PDF Workshop Manual Hitachi AH250 D AH300 D Articulated Dump Truck - 2 MB
Perform expert repairs on your Hitachi AH250-D and AH300-D Articulated Dump Trucks with this detailed workshop manual.
It offers complete service information, including disassembly, assembly, and testing procedures.
Technicians will appreciate the clear illustrations, specifications, and troubleshooting guides.
This manual is the key to reducing downtime and performing cost-effective repairs.
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Workshop Manual
Vol No.: W8TDE-00
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B25D & B30D 6X6 REPAIR 872118
If you spill acid on yourself: Avoid High Pressure Fluids
• Flush your skin with water.
• Apply baking soda or lime to help neutralise Escaping fluid under pressure can penetrate the
the acid. skin causing serious injury. Relieve the pressure
• Flush your eyes with water for 10 - 15 minutes before disconnecting hydraulic or other lines.
and get medical attention immediately. Tighten all connections before applying pressure.
Keep hands and body away from pinholes and
If acid is swallowed: nozzles which eject fluids under high pressure.
Use a piece of cardboard or paper to search for
• Drink large amounts of water or milk.
leaks.
• Then drink milk of magnesia, beaten eggs, or
vegetable oil. If any fluid is injected into the skin it must be
• Get medical attention immediately. surgically removed within a few hours by a doctor
who is familiar with this type of injury or gangrene
Wear Protective Equipment may result.
Stay Clear Of Moving Parts
Entanglements in moving parts can cause serious
injury.
Stop engine before examining, adjusting or
maintaining any part of the machine with moving
parts.
Keep guards and shields in place. Replace any
guard or shield that has been removed for access
GD0013CFM
as soon as service or repair is complete.
Wear a hard hat, protective glasses and other
protective equipment as required by the job
Beware of Toxic Fumes
conditions. Do not wear loose clothing or jewellery
that can catch on controls or other parts of the
machine.
When you drive connecting pins in or out, guard
against injury from flying pieces of debris by
wearing goggles or protective glasses. Prolonged
exposure to loud noise can cause impairment or
loss of hearing. Wear a suitable hearing protective
device such as earmuffs or earplugs. Wear gloves
when handling wire rope cable.
Use the Seat Belt GD0020CFM
Use a seat belt at all times to minimise the chance Prevent asphyxiation. Engine exhaust fumes can
of injury in an accident. cause sickness or death.
The seat belt must not be altered or modified in Operate only in well ventilated indoor areas. Avoid
any way. Such changes can render the belt hazardous fumes by first removing paint on
ineffective and unsafe. painted surfaces before welding.
The seat belt is designed and intended for the Wear an approved respirator when sanding or
seat’s occupant to be of adult build and for one grinding painted surfaces.
occupant of the seat only.
If a solvent or paint stripper is used, wash surface
with soap and water. Remove solvent or paint
containers before welding and allow at least 15
minutes before welding or heating.
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TABLE OF CONTENTS
SECONDARY STEERING PUMP - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 283
SECTION 2. HYDRAULIC SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 287
STEERING VALVE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 287
STEERING CYLINDER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 290
CHAPTER 9. SERVICE BRAKES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 295
SECTION 1. ACTIVE ELEMENTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 295
SERVICE BRAKES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 295
SECTION 2. HYDRAULIC SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 299
BRAKE VALVE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 299
CHAPTER 10. PARK BRAKE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 303
SECTION 1. ACTIVE ELEMENTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 303
PARK BRAKE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 303
CHAPTER 11. FRAME AND SUPPORTING STRUCTURE - - - - - - - - - - - - - - - - - - 307
SECTION 1. FRAME INSTALLATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 307
WELDING ON MACHINE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 307
SEPARATE FRONT AND REAR FRAMES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 307
CHAPTER 12. OPERATOR’s STATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 317
SECTION 1. CAB - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 317
CAB MOUNTINGS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 317
SECTION 2. SEAT AND SEAT BELT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 321
OPERATOR’S SEAT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 321
SECTION 3. HEATING AND AIR CONDITIONING - - - - - - - - - - - - - - - - - - - - - - - - - - - 323
REFRIGERANT CAUTIONS AND PROPER HANDLING - - - - - - - - - - - - - - - - - - - - - - - - - - - - 323
R134a REFRIGERANT OIL INFORMATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 324
CHAPTER 13. SHEET METAL AND STYLING - - - - - - - - - - - - - - - - - - - - - - - - - - 337
SECTION 1. BONNET OR ENGINE ENCLOSURE - - - - - - - - - - - - - - - - - - - - - - - - - - - 337
BONNET - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 337
CHAPTER 14. MAIN HYDRAULIC SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - 341
SECTION 1. HYDRAULIC SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 341
MAIN HYDRAULIC PUMP - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 341
SUCTION STRAINER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 346
HYDRAULIC SYSTEM MANIFOLD ASSEMBLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 347
CHAPTER 15. PNEUMATIC SYSTEMS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 353
SECTION 1. PUMPS AND DRIVES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 353
AIR COMPRESSOR - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 353
SECTION 2. CONTROL VALVES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 363
3
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ISSUE
B25D & B30D 6X6 CHAPTER 2 872118
If degree of inclination for rear axle is not within
specification then:
• To tilt rear axle forward, add shims, as
necessary, equally between lower drag link
and frame mount, on both cap screws, for
each lower drag link.
• To tilt middle axle rearward, add shims, as
necessary, equally between lower drag link
and axle mount, on both cap screws, for each
lower drag link.
Ensure all lower drag link socket head cap screws
are lubricated and tightened to specification.
Drag Link Cap Screw Specification
Link or Stabilizer Cap Screw and Nut Torque - - - - - - -
- - - - - - - - - - - - - - - - - - - - - - - -620 Nm (457.289 lb-ft)
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ISSUE
B25D & B30D 6X6 CHAPTER 2 872118
Carefully remove pinion shaft and calibration ring. Install lock ring (2) and dowel pins (1).
Lubricate and install disks in the following order:
notched disk, notched disk, splined disk and
O notched disk.
120
O 30
3 - Places
1
X
Install bevel gear housing (1) onto dowel pins.
GDS3004CFM
Measure calibration ring JDG1281 at all three pins
and calculate an average dimension.
Install spacer (25) of this thickness on pinion shaft 1
and install pinion shaft in housing.
Heat outer bearing and install on pinion shaft.
Apply cure primer and flexible form-in-place
gasket to outside diameter of seal (26) and lube
seal inner lip.
Install seal. Install axle bevel gear (1). Ensure axle bevel gear
engages both splined disks and contacts thrust
Install dust shield (27), bushing (28), washer (29), washer.
and nut (30) and tighten to specification.
Specification
Pinion Nut Torque- - - - - - - - - - - - - 750 Nm (553 lb-ft) 1
Heat roller bearings (17 and 18) to 110°C (230°F)
and install bearings on housing (10) and carrier
cover (31).
2
2
1
Lubricate and install bevel gears (2) and pinion
4 cross shafts (1) as an assembly.
3
Install thrust washers (3 and 4) in housing.
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ISSUE
B25D & B30D 6X6 CHAPTER 2 872118
Subtract bearing cup height measurement from
3
pinion bearing thickness measurement. Difference
2
will be thickness of bearing shim required. If
thickness is between shim sizes use greater size
shim. 1
1
1
Install spur gear (2) in adapter case with writing
up.
Install shim (1) on spur gear.
Install bearing cup (3).
Install bearing cup (1) into bearing housing (2).
1 2 1
Apply cure primer and form-in-place gasket to
Apply multi-purpose grease to bearing cone (1) mating surfaces of bearing housing.
and install bearing cone.
Install bearing housing and input drive shaft into
Apply cure primer and flexible form-in-place adapter case.
gasket to outer diameter of seal (2) and install seal
flush into bearing housing. Apply cure primer and thread lock and sealer to
threads of cap screws (1). Install and tighten cap
screws.
CAUTION
Avoid overheating seal when heating
bearing cone.
Heat bearing cone to 110°C (230°F). Install
assembled bearing housing over input drive shaft
ensuring bearing is fully seated.
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B25D & B30D 6X6 CHAPTER 2 872118
Drive Shafts Specification
1 2
Drive Shaft Yoke Nut Torque - - - - - 750 Nm (553 lb-ft)
Install park brake disk, caliper, and pads. (See
Park Brake CHAPTER 11, SECTION 1).
Install transfer case-to-oscillation tube drive shaft
and oscillation tube-to-middle axle drive shaft.
Disassemble And Assemble
Oscillation Joint-to-Park Brake Drive
Shaft
Disconnect lubrication line from front seal retainer
(2).
Remove front seal retainer. Remove outer O-ring 1
from front seal retainer seat. Replace seal (1) 2
using a seal driver.
4
1
3
Remove nut and washer (3).
Remove rear yoke (2) using a suitable puller.
Disconnect lubrication line from rear seal retainer
(4). Remove rear seal retainer. Remove outer O-
ring from rear seal retainer seat.
Disconnect lubrication line from rear seal retainer.
Disconnect rear bearing retainer from oscillation
tube. 1 2
Remove drive shaft, rear bearing carrier, and rear
yoke as an assembly.
Clean, inspect, and replace parts as necessary.
Install drive shaft, rear bearing carrier, and rear
yoke as an assembly. Connect rear bearing carrier
to oscillation tube. Connect lubrication line.
Install new outer O-ring in front seal retainer seat. Install new seal (1) in rear seal retainer (2) using a
Install front seal retainer. Connect lubrication line. seal driver.
NOTE:Front and rear yokes must be NOTE:1. Drive shaft must be installed in the
installed in line with each other. same direction as it was removed.
Mark drive shaft ends for ease of
Install front yoke, washer, and nut. Tighten nut to assembly.
specification. 2. Rear bearing retainer (1) is slip fit
over bearing.
Slide rear bearing retainer off of bearing.
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ISSUE
B25D & B30D 6X6 CHAPTER 2 872118
• Install strut in 12 ton hydraulic press with oil • Install strut in 12 ton hydraulic press. Mark rod
plug at top. Compress strut until rod extends at rod guide and 50 mm (2.0 in.) from rod
100 mm (3.9 in.) from rod guide. guide. Compress strut to mark. Decompress.
• Install charging valve in barrel. Ensure Ensure strut expands to original mark. Repeat
charging valve is fully open. this step once.
• Fill strut until overflowing with Transmax-Z oil. • Remove strut from hydraulic press.
Allow time for oil to settle.
• Compress strut until rod extends 30 mm (1.2 Install clamps on boot.
in.) from rod guide. Ensure O-ring is seated
firmly on oil plug. Install oil plug. Replace Bushings
• Remove strut from hydraulic press.
WARNING 1
Use ONLY dry nitrogen to charge strut. Oth-
er gases can cause oxidation or condensa-
tion. 2
Charge strut with dry nitrogen.
• Connect nitrogen source to charging valve. 3
Charge strut to specification. Close charging
valve.
Axle Links, Stabilizers, and Struts Specification
Suspension Strut Nitrogen Charging Pressure: - - - - - - GDS2002CFM
- - - - - - - - - - - - - - - - - - -3585 kPa (35.9 bar) (520 psi)
• Disconnect nitrogen source. Install valve cap.
Install valve guard. Remove snap ring (1) and press old bushing (2)
from bore (3).
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B25D & B30D 6X6 CHAPTER 2 872118
1 1 Specification
2
7 Hub Assembly Weight - - - - - - - - - - - - - 91 kg (200 lb)
Attach hoist with tool JDG909 Lifting Brackets.
6 5 3 1
6
2
4
5
3
Remove cap screws (1) and retainers (2).
Remove brake pads (3).
Remove brake line nuts (6). Close all openings
with caps and plugs.
NOTE:Longer caliper cap screws (5) are Remove lock ring (1), lock pin (2), and remove nut
used to install support plate (7). (3) with hub nut spanner 280173.
Remove caliper cap screws (5) and remove plate
(7).
Remove caliper (4).
Inspect parts for wear or damaged.
1
Repeat steps (12 - 15) for front brake and caliper. 1
2
1
Remove outer ring gear (1) and inner ring gear (2)
with bearing.
6 2
5 4
3 1
CAUTION
Remove outer wheel bearing (6).
Approximate weight of hub assembly is 91
kg (200 lb). Bend retainer lock (2) tabs.
Remove bolts (3), retainers (1), and locks (2).
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ISSUE
B25D & B30D 6X6 CHAPTER 3 872118
Remove Oil Pan and Control Valve
11
13
10
1
6
12
7
9
8
2
3
2 1
1
4
GDS3015CFM
1. Bolt (33 used). 8. Filter Cover.
2. Washer (4 used). 9. Oil Pan.
3. Copper Washer (33 used). 10. Oil Filler Pipe.
4. Bolt (4 used). 11. Sealing Tape.
5. Pan Gasket. 12. Grooved Lock Nut.
6. Filter. 13. Oil Dipstick.
7. O-Ring.
Remove filter cover (8) and filter (6). NOTE:Oil filler pipe should only be removed
when necessary.
Remove oil pan (9) and discard copper washers
(3). Remove oil filler tube (10) if necessary.
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ISSUE
B25D & B30D 6X6 CHAPTER 3 872118
Remove, mark and identify order of clutch E
plates.
NOTE:During removal do not allow guide
pins to drop into transmission.
Remove spring guide centering pin (27). 1
Remove spring plate holder (11) and spring plate
(12).
CAUTION
Wear eye and face protection before using
compressed air. Cover transmission oil GDS3039CFM
ports with a cloth for protection from
transmission oil when using compressed Remove carrier (1).
air.
1
1 2
GDS3040CFM
Remove thrust washer (1) and needle bearings
GDS3037CFM
(2).
Remove clutch E piston (1).
A
2
1 GDS3041CFM
GDS3038CFM
Rotate end of snap rings (1 and 2) to notch
Low air pressure may be applied to port (A) to aid opening and remove.
piston removal.
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B25D & B30D 6X6 CHAPTER 3 872118
E
GDS3060CFM
Measure distance from measuring bar to shim (19) GDS3061CFM
contact surface on turbine cover (18). Record as
dimension E. Install two guide pins to assemble circuit cover and
pump drive cover.
Subtract dimension E from dimension D and
record as dimension F. (D-E) = F
Thrust bearing clearance is 0.1 - 0.3 mm (0.004 -
0.012 in.). Average clearance is 0.2 mm (0.008 in.)
dimension H.
Disassemble and Assemble Torque
Converter Specification
Stator Thrust Bearing Clearance - - - - - - - - - - - - - - - -
- - - - - - - - - - - - - - - - - 0.1 - 0.3 mm (0.004 - 0.012 in.)
To determine shim size subtract dimension F from
dimension C and record as dimension G. (C-F) =
G
Subtract average thrust bearing clearance H from
dimension G. This will give shim (19) size needed.
(G-H) = shim size GDS3062CFM
Place correct shim and washer (20) in turbine Fit cap screws and tighten.
cover with chamfer side of washer toward shim.
Disassemble and Assemble Torque
Apply thin layer of oil to bearing (21) and install Converter Specification
with washer (22). Torque Converter Cap Screws Torque - - - - - - - - - - - -
- - - - - - - - - - - - - - - - - - - - - - - - - - - -35 Nm (26 lb-ft)
Position stator and bearing (28) on turbine pump
cover.
Install O-ring (29).
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ISSUE
B25D & B30D 6X6 CHAPTER 3 872118
CAUTION
Do not damage shaft face when removing
bearings. Use suitable pressure disc on
shaft.
12
GDS3065CFM
Remove needle bearing (16) with suitable puller.
NOTE:Measure planetary pinion end play
GDS3064CFM before disassembly. Disassembly
required only if worn or damaged.
Support output cover. Using press push planetary Planetary pinions must be replaced
carrier (10) from output cover. as a set.
NOTE:Remove bearing race from output Measure planetary pinion end play.
cover only when bearings are
replaced. Disassemble and Assemble Output
Planetary Specification
Remove seal (4) and outer bearing (24). Carrier Pinion End Play - - - - - - - - - - - - - - - - - - - - - -
- - - - - - - - - - - - - - - - - 0.5 - 1.2 mm (0.02 - 0.047 in.)
Remove shims (23).
Planetary pinions are replace as a set.
Remove bushing (22) and bearing (21) with
suitable puller.
Inspect and replace bearings and races as
needed.
CAUTION
Wear protective gloves components will be
hot.
Heat output cover to approximately 85° C (185° F)
and remove bearing races at grooves in housing.
Use press to remove bearing from shaft. GDS3066CFM
Remove thrust ring (8). Carefully drive roll pins (15) into center of pinion
shafts (11 and 17).
Drive pinion shafts from carrier (10) and remove
roll pins.
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ISSUE
B25D & B30D 6X6 CHAPTER 3 872118
1. Oil Control Body. 24. Seal (12 used).
2. Spacer. 25. Fitting (2 used).
3. O-Ring. 26. Oil Feed Flange.
4. O-Ring. 27. Pump.
5. Spring. 28. Cap Screw (2 used).
6. Valve. 29. Washer (31 used).
7. Piston. 30. Cap Screw (7 used).
8. Piston. 31. Intermediate Plate.
9. Bushing. 32. Thrust Ring.
10. Washer. 33. Cap Screw (3 used).
11. Snap Ring. 34. Seal Ring (4 used).
12. Piston. 35. Bearing.
13. Spring. 36. Cap Screw (4 used).
14. Spacer. 37. Not Used.
15. Retainer Pin (2 used). 38. Cap Screw (4 used).
16. Piston. 39. Cap Screw (3 used).
17. Spring. 40. Cap Screw (5 used).
18. Washer. 41. Retarder Stator Ring.
19. Snap Ring. 42. Spring Seat (3 used).
20. Piston. 43. Spring (3 used).
21. Spring. 44. Spring Guide (3 used).
22. Spacer. 45. Disc Spring (48 used.
23. Oil Line. 46. Guide Pin (3 used).
CAUTION
Retaining washers are under spring
pressure. Take care when removing.
Apply pressure and hold spacer (22) to remove
retainer pin (15) and remove spring and valve (20
and 21).
Use 281702 Control Valve Clamp to compress
springs (5 and 17).
Remove snap rings (11 and 19) and release spring
tension.
Remove Parts (6 - 10) and (16 - 18).
35
Apply pressure to spacer (14) with screwdriver
and remove pin (15).
Remove parts (12 - 14).
Remove spacer and O-ring (2 and 3).
If not removed. Remove intake pipe O-ring (4).
With 281699 Pressure Piece and 281680 Puller,
remove bearing (35).
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ISSUE
B25D & B30D 6X6 CHAPTER 3 872118
1. Bolt (18 used). 23. Spring (9 used).
2. Rotor. 24. Retaining Pin (2 used).
3. Seal. 25. Pin (9 used).
4. Rectangular Ring. 26. Clutch B Outer Plate.
5. Disk Seal. 27. Clutch B End Plate.
6. Needle Bearing. 28. Clutch C Inner Plate.
7. Dowel Pin. 29. Clutch C Outer Plate.
8. Hub. 30. Clutch C End Plate.
9. Pin. 31. O-Ring.
10. Snap Ring. 32. Reverse Gear Housing.
11. Retainer Pins (3 used). 33. Lip Seal.
12. Snap Ring. 34. Lip Seal.
13. Lip Seal. 35. Clutch A Piston.
14. Clutch C Piston. 36. Spring Plate.
15. Lip Seal. 37. Retainer Plate.
16. Clutch Carrier. 38. Snap Ring.
17. Seal. 39. Spring Plate.
18. Clutch B Piston. 40. Retainer Plate.