Part of the Hitachi Repair Manuals.
This 267-page Hitachi EX25, EX35, EX40 Excavator Technical Manual (OEM #KM581E-01, T581-01) breaks down every upperstructure, undercarriage, electrical, and hydraulic group your machine runs on. Inside you get full wiring circuit diagrams, a complete hydraulic circuit section, and a dedicated troubleshooting chapter covering diagnosing procedure, hydraulic faults, and electrical faults side by side. You also open to a full operational performance test section: engine test, excavator test, and hydraulic component test, plus torque and fluid data pulled straight from the factory sheets. Change your hydraulic oil every 1000 hours, and swap the coolant twice a year, spring and autumn, per the soft-water spec. No more chasing a jerky boom or a hot engine with guesswork and forum threads. Bookmarked by section and fully text-searchable, so you can jump straight to Group 09 Solenoid Valve or the wiring circuit without scrolling through 267 pages by hand.
What's Inside This Hitachi EX25, EX35, EX40 Manual
| System | Pages | Key Topics |
|---|---|---|
| Safety | 7-18 | - |
| Specifications | 19-64 | Group 01 General Information, Group 02 Dimensions and Weights, Group 03 Fuels and Lubricants, Group 04 Interchangeability |
| Upperstructure | 65-130 | Group 02 Tanks, Group 03 Pump Device, Group 04 Swing Device, Group 05 Pipings, Group 06 Control Valve, Group 07 Pilot Valve, Group 08 Pilot Shut-Off Valve, Group 09 Solenoid Valve |
| Undercarriage | 131-160 | Group 02 Swing Bearing, Group 03 Center Joint, Group 04 Travel Device, Group 05 Adjuster, Group 01 Outline |
| Electrical System | 161-166 | Group 01 Electrical Circuit |
| Hydraulic System | 167-172 | Group 01 Hydraulic Circuit |
| Operational Performance Test | 173-208 | Group 01 Introduction, Group 02 Engine Test, Group 03 Excavator Test, Group 04 Hydraulic Component Test |
| Troubleshooting | 209-267 | Group 01 Diagnosing Procedure, Group 02 Hydraulic System, Group 03 Electrical System |
Every system also includes contents.
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| All Models | ||
| Hydraulic System | SECTION 05 | p. 2 |
| Engine Test | Group 02 | p. 3 |
| Hydraulic oil replacement interval | 1000 (Hours) | p. 57 |
| Coolant change interval (Soft water) | Twice a year in spring and autumn | p. 60 |
| Air cleaner system | electronic indicator system | p. 118 |
| Fuel filter | 11 | p. 117 |
| Gradeability | 30° | p. 24 |
| EX25 | ||
| Engine Output Power | 25 PS / 2400 rpm | p. 117 |
| EX35 | ||
| Engine Output Power | 26 PS / 2200 rpm | p. 117 |
| EX40 | ||
| Engine Output Power | 33 PS / 2200 rpm | p. 117 |
Hitachi EX25, EX35, EX40 Common Problems This Manual Covers
Hitachi EX25/EX35/EX40 hydraulic power loss or jerky boom, arm, and bucket movements under load
Check hydraulic fluid level and condition first; contamination causes most jerky cylinder response. Drain and replace hydraulic oil every 1000 hours per page 57. With engine at operating temperature, measure pilot oil pressure at the pilot valve outlet on page 217; spec is 40 ± 5 kgf/cm² (569 ± 71 psi). Inspect hoses and fittings for weeping seals.
Manual Section: Hydraulic System - Front Attachments p. 217Hydraulic power loss specifically when boom is tipped forward or fully extended
On EX25 units, test main relief valve pressure at the pump outlet with engine running at 2550 ± 50 rpm per page 216; specification is 185 ± 10 kgf/cm² on page 215. A relief valve stuck open or worn drops pressure only under load, matching a forward-tip power loss. Replace the valve if pressure will not hold steady.
Manual Section: Hydraulic System - Actuators p. 215Engine overheating or power loss under load in hot weather or heavy digging cycles
Check the overheat indicator in the operator's cab per page 118; if lit, or if power drops, inspect the radiator core for mud and debris and clean it with low-pressure air or water. Drain and replace coolant twice a year in spring and autumn per page 60. Verify fan belt tension and check for a collapsed lower radiator hose.
Manual Section: Specifications p. 118Final drive motor failure, grinding noise or oil leaking from the travel motor
Inspect final drive motor oil seals for leakage and check case oil level; contaminated or low oil accelerates bearing wear. Verify track tension is correct: sagging or over-tight tracks overload motor bearings and drive sprocket. Clean debris packed around the sprocket and drive motor housing, then test travel speed and rotation under load per the travel system checks.
Manual Section: UndercarriageMachine won't start or loses power intermittently after sitting overnight or in cold weather
Check battery terminals and cable connections for corrosion; clean and torque tight, since a weak connection mimics a dead battery. Test battery voltage with the key on and again while cranking. Replace the fuel filter element per page 53 if the engine starts then stalls, since a clogged filter starves the injection pump. Check the air filter restriction indicator on page 118.
Manual Section: Specifications p. 53Frequently Asked Questions
What is the engine oil capacity for the Hitachi EX25 and EX35 excavators?
The engine oil capacity for the Hitachi EX25 and EX35 excavators is 5.5 liters (1.45 US gal, 1.21 imp gal). The engine oil filter should be replaced at 50 hours for the first time, and then every 250 hours.
How will I receive this Hitachi EX25, EX35, EX40, Excavator Technical Manual?
Instant PDF download (16 MB). You get the full 267-page searchable Technical Manual immediately after payment. Open it on your laptop, tablet, or phone right in the shop.
Are there any print restrictions on this Hitachi EX25, EX35, EX40, Excavator?
Zero restrictions. The PDF is DRM-free. Print whatever sections you need to take out to the shop. Standard letter or A4 paper works.
Does this Hitachi EX25, EX35, EX40, Excavator manual include wiring diagrams?
Yes, an electrical wiring diagram is included to help trace the main circuits.
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