-D Articulated Dump Truck Workshop Manual (KM8TE-E-01)
INDEX_W……………………………………………………………………………………. 1
SAFETY…………………………………………………………………………………….. 7
Specification………………………………………………………………………………. 7
Safety Features…………………………………………………………………………….. 7
Material Safety Data Sheets (MSDS)……………………………………………………………. 8
Unauthorised Modifications of the Roll Over Protective Structure (ROPS) and the Falling Objects P……. 8
Noise Emission Levels……………………………………………………………………….. 8
General Safety……………………………………………………………………………… 8
USER’S INFORMATINON FEEDBACK FORM…………………………………………………………….. 17
CHAPTER 1. WHEELS…………………………………………………………………………… 23
CHAPTER 2. AXLES AND SUSPENSION SYSTEMS……………………………………………………….. 25
CHAPTER 3. TRANSMISSION……………………………………………………………………… 85
CHAPTER 4. ENGINE……………………………………………………………………………183
CHAPTER 5. ENGINE AUXILIARY SYSTEM…………………………………………………………….263
CHAPTER 6. CONNECTOR DRIVE……………………………………………………………………277
CHAPTER 7. TRANSFER CASE……………………………………………………………………..279
CHAPTER 8. STEERING SYSTEM……………………………………………………………………305
CHAPTER 9. SERVICE BRAKES…………………………………………………………………….317
CHAPTER 10. PARK BRAKE……………………………………………………………………….325
CHAPTER 11. FRAME AND SUPPORTING STRUCTURE……………………………………………………..329
CHAPTER 12. OPERATOR’S STATION………………………………………………………………..339
CHAPTER 13. SHEET METAL AND STYLING……………………………………………………………359
CHAPTER 14. MAIN HYDRAULIC SYSTEM……………………………………………………………..363
CHAPTER 15. PNEUMATIC SYSTEMS…………………………………………………………………375
CHAPTER 16. HAULAGE DEVICE……………………………………………………………………397
CHAPTER 17. DEALER FABRICATED TOOLS……………………………………………………………407
INDEX………………………………………………………………………………………425
REVISION REQUEST FORM………………………………………………………………………..427
PLEASE NOTE:
- This is the SAME MANUAL used by the dealerships to diagnose your vehicle
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