This document is an Operator's Manual for the Hitachi EH3500ACII Rigid Dump Truck. It provides comprehensive information for safe and efficient operation, maintenance, and troubleshooting of the machine.
Function Description
The Hitachi EH3500ACII is a rigid dump truck designed for heavy-duty hauling operations, typically in mining and large-scale construction environments. Its primary function is to transport large volumes of material, such as earth, rock, and ore, across various terrains. The "ACII" designation likely refers to an advanced AC drive system, which offers superior traction, control, and efficiency compared to traditional mechanical drive systems. The rigid frame design is optimized for stability and durability when carrying heavy loads over rough and uneven surfaces.
Important Technical Specifications
While specific numerical values are not detailed on the provided pages, the manual highlights several key aspects of the EH3500ACII's design and operational parameters:
- Operating Conditions: The standard specification machine is designed to operate within an atmospheric temperature range of -20 to 50 °C (-4 to 122 °F) and at altitudes from 0 m to 2000 m (0 ft to 6600 ft). Operation outside these conditions requires consultation with a Hitachi dealer.
- Metric Design: The machine is of metric design, with all measurements in the manual provided in metric units (SI Units), with MKS and English units for reference.
- Fuel Type: It requires diesel fuel complying with JIS K-2204, EN-590, or ASTM D-975 standards, with a sulfur content of 15 ppm or lower. The fuel must also meet a solid contamination level of class 18/16/13 of ISO4406-1999.
- Payload Capacity: The manual explicitly warns against exceeding the maximum allowed payload (1.2 × nominal payload), emphasizing the risk of overturning or extended braking distances due to a raised center of gravity.
- Safety Structures: The cab, cab mounting structure, and frame are designed as Roll-Over Protective Structures (ROPS) and Falling-Object Protective Structures (FOPS), meeting ISO 3471 Hauler standards. Unauthorized modifications to these structures are strictly prohibited as they void certification and compromise operator safety.
- Visibility: The machine is equipped with mirrors and cameras to enhance operator visibility. The operator's visibility is assessed according to ISO 5006, with a rectangular 1 m boundary and a 12 m visibility test circle.
- AC Drive System: The "ACII" in the model name indicates an Alternating Current drive system, which is mentioned in the context of maintenance and warning indicators (e.g., "AC Drive System Maintenance Required Warning Indicator," "AC Drive Fault Reset Switch"). This system likely contributes to the truck's performance, particularly in downhill operations where electric braking is crucial.
Usage Features
The manual outlines various features related to the operation of the dump truck:
- Operator's Station: Detailed sections cover cab features, monitor display, key pad usage, and basic screen information including speedometer, odometer, tachometer, shift lever position indicator, and various gauges (engine oil pressure, coolant temperature, wheel motor temperature, brake/steering oil pressure).
- Warning Indicators: A comprehensive list of warning indicators is provided, categorized by engine-related, driving-related, and hydraulic-related issues. These include engine warning, oil pressure, overheat, coolant level, alternator, air cleaner restriction, stop valve, grid dry, traction fault, drive shut down, wheel motor temperature, wheel motor & alternator blower fault, electric brake, parking brake, load/dump brake, engine stop, central warning, AC drive system maintenance required, and hydraulic oil overheat.
- Controls: The manual describes the steering wheel, horn switch, turn signal/high beam lever switch, hazard warning lamp switch, tilt/telescope steering wheel, accelerator pedal, service brake pedal, electric brake pedal, parking brake, and various console panel switches (cruise control/auto retard, grid dry, AC drive shut down, emergency engine stop, key switch, headlight, front tire light, rear light manual, ladder & deck light, wiper/washer, AC drive fault reset, cigar lighter, dimmer, buzzer deactivation, engine room maintenance light).
- Air Conditioning System: The cab is equipped with an air conditioning system, with controls for cooling, heating, dehumidifying, defrosting, and blower operation.
- Camera Monitor: A camera monitor is provided to assist the operator, with instructions on its use and control panel functions.
- Operator's Seat Adjustment: The manual details how to adjust the operator's seat for incline, fore-aft position, armrest angle and height, backrest, and height, as well as absorber adjustment.
- Safety Belt: Emphasizes the importance of fastening the seat belt and provides instructions for inspection and replacement.
- Getting On/Off Machine: Instructions for safe entry and exit using handholds and steps, emphasizing three-point contact.
- Emergency Exit: A dedicated section for emergency exit procedures, including evacuation in case of fire.
- Operating Engine: Covers daily inspection before starting, pre-start checks, system checks, starting in normal and cold weather, using booster batteries, and stopping the engine.
- Driving Machine: Includes instructions for careful driving, starting, propel change, acceleration, cruise control, deceleration, electric brake, auto retard, steering, stopping, parking, and towing.
- Operating Machine: Details procedures for loading, load weighing system, hauling, and dumping, including the speed limitation function when the dump body is raised.
Maintenance Features
The manual provides extensive guidance on maintaining the EH3500ACII to ensure its longevity and safe operation:
- Maintenance Schedule: Emphasizes correct maintenance and inspection procedures, regular hour meter checks, and the use of correct fuels and lubricants.
- Preparation for Maintenance: Instructions on preparing the machine for maintenance, including installing and removing dump body prop pins and cables.
- Inspection/Maintenance Lights: Information on lights designed to aid in inspection and maintenance.
- Component Location Diagrams: Diagrams to help locate main parts and components.
- Periodic Replacement of Parts: Highlights the importance of replacing parts at specified intervals.
- Maintenance Guide: A general guide for maintenance tasks.
- Greasing: Instructions for proper greasing.
- Engine Maintenance: Covers checking and changing engine oil and filters.
- Travel Reduction Gear Maintenance: Includes checking and changing gear oil and filters, and cleaning/replacing the air breather.
- Hydraulic System Maintenance: Details inspection, maintenance, checking hydraulic oil level, draining the hydraulic oil tank sump, and replacing filters.
- Fuel System Maintenance: Covers draining the fuel tank sump and filters, replacing filter elements, checking hoses, and cleaning the fuel tank breather.
- Air Cleaner Maintenance: Instructions for cleaning and replacing outer and inner air cleaner elements and dust cups.
- Cooling System Maintenance: Includes checking coolant level and concentration, replacing coolant filter, changing coolant, cleaning radiators and aftercoolers, and checking fan belts.
- Air Conditioner Maintenance: Covers cleaning and replacing recirculation and ventilation air filters, checking refrigerant quantity, compressor belt tension, and cleaning the condenser core.
- Electrical System Maintenance: Instructions for checking tightening torque, seasonal maintenance, batteries, replacing fuses, checking fusible links, electrical cables and wire harnesses, emergency engine stop switch, lights, horn, backup alarm buzzer, and suspension pressure sensor.
- Brakes & Steering System Maintenance: Details checking brake operation, service brake, parking brake, accumulators, front/rear brake lining and disk.
- Suspension, Wheels & Tires Maintenance: Covers checking suspension, wheels, front axle lubricant, and tire inflation pressure and condition.
- Miscellaneous Maintenance: Includes checking and replacing alternator carbon brush, coolant in the control cabinet, pressurized control cabinet filter, rear axle inside, seat belt, windshield washer tank, steering wheel stroke play, auto-lubrication system, tightening torque of bolts and nuts, and dump body prop cable.
- Special Environmental Conditions: Specific maintenance procedures for machines operating under special environmental conditions.
- Storage: Instructions for storing the machine and preparing it for removal from storage.
- Troubleshooting: Provides guidance on diagnosing and resolving issues, including Cummins fault code lamps and diagnostic switches, and troubleshooting for engine, electrical, hydraulic, hoist, steering, steering pump, steering control valve, front axle, rear axle, hoist pump driveline, rear axle planetary, parking brake, alternator, wheel motor, and blower motor.
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