EH1700 Operator's Manual - English

HITACHI EH1700 350HD
OPERATORS
MANUAL
FROM S.N. 76591
EDITION 2
PUBLICATION
NO. 10185 ENG.
DISTRIBUTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADDRESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PHONE NO .............
DLR/BRCH ..........................................................
ADDRESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PHONE NO . . . . . . . . . . . . .
SERVICE PHONE NO ...................................................
MACHINE:
SERIAL NO ........................................................
ENGINE TYPE NO ..................................................
HYDRAULIC TRANSM. TYPE/NO .....................................
MASTER KEY SWITCH NO ..............................................
CAB KEY NO . . . . . . . . . . . . . . . . . . . FUEL FILLER CAP KEY NO. . . . . . . . . . . . . . .
08/01 PRINTED IN U.S.A.

FOREWORD 1
FOREWORD
This Operators Manual is intended as a guide for
the correct use and maintenance of the machine.
The manual should always be kept in the vehicle.
Carefully read the manual before starting and
operating the machine or before carrying out any
preventive maintenance.
We have taken many hours in designing and

producing the safest and most efficient equipment
possible. All this may be wasted if you do not read CONTENTS 3
the safety instructions or if you do not follow them.
Make yourself familiar with all controls and

instructions and keep this manual in the machine for
handy reference. If the manual is lost, it should be
replaced immediately.
PRESENTATION 5
Machines rarely cause accidents, whereas people
do. A safety conscious person and a well
maintained machine make a safe, efficient and
profitable combination.
This manual has been adapted to cover all INSTRUMENT
markets, thus it may contain information about PANEL 13
equipment not necessarily fitted to the version
of the machine you have purchased.
We therefore ask you to disregard information
which is not applicable to your machine.
We are continually striving to improve our products OPERATORS
and therefore, reserve the right to make changes
and improvements to the design whenever we CONTROLS 43
consider that these increase the efficiency of the
product. However, this does not commit us to
introduce these improvements on products which
have already been delivered or are in service. We
also retain the right to change data and equipment, OPERATING
as well as instructions for service and maintenance INSTRUCTIONS 69
without prior notice.
SAFETY REGULATIONS
Every country (State) has its own safety
regulations. It is the obligation of the operator to BASIC PREVENTIVE
know and follow these. This also applies to local MAINTENANCE 127
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.
SPECIFICATIONS 183
SAFETY ALERT SYMBOL
This symbol, which will appear at various points in
the manual and on the machine together with a
warning statement, means: ”Warning, be alert!
Your safety is involved!” Carefully read the ALPHABETICAL
message that follows. It is the obligation of the INDEX 207
operator to make sure that all warning decals
are in place on the machine and that they are
readable. Accidents may otherwise occur.
KNOW THE CAPACITY AND LIMITS OF YOUR MACHINE!

2 FOREWORD
UNAUTHORIZED MODIFICATION OF ROLLOVER PROTECTIVE STRUCTURE

(ROPS)
Never make any unauthorized modifications or alterations to the 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 Structures (ROPS) have been certified to meet specified test requirements according
to ISO 3471 ROPS.
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 certifying tests.
It is important that each person in your organization, including management, be made fully aware of these
rules involving the ROPS. Whenever anyone sees a machine ROPS with unauthorized modifications or
changes, both the customer and manufacturer should be notified in writing.
OPERATION AND MAINTENANCE OF THE MACHINE

EUCLID-HIT ACHI Heavy Equipment, Ltd is only responsible if:
- the machine has been used in a correct manner and been maintained according
to instructions in this Operator’s Manual and the Service Manuals.
- the prescribed service and prescribed inspections have been carried out at the
stated points in time.
- the recommended lubricants according to the manual have been used.
- no security seals have been broken by other than authorized persons.
- all modifications and repairs have been carried out and methods been followed
in the way prescribed by EUCLID-HIT ACHI.
- only EUCLID-HIT ACHI genuine parts/accessories, or attachments which meet
EUCLID-HIT ACHI requirements, have been used.
Note: Any questions regarding the content of this manual should be directed to your nearest HITACHI
Distributor.
WARNING!
A hauler operator must have sufficient knowledge and instruction before operating and
servicing the machine.
Untrained operators may cause severe injuries or even fatalities.
Therefore, it is important that you read and follow the instructions in this Operator’s Manual.
Never use a hauler if an Operator’s Manual is not available.
Learn to understand the warning plates, symbols and operator instructions before you begin to
operate the machine.
CONTENTS 3
TABLE OF CONTENTS
FOREWORD
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SAFETY REGULATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
UNAUTHORIZED MODIFICATION OF ROLLOVER PROTECTIVE
STRUCTURE (ROPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
OPERATION AND MAINTENANCE OF THE MACHINE . . . . . . . . . 2
PRESENTATION
PRESENTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
POWER TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
INFORMATION AND WARNING PLATES . . . . . . . . . . . . . . . . . . . . . . 6
PRODUCT IDENTIFICATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . 10
MAINTENANCE AND INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSTRUMENT PANEL
INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
OPERATORS CONTROLS
OPERATORS CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
OPERATING INSTRUCTIONS
GENERAL OPERATING RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
OPERATOR’S QUALIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
DUTIES OF THE OPERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
A FEW SIMPLE SAFETY RULES BEFORE OPERATING . . . . . . . . 69
OPERATING WITH THE MACHINE NEAR
OVERHEAD WIRES OR CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . 71
OPERATING WITH THE MACHINE NEAR HIGH VOLTAGE
OVERHEAD POWER LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
SIGNALLING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
PROCEDURE BEFORE STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Daily Walk Around Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
RUN IN INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
STARTING ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
BEFORE OPERATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
OPERATING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
PARKING MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
STORAGE OF HITACHI RIGID HAULERS . . . . . . . . . . . . . . . . . . . . . 105
4 CONTENTS
OPERATING INSTRUCTIONS (continued)

TRANSPORTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
ROADING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
MACHINE STUCK IN DEEP SAND, SNOW OR MUD . . . . . . . . . . . 122
TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
BASIC PREVENTIVE MAINTENANCE

SERVICE POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
A FEW SIMPLE RULES WHEN SERVICING . . . . . . . . . . . . . . . . . . . 128
FIRE PREVENTION MEASURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
WASTE HAZARDOUS TO THE ENVIRONMENT . . . . . . . . . . . . . . . 131
BASIC PREVENTIVE MAINTENANCE INTERVAL CHART . . . . . . . 132
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
AIR CLEANER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
POWER TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
WHEEL SUSPENSION AND STEERING . . . . . . . . . . . . . . . . . . . . . . 167
FRAME, SPRINGS, AND WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
HYDRAULIC SYSTEM AND OTHER FUNCTIONS . . . . . . . . . . . . . . 175
CHASSIS AND DRIVESHAFT GREASE FITTING LOCATIONS . . . 180
SPECIFICATIONS
RECOMMENDED LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
PERFORMANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
RETARDER CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
MACHINE DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
BOLT TORQUE CHART, GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
ALPHABETICAL INDEX
ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
PRESENTATION 5
EL19662
PRESENTATION a circuit for the front dry disc brakes and another
circuit for the rear axle wet disc brakes.
The HITACHI EH1700 (350HD) is a rigid frame
The dry disc parking brake is mounted on the
hauler capable of carrying a 98,365 kg (216,850 lb)
differential input shaft. It is controlled by a toggle
maximum payload, with no options. The HITACHI
switch on the instrument panel. The parking brake
EH1700 Hauler features independent trailing arms
will automatically apply if brake hydraulic pressure
for each front wheel with Neocon suspension
is lost.
cylinders mounted between the trailing arm and
frame. Neocon suspension cylinders are also The foot operated retarder valve allows the operator
utilized on the rear axle. to control the all-hydraulic actuation of the
oil-cooled wet disc brakes on the rear axle. The
ENGINE system provides modulated pressure to the rear
brakes for constant speed control.
The HITACHI EH1700 (350HD) is powered by a
30.5 liter (1861 cu.in), 895 kw (1200 hp), 12 STEERING
cylinder, four cycle, turbocharged Cummins The machine is equipped with a closed center
QST-30 engine. hydraulic system with a brake actuation/steering
system reservoir. The hydraulic power steering
POWER TRANSMISSION uses two double acting cylinders, an accumulator,
and a piston type pump. The accumulator provides
The HITACHI EH1700 (350HD) is equipped with the supplementary steering capability.
Allison M9600-A transmission. The transmission is
remote mounted and has six forward speeds and CAB
two reverse speed. Allison Commercial Electronic The machine is equipped with a cab that has been
Control I (CEC I) provides park brake interlock and ROPS/FOPS tested and approved in accordance
hoist interlock as well as built in diagnostics. with SAE J1040 and ISO 3471.The cab is fully
The drive axles have full floating axle shafts. Double insulated and includes a filtered fresh air heater and
reduction in the Euclid axle is provided by a bevel pressurizing system.
gear set in the center housing and a planetary
BODY
reduction in the wheel.
The dump body is designed with a flat floor, a low
BRAKES center of gravity for maximum stability, and is
continuously exhaust heated. Optional
The machine is equipped with an all-hydraulic superstructures can be mounted if required. An
actuated braking system with dual circuits. There is electronically controlled hoist is standard.
6 PRESENTATION
NAMEPLATES, WARNING, AND INFORMATION DECALS
EL19717
The numbers on the illustration refer to the machine plates, warning and information decals installed
on the machine. The operator of the machine must know and follow warnings and information given
on decals and plates. Decals/plates which have disappeared, been damaged, painted over, or for any
reason are no longer legible, must be replaced immediately.
The part numbers of the respective plates/decals can be found in the Parts Catalog.
PRESENTATION 7
CAB NAMEPLATES, WARNINGS AND INFORMATION DECALS
NO. DESCRIPTION POSITION
1. G.M.W. (Gross Machine Weight) Right side of

the instrument panel
2. Propulsion Inhibit Above windshield, right side

When the body is raised off the frame, reverse propulsion
is inhibited
3. Pedal Location and Function Above wiindshield, right side
4. Warning. Read Operators Manual Above windshield, left side

before starting and operating the machine
5. Hoist Control Lever Function Above windshield, left side
6. Retarder Operation Decal Above windshield. left side

Refer to the Operators Manual
7. Product Identification Number Plate Above door, left side
8. Rollover Protective Structure (ROPS) Left side of cab, behind

operator
9. Proposition 65 Warning Lower left corner of

California, United States of America windshield
CHASSIS/BODY NAMEPLATES, WARNINGS AND INFORMATION DECALS

10. Manual Release Valve Above the release valve
Consult the technical manual for service procedures by the brake accumulators
11. Transmission Filter. Number referenced on the decal On the transmission filter
is the part number for the replacement filter element
12. Made in Canada Left and right hand side of the

front sheet metal
13. Warning, Contents Under Pressure On the steering and brake

accumulators
14. Jump Start Warning Front of the battery box

Electrical shock/electrocution. Refer to Operators Manual
15. Battery Disconnect Top of the battery box
16. Air Cleaner. Numbers referenced on the decal are the On the air cleaners
part numbers for the inner and outer replacement
filter elements
8 PRESENTATION
NAMEPLATES, WARNING, AND INFORMATION DECALS
EL19718
The numbers on the illustration refer to the machine plates, warning and information decals installed
on the machine. The operator of the machine must know and follow warnings and information given
on decals and plates. Decals/plates which have disappeared, been damaged, painted over, or for any
reason are no longer legible, must be replaced immediately.
The part numbers of the respective plates/decals can be found in the Parts Catalog.
PRESENTATION 9
CHASSIS/BODY NAMEPLATES, WARNINGS AND INFORMATION DECALS (Continued)

17 Lock Body Rear of tailchute, above
Refer to the Operator’s Manual body prop cable
18 Warning Limited Visibility - At Rear of Machine On both sides of the body

Stay a safe distance from the machine.
19 NEOCON-E Located on front and rear ride

(Trees indicates friendly to environment.) struts
20 Crush Hazard from Dump Body Located at the back of the

Insert body prop cable before getting in hazardous area. box and at the rear of the cab
21 Hydraulic Filter - Number referenced on decal is the Located on each hydraulic

part number for the replacement filter element. filter housing
22 Steering Filter - Number referenced on decal is the Located on the steering

part number for the replacement filter element. section of the hydraulic tank
23 Engine Start On the hydraulic tank

Indicates where level should be with engine running
24 Front Wheel Crush Area Both sides of the machine

Stay clear of front axle on the frame in the axle area
25 Warning Limited Visibility - At Front of Machine Both sides of the sheet metal
Stay a safe distance from the machine. side member
26 Tie Down - Where chains attach to machine. For example On the front bumper, rear
when transporting on a lowboy. frame lug, and left & right side
of frame.
27 Lifting Locations At the front bumper. In the

rear, at the frame lug.
28 Burn Hazard when machine is hot Radiator top tank (installed

Remove radiator cap slowly after machine has cooled down at the radiator cap)
29 Steering Pressure Test Port Located in front of the test

port, top of the accumulator
10 PRESENTATION
PRODUCT IDENTIFICATION NUMBER

Hitachi Construction Machinery Company is a worldwide company
that produces several product lines under different product names,
one of which is Euclid Rigid Hauler. To aid in production scheduling,
certain machine models are built in several plants and exported to
meet our world market requirements.
At the time of manufacture, every machine is assigned a product

identification (serial) number to identify that machine from all others
built by EUCLID-HITACHI Heavy Equipment, Ltd.
Product Identification Number Locations

1. Product Identification Plate - Located inside the cab
above the passenger door.
2. Frame Serial Number - Stamped into the frame on the top
of the front bumper, located next to the ladder.
3. Engine Serial Number Plate - Located on the right bank
of the engine, under the turbocharger.
4. Transmission Serial Number Plate - Located on the
lower-rear side of the transmission.
EL19901
The following breakdown explains the product identification (serial)
numbering system.
Current Production
>00000 X 00000<
3. Production Sequence Number.
EL19902 2. Engine Manufacturer Designation.

European Community
Market Symbol 1. Model Designation (4 or 5 digits).
Always use the complete product identification (serial) number on

all Delivery & Inspection Reports, parts orders, warranty requests,
correspondence, service reports and literature orders.
PRESENTATION 11
MAINTENANCE AND INSPECTIONS
MAINTENANCE
If the machine is to work as efficiently as possible, thorough

maintenance is necessary. Recommended intervals for
maintenance and lubrication are based on normal working and
environmental conditions. The maintenance work described in this
manual can be carried out by a trained operator. Further
adjustments and repairs to the machine should be performed by an
authorized HITACHI distributor.
INSPECTIONS - Construction Models
Pre-Delivery Inspections
Before the machine left the factory it was tested and adjusted. In
addition to this, your HITACHI distributor has carried out a further
check, the “Pre-Delivery Inspection”, according to our instructions,
before the machine was delivered to you.
Periodic Inspections
It is important that the machine receive further checks.
Re-tightening of bolts, checking adjustments and other minor
measures have to be carried out.
TS40011
Three follow-up inspection should be scheduled.
• The first must be carried out within the first 250 hours
of operation.
• The second is to be completed at 1000 hours of
operation.
• The third at 2500 hours of operation or just before the
expiration of the Standard One Year Warranty period.
Maintenance Inspections
In addition to the maintenance listed in this manual, authorized
HITACHI distributors offer maintenance programs that maximize
machine up time.
Further information about these programs can be obtained from the

nearest authorized HITACHI distributor.
12 PRESENTATION
NOTES
INSTRUMENT PANEL 13
INSTRUMENT PANEL
EL19666
The instrument panel is explained throughout the following pages.

The description and operation of other operator’s controls can be
found in the Operators Controls section in this manual.
WARNING!
Before operating the machine, the operator must know the
location and proper operation of all controls. Read this
manual carefully.
WARNING!
Observe the gauges and warning lights while operating the
machine. Do not operate the machine when gauges and
warning lights are not working properly.
Note: The master key switch must be turned to the “ON”

position when checking instruments and controls.
14 INSTRUMENT PANEL
INSTRUMENTS
2 3 1 4 6 5 7 8 9 10 11 12 13 14 16
18
26
23
32 15 17
26 27 20 19 21 22 24 25 27
28 29 30 31
ELI9668
1. Instrument Lighting Rheostat 19. Electronic Transmission Retarder Switch

2. Headlight Switch (Option)
3. Dome Light Switch 19. Electronic Downhill Speed Control Switch
4. Brake/Steer Oil Pressure Gauge (Option)
5. Brake Temperature Gauge 20. Active Traction Control/Boost Switch
6. Engine Coolant Temperature Gauge (Option)
7. Transmission (Converter) 21. Front Brake Cut-Off Switch
Temperature Gauge 22. Cold Start Fluid Injector Switch (Option)
8. Speedometer 23. Fuel Pre-Heater Switch (Option)
9. Tachometer 24. Master Key Switch
10. Warning Lamp Display 25. Heater Control Assembly
11. Contronic Display Unit
26. Louver
12. Parking Brake Switch
13. Windshield Wiper Switch 27. Panel Outlet
14. Intermittent Wiper/Washer Switch 28. Contronic ECU Programming Port
15. Body Up Light 29. Audible Alarm
16. Traction Boost Indicator Light 30. Contronic Display Service Tool Connector
(With Item 19) Haultronic II (Option) Data Download
17. Active Traction Control (ATC) 31. Engine Diagnostic Connector
Indicator Light (with Item 19) 32. Radio (Option)
18. Electronic Transmission Retarder Light
(Option)
18. Electronic Downhill Speed Control (EDSC)
Light (Option)
INSTRUMENT PANEL 15
1. INSTRUMENT LIGHTING RHEOSTAT

This control is used for regulating the intensity of the instrument
panel lighting (gauges and the control console). Turn the control
clockwise to increase light intensity.
EL14874
2. HEADLIGHT SWITCH
This switch activates the marker lights, instrument panel lights and
headlights. This is a three position switch.
• OFF
• MARKER/INSTRUMENT PANEL LIGHTS
Off Marker Headlights • HEADLIGHTS
Lights ELI14879
3. DOME LIGHT SWITCH

This switch activates the overhead light inside of the cab. This is a
two position switch.
• OFF
• ON
EL14880 See Dome Light in OTHER CONTROLS.

16 INSTRUMENT PANEL
4 5 6 7
ELI19669
Low High
Pressure Pressure
Red Red 4. BRAKE /STEER OIL PRESSURE GAUGE
Zone Normal Zone
This gauge indicates hydraulic oil pressure in the brake and
steering system. The brake/steering gauge has two red zones, low
at 0-12411kPa (0-1800psi) and high 22407-34475kPa
(3250-5000psi). During normal operation, the gauge should
register between the two red zones. 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 consistently, report this
condition to the proper service personnel. If the gauge reads in the
low pressure red zone, immediately move the machine to a safe
parking area and stop the machine. Move the transmission shift
selector to “NEUTRAL”, apply the parking brake and shut down
ELI14875 the machine. Report the condition to the proper service personnel.
WARNING!
Do not operate the machine with low brake/steering pressure.
INSTRUMENT PANEL 17
5. BRAKE TEMPERATURE GAUGE

Normal Red
Operation Zone
This gauge indicates the oil temperature of the wet disc brake
cooling system. During normal operation, this gauge should
register below the red zone. If the gauge reads in the red zone,
immediately apply the service brakes to reduce machine speed,
proceed to a safe parking area, stop the machine, select
“NEUTRAL” and apply the parking brake. Accelerate the engine
until the gauge registers below the red zone, then select a lower
gear to prevent overheating. Consistent operation in the red zone
when the machine is being operated in the proper range should be
reported to the proper service personnel.
EL14876
Normal Red
Operation Zone
6. ENGINE COOLANT TEMPERATURE GAUGE
This gauge indicates the temperature of the engine coolant. During
normal engine operation this gauge should register below the red
zone. If the temperature keeps increasing on Q-engines, the
engine will decelerate. Immediately move the machine to a safe
parking area, stop the machine move the shift selector to
“NEUTRAL” and apply the parking brake. Do not shut down the
engine. If the engine is stopped abruptly before it is cooled
down,engine life may be shortened. Continue to run the engine at
approximately 1500 - 1700 RPM until the gauge returns to the
normal operating range. If engine coolant temperature continues to
ELI14881
increase, shut down the engine and report the condition to the
proper service personnel to prevent engine damage.
Normal Red
Operation Zone
7. TRANSMISSION (CONVERTER)
TEMPERATURE GAUGE
This gauge indicates the converter oil temperature. It should never
register in the red zone. If the gauge reads in the red zone, move the
machine to a safe parking area, stop the machine, select
“NEUTRAL” and apply the parking brake. Remain in “NEUTRAL”
until the gauge reading returns to the normal operating range. Use a
lower gear range to prevent overheating. Consistent overheating
when the machine is being operated in the proper gear range
indicates transmission difficulties that must be corrected
immediately.
EL14882
18 INSTRUMENT PANEL
8 9 10
ELI19670
8. SPEEDOMETER
This instrument indicates the machine’s speed in miles per hour
and kilometers per hour. The range is 0-80 km\h and 0-50 mph.
EL14877
9. TACHOMETER
This instrument indicates the number of revolutions per minute of
the engine crankshaft(RPM). The range is 0-3000 RPM.
EL14878
INSTRUMENT PANEL 19
10A RED 10B RED 10C RED

Engine Oil Central Warning Transmission Oil
Pressure Light Light Pressure Light
10D RED 10E RED 10F RED 10G RED 10H YELLOW
Engine Brake Parking Steering Transmission
Coolant Oil Brake LIght Oil Oil
Temperature Pressure Pressure Temperature
Light Light LIght Light
10I YELLOW 10J RED 10K GREEN 10L RED 10M YELLOW
Engine Engine Turn/Hazard Steering and Brake
Service Shutdown Indicator Hydraulic OIl Temperature
Light Light Light Temperature LIght
Light
10N RED 10O RED 10P BLUE 10Q YELLOW 10R YELLOW
Alternator Engine High Beam Filter Light Transmission
LIght Coolant Indicator Malfunction
Level LIght Light Light
10. WARNING LIGHT DISPLAY
All warning lights are controlled by the Contronic computer with the
exception of the engine shutdown (10I), turn/hazard (10K), high
beams (10P), and transmission malfunction (10R).
A description of each warning lamp follows on the next seven

pages.
20 INSTRUMENT PANEL
10A 10B 10C
10D
10E
10A. ENGINE OIL PRESSURE LIGHT
This red light illuminates if the engine oil pressure is low with the
engine running.
Move the machine to a safe parking area, stop the machine, move
the shift controller lever to “NEUTRAL” and apply the parking
brake. Shut down the engine immediately and report the
EL14883 condition to the proper service personnel.
Note: Included in the central warning system and the

audible alarm.
10B. CENTRAL WARNING LIGHT

Functions with the engine running:
This red light flashes if any of the following major faults occur:
• Low engine oil pressure
• High engine coolant temperature
• Low brake pressure
• Parking brake malfunction
• Low steering pressure
EL14884 • High transmission temperature
• High steering temperature
• High brake temperature
• Low engine coolant level
• Engine overspeed
• Body up and in 1st gear
INSTRUMENT PANEL 21
10C. TRANSMISSION OIL PRESSURE LIGHT
This red light illuminates if the pressure in the transmission

becomes too low. Move the machine to a safe parking area, stop
the machine, and select “NEUTRAL”. Apply the parking brake and
shut down the machine. Report the condition to the proper service
EL14885 personnel.
10D. ENGINE COOLANT TEMPERATURE LIGHT
This red light illuminates to inform the operator of an overheating

condition of the engine coolant. If the temperature keeps
increasing, the central warning light will illuminate and the audible
alarm will sound. Immediately move the machine to a safe
stopping area, stop the machine, select “NEUTRAL” and apply the
parking brake. Do not shutdown the engine. If the engine is
EL14886 stopped abruptly before it is cooled down, engine life may be
shortened. Continue to run the engine at approximately 1500-1700
RPM until the central warning light and engine coolant temperature
light are no longer illuminated, and the audible alarm deactivates. If
the condition persists, shut down the engine and report the
condition to the proper service personnel to prevent engine
damage.

audible alarm.
10E. BRAKE OIL PRESSURE LIGHT
This red light illuminates if the brake supply pressure from the
steering system is too low. Immediately move the the machine to a
safe stopping area, stop the machine, select “NEUTRAL”, apply
the parking brake, and shut down the engine. Report the condition
to the proper service personnel. During start-up, the alarm will
EL14887 sound until proper operating pressure is attained.

audible alarm.
WARNING!
22 INSTRUMENT PANEL
10H
10F 10G
10I
10J
10F. PARKING BRAKE LIGHT
This red light illuminates solid when the parking brake is applied.
The red light will flash in conjunction with the Central
Warning Light and Audible Alarm, indicating that there is a park
brake malfunction or the conditions are not correct to apply the park
brakes. Forward and reverse machine movement will be inhibited
EL14888 when the parking brake is applied.
If a gear is selected after the parking brake is applied, the machine

will stay in neutral, the light will flash, and the parking brake will
remain applied.
INSTRUMENT PANEL 23
10G. STEERING OIL PRESSURE LIGHT
This red light illuminates if the steering oil pressure is low.

Immediately move the machine to a safe stopping area, stop the
machine, select “NEUTRAL”, apply the parking brake and shut
down the machine. Report the condition to the proper service
personnel. During start-up, the alarm will sound until proper
operating pressure is attained.
EL14889
audible alarm.
Note: The machine must not be operated until the control

light is no longer illuminated.
WARNING!
10H. TRANSMISSION (CONVERTER)

OIL TEMPERATURE LIGHT
This yellow light illuminates to inform the operator of an overheating

condition in the transmission. When illuminated, the operator
should use a lower gear range to prevent further overheating. If the
temperature keeps increasing, the central warning light will also
illuminate and the audible alarm will sound. Immediately move the
machine to a safe parking area, stop the machine, select
EL14890 “NEUTRAL” and apply the parking brake. Remain in “NEUTRAL”
until the yellow light and central warning light are no longer
illuminated and the audible alarm deactivates. If the condition
persists, shut down the machine and report the condition to the
proper service personnel.

audible alarm.
10I. ENGINE SERVICE LIGHT

When this yellow light illuminates, it Indicates a malfunction in the
engine and should be reported to service personnel as soon as
possible.
EL15622
10J. ENGINE SHUTDOWN LIGHT

When this red light illuminates, it indicates a malfunction in the
engine, stop the machine then, “SHUT THE MACHINE DOWN
IMMEDIATELY” and report the problem to service personnel.
EL15622
24 INSTRUMENT PANEL
10M
10K
10L
10N
10O
10K. TURN/HAZARD INDICATOR LIGHT

This light flashes green when the direction indicator control is
EL14893
moved for turning left or right and during actuation of the hazard
lights.
10L. STEERING AND HYDRAULIC OIL

TEMPERATURE LIGHT
This red warning light illuminates if the temperature in the hydraulic

or steering system is too high. Immediately move the machine to a
safe stopping area, stop the machine, select “NEUTRAL”, apply
the parking brake and shut the down machine. Report the condition
to the proper service personnel. The Contronic display will tell the
operator which tank is at high temperature.
EL14894 Note: Included in the central warning system and the

audible alarm.
INSTRUMENT PANEL 25
10M. BRAKE TEMPERATURE LIGHT
This yellow light illuminates to inform the operator of an overheating

condition in the rear wet disc brake cooling system. When
illuminated, reduce machine speed by preselecting a lower gear
until the light goes out. If the temperature continues to increase, the
EL14895 central warning light will illuminate and the audible alarm will sound.
Immediately apply the service brakes to reduce machine speed,
proceed to a safe parking area, stop the machine, select
“NEUTRAL” and apply the parking brake. Accelerate the engine
until the yellow light and the central warning light are no longer
illuminated, and the audible alarm deactivates. If the condition
persists, shut down the machine and report it to the proper service
personnel.

audible alarm.
Note: See “Range Preselection” in OPERATING

INSTRUCTIONS.
10N. ALTERNATOR LIGHT
This red light illuminates when the engine is running and indicates a
problem with the battery charging system. Do not continue
operating, machine should be serviced immediately. Report the
condition to the proper service personnel.
EL14896
Note: This light will illuminate if the key is “ON” and the
engine is not running. It indicates low charge voltage
since the alternator is not producing voltage.
10O. ENGINE COOLANT LEVEL LIGHT
This red light illuminates if the coolant level falls below the
acceptable level. Immediately move the machine to a safe
stopping area, stop the machine, select “NEUTRAL”, apply the
parking brake and shut down the machine. Report the condition to
the proper service personnel.
EL14897
audible alarm.
26 INSTRUMENT PANEL
10R
10P
10Q
10P. HIGH BEAM INDICATOR LIGHT
This blue control light is on when the high beams are selected.
Refer to Turn Signal/High Beam Lever in OPERATOR
CONTROLS.
EL14898 This machine is equipped with four High Intensity Discharge

(H.I.D.) headlights.
In the high beam “OFF” position, the two lower (H.I.D.) headlights
are on.
In the high beam “ON” position, all four (H.I.D.) headlights are on.
10Q. FILTER LIGHT
This yellow light illuminates when either the air cleaner, steering,
hydraulic, or transmission filters need service. The Contronic
EL15623 Display Unit will indicate which filter needs to be serviced. See
Alarm Messages under the Contronic Display Unit.
10R. TRANSMISSION MALFUNCTION LIGHT
This yellow light illuminates to indicate a problem with the

transmission. It will display “ERROR” codes for the Allison
Transmission Commercial Electronic Control System.
Immediately move the machine to a safe parking area, stop the
machine, select ”NEUTRAL”, apply the parking brake and shut
EL14892 down the machine. Report the condition to the proper service
service personnel to prevent damage to the transmission.
See Automatic Shifting in OPERATING INSTRUCTIONS.

INSTRUMENT PANEL 27
11
ELI18488E
11. CONTRONIC DISPLAY UNIT

11C 11A The Contronic Display Unit is connected to the electronic control
unit or ECU. The information about the monitored functions is
displayed on the screen in the form of words and numerical values.
When starting, the initial display, illustrated at the left, is displayed
-- EUCLID HITACHI --
-- CONTRONIC -- for four seconds after which the previously selected function group
Rigid Hauler HD will be displayed.
31/86/8
General
ELI19731 • The top line on the screen shows the name of the selected
11D 11B function and any Alarm Messages.
See page 32 for a list of Alarm Messages.
• Five different languages can be selected:
English, Swedish, German, French and Spanish.
(Japanese language is available on a separate software
version.)
• Two different sets of units can be selected
(°C, km/h , km, bar, M-ton) or (° F, mph, mile, psi, S-ton)
• Electronic engines: If data link is lost “--” will be displayed
in all engine data fields.
• CECI transmission: If data link is lost “--” will be displayed
for lever and gear in all transmission data fields.
• A message will be displayed in the first line to indicate the
data link error.
11A. SELECTING FUNCTION GROUP

Allows the operator to select main function displays as follows:
Display Screen 1 Hauler General Information.
ELI19731A Display Screen 2 Operator Information.
Display Screen 3 Engine Information.
Display Screen 4 Electrical Information.
Display Screen 5 Transmission Information.
Display Screen 6 Brake Information.
Display Screen 7 Steering Information.
Display Screen 9 Strut Information.
28 INSTRUMENT PANEL
11C 11A
-- EUCLID HITACHI --
-- CONTRONIC --
Rigid Hauler HD
31/86/8
11D 11B ELI19731
11B. SELECTING SUB MENU WITHIN SAME

FUNCTION GROUP
Allows the operator to select additional sub menus under each

main function group as listed in #11A.
ELI19731B
11C. CHANGES INFORMATION
Allows the operator to change information on various screens.

Examples: On screen 1.2 this key scrolls through different
ELI19731C
languages, on screen 2.2 this key resets all values, on screen 2.3
this key must be pressed to clear messages.
11D. CHANGES INFORMATION
# Allows the operator to change additional information. Example: On

screen 1.2 this key selects units of measure (Kilometers, mph, psi,
ELI19731D
bar, ° C, ° F ).
DISPLAY SCREEN 1.1
Display screen (1.1) is the title screen that is displayed when the
-- EUCLID HITACHI -- Hauler is started.
-- CONTRONIC --
Rigid Hauler LD The Hauler model and tire size/differential/planetary can be
xx/yy/z selected by turning a micro-switch on the side of the computer.
xx Tire size (width in inches)
EL14862 yy Differential (last two digits of ratio)
z Planetary (first digit of ratio)
DISPLAY SCREEN 1.2
Display screen (1.2) allows the operator to select from several

------ SET UP ------ languages and units of measure. To scroll through the different
English *
Units # languages the operator simply presses the “ * ” key. Languages
F mph mile psi s-ton currently available are English, Swedish, German, French, and
Spanish. Japanese language is available on a separate software
EL14864 version. The user selects units of measure by pressing the “ # ” key.
The choices are (C, km/h, bar, m-ton) or (F, mph, mile, psi, s-ton).
INSTRUMENT PANEL 29
DISPLAY SCREEN 1.3
Machine Hours & Total Vehicle Distance

-- MACHINE HOURS --- Maximum hours are 59999. Vehicle distance is shown in miles or
Hours 00001
Miles 000001 kilometers (”Miles” or “Km”). Maximum miles are 999999. Hours
and miles can be reset in the “Service Display Screen”, 1.3S.
EL14865
DISPLAY SCREEN 1.4

---- DATE TIME -----
01-02-15 16:45
Time & Date
#Setting *Alt.1 Can be displayed in six formats. Press the “ * ” Alternate (Alt) key to
alternate between the six formats which are as follows:
EL15657
ALT Date Format Time Format Example Example

February 15, 2001
X=1 yy-mm-dd 24 hour 01-02-15 16:45
X=2 yy-mm-dd AM/PM 01-02-15 2:45 P
X=3 mm-dd-yy 24 hour 02-15-01 16:45
X=4 mm-dd-yy AM/PM 02-15-01 2:45 P
X=5 dd-mm-yy 24 hour 15-02-01 16:45
X=6 dd-mm-yy AM/PM 15-02-01 2:45 P
---- DATE TIME ----- To set the time and date, press the “ # ” key and move the ^ under
01-02-15 16:45 *
^ # the number to change and press the “ * ” key until the correct
number is displayed. After selection, move to another screen and
the format will be saved.
EL15657
DISPLAY SCREEN 2.1
Driving Information
-- INFORMATION 1 --- Engine xxxx Engine speed.
Engine xxxx rpm Speed yy Ground speed.
Speed yy mph
x-ton ↑ Gear zz Gear zz Allison transmission attained gear (1L,1C, 2L, 2C....)
“L”= Lockup, ”C” = Converter.
x-ton uuu s-ton or m-ton weight in short or metric ton,
EL14866 if not calibrated “CAL” , or “ER”
If optional Haultronic II is not installed
NA “Not Applicable” will appear.
↑ OR ↓ Indicates Body position, UP or Down.
Pressing the “ # ” button will display the Time and Date in the
last row.
30 INSTRUMENT PANEL
DISPLAY SCREEN 2.2
Driving Information (additional)

- INFORMATION 2 CL=* With this display active, the operator can monitor fuel level as well
Time xx,xx,xx
Distance yy. y yy
as time, distance and loads during a given period. The “ * “ key
Loads zzz Fuel www % resets Time, Distance, and Loads values.
Time xx,xx,xx Elapsed time since last reset
Distance yy.y Total distance traveled since last reset.
EL14867
Loads zzz Number of loads counted since last reset.
Fuel ww Fuel level as a percent of total or “ER”.
DISPLAY SCREEN 2.3
Service Intervals
--- NEXT SERVICE ---
Residual time xxx h Residual Time xxx Time remaining until next service.
Interval yyyy h Interval yyyy Service interval
Acknowledge *
(250,1000,1250,2000, 2500 hours )
Acknowledge * The “*“ key must be pressed
EL14868 to clear message.
The message appears in the first line. The operator must be in this
screen to clear the message or Service Display Screen 2.3S
DISPLAY SCREEN 3.1
Engine Information
----- ENGINE ------- Temp xxx Engine coolant temperature displayed in
Temp 150 F
Revolution 754 rpm (°F or °C) or “ER”.
Pressure 42 psi Revolution yyyy Engine speed in revolutions per minute.
Pressure zzzz For an electronic engine, oil pressure is displayed
in “ psi” or ”bar”.
EL14869
DISPLAY SCREEN 4.1
Electrical Information
- ELECTRICAL SYSTEM Voltage xx.x System voltage.
Voltage 27.8 V
EL15053
INSTRUMENT PANEL 31
DISPLAY SCREEN 5.1
Transmission Information
--- TRANSMISSION --- Lever xx Selector lever position (1,2,3,4,5,D,N,R1,R2)
Lever D Gear 1L
Temp 200 F Gear yy Active gear (1C,1L,2C,2L,....etc.)
Pressure normal
”L” = Lockup “C” = Converter.
Temp zz Converter temperature. “0°C (<32°F)”or ”ER”.
EL14871 Pressure vv Transmission oil pressure ”normal”,”low” or ”ER”.
DISPLAY SCREEN 6.1
Brake Information
------ BRAKES ------
Pressure normal Pressure xx normal. low or ER.
Temp Rear 185 F Temp Rear yy Brake temperature 0°C (<32°F) or ER.
EL14872
DISPLAY SCREEN 7.1
Steer Information
------ STEER ------ Pressure xx Steer pressure “normal”, “low”, or “ER”
Pressure normal
Temp 130 F Temp yy Steer temperature. “0°C (<32°F)” or “ER”
Filter normal Filter zz Steer filter condition “normal”, “dirty” or “ER”
EL14873
DISPLAY SCREEN 9.1
Strut Information
------ STRUTS ------
N/A
N/A, “Not Applicable” will appear in the screen unless the optional
Haultronic II, Load Weighing System is installed.
EL14871
32 INSTRUMENT PANEL
DISPLAY SCREEN 9.1 (continued)

Haultronic IIE (Option) Load Weighing System
Strut Information
------ STRUTS ------
LF pppp RF pppp zzz If Haultronic II (Option), Load Weighing System, is installed.
LR pppp RR pppp zzz LF pppp Left Front strut pressure (bar or psi)
Grade →xx.x ↓yy.y %
RF pppp Right Front strut pressure (bar or psi)
LR pppp Left Rear strut pressure (bar or psi)
EL14871 RR pppp Right Rear strut pressure (bar or psi)
Grade xx.x Incline in ← (left) or → (right) direction
measured in %
yy.y Incline in ↑ (up) or ↓ (down) direction
measured in %
The central Electronic Control Unit (ECU) determines payload
every cycle using input from four pressure transducers located in
each of the four ride struts. Payload weight in short or metric ton is
displayed on screen 2.1.
Refer also to Haultronic IIE in the OPERATORS CONTROLS

section of this manual and under “Loading” in the OPERATING
INSTRUCTIONS section.
ALARM MESSAGES
Alarm and Error messages flash on the first display line no matter
which screen is being viewed on the Contronic Display Unit. Some
messages will continue to flash on the display even after the error
condition is no longer present. These messages will be erased
when the master key switch is turned OFF.
E Allison link ER E Fuel level ER

E Engine link ER E Brake pressure low
E Voltage high E Brake pressure ER
E Voltage low E Brake temp high
C Voltage high E Brake temp ER
C Voltage low E Park brake on
E Speed restriction E Park brake ER
E Engine link ER E Reverse inhibit E Steer pres low
Lever D Gear 1L
Temp 200 F E Time for service E Steer pres high
Pressure normal E Transm pres low E Steer pres ER
E Transm pres ER E Steer temp high
E Transm temp high E Steer temp ER
EL14871
E Transm temp ER E Clean airfilter 1
C Eng cool level low E Airfilter 1 ER
C Eng cool level ER E Clean hyd filter 1
C Engine temp high E Hyd filter 1 ER
C Engine temp ER E Clean steer filter
C Engine pres low E Steer filter ER
C Engine pressure ER E Cl transm filter
E Fuel level low E Transm filter ER
E LwPressure XX ER where XX=RR,LR,RF, or LF.
E LwIncline X ER where X=X or Y.
INSTRUMENT PANEL 33
12 13 14
ELI18488F
12. PARKING BRAKE SWITCH
This switch activates the parking brakes which are mounted on the
differential input shaft. This is a two position switch “ON” and
“OFF”. Push the switch to the “OFF” position before operating the
machine in range. Machine movement is inhibited with the park
brake applied.
EL15049
13. WINDSHIELD WIPER SWITCH
This switch activates the windshield wiper. This is a three position

switch.
• OFF
• LOW SPEED
• HIGH SPEED
Off Low High

Speed Speed
EL14901
14. INTERMITTENT WIPER/WASHER SWITCH

This switch activates intermittent wiper and the windshield washer
pump. This is a three position switch.
• OFF
• ON to activate, intermittently, the windshield wiper.
• HOLD to activate the windshield washer pump.
Off On Hold Release the switch and it will return to the ON position.
Intermittent ELI19674
Wiper
34 INSTRUMENT PANEL
16
15
18
17
19
ELI18488G
15. BODY UP LIGHT

This yellow light illuminates to indicate that the body is in the “UP”
position.
If the Body is Up:

• Transmission is limited to 1st gear forward
• With the transmission in any forward gear, an “E Speed re-
ELI15526B striction” message will appear on the contronic display
screen.
• If the transmission is in 2nd - 6th forward an audible alarm
will sound.
• If R1 (Reverse 1) or R2 (Reverse 2) is selected the
transmission will shift into (or remain in) neutral. Also,
audible alarm will sound and an “E Reverse inhibit”
message will appear on the contronic display screen.
16. TRACTION BOOST INDICATOR LIGHT (Option)

This blue light illuminates for 15 seconds after the traction boost
switch is depressed.
16
17. ACTIVE TRACTION CONTROL (ATC)
INDICATOR LIGHT (Option)
When the active traction control/traction boost switch is in the ON
17
position, and the ATC system is applying the retarder, this green
light will illuminate. See the Operating Instructions sections of this
ELI19911
manual for details on this system.
INSTRUMENT PANEL 35
Note: The indicator light and the switch illustrated on

this page is used for two optional systems;
ELECTRONIC TRANSMISSION RETARDER
ELECTRONIC DOWNHILL SPEED CONTROL
Refer to original machine order to identify
system on your unit.
18. ELECTRONIC TRANSMISSION RETARDER

LIGHT (Option)
This green light illuminates to indicate that the Electronic

Transmission Retarder system is actively applying the retarder.
See Electronic Transmission Retarder in the OPERATING
INSTRUCTIONS section of this manual for details on this system.
Note: Used also for:

ELI19911
(EDSC) LIGHT (Option)
This green light illuminates to indicate that the Electronic Downhill

Speed Control (EDSC) system is actively applying the retarder.
See the OPERATING INSTRUCTIONS section of this manual for
details on this system.
19. ELECTRONIC TRANSMISSION RETARDER

SWITCH (Option)
Enables the Electronic Transmission Retarder system which

provides automatic retarding. The retarder will be activated by the
ECU when the operator depresses the retarder pedal. Refer to
Retarder Pedal in the OPERATORS CONTROLS section of this
manual. See Electronic Transmission Retarder in the
OPERATING INSTRUCTIONS section of this manual for details on
this system.
ELI19732 Note: Used also for:

(EDSC) SWITCH (Option)
Enables the Electronic Downhill Speed Control (EDSC) system
which provides automatic retarding when the machine is running
down a grade See Electronic Downhill Speed Control (EDSC) in
the OPERATING INSTRUCTIONS section of this manual for
details on this system.
36 INSTRUMENT PANEL
23
20 21 22 24
ELI18488G
20. ACTIVE TRACTION CONTROL/BOOST

SWITCH (Option)
When in the ”ON” position, this switch activates the traction
system to automatically improve traction in slippery ground
conditions. The traction system is active up to a speed of 24 km/h
Off ATC Traction (15 mph). To deactivate the system, move the switch to the ”OFF”
On Boost position.
ELI15336
Depress &
Release
When maximum traction is required, depress and release the
switch to activate the ”Traction Boost”.The traction system will
return to the standard operating range in approximately 15
seconds. When released, the switch will return to the “ON”
position.
21. FRONT BRAKE CUT-OFF SWITCH

This switch is used to change the brake proportioning between the
front and rear brakes. With the switch in the ”OFF” position, the
front and rear brakes apply simultaneously as the service brake
pedal is depressed. With the switch in the ”ON” position and the
service brake pedal is partially depressed, only the rear brakes will
be applied. However, if the brake pedal is fully depressed, the front
EL15103
brakes will also apply. See also Front Brake Cut-Off Switch in the
OPERATING INSTRUCTIONS section of this manual.
INSTRUMENT PANEL 37
22. COLD START FLUID INJECTOR SWITCH

(Option)
This switch activates the cold start fluid injector. To activate the cold
start fluid injector hold the switch for two seconds, then release it.
Turn the key to the start position and crank the engine.
Off Hold
On ELI18486
23. FUEL PRE-HEATER SWITCH (Option)
The fuel pre-heater should be switched on five to ten minutes

before a cold start is attempted. In extreme ambient temperatures,
the pre-heater should be left on for at least 10 minutes. The
pre-heater is self-regulating so it can be left in the “ON” position.
The switch should be returned to the “OFF” position when the
engine reaches normal, operating temperature.
The fuel pre-heaters are installed at the remote mounted fuel

ELI19880 filters.
24. MASTER KEY SWITCH

The purpose of this switch is to control power to the electrical
system. To start the machine, place the center console control lever
in the “NEUTRAL” position. A pre-lubrication system is installed
on the engine. Prior to engine cranking, the system automatically
fills filters and lubricates the crankshaft, camshaft, turbocharger
EL15726 and rockers. Turn the key to “START”. The engine will
pre-lubricate first. When oil pressure is sufficient, there will be a
slight delay, the engine will start to crank. 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
“ACCESSORY” position, which is not used.
Master Cab Fuel In addition to the master key, one other set of keys are supplied with
Switch Key Door Filler Cap the machine:
Key Key A set for the cab door.
(Option) A set for the fuel filler cap will be supplied with the optional locking
ELI19727
fuel cap.
38 INSTRUMENT PANEL
26 26
25
25A 25D 25C 25E 25B
ELI18488I
25. HEATER CONTROL ASSEMBLY
25A. FAN CONTROL

Controls the amount of air forced through the cab. Allows the
operator to regulate the speed of the blower fan with four fan speed
EL19720
positions. Can be used in any mode selected.
25B. MODE KNOB

Selects the direction of air flow. Variable control, air flow direction
blends with the knob between modes.
EL19723
Panel - Air comes through the panel outlets (27).
Bi-Level - Air comes through the panel (27) and floor outlets.
Floor - Air comes through the floor outlets.
Defrost/Floor - Air comes through the defrost or louvers (26)

and floor outlets.
Defrost - Air comes through the defroster or louver (26) outlets.

INSTRUMENT PANEL 39
25C. TEMPERATURE CONTROL KNOB

Controls the temperature of the air delivered to the cab in any mode
selected.
EL19721
25D. AIR CONDITIONING BUTTON
EL19719
Depressing the “A/C” air conditioning button turns on the air
conditioning compressor. The blue button will illuminate to show
that the compressor is ON.
Conditioned air enters the cab via the outlet selected by the mode
knob. Depressing the A/C button a second time turns the
compressor off.
Note: For maximum air conditioning the recirculating

button should be in the ON position.
25E.RECIRCULATING BUTTON
Depressing the “RECR” recirculating button, recirculates the air
EL19722
inside the cab. The green button will illuminate to show that the
recirculating button is ON.
With the recirculating button in the ON position, outside air will be

prevented from entering the cab.
Note: The recirculating button should be in the OFF

position when Mode Knob is in a Defrost position.
26. LOUVER
When the mode knob is placed in a defrost mode, air is directed to
the ducts at the top of the instrument panel toward the windshield
and to two louvers. A louver is located at each side of the instrument
panel. Each louver can be manually turned 360° to direct the air to
the side windows of the cab.
ELI19740
40 INSTRUMENT PANEL
27 27
32 28 29 30 31
ELI18488G
27. PANEL OUTLET

Air directed to the panel is delivered through two outlets. Each
outlet can be manually controlled to direct the air entering the cab.
ELI19733
28. CONTRONIC E.C.U. PROGRAMMING PORT

Plug in for the lap top computer, used for the E.C.U. setup and
troubleshooting.
Note: For service personnel only.
29. AUDIBLE ALARM

Warns the operator of an existing serious condition pertaining to the
operation of the machine. Refer also to CENTRAL WARNING
LIGHT.
INSTRUMENT PANEL 41
30. CONTRONIC DISPLAY SERVICE TOOL

CONNECTOR
Works in conjunction with the Contronic display.
31. ENGINE DIAGNOSTIC CONNECTOR

This is the plug in for the Diesel Engine Electronic System.
32. Radio (Option)

42 INSTRUMENT PANEL
NOTES
OPERATORS CONTROLS 43
EL20032
OPERATORS CONTROLS
1. Hazard Warning CAB SERVICE ACCESS PANELS/PLATES

2. Tilt/Telescope Steering Wheel Adjustment 21. Cab Interior Panel Assembly
3. Turn Signal/High Beam Lever 22. Cab Exterior Panel Assembly
4. Steering Wheel 23. Access Plates, Rear Cab Mounts
5. Horn 24. Access Plate,
6. Sun Visor Rollover Protective Structure Pin
7. Dome Light OPERATORS CONTROLS NOT IN CAB
8. Transmission Shift Selector (Not Appearing in Above Illustration)
9. Load/Dump Brake Switch 25. Manual Release Valve
10. Cigar Lighter
26. Battery Disconnect Switch
11. Ash Tray
27. Body Down Indicator
12. 12 Volt Power Port
28. Mirrors
13. Trainer Seat
(A coat hook is located behind the 29. Fire Suppression System (Option)
trainer’s seat.) 30. Fuel Shut Down (Option)
14. Power Hook-up (12 Volt) 31. Haultonics II
15. Operator Seat Load Weighing System (Option)
16. Hoist Control Lever 32. Centralized Service Panel (Option)
17. Accelerator Pedal 33. Automatic Centralized Lubrication System
18. Brake Pedal (Option)
19. Retarder Pedal
20. Fire Suppression System (Option)
44 OPERATORS CONTROLS
EL20033
1. HAZARD WARNING
This switch activates the Hazard Warning Lights. Pull the switch out
to activate the lights, push in to de-activate. The front and rear turn
signals will flash at the same time.
EL14854
2. TILT/TELESCOPE STEERING WHEEL

ADJUSTMENT
This control lever allows the steering wheel to be adjusted for
operator comfort. Push the lever for the telescope adjustment and
pull the lever for tilt adjustment.
EL14852
3. TURN SIGNAL / HIGH-BEAM LEVER
This combined lever activates:
• Left and Right Turn Signals

• High Beam Headlights
EL14853
4. STEERING WHEEL
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 turning. 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.
EL14922
5. HORN
The horn is located in the center of the steering wheel. The operator
should sound the horn before starting the engine and when putting
the transmission shift selector into gear after the machine has been
stopped for a period of time.
EL14986
EL20034
6. SUN VISOR
Incorporated in the headliner for the operator’s convenience.
Rotate the sun visor down to cut down on sun glare entering the
front windshield. The sun visor can pivot toward the cab door to cut
down on sun glare entering the operator’s side window.
EL16895
7. DOME LIGHT
Located inside and in the top of the cab, the dome light illuminates
the driver’s compartment when required.
See Dome Light Switch in the INSTRUMENT PANEL section of

this manual.
EL16895
8. TRANSMISSION SHIFT SELECTOR

The selector is used to shift the transmission into the desired
forward or reverse gear ranges.
See Automatic Shifting in OPERATING INSTRUCTIONS for

more information on the operation of the transmission shift selector.
ELI
9. LOAD/DUMP BRAKE SWITCH

This switch is used to actuate the rear brakes and should be used
while the machine is being loaded or dumping to prevent machine
movement. It is also used as a secondary brake system application
method in case of a service brake malfunction. The switch is
located on the top right side of the center control console.
Release The switch is locked in the OFF position to prevent accidental

Button application. Slide the release button to the right, and while holding it
depress the switch to the ON position. The switch is NOT locked in
the OFF position. To release the brakes depress the switch to the
OFF position. Propel is inhibited when the Load/Dump Brake is
applied.
OFF
DEPRESS
SLIDE
ON
ELI
10. CIGAR LIGHTER (12 VOLT)

Incorporated for the operator’s convenience. Located on the back
of the shift tower.
ELI
EL20035
11. ASH TRAY

Incorporated for the operator’s convenience. Located on the back
of the shift tower.
ELI
12. 12 VOLT POWER PORT

The accessory plug is located on the back of the Control Console. It
provides a power source for a computer with a 12 volt power supply
adapter.
ELI
13. TRAINER SEAT

A trainer seat with seat belt is incorporated in the cab. The
compartment under the hinged seat can be used for storage. The
backrest of the trainer’s seat hooks to brackets secured to the rear
cover assembly.
EL19871
13A. Trainer Seat, Seat Belt
WARNING!
Anyone riding in the trainer seat must always fasten the seat
belt provided.
Seat Belt Adjustment

• Take hold of the latch plate and pull out the seat belt.
• When the seat is long enough to fit snugly around the hips,
insert the latch plate into the buckle until you hear a “click”.
• To release the seat belt, push the red button marked PRESS on
the buckle.
Latch • Hold the latch plate as the seat belt automatically retracts.
Plate Buckle
EL19912
14. POWER HOOK-UP (12 Volt)

This terminal, on the battery equalizer, can be used to hook-up
accessories that require 12 volts. This would include a C.B. radio.
Located behind the left hand cover assembly, behind the operators
seat. See CAB INTERIOR PANEL ASSEMBLY, later in this
section.
EL19930
15A
See Page
51 15C
See Page
55
AVAILABLE AVAILABLE
MECHANICAL SEATS AIR RIDE SEATS
15D
15B See Page
See Page 57
53
ELI20036
15. OPERATORS SEAT
WARNING!
Do not attempt to adjust seat while the machine is in motion.
The operator’s seat is a fully adjustable. Adjust the seat to a

comfortable position prior to moving the machine.
15A. Mechanical Seat

Head Rest Adjustment
Pull up or push down for vertical adjustment. Pivot forward or
backward for horizontal adjustment.
EL14696A

Arm Rest Angle Adjustment
Rotate control knob located under arm rest to select desired angle.
Pivot up and parallel with backrest when not in use.
EL14696B

Back Rest Adjustment
The back rest is controlled by a rotating handle. Move it upward and
hold to select the backrest angle that feels comfortable.
EL14696D

Seat Base Height and Tilt Adjustment
Front and rear seat height adjustments can be made by lifting the
front or rear handle up and holding it to release the lock spring
loaded seat. Adjust the seat to desired position by adding or
removing body weight to front or rear of the seat cushion. Release
the handle to lock the seat in position.
EL14696E

Seat Base Slide Adjustment
To slide the seat forward or backwards, lift the lever up and hold,
slide seat to desired position, then release lever to lock in place.
EL14696F

Seat Weight Control Knob Adjustment
For suspension adjustment rotate the hand wheel until operator
body weight is selected on the indicator for maximum suspension
performance.
EL14696G
15B. Mechanical Seat

Rotate the control knob to select desired angle. Pivot up and paral-
lel with backrest when not in use.
EL19775

Seat Back Rest Tilt Adjustment
The tilt control allows the operator to adjust the back rest by lifting
the lever up, manually adjusting the back rest and releasing the
lever.
EL19776

Seat Base Height Adjustment
The base height control allows the operator to adjust the seat up or
down to suit his comfort. Lifting the lever to the up or down position,
regulates the air compressor located under the seat.
EL19777

The horizontal seat control allows the operator to manually move
the seat forward or rearward to suit his needs and comfort. Lift the
lever up to adjust. Push down to lock.
EL19778

Seat Base Weight Adjustment
For suspension adjustment rotate the hand wheel until operator
body weight is selected on the indicator for maximum suspension
performance.
EL19779

Lumbar Support Adjustment
For adjustment, rotate the knob until the ideal position is selected.
EL19781
15C. Air Ride Seat

Rotate the control knob to select desired angle. Pivot up and
parallel with backrest when not in use.
EL14819
15C. Air Ride Seat

Seat Back Rest Tilt Adjustment
The tilt control allows the operator to adjust the back rest by lifting
the lever up, manually adjusting the back rest and releasing the
lever.
EL14916
15C. Air Ride Seat

Seat Base Height Adjustment
The base height control allows the operator to adjust the seat up or
down to suit his comfort by pushing the button to either the +or -
position which regulates the air compressor located under the seat.
EL14918
15C. Air Ride Seat

The horizontal seat control allows the operator to manually move
the seat forward or rearward to suit his needs and comfort. Lift the
lever up to adjust. Push down to lock.
EL14915
15C. Air Ride Seat

Seat Base Height Front Tilt Adjustment
This control allows the operator to manually adjust the front of the
seat up or down to suit his comfort. Lift to adjust. Push down to lock.
EL14917
15D. Air Ride Seat

Head Rest Adjustment
Pull up or push down for vertical adjustment. Pivot forward or back-
ward for horizontal adjustment.
EL19774A
15D. Air Ride Seat

Rotate control knob located under arm rest to select desired angle.
Pivot up and parallel with backrest when not in use.
EL19774B
15D. Air Ride Seat

Back Rest Adjustment
The back rest is controlled by a handle on the right hand side of the
driver’s seat. Pull it upward and hold to select the backrest angle
that feels comfortable.
EL19774D
15D. Air Ride Seat

Seat Base Height and Tilt Adjustment
Height adjustments can be made by lifting the handle, on the left-
hand side of the driver’s seat, up and holding it to release the lock
spring loaded seat. Adjust the seat to desired position by adding or
removing body weight to front or rear of the seat cushion. Release
the handle to lock the seat in position.
EL19774E
15D. Air Ride Seat

To slide the seat forward or backwards, lift the lever up and hold,
slide seat to desired position, then release lever to lock in place.
EL19774F
15D. Air Ride Seat

Seat Base Adjustment
For suspension adjustment, pull the knob out which will regulate air
from the air compressor. Pull the knob until the desired comfort
zone for the operator’s body weight is achieved for maximum
suspension performance.
EL19774G
15E. Operator’s, Seat Belt
WARNING!
Always fasten your seat belt when operating the machine.
Seat Belt Adjustment
• Take hold of the latch plate and pull out the seat belt.
• When the seat is long enough to fit snugly around the hips,
insert the latch plate into the buckle until you hear a “click”.
• To release the seat belt, push the red button marked PRESS on
Latch
Buckle Plate the buckle.
EL19912 • Hold the latch plate as the seat belt automatically retracts.
EL20036
16. HOIST CONTROL LEVER
WARNING!
When the body is being raised or lowered, the Load Dump/
Emergency/Rear Brake switch should be activated to prevent
machine movement and the machine should be in
“NEUTRAL”.
This electrical four position hoist control lever is electrically

Raise connected to the hoist controller which in turn is connected to a
solenoid on the circuit board. This provides pilot pressure to actuate
Hold the main hydraulic control valve. When the lever is pushed
Float completely down to the first position,it is in “POWER DOWN”. The
second position is “FLOAT”,the third position is “HOLD”,and the
Power fourth position or pulled completely up, is “RAISE”. The lever is
Down ELI spring centered, leaving the main control valve in “HOLD” or
“FLOAT” based on the previous function.
EL20037
17. 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.
ELI14832C
18. BRAKE PEDAL
The brake pedal is used to slow or to stop the machine. When the
pedal is depressed, hydraulic pressure 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.
ELI14832B
19. RETARDER PEDAL
When the 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 machine on grades. Depress the pedal until sufficient
retarding force is achieved to control the speed of the machine.
See also Using The Retarder in the OPERATING

INSTRUCTIONS section of this manual.
ELI14832A
20. FIRE SUPPRESSION SYSTEM (Option)

Cab Location
The fire suppression system is installed to protect specific hazard
areas on the machine. In case of a fire be prepared to quickly get to
a safe area. If time permits:
• Lower the body to the frame.
• Stop the engine by turning the ignition switch to the “OFF”
position.
• Pull the ring pin on the manual actuator (20) and strike the red,
mushroom, push-button head. Evacuate the cab.
• Start combating the fire with a fire extinguisher and/or call for
help.
(See also FIRE SUPPRESSION SYSTEM Ground Location,
later in this section)
If the decals are no longer readable, new ones should be

EL20026
ordered and installed.
EL20038
CAB SERVICE ACCESS PANELS/PLATES
21. CAB INTERIOR PANEL ASSEMBLY

The interior panel assembly is at the rear of the cab, behind the
operators seat. Removal of this panel assembly gives service
personnel access to most of the electrical systems on the machine.
There are also two side panel covers which attach to brackets on
the sides of the cab. The panel cover on the left side covers the
battery equalizer, the panel on the right side covers harness
assemblies.
EL19897
22. CAB EXTERIOR PANEL ASSEMBLY

The exterior panel assembly is at the front of the cab. Removal of
this panel assembly gives service personnel access to the brake
valve, retarder control valve, and cab heater. A compression latch
on the left side and right side of the panel assembly, secures it to the
cab.
EL19896
23. ACCESS PLATES, REAR CAB MOUNTS

The removal of these two plates at the rear of the cab, offers access
to the two rear cab mounts.
ELI20040
24. ACCESS PLATE

The removal of this plate at the side of the cab, offers access to the
Rollover Protective Structure (R.O.P.S.) Pin.
EL20040
OPERATORS CONTROLS NOT IN CAB
25. MANUAL RELEASE VALVE

The manual release valve allows the operator to safely lower the
dump body when the dump body is raised off the frame rails and the
hoist control valve spool is stuck in the “HOLD” position. The valve
is located on the right-hand side of the service deck, between the
air cleaners. The manual release valve should be checked
periodically. To check it, move the electrical body control lever to the
“RAISE” position shifting the valve electrically to “HOLD”. Step
outside the cab, and pull the manual release valve knob OUT.
EL18528
26. BATTERY DISCONNECT SWITCH

The battery disconnect switch is located on a plate assembly at the
battery box. Turn the battery disconnect switch to the “OFF”
position when the machine is parked for a long period of time or
when transporting or towing the machine.
Note: The battery disconnect switch should be turned and

locked to the “OFF” position when work will be done
on the machine to prevent accidental starting.
EL20015
27. BODY DOWN INDICATOR

Included on the machine is a body down indicator that allows the
operator to determine, at a glance, when the body has been com-
pletely 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.
EL19067
28. MIRRORS
Due to the position of the cab and size of the rigid hauler, an
operator has limited visibility to the rear and to areas close to or near
the machine. Mirrors are installed on the left hand deck, at the cab
door, right hand deck railing, and the left front deck railing. The
mirrors should be kept clean and adjusted for optimum rear
viewing.
EL19964

Ground Location
30. FUEL SHUT DOWN (Option)
If the machine is equipped with the optional Fire Suppression
System and the optional Fuel Shut Down, they will be located in a
box assembly mounted to the left side of the machine.
Note: See detailed description of each below.

ELI20027A

Ground Location
The fire suppression system is installed to protect specific hazard
areas on the machine. In case of a fire be prepared to quickly get to
a safe area. If time permits:
• Stop the engine with the Fuel Shut Down Option.
• Pull the ring pin on the manual actuator and strike the red,
mushroom, push-button head.
• Start combating the fire with a fire extinguisher and/or call for
help.
(See also FIRE SUPPRESSION SYSTEM Cab Location,
previous in this section)

30. FUEL SHUT DOWN (Option)
The fuel shut down should be used when it becomes necessary to

shut the engine down quickly. When the red, handle is pulled, the
fuel supply to the engine is shut-off. The handle is connected to a
fuel shut-off valve mounted to the left side of the machine’s frame in
the engine access area, See next page. The valve can be actuated,
if required, at its mounting location by grasping and pulling up the
attached ring.

EL20027
30. FUEL SHUT DOWN (Option) (continued)
The fuel shut down valve can be actuated, if required while working
in the area, at it’s chassis mounted location by grasping and pulling
up the attached ring.
EL20028
31. HAULTRONIC IIE

LOAD WEIGHING SYSTEM (Option)
An external lamp cluster, mounted on each side of the machine, is

included with the Haultronic II Load Weighing System. It informs
the loader/shovel operator of the amount of material that has been
loaded:
Green light illuminates at 20% of maximum payload
Amber light illuminates at 80% of maximum payload
Red light illuminates at 100% of maximum gross machine weight.
Screen 9.1 will only show a complete display when the optional
Haultronic II Load Weighing System is installed. Refer to
Contronic Display Unit in the INSTRUMENT PANEL section of
this manual. The central Electronic Control Unit (ECU) determines
payload every cycle using input from four pressure transducers
located in each of the four ride struts. Payload weight in short or
EL20023 metric ton is displayed on screen 2.1.
Refer also to Haultronic IIE under Loading in the OPERATING

INSTRUCTIONS section of this manual.
32. CENTRALIZED SERVICE PANEL (Option)

Bolted to and underneath the hydraulic tank. From here and with
the correct connections service personnel can fill vehicle fluid
systems. See Centralized Service Panel in the BASIC
PREVENTIVE MAINTENANCE section of this manual.
33. AUTOMATIC CENTRALIZED LUBRICATION

SYSTEM (Option)
The container assembly and pump assembly for the Automatic
Centralized Lubrication System are located on the right hand
service deck. The container assembly is bolted to the service deck.
A timer for the system is located in the electrical compartment,
behind the operators seat. When the lubrication system times out, it
will initiate a lube cycle. The pump dispenses lubricant through
injectors to the vehicles bearings.
OPERATING INSTRUCTIONS 69
GENERAL OPERATING RULES
The contents of the following pages are intended to be of

assistance when operating the machine. These rules must be
followed to ensure safe operation of the machine. However these
rules do not relieve the operator from taking into account local laws
or National safety regulations. Good judgement and respect for the
safety regulations are factors which makes it possible to avoid the
risk of accidents.
TS41154
OPERATOR’S QUALIFICATIONS:
• Only trained personnel should operate the machine.
• Operator should be of legal machine operating age
according to country (State) regulations and familiar
with the operation and maintenance of the machine.
• Operator must be licensed if required by National
Rules and Regulations.
DUTIES OF THE OPERATOR

Before you operate the machine, read and understand this manual.
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 area and the company rules and regulations.
Due to the position of the cab and size of the rigid hauler, an
operator has limited visibility to areas close to or near the machine.
No person should enter the operating area of the machine when it is
in operation without first notifying the operator. If a person has to
enter the operating area of the machine, they should signal the
operator and wait for an acknowledgement of recognition by the
operator.
During machine operation no one should be allowed to get any

closer than 7m (23 ft.) of the machine. Any closer will limit one’s
time to react and move away from the vehicle when it starts.
A FEW SIMPLE SAFETY RULES BEFORE

OPERATING
• Before putting the machine to work, it must be
operational. That is all faults which may affect
operation and/or cause an accident must first be
remedied.
• Wear suitable clothing to allow for safe operation.
• Wear hard hat to increase head protection. (When out
of operator’s compartment.)
• Never operate the machine while under the influence
of alcohol, medicine or other drugs.
70 OPERATING INSTRUCTIONS
A FEW SIMPLE SAFETY RULES BEFORE

OPERATING (continued)
• When entering or leaving the machine, always use the

steps and the handrails. When mounting and
dismounting the machine, use the three point grip
method (i.e., Two hands and one foot or one hand and
two feet). DO NOT JUMP!
• Before starting the engine, always be seated in the
operator’s seat.
• Use the seat belt during operation.
• Do not step or climb on surfaces which are not
intended for walking.
WARNING!
Step only on the areas provided with the slip resistant
EL18557
surfaces.
• When operating the machine, the doors should be

closed at all times.
• The cab is for the protection of the operator and it
meets the requirements for roll over protective
structures (ROPS) according to the adopted standard
for this machine. Therefore, hold firmly onto the
steering wheel if the machine should roll over. DO NOT
JUMP!
• During all operations, the machine may vibrate or
shake to some extent. Therefore, operate the machine
in such a way that your body is exposed to as little
vibrations as possible such as:
Having the operator’s seat properly adjusted and

wearing the seat belt.
Picking the smoothest path for the machine.
Adapting the speed of the machine to the terrain.
• To avoid getting your hands or fingers pinched, keep

EL19912 your hands away from areas such as covers, doors,
windows, etc.
WARNING!
Engine Exhaust contains or emits chemicals known to cause
cancer and birth defects or other reproductive harm.
WARNING!
Do not place combustible material in the dump body. The
exhaust system does heat up portions of the dump body to a
very high temperature
OPERATING WITH THE MACHINE NEAR

OVERHEAD WIRES OR CABLES
Before operating the machine, check with your
employer/supervisor to find out if there are any overhead cables or
wires on the work site. The machine 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 lines and cables must be
protected against damage in a suitable way. The electricity supply
should be turned off when practical.
OPERATING WITH THE MACHINE NEAR HIGH

VOLTAGE OVERHEAD POWER LINES
Note: 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.
When operating under a live overhead power line, the distance

between the highest point on the machine and the lowest point on
the power line should be at least 4m (13 ft.).
Note: Never operate the machine with the dump body in the
raised position.
WARNING!
If the machine comes into contact with a high voltage line, the
operator must remain in the 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 signalling in some way,
sounding the horn or mobile telephone, so that the power can
be turned off.
EL18575 WARNING!
If the machine is used in potentially dangerous environments,
e.g. explosive atmosphere, areas with dust including
asbestos, special safety regulations must be followed and the
machine shall be equipped for such operations.
SIGNALLING DIAGRAM
The signalling used below is universal and can be used in the operation of all off highway
motorized machines. In this case, the diagram below pertains to the operation of rigid
hauling machines.
If rapid operation of the machine is required, arm movement should be carried out more
lively. If two different machines are used in the same loading area there should be an
agreement beforehand how the loading should be carried out and what signals should
be given to the respective operators. This information should be used in conjunction
with the “Loading, Hauling and Dumping” procedures in this section.
START STOP LOWER RAISE

Both arms are The right arm The right arm The right arm
extended hori- points upward points downward points upward
zontally with the with the palm with palm facing with palm facing
palms facing for- facing forward forward and the forward and the
ward hand slowly hand slowly
makes a circle makes a circle
VERTICAL DISTANCE RIGHT LEFT

The hands indicate the The right arm is extended more or The left arm is extended more or
relevant distance less horizontally with the palm fac- less horizontally with the palm fac-
ing downward and slowly makes ing downward and slowly makes
small movement to the right small movement to the left
MOVE FORWARD MOVE BACKWARD DANGER (EMERGENCY STOP)

Both arms are bent with Both arms are bent with the Both arms point upward with the
the palms facing upward, palms facing downward, palms facing forward
and the forearms make a and the forearms make a
slow movement towards slow movement away from
the body several times the body several times
PROCEDURE BEFORE STARTING
DAILY WALK AROUND INSPECTION

CHECK ENGINE OIL WARNING!
CHECK HYDRAULIC FLUID LEVEL
CHECK TRANSMISSION FLUID LEVEL Note: The machine should be in the “SERVICE POSITION”
CHECK TIRE CONDITION during walk around. Remove blocks from wheels after
walk around is completed.
CHECK FOR LEAKAGES
CHECK FOR LOOSE BOLTS Note: Perform maintenance checks in a sequence to avoid
AND FITTINGS repeatedly mounting and dismounting the machine.
CHECK ROCK EJECTORS
The daily walk around inspection, listed to the left should be
CLEAN HEADLIGHTS
carefully performed.
CLEAN REAR LIGHTS
Note: Any defects should be corrected prior to starting the
ALL LADDERS, STEPS, WALKWAYS,
HANDHOLDS AND GUARD RAILS MUST BE engine.
FREE OF DIRT, SNOW AND ICE
CHECK FOR DAMAGED LADDERS, STEPS,
WALKWAYS, HANDHOLDS, GUARD RAILS
DAMAGED OR MISSING SLIP RESISTANT
STRIPS
CHECK THAT THE BATTERY DISCONNECT
SWITCH IS TURNED ON
CHECK/EMPTY AIR CLEANER DUST

CONTAINER AT VACUATOR VALVE
CHECK WINDSHIELD WASHER FLUID
CHECK TO MAKE SURE ALL WINDOWS ARE

CLEAN AND UNDAMAGED
CHECK TO MAKE SURE ALL MIRRORS ARE

CLEAN, UNDAMAGED AND PROPERLY
ALIGNED
CHECK TO MAKE SURE THAT THE SHIFT
CONTROL LEVER IS IN THE N NEUTRAL
POSITION
CHECK THAT THE BODY HOIST CONTROL
LEVER IS IN THE FLOAT POSITION
CHECK PARKING BRAKE OPERATION AND

THAT THEY ARE APPLIED
CHECK GAUGES AND INDICATOR LIGHTS
CHECK COOLANT LEVEL COOLANT LIGHT

DOES NOT ILLUMINATE
CHECK HORN AND BACK-UP ALARM
CHECK ALL OPERATING CONTROLS

CHECK BRAKE OPERATION
SEAT IS ADJUSTED, SEAT BELT IS

FASTENED DURING MACHINE OPERATION
RUN-IN INSTRUCTIONS
During the first 100 hours of a new machine’s operation, the
machine must be operated with caution until all components are
adequately run in. Monitoring should be on the engine heat,
steer/brake performance, body dump time and the horsepower
availability from the power train.
Engine
See the specific Engine Manufacturer’s Operation and

Maintenance Manual for the recommended break-in instructions
for the engine.
The engine may be put to work, but the operator has an opportunity
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
acceleration 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.
Note: Cleanliness is very important when you work on the

engine, hydraulic systems or any electrical
component.
STARTING ENGINE
WARNING!
Check your company safety rules for special procedures that
may be used for alerting personnel around you of your
intention to start the machine.
EL15049
• Make sure the area around the machine is clear before
starting.
• Sound the horn.
Starting Engine in Warm Weather

1. Make sure the accelerator pedal is released.
2. Check to insure that the parking brake is applied.
3. The Shift Selector should be in the N “Neutral” position.
4. Turn the key switch to the “ON” position.
Note: It is normal for the instrument panel lights to flash and

the audible alarm to sound in this position. The
EL18555 gauges will also cycle momentarily when the key is in
the “ON/IGN. & START” position. If a light does not
illuminate, have the service department check the
bulb.
Note: It is normal for parking brake, brake pressure, steer

pressure and alternator light to be illuminated with the
key on and engine not running.
5. Turn the key switch to the “START” position.
Note: A pre-lubrication system is installed on the engine.

Prior to engine cranking, the system automatically
ELI15847 fills filters and lubricates the crankshaft, camshaft,
turbocharger and rockers.
6. The engine will pre-lubricate first. When oil pressure is

sufficient, there will be a slight delay, the engine will start to
crank.
Note: DO NOT operate the starter for more than 30 seconds

at one time.
7. Release key after engine starts.
ELI15848 8. Check instruments, Contronic display and lights for any

warnings or errors. Refer to the Instrument Panel Section
in the front of this manual for details on each individual
item.
Starting Engine in Cold Weather

Make sure there is a 50/50 glycol mixture in the cooling system, a
battery heater or higher capacity batteries and a coolant heater.
Below - 18° C (0 ° F), add an oil heater and make sure there is a
50/50 glycol mixture in the cooling system. It is important for cold
weather starting that the electrical system, especially the batteries,
be properly maintained.
ELI15847
2. Turn the key switch to the “ON” position.
3. Turn the key switch to the “START” position to engage the

starter motor. Release key when engine starts.
4. If the engine does not start, wait until the engine flywheel
ELI15848 comes to a complete stop.
5. Turn the key switch to the “OFF” position before trying to

start the engine again.
6. Repeat the procedure if necessary.

at one time.
ELI15849 Note: Due to increased safety hazards and potential for
engine damage, the engine manufacturer does NOT
recommend the use of starting fluid without metering
equipment.
Cold Start Fluid Injector (Option)
2. Turn the switch to the “ON” position.
3. Push the Cold Start Fluid Injector switch and hold for two
seconds. Release.
4. Turn the key switch to the “START” position to engage the

starter motor. Crank the engine
Note: The Engine Oil Pressure Light must not remain
illuminated within 15 seconds after starting.
5. If the engine does not start, wait until the engine flywheel
comes to a complete stop.
ELI18486
6. Turn the key switch to the “OFF” position before trying to
start the engine again.
7. Repeat the procedure if necessary.

at one time.
Starting Engine in Cold Weather (continued)
Fuel Pre-Heater (Option)
The fuel pre-heaters are installed on the remote mounted fuel

filters.
1. The fuel pre-heater switch should be placed in the “ON”

position five to ten minutes before a cold start is attempted.
In extreme ambient temperatures, leave the pre-heater on
for at least 10 minutes.
ELI19880 2. Follow the steps under Starting Engine in Cold Weather.

If the machine is equipped with the optional Cold Start
Fluid Injector follow those steps.
3. The pre-heater switch can be left in the “ON” position, as it

is self-regulating. However, place the switch in the “OFF”
position when full operating temperatures have been
achieved.
Measures During Cold Weather
During the cold season or when the temperature is below freezing

the following points should be noted:
• Make sure that the freezing point of the coolant

corresponds to the weather conditions. See Cooling
System, in the Basic Preventive 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
tank.
• When the engine has started, run it at low speed and
with light loading until the oil in the engine, hydraulic
system, and axles has warmed up and become
sufficiently fluid to provide proper lubrication.
Note: At extremely low temperatures the machine must not
be run hard immediately after the engine has been
started.
Note: At temperatures below -25 C (-13 F) the tensile

properties of steel are greatly reduced and therefore
the risk of brittle fracture is great even at small
stresses. The lubricating and hydraulic oils change
their viscosity and thereby their lubricating properties
at low temperatures. Special procedures, lubricants,
etc. are required to operate below this temperature.
Starting with Auxiliary Batteries
WARNING!
Keep open flames and sparks away from the battery at all
times; the gases coming from it are highly explosive. Keep
vent caps in place.
1. Set the park brake and turn off all electrical loads.
2. Use system voltage (24 volts)
3. Remove the three fuses from the battery equalizer, located

ELI19930
behind a removable panel, behind the operator’s seat.
Note Illustration.
4. Connect one end of the first cable to the positive (+)

terminal of the charging battery.
5. Connect the other end of the first cable to the positive (+)
terminal of the battery being charged.
6. Connect one end of the second cable to the negative (-)

terminal of the charging battery.
7. Connect the other end of the second cable to the frame (to
ground) of the machine, e.g. an attaching bolt for the
starter motor or frame member close to the starter motor.
8. If the machine does not start within 30 seconds of cranking,

stop the procedure.
9. After the machine starts, allow the engine to idle before

removing the cable connection to ground. Remove the
other end of the of the cable from the charging battery (-)
terminal.
(+)
Terminal
10. Remove the other cable by disconnecting at the positive
(+) terminal of the battery that needed to be charged.
Remove the other end from the positive (+) terminal of the
charging battery.
11. Replace the three fuses in the battery equalizer.
ELI19891
WARNING!
Battery posts, terminals and related accessories contain lead
and lead compounds. Wash hands after handling.
BEFORE OPERATING
WARNING!
Do not operate machine until red indicator lights are
extinguished. If the lights do not go out, have the problem
identified and corrected.
Make sure your seat belt is properly fastened.
DO NOT run the engine at full speed or place under a

heavy load until it is warmed up. The engine is warm
ELI and ready for maximum operation when the needle of
the engine coolant temperature gauge moves along
the white line, below the “Red Zone” This usually
takes 15 minutes.
1. Keep the engine at l000 rpm for about three to five minutes
after starting. When a cold engine is started, the working
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
Engine Coolant Temperature Gauge that the systems are operating properly.
ELI14881
3. Observe the indicator lights.
a. If the engine oil pressure light does not go out within 2

seconds after starting the engine, shut the engine
down, determine and correct the cause before
restarting the engine.
b. Visually observe the engine coolant temperature
gauge to make sure that the gauge is working properly.
c. Check all CAUTION and WARNING Indicator lights.
All of these lights are off until the master key switch is
turned on, then all warning indicators are on for a 3
second light check.
ELI
4. Check operation of all the switches.
5. Make a functional check of the operating controls for

proper operation:
• Transmission Shift Selector

• Steering
• Hoist Control Lever
• Brakes
6. Unusual noises may indicate a problem. Check out prior to
ELI19951
operating.
OPERATING THE MACHINE
WARNING!
Sound the horn before moving the machine.
Operate the machine with the seat belt properly fastened. Do
not allow riders other than on the trainer’s seat. Riders must
also have their seat belt fastened.
Watch where you are going. Keep the machine a safe distance
from other personnel in the area, the edge of cliffs, slide areas,
other machines and vehicles; etc.
General Information
This machine 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
EL19743
unnecessary engine idling.
Almost all impending failures give some warning to the operator

before parts fail. By paying close attention to gauges, signal lights,
listening for unusual noises and noting engine performance,
malfunctions can be detected early. When an impending difficulty
gives its warning, park the machine in a safe area, shut the engine
off immediately and notify those responsible for maintenance. A
few seconds delay after the first warning might result in costly
repairs.
Put the shift controller lever in the N (Neutral) position when

starting the engine, checking the machine accessories, and for
extended periods of engine idle operation. If the engine starts in any
other position, the N (Neutral) start circuit is malfunctioning and
should be repaired immediately. 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 machine.
Note: Make sure the path of operation is clear of large rocks

or other large debris. Failure to do so may result in
damage to the machine and tires and loss of control of
machine.
WARNING!
Do not allow your machine to coast in “Neutral”. This practice
can result in a possible loss of operator control of the
machine.
Cooling A Hot Engine

If an overheating condition starts to occur:
• Make sure the body electronic control lever is in the float

position.
• Reduce the power output of the engine by releasing the ac-
celerator pedal or shifting the transmission to a lower gear,
or both.
If the engine temperature does not return to normal operating
range:
Engine Coolant Temperature Gauge • Immediately move the machine to a safe parking area.
ELI14881 • Make sure the transmission shift selector is in the ”Neutral”
position.
• Engage the parking brake.
Note: Allow the engine to idle 3 to 5 minutes before turning it
off, unless the red engine coolant level light in the
warning lamp display is illuminated.
• Shutdown the engine.

• Advise service personnel of the problem.
Transmission
The automatic transmission is planetary type, full automatic
shifting. Integral torque converter, with automatic lock-up in all
ranges. Remote mounted. Six forward speeds, two reverse. Trim
Boost Soft Shift provides smooth shifting to help reduce operator
fatigue.
ELI
The Allison Transmission CECI Electronic Control system is a
computerized shift selector system which electronically controls
transmission operation and monitors for conditions that could result
in damage to the transmission or improper equipment operation.
When one of these conditions is detected, the computer is
programmed to automatically respond in a manner which will
ensure safe operation of the equipment and transmission.
Automatic Shifting
WARNING!
In the lower ranges (1Thru 5), the transmission will upshift

above the gear selected if engine speed reaches
approximately 2400 RPM.
Do not allow your machine to coast in “NEUTRAL”. This
practice can result in severe transmission damage and
possible loss of operator control of the machine.
The Allison Transmission (CECI) Electronic Control system

lever-type range selector is an electronic-mechanical control unit.
The shift selector is locked from shifting in or out of “NEUTRAL” and
“REVERSE”. After a forward range has been selected, other
forward ranges can be selected by simply moving the lever to the
desired range.
Note: Machines can only be started in the “Neutral” range.
N. NEUTRAL - Use this when starting the engine, checking

the machine accessories and for periods of engine idle
operation. If the engine starts in any other selected gear,
the neutral start circuit is malfunctioning and should be
repaired immediately. When shutting the engine down,
shift to neutral and apply the parking brake.
EL18555 R1/R2 REVERSE - Use these ranges for backing up the
machine. Completely stop the machine before shifting
from forward to R1 or R2 or from R1 or R2 to forward. R1 is
a low speed reverse, 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 machine speed and low throttle.
Note: The machine will not go into either reverse when over
20% throttle.
D. DRIVE - With this range selected, the transmission will

initially be in first gear. As the speed of the machine
increases, the transmission will automatically upshift
through each gear to the sixth gear operation. As the
machine slows down, the transmission will automatically
downshift to the correct gear.
5, 4, 3, 2 Occasionally, the road, load or traffic conditions will make it

desirable to limit top speed. When conditions allow, select
“D” for full range operation. These positions also provide
progressively 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 machine with its maximum
driving torque and maximum engine retarding torque.
Status Lights
The Allison Transmission Commercial Electronic Control (CEC 1)

is programmed not only to tell you that something is wrong but to
automatically take action to protect you, the machine, and the
transmission. When a problem condition is detected, shifting is
restricted, the Transmission Malfunction light in the warning
lamp display will illuminate or the Do Not Shift light on the shift
tower will illuminate.
The Transmission Malfunction light will illuminate briefly when

the engine is started. Also, the light will come on if a problem is
detected in the system. If the Transmission Malfunction light ON
ELI
and the Do Not Shift light remains OFF, the problem is minor. In
most cases the transmission will continue to operate in a normal
manner. Continue to operate and report to appropriate service
personnel at the end of the shift. However, in some cases the
Allison Transmission Commercial Electronic Control system may
for example prevent operation in the higher gears. In this case, the
machine should be stopped and shut down for service at the first
safe opportunity.
DO NOT If the Do Not Shift light comes on at any time, a potentially serious
SHIFT problem exists in the system. The transmission will “Lock In Range”
and also disengage the lockup clutch. These actions reduce the
possibility of damage to the equipment. The machine should be
stopped and shut down for service at the first safe opportunity.
Lock-In-Range
The lock-in-range feature prevents upshifts and downshifts when a
DO NOT
SHIFT problem is detected in the operation of the transmission. The
hold-in-gear circuit permits the transmission to continue to operate
ELI in the gear it was in at 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 or downshift, 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 lights illuminate, the machine

should be shut down as soon as possible to avoid
possible damage to the transmission.
Reset Procedure
When the status lights come on, a reset procedure can be
performed to clear the system.
To reset, bring the machine to a stop at a safe location and shut off
the engine. Wait about 10 seconds and restart the engine.
• If the problem is temporary, the status lights will not come

back on and your machine will operate 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 operation, permitted by the system, will depend
on the type of problem.
Note: If only the Transmission Malfunction light comes on,

it may not be necessary to interrupt machine service
to reset. If possible, continue operation and have the
transmission checked at the earliest opportunity.
Range Preselection
Range preselection means, selecting a lower, maximum range to
match driving conditions you encounter or expect to encounter.
Learning to take advantage of a downshift will give you better con-
trol on slippery roads and on steep downgrades. Downshifting to
lower ranges increases engine retarding or limits top speed. How-
ever, to prevent an engine overspeed condition, the transmission
will upshift to the next range at approximately 2400 RPM.
The selection of a lower range often prevents cycling between a

gear and the next higher gear on a series of short up and down
grades.
Note: Be aware that even in a preselect mode, if the engine

approaches an overspeed condition, the
transmission will upshift to the next gear range at
approximately 2400 RPM. Use your retarder effectively
to maintain the desired speed to descend a grade.
Preselection To Avoid Stall Shifting

When a machine must travel up a steep grade when loaded, a rapid
loss in machine momentum can occur with a resulting full power
shift into a lower range. Because of the loss of momentum, the shift
may occur when the machine has almost stopped on the grade, at
or near full converter stall which can shorten transmission life. To
prevent these shifts, the operator should preselect the lowest range
anticipated for the steep grade. After negotiating the steep grade,
the shift lever can be repositioned to a range appropriate for the bal-
ance of the haul cycle.
Downshift Or Reverse Inhibitor Feature

Although there is no speed limitation on the upshifting, there is on
downshifting and reverse. The system is designed to protect
against these improper shifts. If a downshift or reverse shift is se-
lected at too high a speed, the system will prevent the shift from tak-
ing effect until the lower speed is reached.
Note: When required, use your service brakes to lower

machine speed to permit a downshift.
Using The Retarder
The retarder pedal is located on the cab floor to the left of the
steering column. This pedal regulates the hydraulic pressure to the
rear wet disc brakes. The retarder pedal should be used to slow or
stop the machine.
The retarder pedal should be used as needed to maintain a

controlled speed on downgrade hauls. The machine speed (and
related gear) should be selected to maintain maximum engine RPM
Service Brake without upshifting to the next gear (2400 RPM). Overspeeding of
Pedal
the engine occurs at 2400 RPM at which time the transmission
Retarder
ELI14832A would upshift to the next range.
Pedal
The optional Electronic Transmission Retarder slows the machine
by creating resistance to the turning of the drive train within the
transmission. For details, see the description under Electronic
Transmission Retarder in this section.
The optional Electronic Downhill Speed Control (EDSC) system will

also provide automatic retarding to prevent overspeeding. For
details, see the description under Electronic Downhill Speed
Control (EDSC) in this section.
WARNING!
Be aware that even in a preselect 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 cooling flow to

the rear wet disc brakes as well as providing the maximum engine
braking. Operate the machine on grade at speeds that maintain the
brake temperature gauge below the red zone. Should overheating
indications occur, the next lower speed(gear) should be selected.
Note: Refer to the (Grade/Speed Chart) Retarder Operation
Decal in the cab for the proper machine speed (gear)
to be utilized for the grade encountered.
Note: When the retarder is being used properly, the service
brakes should not be needed to maintain the desired
downhill speed. If the service brakes are needed, the
operator should select a lower gear range.
EL19746
WARNING!
Do not use the service brakes to maintain speeds on
downgrade hauls. Excessive heat will seriously damage the
front brakes. Use the retarder.
Retarder Operation Decal

The “Grade-Speed “ decal is provided in the cab as a general guideline for proper downgrade operation of the
loaded machine. The chart should be used to determine the maximum recommended speed for each down-
grade encountered. Operation at speeds greater than those recommended may cause the rear wet disc
brakes to overheat.
The absolute maximum grade charted for first gear is further limited by converter lockup rimpull.The machine
should not be operated on sustained downgrades that it cannot climb.
Proper use of this chart in conjunction with the brake temperature gauge provides optimum downgrade per-
formance.
Retarder Operation Decal (EH1700)
EL19873
Transmission Cold Weather Restrictions

Most transmissons are programmed to restrict operation to neutral,
reverse and the lowest gear in the drive (D) range until the following
temperatures are reached:
Shift Transmission
Sump Oil Selector Malfunction
Temperature Flashing Light Operation
-24° C and Below ON ON Neutral only

(-10° F and Below)
-23° C to -7° C OFF OFF Neutral, first,

(-9° F to + 19° F) second, or
reverse
-7° C and Above OFF OFF Full operation

(20° F and Above) in all ranges
Run the engine in neutral to raise the oil temperature to operating

level.
Accelerator Pedal
This pedal is used to accelerate or decelerate the engine. When the

pedal is depressed the engine speed is increased. Maximum
forward speed is approximately 61,3 km/h (38.1 mph). When the
pedal is released the engine speed is allowed to decrease.
When the shift controller lever is shifted into the reverse (R) gear
and the accelerator pedal is depressed the engine speed is
increased. Top speed R2 is approximately 11,9 km/h (7.4 mph).
When the pedal is released the engine speed is allowed to
decrease.
ELI14832C
Steering
WARNING!
If the power steering system fails, apply the service brake to
bring the machine to a stop at the first safe opportunity. Do
not attempt to operate the machine until proper repairs have
been made.
This machine is equipped with a full time hydrostatic power steering
system using two double-acting cylinders, piston type pumps and
combined brake/steering system reservoir. The steering
EL14922 accumulator provides supplementary steering, a means of
temporary steering in the event of a steering loss.
To steer the machine, 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 the
degree of turning. 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. 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 reserve oil
pressure will enable the operator to control the direction of the
machine while bringing it to a stop. The stored energy is limited.
Stop the machine as soon as possible.
Service Brakes
WARNING!
In the event of a steer or brake alarm, always use the service
brake pedal to stop the machine.
This machine 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 pressure 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
Service Brake
Pedal designed to provide maximum braking performance under all
stopping conditions.
Retarder
ELI14832A
Pedal
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. Depending
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
position.) This provides modulated braking effort to
each wheel for optimum machine control.
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 (brake pedal fully depressed and
EL15103 held in that position) the front brakes will apply. This feature insures
that full braking capability 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
depressed, the brakes are applied to the front and rear wheels.
Note: Optimum front brake lining life will be obtained if this

switch s left in the ON position.
Electronic Transmission Retarder (Option)

The Electronic Transmission Retarder system slows the machine
by creating resistance to the turning of the drive train within the
transmission.
The Electronic Transmission Retarder system is enabled by a

switch located on the left side of the instrument panel. The system
will only engage with the switch in the ON position and when the
operator depresses the retarder pedal. The rear wet disc brakes will
assist the Electronic Transmission Retarder system in slowing the
machine. If the operator “taps” the retarder pedal once only the
Electronic Transmission Retarder system will slow the machine.
The system remains engaged until machine speed drops below 5
ELI19732 mph at which time the Electronic Control Unit (ECU) will turn the
system OFF. The system will remain OFF until the operator
depresses or “taps” the retarder pedal.
The Electronic Control Unit (ECU) will turn the Electronic

Transmission Retarder system OFF whenever the operator
depresses or “taps” the accelerator pedal. The system will remain
off until the operator depresses or “taps” the retarder pedal again,
with the machine moving faster than 10 mph.
The green indicator light on the dash will illuminate to indicate that
the Electronic Transmission Retarder system is actively applying
ELI19911
the hydraulic transmission retarder.
Electronic Downhill Speed Control (EDSC) (Option)
The Electronic Downhill Speed Control (EDSC) system provides

retarding for use when the machine is running down a grade. The
system includes a brake control unit, located with other electrical
components in the access panel behind the operator’s seat. The
system will apply the appropriate amount of retarding in order to
maintain the preselected gear and optimum speed in order to
provide maximum brake cooling. The road speed will typically be
held to within a range of approximately ± 1.7 kph (± 1 mph). The
ELI19732 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 accelerator pedal position.
Before a downhill run, the operator will pre-select the appropriate

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 the
transmission range selected, and the engine speed is greater than
2000 rpm, the system will then engage. The EDSC light will
illuminate indicating when the system is actively applying the
retarder.
ELI19911
When the EDSC system is initially engaged, the brake control unit
determines a control set speed and compares that value with the
individual wheel speeds. When there is a difference between the
wheel speed and control speed the brake control unit will output
signals to the brake solenoids as necessary to bring the machine’s
speed down to the control speed. As the wheel speed approaches
the control 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 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.
The transmission gear / shift selector mismatch may occur either

when the transmission downshifts as a result of the operator
manually applying the retarder or as a result of the operator
upshifting from the preselected gear range. If an engine link error,
transmission link error, or wheel speed sensor error should occur
while the EDSC system in engaged, the EDSC light will flash
indicating the error.
Active Traction Control (ATC) (Option)

The Active Traction Control (ATC) system, which is also
incorporated into the brake control unit, monitors the machine’s
rear wheel speeds and applies the appropriate amount of retarding
when necessary in order to automatically transfer power to the rear
wheel with the best traction. The system is engaged by the ATC
Off ATC Boost
system/boost switch located in the instrument panel.
On Depress &
ELI15336
Release
The ATC system continuously monitors the left and right rear wheel
speeds in order to provide optimum traction in slippery conditions.
When in the ON position, when one of the rear wheels spins 45%
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 ATC indicator light,
located in the instrument panel, will illuminate when the system is
applying the retarder.
Traction In cases of extremely slippery conditions, the traction boost mode

Boost in the ATC system may be utilized. This mode is engaged through
Indicator
Light the momentary depression and release of the ATC switch. When
engaged, the wheel speed differential is reduced from 45% to 10%
ATC for a period of approximately 15 seconds. The traction boost light,
Indicator located in the instrument panel, will illuminate, indicating that the
Light boost mode is active. See Active Traction Control/Boost Switch in
the Instrument Panel section of this manual.
ELI19911
The ATC system will be disabled when:
• The ATC System/Boost Switch is placed in the OFF

position.
• Road speed of the hauler goes above 24.1 kph (15 mph).
• Either the brake pedal or the retarder pedal is applied.
• There is a wheel speed sensor error.
Note: If a wheel speed sensor error occurs while the ATC

system is active, the ATC indicator light will flash.
Engine Overspeed Protection

The brake control unit will maintain the wheel speed by applying the
retarder so as not to exceed the engine overspeed limit of 2400
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 ATC and EDSC system switches. The only instance
in which engine protection will not be available is if the engine link is
disabled.
Parking Brake
The differential mounted parking brake must be used to hold the

parked (Engine Off) machine stationary.
With the machine stationary and in neutral, place the switch in the
“ON” position. Observe the parking brake indicator illuminate.
Release the load/dump brake and/or service brake or retarder
pedal. Observe that the machine remains stationary, then shut
down the engine.
EL15049
When parking on a grade cannot be avoided, chock blocks must
also be used for extra security purposes.
Note: The transmission will remain in the ”NEUTRAL”

regardless of shift selector position until the parking
brake is released. When the machine is first started,
the parking brake light 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 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 machine.
This electrical switch applies the rear brakes at full pressure. This
should be used to hold the machine stationary for loading, dumping
and waiting.
WARNING!
Do not apply the Load/Dump brake while the machine is in
motion. This can cause loss of machine control.
Note: Should the service brake pedal fail or malfunction, the

ELI
retarder pedal should be used as a secondary
application method.
Operating The Body with Electronic Control Lever

The body is raised and lowered by hydraulic cylinders which are
Raise controlled by an electronic lever mounted to the seat. The lever has
four positions, controlling a four function main hydraulic valve by a
Hold hydraulic pilot signal and it is possible to meter the body raise time
and the body down time. The engine must be running and ignition
Float
switch “ON” in order to lower the body with the electronic lever.
Power
Down ELI
Body Electronic Control Lever Functions
1. POWER DOWN is used to initiate downward movement

only if the body fails to lower in the “FLOAT” position.
Release the lever and it will still stay in the float detent
position. If electrical power is lost and the body is in the
“RAISED” position or off the frame rail it can safely be
lowered. The body can be lowered using the manual
release valve which is mounted on a plate, on top of the
hydraulic tank. Refer to Manual Release Valve in the
OPERATORS CONTROLS section of this manual.
2. FLOAT is used when the body is being lowered to the

frame. The lever should remain in this position when the
machine is moving. It is possible to slowly lower the body
by metering the valve from the “HOLD” position to the
“FLOAT” mechanical detent. It is possible to meter the
body down time by moving the lever downward until the
desired body descent speed is reached. Releasing the
lever in the float position will allow the lever to spring
upward against a mechanical stop. This will keep the lever
in the “FLOAT” position.
Note: Whenever the machine is moving, whether empty or

EL15673
loaded, always keep the control lever in the “FLOAT”
position.
3. RAISE (All the way up) - Move the lever to this position to
raise the body. When the operator releases the lever in this
position, it will automatically return to the “HOLD” position.
The body can be metered up or down.
Note: Reverse gear is inhibited when the lever is in the

RAISE position.
EL15677
4. HOLD - Move and release the lever to this position to stop

and hold the body at any desired position while the body is
being raised or lowered.
Note: In case of a hydraulic or electrical fault, the valve will

automatically shift to the “HOLD” position.
EL15672
Raising The Body

1. Position the machine so the rear wheels are on level
ground to avoid unnecessary strain on the body and frame.
2. Before attempting to raise the body, move the transmission

shift selector to “N” (NEUTRAL).
ELI
3. Apply the brakes with the “LOAD/DUMP BRAKE

SWITCH” located on the center control console.
4. Move the body electronic control lever all the way back to
the “RAISE” position and accelerate the engine as
required.
Note: It is not recommended to raise the body at engine idle.

EL15677
5. The Body Up LIght will illuminate to indicate that the body

is in the “UP” position.
Note: When the body is up the machine is limited to 1st gear.
6. Decelerate the engine as the final stages of the body

cylinders begin to extend to slow the body raising speed as
the cylinders reach their maximum stroke.
ELI15526B
Raising The Body (continued)
7. When the body is fully raised, the hydraulic control valve

will automatically remain in the “HOLD” position to
maintain the body at fully raised. When the body is fully
raised, release the body electronic control lever allowing it
to move to the “HOLD” position.
EL15672
Lowering The Body

1. Move the body electronic control lever down from the
“HOLD” position, overcoming the detent in the lever, to the
“FLOAT” position and release. This will immediately shift
the hydraulic control valve to the “FLOAT” function.
EL15673
2. If the dump body remains in the “RAISED” position and will

not lower, it will be necessary to momentarily shift the body
electronic control lever to the “POWER DOWN” position.
As the body begins to lower, release the lever and it will
return to the “FLOAT” position. This condition usually
occurs when a load is being dumped on an incline.
3. Make sure the body electronic control lever is in the

“FLOAT” position and that the body is resting on the frame
prior to moving the machine. The Body Up Light will
extinguish indicating that the body is resting on the frame.
Lowering The Body (continued)
4. This machine includes 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 right vent window when the body is all the way
down.
Note: Whenever the machine is moving, whether empty or

loaded, always keep the control 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.
EL19067
Application
Due to its versatility, the HITACHI rigid hauler is used on a wide

variety of jobs. Although the machine applications will vary
considerably, the functions of the hauler 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
EL19662A which the machines may be used. Instead, some general operating
practices have been listed on the following pages which can be
applied to almost any job.
Note: The operator must check with the employer /

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 machine is being loaded.
Stepping out of the cab at this time could result in possible
injury.
Some of the most common methods of loading haulers are with

draglines, shovels, 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 machine. 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 hauler so that the shovel swing is 90 degrees
or less.
Note: Avoid pulling or backing your hauler into the loading

position while the loading machine is moving, as
rocks and debris may fall from the loading machine.
EL14007
Most jobs are planned to eliminate unnecessary turning and

backing of the hauler for loading. One of the most common
methods used is where the haulers follow one another under the
shovel in a semi-circle.
Note: Position your hauler in order that the loader/shovel

boom does not swing over the cab or the front of the
hauler.
EL17178
When working in a loading area of this type, you should remain a

sufficient distance behind the machine being loaded. By doing this,
you avoid having your machine damaged by spillage from the
loading machine. Also, by watching the position of the hauler being
loaded in relation to the loading machine, you can better judge
where you should place your machine when it is your turn to be
loaded.
EL17179
Loading (continued)
When being loaded by a front-end loader, spot your machine at an

angle to the material being loaded to reduce the bucket dumping
time. Position your machine on the side of the loader that is clear
and level to provide quicker, and more accurate loader
maneuvering. Positioning the hauler downwind from the loader,
where possible, will prevent dust from being blown back on the
loader and increase loader operator visibility, air cleaner, and
breather element service life.
EL15805
Aside from the loading machine and other haulers being in the
loading area, be aware of any other machines, vehicles or
personnel in the area.
WARNING!
Make sure machines and personnel are clear of your machine
before moving. Signal your desire to move by sounding the
EL15806 horn.
Another method of loading haulers is to use both sides of the

loading machine. In this method, one hauler is being loaded while
another hauler is being put into position to await loading.
Note: Avoid pulling or backing your hauler into the loading

position while the loading machine is moving, as
rocks and debris may fall from the loading machine.
EL14012
The haulers are usually backed into position under or beside the
loading machine, which necessitates that you make doubly sure
the loaded hauler preceding you is out of the way before you begin
moving into position.
EL17044
Loading (continued)
After your hauler is loaded, the loader operator will signal you to
move your machine from under his loader. You should start for the
haul road reaching the highest practicable gear ratio as soon as
possible.
These are a few common sense precautions you can take to

prolong the life of your machine and make your machine and your
job a safer one:
• Avoid pulling or backing your hauler into loading position

while the loading machine is swinging or while a load is
suspended over the loading area. This is dangerous to
EL19748 both you and the machine as rocks and debris may fall from
the loading machine.
• Apply the Load/Dump Brake.
• Stay in your cab while your hauler is being loaded.

Stepping out of the cab could result in possible injury.
EL19749 • Use the seat belt.
• Sound the horn to signal that you are preparing to move the
hauler.
• When pulling out of the loading area, avoid hitting debris,

rocks and loading machine overflow that can cause tire
damage. Allow the clean-up dozer sufficient time to clear
the loading area.
EL19750
Loading (continued)
Haultronic II (Option)
The Haultronic II load weighting system provides a method to

inform the loader/shovel operator of the amount of material that has
been loaded. The central Electronic Control Unit (ECU) determines
payload every cycle of the loader/shovel using input from pressure
transducers located in each of the four ride struts.
A display screen in the Contronic Display Unit informs the operator
of the pressure in each ride strut. Another screen displays the
payload weight in short or metric ton. See Contronic Display Unit
in the INSTRUMENT PANEL section of this manual.
An external lamp cluster, mounted on each side of the machine
informs the loader/shovel operator of the amount of material that
has been loaded:
Green light illuminates at 20% of maximum payload
EL20023 Amber light illuminates at 80% of maximum payload
Red light illuminates at 100% of maximum gross machine weight.
Hauling
WARNING!
Watch where you are going. Stay away from people, the edge
of cliffs, slide areas, other machines and vehicles; etc.
When moving out of the loading area it may be necessary to

preselect a low gear range until enough momentum has been
gained to prevent the machine from “stalling” after upshifting. It is
normally advisable to stay in low range on the soft material until
reaching firm ground or the haul road where sufficient machine
speed will permit proper transmission shifting.
After reaching the haul road, upshift the transmission to the highest
range possible to obtain the maximum safe speed for the condition
EL19746
of the haul road.
While traveling on the haul road, maintain a sufficient distance

behind the machine ahead (depending on roads, speeds, and haul
road conditions). This practice should always be followed to allow
sufficient safe maneuvering and stopping room.
To avoid excessive retarding and shift cycling on downgrades,
decelerate the machine to a safe descent speed. Depending on
driving conditions, you may preselect a lower gear range to
increase engine retarding. Apply pressure to the retarder pedal as
required to control the machine speed, or use the EDSC feature if
equipped.
EL14019
Note: Be aware that even in a preselected mode, if the
engine approaches 2400 RPM, the transmission will
upshift to the next gear range.
Hauling (continued)
Note: Refer to the retarder operation decal in the cab.
While traveling the haul roads, pay particular attention to the

instrument panel gauges and indicator lights to insure that all
machine components are functioning properly. If there is any
indication of trouble, pull off the haul road at the first safe
opportunity, and stop the machine until the trouble can be
corrected.
Dumping
The dumping procedure to be followed normally depends 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 later 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 hauler to the
designated dumping area. When backing to the edge of the spoil
bank, the “spotter” should be watched continually and his directions
followed carefully. Under no circumstances should you stand or
leave your seat to gain better visibility while backing up. Remain
EL16890 seat belted and use the rear 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 dual wheels from rubbing against the
hopper guard rails.
When hauling material to a fill area, the loads are usually dumped in
EL14022 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.
Dumping (continued)
After the load is dumped, move the body control 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 body control lever to the “POWER
DOWN” position momentarily until the body is brought over center.
Release the body control lever, allowing it to return to the “FLOAT”
position, and the body will come to rest on the frame.
ELI19662A
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.
ELI
3. Where possible, keep the rear wheels level before starting

to raise the body. Greater stress is applied to the body pivot
pins, hydraulic cylinders, and the frame if the wheels are
not level while the body is being raised - especially when it
reaches maximum height.
EL16893
4. Never “jump dump” by bouncing the rear wheels against a

stop rail or by jerking the body control lever. The shocks
imposed on the machine by these practices over stress
many components and can cause excessive damage.
EL16894
Stopping
• Reduce engine speed.
• Apply the retarder pedal to bring the machine to a complete
stop. After the machine has come to a complete stop,
move the shift controller lever to the desired gear to either
continue operation or to N neutral for parking.
Note: The service brake pedal should be used in extremely
slick haul road conditions or if maximum braking
effort is required.
Note: Use the service brake pedal at slow speeds 5 km/h (3
mph) and only when required. This will optimize front
brake lining life.
PARKING MACHINE
WARNING!
When mounting and dismounting the machine, use three
point mount (i.e. Two hands and one foot/one hand and two
feet. DON’T JUMP!
• Move the machine to a safe area for parking.

• 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 machine.
• 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”
EL18557 position.
• Check that all switches and controls are in the “Off”
position.
• Turn the Master 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,
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 or service
required to those responsible for maintenance.
• When leaving the machine unattended, remove the master
key. Lock all the doors and any vandalism guards to
prevent theft or damage.
STORAGE OF HITACHI RIGID HAULERS

Service prior to the storage of a machine 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 an expensive overhaul or delay in
returning the unit to work 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
of storage, and conditions under which the machine
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 unit and make any repairs or adjustments which may
be necessary to prepare the machine for service.
• LUBRICATION - Completely lubricate the machine
according to Chassis and Driveshaft Grease Fitting
Locations in the Basic Preventive Maintenance section of
this manual.
• CLEANING/RUST PREVENTION - Thoroughly clean the

entire unit. Clean all evidence of rust from the machine,
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 tank 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.
• RADIATOR/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 machine,
however, disconnect the ground cable.
Note: Refer to Return to Service in this section before

removing the unit from storage.
Start and Operate Machine Every 30 Days (Minimum)

If the machine 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 machine forward and backward at half-high RPM
(axles to be rotated to assure proper lubrication).
• All hydraulic components to be cycled to assure oil flow
through the complete system.
• Run engine at low idle for 3 minutes to cool engine.
• Set parking brake.
• Stop the engine.
• Remove the master key and lock the cab.
• Lubricate all exposed cylinder rods or any other rod that
cannot be retracted.
• Check for leaks on the machine.
• Fill out the machine card: Data, operator’s name. Note the
conditions to be repaired as well as any discrepancy (rust
not noticed the previous month, etc.).
• Advise of any discrepancy to your supervisor for
immediate rework.
• Remove ground cable from battery and battery equalizer
wires 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 PREVENTION - 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.
• 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 a 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:
w Do not operate the engine.
• The engine does not contain oil.
• BATTERIES - Remove batteries from the vehicle 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.
• 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 unit 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 unit is in storage.
this manual. Repeat these procedures for every 6 month
period the unit 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 is thoroughly 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 a preservative oil. Use Daubert
Chemical NoxRust No. 518, or equivalent. The oil must
meet Military Specification MIL-L-644, Type P-9.
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. 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.
l. 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.
m. 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:
w 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.
• 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 doors should be closed tightly and locked.
Remove all keys.
Store the machine in a position to allow forward and
reverse motion (for scheduled maintenance of stored
machines).
Return to Service
this manual.
• BATTERIES - If returning to service from short term

storage and batteries were left in the machine, 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 anti-freeze to bring up to
proper level.
• ENGINE
From Moderate Term Storage
Prime the lubricating system:
• Fill the oil pan sump, oil filters, and fuel filters.
• Fill the coolant system, if necessary.
• Start the engine. Refer to procedures in the front of this
section of the Operators 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 preventative compound from the cooling system. Fill
the cooling system with coolant.
Prime the lubricating system:
• Start the engine. Refer to procedures in the front of this

section of the Operators Manual.
TRANSPORTING
1. Due to the size and weight of the machine it will have to be
disassembled to conform to the following:
• Capacity of the transporting truck(s).

• Local weight limitations of roadways.
• Necessity of road permits for transporting.
Refer to Loading Dump Body and Loading Chassis
later in this section.
2. Two cranes with a minimum lifting capacity of 32 Tonnes
(35 tons) will be required to load the dump body and
chassis on trailers.
3. Load bearing chains, cables or slings with a minimum

22680 kg (50,000 lb.) capacity will be required.
4. A shipping kit secured the hoist cylinders and rear ride

struts when the machine was shipped from the factory.
These items can be fabricated and are shown, beginning
on the next page.
5. Always load and unload on a level surface.
6. Use adequate chains, blocks, cables, etc. to secure the

dump body and chassis to trailer floor. Reference
NAMEPLATES, WARNING, AND INFORMATION
DECALS in the PRESENTATION section of this manual
for machine tie down locations.
7. Transporting in foggy, dusty, or stormy weather conditions

requires additional care.
Note: Reference; ”Parking Machine, Short Term Storage”

for required procedures prior to transporting of the
machine.
Note: Refer to the EH1600/EH1700 Field Assembly and or

Service Manual for additional references pertaining to
removals and disassemblies.
Note: It is important that you know the overall height, width,

and weight of the dump body and of the chassis when
transporting. Check with local officials for any special
permits, escort requirements, or regulations that may
be necessary.
Note: The body control lever should also be secured in the

hold position to prevent accidental movement of the
body cylinders during shipment.
SHIPPING KIT DETAIL
10 11 7 6
8
9 6
7
EL15414
Installation of Fabricated Shipping Items
ITEM DESCRIPTION ITEM DESCRIPTION

1. Back Plate (Quantity 6) 7. Rod (Quantity 2)
2. Upper Angle ”A” Link 8. Right Hand Hoist Angle
3. Lower Angle ”A” Link 9. Left Hand Hoist Angle
4. Rod (Quantity 2) 10. Front Platform Support (Quantity 2)
5. Rod (Quantity 2) 11. Rear Platform Support (Quantity 2)
6. Rod (Quantity 1)
Note: The items above are detailed on the following pages,

showing the dimensions for their fabrication.
SHIPPING KIT, FABRICATION DETAIL
Item 1 - Back Plate EL15415
Item 2 - Upper Angle ”A” Link EL15416
Item 3 - Lower Angle ”A” Link EL15417

3/4”-16 UNC
Item 4 - Rod EL15418
3/4”-16 UNC
3/4”-16 UNC
3/4”-16 UNC
1117.60mm (44.00”)
Item 7 - Rod ELI
Item 8 - Right Hand Hoist Angle EL15420

SHIPPING KIT, FABRICATION DETAIL (continued)
Item 9 Left Hand Hoist Angle EL15421
Item 10 - Front Platform Support EL15423A
Item 11 - Rear Platform Support EL15423B

Loading Dump Body
The dump body may be shipped one of two ways. Local regulations
will dictate the choice of shipment.
A. Dump body assembled.
EL15426
B. Dump body split in halff
EL15427
Note: The dump body should only be removed when it is
down and resting on the frame.
1. Disconnect the body exhaust assembly from the dump

body.
2. Remove the rock ejectors and the mud guards from the
dump body.
3. Disconnect the body cylinders from the dump body. Secure

the body cylinders as shown in Installation of Fabricated
Shipping Items previous in this section
4. Attach a sling to the dump body that is made up of four

chains with pin assemblies at each end as shown. The pins
should be attached to the lift eyes on the side of the dump
body as shown in the illustration.
5. Remove the grease fittings, nuts, and bolts from the body
pivot pins. Remove the snap rings from the pivot pins.
6. Drive the pivot pins out of the hinge brackets and remove
the shims and bushings.
ELI15832REV
Loading Dump Body (continued)

7. Lift the dump body off the chassis with the lifting device and
sling. Place the dump body on wooden blocks on the trailer.
8. Secure the front and rear of the dump body to the trailer
with chains as shown.
9. Insert the pivot pins into the pin location in the machine’s
frame and secure for shipment.
EL15425
Loading Chassis
1. Attach chains to the rear of the machine.
Note: This is a two- point pickup from the dump body hinge
pin bosses.
2. Lift the machine until the tires clear the ground by

approximately 16 cm. (6 in.) for tire removal.
EL15887
Loading Chassis (continued)

3. Crib the rear axle as shown.
4. Drain and remove the fuel tank.
EL15429
5. Remove the rear tires. Refer to Group 772,

TIRES/RIMS/INFLATION in the Service Manual.
6. Attach a wheel/tire sling around each tire/wheel and secure

the sling to a crane. Remove the tire/wheel from the axle
and load on the trailer or in the dump body.
EL15430
7.Remove spacer band from the rear, dual tires as illustrated.

Load on the trailer or in the dump body.
8. Connect a vacuum pump to the hydraulic tank and apply a

vacuum to prevent the tank from siphoning when the
various hydraulic lines are disconnected.
9. Disconnect brake and brake cooling lines from the rear

axle. Cap off the ends of the lines to prevent the entry of
dirt.
10. Disconnect all lube lines at lube points. Retain connection

at central lube manifold. Tie wrap all lube lines to rear axle.
EL19759
11. Disconnect driveline from differential and transmission.
Load the driveline on the trailer.
12. Raise the rear of the chassis and remove the cribbing.
Lower the rear of unit to the ground. Rear axle is still
connected to machine by the links, A-frame and rear ride
struts.
13. Disconnect brake and hydraulic lines from front axle. Cap
off all lines.
14. Attach clevis and pin with chains to the two front towing
lugs as shown.
EL15432
15. Lift machine with crane and crib with steel stands as
shown.
16. Remove the front tires. Refer to Group 772,

TIRES/RIMS/INFLATION in the Service Manual. Load on
the trailer or in dump body.
17. To secure the rear A-frame and links to the frame refer to
Installation of Fabricated Shipping Items previous in
this section.
18. Lift the front of the machine, remove cribbing and lower the
machine to the ground.
19. Remove the snap ring from the A-frame.
20. Remove pins that connect links to rear axle.

EL19753
21. Remove the lower pins from each rear ride strut. Leave
struts attached to frame. Secure struts as shown in
Installation of Fabricated Shipping Items previous in this
section.
22. The rear axle should be free of the chassis.
EL19754
23. Using two cranes, as shown, lift the chassis off the rear
axle.
24. Set chassis back down on wood cribbing under the front
trailing arms and body cylinder pins.
25. Lift front of machine and remove front ride strut pins.
26. Support front axle with steel stands and remove cap bolts
from suspension tube cap.
EL19755

27. Using two cranes, lift the chassis off the front axle.
28. Using the four chain hook-up, lift the chassis onto the
trailers.
29. Secure the chassis onto the trailer using chains in a

criss-cross pattern.
30. Remove the batteries from the battery box.
31. Remove the railings,right side cat-walk and front platform.

Support with platform angle brackets; items 9A and 9B as
shown in Installation of Fabricated Shipping Items
previous in this section.
EL19756
ROADING
WARNING!
A hauler is a wide and slow moving machine 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 machine.
Note: It is important that you know the overall height, width,

and weight of the machine when roading. Check with
local officials for any special permits, escort
requirements, or regulations that may be necessary.
The transportation of haulers from a port to a job site to another job

site is becoming more and more common. Special precautions are
ELI18290
necessary to reduce the possibility of damage to tires and other
components of the machine.
1. Make sure the windshield and side windows are clean.
2. Check brake pressure.
3. Make sure all loose attachments are safely anchored.

ROADING (continued)
4. Close the cab doors.
5. Operator must be buckled into the seat belt.
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

roading. It is important to stop periodically to allow
cooling.
Note: Tire inflation pressure requirements on roaded

machines vary from tire inflation pressure on working
machines. Roading a machine with the wrong tire
inflation pressure could result in damage to the tires.
If a machine is to be roaded between jobs, it is
important to consult your tire distributor for the
recommended roading inflation pressure. Extended
distances may require stops to cool tires.
MACHINE STUCK IN DEEP SAND, SNOW OR MUD

If the machine 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 machine, do not make shifts from N (Neutral)
to D (Drive) or R (Reverse) 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
released in the next three seconds. That can cause a sudden
movement of the vehicle. Leaving the throttle open longer
than three seconds causes the transmission to remain in N
(Neutral). Avoid this condition by making shifts from N
(Neutral) to D (Drive) or R (Reverse) only when the throttle is
closed.
Note: NO NOT make N (Neutral)-to-D (Drive) or directional

shift changes when the engine 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 overheats, shift to N
(Neutral) and operate the engine at 1200-1500 rpm
until it cools (2-3 minutes).
MACHINE STUCK IN DEEP SAND, SNOW OR MUD

(continued)
Rocking Out
Shift to D (Drive) and apply steady, light throttle (never full throttle).
When the machine has rocked forward as far as it will go, apply and
hold the service brakes. Allow the engine to return to idle; then
select R (Reverse). Release the brakes and apply a steady, light
throttle and allow the vehicle 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) if each directional shift continues to move the machine a
greater distance. Never make N (Neutral)-to-D (Drive) or
directional sift changes when the engine rpm is above idle.
If the machine fails to move a greater distance in each directional

shift the machine should be towed or pushed from the deep sand,
snow, or mud. Refer to TOWING in this section of the Operators
Manual.
TOWING
WARNING!
Before taking any steps in preparation for towing, the parking
brake must be applied and the wheels blocked on the machine
being towed, to prevent the machine from rolling.
Considerable caution should be taken in connection with
towing a machine to avoid serious accidents.
Note: The towing machine must always be at least as heavy

as the machine being towed. The tow points,
illustrated on the next page, are capable of towing the
machine at the listed Gross Machine Weight (GMW)
for this machine. The GMW is listed on a decal, refer to
NAMEPLATES, WARNING, AND INFORMATION
DECALS, in the PRESENTATION section of this
manual.
Note: The tow cable or chain must be capable of towing the

listed GMW for this machine.
When a machine is towed or pushed, with the driveshaft connected,

the power flow going from the machine wheels, through the
driveshaft and into the transmission or converter, causes certain
parts in the transmission or converter to rotate. Even though there
maybe 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 machine is
towed or pushed.
Note: The maximum speed under all circumstances is 10

km/h (6 mph).
TOWING (continued)
With Engine Operable
WARNING!
It is essential that the steering and brake functions are
operational. An operator will be required in the cab to steer
and brake the towed machine.
When towing a machine, the following guide lines should be

observed:
• Dump load if possible.
• Apply park brake and block wheels of machine to be towed.
• Disconnect the rear driveshaft at the differential. Refer to

REAR DRIVESHAFT, Group 451 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 towing

machine and the machine to be towed.
Towing from the front, attach shackle hooks to the two
ELI19757
towing eyelets located underneath the front bumper.
Note: Do not use the body prop cable or the mounting holes
for the body prop cable.
• Make sure tow cables/straps are secure, take up all cable

slack between the two machines machine, and proceed
with caution.
• Remove the blocks from the wheels. Release the parking

brake.
• Shift controller lever to the “N” (NEUTRAL) position.
• Proceed with extreme “CAUTION”.

TOWING (continued)
With Engine Inoperable,

No Brakes No Steering
If the machine cannot be started the following steps must be
followed:
WARNING!
If the machine is not hydraulically connected to the towing
machine by external hoses and the engine cannot be started,
the brakes and steering will not operate. Steer/Brake pressure
must be above 11031 kPa (1600 psi) to tow machine.
• Dump load if possible.
• If the body is off the frame rail, use the manual release
valve to lower the dump body. See MANUAL RELEASE
VALVE in the OPERATORS CONTROLS section in this
manual.
• Block wheels of machine being towed.
• Disconnect the rear driveshaft at the differential. Refer to

REAR DRIVESHAFT, Group 451 in the Service Manual.
EL18528
Note: The differential mounted disc parking brake is still
functional with the rear driveshaft disconnected.
• Place and secure towing cables/straps between the towing

machine and the machine to be towed.
Towing from the front, attach shackle hooks to the two
towing eyelets located underneath the front bumper.
• Make sure tow cables/straps are secure, take up all cable

slack between the two machines machine, and proceed
with caution.
• The machine must have Steer/Brake pressure in order to

release the parking brake, steer the machine and to be able
to use the service brakes. It is recommended to connect,
via external lines, hydraulic power from the towing machine
to the relief check-bleed valve on the machine being
towed. Refer to RELIEF-CHECK-BLEED VALVE,
Group 645 in the Service Manual.
• Remove the wheel blocks and release the parking brake.
• Begin moving the machine, proceeding with extreme

“CAUTION”.
With Engine Inoperable (continued)
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 unit.

Keep the master key switch of the towed unit ON until all
systems have bleed down. Place the disabled machine in
the Service Position. Remove the external hydraulic lines
from each machine.
BASIC PREVENTIVE MAINTENANCE 127
Put the machine in the SERVICE POSITION
SERVICE POSITION
Before working on the machine, park it on a level surface and put it in the “SERVICE POSITION”
1. Engine stopped, ignition key removed 4. The Wheels blocked.

(except when service requires engine 5. Body control lever in “FLOAT” position.
operation). 6. Parking brake applied.
2. Tag the machine following local lockout 7. Allow the machine to cool down.
& tag procedure. Identify machine as 8. Pressure released from all lines,
“Out of Service”. tanks, and accumulators.
3. If body is raised, use body prop cable.
WARNING!
If work must be done on a warm machine, beware of hot fluids and components.
Refer to the SPECIFICATIONS SECTION of this manual for torques, recommended lubricants, capacities, etc.
128 BASIC PREVENTIVE MAINTENANCE
A FEW SIMPLE RULES WHEN SERVICING

• Do not perform any work on the machine 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 machine warranty.
TS41154
• Read all nameplates and decals before you operate the
machine. Each nameplate and decal has important
information about operation or service.
• 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.
• Stand away from the rear exhaust area when the engine is
running.
• When running a machine indoors, be sure the building is

properly ventilated.
WARNING!
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects and other reproductive harm.
• Do not wear loose fitting clothing or jewelry when working

on a machine.
• Always wear a hard hat, safety glasses, gloves, shoes or

other protective articles as the job requires.
• Before you work on the machine always lower the body. If

you must work on the machine with the body raised, always
securely support the body using the body prop cable.
EL13914
• Be sure the machine is in the “SERVICE POSITION”
before lifting the machine. Always support an elevated
machine using proper blocks and/or cribbing before
beginning work on it.
• Be sure the “body prop cable” is engaged when working

beneath a raised dump body.

(continued)
• When lifting or supporting components, use equipment

with a weight capacity as great or greater than the weight of
the component.
• Use the correct tool(s) for the job. Repair or replace any
broken or defective equipment or tools.
• Make sure that no tool(s) or other object(s) are left inside

the machine where they may cause damage.
• Release all system pressure slowly before working on any
V50387 part of the hydraulic system.
• Remove all pressure caps carefully.
• Be careful of hot fluid when changing oil in the engine,

hydraulic system, etc.
• To find leakage, use a piece of cardboard or wood, not your

hand.
• Never adjust a pressure relief valve above the

manufacturer’s recommendations.
EL13917 • Always inspect the cooling system with the engine

stopped.
• Check that there is no damage to electric wires and hoses.
• Check that there is no damage to hydraulic and brake

hoses caused by chafing. When wires have been
disconnected it is important that they are clamped so they
cannot be exposed to chafing.
• When performing any welding operation on a machine,

turn the battery disconnect switch to the “OFF” position
and disconnect the negative (-) and positive (+) wire
connections at the battery.
TS21481
• When welding and cutting, the paint must be removed up to
a distance of 10 cm (4 in) from the welding or cutting point.
Paint which is subject to high temperature may cause
harmful gases.
The following safety instructions should be followed:
• Remove the paint from the area where work is to be

performed through sand blasting.
• If the paint cannot be removed by sand blasting, it must

be removed in some other way e.g., with paint stripper.

(continued)
Note: When using paint stripper, be sure to wear protective
gloves and work in a well ventilated area.
Note: A high speed grinding machine also heats the paint

and must only be used in a well ventilated area.
• Polymer materials such as rubber and certain kinds of

plastics can, when heated, give off gases that may be
dangerous to health and environment.
The following safety instructions should be followed:

• Do not weld or cut near polymer materials without first
having protected them from the heat.
• Never burn polymer materials when scrapping them.
Note: All steps, ladders, stairways, handholds, platforms,

walkways, and guard rails must be free of dirt, snow,
and ice.
Note: All steps, ladders, stairways, platforms, walkways,

and non-skid deck strips must be replaced if
damaged.
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 or water on the floor makes
EL18558 it slippery and dangerous in connection with electrical
equipment or electrically powered tools. Oily clothes are a
serious fire hazard.
• Keep the machine 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.
• Machines should be clean of debris particularly around the

engine, exhaust, and drive shaft components. Keep the
machine 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.
FIRE PREVENTION MEASURES (continued)

• Gasoline is highly flammable and should never be used as
a cleaning fluid. Use an approved solvent for cleaning.
• 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 machine during fueling operations and/or when
the fuel system is open to the atmosphere.
• Prior to welding or brazing on any part of the machine, 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.
V50389A
• There is always a risk of fire. Find out which type of fire
extinguisher to use, where it is and how to use it.
• In case of fire be prepared to run for safety, but if time

permits first:
• Lower the body to the ground.
• Stop the engine by turning the master key switch to the
”OFF” position.
• Start combating the fire and/or call for help.
WASTE HAZARDOUS TO THE ENVIRONMENT

Waste fluids, components such as batteries, plastic objects and
others which might constitute an environment danger, should not
just be thrown away, but taken care of in a correct way in order to
protect the environment.
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 INTERVAL CHART

MAINTENANCE INTERVALS OPERATING HOURS
Note: Disposal of used lubricants, filters
and batteries should be done in ***
Daily Every Every Every Every ****
6 Mo. As
1000 1200
accordance with the rules and or
Every
250 500 or
2500
Req’d
NOTES
regulations of the local governing 10
Hrs.
agencies.
GENERAL
Leaks
Loose Bolts and Fittings
ENGINE
Engine Oil Level, Check
Engine Oil, Change *
Engine Oil Filter, Change *
Crankcase Breather Tube Check/Clean
Air Cleaner Restriction, Check
Air Cleaner Dust Cup, Check/Clean
Air Cleaner Elements, Check
Air Intake Lines and Clamps, Check
Fuel Tank, Drain Sediment
Fuel-W ater Separator
Fuel Filter, Change
Fuel Tank Mounting & Lines, Check
Coolant Level, Check
Coolant, Change/Flush (Add Concentrate D) 2 Years / 6000 Hours.
Coolant Filter, Change Always After Flush
Cooling Fan, Check
Radiator, Clean
Belt Tension, Check
Engine Valve Train Adjustment D Initial 2000 Hours Only
ELECTRICAL SYSTEM
Battery Condition, Check
Battery Cables & Connections, Check
Electrical Wiring & Connections, Check
Fuses, Check
Neutral Start Circuit, Check
Exterior Lights, Check
Back-up Alarm, Horn, Check
Gauges & Indicator Lights, Check
Headlight, Aiming
* Longer with oil sampling program recommended by Engine Manufacturer

and higher quality oil.
*** See Operating Instructions section of this manual for operator Daily Walk Around Inspection.
**** Every 6 months or 2500 hours whichever occurs first.
Vehicles prior to Serial Number 76735.
D Refer to the Engine Manufacturer’s Operation and Maintenance Manual.
Note: Some job-sites may require more frequent checks (i.e. heavy dust, rough roads, & etc.).

Daily Every Every Every
****
6 Mo. As
Every
250 1000 1200 or
2500
Req’d
NOTES
Hrs.
agencies.
POWER TRANSMISSION
Transmission Fluid Level, Check
Transmission Fluid, Change
Transmission Filter, Change
Transmission Breather Element, Change
Transmission Breather Element, Check
Transmission Hydraulic Strainer, Change
Differential Lubricant, Check
Differential Lubricant, Change
Planetary Hubs Lubricant Level, Check
Planetary Hubs Lubricant, Change
Axle Breather Element, Change
Axle Breather Element, Check
ATC Sensor, Check _
ATC Sensor, Change _
BRAKES-SER VICE & PARKING

Operation, Check
Visual, Inspect
Pressure, Check
Front Brake Wear, Check
Rear Brake Wear, Check Every 5,000 Hours
Complete System
Inspection & Function, Check
Accumulator Capacity, Check
STEERING
Steering Operation, Check
Steering System Hyd. Fluid Level, Check
Steering System Hyd. Fluid, Change
Steering System Filter, Change
Steering Accumulator, Check
SUSPENSION, WHEELS, & TIRES

Struts,Check (X-2) Dimension
Wheels, Check *
Front Wheel Lubricant, Check Every 15,000 Hours
Front Wheel Lubricant, Change or at Major Service
Tire Inflation, Check
Tire Condition, Check
Wheel Alignment, Check _
* After wheel removal, check torque of bolts at 5 & 10 hours of operation.
_ Refer to the HITACHI Service Manual.

Daily Every Every Every
****
6 Mo. As
Every
250 1000 1200 or
2500
Req’d
NOTES
Hrs.
agencies.
CAB
Cab Air Filter, Clean/Change
Cab Mounts, Check
Wiper Blade Condition, Check
Windshield Washer Fluid Level, Check
Seat Belt & Mounting, Check
Air Conditioner, Check
Heater & Defroster, Check
HYDRAULIC SYSTEM &

OTHER FUNCTIONS
Hydraulic Fluid Level, Check
Hydraulic Fluid, Change
Hydraulic Filter, Change
Hyd. Res. Breather Element, Change
Hyd. Res. Breather Element, Check
Hydraulic Lines & Hoses, Check
Body Prop Cable, Check
Main Rail, Strut, & Axle Lug Welds, Check
Frame Assembly, Check
GENERAL INFORMATION
WARNING!
When working under a raised dump body, the body must be
blocked securely and the body prop cable must be used.
Block the wheels when any one of the wheels are off the
ground. There is a risk of the machine moving even with the
park brakes applied.
If the machine is to work as economically as possible, thorough

maintenance is necessary. The most important care a machine
receives is the preventive maintenance that you perform, which
comprises of lubrication, various checks and adjustments. The
recommended intervals for maintenance and lubrication refer to
normal working and environmental conditions.
Most of the maintenance procedures are simple to perform. The

necessary detailed instructions are provided in this manual.
TS40011
All maintenance and service work should be performed by qualified
personnel.
Checking Fluid Levels-General

Note: Do not mix oils. Prior to changing lubricants from one
oil company to another, it is recommended that a
complete system flush be done.
• When checking fluid levels, the machine should be on level

ground.
• Fluid levels should be checked prior to the shift when the

fluids are cold and have drained to the reservoir of each
component.
• Schedule servicing to avoid damage to the machine. Keep

good records. Read the machine manuals.
• Make a complete visual inspection.
• Check for loose bolts and capscrews, leaks and worn

parts. Report everything that needs attention.
CENTRALIZED SERVICE PANEL (Option)
1 2 3 Bolted to and underneath the hydraulic tank is the

centralized service panel. From here and with the
correct connectors service personnel can fill:
ELI19805
4. Fuel Quick Fill
1. Engine Coolant
2. Hydraulic Brake/Steer Fluid
5. Crankcase Oil
3. Hydraulic Fluid
6. The ball valve allows for the

relief of coolant pressure.
ENGINE
The engine illustrations which follow show the locations of the major
external engine components, the filters, and other service and
maintenance points. Some external components may be at
different locations for different engine models.
Engine Operation Report
The engine must be maintained in top mechanical condition if the

operator is to get optimum satisfaction from its use. The
maintenance department needs daily running reports from the
operator to make necessary adjustments in the time allotted and to
make provisions for more extensive work as the reports indicate the
necessity.
Comparison and intelligent interpretation of the daily report along

with a practical follow-up action will eliminate most failures and
emergency repairs.
Report to the Maintenance Department any of the following

conditions:
• Low lubricating oil pressure
• Low power
• Abnormal water or oil temperature
• Unusual engine noise
• Excessive smoke
• Excessive use of coolant, fuel or lubricating oil
• Any fuel, coolant or lubricating oil leaks

ELI19631
Check Engine Oil Level

Check the engine oil level daily.
Never operate the engine with the oil level below the ”L” (low) mark
or above the ”H” (high) mark. Wait at least 5 minutes after shutting
off the engine to check the oil. This allows time for the oil to drain to
EL15709 the oil pan.
Note: The machine must be level when checking the oil level
to make sure the measurement is correct.
Change Engine Oil
WARNING!
Hot oil can cause severe burns.
Drain the engine oil when the engine is hot. Hot oil flows more freely
and carries more contaminants with it.
1. Bring the engine to operating temperature and shut down

ELI19625 the engine. Remove the drain plugs from the right and left
sides of the engine oil pan. Drain the oil immediately to be
sure all the oil and suspended contaminates are removed
from the engine.
2. Clean and check the threads of the oil drain plugs and the
seal surface. Install the oil drain plugs. Tighten to 47 N•m
(35 ft-lbs).
Note: Whenever the engine oil is changed, the engine oil

filters should also be changed.
3. Fill the engine with clean oil through the oil fill tube to the
correct level, the “H” (high) mark on the dipstick.
ELI15690
4. Start the engine and visually check for leaks.
5. Shut down the engine and wait at least 5 minutes for the oil
to drain back into the pan. Recheck the oil level with the
dipstick. Add oil as required.
Change Engine Oil Filters
1 2
Note: Units with a Serial Number prior to 76735 have four
full-flow and two bypass oil filters. Units with a Serial
Number 76735 and above have four combination full
flow/bypass oil filters. Change all the engine oil filters
at every oil change. It is important to use the correct
replacement filters.
Full Flow Filter By-Pass Filter Note: The external appearance of the full flow (1) and the
ELI18559 bypass (2) filters is the same. The illustration to the left
identifies the difference between the two filters. The
full flow filter has 1-1/2 16 in. threads. The bypass
filter contains 1-3/8 16 in. threads.
Change Engine Oil Filters (continued)
Note: The two bypass oil filters are located on the left side of
the engine. The four full flow oil filters or four
combination bypass/full flow oil filters are located on
the right side of the engine.
Bypass oil filters are not present on vehicles with

Serial Number 76735 and above.
EL19632
ELI19628
Note: The bypass oil filters, full flow oil filters and
combination bypass/full flow oil filters are all changed
in the same manner.
1. Clean the area around the lubricating oil filter head.
2. Remove the filters with a strap or filter wrench.
Note: Reference the engine manufacturer’s operation and

maintenance manual for their recommended oil
sample plan.
3. Discard the filters after draining remaining oil out of the

filter and into a container.
4. Clean the area around the lubricating oil filter head.
Note: The oil filter O-ring can stick on the filter head. Make
sure it is removed.
5. Fill the oil filters with clean lubricating oil.
Note: If not filled, the lack of lubricating oil during the delay
until the filters are pumped full of oil is harmful to the
engine.
6. Apply a light even coat of lubricating oil to the O-ring

sealing surface prior to installing the new filter.
Change Engine Oil Filters (continued)
7. Position the filter to the filter head. Install the filter as

specified by the filter manufacturer. The tightening
instructions are normally printed on the outside of the filter
housing.
8. Start the engine and check for leaks at the filter head. If the
O-ring leaks, shut down the engine and remove the filter
and check the sealing surface. Usually it does not help to
further tighten the filter.
Crankcase Breather Tube/Hoses Check/Clean

Each tube is to be removed and checked internally for obstructions
or sludge buildup.
If the tube is blocked, it is to be cleaned or replaced to prevent

excess crankcase pressure buildup.
AIR CLEANER SYSTEM

The air cleaner prevents dust and other impurities from entering the
engine. The 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, therefore it is very
important to check the air cleaners regularly and to service them
correctly.
ELI
AIR CLEANER SYSTEM (continued)
Check Filter Light

Check the filter service indicator light and the Contronic display for
an air cleaner message “E Clean airfilter 1”. If the service
indicator light remains illuminated or the Contronic display
continues to scroll a message with the engine operating, service
the outer, primary element. If an air cleaner restriction still remains
after the primary element is serviced, the filter service indicator light
will illuminate and the Contronic display will again scroll a message.
This indicates that the inner, safety element should be changed.
Replacement of the inner, safety element should be done by
E Clean airfilter 1 qualified service personnel only. The Contronic display will scroll “E
Engine xxxx rpm
Speed yy mph Airfilter 1 ER” for an air filter switch error.
x-ton ↑ Gear zz
ELI
Service Air Cleaner
Service the air cleaner when the Contronic display indicates that
the air cleaner is in need of servicing.
1. Shut down the engine, and wipe the dirt off the entire air
cleaner assembly.
2. Undo the clips securing the cover (1) to the upper body
assembly (9). 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 the housing means dirt and dust
that may 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 filter element is not
going to be changed immediately, cover the opening.
The primary element (5) may be cleaned and reused. 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 inspection precautions.
EL20042 Some commercial air filter element washing services do
warranty the elements they wash. Select a service that
does, and make sure their warranty covers repair of engine
damage resulting from a defective washed element.
Service Air Cleaner (continued)
• If a commercial washing service is not available, the most

effective cleaning method is to soak the element in water
which contains a non-sudsing detergent. Prevent dirty
water from making contact with the clean side of the
element. After soaking, rinse the element from the clean
side to the dirty side to dislodge the dirt with water pressure
not exceeding 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 dryers 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 element.
Note: Used heavy-duty air filter elements, after the most

thorough cleaning, usually have 60-80 percent of the
life of new filter elements. Each subsequent cleaning
yields progressively reduced dust capacity.
Note: Reuse of cleaned heavy-duty air filter elements,

because of their shortened service life, increases the
likelihood of improper air cleaner servicing. Each time
the air intake system is serviced, it is exposed to the
chance of mis-service.
Note: Heavy-duty air filter element manufacturers do not

warranty their products once it has been cleaned.
EL20042
5. To remove the safety element (8), first remove the cotter
pin from the service indicator nut (6). Remove the service
indicator nut and the washer (7). Then carefully remove the
safety element (8) from the upper body assembly (9).
9
8 Note: Do not remove the safety element (8) except to change

it. The safety element is not intended to be cleaned.
Replace the safety element after the third cleaning of
the primary element (5). The frequency of air cleaner
6 service depends on the working conditions of the
machine.
ELI18913
8
Service Air Cleaner (continued)
Note: The service indicator nut (6) on the safety element (8)
is a guide for replacing the element. A green dot in the
6 window indicates that the safety element does not
need replacing. If the green dot is not in the window,
the element is dirty and a new element must be
installed. Do not clean the safety element.
Note: To reset the service indicator nut (6), apply air suction
ELI18913
on the window until the green dot reappears.
6. Clean the inside of the upper body assembly (9) carefully.

Dirt left in the housing has the potential of direct entry to the
engine.
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, gasket (12) and dust cup (13) in order to clean
the tubes.
8. If heavy plugging of tubes with fibrous material 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, gasket (15) and then
lower body assembly (10).
WARNING!
When using regulated compressed air, wear proper clothing
and equipment. Use extreme caution to avoid injury.
Note: Use extreme caution when using compressed air to

keep dirt from entering the engine’s intake system.
9. Assembly of the air cleaner is in reverse order of

disassembly. Use new gaskets and O-rings.
EL20043
10. If further service is required, notify service personnel.
Air Cleaner Dust Cup Check/Clean

The dust cup (13) should be checked during the “Daily Walk Around
Inspection” by simply squeezing the vacuator valve (16) to expel
any dirt. Check the valve for damage and replace if necessary. The
dust cup (13) should be checked and cleaned per the hour interval
listed in the BASIC PREVENTIVE MAINTENANCE INTERVAL
CHART. Loosen the clamp (11) then remove it, gasket (12) and
dust cup (13).
EL19929
Check Air Intake Lines and Clamps

Check the intake elbows, tubes and clamps between the air cleaner
and the engine air intake tubes. Replace any elbows and tubes that
are cracked or damaged. Tighten any loose clamps.
FUEL SYSTEM
Clean fuel is essential for trouble free operation of the engine.

2
Clean the area around the fuel filler cap (9) before you remove it.
Avoid spilling fuel to reduce the chance of a fire and to reduce the
4 build up of dirt.
5
1. Fuel Tank
4 2. Fuel Line Shutoff Valve
3. Fuel Inlet
4. Fuel Return to Tank
5. Fuel Filler Cap
3
3 1
ELI20048
Drain Fuel Tank Sediment
Periodically, water and sediment should be removed from the fuel

tank (1). This should be done when the fuel tank is almost empty.
Close the fuel line shutoff valve (2) at the top of the fuel tank.
Remove the drain plug from the bottom of the fuel tank. Drain water
and sediment into a proper container. When clear fuel 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.
Note: Running out of fuel during operation is detrimental to

engine life.
EL15735
Check the fuel tank and fuel system daily for leaks.
Remove the fuel filler cap (6) from the fuel tank (1). Remove the
strainer from the filler neck and clean. Reinstall the cleaned strainer
or replace it with a new one.
Note: There is a fuel consumption display on the Contronics

screen in the cab.
Fuel Filter
Fuel-W ater Separator

The engine is equipped with two fuel-water separators, built into
the fuel filters. The fuel filters are located on the left side of the
engine. Drain the water and sediment from each separator daily.
1. Shut off the engine

Bypass Oil Filters
Not Present On Vehicles 2. Use your hand to open the drain valve. Turn the valve
With Serial Number 76735
counterclockwise approximately 1-1/2 to 2 turns until
and Above
draining occurs.
EL19633
3. Drain the filter sump of water until clear fuel is visible.
Note: Do not overtighten the valve. Overtightening can

damage the threads.
4. Turn the valve clockwise 1-1/2 to 2 turns to close the drain

valve.
EL
Fuel Filter Change
WARNING!
Fuel is flammable. Keep all cigarettes, flames, pilot lights,
arching equipment, and switches out of the work area and
areas sharing ventilation to avoid severe personal injury
when working on the fuel system.
Note: Close the fuel line shutoff valve before changing the
fuel filters. Refer to FUEL SYSTEM.
Note: The illustrations in this section show typical parts.

The parts on your engine can look slightly different
but the instructions given will apply.
1. Clean the area around the fuel filter head.
2. Remove the fuel filter with a filter wrench.
3. Remove the thread adapter sealing ring.
4. Use a clean lint-free towel to clean the sealing surfaces of

each filter head.
Sealing
Ring
5. Install the new thread adapter sealing ring supplied with the
new fuel filter.
6. Apply a light coating of clean engine oil to the surface of the

filter gasket.
7. Fill the fuel filter with clean fuel.
EL
8. Install the filter on the filter head. Turn the filter until the
gasket touches the surface of the filter head.
9. Tighten the filter an additional 1/2 to 3/4 of a turn after the

gasket touches the filter head surface.
10. Open the fuel line shutoff valve and check for leaks.
EL
Check Fuel Tank Mounting, Lines and Fittings

Check for leaks and replace any damaged hose assemblies, or
mounting hardware. Replace missing bolts, nuts, and washers.
Tighten bolts to the torque specified in the standard bolt and torque
specifications chart. Reference Specification section, “Bolt
Torque Chart”.
COOLING SYSTEM
WARNING!
Do not remove the radiator cap from a hot engine. 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 heated coolant spray or steam. Depress the red button in
the pressure cap to relieve system pressure. Remove the
pressure cap slowly.
Check Coolant Level

ELI19699
The cooling system of the machine was shipped with a solution of

equal parts ethylene glycol and water. This concentration is
recommended for subsequent fills. Check the antifreeze
concentration to protect the system to -37° C (-34° F) year round.
Check The Coolant Level Daily
This can be done when starting the engine while observing the
indicator lights before placing the machine into operation. If the
coolant level falls below the acceptable level the red Engine
Coolant Level Light in the Warning Lamp Display will remain
EL14040 illuminated. An alarm message will also flash on the first display line
of the Contronic Display Unit. The message will read:
“C Eng cool level low” or
“C Eng cool level ER” indicating a error with the sensor or a
short in the circuit.
Add Coolant As Required
1. Shutdown the engine.
2. Prior to removing the pressure cap, depress the red button

on top of the cap to relieve system pressure.
C Eng cool level low 3. Look for leakage. Replace hoses and clamps as required.
Engine xxxx rpm Tighten clamps as required. Check condition of the
Speed yy mph
x-ton ↑ Gear zz coolant. If the coolant looks contaminated, flush the
system.
ELI 4. Add coolant with proper coolant additive concentration, as

necessary to the bottom of the fill neck in the radiator.
Note: Refer to the engine manufacturer’s manual for proper

coolant additive concentration.
Note: Do not add a cold coolant mixture to a hot engine.

Engine castings can be damaged. Allow the machine
to cool down before adding coolant mixture.
Change Coolant Filter

1. Turn the valve on the filter head to the “OFF“ position.
2. Clean the area around the coolant filter head.
ELI19631
3. Remove the filter with a strap or filter wrench.
Note: The O-ring can stick on the filter head. Make sure the
O-ring is removed.
4. Discard the filter after draining remaining coolant out of the

filter and into a container.
5. Clean the O-ring sealing surface of the filter head.
6. Apply a light even coat of lubricating oil to the O-ring

sealing surface prior to installing the filter.
Note: Do not allow oil to get into the filter, it adversely affects
the coolant additive concentrate.
7. Position the filter to the filter head. Tighten the filter by hand
until the seal touches the filter head. Tighten an additional
1/2 to 3/4 turn. Move the filter head valve to the ”ON“
position.
Note: Mechanical overtightening of the coolant filter can

distort the threads or damage the filter seal.
8. Start the engine and check for leaks at the filter head. If
seals leak, shut down the engine and remove the filter and
check the sealing surface. Usually it does not help to
tighten the filter further.
Testing Coolant
Testing of the coolant is recommended if not sure of the cooling
system’s condition due to leaks, uncontrolled topping off of the
system, or major coolant loss.
Testing is also recommended twice a year to monitor the coolant

concentrate level. Refer to the engine manufacturer’s manual.
Change Coolant and Flush System
WARNING!
Do not remove the radiator cap from a hot engine. 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 heated coolant spray or steam. Depress the red button in
the pressure cap to relieve system pressure. Remove the
pressure cap slowly.
1. Shutdown the engine and allow it to cool.
2. Open the drain cock located on the right side of the

radiator’s bottom tank assembly. Drain into a suitable
container.
3. Remove the radiator hose on the right side of the radiator’s

bottom tank assembly. Drain into a suitable container.
4. Remove the plug at the bottom of the brake cooler. Drain

into a suitable container. Remove the plug at the bottom of
the transmission cooler. Drain into a suitable container.
Note: Do not allow the cooling system to dry out. Do not

remove the coolant filters.
5. The cooling system must be clean to work correctly. 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 and follow the
manufacturer’s directions.
6. Close thel drain cock. Install the radiator hose. Tighten the
hose clamp to a torque of 27 N•m (20 ft lbs). Install the
plugs to the brake and transmission coolers. Add clean
coolant with proper coolant additive concentration.
Replace the radiator cap.
EL20049
Note: Refer to the engine manufacturer’s manual for proper
coolant additive concentration.
7. Start the engine and check for coolant leaks.
8. After air has been purged from the system, check the
coolant level again.
Cooling Fan Check
WARNING!
Personal injury can result from a fan blade failure. Never pull
or pry on the fan. This can damage the fan blade(s) and cause
fan failure.
Note: Rotate the crankshaft by using the engine barring

gear.
Check the fan for cracks, loose rivets, and bent or loose blades.
Check the fan to make sure it is securely mounted. Tighten the
capscrews if necessary. Replace any fan that is damaged.
Radiator Clean
WARNING!
When using regulated compressed air, wear proper clothing
and equipment. Use extreme caution to avoid injury.
Check the radiator for leaks, damage, and dirt build up. Clean the
outside of the radiator to maintain proper air flow. Remove the
sections of the grill. Clean the radiator using steam, water, or
regulated compressed air. Reinstall the grill.
Check Cold Start System (Optional)
WARNING!
Keep flammable starting aids in a cool well ventilated
location.
Connect or install an ether cylinder as needed.
1. Loosen the clamps on the ether cylinder.

EL14036
2. Disconnect the ether cylinder from the valve and replace.
Note: The weight of a full ether cylinder is 1.0 kg (35 oz). The
weight of an empty cylinder is 0. 5 kg (17 oz).
Check Belts
Visually check all the engine belt(s). Replace he belts that are
cracked or frayed. Adjust belts that have a glazed or shiny surface
that indicates belt slippage. Correctly installed and tensioned belts
will show even pulley and belt wear.
Belt damage can be caused by.

• Incorrect tension
• Incorrect size or length
• Pulley misalignment
• Incorrect Installation
• Severe operating environment
• Oil or grease on the belts
Check Belt Tension

Measure the belt tension in the center span of the pulleys.
Refer to the engine manufacturers, Operation and Maintenance

Manual for the correct gauge and tension value for the belt width
used.
Do not measure the belt tension when using a fan idler pulley. The
spring loaded idler used on this design maintains the correct belt
tension.
ELECTRICAL SYSTEM
Check Battery Condition
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 batteries. In case of contact with
acid, flush immediately with water.
Battery posts, terminals, and related accessories contain lead

and lead compounds. Wash hands after handling.
The two 12-volt heavy duty batteries are located and protected
under a battery cover on the service deck. Check each battery for
obvious damage such as a cracked or broken case or terminal
EL19891
damage. Replace any damaged batteries.
Check Battery Cables and Connections

Check the battery cables and connections for damage, looseness,
and corrosion. Replace damaged cables as needed. Clean pole
studs and cable terminals. Coat with petroleum jelly or spray with a
battery post fluid. Tighten connections as needed.
Charging Batteries
If battery voltage is below 12.50 volts, re-charge the battery at 1%

of the cold crank rating using a constant 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
TS20788 readings change less than .003 specific gravity units.
Charging Batteries (continued)
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. Always turn the battery
charger off before disconnecting or connecting the leads to
the battery. Provide good ventilation, especially if the battery
is being charged in an enclosed area.
V50391 Always use a voltmeter or hydrometer to check the battery

charge. Never use a metal object across the posts to test a
battery. Sparks may cause an explosion.
Never let the fluid be pushed out of the battery or the
temperature 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
battery from holding the charge. Make sure the battery is a
minimum of 16° C (60° F) before charging.
Check Electrical Wiring and Connections

Check the electrical wiring and connections for damaged,
looseness or corrosion. Replace damaged wiring or components
as needed. Clean and tighten connections as required.
FU1 FU4
FU25
DS FU2 FU5
FU26
RE1 RE2 FU3 FU6
FU27
FA
RE3 RE4
FU7
FU8 Check Fuses
FB FU9 30
RE5 RE6
FU10
FC FU11
FU28
RE7 RE8 FU12
FU29
See Specifications Group 3 section at the back of this manual.
FD FU13
FU30
RE9 RE10 FU14

FU31
FU15
EZ FU32
FU33
FU16
RE11
FU17
FU34
FU18
FU35
EX RE12 RE13
FU19
FU36
FU20
FU37
L RE14 RE15 FU21
FU38
FU39
FU22
SP RE16 RE17
FU23
15
FU24
D D14
D13
EY
31 14 FU40
FU41
FU42 R
EL19501
Check Neutral Start Circuit
WARNING!
Set the parking brake and/or block the wheels as required to
prevent machine movement during this test.
1. Put the shift control lever in the “Drive” position and try to
start the engine. If the starter turns the engine, report this to
the appropriate service personnel.
2. Put the shift control lever in the “R1” position. Try to start
the unit. If the starter turns the engine, report this to the
appropriate service personnel.
Note: If the starter will turn the engine with the shift control
ELI lever in the “Neutral” position only, the neutral start
circuit is operating correctly.
Check Exterior Lights

Check that all exterior lights are in proper operating condition and
EL20024 adjusted properly. Replace and/or adjust as required.
1. High Beam Haultronic II Option 6. Stop/Tail Light
2. Low Beam 3. Amber LED Lamp 7. Reverse Light
3. Amber LED Lamp 4. Green LED Lamp 8. Back-up Alarm
5. Red LED Lamp 9. Horn
Check Back-up Alarm (8)

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.
EL18059
Check Horn (9)

Check the horns and make sure they operate correctly. Report a
defective horn to service personnel.
EL14986
Check Gauges and Indicator Lights
Check that all indicator lights are in proper operating condition and
adjusted properly. Replace and/or adjust as required. Turn key to
”ON” position. Do not start engine. Look for flashing lights and
error messages on the Contronic display. Normal operating
conditions allow for parking brake, brake pressure, steer pressure,
and alternator lights to be illuminated. No error messages should be
ELI
flashing on the Contronic display.
Welding on Machines With Allison Transmission

Commercial Electronic Control I (CEC I) System and
Contronic System.
When performing any welding operation on a machine with Allison

Transmission Commercial Electronic Control System follow these
precautions:
1. Turn the battery disconnect switch to the OFF position.
ELI19875
Engine Compartment
2. Disconnect the two electrical leads at the alternator located

on the left side of the engine.
EL19947
3. Never connect the ground cable of the welding equipment

to the engine’s Electronic Control Module (ECM). Welding
on the engine or any engine mounted component is not
recommended. The ECM is located on the right side of the
engine.
ELI19948
Main Electrical Panel
4. Disconnect the EX, EY and EZ connectors at the circuit

board.
5. Disconnect the electronic hoist controller at connector

CN135A.
EZ 6. Disconnect the optional active traction control/electronic
EX downhill speed control ATC/EDSC, brake control unit at
connectors, EA and EB.
EY
ELI19949
Transmission
J1A 7. If welding in close proximity of the Allison ECU, it is

advisable to disconnect the following ECU connectors:
J1A, J1B and J3.
J1B J1A 8. Do not connect welding cables or weld on the Allison

J1B Transmission, Commercial Electronic Control I system
components.
J3 J3
9. If welding is to be done close to Allison Transmission,
Commercial Electronic Control I system components, the
component should be removed while welding.
ECU Disconnects
EL15891 10. When welding is complete, reconnect all cables and wires
in reverse order. Turn the battery disconnect switch to the
ON position.
CENTERLINE OF
LOW BEAM LAMP
C
L
HIGH BEAM
HIGH INTENSITY
51 mm (2 in) ZONE
CENTERLINE OF
C
L LAMP HEIGHT
LOW BEAM
8 m (25 ft) HIGH INTENSITY
ZONE
C
L
CENTERLINE OF
HIGH BEAM LAMP
SIDE VIEW FRONT VIEW ELI14042
Adjusting Headlights
The standard SAE prescribed method of aiming headlamps of a
four-lamp system is outlined as follows. This method should be
used unless specific job conditions indicates otherwise.
The machine should be parked on level ground, 8 m (25 ft) from a

wall or screen, which is perpendicular to the horizontal centerline of
the machine. Once the position of the machine has been
established, proceed as follows:
1. Measure the distance “D” from the lamp center to the

ground level, then transfer this dimension 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 dimension “D” on the
wall or screen. This represents the horizontal centerline of
the high beam lamp center.
3. Adjust the high beam lamp (laterally) so that the center of

the high intensity zone is in a vertical line straight ahead of
the lamp center.
4. Adjust the low beam lamp (up or down) so that the top edge
of the high intensity zone is 51 mm (2 in.) below the
horizontal centerline level of the high beam lamp center.
5. Adjust the low beam lamp (laterally) so that the center of

the high intensity zone is in a vertical line straight ahead of
the lamp center.
POWER TRANSMISSION
Check Transmission Fluid Level
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
engine. If no fluid is present add sufficient fluid at the filler tube to
bring the level within the glass of the sight gauge. The filler tube is
located on the right hand side of the machine in the area just ahead
of the rear tire.
Perform a hot fluid level check.

EL15704
Hot Fluid Level Check

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 if there is sufficient fluid

for working operation of the transmission.
Shift the transmission shift selector to N neutral and start the

engine. Operate the machine 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 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,
middle of sight gauge.
WARNING!
TRANSMISSION Protect eyes (safety glasses) and skin against contact with
FILLER TUBE transmission fluid. If fluid gets on the skin, wash the
contacted area immediately.
EL18565
Change Transmission Fluid and Filter
WARNING!
Hot oil can cause severe burns.
Drain the transmission fluid when it is warm. Warm fluid flows more
freely and carries more contaminants with it. Change the
transmission fluid, transmission filter and clean the transmission
SUCTION
STRAINER strainer at intervals listed in the “Maintenance Interval Chart”.
DRAIN 1. Remove the drain plug from the sump. The drain plug is
PLUG
located at the right hand side of the transmission. Allow the
fluid to run out. Check the fluid carefully for metal particles
ELI15774 and traces of coolant leakage. Replace the plug.
Metal particles in the fluid (except for the minute particles

normally trapped in the filter and strainers) indicate
damage has occurred in the transmission.
If engine coolant leaks into the transmission hydraulic

system, take immediate action to prevent malfunction and
possible serious damage.
2. Remove the cylindrical suction strainer assembly located

in the sump. Clean the suction strainer assembly
thoroughly. At each cleaning, use a new cover gasket when
installing the suction strainer and cover.
Note: The sump strainer should be cleaned only at

transmission overhauls. The cooling line strainer
should be cleaned at fluid and filter changes.
Change Transmission Filter

The transmission filter is remote mounted to the left hand side of the
machine’s frame.
3. Remove the filter shell. Remove the filter element. Inspect

for contamination. Visible dirt or contamination can
indicate possible failure or damage. Discard the old
element. Thoroughly clean the filter shell.
4. Install a new filter element. Install the filter shell, using new
gaskets or seal rings.
TRANSMISSION
HYDRAULIC
5. Refill the transmission with clean transmission fluid at the
TRANSMISSION
STRAINER FILTER filler pipe. Continue to pour fluid into the transmission until
ELI19813 the correct level is indicated at the sight gauge.
6. 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.
7. After enough fluid is added to stabilize the pressure,

operate the machine through all ranges until the
transmission fluid reaches operating temperature. Stop
the machine and check the fluid as outlined in Hot Fluid
Level Check. Add fluid, if required, while the engine is
running.
8. Carefully inspect for fluid leakage while the engine is

running.
Change Transmission Breather

The transmission breather is remote mounted at the service deck.
The breather prevents pressure buildup within the transmission.
Keep the breather clean and the passage open.
EL19711
1 1. Clean the area around the transmission breather.
2. Remove the breather and discard the old breather filter

2 element.
• Loosen and remove the nut (1) at the top of the breather.
• Lift off the breather cover (2).
3 • Remove and discard the old breather filter element (3).
3. Install a new breather element.
ELI14782
Change Transmission Hydraulic Strainer

Change the transmission hydraulic strainer at intervals listed in the
“Basic Preventive Maintenance Interval Chart”. The
transmission hydraulic strainer is remote mounted to the left hand
side of the machine’s frame.
1. Remove the plug and O-ring at the bottom of the canister

and drain the fluid into a suitable container.
2. Loosen the canister (1) at the notched ring lock area.

TRANSMISSION 3. Remove the canister (1) allowing transmission fluid to drain
HYDRAULIC TRANSMISSION into a suitable container.
STRAINER FILTER
ELI19813 4. Remove and discard the filter element (2) and the O-ring
(3). Inspect the canister (1) for contamination. Visible dirt or
contamination can indicate failure or damage.
3
Change Transmission Hydraulic Strainer
2
(continued)
5. Thoroughly clean the canister (1) in a suitable solvent.
1 6. Insert a new filter element (2) in the canister (1). Using the
new O-ring (3), that comes with the new filter element,
install the canister (1) to the mounting.
ELI18987
Check Differential Lubricant Level
Clean the area around the level plug (A). Remove the plug and
check the lubricant level in the differential. Add lubricant as required
until the lubricant level is at the plug opening. Clean and install the
level plug.
A
EL15736
Change Differential Lubricant
WARNING!
Protect eyes (safety glasses) and skin against contact with
lubricant. Contains strong corrosive substance. Flush
exposed areas with clean water and get medical attention.
1. Remove the differential drain plug (B) from the axle

B housing and drain the lubricant. Clean and install the drain
plug.
2. Remove the level plug (A) from the axle housing and add
lubricant until the level is at the plug opening. Clean and
install the level plug.
Note: The lubricant oil in the differential and the rear wheel
planetaries are common with each other. When
changing the differential oil, the planetary oil in each
wheel should also be changed.
Check Rear Planetary Hub Lubricant Level

B A 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. Clean the area around the axle
shaft cover bolt (A) that is immediately next to the “Oil Level”
indicator mark. Remove cover bolt (A) and check that lubricant is at
the opening. If lubricant is not seen, clean the area around fill plug
(B). Loosen and remove fill plug (B) and add lubricant until the level
is at the opening of bolt (A). Clean and install bolt (A) and plug (B).
ELI15780
Change Rear Planetary Hub Lubricant
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.

B A 1. Turn the wheel until the planetary drain plug (C) is at the 6
o’clock position. Clean the area around the drain plugs
from each planetary and remove the plugs.
2. Drain the lubricant from each planetary. Clean and install

the drain plugs.
C 3. Clean the area around the axle shaft cover bolt (A) and
remove. Clean the area around the oil fill plug (B) and
remove.
ELI15781
4. Add lubricant as needed at fill plug (B) until the lubricant
flows from cover bolt hole (A). Clean and install both the
plug and the bolt. Do Not Over-Fill.
Change Axle Breather

The axle breather is remote mounted on the frame, directly above
the rear axle.
1. Clean the area around the axle breather.

element.
EL18566 • Remove and discard the old breather filter element (3).
1
4. Inspect the hose leading to the breather and make sure it
has no bends which will trap oil and prevent proper
2
breathing.
ELI14782
BRAKE SYSTEM
Check Brake Operation
WARNING!
The testing of brakes should only be performed by trained
personnel in areas approved for such testing.
Be careful of personnel around the machine.
High pressure hydraulic oil, hot oil hazard. The brake system
must be relieved of pressure before any attaching lines are
removed. The brake accumulators store pressure that may
release without warning
Brake Pressure Release Procedure
• With the machine “OFF”, pump the service brake pedal

(approximately 9 times) until the low pressure sensor
automatically applies the brakes.
• Brakes are now applied to all 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 container.
Rear Brake
Apply Port OR at the Brake Valve which is located at the front of the
cab, behind the exterior panel. (Will require the
EUCLID-HIT ACHI Pressure Testing Kit. Refer to
SPECIAL TOOLS , Group 179 in the Service Manual.
• Place one end of a hose line, from the Pressure Testing Kit,
into a suitable container. Attach the fitting end to the front
brake apply port. Slowly tighten the fitting until oil flows into
a suitable container. When the oil flow stops, remove the
fitting and repeat the procedure at the rear brake apply
port.
Check the service brakes, retarder, and the parking brake for
correct operation daily. Report any unusual performance to proper
service personnel. A daily check of the brake operation is a must.
Front Brake
Apply Port Supply Port Note: Refer to Group 5 of the Service Manual for specific
adjustment and inspection procedures as required.
Check Brake Operation (continued)
Service Brakes/Retarder
Daily
• Inspect visually for damage or leaks.
• Immediately report any stopping or grade holding deviation

from “ familiar” performance.
Every 1000 Hrs.
• Check brake pressures.
• Completely inspect the brakes, valves, accumulators and

related plumbing for leaks and/or damage.
• Check front brakes for wear and damage.
Perform the following procedure only if the performance of

the brake system is in question. This procedure should not be
used as a scheduled performance check and never more fre-
quently than every 1000 hours.
• Static capacity procedure: Move the machine to an ap-

proved testing location. Apply the service brakes and se-
lect 1st. gear. Slowly accelerate the engine until the stall
speed listed in the Specifications section of this manual for
the particular engine is attained. The machine should not
move. Release the throttle.
• Retarder static capacity procedure: Move the machine

to an approved testing location. Place the transmission in
manual mode as shown .Terminals 309, 311, 313 and 315
EL18552 should be connected together to obtain the manual shift
mode feature. Install jumper wires between terminals 309,
311 and 313. Terminals 313 and 315 are already connected
together with a jumper wire. These are located on the panel
behind the buddy seat. Apply the retarder pedal fully and
select 2nd gear. Slowly accelerate the engine until the stall
speed listed in the Specification Section of this manual, for
the particular engine, is attained. The machine should not
move. Release the throttle. Remove test jumpers to return
transmission to automatic mode.
Parking Brake
Daily
• Inspect visually for damage and leaks.
• Check operation.
1000 Hours.
• Inspect the brake, linkage and actuator for leaks or

damage. Adjust per Service Manual if required.
The following procedure may be performed as often as based on

specific operating environment.
• Holding capacity procedure: With the machine fully loaded,

descend a typical grade on your job site and completely
stop the machine. Hold the machine using the service
brakes. Select neutral. Apply the parking brake and
release the service brakes. The machine should not move.
Note: While performing above test make sure the

Load/Dump brake is not applied.
Brake Accumulators & Secondary Brake System
Daily
• Inspect visually for leaks and damage.

250 Hours.
• Secondary capacity check procedure: Insure that all

systems are at operating range. Select neutral and apply
parking brake with hoist lever in ”HOLD”. Release service
brakes and/or the load/dump brake. Shut down the
machine and wait 3 minutes for the steer accumulator to
bleed down. Apply the service brakes and release rapidly.
Three (3) complete applies should be achieved without
(low pressure sensor) automatic application. Check
accumulator pre-charge and/or inspect system for
excessive leakage if capacity is less than above stated.
Note: Above procedure insures that at least one axle has

capacity for 3 full applies.
1000 Hours.
• Check the accumulators for proper pre-charge by

removing the bolts that secure the cover plates over each
test port. Attach a suitable gauge and check the pressure
as listed in the Specifications section of this manual.
Note: The hydraulic pressure must be bled from the

EL15723 accumulators to insure an accurate precharge
reading.
WHEEL SUSPENSION AND STEERING
WARNING!
STEERING
BRAKE Release all system pressure slowly before working on any
APPLY part of the steering system. Once the engine is shutdown,
SECTION
turn the steering wheel several times to relieve the hydraulic
HOIST/BRAKE pressure that may be present in the lines.
COOLING High pressure hydraulic oil can cause severe injury.
SECTION
Check Steering Operation

The steering system can be checked with the engine running as
follows:
EL15705
1. The steering wheel should turn the wheels easily to the left
------ STEER ------ and right without any binding.
Pressure normal
Temp 130 F
Filter normal 2. The Contronic display should show system pressure
“normal”.
EL14873
Check Steering System Fluid Level
The dual purpose hydraulic tank is divided into two sections. One
section contains the steering and brake apply oil, and the other
ENGINE NOT section contains the hoist and brake cooling system oil.
RUNNING
Note: Refer also to Check Hydraulic Fluid Level later in this
section.
1. Check the fluid level prior to the start of each shift, with the
machine 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
ENGINE cap before opening.
RUNNING
3. If fluid is needed, remove the cap and add clean fluid as
needed. See Specifications section in this manual for
recommended fluid.
EL15942
4. With the engine running, the oil level in the steering-brake
section of the hydraulic tank will drop and should be seen in
opposite the “Engine Start” decal as illustrated at the left.
Change Steering System Fluid
WARNING!
Release all system pressure slowly before working on any
part of the steering system. Once the engine is shutdown,
turn the steering wheel several times to relieve any hydraulic
pressure that may be present in the lines.
High pressure hydraulic oil can cause severe burns.
STEERING HOIST/BRAKE
BRAKE COOLING 1. Clean any dirt away from the top of the hydraulic tank.
APPLY SECTION
SECTION 2. Remove the drain plug from the bottom of the
steering-brake section of the hydraulic tank and allow the
fluid to drain into a suitable container.
3. Remove the bolts and washers which secures the adapter

assembly for the steering suction hose assembly to the
back of the tank. Carefully remove the adapter assembly
EL14060 and the attached strainer from the tank. Remove and
discard the O-ring.
4. Make sure the strainer is clean and free of contaminants.

Clean and or replace as necessary.
5. Clean the inside of the hydraulic tank.
6. 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 plugs.
7. 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.
8. Start the engine. Allow the fluid to reach operating

temperature. Turn the steering wheel several times. Check
the tank, hydraulic steering lines, and cylinders for
leakage.
9. 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. See Specifications
section in this manual for recommended fluid.
Change Steering System Hydraulic Filter

1. Shut the engine off and block the wheels.
2. Remove the cover with a spanner wrench or open end

wrench.
3. Remove the relief valve and the hold down assembly.

EL18573
4. Remove and replace the element.
5. Reverse the removal procedure and check for leaks.
COVER
HOLD
DOWN
ASSEMBLY
RELIEF
VALVE
ELEMENT
ELI14620
Check Steering Accumulator

The steering accumulator should be checked at the beginning of
each shift as follows:
1. With engine ”OFF”, check oil level per Check Steering

ENGINE System Fluid Level, explained previously in this section.
RUNNING
2. Start engine, after one minute at idle, fluid level should be
at the ”ENGINE RUNNING” decal.
EL15942
Steering Reservoir Breather

This breather is also for the Hydraulic Reservoir. See Change
Hydraulic Reservoir Breather later in this section.
FRAME, SPRINGS, AND WHEELS
Check Suspension Struts

During the first 48 hours of operation the helium gas and the
Neocon-E in the struts will mix in a dissolution 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
period, the struts should be checked at regular intervals (See
Maintenance Interval Chart, in this manual). To monitor the
GLAND ASSEMBLY condition of the strut, there is only one dimension to be checked.
That is the X-2 space between the cylinder gland assembly and the
top of the rod assembly. This check is to be accomplished only with
FRONT STRUT
X-2 X-2 = 260 + 38 mm the machine empty and parked on level ground. Prior to checking,
(10.25 + 1.50″) the machine should be operated a minimum of one hour. Avoid hard
braking of the machine. Failure to follow this procedure may result
ROD ASSEMBLY in false readings.
EL15735
Front Strut X-2 - Rod length - empty machine, 260 ± 38 mm

(10.25 ± 1.50”).
GLAND ASSEMBLY
REAR STRUT
X-2 X-2 = 127 + 13 mm
(5.0” + 0.50″)
ROD ASSEMBLY
Rear Strut X-2 - Rod length - empty machine, 127 ± 13 mm
(5.0 ± 0.50”).
Check Wheels
Check wheels for damage, looseness and missing bolts. Replace
or tighten as needed.
• Replace any missing or damaged wheel mounting bolts.

• Tighten all wheel mounting nuts to 942 N•M (695ft.lbs.).
Note: After wheel removal, wheel bolt torque must be
checked again after the first five and ten hours of
operation. Refer to SERVICE MANUAL, Group 7,
Tire/Rims/Inflation for additional removal
instructions.
Check/Change Front Wheel Bearing Lubricant
The front wheel bearings on this machine use a synthetic base

grease lubricant (Mobil ”Mobilith 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 accumulates hours, the grease will
become black. This does not mean the grease needs to be
changed - it is considered normal for this type of grease.
EL19814 Check Tire Pressure
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 an antifreeze.
With the machine empty and the tires cold, check the pressure in all
six tires. Refer to the Specifications section in the back of this
manual under Wheels (Group 7) for tire inflation pressures. 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

manufacturer for tire inflation pressures.
Note: For wheel removal, consult the Service Manual for this
machine. For complete information pertaining to
dismounting and mounting the tires on the rims, refer
to the tire manufacturer’s tire maintenance manual or
contact your local off-highway tire dealer.
EL18067
Check Tire Condition

Check the condition of the tires with the machine empty. Make a
report of any damaged tires.
See your service manual for alignment procedures if tires show

excessive wear.
WARNING!
Let the air out of the tire before 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 remove the
dirt and rust from the lock ring groove before installing the
ring.
For complete information pertaining to dismounting and

mounting the tires on rims, refer to the tire manufacturer’s tire
maintenance manual or contact your local off-highway tire
dealer.
CAB
Check and Clean Cab Air Filter

Remove the screws from the filter cover on the right-hand side of
the cab. Remove the cover and the air filter. Check the filter, clean
or replace as required. Install the filter and the filter cover.
CLEANING METHODS:
TAPPING Tap gently on a flat surface, dirty side down.
AIR Direct compressed air through the air filter opposite the
direction of the “Airflow” arrows.
(.3175 cm [.125 in.] diameter nozzle at least 5.08 cm [2 in.] away
from filter element and maximum air pressure 689 kpa [100 psi] .)
WATER
• Soak 15 minutes in water and element cleaner.
• Rinse until clean (Maximum pressure 276 kpa (40 psi).
• Air dry. DO NOT USE compressed air.
EL15043
Check Cab Mounts

Check all cab mounts daily. Report damaged shock mounts to ser-
vice personnel. Replace as required. The two rear cab mounts are
accessible by two plates at the rear of the cab. The front cab mount
can be checked by removing the exterior panel assembly at the
front of the cab.
EL
Check Wiper Blade Condition

Check the wiper blade for wear or damage. Replace as needed.
EL18569
Check Windshield Washer Fluid Level

The windshield washer fluid reservoir is located on the service
deck, between the battery and air cleaner. Check the fluid level of
the windshield washer daily. Add fluid as needed.
EL15775
Check Seat Belt and Seat Belt Mounting

Inspect the seat belts for damage or wear. Check the buckle for cor-
rect operation. Repair or replace as needed.
Check for loose mounting support bolts. Tighten all loose bolts. Re-
place as needed.
Note: Your style of seat may vary from the description

shown. This inspection applies to all seats. Check the
belts and all mounting bolts. Repair or replace as
needed.
ELI
Check Air Conditioning
WARNING!
The air conditioning system is pressurized, and filled with
refrigerant. Never disconnect any hoses or remove the
compressor 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, poisonous gas may be produced that can be very
dangerous. Always wear acceptable eye protection when
working with refrigerant. Do not let refrigerant come in
contact with any part of the body. If refrigerant makes contact
with the skin, seek medical attention immediately, it can cause
severe frostbite.
WARNING!
The air conditioning unit uses the refrigerant Freon 134a.
Refrigerant Freon R134a is hazardous to the environment and
EL19719
is not to be released into the open air. Any service, refilling
(charging) or emptying (discharging) of refrigerant Freon
R134a must be carried out by trained and qualified service
personnel.
Note: To lubricate the air conditioning compressor seals,

the unit should be run for about 5 minutes at least
once a month.
Check Heater and Defroster
Check switches daily to make sure the heater and defroster

operates correctly. Refer to the Instrument Panel section in this
manual for correct operation. Repair as needed.
HYDRAULIC SYSTEM AND OTHER FUNCTIONS
Check Hydraulic Fluid Level
WARNING!
STEERING
BRAKE
APPLY Release all system pressure slowly before working on any
SECTION part of the hydraulic system.
HOIST/BRAKE Hot fluids can cause severe burns.
COOLING
SECTION
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.
Note: Refer also to Check Steering System Fluid Level

EL15705 earlier in this section.
1. Check the fluid level prior to the start of each shift, with the
machine on level ground, the body lowered, and the engine
ENGINE OFF off.
OIL LEVEL
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.
3. If fluid is needed, remove the cap and add clean fluid as

needed. See Specifications section in this manual for
recommended fluid.
EL14997
Change Hydraulic Fluid
WARNING!
Release all system pressure slowly before working on any
part of the hydraulic system.
Hot fluids can cause severe burns.
STEERING HOIST/BRAKE Note: Refer also to Change Steering-Brake Fluid, previous

BRAKE COOLING
APPLY SECTION in this section.
SECTION 1. Clean any dirt away from the top of the hydraulic tank.
Note: Refer to the Service Manual, Group 911 Hydraulic Oil

Tank, for an exploded view of the hydraulic tank.
2. Remove the drain plug from the bottom of the hoist/brake

EL15174 cooling section of the hydraulic tank and allow the fluid to
drain into a suitable container.
3. Remove the three hose assemblies from the three adapter

assemblies at the back of hydraulic tank, hoist/brake
cooling section. Be prepared to catch any fluid into a
suitable container.
4. Remove the bolts and washers which secure the three

adapter plates to the tank. Remove each adapter plate,
O-ring and diffuser or suction strainer. Discard the
O-rings.
5. Make sure that the suction strainers and diffuser are clean
and free of contaminants. Clean and or Replace if
necessary.
6. Clean the inside of the hydraulic tank, hoist/brake cooling

section.
7. With the suction strainer and diffusers installed on the

appropriate adapter 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 “Full” mark next to the sight gauge. Refer
to Check Hydraulic Fluid Level. Replace the filler cap.
10. Start the engine. Allow the fluid to reach operating

temperature. Raise the body several times. Check the
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 fluid as
needed until the level is at the “Full” mark next to the sight
gauge. See the Specifications section in this manual for
recommended fluid.
Change Hydraulic and Brake Cooling Filters
WARNING!
Hot fluids can cause severe burns.
The hydraulic and brake cooling filters are located on the right hand
side of the machine, mounted at the frame
1. Shut the engine off and block the wheels.
EL18574
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 contamination can indicate
possible component damage. Discard the element.
O-RING 4. Visually inspect the remaining components for possible
BOWL damage or malfunction. Replace as necessary. Clean the
inside of the bowl.
5. Using a new filter element and O-ring, reverse the removal

procedure, tighten the cap in the motion control valve pilot
line and check for leaks.
ELEMENT
O-RING
PLUG
ELI20053
Change Hydraulic Reservoir Breather

The hydraulic reservoir breather is remote mounted at the service
deck. Keep the breather clean and the passage open.
1. Clean the area around the hydraulic breather.

element.
EL19712
• Remove and discard the old breather filter element (3).
1
2
Clean and Check All Lines and Hoses,

3
Brake, Steering and Hydraulic
WARNING!
ELI14782
Improper selection, installation or maintenance may result in
premature failures. Which could result in bodily injury or
property damage.
To find leakage, use a piece of cardboard or wood, NOT your

hand. If hydraulic fluid is injected into your skin, it must be re-
moved immediately by a doctor.
Inspect all hoses daily and check for the following:
• Leaks at fitting or in hose (leaking fluid is a fire hazard).

• Damaged, cut or abraded cover (any reinforcement ex-
posed).
• Kinked, crushed, flattened or twisted hose.
• Hard, stiff, heat cracked or charred hose.
• Blistered, soft, degraded or loose cover.
• Cracked, damage or badly corroded fittings.
• Fitting slippage on hose.
The following items must be tightened, repaired or replaced as re-
quired:
• Leaking port conditions.

• Clamps, guards and shields.
• Remove excessive dirt build-up.
• Clean hoses completely, inspect and replace.
Check Body Prop Cable
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.
EL19788
When working on a machine 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.
EL19789
Automatic Centralized Lubrication System (Option)

Level Check and Fill
The level indicator, a follower rod and bracket are located on the top
of the reservoir’s cover. The rod in relation to markings on the
bracket will indicate the lubricant level in the reservoir. The
markings will indicate; “FULL”, “LOW LEVEL”, and “EMPTY”.
Note: Never allow the reservoir to run dry of grease. With no

lubricant the pump will speed up quickly, creating
friction heat, which can damage the pumps internal
seals.
Clean around the pipe plugs at the inlet and vent areas. Remove the
lower and upper pipe plugs. Attach the appropriate bulk-filling
pump to the lower inlet (3/4 NPT). Fill the reservoir until grease
appears at the upper (1/2 NPT) vent high level port. Remove the
bulk-filling pump. Replace both pipe plugs.
VENT
WARNING!
When filling the reservoir, caution should be used as extreme
pressure can cause damage to the reservoir or serious
INLET personal injury.
ELI19665
Chassis And Driveshaft Grease Fitting Locations (50 HOUR INTERVAL)
No. Location Lube Interval Hours No. of Fittings

1 Trailing Arm Bushings 50 4
2 Front Ride Strut Bearings 50 4
3 Rear Axle Linkage Bearings 50 7
4 Body Hinge Pins 50 2
5 Rear Ride Strut Bearings 50 4
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.
2 1 2 3 5 5 6
2 1 2 3 8 4 4 6 ELI19666
Chassis And Driveshaft Grease Fitting Locations (50/1000 HOUR INTERVAL)
No. Location Lube Interval Hours No. of Fittings

1 King Pin 50 4
2 Steering Cylinder Bearings 50 4
3 Tie Rod End Bearings 50 2
4 Driveline Slip Joint 50 1
5 Driveline Universal Joint 50 4
6 Hoist Pin, Upper and Lower 50 4
7 Park Brake Linkage 50
8 Steering Column Driveshaft 1000 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.
NOTES
SPECIFICATIONS 183
RECOMMENDED LUBRICANTS
OPERATING OIL TEMPERATURE (AMBIENT) -18° C TO 43° C (0° F TO 110° F)
OIL GRADE °C -20

-30 -10 -0 10 20 30 40 50
°F -22 -4 14 32 50 68 86 104 122
Cummins Engine Heavy Duty Engine oil
API Classification CE or
CF4 SAE 15W-40
Use Synthetic CE/SF
(or equivalent) When
consistently operating 5W-40
Below -18°C (0°F)
Transmission and Allison C-4  Fluid

Converter Preheat fluid when op-
SAE 15W-40 (SEE NOTE #3)
erating below -18°C
(0°F), if preheating
equipment is not avail-
able, run the transmis- PREHEAT
sion a minimum of 20
minutes prior to range
operation.
Differential, Plane- Multi-Purpose Gear Oil SAE 140
taries Meeting MIL- L 2105C or
API GL-5 Spec.
SAE 85W-140
Below -18°C (0°F) use
80W-90 Synthetic 80W-90
Body Hydraulics and SAE 10W (SEE NOTES #1, #2, & #3)
Brake Cooling System Allison C-4  Fluid
Grease Fittings: Multi-Purpose Lithium
Base Extreme Pressure NLGI GRADE NO. 2
Grease
Grease Fittings King
Pin
Standard Machines Mobilgrease CM-P MOBILGREASE CM-P
(or equivalent)
Automated/Central Mobilgrease CM-L MOBILGREASE CM-L

Lube Systems (or equivalent)
NEOCON-E Fluid:
Ride Struts NEOCON-E
NEOCON-E Fluid can
be used in temperatures
to -40 °C (-40 °F).
Body Prop Cable and Corrosion Preventing

Body Pin Prop Gear Lube
Brake Actuation and Allison C-4  Fluid SAE 10W (SEE NOTE #1 & #3)
Steer System
Front Wheel Bearings Mobilith SHC 007

or Equivalent Mobilith SHC 007
184 SPECIFICATIONS
RECOMMENDED LUBRICANTS (continued)
Note 1: For ambient temperatures below -18° C (O° 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 II  or Dexron III  automotive
transmission fluid.
Note 3: Can substitue CAT TO2 qualified oil. DO NOT USE CAT TO4 qualified oil
When start- up conditions are colder than specified in the chart, an anti-wear hydraulic oil with Viscosity Index
(VI) improvers or a synthesized hydrocarbon oil should be used to obtain the desired viscosities. During start
up, when the oil is at atmospheric temperature, the viscosity should not exceed 4,600 SUS or 1,000 cen-
tistrokes (mm 2/s). Higher viscosities may cause pump damage from cavitation and/or incomplete bearing
lubrication. At the same time the viscosity should be maintained between 80-280 SUS of 16 to 60 cST when
the system has reached its operating temperature. Consult your local lubrication specialist to obtain an oil to
meet these requirements. If a suitable oil cannot be identified, consult the factory for a preheating system.
Fuel Specifications
Number 2 Diesel Fuel
Grade C for ambient temperature above -18° C (0° F)
Grade B for ambient temperature below -18° C (0° F)
Capacities
Liters Gallons
Engine Crankcase with Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143 38
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276 73
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1003 265
Torque Converter and Transmission . . . . . . . . . . . . . . . . . . . . . . . 99 26
Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 39
Planetaries (per side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 23
Front Wheel Bearings (per side) . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6 2
Steer System Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189 50
Steering Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 31
Windshield Washer Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6 2
Hydraulic System Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 473 125
Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318 84
Front Ride Strut (both struts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.5 7
Rear Ride Strut (both struts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30.3 8
SPECIFICATIONS 185
SERVICE SPECIFICATIONS (Group 2)
Engine:
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cummins
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . QST 30
Number of Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 mm (5.51 in)
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 mm (6.50 in)
Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30.5 l (1861 in3)
Maximum Torque @ 1400 RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5084 N•M (3750 ft. lbs.)
Rated Output @ 2100 RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 895 kW (1200 HP)
ISO Net HP @ 2100 RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 836kW (1121 HP)
Speed
Rate Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2100 RPM
Maximum No Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2350 RPM
Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 650 RPM
Maximum Safe Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2400 RPM
Stall Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1925 ± 100 RPM
186 SPECIFICATIONS
Electrical (Group 3)
Batteries
Group Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8D
Reserve Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440 Minutes @ (25A, 80 deg. F)
Cold Crank Amps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1150 @ 0 deg. F
Voltage each . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Volt
Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 (connected in series/parallel)
System Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Volts
Alternator
Ampere . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Volt
Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Negative
Starting Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Volt
Allison Commercial Electronic Control System (C.E.C.) . . . . . . . . 12 Volt
Lights
Headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 H.I.D
Stop/Tail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 L.E.D.
Backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Halogen
Turn & Clearance-Std. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 L.E.D. Front/2 L.E.D. Rear
Circuit Board
FU1 FU4
FU25
DS FU2 FU5
RE1 RE2 FU26
FU3 FU6
FU27
FA FU7
RE3 RE4 FU8
FB FU9 30
RE5 RE6 FU10
FC FU11 FU28
RE7 RE8 FU12 FU29
FD FU13 FU30
RE9 RE10 FU14 FU31
EZ FU15 FU32
FU16 FU33
RE11
FU17 FU34
FU18 FU35
EX RE12 RE13 FU36

FU19
FU20 FU37
L RE14 RE15 FU21 FU38
FU22 FU39
SP RE16 RE17
FU23
15
FU24
D D14
D13
EY
FU40
31 14
FU41
R
FU42
EL17114
SPECIFICATIONS 187
FUSES
NUMBER RATING (Amps) DESCRIPTION VEHICLE LOCATION
FU1 10 IGNITION SWITCH CIRCUIT BOARD

FU2 15 START RELAY (RE 1) CIRCUIT BOARD
FU3 20 MAIN LIGHT SWITCH CIRCUIT BOARD
FU4 15 HORN RELAY (RE3) CIRCUIT BOARD
FU5 10 STEER BLEEDDOWN CIRCUIT (RE4) CIRCUIT BOARD
FU6 5 SPARE CIRCUIT BOARD
FU7 20 ENGINE CONTROL SYSTEM CIRCUIT BOARD
FU8 10 FLASHER CIRCUIT BOARD
FU10 5 LEFT FRONT MARKER LIGHTS CIRCUIT BOARD
FU11 5 RIGHT FRONT MARKER LIGHTS CIRCUIT BOARD
FU12 5 LEFT & RIGHT TAILLIGHTS CIRCUIT BOARD
FU13 10 WINDSHEILD WIPER CIRCUIT BOARD
FU14 5 DYNAMIC RETARD CIRCUIT (RE8) CIRCUIT BOARD
FU15 10 REVERSE LIGHT AND ALARM CIRCUIT BOARD
FU16 10 AIR SEAT & LINCOLN LUBE CIRCUIT BOARD
FU17 5 ENGINE SHUTDOWN SWITCH(RE12,13) CIRCUIT BOARD
FU18 5 ELECTRONIC HOIST CONTROLLER CIRCUIT BOARD
FU19 5 LOAD WEIGH LIGHTS (RE14,15,16) CIRCUIT BOARD
FU20 20 HEATER BLOWER SWITCH CIRCUIT BOARD
FU21 5 FRONT BRAKE DISABLE CIRCUIT BOARD
FU22 10 LEFT & RIGHT LOW LOWBEAMS CIRCUIT BOARD
FU24 5 PRESSURE/TEMPERATURE/LEVEL CIRCUIT BOARD
FU25 10 HEATED MIRROR OPTION CIRCUIT BOARD
FU27 5 ENGINE SHUTDOWN CIRCUIT BOARD
FU28 10 ENGINE SERVICE LIGHTS CIRCUIT BOARD
FU29 10 RETARDER CIRCUIT BOARD
FU30 15 DOME LIGHT CIRCUIT BOARD
FU31 5 ENGINE DIAGNOSTICS CIRCUIT BOARD
FU33 10 LEFT & RIGHT HID HIGHBEAMS CIRCUIT BOARD
FU34 5 LOAD/DUMP BRAKE CIRCUIT BOARD
FU35 5 PARK BRAKE CIRCUIT BOARD
FU36 5 ELECTRONIC TRANSMISSION CIRCUIT BOARD
FU37 5 24VDC POWER CONTRONIC ECU CIRCUIT BOARD
FU38 10 HEATED SEAT OPTION CIRCUIT BOARD
FU39 5 BODY UP CIRCUIT CIRCUIT BOARD
FU40 15 RADIO OPTION CIRCUIT BOARD
FU41 15 CIGAR LIGHTER CIRCUIT BOARD
FU42 20 POWER PORT CIRCUIT BOARD
FU43 20 HEATED SEAT REMOTE BLOCK
FU44 SPARE REMOTE BLOCK
FU50 10 ELECTRONIC TRANSMISSION CAB REAR
Note: For more information refer to the Schematic Book included in the cab at delivery for Electrical
Schematics. Refer also to Group 300, Electrical System-General in the Service Manual.
188 SPECIFICATIONS
RELAYS
RELAY NUMBER DESCRIPTION VEHICLE LOCATION
AFCR AIR CONDITIONER FAN CONTROL CAB REAR

BUR BODY UP CAB REAR
CSR COLD START CAB REAR
EDSCR F SPEED CONTROL CAB REAR
ESMR #1 STARTER #1 FRAME
ESMR #2 STARTER #2 (PRELUBE) FRAME
FCR FAN CONTROL CAB REAR
HMR HEATED MIRROR CAB REAR
HSR HEATED SEAT CAB REAR
MCR MAXIMUM COOL CAB REAR
NDR NEUTRAL DUMP CAB REAR
PBR PARK BRAKE CAB REAR
PMR PRELUBE MOTOR FRAME
RE1 START CIRCUIT BOARD
RE2 NEUTRAL START CIRCUIT BOARD
RE3 HORN CIRCUIT BOARD
RE4 STEER BLEEDDOWN CIRCUIT BOARD
RE5 REVERSE ALARM AND LIGHTS CIRCUIT BOARD
RE6 WINDSHIELD WIPER CIRCUIT BOARD
RE7 HILL HOLD CIRCUIT BOARD
RE8 CEC HOLD CIRCUIT BOARD
RE9 24 VOLT KEY SWITCH CIRCUIT BOARD
RE11 HIGH BEAM CIRCUIT BOARD
RE12 CIRCUIT BOARD
RE13 CHECK TRANSMISSION CIRCUIT BOARD
RE14 LOAD WEIGH LIGHTS RED CIRCUIT BOARD
RE15 LOAD WEIGH LIGHTS YELLOW CIRCUIT BOARD
RE16 LOAD WEIGH LIGHTS GREEN CIRCUIT BOARD
1CR CEC CAB REAR
2CR CEC CAB REAR
Note: For more information refer to the Schematic Book included in the cab at delivery for Electrical
Schematics. Refer also to Group 300, Electrical System-General in the Service Manual.
SPECIFICATIONS 189
Power Transmission (Group 4)
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Allison
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 9600-A
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remote
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Commercial Electronic Control (CEC)
Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Forward, 2 Reverse
Gearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Planetary
Travel Speeds
With Standard Differential, Planetary and Tires
Gear Range Gear Ratio km/h mph
First . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.24 10,5 6.5

Second . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.05 14,5 9.0
Third . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32 19,2 11.9
Fourth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.67 26,6 16.5
Fifth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.00 44,3 27.5
Sixth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.72 61,6 38.3
1st Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.75 7,7 4.8
2nd Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13 10,8 6.7
Lockup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . All forward gears

Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TC 1060
Planetary
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Euclid
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1080
Ratio, Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.00:1
Ratio, Optional (with Engineering Approval) . . . . . . . . . . . . . . . . 7.125:1
Differential
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Euclid
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2657
Ratio, Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.86:1
Ratio, Optional (with Engineering Approval) . . . . . . . . . . . . . . . . 3.15:1
Filter Assembly
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . After Pump
Beta 6 Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Microns - Absolute
Light Activation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241 kPa (35 psi)
In By- Pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345 kPa (50 psi)
190 SPECIFICATIONS
Brake System (Group 5)

Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . All Hydraulic
Brake Accumulator Precharge (Dry Nitrogen) . . . . . . . . . . . . . . . . 8274 kPa (1200 psi).
Front
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dry Disc
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wheel
Size-Disc Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101,6 cm (40 in.)
Number of Disc per Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Number of Pads per Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Lining Area per Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4,129 cm2 (640 sq. in.)
Braking Surface per Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14,194 cm2 (2,200 sq. in.)
Brake Pressure (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18,960 kPa (2,750 psi)
Rear
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wet Disc
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wheel
Size-Disc Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82,8 cm (32.6 in.)
Number of Friction Discs per Axle . . . . . . . . . . . . . . . . . . . . . . . 16 (32 Surfaces)
Area per Friction Disc Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,478 cm2 (384 sq. in.)
Braking Surface per Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79,282 cm2 (12,288 sq. in.)
Brake Pressure (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13,790 kPa (2,000 psi)
Parking Brake
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disc, Dry

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Differential Input, Flange
Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 cm (27.0 in.)
Number of Discs per Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Number of Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Lining Area per Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284 cm2 (44 sq. in.)
Filter (Brake Cooling)

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Return Line
Beta 6 Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Microns - Absolute
Retarder (Optional)
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Foot operated, all hydraulic actuation of oil

cooled wet disc brakes on the rear axle
Capacity (Continuous) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1051 kW (1410 hp)
Capacity (Intermittent) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1820 kW (2440 hp)
SPECIFICATIONS 191
Steering System(Group 6)
Pump
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston, Pressure Compensation
(with unload feature)
Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0737 l/rev. (4.50 cu.in./rev.)
Rated Flow 158 1/m @ Engine Speed x PTO Ratio . . . . . . . . (41.8 gpm) (2100 rpm) (1.022:1)
Unload Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18,961 kPa (2,750 psi)
Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Counterclockwise
Reset Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16,893 kPa (2,450 psi)
Rated Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24,822 kPa (3,600 psi)
Cylinder
Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Double Acting
Stages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . One
Piston Rod Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.8 mm (2.0 in.)
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 533.4 mm (21.0 in.)
Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101.6 mm (4.0 in.)
Valve
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Closed Center
with Internal Crossover Port Relief
Pressure Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24,132 kPa (3,500 psi)
Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.98 l/rev. (60 in3 / rev.)
RCB Valve (Relief Check Bleed)

Relief Valve Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22,064 kPa (3,200 psi)
Filter
Beta 6 Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Micron Absolute
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Return Line
Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Welded Steel Fabricated with Separate

Hydraulic and Steering Compartments
Accumulator
Nitrogen Precharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6,895 kPa (1,000 psi)
Maximum Steering Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Degrees

Turning Circle, Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23,44m (76’11”)
Turning Circle, Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23,19m (76’1”
192 SPECIFICATIONS
Wheels (Group 7)
Tire Inflation Pressures
Tire Size Front Rear
Standard - 31/80 R49 XDTA**E4 . . . . . . . . . . . . . . . . . . . . . . . . . . . 614 kPa (89psi) 614 kPa (89psi)
Note: For operating at Max. 65 km/h (40 mph). Check manufacturing information for proper
inflation.
Note: Before selecting either bias or radial tires, it is recommended that all necessary machine
applications be supplied to the tire manufacturer. The tire manufacturer can then make a
recommendation as to which tire will give the most economical operation.
Cab (Group 8)
The machine is equipped with a cab that has been ROPS/FOPS tested and approved in accordance with SAE
J1040 and ISO 3471.The cab is fully insulated, and includes a filtered fresh air heater/air conditioning and
pressurizing system .
SPECIFICATION MEASURED SOUND LEVEL

SAE J919-Operator Windows Open: 96.4 dbA
Windows Closed: 78.4 dbA
SAE J88-External Average: 89.7 dbA
SAE J1166-W ork Cycle Total: 74.9 dbA
EEC 86/662-Hemisphere External Sound Power: 121.27 bels

Sound Power Cab: 78.4 dbA
SPECIFICATIONS 193
Hydraulic System (Group 9)
Pump
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear - Tandem
Hoist Section
Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.220 l/rev. (13.42 cu. in./ rev.)
Rated Flow @ 2100 RPM 448.2 l/min @ engine speed x PTO ratio
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (118.46 gpm) (2100 rpm) x (1.022:1)
Above Flow @ 17,238 kPa (2,500 psi)
Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise
Brake Cooling Section
Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.220 l/rev. (13.42 cu. in./ rev.)
Rated Flow 469 l/min @ engine speed x PTO ratio . . . . . . . (124 gpm) (2100 rpm) x (1.022:1
Above Flow @ 587 kPa (85 psi)
Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise
Cylinder
Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Double Acting in Second Stage Only
Stages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Piston Rod Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177.8 - 101.6 mm (7.00 - 4.00 in.)
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1122.7 - 1187.5 mm (44.20 - 46.75 in.)
Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203.2 - 152.4 mm (8.00 - 6.00 in.)
Effective Bore Diameter (1st Stage)
177.8 mm (7.00 in.)
Internal Cushioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Extend & Retract
Hoist Control Valve

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Four Position Electronic Pilot Operated
Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 568 l/min (150 gpm)
Relief Valve Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20,340 kPa (2950 psi) for raising
Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Welded Steel Fabricated with Separate

Hydraulic and Steering Compartments
Filter Assembly (Hoist)

Beta 6 Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Micron Absolute
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Return Line
Body Raise Time (Std. Body) Loaded . . . . . . . . . . . . . . . . . . . . . . . Approximately 12.8 Seconds

Body Float Down Time (Std. Body) . . . . . . . . . . . . . . . . . . . . . . . . . Approximately 12.1 Seconds
194 SPECIFICATIONS
Machine Weights kg (lbs)

Chassis with Hoists 57,086 125,850
Body 15,178 33,461
Net Weight 71,737 158,150
Gross Weight
Maximum GMW Not to Exceed 170,100 375,000
Maximum Payload with No Options 98,365 216,850
* Major Options
Approximate change in Net Machine Weight:
Body Liners - complete - 400 BHN Steel 4,030 8,884
Maximum Payload with Body Liners, Complete 94,344 207,966
PERFORMANCE CHART
kg lbs 0 25 50 75 100 125 150 175 kg x 1000

x x
1000 1000 0 50 100 150 200 250 300 350 400 lbs x 1000
130
120 30
50 110
MAX
100 GMW 25
PERFORMANCE CHART
90 NMW EH1700
40
80 20
70
30
60 15
50
20
40 10
30
10 20 5
10
0 0 0
mph 0 5 10 15 20 25 30 35 40
km/h 0 10 20 30 40 50 60
INSTRUCTIONS:
Diagonal lines represent total resistance (Grade % plus rolling resistance %). Charts based on
0% resistance, standard tires and gearing unless otherwise stated.
1. Find the total resistance on diagonal lines on right-hand border of performance or retarder chart.
2. Follow the diagonal line downward and intersect the NWM or GMW weight line.
3. From intersection, read horizontally right or left to intersect the performance or retarder curve.
4. Read down for machine speed.
SPECIFICATIONS 195
RETARDER CHARTS
kg lbs 0 40 80 120 160 200 kg x 1000
x x
1000 1000 0 50 100 150 200 250 300 350 400 450 500 lbs x 1000
30 25
100 20
90 NMW MAX 18
40
GMW
80 16
1st
70 14
30
60 2nd RETARDER CHART 12
EH1700
50 Grade Length 10
20 3rd Continuous
40 8
30 4th 6
10 5th 4
20
6th
10 2
0 0 0
mph 0 5 10 15 20 25 30 35 40 45 50
km/h 0 10 20 30 40 50 60 70 80
kg lbs 0 40 80 120 160 200 kg x 1000 kg lbs 0 40 80 120 160 200 kg x 1000
x x x x
1000 1000 0 50 100 150 200 250 300 350 400 450 500 lbs x 1000 1000 1000 0 50 100 150 200 250 300 350 400 450 500 lbs x 1000
30 25 30 25
100 20 100 20
90 1st NMW MAX 18 90 1st NMW MAX 18
40 40
GMW GMW
80 16 80 16
70 2nd 14 70 2nd 14
30 30
60 RETARDER CHART 12 60 RETARDER CHART 12
3rd EH1700 3rd EH1700
50 Grade Length 10 50 Grade Length 10
20 4th 450m (1,475’) 20 4th 602m (1,975’)
40 8 40 8
30 5th 6 30 5th 6
6th 6th
10 20 4 10 20 4
10 2 10 2
0 0 0 0 0 0
mph 0 5 10 15 20 25 30 35 40 45 50 mph 0 5 10 15 20 25 30 35 40 45 50
km/h 0 10 20 30 40 50 60 70 80 km/h 0 10 20 30 40 50 60 70 80
kg lbs 0 40 80 120 160 200 kg x 1000 kg lbs 0 40 80 120 160 200 kg x 1000
x x x x
1000 1000 0 50 100 150 200 250 300 350 400 450 500 lbs x 1000 1000 1000 0 50 100 150 200 250 300 350 400 450 500 lbs x 1000
30 25 30 25
100 20 100 20
90 NMW MAX 18 90 NMW MAX 18
40 1st 40
GMW 1st GMW
80 16 80 16
70 14 70 14
30 2nd 30 2nd
60 RETARDER CHART 12 60 RETARDER CHART 12
EH1700 EH1700
50 3rd Grade Length 10 50 3rd Grade Length 10
20 899m (2,950’) 20 1,494m (4,900’)
40 4th 8 40 8
4th
30 6 30 6
5th 5th
10 20 6th 4 10 20 4
6th
10 2 10 2
0 0 0 0 0 0
mph 0 5 10 15 20 25 30 35 40 45 50 mph 0 5 10 15 20 25 30 35 40 45 50
km/h 0 10 20 30 40 50 60 70 80 km/h 0 10 20 30 40 50 60 70 80
INSTRUCTIONS:
Diagonal lines represent total resistance (Grade % plus rolling resistance %). Charts based on
0% resistance, standard tires and gearing unless otherwise stated.
1. Find the total resistance on diagonal lines on right-hand border of performance or retarder chart.
2. Follow the diagonal line downward and intersect the NWM or GMW weight line.
3. From intersection, read horizontally right or left to intersect the performance or retarder curve.
4. Read down for machine speed.
196 SPECIFICATIONS
MACHINE DIMENSIONS
The following machine specifications are provided for your convenience. All specifications are approximate
and are subject to change without notice or obligation.
Load Capacity
CU.M (CU.Yd.)
Struck (SAE) 39 (51)
Heap 3:1 53 (70)
Heap 2:1 (SAE) 60 (79)
Euclid-Hitachi 57 (75)
Field Heap
6,10m
(20’)
2,51m 3,23m
(8’3”) (10’7”)
10.38m 5,59m
(34’0”) (18’4”)
ELI19724
Note: Dimensions shown are for empty vehicle with 31/80 R49E4 tires.
The Euclid-Hitachi Field Heap illustrated in the side view above maintains a 2:1 heap ratio from the floor / tail
chute junction to the peak of the load profile. 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 Euclid-Hitachi
Field Heap is more representative of field loading practices and payload distribution. Euclid-Hitachi body
capacity ratings are based on the field heap philosophy.
SPECIFICATIONS 197
BOLT TORQUE CHART, GENERAL
TIGHTENING TORQUE VALUES

F835 Alloy Steel -- Hex Socket Button Head
Plain Finish with Oil, Black Oxide with Oil, or Zinc Phosphate with Oil
No Loctite
Thread Diameter Clamp Torque Torque
Size Lbs Ft - Lbs N-M
* = in-lbs
1/4-20 0.2500 3,784 * 142 16
5/16-18 0.3125 6,236 24 33

3/8-16 0.3750 9,223 43 59
1/2-13 0.5000 16,886 106 143
5/8-1 1 0.6250 26,894 210 285
The torque value used should be within ±%5 of the specified torque.
Plain Finish with Oil, Black Oxide with Oil, or Zinc Phosphate with Oil
With Red Loctite and Blue Loctite
* = in-lbs
1/4-20 0.2500 3,784 * 189 21
5/16-18 0.3125 6,236 32 44

3/8-16 0.3750 9,223 58 78
1/2-13 0.5000 16,886 141 191
5/8-1 1 0.6250 26,894 280 380
198 SPECIFICATIONS

Grade 5 Hex Hd
LENGTH
Plain Finish with Oil, Black Oxide with Oil or Zinc Phosphate with Oil
No Loctite
* = in-lbs
1/4-20 0.2500 2,298 * 86 10

1/4-28 0.2500 2,630 * 99 11
5/16-18 0.3125 3,786 * 177 20
5/16-24 0.3125 4,191 * 196 22
3/8-16 0.3750 5,599 26 36

3/8-24 0.3750 6,344 30 40
7/16-14 0.4375 7,680 42 57
7/16-20 0.4375 8,576 47 64
1/2-13 0.5000 10,252 64 87
1/2-20 0.5000 11,553 72 98
9/16-12 0.5625 13,150 92 125
9/16-18 0.5625 14,667 103 140
5/8-1 1 0.6250 16,329 128 173
5/8-18 0.6250 18,496 145 196
3/4-10 0.7500 24,132 226 307
3/4-16 0.7500 26,949 253 343
7/8-9 0.8750 33,380 365 495
7/8-14 0.8750 36,775 402 545
1-8 1.0000 43,784 547 742
1-14 1.0000 49,058 613 832
11/4-7 1.2500 60,950 952 1291
11/4-12 1.2500 67,492 1055 1430
11/2-6 1.5000 88,375 1657 2247
11/2-12 1.5000 99,445 1865 2528
SPECIFICATIONS 199

Grade 5 Hex Hd
LENGTH
With Red Loctite and Blue Loctite
* = in-lbs
1/4-20 0.2500 2,298 * 115 13

1/4-28 0.2500 2,630 * 131 15
5/16-18 0.3125 3,786 20 27

5/16-24 0.3125 4,191 22 30
3/8-16 0.3750 5,599 35 47
3/8-24 0.3750 6,344 40 54
7/16-14 0.4375 7,680 56 76
7/16-20 0.4375 8,576 63 85
1/2-13 0.5000 10,252 85 116
1/2-20 0.5000 11,553 96 131
9/16-12 0.5625 13,150 123 167
9/16-18 0.5625 14,667 138 186
5/8-1 1 0.6250 16,329 170 231
5/8-18 0.6250 18,496 193 261
3/4-10 0.7500 24,132 302 409
3/4-16 0.7500 26,949 337 457
7/8-9 0.8750 33,380 487 660
7/8-14 0.8750 36,775 536 727
1-8 1.0000 43,784 730 990
1-14 1.0000 49,058 818 1109
11/4-7 1.2500 60,950 1270 1722
11/4-12 1.2500 67,492 1406 1907
11/2-6 1.5000 88,375 2209 2996
11/2-12 1.5000 99,445 2486 3371
200 SPECIFICATIONS

Property Class 8.8 Hex hd cap screw
8.8
No Loctite
Size Pitch Diameter Clamp Torque Torque
mm Inches Lbs Ft - Lbs N-M
* = in-lbs
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
SPECIFICATIONS 201

Property Class 8.8 Hex hd cap screw
8.8
With Red Loctite or Blue Loctite
* = in-lbs
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
202 SPECIFICATIONS

Property Class 10.9 Hex hd Cap Screw
10.9
No Loctite
* = in-lbs
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
SPECIFICATIONS 203

Property Class 10.9 Hex Hd Cap Screw
10.9
* = in-lbs
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
204 SPECIFICATIONS

Grade 8 Hex Hd & 12 pt Flange Hd
LENGTH
No Loctite

* = in-lbs
1/4-20 0.2500 3,244 * 122 14

1/4-28 0.2500 3,713 * 139 16
5/16-18 0.3125 5,345 21 28

5/16-24 0.3125 5,916 23 31
3/8-16 0.3750 7,905 37 50
3/8-24 0.3750 8,956 42 57
7/16-14 0.4375 10,843 59 80
7/16-20 0.4375 12,107 66 90
1/2-13 0.5000 14,474 90 123
1/2-20 0.5000 16,310 102 138
9/16-12 0.5625 18,564 131 177
9/16-18 0.5625 20,706 146 197
5/8-1 1 0.6250 23,052 180 244
5/8-18 0.6250 26,112 204 277
3/4-10 0.7500 34,068 319 433
3/4-16 0.7500 38,046 357 484
7/8-9 0.8750 47,124 515 699
7/8-14 0.8750 51,918 568 770
1-8 1.0000 61,812 773 1048
1-14 1.0000 69,258 866 1174
11/4-7 1.2500 98,838 1544 2094
11/4-12 1.2500 109,446 1710 2319
11/2-6 1.5000 143,310 2687 3644
11/2-12 1.5000 161,262 3024 4100
SPECIFICATIONS 205

Grade 8 Hex Hd & 12 pt Flange Hd
LENGTH

* = in-lbs
1/4-20 0.2500 3,244 * 162 18

1/4-28 0.2500 3,713 * 186 21
5/16-18 0.3125 5,345 28 38

5/16-24 0.3125 5,916 31 42
3/8-16 0.3750 7,905 49 67
3/8-24 0.3750 8,956 56 76
7/16-14 0.4375 10,843 79 107
7/16-20 0.4375 12,107 88 120
1/2-13 0.5000 14,474 121 164
1/2-20 0.5000 16,310 136 184
9/16-12 0.5625 18,564 174 236
9/16-18 0.5625 20,706 194 263
5/8-1 1 0.6250 23,052 240 326
5/8-18 0.6250 26,112 272 369
3/4-10 0.7500 34,068 426 577
3/4-16 0.7500 38,046 476 645
7/8-9 0.8750 47,124 687 932
7/8-14 0.8750 51,918 757 1027
1-8 1.0000 61,812 1030 1397
1-14 1.0000 69,258 1154 1565
11/4-7 1.2500 98,838 2059 2792
11/4-12 1.2500 109,446 2280 3092
11/2-6 1.5000 143,310 3583 4858
11/2-12 1.5000 161,262 4032 5467
206 SPECIFICATIONS
SPLIT FLANGE CLAMP TORQUE VALUES
RECOMMENDED TORQUE VALUES PROPERTY OF ZINC AND PLAIN FLANGES
ZINC PLATED PLAIN PLATED

FLANGE TORQUE FLANGE TORQUE
DASH SIZE DASH SIZE
(N•m) (N•m)
-8 23 (17 ft. lbs.) -8 23 (17 ft. lbs.)
-12 43 (32 ft. lbs.) -12 34 (25 ft. lbs.)
-16 43 (32 ft. lbs.) -16 42 (31 ft. lbs.)
-20 72 (53 ft. lbs.) -20 54 (40 ft. lbs.)
-24 106 (78 ft. lbs.) -24 74 (52 ft. lbs.)
-32 106 (78 ft. lbs.) -32 81 (60 ft. lbs.)
-40 106 (78 ft. lbs.) -40 115 (85 ft. lbs.)
-48 207 (153 ft. lbs.) -48 197 (145 ft. lbs.)
-56 207 (153 ft. lbs.) -56 169 (125 ft. lbs.)
-64 207 (153 ft. lbs.) -64 169 (125 ft. lbs.)
-80 207 (153 ft. lbs.) -80 169 (125 ft. lbs.)
FLANGE ON ALUMINUM
HYDRAULIC PUMP ONLY
FLANGE
DASH SIZE TORQUE
-20 43 N•m (32 FT. LBS)
-24 72 N•m (53 FT. LBS)
-32 72 N•m (53 FT. LBS)

-40 43 N•m (32 FT. LBS)
-48 43 N•m (32 FT. LBS)
EL15765
CAPSCREW TORQUE SEQUENCE: Tighten capscrews in a diagonal sequence in

small increments until the appropriate torque is obtained for the specific nominal flange size.
ALPHABETICAL INDEX 207
A Parking Brake, . . . . . . . . . . . . . . . . . . . . . . . . 92
Service, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Accelerator Pedal, . . . . . . . . . . . . . . . . . . . . . . 87
Brakes/Retarder, Service, . . . . . . . . . . . . . . . 165
Active Traction Control (ATC) (Option), . . . . 91
Air Cleaner, Filter Light, Check, . . . . . . . . . . 141
C
Air Cleaner System, . . . . . . . . . . . . . . . . . . . . 140
Dust Cup Check/Clean, . . . . . . . . . . . . . . . 143 Cab, . . . . . . . . . . . . . . . . . . . . . . . . . . 5, 172, 192
Service, . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 Cab Mounts, Check, . . . . . . . . . . . . . . . . . . . 173
Service Indicator Nut, Secondary Filter,
Check, . . . . . . . . . . . . . . . . . . . . . . . . . . 143 Capacities, . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Air Conditioning, Check, . . . . . . . . . . . . . . . . 174 Centralized Service Panel (Option), . . . . . . 136
Air Filter, Cab, Check and Clean, . . . . . . . . 172 Checking Fluid Level, General, . . . . . . . . . . 135
Air Intake Lines and Clamps, Check, . . . . . 144 Circuit Board, . . . . . . . . . . . . . . . . . . . . . . . . . 186
Alarm Messages, Contronic Display Unit, . . 32 Cold Start System, Check, Option, . . . . . . . 150
Application, . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Cold Weather Restrictions, Transmission, . . 87
Automatic Centralized Lubrication System Cold Weather, Measures During, . . . . . . . . . . 77
(Option), Check Level and Fill, . . . . . . . 179 Coolant
Automatic Shifting, . . . . . . . . . . . . . . . . . . . . . . 82 Change & Flush, . . . . . . . . . . . . . . . . . . . . . 149
Check Level, . . . . . . . . . . . . . . . . . . . . . . . . 147
Axle Breather, Change, . . . . . . . . . . . . . . . . . 163
Coolant Filter, Change, . . . . . . . . . . . . . . . . . 148
Cooling Fan, Check, . . . . . . . . . . . . . . . . . . . 150
B
Cooling System, . . . . . . . . . . . . . . . . . . . . . . . 147
Back-up Alarm, Check, . . . . . . . . . . . . . . . . . 154 Crankcase Breather Tube/Hose,
Basic Preventive Maintenance Interval Chart, 132 Check/Clean, . . . . . . . . . . . . . . . . . . . . . . 140
Battery
Cables and Connections, Check, . . . . . . . 152 D
Charging, . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Condition, Check, . . . . . . . . . . . . . . . . . . . . 152 Daily Walk Around Inspection, . . . . . . . . . . . . 73
Starting with Auxiliary, . . . . . . . . . . . . . . . . . 78 Differential, . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Before Operating, . . . . . . . . . . . . . . . . . . . . . . . 79 Differential Lubricant, Change, . . . . . . . . . . . 161
Belt Tension, Check, . . . . . . . . . . . . . . . . . . . 151 Differential Lubricant Level, Check, . . . . . . . 161
Belts, Check, . . . . . . . . . . . . . . . . . . . . . . . . . . 151 Down Shift Or Reverse Inhibitor, . . . . . . . . . . 85
Body, .................................. 5 Dumping, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Body Prop Cable, Check, . . . . . . . . . . . . . . . 179 Precautions, . . . . . . . . . . . . . . . . . . . . . . . . . 103
Body, Lowering, . . . . . . . . . . . . . . . . . . . . . . . . 96 Duties of the Operator, . . . . . . . . . . . . . . . . . . 69
Body, Raising, . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Bolt Torque Chart, General, . . . . . . . . . . . . . 197 E
Brake, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Electrical, Specifications, . . . . . . . . . . . . . . . 186
Brake Accumulator, Check, . . . . . . . . . . . . . 166 Electrical System, . . . . . . . . . . . . . . . . . . . . . . 152
Brake Operation, Check, . . . . . . . . . . . . . . . . 164 Electrical Wiring Connections, Check, . . . . 153
Brake System, . . . . . . . . . . . . . . . . . . . . . . . . 164 Electronic Control Lever Functions, . . . . . . . 93
Specifications, . . . . . . . . . . . . . . . . . . . . . . . 190
Electronic Control Lever,
Brake System, Secondary, Check, . . . . . . . 166 Operating the Body with, . . . . . . . . . . . . . 93
Brakes Electronic Downhill Speed Control
Load/Dump, . . . . . . . . . . . . . . . . . . . . . . . . . . 92 (EDSC) (Option), . . . . . . . . . . . . . . . . . . . . 90
208 ALPHABETICAL INDEX
Electronic Transmission Retarder (Option), . 89 H

Engine, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5, 137 Hauling, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Crankcase Breather Tube/Hoses
Check/Clean, . . . . . . . . . . . . . . . . . . . . 140 Haultronic II (Option), . . . . . . . . . . . . . . . 32, 101
Operation Report, . . . . . . . . . . . . . . . . . . . . 137 Hazardous Waste, . . . . . . . . . . . . . . . . . . . . . 131
Storage of Rigid Haulers, Returning to Service
Headlights, Adjusting, . . . . . . . . . . . . . . . . . . 157
From Long Term Storage, . . . . . . . . . . . 111
From Moderate Term Storage, . . . . . . . 111 Heater and Defroster, Check, . . . . . . . . . . . . 175
Engine Overspeed Protection, . . . . . . . . . . . . 91 Horn, Check, . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Engine Oil Hydraulic and Brake Cooling Filters, Change, 177
Change, . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 Hydraulic Fluid, Change, . . . . . . . . . . . . . . . . 176
Check Level, . . . . . . . . . . . . . . . . . . . . . . . . 137
Hydraulic Fluid Level, Check, . . . . . . . . . . . . 175
Engine Oil Filter, Change, . . . . . . . . . . . . . . . 138
Hydraulic Reservoir Breather, Change, . . . 178
Engine Serial Number Plate, . . . . . . . . . . . . . 10
Hydraulic System
Engine Specifications, . . . . . . . . . . . . . . . . . . 185 Lines and Hoses, Clean and Check, . . . . 178
Specifications, . . . . . . . . . . . . . . . . . . . . . . . 193
Engine, Hot, Cooling A, . . . . . . . . . . . . . . . . . . 81
Hydraulic System and Other Functions, . . . 175
Euclid-Hitachi, Responsibility, . . . . . . . . . . . . . 2
Exterior Lights, Check, . . . . . . . . . . . . . . . . . 154
I
Inspections
F Construction Models, . . . . . . . . . . . . . . . . . . 11
Filter Assembly, Transmission, . . . . . . . . . . . 189 Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . 11
Periodic, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Filters, Fuel, Change the, . . . . . . . . . . . . . . . 145 Pre-Delivery , . . . . . . . . . . . . . . . . . . . . . . . . . 11
Fire Prevention Measures, . . . . . . . . . . . . . . 130 Instrument Panel, . . . . . . . . . . . . . . . . . . . . . . . 13
Fluid Levels, Check, . . . . . . . . . . . . . . . . . . . . 135 Active Traction Control (ATC) Indicator Light,
(Option), . . . . . . . . . . . . . . . . . . . . . . . . . 34
Foreword, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Active Traction Control/Boost Switch,
(Option), . . . . . . . . . . . . . . . . . . . . . . . . . 36
Frame Serial Number, . . . . . . . . . . . . . . . . . . . 10
Audible Alarm, . . . . . . . . . . . . . . . . . . . . . . . . 40
Front Brake Cut-Off Swirch, . . . . . . . . . . . . . 89 Body Up Light, . . . . . . . . . . . . . . . . . . . . . . . . 34
Fuel, Specifications, . . . . . . . . . . . . . . . . . . . . 184 Brake Temperature Gauge, . . . . . . . . . . . . . 17
Brake/Steer Oil Pressure Gauge, . . . . . . . 16
Fuel Filter, . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 Contronic Display Service Tool Connector, 41
Fuel-W ater Separator, . . . . . . . . . . . . . . . . 145 Contronic Display Unit, . . . . . . . . . . . . . . . . 27
Fuel Filter Change, . . . . . . . . . . . . . . . . . . . . . 145 Contronic E,C.U. Programming Port, . . . . 40
Dome Light Switch, . . . . . . . . . . . . . . . . . . . 15
Fuel System, . . . . . . . . . . . . . . . . . . . . . . . . . . 144 Electronic Downhill Speed Control (EDSC)
Fuel Tank Light, (Option), . . . . . . . . . . . . . . . . . . . . 35
Drain Sediment, . . . . . . . . . . . . . . . . . . . . . 144 Electronic Downhill Speed Control (EDSC)
Switch, (Option), . . . . . . . . . . . . . . . . . . 35
Mounting Lines and Fittings, Check, . . . . 146
Electronic Transmission Retarder Light,
Fuses, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187 (Option), . . . . . . . . . . . . . . . . . . . . . . . . . 35
Check, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153 Electronic Transmission Retarder Switch,
(Option), . . . . . . . . . . . . . . . . . . . . . . . . . 35
Engine Coolant Temperature Gauge, . . . . 17
G Engine Diagnostic Connector, . . . . . . . . . . 41
Front Brake Cut-Off Switch, . . . . . . . . . . . . 36
Gauges and Indicator Lights, Check, . . . . . 155 Headlight Switch, . . . . . . . . . . . . . . . . . . . . . 15
Heater Control Assembly, . . . . . . . . . . . . . . 38
General Information, . . . . . . . . . . . . . . . . 80, 135
Air Conditioning Button, . . . . . . . . . . . . . . 39
General Operating Rules, . . . . . . . . . . . . . . . . 69 Fan Control, . . . . . . . . . . . . . . . . . . . . . . . . 38
Mode Knob, . . . . . . . . . . . . . . . . . . . . . . . . 38 Maintenance, Basic, Interval Chart, . . . . . . 132

Recirculating Button, . . . . . . . . . . . . . . . . . 39
Temperature Control Knob, . . . . . . . . . . . 39
Intermittent Wiper/Washer Switch, . . . . . . . 33
N
Lighting Rheostat, . . . . . . . . . . . . . . . . . . . . . 15 Nameplates, Warning, and Information Decals, 6
Louver, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Neutral Start Circuit, Check, . . . . . . . . . . . . . 154
Master Key Switch, . . . . . . . . . . . . . . . . . . . . 37
Cold Start Fluid Injector Switch, (Option), 37 Notes, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12, 42
Fuel Pre-Heater Switch, (Option), . . . . . . . 37
Panel Outlet, . . . . . . . . . . . . . . . . . . . . . . . . . 40 O
Parking Brake Switch, . . . . . . . . . . . . . . . . . 33
Radio, (Option), . . . . . . . . . . . . . . . . . . . . . . . 41 Operating The Machine, . . . . . . . . . . . . . . . . . 80
Speedometer, . . . . . . . . . . . . . . . . . . . . . . . . 18 Operator Controls
Tachometer, . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Ash Tray, . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Traction Boost Indicator Light, (Option), . . 34 Cigar Lighter (12 Volt), . . . . . . . . . . . . . . . . . 47
Transmission (Converter) Horn, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Temperature Gauge, . . . . . . . . . . . . . . . 17 Load/Dump Brake Swtich, . . . . . . . . . . . . . . 47
Warning Lamp, Transmission Oil Pressure, 21 Operator’s Qualifications, . . . . . . . . . . . . . . . . 69
Warning Light Display, . . . . . . . . . . . . . . . . . 19
Alternator Light, . . . . . . . . . . . . . . . . . . . . . 25 Operators Controls, . . . . . . . . . . . . . . . . . . . . . 43
Brake Oil Pressure Light, . . . . . . . . . . . . . 21 12 Volt Power Port, . . . . . . . . . . . . . . . . . . . . 48
Brake Temperature Light, . . . . . . . . . . . . . 25 Accelerator Pedal, . . . . . . . . . . . . . . . . . . . . 60
Central Warning Light, . . . . . . . . . . . . . . . 20 Operator’s Seat Belt, . . . . . . . . . . . . . . . . . 59
Engine Coolant Level Light, . . . . . . . . . . . 25 Brake Pedal, . . . . . . . . . . . . . . . . . . . . . . . . . 61
Engine Coolant Temperature Light, . . . . 21 Cab Service Access Panels/Plates, . . . . . . 62
Engine Oil Pressure Light, . . . . . . . . . . . . 20 Access Plate, Rollover Protective Structure
Pin, . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Engine Service Light, . . . . . . . . . . . . . . . . 23
Access Plates, Rear Cab Mounts, . . . . . 63
Engine Shutdown Light, . . . . . . . . . . . . . . 23
Cab Exterior Panel Assembly, . . . . . . . . . 63
Filter Light, . . . . . . . . . . . . . . . . . . . . . . . . . 26
Cab Interior Panel, . . . . . . . . . . . . . . . . . . 62
High Beam Indicator Light, . . . . . . . . . . . 26
Dome Light, . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Parking Brake Light, . . . . . . . . . . . . . . . . . 22
Fire Suppression System (Option), Cab
Steering & Hydraulic Oil Temperature Light, Location, . . . . . . . . . . . . . . . . . . . . . . . . . 61
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Hazard Warning, . . . . . . . . . . . . . . . . . . . . . . 44
Steering Oil Pressure Light, . . . . . . . . . . . 23
Hoist Control Lever, . . . . . . . . . . . . . . . . . . . 59
Transmission (Converter) Oil Temperature, 23 Operators Seat, . . . . . . . . . . . . . . . . . . . . . . . 50
Transmission Malfunction Light, . . . . . . . 26 Air Ride, Adjustment, . . . . . . . . . . . . . . . . 55
Turn/Hazard Indicator Light, . . . . . . . . . . 24 Mechanical, Adjustment, . . . . . . . . . . . . . 51
Windshield Wiper Switch, . . . . . . . . . . . . . . 33 Not in Cab, . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Automatic Centralized Lubrication System
(Option), . . . . . . . . . . . . . . . . . . . . . . . . 68
L Battery Disconnect Switch, . . . . . . . . . . . 64
Body Down Indicator, . . . . . . . . . . . . . . . . 65
Load/Dump Brake, . . . . . . . . . . . . . . . . . . . . . . 92
Centralized Service Panel (Option), . . . . 68
Loading, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Fire Suppression System (Option), Ground
Haultronic II (Option), . . . . . . . . . . . . . . . . . 101 Location, . . . . . . . . . . . . . . . . . . . . . . . 66
Lock-In-Range, . . . . . . . . . . . . . . . . . . . . . . . . 83 Fuel Shut Down (Option), . . . . . . . . . . . . 66
Haultronic II, Load Weighing System (Option),
Lowering The Body, . . . . . . . . . . . . . . . . . . . . . 96 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Lubricants, Recommended, . . . . . . . . . . . . . 183 Manual Release Valve, . . . . . . . . . . . . . . . 64
Mirrors, . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Power Hook-Up (12 Volt), . . . . . . . . . . . . . . 49
M Retarder Pedal, . . . . . . . . . . . . . . . . . . . . . . . 61
Steering Wheel, . . . . . . . . . . . . . . . . . . . . . . 45
Machine Dimensions, . . . . . . . . . . . . . . . . . . 196 Sun Visor, . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Tilt/Telescope Steering Wheel Adjustment, 44
Machine Weights, Specifications, . . . . . . . . 194
Trainer Seat, . . . . . . . . . . . . . . . . . . . . . . . . . 49
Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Seat Belt, . . . . . . . . . . . . . . . . . . . . . . . . . . 49
210 ALPHABETICAL INDEX
Transmission Shift Selector, . . . . . . . . . . . . 47 S

Turn Signal / Hi-Beam Lever, . . . . . . . . . . . 45
SAFETY ALERT SYMBOL, WARNING, .... 1
Safety Regulations, . . . . . . . . . . . . . . . . . . . . . . 1
P Safety Rules Before Operating, A Few Simple,69
Parking Brake, . . . . . . . . . . . . . . . . . . . . . . . . . 92 Sand, Snow or Mud, Deep, Machine Stuck in, 122
Parking Brake, Operation, Check, . . . . . . . . 166 Seat Belt and Seat Belt Mounting, Check, . 174
Service Brakes, . . . . . . . . . . . . . . . . . . . . . . . . 88
Parking Machine, . . . . . . . . . . . . . . . . . . . . . . 104
Service Position. See A Few Simple Rules When
Performance Chart, . . . . . . . . . . . . . . . . . . . . 194 Servicing
Planetary, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189 Service Specifications, . . . . . . . . . . . . . . . . . 185
Planetary Hub, Rear Lubricant Level Servicing, A Few Simple Rules, . . . . . . . . . . 128
Change, . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162 Signalling Diagram, . . . . . . . . . . . . . . . . . . . . . 72
Check, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Starting Engine, . . . . . . . . . . . . . . . . . . . . . . . . 75
Power Lines, Operating the Machine Near High In Warm Weather, . . . . . . . . . . . . . . . . . . . . . 75
Voltage Overhead, . . . . . . . . . . . . . . . . . . 71
Starting Engine in Cold Weather, . . . . . . . . . . 76
Power Transmission, . . . . . . . . . . . . . . . . . 5, 158 Cold Start Fluid Injector (Option), . . . . . . . 76
Specifications, . . . . . . . . . . . . . . . . . . . . . . . 189 Fuel Pre-Heater (Option), . . . . . . . . . . . . . . 77
Presentation, . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Starting with Auxiliary Batteries, . . . . . . . . . . 78
Procedure Before Starting, . . . . . . . . . . . . . . . 73 Status Lights, Transmission Shift Selector, . 83
Product Identification Number, . . . . . . . . . . . . 10 Steering, . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5, 87
Locations, . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Steering Accumulator, Check, . . . . . . . . . . . 169
Product Identification Plate, . . . . . . . . . . . . . . 10 Steering Operation, Check, . . . . . . . . . . . . . 167
Steering Reservoir Breather, . . . . . . . . . . . . 169
Steering System, Specifications, . . . . . . . . . 191
R
Steering System Fluid, Change, . . . . . . . . . 168
Radiator, Clean, . . . . . . . . . . . . . . . . . . . . . . . 150 Steering System Fluid Level, Check, . . . . . 167
Raising The Body, . . . . . . . . . . . . . . . . . . . . . . 95 Steering System Hydraulic Filter, Change, 169
Range Preselection, . . . . . . . . . . . . . . . . . . . . . 84 Stopping, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
To Avoid Stall Shifting, . . . . . . . . . . . . . . . . . 85 Storage of Rigid Haulers, . . . . . . . . . . . . . . . 105
Relays, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188 Long Term, . . . . . . . . . . . . . . . . . . . . . . . . . . 108
6 Months or more, . . . . . . . . . . . . . . . . . . 105
Reset Procedure, . . . . . . . . . . . . . . . . . . . . . . . 84
Moderate Term, . . . . . . . . . . . . . . . . . . . . . . 107
Retarder, Operation Decal, . . . . . . . . . . . . . . . 86 More than 30 days, less than 6 months, 105
Returning to Service, . . . . . . . . . . . . . . . . . 110
Retarder Charts, . . . . . . . . . . . . . . . . . . . . . . . 195
Short Term, (30 Days or Less), . . . . . . . . 105
Retarder Operation Decal, Location, . . . . . . . . 7 Suspension Struts, Check, . . . . . . . . . . . . . . 170
Retarder, Using, . . . . . . . . . . . . . . . . . . . . . . . . 85
Return to Service, From Storage, . . . . . . . . 110 T
Roading, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 Table Of Contents, . . . . . . . . . . . . . . . . . . . . . . . 3
Rocking Out, Stuck in Deep Sand, Snow, or Mud, Tire Condition, Check, . . . . . . . . . . . . . . . . . . 172
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Tire Inflation Pressures, . . . . . . . . . . . . . . . . 192
Roll Over Protection Structure, . . . . . . . . . . . 70 Tire Pressure, Check, . . . . . . . . . . . . . . . . . . 171
Rollover Protection Structure, Unauthorized Tire Size, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Modification of, . . . . . . . . . . . . . . . . . . . . . . 2
Towing, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Run In Instructions, . . . . . . . . . . . . . . . . . . . . . 74 Engine Inoperable, No Brakes No Steering,
Engine, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Engine Operable, . . . . . . . . . . . . . . . . . . . . 124

Transmission, . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Cold Weather Restrictions, . . . . . . . . . . . . . 87
Down Shift Or Reverse Inhibitor, . . . . . . . . 85
Lock-In-Range, . . . . . . . . . . . . . . . . . . . . . . 83
Range Preselection, . . . . . . . . . . . . . . . . . . . 84
To Avoid Stall Shifting, . . . . . . . . . . . . . . . 85
Reset Procedure, . . . . . . . . . . . . . . . . . . . . . 84
Transmission Fluid Level
Check, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Cold Check, . . . . . . . . . . . . . . . . . . . . . . . . . 158
Hot Check, . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Transmission Breather, Change, . . . . . . . . . 160
Transmission Fluid and Filter, Change, . . . 159
Transmission Hydraulic Strainer, Change, . 160
Transmission Serial Number Plate, . . . . . . . . 10
Transmission Shift Selector, Status Lights, . 83
Transporting, . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Travel Speeds, . . . . . . . . . . . . . . . . . . . . . . . . 189
W
Warning, Protect Eyes and Skin Against
Lubricant, . . . . . . . . . . . . . . . . . . . . . . . . . 162
WARNING!, 13, 16, 21, 23, 49, 50, 59, 70, 71, 73,
75, 78, 79, 80, 82, 86, 87, 88, 92, 98, 99,
101, 104, 108, 109, 121, 122, 123, 124, 125,
128, 135, 138, 143, 145, 147, 149, 150, 152,
153, 154, 158, 159, 164, 168, 171, 172, 174,
175, 176, 177, 178, 179
Waste, Hazardous, . . . . . . . . . . . . . . . . . . . . . 131
Welding on Machines, With Allison Transmission
CEC I System, And Contronic System, 155
Wheel Bearing Lubricant, Front, Check/Change,
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Wheels
Check, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Specifications, . . . . . . . . . . . . . . . . . . . . . . . 192
Windshield Washer Fluid Level, Check, . . . 173
Wiper Blade Condition, Check, . . . . . . . . . . 173
Wires or Cables Overhead, Operating the
Machine Near, . . . . . . . . . . . . . . . . . . . . . . 71

EH1700 Operator's Manual - English

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EH1700 Operator's Manual - English

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HITACHI EH1700 350HD

08/01 PRINTED IN U.S.A.

We have taken many hours in designing and

Make yourself familiar with all controls and

KNOW THE CAPACITY AND LIMITS OF YOUR MACHINE!

UNAUTHORIZED MODIFICATION OF ROLLOVER PROTECTIVE STRUCTURE

OPERATION AND MAINTENANCE OF THE MACHINE

OPERATING INSTRUCTIONS (continued)

BASIC PREVENTIVE MAINTENANCE

NAMEPLATES, WARNING, AND INFORMATION DECALS

CAB NAMEPLATES, WARNINGS AND INFORMATION DECALS

NO. DESCRIPTION POSITION

1. G.M.W. (Gross Machine Weight) Right side of

2. Propulsion Inhibit Above windshield, right side

3. Pedal Location and Function Above wiindshield, right side

4. Warning. Read Operators Manual Above windshield, left side

5. Hoist Control Lever Function Above windshield, left side

6. Retarder Operation Decal Above windshield. left side

7. Product Identification Number Plate Above door, left side

8. Rollover Protective Structure (ROPS) Left side of cab, behind

9. Proposition 65 Warning Lower left corner of

CHASSIS/BODY NAMEPLATES, WARNINGS AND INFORMATION DECALS

NO. DESCRIPTION POSITION

12. Made in Canada Left and right hand side of the

13. Warning, Contents Under Pressure On the steering and brake

14. Jump Start Warning Front of the battery box

15. Battery Disconnect Top of the battery box

NAMEPLATES, WARNING, AND INFORMATION DECALS

CHASSIS/BODY NAMEPLATES, WARNINGS AND INFORMATION DECALS (Continued)

NO. DESCRIPTION POSITION

18 Warning Limited Visibility - At Rear of Machine On both sides of the body

19 NEOCON-E Located on front and rear ride

20 Crush Hazard from Dump Body Located at the back of the

21 Hydraulic Filter - Number referenced on decal is the Located on each hydraulic

22 Steering Filter - Number referenced on decal is the Located on the steering

23 Engine Start On the hydraulic tank

24 Front Wheel Crush Area Both sides of the machine

27 Lifting Locations At the front bumper. In the

28 Burn Hazard when machine is hot Radiator top tank (installed

29 Steering Pressure Test Port Located in front of the test

PRODUCT IDENTIFICATION NUMBER

At the time of manufacture, every machine is assigned a product

Product Identification Number Locations

3. Production Sequence Number.

EL19902 2. Engine Manufacturer Designation.

Always use the complete product identification (serial) number on

MAINTENANCE AND INSPECTIONS

If the machine is to work as efficiently as possible, thorough

INSPECTIONS - Construction Models

Further information about these programs can be obtained from the

The instrument panel is explained throughout the following pages.

Note: The master key switch must be turned to the “ON”

1. Instrument Lighting Rheostat 19. Electronic Transmission Retarder Switch

1. INSTRUMENT LIGHTING RHEOSTAT

3. DOME LIGHT SWITCH

EL14880 See Dome Light in OTHER CONTROLS.

5. BRAKE TEMPERATURE GAUGE

10A RED 10B RED 10C RED