CONFIDENTIAL

Page

of 11

SERVICE BULLETIN CODE

DESCRIPTION

3 2005 100
FILING LOCATION

EH4500-227
EH5000-213

SUBJECT
Rear Axle Tie Rod Maintenance(HTM SB4600-10)

OUTLINE
Rear Axle Tie Rods partially hold the spindle assemblies onto the rear axle box and share clamp
load. Specific assembly instruction must be followed to properly install and torque the rear axle Tie
Rods. If a single Tie Rod is damaged or broken, all Tie Rods should be replaced as a matched set.
Replacement of a single Tie Rod may create a secondary failure due to a Tie Rod being over
stressed during hauler operation. To alleviate this possibility always replace Tie Rods as a set.

Thoroughly read the safety section in the service manual before starting the work to ensure safe operation.
Welding work, if any, should only be done by qualified welders.

APPLICABLE MODELS / SERVICE BULLETIN NO. FOR EACH MODEL

Machine Model(s):

EH4500, EH5000 Series

Machine Serial Nos.:

Refer to the following page.

EXPENSES
Charge to the customer.

PARTS
When performing the described rework, place an order with the EUCLIC-HITACHI Parts Department.

DESCRIPTION
Refer to the following page(s).

SA/GI: EH4500-028,
EH5000-015

WHITE

DWN
CHKD
APPD

CONFIDENTIAL

Page

of 11

SERVICE BULLETIN CODE

DESCRIPTION

3 2005 100
FILING LOCATION

EH4500-227
EH5000-213

Hitachi Construction
Truck Manufacturing Ltd.

Service Bulletin
Distribute to PARTS and SERVICE Department Employees
MODELS

GROUP

EH4500 (411/412 MD), EH5000 (401/402 RD)

Mandatory Update

NO.

4600

10

DATE

02/05

PAGE

1/10

Technical Information

SUBJECT:
Rear Axle Tie Rod Maintenance

PURPOSE:
Rear Axle Tie Rods partially hold the spindle assemblies onto the rear axle box and share
clamp load. Specific assembly instruction must be followed to properly install and torque
the rear axle Tie Rods. If a single Tie Rod is damaged or broken, all Tie Rods should be
replaced as a matched set. Replacement of a single Tie Rod may create a secondary
failure due to a Tie Rod being over stressed during hauler operation. To alleviate this
possibility always replace Tie Rods as a set.

EFFECTIVE POINTS:
The described change has been incorporated effective with the serial numbers listed:
EH4500 (411/412MD)
EH5000 (401/402MD)

77165 and above

77299 and above

DETAILS:
The Tie Rod mounting system has been improved to simplify service. Early haulers
require the Traction Drive Spindle Assembly be removed to replace Tie Rods. Reason for
the Traction Drive Spindle Assembly removal is because the threaded spacer on early
units is located inside the axle box mounting flange. The Traction Drive Spindle Assembly
must be removed to be able to slide the Tie Rod out of the axle box.
As a product improvement current production units incorporate a special plate that
captivates the threaded spacer. The special plate is reversible and can be easily replaced
if galling occurs beneath the Tie Rod washers. The improved installation now allows for
Tie Rod replacement without removal of Traction Drive Spindle Assembly. This
dramatically reduces labor required to service a damaged Tie Rod. Therefore it is highly
recommended that former units be upgraded to incorporate this feature during a Traction
Drive Spindle Assembly service or during a Tie Rod repair.

Hitachi Construction Truck Manufacturing Ltd. Technical Center

Cleveland, Ohio
Template Last revised 3/5/04

CONFIDENTIAL

Page

of 11

SERVICE BULLETIN CODE

DESCRIPTION

3 2005 100
FILING LOCATION

EH4500-227
EH5000-213
MODELS

GROUP

NO.

DATE

PAGE

EH4500 (411/412 MD), EH5000 (401/402 RD)

4600

10

02/05

2/10

Recommend a thorough visual inspection of the axle structure be performed whenever

Axle Tie Rod is found broken. Clean the entire axle box, spindle assemblies, and inspect
for damage or evidence of crack development. Special attention should be used during
inspection of all welds. Any area suspect of crack development should additionally be
inspected using NDT method to verify crack is not present.
Caution: Never install a Tie Rod without the proper threaded spacer in place. In the
event of a Tie Rod break the threaded spacer dissipates force.

Figure 1 Former Tie Rod Installation

Figure 2 Current Tie Rod Installation

Before working on the machine, park it on a level surface and put it in the SERVICE POSITION.
1. Engine stopped, ignition key removed
(except when service requires engine
operation).
2. Tag the machine following local lockout &
tag procedures. Identify machine as Out
of Service.
3. If body is raised, use body prop cable or
pin.
4. The wheels blocked.
5. Body control lever in FLOAT position.
6. Parking brake applied.
7. Allow machine to cool down.
8. Pressure released from all lines,
tanks, and accumulators.

Hitachi Construction Truck Manufacturing Ltd. Technical Center

Cleveland, Ohio
Template Last revised 3/5/04

CONFIDENTIAL

Page

of 11

SERVICE BULLETIN CODE

DESCRIPTION

3 2005 100
FILING LOCATION

EH4500-227
EH5000-213
MODELS

GROUP

NO.

DATE

PAGE

EH4500 (411/412 MD), EH5000 (401/402 RD)

4600

10

02/05

3/10

Please pay attention to the safety instructions in the Operators and Service Manuals
concerned.

Hitachi Construction Truck Manufacturing Ltd. Technical Center

Cleveland, Ohio
Template Last revised 3/5/04

CONFIDENTIAL

Page

of 11

SERVICE BULLETIN CODE

DESCRIPTION

3 2005 100
FILING LOCATION

EH4500-227
EH5000-213
MODELS

GROUP

NO.

DATE

PAGE

EH4500 (411/412 MD), EH5000 (401/402 RD)

4600

10

02/05

4/10

MATERIAL REQUIRED:
The components listed in Table 1 are required for the field upgrade of one unit.

ITEM NO.
1
2
3
4
5
6

PART NO.
E12639017
E13813968
E12001555
E4025147
E12633971
E12640944

Table 1. Rework Parts List

DESCRIPTION
THREADED ROD
NUT SLOTTED
COTTER PIN
WASHER
THREADED SPACER
SPECIAL PLATE

QTY
6
12
12
24
12
10

REQUIRED TOOLS:
Standard mechanics toolbox.
Magnetic base drill press capable of boring 39 mm [1.500] holes through steel plate
Alignment fixture for magnetic base drill, fabricated from mild steel plate 20long x
12wide x 1 thick
Pilot rods of all thread -13 approximately 610 mm [24] long
Tire handler
Support stands
Six, diameter cap screws, grade eight material, with hardened nuts

Hitachi Construction Truck Manufacturing Ltd. Technical Center

Cleveland, Ohio
Template Last revised 3/5/04

CONFIDENTIAL

Page

of 11

SERVICE BULLETIN CODE

DESCRIPTION

3 2005 100
FILING LOCATION

EH4500-227
EH5000-213
MODELS

GROUP

NO.

DATE

PAGE

EH4500 (411/412 MD), EH5000 (401/402 RD)

4600

10

02/05

5/10

INSTALLATION:
Figures 3 through 5 illustrate the upgrade. Standard assembly instruction is outlined in
attached drawing 12634292. All item numbers listed refer to Table 1 under MATERIAL
REQUIRED.
1. The hauler must be properly
cleaned and the body empty of
all material. It is preferred to
have the body removed or resting
on the frame when performing
this upgrade.
2. The rear of the hauler must be
raised and supported on properly
fabricated and rated saddle style
stands.
3. Inspect and isolate all potential
energy sources prior to repair.
Follow all local regulations with
regard to Risk assessment
documentation and work
assignment review. Inspect
Electrical, Hydraulic, Mechanical,
and Pneumatic sources for
potential energy release and
isolate system or component
prior to commencement of
upgrade.
4. Using a properly rated tire
handler remove the rear tire/rim
equipment from both left and
right sides. Refer to appropriate
section of service manual for
model specific information.

8. Paint mark clocking reference

marks across the flange between
the Spindle and axle box to aid
assembly.
9. Paint mark holes on Spindle
where the Tie Rods are located.
These holes are identified for
drilling to a larger diameter later.
10. Use either a Traction Drive
Spindle Assembly transport stand
[Hedweld] or overhead crane
with properly selected rigging to
support Traction Drive Spindle
and prepare for removal.
Note: Mass EH5000 Spindle
Assembly approx. = 17,395 kg
[38,950 lbs]
11. Remove balance of mounting
hardware and then remove
Traction Drive Spindle Assembly.
12. Remove the Tie Rods from the
axle box.

5. Remove traction drive cables and

wiring from one Traction Drive
Spindle Assembly. Mark all
connections using tags for easy
identification during assembly.
6. Remove drain and vent hoses
from Traction Drive Spindle
Assembly.
7. Loosen all Spindle to axle box
mounting cap screws and Tie
Rod Nuts.

Photo Spindle Assembly Removal

Note: Only one Traction Drive
Spindle Assembly should need to
be removed from axle box to
perform upgrade. If rear of hauler
is supported by stands under the

Hitachi Construction Truck Manufacturing Ltd. Technical Center

Cleveland, Ohio
Template Last revised 3/5/04

CONFIDENTIAL

Page

of 11

SERVICE BULLETIN CODE

DESCRIPTION

3 2005 100
FILING LOCATION

EH4500-227
EH5000-213
MODELS

GROUP

NO.

DATE

PAGE

EH4500 (411/412 MD), EH5000 (401/402 RD)

4600

10

02/05

6/10

axle box do not remove both

Traction Drive Spindle Assemblies
at the same time. Drill holes in
both the removed Spindle and
opposite mounted Spindle at same
time. Then slide new Tie Rods into
place. Removal of both Traction
Drive Spindle Assemblies together
at the same time may allow axle
box distortion to occur. This could
make assembly difficult.
13. Locate the fabricated drilling fixture
over the Tie Rod hole and bolt fixture
to mating flange of Traction Drive
Spindle Assembly. Use a 33, 32 mm
[1.312] drill to pilot and center the
drill press over the hole. Remove and
change drill bit after setup is locked
in place. Enlarge the Tie Rod holes
only to 38,10 mm [1.500] diameter
drilling from inside flange through to
outside using the magnetic base drill.

Photo Magnetic Base Drill Alignment

Fixture
Note: Table 1 item 6 can be used as
hole locating template to fabricate
alignment fixture shown.
15. Thoroughly clean all machining
debris from the holes and deburr
edges using a die grinder.
16. Screw the threaded spacers onto the
Tie Rod at both ends (note 3 and
view C of drawing 12634292). Screw
threaded pilot rod (special tool) into
end of Tie Rod and slide Tie Rod into
place from open cavity side of axle
box. Use the pilot rod to guide the
Tie Rod into place then remove the
pilot rod.

Photo Magnetic Drill & Attachments

14. Now center the drilling fixture over
the Tie Rod holes of the Traction
Drive Spindle Assembly still mounted
to the axle box. Again drill the holes
oversize to 38,10 mm [1.500]
diameter drilling from outside of
flange through towards center of axle
box.
Photo -13 Pilot Rod, Grade #8
Bolts, Plate Item 6, Shown for Clarity
Hitachi Construction Truck Manufacturing Ltd. Technical Center
Cleveland, Ohio
Template Last revised 3/5/04

CONFIDENTIAL

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of 11

SERVICE BULLETIN CODE

DESCRIPTION

3 2005 100
FILING LOCATION

EH4500-227
EH5000-213
MODELS

GROUP

NO.

DATE

PAGE

EH4500 (411/412 MD), EH5000 (401/402 RD)

4600

17. After all Tie Rods are in place in axle

box, with threaded spacers in place,
install nuts and cotter pins following
note 4 of drawing 12634292.
Note: Instead of installing the cotter
pins, use grade #8 bolts and nuts
in cotter pin holes during the process
of tightening the Tie Rod nuts. The
Tie Rod nuts can be retained from
rotation during the tightening torque
sequence by use of an open end
wrench.
18. Install pilot rods in the opposite ends
of the Tie Rods just before hoisting
Traction Drive Spindle Assembly
back into place. Use pilot rods as
guides for Tie Rods during assembly.
19. Install mounting cap screws into
Traction Drive Spindle Assembly and
lubricate and torque all mounting Tie
Rod nuts as described in Wheel
Motor Mounting drawing 12634292.
Tighten additional cap screws evenly
to specified torque using alternating
criss- cross torque pattern.
Note: When final torque is achieved
on Tie Rod nuts, remove the bolts
and replace with cotter pins (Table 1
item 3) for final assembly.

10

02/05

7/10

20. Reconnect balance of traction cables,

hoses etc. to Traction Drive Spindle
Assembly.
21. Start unit and bleed both the parking
brake circuit and service brake
hydraulic circuits.
22. At engine idle speed check Traction
Drive system operation for correct
wheel travel direction with range
select.
23. Reinstall tires/rim equipment. Torque
each dagger nut [star pattern] until
torque measurement is stabilized
and nut does not yield.
24. Perform hauler systems operational
check.
25. Operate unit a minimum of 15
minutes without pay load to verify
hauler performance.
26. Begin 100% re-inspection of wheel
nut torque. If nuts have not stabilized
at torque value, repeat step 25~26
until wheel nut torque is stabilized.
27. Record operational hours and date of
upgrade on service work order.
Return unit to operation.
28. Destroy all Tie Rods removed by
cutting in half with torch.

Hitachi Construction Truck Manufacturing Ltd. Technical Center

Cleveland, Ohio
Template Last revised 3/5/04

CONFIDENTIAL

Page

of 11

SERVICE BULLETIN CODE

DESCRIPTION

3 2005 100
FILING LOCATION

EH4500-227
EH5000-213
MODELS

GROUP

NO.

DATE

PAGE

EH4500 (411/412 MD), EH5000 (401/402 RD)

4600

Figure 3
Hitachi Construction Truck Manufacturing Ltd. Technical Center
Cleveland, Ohio
Template Last revised 3/5/04

10

02/05

8/10

CONFIDENTIAL

Page 10 of 11
SERVICE BULLETIN CODE

DESCRIPTION

3 2005 100
FILING LOCATION

EH4500-227
EH5000-213
MODELS

GROUP

NO.

DATE

PAGE

EH4500 (411/412 MD), EH5000 (401/402 RD)

4600

Figure 4
Hitachi Construction Truck Manufacturing Ltd. Technical Center
Cleveland, Ohio
Template Last revised 3/5/04

10

02/05

9/10

CONFIDENTIAL

Page 11 of 11
SERVICE BULLETIN CODE

DESCRIPTION

3 2005 100
FILING LOCATION

EH4500-227
EH5000-213
MODELS

GROUP

NO.

DATE

PAGE

EH4500 (411/412 MD), EH5000 (401/402 RD)

4600

Figure 5
Hitachi Construction Truck Manufacturing Ltd. Technical Center
Cleveland, Ohio
Template Last revised 3/5/04

10

02/05

10/10