Hitachi ZAXIS 27U-2 User manual

INTRODUCTION
© 2007 Hitachi Construction Machinery Co., Ltd.
All rights reserved.
Read this manual carefully to learn how to operate
and service your machine correctly. Failure to do so
could result in personal injury or equipment damage.
This standard specification machine can be
operated under the following conditions without being
modified.
Atmospheric Temperature: 20 C to 40 C ( 4 F to
104 F)
Altitude: 0 m to 1500 m (0 ft to 4900 ft)
In case the machine is used under conditions other
than described above, consult your authorized dealer.
This manual should be considered a permanent
part of your machine and should remain with the
machine when you sell it.
This machine is of metric design. Measurements in
this manual are metric. Use only metric hardware and
tools as specified.
SI Units (International System of Units) are used in
this manual.
For reference MKS system units and English units
are also indicated in parentheses after the SI units.
Example : 24.5 MPa (250 kgf/cm2, 3560 psi)
Right-hand and left-hand sides are determined by
facing in the direction of forward travel.
Write product identification numbers in the
Machine Numbers section. Accurately record all the
numbers to help in tracing the machine should it be
stolen. Your dealer also needs these numbers when
you order parts. If this manual is kept on the machine,
also file the identification numbers in a secure place off
the machine.
Warranty is provided as a part of Hitachi's support
program for customers who operate and maintain their
equipment as described in this manual. The warranty
is explained on the warranty certificate which you
should have received from your dealer.
This warranty provides you the assurance that Hitachi
will back its products where defects appear within the
warranty period. In some circumstances, Hitachi also
provides field improvements, often without charge to
the customer, even if the product is out of warranty.
Should the equipment be abused, or modified to
change its performance beyond the original
factory specifications, the warranty will become
void and field improvements may be denied.
Setting fuel delivery above specifications or otherwise
overpowering machines will result in such action.
Only qualified, experienced operators officially
licensed (according to local law) should be allowed to
operate the machine. Moreover, only officially licensed
personnel should be allowed to inspect and service the
machine.
Prior to operating this machine in a country other than
a country of its intended use, it may be necessary to
make modifications to it so that it complies with the
local standards (including safety standards) and re-
quirements of that particular country. Please do not
operate this machine outside of the country of its in-
tended use until such compliance has been confirmed.
Please contact Hitachi Construction Machinery Co.,
Ltd. or any of our authorized distributor or dealer if you
have any questions concerning compliance.
All information, illustrations and specifications in this manual are based on the latest product information available
at the time of publication. The right is reserved to make changes at any time without notice.

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CONTENTS
MACHINE NUMBERS
SAFETY
Recognize Safety Information ............................ S-1
Understand Signal Words................................... S-1
Follow Safety Instructions................................... S-2
Prepare for Emergencies.................................... S-2
Wear Protective Clothing.................................... S-3
Protect Against Noise ......................................... S-3
Inspect Machine.................................................. S-3
Tidy Up Inside Operators Space........................ S-4
Use Handholds and Steps.................................. S-4
Adjust the Operators Seat.................................. S-5
Ensure Safety Before Rising From or
Leaving Operators Seat............................... S-5
Fasten Your Seat Belt......................................... S-5
Move and Operate Machine Safely .................... S-6
Operate Only from Operators Seat.................... S-7
Jump Starting...................................................... S-7
Keep Riders Off Machine.................................... S-7
Precautions for Operations................................. S-8
Investigate Job Site Beforehand......................... S-9
Protect Against Falling Stones and Debris....... S-10
Provide Signals for Jobs Involving
Multiple Numbers of Machines................... S-10
Confirm Direction of Machine to be Driven....... S-10
Drive Machine Safely........................................ S-11
Avoid Injury from Rollaway Accidents .............. S-13
Avoid Injury from Back-Over
and Swing Accidents .................................. S-14
Keep Person Clear from Working Area ............ S-15
Never Position Bucket Over Anyone ................ S-15
Avoid Undercutting ........................................... S-15
Avoid Tipping .................................................... S-16
Never Undercut a High Bank............................ S-16
Dig with Caution................................................ S-17
Operate with Caution ........................................ S-17
Avoid Power Lines............................................ S-17
Precautions for Lightening................................ S-18
Do Not Use for Craning Operations.................. S-18
Protect Against Flying Debris ........................... S-18
Park Machine Safely......................................... S-19
Handle Fluids Safely  Avoid Fires................... S-19
Safety Transporting .......................................... S-20
Practice Safe Maintenance............................... S-21
Warn Others of Service Work........................... S-22
Support Machine Properly ................................ S-23
Stay Clear of Moving Parts............................... S-23
Prevent Parts from Flying ................................. S-23
Store Attachments Safely ................................. S-24
Prevent Burns ................................................... S-24
Replace Rubber Hoses Periodically................. S-25
Avoid High-Pressure Fluids .............................. S-25
Prevent Fires .................................................... S-26
Evacuating in Case of Fire................................ S-28
Beware of Exhaust Fumes................................ S-28
Beware of Asbestos Dust..................................S-28
Precautions for Welding and Grinding ..............S-29
Avoid Heating Near Pressurized Fluid Lines ....S-29
Avoid Applying Heat to Lines
Containing Flammable Fluids .....................S-29
Remove Paint before Welding or Heating.........S-30
Prevent Battery Explosions ...............................S-30
Precautions for Handling Refrigerant................S-31
Handle Chemical Products Safely ....................S-31
Dispose of Waste Properly................................S-32
SAFETY SIGNS...........................................S-33
COMPONENTS NAME ............................... 1-1
OPERATORS STATION
Pedals, Levers and Monitor Panel ...................... 1-2
Key Switch........................................................... 1-4
Switch Panel........................................................ 1-4
Monitor Panel ......................................................1-5
Coolant Temperature Gauge ........................ 1-5
Fuel Gauge ................................................... 1-5
System Failure Indicator ............................... 1-6
Engine Oil Pressure Indicator ....................... 1-6
Overheat Indicator......................................... 1-6
Fuel Level Indicator....................................... 1-6
Alternator Indicator........................................ 1-7
Preheat Indicator........................................... 1-7
Fast Travel Mode Indicator ........................... 1-7
Liquid Crystal display (LCD),
Display Selection Switch, and Set Switch..... 1-8
How to Operate Trip Meter.................................. 1-9
Auto-Idle Switch (Except ZX27U-2) ................... 1-11
Air Conditioner Operation.................................. 1-12
Tips for Air Conditioner Usage.......................... 1-14
Radio (Cab Equipped Machines) ...................... 1-15
AM/FM Radio Operation ................................... 1-16
Cab Door Release lever
(Cab-equipped machines)........................... 1-18
Opening/Closing Cab Front Window
(Cab-equipped machines) ......................... 1-19
Adjusting Operators Seat ................................. 1-20
Tool and Operators manual Boxes .................. 1-20
Emergency Exit (Cab-equipped machines) ...... 1-21
Seat Belt (Optional) ........................................... 1-22
Cab Light (Cab-equipped machines) ................ 1-22
BREAK-IN
Breaking in New Machine ................................... 2-1
OPERATING THE ENGINE
Before Starting Engine........................................ 3-1
Starting Engine.................................................... 3-2
Starting in Ordinary Temperature ................. 3-2
Starting in Cold Weather............................... 3-3
Check Machine After Starting Engine ................. 3-4

CONTENTS
Using Booster Batteries.......................................3-5
Stopping the Engine ............................................3-6
DRIVING THE MACHINE
Travel Levers and Pedals....................................4-1
Travel Mode Switch .............................................4-3
Traveling on Soft Ground.....................................4-4
Raise One Track Using Boom and Arm ..............4-4
Towing Machine...................................................4-5
Driving In Water or on Soft Ground .....................4-6
Precautions for Traveling on Slopes....................4-7
Parking and Stopping on Slopes .........................4-8
Parking on Slopes................................................4-8
OPERATING THE MACHINE
Control Lever (ISO Excavator Pattern)................5-1
Control Lever
(H-Pattern: HITACHI Excavator Pattern).......5-2
Control Lever (SAE-Backhoe Pattern)
--- If Equipped (2 Way Multi Valve) ...............5-3
Boom-Swing Pedal ............................................5-4
Auxiliary Pedal (Optional) ....................................5-5
Blade Lever..........................................................5-6
Precautions for Blade Operation .........................5-7
Pilot Control Shut-Off Lever.................................5-8
Warming Up Operation ........................................5-9
Warming Up in Cold Weather..............................5-9
Auto-Idle Control (Except ZX27U-2) ..................5-10
Operating Backhoe............................................5-11
Grading Operation .............................................5-12
Avoid Driving Bucket Teeth Into Ground ...........5-12
Avoid Abusive Operation ...................................5-12
Avoid Striking with Bucket .................................5-13
Avoid Excavation Using Upperstructure
and/or Boom Swing Power..........................5-13
Use Correct Track Shoe ....................................5-13
Avoid Other than Specified Machine
Operations ...................................................5-14
Boom Cylinder May Hit Blade............................5-15
Avoid Hitting Blade with Bucket.........................5-16
Avoid Colliding Blade Against Rocks.................5-16
Avoid Colliding Boom Cylinder with Track.........5-16
Precautions for Installing Wide Bucket
or Special Type Bucket................................5-16
Using Rubber Crawler .......................................5-17
Hydraulic Breaker (Optional) .............................5-19
Crusher Operation (Optional) ............................5-22
Precautions for After Operating the Machine ....5-23
Auxiliary Flow Rate Control
(Optional) (Except ZX27U-2)........................5-24
Emergency Boom Lowering Procedure.............5-25
TRANSPORTING
Transporting by Road ..........................................6-1
Trailer Loading/Unloading ...................................6-1
Loading ................................................................6-2
Securing the Machine to the Trailer
for Transportation.......................................... 6-3
Unloading ............................................................ 6-4
Lifting Machine with Crane.................................. 6-5
MAINTENANCE
Procedures........................................................... 7-1
Prepare Machine for Inspection/Maintenance .... 7-2
Opening/Closing Engine Access Covers ............ 7-3
Opening/Closing Tank Covers ............................ 7-4
Daily Inspection................................................... 7-5
Periodic Replacement of Parts............................ 7-6
Maintenance Guide ............................................. 7-7
The Brand Names of Recommended
Oils and Lubricants ..................................... 7-10
A. Greasing...................................................... 7-11
Front Joint Pins ........................................... 7-11
Bucket and Link Pins................................... 7-14
Blade Pins ................................................... 7-14
Precautions for Front Attachment and
Blade Removal ...................................... 7-14
Swing Bearing............................................. 7-15
Swing Internal Gear .................................... 7-16
Control Lever Universal Joint...................... 7-16
Tilt Mechanism ............................................ 7-17
B. Engine ......................................................... 7-18
Engine Oil.................................................... 7-18
Change Engine Oil ...................................... 7-18
Replace Engine Oil Filter ............................ 7-18
C. Transmission............................................... 7-20
Travel Reduction Gear................................ 7-20
D. Hydraulic System ........................................ 7-22
Inspection and Maintenance of
Hydraulic Equipment ............................. 7-22
Check Hydraulic Oil Level........................... 7-23
Drain Hydraulic Oil Tank Sump................... 7-24
Change Hydraulic Oil .................................. 7-25
Clean Suction Filter..................................... 7-28
Replace Full Flow Filter Element ................ 7-29
Replace Pilot Filter Element........................ 7-30
Check Hoses and Lines.............................. 7-32
E. Fuel System ................................................ 7-37
Check Water Separator .............................. 7-38
Drain Fuel Tank Sump ................................ 7-38
Replace Fuel Filter...................................... 7-39
Check Fuel Hoses....................................... 7-40
F. Air Cleaner .................................................. 7-41
Clean the Air Cleaner Element ................... 7-41
Replace the Air Cleaner Element................ 7-41
G. Cooling System ........................................... 7-42
Check Coolant Level................................... 7-43
Check and Adjust Fan Belt Tension............ 7-44
Change Coolant .......................................... 7-45
Clean Radiator Core ................................... 7-46
H. Electrical System......................................... 7-47
Batteries ...................................................... 7-47

CONTENTS
Replacing Fuses..........................................7-50
I. Miscellaneous..............................................7-51
Check Bucket Teeth for Looseness
and/or Wear...........................................7-51
Replace Bucket ...........................................7-53
Adjust Track Sag (Rubber Crawler)
and Check for Damage .........................7-54
Replace Rubber Crawler .............................7-56
Check Track Sag
(Steel Crawler) (Optional)......................7-58
Check and Replace Seat Belt .....................7-61
Check Air conditioner
(Machine with Cab) ...............................7-62
Clean and Replace Air Conditioner
Re-circulation Filter ...............................7-63
Clean Re-circulation Filter ...........................7-63
Replace Re-circulation Filter .......................7-63
Clean Cab Floor ..........................................7-65
Check Injection Nozzle................................7-66
Check and Adjust Valve Clearance.............7-66
Check Injection Timing ................................7-66
Measure Engine Compression Pressure ....7-66
Check Starter and Alternator.......................7-67
Check Radiator Cap ....................................7-67
Check Tightening Torque of
Bolts and Nuts .......................................7-68
Check Tilt Mechanism Fulcrum
Bolts for Looseness .....................................7-71
Preparation for Inspection and Maintenance.....7-72
Tilting Floor Down..............................................7-74
CONSUMABLE PARTS LIST....................8-1
MAINTENANCE UNDER SPECIAL
ENVIRONMENTAL CONDITIONS.......9-1
STORAGE
Storing the Machine...........................................10-1
Removing the Machine From Storage...............10-2
TROUBLESHOOTING...............................11-1
SPECIFICATIONS
Specifications.....................................................12-1
Working Ranges ................................................12-6
Shoe Types and Applications ..........................12-11
Bucket Types and Applications .......................12-16
REFERENCE
Additional Counterweight...................................13-1
INDEX..............................................................14-1

MACHINE NUMBERS
The manufacturing Nos. explained in this group is the
individual number (serial No.) given to each machine and
hydraulic components. These numbers are requested
when inquiring any information on the machine and/or
components. Fill these serial Nos. in the blank spaces in
this group to immediately make them available upon
request.
MACHINE
MODEL/TYPE:
PRODUCT
IDENTIFICATION
NUMBER:
PRODUCT IDENTIFICATION NUMBER
PRODUCT
IDENTIFICATION
NUMBER:
NOTE:
HCM1M700X00010001
PRODUCT IDENTIFICATION
NUMBER (PIN)
M1M7-00-001
M1M7-00-002
Marks to indicate the start and
end of the PIN

SAFETY
S-1
RECOGNIZE SAFETY INFORMATION
These are the SAFETY ALERT SYMBOLS.
 When you see these symbols on your machine or in
this manual, be alert to the potential for personal in-
jury.
 Follow recommended precautions and safe operating
practices.
SA-688
UNDERSTAND SIGNAL WORDS
On machine safety signs, signal words designating the
degree or level of hazard - DANGER, WARNING, or
CAUTION - are used with the safety alert symbol.
DANGER indicates an imminently hazardous situation
which, if not avoided, will result in death or serious in-
jury.
WARNING indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury.
CAUTION indicates a potentially hazardous situation
which, if not avoided, may result in minor or moderate
injury.
DANGER or WARNING safety signs are located
near specific hazards. General precautions are listed
on CAUTION safety signs.
 Some safety signs dont use any of the designated
signal words above after the safety alert symbol are
occasionally used on this machine.
To avoid confusing machine protection with personal
safety messages, a signal word IMPORTANT indicates a
situation which, if not avoided, could result in damage to
the machine.
NOTE indicates an additional explanation for an
element of information.
SA-1223

SAFETY
S-2
FOLLOW SAFETY INSTRUCTIONS
Carefully read and follow all safety signs on the machine
as well as all safety messages in this manual.
Safety signs must be installed, maintained and replaced
if damaged.
 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 or-
dering).
Allow only properly trained, qualified, authorized per-
sonnel to operate the machine.
Learn how to correctly operate and service the machine.
Keep your machine in proper working condition.
Always operate the machine within the specification.
 Unauthorized modifications of the machine may impair
the functions and/or safety and affect machine life and
the warranty will become void.
The safety messages in this SAFETY chapter are in-
tended to illustrate basic safety procedures of machines.
However it is impossible for these safety messages to
cover every possible hazardous situation you may en-
counter. If you have any questions concerning safety,
you should first consult your supervisor and/or your au-
thorized dealer before operating or performing mainte-
nance work on the machine.
SA-003
PREPARE FOR EMERGENCIES
Be prepared if a fire starts or if an accident occurs.
 Keep a first aid kit and fire extinguisher on hand.
 Thoroughly read and understand the label attached on
the fire extinguisher and use it properly.
 To ensure that a fire-extinguisher can be always used
when necessary, check and service the
fire-extinguisher at the recommended intervals as
specified in the fire-extinguisher manual.
 Establish emergency procedure guidelines to cope
with any fire or accidents which may occur.
 Keep emergency numbers for doctors, ambulance
service, hospitals, and fire department posted near
your telephone.
SA-437

SAFETY
S-3
WEAR PROTECTIVE CLOTHING
Wear close fitting clothing and safety equipment appro-
priate to the job.
You may need:
A hard hat
Safety belt
Safety shoes
Safety glasses, goggles, or face shield
Heavy gloves
Hearing protection
Reflective clothing
Wet weather gear
Respirator or filter mask.
Be sure to wear the correct equipment and clothing
for the job. Do not take any chances.
 Avoid wearing loose clothing, jewelry, or other items
that can catch on control levers or other parts of the
machine.
Operating equipment safely requires the full attention of
the operator.
 Do not wear radio or music headphones while oper-
ating the machine.
SA-438
PROTECT AGAINST NOISE
Prolonged exposure to loud noise can cause impairment
or loss of hearing.
 Wear a suitable hearing protective device such as
earmuffs or earplugs to protect against objectionable
or uncomfortably loud noises.
SA-434
INSPECT MACHINE
If any abnormality is found, be sure to repair it immedi-
ately before operating the machine.
 In the walk-around inspection, be sure to cover all
points described in the PRE-START INSPECTION
chapter in the operators manual.
SA-435

SAFETY
S-4
TIDY UP INSIDE OPERATORS SPACE
Always keep inside the cab clean by observing instruc-
tions below, to prevent any personal accidents from oc-
curring.
Remove mud and/or oily material from the shoe soles
before entering the operators space. If pedals are oper-
ated without removing mud or oily matter, the foot may
slip off the pedal, possibly creating a hazardous situa-
tion.
Do not leave parts and/or tools around the operators
seat.
Do not keep a transparent water bottle in the cab. The
transparent water bottle may concentrate the sun light
like a lens, possibly causing a fire.
Do not wear radio or music headphones and do not use
a cell phone while traveling or operating the machine.
Never allow hazardous materials such as combustible
and/or explosive material in the operators space.
Do not leave cigarette lighters in the cab. If the tem-
perature in the cab increases, the lighter may explode.
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.
 Maintain a three-point contact with the steps and
handrails.
 Do not use any controls as handholds.
 Never jump on or off the machine. Never mount or
dismount a moving machine.
 In case adhered slippery material such as oil, grease,
or mud is present on steps, handrails, or platforms,
thoroughly remove such material.
SA-439

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