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Hitachi AH500-D Articulated Dump Truck Service Manual

533 pages · Publication KM8TJG-E-01

$69.59
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Models
AH500-D
Serial coverage
001954 and up
Manual type
Service Manual
Pages
533
Publication
KM8TJG-E-01
Condition
Brand new
Hitachi AH500-D Articulated Dump Truck Service Manual, publication KM8TJG-E-01

What's inside

From the manual's own table of contents: 202 sections, 208 entries. See sample pages (PDF, 448 KB)

General1 topic
  • TABLE OF CONTENTS SAFETY
SAFETY FEATURES
GENERAL SAFETY
SAFETY REGULATION
SAFETY DECALS
CHAPTER 1. OPERATIONAL CHECK-OUT PROCEDURE
OPERATIONAL CHECK-OUT
OPERATIONAL CHECKS - KEY SWITCH ON, ENGINE OFF
CHAPTER 2. ENGINE
SECTION 1. THEORY OF OPERATION
ENGINE
SECTION 2. DIAGNOSE ENGINE MALFUNCTIONS
SECTION 3. ADJUSTMENTS
DISPLAY MENU TACHOMETER
SLOW AND FAST IDLE ADJUSTMENT
VALVE CLEARANCE ADJUSTMENT
EXHAUST BRAKE ADJUSTMENT
SECTION 4. TESTS
CYLINDER COMPRESSION TEST
FUEL PUMP PRESSURE TEST
OIL PUMP PRESSURE TEST
WHAT EXACTLY IS A “CAN BUS
CANBUS
TESTING THE “CANBUS
Show all 203 sections
CHECKING THE CABLES
HARNESS
MAIN “CAN” HARNESS
CAN” SHORT TO GROUND
CAN “OPEN CIRCUIT
CAN” SHORT TO POSITIVE 0 -24 VOLTS
CHAPTER 3. ELECTRICAL SYSTEM
SECTION 1. SYSTEM INFORMATION
ELECTRICAL SCHEMATIC SYMBOLS
CHASSIS CONTROL UNIT (CCU & OEU)
MDU2 (MONITOR DISPLAY UNIT)
MDU2 LAYOUT
MDU2 INPUT AND OUTPUTS
RELAY
START-UP DISPLAY
DEFAULT SCREEN
TO GO TO MAIN MENU FROM DEFAULT SCREEN
MAIN MENU
EXPLANATION OF WIRE MARKINGS
SECTION 2. DESCRIPTION OF CIRCUITS
MDU2 WARNING LIGHTS
MDU2 GAUGES
CCU2 OUTPUT SPECIFICATION
OEU OUTPUT SPECIFICATION
SECTION 3. REFERENCES
ENGINE FAULT CODES (ADM)
ENGINE FAULT CODES (PLD-MR)
SSM FAULT CODES
PART 2. DM1 FAULT CODES
KEY SWITCH TEST
RELAYS
Diode Test
Pneumatic System Solenoids, Pressure Switches, and Sensor Tests
Steering Column Switch Test
CHAPTER 4. TRANSMISSION
GENERAL DESCRIPTIONS
STALL SPEEDS
PLANETARY GEARS AND POWER FLOWS
THE BASIC LAWS OF PLANETARY GEAR SETS
HD TRANSMISSION PLANETARY CONFIGURATION
HD TRANSMISSION CLUTCH CONFIGURATION
POWER FLOW
HYDRAULIC SYSTEM
SOLENOIDS
and 4000 4th Generation Control Valve Body
HYDRAULIC CIRCUITS
TORQUE CONVERTER AND LUBE PRESSURE CIRCUITS - OVERVIEW
EXHAUST BACKFILL PRESSURE
PRESSURE TABLE AND TEST POINTS
RETARDER
APPLICATIONS AND CAPACITIES
INPUTS AND OUTPUTS
RETARDER CONTROL HYDRAULICS
TESTING RETARDER CHARGING PRESSURE
HD RETARDER HYDRAULIC SCHEMATIC RETARDER OFF
HD RETARDER HYDRAULIC SCHEMATIC RETARDER ON
ELECTRONIC CONTROL SYSTEM
PUSH BUTTON SHIFT SELECTOR
SPEED SENSORS
WIRING HARNESSES
RANGE / SHIFT TESTS
DO NOT SHIFT LIGHT
SECTION 2. DIAGNOSTIC INFORMATION
DIAGNOSTIC PROCEDURE
DIAGNOSE POWER TRAIN SYSTEM MALFUNCTIONS
CHECK THE TRANSMISSION FLUID LEVEL
TRANSMISSION CONTROL UNIT ERROR CODES1 topic
  • TABLE OF CONTENTS TABLE OF ERROR CODES
ALLISON HD 4560R ELECTRONIC CONTROL WTEC III
SECTION 3. ADJUSTMENTS AND TESTS
TRANSMISSION WARM-UP PROCEDURE
TRANSMISSION OIL COOLER RESTRICTION TEST
CHAPTER 5. PNEUMATIC SYSTEM
PNEUMATIC SYSTEM OPERATION
PNEUMATIC SYSTEM SCHEMATIC
DIAGNOSE PNEUMATIC SYSTEM MALFUNCTIONS
PNEUMATIC SYSTEM MAIN PRESSURE TEST AND ADJUSTMENT
PARK BRAKE PRESSURE TEST
PARK BRAKE ADJUSTMENT
GRAMMER SEAT FUNCTIONAL TEST
CHAPTER 6. HYDRAULIC SYSTEM
ARTICULATED DUMP TRUCK HYDRAULIC SYSTEM OPERATION
DIAGNOSE HYDRAULIC SYSTEM MALFUNCTIONS
SECTION 3. TESTS
JT05800 DIGITAL THERMOMETER INSTALLATION
JT02156A DIGITAL ANALOGUE PRESSURE/TEMPERATURE ANALYSER INSTALLATION
HYDRAULIC OIL CLEANUP PROCEDURE USING PORTABLE FILTER CADDY
HYDRAULIC SYSTEM WARM-UP PROCEDURE
CYCLE TIME TEST
SYSTEM RELIEF VALVE AND BIN RAISE CIRCUIT RELIEF VALVE TEST
PRIORITY VALVE TEST
ACCUMULATOR PRESSURE REDUCING VALVE TEST AND ADJUSTMENT
BRAKE ACCUMULATOR CHARGE VALVE TEST AND ADJUSTMENT
BRAKE LOW PRESSURE SWITCH AND BRAKE ACCUMULATOR TEST
SERVICE BRAKE VALVE TEST
STEERING RELIEF VALVE PRESSURE TEST AND ADJUSTMENT
STEERING CYLINDER LEAKAGE TEST
ADJUSTMENT
BIN LOWER CIRCUIT RELIEF VALVE TEST
SUSPENSION CALIBRATION PROCEDURE
SUSPENSION SERVICE CHECK
Hydraulic Pressure Setting and Fault Finding Procedure
CHAPTER 7. HEATING AND AIR CONDITIONING
AIR CONDITIONING SYSTEM CYCLE OF OPERATION
HEATER CORE OPERATION
DIAGNOSE AIR CONDITIONING SYSTEM MALFUNCTIONS
HEATING/AIR CONDITIONING COMPONENT LOCATION
AIR CONDITIONING OPERATIONAL CHECKS
R134A AIR CONDITIONING SYSTEM TEST
OPERATING PRESSURE DIAGNOSTIC CHART
A/C FREEZE CONTROL SWITCH TEST
A/C COMPRESSOR CLUTCH TEST
A/C HIGH/LOW PRESSURE SWITCH TEST
A/C EXPANSION VALVE TEST
EXPANSION VALVE BENCH TEST
REFRIGERANT LEAK TEST
CHAPTER 8. MAINTENANCE SCHEDULES
NOTES
CHAPTER 9. DAILY OR 10 HOURLY SERVICE CHECKS
CHAPTER 10. 500 HOURS SERVICE AND CHECKS
SECTION 1. DRIVE TRAIN
INTRODUCTION
SERVICE INSTRUCTIONS
TRANSMISSION
BRAKES1 topic
  • TABLE OF CONTENTS AXLES
TRANSFER CASE
SECTION 2. CLEAN, CHECK AND REPLACE BREATHERS
GENERAL CHECK DRIVE LINE & SUSPENSION FASTENERS
TRANSMISSION BREATHER (LOCATED UNDER CAB)
REPLACE FUEL TANK BREATHER
TRANSFER CASE BREATHER (LOCATED BEHIND CAB)
AXLE BREATHERS
SECTION 3. CAB AND ELECTRICAL
INSPECT, CLEAN AND REPLACE CAB AIR FILTER
CHECK BATTERIES, CLEAN AND TIGHTEN TERMINALS
CHECK ELECTRICAL CONNECTORS, HARNESSES AND LOOMS
CHECK WORK LIGHTS, REVERSE BUZZER AND HORNS
RECORD & DELETE FAULT CODES ON THE MDU
CHECK THE OPERATOR CONTROLS AND INSTRUMENTS
SECTION 4. LUBRICATION
CHECK GREASE LEVEL OF AUTO GREASING SYSTEM
REPLACE AUTO GREASING SYSTEM FILTER
HYDRAULICS
CHAPTER 11. 500 HOURS SERVICE AND CHECKS
TRANSFER CASE BREATHER (LOCATED UNDER THE CAB)1 topic
  • TABLE OF CONTENTS CHAPTER 12. 1 000 HOURS SERVICE AND CHECKS
SECTION 2. HYDRAULICS AND LUBRICATION
REPLACE HYDRAULIC RESERVOIR BREATHER
SECTION 4. AXLES AND CHASSIS & SUSPENSION
CHECK AXLE OIL LEVEL
CHECK FINAL DRIVE OIL LEVELS
CHECK BIN SHOCK PAD CLEARANCE
CHAPTER 13. 2 000 HOURS SERVICE AND CHECKS
REPLACE HYDRAULIC OIL RETURN FILTER
SECTION 3. CAB, PNEUMATICS AND ELECTRICAL
REPLACE PNEUMATIC SYSTEM DRYER FILTER
DRYER FILTER
CHAPTER 14. 3 000 HOURS SERVICE AND CHECKS
SECTION 2. HYDRAULICS AND PNEUMATICS
CHAPTER 15. 4 000 HOURS SERVICE AND CHECKS
REPLACE FAN BELT
CHAPTER 16. AS REQUIRED SERVICE
SECTION 1. ENGINE1 topic
  • TABLE OF CONTENTS INTRODUCTION
SECTION 2. CAB AND LUBRICATION
CLEAN AIR CONDITIONING FILTERS
GREASE HINGES
CHAPTER 17. MISCELLANEOUS SERVICE AND CHECKS
WHEELS
SECTION 2. ELECTRICAL
USING BATTERY CHARGER
ADJUST HEADLIGHTS
SECTION 3. OPERATIONAL CHECKOUT
CHAPTER 18. TROUBLE SHOOTING
SECTION 1. SYMPTOMS AND REMEDIES
CHAPTER 19. APPENDIX
INTRODUCTION
CHASSIS CONTROL UNIT SOFTWARE REQUIREMENTS
HEADLIGHT LOGIC AND CONTROL1 topic
  • TABLE OF CONTENTS 2. WIPER CONTROL LOGIC AND TIMING
INPUTS/OUTPUTS
BIN CONTROL LOGIC
PR001_PARK BRAKE FUNCTION

Inside this manual

Real pages from this service manual (533 pages). Open the sample pages (PDF, 447 KB)

Sample pages from the Hitachi AH500-D Articulated Dump Truck Service Manual: Diagram, Specifications, Troubleshooting, Color page, Color page
  • Diagram, page 288: Symptom
  • Specifications, page 312: TRANSMISSION OIL COOLER
  • Troubleshooting, page 512: Electrical
  • Color page, page 124: OEU PIN LAYOUT
  • Color page, page 436: Inspect breather for clogging, damage and

This is a service manual

Here's how it compares to the other manual types.

This manual

Service manual

Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.

Operator's manual

Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.

Parts manual

Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.

Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.

What it's used for

Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.

Service shops and owner/operators who repair their own equipment

Identifying correct parts and seeing how assemblies come apart and go back together

Keeping equipment running with less downtime

Factory manual, 533 pages

Quantity one is the manual described above.

Fast free USA shipping

Ships in 1 business day.

60-day returns

Free if the mistake is ours. A manual ordered in error must come back unopened in its shrink-wrap; you pay return shipping and a 20% restocking fee applies. Return policy

Binder not included

Manuals over about 300 pages may need a standard 3-ring binder, which you can buy locally to keep the pages organized for shop use.

Other editions and similar models

Hitachi AH500-DTroubleshooting Technical Service Manual · T8TJ-E-01 · $79.57

Questions about model, serial number, engine coverage or contents? Contact us before purchasing and we'll help confirm it's the right manual. Please verify the manual type, machine model, serial number range and engine coverage before purchasing: manuals ordered in error carry a 20% restocking fee (return policy).