INTRODUCTION

Read this manual carefully to learn how to operate
and service your machine correctly. Failure to do so
could result in personal injury or machine damage.
This manual should be considered a permanent
part of your machine and should remain with the
machine when you sell it.
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: to 2000 m (0 ft to 6600 ft)
In case the machine is used under conditions other
than described above, consult your nearest Hitachi
dealer.
This machine is of metric design. Measurements in
this manual are metric. Use only metric hardware and
tools as specified.
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.

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.
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
requirements of that particular country. Please do not
operate this machine outside of the country of its
intended 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.

Hitachi machine models are classified into 2 models as shown in the

table below. When referring to the texts and/or illustrations indicated
with the applicable machine class names in this manual, check that the
machine models concerned are included using this table.

Model
Std. Model ZAXIS125US, 135US, 225US, 225USLC
K Model

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.

©2002 Hitachi Construction Machinery Co., Ltd.

All rights reserved.
 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

SS3097499

1. MODEL/TYPE M157-00-001

2. Product Identification Number

3. Year of Manufacturing
4. Operating mass (standard version)
5. Engine power in KW according to ISO9249

PRODUCT IDENTIFICATION NUMBER

PRODUCT
IDENTIFICATION
NUMBER:

NOTE:
Marks to indicate the
HCM1GF00L00100001 start and end of the PIN

PRODUCT IDENTIFICATION M157-12-008

NUMBER (PIN)

ENGINE

TYPE:
MFG. NO.:

M178-00-001
 MACHINE NUMBERS

TRAVEL MOTOR

TYPE:
MFG. NO.:

SWING MOTOR
M178-07-047

TYPE:
MFG. NO.:

HYDRAULIC PUMP M1GF-07-002

TYPE:
MFG. NO.:

M1GF-07-006
 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
General Precautions for Cab............................... S-4
Use Handholds and Steps................................... S-5
Adjust the Operator’s Seat .................................. S-5
Fasten Your Seat Belt ......................................... S-6
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
Investigate Job Site Beforehand ......................... S-8
Protect Against Falling Stones and Debris.......... S-8
Provide Signals for Jobs Involving Multiple
Numbers of Machines ................................... S-9
Confirm Direction of Machine to be Driven ......... S-9
Drive Machine Safely......................................... S-10
Avoid Injury from Rollaway Accidents ............... S-11
Avoid Injury from Back-Over
and Swing Accidents ................................... S-12
Keep Person Clear from Working Area............. S-13
Never Position Bucket Over Anyone ................. S-13
Avoid Undercutting ............................................ S-13
Avoid Tipping..................................................... S-14
Never Undercut a High Bank............................. S-14
Dig with Caution ................................................ S-15
Operate with Caution......................................... S-15
Avoid Power Lines............................................. S-15
Object Handling................................................. S-16
Protect Against Flying Debris ............................ S-16
Park Machine Safely ......................................... S-17
Handle Fluids Safely --- Avoid Fires .................. S-17
Safety Transporting ........................................... S-18
Practice Safe Maintenance ............................... S-19
Warn Others of Service Work ........................... S-20
Support Machine Properly................................. S-20
Stay Clear of Moving Parts................................ S-20
Prevent Parts from Flying ................................ S-21
Store Attachments Safely.................................. S-21
Prevent Burns.................................................... S-22
Replace Rubber Hoses Periodically.................. S-22
Avoid High-Pressure Fluids............................... S-23
Prevent Fires ..................................................... S-24
Evacuating in Case of Fire ................................ S-25
Beware of Exhaust Fumes ................................ S-25
Precautions for Welding and Grinding .............. S-26
Avoid Heating Near Pressurized Fluid Lines ..... S-27
Avoid Applying Heat to Lines Containing
Flammable Fluids........................................ S-27
Remove Paint Before Welding or Heating ........ S-27
Prevent Battery Explosions ............................... S-28
Service Air Conditioning System Safely............ S-28
Handle Chemical Products Safely .................... S-29
Dispose of Waste Properly ............................... S-29
SAFETY SIGNS................................... S-30
COMPONENTS NAME .......................... 1-1
OPERATOR’S STATION
Cab Features .......................................................1-2
Monitor Panel.......................................................1-4
Coolant Temperature Gauge .......................1-5
Fuel Gauge ..................................................1-5
Auto-Idle Indicator..........................................1-5
Auto-Acceleration Indicator ...........................1-5
Fuel Level Indicator .......................................1-6
Air Filter Restriction Indicator ........................1-6
Overheat Indicator .........................................1-6
Engine Oil Pressure Indicator ........................1-6
Alternator Indicator ........................................1-6
Preheat Indicator ...........................................1-7
Hydraulic Oil Filter Restriction Indicator
(K Model) .................................................1-7
Liquid Crystal Display (LCD), Display
Selection Switch, Set Switch ...................1-8
Hour Meter..................................................... 1-8
Trip Meter (Trip Meter1 and Trip Meter 2 ......1-9
Engine Speed ................................................1-9
Hydraulic Oil Temperature............................. 1-9
Trip Meter Function .....................................1-10
Work Mode Switch ......................................1-12
Switch Panel ....................................................1-13
Engine Control Dial......................................1-13
Auto-Idle/Acceleration Selector ...................1-14
Power Mode Switch .....................................1-15
Travel Mode Switch .....................................1-15
Work Light Switch........................................1-16
Wiper/Washer Switch ..................................1-17
Switch Panel2 (K Model)....................................1-19
Switch Panel (Optional) .....................................1-20
Key Switch .........................................................1-21
Power Boost Switch ...........................................1-21
Horn Switch........................................................1-21
Cigar Lighter ......................................................1-22
12-V Power Source............................................1-23
Cab Light............................................................ 1-24
Installing Fire Extinguisher (Optional)................1-24
Pilot Control Shut-Off Lever...............................1-25
Engine Stop Knob ..............................................1-25
Fuse Box............................................................ 1-26
Additional Fuse Box (Optional) ..........................1-26
Auto Air Conditioner (optional)...........................1-27
Cab Heater Operation........................................1-32
Cooling Operation ..............................................1-33
Defroster Operation ...........................................1-33
Tips for Optimal Air Conditioner Usage .............1-35
Cab Heater (optional) ........................................1-36
 CONTENTS
Cab Heater Operation ....................................... 1-37
Defroster Operation........................................... 1-38
AM/FM Radio Operation.................................... 1-39
Digital Clock Setting Procedure......................... 1-40
Cab Door Release Lever................................... 1-41
Opening Upper Front Window........................... 1-41
Closing Upper Front Window ............................ 1-42
Removing and Storing Lower
Front Window.............................................. 1-43
Opening Side Windows ..................................... 1-43
Opening/Closing Overhead Window ................. 1-44
Emergency Exit ................................................. 1-45
Sunvisor (Optional)............................................ 1-46
Adjusting the Seat ............................................. 1-47
Adjusting the Seat --- If Equipped ..................... 1-49
Adjusting the Air-Suspension Seat (Optional) ... 1-51
Adjust Console Height....................................... 1-53
Seat Belt ............................................................ 1-54
BREAK-IN
Observe Engine Operation Closely ..................... 2-1
Every 8 Hours or Daily......................................... 2-1
After the First 50 Hours ....................................... 2-1
After the First 100 Hours ..................................... 2-1
OPERATING THE ENGINE
Inspect Machine Daily Before Starting ................ 3-1
Before Starting Engine ........................................ 3-2
Starting the Engine in Ordinary Temperature...... 3-3
Starting the Engine in Cold Weather ................... 3-4
Check Instruments After Starting ........................ 3-5
Using Booster Batteries....................................... 3-6
Stopping the Engine ............................................ 3-8
DRIVING THE MACHINE
Drive the Machine Carefully ................................ 4-1
Steering the Machine Using Pedals .................... 4-2
Steering the Machine Using Levers .................... 4-3
Travel Mode Switch............................................. 4-4
Travel Alarm (Optional) ....................................... 4-4
Traveling.............................................................. 4-5
Operating on Soft Ground ................................... 4-6
Raise One Track Using Boom and Arm .............. 4-6
Towing Machine a Short Distance....................... 4-7
Operating in Water or Mud.................................. 4-8
Precautions for Traveling on Slopes ................... 4-9
Parking the Machine on Slopes......................... 4-10
Parking the Machine.......................................... 4-10
OPERATING THE MACHINE
Control Lever (ISO Pattern) ............................... 5-1
Attachment Pedal (Breaker)................................ 5-2
Attachment Pedal (Hydraulic Crusher)................ 5-3
Pilot Control Shut-Off Lever ................................ 5-4
Engine Speed Control ......................................... 5-7
Auto-Idle .............................................................. 5-8
Auto Acceleration ................................................ 5-9
Work Mode ........................................................5-11
Power Boost.......................................................5-11
Power Mode.......................................................5-12
Precautions for Operation Using a Bucket ........5-13
Precautions for Operations ................................5-14
Operate the Machine Safely ..............................5-15
Operating Backhoe ............................................5-16
Grading Operation .............................................5-16
Face Shovel Operation ......................................5-17
Avoid Abusive Operation ...................................5-17
Operating Tips ...................................................5-18
Select Correct Track Shoes...............................5-18
Hydraulic Breaker and Hydraulic Crusher.......... 5-19
Pipings for Breaker and Crusher ....................... 5-20
Secondary Relief Pressure Adjustment ............. 5-22
Precautions for Braker Operation ......................5-23
Breaker Maintenance......................................... 5-26
Precautions for Crusher Operation....................5-27
Attachment.........................................................5-29
Precaution for Arm Roll-In/Bucket Roll-In
Combined Operation ................................... 5-32
When Installing an Attachment Longer than
Standard Bucket ..........................................5-32
Shackle Hole Usage ..........................................5-33
Overnight Storage Instructions .......................... 5-33
Emergency Boom Lowering Procedure .............5-34
Object Handling --- If Equipped ......................... 5-37
Long Arm Operation --- If Equipped...................5-39
TRANSPORTING
Transporting by Road ..........................................6-1
Loading/Unloading on a Trailer............................6-1
Machine Lifting Procedure ...................................6-5
MAINTENANCE
Correct Maintenance
and Inspection Procedures............................ 7-1
Check the Hour Meter Regularly .........................7-2
Use Correct Fuels and Lubricants .......................7-2
Layout ................................................................. 7-3
Maintenance Guide Table....................................7-4
Prepare Machine for Maintenance....................... 7-6
Hood and Access Covers ....................................7-7
Periodic Replacement of Parts ............................7-9
Maintenance Guide............................................7-10
A. Greasing ....................................................7-15
Front Joint Pins............................................7-15
Swing Bearing..............................................7-17
Swing Internal Gear .....................................7-18
B. Engine.......................................................... 7-19
Engine Oil Level...........................................7-19
Change Engine Oil.......................................7-19
Replace Engine Oil Filter .............................7-19
C. Transmission .............................................7-21
Pump Transmission.....................................7-21
Swing Reduction Gear................................. 7-22
Travel Reduction Gear ................................7-23
D. Hydraulic System .........................................7-25
 CONTENTS
Inspection and Maintenance
of Hydraulic Equipment ......................... 7-25
Replacement of Hydraulic Oil and Filter...... 7-26
Check Hydraulic Oil Level ........................... 7-27
Drain Hydraulic Tank Sump ........................ 7-28
Change Hydraulic Oil .................................. 7-29
Suction Filter Cleaning ................................ 7-29
Replace Hydraulic Tank Oil Filter................ 7-32
Replace Pilot Oil Filter................................. 7-34
Replace Air Breather Element..................... 7-35
Check Hoses and Lines .............................. 7-36
Service Recommendations for
Hydraulic Fittings................................... 7-39
E. Fuel System ................................................ 7-41
Drain Fuel Tank Sump ................................ 7-43
Check Water Separator .............................. 7-43
Replace Fuel Filter ...................................... 7-46
Clean Feed Pump Strainer.......................... 7-47
Check Fuel Hoses....................................... 7-48
F. Air Cleaner .................................................. 7-49
Clean the Air Cleaner Outer Element.......... 7-49
Replace the Air Cleaner Outer
and Inner Elements............................... 7-49
G. Cooling System ........................................... 7-51
Check Coolant Level ................................... 7-52
Check and Adjust Fan Belt Tension............ 7-53
Change Coolant .......................................... 7-54
Clean Radiator Interior ................................ 7-54
Clean Intercooler Core (ZAXIS135US,
135USK, 225US, 225USLC),
Radiator, and Oil Cooler Core............... 7-55
Clean Oil Cooler Front Screen .................... 7-55
Clean Air Conditioner Condenser ............... 7-56
Clean Inter Cooler Front Screen ................. 7-56
H. Electrical System ....................................... 7-57
Batteries ...................................................... 7-57
Remove and Installing Battery .................... 7-61
Replacing Fuses ......................................... 7-61
Additional Fuse Box (Optional) ................... 7-61
I. Miscellaneous ............................................ 7-63
Check Bucket Teeth.................................... 7-63
Change Bucket .......................................... 7-65
Convert Bucket Connection Into
Face Shovel .......................................... 7-66
Adjust the Bucket Linkage .......................... 7-67
Remove the Travel Levers .......................... 7-68
Check and Replace Seat Belt ................... 7-69
Check Windshield Washer Fluid Level ....... 7-69
Check Track Sag ........................................ 7-70
Adjust Track Sag......................................... 7-70
Loosen the Track ........................................ 7-71
Tighten the Track ........................................ 7-71
Clean and Replace Air Conditioner
Filter ...................................................... 7-72
Check the Air Conditioner ........................... 7-75
Cleaning Cab Floor ..................................... 7-77
Check Injection Nozzle................................ 7-78
Retighten Cylinder Head Bolt ...................... 7-78
Inspect and Adjust Valve Clearance ........... 7-78
Check Fuel Injection Timing ........................7-78
Measure Engine Compression
Pressure ................................................ 7-78
Check Starter and Alternator .......................7-78
Change Water Pump Grease ...................... 7-78
Check Tightening Torque of Bolts
and Nuts ................................................7-79
HYDRAULIC CIRCUIT AND
ELECTLICAL CIRCUIT
Hydraulic Circuit...................................................8-1
Electlical Circuit....................................................8-2
Electrical Circuit Diagram ....................................8-3
MAINTENANCE UNDER SPECIAL
ENVIRONMENTAL CONDITIONS
Maintenance Under Special
Environmental Conditions..............................9-1
STORAGE
Storing the Machine ...........................................10-1
Removing the Machine from Storage ................10-2
Installing Vandal-Proof Covers ..........................10-3
Help Prevent Crime ...........................................10-4
Record Identification Numbers ..........................10-4
Keep Proof of Ownership...................................10-4
Park Indoors Out of Sight ..................................10-4
When Parking Outdoors ....................................10-5
Reduce Vandalism............................................. 10-5
Report Thefts Immediately................................. 10-5
TROUBLESHOOTING
Engine ...............................................................11-1
Electrical System ...............................................11-6
Mode Selection ..................................................11-8
Control Levers ...................................................11-9
Hydraulic System ...............................................11-9
SPECIFICATIONS
ZAXIS125US
Specifications .............................................12-1
Working Ranges..........................................12-2
Shoe Types and Applications ...................... 12-3
ZAXIS135US
Specifications .............................................12-4
Working Ranges..........................................12-5
Shoe Types and Applications ...................... 12-6
ZAXIS225US, ZAXIS225USLC
Specifications .............................................12-7
Working Ranges..........................................12-8
Shoe Types and Applications ...................... 12-9
Sound Level Results (2000/14/EC) .................12-11
 CONTENTS

OPTIONAL ATTACHMENTS AND

DEVICES
Bucket Teeth (Transverse-Type-Pin
-Used Type) ............................................... 13-1
Blade Lever ....................................................... 13-2
Precautions for Blade Operation ....................... 13-2
Avoid Hitting Blade with Front-End
Attachment .................................................. 13-3
Avoic Hitting Blade with Bucket ......................... 13-3
Avoid Striking the Blade into a Rock ................. 13-3
Blade Maintenance............................................ 13-4
ZAXIS125US
Specifications ............................................ 13-5
Working Ranges ......................................... 13-6
Shoe Types and Applications...................... 13-7
ZAXIS135US
Specifications ............................................ 13-8
Working Ranges ......................................... 13-9
Shoe Types and Applications.................... 13-10
Using Rubber Pad Shoe.................................. 13-11
Traveling and Other Cautions ......................... 13-12
Transporting .................................................... 13-13
Precautions for Transporting Machines
with Rubber-Pad Shoes ............................ 13-13
Electronic Key Lock Operation Manual ........... 13-16
Registration/Registration Cancellation
of Ordinary Operation Key......................... 13-19
Additional Registration Procedure................... 13-20
Registration Cancellation Procedure............... 13-21
Lifting Capacities ............................................. 13-22

INDEX ............................................................. 14-1

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