Hitachi EX27U Operator's Manual
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Hitachi EX27U Operator's Manual

Hitachi EX27U Operator's Manual

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PART NO. EM1BU-NA3-1
Operator's Manual
EX27U
EX35U
EX50U
Excavator

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Summary of Contents for Hitachi EX27U

  • Page 1 PART NO. EM1BU-NA3-1 Operator’s Manual EX27U EX35U EX50U Excavator...
  • Page 2 INTRODUCTION Read this manual carefully to learn how to operate Warranty is provided as a part of Hitachi's support and service your machine correctly. Failure to do so program for customers who operate and maintain their could result in personal injury or equipment damage.
  • Page 3 MACHINE NUMBERS SAFETY SAFETY SIGNS COMPONENTS NAME OPERATOR’S STATION BREAK-IN OPERATING THE ENGINE DRIVING THE MACHINE OPERATING THE MACHINE TRANSPORTING MAINTENANCE STORAGE TROUBLESHOOTING SPECIFICATIONS INDEX...

  • Page 4: Table Of Contents

    Never Position Bucket Over Anyone ....S12 Cab Light............1-11 Avoid Undercutting ..........S12 Adjusting the Operator’s Seat......1-12 Avoid Tipping............S13 Seat Belt (EX27u, EX35u) .........1-13 Never Undercut a High Bank......S13 Seat Belt (EX50u) ..........1-14 Dig with Caution ..........S14 BREAK-IN Operate with Caution..........
  • Page 5 CONTENTS Parking and Stopping on a Slope......4-8 Maintenance Guide..........7-8 Parking the Machine..........4-8 The Brand Names of Recommended Oils and Lubricants ........7-10 OPERATING THE MACHINE A. Greasing ............7-11 Control Lever (ISO Excavator Pattern)....5-1 Front Joint Pins..........7-11 Control Lever (SAE-Backhoe Pattern) ....5-2 Bucket and Link Pins ........7-13 Shifting the Control Lever Control Pattern...
  • Page 6 SPECIFICATIONS Specifications (EX27u) ........12-1 Working Ranges (EX27u) ......... 12-2 Shoe Types and Applications (EX27u)....12-3 Bucket Types and Applications (EX27u) ... 12-4 Specifications (EX35u) ........12-5 Working Ranges (EX35u) ......... 12-6 Shoe Types and Applications (EX35u)....12-7 Bucket Types and Applications (EX35u) ... 12-8 Specifications (EX50u) ........

  • Page 7: Machine Numbers

    INDEX MACHINE NUMBERS MACHINE TYPE AND SERIAL NUMBER MODEL/TYPE: PRODUCT IDENTIFICATION NUMBER: PRODUCT IDENTIFICATION NUMBER (PIN) M571-01-018 PRODUCT IDENTIFICATION NUMBER: NOTE: Marks to indicate the start and ∗1BUP001001∗ end of the PIN PRODUCT IDENTIFICATION NUMBER (PIN) M570-07-009...
  • Page 8 MACHINE NUMBERS MEMO ..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................

  • Page 9: Safety

    INDEX SAFETY RECOGNIZE SAFETY INFORMATION • This is the SAFETY ALERT SYMBOL. • When you see this symbol on your machine or in this manual, be alert to the potential for personal injury. • Follow recommended precautions and safe operating practices.

  • Page 10: Follow Safety Instructions

    SAFETY FOLLOW SAFETY INSTRUCTIONS • Carefully read and follow all safety signs on the machine and all safety messages in this manual. • Safety signs should be installed, maintained and re- placed when necessary. • If a safety sign or this manual is damaged or missing, order a replacement from your authorized dealer in the same way you order other replacement parts (be sure to state machine model and serial number when...

  • Page 11: Wear Protective Clothing

    SAFETY WEAR PROTECTIVE CLOTHING • Wear close fitting clothing and safety equipment appro- priate to the job. You may need: A hard hat Safety shoes Safety glasses, goggles, or face shield Heavy gloves Hearing protection Reflective clothing Wet weather gear SA-438 Respirator or filter mask.

  • Page 12: Use Handholds And Steps

    SAFETY USE HANDHOLDS AND STEPS • Falling is one of the major causes of personal injury. • When you get on and off the machine, always face the machine and maintain a three-point contact with the steps and handrails. • Do not use any controls as handholds. •...

  • Page 13: Fasten Your Seat Belt

    SAFETY FASTEN YOUR SEAT BELT • If the machine should overturn, the operator may be- come injured and/or thrown from the cab. Additionally the operator may be crushed by the overturning machine, resulting in serious injury or death. • Prior to operating the machine, thoroughly examine webbing, buckle and attaching hardware.

  • Page 14: Operate Only From Operator's Seat

    SAFETY OPERATE ONLY FROM OPERATOR'S SEAT • Inappropriate engine starting procedure may cause the machine to runaway, possibly resulting in serious injury or death. • Start the engine only from the operator's seat. • NEVER start the engine while standing on the track or on ground.

  • Page 15: Investigate Job Site Beforehand

    SAFETY INVESTIGATE JOB SITE BEFOREHAND • When working at the edge of an excavation or on a road shoulder, the machine could tip over, possibly resulting in serious injury or death. • Investigate the configuration and ground conditions of the job site beforehand to prevent the machine from falling and to prevent the ground, stockpiles, or banks from collapsing.

  • Page 16: Provide Signals For Jobs Involving Multiple Numbers Of Machines

    SAFETY PROVIDE SIGNALS FOR JOBS INVOLVING MULTIPLE NUMBERS OF MACHINES • For jobs involving multiple numbers of machines, pro- vide signals commonly known by all personnel involved. Also, appoint a signal person to coordinate the job site. Make sure that all personnel obey the signal person’s directions.

  • Page 17: Drive Machine Safely

    SAFETY DRIVE MACHINE SAFELY • Before moving the machine, confirm which way to move travel pedals/levers for the corresponding direction you wish to go. • Pushing the travel levers forward moves the machine towards the idlers. (Refer to the Driving the Machine “Travel Levers”...

  • Page 18: Avoid Injury From Rollaway Accidents

    SAFETY AVOID INJURY FROM ROLLAWAY ACCI-DENTS • Death or serious injury may result if you attempt to mount or stop a moving machine. To avoid rollaways: • Select level ground when possible to park machine. • Do not park the machine on a grade. •...

  • Page 19: Avoid Injury From Back-Over And Swing Accidents

    SAFETY AVOID INJURY FROM BACK-OVER AND SWING ACCIDENTS • If any person is present near the machine when backing or swinging the upperstructure, the machine may hit or run over that person, resulting in serious injury or death. To avoid back-over and swing accidents: •...

  • Page 20: Keep Person Clear From Working Area

    SAFETY KEEP PERSON CLEAR FROM WORKING AREA • A person may be hit severely by the swinging front attachment or counterweight and/or may be crushed against an other object, resulting in serious injury or death. • Keep all persons clear from the area of operation and machine movement.

  • Page 21: Avoid Tipping

    SAFETY AVOID TIPPING • The danger of tipping is always present when operating on a grade, possibly resulting in serious injury or death. To avoid tipping: • Be extra careful before operating on a grade. • Prepare machine operating area flat. •...

  • Page 22: Dig With Caution

    SAFETY DIG WITH CAUTION • Accidental severing of underground cables or gas lines may cause an explosion and/or fire, possibly resulting in serious injury or death. • Before digging check the location of cables, gas lines, and water lines. • Keep the minimum distance required, by law, from cables, gas lines, and water lines.

  • Page 23: Do Not Use For Craning Operation

    SAFETY DO NOT USE FOR CRANING OPERATION • This machine is not equipped with any devices that could allow the machine to be used for craning operation. If the machine is used for craning operation, the machine may tip over and/or lifted load may fall, possibly resulting in serious injury or death.

  • Page 24: Handle Fluids Safely - Avoid Fires

    SAFETY HANDLE FLUIDS SAFELY－ － － － AVOID FIRES • Handle fuel with care; it is highly flammable. If fuel ignites, an explosion and/or a fire may occur, possibly resulting in serious injury or death. • Do not refuel the machine while smoking or when near open flame or sparks.

  • Page 25: Safety Transporting

    SAFETY SAFETY TRANSPORTING • The danger of tipping is present when loading/unloading the machine onto/from a truck or trailer bed. • Be sure to observe local regulations when transporting the machine on public roads. • Provide an appropriate truck or trailer for transporting the machine.

  • Page 26: Practice Safe Maintenance

    SAFETY PRACTICE SAFE MAINTENANCE To avoid accidents: • Understand service procedures before doing work. • Keep the work area clean and dry. • Do not spray water or steam inside cab. • Never lubricate or service the machine while it is moving.

  • Page 27: Support Machine Properly

    SAFETY SUPPORT MACHINE PROPERLY • Never attempt to work on the machine without securing the machine first. • Always lower the attachment to the ground before you work on the machine. • If you must work on a lifted machine or attachment, securely support the machine or attachment.

  • Page 28: Prevent Parts From Flying

    SAFETY PREVENT PARTS FROM FLYING • Grease in the track adjuster is under high pressure. Failure to follow the precautions below may result in serious injury, blindness, or death. • Do not attempt to remove GREASE FITTING or VALVE ASSEMBLY. •...

  • Page 29: Prevent Burns

    SAFETY PREVENT BURNS Hot spraying fluids: • After operation, engine coolant is hot and under pressure. Hot water or steam is contained in the engine, radiator and heater lines. Skin contact with escaping hot water or steam can cause severe burns. •...

  • Page 30: Avoid High-Pressure Fluids

    SAFETY AVOID HIGH-PRESSURE FLUIDS • Fluids such as diesel fuel or hydraulic oil under pressure can penetrate the skin or eyes causing serious injury, blindness or death. • Avoid this hazard by relieving pressure before disconnecting hydraulic or other lines. •...

  • Page 31: Prevent Fires

    SAFETY PREVENT FIRES Check for Oil Leaks: • Fuel, hydraulic oil and lubricant leaks can lead to fires. • Check for missing or loose clamps, kinked hoses, lines or hoses that rub against each other, damage to the oil-cooler, and loose oil-cooler flange bolts, for oil leaks.

  • Page 32: Evacuating In Case Of Fire

    SAFETY EVACUATING IN CASE OF FIRE • If fire breaks out, evacuate the machine in the following way: • Stop the engine by turning the key switch to the OFF position if there is time. • Use a fire extinguisher if there is time. •...

  • Page 33: Avoid Heating Near Pressurized Fluid Lines

    SAFETY AVOID HEATING NEAR PRESSURIZED FLUID LINES • Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders. • Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials.

  • Page 34: Prevent Battery Explosions

    SAFETY PREVENT BATTERY EXPLOSIONS • Battery gas can explode. • Keep sparks, lighted matches, and flame away from the top of battery. • Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer. •...

  • Page 35: Handle Chemical Products Safely

    • Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with HITACHI equipment includes such items as oil, fuel, coolant, brake fluid, filters, and batteries. • Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them.

  • Page 36: Safety Signs

    INDEX SAFETY SIGNS SS-1827 SS-259 SS-024 EX27u, EX35u SS-1833 EX50u SS-1807 S-28...
  • Page 37 SAFETY SIGNS SS4433590 EX27u, EX35u SS-1890 EX50u SS-1821 S-29...
  • Page 38 SAFETY SIGNS SS-1824 SS-1819 M589-01-001 EX27u, EX35u SS-1032 SS-1889 EX50u S-30...
  • Page 39 SAFETY SIGNS EX27u, EX35u SS-1786 SS-4432070 EX50u SS-1820 S-31...
  • Page 40 SAFETY SIGNS SS3088058 SS-1828 (Cab-Equipped Machines) SS3088058 SS-1830 S-32...
  • Page 41 SAFETY SIGNS (Cab-Equipped Machines) SS-1829 SS-1819 (Cab-Equipped Machines) SS-1829 SS-259 S-33...
  • Page 42 SAFETY SIGNS (Cab-Equipped Machines) SS-1832 SS-1835 SS-1194 SS4430516 S-34...
  • Page 43 INDEX COMPONENTS NAME COMPONENTS NAME 1- Blade 2- Blade Cylinder 3- Boom Swing Cylinder 4- Boom Cylinder 5- Bucket 6- Arm 7- Bucket Cylinder 8- Arm Cylinder 9- Boom 10- Work Light 11- Canopy 12- Counterweight 13- Travel Device 14- Track Frame 15- Front Idler 16- Track Shoe M586-01-001...

  • Page 44: Operator's Station

    6- Switch Panel and Monitor Panel 7- Engine Speed Control Lever 8- Operator’s Seat M586-01-010 9- Boom-Swing Pedal 10- Pilot Control Shut-Off Lever 11- Fast Speed Travel Pedal 12- Operator’s Manual Box 13- Tool Box 12, 13 M589-01-006 EX27u, 35u M586-01-062 EX50u...

  • Page 45: Monitor Panel And Switch Panel

    OPERATOR’S STATION MONITOR PANEL AND SWITCH PANEL M586-01-012 1- Switch Panel 2- Monitor Panel 3- Key Switch 4- Engine Speed Control Lever 5- Blade Lever 6- Fuse Box 7- Electrical Socket 8- Travel Alarm Cancel Switch M586-01-062...

  • Page 46: Key Switch

    OPERATOR’S STATION KEY SWITCH 1- OFF (Engine Off) 2- ON (Engine On, Preheat) 3- START (Engine Start) M588-01-012 WORK LIGHT SWITCH Push work light switch (6) to turn on work lights (4) and work lights (5) (optional), located on the boom, and at the lower front of the operator’s station.

  • Page 47: Monitor Panel

    OPERATOR’S STATION MONITOR PANEL 1- Preheat Indicator 2- Engine Oil Pressure Indicator 3- Alternator Indicator 4- Fuel Gauge and Fuel Level Indicator 5- Coolant Temperature Gauge and Overheat Indicator 6- Hour Meter M586-01-014 ALTERNATOR INDICATOR Red indicator will light with low alternator output. Check electrical system.

  • Page 48: Preheat Indicator

    OPERATOR’S STATION PREHEAT INDICATOR Yellow indicator will light when key switch is turned to ON position in cold weather. Light will turn off after a few sec- onds, indicating that the preheat is completed. M424-01-009 COOLANT TEMPERATURE GAUGE AND OVERHEAT INDICATOR COOLANT TEMPERATURE GAUGE The engine coolant temperature is indicated.

  • Page 49: Fuel Gauge And Fuel Level Indicator

    OPERATOR’S STATION FUEL GAUGE AND FUEL LEVEL INDICATOR FUEL GAUGE The fuel amount remaining in the fuel tank is indicated. E indicates that the fuel tank is empty. F indicates that the fuel tank is full. When the left most segment comes ON, the fuel tank is almost empty.

  • Page 50: Cab Heater

    OPERATOR’S STATION CAB HEATER (Optional unit for the cab-equipped machine) The cab heater is controlled in two modes by operating switch (1). NOTE: Be sure to close the shutoff valve on the engine side when the heater is not being used. M586-01-015 WIPER/WASHER SWITCH (Only on cab-equipped machines)

  • Page 51: Opening And Closing Front Window

    OPERATOR’S STATION OPENING AND CLOSING FRONT WINDOW (Only on cab-equipped machines) Opening: CAUTION: After opening the front window, be sure to engage lock pin (1). 1. Disengage both right and left lock pins (1) from the upper front window frame. 2.

  • Page 52: Emergency Exit

    OPERATOR’S STATION EMERGENCY EXIT (Only on cab-equipped machines) If the operator’s cab door should not open in an emergency, escape in the following methods: 1. Open the front windows. Escape through the win- dows. NOTE: See page “OPENING UPPER FRONT WIN- DOWS”...

  • Page 53: Tool Box And Operator's Manual Box

    OPERATOR’S STATION TOOL BOX AND OPERATOR’S MANUAL BOX Tool box (1) and an operator’s manual box (2) are around the operator’s seat. EX27u, EX35u M589-01-005 M586-01-018 EX50u CAB DOOR RELEASE LEVER (Only on cab-equipped machines) CAUTION: Open the cab door all the way until it securely locks in the latch on the side of the cab.

  • Page 54: Adjusting The Operator's Seat

    OPERATOR’S STATION ADJUSTING THE OPERATOR’S SEAT 1. Pull lever (1) to the right to slide the seat forward or rearward. Release the lever to lock. NOTE: Seat slide has positioning stops every 20 mm (0.8 in). Length adjustment from full rearward to full forward is 120 mm (4.7 in).

  • Page 55: Seat Belt (Ex27U, Ex35U)

    OPERATOR’S STATION SEAT BELT (EX27u, EX35u) CAUTION: Be sure to use the seat belt when op- erating the machine. Before operating the machine, be sure to exam- ine seat belt (1), buckle (2), or attaching hardware. Replace seat belt (1), buckle (2), or attaching hardware if they are damaged, or worn.

  • Page 56: Seat Belt (Ex50U)

    OPERATOR’S STATION SEAT BELT (EX50u) CAUTION: Be sure to use the seat belt when op- erating the machine. Before operating the machine, be sure to exam- ine seat belt (1), buckle (2), or attaching hardware. Replace seat belt (1), buckle (2), or attaching hardware if they are damaged, or worn.

  • Page 57: Break-In

    INDEX BREAK-IN BREAKING IN A NEW MACHINE Each machine is thoroughly inspected and adjusted at the factory. However, it is important to correctly break in your machine, following the table below: HOURS OPERATING First 50 hours Up to about 80% of full load After the first 50 hours Full load Operating a new machine at full load without first breaking...
  • Page 58 BREAK-IN MEMO ..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................

  • Page 59: Operating The Engine

    INDEX OPERATING THE ENGINE BEFORE STARTING ENGINE 1. Confirm that pilot control shut-off lever (1) is in the LOCK position. 2. Confirm that all control levers are placed in neutral. 3. Check indicator bulbs as follows: Turn key switch to ON position. All indicator lights and warning lamps will come on.

  • Page 60: Starting The Engine

    OPERATING THE ENGINE STARTING THE ENGINE AUTOMATICALLY START RETURN 1. Turn the key switch to the ON position. In cold weather, the preheat indicator will light. 2. Sound the horn to alert persons nearby. If the horn does not sound, be sure to repair the trou- ble before operating the machine.

  • Page 61: Using Booster Batteries

    (3) of the ma- chine to be started with the other end of black (–) ca- ble (2). d. Start the engine EX27u, 35u M586-01-052 2. Disconnecting the booster batteries a. Disconnect black negative (–) cable (2) from machine bracket (3) first.

  • Page 62: Stopping The Engine

    OPERATING THE ENGINE STOPPING THE ENGINE AUTOMATICALLY START 1. Park the machine on a level surface. RETURN 2. Lower the bucket and blade to the ground. 3. Run engine at slow idle speed without load for 5 min- utes. 4. Turn the key switch OFF to stop the engine. 5.
  • Page 63 INDEX DRIVING THE MACHINE TRAVEL LEVERS CAUTION: In the standard travelling position, the blade is located in front of the operator’s seat and the travel motors at the rear. If the travel motors are positioned at the front of the machine, Blade the actions of the travel levers will be reversed.

  • Page 64: Fast Speed Travel Pedal

    DRIVING THE MACHINE FAST SPEED TRAVEL PEDAL CAUTION: Never attempt to shift the travel mode from the slow to fast while descending a slope. Otherwise, the machine may run away, possibly causing personal injury or death. The machine travel speed is increased to the fast mode as long as fast speed travel pedal (1) is depressed.

  • Page 65: Traveling

    DRIVING THE MACHINE TRAVELING CAUTION: Use a signal person when moving, swinging or operating the machine in congested areas. Coordinate hand signals before starting the machine. 1. Determine which way to move travel levers for the direction you want to go before moving machine. When the travel motors are in the rear, pushing the levers forward moves the machine forward, towards the idlers.

  • Page 66: Operating On Soft Ground

    DRIVING THE MACHINE OPERATING ON SOFT GROUND Avoid traveling on very soft ground that does not have suf- ficient strength to firmly support the machine. If the machine is operated on very soft ground or becomes stuck, it may be necessary to clean the track frame area. Swing the upperstructure 90°...

  • Page 67: Towing Machine A Short Distance

    DRIVING THE MACHINE TOWING MACHINE A SHORT DISTANCE CAUTION: Cables, straps, or wire ropes can break causing serious injury. Do not tow machine Wire Rope with damaged chains, slings, straps, wire ropes or frayed cables. Always wear gloves when handling cable, straps or wire ropes.

  • Page 68: Operating In Water Or Mud

    (A). 2. When operating in such conditions, check the ma- chine’s position often. Reposition the machine if nec- essary. EX27u 470 mm (1ft 7in) EX35u 470 mm (1ft 7in) EX50u...

  • Page 69: Precautions For Traveling On Slopes

    DRIVING THE MACHINE PRECAUTIONS FOR TRAVELING ON SLOPES CAUTION: Avoid possible injury from traveling on slopes. Tipping over or skidding down of the machine may result. Thoroughly read and under- stand precautions below and be sure to travel at slow speed on slopes. Never attempt to travel on slopes with the bucket loaded or any load sus- pended by the bucket.

  • Page 70: Parking And Stopping On A Slope

    DRIVING THE MACHINE PARKING AND STOPPING ON A SLOPE CAUTION: Parking and stopping on a slope is extremely dangerous. If parking or stopping on a slope is unavoidable, follow these precautions. 1. If the engine stalls on a slope, lower the blade, place all levers in the neutral position, and then restart the engine.
  • Page 71 INDEX OPERATING THE MACHINE CONTROL LEVER (ISO EXCAVATOR PATTERN) CAUTION: Make sure you know the location and function of each control lever before operating. The upperstructure and/or front attachment may unexpectedly move in an attempt to look back because a part of operator’s body may come into contact with the control lever(s).
  • Page 72 OPERATING THE MACHINE CONTROL LEVER (SAE-BACKHOE PATTERN) CAUTION: Make sure you know the location and function of each control lever before operating. The upperstructure and/or front attachment may unexpectedly move in an attempt to look back because a part of operator’s body may come into contact with the control lever(s).

  • Page 73: Shifting The Control Lever Control Pattern

    OPERATING THE MACHINE SHIFTING THE CONTROL LEVER CONTROL PATTERN The control lever control pattern can be shifted between the ISO-EXCAVATOR PATTERN and SAE-BACKHOE PATTERN by selector valve (9). Before shifting the control lever control pattern, be sure to stop the engine. Rotate selector valve (9) to the desired control pattern position using the attached tool.

  • Page 74: Boom-Swing Pedal

    OPERATING THE MACHINE BOOM-SWING PEDAL Boom-swing pedal (1) is located at the operator’s right foot. Use this pedal to control the boom-swing function. Unlocked M586-05-009 Boom-Swing Operation 1. Turn cover (2) forward to unlock boom-swing pedal (1). 2. Push down on the left side of the pedal to swing left. 3.

  • Page 75: Optional Pedal

    OPERATING THE MACHINE OPTIONAL PEDAL Optional pedal operation in the operator’s station (for use of hydraulic breaker, crusher, tilt bucket, etc.) Operation 1. Turn cover (1) forward to unlock optional pedal (2). 2. Step on the right or the left of optional pedal (2) to operate the front-end attachment located on the top of the arm.
  • Page 76 OPERATING THE MACHINE Shifting Auxiliary Pipe Line Selector Valve When a hydraulic breaker (or other single actuating cylin- der attachment) or a crusher (or other double actuating cylinder attachment) is installed, selector valve (3) must be positioned according to the type of attachment to be oper- ated.

  • Page 77: Blade Lever

    OPERATING THE MACHINE BLADE LEVER Use blade lever (1) on the operator’s right to raise and lower the blade. When the lever is released, it automatically returns to neu- tral, keeping the blade in its position until the lever is oper- ated again.

  • Page 78: Pilot Control Shut-Off Lever

    OPERATING THE MACHINE PILOT CONTROL SHUT-OFF LEVER The pilot control shut-off lever is a device to prevent the machine from being unexpectedly operated if the control levers are accidentally moved when the operator is getting in or out of the operator’s station. However, this pilot control shut-off function does not apply to the boom swing pedal, blade lever, and auxiliary pedal.
  • Page 79 OPERATING THE MACHINE 2. Before Starting Operation: CAUTION: Never attempt to lower raised console (to reactivate the pilot control shut-off function) by holding and pushing down control lever (3) and/or console (2). Always lower the console us- ing pilot control shut-off lever (1). Be sure to keep pilot control shut-off lever (1) in LOCK (raised) position when starting the engine.

  • Page 80: Warming Up Operation

    OPERATING THE MACHINE WARMING UP OPERATION The normal operating temperature of hydraulic oil is from 50 to 80°C (122 to 176°F). Hydraulic components may be seriously damaged if the machine is operated with hydrau- lic oil temperature below 20°C (68°F). Before starting work, be sure to follow these warm-up pro- cedures until the temperature of the hydraulic oil reaches above 20°C (68°F).

  • Page 81: Precautions For Operations

    OPERATING THE MACHINE PRECAUTIONS FOR OPERATIONS CAUTION: Investigate the work site before start- ing operations. 1. Be sure to install an overhead cab guard when operating in a work site which has a possibility of falling objects. 2. If operation on soft ground is required, suffi- ciently reinforce the ground beforehand.

  • Page 82: Avoid Tipping

    OPERATING THE MACHINE AVOID TIPPING CAUTION: Operating on slopes is dangerous. Reduce operating speeds to avoid tipping or slip- ping. 1. To the extent possible, avoid turning on slopes. When you must turn on a slope, try to do so in an area with solid footing and not so steep.

  • Page 83: Operating Backhoe

    OPERATING THE MACHINE OPERATING BACKHOE 1. Place the bucket teeth on the ground with the bottom of the bucket at a 45° degree angle to the ground. 2. Pull the bucket toward the machine using the arm as the main digging force. 3.

  • Page 84: Grading Operation

    OPERATING THE MACHINE GRADING OPERATION In most cases, use the blade for soil refilling and general grading operations. When needed, the front attachment can be used to perform grading operations. IMPORTANT: Don’t pull or push dirt with the bucket when traveling. Position the arm slightly forward of the vertical position with bucket rolled back, as shown.

  • Page 85: Select Correct Track Shoes

    OPERATING THE MACHINE SELECT CORRECT TRACK SHOES Rubber and marsh shoes are only for use on soft ground, not on hard, abrasive surfaces such as gravels, rocks, min- erals, etc. Using these shoes on such surfaces can cause shoes to be damaged or warped, and further cause damage to the track link and/or rollers.

  • Page 86: Object Handling

    OPERATING THE MACHINE OBJECT HANDLING --- IF EQUIPPED CAUTION: When you use machine for object handling, be sure to comply with all local regula- tions. Cables, straps, or ropes can break, causing seri- ous injury. Don’t use damaged chains, frayed ca- bles, slings, straps, or ropes to crane.

  • Page 87: Avoid Hitting Blade With Front Attachment

    OPERATING THE MACHINE AVOID HITTING BLADE WITH FRONT AT- TACHMENT When operating the machine with the blade positioned to- wards the front, the bucket or boom cylinder may come into contact with the blade if you are not careful. Be sure to prevent this from happening.

  • Page 88: Boom Cylinder May Hit Track

    Be sure to install the bucket having the width dimensions shown below or less: EX50u: 700 mm (28 in) EX35u: 600 mm (24 in) EX27u: 600 mm (24 in) 5-18...

  • Page 89: Operate The Machine Safely

    OPERATING THE MACHINE OPERATE THE MACHINE SAFELY CAUTION: Prevent the machine from tipping over and from being involved in a ground col- lapse. Take the necessary precautions as follows: 1. Make sure the work site has sufficient strength to firmly support the machine. When working close to an excavation or on road shoulders, operate the machine with the tracks positioned perpendicular to the cliff...

  • Page 90: Using Rubber Crawler

    OPERATING THE MACHINE USING RUBBER CRAWLER Rubber crawlers are designed for traveling on paved roads. Avoid damage to the rubber crawlers by following the pre- cautions below: Forbidden Operations Don’t operate on sharp, rocky, uneven surfaces, such as river rock, gravel, etc. Don’t allow engine oil, gasoline, etc.

  • Page 91: Traveling And Other Cautions

    OPERATING THE MACHINE TRAVELING AND OTHER CAUTIONS CAUTION: The rubber crawler machine is less stable than the steel crawler machine, as the edge of the rubber crawler may deform when loaded. Pay attention when digging with the boom positioned at a right angle to the tracks. 1.

  • Page 92: Emergency Stop Procedure To Lower Front Attachment

    OPERATING THE MACHINE EMERGENCY STOP PROCEDURE TO LOWER FRONT ATTACHMENT CAUTION: Prevent personal injury. Confirm that no one is under the front attachment before start- ing the procedure below. If the engine stalls and cannot be restarted, lower the boom to lower the bucket to the ground referring to the emergency boom lowering procedure stated below.

  • Page 93: Hydraulic Breaker Operating Tips

    OPERATING THE MACHINE HYDRAULIC BREAKER OPERATING TIPS --- OPTIONAL Select a breaker that is the correct size and weight for your machine. See your authorized dealer for correct breaker information. Carefully study the operator’s manuals of the machine and breaker, and perform the required checks and/or inspec- tion before connecting the breaker to the arm.
  • Page 94 OPERATING THE MACHINE 3. Do not operate the breaker with the hydraulic cylinder rod fully retracted or fully extended. Doing so may cause cylinder or machine damage. Always leave at WRONG least 50 mm (2 in.) from the fully retracted/extended position in order to reduce shocks.

  • Page 95: Replacement Of Hydraulic Oil And Filter Element

    2000* nary Bucket Machine with Hy- draulic Breaker * Hitachi New Landy HN was used. NOTE: Replacement intervals shown here are for 100% bucket or breaker application. When breaker /bucket applications are alternated, re- placement intervals may be extended, depend- ing upon the percent of time the bucket is ap- plied.

  • Page 96: Operating Hydraulic Crusher

    OPERATING THE MACHINE OPERATING HYDRAULIC CRUSHER --- IF EQUIPPED WRONG Select a crusher that is the correct size and weight for the machine. See your authorized dealer for correct crusher information. The crusher is much heavier than the bucket. Operate the machine slowly to prevent tipping the machine.

  • Page 97: After Finishing Work

    OPERATING THE MACHINE 3. When operating the crusher up high with the boom fully raised, be careful of falling objects. WRONG 4. When operating the crusher on a floor in a building, first confirm that the floor has sufficient strength to support the load caused by crushing, in addition to the machine weight.
  • Page 98 OPERATING THE MACHINE MEMO ..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5-28...

  • Page 99: Transporting

    INDEX TRANSPORTING TRANSPORTING BY ROAD When transporting the machine on public roads, be sure to first understand and follow all local regulations. 1. For transporting using a truck, check the width, height, length and weight of the truck when the machine is loaded.
  • Page 100 TRANSPORTING Loading/Unloading CAUTION: ･ ･ ･ ･ Avoid steering while driving up or down a ramp as it is extremely dangerous. If steering is un- avoidable, first move back to the ground or flatbed, modify traveling direction, and begin to drive again. ･...

  • Page 101: Precautions For Transporting Machines With Rubber Tracks

    TRANSPORTING Transporting CAUTION: Fasten chains or cables to the ma- chine frame. Do not place chains or cables over or against the hydraulic lines or hoses. 1. Place blocks in front of and behind the tracks. 2. Fasten each corner of the machine and front attach- ment to the truck with a chain or cable.
  • Page 102 TRANSPORTING Unloading CAUTION: The rear end of the flatbed where it meets the ramp is a sudden bump. Take care when traveling over it. IMPORTANT: Prevent possible damage to the front attachment. Always position the arm at 90° to the boom when unloading the machine.

  • Page 103: Lifting The Entire Machine With Acrane

    CAUTION: Be sure to operate the blade while the engine is running. If the blade is operated after EX27u: 2600 mm (8 ft 6 in) EX27u: 4300 mm the engine stopped, the blade will drift when lift-...
  • Page 104 TRANSPORTING MEMO ..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................

  • Page 105: Maintenance

    • Use only genuine HITACHI parts. • Failure to use recommended fuel, lu- bricants, and genuine Hitachi parts will result in loss of Hitachi product warranty. • Never adjust engine governor or hy- draulic system relief valve. • Protect electrical parts from water and steam.

  • Page 106: Service Your Machine At Specified Intervals

    MAINTENANCE SERVICE YOUR MACHINE AT SPECIFIED INTERVALS Perform all service procedures described in this mainte- nance guide. Lubricate, make service checks and adjustments at inter- vals shown on the periodic maintenance chart located on the left of the seat stand. CHECK THE HOUR METER REGULARLY Check hour meter (1) to determine when your machine needs periodic maintenance.

  • Page 107: Prepare Machine For Maintenance

    MAINTENANCE PREPARE MACHINE FOR MAINTENANCE Before performing the maintenance procedures given in the following chapters, park the machine as described be- low, unless otherwise specified. 1. Park the machine on a level surface. 2. Lower the bucket and blade to the ground. 3.

  • Page 108: Hood And Access Covers

    • Secure Engine Hood in Position Pull open latch to unlock hood (1). Raise hood (1) until the end of bar (2) is securely locked into catch (3). A “Click” sound will be heard. EX27u, EX35u EX27u, EX35u • Secure Access Covers in Position M589-07-001 Pull lever (4) to open access cover (5).

  • Page 109: Daily Inspection

    MAINTENANCE DAILY INSPECTION 1- Tooth 2- Side Cutter 3- Bucket 4- Bucket Cylinder 5- Arm 6- Arm Cylinder 7- Swing Bearing 8- Center Joint 9- Swing Device 10- Control Valve 11- Hydraulic Oil Tank 12- Full-Flow Filter 13- Suction Filter 14- Muffler 15- Radiator, Oil Cooler 16- Air Cleaner...

  • Page 110: Daily Inspection Check List

    MAINTENANCE DAILY INSPECTION CHECK LIST Checkpoint Engine 1. Oil and coolant quantity, contami- nation. 2. Rough engine operation, exhaust gas color, abnormal noise. 3. Oil and coolant leakage. Damaged hoses and pipes. 4. Clogged or damaged radiator/oil cooler. 5. Loose or missing bolts and nuts. 1.

  • Page 111: Periodic Replacement Of Parts

    MAINTENANCE PERIODIC REPLACEMENT OF PARTS To ensure safe operation, be sure to conduct periodic in- spection of the machine. In addition, the parts listed below, if defective, may pose serious safety/fire hazards. It is very difficult to gauge the extent of deterioration, fatigue, or weakening of the parts listed below simply by visual in- spection alone.

  • Page 112: Maintenance Guide

    Interval (hours) Parts Quantity 1000 2000 1. Engine Oil Oil Lever Check – EX27u, EX35u 6.8 L (1.8 US gal) 2. Engine Oil Change EX50u 8.7 L (2.3 US gal) 3. Engine Oil Filter Replacement C. TRANSMISSION (See Page 7-20)
  • Page 113 Interval (hours) Parts Quantity 1000 2000 1. Check Coolant Level 2. Check and Adjust Fan Belt Tension EX27u 5.2 L (1.4 US gal) ### Twice a year (in spring and autumn) 3. Change Coolant EX35u 6.0 L (1.6 US gal) EX50u 7.2 L (1.9 US gal)
  • Page 114 –20 to 0°C –10 to 40°C (–6 to 32°F) (14 to 95°F) (–6 to 32°F) (14 to 95°F) Manufacturer Hitachi * New Landy HN Malti M Use high quality Die- Idemitsu Kosan Dephne Superhydro LW46H sel Fuel only. British Petroleum...
  • Page 115 MAINTENANCE A. GREASING Front Joint Pins --- every 500 hours or every years Position machine with the arm cylinder fully retracted and the bucket cylinder fully extended. Lower bucket to the ground. M586-05-030 (1) Boom cylinder rod end M156-07-005 (2) Boom cylinder bottom end M571-07-005 (3) Boom foot M570-07-009...
  • Page 116 MAINTENANCE (4) Arm cylinder rod side. Bucket cylinder bottom side. M571-07-006 (5) Boom and Arm connecting pin. Arm cylinder bottom side. M585-07-046 (6) Swing cylinder. M570-07-010 (7) Swing post. M570-07-011 7-12...

  • Page 117: Precautions For Front Attachment And Blade Removal

    MAINTENANCE Bucket Cylinder Rod End Bucket and link connecting pins --- every 50 hours M503-07-092 PRECAUTIONS FOR FRONT ATTACHMENT AND BLADE REMOVAL 1. When pins are removed to replace the front attach- ment or blade, do not attempt to clean the bore in- sides of the bushings.

  • Page 118: Swing Bearing

    • Pull the pilot control shut-off lever to the LOCK position. 1. Park the machine on a level surface. EX27u, EX35u 2. Lower the bucket and blade to the ground. M589-01-001 3. Run the engine at slow idle speed without load for three minutes.

  • Page 119: Swing Internal Gear

    5. Pull the pilot control shut-off lever to the LOCK posi- tion. 6. Remove the cover from the bottom of the un- der-carriage. EX27u, EX35u M589-01-001 Check if grease inside is cloudy, due to contamina- tion by water or dirt.

  • Page 120: Control Lever Universal Joint

    MAINTENANCE Control Lever Universal Joint --- every 500 hours or yearly Remove the boot from the pilot valve and apply grease to the four places of the universal joint, as indicated by ar- rows. M588-07-016 M588-07-020 7-16...

  • Page 121: Engine

    Engine Oil Chart). NOTE: Checking the oil level immediately after shut down will result in inaccurate readings. Be sure to allow the oil to settle for at least 10 minutes before checking. M589-07-006 EX27u, EX35u EX27u, EX35u M589-07-007 EX50u M571-07-008 7-17...

  • Page 122: Change Engine Oil

    MAINTENANCE Change Engine Oil --- every 250 hours Replace Engine Oil Filters --- every 250 hours 1. Run the engine to warm oil. DO NOT run the engine until oil is hot. 2. Park the machine on a level surface. Oil Pan 3.
  • Page 123 Be sure not to damage the gasket when installing the fil- ter. 14. Tighten engine oil filter (3) 1-1/4 turn more using the EX27u, EX35u M589-07-006 filter wrench. 15. Remove filler cap (4). Fill the engine with recom- mended oil.

  • Page 124: Transmission

    MAINTENANCE C. TRANSMISSION Travel Reduction Gear Check Oil Level --- every 250 hours 1. Park the machine on a level surface. 2. Rotate the travel motor until plugs position is as illus- trated on the right. 3. Lower the bucket and blade to the ground. 4.
  • Page 125 MAINTENANCE Change Gear Oil --- every 1000 hours 1. Park the machine on a level surface. 2. Rotate the travel motor until plugs position is as illus- trated on the right. 3. Lower the bucket and blade to the ground. 4.

  • Page 126: Hydraulic System

    MAINTENANCE D. HYDRAULIC SYSTEM INSPECTION AND MAINTENANCE OF HYDRAULIC EQUIPMENT CAUTION: During operation the parts of the hy- draulic system become very hot. Allow the machine to cool down before beginning inspection or maintenance. 1. Be sure that the machine is parked on a level, solid surface before servicing hydraulic equipment.

  • Page 127: Check Hydraulic Oil Level

    Turn cap slowly and remove the cap only after releasing the internal pressure com- pletely. 8. Turn cap (2) slowly to release the air. EX27u, EX35u M579-07-009 9. Turn cap further and remove cap or plug. 10. Add oil. Recheck oil level gauge (1).

  • Page 128: Drain Hydraulic Tank Sump

    6. Turn the cap slowly to release the air. CAUTION: Do not loosen the drain plug until oil EX27u, EX35u M589-07-012 is cool. Hydraulic oil may be hot, potentially causing serious injury.

  • Page 129: Change Hydraulic Oil

    Slowly loose cap (1) to release pressure. 8. Slowly loosen cap (1) to release pressure. 9. Remove cap (1). EX27u, EX35u SS-1789 10. Drain oil using a suction pump. The hydraulic oil tank capacity, up to specified oil level, is approximately 70 liters.
  • Page 130 MAINTENANCE EX27u, EX35u 11. Remove drain plug (2). Allow oil to drain. 12. Remove cover (4) with O-ring. 13. Remove suction filter (7) with rod (6). 14. Clean suction filter (7) and tank interior. If suction fil- ter (7) is to be replaced, install new filter.
  • Page 131 MAINTENANCE EX50u 11. Remove drain plug (2). Allow oil to drain. 12. Remove suction filter (4) with cover (5). 13. Clean the suction filter and tank interior. If the suction filter is to be replaced, install new suction filter. 14. Install suction filter (4) on cover (5). Then install the filter assembly into the hydraulic oil tank.
  • Page 132 (1) Connect all hydraulic lines to the hydraulic pump. Fill any hydraulic components, that can be filled with hydraulic oil, with hydraulic oil as much as possible. EX27u, EX35u (2) Add hydraulic oil to the hydraulic oil tank to the M589-07-010 specified level.

  • Page 133: Replace Hydraulic Oil Tank Filter

    6. Slowly loosen the cap to release the pressure, then M586-05-030 remove the cap. EX27u, EX35u NOTE: There is spring tension under the cover. Hold down the cover when removing last two bolts. 7. Hold down filter cover (2) against light spring load when removing the last two bolts (1).
  • Page 134 MAINTENANCE EX50u 7. Remove five bolts (1), cover (2) and O-ring (3). 8. Pull rod (4) up to remove element (5) assembly. NOTE: Remove the element and inspect for metal par- ticles and debris in the bottom of the filter can. Excessive amounts of brass and steel particles can indicate a failed hydraulic pump, motor, valve or an impending failure.
  • Page 135 MAINTENANCE Replace Pilot Oil Filter --- every 1000 hours EX27u, EX35u 1. Park the machine on a level surface. 2. Lower the bucket and blade to the ground. 3. Run the engine at slow idle speed without load for three minutes.
  • Page 136 MAINTENANCE 11. Rotate the hexagon on filter case (9) counterclock- wise using a tool such as a wrench to remove filter case (9) from filter head (7). 12. While rotating filter element (10), pull to remove filter element (10) downward. 13.
  • Page 137 MAINTENANCE EX50u 1. Park the machine on a level surface. 2. Lower the bucket and blade to the ground. 3. Run the engine at slow idle speed without load for three minutes. 4. Stop the engine. Remove the key from the key switch.

  • Page 138: Check Hoses And Lines

    MAINTENANCE Check Hoses and Lines --- daily --- every 250 hours CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. To avoid this hazard, search for leaks with a piece of cardboard. Take care to protect hands and body from high-pressure fluids.
  • Page 139 (Use proper bend radius) Hose ends and Deformation or Replace M115-07-147 fittings Corrosion (10) NOTE: Refer to the illustrations in Fig.1 for each check point location or for a descrip- tion of the abnormality. Use genuine Hitachi parts. M115-07-148 M115-07-149 Fig.1 7-35...
  • Page 140 Replace M137-07-007 Loose Retighten Fig.2 NOTE: Refer to the illustrations in Fig.2 for each check point location or for a descrip- tion of the abnormality. Use genuine Hitachi parts. Table 3. Oil cooler Interval(hours) Check Points Abnormalities Remedies Every 250 hours...
  • Page 141 MAINTENANCE Metal Face Seal Fittings Fittings are used on smaller hoses and consist of a metal flare and a metal flare seat. a. Inspect flare (5) and flare seat (4). They must be free of dirt or obvious defects. IMPORTANT: Defects in the tube flare cannot be re- paired.

  • Page 142: Fuel System

    Take care not to spill fuel on the machine or ground. M586-01-014 Fuel Tank Capacity EX27u, EX35u 40 L (10.6 US gal) EX50u 50 L (13.2 US gal) 8. Install and lock fill cap (2) immediately after fueling.

  • Page 143: Drain Fuel Tank Sump

    4. Turn the key switch OFF. Remove the key from the key switch. 5. Pull the pilot control shut-off lever to the LOCK posi- tion. 6. Open drain cock (1) for several seconds to drain wa- ter and sediment. Close the drain cock. M589-07-013 EX27u, EX35u EX50u M571-07-020 7-39...

  • Page 144: Check Water Separator

    MAINTENANCE Check Water Separator --- daily When water is seen collected in transparent filter cup (1), remove it and dispose of sediment. Reinstall filter cup (1). M589-07-013 EX27u, EX35u M573-07-001 EX50u 7-40...

  • Page 145: Replace Fuel Filter

    7. Tighten plug (5) when fuel flows from the plug hole. 8. Turn the key switch ON and hold for 10 to 15 sec- onds to engage automatic bleeding. 9. Start the engine and check for fuel leakage. M503-07-038 M589-07-013 EX27u, EX35u M573-07-001 EX50u 7-41...

  • Page 146: Air Cleaner

    (indicator 3 turns red). Replace the Air Cleaner Elements --- after cleaning eight times or after one year EX27u, EX35u 1. Park the machine on a level surface. 2. Lower the bucket and blade to the ground.
  • Page 147 MAINTENANCE EX50u 1. Park the machine on a level surface. 2. Lower the bucket and blade to the ground. 3. Run the engine at slow idle speed without load for three minutes. 4. Stop the engine. Remove the key from the key switch.

  • Page 148: Cooling System

    MAINTENANCE G. COOLING SYSTEM NOTE: ✱ Before leaving the Hitachi factory, the cool- ing system is filled with a mixture of water and long-life coolant, Hitachi Genuine Long-Life Coolant. As long as Hitachi Genuine Long-Life Coolant is used, the service intervals between...

  • Page 149: Check Coolant Level

    FULL and LOW marks on coolant reservoir (2). If the coolant level is below the low mark, add coolant to coolant reservoir (2). If coolant reservoir (2) is empty, add coolant to the radiator and then to the coolant reservoir. SS-1786 EX27u, EX35u EX50u M571-07-001 7-45...

  • Page 150: Check And Adjust Fan Belt Tension

    Visually check the belt for wear. Replace if necessary. Check fan belt tension by depressing the mid-point with the thumb. Deflection must be A at a depressing force of ap- EX27u, EX35u M589-07-014 proximately 98 N (10 kgf, 22 lbf).

  • Page 151: Change Coolant

    Change Coolant --- twice a year (in spring and autumn) EX27u, EX35u NOTE: Before leaving the Hitachi Factory, the cooling system is filled with a mixture of water and Hi- tachi Genuine Long-Life Coolant. As long as Hitachi Genuine Long-Life Coolant is...
  • Page 152 MAINTENANCE EX50u NOTE: Before leaving the Hitachi Factory, the cooling system is filled with a mixture of water and Hi- tachi Genuine Long-Life Coolant. As long as Hitachi Genuine Long-Life Coolant is used, the service intervals between changing the coolant is once every two years (in autumn), or every 2000 hours, whichever comes first.

  • Page 153: Clean Radiator Core

    MAINTENANCE Clean Radiator --- every 500 hours CAUTION: Always wear safety glasses or gog- gles when using compressed air to clean radiator core. IMPORTANT: (1) Cover air cleaner inlet opening to prevent entry of dust and water while cleaning the radiator. (2) High-pressure air or water can dam- age radiator fins.

  • Page 154: Electrical System

    MAINTENANCE H. ELECTRICAL SYSTEM Batteries 1. Check battery electrolyte level and terminals CAUTION: Battery gas can explode. Keep sparks and flames away from batteries. Use a flashlight to check battery electrolyte level. Do not continue to use or charge the battery when the electrolyte level is lower than specified.
  • Page 155 MAINTENANCE 2. Check electrolyte specific gravity If acid is swallowed: CAUTION: Battery gas can explode. Keep sparks 1. Drink large amounts of water or milk. and flames away from batteries. Use a flashlight 2. Then drink milk of magnesia, beaten to check battery electrolyte level.

  • Page 156: Replacing Fuses

    MAINTENANCE REPLACING FUSES If any electrical equipment fails to operate, first check the fuses. Fuse box is located the side of the switch panel. A fuse location/specification decal is attached to the fuse box cover. Remove the fuse box cover by lifting it upward. Spare fuses are located on the underside of the cover.

  • Page 157: Electical Socket

    MAINTENANCE ELECTICAL SOCKET Use: Connection of a lighting device for service and main- tenance. Specification of electrical socket: maximum charge 5A at 12V. M586-01-011 M586-12-013 7-53...

  • Page 158: Miscellaneous

    MAINTENANCE I. MISCELLANEOUS Check Bucket Teeth --- daily 1. Check the bucket teeth for wear and looseness Replace teeth (1) if tooth wear exceeds the desig- nated service limit shown below. Dimension A in mm (in.) Limit of Use 128 (5.0″) 65 (2.6″) M104-07-056 2.
  • Page 159 MAINTENANCE c. Clean shank (6) surface. d. Install rubber pin lock (4) into shank (6) hole as shown. RIGHT WRONG WRONG M104-07-060 e. Position new tooth (1) over shank (6). RIGHT WRONG WRONG M104-07-061 f. Drive locking pin (5) into the hole fully as shown. WRONG RIGHT M104-07-062...

  • Page 160: Replace Bucket

    MAINTENANCE Replace Bucket O-Ring Shift CAUTION: When driving the connecting pins in or out, guard against injury from flying pieces of metal or debris; wear goggles or safety glasses, and safety equipment appropriate for the job. 1. Park the machine on a level surface. Lower the bucket to the ground and position it with the flat sur- Bucket Boss face resting on the ground.

  • Page 161: Adjusting Bucket Linkage

    MAINTENANCE Adjusting Bucket Linkage The machine has a bucket adjustment system to take up play in the linkage. When play in the linkage increases, first remove shims. Then, install shims as follows: 1. Park the machine on a firm, level surface. Lower the bucket to the ground with the flat side down so the bucket will not roll.

  • Page 162: Check Track Sag (Rubber Crawler)

    MAINTENANCE Check Track Sag (rubber crawler) --- every 8 working hours Proper track sag adjustment is necessary to extend the service life of the rubber track and the travel device. Check Track Sag 1. Position the blade to the rear of the upperstructure. Lower the bucket and blade to raise both tracks off ground, as shown.
  • Page 163 MAINTENANCE Loosen Track CAUTION: Do not loosen valve (1) too quickly or too much as high-pressure grease in the adjust- ing cylinder may spout out. Loosen carefully, keeping body parts and face away from valve (1). Never loosen grease fitting (2). IMPORTANT: When gravel or mud is packed between sprockets and track links, remove it be- fore loosening valve (1).

  • Page 164: Replace Rubber Track

    MAINTENANCE Replace Rubber Track CAUTION: Do not loosen valve (1) quickly or loosen it too much as high-pressure grease in the adjusting cylinder may spout out. Loosen carefully, keeping body parts and face away from valve (1). Never loosen grease fitting (2). When removing the rubber track, do not allow anyone to stand in front of the front idler.

  • Page 165: Check Track Sag (Steel Crawler)

    Measure distance (A) at the middle of track frame from the bottom of track frame to the back face of the track shoe. Track sag specifications EX27u, EX35u: 120 to 140 mm (4.7 to 5.5 in) EX50u: 140 to 160 mm (5.5 to 6.3 in) M552-07-089 NOTE: Check track sag after thoroughly removing soil stuck on track area by washing.
  • Page 166 MAINTENANCE Loosen Track CAUTION: Do not loosen valve (1) quickly or loosen it too much as high-pressure grease in the adjusting cylinder may spout out. Loosen carefully, keeping body parts and face away from valve (1). Never loosen grease fitting (2). IMPORTANT: When gravel or mud is packed between sprockets and track links, remove it be- fore loosening.
  • Page 167 MAINTENANCE Converting the Track The rubber track uses a track adjuster different from that used for the steel track. CAUTION: 1. Before converting the track, contact your nearest authorized dealer. Be sure to change track adjusters when converting the track from steel to rubber or rubber to steel.

  • Page 168: Check And Replace Seat Belt

    We recommend that the seat belt be replaced every three years regardless of its apparent condition. EX27u, EX35u M586-07-008 EX50u M586-07-007 Check Fuel Injection Nozzles --- every 500 hours Consult your authorized dealer for inspection and repair.

  • Page 169: Check Injection Timing

    MAINTENANCE Check Injection Timing --- as required Consult your authorized dealer for inspection and repair. Measure Engine Compression Pressure --- every 1000 hours Consult your authorized dealer for inspection and repair. Check Starter and Alternator --- every 1000 hours Consult your authorized dealer for inspection and repair. Check Radiator Cap --- as required Consult your authorized dealer for inspection and repair.

  • Page 170: Check Tightening Torque Of Bolts And Nuts

    For tightening nuts and bolts other then specified in the table below, refer to the Tightening Torque Chart at the end of this section. IMPORTANT: Check and tighten bolts and nuts using a torque wrench. EX27u, EX35u Bolt Dia. Wrench Size Torque Descriptions Q’ty...
  • Page 171 MAINTENANCE EX50u Bolt Dia. Wrench Size Torque Descriptions Q’ty N⋅m (kgf⋅m) (lbf⋅ft) Engine cushion rubber mounting bolt (14) (101) Engine cushion rubber mounting bolt (65) and nut Engine bracket mounting bolt (Front) (36) Engine bracket mounting bolt (Rear) (36) Hydraulic oil tank mounting bolt (65) Fuel tank mounting bolt (15)
  • Page 172 MAINTENANCE Tightening Torque Chart Hexagon Wrench Wrench Bolt Dia. Size Size M552-07-091 M552-07-090 M157-07-225 Socket Bolt (kgf m) (lbf ft) (kgf m) (lbf ft) (kgf m) lbf ft) 29.5 (22) 19.5 (14.5) (7.2) (6.5) (47) (36) 19.5 (14.5) (11) (80) (65) (3.5) (25.5)

  • Page 173: Often-Replaced Parts

    4373419 4373419 Fuel Filter 4376643. 4376643 4374591 Air Cleaner Element 4417516 4417516 4357443 Water Separator 4418776 4418776 – Bucket Parts EX27u, EX35u EX50u Parts No. Q’ty Parts No. Q’ty Teeth 4339865 4339865 Tooth Locking Pin 4339868 4339868 Locking Rubber 4339867...

  • Page 174: Maintenance Under Special Environmental Conditions

    MAINTENANCE MAINTENANCE UNDER SPECIAL ENVIRON- MENTAL CONDITIONS Operating Precautions for Maintenance Conditions Muddy Soil, Before Operation: Check the tightness of plugs and all drain cocks. Rainy or After Operation: Clean the machine and check for cracks, dam- Snowy aged, loose or missing bolts and nuts. Lubricate Weather all necessary part without delay.

  • Page 175: Storing The Machine

    INDEX STORAGE STORING THE MACHINE 1. Thoroughly wash the machine to remove dirt, soil and debris from the machine. 2. Inspect the machine. Repair worn or damaged parts. Install new parts if necessary. 3. Clean the primary air cleaner element. 4.

  • Page 176: Removing The Machine From Storage

    STORAGE REMOVING THE MACHINE FROM STORAGE CAUTION: Start the engine ONLY in a well-ventilated place. 1. Remove grease from the cylinder rods if coated. 2. Adjust alternator and fan belt tension. 3. Fill the fuel tank. Bleed air from the fuel system. Check all fluid levels.

  • Page 177: Troubleshooting

    INDEX TROUBLESHOOTING TROUBLESHOOTING If any problem is found, troubleshoot to pinpoint the cause CAUTION: Never attempt to adjust, disas- and take appropriate action to prevent the problem from semble, or repair hydraulic or electrical occurring again. If the cause cannot be pinpointed, contact components by yourself.
  • Page 178 TROUBLESHOOTING 3. Hydraulic System Trouble Cause Solution • Insufficient engine power • Inspect and repair. Insufficient power: all actuators • Excessively worn hydraulic pump • Replace. • Main relief valve failure • Re-adjust pressure setting, or re- place. • Hydraulic oil is low. •...

  • Page 179: Specifications Specifications (Ex27U)

    INDEX SPECIFICATIONS SPECIFICATIONS EX27u M586-11-003 EX27u Type Canopy Type of Front-End Attachment Boom Swing Type Bucket Capacity (Heaped) 0.08 m (0.10 yd Operating Weight 2930 kg (6459 lb) 3050 kg (6724 lb) Basic Machine Weight 2200 kg (4850 lb) 2320 kg (5115 lb)

  • Page 180: Working Ranges (Ex27U)

    SPECIFICATIONS WORKING RANGES EX27u Left (L) Right (L) M586-11-002 M571-11-002 EX27u Canopy (ft⋅in) (ft⋅in) A: Maximum Digging Reach 4700 (15′5″) 4700 (15′5″) B: Maximum Digging Depth 2650 (8′8″) 2650 (8′8″) C: Maximum Cutting Height 4240 (13′11″) 4240 (13′11″) D: Maximum Dumping Height 3000 (9′10″)

  • Page 181: Shoe Types And Applications (Ex27U)

    SPECIFICATIONS SHOE TYPES AND APPLICATIONS EX27u (Canopy) 300 mm (12″) 300 mm (12″) Shoe Width Grouser Shoe Rubber Shoe For Ordinary Ground For Paved Road Application (Option) (Standard) Operating Weight kg (lb) 3000 (6614) 2930 (6459) Minimum Ground 315 (12″) 325 (13″)

  • Page 182: Bucket Types And Applications (Ex27U)

    SPECIFICATIONS BUCKET TYPES AND APPLICATIONS EX27u Select a proper bucket from the list below. Using an oversized or specialty type bucket different from those listed in the table below may cause reduced machine stability during operation. At the same time, abnormal...

  • Page 183: Specifications (Ex35U)

    SPECIFICATIONS SPECIFICATIONS EX35u M586-11-003 EX35u Type Canopy Type of Front-End Attachment Boom Swing Type Bucket Capacity (Heaped) 0.11 m (0.14 yd Operating Weight 3530 kg (7782 lb) 3650 kg (8047 lb) Basic Machine Weight 2660 kg (5864 lb) 2780 kg (6129 lb) Isuzu 3LD1 Engine 21.3 kW/2450 min...

  • Page 184: Working Ranges (Ex35U)

    SPECIFICATIONS WORKING RANGES EX35u Left (M) Right (M) M586-11-002 M571-11-002 EX35u Canopy (ft⋅in) (ft⋅in) A: Maximum Digging Reach 5210 (17′1″) 5210 (17′1″) B: Maximum Digging Depth 3150 (10′4″) 3150 (10′4″) C: Maximum Cutting Height 4470 (14′8″) 4470 (14′8″) D: Maximum Dumping Height 3100 (10′2″) 3100...

  • Page 185: Shoe Types And Applications (Ex35U)

    SPECIFICATIONS SHOE TYPES AND APPLICATIONS EX35u (Canopy) 300 mm (12″) 300 mm (12″) Shoe Width Grouser Shoe Rubber Shoe For Ordinary Ground For Paved Road Application (Option) (Standard) Operating Weight kg (lb) 3580 (7892) 3530 (7782) Minimum Ground 315 (12″) 325 (13″) Clearance mm (in)

  • Page 186: Bucket Types And Applications (Ex35U)

    SPECIFICATIONS BUCKET TYPES AND APPLICATIONS EX35u Select a proper bucket from the list below. Using an oversized or specialty type bucket different from those listed in the table below may cause reduced machine stability during operation. At the same time, abnormal loads may be exerted on the machine, front attachment, and/or cylinders, resulting in damage and/or unnecessary repairs.

  • Page 187: Specifications (Ex50U)

    SPECIFICATIONS SPECIFICATIONS EX50u M586-11-001 EX50u Type Canopy Type of Front-End Attachment Boom Swing Type Bucket Capacity (Heaped) 0.16 m (0.21 yd Operating Weight 4590 kg (10119 lb) 4700 kg (10362 lb) Basic Machine Weight 3390 kg (7474 lb) 3500 kg (7716 lb) Isuzu 4LE1 Engine 27.9 kW/2000 min...

  • Page 188: Working Ranges (Ex50U)

    SPECIFICATIONS WORKING RANGES EX50u Left (M) Right (M) M586-11-002 M571-11-002 EX50u Canopy (ft⋅in) (ft⋅in) A: Maximum Digging Reach 5800 (19′0″) 5800 (19′0″) B: Maximum Digging Depth 3600 (11′10″) 3600 (11′10″) C: Maximum Cutting Height 5145 (16′11″) 5145 (16′11″) D: Maximum Dumping Height 3515 (11′6″) 3515...

  • Page 189: Shoe Types And Applications (Ex50U)

    SPECIFICATIONS SHOE TYPES AND APPLICATIONS EX50u (Canopy) 400 mm (16″) 400 mm (16″) Shoe Width Grouser Shoe Rubber Shoe For Ordinary For Paved Application Ground Road (Option) (Standard) Operating Weight kg (lb) 4735 (10439) 4590 (10119) Minimum Ground 315 (12″) 335 (13″) Clearance mm (in)

  • Page 190: Bucket Types And Applications (Ex50U)

    SPECIFICATIONS BUCKET TYPES AND APPLICATIONS EX50u Select a proper bucket from the list below. Using an oversized or specialty type bucket different from those listed in the table below may cause reduced machine stability during operation. At the same time, abnormal loads may be exerted on the machine, front attachment, and/or cylinders, resulting in damage and/or unnecessary repairs.

  • Page 191: Index

    Boom-Swing Pedal ..........5-4 Handle Fluids Safely – Avoid Fires .....S16 Breaking in a New Machine......... 2-1 Hood and Access Covers ........7-4 Bucket Types and Applications (EX27u) ... 12-4 Hour Meter ............1-7 Bucket Types and Applications (EX35u) ... 12-8 Hydraulic Breaker Operating Tips Bucket Types and Applications (EX50u) ..
  • Page 192 Service Your Machine at Specified Intervals ..7-2 Operate Only from Operator’s Seat ..... S6 Shifting the Control Lever Control Pattern ...5-3 Operate the Machine Safely......5-19 Shoe Types and Applications (EX27u) ....12-3 Operate with Caution.......... S14 Shoe Types and Applications (EX35u) ....12-7 Operating Backhoe..........5-13 Shoe Types and Applications (EX50u) ....12-11...
  • Page 193 Warming Up in Cold Weather ......5-10 Warn Others of Service Work ......S19 Wear Protective Clothing ........S3 Wiper/Washer Switch.......... 1-8 Work Light Switch ..........1-4 Working Ranges (EX27u) ......... 12-2 Working Ranges (EX35u) ......... 12-6 Working Ranges (EX50u) ....... 12-10 14-3...
  • Page 196 Hitachi Construction Machinery Co., Ltd. Head Office : 5-1, Koraku 2-chome, Bunkyo-ku, Tokyo 112-0004, Japan Recycle This manual is printed on recycled paper.

This manual is also suitable for:

Ex35uEx50u

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