Manual No.

EM 8R4-1-1

Operator’s Manual
EH750-3
EH1100-3
Rigid Dump Truck

Serial No.
EH750-3 411TD: 77598 and Up
EH1100-3 441LD: 77589 and Up
 Hitachi Construction Machinery Co. Ltd.
Head Office: 5-1, Koraku 2-chome, Bunkyo-ku
Tokyo 112-0004 Japan

Hitachi Construction Truck Manufacturing Ltd.

200 Woodlawn St. West
Guelph, Ontario, Canada
N1H 1B6
 INTRODUCTION
Read this manual carefully to learn how to operate
and service your rigid dump truck correctly. Failure to
do so could result in personal injury and/or rigid dump
truck damage.
This manual should be considered a permanent
part of your rigid dump truck and should remain with
the rigid dump truck when you sell it.
This rigid dump truck is of metric design. Meas-
urements in this manual are metric. Use only metric
hardware and tools as specified.
Write product identification numbers in the Ma-
chine Numbers section. Accurately record all the
numbers to help in tracing the rigid dump truck should
it be stolen. Your dealer also needs these numbers
when you order parts. If this manual is kept in the rigid
dump truck, also file the identification numbers in a
secure place off the rigid dump truck.
Warranty is provided as a part-Hitachi’s support pro-
gram 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.
This warranty provides you the assurance that Hitachi
will back its products when defects occur within the
warranty period. In some circumstances, Hitachi also
provides field improvements, often without charge to
the customer, even if the product is out of warranty.
Should the equipment be abused or modified to
change its performance beyond the original fac-
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.
04/06
tory specifications, the warranty will become void
and field improvements may be denied. Setting fuel
delivery above specifications or otherwise overpow-
ering rigid dump trucks will result in such action.
Moreover, when replacement parts are required, be
sure to use genuine Hitachi parts. Failure to do so
may result in voiding the warranty and/or denial of
field improvements.
Only qualified, experienced operators officially li-
censed (according to local law) should be allowed
to operate the rigid dump truck.
Moreover, only officially licensed personnel
should be allowed to inspect/service the rigid
dump truck.
The Yellow Pages in this operator’s manual con-
tain IMPORTANT SAFETY INFORMATION.
Read these pages thoroughly and familiarize
yourself with the safety standards and
recommendations set forth in these yellow pages
of the manual.
Follow all safety instructions prior to and while
operating the rigid frame rear dumper.
Prior to operating this rigid dump truck, it may be
necessary to make modifications to it so that it com-
plies with the local standards (including safety stan-
dards) and requirements of your country. Please do
not operate this rigid dump truck until such compli-
ance has been confirmed. Please contact-Hitachi
Construction Truck Manufacturing Ltd. or any of our
authorized Hitachi dealers concerning compliance.
EL20110NS750
Manual No. EM 8R4-1-1
 MACHINE NUMBERS

SAFETY

INDEX SAFETY SIGNS

COMPONENTS NAME
OPERATOR’S STATION

BREAK-IN

OPERATING THE ENGINE

OPERATING METHODS
OPERATING THE RIGID DUMP

TRUCK
TRANSPORTING THE RIGID

DUMP TRUCK
MAINTENANCE

STORAGE

TROUBLESHOOTING

SPECIFICATIONS

INDEX
 MACHINE NUMBERS

The numbers asked for in this section are the

individual numbers; model, product identification,
serial, type and manufacturer given to each machine
and major components. These numbers are
requested when inquiring about replacement parts or
machine service. Fill in the blank spaces in this
section to immediately have them available upon
request.

MACHINE TYPE, SERIAL NUMBER, AND

ROLLOVER PROTECTIVE STRUCTURE
NAMEPLATE

MODEL:

PRODUCT
IDENTIFICATION
NUMBER:

ROPS
MODEL
NUMBER:

MAX
MACHINE
MASS, M-kg:

OM21000
 MACHINE NUMBERS

FRAME PRODUCT IDENTIFICATIION

NUMBER

OM21001

ENGINE TYPE AND SERIAL NUMBER

TYPE:
MFG. NO.: OM21002

OM21003EH1100-3
OM21004EH750-3

TRANSMISSION TYPE AND SERIAL

NUMBER
TYPE:
MFG. NO.:

OM21005
OM21006
 CONTENTS
MACHINE NUMBERS
SAFETY
Recognize Safety Information............................. S-1
Understand Signal Words ................................... S-1
Operator’s Qualifications..................................... S-2
Duties of the Operator ....................................... S-2
Inspect Rigid Dump Truck................................... S-2
Follow Safety Instructions ................................... S-3
Prepare for Emergencies .................................... S-3
Wear Protective Clothing .................................... S-4
Protect Against Noise ......................................... S-4
Protect Against Flying Debris.............................. S-4
General Precautions for Cab .............................. S-5
Use Handholds and Steps .................................. S-6
Adjust the Operator’s Seat.................................. S-6
Fasten Your Seat Belt ......................................... S-7
Operate Only from Operator’s Seat .................... S-8
Jump Starting ...................................................... S-8
Keep Riders Off Rigid Dump Truck .................... S-8
Protect Against Falling Stones and Debris ......... S-9
Provide Signals for Jobs Involving Multiple
Numbers of Vehicles..................................... S-9
Operate The Rigid Dump Truck Safely............. S-10
Avoid Injury From Running Over, Front
and Back, And Front Wheel Crush Area .... S-11
Avoid Tipping .................................................... S-12
Avoid Injury From Rollaway Accidents ............. S-13
Never Travel With the Body Off The Frame ..... S-14
Operating With the Rigid Dump Truck Near
Overhead Wires or Cables ......................... S-15
Operating With the Rigid Dump Truck Near
High Voltage, Overhead Power Lines ........ S-15
Park Rigid Dump Truck Safely.......................... S-16
Safe Handling of Off Road Tires ....................... S-17
Discharge Accumulators ................................... S-17
Handle Fluids Safely-Avoid Fires...................... S-18
A Few Simple Rules When Servicing ............... S-19
Use Tools Properly ...........................................S-21
Prevent Burns ................................................... S-22
Replace Rubber Hoses Periodically ................. S-22
Avoid High-Pressure Fluids .............................. S-23
Fire Prevention Measures................................. S-24
Evacuating in Case of Fire................................ S-26
Beware of Exhaust Fumes................................ S-26
Precautions for Welding, Cutting, and Grinding.. S-27
Remove Paint before Welding or Cutting ......... S-27
Avoid Heating Near Pressurized Fluid Lines .... S-28
Avoid Applying Heat to Lines
Containing Flammable Fluids ..................... S-28
Prevent Battery Explosions............................... S-29
Service Air Conditioning System Safely ........... S-29
Handle Chemical Products Safely .................... S-30
Dispose of Waste Properly................................S-30
SAFETY SIGNS ...................................S-32
COMPONENTS NAME ..........................1-1
OPERATOR’S STATION
Cab Features....................................................... 2-1
Monitor Panel ................................................ 2-2
Brake/Steer Hydraulic Oil
Pressure Gauge ................................ 2-3
Fuel Gauge.................................................... 2-3
Coolant Temperature Gauge .................. 2-3
Converter Oil Temperature Gauge ......... 2-4
Brake Cooling Oil Temperature Gauge .. 2-4
Hour Meter .............................................. 2-4
Speedmeter............................................. 2-4
Odometer ................................................ 2-5
Tachometer ............................................. 2-5
Engine Light ............................................ 2-5
Haultrinic IIITM Load
Monitoring System ....................... 2-5
Laod Counter .......................................... 2-5
Monitoring Alarm System ........................ 2-6
Engine Stop Indicator.............................. 2-7
Caution Indicator ..................................... 2-7
Engine Oil Pressure Indicator ................. 2-8
Engine Coolant Level Indicator ............... 2-8
Engine Malfunction Indicator................... 2-8
Battery Charging System Indicator ......... 2-8
Transmission Malfunction Indicator ........ 2-8
Transmission Oil Pressure Indicator....... 2-8
Filter, Air, Steer,
Hoist, Transmission Indicator....... 2-8
Steering Hydraulic Oil
Temperature Indicator ........................ 2-8
Steering Hydraulic Oil
Pressure Indicator ............................. 2-9
Brake Hydraulic Oil Pressure Indicator... 2-9
Parking Brake Indicator........................... 2-9
Active Traction Control Indicator............. 2-9
Electronic Downhill Speed
Contol (EDSC)Indicator .......... 2-9
ATC/EDSC Error Indicator ...................... 2-9
Turn Hazard Indicator ............................. 2-9
High Beam Indicator................................ 2-9
Body Up Indicator .................................... 2-9
Instrument Panel ......................................... 2-10
WindShield Wiper and
Washer Switch........................ 2-11
Headlight Switch ................................... 2-12
Instrument Lighting Rheostat ................ 2-12
Key Switch ............................................ 2-13
Front Brake Cut-Off Switch ................... 2-13
 CONTENTS
Parking Brake Switch............................ 2-13
Heater/Air Conditioner .......................... 2-14
ECC Controls........................................ 2-15
ECC User Display................................. 2-15
Modes of Operation .............................. 2-17
Steering Wheel ..................................... 2-18
Hazard Warning Switch ........................ 2-18
Tilt/Telescope Steering Wheel.............. 2-18
Turn Signal/High Beam Lever Switch... 2-19
Horn Switch .......................................... 2-19
Pedal Location ............................................ 2-20
Pedal Location and Function Decal...... 2-20
Retarder Pedal...................................... 2-21
Brake Pedal .......................................... 2-21
Accelerator Pedal ................................. 2-22
Hoist Lever............................................ 2-22
Transmission Shift Selector.................. 2-23
Load/Dump Brake Switch ..................... 2-23
DC 24-Volt Power Port ......................... 2-23
Operator’s Seat Adjustment........................ 2-24
Standard Seat....................................... 2-24
Air-Ride Seat ........................................ 2-25
Semi-Active Seat ................................ 2-26
Seat Belt...................................................... 2-27
Pasenger Seat ............................................ 2-27
Dome Light.................................................. 2-28
Body Down Indicator................................... 2-28
Diagnostic Connectors................................ 2-28
Mirrors ......................................................... 2-29
Manual Release Valve ................................ 2-29
Battery Disconnect Switch .......................... 2-30
BREAK-IN
Observe Rigid Dump Truck Closely.................... 3-1
Engine ........................................................... 3-1
Daily or Every 10 Hours ................................ 3-1
After the First 50 Hours................................. 3-1
OPERATING THE ENGINE
Inspect Rigid Dump Truck
Daily before Starting.................................... 4-1
Daily Walk Around Inspection ........................... 4-2
Daily Walk Around Inspection Check Sheet ....... 4-3
Leaks, Oil and Water Leaks
Clean and Check All Lines and Hoses ... 4-4
Check Instruments before Starting ..................... 4-5
Starting the Engine.............................................. 4-6
Starting in Warm Weather ............................ 4-6
Starting in Cold Weather............................... 4-7
Measures During Cold Weather ................... 4-8
Check Instruments after Starting ........................ 4-9
Using Booster Batteries .................................... 4-10
Stopping the Engine.......................................... 4-12
OPERATING METHODS
General Information............................................. 5-1
Cooling a Hot Engine .................................... 5-2
Transmission ................................................. 5-2
Automatic Shifting ......................................... 5-3
Mode Buttons ................................................ 5-4
Status Lights.................................................. 5-5
Lock-In-Range for EH750-3&EH1100-3 ....... 5-6
Reset Procedure ........................................... 5-7
Downshift or Reverse Inhibitor Feature ........ 5-7
Using The Retarder ....................................... 5-8
Retarder Operation Decal ........................... 5-10
Performance Chart ............................................ 5-11
Retarder Charts ................................................. 5-12
Transmission Cold Weather Restrictions .......... 5-16
Accelerator Pedal .............................................. 5-16
Steering ............................................................. 5-17
Service Brakes .................................................. 5-17
Front Brake Cut-Off Switch ............................... 5-18
Electronic Downhill Speed Control (EDSC) .... 5-19
Electronic Downhill Speed Control Switch ...... 5-20
Active Traction Control ...................................... 5-21
Engine Overspeed Protection ........................... 5-22
Parking Brake .................................................... 5-22
Load/Dump Brake ............................................. 5-22
Operating the Body with the Hoist Lever........... 5-23
Rigid Dump Truck Stuck in Deep Sand,
Snow or Mud.................................................... 5-26
Rocking Out................................................. 5-26
Towing .............................................................. 5-27
With Engine Operable ................................. 5-28
With Engine Inoperable............................... 5-29
Parking The Rigid Dump Truck ......................... 5-31
OPERATING THE RIGID DUMP TRUCK
Loading................................................................ 6-1
Hauling ................................................................ 6-5
Dumping .............................................................. 6-6
Dumping Precautions .......................................... 6-7
Stopping .............................................................. 6-8
Overnight Storage Instructions............................ 6-8
TRANSPORTING THE RIGID DUMP TRUCK
Transporting - General ........................................ 7-1
Transporting EH750-3 ......................................... 7-2
Transporting EH1100-3 ....................................... 7-3
Traveling on Roadways....................................... 7-5
MAINTENANCE
Correct Maintenance and Inspection Procedures.. 8-1
Service Your Rigid Dump Truck
at Specified Intervals ................................... 8-2
Check the Hour Meter Regularly......................... 8-2
 CONTENTS
Use Correct Fuels and Lubricants ...................... 8-2
Prepare Rigid Dump Truck for Service ............... 8-3
Installing Body Prop Pins for EH750-3 ......... 8-4
Removal and Storage of Body Prop Pins ..... 8-6
Installing Body Prop Cable for EH1100-3..... 8-7
Electrical Disconnects Before
Welding on the Rigid Dump Truck.......... 8-8
Recommended Lubricants ................................ 8-11
Recommended Fuel.................................... 8-12
Maintenance Interval Guide .............................. 8-13
A. Greasing ............................................... 8-15/8-21
B. Engine........................................................... 8-15
Engine Oil Level.......................................... 8-24
Change Engine Oil...................................... 8-25
Replace Engine Oil Filter ............................ 8-25
Check and Clean Crankcase Breather Tube 8-27
Adjust, Valves / Injectors............................. 8-27
C. Transmission ................................................ 8-28
Check Transmission Oil Level .................... 8-29
Change Transmission Oil ........................... 8-30
Replace Transmission Filter ....................... 8-30
Clean Transmission Sump Strainer ............ 8-32
Clean Cooling Line Strainer........................ 8-32
CheckTransmission Breather ..................... 8-33
Replace Transmission Breather ................. 8-33
Check Differential Oil Level ........................ 8-34
Change Differential Oil................................ 8-34
Check Rear Planetary Hub Oil Level .......... 8-35
Change Rear Planetary Hub Oil ................. 8-35
Check Axle Breather Element..................... 8-36
Replace Axle Breather Element.................. 8-36
D. Hydraulic Steering/Brake Apply System ...... 8-37
Check Hydraulic Fluid Level ....................... 8-38
Change Hydraulic Fluid .............................. 8-39
Replace Hydraulic Filter.............................. 8-41
Check Steering Accumulator ...................... 8-42
Check Brake Accumulator Capacity ........... 8-43
Check Barke Pressure Release Procedure 8-44
Check Hydraulic Hoses and Lines.............. 8-44
E. Hydraulic Hoist/Brake Cooling System......... 8-45
Check Hydraulic Fluid Level ....................... 8-46
Change Hydraulic Fluid .............................. 8-47
Replace, Hoist Filter.................................... 8-49
Check Hydraulic Tank Breather Element ... 8-50
Change Hydraulic Tank Breather Element . 8-50
Check Hydraulic Hoses and Lines.............. 8-50
F. Brakes, Service & Parking / Steering ........... 8-51
Check Brake Operation .............................. 8-52
Check Parking Brake...............................................8-53
Check Steering Operation .......................... 8-53
G. Fuel System ................................................. 8-54
Drain Fuel Tank Sediment .......................... 8-55
Drain Fuel-Water Separator ........................ 8-56
Replace Fuel Filter ...................................... 8-57
Check Fuel Tank Mounting.....................................8-59
Check Hoses and Lines .............................. 8-59
H. Air Cleaner .................................................... 8-60
Check Vacuator Valve................................. 8-61
Check/Clean Dust Cup................................ 8-61
Service Air Cleaner, Primary Element......... 8-62
Service Air Cleaner, Safety Element........... 8-64
Check Air Intake Lines and Clamps............ 8-65
I. Cooling System .............................................. 8-66
Check Coolant Level ................................... 8-67
Check SCA.................................................. 8-68
Coolant Change and Flush System ............ 8-71
Replace Coolant Filter .................................... 8-72
Check Cooling Fan...................................... 8-73
Clean Radiator ............................................ 8-73
Check Fan Belt............................................ 8-74
J. Electrical System ........................................... 8-75
Check Battery Condition ............................. 8-76
Check Battery Cables and Connections ..... 8-77
Check Electrical Wiring and Connections... 8-77
Check Fuse/Relay....................................... 8-78
Check Neutral Start Circuit ......................... 8-81
Check Exterior Lights .................................. 8-81
Check Back-up Alarm ................................. 8-82
Check Horn .................................................8-82
Check Gauges ............................................ 8-82
Check Indicator Lights ................................ 8-82
Headlight Aiming ......................................... 8-83
Check Alternator/Air Conditioning Belt ....... 8-84
K. Suspension, Wheels & Tires......................... 8-85
Check Struts................................................ 8-86
Check Wheels ............................................. 8-87
Check Front Wheel Lubricant ..................... 8-87
Change Front Wheel Lubricant ................... 8-87
Check Tire Inflation ..................................... 8-88
Check Tire Condition .................................. 8-89
Check Wheel Alignment.............................. 8-89
L. Cab ................................................................ 8-90
Clean/Change Air Filter............................... 8-91
Clean/Change Air Conditioner Filters ......... 8-92
Check Mounts ............................................. 8-93
Check Wiper Blade Condition ..................... 8-93
Check Windshield Washer Fluid Level ....... 8-93
Check Seat Belt and Mounting ................... 8-94
Check Air Conditioning ............................... 8-95
Check Heater and Defroster ....................... 8-95
M. General......................................................... 8-96
Check for Fluid Leaks ................................. 8-97
Check Body Prop Pins or Cable ................. 8-97
Check Main Rail, Strut
and Axle Lug Welds............................... 8-98
 CONTENTS

Check Frame Assembly ............................. 8-98

Check Tightening Torque
of Bolts and Nuts ................................... 8-98
Torque Values................................................. 8-103

STORAGE
Storage of Hitachi Rigid Dump Truck ................. 9-1
Short Term Storage ....................................... 9-1
Moderate Term Storage ................................ 9-3
Long Term Storage........................................ 9-5
Return to Service........................................... 9-7

TROUBLESHOOTING
Engine ............................................................... 10-1
Engine Coolant.................................................. 10-4
Drive Coupling................................................... 10-4
Starter And Mounting ........................................ 10-5
Air Cleaner ........................................................ 10-5
Transmission..................................................... 10-7
Electrical System............................................. 10-12
Hydraulic Sysem ............................................. 10-16
Hydraulic Hoist System................................... 10-18
Hydraulic Steering System.............................. 10-19
Steering Pump ................................................ 10-20
Steering Control Valve .................................... 10-21
Front Axle........................................................ 10-23
Rear Axle ........................................................ 10-24
Front Driveshaft............................................... 10-25
Reat Driveshaft ............................................... 10-25
Differential ....................................................... 10-26
Rear Axle Planetary ........................................ 10-27
Dry Disc Parking Brake................................... 10-28

SPECIFICATIONS
Service Specifications ........................................11-1
Rigid Dump Truck Weights........................ 11-1
Capacities .................................................. 11-1
Engine........................................................ 11-2
Electrical System ....................................... 11-2
Power Transmission .................................. 11-3
Travel Speeds ........................................... 11-3
Planetary ................................................... 11-3
Differential ................................................. 11-3
Brake System.................................................... 11-4
Steering System................................................ 11-5
Wheels .............................................................. 11-6
Cab .............................................................. 11-7
Hoist System ..................................................... 11-8
Rigid Dump Truck Dimensions ......................... 11-9

INDEX ............................................................. 12-1

 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 warning decals are in place on
the rigid dump truck and that they are readable.
Accidents may otherwise occur.
• Follow recommended precautions and safe operating
practices.
• Every country (Jurisdiction) 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 a potential hazardous
situation which, if not avoided, could result in death
or serious injury.
• CAUTION indicates a potentially hazardous
situation which, if not avoided, may result in minor
or moderate injury.
• DANGER or WARNING safety signs are located
near specific hazards. General precautions are
listed on CAUTION safety signs.
• These signal words also call attention to safety
messages in this manual.
To avoid confusing rigid dump truck protection with
personal safety messages, a signal word IMPORTANT
indicates a situation which, if not avoided, could result
in damage to the rigid dump truck.

NOTE: indicates an additional explanation for an

element of information.

S-1
 SAFETY

OPERATOR’S QUALIFICATIONS

• Only trained personnel should operate the rigid dump

truck.

• Operator should be of legal operating age according

to country (Jurisdiction) regulations and familiar with
the operation and maintenance of the rigid dump
truck.

• Operator must be licensed if required by National

Rules and Regulations.

DUTIES OF THE OPERATOR

• Before operating the rigid dump truck, this manual

must be read and understood. Contact your
supervisor if you do not understand any portion of
this manual. By reading and understanding the
manual, you will become aware of and observe
how to avoid injury and damage.
• Know the work area and the company rules and
regulations

• Never operate any vehicle while under the

influence of alcohol, medicine or other drugs.

Due to the position of the cab and size of the rigid

dump truck, the operator has limited visibility to areas
close to or near the rigid dump truck. No person
should enter the operating area of the rigid dump
truck when it is in operation without first notifying the
operator. If a person has to enter the operating area
of the rigid dump truck, they should signal the
operator and wait for an acknowledgement of
recognition by the operator.

During rigid dump truck operation no one should be

allowed to get any closer than 7m (23 ft.). Any closer
will limit one’s time to react and move away from the
vehicle when it starts.

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 points described under “INSPECT

RIGID DUMP TRUCK DAILY BEFORE STARTING”
found in the OPERATING THE ENGINE section in
this operator’s manual.
SA-435

S-2
 SAFETY

FOLLOW SAFETY INSTRUCTIONS

• Carefully read and follow all safety signs on the rigid

dump truck and all safety messages in this manual.

• Safety signs should be installed, maintained and

replaced when necessary.

• If a 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).
SA-003

• 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 condition.

• Unauthorized modifications of the rigid dump truck
may impair its function and/or safety and affect its life.
• The safety messages in this SAFETY chapter are
intended to illustrate basic safety procedures of the rigid
dump truck. 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 and/or your authorized Hitachi
dealer before operating or performing maintenance work
on the rigid dump truck.

PREPARE FOR EMERGENCIES

• Be prepared if fire starts or if an accident occurs.

• It is recommended that a first aid kit and fire

extinguisher be kept on hand.
• Thoroughly read and understand the label attached
on the fire extinguisher to use it properly.
• To ensure that a fire extinguisher can be always
used when necessary, check and service the fire SA-437

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.

S-3
 SAFETY

WEAR PROTECTIVE CLOTHING

• Wear close fitting clothing and safety equipment

appropriate to the job.

You may need:

A hard hat
Safety shoes
Safety glasses, goggles, or face shield
Heavy gloves
Hearing protection
Reflective clothing
Wet weather gear SA-438

Respirator or filter mask.

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 attention
of the operator. Do not wear radio or music
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

earmuffs or earplugs to protect against
objectionable or uncomfortably loud noises. This
may be necessary when working outside of the
cab, during the Daily Walk Around Inspection, for
example.

SA-434

PROTECT AGAINST FLYING DEBRIS

• If flying 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.

SA-432

S-4
 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
and/or oil on the soles of the operator’s work boots
the operator’s foot may slip off the pedal, possibly
resulting in a personal accident.
• Don’t leave parts and/or tools lying around the
operator’s seat. Store them in their specified
locations.
• Avoid storing transparent bottles in the cab. Don’t
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 objects and/or explosives away
from the rigid dump truck.
• After using the ashtray, always cover it to
extinguish the match and/or tobacco.
• Don’t 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.

S-5
 SAFETY

USE HANDHOLDS AND STEPS

• Falling is one of the major causes of personal injury.

• When entering or leaving the rigid dump truck,

always use the steps and the handrails.
• Do not use any controls as handholds.
• When you get on and off the rigid dump truck,
always face it and maintain a three-point grip with
the steps and handrails. (i.e., two hands and one
foot or one hand and two feet.)
• DO NOT JUMP on or off the rigid dump truck.
SA-439

Never mount or dismount a moving rigid dump

truck.
• Do not step or climb on surfaces, which are not
intended for walking. Step only on the areas
provided with 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 dirt,
snow, and ice.
• All steps, ladders, stairways, platforms, walkways,
and non-skid deck strips must be replaced if EL20273
damaged.
• The use of a rope is recommended to bring up to
the deck or cab lunch box, tools, etc so as to
maintain a three-point grip when entering or
leaving the rigid dump truck.

ADJUST THE OPERATOR’S SEAT

• A poorly adjusted seat for either the operator or for

the work at hand may quickly fatigue the operator.

• The seat should be adjusted whenever changing

rigid dump truck operator.
• 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, and
SA-378
check again.

S-6
 SAFETY

FASTEN YOUR SEAT BELT

• If the rigid dump truck should overturn, the operator

may become injured and/or thrown from the cab.
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 to remain seated with the seat belt
securely fastened at all times when the rigid dump
truck is in operation to minimize the chance of SA-237

injury from an accident.

• We recommend that the seat belt be replaced
every three years regardless of its apparent
condition.

S-7
 SAFETY

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
activated.

EL20368

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 Starting with
Auxiliary Batteries in the OPERATING
INSTRUCTIONS 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 a two-person
operation. SA-032

• Never use a frozen battery.

• Failure to follow correct jump starting procedures
could result in a battery explosion or a runaway
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 EL20369
in an unsafe manner.

S-8
 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.

EL20380-1

PROVIDE SIGNALS FOR JOBS INVOLVING

MULTIPLE NUMBERS OF VEHICLES

• For jobs involving multiple 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 directions.

SA-481

S-9
 SAFETY

OPERATE THE RIGID DUMP TRUCK

SAFELY
• When pulling out of the loading area, avoid hitting
debris, rocks and loading rigid dump 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 cliffs, slide areas, other machines and
vehicles, etc.

• While traveling on the haul road, maintain a sufficient

distance behind the vehicle ahead (depending on
roads, speeds, and haul road conditions). This
practice should always be followed to allow sufficient EL14019

safe maneuvering and stopping room.

• During all operations, the rigid dump truck may

vibrate or shake to some extent. Therefore, operate
the rigid dump truck in such a way that your body is
exposed to as little vibration as possible.

• Have the operator’s seat properly adjusted and

wear the seat belt.
• Pick the smoothest path for the rigid dump truck.
• Adjust the speed of the rigid dump truck to the
terrain, and driving conditions.

S-10
 SAFETY

AVOID INJURY FROM RUNNING OVER,

FRONT AND BACK, AND FROM 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 death. If any person is present in the area
between the engine and the front wheel, the person
could be crushed when the front wheels are turned.

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.
EL20370
ALWAYS BE ALERT FOR BYSTANDERS MOVING
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 signalman
and operator.
• Learn the meanings of all flags, signs, and
markings used on the job and confirm who has the EL20371

responsibility for signaling.

• Keep windows, mirrors, and lights clean and in
good condition.
• Dust, heavy rain, fog, etc., can reduce visibility. As
visibility decreases, reduce speed and use proper
lighting.
• Read and understand all operating instructions in
the operator’s manual.

EL20372

S-11
 SAFETY

AVOID TIPPING

• Keep the rigid dump truck at safe distance from the

edge of cliffs and slide areas. There is the danger of
tipping or roll over.

• Avoid operating on the side of slopes.

• Use the seat belt 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 protection
structures (ROPS) according to the adopted standard
for this rigid dump truck.

THE OPERATOR AND PASSENGER SHOULD NOT

ATTEMPT TO JUMP CLEAR OF A TIPPING RIGID
DUMP TRUCK --- SERIOUS OR FATAL CRUSHING EL20373
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, 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.

S-12
 SAFETY

AVOID INJURY FROM ROLLAWAY ACCI-

DENTS

• 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.
• Do not park the rigid dump truck on a grade.
• Reference: PARK RIGID DUMP TRUCK SAFELY in
this section.
• Chock the wheels if you must park on a grade.
• Position the rigid dump truck to prevent rolling.
• Park a reasonable distance from other vehicles.

EL20374

S-13
 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.
• If the raised body hits against 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 EL20375

against a stop rail or by jerking the body control

lever.

EL20376

S-14
 SAFETY

OPERATING 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
overhead 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 and/or 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 electricity EL20377
should be turned off when practical.

OPERATING 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 not kept a safe distance from electric lines.

• When operating near an electric line, NEVER move

any part of the rigid dump truck or load closer than
3 m (10 ft.) plus twice the line insulator length.
• Never operate the rigid dump truck with the dump
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 life is in danger. Call for help by signaling in
some way, sounding the horn or mobile telephone,
so that the power can be turned 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
site.
• 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 shall be equipped for such
operations.

S-15
 SAFETY

PARK RIGID DUMP TRUCK SAFELY

• Park rigid dump truck on a level surface.

• Lower the body to the frame.
• Move the shift controller lever 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.
• Let the engine run at idle for three to five minutes
for cool down.
• Make sure the body hoist control lever is in the
Float position.
• Check that all switches and controls are in the OFF
position.
• Turn the Key Switch to the OFF position.
EL20378

• Turn the Battery Disconnect Switch to the OFF

position.
• Fill the fuel tank to minimize water condensation in
the tank.

NOTE: Running out of fuel with the engine running,

especially under load, is very detrimental to
engine life and requires a time consuming
restart procedure.

• 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.

S-16
 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-attaching air chuck with a hose long

enough to be out of the trajectory path when filling
a 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 if alcohol has been used as antifreeze.
• Inspect all rims, wheels and components.

• Replace any worn or damaged rims, wheels and

components.
• Do not remove any wheel nuts; rim clamps or dagger
clamps until the tire is deflated.

• No personnel should be touching the rim, rim

clamp, or tire when dislodging the rim clamps or
dagger clamps on larger dumps.
• 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 EL20379

recommended that a certified tire repair service be

hired to perform the dismounting and mounting of
tires from rims.

DISCHARGE ACCUMULATORS

• Before removing and disassembling brake or

steering accumulators, they must be discharged to
prevent serious injury. Refer to the appropriate
Maintenance Manual section for BRAKE
ACCUMULATOR and STEERING
ACCUMULATOR.

S-17
 SAFETY

HANDLE FLUIDS SAFELY; AVOID FIRES

• Handle fuel with care; it is highly flammable. If fuel

ignites, an explosion and/or a fire may occur,
possibly resulting in serious injury or death.

• Do not refuel the rigid dump 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.
SA-018

• All fuels, 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.
• Securely tighten the fuel and oil filler caps. SA-019

S-18
 SAFETY

A FEW SIMPLE RULES WHEN

SERVICING

Before working on the rigid dump truck, park it on a

level surface and put it in the SERVICE POSITION:

1. 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. If the body is raised, use body prop pins, or
body prop cable.
4. The wheels blocked.
5. Body control lever in “FLOAT” position.
6. Parking brake applied.
7. Allow the rigid dump truck to cool down.
8. Pressure released from all lines, tanks, and
accumulators.
EL20300R
• If work must be done on a warm rigid dump
truck, beware of hot fluids and 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 skills, information, correct tools,
and 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.

• Failure to perform the Basic Preventive

Maintenance as outlined may void rigid dump
truck warranty.
• Deflate tires before loosening any rim clamp
bolts.
• Always stop the engine before removing
inspection covers. Do not let tools 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.

S-19
 SAFETY

A FEW SIMPLE RULES WHEN

SERVICING
(continued)

• 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 pins or body prop cable

are engaged when working beneath a raised
dump body.

• Inspect recommended parts periodically and repair

or replace as necessary. Refer to the maintenance
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.

• Take care to ensure that hands, feet, clothing,

jewelry and hair do not become entangled when
working around rotating parts.

• Do not wear loose fitting clothing or jewelry when SA-026

working on a rigid dump truck.

• When cleaning parts, always use nonflammable

detergent oil. Never use highly flammable oil such
as fuel oil and gasoline to clean parts or surfaces.

• Sufficiently illuminate the work site. Use a

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 SA-037

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 scrapping
them.

S-20
 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 broken or defective equipment or tool(s).
• 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 for example.
• Make sure that no tool(s) or other object(s) are
left inside the rigid dump truck where they may
cause damage.
SA-034

• When lifting or supporting components, use

equipment with a weight capacity as great or
greater then the weight of the component.

EL20380

S-21
 SAFETY

PREVENT BURNS

Hot spraying fluids:

• After operation, engine coolant is hot and 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 burns.

• To avoid possible injury from hot spraying water.

DO NOT remove the pressure cap from the
surge tank for the cooling system until the SA-039

engine is cool. When removing, depress the red

button on top of the pressure cap to relieve
system pressure. Then turn and remove the cap.

Hot fluids and surfaces:

• Engine oil, gear oil and hydraulic oil also become

hot during operation.
The engine, hoses, lines and other parts become
hot as well.

• Wait for the oil and components to cool before

starting any maintenance or inspection work.

SA-225

REPLACE RUBBER HOSES PERIODICALLY

• Rubber hoses that contain flammable fluids under

pressure may break due to aging, fatigue, and abrasion.
It is very difficult to gauge the extent of deterioration due
to aging, fatigue, and abrasion of rubber hoses by
inspection alone.

• Periodically replace the rubber hoses.

• Failure to periodically replace rubber hoses may cause a

fire, fluid injection into skin, or the dump body to fall, SA-019

which may result in severe burns, infection, or other

serious injury.

S-22
 SAFETY

AVOID HIGH-PRESSURE FLUIDS

• Fluids such as diesel fuel or hydraulic oil 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. SA-031

• Never adjust a 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 a 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 SA-292

skin must be surgically removed within a few hours or

gangrene may result.

SA-044

S-23
 SAFETY

FIRE PREVENTION MEASURES

• Fire prevention features provided by the manufacturer

should be maintained in operational condition and
should be used to supplement operator’s fire prevention
efforts. In no case should the features be used or
assumed as replacement for diligent operator efforts at
preventing fires.

• Keep the work place clean. Oil and water on the floor
makes it slippery and particularly dangerous in
connection with electrical equipment or electrically
powered tools. Oily clothes are a serious fire hazard.
SA-019

• Keep the rigid dump truck and all equipment free of dirt
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.

• Rigid dump trucks should be clean of debris particularly

around the engine, exhaust, and drive shaft
components. Keep the rigid dump truck extra clean
when working in a sensitive environment.

NOTE: If a high-pressure jet is used for cleaning, take

great care as the insulation of electrical wires
can become damaged even at moderately high
pressure and temperature. Protect electrical
wires in a suitable way.

• Gasoline is highly flammable and should never be used

as a cleaning fluid. Use an approved solvent for
cleaning.
SA-028

• Some solvents can cause skin rashes and or fire

dangers. Do not inhale solvent vapors.

• Store flammable starting aids in a cool, well-ventilated

location.

• Smoking, open flames, etc. should not be permitted

around any rigid dump truck during fueling operations
and/or 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.

• 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.

S-24
 SAFETY

FIRE PREVENTION MEASURES

(continued)

Check for Oil Leaks:

• Fuel, hydraulic oil 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 oil-cooler
flange bolts.
• Tighten, repair or replace any missing, loose or
damaged clamps, lines, hoses, oil-cooler and oil-
cooler flange bolts.
• Do not bend or strike high-pressure lines.
• Never install bent or damaged lines, pipes or hoses.

Check for 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.
• DO NOT OPERATE RIGID DUMP TRUCK if cable or
wires are loose, kinked, etc.

Clean up Flammables:

• Spilled fuel, oil, antifreeze fluid and window washer fluid,

and trash, grease, debris, accumulated coal dust, and
other flammables may cause fires.

• Prevent fires by inspecting and cleaning the rigid

dump truck daily, and by removing spilled or
accumulated flammables immediately.

S-25
 SAFETY

EVACUATING IN CASE OF FIRE

• If a fire breaks out, evacuate the rigid dump truck in the

following way:
• Lower the hauler body all the way down.
• Set parking brake.
• Stop the engine by turning the key switch to the OFF
position.
• Exit and get away from the rigid dump truck. If
possible take a hand-held portable extinguisher along.
• Call for help SA-393

• Stand by with a hand-held 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.
• If you must operate in a building, be sure there is
SA-016
adequate ventilation. Either use an exhaust pipe
extension to remove the exhaust fumes or open doors
and windows to bring enough outside air into the
area.

• Diesel engine exhaust and some of its constituents

are known to cause cancer, birth defects and other
reproductive harm.

S-26
 SAFETY

PRECAUTIONS FOR WELDING, CUTTING,

AND GRINDING
• When performing any welding operation on a 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
grinding.

NOTE: A high speed-grinding rigid dump truck

will heat the paint and must only be used in a well-
ventilated area.
• Be sure to perform welding in a well ventilated and
SA-818

prepared area. Store flammable materials in a safe place

before starting welding.

• Protect the working areas with flame retardant blankets.

• Welding should be done by a qualified person.

• After completing the weld repair, check the surrounding

area for possible smoldering spots.

REMOVE PAINT BEFORE WELDING OR

CUTTING
Paint must be removed up to a distance of 10 cm (4 in) from
the welding or cutting point.

• Remove the paint from the area where 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 either outside or in a well- SA-029

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.

S-27
 SAFETY

AVOID HEATING NEAR PRESSURIZED

FLUID LINES

• Flammable spray 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 other
materials before engaging in welding, soldering, etc.
SA-030

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.

S-28
 SAFETY

PREVENT BATTERY EXPLOSIONS

• Battery gas is explosive.

• 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 result.
SA-032

• Loose terminals may produce sparks. Securely tighten

all terminals.

• Battery electrolyte is acidic and poisonous. If the battery

should explode battery electrolyte may be splashed onto
the skin or into eyes, possibly resulting in burns or
blindness.

• Be sure to wear eye protection 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 birth defects or other
reproductive harm. Wash hands after handling.

SERVICE AIR CONDITIONING SYSTEM

SAFELY

NOTE: Only certified technicians should be allowed

to service air conditioning systems.

• If spilled onto skin, refrigerant may cause a cold contact

burn (frostbite).

• Refer to the Freon container for proper use when

servicing the air conditioning system.
• Use a recovery and recycling system to avoid venting SA-405

Freon into the atmosphere.

• Never let the Freon stream make contact with the skin.

S-29
 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 (MSDS) provides specific

details on chemical products: physical and health
hazards, safety procedures, and emergency response
techniques (MSDS may be known by other names in
different jurisdictions).
• Check the MSDS before you start any job using a
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.
• See your authorized Hitachi dealer for MSDS (available SA-309

only in English) on chemical products used 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, brake fluid, filters, 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 refrigerants escaping into the air can SA-226

damage the Earth’s 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.

S-30
 SAFETY SIGNS

OM21007

Safety signs should be installed, maintained and replaced when necessary. If a safety sign is damaged or
missing, order a replacement from your authorized dealer in the same way you order replacement parts.

More detail illustrations of each of the above safety signs and their location on the rigid dump truck appear on the
following pages.

S-31
 SAFETY SIGNS

E12645237

• Sign indicates contents under pressure, an

OM21008

explosion hazard. Refer to the Maintenance

Manual.

E12645239

• Sign indicates a hazard of being hit by the rigid dump

truck. Limited visibility for the operator at the front of
the rigid dump truck. Keep a safe distance away from
the rigid dump truck during operation.
OM21009

OM21010

S-32
 SAFETY SIGNS

• Sign indicates a hazard of personnel being

injured in this area. Keep a safe distance away
from this area during rigid dump truck operation.

E12645238

OM21012

OM21011

S-33
 SAFETY SIGNS

E12613924

• Sign indicates contents under pressure, an explosion

hazard. Refer to the Maintenance Manual.

OM21014
OM21013

OM21015

S-34
 SAFETY SIGNS

OM21016

E12645236

• Sign indicates a hazard from falling body in this

area. After raising the dump body, lock it in
place with the body prop pins.

OM21017

OM21018

E12645242

• Sign indicates the area where the body is locked in

the raised position. Sign indicates a hazard if not
done properly. Refer to the Operator’s Manual.

OM21019

S-35
 SAFETY SIGNS

away from the rigid dump truck during

operation.

EL2645240

• Sign indicates a hazard of being hit by the rigid

dump truck. Limited visibility for the operator at the
rear of the rigid dump truck. Keep a safe distance OM21020

EL2645241

• Sign indicates an electrical hazard when

connecting auxiliary batteries. Read the Operator’s OM21021

Manual for safe and proper handling.

S-36
 SAFETY SIGNS

E12645100 OM21022

• Sign indicates a burn hazard from spurting hot

coolant if the cap of the radiator surge tank is
uncapped while hot. Allow to cool before removing
and then remove slowly.

E12645238 E12644596

• Sign indicates the location of the manual release

valve. Allows the operator to safely lower the body
should the hoist control valve spool get stuck in the
HOLD position. Hazard in this area from falling
OM21023
body. Refer to Maintenance Manual.

S-37
 SAFETY SIGNS

E12645260

• Grade Speed sign as a general guideline for proper

downgrade operation of a loaded rigid dump truck.
Warning, read the manual so as to understand.
• Rigid dump truck weight sign, showing empty
weight and maximum loaded weight. Tire size and
O
type are also indicated.
M21024

E12645213

• Sign indicates a Warning. When the body is

raised off the frame, reverse propulsion is
inhibited.

OM21025

S-38
 COMPONENTS NAME

VIEW OF EH750-3 and EH1100-3

OM21026

1. Headlight 5. Body
2. Turn Signal/Clearance Light 6. Reverse Light
3. Front Axle 7. Back-Up Alarm
4. Rear Axle

Front, Rear, Right and Left sides of the rigid dump truck are determined by sitting in the operator’s seat, facing
the direction of forward travel.

1-1
 COMPONENTS NAME

MEMO
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1-2
 OPERATOR’S STATION

CAB FEATURES

OM21027

1. Monitor Panel 8. Hoist Lever

2. Steering Wheel/Column 9. Shift Selector
3. Instrument Panel 10. Center Console Switches
4. Overhead Instrument Panel 11. Operator’s Seat
5. Retarder Pedal 12. Passenger’s Seat
6. Brake Pedal 13. 24 Volt Power Port
7. Accelerator Pedal 14. Ash Tray

2-1
 OPERATOR’S STATION

MONITOR PANEL

OM21028

1. Brake/Steer Hydraulic Oil Pressure Gauge 7. Speedometer

2. Fuel Gauge 8. Odometer
3. Coolant Temperature Gauge 9. Tachometer
4. Converter Oil Temperature Gauge 10. Indicator, Engine Lights
5. Brake Cooling Oil Temperature Gauge 11. Indicator, Load Monitoring System (Option)
6. Hour Meter 12. Load Counter

2-2
 OPERATOR’S STATION

1. BRAKE/STEER HYDRAULIC OIL PRESSURE

GAUGE

This gauge indicates hydraulic oil pressure in the

brake and steering system. During normal operation
the gauge should register between the two red 1
2
zones (1 & 2). It is normal for the gauge indicator to
sweep between the red zones during operation. If
the gauge reads in the high-pressure red zone (2)
consistently, report this condition to the proper ser-
vice personnel. If the gauge reads in the low-
pressure zone (1), IMMEDIATELY move the rigid
dump truck to a safe parking area and stop the en-
gine. Move the transmission shift selector to N (Neu-
tral), apply the parking brake and shut down the
engine. Report the condition to the proper service OM21029

personnel.

2. FUEL GAUGE
The fuel gauge indicates the level in the fuel tank
when the key switch is in the ON position. The vol-
ume of the fuel tank for EH750-3 is 454 liters (120
U.S. gallons), for EH1100-3 is 700 liters (185 U.S
gallons).

OM21030

3. COOLANT TEMPERATURE GAUGE

Start the engine. Run at slow idle until the needle
moves above C (cold), normal operating tempera-
ture.

IMPORTANT: To prevent possible engine dam-

age. Do not stop the engine when
the needle enters the red zone H
(hot), as temperature will rise fur-
ther. Instead, reduce load and run
engine at slow idle.

If the needle enters the red zone, reduce load im-

mediately and run engine at slow idle. If problem
continues, inspect for plugged radiator or coolant
leakage.
OM21031

2-3
 OPERATOR’S STATION

4. CONVERTER OIL TEMPERATURE GAUGE

The gauge should register in the normal range,
above C (cold). If the pointer rises to the red zone H
(hot), immediately move the rigid dump truck to a
safe stopping area. Stop the engine select N (Neu-
tral) with the transmission shift selector and apply
the parking brake. Remain in N (Neutral) until the
pointer returns to the normal range. If the condition
persists or if he pointer does not return to the normal
range, shut down the engine and report the condi-
tion to the proper service personnel.

OM21032
5. BRAKE COOLING OIL TEMPERATURE
GAUGE
The gauge, which indicates the temperature in the
rear-wet disc brake cooling system, should register
in the normal range, above C (cold). If the pointer
rises to the red zone (H) hot, reduce rigid dump truck
speed by reselecting a lower gear until the pointer
registers in the normal range. If the pointer does not
register in the normal range, IMMEDIATELY apply
the service brakes to reduce rigid dump truck speed.
Proceed to a safe stopping area, stop the rigid dump
truck, select N (Neutral) with the transmission shift
selector and apply the parking brake. Accelerate the
engine until the pointer returns to the normal range. OM21033

If the condition persists shut down the engine and

report the condition to the proper service personnel.

6. HOUR METER
This auxiliary hour meter is engaged when the en-
gine is started and continuously records the time that
the engine is operating.

OM21034

7. SPEEDOMETER
This instrument indicates the rigid dump truck’s
speed in kilometers per hour (km/h) and miles per
hour (mph). The range is 0-80 km/h and 0-50 mph.

OM21035

2-4
 OPERATOR’S STATION

8. ODOMETER

This auxiliary odometer shows the total distance in

kilometers the rigid dump truck has been driven.

OM21036

9. TACHOMETER
This instrument indicates the number of revolutions
per minute min-1(rpm) of the engine crankshaft. The
range is 0-3000 min-1(rpm).

OM21037

10. ENGINE LIGHT

Check engine light (Yellow), indicates that there is a
problem in the engine that needs to be diagnosed as
soon as possible. (Red) indicates that the ECM has
detected a potential engine damaging fault, in this
case both yellow and red lights turn on. Stop the
rigid dump truck shift the transmission shift selector OM21038
to N (Neutral) position and apply the parking brake.
Shut the engine immediately and report the condi-
tion to the proper service personnel.

11. HAULTRONIC lII™

LOAD MONITORING SYSTEM
It includes four patterns to monitor the load:
Yellow: 95-110% of nominal payload. OM21039
Flashing Yellow: 70-95% of nominal payload.
Red: Over 120% of nominal payload.
Flashing Red: 110-120% of nominal payload.

12. LOAD COUNTER

Counts the number of load cycles. To reset the load
counter push and hold the Reset Switch until
“88888888” and then “0” is displayed. OM21040 OM21041

2-5
 OPERATOR’S STATION
MONITORING ALARM SYSTEM
13. Engine Stop Indicator (Warning)
14. Central Warning Indicator
15. Engine Oil Pressure Indicator
16. Engine Coolant Level Indicator
17. Engine Shutdown Indicator
18. Alternator Indicator
19. Transmission Malfunction Indicator
20. Transmission Oil Pressure Indicator
21. Engine Filter Indicator
22. Steering Oil Temperature Indicator
OM21042
23. Steering Oil Pressure Indicator
24. Brake Oil Pressure Indicator
25. Parking Brake Indicator
26. Active Traction Control Indicator (Option)
27. Electronic Downhill Speed Control Indicator (Option)
28. ATC/EDSC Error Indicator (Option)
29. Turn/Hazard Indicator
30. High Beam Indicator
31. Body Up Indicator
2-6
 OPERATOR’S STATION

13. ENGINE STOP INDICATOR

This red light flashes if any critical condition arises
requiring the engine to be shut down. This is fol-
lowed by buzzer and some other indicator lamp. This
lamp will come on when errors occur for any of the
following major faults:
y • Reverse Inhibit Warning
y • Low Engine Oil Pressure
y • High Engine Coolant Temperature
y • Low Engine Coolant Level
y • Engine Over-speed
y • Low Transmission Oil Pressure
OM21043
y • High Transmission Oil Temperature
y • Low Brake Oil Pressure
y • High Steering Temperature
y • High Brake Temperature
y • Low Steer Oil Pressure
y • Low Park Brake Pressure

Move the rigid dump truck to a safe stopping area.

Stop the rigid dump truck, move the transmission
shift selector to the N (Neutral) position and apply
the parking brake. Shut down the engine immedi-
ately and report the condition to the proper service
personnel

14. CAUTION INDICATOR

This yellow light illuminates for less critical warnings
in the system. It informs the operator that a function
needs to be kept under observation. This is followed
by another warning lamp. This lamp will come on
when system errors occur for if any of the following
faults:
y • Clogged Filter
y • High engine coolant temperature
y • Engine Service
y • Parking brake malfunction
y • High transmission temperature
y • Alternator Malfunction OM21044

2-7
 OPERATOR’S STATION

CORRECTIVE ACTION ACTION REQUIRED

A Serious problem has occurred. Pull the rigid dump truck to a safe stopping
area. Stop the rigid dump truck, move the shift selector to the N (Neutral)
position and apply the parking brake. Shut down the engine immediately
and report the condition to the proper service personnel.
B The filter has become clogged. Report the condition to the proper service
personnel.
C Indicator illuminated to advise operator that a particular function has been
activated normally.
D Report the condition to the proper service personnel.

ENGINE
AUDIBLE CORRECTIVE
NUMBER SYMBOL DESCRIPTION INDICATOR STOP
ALARM ACTION
INDICATOR
Low Engine Oil
ON FLASHING ON A
Pressure with
15
Engine Running
FLASHING OFF OFF D
(Red)
Low Engine Cool- ON FLASHING ON A
16 ant Level (Red)
FLASHING OFF OFF D

Engine Malfunc-
17 tion Indicator ON OFF OFF A
(Red)

Problem with ON OFF OFF A

18 Battery Charging
System (Red) FLASHING OFF OFF D

Transmission
Malfunction (Red)
19 Error code will ON OFF OFF A
flash in the shift
selector display.
Low Transmis- ON FLASHING ON A
20 sion Oil Pressure
(Red) FLASHING OFF OFF D
Air Filter 2 FLASHES OFF OFF B
Steer Filter 3 FLASHES OFF OFF B
21 Hoist Filter 4 FLASHES OFF OFF B
Transmission
5 FLASHES OFF OFF B
Filter
Steering ON OFF OFF A
Hydraulic Oil
22
Temperature
(Red) FLASHING OFF OFF D

2-8
 OPERATOR’S STATION

ENGINE
AUDIBLE CORRECTIVE
NUMBER SYMBOL DESCRIPTION INDICATOR STOP
ALARM ACTION
INDICATOR
Steering Oil ON FLASHING ON A
23 Pressure Indica-
tor (Red) FLASHING OFF OFF D

Brake, Hydraulic ON FLASHING ON A

24 Oil Pressure
Indicator (Red) FLASHING OFF OFF D

ON OFF OFF C
Parking Brake
25
Indicator (Red)
FLASHING FLASHING ON D

Active Traction
26 Control (Blue) ON OFF OFF C
(Option)
Electronic Down-
hill Speed Control
27 ON OFF OFF C
Indicator (Blue)
(Option)
ATC/EDSC ON OFF OFF A
28 Error Indicator
(Red) (Option) FLASHING OFF OFF D

29. TURN/HAZARD INDICATOR

The green arrows will illuminate in unison with the
exterior turn signal when using the turn signal lever
or hazard-warning switch. Refer to Steering Wheel
Column in this section.

30. HIGH BEAM INDICATOR OM21045

This blue indicator light will illuminate when the high
beams are selected. Refer to Steering Wheel Col-
umn in this section.

31. BODY UP INDICATOR

This yellow indicator light will illuminate when the OM21046

body is in the UP position.

If Body is up:
• If transmission is in forward position, up
shifts are prevented, but downshifts are
permitted.
• If R1 (Reverse 1) or R2 (Reverse 2) is se-
OM21047
lected, the transmission will shift into (or
remain) in Neutral. Also audible alarm will
sound and the Engine stop indicator will
flash.

2-9
 OPERATOR’S STATION

INSTRUMENT PANEL

OM21048

1. Windshield Wipers and Washer Switch 5. Parking Brake Switch

2. Headlight Switch 6. Front Brake Cut Off Switch
3. Rheostat 7. Heater/Air Conditioner Controls
4. Key Switch 8. Counter Reset Switch

2-10
 OPERATOR’S STATION

1. WINDSHIELD WIPER AND WASHER SWITCH

Turning this switch activates the windshield wiper and

intermittent wiper. This is a four-position switch:
INT (intermittent) only one fixed interval
OFF
LO (low speed)
HI (high speed)
To activate the windshield washer pump, press the
switch in and hold for the desired amount of spray. If
the switch is pressed when it is in the INT position
and released, the wiper will operate for several wiper
cycles then resume in the INT mode.
If the switch is pressed in when in the OFF position
and released the wiper will operate for several wiper
cycles then turn OFF. OM21049

2-11
 OPERATOR’S STATION

2. HEADLIGHT SWITCH
This switch activates the clearance lights and the
display panel lights:
brake/steer hydraulic oil pressure gauge,
fuel gauge,
coolant temperature gauge,
converter oil temperature gauge,
brake cooling oil temperature gauge,
speedometer, odometer, and headlights.
OM21050
This is a three-position switch: 1 2 3
1. OFF
2. CLEARANCE LIGHTS (A)
INSTRUMENT PANEL LIGHTS
3. CLEARANCE LIGHTS (A)
INSTRUMENT PANEL LIGHTS AND
HEADLIGHTS(B)

OM21051

OM21052

3. INSTRUMENT LIGHTING RHEOSTAT

Regulates the intensity of the instrument panel light-
ing (gauges and the control console). Turn the rheo- Darker Brighter
stat clockwise to increase light intensity, (brighter);
counterclockwise to decrease light intensity,
(darker).
OM21053

2-12
 OPERATOR’S STATION

4. KEY SWITCH
To start the engine the transmission control lever
must be in the N neutral position and park brake
switch should be in ON position. Turn the key to
START. When the engine is running, allow the switch
to return to the ON position. To stop the engine, turn
the key to the OFF position. There is also an ACC
(accessory) position.

OFF (Engine Off, Horn)

ACC (Horn, Radio, etc.)
ON (Engine On) OM21054

START (Engine Start)

This key also locks and unlocks the cab door. A
separate key is supplied for the lockable cap to the
fuel tank.

5. FRONT BRAKE CUT-OFF SWITCH

This switch is used to change the brake proportion-
ing between the front and rear brakes. With the
switch in the OFF position, the front and rear brakes
apply simultaneously as the brake pedal is de-
pressed. With the switch in the ON position and the
brake pedal is partially depressed, only the rear
brakes will be applied. However, if the brake pedal is
fully depressed, the front brakes will also apply. See
Front Brake Cut-Off Switch in Operating Methods.

OM21055

6. PARKING BRAKE SWITCH

This switch applies the parking brakes which are
mounted on the differential input shaft. With the
switch in the OFF position, the parking brake is off.
With the switch in the ON position the parking brake
is on, applied.

OM21056

2-13
 OPERATOR’S STATION

7. HEATER/AIR CONDITIONER

7A
7A 7B

7B

7C OM21057

7C
7C
7D 7D
7A. Defrost Vents, Windshield 7F. Display ON/OFF Switch
7B. Defrost Vents, Side Windows 7G. Temperature Control Switch
7C. Face Vents, Operator and Passenger 7H. ON/OFF Switch
7D. Foot Vents 7I. Fan Speed Control Switches
7E. Vent Mode Switches 7J. Recirculation Mode Switch

OM21058

NOTE: The side Defrost Vents (7B) and Face Vents (7C) are provided with louvers to adjust the air flow
direction.

2-14
 OPERATOR’S STATION

Electronic Climate Controls (ECC)

7E. Vent Mode Switch

The HVAC System’s modes (Automatic, Heat, Cool, or Defrost) can be set by operator.

7F. Display ON/OFF Switch

Both inside and outside temperatures can be displayed in Celsius or Fahrenheit.

NOTE: One of the fan speed control switches (7H) must be ON

7G. Temperature Control Switch

The temperature is set with the temperature set point keys. The controlled temperature range is between 16˚C
(60˚F) and 28˚C (82˚F). If the temperature is adjusted to the coldest setting 16˚C (60˚F), the setting will be at
minimum and the heater valve will be closed. If the temperature is set to the hottest setting 28˚C (82˚F), the setting
will be at maximum.

7H. ON/OFF Switch

Press this switch to redirect the air flow.

7I. Fan Speed Control Switches

These switches adjust the blower speed up/down keys. Blower speed is variable between 0 and 100%.

7J. Recirculation Mode Switch

This Switch can be set on full fresh air or full re-circulated air.

OM21057

2-15
 OPERATOR’S STATION

ECC User Display

OM21059

1. Temperature Display
It displays inside and outside temperature in Celsius or Fahrenheit. This section also displays an error if any
of the temperature sensors malfunctions.

2. Blower Speed

Blower speed is displayed in both numeric (0-20) and bar graph form.

3. Operation Mode

Mode of operation of the HVAC system is displayed (Cool, Heat, Defrost and Auto).

4. Air Mixture Option

This displays air mixture mode being selected (Fresh or Re-circulated air).

2-16
 OPERATOR’S STATION

Modes of Operation

When pressing the button on the ECC, the HVAC system will cycle through the following modes.

Automatic Mode
Operator chooses an interior temperature Setpoint. The ECC takes over and constantly analyzing system’s elec-
tronic temperature sensors (Inside, Aftercoil, Deice and outside), adjusting individual component (Blowers, Heater
Valve, A/C Compressor and Air Mix) to maintain a comfortable climate at all times.

Heat Mode
Interior Temperature is regulated with the electronic heater valve. Algorithm applied to inside and after coil sensor
data to control heater valve position to achieve accurate temperature control. A/C compressor will remain off when
heat mode is active.

Cool Mode
Interior Temperature is controlled by cycling of the A/C compressor. (The A/C compressor will only turn ON when
the outside temperature rises above 10˚C and turns OFF again when it drops below 8˚C to prevent coil from freez-
ing). Inside sensor and after coil sensors are used to control blower speed to hold Setpoint while minimizing
blower noise. When in cool mode, the heater valve will remain closed.

Defrost Mode
When this mode activated, the heater valve is opened to full, A/C compressor is on and blower is turned to full
speed. A signal to open a defrost flapper is also sent.

2-17
 OPERATOR’S STATION

STEERING WHEEL

1. Hazard Warning Switch

2. Tilt/Telescope Adjustment Lever
3. Turn Signal/High Beam Lever Switch
4. Horn Switch
Rotate the steering wheel in the desired direction of
the required radius of turn. When the desired radius
has been reached, hold the steering wheel at this
point to maintain this degree of turn. To return the
front wheels to the straight-ahead position or to the
opposite direction of turn, the steering wheel must
be turned in the opposite direction. OM21060

1. HAZARD WARNING SWITCH

This switch activates the Hazard Warning Lights.
Pull the switch out to activate the hazard warning
lights. Push the switch to deactivate. The front and
rear turn signals will flash at the same time.

OM21061

2. TILT/TELESCOPE STEERING WHEEL

This control lever allows the steering wheel to be
adjusted for operator comfort. Push (1) the lever for
telescope adjustment. Pull (2) the lever for tilt ad-
justment.

OM21062

2-18
 OPERATOR’S STATION

3. TURN SIGNAL/HIGH BEAM LEVER SWITCH

This combined lever activates:
1. Left Turn Signal
2. Right Turn Signal
3. High Beam On
4. High Beam Off

OM21063

4. HORN SWITCH
A horn switch is located in the center of the steering
wheel. The horn continuously sounds as long as the
switch is pressed.

The operator should sound the horn before starting

OM21064
the engine and when putting the transmission shift
selector into gear after the rigid dump truck has been
stopped for a period of time.

CAUTION: If horns do not sound when the

horn switch is pushed, immediately stop
the engine and contact your authorized Hi-
tachi dealer for repair. Operating the rigid
dump truck with a malfunctioning horn may
result in personal injury or death.

OM21065

2-19
 OPERATOR’S STATION

Pedal Location

OM21066

1. Retarder Pedal 5. Transmission Shift Selector

2. Brake Pedals 6. Load/Dump Brake Switch
3. Accelerator Pedal 7. 24 Volt Power Port
4. Hoist Lever

Pedal Location and Function Decal

A decal applied to the overhead panel, graphically
shows the location of each pedal. Symbols relate the
function of each pedal

OM21067

2-20
 OPERATOR’S STATION

1. RETARDER PEDAL
When this pedal is depressed, hydraulic pressure is
directed to the rear wet disc brakes. The purpose of
the retarder is to control the speed of the rigid dump
truck on grades. Depress the pedal until sufficient
retarding force is achieved to control the speed of
the rigid dump truck.

See also using the Retarder in the Operating the

Rigid Dump Truck section of this manual.

OM21068

2. BRAKE PEDAL
This pedal is used to slow or to stop the rigid dump
truck. When the pedal is depressed, hydraulic pres-
sure is directed to the front and rear brakes. When
the pedal is released, the pressure is relieved and
the front and rear brakes are released.

OM21069

2-21
 OPERATOR’S STATION

3. ACCELERATOR PEDAL
This pedal is used to accelerate or decelerate the
engine. When the pedal is depressed, the engine
speed is increased. When the pedal is released, the
engine speed is allowed to decrease.

OM21070

4. HOIST LEVER
WARNING: When the body is being raised
or lowered, the Load/Dump Brake switch
should be activated to prevent rigid dump
truck movement and the transmission shift
selector should be in NEUTRAL.

A decal applied to the top of the hoist lever control

box, graphically shows the position of the lever and
the corresponding body function.

OM21071

Hoist lever functions are as follows:

POWER DOWN position (1),
FLOAT position (2),
HOLD position (3), and
RAISE position (4).
The hoist lever is spring centered, leaving the main
control valve in HOLD or FLOAT based on the pre-
vious function. OM21072

2-22
 OPERATOR’S STATION

5. TRANSMISSION SHIFT SELECTOR

The selector is used to shift the transmission into the
desired forward or reverse gear ranges.

See Automatic Shifting in OPERATING THE RIGID

DUMP TRUCK.

OM21073

6. LOAD/DUMP BRAKE SWITCH

This switch actuates the rear brakes. This is a two-
position switch, ON and OFF. This switch should be
used while the rigid dump truck is being loaded or
when dumping to prevent rigid dump truck move-
ment.

Depress the lower part of the switch to actuate the

rear brakes. Propel is inhibited when the Load/Dump
Brake Switch is applied. To release the brakes, de-
press the upper part of the switch.
OM21074

7. DC 24-VOLT POWER PORT

This accessory is located on the back of the Control
Console. It provides a power source for a computer
with a DC 24-volt power supply adapter.

OM21075

2-23
 OPERATOR’S STATION

OPERATOR’S SEAT ADJUSMENT

Standard Seat

MECHANICAL SUSPENSION

OM21076

2-24
 OPERATOR’S STATION

Air-Ride Seat

AIR-SUSPENSION (PASSIVE)

OM21077

2-25
 OPERATOR’S STATION

Semi-Active Seat

AIR-SUSPENSION (SEMI-ACTIVE)

OM21078

2-26
 OPERATOR’S STATION

SEAT BELT

CAUTION: Be sure to use the seat belt

when operating the rigid dump truck.
Before operating the rigid dump truck, be
sure to examine the seat belt: latch plate
(1), buckle (2), and attaching hardware. Re-
place the seat belt and attaching hardware
if they are damaged, or worn. 1
Replace seat belt every three years, regard-
less of appearance.
2
1. This rigid dump truck is equipped with a re-
tractable seat belt latch (1).
2. Pull out the latch (1) and securely insert it into
buckle (2). Confirm that the seat belt is not
twisted.

NOTE: If seat belt (1) is locked before the end is

securely inserted into buckle (2), release
the end of seat belt (1) to completely re-
turn it to the original position. Then, retry.

3. Push button (3) on buckle (2) to unfasten the 3

seat belt. OM21079

PASSENGER SEAT

The rigid dump truck is designed for one person

operation. At times a person may be required to ac-
company the operator; instructor for new operator
training, operator evaluation or service personnel in
order to observe rigid dump truck performance. A
passenger seat is incorporated in the cab for such
times as no one should be allowed to ride on the
rigid dump truck unless they are in the cab, in the
seat, with seat belt (3) fastened.

The Installation compromises of a document box (4),

storage net (5), and a cup holder (6). The cushion (2)
and back rest (1) can flip up and down respectively
to allow access to rear electrical compartment.

OM21080

2-27
 OPERATOR’S STATION

DOME LIGHT

Located in the ceiling of the cab above the operator’s

seat. A two position ON / OFF switch is incorporated
into the dome light.

OM21081

BODY DOWN INDICATOR

Included on the rigid dump truck is a body down

indicator that allows the operator to determine, at a
glance, when the body has been completely lowered
to the frame. The body down indicator is located on
the underside of the canopy guard and comes into
the operator’s view at the upper corner of the cab’s
right vent window when the body is all the way down.

OM21082

ENGINE DIAGNOSTIC CONNECTORS

This is the plug in for the Diesel Engine Electronic

System.

NOTE: For service personnel use only.

OM21083

2-28
 OPERATOR’S STATION

MIRRORS

Due to the position of the cab and size of the rigid

dump truck, an operator has limited visibility to the
rear and to areas close to or near the rigid dump
truck. Mirrors are installed on the cab door and right
hand deck railing. The mirrors should be kept clean
and adjusted for optimum rear viewing.

OM21084

MANUAL RELEASE VALVE

The manual release valve allows the operator to

safely lower the dump body when it is raised off the
frame rails and the normal cab hoist lever cannot be
used. This may occur for a number of reasons, such
as stuck valve pool, no hydraulic power during ser-
vicing, no electric power, etc. The manual release
valve is located near the hoist valve on top of the
hydraulic tank.

The manual release valve should be checked peri-

odically. To check it, pull up on the electrical hoist
lever in the cab, to raise the dump body, Release
the hoist lever when the dump body has been raised
substantially. Leave the cab and go to the manual
release valve location. Pull and hold the manual
release valve (1) until the dump body lowers and
rests on the frame rails. Be careful to stay clear of
the dump body as it comes down.
OM21085

2-29
 OPERATOR’S STATION

BATTERY DISCONNECT SWITCH

The battery disconnect switch is located on a plate

assembly at the battery box. Turn the battery discon-
nect switch to the OFF position when the rigid dump
truck is parked for a long period of time or when
transporting or towing the rigid dump truck.

NOTE: The battery disconnect switch should be

turned and locked in the OFF position
when work will be done on the rigid dump
truck to prevent accidental starting.

OM21086

2-30
 BREAK-IN

OBSERVE RIGID DUMP TRUCK CLOSELY

IMPORTANT: Be extra cautious during the first 100 hours

of a new rigid dump truck’s operation.
The rigid dump truck must be operated with
caution until all components are adequately
run in.
Monitoring should be on the engine tem-
perature, steer/brake performance, body
dump time and the horsepower availability
from the power train.

ENGINE

See the specific Engine manufacturer’s Operation and Mainte-

nance Manual for the recommended break-in instructions for
the engine.
OM21087EH1100-3

The engine may be put to work, but the operator has an oppor-
tunity to establish conditions for optimum service life by:

• Avoiding operation for long periods at engine idle speeds.

• Developing the habit of watching the engine instruments
closely during operation and taking the appropriate action
when a system malfunction occurs.
• Operating with a power requirement that allows accelera-
tion to governed speed when conditions require more
power.

NOTE: Operate as much as possible at three-quarters

throttle load range.

• Checking the oil level every 8 to 10 hours.

OM21088EH750-3

NOTE: Cleanliness is very important when you work on the

engine, hydraulic systems or any electrical compo-
nent.

DAILY OR EVERY 10 HOURS

1. Perform daily or every 10 hour service. (See “Inspect

Rigid Dump Truck Daily Before Starting”.)
2. Watch for fluid leaks.

AFTER THE FIRST 50 HOURS

1. Refer to the Chassis and Driveshaft Grease Fitting Loca-

SA435
tions chart.

3-1
 BREAK-IN

MEMO
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3-2
 OPERATING THE ENGINE

INSPECT RIGID DUMP TRUCK DAILY BEFORE STARTING

Inspect your rigid dump truck carefully each day or

shift by walking around it before you start it to avoid
personal injury.

ELECTRICAL SYSTEM: Check for worn or frayed

wires and loose or corroded connections.

FRAME, BODY, SHEET METAL, HARDWARE:

Check for bent, broken, loose, or missing parts.

SA-435
B

HYDRAULIC SYSTEM: Check for leaks, missing

or loose clamps, kinked hoses, and lines or hoses
that rub against each other or other parts.

LUBRICATION: Check lubrication points.

PROTECTIVE DEVICES: Check guards, shields,

and covers.

SAFETY: Walk around rigid dump truck to clear all

persons from rigid dump truck area.

For other inspection and maintenance procedures,

refer to the MAINTENANCE Section

4-1
 OPERATING THE ENGINE

DAILY WALK AROUND INSPECTION

OM21089
B

4-2
 OPERATING THE ENGINE

DAILY WALK AROUND INSPECTION CHECK SHEET

Interval
Daily or
Item Every
10 Hrs.
LEAKS, OIL AND WATER
LOOSE BOLTS AND FITTINGS
1 FUEL-WATER SEPARATOR. WHEN APPLICABLE
2 ENGINE OIL LEVEL
3 STEERING/BRAKE APPLY / STEERING HYDRAULIC OIL TANK LEVEL
4 HOIST/BRAKE COOLING / HOIST HYDRAULIC OIL TANK LEVEL
5 TRANSMISSION OIL LEVEL
6 TIRE CONDITION
7 VISUALLY INSPECT BRAKES
8 ROCK EJECTORS
9 BODY PROP PINS. BODY PROP CABLE ON EH1100-2
10 CLEAN REAR LIGHTS.
11 CLEAN HEADLIGHTS
12a ALL LADDERS, STEPS, WALKWAYS, HANDHOLDS AND GUARD RAILS
MUST BE FREE OF DIRT, SNOW AND ICE
12b DAMAGED LADDERS, STEPS WALKWAYS, HANDHOLDS AND GUARD RAILS
12c DAMAGED OR MISSING SLIP RESISTANT STRIPS
13 BATTERY DISCONNECT SWITCH IS TURNED ON
14 EMPTY AIR CLEANER DUST CONTAINER AT VACUATOR VALVE
15 COOLANT LEVEL
16 WINDSHIELD WASHER FLUID LEVEL
17 STEERING ACCUMULATOR
18 MAKE SURE ALL WINDOWS ARE CLEAN AND UNDAMAGED
19 MAKE SURE ALL MIRRORS ARE CLEAN, UNDAMAGED AND PROPERLY ALIGNED
20 MAKE SURE THAT THE SHIFT CONTROL LEVER IS IN THE NEUTRAL POSITION
21 THE BODY HOIST CONTROL LEVER IS IN THE FLOAT POSITION
22 PARKING BRAKE OPERATION AND THAT THE PARKING BRAKE IS APPLIED
23 GAUGES AND INDICATOR LIGHTS
24 STEERING OPERATION
25 HORN
26 BACK-UP ALARM
27 ALL OPERATING CONTROLS
28 BRAKE OPERATION
29 SEAT IS ADJUSTED, SEAT BELT IS FASTENED DURING RIGID DUMP TRUCK
OPERATION
30 BACK-UP LIGHT

4-3
 OPERATING THE ENGINE

OIL AND WATER LEAKS

CLEAN AND CHECK ALL LINES AND HOSES

WARNING: Improper selection, installation or

maintenance may result in premature failures,
which could result in bodily injury or property
damage.
SA-044
B

To find leakage, use a piece of cardboard or

wood, not your hand. If hydraulic fluid is in-
jected into you skin, it must be removed im-
mediately by a doctor.

Inspect all hoses daily and check for the following:

• Leaks at fitting or in hose. (Leaking hydraulic fluid is

a fire hazard.)
SA-031
B

• Damaged, cut, or a braded hose cover (any rein-

forcement exposed)

• Kinked, crushed, flattened or twisted hose.

• Hard, stiff, heat cracked or charred hose.

• Blistered, soft, degraded or loose cover.

• Cracked, damaged or badly corroded fittings.

• Fitting slippage on hose.

The following items must be tightened, repaired, or re-

placed as required:

• Leaking ports.

• Clamps, guards, and shields.

• Remove excessive dirt build-up.

• Clean hoses completely, inspect and replace.

4-4
 OPERATING THE ENGINE

CHECK INSTRUMENTS BEFORE STARTING

1. Turn the battery disconnect switch (1) to the ON
position

OM21086
B

2. Make sure that the accelerator pedal (2) is re-

leased.
3. Check to insure that the parking brake (3) is ap-
plied.
4. The Shift Selector (4) should be in the N Neutral
position.
5. Indicator Light Check
Turn the key switch (5) to the ON position. All of
the indicator lights should come ON momentarily,
for 3 seconds. If any indicator fails to light the
bulb may be burned out.
6. Level Check
After the indicator light check, if the coolant level
indicator (6) remains illuminated for 5 seconds
after turning the key switch (5) ON, check the
coolant level. The coolant level sight gauge is lo- OM21090
B

cated on the surge tank for the EH750-3 and

EH1100-3
7. Adjust the seat to allow for full pedal and control
lever stroke with operators back against the seat
back. Fasten the seat belt.

NOTE: Use a damp cloth when wiping dust off the

gauges and indicator lights to prevent dam-
aging the gauge and light faces.

OM21091
B

4-5
 OPERATING THE ENGINE

STARTING THE ENGINE

WARNING: Check your company safety rules

for special procedures that may be used for
alerting personnel around you of your inten-
tion to start the rigid dump truck. 1

• Turn the battery disconnect switch (1) to the ON

position.

• Make sure the area around the rigid dump truck is

OM21086
clear before starting.
B

• Sound the horn. (2).

Starting In Warm Weather

1. Make sure the accelerator pedal (3) is released.
2. Check to insure that the parking brake (4) is ap-
plied.
3. The shift selector (5) should be in the N Neutral
position.
4. Turn the key switch (6) to the ON position.

NOTE: It is normal for the warning and indicator

lights to flash and the audible alarm to
sound with the key switch in the ON posi-
tion. The gauges will also cycle momentarily
when the key is in the ON position.

5. Turn the key switch (6) to the START position to

engage the starter motor.

NOTE: DO NOT operate the starter motor for

more than 30 seconds at one time.

6. Release the key after the engine starts.

OM21092
B

7. Check the gauges, indicator lights (7) and display

for any warnings or errors.

4-6
 OPERATING THE ENGINE

Starting In Cold Weather

Make sure the freezing point of the coolant corre-
sponds to the local weather conditions. For
temperature between 0˚C (32˚F) and -20˚C (-4˚F), the
rigid dump truck should be equipped with a sup-
plemental coolant heater. For temperature between
-20˚C (-4˚F) and -35˚C (-31˚F), the rigid dump truck
should be equipped with a supplemental coolant heater,
a fuel heater and viton brake seals. It is important for
cold weather starting that the electrical system,
especially the batteries be properly maintained.
OM21086
B

NOTE: Refer to the Cold Weather Package in the

OPTIONS section of this manual.

• Turn the battery disconnect switch (1) to the ON

position.

• Make sure the area around the rigid dump truck is

clear before starting.

• Sound the horn. (2).

1. Make sure that the accelerator pedal (3) is re-

leased.
2. Check to insure that the parking brake (4) is ap-
plied.
3. The shift selector (5) should be in the N Neutral
position.
4. Turn the key switch (6) to the ON position.

NOTE: It is normal for the warning and indicator

lights to flash and the audible alarm to
sound with the key switch in the ON posi-
tion. The gauges will also cycle momentarily
when the key is in the ON position.

5. Turn the key switch (6) to the START position to B

OM21092

engage the starter motor. Release the key when

the engine starts.
6. Check the gauges, indicator lights (7) and display
for any warnings or errors.
7. If the engine does not start, wait until the engine
flywheel comes to a complete stop.
8. Turn the key switch to the OFF position before
trying to start the engine again.
9. Repeat the procedure if necessary.

4-7
 OPERATING THE ENGINE

NOTE: DO NOT operate the starter motor for more

than 30 seconds at one time.

NOTE: Due to increased safety hazards and poten-

tial for engine damage, the vehicle manu-
facturer does not recommend the use of
starting fluid.

Measures During Cold Weather

During the cold season or when the temperature is be-

low freezing, the following points should be noted:
• Make sure that the freezing point of the coolant cor-
responds to the weather conditions. See Cooling
System in the Maintenance section of this manual.
• Use the recommended lubricating oil for winter use.
• Always fill the fuel tank at the end of the day’s work
to minimize the formation of water condensation in
the fuel tank.
• When the engine has started, run it at low speed and
with light loading until the oil in the engine, hydraulic
systems and axles have warmed up and become
sufficiently fluid to provide proper lubrication.

NOTE: At extremely low temperatures the rigid

dump truck must not be run under high
loads immediately after the engine has been
started.
NOTE: At temperatures below -25°C (-13°F) the
tensile properties of steel are greatly re-
duced and therefore the risk of brittle frac-
ture is great even at small stresses. The lu-
bricating and hydraulic oils change their
viscosity and thereby their lubricating prop-
erties at low temperatures. Special proce-
dures, lubricants, etc. are required to oper-
ate below this temperature.

4-8
 OPERATING THE ENGINE

CHECK INSTRUMENTS AFTER STARTING

IMPORTANT: Do not operate the rigid dump truck if

any red indicators (1) do not go out
after the engine is started. IMMEDI-
ATELY STOP THE ENGINE and cor-
rect the cause.

IMPORTANT: Make sure the operator’s seat is ad-

justed and that the seat belt is prop-
erly fastened.

NOTE: DO NOT run the engine at full speed or

place under a heavy load until it is warmed
up. The engine is warm and ready for
maximum operation when the needle of the
engine coolant temperature gauge (2) OM21093
B

moves along the white line, below the “Red

Zone”. This usually takes 15 minutes.

1. Keep the engine at 1,000 rpm as read on the ta-

chometer (3) for about three to five minutes after
starting. When a cold engine is started, the work-
ing parts are partially dry and the lubricating oil is
thick. To avoid possible engine damage, allow the
engine to warm up gradually.
2. As the engine coolant temperature increases to
normal operating temperature, check the gauges
to determine that the systems are operating prop-
erly.
3. Observe the indicator lights (1)
(1) If the engine oil pressure indicator (4) does not
go off within 2 seconds after starting the en-
gine, immediately stop the engine and correct
the cause.
(2) Visually observe the engine coolant tempera-
ture gauge (2) to make sure that the gauge is
working properly.
4. Check operation of all switches.
5. Make a functional check of the operating controls
for proper operation.
• Transmission shift selector
• Steering
• Hoist Lever
• Brakes
6. Engine noise and exhaust gas are normal. (Un-
usual noises may indicate a problem.)

4-9
 OPERATING THE ENGINE

Using Booster Batteries

CAUTION:
1. An explosive gas is produced while batter-
ies are in use or being charged. Keep
flames or sparks away from the battery area.
Charge the batteries in a well ventilated
area.
2. Never connect a positive terminal to a
negative terminal, as a dangerous short
circuit will occur.
3. Apply the parking brake after moving the SA-032
B

shift selector to Neutral position.

4. Do not lean over batteries during jump start
procedure.
5. Do not jump start / charge a frozen battery.
It may explode due to gas trapped in the
frozen battery. Allow the battery to warm to
16˚C (60˚F).
6. The operator must be in the operator’s seat
so that the rigid dump truck will be under
control when the engine starts. Jump start-
ing is a two person operation.

IMPORTANT: The rigid dump truck electrical sys-

tem is a 24 volt negative (-) ground.
Use only 24 volt booster batteries.

When the rigid dump truck batteries are exhausted,

start the engine using booster batteries as described
below and illustrated at the right.

Connecting the booster batteries

1. Stop the engine of the rigid dump truck, on which
booster batteries are mounted.
2. Switch off the battery disconnect switch.
3. Connect the end of the red cable (1) to the positive
(+) terminal of the rigid dump truck batteries, and B
OM21094

the other end to the positive (+) terminal of the

booster batteries.
4. Connect one end of the black cable (2) to the
negative (-) terminal of the booster batteries, and
then make ground connection to the frame of the
rigid dump truck to be started with the other end of
the black, negative (-) cable (2). In the last connec-
tion to the frame, be sure to connect the cable as

4-10
 OPERATING THE ENGINE

far away from the rigid dump truck batteries as

possible.
5. Switch on the battery disconnect switch.
6. Start the engine of the rigid dump truck, on
which booster batteries are mounted.
7. Start the engine of the rigid dump truck with the
discharged batteries. If the engine does not
start, release the key switch and wait for 2 min-
utes to cool the starter motor before trying
again. If the engine does not start in the sec-
ond or third attempt, report the problem to
qualified personnel.
8. After the engine starts, disconnect cables (2)
and (1) following the procedure below.

Disconnecting the booster batteries

1. Disconnect the black, negative (-) cable (2) from
the rigid dump truck frame first.
2. Disconnect the other end of the black, negative (-)
cable (2) from the booster batteries.
3. Disconnect the red, positive (+) cable (1) from the
booster batteries.
4. Disconnect the red, positive (+) cable (1) from the
rigid dump truck batteries.

OM21094

4-11
 OPERATING THE ENGINE

STOPPING THE ENGINE

Engine stop procedure

1. Park the rigid dump truck in a safe area on a hard,
dry, level surface.
2. Move the shift controller lever (1) to the N neutral
position.
3. Apply the parking brake (2) and release the ser-
vice brake pedal (3) to insure that the parking
brake is holding the rigid dump truck.
4. Let the engine run at idle for three to five minutes
for cool down.
5. Make sure the hoist lever (4) is in the Float posi-
tion.
6. Check that all switches and control are in the OFF
position.
7. Turn the key switch (5) to the OFF position. If
leaving the rigid dump truck unattended, remove
the key. Lock all the doors and any vandalism
guards to prevent theft or damage.
8. Turn the battery disconnect switch to the OFF po-
sition. OM21095
B

OM21086
B

4-12
 OPERATING METHODS

General Information

WARNING: Sound the horn before moving the

rigid dump truck.
Operate the rigid dump truck with the seat belt
properly fastened. Do not allow riders other than
on the trainer’s seat. Riders must also fasten seat
belt.
Watch where you are going. Keep the rigid dump
truck a safe distance from other personnel in the
area, the edge of cliffs, slide areas, and vehicles;
etc.

This rigid dump truck is equipped with an engine capable of

delivering adequate power under working conditions for
which it is designed.

An early indication that a diesel is being improperly

operated is excessive exhaust smoke as a result of
unburned fuel. To avoid possible internal engine damage
due to unburned fuel deposits, shut down the engine when
stopping for extended periods. Avoid unnecessary engine
idling.

Almost all impending failures give some warning to the op- OM21096
erator before parts fail. By paying close attention to
gauges: indicator lights, listening for unusual noises and
noting engine performance, malfunctions can be detected
early. When an impending difficulty gives its warning, park
the rigid dump truck in a safe area, shut the engine off im-
mediately and notify those responsible for maintenance. A
few seconds delay after the first warning might result in
costly repairs.

Put the shift control lever in the N (Neutral) position when:

• Starting the engine
• Checking the rigid dump truck accessories
• For extended periods of engine idle operation.
If the engine starts in any other position, the neutral start
circuit is malfunctioning and should be repaired immedi-
ately. When shutting the engine down, shift to neutral and
apply the park brake.

NOTE: Do not try to work too fast. Know your capability

and that of the rigid dump truck.

NOTE: Make sure the path of operation is clear of large

rocks or other debris. Failure to do so may re-
sult in damage to the rigid dump truck and tires
and loss of control of the rigid dump truck.

5-1
 OPERATING METHODS

WARNING: Do not allow the rigid dump truck to

coast in NEUTRAL. This practice can result in a
possible loss of operator control of the rigid
dump truck.

Cooling a Hot Engine

If an overheating condition starts to occur:

• Make sure the hoist lever is in the float position.

• Reduce the power output of the engine by releasing
the accelerator pedal or shifting the transmission to a
lower gear, or both.
If the engine temperature does not return to normal op-
erating range:

• Immediately move the rigid dump truck to a safe park-

ing area.
• Make sure the transmission shift selector is in the
neutral position.
• Engage the parking brake.

NOTE: Allow the engine to idle three to five minutes

before turning it off, unless the red engine cool-
ant level indicator in the monitor panel is illumi-
nated.
OM21097

• Shutdown the engine.

• Advise service personnel of the problem.

Transmission
The automatic transmission is a remote mounted,
planetary type, with integral torque converter, fully auto-
matic shifting and lock-up in all forward gears. There are
six forward gears and two reverse gears. Shift Energy
Management (SEM) provides smooth shifting to help re-
duce operator fatigue.

The Allison Transmission CEC II Electronic Control sys-

tem is a computerized shift selector system which elec-
tronically controls transmission operation and monitors
for conditions that could result in damage to the trans- OM21098

mission or improper equipment operation. When one of

these conditions is detected, the computer is pro-
grammed to automatically respond in a manner which
will ensure safe operation of the equipment and trans-
mission.

5-2
 OPERATING METHODS

Automatic Shifting

WARNING: In the lower ranges (1 through 5) the

transmission will upshift above the gear selected
if engine speed reaches approximately 2400 rpm.

Do not allow your rigid dump truck to coast in

NEUTRAL. This practice can result in severe
transmission damage and possible loss of op-
erator control of the rigid dump truck. 1

The Allison Transmission CEC II Electronic Control sys-

tem, lever-type range selector is an elec-
tronic-mechanical control unit. The shift selector features
a detent to prevent inadvertent shifting between R1 and
R2, N and D. To release the shift selector from any of
these positions, the detent must first be unlocked by de-
pressing the unlock button (1) on the shifter handle. After
a forward range has been selected, other forward ranges
can be selected by simply moving the lever to the de- 2
sired range.

The range selected by the shift selector will appear in the OM21099

digital display (2). For forward ranges the number dis-

played is the highest range available for the selected
position.

NOTE: Rigid dump trucks can only be started in the

“Neutral” range.

N NEUTRAL – Use this when starting the engine,

checking the rigid dump truck accessories and
for periods of engine idle operation. The trans-
mission will automatically select “Neutral” when
the key switch is turned to the ON position. If the
engine starts in any other selected gear, the neu-
tral start circuit is malfunctioning and should be
repaired immediately. When shutting the engine
down, shift to neutral and apply the parking
brake.

R1/R2 REVERSE – Use these ranges for backing up the

rigid dump truck. Completely stop the rigid dump
truck before shifting from forward to R1 or R2 or
from R1 or R2 to forward. R1 is a low speed re-
verse, and R2 is a high speed reverse. The
back-up alarm is activated when either reverse
gear is selected. Selection of R1 from R2 or R2
from R1 can only be accomplished at low rigid
dump truck speed and low throttle.

5-3
 OPERATING METHODS

NOTE: The rigid dump truck will not go into either re-
verse gear when over 20% throttle.

D DRIVE –With this range selected, the transmis-

sion will initially be in first gear. As the speed of
the rigid dump truck increases, the transmission
will automatically upshift through each gear to the
sixth gear operation. As the rigid dump truck
slows down, the transmission will automatically
downshift to the correct gear.

5,4,3,2 Occasionally, the road, the load or traffic condi-

tions will make it desirable to limit top speed.
When conditions allow, select D for full range op-
eration. These positions also provide progres-
sively greater engine retarding for going down
medium grades (the lower the gear range, the
greater the retarding effect).

1 Use this range when pulling through mud, deep snow,

maneuvering in tight spaces; while driving up and
down steep grades or when maximum output power
is required. First gear range provides the rigid dump
truck with its maximum driving torque and maximum
engine retarding torque.

Mode Button
The mode button (3) will allow the operator to enable a
secondary shift schedule that has been programmed into
the electronic control unit if requested. The name of the
secondary function should appear in the Mode Identifica-
tion area just under the mode button. Pressing the mode
button activates the secondary shift schedule and illumi-
nates the red mode indicator light. 3

OM21100

5-4
 OPERATING METHODS

Status Lights
The Allison Transmission CEC II Electronic Control is
programmed not only to tell you that something is
wrong but also to automatically take action to protect
you, the rigid dump truck, and the transmission. When
a problem condition is detected, shifting is restricted.
The Transmission Malfunction indicator (1) in the
monitor panel will illuminate and a diagnostic code is
registered. Continued illumination of the Transmission
Malfunction indicator during vehicle operation (other
than start-up) indicates the registration of a diagnostic
code. When the illumination of the Transmission Mal-
function indicator is accompanied by a flashing display OM21101

from the shift selector, the shift selector will show the
actual range attained and the transmission will not re-
spond to shift selector requests.

5-5
 OPERATING METHODS

The indications from the shift selector are provided to in-

form the operator that the transmission is not performing
as designed and is operating with reduced capabilities.
Before turning the ignition off, the transmission may be
operated for a short time in the selected range in order to
proceed to the service area at a reduced rate. Service
should be performed immediately in order to minimize
the potential for damage to the transmission.

When the Transmission Malfunction indicator comes on

and the key switch is turned off, the transmission will
remain in N Neutral until the condition causing the indi-
cator to illuminate is corrected.

Generally, while the Transmission Malfunction indicator

is on, upshifts and downshifts will be restricted and direc-
tion changes will not occur. The shift selector will not re-
spond to any operator shift requests while the Transmis-
sion Malfunction indicator is illuminated. The lockup
clutch is disengaged when transmission shifting is re-
stricted or during any critical transmission malfunction.

Lock-In-Range for EH750-3 and EH1100-3

The lock-in-range feature prevents upshifts and down-

shifts when a problem is detected in the operation of the
transmission. The hold-in-gear circuit permits the trans-
mission to continue to operate in the gear it was in the
time the Do Not Shift lights came on. Selection of a
different gear range will have no effect on the
transmission. The transmission will not upshift, but will
remain in the gear it was in when the problem was
detected. The lock-in-range circuit is released when the
engine is shut off. If the problem causing the
lock-in-range is still present when the engine is restarted,
the transmission will be in neutral and will remain in
neutral until the problem is corrected.

NOTE: Should the Do Not Shift light illuminate, the

rigid dump truck should be shut down as soon
as possible to avoid possible damage to the
transmission.

5-6
 OPERATING METHODS

Reset Procedure

When the status lights come on, a reset procedure can

be performed to clear the system.

To reset, bring the rigid dump truck to a stop at a safe

location and shut off the engine.

• If the problem is temporary, the status lights will

come back on and your rigid dump truck will op-
erate in a normal manner.

• If the problem is not temporary, the status lights

will come back on and the transmission may stay
in neutral, operate in only the lower ranges, or
operate in a normal manner. The type of opera-
tion, permitted by the system, will depend on the
type of problem.

NOTE: If only transmission malfunction light comes on,

it may not be necessary to interrupt rigid dump
truck service to reset. If possible, continue op-
eration and have the transmission checked at
the earliest opportunity.

Downshift or Reverse Inhibitor Feature

Although there is no speed limitation on the upshifting,
there is on downshifting and reverse. The system is de-
signed to protect against these improper shifts. If a
downshift or reverse shift is selected at too high a speed,
the system will prevent the shift from taking effect until
the lower speed is reached.

NOTE: When required, use your service brakes to

lower rigid dump truck speed to permit a down-
shift.

5-7
 OPERATING METHODS

Using the Retarder

The retarder pedal is located on the cab floor to the left

of the steering column. This pedal regulates the hydrau-
lic pressure to the rear wet disc brakes. The retarder
pedal should be used to slow or stop the rigid dump
truck.
The retarder pedal should be used as needed to main-
tain a controlled speed on downgrade hauls. The rigid
dump truck speed (and related gear) should be selected
to maintain maximum engine rpm without upshifting to
the next gear (2400 rpm). Overspeeding of the engine
occurs at 2400 rpm, at which time the transmission will
upshift to the next range.

The optional Electronic Downhill Speed Control (EDSC)

system will also provide automatic retarding to prevent
overspeeding. For details, read the description under
Electronic Downhill Speed Control (EDSC) in the OP-
TION section of this manual.
OM21068

5-8
 OPERATING METHODS

WARNING: Be aware that even in a pre-select

mode, if the engine approaches an overspeed
condition, the transmission will upshift to the next
gear range at approximately 2400 rpm.

Maintaining maximum engine rpm ensures proper cool-

ing flow to the rear wet disc brakes as well as providing
the maximum engine braking. Operate the rigid dump
truck on grade speeds that maintain the brake cooling oil
temperature gauge below the red zone. Should over-
heating indications occur the next lower speed (gear)
should be selected.

NOTE: Refer to the Retarder Operation Decal

(Grade/Speed Chart) in the cab for the proper
rigid dump truck speed (gear) to be utilized for
the grade encountered.
OM21102

NOTE: When the retarder is being used properly, the

service brakes should not be needed to main-
tain the desired downhill speed. If the service
brakes are needed, the operator should select a
lower gear range.

WARNING: Do not use the service brakes to main-

tain speeds on downgrade hauls. Excessive heat
will seriously damage the front brakes. Use the
retarder.

5-9
 OPERATING METHODS

Retarder Operation Decal

The “Retarder Decal” is provided in the cab as a general
guideline for proper downgrade operation of the loaded
rigid dump truck. The chart should be used to determine
the maximum recommended speed for each downgrade
encountered. Operation at speeds greater than those
recommended may cause the rear wet disc brakes to
overheat.
A B
(A) km/h kilometer/hour C
(mph) mile/hour

(B) Downgrade length is infinite, greater than 450 m

(1500 ft).
Numbers are grade measured in percent of slope.

(C) Downgrade length is < (less than) 450 m (1500 ft).

Numbers are grade measured in percent of slope.

(D) Total combined planetary-differential reduction ratio.

12645260A
E
For example, you will be coming to a haul road less than D
450 m (1500 ft) in length with a 16% slope and the total
combined planetary-differential reduction ratio is 16.43:1.
(16:43:1 is for example only. Refer to actual decal in the
cab for correct operation). You start at (D) and read right
to left following the line.

While approaching the grade, slow the rigid dump truck

to less than or equal to the speed under (A) 22 km/h (14
(mph). Place the transmission shift selector in 3rd gear.
All should be set before getting to the crest and heading
down the grade.

The absolute maximum grade charted for first gear is

further limited by converter lockup rimpull. The rigid
dump truck should not be operated on sustained down-
grades that it cannot climb.

Proper use of this chart in conjunction with the brake

cooling oil temperature gauge provides optimum down-
grade performance.

5-10
 OPERATING METHODS

PERFORMANCE CHART

The diagonal lines in each chart rep-

resent total resistance (Grade % plus
rolling resistance %. Charts are based
on 0% resistance, standard tires and A
gearing. B1
NMW = Net Machine Weight C1
MAX GMW = Maximum Gross Ma-
chine Weight. B2
INSTRUCTIONS:

A. Find the total resistance on the di-

agonal lines at the right-hand bor-
C2
der of the chart. For this example,
using approximately 25%.
B. Follow the diagonal line downward
to where it intersects with the NMW
(B2) or MAX GMW (B1) line.
D1
C. From the intersect, read horizontally D2
right or left to intersect the per-
formance curve, shaded area.
D. Read down for vehicle speed. At
NMW vehicle speed should be
approximately 14 km/h (9 mph) (D2)
to climb the grade. At MAX GMW
vehicle speed should be approxi-
mately 5 km/h (3 mph) (D1) to climb
the grade.

5-11
 OPERATING METHODS

RETARDER CHARTS

The diagonal lines in each chart rep-

resent total resistance (Grade % plus
rolling resistance %. Charts are
based on 0% resistance, standard C1
tires and gearing.
NMW = Net Machine Weight A
B1
MAX GMW = Maximum Gross Ma-
chine Weight.

INSTRUCTIONS: B2
(Using the retarder chart for 899 m
(2,950 feet) grade length:
C2
E. Find the total resistance on the di-
agonal lines at the right-hand bor-
der of the chart. For this example,
using approximately 15% (A).
F. Follow the diagonal line downward D1
to where it intersects with the NMW
(B2) or MAX GMW (B1) line. D2

G. From the intersection, read hori-

zontally right or left to intersect the
retarder curve, shaded area. At this
intersect the gear which the trans-
mission shift selector should be
pre-selected is listed.
1st gear (C1), 4th gear (C2).
H. Read down for vehicle speed. At
NMW vehicle speed should just be
under 21 km/h (13 mph) (D2). At
MAX GMW vehicle speed should
about 13 km/h (8 mph) (D1).

5-12
OPERATING METHODS

5-13
OPERATING METHODS

5-14
OPERATING METHODS

5-15
 OPERATING METHODS

Transmission Cold Weather Restrictions

Sump Oil Shift Transmis- Operation
Most transmissions are programmed to restrict
Temperature Selector sion
operation to neutral, reverse and the lowest gear
Flashing Malfunction
in the drive (D) range until the temperatures
Light
shown in the chart are reached.
-24°C and Below ON ON Neutral Only
(-10°F and Below)
Run the engine in neutral to raise the oil tem-
-23°C to -7°C OFF OFF Neutral,
perature to operating level.
(-9°F to +19°F) First,
Second, or
Reverse
-7° C and Above OFF OFF Full
(20°F and Above) operation
in all ranges

Accelerator Pedal
This pedal is used to control engine speed. When
the pedal is depressed the engine speed is in-
creased. When the pedal is released the engine
speed is allowed to decrease.

OM21070

5-16
 OPERATING METHODS

Steering

WARNING: If the power steering system fails, apply

the service brake to bring the rigid dump truck to a
stop at the first safe opportunity. Do not attempt to
operate the rigid dump truck until proper repairs have
been made.

This rigid dump truck is equipped with a full time hydrostatic

power steering system using two double acting steer cylin-
ders, piston type pumps and a combined brake/steering
system reservoir. The steering accumulator provides sup-
plementary steering, a means of temporary steering in the
event of a steering loss.

To steer the rigid dump truck, rotate the steering wheel in the
desired direction of the required radius of turn. When the de-
sired radius has been reached, hold the steering wheel at
this point to maintain the degree of turning. To return the OM21103

front wheels to the straight-ahead position or to the opposite

direction of turn, the steering wheel must be turned in the
opposite direction. When the desired direction has been
accomplished, return the front wheels to the straight-ahead
position. This is a stored energy steering system. If the steer
pump should fail or the engine stalls, the accumulated re-
serve oil pressure will enable the operator to control the di-
rection of the rigid dump truck while bringing it to a stop.

IMPORTANT: The stored energy is limited. Stop the rigid

dump truck as soon as possible.

Service Brakes

WARNING: In the event of a steer or brake alarm, al-

ways use the service brake pedal to stop the rigid
dump truck.

This rigid dump truck is equipped with a full hydraulic brake

system with dry disc front brakes and forced cooled rear wet
disc brakes. The steering system supplies hydraulic pres-
sure to the brake valve. The brake valve has two
independent circuits, front and rear, protected by
accumulators. The accumulator provides limited hydraulic
pressure for brake application in the event that supply
pressure is lost. Depress the service brake pedal to supply
modulated pressure to the front and rear brakes. Distribution
to the front/rear brakes is designed to provide maximum
braking performance under all stopping conditions.
OM21069

5-17
 OPERATING METHODS

NOTE: Should the service brake pedal fail or malfunction,

the retarder pedal should be used as a secondary
application method.

The retarder pedal applies only the rear axle brakes. De-
pending upon conditions, the retarder can be used in place
of the service brakes. This increases the time between front
brake lining replacement.

NOTE: When ground conditions are extremely bad (ice,

snow mud, etc.) the service brakes should be used.
(The Front Brake Cut-Off Switch is in the OFF posi-
tion.)
WARNING: Do not use the service brakes to maintain
speeds on downgrade hauls. Excessive heat will
seriously damage the front brakes. Use the retarder.

Front Brake Cut-Off Switch

This switch, located on the left side of the instrument panel,
provides the operator with a choice of front brake application
schedules. This choice is dependent upon ground conditions
and operator preference. With the switch in the ON position,
during a typical braking application, the front brakes will not
be applied. In maximum braking applications (service brake
pedal fully depressed and held in that position) the front
brakes will apply. This feature insures that full braking capa-
bility is always available if stopping requirements demand it.
The operator does not have to reach and turn the switch
OFF if stopping requirements demand full braking. When the
switch is in the OFF position and the brake pedal is de-
pressed, the brakes are applied to the front and rear wheels.

NOTE: Optimum front brake lining life will be obtained if this

switch is left in the ON position.

OM21104

5-18
 OPERATING METHODS

Electronic Downhill Speed Control (EDSC)

The Electronic Downhill Speed Control (EDSC) system pro-

vides retarding for use when the rigid dump truck is running
down a grade. The system will apply the appropriate amount
of retarding in order to maintain the pre selected gear and
optimum speed. The road speed will typically be held within
approximately ± 1.7km/h (± 1mph). The system is enabled
through the EDSC switch located on the instrument panel.

The EDSC system will engage, depending on a number of

inputs such as: transmission range selected, range attained,
transmission output shaft speed, engine speed, and accel-
erator pedal position.

Before a downhill run, the operator will pre select the appro-
priate transmission range using the shift selector lever,
depending on the grade, load, and road conditions present
at the time. When the transmission range attained is equal to
or greater than 2000min-1(rpm), the system will then engage.
The EDSC indicator will illuminate indicating the system is
OM21105
actively applying the retarder.

When the EDSC system is initially engaged, the brake con-

trol unit determines a control set speed and compares that
value with the individual wheel speeds. When there is a dif-
ference between the wheel speed and control speed the
brake control unit will output signals to the brake solenoids
as necessary to bring the rigid dump truck’s speed down to
the control speed. As the wheel speed approaches the con-
trol speed, the processor will decrease the applied brake
pressure. The applied brake pressure is further decreased if
the wheel speed drops below the control speed.

The EDSC system switch will be disabled when:

• The EDSC system switch is placed in the OFF position.
• The accelerator pedal is depressed.
• A mismatch occurs between the position the shift selector
is in and the gear the transmission is in.
• There is an engine link error or wheel speed sensor error.

5-19
 OPERATING METHODS

NOTE: If an engine link error or wheel speed sensor er-

ror occurs while the EDSC system is active, the red
indicator will flash.

The transmission gear/shift selector mismatch may occur ei-

ther when the transmission downshifts as a result of the op-
erator manually applying the retarder or as a result of the
operator up shifting from the pre selected gear range. If an
engine link error, transmission link error, or wheel speed
sensor error should occur while the EDSC system is en-
gaged; the EDSC indicator will flash indicating the error.

Electronic Down Hill Speed Control Switch

The two position OFF and ON switch enables the EDSC sys-
tem, providing automatic retarding when the rigid dump truck
is running down a grade.

OM21106

A blue indicator will illuminate in the monitoring and alarm

system to indicate that the EDSC system is actively applying
the retarder.

OM21107
A red indicator will illuminate in the monitoring and alarm
system to indicate that there is an error with the EDSC sys-
tem. An engine link error or wheel speed sensor error will
cause the indicator to flash. If it does the operator will need
to manually apply the retarder.

5-20
 OPERATING METHODS

Active Traction Control (ATC)

The Active Traction Control (ATC) system is an option that
monitors the rigid dump truck’s rear wheel speeds and ap-
plies the appropriate amount of retarding when necessary in
order to automatically transfer torque to the rear wheel with
the best traction.

The ATC system/boost switch

A three position switch; OFF, ON, and DEPRESS. The
switch will return to ON after DEPRESS is pushed and re-
leased. While in the ON position’ when one of the rear
wheels spins 50% faster than the other, the ATC system will
apply the retarder to decrease the speed of the faster wheel.
Torque is transferred to the slower wheel providing better
traction. The blue ATC indicator located in the instrument
panel will illuminate when the system is applying the re-
tarder.
OM21108

In cases of extremely slippery conditions, the traction boost

mode in the ATC system may be utilized. This mode is en-
gaged through the momentary depression and release of the
ATC switch. When engaged, the wheel speed differential is
reduced from 50% to 10% for a period of 15 seconds.

The ATC system will be disabled when:

The ATC System/Boost Switch is placed in the OFF position.

Road speed of the rigid dump truck goes above 24.1km/h
(15mph).
Either the brake pedal or the retarder pedal is applied.
There is a wheel speed sensor error.

A blue indicator will illuminate in the monitoring and alarm

system to indicate that the ATC system is actively applying
the retarder.

A red indicator will flash in the monitoring and alarm system

to indicate that there is an error with ATC system. A wheel
speed sensor error will cause the indicator to flash. If it does,
the operator will have to apply the retarder manually. If the
indicator illuminates solid, this is a warning, “Exceeding the
ATC speed limit or using one of the reverse gears will
result in a warning”

OM21109

5-21
 OPERATING METHODS

Engine Overspeed Protection

The brake control unit will maintain the wheel speed by ap-
plying the retarder so as not to exceed the engine overspeed
limit of 2400 min-1 (rpm). This feature is enabled when the
shift selector is in the D position and the gear range is
attained regardless of the accelerator position or the optional
ATC and optional EDSC system switches. The only instance
in which engine protection will not be available is if the en-
gine link is disabled.

Parking Brake OM21110

The Rear axle mounted parking brake must be used to hold

the parked (Engine Off) rigid dump truck stationary.

With the rigid dump truck stationary and in neutral, place the
switch in the ON position. Observe the parking brake indica-
tor will illuminate. Release the load/dump brake and/or ser-
vice brake or retarder pedal. Observe that the rigid dump
truck remains stationary, and then shut down the engine.

When parking on a grade cannot be avoided, chock blocks

must also be used for extra security purposes.

NOTE: The transmission will remain in NEUTRAL regard-

less of shift selector position until the parking brake
is released. When the rigid dump truck is first
started, the parking brake indicator on the dash will
stay illuminated even if the parking brake switch is
off until the brake system reaches normal operating
pressure.

Load/Dump Brake

WARNING: The Load/Dump brake is not a parking

brake. If the Load/Dump brake was applied and the
key turned to the OFF position, the Load/Dump brake OM21111

would be immediately released because it requires

24-volt electrical power to apply the brakes. Always
apply the parking brake when leaving the cab of the
rigid dump truck.

NOTE: The service brake or park brake should not be ap-

plied when either loading or dumping the rigid dump
truck.

This electrical switch applies the rear brakes at full pressure.

This switch should be used to hold the rigid dump truck sta-
tionary for loading, dumping, and waiting.

5-22
 OPERATING METHODS

WARNING: Do not apply the Load/Dump brake while

the rigid dump truck is in motion. This can cause loss
of rigid dump truck control.

Operating The Body With The Hoist Lever

The body is raised and lowered by hydraulic cylinders which
are controlled by a hoist lever mounted to the side of the op-
erator’s seat. The lever has four positions, controlling a four
function main hydraulic valve by a hydraulic pilot signal. It is
possible to meter the body raise time and the body down 4
time. The engine must be operating and the key switch must
be at ON in order to lower the body with the hoist lever. 3

2
Hoist Lever Functions
1
1. POWER DOWN (1) is used to initiate downward move-
ment, only if the body fails to lower in the FLOAT (2) posi-
tion. Release the lever and it will stay in the float detent
position.
If electrical power is lost and the body is in the RAISED
(4) position or is off the frame rail the operator can still
safely lower it by using the manual release valve (5)
which is part of the hydraulic control valve. Refer to
Manual Release Valve in the OPERATING METHODS
section of this manual.

OM21112

2. FLOAT (2) is used when the body is being lowered to the

frame. The lever should remain in the float position when
the rigid dump truck is moving. It is possible to slowly
lower the body, metering the valve from the HOLD (3) po-
sition to the FLOAT (2) mechanical detent. It is possible
to meter the body down time, by moving the lever down-
ward until the desired body descent speed is reached.
Releasing the lever in the FLOAT (2) position will allow
the lever to spring upward against a mechanical stop.
This will keep the hoist lever in the FLOAT (2) position.

NOTE: Whenever the rigid dump truck is moving, whether

empty or loaded, always keep the hoist lever in the
FLOAT (2) position.

OM21113

5-23
 OPERATING METHODS

3. RAISE (4) Move the hoist lever to this position to raise

the body. When the operator releases the lever in the
RAISE (4) position, it will automatically return to the
HOLD (3) position. The body can be metered up only.

NOTE: Reverse gear is inhibited when the body is RAISED.

4. HOLD (3) Move and release the hoist lever to this posi-
OM21072
tion to stop and hold the body at any desired position
while the body is raised or lowered.

NOTE: In case of a hydraulic or electrical fault, the hydrau-

lic control valve will automatically shift to the HOLD
(3) position.

Raising the Body

1. Position the rigid dump truck so the rear wheels are on
level ground to avoid unnecessary stress on the body and
frame.
2. Before attempting to raise the body, move the transmis- OM21111

sion shift selector to N neutral.

3. Apply the brakes with the LOAD/DUMP BRAKE SWITCH
located on the center control console. Do not apply the
parking brake or service brake.
4. Move the hoist lever all the way back to the RAISE posi-
tion and accelerate the engine as required.

NOTE: It is not recommended to raise the body at engine

idle.

5. The BODY UP indicator will illuminate indicating that the OM21114

body is in the UP position.

NOTE: When the body is up the rigid dump truck will not be
able to shift to a higher gear.

6. Decelerate the engine as the final stages of the body OM21047

cylinders reach their maximum stroke.

7. When the body is fully raised, release the hoist lever al-
lowing it to move to the HOLD position.

OM21115

5-24
 OPERATING METHODS

Lowering the Body

OM21072

1. Move the hoist lever down from the HOLD (3) position,
overcoming the detent in the lever, to the FLOAT (2) posi-
tion and release.

OM21116

2. If the body remains in the raised position and will not

lower it will be necessary to momentarily shift the hoist
lever to the POWER DOWN (1) position. As the body be-
gins to lower, release the lever and it will return to the
FLOAT (2) position. This condition usually occurs when a
load is being dumped on an incline.
3. Make sure the hoist lever is in the FLOAT (2) position and
that the body is resting on the frame prior to moving the
rigid dump truck. The BODY UP INDICATOR will turn off,
OM21117
indicating that the body is resting on the frame.
This rigid dump truck includes a mechanical BODY
DOWN INDICATOR that allows the operator to determine,
at a glance, when the body has completely lowered to the
frame. The BODY DOWN INDICATOR is located on the
underside of the canopy guard and comes into the op-
erator’s view at the upper corner of the cab’s right vent
window when the body is completely down and resting on
the frame.

NOTE: Whenever the rigid dump truck is moving, whether

empty or loaded, always keep the hoist lever in the
FLOAT position.

NOTE: Prior to departure, release the LOAD/DUMP

BRAKE switch and be sure that the engine is at idle
when shifting into gear.
OM21118

5-25
 OPERATING METHODS

RIGID DUMP TRUCK STUCK IN DEEP SAND,

SNOW OR MUD

If the rigid dump truck is stuck in deep sand, snow or mud, it

may be possible to rock it out.

WARNING: To help avoid injury or property damage

caused by sudden movement of the rigid dump truck,
do not make shifts from N neutral to D drive or R re-
verse when the throttle pedal is depressed. If you
shift while the throttle is depressed too much, the
transmission will only engage if the throttle is re-
leased in the next three seconds. That can cause a
sudden movement of the vehicle. Leaving the throttle
open longer than three seconds causes the trans-
mission to remain in N neutral. Avoid this condition
by making shifts from N neutral to D drive or R re-
verse only when the throttle is closed.

NOTE: DO NOT make N neutral to D drive or directional

shift changes when engine min-1 (rpm) is above idle.
Also, if the wheels are stuck and not turning, do not
apply full power for more than 30 seconds in either
D drive or R reverse. Full power for more than 30
seconds under these conditions will cause the
transmission to overheat. If the transmission over-
heats, shift to N neutral and operate the engine at
1200-1500min-1(rpm) until it cools (2 to 3 minutes).

Rocking Out

Shift to D (Drive) and apply steady, light throttle (never full

throttle). After the rigid dump truck has rocked forward as far as
it will go, apply and hold the service brakes. Allow the engine to
return to idle, and then select R (Reverse). Release the brakes
and apply a steady, light throttle and allow the rigid dump truck
to rock in R (Reverse) as far as it will go. Again, apply and hold
the service brakes and allow the engine to return to idle. This
procedure may be repeated in D (Drive) and R (Reverse) in
each directional shift continues to move the rigid dump truck a
greater distance. Never make N (Neutral)-to-D (Drive) or direc-
tional shift changes when the engine min-1(rpm) is above idle.

If the rigid dump truck fails to move a greater distance in each

directional shift the rigid dump truck should be towed or pushed
from the deep sand, snow, or mud. Refer to TOWING in this
section.

5-26
 OPERATING METHODS

TOWING

WARNING: Before taking any steps in preparation for

towing, the parking brake must be applied and the
wheels blocked from rolling. Considerable caution
should be taken in connection with towing a rigid
dump truck to avoid serious accidents.

NOTE: The towing rigid dump truck must always be at least

as heavy as the rigid dump truck being towed. The
tow points are capable of towing the rigid dump
truck at the listed Gross Machine Weight (GMW) of
the rigid dump truck being towed. The GMW is
listed on a decal applied to the side of the monitor
panel.
OM21119

NOTE: The tow cable or chain must be capable of towing

the listed GMW for the machine being towed.

When a rigid dump truck is towed or pushed, with the drive-

shaft connected, the power flow going from the rigid dump
truck wheels, through the driveshaft and into the transmission
or converter, causes certain parts in the transmission or con-
verter to rotate. Even thought there may be little or no load on
the parts, they require sufficient lubrication to prevent damage
due to friction and heat. This is why the driveshaft should be
disconnected when the rigid dump truck is towed or
pushed regardless of distance or speed traveled.

OM21120
NOTE: The maximum speed under all circumstances is 10
km/h (6 mph).

OM21067

5-27
 OPERATING METHODS

Towing With Engine Operable

WARNING: It is essential that the steering and brake

functions are operational. An operator will be re-
quired in the cab of the towed rigid dump truck to
steer and brake the towed rigid dump truck.

When towing the rigid dump truck, the following guidelines

should be observed:

• Dump load if possible

• Apply park brake and block wheels of rigid dump truck to
be towed.
• Disconnect the rear driveshaft at the differential. Refer to
REAR DRIVESHAFT in the Service Manual.

NOTE: The differential mounted disc parking brake is still

functional with the rear driveshaft disconnected.

• Place and secure towing cables/straps between the tow-

ing vehicle and the rigid dump truck to be towed.
Towing from the front, attach shackle hooks to the two
towing eyelets located underneath the front bumper (See
illustration on previous page).
Towing from the rear, attach shackle hooks to the two
eyelets located at the rear of the frame (see illustration on
previous page).

NOTE: Do not use the body prop pins or the body prop pin-
holes in the body.

• Make sure tow cables/straps are secure, take up all cable

slack between the two vehicles.
• Remove the blocks from the wheels. Release the park
brake.
• Shift controller lever to N neutral.
• Proceed with extreme CAUTION.

5-28
 OPERATING METHODS

Towing With Engine Inoperable

No Brakes No Steering

If the rigid dump truck cannot be started the following steps

must be followed:
WARNING: If the rigid dump truck is not hydraulically
connected to the towing vehicle by external hoses
and the engine cannot be started, the brakes and
steering will not operate. Steer/Brake pressure must
be above 11 MPa (1,600 psi) to tow the rigid dump
truck.

• Dump load if possible

• If the body is off the frame rail, use the manual release
valve to lower the body. See MANUAL RELEASE VALVE
in the OPERATOR’S CONTROLS section of this manual.
• Block the wheels of the rigid dump truck being towed.
• Disconnect the rear driveshaft at the differential. Refer to
REAR DRIVESHAFT, in the Service Manual.

NOTE: The differential mounted disc parking brake is still

functional with the rear driveshaft disconnected.

• Place and secure towing cables/straps between the tow-

ing vehicle and the rigid dump truck to be towed.
Towing from the front, attach shackle hooks to the two
towing eyelets located underneath the front bumper (see
illustration on page 5-27).
Towing from the rear, attach shackle hooks to the two eye-
lets located at the rear of the frame (see illustration on
page 5-27).

NOTE: Do not use the body prop pins or the body prop pin-
holes in the body.

• Make sure tow cables/straps are secure, take up all cable

slack between the two vehicles.
• The rigid dump truck must have Steer/Brake pressure in
order to release the parking brake, to steer the rigid dump
truck, and to be able to use the service brakes.
It is recommended to connect, via external lines, hydraulic
power from the towing vehicle to the relief check-bleed
valve on the rigid dump truck being towed. Refer to RE-
LIEF-CHECK-BLEED VALVE in the maintenance manual.

5-29
 OPERATING METHODS

• Remove the wheel blocks and Release the parking brake.

• Begin moving the rigid dump truck, proceeding with ex-
treme CAUTION.

NOTE: Steer the unit as little as possible because the

hydraulic oil in the steer/brake section of the
hydraulic tank will be quickly drained.

NOTE: Watch the sight gauge on the steer/brake section of

the hydraulic tank of the unit towing, to be sure
enough hydraulic oil is in the tank.

• When the destination is reached shut down the towing

rigid dump truck. Keep the key switch of the towed unit ON
until all systems have bled down. Place the disabled rigid
dump truck in the Service Position. Remove the external
hydraulic lines from each rigid dump truck.

5-30
 OPERATING METHODS

PARKING THE RIGID DUMP TRUCK

WARNING: When mounting and dismounting the

rigid dump truck, maintain three- point contact with
steps on rails (i.e. two hands and one foot/one hand
and two feet). DON’T JUMP!

• Move the rigid dump truck to a safe area for parking.

• Move the shift controller lever to the N (Neutral) position.
• Apply the parking brake before releasing the service
brakes to insure that the parking brake is holding the rigid
dump truck.
• Let the engine run at idle for three to five minutes for cool
down.
• Make sure the hoist lever is in the FLOAT position.
• Check that all switches and controls are in the OFF posi-
tion.
• Turn the Key Switch to the OFF position.
• Turn the Battery Disconnect Switch to the OFF position.
• Fill the fuel tank to minimize water condensation in the
tank.

NOTE: Running out of fuel with the engine running, espe-

cially under load, is very detrimental to engine life
and requires a time consuming restart procedure.

• 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 or service
required to those responsible for maintenance.
• When leaving the rigid dump truck unattended, remove
the key. Lock all the doors and any vandalism guards to
prevent theft or damage.

5-31
 OPERATING METHODS

MEMO

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5-32
 OPERATING THE RIGID DUMPER TRUCK

APPLICATION

Due to its versatility the Hitachi rigid dump truck is

used on a wide variety of jobs. Although the rigid
dump truck applications will vary condierably, the
functions of the rigid dump truck can be divided into
three phases: loading, hauling and dumping. The best
method for performing each of these functions will
depend upon the job layout, materials, length of haul,
terrain, dumping area etc. Therefore, it is not practical
to attempt to describe in this manual every job on
which the rigid dump trucks may be used. Instead,
some general operating practices have been listed on
the following pages which can be applied to almost
OM21121
any job.

NOTE: The operator must check with the em-

ployer/supervisor to determine if special
hazards exist in his application such as
toxic gases, ground (underfoot) conditions
etc. that require special precautions.

NOTE: The operator should make a cautious first

pass to test the haul roads to determine
different application characteristics.

Loading

WARNING: Stay in your cab while your rigid

dump truck is being loaded. Stepping out of
the cab at this time could result in possible
injury.

Some of the most common methods of loading rigid

dump trucks are with draglines, excavators, and
front-end loaders. When working with this type of
equipment, you can speed up the production by
keeping within the most efficient working area of the
loading vehicle. For example, the less degree of
swing the shovel boom must take between the cut
and the body, the more work the shovel can perform.
Position the rigid dump truck so that the shovel swing
is 90 degrees or less.

NOTE: Avoid pulling or backing your rigid dump

truck into the loading position while the
loading vehicle is moving, as rocks and
OM21122
debris may fall from the loading vehicle.

6-1
 OPERATING THE RIGID DUMPER TRUCK

Most jobs are planned to eliminate unnecessary

turning and backing of the rigid dump truck for
loading. One of the most common methods used is
where the rigid dump trucks follow one another under
the shovel in a semi-circle.

NOTE: Position your rigid dump truck in order that

the loader/shovel boom does not swing
over the cab or the front of rigid dump
truck.

OM21123

When working in a loading area of this type, you

should remain a sufficient distance behind the rigid
dump truck being loaded. By doing this, you avoid
having your rigid dump truck damaged by spillage
from the loading vehicle. Also, by watching the posi-
tion of the rigid dump truck being loaded in relation to
the loading vehicle, you can better judge where you
should place your rigid dump truck when it is your turn
to be loaded.
OM21124

When being loaded by a front-end loader, spot your

rigid dump truck at an angle to the material being
loaded to reduce the bucket dumping time. Position
your rigid dump truck on the side of the loader that is
clear and level to provide quicker and more accurate
loader maneuvering. Positioning the rigid dump truck
downward from the loader, where possible, will pre-
vent dust from being blown back on the loader and
increase loader operator visibility, air cleaner, and
breather element service life. OM21125

6-2
 OPERATING THE RIGID DUMPER TRUCK

Aside from the loading vehicle, other vehicles, and

possibly a clean up dozer being in the loading area,
be aware of any other vehicles or personnel in the
area.

WARNING: Make sure vehicles and person-

nel are clear of your rigid dump truck before
moving. Sound your horn and wait for 5
seconds before starting the engine, revers-
ing or moving forward.

OM21126

Another method of loading rigid dump trucks is to use

both sides of the loading vehicle. In this method, one
dump truck is being loaded while another dump truck
is being put into position to await loading.

NOTE: Avoid pulling or backing your rigid dump

truck into the loading position while the
loading vehicle is moving, as rocks and
debris may fall from the loading vehicle.

OM21127

The rigid dump trucks are usually backed into position

under or beside the loading vehicle, which necessi-
tates that you make doubly sure the loaded rigid
dump truck preceding you is out of the way before
you begin moving into position.

OM21128

6-3
 OPERATING THE RIGID DUMPER TRUCK

After your rigid dump truck is loaded, the loader op-

erator will signal you to move your rigid dump truck
from under his loader. You should start for the haul
road reaching the highest practicable gear ratio as
soon as possible.

There are a few common sense precautions you can

take to prolong the life of your rigid dump truck and
make your job a safer one:

• Avoid pulling or backing your rigid dump truck into

loading position while the loading vehicle is swing-
ing or while a load is suspended over the loading
area. This is dangerous to both you and the rigid
dump truck as rocks and debris may fall from the
loading vehicle.

• Apply the Load/Dump Brake.

OM21129

• Stay in your cab while your rigid dump truck is be-

ing loaded. Stepping out of the cab could result in
possible injury.

• Use the seat belt.

OM21130

• Sound the horn to signal that you are preparing to

move the rigid dump truck.

• When pulling out of the loading area, avoid hitting

debris, rocks, and loading vehicle overflow that can
cause tire damage. Allow the clean-up dozer suffi-
cient time to clear the loading area.

OM21131

6-4
 OPERATING THE RIGID DUMPER TRUCK

HAULING

WARNING: Watch where you are going. Stay

away from people, the edge of cliffs, slide
areas, vehicles, etc.
When moving out of the loading area it may be nec-
essary to pre select a low gear range until enough
momentum has been gained to prevent the rigid
dump truck from “stalling” after up shifting. It is nor-
mally advisable to stay in low range on the soft mate-
rial until reaching firm ground or the haul road where
sufficient rigid dump truck speed will permit proper
transmission shifting.

After reaching the haul road, up shift the transmission

to the highest range possible to obtain the maximum
safe speed for the condition of the haul road.

While traveling on the haul road, maintain a sufficient

distance behind the vehicle ahead (depending on
roads, speeds, and haul road conditions). This prac- OM21132
tice should always be followed to allow sufficient safe
maneuvering and stopping room.

To avoid excessive retarding and shift cycling on

downgrades, decelerate the rigid dump truck to a safe
descent speed. Depending on driving conditions, you
may pre select a lower gear range to increase engine
retarding. Apply pressure to the retarder pedal as re-
quired to control the rigid dump truck speed, or use
the Electronic Downhill Speed Control (EDSC) feature
if equipped. See Electronic Downhill Speed Control
(EDSC) in the Operating Methods section of this
manual. Do not use brakes as this will cause exces-
sive wear at the front brake liners.

NOTE: Be aware that even in a pre selected OM21133

mode, if the engine approaches 2400 rpm,
the transmission will up shift to the next
gear range.

NOTE: Refer to the retarder operation decal in the

cab.

While traveling the haul roads, pay particular attention

to the instrument panel gauges and indicators to in-
sure that all rigid dump truck components are func-
tioning properly. If there is any indication of trouble,
pull off the haul road at the first safe opportunity, park
the rigid dump truck and stop the engine until the
trouble can be corrected.

6-5
 OPERATING THE RIGID DUMPER TRUCK

DUMPING

The dumping procedure to be followed normally de-

pends upon the type of material being hauled. Waste
materials such as overburden from a mine pit are
usually dumped over the edge of a spoil bank or piled
into large mounds. Ore, limestone, and rock to be
processed for shipment are normally dumped into a
hopper or crusher. Earth or rock hauled to a fill area,
such as a dam site or roadbed, may be dumped in a
line with other loads which are leveled by a dozer.

When waste material is being dumped over a spoil

bank, you may be directed by a dump “spotter” who
directs the dump to the designated dumping area.
When backing to the edge of the spoil bank, the
“spotter” should be watched continually and his direc-
tions followed carefully. Under no circumstances
should you stand or leave the operator’s seat to gain
better visibility while backing up. Remain in the op-
erator’s seat with the seat belt fastened. Use the rear
OM21134
view mirrors.

When dumping into a hopper or a crusher, avoid

bumping or rubbing any protective rails or timbers. If
dumping into a drive-over type hopper, care must be
taken to approach the hopper properly to prevent the
inside tires of the rear, dual wheels from rubbing
against the hopper guard rails.

When hauling material to a fill area, the loads are usu-

ally dumped in a row and leveled later with a dozer.
Each load should be dumped as close as possible to
the preceding loads. The normal dumping procedure
is to go past the preceding load and turn in line with
the dump row, then back to within a few feet of the
last load in the row before dumping. OM21135

After the load is dumped, move the hoist lever to the

FLOAT position and allow the weight of the body to
lower itself to the frame. If the body will not lower on
its own accord in the FLOAT position, move the hoist
lever to the POWER DOWN position momentarily un-
til the body is brought over center. Release the hoist
lever, allowing it to return to the FLOAT position, and
the body will come to rest on the frame.

6-6
 OPERATING THE RIGID DUMPER TRUCK

DUMPING PRECAUTIONS

The following precautions are common to dumping

procedures and should be observed:

1. Shift to N (Neutral).
2. Make sure the Load/Dump Switch is applied.

OM21136

3. Where possible, keep the rear wheels level be-

fore starting to raise the body. Greater stress is
applied to the body pivot pins, hydraulic cylin-
ders, and the frame if the wheels are not level
while the body is being raised, especially when it
reaches maximum height.

OM21137

4. Never “jump dump” by bouncing the rear wheels

against a stop rail or by jerking the hoist lever.
The shocks imposed on the rigid dump truck by
these practices over stress many components
and can cause excessive damage.

OM21138

6-7
 OPERATING THE RIGID DUMPER TRUCK

STOPPING

• Reduce engine speed.

• Apply the retarder pedal to bring the rigid dump

truck to a complete stop. After the rigid dump truck
has come to a complete stop, move the shift selec-
tor lever to the desired gear to either continue op-
eration or to N (Neutral) for parking.

NOTE: The brake pedal should be used on ex-

tremely slick haul road conditions or if
maximum braking effort is required.

NOTE: Use the brake pedal at slow speeds 5

km/h (3 mph) and only when required. This
will optimize front brake lining life.

OVERNIGHT STORAGE INSTRUCTIONS

Park the rigid dump truck, referring to “PARKING

THE RIGID DUMP TRUCK” in the “OPERATING
METHODS” section of this manual.

6-8
 TRANSPORTING THE RIGID DUMP TRUCK

TRANSPORTING - GENERAL

Specialized haul trailers for the transportation of

heavy duty construction equipment should be used.

Do not lift the rigid dump truck by the dump body

(View A). Lift the rigid dump truck with the use of an
adequate spreader bar with chains or cables
attached to shackles at the lifting locations. Lifting
locations on the rigid dump truck are identified by a
decal (View B).

When lifting or supporting the rigid dump truck, use

equipment with a weight capacity as great as or
greater than the weight of the component.

Refer to “Parking rigid dump truck, Short Term

Storage” for required procedures prior to
transporting the rigid dump truck.

NOTE: Disconnect the hoist control lever (View

C) electrical connection when the dump
body is not attached to the hoist
cylinders. This will prevent inadvertent
raising of the body or hoist cylinders
when the rigid dump truck is operated
without a dump body or when the hoist
cylinders are not attached to the dump
body.

OM21139

View C

NOTE: It is important that you know the overall

height, width, and weight of the rigid
dump truck when transporting. Check
with local officials for any special permits,
escort requirements, or regulations that OM21140
may be necessary.

7-1
 TRANSPORTING THE RIGID DUMP TRUCK

TRANSPORTING EH750-3

OM21142
OM21141

Loading Chassis with body

1. Always load and unload on a level surface.

2. The preferable shipping configuration is

presented in to the picture above, Due to the size
and weight of the rigid dump truck, it may be
disassembled to conform to the following:
y Capacity of the transporting trailer(s).
y Local weight limitations of roadways.

3. Use adequate chains, blocks (View A), cables,

etc. to secure rigid dump truck to the floor of the
trailer. Tie down locations on the rigid dump truck
are identified by decals at the front of the rigid
dump truck (1), at the sides (2) and at the rear
(3). (View C).

4. The front struts (View B) should be collapsed

and secured as shown, to lower the overall height
of the rigid dump truck and prevent the front tires
from touching the ground.

5. Transporting in foggy, dusty, or stormy weather

conditions requires additional care.

7-2
 TRANSPORTING THE RIGID DUMP TRUCK

TRANSPORTING EH1100-3

OM21143 OM21144

1. Always load and unload on a level surface.

2. The preferable shipping configuration is

presented in to the picture above, Due to the
size and weight of the rigid dump truck, it may
be disassembled to conform to the following:

yCapacity of the transporting trailer(s).

yLocal weight limitations of roadways.
y Necessity of road permits for transport.

Loading Chassis

1. The front struts (View B) should be collapsed

and secured as shown, to lower the overall height
of the rigid dump truck and prevent the front tires
from touching the ground.

2. Secure the body cylinders with a threaded

steel rod, two plates and nuts (View C) to prevent
damage to the cylinders during transportation.

3. Use adequate chains, blocks (View A), cables,

etc. to secure rigid dump truck to the floor of the
trailer. Tie down locations on the rigid dump truck
are identified by decals at the front of the rigid
dump truck (1), at the sides (2) and at the rear
(3). (View D)

7-3
 TRANSPORTING THE RIGID DUMP TRUCK

Loading Body

OM21145

OM21146

Note: The body should only be removed when

it is down and resting on the frame.

1. Disconnect the body assembly from the

following the proper procedure. See “Service
Manual”.

2. Lift the body off the chassis with the lifting

device and sling. Place the rigid dump truck
body on wooden blocks on the trailer (View A).

3. Secure the front of the body assembly to the

trailer with chains as shown; secure the rear of
the body assembly to the trailer with chains as
shown (View B).

7-4
 TRANSPORTING THE RIGID DUMP TRUCK

TRAVELING ON ROADWAYS

The transportation of rigid dump trucks from a port to a job site to another job site is becoming more and
more common.

WARNING: A rigid dump truck is a wide and slow moving rigid dump truck that may obstruct traffic
flow. Pay attention to traffic, do not allow riders other than in the trainer seat, and operate with
CAUTION.
Attach “Slow Moving Vehicle” emblem on the rear of the rigid dump truck.

NOTE: It is important that you know the overall height, width, and weight of the rigid dump truck when
traveling. Because of the oversize of the rigid dump truck, there is a high risk of producing damages
to the roads, bridges or power lines. Check with local officials for any special permits, escort
requirements, or regulations that may be necessary.

Special precautions are necessary to reduce the possibility of damage to tires and other components of the
rigid dump truck.

1. Make sure the windshield and side windows are clean.

2. Check brake pressure.
3. Make sure all loose attachments are safely anchored.
4. Close the cab door.
5. Operator must have the seat belt buckled.
6. Adjust speed according to road conditions.
7. Remember, you are responsible to know and follow the existing traffic laws and regulations.

NOTE: Axle oil can overheat during extensive high-speed traveling. It is important to stop periodically to allow
for cooling.

NOTE: Tire inflation pressure requirements on roaded rigid dump trucks vary from tire inflation pressure
requirements on working rigid dump trucks. Roading a rigid dump truck with the wrong tire inflation
pressure could result in damage to the tires. If a rigid dump truck is to be roaded between job sites, it
is important to consult your tire distributor for the recommended roading inflation pressure. Extended
distances may require stops to cool tires.

7-5
 TRANSPORTING THE RIGID DUMP TRUCK

MEMO
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7-6
 MAINTENANCE

CORRECT MAINTENANCE AND

INSPECTION PROCEDURES
Learn how to service your rigid dump truck correctly.
Follow the correct maintenance and inspection pro-
cedures shown in this manual.

Inspect the rigid dump truck daily before starting.

See Daily Walk Around Inspection Check Sheet in
OPERATION THE ENGINE section in this manual.

• Check coolant, fuel, engine oil and other fluid lev-

els.

• Check for leaks, kinked, frayed or damaged hoses SA435

and lines.

• During the walk around inspection check the gen-

eral appearance, check for noise, heat, etc.

• Check for loose or missing parts.

It there is any problem with your rigid dump truck,

have it fixed or repaired before operating or contact
your authorized Hitachi dealer.

IMPORTANT
y Use only recommended fuel and lubricants.
y Use only genuine Hitachi replacement parts.
y Failure to use recommended fuel, lubricants,
and genuine Hitachi replacement parts will
result in the loss of the Hitachi product war-
ranty.
y Never adjust the engine governor or hydrau-
lic system relief valve.
y Protect electrical parts from water and
steam.
y Never disassemble electrical components
such as engine controller, sensors, etc.

8-1
 MAINTENANCE

SERVICE YOUR RIGID DUMP TRUCK AT

SPECIFIED INTERVALS
Perform all service procedures described in this
maintenance guide.

Lubricant, make service checks, and adjustments at

intervals shown in the Maintenance Interval Guides
on the following pages.

CHECK THE HOUR METER

REGULARLY
Check the hour meter to determine when your rigid
dump truck needs periodic maintenance.
OM21034

Intervals in the Maintenance Interval Guides are for

operating in normal conditions. If your rigid dump
truck is operated in more adverse conditions, you
should service it at SHORTER INTERVALS.

USE CORRECT FUELS AND LUBRICANTS

IMPORTANT: Always use recommended fuels
and lubricants. Failure to do so will
result in rigid dumper truck

8-2
 MAINTENANCE

EH750-3, EH1100-3

PREPARE RIGID DUMP TRUCK FOR

SERVICE

Before working on the rigid dump truck, park it on a

level surface and put it in the SERVICE POSITION:

1. Engine stopped, ignition key removed (ex-

cept when service requires engine operation).

2. Tag the rigid dump truck following local lock-

out and tag procedure. Identify rigid dump truck
as “Out of Service”.

3. If body is raised, use body prop pins for

EH750-3 or body prop cable for EH1100-3.

4. The wheels blocked.

5. Dump lever in “FLOAT” position.

6. Parking brake applied.

7. Allow the rigid dump truck to cool down. For EH750-3 OM21147

8. Pressure released from all lines, tanks and

accumulators.

WARNING!
If work must be done on a warm rigid dump truck,
beware of hot fluids and components.

For EH1100-3 OM21148

8-3
 MAINTENANCE

INSTALLING BODY PROP PINS FOR EH750-3

WARNING: It is recommended that three people

be involved when installing the body prop pins:
• a rigid dump truck operator, sitting in the op-
erator’s seat,
• the person installing the body prop pins,
• and a signal person, coordinating between the
operator and the installer.

Signals commonly known by all personnel in-

volved should be provided.

WARNING: An area directly below the rear of the

body should be designated and marked as a re-
stricted area whenever the body is secured in the OM21149

raised position. No personnel should enter. Al-

though the body should be empty, material may
be stuck in the bed. This material could dislodge
and fall while the body is in the raised position.

1. Undo the lock pin (1) on each body prop pin. Care-
fully remove each, one at a time, from where they are
stored in the body. After they are removed the installer
should move away from the hinge area of the body and
frame, a safe distance.

CAUTION: Each body prop pin weighs in excess

of 4.5 kg (10 lbs).
OM21150

2. The operator can now start the engine. With the

parking brake on and set, apply the load/dump brake.

3. Lift the dump lever all the way up to the RAISE posi-
tion.

4. The pin installer then informs the signal person as to

when the body prop holes in the dump body are aligned
with the body prop holes in the frame of the rigid dump
truck.

WARNING: The pin installer should enter the

hinge area from the cab side of the rigid dump
truck, not from the rear, restricted area.

5. When this has been accomplished the operator will

release the dump lever allowing it to move to the HOLD
position.

8-4
 MAINTENANCE

6. The installer then installs each pin, one at a time,

through the aligned holes in the body and the frame,
securing each with the lock pin (1).

7. The installer then moves out from the hinge area, a

safe distance from the rigid dump truck.

8. The operator will then place the dump lever in the

FLOAT position and then shut off the engine. Before
leaving the cab he should make sure the “Out of Ser-
vice” tag is in place on the steering wheel and the key
is removed.

OM21151

OM21150

8-5
 MAINTENANCE

REMOVAL AND STORAGE OF BODY PROP PINS

FOR EH750-3

WARNING: Follow all WARNINGS and CAUTIONS

listed under INSTALLING BODY PROP PINS.

1. The operator starts and runs the engine. He makes

sure that both the parking brake and the load/dump
brake are on.

2. The operator then moves the dump lever slowly to

the RAISE position. There will have been some bleed
off of hydraulic fluid in the hoist cylinders while the body
was in the locked position. The dump lever is released,
allowing it to move to the HOLD position.

3. The person removing the body prop pins will then go

to the hinge area, undo the lock pin (1) on a body prop
pin then pull the body prop pin from the aligned holes in
the body and frame. The other body prop pin is re-
moved in the same way.

4. The installer moves out from the hinge area, a safe

distance from the rigid dump truck.

5. The operator is signaled that the body can be low-

ered, and moves the dump lever to the FLOAT position.
If the body remains in the raised position, it will be nec-
essary to momentarily shift the dump lever to the
OM21152
POWER DOWN position.

6. With the body completely down, resting on the

frame, the operator shuts off the engine.

7. The installer can now insert each body prop pin into
its storage hole in the dump body, securing it with the
lock pin (1).

IMPORTANT: Be sure the body prop pins are in their

proper storage holes.

OM21150

8-6
 MAINTENANCE

INSTALLING BODY PROP CABLE FOR

EH1100-3

WARNING: It is recommended that three people

be involved when installing the body prop Cable:
• a rigid dump truck operator, sitting in the op-
erator’s seat,
• the person installing the body prop cable,
• and a signal person, coordinating between the
operator and the installer.

Signals commonly known by all personnel in-

volved should be provided.

WARNING: An area directly below the rear of the

body should be designated and marked as a re-
stricted area whenever the body is secured in the
raised position. No personnel should enter. Al-
though the body may seem empty, material may
be stuck in the bed. This material could dislodge
and fall while the body is in the raised position.
OM21149

WARNING!
Do not use the body prop cable for towing.

The body prop cable must be inspected on a daily basis.

The illustration above shows the body prop cable in its
stored position.
OM21153

When working on a rigid dump truck with the body raised,

always securely support the body using the body prop
cable. The illustration at left shows the body prop cable
attached to the lug at the rear axle.

OM21154

8-7
 MAINTENANCE

ELECTRICAL DISCONNECTS BEFORE WELDING ON Disconnect Disconnect

THE RIGID DUMP TRUCK

Disconnect the following before performing any welding

operation on the rigid dump truck.

1. Turn the battery disconnect switch to the OFF posi-

tion.

ON21155

Main Electrical Compartment

2. At the Central Control Unit (CCU) disconnect all
connections as shown in the illustration, 2A, 2B, 1A,
1B, 1C, 1D, 3B, and 3A.

OM21156

3. At the Transmission’s Control Unit controller (TCU)

disconnect all connections as shown in the illustration,
S, T, and V.

OM21157

8-8
 MAINTENANCE

Engine Compartment

4. At the engine’s Electronic Control Module (ECM),

disconnect the 31 Pin Connectors as shown in the illus-
tration.

Disconnect

OM21261

8-9
 MAINTENANCE

Grills Removal
Some maintenance procedures will require access to the
front of the rigid dump truck. The front engine grilles are
hinged and can be removed from the rigid dump truck. The
arrows in the illustration to the right are pointing to the
location of bolts and washers that secure the front engine
grilles. Bolts and washers secure them to the frame at
both side members.

Loosen and remove all of the bolts and washers. Carefully

remove each front engine grille out and away from the
rigid dump truck.

OM2

1160

OM21161

8-10
 MAINTENANCE

RECOMMENDED LUBRICANTS for EH750-3 AND EH1100-3

NOTE: The rigid dump truck was filled at the factory to capacity with recommended lubricants meeting ambi-
ent temperatures or -18° C to 43°C (0°F to 110°F).

8-11
 MAINTENANCE

NOTE 1: For ambient temperatures below -18°C (0°F) oil viscosity should not exceed 5000 CST (2,250 SUS)
at start up. Higher viscosities may cause pump damage from cavitation and/or insufficient bearing
lubrication. Optimum viscosity at system operating temperature is 16-40 CST (80-180 SUS).

NOTE 2: Select an Allison C-4 fluid that is not a qualified Dexron III® automotive transmission fluid.

NOTE 3: Can substitute Cat T02 qualified oil, DO NOT USE CAT T04 qualified oil.
DO NOT USE EXTREME PRESSURE (EP) ADDITIVES. EP additives are known to react negatively
with friction materials in brake systems.

NOTE 4: When using a conventional Allison C-4 fluid, fluid preheat is required when operating below
-15 ˚C (5 ˚F). If preheating equipment is not available, run the transmission a minimum of 20minutes
prior to range operation.

When start-up conditions are colder than specified in the Recommended Lubricants chart, anti-wear hydraulic oil
with Viscosity Index (VI) improvers or synthesized hydrocarbon oil should be used to obtain the desired viscosi-
ties. During start-up, when the oil is at atmospheric temperature, the viscosity should not exceed 4,600 SUS or
1,000 centistokes (mm 2/s). Higher viscosities may cause pump damage from cavitations and/or incomplete bear-
ing lubrication. At the same time the viscosity should be maintained between 80-280 SUS or 16-60 CST when the
system has reached operating temperature. Consult your local lubrication specialist to obtain an oil to meet these
requirements. If suitable oil cannot be identified, consult the factory for preheating system.

Recommended Fuel
Number 2 Diesel Fuel
Grade C for ambient temperature above -18°C (0°F)
Grade B for ambient temperature below -18°C (0°F)

8-12
 MAINTENANCE

EH750-3
MAINTENANCE INTERVAL GUIDE

NOTE: Disposal of used lubricants, filters, and batteries should be done in accordance with the
rules and regulations of the local governing agencies.

BASIC PREVENTIVE MAINTENANCE REPLACEMENT PARTS

Interval (hours)
6 Months
Parts Quantity Daily As
250 500 1000 1200 or
or Required
2500
Every 10
Engine Oil Filter 2
Transmission Filter 1 Upon Indication
Transmission Breather Ele- 1
ment
Axle Breather Element 1
Hydraulic Filter Element, 1
Steering/Brake Apply
Hydraulic Filter, Hoist/Brake 1
Cooling, Element
Hydraulic Tank Breather 1
Element
Fuel Filter 1 Every 1500 Hours or 1 Year
Air Cleaner, Primary Ele- 1
ment
Air Cleaner, Safety Element 1 Replace at third cleaning or Primary Element
or as indicated by service indicator nut
Coolant Filter 1 Every 1500 Hours
Always after the system has been flushed
Cooling System, Supple-
Check concentration level every 6 months and anytime coolant
mental Coolant Additive ✮
condition is unknown.
(SCA)
Cooling Fan 1
Fan Belt 1
Filter, Air Conditioner Unit 2
Seat Belt 2 Replace every three years
Filter, Cab 2
Windshield Wiper Blade 2
Alternator Belt 1

NOTE: ✮ Supplemental Coolant Additive is to be added as per Engine Manufacturers Requirements.

8-13
 MAINTENANCE

EH1100-3
MAINTENANCE INTERVAL GUIDE

NOTE: Disposal of used lubricants, filters, and batteries should be done in accordance with the
rules and regulations of the local governing agencies.

BASIC PREVENTIVE MAINTENANCE REPLACEMENT PARTS

Interval (hours)

Parts Quantity Daily 6 Months As

250 500 1000 1200
or or 2500 Required
Every 10
Engine Oil Filter 3
Transmission Filter 1 Upon Indication
Transmission Breather Element 1
Axle Breather Element 1
Hydraulic Filter Element, Steer- 1
ing/Brake Apply
Hydraulic Filter Element, 1
Hoist/Brake Cooling
Hydraulic Tank Breather Ele- 1
ment
Fuel Filter, Secondary 2 Every 1500 Hours or 1 Year
Air Cleaner, Primary Element 1
Air Cleaner, Safety Element 1 Replace at third cleaning or Primary Element
or as indicated by service indicator nut
Coolant Filter 1 Every 1500 Hours
Always after the system has been flushed
Cooling System, Supplemental Check concentration level every 6 months and anytime coolant
✮
Coolant Additive (SCA) condition is unknown.
Cooling Fan 1
Fan Belt 1
Filter, Air Conditioner Unit 2
Seat Belt 2 Replace every three years
Filter, Cab 2
Windshield Wiper Blade 2
Alternator Belt 1

NOTE: ✮ Supplemental Coolant Additive is to be added as per Engine Manufacturers Requirements.

8-14
 MAINTENANCE

A. GREASING EH750-3 and EH1100-3

Interval (hours)
Parts Quantity
10 50 250 500 1000 1500 2000
1. Trailing Arm Bushings 4
2. King Pin 4
3. Front Axle Ride Strut 4
4. Track Rod 2
5. Body Hinge Pin 2
6. Rear Axle Ride Strut 4
7. A-Frame Pivot Bearing 1
8. Steering Cylinder 4
9. Tie Rod 2
10. Driveshaft Slip Joint 1
11. Driveshaft U-Joint 2
12. Driveshaft Slip Joint 1
13. Body Cylinder 4
14. Driveshaft U-Joint 2
15. Steering Column Driveshaft 2

NOTE: There may exist applications or severe operating conditions where the hour grease intervals shown
are not adequate. If such a situation exists, reduce the intervals to fit the conditions.

B. ENGINE EH750-3 and EH1100-3

Interval (hours)
6
Parts Quantity Daily or As
250 500 1000 1200 Months
Every Required
or 2500
10
1. Engine Oil Level, Check 1
2. Engine Oil, Change
30.3L (8.0 US gal)
a) EH750-3
83.3L (22.0 US gal)
b) EH1100-3
3. Engine Oil Filter, Replace 2
4. Crankcase Breather Tube,
Check/ Clean
1 Every 2 years or 3000 hours
a) EH750-3
3
b) EH1100-3
5. Valves Injectors, Replace
6 Every 3000 hours
a) EH750-3
12 Refer to the engine manufacturer’s manual
b) EH1100-3

8-15
 MAINTENANCE

C. TRANSMISSION EH750-3 and EH1100-3

Interval (hours)

Parts Quantity Daily or 6 Months As

250 500 1000 1200
Every or 2500 Required
10
1. Transmission Fluid Level, Check 1
2. Transmission Fluid, Change
a) EH750-3 83.8L (22.0 US gal)
b) EH1100-3 93.3L (24.6 US gal)
3. Transmission Filter, Replace 1 Upon Indication
4. Transmission Sump Strainer,
1 ✮✮
Clean
5. Transmission Cooling Line
1
Strainer, Clean
6. Transmission Breather Element,
1
Check
7.Transmission Breather Element,
1
Change
8. Differential Lubricant, Level
1
Check
9. Differential Lubricant, Change 55.0L (14.5 US gal)
for both EH750-3
& EH1100-3
10. Planetary Hubs Lubricant
1
Level, Check
11. Planetary Hubs Lubricant, 24.0L (6.3 US gal)
Change for both EH750-3
& EH1100-3
12. Axle Breather Element, Check 1
13. Axle Breather Element, Change 1

NOTE: ✮ The transmission was filled at the factory with Allison C-4 Approved Fluid 15W-40. A decal is at-
tached near the filler tube on the rigid dump truck’s frame as a reminder. It should then be changed
every 1200 hours.

NOTE: ✮ ✮ Change at transmission overhaul

8-16
 MAINTENANCE

D. HYDRAULIC STEERING/BRAKE APPLY SYSTEM EH750-3 and EH1100-3

Interval (hours)

Parts Quantity Daily or 6 Months As

250 500 1000 1200
Every or 2500 Required
10
1. Hydraulic Fluid Level, Check
2. Hydraulic Fluid, Change 112.0 L (29.6 US gal)
for both EH750-3
& EH1100-3
3. Hydraulic Filter, Replace 1
4. Accumulator, Steering, Check 1
5. Accumulator, Brake, Check 2
6. Brake Pressure, Check
7. Check Hoses and Lines All

E. HYDRAULIC HOIST/BRAKE COOLING SYSTEM EH750-3 and EH1100-3

Interval (hours)

Parts Quantity Daily or 6 Months As

250 500 1000 1200
Every or 2500 Required
10
1. Hydraulic Fluid Level, Check
265 L (70.0 US gal)
2. Hydraulic Fluid, Change for both EH750-3
& EH1100-3
3. Hydraulic Filter, Replace 1
4. Hydraulic Tank Breather Ele-
1
ment, Check
5. Hydraulic Tank Breather Ele-
1
ment, Change
6. Check Hoses and Lines All

8-17
 MAINTENANCE

F. BRAKES-SERVICE & PARKING STEERING EH750-3 and EH1100-3

Interval (hours)

Parts Quantity Daily or 6 Months As

250 500 1000 1200
Every or 2500 Required
10
1. Brake/Retarder Operation,
Check
2. Parking Brake, Check
3. Steering Operation, Check
4. Brake Visual Inspection,
Check
5. Front Brake Wear, Check
6. Rear Brake Wear, Check Every 5000 hours
7. Brake System Complete
1
Inspection and Function,

G. FUEL SYSTEM EH750-3 and EH1100-3

Interval (hours)
6
Parts Quantity Daily or As
250 500 1000 1200 Months
Every Required
or 2500
10
1. Fuel Tank Sediment, Drain 1
2. Fuel-Water Separator, Drain 1
3. Fuel Filter, Replace 1 Every 1500 Hours or 1 Year
4. Fuel Tank Mounting, Check 1
5. Hoses and Lines, Check All

H. AIR CLEANER EH750-3 and EH1100-3

Interval (hours)

Parts Quantity Daily or 6 Months As

250 500 1000 1200
Every or 2500 Required
10
1. Vacuator Valve, Check 1
2. Dust Cup, Check/Clean 1
3. Primary Filter Element,
1
Check
Replace at third cleaning of
4. Safety Filter Element,
1 Primary Filter Element
Check
or as indicated by service indicator nut
5. Intake Lines & Clamps,
All
Check

8-18
 MAINTENANCE

I. COOLING SYSTEM EH750-3 and EH1100-3

Interval (hours)
6
Item Quantity Daily or As
250 500 1000 1200 Months
Every Required
or 2500
10
1. Coolant Level, Check
2. Supplemental Coolant Addi- Concentration Level Every 6 Months and
✮
tive (SCA), Check Anytime Coolant Condition is Unknown
3. Coolant, Change
211.1L(55.8 US gal) Drain and Flush After 6000 Hours or
a) EH750-3
224.5L(59.3 US gal) 3 Years of Service
b) EH1100-3
4. Coolant Filter, Replace Every 1500 Hours
1
Always After the System has been Flushed
5. Cooling Fan, Check 1
6. Radiator, Clean 1
7. Fan Belt, Check 1

NOTE: The cooling system of the rigid dump truck was shipped with a mixture of 55% ethylene glycol and
45% water. A supplemental coolant additive (SCA), anti-corrosive agent, was also added to protect
the cooling system components. Check the coolant concentration to protect the system to -37° C (-
34° F) year round.

NOTE: ✮ Supplemental Coolant Additive is to be added as per Engine Manufacturers Requirements.

J. ELECTRICAL SYSTEM EH750-3 and EH1100-3

Interval (hours)

Quantity Daily or 6 Months As

Item 250 500 1000 1200
Every or 2500 Required
10
1. Battery Condition, Check All
2. Battery Cables and Con-
All
nections, Check
3. Electrical Wiring and Con-
All
nections, Check
4. Fuse/Relay, Check All
5. Neutral Start Circuit, Check
6. Exterior Lights, Check All
7. Back-up Alarm, Check 1
8. Horn, Check 4
9. Gauges, Check All
10. Indicator Lights, Check All
11. Headlight Aiming, Check All
12. Alternator A/C Belt, Check 1

8-19
 MAINTENANCE

K. SUSPENSION, WHEELS & TIRES EH750-3 and EH1100-3

Interval (hours)

Item Quantity Daily or 6 Months As

250 500 1000 1200
Every or 2500 Required
10
1. Struts, (X) Dimension,
4
Check
2. Wheels, Check ✮
3. Front Wheel Lubricant,
Every 15,000 hours or at major service
Check
4. Front Wheel Lubricant,
Change (per wheel)
a) EH750-3 2.8L(0.74 US gal)
Every 15,000 hours or at major service
per wheel
b) EH1100-3 4.2L(1.1 US gal) per
wheel
Refer to following
5. Tire Inflation, Check ✮✮
chart
6. Tire Condition, Check 6
7. Wheel Alignment, Check ✮✮✮

EH750-3 Tire Make and Size Michelin Bridgestone Goodyear

18.00 R 33 18.00 R 33 18.00 R 33
Tire inflation pressure 600 (87) 700 (102) 625 (91)
kPa (psi)
EH1100-3 Tire Make and Size Michelin Michelin Bridgestone Goodyear
24.00 R 35 24.00 R 35 24.00 R 35 24.00 R 35
Quarry Transport
Transport
Tire inflation pressure 550 (80) 650 (94) 700 (102) 700 (102)
kPa (psi)

NOTE: ✮ After wheel removal, check torque of bolts at 5 and 10 hours of operation.

NOTE: ✮ ✮ The tires are inflated at the factory to a minimum inflation pressure for shipping. Before placing
the rigid dump truck in service the tires must be inflated to the pressure shown which is for stan-
dard tires for rigid dump truck operation at maximum 48 km/h (30 mph). Check tire manufacturer’s
information for proper inflation.

NOTE: ✮ ✮ ✮ See your authorized Hitachi Dealer.

8-20
 MAINTENANCE

L. CAB EH750-3 and EH1100-3

Interval (hours)

Item Quantity Daily or 6 As

250 500 1000 1200
Every Months Required
10 or 2500
1. Air Filter, Clean/Change 1
2. Air Conditioner Filter,
2
Clean/Change
3. Mounts, Check 3
4. Wiper Blade Condition, Check 1
5. Windshield Washer Fluid 5.7 L (1.5 US gal)
Level, Check for both EH750-3
& EH1100-3
6. Seat Belt & Mounting, Check 2
7. Seat Belt, Replace 2 Every 3 Years
8. Air Conditioner, Check
9. Heater & Defroster, Check

M. GENERAL EH750-3 and EH1100-3

Interval (hours)
6
Item Quantity Daily or As
250 500 1000 1200 Months
Every Required
or 2500
10
1. Leaks, Check
2a. Body Prop Pins, Check
(EH750-3) 2
2b. Body Prop Cable, Check 1
(EH1100-3)
3. Main Rail, Strut and Axle Lug
Welds, Check
4. Frame Assembly, Check
5. Tightening Torque of Bolts and
Nuts, Check
6. Loose Bolts & Fittings, Check
* Oil sampling program recommended by Engine Manufacturer can be used.
*** See Operating Instructions section of this manual for operator Daily Walk Around Inspection.
**** Every 6 months or 2500 hours whichever occurs first.

NOTE: Some job–sites may require more frequent checks (i.e. heavy dust, rough roads, & etc.).

8-21
 MAINTENANCE

A. GREASING TYPICAL FOR ALL EH750-3, AND EH1100-3

Interval (hours)
Parts Quantity
10 50 250 500 1000 1500 2000
1. Trailing Arm Bushings 4
2. King Pin 4
3. Front Axle Ride Strut 4
4. Track Rod 2
5. Body Hinge Pin 2
6. Rear Axle Ride Strut 4
7. A-Frame Pivot Bearing 1

OM21158

8-22
 MAINTENANCE

A. GREASING TYPICAL FOR ALL EH750-3, AND EH1100-3

Interval (hours)
Parts Quantity
10 50 250 500 1000 1500 2000
8. Steering Cylinder 4
9. Tie Rod 2
10. Driveshaft Slip Joint 1
11. Driveshaft U-Joint 2
12. Driveshaft Slip Joint 1
13. Body Cylinder 4
14. Driveshaft U-Joint 2
15. Steering Column Driveshaft 2

8 9 11 14 13

15 8 9 10 12 13
OM21159

8-23
 MAINTENANCE

B. ENGINE EH750-3 and EH1100-3

Interval (hours)
6
Parts Quantity Daily or As
250 500 1000 1200 Months
Every Required
or 2500
10
1. Engine Oil Level, Check 1
2. Engine Oil, Change
30.3L (8.0 US gal)
a) EH750-3
83.3L (22.0 US gal)
b) EH1100-3
3. Engine Oil Filter, Replace 2
4. Crankcase Breather Tube,
Check/ Clean
1 Every 2 years or 3000 hours
a) EH750-3
3
b) EH1100-3
5. Valves Injectors, Replace
6 Every 3000 hours
a) EH750-3
12 Refer to the engine manufacturer’s manual
b) EH1100-3

8-24
 MAINTENANCE

Check, Engine Oil Level

--- Daily or Every 10 Hours

IMPORTANT: For most accurate readings, check

the oil level every day before start-
ing the rigid dump truck. Be sure
the rigid dump truck is on a level
surface.

1. Remove dipstick (1). Wipe oil off with a clean

cloth. Reinsert dipstick (1).

2. Remove dipstick (1) again. Read level. Oil

level must be between the “H” (high) mark and
the “L” (low) mark.

NOTE: Never operate the engine with the oil

level below the “L” (low) mark or above
the “H” (high) mark.

3. If necessary, add oil at the filler cap (2). Be

sure to use only recommended.

NOTE: Wait at least 15 minutes after shutting off OM21162

the engine to check the oil. This allows
time for the oil to drain to the oil pan.

8-25
 MAINTENANCE

Change Engine Oil

--- Every 500 Hours
Oil Pan

Clean Cloth
Replace Engine Oil Filter
Container
--- Every 500- Hours

4. Prepare a container of suitable capacity for the

drain oil.
OM21163

CAUTION: Engine oil may be hot. Use care

to be sure you are not burned from hot oil.

5. Bring the engine to operating temperature and

shut down the engine. Remove the oil drain
plug. Drain the oil immediately to make sure all
the oil and suspended contaminants are re-
moved from the engine.

6. Check if foreign materials like metal particles are

included in the drain oil by filtering it with a clean
cloth.
OM21164
7. Clean and check the oil drain plug threads and
the seal surface. Install the oil drain plug.
Tighten to 47 N ٠m (35 lbf ٠ ft).

8. Clean the area around the engine oil filter head.

9. Remove the filter with a strap or filter wrench.

10. Discard the filter after draining remaining oil out

of the filter and into a suitable container.

11. Clean the area around the engine oil filter head.

NOTE: The oil filter O-ring can stick on the filter

head. Make sure it is removed.

OM21165

8-26
 MAINTENANCE

12. Fill the new oil filter with clean lubricating oil.

NOTE: If not filled, the lack of lubricating oil dur-

ing the delay until the filter is pumped full
of oil is harmful to the engine.

13. Position the new filter to the filter head. Tighten

by hand until the seal touches the filter head.

14. Tighten the filter an additional three-fourths turn

after the seal contacts the filter head.
OM21166

15. Remove the oil filler cap (2) and fill with clean oil
to the correct level on the dipstick, between the
“H” (high) mark and the “L” (low) mark.

16. Operate the engine at idle speed to inspect for

leaks at the oil filter and the drain plug.

17. Shut down the engine and wait at least 15 min-

utes for the oil to drain back into the oil pan. Re-
check the oil level with the dipstick (1). Add
clean oil if necessary.

OM21167

OM21162

8-27
 MAINTENANCE

Check/Clean Crankcase Breather Tube(s)

--- Every 2 Years or 3000 Hours

1. Remove the crankcase breather tube(s) from the

breather vent tube.

2. Use solvent to clean the inside of the crankcase

breather tube(s), and dry with compressed air.

3. Use air pressure to blow through the vent tube.

4. Install a new vent tube if the one removed is

clogged.

Breather
Tube

EH750-3 OM21168

Breather
Tube

Adjust, Valves / Injectors OM21169

EH1100-3 Breather
Refer to the engine manufacturer’s manual for ser- Tubes
vice intervals.

8-28
 MAINTENANCE

C. TRANSMISSION EH750-3 and EH1100-3

Interval (hours)

Parts Quantity Daily or 6 Months As

250 500 1000 1200
Every or 2500 Required
10
1. Transmission Fluid Level, Check 1
2. Transmission Fluid, Change
a) EH750-3 83.8L (22.0 US gal)
b) EH1100-3 93.3L (24.6 US gal)
3. Transmission Filter, Replace 1 Upon Indication
4. Transmission Sump Strainer,
1 ✮✮
Clean
5. Transmission Cooling Line
1
Strainer, Clean
6. Transmission Breather Element,
1
Check
7.Transmission Breather Element,
1
Change
8. Differential Lubricant, Level
1
Check
9. Differential Lubricant, Change 55.0L (14.5 US gal)
for both EH750-3
& EH1100-3
10. Planetary Hubs Lubricant Level,
1
Check
11. Planetary Hubs Lubricant, 24.0L (6.3 US gal)
Change for both EH750-3
& EH1100-3
12. Axle Breather Element, Check 1
13. Axle Breather Element, Change 1

NOTE: ✮ Transmission fluid should be changed every 1200 hours.

OM21170

NOTE: ✮ ✮ Change at transmission overhaul

8-29
 MAINTENANCE

Check, Transmission Fluid Level

--- Daily or Every 10 Hours

Cold Fluid Level Check

Before starting the engine, check the sight gauge

on the lower, left hand side of the transmission. If
fluid is present in the sight gauge, the transmission
has sufficient fluid to permit safe starting of the en-
gine. If no fluid is present, remove the ADD (lower OM21171

plug located at the rear of the transmission. Add

sufficient fluid to bring the level within the glass of
the sight gauge or to cause a flow from the ADD
plug opening. Replace the plug. The transmission
filler tube (2) is located on the left hand side of the
rigid dump truck near where the left hoist cylinder is
mounted.

Perform a hot fluid level check.

Hot Fluid Level Check

OM21172
NOTE: Observe the condition of the oil in the
sight gauge. Foaming or spurting may
indicate a false level.

A hot fluid level check is made to determine it there

is sufficient fluid for working operation of the trans-
mission.

Shift the transmission shift selector to N neutral and

start the engine. Operate the rigid dump truck until
the transmission fluid reaches normal operating
temperature of 82-103°C (180-220°F). Then idle the
engine and apply the parking brake. Shift through
all range positions slowly to ensure all areas of the OM21173

system are filled with fluid.

Shift to N neutral and set the engine speed at idle.

Check the sight gauge. The fluid should be in the
“Safe Operational Level Area”. Add or drain oil as
necessary to bring the fluid level to this limit, the
middle of the sight gauge.

WARNING: Protect eyes (safety glasses)

and skin against contact with transmission
fluid. If fluid gets on the skin, wash the
contacted area immediately.
OM21174

8-30
 MAINTENANCE

Change, Transmission Fluid

WARNING: Hot fluid can cause severe

burns.

Drain the transmission fluid when it is warm. Warm

fluid flows more freely and carries more contami-
nants with it.

1. Prepare a container of suitable capacity for

the drain fluid.

2. Remove the drain plug from the sump to drain OM21175

the fluid. The drain plug is located at the lower

left hand side of the transmission.
Sump Drain

3. Check if foreign material like metal particles is

included in the drain fluid by filtering it with a Clean Cloth
clean cloth. Metal particles (except for the minute Container
particles indicate damage), has occurred in the
transmission.

4. Remove the drain plug located at the bottom OM21176

end of the heat exchanger. Illustration is looking

at the heat exchanger from the front of the rigid
dump truck.

OM21177

Replace Transmission Filter

--- Upon Indication

The transmission filter should be replaced when

indicated by the filter indicator. The filter indicator
light will flash 5 times. OM21178

The transmission filter is remote mounted to the

frame of the rigid dump truck on the right hand side
near the front tire.

8-31
 MAINTENANCE

5. Remove the filter bowl (1) and element (2).

Inspect for contamination. Visible dirt or con-
tamination can indicate possible failure or dam-
age. Discard the old element. Thoroughly clean
the filter bowl.

6. Using a new filter element (2) and O-ring (3),

install the filter bowl (1) to the filter head.

Refill the Transmission OM21180

7. Refill the transmission with clean transmis-

sion fluid, at the filler tube (2). Continue to pour
fluid into the transmission until the correct level is
indicated at the sight gauge or at the ADD check
plug.

NOTE: The transmission was filled at the factory

with Allison C-4 Approved Fluid 15W-40.
A decal is attached near the filler tube on
the rigid dump truck’s frame as a re-
minder.
NOTE: Transmission fluid should be changed
every 1200 hours.

8. Start the engine and let it idle for two or three

minutes with the gear selector in neutral. If the
transmission oil pressure gauge fluctuates and
will not stabilize during this period, add more
fluid.

9. After enough fluid is added to stabilize the

pressure, operate the rigid dump truck through
all gear ranges until the transmission fluid
reaches operating temperature. Stop the rigid
dump truck and check the fluid as outlined under
Hot Fluid Level Check.

10. Carefully inspect for fluid leakage while the OM21181

engine is running.

8-32
 MAINTENANCE

Clean, Transmission Sump Strainer

--- As Required
Change at Transmission Overhaul

1. Drain the transmission fluid. Refer to Drain

Transmission Fluid.

2. Remove the cylindrical strainer assembly lo-

cated in the sump.

3. Clean the strainer assembly thoroughly.

4. Install the strainer and cover using a new

cover gasket.

5. Refill the transmission with clean transmis-

sion fluid. Refer to Refill the Transmission. OM21182

Clean, Cooling Line Strainer

--- Every 1200 Hours

1. Clean the area around the strainer which is

located in the line between the transmission and
the transmission oil cooler on the left hand side
of the rigid dump truck.

2. Remove the plug in the flange cover, allowing

removal of the screen.

3. Clean the screen in a suitable cleaning sol-

vent or by using a brush. Do not allow trapped
material to harden on the screen as it will be dif-
ficult to remove.

4. Reinstall the screen and secure in place with OM21183

the plug.

8-33
 MAINTENANCE

Check, Transmission Breather Element

--- Every 1000 Hours

The Transmission breather is remote mounted be-

hind the cab. The breather prevents pressure
buildup within the transmission. Keep the breather
clean and the passage open.

5. Clean the area around the transmission

breather.

6. Loosen and remove the nut and washer (1) at

the top of the breather.

7. Lift off the breather cover (2).

8. Check the breather filter element (3).

1

2
Change, Transmission Breather Element
--- Every 6 Months or 2500 Hours or
As Required
3
9. Clean the area around the transmission
breather.

10. Loosen and remove the nut and washer (1) at

OM21184
the top of the breather.

11. Lift off the breather cover (2).

12. Remove and discard the old breather filter

element (3).

13. Install a new breather element (3)

8-34
 MAINTENANCE

Check Level, Differential Lubricant

--- Every 250 Hours

1. Clean the area around the level plug (1).

2. Remove the plug and check the lubricant

level.

3. Add lubricant as required at plug (1) opening

until the level is at the plug opening.

4. Clean and install the level plug (1).

Change, Differential Lubricant

--- Every 1000 Hours

WARNING: Protect eyes (safety glasses)

and skin against contact with lubricant. If
fluid gets on the skin, wash the contacted
area immediately.

1. Clean the area around the level plug (1) and

the drain plug (2).

2. Remove the differential drain plug (2) from

the axle housing and drain the lubricant into a
container of suitable capacity. Clean and install
the drain plug (2).

3. Remove the level plug (1) from the axle hous-

ing and add lubricant until the level is at the plug
opening. Clean and install the level plug (1). OM21185

NOTE: The lubricant oil in the differential and

the rear wheel planetary are common
with each other. When changing the dif-
ferential oil, the planetary oil in each
wheel should also be changed.

8-35
 MAINTENANCE

Check Level, Planetary Hubs Lubricant

--- Every 250 Hours

Check the lubricant level in both rear planetary

hubs. Make sure the horizontal “Oil Level” indicator
mark on the planetary carrier is parallel with the
ground.

1. Clean the area around the axle shaft cover

bolt (1) that is immediately next to the “Oil Level”
indicator mark.

2. Remove cover bolt (1) and check that the lu-

bricant is at the opening.

3. If lubricant is not seen, clean the area around

the fill plug (2).

4. Loosen and remove fill plug (2) and add lubri- OM21186
cant until the level is at the opening of cover bolt
(1).

5. Clean and install bolt (1) and plug (2).

Change, Planetary Hubs Lubricant

--- Every 1000 Hours

WARNING: Protect eyes (safety glasses)

and skin against contact with lubricant. If
fluid gets on the skin, wash the contacted
area immediately.

Change the lubricating oil in both rear planetary

hubs.

1. Turn both wheels until the planetary drain

plugs (3) are at the 6 o’clock position.

2. Clean the area around the drain plug (3) from

each planetary and remove the plugs.

OM21187
3. Drain the lubricant from each planetary into a
suitable container. Clean and install the drain
plugs (3).

4. Clean the area around the axle shaft cover

bolt (1) and remove. Clean the area around the
oil fill plug (2) and remove.

8-36
 MAINTENANCE

5. Add lubricant as needed at fill plug (2) until

the lubricant flows from cover bolt (1) hole. Clean
and install both the cover bolt (1) and the oil fill
plug (2). Do not Over-Fill.

12 Check, Axle Breather Element

--- Every 1000 Hours

The axle breather is remote mounted on the frame,

directly above the rear axle.

1. Clean the area around the axle breather.

2. Loosen and remove the nut (1) at the top of

the breather.

3. Lift off the breather cover (2).

OM21188

4. Check the breather filter element (3).

13 Change, Axle Breather Element

--- Every 6 Months or 2500 Hours or
As Required

1. Clean the area around the axle breather.

2. Loosen and remove the nut (1) at the top of

the breather.

3. Lift off the breather cover (2).

4. Remove and discard the old breather filter

element (3). OM21189

5. Install a new breather element (3)

8-37
 MAINTENANCE

D. HYDRAULIC STEERING/BRAKE APPLY SYSTEM EH750-3 and EH1100-3

Interval (hours)
Parts Quantity 6 Months As
Daily or 250 500 1000 1200
or 2500 Required
Every 10
1. Hydraulic Fluid Level, Check 1
2. Hydraulic Fluid, Change 112.0 L (29.6 US gal)
for both EH750-3
& EH1100-3
3. Hydraulic Filter, Replace 1
4. Accumulator, Steering, Check 1
5. Accumulator, Brake, Check 2
6. Brake Pressure, Check
7. Check Hoses and Lines All

8-38
 MAINTENANCE

Check, Hydraulic Fluid Level

Steering/Brake Apply
--- Daily or Every 10 Hours

The dual purpose hydraulic tank is divided into two

sections. One section contains the steering and
brake apply oil and the other section contains the
hoist and brake cooling system oil.

1. Check the fluid level prior to the start of each

shift, with the rigid dump truck on level ground,
the body lowered and the engine off.

2. The level should be between the two welded

tabs next to the sight gauge.

NOTE: Observe the condition of the oil in the

sight gauge. Foaming or spurting may
indicate a false level.

NOTE: If fluid is needed, remove any dirt from

around the filler cap before opening.

OM21190
NOTE: A thermometer is incorporated into the
sight gauge.

3. If fluid is needed, remove the filler cap and

add clean fluid as needed.

4. With the engine running, the oil level in the

steering and brake apply section of the hydraulic
tank will drop and should be seen in the sight
gauge opposite the “Engine Running” symbol
decal.

8-39
 MAINTENANCE

Change, Hydraulic Fluid

Steering/Brake Apply
--- Every 6 Months or 2500 Hours

WARNING: Release all system pressure

slowly before working on any part of the
steering system. Once the engine is shut-
down, turn the steering wheel several
times to relieve any hydraulic pressure
that may be present in the lines.

High pressure hydraulic oil can cause se-

vere burns.

1. Clean any dirt away from the top of the hy-

draulic tank.

2. Prepare a container of suitable capacity for

the drain fluid.

3. Clean dirt away from the drain plug. Remove

the drain plug from the bottom of the steer-
ing/brake apply section of the hydraulic tank and
allow the fluid to drain. OM21191

4. Remove the bolts and washers which secure

the adapter assembly for the steering suction
hose assembly to the back of the hydraulic tank.
Carefully remove the adapter assembly and the
attached strainer from the tank. Remove and
discard the O-ring.

5. Make sure the strainer is clean and free of

contaminants. Clean and or replace as neces-
sary.

8-40
 MAINTENANCE

6. Clean the inside of the hydraulic tank.

7. Install a new O-ring to the adapter assembly.

Install the strainer into the tank and secure the
adapter assembly with bolts and washers. Install
the drain plug.

8. Remove the filler cap and add clean hydraulic

fluid until the fluid level is between the welded
tabs next to the sight gauge. Replace the filler
cap.

9. Start the engine. Allow the fluid to reach op-

erating temperature. Turn the steering wheel
several times. Check the hydraulic tank, the hy-
draulic steering lines and the steering cylinders
for leaks.

10. Stop the engine and wait for three minutes for
the fluid to drain back into the tank. Check the
fluid level. Add clean hydraulic fluid as needed
until the level is between the welded tabs next to
the sight gauge.

8-41
 MAINTENANCE

Replace, Hydraulic Filter

--- Every 6 Months or 2500 Hours

1. Shut the engine off and block the wheels.

2. Remove the filter cover with a spanner

wrench or an open end wrench.

3. Remove the hold down assembly and the re-

lief valve.

4. Remove the old element and replace with a

new element.

5. Reverse the removal procedure and check for

leaks.

OM21192

8-42
 MAINTENANCE

Check, Steering Accumulator

--- Daily or Every 10 hours

The steering accumulator should be checked at

the beginning of each shift as follows:

OM21194

1. With the engine off, check hydraulic steer-

ing/brake fluid level explained previously.

2. Start the engine, after running the engine for

one minute at idle, the fluid level in the sight
gauge should be at the symbol decal for “engine
running”.

OM21190

8-43
 MAINTENANCE

Check, Brake Accumulator Capacity

--- Every 250 Hours and
--- Every 1000 Hours

Visually inspect daily for leaks and damage.

250 Hours. Secondary capacity check procedure:

Insure that all systems are at operating range.
Place the shift selector in N, neutral, apply the
parking brake and place the hoist lever in the hold
position. Release the brakes and/or the load
dump brake. Shut the engine off and wait 3 min-
utes for the steering accumulator to bleed down.
Apply the brakes and release rapidly. Five (5)
complete applies should be achieved without (low
pressure sensor) automatic application. Check
accumulator pre-charge (refer to 1000 Hour
check) and/or inspect system for excessive leak-
age if capacity is less than above stated.

NOTE: Above procedure insures that at least OM21195

one axle has capacity for 5 full applies.

1000 Hours. Check the accumulator for proper pre-

charge by removing the bolts that secure the cover
plate over the test port.

With the engine off, fully stroke the brake pedal until
no force is required to pump the pedal. This should
happen suddenly. This means that the automatic
application of the Low Pressure Sensor Valve has
occurred. Brakes are now applied to all four wheels.

Use the bleeder at each of the front brake heads,

and at each of the rear wet disc brake assemblies
and slowly exhaust brake oil into a suitable con-
tainer.

Or the check can be made at the brake valve which

is located at the front of the cab, behind the exterior
panel. Checking it at the brake valve will require the
Hitachi pressure testing kit. Refer to Special Tools in
the Technical Manual.

From the pressure testing kit, take a hose line and

place one end into a suitable container. Attach the
end with the fitting to the front brake apply port.
Slowly tighten the fitting until oil flows into the con-
tainer. When the oil flow stops, remove the fitting
and hose and repeat the procedure by attaching the
end with the fitting at the rear brake apply port.

8-44
 MAINTENANCE

Now that it is confirmed that all brake apply pres-

sure has been removed from the front and rear
brake circuits, it should also be understood that
there is no longer any oil pressure remaining in the
accumulators. Attach a suitable gauge to the front
accumulator and check the pressure. Then attach
the pressure gauge to the rear accumulator and
check the pressure. Precharge pressure should
read 8.3 MPa ± 0.18 MPa (1200 ± 25 psi).

NOTE: The hydraulic pressure must be bled

from the accumulators to insure an ac-
curate precharge reading.

Check, Brake Pressure.

Release Procedure --- Every 1000 Hours

With the engine off, pump the brake pedal (ap-

proximately 9 times) until the low pressure sensor
automatically applies the brakes.

Brakes are now applied to all four wheels.

Use the bleeder at each of the front brake heads,

and at each of the rear wet disc brake assemblies,
and slowly exhaust brake oil into a suitable con-
tainer.

Or the check can be made at the brake valve which

is located at the front of the cab, behind the exterior
panel. Checking it there will require the Hitachi
pressure testing kit. Refer to Special Tools in the
Technical Manual.

From the pressure testing kit take a hose line and

place one end into a suitable container. Attach the
end with the fitting to the front brake apply port.
Slowly tighten the fitting until oil flows into the con-
tainer. When the oil flow stops, remove the fitting
and hose and repeat the procedure by attaching the
end with the fitting at the rear brake apply port.

Check the brakes, retarder, and the parking brake

for correct operation daily. Report any unusual per-
formance to proper service personnel. A daily check
of the brake operation is a must.

Check, Hydraulic Steering/Brake Apply

Hoses and Lines
--- Every 250 Hours

8-45
 MAINTENANCE

E. HYDRAULIC HOIST/BRAKE COOLING SYSTEM EH750-3 and EH1100-3

Interval (hours)

Parts Quantity Daily or 6 Months As

250 500 1000 1200
Every or 2500 Required
10
1. Hydraulic Fluid Level, Check 1
2. Hydraulic Fluid, Change 265 L (70.0 US gal)
for both EH750-3
& EH1100-3
3. Hydraulic Filter, Replace 1
4. Accumulator, Steering, Check 1
5. Accumulator, Brake, Check 2
6. Brake Pressure, Check
7. Check Hoses and Lines All

8-46
 MAINTENANCE

Check, Hydraulic Fluid Level

Hoist/Brake Cooling System
--- Daily or Every 10 Hours

The dual purpose hydraulic tank is divided into two

sections. One section contains the hoist and brake
cooling system oil and the other section contains
the steering and brake apply oil.

1. Check the fluid level prior to the start of each

shift, with the rigid dump truck on level ground,
the body lowered and the engine off.

2. The level should be between the two welded

tabs next to the sight gauge.

NOTE: If fluid is needed, remove any dirt from

around the filler cap before opening.

NOTE: A thermometer is incorporated into the OM21196

sight gauge.

3. If fluid is needed, remove the filler cap and

add clean fluid as needed.

8-47
 MAINTENANCE

Change, Hydraulic Fluid

Hoist/Brake Cooling
---Every 6 Months or 2500 Hours

WARNING: Release all system pressure

slowly before working on any part of the
hydraulic system.

High pressure hydraulic oil can cause se-

vere burns.

1. Clean any dirt away from the top of the hy-

draulic tank.

2. Prepare a container of suitable capacity for

the drain fluid.
OM21197

3. Clean dirt away from the drain plug. Remove

the drain plug from the bottom of the hoist/brake
cooling section of the hydraulic tank and allow
the fluid to drain.

4. Remove the bolts and washers which secure

the three adapter plates to the back of the hy-
draulic tank. Carefully remove each adapter
plate, O-ring and diffuser or suction strainer. Dis-
card the O-rings.

5. Make sure the strainer strainers and diffuser

are clean and free of contaminants. Clean and or
replace as necessary.

8-48
 MAINTENANCE

6. Clean the inside of the hydraulic tank.

7. With the suction strainer and diffusers In-

stalled on the appropriate plates, install new O-
rings to the adapter plates and secure each to
the back of the hydraulic tank with the bolts and
washers.

8. Install the hose assemblies.

9. Remove the filler cap and add clean hydraulic

fluid until the fluid level is at the two welded tabs
next to the sight gauge. Replace the filler cap.

10. Start the engine. Allow the fluid to reach op-

erating temperature. Raise the body several
times. Check the hydraulic tank, hydraulic lines,
and hoist cylinders for leakage.

11. Stop the engine and wait for three minutes for
the fluid to drain back into the tank. Check the
fluid level. Add clean hydraulic fluid as needed
until the level is between the welded tabs next to
the sight gauge.

8-49
 MAINTENANCE

Replace, Hoist Filter Element

--- Every 6 Months or 2500 Hours

WARNING: Hot fluids can cause severe

burns.

1. Shut the engine off and block the wheels.

2. Remove the plug and O-ring at the bottom of

the filter bowl and drain the oil into a suitable
container.

3. Remove the bowl and element and carefully

inspect for contamination. Visible dirt or contami-
nation can indicate possible component damage.
Discard the element.

4. Visually inspect the remaining components for

possible damage or malfunction. Replace as
necessary. Clean the inside of the bowl.

5. Using a new filter element and O-ring, re-

verse the removal procedure, tighten the cap in
the motion control valve pilot line and check for
leaks.

OM21198

8-50
 MAINTENANCE

Check, Hydraulic Tank Breather Element

--- Every 1000 Hours
1
The hydraulic reservoir breather is remote
mounted behind the cab. Keep the breather clean
and the passage open.
2
6. Clean the area around the hydraulic breather.

7. Loosen and remove the nut and washer (1) at

the top of the breather.
3
8. Lift off the breather cover (2).

9. Check that the breather filter element (3) is

not clogged and that passages are open. OM21200

Change, Hydraulic Tank

Breather Element
--- Every 6 Months or 2500 Hours

1. Clean the area around the hydraulic breather.

2. Loosen and remove the nut and washer (1) at

the top of the breather.

3. Lift off the breather cover (2).

4. Remove and discard the old breather filter

element (3).

5. Install a new breather element (3)

Check, Hydraulic Hoist/Brake

Cooling System Hoses and Lines
--- Every 250 Hours

8-51
 MAINTENANCE

F. BRAKES-SERVICE & PARKING STEERING EH750-3 and EH1100-3

Interval (hours)

Parts Quantity Daily or 6 Months As

250 500 1000 1200
Every or 2500 Required
10
1. Hydraulic Fluid Level, Check
112.0 L (29.6 US gal)
2. Hydraulic Fluid, Change for both EH750-3
& EH1100-3
3. Hydraulic Filter, Replace 1
4. Hydraulic Tank Breather Ele-
1
ment, Check
5. Hydraulic Tank Breather Ele-
1
ment, Change
6. Check Hoses and Lines All

8-52
 MAINTENANCE

Check, Brake Operation

Check, Brakes/Retarder
Operation
--- Daily or Every 10 Hours

1. Inspect visually for damage or leaks.

2. Immediately report any stopping or grade

holding deviation from “familiar” performance.

Check, Brakes/Retarder
Operation
--- Every 1000 hours OM21069

1. Check brake pressure.

2. Completely inspect the brakes, brake valve,

brake accumulators and related hoses, plumb-
ing, for leaks and/or damage.

3. Check front brakes for wear and damage.

OM21068

8-53
 MAINTENANCE

Check, Parking Brake

--- Daily or Every 10 Hours

1. Inspect visually for damage and leaks.

2. Check Operation.

Check, Parking Brake

--- Every 1000 Hours

1. Inspect the brake, the linkage and the actua-

tor for leaks or damage.

The following procedure may be performed as often

as based on specific operating environment.

Holding Capacity Procedure

With the rigid dump truck is fully loaded, descend a
typical grade on the job site and completely stop the
rigid dump truck. Hold the rigid dump truck using
the brakes. Select neutral. Apply the parking brake
and release the brakes. The rigid dump truck
should not move.

NOTE: While performing the above test, make

sure that the Load/Dump brake is not OM21103

applied.

Check, Steering Operation

--- Daily or Every 10 Hours

The steering system can be checked with the en-

gine running as follows:

1. The steering wheel should turn the front

wheels easily to the left and to the right without
and binding.

2. The panel gauge should show system pres-

sure at “normal”. OM21201

8-54
 MAINTENANCE

G. FUEL SYSTEM EH750-3 and EH1100-3

Interval (hours)
6
Parts Quantity Daily or As
250 500 1000 1200 Months
Every Required
or 2500
10
1. Fuel Tank Sediment, Drain 1
2. Fuel-Water Separator, Drain 1
3. Fuel Filter, Replace 1 Every 1500 Hours or 1 Year
4. Fuel Tank Mounting, Check 1
5. Hoses and Lines, Check All

8-55
 MAINTENANCE

Drain, Fuel Tank Sediment

--- As Required

Periodically, water and sediment should be removed

from the fuel tank. This should be done when the
fuel tank is almost empty. Close the fuel line shutoff
valve at the back of the fuel tank. Remove the drain
plug from the bottom of the fuel tank. Drain water
and sediment into a suitable container. When clean
fluid is visible install the drain plug. Fill the fuel tank
before opening the fuel line shutoff valve.

Fill the fuel tank at the end of each work shift to

minimize moisture and condensation within the tank.

OM21202
NOTE: Running out of fuel during operation is
detrimental to engine life.

Check the fuel tank and fuel system daily for leaks.

Remove the fuel filler cap from the fuel tank. Re-
move the strainer from the filler neck and clean.
Reinstall the cleaned strainer or replace it with a new
one.

8-56
 MAINTENANCE

Drain, Fuel-Water Separator

--- Daily or Every 10 hours

The engine is equipped with a fuel-water separator,

built into the fuel filter. Drain the water and sediment
from the separator daily.

1. Shut off the engine.

2. Loosen the drain valve nut completely so the

valve drops down from the filter 25.4 mm (1 inch).

3. Drain the filter sump of water until clear fuel is

visible.

NOTE: The thumb nut must be loosened enough

so that the valve drops down to expose
the vent slots in the valve.

4. Tighten the drain valve nut to stop draining.

OM21203

8-57
 MAINTENANCE

Replace, Fuel Filter

--- Every 1500 Hours or 1 Year

WARNING: Fuel is flammable. Keep all

cigarettes, flames, pilot lights, arching equip-
ment, and switches out of the work area and
areas sharing ventilation to avoid severe per-
sonal injury when working on the fuel system.

1. Disconnect the wiring harness from the water-

in-fuel sensor. Clean the area around the fuel fil-
ter head and filter.
OM21204

2. Remove the fuel filter with a filter wrench.

3. Use a clean, lint-free towel to clean the filter

head gasket surface.

OM21205

4. Install a Hitachi genuine replacement fuel fil-

ter/water separator.

OM21206

8-58
 MAINTENANCE

5. Apply a thin coating of clean engine oil to the

filter gasket surface.

6. Fill the filter with clean fuel prior to installation.

OM21207

7. Install the filter on the filter head. Turn the filter

until the gasket contacts the filter head surface.

8. Tighten the filter an additional ¾ of a turn after

the gasket contacts the filter head surface.

CAUTION: Mechanical over tightening of

the filter can distort the threads or damage the
OM21208
filter element seal.

9. Rotate the water-in-fuel sensor on the filter to

desired location and connect the wiring harness.

8-59
 MAINTENANCE

Check, Fuel Tank Mounting

--- Every 1000 hours

Check the three strap assemblies and the lock

nuts securing them to brackets.

OM21209

Check Hoses and Lines

--- Every 1000 hours

Check for leaks and replace any damaged hose

assemblies, (2), tube assembly (7) or mounting
hardware. Replace missing bolts, nuts, and washers.
Tighten bolts to the specified torque.

1. Fuel Tank 5. Hose Assembly

2. Hose Assembly 6. Fuel Cooler
3. Fuel Filter 7. Tube Assembly
4. Fuel Pump 8. Hose Assembly

OM21210

8-60
 MAINTENANCE

H. AIR CLEANER EH750-3 and EH1100-3

Interval (hours)
Parts Quantity 6 Months As
Daily or 250 500 1000 1200
or 2500 Required
Every 10
1. Vacuator Valve, Check 1
2. Dust Cup, Check/Clean 1
3. Primary Filter Element,
1
Check
Replace at third cleaning of
4. Safety Filter Element, Check 1 Primary Filter Element
or as indicated by service indicator nut
5. Intake Lines & Clamps,
All
Check

8-61
 MAINTENANCE

Check, Vacuator Valve

--- Daily or Every 10 Hours

The vacuator valve at the dust cup should be

checked during the “Daily Walk Around Inspection”.
Squeeze the vacuator valve to expel any dirt. Check
the valve also for damage and replace if necessary

Check/Clean, Dust Cup

--- Every 250 Hours

1. Loosen the clamp (1).

2. Remove the dust cup (2).

OM21211

3. Clean the inside of the dust cup.

4. There is a gasket between the dust cup and

body assembly. Check to be sure it is not dam-
aged or twisted when reinstalling the dust cup.

The air cleaner prevents dust and other impurities

from entering the engine. Intake air first passes
through the outer, primary element and then through
the inner, safety element. Engine wear is largely
affected by the cleanliness of the intake air; there-
fore it is very important to check the air cleaners
regularly and to service them correctly.

The yellow filter light in the monitor panel, illumi-

nates when the air cleaner, steering, hydraulic, or
transmission filters need service. The Contronic
Display Unit will indicate which of these filters need
to be serviced. See Alarm Messages under the Con-
tronic Display Unit. “E Clean air filter 1” will be dis-
played to indicate air cleaner service is required.
Service the outer, primary element. If, after the pri-
mary element is serviced, the filter light still illumi-
nates and “E Clean air filter 1” continues to be dis-
played, the inner, safety element should be OM21212

changed. Replacement of the inner, safety element

should be done by qualified service personnel only.

8-62
 MAINTENANCE

Service Air Cleaner,

Primary Filter Element
--- As Required

Service the air cleaner primary filter element when

the Contronic display indicates, “E Clean air filter 1”.

1. Shut down the engine. Wipe the dirt off of the

entire air cleaner assembly.

2. Undo the clips securing the cover (1) to the

upper body assembly (6). Remove the cover and
the gasket (2).

3. Loosen and remove the wing nut (3) and

washer (4). Remove the primary element (5)
carefully. Accidentally bumping it while still inside 6
the housing means dirt and dust trapped by the
element can dislodge and contaminate the clean
side of the filter housing.

4. Replace the primary element (5).

NOTE: Never leave an air cleaner open longer

than necessary. An open air cleaner is a
potential direct dust entry to your engine.
If the primary filter element is not going
to be changed immediately, cover the
opening.

4
3

2
1

OM21213

8-63
 MAINTENANCE

The primary element (5) may be cleaned and re-

used. Two methods are most commonly used.

• It is best to use a commercial heavy-duty air filter

element washing service whose operators are
trained in proper washing techniques and inspec-
tion precautions. Some commercial air filter ele-
ment washing services do warranty the elements
they wash. Select a service that does, and make
sure their warranty covers repair of engine dam-
age resulting from a defective washed element.

• If a commercial washing service is not available,

the most effective cleaning method is to soak the
element in water which contains a non-sudsy de-
tergent. Prevent dirty water from making contact
with the clean side of the element. After soaking, 6
rinse the element from the clean side to the dirty
side to dislodge the dirt with pressure not exceed-
ing 276 kPa (40 psi) without a nozzle. A pressure
nozzle must not be used, as it may damage the
filter element. The element will dry by itself in one
or two days time, or less if special convection dry-
ers are available for this purpose. Warm air must
be circulated with temperature less than 71° C
(160° F). Do not use a light bulb to dry the ele-
ment.

NOTE: Used heavy-duty air filter elements, after

the most thorough cleaning, usually have
5
60-80 percent of the life of new filter
elements. Each subsequent cleaning 4
yields progressively reduced dust capac-
3
ity.
2
NOTE: Reuse of cleaned heavy-duty air filter 1
elements, because of their shortened
service life, increases the likelihood of
improper air cleaner servicing. Each time OM21213

the air intake system is serviced, it is ex-

posed to the chance of miss-service.

NOTE: Heavy-Duty air filter element manufac-

turers do not warranty their products
once is has been cleaned.

8-64
 MAINTENANCE

Service Air Cleaner,

Safety Filter Element
--- At third cleaning of primary filter
element or as indicated by the service
indicator nut.

NOTE: Do not remove the safety element (9)

except to change it. The safety element
is not intended to be cleaned. Replace
the safety element after the third clean-
ing of the primary element (5). The fre-
quency of air cleaner service depends on
the working conditions of the rigid dump
truck,

NOTE: The service indicator nut (7) on the sec- 6

ondary filter element (9) is a guide for
replacing the secondary filter element. A
green dot in the window indicates that
the filter does not need replacing. If the
green dot is not in the window, the filter 9
is dirty and a new filter must be installed.
Do not clean the secondary filter ele-
ment. 8

5. To remove the safety element (9), first remove

the cotter pin from the service indicator nut (7).
Remove the nut and the washer (8). Then care- 7
fully remove the safety element (9) from the up-
per body assembly (6).
5
NOTE: To reset the service indicator nut (7),
apply air suction on the window until the
green dot reappears.

6. Clean the inside of the upper body assembly

carefully. Dirt left in the housing has the potential
of direct entry to the engine. OM21214

8-65
 MAINTENANCE

7. Check the pre-cleaner filter tubes in the lower

body assembly (10). Light dust plugging of tubes
can be removed with a stiff fiber brush. Loosen
the clamp (11) then remove it, also gasket (12)
and dust cup (13) in order to clean the tubes.

8. If heavy plugging of tubes with fibrous mate-

rial is evident, remove the lower body assembly
(10) for cleaning with compressed air or water
not exceeding 71° C (160° F). Loosen clamp (14)
then remove it and gasket (15) then the lower
body assembly (10).

WARNING: When using regulated com-

pressed air, wear proper clothing and equip- 11
12
ment. Use extreme caution to avoid injury.
10

NOTE: Use extreme caution when using com-

pressed air. Keep dirt from entering the 13
engine’s intake system.

9. Assembly of the air cleaner is in reverse order

of disassembly. Use new gaskets and O-rings.

10. If further service is required, notify service

personnel.

14
15

10 OM21215

Check, Air Intake Lines and Clamps

--- Every 250 Hours or as Required

Check the intake elbows, tubes and clamps be-

tween the air cleaner and the engine air intake
tubes. Replace any elbows and tubes that are
cracked or damaged. Tighten any loose clamps.

OM21216

8-66
 MAINTENANCE

I. COOLING SYSTEM EH750-3 and EH1100-3

Interval (hours)
Item Quantity 6 Months As
Daily or 250 500 1000 1200
or 2500 Required
Every 10
1. Coolant Level, Check
2. Supplemental Coolant Addi- Concentration Level Every 6 Months and
✮
tive (SCA), Check Anytime Coolant Condition is Unknown
3. Coolant, Change
211.1L(55.8 US gal) Drain and Flush After 6000 Hours or
a) EH750-3
224.5L(59.3 US gal) 3 Years of Service
b) EH1100-3
4. Coolant Filter, Replace Every 1500 Hours
1
Always After the System has been Flushed
5. Cooling Fan, Check 1
6. Radiator, Clean 1
7. Fan Belt, Check 1

NOTE: The cooling system of the rigid dump truck was shipped with a mixture of 55% ethylene glycol and
45% water. A supplemental coolant additive (SCA), anti-corrosive agent, was also added to protect
the cooling system components. Check the coolant concentration to protect the system to -37° C (-
34° F) year round.

NOTE: ✮ Supplemental Coolant Additive is to be added as per Engine Manufacturers Requirements.

8-67
 MAINTENANCE

Check, Coolant Level

--- Daily or Every 10 Hours

WARNING: Do not remove the pressure cap

from the surge tank when the engine is hot.
Wait until the temperature is below 50° C
(120° F) before removing the pressure cap.
Failure to do so can result in personal injury
from hot coolant spray or steam.

1. When the engine is cold, coolant should be

seen in the sight gauge at the front of the surge
tank.
OM21091

Add Coolant as Required

2. Depress the red button on top of the pressure

cap to relieve system pressure. Then remove the
pressure cap slowly.

3. Add coolant as necessary till it is seen in the

sight gauge.

NOTE: Do not add a cold coolant mixture to a hot

engine. Engine castings can be damaged.
Allow the rigid dump truck to cool down
before adding coolant.

OM21217

8-68
 MAINTENANCE

Check, Supplemental Coolant Additive

(SCA)
--- Every 500 Hours or As Required

Supplemental Coolant Additive (SCA), Part Number

E12977347, is available through your authorized Hi-
tachi distributor. It comes in 20 units or 1.89 L (2 US
quarts). SCA protects the cooling system from rusting.
A protective film adheres to the to the cylinder liner to
prevent the liner from cavitations. It also reduces
sediments in the engine coolant passage.

NOTE: An insufficient concentration of Supple-

mental Coolant Additives will result in liner
pitting and engine failure.

The Supplemental Coolant Additive (SCA) concentra-

tion must not fall below 1.2 units or exceed 3 units per
gallon of cooling system capacity.

OM21218

Test Kit

Order a test kit from your authorized Hitachi distribu-

tor. Order Part Number E12980179. The kit, shown in
the illustration, includes; a bottle of 50 test strips (a
color chart is printed on the outside of the bottle), a
plastic syringe, and a small plastic container.

Test Kit Precautions

• The coolant sample to be tested must be between

10 and 54° C (50 and 130° F). If the sample is too
cold or too hot, you will get incorrect results.

• To get the best color match results, compare test

strip pads to the color chart on the bottle in day-
light or under cool white florescent lighting. If un-
sure about a specific color match when a test
does fall between two colors on the color chart, OM21219
choose the lower numbered block. It is safer to
underestimate your results than to overestimate.

• The test strips do have a limited shelf life and are

sensitive to humidity and extreme heat. Proper
handling and storage is necessary to protect the life
of the strips.

8-69
 MAINTENANCE

• Keep the cap tightly sealed on the test strips bottle

except when removing a strip. Store away from di-
rect sunlight and in an area where the temperature
will generally stay below 32° C (90° F).

• Do not use the test strips after the expiration date

stamped on the bottle.

• Discard the kit if any of the pads on the unused

strips have turned light brown or pink.

• Use one strip at a time, and take care not to touch

any of the pads on the strip. Doing so will contami-
nate the pads and affect the test results.

• If the strip container is left uncapped for 24 hours,

moisture in the air will render the strips useless, al-
though no discoloration will be evident.

• Only use the color chart (printed on the outside of

the bottle) supplied with the kit.

• Clean and dry the sample cup and syringe after

each use. This will prevent contaminating future
samples.

• Following the correct test times is very important.

Use a clock or stopwatch.

Test Intervals

Testing is recommended if the operator is not sure of

the cooling system’s condition due to leaks, uncon-
trolled topping off of the system, or major coolant loss.
Testing is also recommended twice a year to monitor
the SCA level.

If the concentration is below 1.2 units per gallon pre-

change the liquid.

8-70
 MAINTENANCE

Test Instructions

1. Collect coolant sample from one of the radiator

pet cocks. DO NOT collect the sample from the
surge tank. Coolant must be between 10 °C and 54
°C (50 °F and 130 °F). Room temperature is pre-
ferred.

2. Remove one strip from the bottle and replace

the cap immediately. DO NOT touch the pads on
the end of the strip. Discard the strip if the nitrite
test pad has turned brown.

3. Dip the strip in the coolant sample for one sec-

ond, remove and shake the strip briskly to re-
move excess liquid.

4. 45 SECONDS after dipping the strip compare

and record results in the following order:

y Compare FREEZEPOINT (end pad) to color chart OM21220

and record result.

y Next compare MOLYBDATE (middle pad) to color
chart and record result.
y Finally compare NITRITE test to color chart and
record result.
5. All three readings must be completed NO
LATER THAN 75 SECONDS after dipping the strip.

6. It is okay to estimate a value BETWEEN color

blocks, but if uncertain about the color match, pick
the lower numbered block (example, if nitrite color
is not F, use column E).

7. Determine where the MOLYBDATE level inter-

sects the NITRITE level on the chart. The amount
of SCA units per gallon in the cooling system is
given where the MOLYBDATE row intersects with
the NITRITE column.

8. For best results follow test times carefully, use a

stop watch or clock with a sweep second hand,
comparing the test strip to the color chart too soon OM21221

before, or too late after the required test time will

result in incorrect readings and improper treatment
and could result in linear pitting and engine dam-
age.

9. All readings should be recorded on the rigid

dump truck’s maintenance record for future refer-
ence.

8-71
 MAINTENANCE

Coolant Change and Flush System

--- Every 2 Years or 6000 Hours

WARNING: Do not remove the pressure cap

from the surge tank when the engine is hot. .
Wait until the temperature is below 50° C
(120° F) before removing the pressure cap.
Failure to do so can result in personal injury
from hot coolant spray or steam.

1. Shutdown the engine and allow it to cool.

2. When the engine has cooled, depress the red

button on top of the pressure cap to relieve system
pressure. Then remove the pressure cap slowly.

3. Remove the plug located on the lower, left and

right sides of the radiator. The grille can be swung
open to access the drain cocks.
OM21222

4. Open the drain cock located at the bottom end

of the heat exchanger. Illustration is looking at the
heat exchanger from the front of the rigid dump
truck.

5. The cooling system must be clean to work cor-

OM21223
rectly. After draining the system, flush with clean
water. If the system shows mineral buildup, scale,
rust, or oil, clean with a heavy duty engine coolant
cleaner, following the manufacturer’s directions.

6. Check that all drain cocks are closed. Add clean

coolant with proper concentration of supplemental
coolant additive. Replace the pressure cap.

7. Start the engine. Operate the engine until the

coolant temperature is above 82° C (180° F), and
check for coolant leaks.

8. When air has been purged from the system,

check the coolant level again.

8-72
 MAINTENANCE

Replace, Coolant Filter

--- Every 250 Hours / Always after the
system has been flushed

An on/off valve is provided to prevent coolant leakage

while changing the filter.

With the valve in the ON position, the coolant flows to

and from the coolant filter. In the off position, the cool-
ant flow is cut off to and from the coolant filter.

WARNING: Do not remove the pressure cap

from the surge tank when the engine is hot.
Wait until the temperature is below 50° C
(120° F) before removing the pressure cap.
Failure to do so can result in personal injury
from hot coolant spray or steam.
OM21224
1. Turn the valve on the filter head to the off posi-
tion.

2. Remove and discard the coolant filter. Clean the

gasket surface of the filter head.

3. Apply a thin film of clean engine oil, or its

equivalent, to the coolant filter gasket sealing sur-
face before installing the coolant filter.

CAUTION: Mechanical over tightening can

distort the threads or damage the filter head.
OM21225

NOTE: After installing the coolant filter, the ON

mark on the coolant filter collar must be
properly aligned. If necessary, rotate the
collar by hand to the proper position.

4. Tighten the coolant filter ½ to ¾ of a turn after

initial gasket contact, or as specified by the filter’s
manufacturer.

5. Install the pressure cap to the surge tank.

6. Start the engine. Operate the engine until the

coolant temperature is above 82° C (180° F), and OM21226

check for coolant leaks.

7. When air has been purged from the system,

check the coolant level again.

8-73
 MAINTENANCE

Check, Cooling Fan

--- Every 250 Hours

WARNING: Do not straighten a bent fan

blade or continue to use a damaged fan. A
bent or damaged fan blade can fail during
operation and cause personal injury or prop-
erty damage.

1. Check for cracks, loose rivets, bent or loose OM21227

blades, and for contact between the fan blade tips
and the fan shroud.

2. Check the fan to make sure it is securely

mounted. Tighten the cap screws if necessary.

3. Replace the fan if damaged.

OM21228

Clean, Radiator
--- Every 6 Months or 2500 Hours
As Required

WARNING: When using regulated com-

pressed air, wear proper clothing and
equipment. Use extreme caution to avoid in-
jury.

Check the radiator for leaks, damage, and dirt build

up. Clean the outside of the radiator to maintain
proper air flow. Swing the grill out and clean the radia-
tor using steam, water, or regulated compressed air.
Swing the grill back into position when finished.

8-74
 MAINTENANCE

Check, Fan Belt

--- Every 250 Hours

Inspect the belt for damage. Transverse (across the

belt width) cracks are acceptable. Longitudinal (direc-
tion of belt length) cracks that intersect with trans-
verse cracks are not acceptable. Replace the belt if it
has unacceptable cracks, is frayed, or has pieces of
material missing.

Belt damage can be caused by:

y Incorrect tension
y Incorrect size or length
y Pulley misalignment
y Incorrect installation
y Severe operating environment
y Oil or grease on the belt

OM21229

8-75
 MAINTENANCE

J. ELECTRICAL SYSTEM EH750-3 and EH1100-3

Interval (hours)

Quantity Daily or 6 Months As

Item 250 500 1000 1200
Every or 2500 Required
10
1. Battery Condition, Check All
2. Battery Cables and Con-
All
nections, Check
3. Electrical Wiring and Con-
All
nections, Check
4. Fuse/Relay, Check All
5. Neutral Start Circuit, Check
6. Exterior Lights, Check All
7. Back-up Alarm, Check 1
8. Horn, Check 4
9. Gauges, Check All
10. Indicator Lights, Check All
11. Headlight Aiming, Check All
12. Alternator A/C Belt, Check 1

8-76
 MAINTENANCE

Check, Battery Condition

--- Every 250 Hours

WARNING: All lead-acid batteries generate

hydrogen gas that is highly flammable. If
ignited by a spark or flame, the gas may
explode violently, causing spraying of
acid, fragmentation of the battery, and
possible severe personal injuries. Wear
safety glasses when working near batter-
ies. In case of contact with acid, flush im-
mediately with water.
Battery posts, terminals, and related ac-
cessories contain lead and lead com-
pounds. Wash hands after handling.

The two 12-volt heavy duty batteries are located

and protected under battery cover on the service
deck. Check each battery for obvious damage such OM21230
as cracked or broken case or terminal damage.
Replace any damaged batteries.

Charging Batteries

If battery voltage is below 12.50 volts, re-charge the

battery at 1% of the cold crank rating using a con-
stant current charger. If using a constant voltage
(tapering current charger) use a setting of 2.4 to
2.45 volts per cell and monitor current into battery.
Each cell should read at least 1.260 specific gravity.
Monitor specific gravity hourly. Battery is fully
charged when 3 consecutive hourly specific gravity
readings change less than .003 specific gravity
units.

WARNING: When batteries are being

charged, explosive gasses are formed. A
short circuit, open flame or spark near the
battery can cause a serious explosion. Al-
ways turn the battery charger off before
disconnecting or connecting the leads to
the battery. Provide good ventilation, es-
pecially if the battery is being charged in
and enclosed area.
SA-032

8-77
 MAINTENANCE

Always us a voltmeter or hydrometer to

check the battery charge. Never use a
metal object across the posts to test a bat-
tery. Sparks may cause an explosion.
Never let the fluid be pushed out of the
battery or allow the temperature to go
above 52° C (125° F). If the battery case
feels hot, stop charging for 20 minutes
then start the charger at a lower amperage
rate. High temperature will prevent the bat-
tery from holding the charge. Make sure
the battery is a minimum of 16° C (60° F)
before charging.

Check, Battery Cables and Connections

--- Every 250 Hours

Check the battery cables and connections for dam-

age, looseness, and corrosion. Replace damaged
cables as needed. Clean pole studs and cable ter-
minals. Coat with petroleum jelly or spray with a
battery post fluid. Tighten connections as needed.

Check, Electrical Wiring

and Connections
--- Every 250 Hours

Check the electrical wiring and connections for

damage, looseness or corrosion. Replace damaged
wiring or components as needed. Clean and tighten
connections as required.

8-78
 MAINTENANCE

Check, Fuse/Relay
--- Every 250 Hours and As Required

The fuses and relays are located in the main elec-

trical compartment, located behind two cover panels
behind the operator’s seat. Decals attached to the
inside of the cover panel immediately behind the
operator’s seat identify the fuse and relay cavity,
amps, and circuit(s).

OM21231

8-79
MAINTENANCE

OM21232

8-80
MAINTENANCE

OM21233

8-81
 MAINTENANCE

Check, Neutral Start Circuit

--- Every 250 Hours

Set the parking brake and/or block the

wheels as required to prevent rigid dump
truck movement during this test.

1. Place the shift selector in D, drive position

and try to start the engine. If the starter turns the
engine, report this to the appropriate service
personnel.

2. Place the shift selector in the R1 position and

try to start the engine. If the starter turns the en-
gine, report this to the appropriate service per-
sonnel.

NOTE: If the starter will turn the engine with the

shift selector in N neutral position only, OM21100

the neutral start circuit is operating cor-

rectly.

Check, Exterior Lights

--- Daily or Every 10 Hours

Check that all exterior lights are in proper operating

condition and adjusted properly. Replace and/or
adjust as required

OM21234

1. Low Beam 4. Stop/Turn Light

2. High Beam 5. Reverse Light
3. Amber Turn/Clearance Lights

8-82
 MAINTENANCE

Check, Back-up Alarm

--- Daily or Every 10 Hours

Check the back-up alarm for proper operation. If a

problem is found in the back-up alarm it must be
replaced. There is no adjustment to the alarm itself.

OM21235

Check, Horn
--- Daily or Every 10 Hours

Check the horns (1) and make sure they operate

correctly. Report a defective horn to service person-
nel.

Check, Gauges
--- Daily or Every 10 Hours

Check Indicator Lights OM21065

--- Daily or Every 10 Hours

Check that all gauges and indicator lights are in

proper operating condition and adjusted properly.
Replace and/or adjust as required. Turn the key
switch to ON. Do not start the engine but look for
flashing indicator lights and error messages on the
Contronic display. The parking brake, brake pres-
sure, steer pressure and alternator indicator lights
should be illuminated.

NOTE: It is normal for the warning and indicator

lights to flash and the audible alarm to OM21236

sound with the key switch in the ON posi-

tion. The gauges will also cycle momen-
tarily when the key is in the ON position.

8-83
 MAINTENANCE

SIDE VIEW FRONT VIEW

OM21237

Headlight Aiming
--- As Required
3. Adjust the high beam lamp (laterally) so that
The standard SAE prescribed method of aiming
the center of the high intensity zone is in a verti-
headlights of a four-lamp system is outlined as fol-
cal line straight ahead of the lamp center.
lows. This method should be used unless specific
job conditions indicate otherwise.
4. Adjust the low beam lamp (up or down) so
that the top edge of the high intensity zone is 51
The rigid dump truck should be parked on level
mm (2 inches) below the horizontal centerline
ground 8 m (25 ft.) from a wall or screen, which is
level of the high beam lamp center.
perpendicular to the horizontal centerline of the rigid
dump truck. Once the position of the rigid dump
5. Adjust the low beam lamp (laterally) so that
truck has been established, proceed as follows:
the center of the high intensity zone is in a verti-
cal line straight ahead of the lamp center.
1. Measure the distance “D” from the lamp cen-
ter to the ground level, and then transfer this di-
mension to the vertical wall or screen.

2. Adjust the high beam lamp (up or down) to

locate the center of the high intensity zone at di-
mension “D” on the wall or screen. This repre-
sents the horizontal centerline of the high beam
lamp center.

8-84
 MAINTENANCE

12 Check, Alternator/Air Conditioner Belt

--- Every 250 Hours

Inspect the belt for damage. Transverse (across the

belt width) cracks are acceptable. Longitudinal
(direction of belt length) cracks that intersect with
transverse cracks are not acceptable. Replace the
belt if it has unacceptable cracks, is frayed, or has
pieces of material missing.

Belt damage can be caused by:

y Incorrect tension
y Incorrect size or length
y Pulley misalignment
y Incorrect installation
y Severe operating environment
y Oil or grease on the belt

OM21238

8-85
 MAINTENANCE

Check, Struts
--- Every 250 Hours

During the first 48 hours of operation the helium gas

and the Neocon-E in the struts will mix in a dissolu-
tion process. As dissolution occurs, the strut lengths
will change and a reduction in the strut height is to
be expected. After the initial 48 hour operation pe-
riod, the struts should be checked every 250 hours.
To monitor the condition of the strut, there is only
one dimension to be checked. That is the X space
between the cylinder gland assembly and the top of
the rod assembly. This check is to be accomplished
only with the rigid dump truck empty and parked on
level ground. Prior to checking, the rigid dump truck
should be operated a minimum of one hour. Avoid
hard braking of the rigid dump truck. Failure to follow
this procedure may result in false readings.

Front Strut
EH750-3
X Rod length – empty rigid dump truck
X = 177.8 mm (7.00 in)
Tolerance ± 19.1 mm (0.75 in)
EH1100-3
X-2 Rod length – empty rigid dump truck OM21239

X = 201± 19.1 mm (7.93 ± 0.75 in).

Rear Strut
EH750-3
X Rod length – empty rigid dump truck
X = 82.3 mm (3.24 in)
Tolerance ± 12.7 mm (0.50 in)

EH1100-3
X-2 Rod length – empty rigid dump truck
X = 95 ± 13 mm (3.75 ± 0.50 in).

OM21240

8-86
 MAINTENANCE

Check, Wheels
--- Every 1000 Hours

Check wheels for damage, looseness, missing nuts,

clamps and or studs. Replace or tighten as needed.

Tighten all wheel mounting bolts to 942 N ٠m (695

lbf ٠ft)

NOTE: After wheel removal, wheel nut torque

must be checked again after the first five
and ten hours of operation.

Check, Front Wheel Lubricant

--- Every 15,000 Hours

Change, Front Wheel Lubricant

--- Every 15,000 Hours

The front wheel bearings on this rigid dump truck

use a synthetic base grease lubricant (Mobile “Mo-
OM21241
bilith SHC 007” or equivalent). This lubricant should
be checked and changed every 15,000 hours or at
time of major service to the front wheel. Initially, this
grease has a bright red color. As the truck accumu-
lates hours, the grease will become black. This does
not mean the grease needs to be changed, it is con-
sidered normal for this type of grease.

8-87
 MAINTENANCE

Check, Tire Inflation

--- Every 250 Hours

WARNING: 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 attaching air chuck with a hose long

enough to be out of the trajectory path when
filling a 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 if alcohol has been used as anti-
freeze.

With the rigid dump truck empty and the tires cold,
check the pressure in all six tires. When checking
the air pressure of the tires, examine the valves
and make sure all valve caps are in place.

NOTE: For special applications, consult the tire OM21242

manufacturer for tire inflation pressures.

NOTE: For wheel removal, refer to the Workshop

Manual for this rigid dump truck.

NOTE: For complete information pertaining to

dismounting and mounting of tires on the
rims, refer to the tire manufacturer’s tire
maintenance manual. It is recommended
that a certified tire repair service be hired
to perform dismounting/mounting of tires
from rims.

OM21243

8-88
 MAINTENANCE

Check, Tire Condition.

--- Daily or Every 10 Hours

Check the condition of the tires with the rigid dump

truck empty. Check for shallow and deep cuts,
thread separation, belt edge separation, rim chaf-
ing, side impact breaks and worn tires. Consult the
tire manufacturer’s maintenance guide. Make a
report of any damaged tires.

WARNING: Let the air out of the tire be-

fore removing foreign material from the tire
tread. Keep fingers away from bead breakers
and rims, and stay out of the trajectory path
when removing foreign material. If a bead
breaker disengages, it will release with enough
force to cause injury or death. Be sure to re-
move the dirt and rust from the lock ring
groove before installing the ring.

NOTE: For complete information pertaining to

dismounting and mounting of tires on the
rims, refer to the tire manufacturer’s tire
maintenance manual. It is recommended
that a certified tire repair service be hired
to perform dismounting/mounting of tires
from rims.

Check, Wheel Alignment

--- As Required

If a tire shows abnormal or excessive wear, wear-

ing of one shoulder, check tire alignment. See your
authorized Hitachi Dealer.

8-89
 MAINTENANCE

L. CAB EH750-3 and EH1100-3

Interval (hours)

Item Quantity Daily or 6 As

250 500 1000 1200
Every Months Required
10 or 2500
1. Air Filter, Clean/Change 1
2. Air Conditioner Filter,
2
Clean/Change
3. Mounts, Check 3
4. Wiper Blade Condition, Check 1
5. Windshield Washer Fluid 5.7 L (1.5 US gal)
Level, Check for both EH750-3
& EH1100-3
6. Seat Belt & Mounting, Check 2
7. Seat Belt, Replace 2 Every 3 Years
8. Air Conditioner, Check
9. Heater & Defroster, Check

8-90
 MAINTENANCE

Clean/Change Air Filter

--- As Required

Remove the four screws and washers that secures

the filter cover to the side of right side of the cab.
Remove the filter cover and the two filters. Check
each filter. Clean the filters or replace them as re-
quired.
Cleaning Methods:
Tapping-With the dirty side down, gen-
tly tap the filter on a flat surface,
Air-Direct compressed air through the air
filter opposite the direction of the “Airflow”
arrows. Use a (.3175 cm {.125 in} diame- OM21244

ter nozzle at least 5.08 cm {2 in} away

from the filter, maximum air pressure 689
kPa {100 psi}.)
Water-Soak for 15 minutes in water and
filter element cleaner.
Rinse until clean. Maximum water
pressure 276 kPa (40 psi).
Air dry. DO NOT USE compressed
air.
Install the filters. Install the filter cover securing it to
the cab with four screws and washers.

8-91
 MAINTENANCE

Clean/Change Air Conditioner Filters

--- As Required

Remove the filter cover and the two filters. Check

each filter. Clean the filters or replace them as re-
quired.
Cleaning Methods:
Tapping-Tap the dirty side down of the fil-
ter gently on a flat surface,
Air-Direct compressed air through the air
filter opposite the direction of the “Airflow”
arrows. Use a (.3175cm {.125in} diameter
OM21245
nozzle at least 5.08cm {2in} away from the
filter, maximum air pressure 689kPa
{100psi}.)
Water-Soak for 15 minutes in water and
filter element cleaner.
Rinse until clean. Maximum water
pressure 276kPa (40psi).
Air dry. DO NOT USE compressed
air.
Install the filters. Install the filter cover securing it to
the cab with four screws and washers.

8-92
 MAINTENANCE

Check, Mounts
Every 6 Months or 2500 Hours

The single, front cab mount can be checked by re-

moving the exterior panel at the front of the cab.

The two, rear cab mounts are accessible at two

plates secured at the rear of the cab by bolts and
washers.

Report damaged shock mounts to service person-

nel. Replace mounts and hardware as required.

OM21246

Check, Wiper Blade, Condition

--- As Required

Check the wiper blade for wear, damage or deterio-

ration. Replace as needed.

OM21247

Check, Windshield Washer Fluid Level

--- Daily or Every 10 Hours

The windshield washer fluid reservoir is located on

the service deck, just outside and to the right of the
cab. Add fluid as needed.

OM21248

8-93
 MAINTENANCE

Check, Seat Belt and Mounting

--- Every 250 Hours

Always maintain the seat belt in a functional condi-

tion and replace when necessary to ensure proper
performance.

Prior to operating the rigid dump truck, thoroughly

examine the seat belt.

• Pull the belt from its retractor completely and ex-

amine the webbing for cuts, fraying, unusual wear
and any environmental condition. Environmental
condition causing deterioration or making the belt
so dirty that the operator will not wear it. Inspect
for deterioration caused by a spill of some sub-
stance onto the belt or caused by exposure to the
ultraviolet rays of the sun.

• Check each retractor for proper operation. Pull

each belt out of its retractor completely to see that OM21249

it spool out, locks properly, and retracts properly.

• Check the buckle and latch for proper and easy

operation. Check buckle casing for damage or
cracks and the buckle for breakage. Check the
latch plate for excessive wear or deformation.

NOTE: If any part of the seat belt needs re-

placement: webbing, retractor, buckle
casing, or latch, the entire seat belt must
be replaced.
The entire seat belt must be replaced if
the rigid dump truck was involved in an
accident in which the seat belt was sub-
jected to an impact load.

Replace, Seat Belt

--- Every 3 Years
It is recommended that the seat belt be
replaced every three years regardless of
its apparent condition.

• Check for loose mounting support bolts and dam-

aged hardware. Tighten all loose bolts. Replace
damaged mounting hardware as needed.

8-94
 MAINTENANCE

Check, Air Conditioning

--- Every 250 Hours

WARNING: The air conditioning system

is pressurized, and filled with refrigerant. Never
disconnect any hoses or remove the compres-
sor fill plug except when repairing the system.
Do not release refrigerant near an open flame
or hot metal. If refrigerant comes in contact
with an open flame or very hot metal, poison-
ous gas may be produced that can be very
dangerous. Always wear acceptable eye pro-
tection when working with refrigerant. Do not
let refrigerant come in contact with any part of
SA-405
the body. If refrigerant makes contact with the
skin, seek medical attention immediately, it can
cause frostbite.

WARNING: The air conditioning unit

uses refrigerant, Freon R134a. Refrigerant
Freon R134a is hazardous to the environment
and is not to be released into the open air. Any
service, refilling (charging) or emptying (dis-
charging) of refrigerant Freon R134a must be
carried out by trained and qualified service
personnel.

NOTE: To lubricate the air conditioning com-

pressor seals, the unit should be run at
least once a month for about 5 minutes.

Check, Heater and Defroster

--- Every 250 Hours

Check switches daily to make sure the heater and

defroster operates correctly. Refer to the OPERA-
TOR’S STATION section in this manual for correct
switch operation. Repair as needed.

8-95
 MAINTENANCE

M. GENERAL EH750-3 and EH1100-3

Interval (hours)
6
Item Quantity Daily or As
250 500 1000 1200 Months
Every Required
or 2500
10
1. Leaks, Check
2a. Body Prop Pins, Check
(EH750-3) 2
2b. Body Prop Cable, Check 1
(EH1100-3)
3. Main Rail, Strut and Axle Lug
Welds, Check
4. Frame Assembly, Check
5. Tightening Torque of Bolts and
Nuts, Check
6. Loose Bolts & Fittings, Check

8-96
 MAINTENANCE

Check for Fluid Leaks

--- Daily or Every 10 Hours
As Required

Check Body Prop Pins

--- Daily or Every 10 Hours

The body prop pins must be inspected on a daily

basis. Any pin that is broken, rusted, or damaged
must be removed from service and replaced.

The illustration shows the body prop pins in their

stored position.

When working on the rigid dump truck with the body

raised, always use the body prop pins to support the
body in the raised position. Refer to INSTALLING
BODY PROP PINS earlier in this section
OM21152

WARNING: Do not use body prop pin

holes for attaching towing chains. This could
damage the bores. Use the tow lugs. Refer to
TOWING in this manual.

Check Body Prop Cable for EH1100-3

--- Daily or every 10 Hours

OM21153

WARNING!
Do not use the body prop cable for towing.

The body prop cable must be inspected on a daily

basis. Damaged cable must be removed from ser-
vice and replaced.

The illustration shows the body prop cable.

When working on the rigid dump truck with the body

raised, always use the body prop pins to support the
body in the raised position. Refer to INSTALLING
BODY PROP CABLE earlier in this section.
OM21154

8-97
 MAINTENANCE

Check Main Rail, Strut

And Axle Lug Welds
--- Every 250 Hours

Check, Frame Assembly

--- Every 6 Months or 2500 Hours

Check, Tightening Torque of Bolts

and Nuts
--- Every 250 Hours
(first time after 50 hours)

Check tightness after the first 50 hours then every

250 hours. Tighten to torque shown if any are loose.
Bolts and nuts should be replaced with those of the
same or higher grade.

IMPORTANT: Check and tighten bolts and nuts

using a torque wrench.
Torque Specifications
Number Description Quantity Socket Torque
Size(in) N ٠m (kgf ٠m) (lbf ٠ft)
1 Steering driveshaft mounting
9
A 1 /16 85-102 9-10 63-75
9
B 1 /16 54-65 5-7 40-48
9
C 4 /16 36 4 26
2 Mounting plate assembly to frame
15
A 3 /16 242 25 179
3 Air cleaner mounting
9
B 4 /16 50 5 37
4 Coolant surge tank mounting
3
A 4 /4 87 9 64
5 Radiator mounting
A 2 1-1/8 307 31 226
3
B 4 /4 87 9 64
6 Engine mounting
A 2 1 1/8 307 31 226
B 2 1 1/8 433 32 319
15
C 8 /16 173 18 128
3
D 4 /4 87 9 64
E 2 1 1/8 433 32 319
7 Drive coupling mounting
3
A 8 /4 87 9 64
8 Transmission mounting brackets
15
A 8 /16 244 25 180
9 Transmission mounting
15
A 4 /16 244 25 180

8-98
 MAINTENANCE

1. Steering driveshaft mounting.

A
9
Tool: /16 Socket
Torque: 85-102 N ٠m (9-10 kgf ٠m, 63-75
lbf ٠ft)

B
9
Tool: /16 Socket
Torque: 54-65 N ٠m (5-7 kgf ٠m, 40-48
lbf ٠ft)

C
9
Tool: /16 Socket
Torque: 36 N ٠m (4 kgf ٠m, 26 lbf ٠ft)

OM21252

2. Mounting plate assembly to frame.

A
15
Tool: /16 Socket
Torque: 242 N ٠m (25 kgf ٠m, 179 lbf ٠ft)

OM21253
3. Air cleaner mounting
B
9
Tool: /16 Socket
Torque: 50 N ٠m (5 kgf ٠m, 37 lbf ٠ft)

OM21254

8-99
 MAINTENANCE

4. Coolant surge tank mounting.

A
3
Tool: /4 Socket
Torque: 87 N ٠m (9 kgf ٠m, 64 lbf ٠ft)

OM21255

5. Radiator mounting.
A
Tool: 1 1/8 Socket
Torque: 307 N ٠m (31 kgf ٠m, 226 lbf ٠ft)

B
3
Tool: /4 Socket
Torque: 87 N ٠m (9 kgf ٠m, 64 lbf ٠ft)

OM21256

8-100
 MAINTENANCE

6. Engine mounting.

A
Tool: 1 1/8 Socket
Torque: 307 N ٠m (31 kgf ٠m, 226 lbf ٠ft)

B
Tool: 1 1/8 Socket
Torque: 433 N ٠m (32 kgf ٠m, 319 lbf ٠ft)

C
15
Tool: /16 Socket
Torque: 173 N ٠m (18 kgf ٠m, 128 lbf ٠ft)

D
3
Tool: /4 Socket
Torque: 87 N ٠m (9 kgf ٠m, 64 lbf ٠ft)

E OM21257

Tool: 1 1/8 Socket

Torque: 433 N ٠m (32 kgf ٠m, 319 lbf ٠ft)

7. Drive coupling mounting.

A
3
Tool: /4 Socket
Torque: 87 N ٠m (9 kgf ٠m, 64 lbf ٠ft)

OM21258

8-101
 MAINTENANCE

8. Transmission mounting brackets.

A
15
Tool: /16 Socket
Torque: 244 N ٠m (25 kgf ٠m, 180 lbf ٠ft)

OM21259

9. Transmission mounting.

A
15
Tool: /16 Socket
Torque: 244 N ٠m (25 kgf ٠m, 180 lbf ٠ft)

OM21260

8-102
 MAINTENANCE

TORQUE VALUES
Grade 8 Hex Hd & 12 pt Flange Hd

Plain Finish with Oil, Black Oxide with Oil or Zinc Phosphate with Oil No Loctite
Thread Dia. Clamp Calculated Calculated
Size Torque Torque
Lbs Ft ٠Lbs N ٠M
* = in ٠lbs
¼ -20 0.2500 3,244 * 122 14
¼ -28 0.2500 3,713 * 139 16

5
/16 -18 0.3125 5,345 21 28
5
/16 -24 0.3125 5,916 23 31
⅜ -16 0.3750 7,905 37 50
⅜ -24 0.3750 8,956 42 57
7
/16 -14 0.4375 10,843 59 80
7
/16 -20 0.4375 12,107 66 90
½ -13 0.5000 14,474 90 123
½ -20 0.5000 16,310 102 138
9
/16 -12 0.5625 18,564 131 177
9
/16 -18 0.5625 20,706 146 197
⅝ -11 0.6250 23,052 180 244
⅝ -18 0.6250 26,112 204 277
¾ -10 0.7500 34,068 319 433
¾ -16 0.7500 38,046 357 484
⅞ -9 0.8750 47,124 515 699
⅞ -14 0.8750 51,918 568 770
1 -8 1.0000 61,812 773 1048
1 -14 1.0000 69,258 866 1174
1¼ -7 1.2500 98,838 1544 2094
1¼ -12 1.2500 109,446 1710 2319
1½ -6 1.5000 143,310 2687 3644
1½ -12 1.5000 161,262 3024 4100
The torque value used should be within ±5% of the calculated torque.

8-103
 MAINTENANCE

TORQUE VALUES
Grade 8 Hex Hd & 12 pt Flange Hd

Plain Finish with Oil, Black Oxide with Oil, or Zinc Phosphate with Oil
With Red Loctite or Blue Loctite
Thread Dia. Clamp Calculated Calculated
Size Torque Torque
Lbs Ft ٠Lbs N ٠M
* = in ٠lbs
*
¼ -20 0.2500 3,244
162 18
¼ -28 0.2500 3,713 *
186 21

5
/16 -18 0.3125 5,345 28 38
5
/16 -24 0.3125 5,916 31 42
⅜ -16 0.3750 7,905 49 67
⅜ -24 0.3750 8,956 56 76
7
/16 -14 0.4375 10,843 79 107
7
/16 -20 0.4375 12,107 88 120
½ -13 0.5000 14,474 121 164
½ -20 0.5000 16,310 136 184
9
/16 -12 0.5625 18,564 174 236
9
/16 -18 0.5625 20,706 194 263
⅝ -11 0.6250 23,052 240 326
⅝ -18 0.6250 26,112 272 369
¾ -10 0.7500 34,068 426 577
¾ -16 0.7500 38,046 476 645
⅞ -9 0.8750 47,124 687 932
⅞ -14 0.8750 51,918 757 1027
1 -8 1.0000 61,812 1030 1397
1 -14 1.0000 69,258 1154 1565
1¼ -7 1.2500 98,838 2059 2792
1¼ -12 1.2500 109,446 2280 3092
1½ -6 1.5000 143,310 3583 4858
1½ -12 1.5000 161,262 4032 5467
The torque value used should be within ±5% of the calculated torque.

8-104
 MAINTENANCE

TORQUE VALUES
Grade 8 Hex Hd & 12 pt Flange Hd

Zinc Plated with Yellow Dichromate No Loctite

Thread Dia. Clamp Calculated Calculated
Size Torque Torque
Lbs Ft ٠Lbs N ٠M
* = in ٠lbs
*
¼ -20 0.2500 3,244 170 19
*
¼ -28 0.2500 3,713 195 22

5
/16 -18 0.3125 5,345 29 40
5
/16 -24 0.3125 5,916 32 44
⅜ -16 0.3750 7,905 52 70
⅜ -24 0.3750 8,956 59 80
7
/16 -14 0.4375 10,843 83 113
7
/16 -20 0.4375 12,107 93 126
½ -13 0.5000 14,474 127 172
½ -20 0.5000 16,310 143 194
9
/16 -12 0.5625 18,564 183 248
9
/16 -18 0.5625 20,706 204 276
⅝ -11 0.6250 23,052 252 342
⅝ -18 0.6250 26,112 286 387
¾ -10 0.7500 34,068 447 606
¾ -16 0.7500 38,046 499 677
⅞ -9 0.8750 47,124 722 978
⅞ -14 0.8750 51,918 795 1078
1 -8 1.0000 61,812 1082 1467
1 -14 1.0000 69,258 1212 1643
1¼ -7 1.2500 98,838 2162 2932
1¼ -12 1.2500 109,446 2394 3246
1½ -6 1.5000 143,310 3762 5101
1½ -12 1.5000 161,262 4233 5740
The torque value used should be within ±5% of the calculated torque.

8-105
 MAINTENANCE

TORQUE VALUES
Grade 8 Hex Hd & 12 pt Flange Hd

Zinc Plated with Yellow Dichromate With Red Loctite

Thread Dia. Clamp Calculated Calculated
Size Torque Torque
Lbs Ft ٠Lbs N ٠M
* = in ٠lbs
¼ -20 0.2500 3,244 * 219 25

¼ -28 0.2500 3,713 21 28

5
/16 -18 0.3125 5,345 38 51
5
/16 -24 0.3125 5,916 42 56
⅜ -16 0.3750 7,905 67 90
⅜ -24 0.3750 8,956 76 102
7
/16 -14 0.4375 10,843 107 145
7
/16 -20 0.4375 12,107 119 162
½ -13 0.5000 14,474 163 221
½ -20 0.5000 16,310 183 249
9
/16 -12 0.5625 18,564 235 319
9
/16 -18 0.5625 20,706 262 355
⅝ -11 0.6250 23,052 324 440
⅝ -18 0.6250 26,112 367 498
¾ -10 0.7500 34,068 575 780
¾ -16 0.7500 38,046 642 871
⅞ -9 0.8750 47,124 928 1258
⅞ -14 0.8750 51,918 1022 1386
1 -8 1.0000 61,812 1391 1886
1 -14 1.0000 69,258 1558 2113
1¼ -7 1.2500 98,838 2780 3769
1¼ -12 1.2500 109,446 3078 4174
1½ -6 1.5000 143,310 4837 6559
1½ -12 1.5000 161,262 5443 7380
The torque value used should be within ±5% of the calculated torque.

8-106
 MAINTENANCE

TORQUE VALUES
Grade 8 Hex Hd & 12 pt Flange Hd

Zinc Plated with Yellow Dichromate With Blue Loctite

Thread Dia. Clamp Calculated Calculated
Size Torque Torque
Lbs Ft ٠Lbs N ٠M
*=
in ٠lbs
¼ -20 0.2500 3,244 * 187 21
¼ -28 0.2500 3,713 * 213 24

5
/16 -18 0.3125 5,345 32 43
5
/16 -24 0.3125 5,916 35 48
⅜ -16 0.3750 7,905 57 77
⅜ -24 0.3750 8,956 64 87
7
/16 -14 0.4375 10,843 91 123
7
/16 -20 0.4375 12,107 102 138
½ -13 0.5000 14,474 139 188
½ -20 0.5000 16,310 156 212
9
/16 -12 0.5625 18,564 200 271
9
/16 -18 0.5625 20,706 223 303
⅝ -11 0.6250 23,052 276 374
⅝ -18 0.6250 26,112 313 424
¾ -10 0.7500 34,068 490 664
¾ -16 0.7500 38,046 547 742
⅞ -9 0.8750 47,124 790 1072
⅞ -14 0.8750 51,918 871 1181
1 -8 1.0000 61,812 1185 1606
1 -14 1.0000 69,258 1327 1800
1¼ -7 1.2500 98,838 2368 3211
1¼ -12 1.2500 109,446 2622 3556
1½ -6 1.5000 143,310 4120 5587
1½ -12 1.5000 161,262 4636 6287
The torque value used should be within ±5% of the calculated torque.

8-107
 MAINTENANCE

TORQUE VALUES
Grade 5 Hex Hd

Plain Finish with Oil, Black Oxide with Oil or Zinc Phosphate with Oil No Loctite
Thread Dia. Clamp Calculated Calculated
Size Torque Torque
Lbs Ft ٠Lbs N ٠M
*=
in ٠lbs
¼ -20 0.2500 2,298 * 86 10
¼ -28 0.2500 2,630 * 99 11
5
/16 -18 0.3125 3,786 * 177 20
5
/16 -24 0.3125 4,191 * 196 22

⅜ -16 0.3750 5,599 26 36

⅜ -24 0.3750 6,344 30 40
7
/16 -14 0.4375 7,680 42 57
7
/16 -20 0.4375 8,576 47 64
½ -13 0.5000 10,252 64 87
½ -20 0.5000 11,553 72 98
9
/16 -12 0.5625 13,150 92 125
9
/16 -18 0.5625 14,667 103 140
⅝ -11 0.6250 16,329 128 173
⅝ -18 0.6250 18,496 145 196
¾ -10 0.7500 24,132 226 307
¾ -16 0.7500 26,949 253 343
⅞ -9 0.8750 33,380 365 495
⅞ -14 0.8750 36,775 402 545
1 -8 1.0000 43,784 547 742
1 -14 1.0000 49,058 613 832
1¼ -7 1.2500 60,950 952 1291
1¼ -12 1.2500 67,492 1055 1430
1½ -6 1.5000 88,375 1657 2247
1½ -12 1.5000 99,445 1865 2528
The torque value used should be within ±5% of the calculated torque.

8-108
 MAINTENANCE

TORQUE VALUES
Grade 5 Hex Hd

Plain Finish with Oil, Black Oxide with Oil or Zinc Phosphate with Oil
With Red Loctite and Blue Loctite
Thread Dia. Clamp Calculated Calculated
Size Torque Torque
Lbs Ft ٠Lbs N ٠M
* = in ٠lbs
¼ -20 0.2500 2,298 * 115 13
¼ -28 0.2500 2,630 * 131 15

5
/16 -18 0.3125 3,786 20 27
5
/16 -24 0.3125 4,191 22 30
⅜ -16 0.3750 5,599 35 47
⅜ -24 0.3750 6,344 40 54
7
/16 -14 0.4375 7,680 56 76
7
/16 -20 0.4375 8,576 63 85
½ -13 0.5000 10,252 85 116
½ -20 0.5000 11,553 96 131
9
/16 -12 0.5625 13,150 123 167
9
/16 -18 0.5625 14,667 138 186
⅝ -11 0.6250 16,329 170 231
⅝ -18 0.6250 18,496 193 261
¾ -10 0.7500 24,132 302 409
¾ -16 0.7500 26,949 337 457
⅞ -9 0.8750 33,380 487 660
⅞ -14 0.8750 36,775 536 727
1 -8 1.0000 43,784 730 990
1 -14 1.0000 49,058 818 1109
1¼ -7 1.2500 60,950 1270 1722
1¼ -12 1.2500 67,492 1406 1907
1½ -6 1.5000 88,375 2209 2996
1½ -12 1.5000 99,445 2486 3371
The torque value used should be within ±5% of the calculated torque.

8-109
 MAINTENANCE

TORQUE VALUES
Grade 5 Hex Hd

Zinc Plated with Yellow Dichromate No Loctite

Thread Dia. Clamp Calculated Calculated
Size Torque Torque
Lbs Ft ٠Lbs N ٠M
* = in ٠lbs
¼ -20 0.2500 2,298 * 121 14
¼ -28 0.2500 2,630 * 138 16

5
/16 -18 0.3125 3,786 21 28
5
/16 -24 0.3125 4,191 23 31
⅜ -16 0.3750 5,599 37 50
⅜ -24 0.3750 6,344 42 56
7
/16 -14 0.4375 7,680 59 80
7
/16 -20 0.4375 8,576 66 89
½ -13 0.5000 10,252 90 122
½ -20 0.5000 11,553 101 137
9
/16 -12 0.5625 13,150 129 176
9
/16 -18 0.5625 14,667 144 196
⅝ -11 0.6250 16,329 179 242
⅝ -18 0.6250 18,496 202 274
¾ -10 0.7500 24,132 317 429
¾ -16 0.7500 26,949 354 480
⅞ -9 0.8750 33,380 511 693
⅞ -14 0.8750 36,775 563 764
1 -8 1.0000 43,784 766 1039
1 -14 1.0000 49,058 859 1164
1¼ -7 1.2500 60,950 1333 1808
1¼ -12 1.2500 67,492 1476 2002
1½ -6 1.5000 88,375 2320 3146
1½ -12 1.5000 99,445 2610 3540
The torque value used should be within ±5% of the calculated torque.

8-110
 MAINTENANCE

TORQUE VALUES
Grade 5 Hex Hd

Zinc Plated with Yellow Dichromate With Red Loctite

Thread Dia. Clamp Calculated Calculated
Size Torque Torque
Lbs Ft ٠Lbs N ٠M
* = in ٠lbs
¼ -20 0.2500 2,298 * 155 18
¼ -28 0.2500 2,630 * 178 20

5
/16 -18 0.3125 3,786 27 36
5
/16 -24 0.3125 4,191 29 40
⅜ -16 0.3750 5,599 47 64
⅜ -24 0.3750 6,344 54 73
7
/16 -14 0.4375 7,680 76 103
7
/16 -20 0.4375 8,576 84 114
½ -13 0.5000 10,252 115 156
½ -20 0.5000 11,553 130 176
9
/16 -12 0.5625 13,150 166 226
9
/16 -18 0.5625 14,667 186 252
⅝ -11 0.6250 16,329 230 311
⅝ -18 0.6250 18,496 260 353
¾ -10 0.7500 24,132 407 552
¾ -16 0.7500 26,949 455 617
⅞ -9 0.8750 33,380 657 891
⅞ -14 0.8750 36,775 724 982
1 -8 1.0000 43,784 985 1336
1 -14 1.0000 49,058 1104 1497
1¼ -7 1.2500 60,950 1714 2324
1¼ -12 1.2500 67,492 1898 2574
1½ -6 1.5000 88,375 2983 4044
1½ -12 1.5000 99,445 3356 4551
The torque value used should be within ±5% of the calculated torque.

8-111
 MAINTENANCE

TORQUE VALUES
Grade 5 Hex Hd

Zinc Plated with Yellow Dichromate With Blue Loctite

Thread Dia. Clamp Calculated Calculated
Size Torque Torque
Lbs Ft ٠Lbs N ٠M
* = in ٠lbs
¼ -20 0.2500 2,298 * 132 15
¼ -28 0.2500 2,630 * 151 17

5
/16 -18 0.3125 3,786 23 31
5
/16 -24 0.3125 4,191 25 34
⅜ -16 0.3750 5,599 40 55
⅜ -24 0.3750 6,344 46 62
7
/16 -14 0.4375 7,680 64 87
7
/16 -20 0.4375 8,576 72 98
½ -13 0.5000 10,252 98 133
½ -20 0.5000 11,553 111 150
9
/16 -12 0.5625 13,150 142 192
9
/16 -18 0.5625 14,667 158 214
⅝ -11 0.6250 16,329 196 265
⅝ -18 0.6250 18,496 222 300
¾ -10 0.7500 24,132 347 470
¾ -16 0.7500 26,949 387 525
⅞ -9 0.8750 33,380 560 759
⅞ -14 0.8750 36,775 617 836
1 -8 1.0000 43,784 839 1138
1 -14 1.0000 49,058 940 1275
1¼ -7 1.2500 60,950 1460 1980
1¼ -12 1.2500 67,492 1617 2193
1½ -6 1.5000 88,375 2541 3445
1½ -12 1.5000 99,445 2859 3877
The torque value used should be within ±5% of the calculated torque.

8-112
 MAINTENANCE

TORQUE VALUES
A574 Alloy Steel -- Hex socket Hd

Plain Finish with Oil, Black Oxide with Oil or Zinc Phosphate with Oil No Loctite
Thread Dia. Clamp Calculated Calculated
Size Torque Torque
Lbs Ft ٠Lbs N ٠M
* = in ٠lbs
¼ -20 0.2500 3,784 * 142 16
¼ -28 0.2500 4,332 * 162 18

5
/16 -18 0.3125 6,236 24 33
5
/16 -24 0.3125 6,902 27 37
⅜ -16 0.3750 9,223 43 59
⅜ -24 0.3750 10,448 49 66
7
/16 -14 0.4375 12,650 69 94
7
/16 -20 0.4375 14,125 77 105
½ -13 0.5000 16,886 106 143
½ -20 0.5000 19,028 119 161
9
/16 -12 0.5625 20,885 147 199
9
/16 -18 0.5625 23,294 164 222
⅝ -11 0.6250 25,934 203 275
⅝ -18 0.6250 29,376 230 311
¾ -10 0.7500 38,327 359 487
¾ -16 0.7500 42,802 401 544
⅞ -9 0.8750 53,015 580 786
⅞ -14 0.8750 58,408 639 866
1 -8 1.0000 69,539 869 1179
1 -14 1.0000 77,915 974 1321
1¼ -7 1.2500 111,193 1737 2356
1¼ -12 1.2500 123,127 1924 2609
1½ -6 1.5000 161,224 3023 4099
1½ -12 1.5000 181,420 3402 4613
The torque value used should be within ±5% of the calculated torque.

8-113
 MAINTENANCE

TORQUE VALUES

A574 Alloy Steel -- Hex socket Hd

Plain Finish with Oil, Black Oxide with Oil or Zinc Phosphate with Oil
With Red Loctite and Blue Loctite
Thread Dia. Clamp Calculated Calculated
Size Torque Torque
Lbs Ft ٠Lbs N ٠M
* = in ٠lbs
¼ -20 0.2500 3,784 * 189 49
¼ -28 0.2500 4,332 * 217 24

5
/16 -18 0.3125 6,236 32 44
5
/16 -24 0.3125 6,902 36 49
⅜ -16 0.3750 9,223 58 78
⅜ -24 0.3750 10,448 65 89
7
/16 -14 0.4375 12,650 92 125
7
/16 -20 0.4375 14,125 103 140
½ -13 0.5000 16,886 141 191
½ -20 0.5000 19,028 159 215
9
/16 -12 0.5625 20,885 196 265
9
/16 -18 0.5625 23,294 218 296
⅝ -11 0.6250 25,934 270 366
⅝ -18 0.6250 29,376 306 415
¾ -10 0.7500 38,327 479 650
¾ -16 0.7500 42,802 535 725
⅞ -9 0.8750 53,015 773 1048
⅞ -14 0.8750 58,408 852 1155
1 -8 1.0000 69,539 1159 1572
1 -14 1.0000 77,915 1299 1761
1¼ -7 1.2500 111,193 2317 3141
1¼ -12 1.2500 123,127 2565 3478
1½ -6 1.5000 161,224 4031 5465
1½ -12 1.5000 181,420 4535 6150
The torque value used should be within ±5% of the calculated torque.

8-114
 MAINTENANCE

TORQUE VALUES

A574 Alloy Steel -- Hex socket Hd

Zinc Plated with Yellow Dichromate No Loctite

Thread Dia. Clamp Calculated Calculated
Size Torque Torque
Lbs Ft٠Lbs N ٠M
* = in ٠lbs
¼ -20 0.2500 3,784 * 199 22
¼ -28 0.2500 4,332 * 227 26

5
/16 -18 0.3125 6,236 34 46
5
/16 -24 0.3125 6,902 38 51
⅜ -16 0.3750 9,223 61 82
⅜ -24 0.3750 10,448 69 93
7
/16 -14 0.4375 12,650 97 131
7
/16 -20 0.4375 14,125 108 147
½ -13 0.5000 16,886 148 200
½ -20 0.5000 19,028 166 226
9
/16 -12 0.5625 20,885 206 279
9
/16 -18 0.5625 23,294 229 311
⅝ -11 0.6250 25,934 284 385
⅝ -18 0.6250 29,376 321 436
¾ -10 0.7500 38,327 503 682
¾ -16 0.7500 42,802 562 762
⅞ -9 0.8750 53,015 812 1101
⅞ -14 0.8750 58,408 894 1213
1 -8 1.0000 69,539 1217 1650
1 -14 1.0000 77,915 1364 1849
1¼ -7 1.2500 111,193 2432 3298
1¼ -12 1.2500 123,127 2693 3652
1½ -6 1.5000 161,224 4232 5739
1½ -12 1.5000 181,420 4762 6458
The torque value used should be within ±5% of the calculated torque.

8-115
 MAINTENANCE

TORQUE VALUES

A574 Alloy Steel -- Hex socket Hd

Zinc Plated with Yellow Dichromate With Red Loctite

Thread Dia. Clamp Calculated Calculated
Size Torque Torque
Lbs Ft ٠Lbs N ٠M
* = in ٠lbs
¼ -20 0.2500 3,784 21 29
¼ -28 0.2500 4,332 24 33
5
/16 -18 0.3125 6,236 44 59
5
/16 -24 0.3125 6,902 49 66
⅜ -16 0.3750 9,223 78 106
⅜ -24 0.3750 10,448 88 120
7
/16 -14 0.4375 12,650 125 169
7
/16 -20 0.4375 14,125 139 189
½ -13 0.5000 16,886 190 258
½ -20 0.5000 19,028 214 290
9
/16 -12 0.5625 20,885 264 358
9
/16 -18 0.5625 23,294 295 400
⅝ -11 0.6250 25,934 365 495
⅝ -18 0.6250 29,376 413 560
¾ -10 0.7500 38,327 647 877
¾ -16 0.7500 42,802 722 979
⅞ -9 0.8750 53,015 1044 1415
⅞ -14 0.8750 58,408 1150 1559
1 -8 1.0000 69,539 1565 2122
1 -14 1.0000 77,915 1753 2377
1¼ -7 1.2500 111,193 3127 4241
1¼ -12 1.2500 123,127 3463 4696
1½ -6 1.5000 161,224 5441 7378
1½ -12 1.5000 181,420 6123 8303
The torque value used should be within ±5% of the calculated torque.

8-116
 MAINTENANCE

TORQUE VALUES

A574 Alloy Steel -- Hex socket Hd

Zinc Plated with Yellow Dichromate With Blue Loctite

Thread Dia. Clamp Calculated Calculated
Size Torque Torque
Lbs Ft ٠Lbs N ٠M
* = in ٠lbs
¼ -20 0.2500 3,784 * 218 25
¼ -28 0.2500 4,332 21 28
5
/16 -18 0.3125 6,236 37 51
5
/16 -24 0.3125 6,902 41 56
⅜ -16 0.3750 9,223 66 90
⅜ -24 0.3750 10,448 75 102
7
/16 -14 0.4375 12,650 106 144
7
/16 -20 0.4375 14,125 118 161
½ -13 0.5000 16,886 162 219
½ -20 0.5000 19,028 182 247
9
/16 -12 0.5625 20,885 225 305
9
/16 -18 0.5625 23,294 251 341
⅝ -11 0.6250 25,934 311 421
⅝ -18 0.6250 29,376 352 477
¾ -10 0.7500 38,327 551 747
¾ -16 0.7500 42,802 615 834
⅞ -9 0.8750 53,015 889 1206
⅞ -14 0.8750 58,408 980 1328
1 -8 1.0000 69,539 1333 1807
1 -14 1.0000 77,915 1493 2025
1¼ -7 1.2500 111,193 2664 3612
1¼ -12 1.2500 123,127 2950 4000
1½ -6 1.5000 161,224 4635 6285
1½ -12 1.5000 181,420 5216 7073
The torque value used should be within ±5% of the calculated torque.

8-117
 MAINTENANCE

TORQUE VALUES
F835 Alloy Steel -- Hex socket button Hd

Plain Finish with Oil, Black Oxide with Oil or Zinc Phosphate with Oil No Loctite
Thread Dia. Clamp Calculated Calculated
Size Torque Torque
Lbs Ft ٠Lbs N ٠M
* = in ٠lbs
¼ -20 0.2500 3,784 * 142 16
5
/16 -18 0.3125 6,236 24 33
⅜ -16 0.3750 9,223 43 59
½ -13 0.5000 16,886 106 143
⅝ -11 0.6250 26,894 210 285
The torque value used should be within ±5% of the calculated torque.

Plain Finish with Oil, Black Oxide with Oil, or Zinc Phosphate with Oil
With Red Loctite and Blue Loctite
Thread Dia. Clamp Calculated Calculated
Size Torque Torque
Lbs Ft ٠Lbs N ٠M
* = in ٠lbs
¼ -20 0.2500 3,784 * 189 21

5
/16 -18 0.3125 6,236 32 44
⅜ -16 0.3750 9,223 58 78
½ -13 0.5000 16,886 141 191
⅝ -11 0.6250 26,894 280 380
The torque value used should be within ±5% of the calculated torque.

8-118
 MAINTENANCE

TORQUE VALUES
F835 Alloy Steel -- Hex socket button Hd

Zinc Plated with Yellow Dichromate No Loctite

Thread Dia. Clamp Calculated Calculated
Size Torque Torque
Lbs Ft ٠Lbs N ٠M
* = in ٠lbs
¼ -20 0.2500 3,784 * 199 22

5
/16 -18 0.3125 6,236 34 46
⅜ -16 0.3750 9,223 61 82
½ -13 0.5000 16,886 148 200
⅝ -11 0.6250 26,894 294 399
The torque value used should be within ±5% of the calculated torque.

8-119
 MAINTENANCE

TORQUE VALUES
F835 Alloy Steel -- Hex socket button Hd

Zinc Plated with Yellow Dichromate with Red Loctite

Thread Dia. Clamp Calculated Calculated
Size Torque Torque
Lbs Ft ٠Lbs N ٠M
* = in ٠lbs
¼ -20 0.2500 3,784 21 29
5
/16 -18 0.3125 6,236 44 59
⅜ -16 0.3750 9,223 78 106
½ -13 0.5000 16,886 190 258
⅝ -11 0.6250 26,894 378 513
The torque value used should be within ±5% of the calculated torque.

Zinc Plated with Yellow Dichromate with Blue Loctite

Thread Dia. Clamp Calculated Calculated
Size Torque Torque
Lbs Ft ٠Lbs N ٠M
* = in ٠lbs
¼ -20 0.2500 3,784 * 218 25

5
/16 -18 0.3125 6,236 37 51
⅜ -16 0.3750 9,223 66 90
½ -13 0.5000 16,886 162 219
⅝ -11 0.6250 26,894 322 437
The torque value used should be within ±5% of the calculated torque.

8-120
 MAINTENANCE

TORQUE VALUES
Property Class 10.9 Hex Hd cap screw

Plain Finish with Oil, Black Oxide with Oil or Zinc Phosphate with Oil No Loctite
Size Pitch Dia. Clamp Calculated Calculated
Torque Torque
mm in Lbs Ft ٠Lbs N ٠M
* = in ٠lbs
M 5 0.80 0.1969 2,253 * 67 8
M 6 1.00 0.2362 3,188 * 113 13

M 8 1.25 0.3150 5,806 23 31

M 10 1.50 0.3937 9,200 45 61
M 12 1.75 0.4724 13,372 79 107
M 14 2.00 0.5512 18,242 126 170
M 16 2.00 0.6299 24,904 196 266
M 20 2.50 0.7874 38,864 383 519
M 24 3.00 0.9449 55,995 661 897
M 30 3.50 1.1811 88,990 1314 1782
M 36 4.00 1.4173 129,599 2296 3113
The torque value used should be within ±5% of the calculated torque.

Size Ft ٠Lbs N ٠M
M22 …… ………………………….. …...………………547-602 ……741-816

8-121
 MAINTENANCE

TORQUE VALUES
Property Class 10.9 Hex Hd cap screw

Plain Finish with Oil, Black Oxide with Oil, or Zinc Phosphate with Oil
With Red Loctite or Blue Loctite
Size Pitch Dia. Clamp Calculated Calculated
Torque Torque
mm in Lbs Ft٠Lbs N ٠M
* = in ٠lbs
M 5 0.80 0.1969 2,253 * 89 10
M 6 1.00 0.2362 3,188 * 151 17

M 8 1.25 0.3150 5,806 30 41

M 10 1.50 0.3937 9,200 60 82
M 12 1.75 0.4724 13,372 105 143
M 14 2.00 0.5512 18,242 168 227
M 16 2.00 0.6299 24,904 261 355
M 20 2.50 0.7874 38,864 510 692
M 24 3.00 0.9449 55,995 882 1196
M 30 3.50 1.1811 88,990 1752 2375
M 36 4.00 1.4173 129,599 3061 4151
The torque value used should be within ±5% of the calculated torque.

8-122
 MAINTENANCE

TORQUE VALUES
Property Class 10.9 Hex Hd cap screw

Zinc Plated with Yellow Dichromate No Loctite

Size Pitch Dia. Clamp Calculated Calculated
Torque Torque
mm in Lbs Ft ٠Lbs N ٠M
* = in ٠lbs
M 5 0.80 0.1969 2,253 * 93 11
M 6 1.00 0.2362 3,188 * 158 18

M 8 1.25 0.3150 5,806 32 43

M 10 1.50 0.3937 9,200 63 86
M 12 1.75 0.4724 13,372 111 150
M 14 2.00 0.5512 18,242 176 239
M 16 2.00 0.6299 24,904 275 372
M 20 2.50 0.7874 38,864 536 726
M 24 3.00 0.9449 55,995 926 1256
M 30 3.50 1.1811 88,990 1839 2494
M 36 4.00 1.4173 129,599 3214 4359
The torque value used should be within ±5% of the calculated torque.

8-123
 MAINTENANCE

TORQUE VALUES
Property Class 10.9 Hex Hd cap screw

Zinc Plated with Yellow Dichromate With Red Loctite

Size Pitch Dia. Clamp Calculated Calculated
Torque Torque
mm in Lbs Ft ٠Lbs N ٠M
* = in ٠lbs
M 5 0.80 0.1969 2,253 * 120 14
M 6 1.00 0.2362 3,188 * 203 23

M 8 1.25 0.3150 5,806 41 56

M 10 1.50 0.3937 9,200 81 111
M 12 1.75 0.4724 13,372 142 193
M 14 2.00 0.5512 18,242 226 307
M 16 2.00 0.6299 24,904 353 479
M 20 2.50 0.7874 38,864 689 934
M 24 3.00 0.9449 55,995 1190 1614
M 30 3.50 1.1811 88,990 2365 3207
M 36 4.00 1.4173 129,599 4133 5604
The torque value used should be within ±5% of the calculated torque.

8-124
 MAINTENANCE

TORQUE VALUES
Property Class 10.9 Hex Hd cap screw

Zinc Plated with Yellow Dichromate With Blue Loctite

Size Pitch Dia. Clamp Calculated Calculated
Torque Torque
mm in Lbs Ft ٠Lbs N ٠M
* = in ٠lbs
M 5 0.80 0.1969 2,253 * 102 12
M 6 1.00 0.2362 3,188 * 173 20

M 8 1.25 0.3150 5,806 35 48

M 10 1.50 0.3937 9,200 69 94
M 12 1.75 0.4724 13,372 121 164
M 14 2.00 0.5512 18,242 193 261
M 16 2.00 0.6299 24,904 301 408
M 20 2.50 0.7874 38,864 587 795
M 24 3.00 0.9449 55,995 1014 1375
M 30 3.50 1.1811 88,990 2015 2732
M 36 4.00 1.4173 129,599 3521 4774
The torque value used should be within ±5% of the calculated torque.

8-125
 MAINTENANCE

TORQUE VALUES
Property Class 8.8 Hex Hd cap screw

Plain Finish with Oil, Black Oxide with Oil, or Zinc Phosphate with Oil No Loctite
Size Pitch Dia. Clamp Calculated Calculated
Torque Torque
mm inches Lbs Ft ٠Lbs N ٠M
* = in ٠lbs
M 5 0.80 0.1969 1,573 * 46 5
M 6 1.00 0.2362 2,227 * 79 9
M 8 1.25 0.3150 4,055 * 192 22

M 10 1.50 0.3937 6,427 32 43

M 12 1.75 0.4724 9,341 55 75
M 14 2.00 0.5512 12,742 88 119
M 16 2.00 0.6299 17,396 137 186
M 20 2.50 0.7874 28,083 276 375
M 24 3.00 0.9449 40,462 478 648
M 30 3.50 1.1811 64,303 949 1287
M 36 4.00 1.4173 93,647 1659 2250
The torque value used should be within ±5% of the calculated torque.

8-126
 MAINTENANCE

TORQUE VALUES
Property Class 8.8 Hex Hd cap screw

Plain Finish with Oil, Black Oxide with Oil or Zinc Phosphate with Oil
With Red Loctite or Blue Loctite
Size Pitch Dia. Clamp Calculated Calculated
Torque Torque
mm in Lbs Ft ٠Lbs N ٠M
* = in ٠lbs
M 5 0.80 0.1969 1,573 * 62 7
M 6 1.00 0.2362 2,227 * 105 12

M 8 1.25 0.3150 4,055 21 29

M 10 1.50 0.3937 6,427 42 57
M 12 1.75 0.4724 9,341 74 100
M 14 2.00 0.5512 12,742 117 159
M 16 2.00 0.6299 17,396 183 248
M 20 2.50 0.7874 28,083 369 500
M 24 3.00 0.9449 40,462 637 864
M 30 3.50 1.1811 64,303 1266 1716
M 36 4.00 1.4173 93,647 2212 3000
The torque value used should be within ±5% of the calculated torque.

8-127
 MAINTENANCE

TORQUE VALUES
Property Class 8.8 Hex Hd cap screw

Zinc Plated with Yellow Dichromate No Loctite

Size Pitch Dia. Clamp Calculated Calculated
Torque Torque
mm in Lbs Ft ٠Lbs N ٠M
* = in ٠lbs
M 5 0.80 0.1969 1,573 * 65 7
M 6 1.00 0.2362 2,227 * 110 12

M 8 1.25 0.3150 4,055 22 30

M 10 1.50 0.3937 6,427 44 60
M 12 1.75 0.4724 9,341 77 105
M 14 2.00 0.5512 12,742 123 167
M 16 2.00 0.6299 17,396 192 260
M 20 2.50 0.7874 28,083 387 525
M 24 3.00 0.9449 40,462 669 907
M 30 3.50 1.1811 64,303 1329 1802
M 36 4.00 1.4173 93,647 2323 3150
The torque value used should be within ±5% of the calculated torque.

8-128
 MAINTENANCE

TORQUE VALUES
Property Class 8.8 Hex Hd cap screw

Zinc Plated with Yellow Dichromate with Red Loctite

Size Pitch Dia. Clamp Calculated Calculated
Torque Torque
mm in Lbs Ft ٠Lbs N ٠M
* = in ٠lbs
M 5 0.80 0.1969 1,573 * 84 9
M 6 1.00 0.2362 2,227 * 142 16

M 8 1.25 0.3150 4,055 29 39

M 10 1.50 0.3937 6,427 57 77
M 12 1.75 0.4724 9,341 99 135
M 14 2.00 0.5512 12,742 158 214
M 16 2.00 0.6299 17,396 247 334
M 20 2.50 0.7874 28,083 498 675
M 24 3.00 0.9449 40,462 860 1166
M 30 3.50 1.1811 64,303 1709 2317
M 36 4.00 1.4173 93,647 2986 4050
The torque value used should be within ±5% of the calculated torque.

8-129
 MAINTENANCE

TORQUE VALUES
Property Class 8.8 Hex Hd cap screw

Zinc Plated with Yellow Dichromate With Blue Loctite

Size Pitch Dia. Clamp Calculated Calculated
Torque Torque
mm in Lbs Ft ٠Lbs N ٠M
* = in ٠lbs
M 5 0.80 0.1969 1,573 * 71 8
M 6 1.00 0.2362 2,227 * 121 14

M 8 1.25 0.3150 4,055 24 33

M 10 1.50 0.3937 6,427 48 66
M 12 1.75 0.4724 9,341 85 115
M 14 2.00 0.5512 12,742 135 183
M 16 2.00 0.6299 17,396 210 285
M 20 2.50 0.7874 28,083 424 575
M 24 3.00 0.9449 40,462 733 994
M 30 3.50 1.1811 64,303 1456 1974
M 36 4.00 1.4173 93,647 2544 3450
The torque value used should be within ±5% of the calculated torque.

8-130
 MAINTENANCE

TORQUE VALUES – WHEEL LUG NUTs

APPENDIX A

8-131
 MAINTENANCE

TORQUE VALUES – WHEEL LUG NUTs

APPENDIX A

8-132
 MAINTENANCE

SPLIT FLANGE CLAMP HALFs

Standard Pressure Series

MATERIAL H.T. & HARDNESS

See MATERIAL call out

GENERAL All detailed general and dimensional requirements are as specified in SAE standard J518 (ANSI
B117.1) for Hydraulic Flanged Connections, Standard Pressure Series (Code 61). Excerpts form that SAE stan-
dard are repeated herewith as design aids.

MATERIAL All mechanical and material requirements are as specified in SAE J518. Split flange clamp halves
shall be made from a material with the following properties:

(a) 0.500 inch (-8) size minimum yield, 32 000 psi minimum elongation, 3%
(b) All other sizes, minimum yield, 60 000 psi minimum elongation, 3%
PROTECTIVE TREATMENT Split Flange Clamps will be furnished with an electroplated coating of zinc with yel-
low chromate (Fe/Zn 5 C2).

CAPSCREW TORQUE SEQUENCE Tighten capscrews in a diagonal sequence in small increments until the
appropriate torque range is obtained for the specific nominal flange size.

8-133
 MAINTENANCE

SPLIT FLANGE CLAMP HALFs

Standard Pressure Series

8-134
 MAINTENANCE

SPLIT FLANGE CLAMP HALFs

Standard Pressure Series

8-135
 MAINTENANCE

SPLIT FLANGE CLAMP HALFs

Standard Pressure Series

HCM STANDARD PARTS

HCM hardware shown here is for cross reference information only.

ALL requirements for the EH4510173, EHZ986910, EHZ962453, EH4024049, EHZ965946, & EH4510174 part
numbers are as specified by HCM std. 9920126.

BILL-OF-MATERIAL STRUCTURE
Within the BOM structure please specify a quantity of "2" split flange clamp halfs for each connection. (The
quantity for split flange clamp halfs should always be an even number.)

8-136
 STORAGE

STORAGE OF HITACHI RIGID DUMP TRUCK

Service prior to the storage of a rigid dump truck for short

periods of time or for long periods, the off-season, is
important if damage to components and systems is to be
avoided. The purpose of this section is to help prevent any
expensive overhaul or delay in returning the rigid dump truck
to operation and covers three storage durations:

Short Term Storage – 30 days or less

Moderate Term Storage – Longer than 30 days but
less than 6 months.
Long Term Storage – 6 months or more

NOTE: The procedures outlined below should be used

as a guide only. They do not attempt to cover all
possible details of storage, servicing or
inspection. Instead, consider them to be the
minimum requirements of preservation
maintenance. In addition, the age, length or
storage and conditions under which the rigid
dump truck is stored contribute to the amount and
kind of maintenance required.

Short Term Storage (30 Days or Less)

• INSPECTION AND REPAIR – Thoroughly inspect and test

the rigid dump truck and make any repairs or adjustments
which may be necessary to prepare it for service.

• LUBRICATION – Completely lubricate the rigid dump truck

according to GREASING in the MAINTENANCE section of
this manual.

• CLEANING/RUST PREVENTION – Thoroughly clean the

entire unit. Clean all evidence of rust from the rigid dump
truck, and repaint rusted areas.

• PARKING
a. Park on hard, dry, level surface that is free
from grease and oil.
b. Position chock blocks at each wheel.

• FUEL AND HYDRAULIC OIL TANKS – Fill fuel and

hydraulic oil tanks to minimize moisture and condensation
within the tanks. If filling is not possible or practical, use
alternate methods to ensure that moisture condensation
will not develop within the fuel or hydraulic tanks.

• TIRES – Clean off all grease and oil and inflate all tires to
the correct pressure. Check inflation pressure
approximately once every two weeks.

9-1
 STORAGE

• RADITATOR/COOLING LINES – Fill the radiator with

permanent type antifreeze with rust inhibitor added for
temperatures to -40°C (-40°F).

• ENGINE – Fill the engine oil pan to the correct oil level.

• BATTERIES – When moderate temperatures are

expected, the batteries may be left in the rigid dump truck,
however, disconnect the ground cable.

NOTE: Refer to Return to Service in this section before

removing the rigid dump truck from storage.

Start and Operate Rigid dump truck Every 30 Days

(Minimum)

If the rigid dump truck has not been prepared for Moderate
or Long Term Storage, the following should be performed
every 30 days.

• Hook up ground cable to battery. Install batteries if

removed.

• Check all fluid levels (hydraulic, axles, engine oil, coolant,

check for proper anti-freeze protection and battery
electrolyte level). Refill as required.

• Check air filters and piping.

• Check tire pressure.

• Check condition of the fans and belts.

• Remove any hardened grease on the cylinder rods.

• Start engine – run at low idle.

• Check all instrument panel gauges – pressure,

temperature, warning lights, and fuses.

• Check operation of all accessories (air conditioning,

wipers, turn signals, etc.).

• Operate engine at low idle for at least 15 minutes.

• Release parking brake.

• Check the brakes (service and parking).

•
• Move the rigid dump truck forward and backward at half-
high rpm (axles to be rotated to assure proper lubrication).

9-2
 STORAGE

• All hydraulic components to be cycled to assure oil flow

through the complete system.

• Run engine al low idle for 3 minutes to cool engine.

• Set parking brake.

• Stop the engine.

• Remove the master key and lock the cab door.

• Lubricate all exposed cylinder rods or any other rod that

cannot be retracted.

• Check for leaks on the rigid dump truck.

• Fill out the rigid dump truck card, requested data and
operator’s name. Note the conditions to be repaired as
well as any discrepancy (rust not noticed the previous
month, etc.).

• Advise your supervisor of any discrepancy for immediate

rework.

• Remove ground cable from battery or remove batteries if

storage is for moderate or long term.

• Chock the wheels.

Moderate Term Storage

(Longer than 30 days but less than 6 months)

• INSPECTION AND REPAIR – Same as under Short Term

Storage.
• LUBRICATION – Same as under Short Term Storage.

• CLEANING/RUST PREVEINTION – Same as under Short

Term Storage.

• PARKING – Same as under Short Term Storage.

• FUEL AND HYDRAULIC OIL TANKS – Same as under

Short Term Storage.

• TIRES – Same as under Short Term Storage. In addition

protect the tires from direct sunlight and water, with a
suitable cover.

• RADIATOR/COOLING LINES – Same as under Short

Term Storage.

9-3
 STORAGE

• ENGINE
a. Start the engine. Gradually increase
engine speed to high idle until the engine
coolant is warm.
b. Turn the engine off.
c. Disconnect the fuel lines to the engine fuel
filter and the injector return line.
d. Fill two, clean portable containers; one
with diesel fuel the second with
preservative oil. Use Daubert Chemical
NoxRust No. 518, or equivalent. The oil
must meet Military Specification MIL-L-
644, Type P-9.
e. Place the disconnected fuel lines in the
container of diesel fuel. Start the engine.
f. After the engine is operating smoothly,
transfer the fuel supply line to the
container of preservative oil. Continue to
operate the engine until the preservative
oil flows out of the injector return line.
g. Turn the engine off. Connect the fuel lines
to the fuel filter and the injector return line.
h. Drain the oil pan sump, oil filters, and fuel
filters.
i. Install the drain plugs in the oil sump. The
sump can remain empty until the engine is
ready to be placed back in service.
j. Spray lubricating oil into the intake
manifold.

WARNING: Put a warning tag on the engine. The

tag must indicate.
• Do not operate the engine.
• The engine does not contain oil.

• BATTERIES- Remove batteries from the rigid dump truck

and store them in a suitable place where they can be
inspected and charged at least every 30 days, or placed
on a trickle charge.

9-4
 STORAGE

• CHROME SURFACES – Protect the chrome surface with

multi-purpose lithium base grease No. 2. Ride struts, hoist
cylinders, steering cylinders, driveshaft splines and
hydraulic valve spools.

• VENTS AND BREATHERS – Remove all vents and

breathers. Plug openings with pipe plugs. If this is not
possible or practical, seal vents and breathers with
waterproof tape.

NOTE: Refer to Return to Service in this section before

removing the rigid dump truck from storage.

Long Term Storage (6 months or more)

Follow the procedures outlined previously under Moderate

Term Storage. Repeat these procedures for every 6 month
period the rigid dump truck is in storage.

• LUBRICATION – Completely lubricate the rigid dump truck

according to GREASING in the MAINTENANCE section of
this manual. Repeat these procedures for every 6 month
period the rigid dump truck is in storage.

• RADIATOR/COOLING LINES – After 24 months in

storage, the radiator and cooling system must be flushed
with a suitable solvent or a hot, lightweight mineral oil. Fill
the radiator with permanent type antifreeze with rust
inhibitor added for temperatures to -40°C (-40°F).

• ENGINE
a. Start the engine. Gradually increase engine
speed to high idle until the engine coolant is
warm.
b. Turn the engine off.
c. Drain the oil. Install the drain plugs. Use Shell
66202 or equivalent, preservative oil. The oil
must meet Military Specification MIL-L21260,
Type P-10, Grade 2, SAE 30. Fill the engine to
the “High” mark.
d. Disconnect the fuel lines to the engine fuel
filter and the injector return line.
e. Fill two, clean portable containers; one with
diesel fuel the second with preservative oil.
Use Daubert Chemical NoxRust No. 518, or
equivalent. The oil must meet Military
Specification MIL-L-644, Type P-9.

9-5
 STORAGE

f. Place the disconnected fuel lines in the

container of diesel fuel. Start the engine.
g. After the engine is operating smoothly,
transfer the fuel supply line to the container of
preservative oil. Continue to operate the
engine until the preservative oil flows out of
the injector return line.
h. Turn the engine off. Connect the fuel lines to
the fuel filter and the injector return line.
i. Drain the preservation oil from the engine oil
pan sump, oil filters, and fuel filters.
j. Remove the intake and exhaust manifolds.
Spray preservative oil into the intake and
exhaust ports in the cylinder heads and in the
manifolds.
k. Spray preservative oil in the intake port on the
air compressor.
l. Use a rust preventive compound that meets
Military Specification MIL-C-16173C, Type P-
2, Grade 1 or 2. Brush or spray the compound
on all of the exposed surfaces that are not
painted.
m. Remove the rocker lever covers. Spray the
rocker levers, the valve stems, the springs, the
valve guides, the crossheads, and the push
rods with preservative oil. Install the covers.
n. Cover all of the openings with heavy paper
and tape to prevent dirt and moisture from
entering the engine.

WARNING: Put a warning tag on the engine. The

tag must indicate.
• Do not operate the engine.
• The engine has been treated with preservatives.
• Do not bar the crankshaft.
• The coolant has been removed.
• The date of treatment.

9-6
 STORAGE

• OTHER CHECKS AND SERVICE.

Check fluid levels for the planetary hub gears, and
brake system anti-freeze. Add recommended
lubricants to bring up to proper levels.
Apply anti-corrosion spray to exposed pin ends and
lock plates.
Check for signs of oil or water leaks.
Check air filters and piping.
Check fan and all belts.
Cab door should be closed tightly and locked.
Remove all keys.
Store the rigid dump truck in a position to allow
forward and reverse motion (for scheduled
maintenance of stored rigid dump trucks).

Return to Service

• LUBRICATION – Completely lubricate the rigid dump truck

according to GREASING in the MAINTENANCE section of
this manual.

• BATTERIES – If returning to service from short term

storage and batteries were left in the rigid dump truck,
connect the ground cable. Install the batteries if they were
removed. Make sure that the batteries have a full charge.

• TIRES – Inflate the tires to the correct pressure.

• FUEL AND HYDRAULIC OIL TANKS – Check fluid in fuel

and hydraulic oil tanks, add fluid as required to obtain
proper level.

• VENTS AND BREATHERS – Remove seals and plugs

from all breather openings and install all breathers and
vents. Make sure they are cleaned before installation is
made.

• RADIATOR/COOLING LINES – Check fluid and add

recommended cooling system antifreeze to bring up to
proper level.

• ENGINE

9-7
 STORAGE

From Moderate Term Storage

Prime the lubricating system:

y Fill the oil pan sump, oil filters, and fuel filters.

y Fill the coolant system, if necessary.

y Rotate the crankshaft by the starting motor until the oil

pressure appears on the gauge or the warning light goes
out.

y Start the engine. Refer to procedures in Operating The

Engine in this manual.

From Long Term Storage

Remove the plug from the main oil rifle. Use a hot,
lightweight mineral oil. Flush all of the preservative oil from
the engine. Bar the engine crankshaft three to four
revolutions during the flushing procedure.

Fill the oil pan sump, oil filters, and fuel filters.

Drain the rust preventive compound from the cooling system.

Fill the cooling system with coolant.

Prime the lubricating system:

y Rotate the crankshaft by the starting motor until the oil
pressure appears on the gauge or the warning light goes
out.

y Start the engine. Refer to procedures in Operating the

Engine in this manual.

9-8

Problem
Engine Cranks But Will Not
Start or Hard to Start
Engine knocks, runs irregularly
or stops
TROUBLESHOOTING
ENGINE
Cause
Check Contronics display screen
for engine fault code(s).
No fuel.
Fuel grade is not correct or the fuel
is contaminated or of poor quality.
Contaminated fuel.
Low battery power.
Poor electrical connection.
Air filter plugged.
Fuel filter plugged.
Air in fuel system.
Engine is operating at low ambient
temperature.
Check Contronics display screen
for engine fault code(s).
Fuel grade is not correct or the fuel
is contaminated or of poor quality.
Air in fuel system.
Fuel filter plugged.
Plugged air intake system.
Low cooltant temperature.
10-1
Solution
Take appropriate action based on
fault code(s).
Add fuel. Bleed air.
Drain fuel tank. Fill with correct
fuel.
Drain fuel tank. Fill with correct
fuel.
Charge batteries or install new
batteries.
Clean and tighten battery and
starter engine connections.
Replace filter element(s).
Replace filter. Bleed air.
Bleed air. Check fuel system for
leaks.
Make sure oil is of correct
specification for operating
conditions. Use appropriate cold
weather operating equipment.
Take appropriate action based on
fault code(s).
Drain fuel tank. Fill with correct
fuel.
Bleed air. Check fuel system for
leaks.
Replace filter. Bleed air.
Replace the appropriate filter
element(s).
Run engine until warm. See below,
PROBLEM “Coolant Temperature
Too Low”.
 TROUBLESHOOTING

ENGINE
Problem Cause Solution
Engine Not Developing Full Check Contronics display screen Take appropriate action based on
Power for engine fault code(s). fault code(s).

Fuel grade is not correct or the fuel Drain fuel tank. Fill with correct
is contaminated or of poor quality. fuel.

Contaminated fuel.
Drain fuel tank. Fill with correct
Excessive fuel restriction. fuel.

Check fuel system for restrictions.

Plugged fuel tank breather. Replace filter if necessary.

Exhaust restriction. Clean or install new breather.

Check exhaust system for

Excessive air intake restriction. restrictions.

Check air intake system for

respriction. Replace the air filter
element(s) if necessary.
Engine Overheats Check Contronics display screen Take appropriate action based on
for engine fault code(s). fault code(s).

Low coolant level. Add coolant, check for leaks.

Thermostat malfunctioning. Check thermostat for correct

operation.

Radiator or charge air cooler fins Inspect radiator and chage air
damaged or plugged. cooler. Clean if necessary.

Fan belt loose or broken. Inspect fan belt tension or install

new belt.

Cooling system passages dirty. Flush cooling system.

Cooling system hose is collapsed, Inspect hoses, replace if

restricted, or leaking necessary.
Temperature gauge or sending unit.
Coolant Temperature Too Low Check Contronics display screen Take appropriate action based on
for engine fault code(s). fault code(s).

Thermostat malfunctioning. Check thermostat for correct

operation.

Engine is operating at low ambient Avoid prolonged periods of idle,

temperature. Use appropriate cold weather
equipment.

10-2
 TROUBLESHOOTING

ENGINE
Problem Cause Solution
Low Engine Oil Pressure Low oil level. Add oil, check for leaks.

Plugged oil filter. Install a new oil filter.

Oil diluted with fuel or coolant. Contact your authorized dealer.

Engine temperature too high. Check cooling system. See above,

PROBLEM “Engine Overheats”.

Oil does not meet specifications for Drain oil. Use correct oil.
operating conditions.
Engine Uses Too Much Oil Oil leaks. Check for oil leaks.

Engine temperature too high. Check cooling system. See above,

PROBLEM “Engine Overheats”.

Oil does not meet specifications for Drain oil. Use correct oil.
operating conditions.

Crankcase ventilation system is Check and clean crankcase

plugged. breather and vent tube.

Oil is contaminated with coolant or Contact your authorized dealer.

fuel.

Turbocharger oil seal is leaking. Contact your authorized dealer.

Engine Uses Too Much Fuel Check Contronics display screen Take appropriate action based on
for engine fault code(s). fault code(s).

Fuel leak. Check fuel lines for leak.

Excessive air intake restriction. Check air intake system for

restriction. Replace the air filter
element(s) if necessary.

Fuel grade is not correct or the fuel Drain fuel tank. Use correct fuel.
quality is poor.
Excessive Black or Gray Check Contronics display screen Take appropriate action based on
Exhaust Smoke for engine fault code(s). fault code(s).

Fuel grade is not correct or the fuel Drain fuel tank. Use correct fuel.
quallity is poor.

Excessive air intake restriction. Check air intake system for

restriction. Replace the air filter
element(s) if necessary.

Excessive exhaust restriction. Check exhaust system for

restirctions.

Turbocharger oil seal is leaking. Contact your authorized dealer.

10-3
 TROUBLESHOOTING

ENGINE
Problem Cause Solution
Exhaust White Exhaust Smoke Check Contronics display screen Take appropriate action based on
for engine fault code(s). fault code(s).

Fuel grade is not correct or the fuel Drain fuel tank. Use correct fuel.
quality is poor.

Cold engine. Run engine until warm See above,

PROBLEM “Coolant Temperature
too Low”.

ENGINE COOLANT
Problem Cause Solution
Engine coolant temperature too Lack of coolant. Fill cooling system with proper
high. amount of coolant.
Check for coolant leaks.

Front of radiator obstructed Remove obstruction.

preventing free passage of air.

Fan belt broken or slipping. Adjust or replace fan belt.

Thermostat not opening. Replace thermostat.

Cooling system clogged with rust or Flush cooling system.

scale.

Water pump not functioning Repair or replace water pump.

properly.
Engine coolant temperature too Thermostat remains open or opens Replace thermostat.
low. at too low a temperature.

Extremely cold weather. Cover radiator and install radiator

shutters.

DRIVE COUPLING
Problem Cause Solution
Vibration or visible “whirl” Mounting bolts are loose. Check thread and retorque.

Rubber element is twisted so that Replace.

inner member is no longer square
with flywheel.

Driveshaft is loose or unbalanced. Refer to section on FRONT

Adapter not properly seated. DRIVESHAFT.
Burning rubber smell. Element is slipping excessively. Replace.

10-4
 TROUBLESHOOTING

STARTER AND MOUNTING

Problem Cause Solution
Restriction of free longitudinal Drive rusted to armature shaft.. Clean shaft and relubricate with
movement very light oil.

Rough or burred armature shaft.. Use a file or emery cloth to smooth

it, clean and lubricate.
Failure of pinion to mesh or Gummy or oily condition of screw Clean with Kerosene and re-oil
release. shaft threads. sparingly with very light oil.

Rusty condition of screw shaft Clean threads and relubricate with

threads. very light oil.

Broken return spring. Replace spring.

AIR CLEANER
Problem Cause Solution
Short element life Check the air supply to the air
Leaking dust cup to air cleaner cleaner inlet; it must be
body joint. unrestricted.

Damaged or missing vacuator Check to make sure the air cleaner

valve.
Injection nozzles dirty or not
working correctly.
Plugged or buildup in the vanes of
the pre-cleaner.
Damage to the pre-cleaning section
of the air cleaner.
element was new or properly
cleaned when installed.
Check the clean air ducting after
the air cleaner to be certain it is
unrestricted.
Check service indicator and air
filter restriction indicator lamp for
damage.

Dust cup must seal 360° around

the air cleaner.

Replace vacuator valve.

Clean and or replace filter

element(s).

Clean vanes in lower body

assembly.

Replace the lower body assembly

valve.

10-5
 TROUBLESHOOTING

AIR CLEANER
Problem Cause Solution
Airborne contaminants entering Engine oil level low. Check to make sure the element
the engine has not been damaged in handling.
Plugged air intake system. Examine for dents and holes.

Injection pump out of time. Check to make sure all gaskets are
sealing. Examine for dust trails
Low coolant temperature. which indicate leaks. Check to be
certain wing nut is tight.

Water, dirt or air in fuel system. Examine the clean air transfer
tubing for cracks, loose clamps, or
loose flange joints.

10-6

Problem
Transmission Overheats
Transmission Fluid is Aerated
(Foaming)
Heavy Metal Debris is Found in
Transmission fluid, Strainer, or
Pan
TROUBLESHOOTING
TRANSMISSION
Cause
High or low fluid level.
Aerated (foaming) fluid.
Vehicle equipment overloaded.
Engine coolant overheated.
Heat exchanger or lines kinked or
clogged.
Low coolant level.
Transmission fluid leaking.
Low main pressure.
Low converter-out pressure.
Vehicle brakes dragging.
Torque converter stator locked.
Clutch slipping.
Retarder engaged.
Incorrect fluid used.
High or low fluid level.
Air entering suction side of pump.
Water in transmission fluid.
Transmission internal failure.
10-7
Solution
Restore proper fluid level.
See below TRANSMISSION FLUID
IS AERATED (FOAMING).
Reduce load.
Correct engine overheating.
Clean or replace heat exchanger or
lines.
Add coolant, check for leaks.
Check transmission and all external
lines. Correct leaks.
See below LOW MAIN
PRESSURE.
See below LOW.
CONVERTER-OUT PRESSURE.
Check parking and service brakes.
Check for low top speed of rigid
dump truck. Check torque
converter components.
Overhaul transmission. Replace
worn piston sealrings and/or clutch
plates.
Disengage the retarder.
Change fluid. Use proper fluid.
Restore proper fluid level.
Check oil pump bolts and gasket.
Check for source. Clean system.
Check for coolant (Glycol) in
system.
Completely disassemble, clean,
and repair transmission. Replace
filters and clean external lines and
cooler.
 TROUBLESHOOTING

Problem
Coolant is Found in
Transmission Fluid
Transmission Will Not Operate
in Any Range, Regardless of
Selector Position
TRANSMISSION
Cause
Heat exchanger leaking.
Loss of electrical power.
Internal mechanical failure.
Solution
Completely disassemble and
thoroughly clean transmission.
Replace all friction-faced clutch
plates. Repair or replace heat
exchanger. Replace filters and
clean external lines.
Contact your authorized dealer.
Overhaul transmission.

Driveline failure. Check input and output of

transmission.

Low fluid level. Restore proper fluid level.

Low main pressure. See Below. LOW MAIN

PRESSURE.
Transmission Continues in The Contact your authorized dealer.
Same Forward Range
Regardless of Selector Position
Shifting is Erratic Contact your authorized dealer.
Transmission Operates Only in Contact your authorized dealer.
First, Neutral, and Reverse
Transmission Shifts to Neutral Contact your authorized dealer.
During Reverse Operation, But
Will Operate Normally in All
Forward Ranges
Rigid dump truck Operates in Reverse clutch failed (won’t Overhaul transmission.
Reverse And Moves Backward release).
in Neutral When Engine is
Accelerated, But Stalls in All
Other Ranges When Engine is
Accelerated – Electronic
Troubleshooting OK
Rigid dump truck Operates in Low-range clutch failed (won’t Overhaul transmission.
First And Second Ranges And release).
Moves Forward in Neutral When
Engine is Accelerated, But
Stalls in All Other Ranges When
Engine is Accelerated –
Electronic Troubleshooting OK
Rigid dump truck Operates in Immediate-range clutch has failed Overhaul transmission.
Third And Fourth Ranges And (won’t release).
Moves Forward in Neutral When
Engine is Accelerated, But
Stalls in All Other Ranges When
Engine is Accelerated –
Electronic Troubleshooting OK

10-8

Problem
Rigid dump truck Operates in
Fifth And Sixth Ranges And
Moves Forward in Neutral When
Engine is Accelerated, But Stalls
in All Other Ranges When
Engine is Accelerated –
Electronic Troubleshooting OK
No Power is Transmitted in One
Range (Low Range, Intermediate
Range, High Range, or Reverse)
– Electronic Troubleshooting OK
Rigid dump truck will operate in
Second, Fourth, Sixth, and
Reverse Ranges But Will Not
Operate in All Other Ranges –
Electronic Troubleshooting OK
Rigid dump truck will operate in
First, Third, and Fifth Ranges
But Will Not Operate in All Other
Ranges – Electronic
Troubleshooting OK
Slow Clutch Engagement
Vehicle Lacks Power and
Acceleration
TROUBLESHOOTING
TRANSMISSION
Cause
High-range clutch has failed (won’t
release).
Range clutch failed (won’t release)
Splitter-high clutch won’t release or
splitter-low clutch won’t apply,
slipping.
Splitter-low clutch won’t release or
splitter-high clutch won’t apply,
slipping.
Low transmission fluid level.
Foaming transmission fluid.
Worn piston seals.
Low main pressure.
Low transmission fluid temperature.
Strator freewheel clutch failed.
Engine malfunction.
Aerated transmission fluid.
Low engine speed at converter
stall.
High engine speed at converter
stall.
Hydralulic retarder partially applied.
Rigid dump truck brakes dragging.
10-9
Solution
Overhaul transmission.
Overhaul transmission. Check for
worn piston seals, broken piston
housing, or worn clutch plates in
that range.
Overhaul transmission. Check
splitter clutches for worn
components.
Overhaul transmission. Check
splitter clutches for worn
components.
Add fluid to proper level.
See Above. TRANSMISSION
FLUID IS AERATED (FOAMING)
Overhaul transmission.
See Below. LOW MAIN
PRESSURE.
Use recommended fluid. Preheat if
required.
Overhaul transmission.
Check engine. Refer to appropriate
engine service manuals.
See Above. TRANSMISSION
FLUID IS AERATED (FOAMING).
See Below. LOW ENGINE SPEED
AT CONVERTER STALL.
See Below. HIGH ENGINE SPEED
AT CONVERTER STALL.
Check linkage.
Check parking and service brakes.
 TROUBLESHOOTING

TRANSMISSION
Problem Cause Solution
High Engine Speed at Low transmission fluid level. Add fluid to proper level.
Converter Stall
Low converter-out pressure. See Below. LOW
CONVERTER-OUT PRESSURE

High fluid temperature (above See Above. TRANSMISSION

135°C, 275°F). OVERHEATS.

Clutch slipping-main pressure Overhaul transmission. Replace

normal. clutch piston sealrings or clutch
plates.

Foaming transmission fluid. See Above. TRANSMISSION

FLUID IS AERATED (FOAMING)
Low Engine Speed at Low engine output torque. Tune engine and check output.
Converter Stall
Converter element interference. Check for noise at stall; overhaul
converter if necessary.

Transmission fluid below operating Warm up transmission to 82-103°C

temperature. (180-220°F).
Low Converter-Out Pressure Low transmission fluid level. Add fluid to proper level.

Fluid line leakage (remote-mounted Check for fluid leaks-correct leaks.

cooler or filter).

Plugged strainer. Clean strainer.

Defective pump. Rebuild or replace pump assembly.

High fluid temperature. See above. TRANSMISSION

OVERHEATS

Foaming transmission fluid. See Above. TRANSMISSION

FLUID IS AERATED (FOAMING)

10-10

Problem
Low Main Pressure
Downshift of Transmission is
Permitted During Lockup
Operation
Shift Quadrant Not Illuminated
Reverse Signal Not Energized
TROUBLESHOOTING
TRANSMISSION
Cause
Low transmission fluid level.
Leaks in hydraulic system.
Failure in main-pressure regulator
valve.
Worn input pump assembly.
Clogged strainer.
Air leaks at suction side of input
pump.
Converter-in check valve stuck
open or spring failed.
Lubrication regulator valve stuck
open or spring failed.
Failed light bulb.
10-11
Solution
Add fluid to proper level.
Check all external points for leaks;
check each range for localizing
internal leaks.
Overhaul valve assembly.
Rebuild or replace pump assembly.
Clean oil strainer.
Check input pump; correct leaks.
Repair valve.
Repair valve.
Contact your authorized dealer.
Replace the light bulb.
Contact your authorized dealer.
 TROUBLESHOOTING

ELECTRICAL SYSTEM
Problem Cause Solution
Nothing Works Battery disconnect switch in off Turn battery disconnect switch to
position. the on position.

Battery. Recharge or replace.

Nothing Works (Except clock) Battery relay Replace relay
Batteries Undercharged Loose or corroded connections. Clean and tighten or replace
batteries.

Alternator belt loose. Tighten or install new belt.

Alternator not charging. Contact your authorized dealer.

Fuse. Replace fuse.

Key switch failure. Replace key switch.

Starting Motor Will Not Turn Battery undercharged or dead. Recharge or replace battery.

Battery cables making poor Clean connections.

connections.

Fusible link. Replace fusible link.

Key switch. Contact your authorized dealer.

Start relay. Contact your authorized dealer.

Starter solenoid. Contact your authorized dealer.

Starter. Repair or replace starter motor.

Starter pinion jammed in flywheel Repair or replace starter.

gear.

Major engine failure. Contact your authorized dealer.

Starter Solenoid Chatters Poor connections at batteries or Clean connections.
starter.

Low battery charge. Recharge or replace batteries.

Starter solenoid “hold-in” windings Contact your authorized dealer.

open.
Starter Motor Turns But Will Not Starter Pinion gear not engaging Contact your authorized dealer
Crank Engine flywheel ring gear.

Pinion shift mechanism jammed or Contact your authorized dealer.

malfunctioning.

Pinion gear teeth broken. Contact your authorized dealer.

Flywheel gear teeth broken. Contact your authorized dealer.

10-12
 TROUBLESHOOTING

ELECTRICAL SYSTEM
Problem Cause Solution
Engine Cranks Slowly Battery cables damaged or broken Inspect and replace cables.
internally.

Battery or starter cable connections Clean and tighten connections.

loose or corroded.

Battery discharged or will not hold Replace battery.

a charge.

Starter “dragging”. Contact your authorized dealer.

Low battery voltage. Recharge or replace battery.

Starter Motor Continues To Run Start relay stuck. Contact your authorized dealer.
After Engine Starts
Starter solenoid stuck. Contact your authorized dealer.

Starter not disengaging. Contact your authorized dealer.

Key switch. Contact your authorized dealer.

Charging Indicator Light On Loose or glazed alternator belt. Check belt
Engine Running Replace if glazed, tighten if loose

Engine speed low. Adjust rpm to specifications

Excessive electrical load from Remove accessories or install

added accessories. higher output alternator

Loose or corroded electrical Inspect, clean, or tighten electrical

connections on battery, grond connections
strap, starter, or alternator

Battery voltage low. Change or replace battery

Alternator or regulator. Contact your authorized dealer

Indicator circuit. Contact your authorized dealer

Noisy Alternator Worn drive belt. Replace belt.

Worn pulleys. Replace pulleys and belt.

Pulley misaligned. Adjust alternator mount.

Alternator bearing. Loosen alternator belts.

Turn pulley by hand.
If any roughness is felt, repair
alternator.
No Monitor Panel Indicators Fuse. Replace fuse.
Work
Wiring harness. Contact your authorized dealer.

10-13
 TROUBLESHOOTING

ELECTRICAL SYSTEM
Problem Cause Solution
Individual Light in Monitor Bulb. Replace bulb.
Panel is Not Working
Fuse. Replace fuse.

Wiring harness. Contact your authorized dealer.

No Indicators in Gauge Panel Circuit board. Contact your authorized dealer.
Operate
Wiring harness. Contact your authorized dealer.

Fuse. Replace fuse.

Indicator Light in Gauge Panel Bulb. Replace bulb.
is Inoperative
Fuse. Replace fuse.

Sender. Do sender check.

Wiring harness. Contact your authorized dealer.

Coolant Temperature Gauge Fuse. Replace fuse.
Does Not Work
Gauge. Contact your authorized dealer.

Gauge sender. Do coolant temperature gauge

sender check.

Wiring harness. Contact your authorized dealer.

Fuel Gauge Does Not Work Fuse. Replace fuse.

Gauge. Contact your authorized dealer.

Wiring harness. Contact your authorized dealer.

Brake/Steer Hydraulic Oil Fuse. Replace fuse.
Pressure Gauge Does Not Work
Gauge. Contact your authorized dealer.

Gauge sender. Do coolant temperature gauge

sender check.

Wiring harness. Contact your authorized dealer.

Converter Oil Temperature Fuse. Replace fuse.
Gauge Does Not Work
Gauge. Contact your authorized dealer.

Gauge sender. Do coolant temperature gauge

sender check.

Wiring harness. Contact your authorized dealer.

10-14
 TROUBLESHOOTING

ELECTRICAL SYSTEM
Problem Cause Solution
Brake Cooling Oil Temperature Fuse. Replace fuse.
Gauge Does Not Work
Gauge. Contact your authorized dealer.

Gauge sender. Do coolant temperature gauge

sender check.

Wiring harness. Contact your authorized dealer.

HYDRAULIC SYSTEM
Problem Cause Solution
Hydraulic Functions Are Slow Low oil level. Fill reservoir to full mark.

Cold oil. Warm up hydraulic oil to normal

cycle times.

Wrong oil. Drain hydraulic tank. Use correct oil

Engine speed too low. Increase speed or contact your

dealer.

Pilot circuit. Contact your authorized dealer.

Worn pump. Contact your authorized dealer.

Restricted pump suction line. Contact your authorized dealer.

Hydraulic Oil Overheats Wrong oil. Drain hydraulic tank. Use correct oil

Air leak in pump suction line. Contact your authorized dealer.

Oil lines restricted. Contact your authorized dealer.

Low oil level. Fill reservoit to full mark.

Plugged filters. Install new filters.

Worn pump. Contact your authorized dealer.

Plugged radiator or oil cooler. Clean and straighten fins.

Oil cooler bypass. Contact your authorized dealer.

Relief valve. Contact your authorized dealer.

Contaminated oil. Drain hydraulic tank. Use correct oil

Improperly adjusted hydraulic Contact your authorized dealer.

components.

10-15
 TROUBLESHOOTING

HYDRAULIC SYSTEM
Problem Cause Solution
Oil Foams Air leak in line from reservoir to Repair leak or contact your
pump authorized dealer.

Kinks or dents in oil lines Check lines.

Wrong oil Use correct oil.

Water in oil Change oil.

High or low oil level Correct level.

Low Or No Oil Pressure Wrong oil. Repair leak or contact your
authorized dealer.

Improperly adjusted hydraulic Contact your authorized dealer.

components.

No oil in system. Fill with correct oil.

Worn cylinder packings. Contact your authorized dealer.

Relief valve. Contact your authorized dealer.

No Hydraulic Functions Hydraulic pump. Contact your authorized dealer.
(Noise from pumps)
Lack of hydraulic oil. Add oil.

Damaged suction line or hose. Contact your authorized dealer.

Clogged suction filter. Clean.

Hydraulic Cylinders Operate Hydraulic pump worn. Contact your authorized dealer.
But Cannot Lift Load
Main relief valve pressure low. Contact your authorized dealer.

Hydraulic oil level low. Add oil.

Suction screen plugged. Clean stainer and syhstem.

Pump suction line leaking. Inspect suction line.

Control Lever Does Not Work Relief valve pressure low. Contact your authorized dealer.

Tube or hose damaged. Repair or replace.

Hydraulic fittings loose. Tighten.

Damaged O-rings in fittings. Install new O-ring.

Hydraulic pump. Contact your authorized dealer.

Pilot valve. Contact your authorized dealer.

Pilot lines. Repair or replace.

10-16
 TROUBLESHOOTING

HYDRAULIC SYSTEM
Problem Cause Solution
One Cylinder Does Not Work Control valve spool damaged or Contact your authorized dealer.
contaminated with dirt.

Hydraulic lines damaged. Repair or replace.

Fittings loose. Tighten.

O-ring in fitting damaged. Install new O-ring.

Pilot valve. Contact your authorized dealer.

Pilot lines. Repair or replace.
One Cylinder Does Not Work Piston seals leaking. Contact your authorized dealer.
Or Has Little Power
Cylinder rod damaged. Contact your authorized dealer.

Pilot lines. Repair or replace.

Pilot valve. Contact your authorized dealer.

10-17

Problem
Body will not raise or raises
too slowly
Body will not raise or raises
too slowly
Body will not lower
Body stuck in a position other
than the extreme upper or
lower position
Gurgling pump
TROUBLESHOOTING
HYDRAULIC HOIST SYSTEM
Cause
Pump is not being driven.
Insuffinient oil pressure.
Faulty control valve operation.
Faulty hoist operation.
Faulty control valve operation.
Bent piston rod or cylinders.
An obstruction on the fame or other
structural members preventing
body from lowering.
Low oil level in tank.
Air leak in suction hose or
connections.
10-18
Solution
Check pump drive lines.
Check oil in tank and add oil if
necessary.
Clean clogged or dirty oil filters.
Check pump output pressure.
Check suction line for air leaks
which can cause faulty pump
operation.
Check for broken or bent valve
lingkage.
Check relief valve for weak or
broken spring.
Check oil pressure at the bottom of
the hoist.
Check oil pressure at the top of the
hoist.
Check for broken or bent valve
lingkage.
Check oil pressure at the top of the
hoist.
Replace piston rod or cylinders.
Remove obstruction.
Till tank to correct level.
Tighten connections or replace
suction line.
 TROUBLESHOOTING

HYDRAULIC STEERING SYSTEM

Problem Cause Solution
Hard steering in both Trouble in the steering pump. Check steering pump.
directions
Trouble in steering control valve. Check steering control valve.

Trouble in front axle. Check front axle.

Low oil level in system. Fill tank to proper level.

Hard steering in one direction Trouble in front axle. Check front axle.
Erratic steering, shimmy or Trouble in front axle. Check front axle.
wobble

10-19
 TROUBLESHOOTING

STEERING PUMP
Problem Cause Solution
Excessive Pump Noise. Low oil level in the reservoir. Fill reservoir to proper level with
recommended lubricant, (filtered).

Blocked inlet strainers. Drain tank and clean/replace inlet

strainers.

Air in the system. Check inlet lines and fittings for air
leaks.

Oil too thick. Be certain correct type of oil is

used for refilling or adding to the
system.
Cold weather.
Run hydraulic system until pump
is warm to the touch and noise
disappears.
Worn or damaged pump.
Replace Pump.
Pump Overheating Internal leakage. Replace Pump.

Fluid level low. Fill reservoir to proper level with

recommended lubricatn, (filtered).
System Not Developing Fluid Level Low Fill reservoir to proper level with
Pressure recommended lubricatn, (filtered).

System leak. Check for and repair any leaking

lines, valves. Or cylinders.

Relief valve malfunciton or Adjust, replace or repair.

misadjustment.

Compensator misadjusted. Adjust, replace or repair.

Pump malfunction. Replace pump.

Loss of Fluid Ruptured hydraulic lines. Cheak all external connections,
tubing and hoses.

Loose fittings. Tighten connectinons, replace

ruptured tube or hose.
Observe mating sections of pump
for leaks.

Leaking gaskets or seals in pump or Replace seals or gaskets in

circuit. possible.

10-20
 TROUBLESHOOTING

STEERING PUMP
Pump Cycles Rapidly System leak. Check for and repair and leaking
“On & Off” lines, valves, or cylinders.

Steering accumulator pre-charge low. Recharge with Nitrogen.

RCB Valve bleed down solenoid is Replace or clean cartridge.

leaking.

RCB Valve relief setting is low or Adjust or replace RCB Valve.

leaking.

STEERING CONTROL VALVE

Problem Cause Solution
Steering Wheel Does Not Binding in steering column
Center Thermal. Check for blockage in thermal
bleed line and orifice.
Contamination. Flush steering valve.

Broken centering springs. Replace spring.

No Response When Steering Low accumulator pressure. Check system pressure.
Wheel is Turned Verify pre-charge pressure.

Steering valve sleeve and spool Disassemble, repair or replace.

locked.

Pump failure. Replace pump.

Hose or filter clogged. Flush or replace hoses; replace

filter elements with Euclid-Hitachi
recommended elements.

Relief valve failure. Replace relief valve.

Slow or Hard Steering Dirt in system. Drain, flush and refill with clean
filtered oil.

Wear on sleeve and spool. Replace orbiltal valve.

Wear on drive gear. Replace drive gear.

Fluid level low. Fill reservoir to proper level with

recommended lubricant, (filtered).

Pump failure. Repair or replace pump.

Pump compensator failure. Adjust or replace.

Trouble in lines or filter. Flush or replace lines as required.

Change filter elements.
Wrong Response to Steering Lines hooked up to wrong ports. Reconnect.
Wheel
Drive gear misaligned. Re-align.

10-21
 TROUBLESHOOTING

STEERING CONTROL VALVE

Problem Cause Solution
Continuous Steering Wheel Dirty fluid. Drain, flush and refill with clean
filtered oil

Broken centering springs. Replace springs

Input linkage is binding. Re-align

Burr on sleeve or spool. Clean components and remove

burrs

Steering Pump Pressure Does
Not Cycle On/Off
Major component leak. Inspect hoses and major system
components for leakage
Wrong steer valve.
Replace or repair
RCB Valve malfunction.
Replace or repair

FRONT AXLE
Problem Cause Solution
Noise Loose ride strut mounting See Maintenance for Front
assemblies. Suspension.

Worn king pins, bushings, or thrust Replace worn parts.

bearings.

Insufficient or incorrect lubrication Check level. Fill with proper type

and grande of lubricant.

Misalignment of wheels. Align front axle assembly.

Wheel bearings defective or out of See Maintenance for Front Wheels.

adjustment.
Shimmy IMisalignment of wheels. Align front axle assembly.

Wheel bearings defective or out of See Maintenance for Front Wheels.

adjustment.

Tie rod or steering cylinder rod Replace.

ends worn.

Worn king pins or bushings. Replace worn parts.

Bent spindle. Replace.

Worn trailing arm bushings. See Maintenance for Front

Suspension.

Excessive wheel or tire run-out. See Maintenance for

Tires/Rims/Inflation.

10-22
 TROUBLESHOOTING

FRONT AXLE
Problem Cause Solution
Hard Steering Misalignment of wheels. Align front axle assembly.

Steering system out of adjustment. See Maintenance for Steering Lines

and Fittings.

Incorrect tire inflation. Inflate tire correctly. See

Maintenance for
Tires/Rims/Inflation.

Defective king pin thrust bearing. Replace.

Lack of lubrication. Lubricate according to Operator’s

Manual Lubrication section.

Worn ride strut. See Maintenance for Front

Suspension.
Wander Misalignment of wheels. Align front axle assembly.

Worn tie rod or steering cylinder rod Replace.

ends.

Steering system out of adjustment. See Maintenance Steering Lines

and Fittings.

Bent spindle. Replace.

Excessive or uneven tire wear Misalignment of wheels. Align front axle assembly.

Worn tie rod or steering cylinder rod Replace.

ends.

Improper tire inflation pressure. Inflate tires correctly. See

Maintenance for Tire/Rims/Inflation.

10-23
 TROUBLESHOOTING

REAR AXLE
Problem Cause Solution
Noise Planet bearing failure. Replace bearing

Insufficient or incorrect lubrication. Check planetary bearings.

Wheel bearings scored or rough. Check level, fill with proper type
and grade of lubricant.
Gear teeth in planetary chipped.
Replace bearings.

Replace gears.
Loss of Lubricant Lubricant level too high. Drain and fill with correct amount of
lubricant.

Lubricant foams excessively. Drain and fill with correct type and
grade of lubricant.

Worn or broken oil seal. Replace oil seal.

Restricted vent. Replace breather element. Clean

breather body. Check hose for
blockage.

Loose nuts or bolts. Tighten nuts or bolts.

Gain of Lubricant Restricted differential housing vent. Clean vent.

Leaking inner face seal or O-ring. Replace face seal or O-ring.

Planetary running hot Too much lubricant. Check level, fill with proper type
and grade of lubricant.

Planet bearing failure. Replace bearings.

Too much oil. Drain oil into proper level.

10-24
 TROUBLESHOOTING

FRONT DRIVESHAFT
Problem Cause Solution
Noise Lack of lubricant. Check grease seals. Install proper
grade of lubricant.

Out of balance driveshaft assembly. Check to see if arrows at slip joint

and grease fittings are in line.

Cleand dirt from driveshaft.

Backlash due to worn trunnion or Replace worn parts.

bearing.
Vibration. Yokes not in line. Remove driveshaft and assembly
correctly.

Driveshaft out of balance. Replace driveshaft.

Driveshaft sprung from contact with Replace driveshaft.

obstruction.

Excessive run-out or distorted Disassemble and correct or replace

yokes. damaged part.

REAR DRIVESHAFT
Problem Cause Solution
Noise Lack of lubricant. Check grease seals. Install proper
grade of lubricant.

Out of balance driveshaft assembly. Check to see if arrows at slip joint

and grease fittings are in line.

Cleand dirt from driveshaft.

Backlash due to worn trunnion or Replace worn parts.

bearing.
Vibration. Yokes not in line. Remove driveshaft and assembly
correctly.

Driveshaft out of balance. Replace driveshaft.

Driveshaft sprung from contact with Replace driveshaft.

obstruction.

Excessive run-out or distorted Disassemble and correct or replace

yokes. damaged part.

10-25
 TROUBLESHOOTING

DIFFERENTIAL
Problem Cause Solution
Vibration Broken gear teeth. Replace damaged gear.

Excessive run-out of pinion or Disassemble, correct, or replace

flanged cage. faulty part.
Continual Noise Bearing worn. Replace worn parts.

Gears damaged or worn. Replace gears.

Noise on Drive Ring and pinion gear adjustment Readjust.
tight.
Noise on Coast Bearings damaged. Replace bearings.

Loose ring and pinion gear Re-adjust.

adjustment.

Excessive pinion gear end play. Replace pinion bearings.

Noise on Turns Worn spider gear or side gears. Replace gears.

Worn or damaged spider bearings. Replace bearings, spider pinions

and spider.
Loss of Lubricant Oil seals worn. Replace seals.

Loose bolts. Tighten bolts to correct torque.

Cracked housing. Repair or replace housing.

Does not install into the rear Excessive side bearing preload.
axle housing (bearing cap deflection)
Pinion Seal Leak Loss of Preload in Pinion Bearings.
Excessive end play in pinion.
bearings or lose nut.
Readjust the side bearings per
instruction in the Maintenance
Manual.
Replace pinion bearing.

Worn Seal. Inspect and replace seal.

Work Yoke splines or groove in Inspect and replace yoke.

seal contact area.

10-26

Problem
Noise
Loss of Lubricant
Planetaries Running Hot
Planet Pin Bolts Loosen
Internal gear lock plate bolts
breaking
TROUBLESHOOTING
REAR AXLE PLANETARY
Cause
Insufficient lubricant.
Gear teeth in planetary chipped.
Planet bearing failure.
Lubricant foams excessively.
Worn or broken oil seal or O-ring.
Loose nuts or bolts.
Insufficient or incorrect lubricant.
Too much lubricant.
Worn pin bores in planet carrier.
Worn threads in pin.
Over-torquing bolts.
Worn spindles.
Loose wheel bearings.
10-27
Solution
Check level; fill with proper type
and grade of lubricant.
Replace gears.
Replace bearings
Drain and fill with correct type and
grade of lubricant.
Replace oil seal or O-ring
Tighten nuts or bolts to specified
torque.
Check level; fill with proper type
and grade of lubricant.
Replace planet carrier and pins.
Tighten bolts to specified torque.
Replade spindles.
Adjust wheel bearings.

Problem
Brake fails to hold when parked
on grades,
Caliper contacts disc with
brake released/Disc iverheats
Brake Fails to Release
TROUBLESHOOTING
DRY DISC PARKING BRAKE
Cause
Excessive lining to disc clearance.
Cracked disc.
Worn out linings.
Transmission not in neutral.
Caliper not centered on disc.
Canister is out of stroke.
Caliper is binding on the guides,
guides not parallel.
Centering springs are worn.
Lack of clearance between disc
and linings.
Caliper not centered on disc.
Binding at spring housing.
Damaged release canister.
No oil pressure at release canister.
10-28
Solution
Adjust shoe clearance and center
caliper on disc.
Install new disc.
Replace linings, readjust clearance
and recenter caliper over the disc.
Place transmisssion shift selector
in neutral.
Adjust caliper using caliper stop
bolt and locknut.
Turn slack adjuster screw ¼ turn
clockwise, readjust the caliper
center on the disc.
Recheck the brake and monitor for
signs of heat build-up.
Loosen guides and realign,
retorque the guides. Clean guide
surfaces.
Replace or shim the centering
springs.
Readjust shoe clearance and
center caliper on disc.
See Above
Adjust caliper using caliper stop
bolt and locknut.
Remove, clean and lubricate the
springs, spring housing, and mating
components.
Replace canister, do not attempt to
service.
Investigate pressure loss

Problem
Noise
Loss of Lubricant
Planetaries Running Hot
Planet Pin Bolts Loosen
Internal gear lock plate bolts
breaking
TROUBLESHOOTING
DRY DISC PARKING BRAKE
Cause
Insufficient lubricant.
Gear teeth in planetary chipped.
Planet bearing failure.
Lubricant foams excessively.
Worn or broken oil seal or O-ring.
Loose nuts or bolts.
Insufficient or incorrect lubricant.
Too much lubricant.
Worn pin bores in planet carrier.
Worn threads in pin.
Over-torquing bolts.
Worn spindles.
Loose wheel bearings.
10-29
Solution
Check level; fill with proper type
and grade of lubricant.
Replace gears.
Replace bearings
Drain and fill with correct type and
grade of lubricant.
Replace oil seal or O-ring
Tighten nuts or bolts to specified
torque.
Check level; fill with proper type
and grade of lubricant.
Replace planet carrier and pins.
Tighten bolts to specified torque.
Replade spindles.
Adjust wheel bearings.
 TROUBLESHOOTING

MEMO

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10-30
 SPECIFICATIONS

SERVICE SPECIFICATIONS
Machine Weights
EH750-3 EH1100-3
Model code: 8R1-411TD Model code: 8R4-441LD
kg lbs kg lbs
Maximum GMW
75400 166230 110677 244000
Not to Exceed
Net Machine Weight 45813
33475 73800 101000
With Body
Chassis With Hoist 25723 56710 33325 73469
Body 7800 17090 12488 27531
Nominal Payload with
38100 83996 58967 130000
Standard Equipment

NOTE: Major options will affect the payload. See the “Hitachi Truck Loading Policy” for further details.

Capacities
EH750-3 EH1100-3
Liters Gallons Liters Gallons

Engine Oil Pan + Filters 30.3 8.0 83.3 22

Cooling System 211.1 55.8 224.5 59.3
Fuel Tank 454.0 120.0 700.0 185.0
Front Wheel Bearing (per wheel) 2.8 0.74 4.2 1.1
Transmission Only 68.0 18.0 68.0 18.0
Transmission And Cooler (Including
83.3 22.0 93.3 24.6
lines)
Differential 55.0 14.5 55.0 14.5
Planetary (per wheel) 24.0 6.3 24.0 6.3
Windshield Washer Fluid 5.7 1.5 5.7 1.5

Hydraulics
Hoist System Tank Capacity 178.0 47.0 178.0 47.0
Hoist System Fill Capacity 265.0 70.0 265.0 70.0
Steering System Tank Capacity 97.0 25.6 97.0 25.6
Steering System Fill Capacity 112.0 29.6 112.0 29.6
Front Ride Struts (Both) 14.4 3.8 14.4 3.8
Rear Ride Struts (Both) 6.4 1.7 6.4 1.7

11-1
 SPECIFICATIONS

Engine (Group 2)
EH750-3 EH1100-3
Make Detroit Diesel Detroit Diesel
Model Series 60 12V–2000
Type 4 Cycle Diesel 4 Cycle Diesel
Turbocharged & Charge Air Turbocharged & Charge Air
Aspiration
Cooled(Air to Air) Cooled(Air to Water)
Number of Cylinders 6 12
Bore 133mm (5.24in) 130mm (5.12in)
Stroke 168mm (6.61in) 150mm (5.91 in)
Displacement 14.0 L (855in3) 23.9L(1458n3)
@ 1400 min-1(rpm): @ 1350 min-1(rpm):
Maximum Torque
2373 N ٠m (1750 lbf ٠ft.) 3091 N ٠m (2280 lbf ٠ft.)
Low Idle 600 min-1(rpm) 600 min-1(rpm)
High Idle 2225 min-1(rpm) 2250 min-1(rpm)
Stall Speed Maximum time to stall, 15 seconds Maximum time to stall, 12 seconds
Rated Output (SAE) @
391kw (525hp) 567kw (760hp)
2100 min-1(rpm)
Weight (Dry) 1216 kg (2681lb) 2223kg (4901lb)
Speed Full Load 2100 min-1(rpm) 2100 min-1(rpm)
Maximum No Load 2250 min-1(rpm) 2250 min-1(rpm)
Maximum Safe Speed 2400 min-1(rpm) 2400 min-1(rpm)

Electrical System (Group 3)

EH750-3 EH1100-3
Batteries
System Voltage 24 volts 24 volts
Number 2 2
Voltage each 12 volt (connected in series) 12 volt (connected in series)
Ground Negative Negative
Reserve Capacity 430 min @ 25 amps 430 min @ 25 amps
Cold Crank Amps 1300 @ 0°F 1300 @ 0°F
Alternator 24 Volt, 70 Ampere 24 Volt, 75 Ampere
Starting Motor 24 Volt 24 Volt
Lights
Headlights 4 Halogen (24V, 70/75W) 4 Halogen (24V, 70/75W)
Stop/Turn/Clearance 2 (21W/5W) 2 (21W/5W)
Backup 1 Halogen (2 Optional) (70W) 1 Halogen (2 Optional) (70W)
Clearance-Std. 4 (21W) 4 (21W)

11-2
 SPECIFICATIONS

Power Transmission (Group 4)

EH750-3 EH1100-3
Make Allison Allison
Model H5610A H6610A
Mounting Remote Remote
Allison Transmission Commercial Allison Transmission Commercial
Control
CEC II CEC II
Speeds 6 Forward, 2 Reverse 6 Forward, 2 Reverse
Weight (Dry) 1080 kg (2380lbs) 1025kg(2260lbs) Planetary

Travel Speeds
EH750-3 EH1100-3
Standard High
Gradeability
Transmission
Gear Range km/h (mph) km/h (mph) km/h (mph)
Gear Ratio
First 4.00 9.5 (5.9) 8.5 (5.3) 9.7 (6.0)
Second 2.68 16.9 (10.5) 15.2 (9.4) 14.5 (9.0)
Third 2.01 22.5 (14.0) 20.2 (12.6) 19.3(12.0)
Fourth 1.35 33.5 (20.8) 30.1 (18.7) 28.8 (17.9)
Fifth 1.00 45.2 (28.1) 40.6 (25.3) 38.8 (24.1)
Sixth 0.67 68.2 (42.5) 61.3 (38.1) 57.9(36.0)
Reverse 1 5.12 6.8 (4.2) 6.1 (3.8) 7.6 (4.7)
Reverse 2 3.46 13.2 (8.2) 11.9 (7.4) 11.3 (7.0)
Lockup All ranges
Torque Converter TC-683

EH750-3 EH1100-3
Planetary
Make Hitachi Hitachi Hitachi
Ratio 5.25:1 6.00:1 5.80:1
(with Optional Planetary)

Differential
Make Hitachi Hitachi Hitachi
Model 2052 2052 2354
Ratio 3.13:1 3.13:1 3.64:1
Total Gear Ratio 16.43:1 18.78:1 21.11:1

11-3
 SPECIFICATIONS

Brake System (Group 5)

EH750-3 EH1100-3

Control System All Hydraulic Actuated System All Hydraulic Actuated System
Front
Type Dry Disc Dry Disc
Number of Discs Per Axle 2 2
Number of Pads Per Axle 4 4
Disc Diameter 67.3 cm (26.5 in) 68.6 cm (27.0 in)
Lining Area Per Axle 1394 cm² (216in²) 2787 cm² (432 in²)
Brake Pressure (Max.) 15859 kPa (2300 psi) 15858 kPa (2300 psi)
2 2
Braking Surface Area Per Axle 4129 cm² (640 in²) 4129 cm (640 in )
Brake Heads per Axle 2 2
Rear
Type Wet Disc, Oil Cooled Wet Disc, Oil Cooled
Number of Discs
12 (16 Optional) 20
Disc Diameter 64.5 cm (25.4 in) 64.0 cm (25.2 in)
2 2
Area Per Friction Disc Surface 1548 cm² (240 in²) 1548 cm (240 in )
8274 kPa (1200 psi) 4826 kPa (700psi)(Standard)
Brake Pressure (Max.)
6205 kPa (900psi)(Optional)
37209 cm² (5767 in²)
Braking Surface Area Per Axle (12
Discs) 49551cm² (7680 in²)
Braking Surface Area Per Axle (16
Discs) 2 2
Braking Surface Area Per Axle (20 59616 cm (9240 in )
Discs)
Brake Pressure (Maximum) (Stan-
8274 kPa (1200 psi) 4826 kPa (700 psi)
dard)
Brake Pressure (Maximum) (Op-
Not Available 6205 kPa (900 psi)
tional)
Parking Brake
Type Disc, spring apply/hydraulic Disc, spring apply/hydraulic
release release
Location Differential input Differential input
Size 56 cm (22 in) 59.6 cm (23.5 in)
Number of Discs 1 1
2 2
Lining Surface Area 306.4 cm² (47.5 in²) 284 cm (44 in )
Number of Heads 3 1
Retarder
Type of Axle Foot operated, all hydraulic Foot operated, all hydraulic
actuation of oil cooled, wet actuation of oil cooled, wet
disc brakes on rear axle disc brakes on rear axle
Capacity (Continuous) 656 kw (880 hp) 656 kw (880 hp)
Capacity (Intermittent) 1268 kw (1700 hp) 1268 kw (1700 hp)
Brake Accumulator Pre-charge 8274 ±173 kPa (1200 ±25 psi) 8274 ±173 kPa (1200 ±25 psi)
(Dry Nitrogen)

11-4
 SPECIFICATIONS

Steering System (Group 6)

EH750-3 EH1100-3
Pump
Type Piston Piston
Displacement 0.045 l/rev (2.75 in3/rev) 0.045 l/rev (2.75 in3/rev)
Rated Flow @ 2100
95.7 l/min (25.3 gpm) 95.7 l/min (25.3 gpm)
min-1(rpm) x 1.013 (PTO
Ratio)
Rotation Counterclockwise Counterclockwise
Main Steering Relief Pres-
22 070 kPa (3200 psi) 22 070 kPa (3200 psi)
sure
Unload Pressure 18 960 kPa (2750 psi) 18 960 kPa (2750 psi)
Standby Pressure 1 724 to 3447 kPa (250 to 500 psi) 1 724 to 3447 kPa (250 to 500 psi)
Steer Valve
Type Closed Center with Thermo-Bleed Closed Center with Thermo-Bleed
Pressure Rating 23 460 kPa (3400 psi) 23460 kPa (3400 psi)
Displacement 0.74 l/rev (45.1 in3/rev) 0.74 l/rev (45.1 in3/ rev)
Cylinder
Quantity 2 2
Type Double Acting Double Acting
Stages 1 1
Piston Rod Diameter 44.5 mm (1.75 in) 44.5 mm (1.75 in)
Bore 82.6 mm (3.25 in) 82.6 mm (3.25 in)
Stroke 381.0 mm (15.0 in) 457.0 mm (18 in)
Filter
Beta 10 Ratio 10 Ratio
Ration 800 800
Rating 6 Microns Absolute 6 Microns Absolute
Type Pressure Pressure
Tank Welded Steel Fabrication with Welded Steel Fabrication with
Separate Hydraulic and Steer Separate Hydraulic and Steer
Compartments Compartments
Maximum Steering Angle 42 Degrees 39 Degrees
Supplementary Steering
Type Accumulator Accumulator
Quantity 1 1
Operating Pressure 20684 kPa (3000 psi) 20684 kPa (3000 psi)
Pre-Charge Pressure 6895 ±173 kPa (1000 ± 25 psi) 6895 ±173 kPa (1000 ± 25 psi)
Steer Filter Light Activation 241 kPa (35 psi) 241 kPa (35 psi)
By Pass 344 kPa (50 psi) 344kPa (50 psi)
Maximum Steering Wheel Rotations
Stop to Stop (Approximate) Not Available 5 Rotations
Turning Diameter
Not Available 19.28 m (63’ 3”)
(SAE)Right
Accumulator
Oil Discharge 12.75 L (778 in3 Max) 12.75 L (778 in3 Max)
Gross Volume 17.1 L (1040 in3 ) 17.1 L (1040 in3 )

11-5
 SPECIFICATIONS

Wheels (Group 7)

Tire Sizes

For EH750-3
Tire Size (Front and Rear) ............................................................. Std. – 18.00R33 (**) Radial
Rim Width................................................................................ 330 mm (13 in)

For EH1100-3
Tire Size (Front and Rear) ............................................................. Std. – 24.00R35 (**) Radial
Rim Width................................................................................ 431.8 mm (17 in)

NOTE: Before selecting the tires, it is recommended that all necessary rigid dump truck applications be sup-
plied to the tire manufacturer. Characteristics such as tire inflation pressure, rubber compound and tire
thread are site and application specific. The tire manufacturer can then make a recommendation as to
which tire will give the most economical operation.

Tire Inflation Pressures

NOTE: The tires are inflated at the factory to a minimum inflation pressure for shipping. Before placing the
rigid dump truck in service, the tires must be inflated to the proper inflation pressure indicated by the
manufacturer. Guideline numbers are given in the table below.

EH750-3 Tire Make and Size Michelin Bridgestone Goodyear

18.00 R 33 18.00 R 33 18.00 R 33
Tire inflation pressure 600 (87) 700 (102) 625 (91)
kPa (psi)
EH1100-3 Tire Make and Size Michelin Michelin Bridgestone Goodyear
24.00 R 35 24.00 R 35 24.00 R 35 24.00 R 35
Quarry Trans- Transport
port
Tire inflation pressure 550 (80) 650 (94) 700 (102) 700 (102)
kPa (psi)

Suspension

Front Suspension
Type......................................................................................... Strut-NEOCON ‘E’ (Silicone/Helium)
Rear Suspension
Type......................................................................................... Strut-NEOCON ‘E’ (Silicone/Helium)

11-6
 SPECIFICATIONS

Cab (Group 8)
The rigid dump truck is equipped with a cab that has been ROPS/FOPS tested and approved in accordance
with:
-ROPS ISO 3471
-FOPS ISO 3449
The cab is fully insulated, and includes a filtered fresh air heater and pressurizing system.

Sound Pressure Level at Operator’s Exterior Sound Power As Per

Station As Per Static Conditions And ISO 3744:1994
Testing Procedure Described in ISO And
6394: 1998 dB(A) EEC/2000/14
EH750-3
Without Any Special Consult your dealer for the latest infor- Consult your dealer for the latest
Noise Attenuation. mation. information.
EH750-3 Consult your dealer for the latest infor- Consult your dealer for the latest
With Noise Attenuation mation. information.
EH1100-3
Without Any Special 81 dB(A) 122 dB(A)
Noise Attenuation.

11-7
 SPECIFICATIONS

Hoist System (Group 9)

EH750-3 EH1100-3
Pump
Type Gear- Tandem Hoist Section Gear – Tandem Hoist Section
Displacement 0.149 l/rev (9.10 in3/rev) 0.220 l/rev (13.4 in3 /rev)
Rated Flow 301.4 l/m @ 2100 min-1(rpm)x1.013 468.2 l/min @ 2100 min-1(rpm) x 1.013
(PTO Ratio) (79.6 gpm) (PTO Ratio) (123.7gpm)
Brake Cooling
Displacement 0.149 l/rev (9.10 in.3/rev 0.083 l/rev (5.06in3/rev)
Rated Flow 301.4 l/m@2100 min-1(rpm)x1.013 176,4 l/min@2100 min-1(rpm)x
(PTO Ratio (52.9 gpm) 1.013 (PTO Ratio (46.6 gpm)
Cylinder
Quantity 2 2
Type Double Acting with Retract Cushion-
ing Double Acting with Retract Cushioning
Stages 2 2
Stroke 769.87–779.53 mm (30.3–30.69 in) 947.93-946.15 mm (37.32-37.25 in)
Bore 177.8–127.0 mm (7.00–5.00 in) 203.2 - 152.4 mm (8.00-6.00 in)
Piston Rod Diameter 152.4–101.6 mm (6.00–4.00 in) 177.8 – 101.6 mm (7.00-4.00 in)
Valve
Type Four Position–Electronic Pilot Con- Four Position–Electronic Pilot Controlled
trolled 454.2 l/m (120 gpm) @ 50psi 454.2 l/min (120gpm) @ 50psi pressure
pressure drop drop
Relief Setting 17237 kPa (2500 psi) 17237 kPa (2500 psi)
Filters
Beta 10 Ratio 800 800
Rating 6 microns-absolute 6 microns-absolute
Type Return Line Return Line
Light Activation 241 kPa (35 psi) 241 kPa (35 psi)
By-pass 345 kPa (50 psi) 345 kPa (50 psi)
Body Raise Time 13.9 Seconds @ 1700 min-1(rpm) 12.0 Seconds @ 2100 min-1(rpm) En-
Engine. gine
Body Down Time 15.0 Seconds @ Idle 16.0 Seconds @ Idle

Brake Cooling
EH750-3 EH1100-3
Rotation Clockwise Clockwise
Filter Assembly
Brake Cooling Check
550 kPa (80 psi) 550 kPa (80 psi)
Valve

11-8
 SPECIFICATIONS

MACHINE DIMENSIONS – EH750-3

Load Capacity (M3) (Yd3)
Stuck (SAE) (20.8) (27)
Heap 3:1 (25.4) (33)
Heap 2:1 (SAE) (27.5) (36)
Field Heap (25.7) (34)

NOTE: Dimensions shown are for an empty machine with 18.00R33 (**) E4 radial tires.

The HITACHI Field Heap maintains a 2:1 heap ratio from the floor / tail chute junction to the peak of the load pro-
file. The SAE 2:1 heap ratio is actually a 1:1 heap ratio from the floor / tail chute junction to the top body edge,
then switches to a 2:1 heap ratio to the load peak. The HITACHI Field Heap is more representative of field loading
practices and payload distribution. HITACHI body capacity ratings are based on the field heap philosophy.

11-9
 SPECIFICATIONS

MACHINE DIMENSIONS – EH1100-3

Load Capacity (M3) (Yd3)
Stuck (SAE) 28 (37)
Heap 3:1 35 (46)
Heap 2:1 (SAE) 39 (51)
Field Heap 37 (48)

NOTE: Dimensions shown are for an empty machine with 24.00R35 (**) E4 radial tires.

The HITACHI Field Heap maintains a 2:1 heap ratio from the floor / tail chute junction to the peak of the load pro-
file. The SAE 2:1 heap ratio is actually a 1:1 heap ratio from the floor / tail chute junction to the top body edge,
then switches to a 2:1 heap ratio to the load peak. The HITACHI Field Heap is more representative of field loading
practices and payload distribution. HITACHI body capacity ratings are based on the field heap philosophy.

11-10
 INDEX
A ...............................................................8-13
Accelerator Pedal ..................................... 2-22/5-16
Accumulator
Brake, Check Capacity ................................8-43
Discharge ................................................... S-16
Steering, Check ...........................................8-42
Active Traction Control (ATC)............................5-21
Adjust The Operator’s Seat .......................... S-6
A Few Simple Rules When Servicing ............... S-19
Air Cleaner
Dust Cup Check/Clean ................................8-61
Maintenance Interval Guide ........................8-18
...............................................................8-57
Primary Filter Element, Service...................8-62
Safety Filter Element, Service .....................8-64
Troubleshooting...........................................10-5
Vacuator Valve, Check ................................8-61
Air Conditioner
(See Heater/Air Conditioner) .......................2-14
Belt (Alternator), Check ...............................8-84
Check...........................................................8-95
Air Conditioner Filter Clean/Change..................8-92
Air Conditioning System, Service Safely .......... S-28
Air Filter (Cab) Clean/Change ...........................8-91
Air Intake Lines and Clamps, Check .................8-65
Air Mixture Option ..............................................2-16
Alarm Messages, Contronic II ...........................2-15
Application, Rigid Dump Truck ............................6-1
Alternator
Belt (Air Conditioner) Check........................8-84
Light ...............................................................2-7
Automatic Shifting, Transmission ........................5-3
Avoid
Applying Heat to Lines Containing Flammable .
Fluids .................................................... S-27
Heating Near Pressurized Fluid Lines........ S-27
High Pressure Fluids .................................. S-23
Injury from Rollaway Accidents .................. S-13
Injury From Running Over, Front and Back, and
Front Wheel Crush Area....................... S-11
Tipping ........................................................ S-12
Axle
Breather Element
Change ..................................................8-36
Check ....................................................8-36
Front, Troubleshooting ..............................10-23
Rear, Troubleshooting ...............................10-24
B Air Filter, Clean/Change ..............................8-91
Back-up Alarm
Check...........................................................8-82
Location ......................................................... 1.1
Basic Preventive Maintenance Replacement Parts
12-1
Battery
Battery Charging Problem Indicator ........2-8
Cables and Connections, Check .................8-77
Charging ......................................................8-76
Condition, Check .........................................8-76
Electrical Wiring and Connections...............8-77
Explosions, Prevent .................................... S-28
Disconnect Switch .......................................2-29
Using Booster ..............................................4-10
Connecting ............................................4-10
Disconnecting ........................................4-11
Beware of Exhaust Fumes................................ S-26
Blower Speed.....................................................2-16
Body Off The Frame, Never Travel With .......... S-13
Body
Down Indicator.............................................2-27
Lowering ......................................................5-25
Prop Pins, or Cable
Check.....................................................8-97
Installing Pins for EH750-3 ......................8-6
Installing Cable for EH1100-3 ………….. 8-7
Removal and Storage of Pins..................8-6
Up Indicator ...................................................2-9
Raising.........................................................5-24
Bolts and Fittings, Check if Loose .....................8-98
Brake
Accumulator, Check Capacity .....................8-43
Cooling Oil Temperature Gauge....................2-4
Hydraulic Oil Pressure Indicator ....................2-9
Load/Dump ..................................................5-22
Operation, Check.........................................8-52
Parking.........................................................5-22
Parking, Check ............................................5-53
Pedal............................................................2-21
Pressure, Check ..........................................8-44
Service.........................................................5-17
Specifications...............................................11-4
Brake/Steer Hydraulic Oil Pressure Gauge .........2-3
Brakes-Servcie & Parking Steering
Maintenance Interval Guide.........................8-17
...............................................................8-51
BREAK-IN ............................................................3-1
Burns, Prevent .................................................. S-21
C
Cab
Air Conditioner Filter, Clean/Change...........8-92
Features.........................................................2-1
General Precautions For .............................. S-5
Maintenance Interval Guide.........................8-20
 INDEX
...............................................................8-90
Mounts, Check.............................................8-93
Specifications ..............................................11-7
Capacities (Service Specifications) ...................11-1
Central Warning Indicator....................................2-6
Check
Hour Meter Regularly ....................................8-2
Instruments After Starting..............................4-9
Instruments Before Starting...........................4-5
Chemical Products, Handle Safely ................... S-29
COMPONENTS NAME........................................1-1
Alarm Messages..........................................2-15
Monitoring and Alarm System .....................2-12
Converter Oil Temperature Gauge ......................2-4
Coolant
Add as Required..........................................8-67
Change & Flush System..............................8-71
Filter, Replace .............................................8-72
Level, Check................................................8-67
Temperature Gauge ......................................2-3
Supplemental Additive (SCA) Check...........8-68
Cooling
a Hot Engine..................................................5-2
Fan, Check ..................................................8-73
Fan Belt, Check ...........................................8-74
System. Maintenance Interval Guide
...............................................................8-18
...............................................................8-66
Radiator, Clean .....................................8-73
Crush Area........................................................ S-11
Cutting
Precautions For .......................................... S-26
Remove Paint Before ................................. S-26
D Oil Pressure Indicator ....................................2-6
Daily Walk Around Inspection..............................4-2
DC 24 Volt Power Port......................................2-23
Diagnostic
Connectors ..................................................2-28
Differential
Lubricant
Change ..................................................8-34
Check Level...........................................8-34
Specifications ..............................................11-3
Troubleshooting.........................................10-26
Dimensions, Machine ........................................11-9
Discharge Accumulators................................... S-17
Dispose of Waste Properly ............................... S-30
Dome Light
Downshift or Reverse Inhibitor Feature ...............5-7
Drive Coupling, Troubleshooting .......................10-4
Driveshaft
12-2
Front, Troubleshooting...............................10-25
Rear, Troubleshooting ...............................10-25
Dumping...............................................................6-6
Precautions....................................................6-7
Dust Cup, Check/Clean (Air Cleaner)................8-61
Duties of the Operator ........................................ S-2
E
Electrical
Disconnects Before Welding on
the Rigid Dump Truck..............................8-8
Main Compartment ........................................8-8
System
Maintenance Interval Guide ..................8-19
...............................................................8-75
Specifications ........................................11-2
Troubleshooting .........................................10-12
Wiring and Connections, Check ..................8-77
Electronic Climate Controls(ECC) .....................2-15
Electronic Downhill Speed Control (EDSC).......5-19
Engine
Break-In .........................................................3-1
Compartment .................................................8-9
Coolant
Level Indicator .........................................2-6
Troubleshooting.....................................10-4
Cooling a Hot .................................................5-2
Crankcase Breather Tube, Check/Clean.....8-27
Diagnostic Connectors.................................2-28
Light ...............................................................2-5
Maintenance Interval Guide.........................8-15
...............................................................8-23
Oil, Change..................................................8-25
Oil Filter, Replace ........................................8-25
Oil Level, Check...........................................8-24
Overspeed Protection ..................................5-22
Service Specifications..................................11-2
Stop Indicator.................................................2-7
Starting ..........................................................4-6
In Cold Weather.......................................4-7
Measures During ................................4-8
In Warm Weather ....................................4-6
Stopping.......................................................4-12
Stop Indicator (Warning)................................2-7
Troubleshooting ...........................................10-1
Valves/Injectors, Adjust ...............................8-27
Evacuating in Case of Fire................................ S-26
Exhaust Fumes, Beware of............................... S-25
Exterior Lights, Check........................................8-81
F
Fan Belt, Check .................................................8-74
 INDEX
Fan, Cooling,Check ...........................................8-73
Fasten Your Seat Belt......................................... S-7
Filter Indicator ......................................................2-8
Fire, Evacuating in Case of .............................. S-25
Fire Prevention Measures ................................ S-24
Fluids
Flamable in Lines Containing, Avoid Applying
Heat To................................................. S-27
Handle Safely, Avoid Fires ......................... S-17
High Pressure, Avoid.................................. S-22
Leaks, Check For ........................................8-97
Fluid Lines, Pressurised, Avoid Heating Neat .. S-27
Follow Safety Instructions................................... S-3
Frame Assembly, Check ...................................8-98
Front Axle, Troubleshooting ............................10-23
Front Brake Cut-off Switch ................................2-23
...............................................................5-18
Front Driveshaft, Troubleshooting ...................10-25
Front Wheel Lubricant Check/Change ..............8-87
Fuel
Filter, Replace .............................................8-57
Gauge ............................................................2-3
Hoses and Lines, Check..............................8-59
Recommended ............................................8-12
System
Maintenance Interval Guide ..................8-13
...............................................................8-49
Tank
Drain Sediment......................................8-55
Mounting, Check ...................................8-59
Use Correct ...................................................8-2
Water Separator, Drain................................8-56
Fuse, Check (Relay) ..........................................8-78
G Switch ..........................................................2-19
Gauge
Check...........................................................8-82
Converter Oil Temperature............................2-4
Coolant Temperature.....................................2-3
Brake Cooling Oil Temperature.....................2-4
Brake/Steer Hydraulic Oil Pressure...............2-3
Fuel................................................................2-3
General
Information.....................................................5-1
Maintenance Interval Guide ........................8-15
...............................................................8-90
Precautions For Cab..................................... S-5
Greasing, Maintenance Interval Guide ..............8-15
...............................................................8-16
...............................................................8-17
Grills Removal ...................................................8-10
Grinding, Recautions For.................................. S-26
12-3
H
Handle
Chemical Products Safely .......................... S-30
Fluids Safely Avoid Fires ............................ S-18
Starting Aids Safely ...................................... S-7
Hauling .................................................................6-5
Haultronics III™ Load Monitoring
System ...........................................................2-5
Hazard Waring Switch .......................................2-18
Headlight
Aiming ..........................................................8-83
Location .............................................. 1-1 / 2-21
Switch ..........................................................2-12
Heater/Air Conditioner .......................................2-14
Air Conditioner Switch .................................2-25
Check...........................................................8-95
Fan Speed Control Switch...........................2-25
Off Switch ....................................................2-25
Temperature Control Switch........................2-25
Vent Mode Switch........................................2-24
Heater & Defroster, Check.................................8-95
High Beam
Indicator .........................................................2-9
Lever Switch ................................................2-19
High Pressure Fluids, Avoid ............................. S-22
High Voltage Overhead Power Lines, Operating
The Machine Near ...................................... S-14
Hoist Lever.........................................................2-22
Filter Element, Replace ...............................8-49
Functions .....................................................5-23
Operation .....................................................5-23
Horn
Check...........................................................8-82
Location .......................................................2-27
Hot Engine, Cooling A .........................................5-2
Hour Meter ...........................................................2-4
Check Regularly ............................................8-2
Hydraulic
Hoist/Brake Cooling System
Maintenance Interval Guide ..................8-17
...................................................... 8-46/8-50
Filter, Replace .......................................8-41
Fluid
Level Check.......................................8-38
Change ..............................................8-39
Hoses and Lines, Check........................8-50
Tank
Breather Element
Change .............................................8-50
Check ...............................................8-50
Steering/Brake Apply System
Maintenance Interval Guide ..................8-16
 INDEX
...............................................................8-37
Filter, Replace .......................................8-41
Fluid
Change .............................................8-39
Level Check......................................8-38
Hoses and Lines, Check .......................8-44
Specifications ..............................................11-8
System, Troubleshooting...........................10-16
I Leaks
Indicator
Active Traction Control (ATC) (Option) .........2-9
ATC/EDSCError (Option) ........................2-9
Alternator .......................................................2-6
Battery Charging Problem .............................2-8
Brake, Hydraulic Oil Pressure .......................2-9
Body Down ..................................................2-28
Body Up .........................................................2-9
Central Warning ......................................2-6
Caution .........................................................2-7
Chart(Indicators description
& Function) ........................................2-8/2-9
High Beam.....................................................2-9
Turn/Hazard...................................................2-9
Engine Coolant Level ....................................2-8
Engine Malfunction ........................................2-8
Engine Oil Pressure.......................................2-8
Engine Stop (Warning) ..................................2-7
Filter
Air ............................................................2-8
Hoist ........................................................2-8
Steer ........................................................2-8
Transmisson............................................2-8
High Beam.....................................................2-9
Lights, Check...............................................8-82
Parking Brake ................................................2-9
Steering Hydraulic Oil Temperature ..............2-8
Steering Oil Pressure ...................................2-9
Transmission Malfunction..............................2-8
Transmission Oil Pressure ............................2-8
Turn/Hazard...................................................2-9
Information, General ............................................5-1
Inspect the Rigid Dump Truck ............................ S-2
Daily Before Starting......................................4-1
Daily Walk Around .........................................4-2
Daily Walk Around
Check List................................................4-3
Installing Body Prop Pins-EH750-3 .....................8-4
Installing Body Prop Cable-EH1100-3.................8-9
Instrument Panel................................................2-10
Instruments
Check After Starting ......................................4-9
Check Before Starting ...................................4-5
12-4
J
Jump Starting...................................................... S-8
K
Keep Riders Off Rigid Dump Truck .................... S-8
Key Switch .........................................................2-13
L
Fluid, Check For ..........................................8-97
Oil and Water.................................................4-4
Light
Exterior, Check ............................................8-81
Dome ...........................................................2-28
Load/Dump Brake ..............................................5-22
Load Counter .......................................................2-5
Switch ..........................................................2-31
Loading, Rigid Dump Truck .................................6-1
Lock-In-Range for EH750-3&EH1100-3 ..............5-6
Lowering the Body .............................................5-19
Lubricants
Differential, Check level/Change .................8-34
Planetary Hubs, check level/change..................8-35
Recommended...................................................8-11
Use Correct....................................................8-2
M
Machine
Dimensions ..................................................11-9
Weights........................................................11-1
MAINTENANCE...................................................8-1
Correct Procedures and Inspection ...............8-1
Interval Guide ..............................................8-13
Air Cleaner.................................... 8-18/8-60
Basic Preventive Maintenance
Replacement Parts ...........................8-13
Brakes-Service & Parking Steering
...................................................... 8-17/8-46
Cab ............................................... 8-20/8-90
Cooling System ............................ 8-18/8-66
Electrical System .......................... 8-19/8-75
Engine........................................... 8-15/8-23
Fuel System.................................. 8-17/8-54
General ......................................... 8-20/8-96
Greasing ............................... 8-15/8-21/8-22
Transmission ................8-13/8-14/8-16/8-28
Hydraulic Steering/Brake Apply System
...................................................... 8-16/8-37
Hydraulic Hoist/Brake Cooling System
.............................................. 8-17/8-46/8-47
Steering ........................................ 8-15/8-53
Suspension, Wheels & Tires ........ 8-18/8-85
 INDEX
Manual Release Valve.......................................2-29
Measures During Cold Weather ..........................4-8
Mirrors ...............................................................2-29
Modes of Operation .....................................2-17
Automatic.....................................................2-17
Cool .............................................................2-17
Defrost .........................................................2-17
Heat .............................................................2-17
Monitor Panel.......................................................2-2
Monitoring Alarm System ....................................2-6
Mud, Stuck In.....................................................5-26
N Check Level......................................8-35
Neutral Start Circuit, Check ...............................8-81
Never Travel With The Body Off The Frame.... S-14
O Power Transmission, Specifications ..................11-3
Observe Rigid Dump Truck Closely ....................3-1
Odometer.............................................................2-5
Operate Only From Operator’s Seat................... S-8
Operate The Rigid Dump Truck Safely............. S-10
OPERATING METHODS ....................................5-1
OPERATING THE ENGINE ................................4-1
OPERATING THE RIGID DUMP TRUCK ...........6-1
Operation Mode .................................................2-16
OPERATOR’S STATION.....................................2-1
Operator’s Seat Adjustment ..............................2-24
Air-Ride Seat ...............................................2-25
Seme-Active Seat........................................2-26
Standard Seat..............................................2-24
Operating
The Body, with Hoist Lever .........................5-23
The Rigid Dump Truck Near High Voltage
Overhead Power Lines......................... S-15
The Rigid Dump Truck Near Overhead
Wires or Cables.................................... S-15
Operator’s
Seat .............................................................2-32
Adjust The .............................................. S-6
Adjustment ............................................2-24
Operate Only From................................. S-8
Qualifications ................................................ S-2
Overnight Storage Insructions .............................6-8
P ...............................................................8-13
Paint, Remove Before Welding or Cutting........ S-26
Park The Rigid Dump Truck Safely .................. S-16
Parking
Brake ...........................................................5-22
Check ....................................................8-53
Indicator .........................................................2-9
Rigid Dump Truck........................................5-31
Switch ..........................................................2-23
12-5
Dry Disc Troubleshooting ....................10-28
Passenger Seat .................................................2-26
Pedal
Accelerator...................................................5-16
Brake............................................................2-21
Location and Function Decal .......................2-20
Retarder.......................................................2-21
Performance Chart.............................................5-11
Planetary
Hubs
Lubricant
Change .............................................8-35
Specifications...............................................11-3
Troubleshootng..........................................10-27
Power Port, DC 24 Volt......................................2-23
Precautions for Welding, Cutting, and Grinding S-27
Prepare
For Emergensies .......................................... S-3
Rigid Dump Truck for Service........................8-3
Pressurized Fluid Lines, Avoid Heating Near ... S-27
Prevent
Battery Explosions ...................................... S-29
Burns........................................................... S-22
Primary Filter Element, Service (Air Cleaner)....8-62
Protect
Agianst Falling Stones and Debris ............... S-9
Against Flying Debris.................................... S-4
Against Noise................................................ S-4
Provide Signals For Jobs Involving
Multiple Numbers of Vehicles................. S-9
R
Radiator, Clean ..................................................8-73
Raising the Body................................................5-24
Rear Driveshaft Troubleshooting .....................10-25
Rear Axle Troubleshooting ..............................10-24
Recognize Safety Information............................. S-1
Relay, Check (Fuse) ..........................................8-78
Remove Paint Before Welding or Cutting......... S-27
Removal and Storage of Body Prop Pins ............8-6
Replace Rubber Hoses Periodically ................. S-22
Replacement Parts, Basic Preventive Maintenance
Reset Procedure ..................................................5-7
Retarder
Charts ..........................................................5-12
Operation
Check.....................................................8-52
Decal......................................................5-10
Pedal............................................................2-21
Using..............................................................5-8
 INDEX
Return to Service .................................................9-7
Riders, Keep Off Rigid Dump Truck ................... S-8
Rigid Dump Truck Stuck in Deep Sand,
Snow or Mud .........................................5-26
Rigid Dump Truck, Application ............................6-1
Rocking Out .......................................................5-26
Rollwaway Accidents, Avoid Injury From.......... S-13
Rubber Hoses, Replace Periodically ................ S-21
Rules When Servicing, A Few Simple .............. S-18
S Pump, Troubleshooting..............................10-20
Safe Handling Of Off Road Tires...................... S-17
SAFETY.............................................................. S-1
Safety
Alert Symbol ................................................. S-1
Filter Element, Service (Air Cleaner)...........8-64
Safety Signs ............................................... S-32
Sand, Deep, Stuck In.........................................5-26
Rocking Out.................................................5-26
Seat
Adjustment, Operator’s................................2-24
Belt...............................................................2-27
Mounting, Check, Replace ....................8-94
Belt, Fasten .................................................. S-7
Passenger ...................................................2-27
Service Brakes...................................................5-17
Service Your Rigid Dump Truck at Specified
Intervals ...................................................8-2
Servicing, A Few Simple Rules When .............. S-19
Servicing Air Conditioning System Safely ........ S-29
Snow, Stuck In...................................................5-26
Rocking Out.................................................5-26
SPECIFICATIONS.............................................11-1
Brake System ..............................................11-4
Cab ..............................................................11-7
Capacities....................................................11-1
Electrical ......................................................11-2
Engine..........................................................11-2
Hoist System ...............................................11-8
Machine
Dimensions............................................11-9
Weights..................................................11-1
Power Transmission ....................................11-3
Steering System ..........................................11-5
Wheels.........................................................11-6
Speedometer .......................................................2-4
Starter & Mounting, Troubleshooting.................10-5
Starting
Aids, Handle Safely ...................................... S-7
The Engine ....................................................4-6
In Cold Weather ......................................4-7
Measures During ..................................4-8
12-6
In Warm Weather ....................................4-6
Status Lights, Transmission.................................5-5
Steering..............................................................5-17
Accumulator, Check.....................................8-42
And Brakes-Service Parking
Maintenance Interval Guide ..................8-16
Control Valve, Troubleshooting .................10-21
Hydraulic Oil Pressure Indicator ....................2-8
Hydraulic Oil Trmperature Indicator...............2-8
Operation, Check.........................................8-53
Specifications...............................................11-5
Wheel...........................................................2-18
Tilt/Telescope ........................................2-18
Stopping
Engine..........................................................4-12
Rigid Dump Truck ..........................................6-8
STORAGE ...........................................................9-1
Body Prop Pins (Removal) ............................8-8
Long Term .....................................................9-5
Moderate Term ..............................................9-3
Overnight .......................................................6-8
Short Term.....................................................9-1
Struts, Check .....................................................8-86
Stuck, Machine in Deep Sand, Snow or Mud ....5-26
Supplemental Coolant Additive (SCA) Check ...8-68
Suspension, Wheels & Tires
Maintenance Interval Guide.........................8-19
...............................................................8-85
Switch
Active Traction Control (ATC) Boost Switch......5-21
Battery Disconnect.............................................2-30
Display ON/OFF switch ...............................2-15
Electronic Downhill Speed
Control (EDSC) Switch ..........................5-20
Fan Speed Control Switches .......................2-15
Front Brake Cut-Off .....................................5-18
Hazard Warning...........................................2-18
Headlight......................................................2-12
Horn .............................................................2-19
Key...............................................................2-13
Load/Dump Brake........................................2-23
ON/OFF Switch............................................2-15
Parking Brake ..............................................2-13
Circulation Switch ........................................2-15
Temperature Control Switch........................2-15
Turn Signal/High Beam Lever .....................2-19
Vent Mode Switch........................................2-15
Windshiled Wiper and Washer ....................2-11
T
Tachometer..........................................................2-5
Temperature Display..........................................2-16
 INDEX
Tightening Torque of Bolts and Nuts ...............8-103
Tilt/Telescope Steering Wheel...........................2-18
Tipping, Avoid ................................................... S-12
Tires
Condition, Check .........................................8-88
Inflation, Check............................................8-88
Safe Handling Of Off Road......................... S-16
Tool Box.............................................................2-37
Tools, Use Properly .......................................... S-20
Torque Values .................................................8-103
Towing ...............................................................5-27
With Engine Operable .................................5-28
With Engine Inoperable ...............................5-29
Transmission .......................................................5-2
Automatic Shifting..........................................5-3
Breather Element
Change ..................................................8-33
Check ....................................................8-33
Cold Weather Restrictions...........................5-16
Cooling Line Strainer, Clean .......................8-32
Downshift or Reverse Inhibitor Feature.........5-7
Filter, Replace .............................................8-30
Fluid Change ...............................................8-30
Fluid Level Check ........................................8-29
Cold Fluid Level Check .........................8-24
Hot Fluid Level Check ...........................8-24
Maintenance Interval Guide ........................8-16
...............................................................8-28
Malfunction Indicator .....................................2-7
Oil Pressure Indicator ....................................2-7
Refill.............................................................8-31
Shift Selector ...............................................2-23
Specifications ..............................................11-3
Status Lights..................................................5-4
Sump Strainer
Change ..................................................8-32
Clean .....................................................8-32
Troubleshooting...........................................10-7
TRANSPORTING ................................................7-1
Transporting EH750-3 ...................................7-2
Transporting EH750-3 ...................................7-2
Traveling on Roadways .................................7-5
TROUBLESHOOTING.......................................10-1
Air Cleaner...................................................10-5
Differential .................................................10-26
Drive Coupling .............................................10-4
Electrical System .......................................10-12
Engine..........................................................10-1
Coolant ..................................................10-4
Front Axle ..................................................10-23
Front Driveshaft .........................................10-25
Hydraulic Hoist System .............................10-18
Hydraulic Steering System ........................10-19
12-7
Hydraulic System.......................................10-16
Parking Brake, Dry Disc.............................10-28
Planetary....................................................10-27
Rear Axle ...................................................10-24
Rear Driveshaft..........................................10-25
Starter and Mounting ...................................10-5
Steering Control Valve...............................10-21
Steering Pump ...........................................10-20
Transmission ...............................................10-7
Turn/Hazard Indicator ..........................................2-9
Turn Signal/High Beam Lever Switch ................2-19
U
Understand Signal Word..................................... S-1
Use
Correct Fuels and Lubricants ........................8-2
Handholds and Steps ................................... S-6
Tools Properly............................................. S-21
Using Booster Batteries .....................................4-10
Connecting...................................................4-10
Disconnecting ..............................................4-11
Using the Retarder...............................................5-8
V
Vacuator Valve, Check (Air Cleaner).................8-61
View of EH750-3 and EH1100-3..........................1-1
W
Waste, Dispose of Properly .............................. S-29
Wear Protective Clothing .................................... S-4
Weights, Machine ..............................................11-9
Welding
Electrical Disconnects Before
Welding on the Machine ..........................8-8
Precautions for............................................ S-26
Remove Paint, Before................................. S-26
Wheels
Alignment, Check.........................................8-89
Check...........................................................8-87
Front, Lubricant
Check.....................................................8-87
Change ..................................................8-87
Specifications...............................................11-6
Suspension, Wheels & Tires
Maintenance Interval Guide ..................8-19
Windshield
Washer Fluid Level, Check..........................8-93
Wiper and Washer Switch ...........................2-11
Wiper Blade, Check Condition...........................8-93
Wires or Cables, Overhead, Operating
The Rigid Dump Truck Near....................... S-14