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: 0 m 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.
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.
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.
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
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.
©2004 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
!HCM1SE00000010570! 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.:

M1GF-07-002

HYDRAULIC PUMP

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-31
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 Panel (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
Cab Light............................................................1-23
Installing Fire Extinguisher.................................1-23
Pilot Control Shut-Off Lever...............................1-24
Engine Stop Knob ..............................................1-24
Fuse Box............................................................1-25
Air Conditioner (Optional) ..................................1-26
Cab Heater Operation........................................1-30
Cooling Operation ..............................................1-31
Defroster Operation ...........................................1-31
Tips for Optimal Air Conditioner Usage .............1-33
Cab Heater (Optional)........................................1-34
Cab Heater Operation........................................1-36
Defroster Operation ...........................................1-37
 CONTENTS
AM/FM Radio Operation.................................... 1-38
Digital Clock Setting Procedure......................... 1-39
AM/FM Radio Operation.................................... 1-40
Digital Clock Setting Procedure......................... 1-41
Cab Door Release Lever................................... 1-42
Opening Upper Front Window........................... 1-42
Closing Upper Front Window ............................ 1-43
Removing and Storing Lower
Front Window.............................................. 1-44
Opening Side Windows ..................................... 1-45
Opening/Closing Overhead Window ................. 1-46
Emergency Exit ................................................. 1-47
Adjusting the Seat ............................................. 1-48
Adjusting the Seat --- If Equipped ..................... 1-50
Adjusting Console Height .................................. 1-52
Seat Belt............................................................ 1-53
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 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
Control Lever (HITACHI Pattern) ...................... 5-2
Attachment Pedal (Breaker)................................ 5-3
Attachment Pedal (Hydraulic Crusher)................ 5-4
Pilot Control Shut-Off Lever ................................ 5-5
Engine Speed Control ......................................... 5-8
Auto-Idle .............................................................. 5-9
Auto Acceleration .............................................. 5-10
Work Mode........................................................ 5-12
Power Boost.......................................................5-12
Power Mode.......................................................5-13
Precautions for Operation Using a Bucket ........5-14
Precautions for Operations ................................5-15
Operate the Machine Safely ..............................5-16
Operating Backhoe ............................................5-17
Grading Operation .............................................5-17
Face Shovel Operation ......................................5-18
Avoid Abusive Operation ...................................5-18
Operating Tips ...................................................5-19
Select Correct Track Shoes...............................5-19
Hydraulic Breaker and Hydraulic Crusher..........5-20
Pipings for Breaker and Crusher .......................5-21
Secondary Relief Pressure Adjustment .............5-23
Precautions for Breaker Operation ....................5-24
Breaker Maintenance.........................................5-27
Precautions for Crusher Operation ....................5-28
Attachment.........................................................5-30
Attachment Connection Parts ............................5-33
Precaution for Arm Roll-In/Bucket Roll-In
Combined Operation ...................................5-34
When Installing an Attachment Longer than
Standard Bucket ..........................................5-34
Shackle Hole Usage ..........................................5-35
Overnight Storage Instructions ..........................5-35
Emergency Boom Lowering Procedure .............5-36
Object Handling --- If Equipped .........................5-39
Long Arm Operation --- If Equipped...................5-40
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 Full-Flow 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, 135USL, 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
Replace Batteries........................................ 7-61
Replacing Fuses ......................................... 7-61
I. Miscellaneous ............................................ 7-62
Check Bucket Teeth.................................... 7-62
Change Bucket .......................................... 7-64
Convert Bucket Connection Into
Face Shovel .......................................... 7-65
Adjust the Bucket Linkage .......................... 7-66
Remove the Travel Levers .......................... 7-67
Check and Replace Seat Belt ................... 7-68
Check Windshield Washer Fluid Level ....... 7-68
Check Track Sag ........................................ 7-69
Adjust Track Sag......................................... 7-69
Loosen the Track ........................................ 7-70
Tighten the Track ........................................ 7-70
Clean and Replace Air Conditioner
Filter ...................................................... 7-71
Check the Air Conditioner ........................... 7-74
Cleaning Cab Floor ..................................... 7-76
Check Injection Nozzle................................ 7-77
Retighten Cylinder Head Bolt ...................... 7-77
Inspect and Adjust Valve Clearance ........... 7-77
Check Fuel Injection Timing........................ 7-77
Measure Engine Compression
Pressure ................................................7-77
Check Starter and Alternator .......................7-77
Change Water Pump Grease ......................7-77
Check Tightening Torque of Bolts
and Nuts ................................................7-78
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
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
Bucket Types and Applications ...................12-4
ZAXIS135US
Specifications .............................................12-5
Working Ranges..........................................12-6
Shoe Types and Applications ......................12-7
Bucket Types and Applications ...................12-8
ZAXIS135USK
Specifications .............................................12-9
Working Ranges........................................12-10
Shoe Types and Applications ....................12-11
Bucket Types and Applications .................12-12
ZAXIS135USL
Specifications ...........................................12-13
Working Ranges........................................12-14
Shoe Types and Applications ....................12-15
Bucket Types and Applications .................12-16
ZAXIS225US, ZAXIS225USLC
Specifications ...........................................12-17
Working Ranges........................................12-18
Shoe Types and Applications ....................12-19
Bucket Types and Applications .................12-21
OPTIONAL ATTACHMENTS AND
DEVICES
Bucket Teeth (Transverse-Type-Pin
-Used Type) ...............................................13-1
Blade Lever........................................................13-2
Precautions for Blade Operation........................13-2
 CONTENTS
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
ZAXIS135USL
Specifications (With Blade) ....................... 13-11
Working Ranges ....................................... 13-12
Shoe Types and Applications.................... 13-13
Using Rubber Pad Shoe.................................. 13-14
Traveling and Other Cautions ......................... 13-15
Transporting .................................................... 13-16
Precautions for Transporting Machines
with Rubber-Pad Shoes ............................ 13-16
Electronic Key Lock Operation Manual ........... 13-19
Registration/Registration Cancellation
of Ordinary Operation Key......................... 13-22
Additional Registration Procedure................... 13-23
Registration Cancellation Procedure............... 13-24

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

 SAFETY
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

001-E01A-0001

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. SA-1223

!" CAUTION also calls attention to safety messages in this

manual.

!" 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.

002-E01A-1223

S-1
 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
ordering). SA-003

!" Learn how to operate the machine and its controls cor-
rectly and safely.

!" Allow only trained, qualified, authorized personnel to op-

erate the machine.

!" Keep your machine in proper working condition.

• Unauthorized modifications of the machine may impair

its function and/or safety and affect machine life.

!" 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 hazardous situation you may encounter. If
you have any questions, you should first consult your
supervisor and/or your authorized dealer before operat-
ing or performing maintenance work on the machine.
003-E01B-0003

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 to 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.
SA-437
• Establish emergency procedure guidelines to cope
with fires and accidents.
• Keep emergency numbers for doctors, ambulance
service, hospital, and fire department posted near
your telephone.

004-E01A-0437

S-2
 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.

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 operating the machine.
005-E01A-0438

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
006-E01A-0434

INSPECT MACHINE

!" Inspect your machine carefully each day or shift by walk-

ing around it before you start it to avoid personal injury.

• In the walk-around inspection, be sure to cover all

points described in the “PRE-START INSPECTION”
chapter in the operator’s manual.

007-E01A-0435 SA-435

S-3
 SAFETY
GENERAL PRECAUTIONS FOR CAB

• Before entering the cab, thoroughly remove all dirt

and/or oil from the soles of your work boots. If any
controls such as a pedal is operated while with dirt
and/or oil on the soles of the operator’s work boots the
operator’s foot may slip off the pedal, possibly result-
ing in a personal accident.
• Don’t leave parts and/or tools lying around the opera-
tor’s seat. Store them in their specified locations.
• Avoid storing transparent bottles in the cab. Don’t at-
tach any transparent type window decorations on the
windowpanes as they may focus sunlight, possibly
starting a fire.
• Refrain from listening to the radio, or using music
headphones or mobile telephones in the cab while
operating the machine.
• Keep all flammable objects and/or explosives away
from the machine.
• After using the ashtray, always cover it to extinguish
the match and/or tobacco.
• Don’t leave cigarette lighters in the cab. When the
temperature in the cab increases, the lighter may ex-
plode.

524-E01A-0000

S-4
 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.
• Never jump on or off the machine. Never mount or
dismount a moving machine.
• Be careful of slippery conditions on platforms, steps,
SA-439
and handrails when leaving the machine.

008-E01A-0439

ADJUST THE OPERATOR’S SEAT

!" A poorly adjusted seat for either the operator or for the
work at hand may quickly fatigue the operator leading to
misoperations.

• The seat should be adjusted whenever changing the

operator for the machine.
• The operator should be able to fully depress the ped-
als and to correctly operate the control levers with his
back against the seat back.
• If not, move the seat forward or backward, and check SA-378

again.

009-E01A-0378

S-5
 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. If any item is
damaged or worn, replace the seat belt or component
before operating the machine.
• Be sure to remain seated with the seat belt securely SA-237
fastened at all times when the machine is in operation
to minimize the chance of injury from an accident.
• We recommend that the seat belt be replaced every
three years regardless of its apparent condition.
010-E01A-0237

MOVE AND OPERATE MACHINE SAFELY

!" Bystanders can be run over.

• Take extra care not to run over bystanders. Confirm

the location of bystanders before moving, swinging, or
operating the machine.
• Always keep the travel alarm and horn in working con-
dition (if equipped). It warns people when the machine
starts to move.
• Use a signal person when moving, swinging, or oper-
ating the machine in congested areas. Coordinate
hand signals before starting the machine. SA-426

011-E01A-0426

S-6
 SAFETY
OPERATE ONLY FROM OPERATOR’S SEAT

!" Inappropriate engine starting procedures 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.
• Do not start engine by shorting across starter termi-
nals.
SA-444
• Before starting the engine, confirm that all control lev-
ers are in neutral.

012-E01B-0444

JUMP STARTING

!" Battery gas can explode, resulting in serious injury.

• If the engine must be jump started, be sure to follow

the instructions shown in the “OPERATING THE EN-
GINE” chapter.
• The operator must be in the operator’s seat so that
the machine will be under control when the engine
starts. Jump starting is a two-person operation.
• Never use a frozen battery.
SA-032

• Failure to follow correct jump starting procedures

could result in a battery explosion or a runaway ma-
chine.

S013-E01A-0032

KEEP RIDERS OFF MACHINE

!" Riders on machine are subject to injury such as being

struck by foreign objects and being thrown off the ma-
chine.

• Only allow the operator on the machine. Keep riders

off.
• Riders also obstruct the operator’s view, resulting in
the machine being operated in an unsafe manner.

SA-379

014-E01B-0379

S-7
 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.
• Make a work plan. Use machines appropriate to the
work and job site.
• Reinforce ground, edges, and road shoulders as nec-
SA-380

essary. Keep the machine well back from the edges of

excavations and road shoulders.
• When working on an incline or on a road shoulder,
employ a signal person as required.
• Confirm that your machine is equipped a FOPS cab
before working in areas where the possibility of falling
stones or debris exist.
• When the footing is weak, reinforce the ground before
starting work.
• When working on frozen ground, be extremely alert.
As ambient temperatures rise, footing becomes loose
and slippery.
• Beware the possibility of fire when operating the ma-
chine near flammable objects such as dry grass.
015-E01A-0380

PROTECT AGAINST FALLING STONES AND

DEBRIS

• Confirm that your machine is FOPS cab equipped

before working in areas where the possibility of falling
stones or debris exist.

SA-490

015-E01A-0380

S-8
 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.

018-E01A-0481
SA-481

CONFIRM DIRECTION OF MACHINE TO BE

DRIVEN

!" Incorrect travel pedal/lever operation may result in seri-

ous injury death.

• Before driving the machine, confirm the position of the

undercarriage in relation to the operator’s position. If
the travel motors are located in front of the cab, the
machine will move in reverse when travel ped-
als/levers are operated to the front.

SA-491
017-E01A-0491

S-9
 SAFETY
DRIVE MACHINE SAFELY

!" Before driving the machine, always confirm that the

travel levers/pedals direction corresponds to the direc-
tion you wish to drive.

• Be sure to detour around any obstructions.

• Avoid traveling over obstructions. Soil, fragments of
rocks, and/or metal pieces may scatter around the
machine. Don’t allow personnel to stay around the
machine while traveling.
SA-387

!" Driving on a slope may cause the machine to slip or

overturn, possibly resulting in serious injury or death.

• When driving up or down a slope, keep the bucket

facing the direction of travel, approximately 0.5 to 1.0
m (1 ft 8 in to 3 ft 3 in) (A) above the ground.
• If the machine starts to skid or becomes unstable,
immediately lower the bucket to the ground and stop.

SA-388

SA-441

• Driving across the face of a slope or steering on a

slope may cause the machine to skid or turnover. If
the direction must be changed, move the machine to
level ground, then, change the direction to ensure
sage operation.

SA-589

019-E01C-0492

S-10
 SAFETY
AVOID INJURY FROM ROLLAWAY
ACCIDENTS

!" 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.
• Lower the bucket and/or other work tools to the
ground.
• Turn the auto-idle switch and the H/P mode switch off. SA-391

• Run the engine at slow idle speed without load for 5

minutes to cool down the engine.
• Stop the engine and remove the key from the key
switch.
• Pull the pilot control shut-off lever to LOCK position.
• Block both tracks and lower the bucket to the ground.
Thrust the bucket teeth into the ground if you must
park on a grade.
• Position the machine to prevent rolling.
• Park a reasonable distance from other machines.
SA-392
020-E02A-0493

S-11
 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:

• Always look around BEFORE YOU BACK UP AND
SWING THE MACHINE. BE SURE THAT ALL BY-
STANDERS ARE CLEAR.
• Keep the travel alarm in working condition (if SA-383
equipped).
ALWAYS BE ALERT FOR BYSTANDERS MOVING
INTO THE WORK AREA. USE THE HORN OR
OTHER SIGNAL TO WARN BYSTANDERS BEFORE
MOVING MACHINE.
• USE A SIGNAL PERSON WHEN BACKING UP IF
YOUR VIEW IS OBSTRUCTED. ALWAYS KEEP THE
SIGNAL PERSON IN VIEW.
Use hand signals, which conform to your local regula-
tions, when work conditions require a signal person.
• No machine motions shall be made unless signals are
clearly understood by both signalman and operator. SA-384

• Learn the meanings of all flags, signs, and markings

used on the job and confirm who has the responsibility
for signaling.
• Keep windows, mirrors, and lights clean and in good
condition.
• Dust, heavy rain, fog, etc., can reduce visibility. As
visibility decreases, reduce speed and use proper
lighting.
• Read and understand all operating instructions in the
operator’s manual.

021-E01A-0494

S-12
 SAFETY
KEEP PERSON CLEAR FROM WORKING
AREA

!" A person may be hit severely by the swinging front at-

tachment 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.
• Before operating the machine, set up barriers to the
sides and rear area of the bucket swing radius to pre-
vent anyone from entering the work area.

SA-386
022-E01A-0386

NEVER POSITION BUCKET OVER ANYONE

!" Never lift, move, or swing bucket above anyone or a

truck cab.
Serious injury or machine damage may result due to
bucket load spill or due to collision with the bucket.

SA-487
023-E01A-0487

AVOID UNDERCUTTING

!" In order to retreat from the edge of an excavation if the

footing should collapse, always position the undercar-
riage perpendicular to the edge of the excavation with
the travel motors at the rear.

• If the footing starts to collapse and if retreat is not

possible, do not panic. Often, the machine can be
secured by lowering the front attachment, in such
cases.

SA-488
024-E01A-0488

S-13
 SAFETY
AVOID TIPPING

DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING

MACHINE --- SERIOUS OR FATAL CRUSHING INJU-
RIES WILL RESULT
MACHINE WILL TIP OVER FASTER THAN YOU CAN
JUMP FREE
FASTEN YOUR SEAT BELT
!" The danger of tipping is always present when operating
on a grade, possibly resulting in serious injury or death.

To avoid tipping: SA-012

!" Be extra careful before operating on a grade.

• Prepare machine operating area flat.

• Keep the bucket low to the ground and close to the
machine.
• Reduce operating speeds to avoid tipping or slipping.
• Avoid changing direction when traveling on grades.
• NEVER attempt to travel across a grade steeper than
15 degrees if crossing the grade is unavoidable.
• Reduce swing speed as necessary when swinging
loads. SA-440

!" Be careful when working on frozen ground.

• Temperature increases will cause the ground to be-
come soft and make ground travel unstable.
025-E01B-0495

NEVER UNDERCUT A HIGH BANK

!" The edges could collapse or a land slide could occur

causing serious injury or death.

SA-489

026-E01A-0489

S-14
 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 ca-
bles, gas lines, and water lines.
• If a fiber optic cable should be accidentally severed,
do not look into the end. Doing so may result in seri-
SA-382
ous eye injury.
• Contact your local “diggers hot line” if available in your
area , and/or the utility companies directly.
Have them mark all underground utilities.
027-E01A-0382

OPERATE WITH CAUTION

!" If the front attachment or any other part of the machine

hits against an overhead obstacle, such as a bridge,
both the machine and the overhead obstacle will be
damaged, and personal injury may result as well.

• Take care to avoid hitting overhead obstacles with the

boom or arm.

028-E01A-0389 SA-389

AVOID POWER LINES

!" Serious injury or death can result if the machine or front

attachments are not kept a safe distance from electric
lines.

• When operating near an electric line, NEVER move

any part of the machine or load closer than 3 m plus
twice the line insulator length.
• Check and comply with any local regulations that may
apply.
• Wet ground will expand the area that could cause any
person on it to be affected by electric shock. Keep all
bystanders or co-workers away from the site.
SA-381

029-E01A-0381

S-15
 SAFETY
OBJECT HANDLING

!" If a lifted load should fall, any person nearby may be

struck by the falling load or may be crushed underneath
it, resulting in serious injury or death.

• When using the machine for craning operations, be

sure to comply with all local regulations.
• Do not use damaged chains or frayed cables, sables,
slings, or ropes.
• Before craning, position the upperstructure with the
travel motors at the rear.
SA-014

• Move the load slowly and carefully. Never move it sud-

denly.
• Keep all persons will away from the load.
• Never move a load over a person’s head.
• Do not allow anyone to approach the load until it is
safely and securely situated on supporting blocks or
on the ground.
• Never attach a sling or chain to the bucket teeth. They
may come off, causing the load to fall.

030-E01A-0014

PROTECT AGAINST FLYING DEBRIS

!" If flying debris hit eyes or any other part of the body, se-
rious injury may result.

• Guard against injury from flying pieces of metal or de-

bris; wear goggles or safety glasses.
• Keep bystanders away from the working area before
striking any object.

SA-432
031-E01A-0432

S-16
 SAFETY
PARK MACHINE SAFELY

To avoid accidents:
• Park machine on a level surface.
• Lower bucket to the ground.
• Turn auto-idle / acceleration selector off.
• Run engine at slow idle speed without load for 5 min-
utes.
• Turn key switch to OFF to stop engine.
• Remove the key from the key switch.
• Pull the pilot control shut-off lever to the LOCK posi- SA-390

tion.
• Close windows, roof vent, and cab door.
• Lock all access doors and compartments.

033-E08B-0390

－AVOID FIRES
HANDLE FLUIDS SAFELY－

!" Handle fuel with care; it is highly flammable. If fuel ig-

nites, an explosion and/or a fire may occur, possibly re-
sulting in serious injury or death.

• Do not refuel the machine while smoking or when

near open flame or sparks.
• Always stop the engine before refueling the machine.
• Fill the fuel tank outdoors.

!" All fuels, most lubricants, and some coolants are flam- SA-018
mable.

• Store flammable fluids well away from fire hazards.

• Do not incinerate or puncture pressurized containers.
• Do not store oily rags; they can ignite and burn spon-
taneously.
• Securely tighten the fuel and oil filler cap.

SA-019

034-E01A-0496

S-17
 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.

Take the following precautions when loading/unloading the

machine:
1) Select firm level ground. SA-395

2) Be sure to use a loading dock or ramp.

3) Be sure to have a signal person when loading/
unloading the machine.
4) Always turn the auto-idle/acceleration selection OFF
when loading or unloading the machine, to avoid un-
expected speed increase due to unintentional opera-
tion of a control lever.
5) Always select the slow speed mode with the travel
mode switches. In the high speed mode, travel speed
may automatically increases.
6) Avoid steering while driving up or down the ramp as it
is extremely dangerous. If steering is unavoidable,
first move back to the ground or flatbed, modify trav-
eling direction, and begin to drive again.
7) Do not operate any levers besides the travel levers
when driving up or down the ramp.
8) The top end of the ramp where it meets the flatbed is
a sudden bump. Take care when traveling over it.
9) Prevent possible injury from machine tipping while
the upperstructure is rotating.
10) Keep the arm tucked under and rotate the upper-
structure slowly for best stability.
11) Securely fasten chain or cables to the machine frame.
Refer to “transporting” chapter in this manual for de-
tails.

S035-E08A-0395

S-18
 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 mov-
ing.
• Keep hands, feet and clothing away from
power-driven parts.

Before servicing the machine:

1. Park the machine on a level surface.
SA-028
2. Lower the bucket to the ground.
3. Turn the auto-idle/acceleration selector off.
4. Run the engine at slow idle speed without load for 5
minutes.
5. Turn the key switch to OFF to stop engine.
6. Relieve the pressure in the hydraulic system by mov-
ing the control levers several times.
7. Remove the key from the switch.
8. Attach a “Do Not Operate” tag on the control lever.
9. Pull the pilot control shut-off lever to the LOCK posi-
tion.
10. Allow the engine to cool.

• If a maintenance procedure must be performed with

the engine running, do not leave machine unattended.
• If the machine must be raised, maintain a 90 to 110#
SA-527
angle between the boom and arm. Securely support
any machine elements that must be raised for service
work.
• Never work under a machine raised by the boom.
• Inspect certain parts periodically and repair or replace
as necessary. Refer to the section discussing that part
in the “MAINTENANCE” chapter of this manual.
• Keep all parts in good condition and properly installed.
• Fix damage immediately. Replace worn or broken
parts. Remove any buildup of grease, oil, or debris.
• When cleaning parts, always use nonflammable de-
tergent oil. Never use highly flammable oil such as
fuel oil and gasoline to clean parts or surfaces.
• Disconnect battery ground cable (–) before making
adjustments to electrical systems or before performing
welding on the machine.
500-E02B-0497

S-19
 SAFETY
• Sufficiently illuminate the work site. Use a mainte-
nance work light when working under or inside the
machine.
• Always use a work light protected with a guard. In
case the light bulb is broken, spilled fuel, oil, anti-
freeze fluid, or window washer fluid may catch fire.

SA-037

WARN OTHERS OF SERVICE WORK

!" Unexpected machine movement can cause serious in-

jury.

• Before performing any work on the machine, attach a

“Do Not Operate” tag on the control lever.
This tag is available from your authorized dealer.

501-E01A-0287 SA-287 SS2045102

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. Do not
support the machine on cinder blocks, hollow tires, or
props that may crumble under continuous load. Do not
work under a machine that is supported solely by a SA-527
jack.
519-E01A-0527

STAY CLEAR OF MOVING PARTS

!" Entanglement in moving parts can cause serious injury.

• To prevent accidents, care should be taken to ensure

that hands, feet, clothing, jewelry and hair do not be-
come entangled when working around rotating parts.

502-E01A-0026

SA-026

S-20
 SAFETY
PREVENT PARTS FROM FLYING

!" Grease in the track adjuster is under high pressure.

Failure to follow the precautions below may result in se-
rious injury, blindness, or death.

• Do not attempt to remove GREASE FITTING or

VALVE ASSEMBLY.
• As pieces may fly off, be sure to keep body and face
away from valve.

!" Travel reduction gears are under pressure. SA-344

• As pieces may fly off, be sure to keep body and face

away from AIR RELEASE PLUG to avoid injury.
GEAR OIL is hot.
• Wait for GEAR OIL to cool, then gradually loosen AIR
RELEASE PLUG to release pressure.

503-E01B-0344

STORE ATTACHMENTS SAFELY

!" Stored attachments such as buckets, hydraulic ham-

mers, and blades can fall and cause serious injury or
death.

• Securely store attachments and implements to pre-

vent falling. Keep children and bystanders away from
storage areas.

SA-034

504-E01A-0034

S-21
 SAFETY
PREVENT BURNS

Hot spraying fluids:

!" After operation, engine coolant is hot and under pres-

sure. Hot water or steam is contained in the engine, ra-
diator and heater lines.
Skin contact with escaping hot water or steam can
cause severe burns.

• To avoid possible injury from hot spraying water. DO

NOT remove the radiator cap until the engine is cool.
SA-039
When opening, turn the cap slowly to the stop. Allow
all pressure to be released before removing the cap.
• The hydraulic oil tank is pressurized. Again, be sure to
release all pressure before removing the cap.

Hot fluids and surfaces:

!" Engine oil, gear oil and hydraulic oil also become hot
during operation.
The engine, hoses, lines and other parts become hot as
well.
SA-225
• Wait for the oil and components to cool before starting
any maintenance or inspection work.

505-E01B-0498

REPLACE RUBBER HOSES PERIODICALLY

!" Rubber hoses that contain flammable fluids under pres-

sure may break due to aging, fatigue, and abrasion. It is
very difficult to gauge the extent of deterioration due to
aging, fatigue, and abrasion of rubber hoses by inspec-
tion alone.

• Periodically replace the rubber hoses. (See the page

of “Periodic replacement of parts” in the operator’s
manual).
SA-019
!" Failure to periodically replace rubber hoses may cause a
fire, fluid injection into skin, or the front attachment to fall
on a person nearby, which may result in severe burns,
gangrene, or otherwise serious injury or death.

S506-E01A-0019

S-22
 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 dis-

connecting hydraulic or other lines.
• Tighten all connections before applying pressure.
• Search for leaks with a piece of cardboard; take care SA-031

to protect hands and body from high-pressure fluids.

Wear a face shield or goggles for eye protection.
• If an accident occurs, see a doctor familiar with this
type of injury immediately. Any fluid injected into the
skin must be surgically removed within a few hours or
gangrene may result.

SA-292

SA-044
507-E03A-0499

S-23
 SAFETY
PREVENT FIRES

Check for Oil Leaks:

!" Fuel, hydraulic oil and lubricant leaks can lead to fires.
• Check for oil leaks due to 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.
• Tighten, repair or replace any missing, loose or damaged
clamps, lines, hoses, oil-cooler and oil-cooler flange bolts.
• Do not bend or strike high-pressure lines.
• Never install bent or damaged lines, pipes or hoses.
SA-019

Check for Shorts:

!" Short circuits can cause fires.
• Clean and tighten all electrical connections.
• Check before each shift or after eight (8) to ten (10)
hours operation for loose, kinked, hardened or frayed
electrical cables and wires.
• Check before each shift or after eight (8) to ten (10)
hours operation for missing or damaged terminal caps.
• DO NOT OPERATE MACHINE if cable or wires are
loose, kinked, etc..

Clean up Flammables:
!" Spilled fuel, oil, antifreeze fluid and window washer fluid,
and trash, grease, debris, accumulated coal dust, and
other flammables may cause fires.
• Prevent fires by inspecting and cleaning the machine
daily, and by removing spilled or accumulated flam-
mables immediately.
!" The engine access cover openings for the logging work
model machines are protected by wire mesh so that for-
eign potentially flammable materials such as dead
leaves are prevented to enter the access spaces around
the engine. However, potentially flammable materials
smaller than the wire mesh may pass through the wire
net and may become accumulated in the vicinity of the
engine, possibly causing a fire. Check and clean the
machine every day. Be sure to remove any flammable
material immediately.

Check Key Switch:

!" If fire breaks out, failure to stop the engine will escalate
fire, hampering fire fighting.
Always check key switch function before operating the
machine every day:
1. Start the engine and run it at slow idle.
2. Turn the key switch to the OFF position to confirm
that the engine stops.
• If any abnormalities are found, be sure to repair them
before operating the machine.
508-E02B-0019

S-24
 SAFETY
Check Heat Shields:
!" Damaged or missing heat shield may lead to fires.
• Damaged or missing heat shields must be repaired or
replaced before operating the machine.
508-E02A-0393

EVACUATING IN CASE OF FIRE

!" If a fire breaks out, evacuate the machine in the follow-

ing 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.
• Exit the machine.
!" In an emergency, if the cab door or front window can not
be opened, break the front or rear window panes with SA-393
the emergency evacuation hammer to escape from the
cab. Refer the explanation pages on the Emergency
Evacuation Method.
518-E02B-0393

SS-1510

BEWARE OF EXHAUST FUMES

!" Prevent asphyxiation. Engine exhaust fumes can cause

sickness or death.
• If you must operate in a building, be sure there is
adequate ventilation. Either use an exhaust pipe ex-
tension to remove the exhaust fumes or open doors
and windows to bring enough outside air into the area.
509-E01A-0016 SA-016

S-25
 SAFETY
PRECAUTIONS FOR WELDING AND GRIND-
ING

!" Welding may generate gas and/or small fires.

• Be sure to perform welding in a well ventilated and
prepared area. Store flammable objects in a safe
place before starting welding.
• Only qualified personnel should perform welding.
Never allow an unqualified person to perform welding.
!" Grinding on the machine may create fire hazards. Store
flammable objects in a safe place before starting grind-
ing.
!" After finishing welding and grinding, recheck that there SA-818

are no abnormalities such as the area surrounding the

welded area still smoldering.

523-E01A-0818

S-26
 SAFETY
AVOID HEATING NEAR PRESSURIZED FLUID
LINES

!" Flammable spray can be generated by heating near

pressurized fluid lines, resulting in severe burns to your-
self and bystanders.

• Do not heat by welding, soldering, or using a torch

near pressurized fluid lines or other flammable mate-
rials.
• Pressurized lines can be accidentally cut when heat
goes beyond the immediate flame area. Install tem- SA-030
porary fire-resistant guards to protect hoses or other
materials before engaging in welding, soldering, etc..

AVOID APPLYING HEAT TO LINES CONTAIN-

ING FLAMMABLE FLUIDS

• Do not weld or flame cut pipes or tubes that contain

flammable fluids.
• Clean them thoroughly with nonflammable solvent
before welding or flame cutting them.

510-E01B-0030

REMOVE PAINT BEFORE WELDING OR

HEATING

!" Hazardous fumes can be generated when paint is

heated by welding, soldering, or using a torch. If inhaled,
these fumes may cause sickness.

• Avoid potentially toxic fumes and dust.

• Do all such work outside or in a well-ventilated area.
Dispose of paint and solvent properly.
SA-029

•Remove paint before welding or heating:

1. If you sand or grind paint, avoid breathing the dust.
Wear an approved respirator.
2. If you use solvent or paint stripper, remove stripper
with soap and water before welding. Remove solvent
or paint stripper containers and other flammable ma-
terial from area. Allow fumes to disperse at least 15
minutes before welding or heating.
511-E01A-0029

S-27
 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.
• Do not charge a frozen battery; it may explode. Warm
the battery to 16 #C (60 #F) first.
• Do not continue to use or charge the battery when
SA-032
electrolyte level is lower than specified. Explosion of
the battery may result.
• Loose terminals may produce sparks. Securely tighten
all terminals.

!" Battery electrolyte is poisonous. If the battery should ex-

plode battery electrolyte may be splashed into eyes, pos-
sibly resulting in blindness.

• Be sure to wear eye protection when checking elec-

trolyte specific gravity.

512-E01B-0032

SERVICE AIR CONDITIONING SYSTEM

SAFELY

!" If spilled onto skin, refrigerant may cause a cold contact

burn.

• Refer to the freon container for proper use when ser-

vicing the air conditioning system.
• Use a recovery and recycling system to avoid venting
freon into the atmosphere.
• Never let the freon stream make contact with the skin.

SA-405

513-E01A-0405

S-28
 SAFETY
HANDLE CHEMICAL PRODUCTS SAFELY

!" Direct exposure to hazardous chemicals can cause se-

rious injury. Potentially hazardous chemicals used with
your machine include such items as lubricants, coolants,
paints, and adhesives.

• A Material Safety Data Sheet (MSDS) provides spe-

cific details on chemical products: physical and health
hazards, safety procedures, and emergency response
techniques.
• Check the MSDS before you start any job using a haz-
ardous chemical. That way you will know exactly what SA-309
the risks are and how to do the job safely. Then follow
procedures and use recommended equipment.
• See your authorized dealer for MSDS’s (available only
in English) on chemical products used with your ma-
chine.

515-E01A-0309

DISPOSE OF WASTE PROPERLY

!" Improperly disposing of waste can threaten the envi-

ronment 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.
• Do not pour waste onto the ground, down a drain, or
into any water source.
• Air conditioning refrigerants escaping into the air can SA-226

damage the Earth’s atmosphere. Government regula-

tions may require a certified air conditioning service
center to recover and recycle used air conditioning re-
frigerants.
• Inquire on the proper way to recycle or dispose of
waste from your local environmental or recycling cen-
ter, or from your authorized dealer.

516-E01A-0226

S-29
 SAFETY
MEMO

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S-30
 SAFETY SIGNS/ Oceania Model Only
All safety signs and their locations affixed on the machine
are illustrated in this group. Make sure of the contents de-
scribed in the safety signs through reading actual ones af-
fixed on the machine to ensure safe machine operation.
Always keep the safety signs clean. In case a safety sign is
broken or lost, immediately, obtain a new replacement and
affix it again in position on the machine. Use the part No.
indicated under the right corner of each safety sign illustra-
tion when placing an order of it to the Hitachi dealer.

M1CC-00-006
SS-862

SS-863 M1CC-00-007

SS-859

M1CC-00-005

S-31
SAFETY SIGNS/ Oceania Model Only

SS3098290
M1CC-00-006

SS-2042

SS3092349

SS-1737

SS-408

S-32
 SAFETY SIGNS/ Oceania Model Only

ZAXIS125US, 135US, 135USK, 135USL SS-2096

SS-864

ZAXIS225US, 225USLC SS-2086

Caution: Possibility of Push down with the SS-955

pinch fingers palm.

M1SE-01-002

S-33
SAFETY SIGNS/ Oceania Model Only

ZAXIS125US, 135US, 135USK, 135USL

SS-2095

SS3092350

SS-2085
ZAXIS225US, 225USLC

SS-024

SS-2093

S-34
SAFETY SIGNS/ Oceania Model Only

SS3092352

ZAXIS125US, 135US, 135USK, 135USL M1SE-07-010

SS-2111
ZAXIS225US, 225USLC

SS-411 M1SE-07-014
ZAXIS125US, 135US, 135USK, 135USL

M1GF-07-015
ZAXIS225US, 225USLC

S-35
 SAFETY SIGNS/ Asia/Middle and Near East Model Only

SS-1613
!" Sign indicates an electrocution hazard if machine is
brought too near electric power lines.
Keep a safe distance from electric power lines.
M1CC-00-006

SS-1618
!" Sign indicates a hazard form falling window.
After raising window, be sure to lock it in place with lock
pins.
M1CC-00-007

SS4459990
!" Don’t extend your hands or head from the window. Your
hands or head may come in contact with the boom.
M1CC-00-005

SS4420333
Caution: If the parked machine is unexpectedly moved, se-
rious injury or death due to crushing may result. Be sure to
lower the front attachment to the ground, lock the control
levers, and remove the engine key before leaving the ma-
chine unattended. SS-2374

S-36
 SAFETY SIGNS/ Asia/Middle and Near East Model Only

SS3098290

M1CC-00-006

SS-2042

SS3089581
!" Sign indicates a hazard of being hit by the working de-
vice of the machine.
Keep away from machine during operation.

S-37
 SAFETY SIGNS/ Asia/Middle and Near East Model Only

SS-1615
!" Sign indicates a hazard of a flying plug from track ad- SS-1737
juster that could cause injury.
Read manual before adjusting track for safe and proper
handing.

SS-4459928
!" Sign indicates a burn hazard from compressed air and SS-2096

spurting hot oil if the oil inlet is uncapped during or right

after operation.
Read manual for safe and proper handing.

S-38
 SAFETY SIGNS/ Asia/Middle and Near East Model Only

SS4420336
!" Sign indicates a burn hazard from spurting hot water or
oil if radiator or hydraulic tank is uncapped while hot.
SS-2096
Allow radiator or hydraulic tank to cool before removing
cap.

SS-2095
ZAXIS125US, 135US, 135USK, 135USL

SS3092125
Sign indicates a hazard of falling off the fender or hood.
Never stand close to the edge.

SS-2085
ZAXIS225US, 225USLC

S-39
 SAFETY SIGNS/ Asia/Middle and Near East Model Only

SS-1614
!" Sign indicates a crush hazard by rotation of upper struc-
ture of the machine.
Keep away from swinging area of machine.
SS-2093

SS4420336
!" Sign indicates a burn hazard from spurting hot water or
oil if radiator or hydraulic tank is uncapped while hot. ZAXIS125US, 135US, 135USK, 135USL SS-2092

Allow radiator or hydraulic tank to cool before removing

cap.

SS-2110
ZAXIS225US, 225USLC

S-40
 SAFETY SIGNS/ Asia/Middle and Near East Model Only

SS3092127
!" Sigh indicates a hazard of rotating parts, such as belt.
Turn off before inspection and maintenance. ZAXIS125US, 135US, 135USK, 135USL M1SE-07-010

ZAXIS225US, 225USLC SS-2111

SS4459714
!" Sign indicates an electrical hazard from handling the ca-
ble.
Read manual for safe and proper handling. ZAXIS125US, 135US, 135USK, 135USL M1SE-07-014

ZAXIS225US, 225USLC M1GF-07-015

S-41
 SAFETY SIGNS/ Asia/Middle and Near East Model Only

M1SE-07-014

SS4460067
!" Sign indicates an explosion hazard.
Keep fire and open flames away from this area.

SS4460056
!" Skin contact with electrolyte will cause burns. Splashed
electrolyte into eyes will cause blindness. Take care not
to touch electrolyte.

S-42
 COMPONENTS NAME
COMPONENTS NAME

1- Bucket
2- Bucket Cylinder 3
2 4
3- Arm
4- Arm Cylinder
5- Boom Cylinder
6- Boom
7- Fuel Tank 5
8- Hydraulic Oil Tank
6
9- Engine
1
10- Counterweight 7
11- Travel Device
12- Track 8

13- Front Idler 9

14- Cab

14

13

12
10

11

M1SE-01-004

1-1
 OPERATOR'S STATION
CAB FEATURES 5 6
14 2 3 4
Std/L model
1- Left Control Lever/Horn Switch
(On Top of Lever)
2- Left Travel Pedal 7
3- Left Travel Lever
1
4- Right Travel Lever
8
5- Right Travel Pedal
13
6- Right Control Lever/Power Boost Switch 9
(On Top of Lever: ZAXIS225US, 225USLC) 12
10
7- Monitor Panel
8- Switch Panel
9- Key Switch 11

10- Air Conditioner Panel --- If Equipped

11- Operator’s Seat
12- Radio
13- Cab Door Release Lever
14- Pilot Control Shut-Off Lever
15- Fuse Box M1GF-01-004

16- Glove Compartment (Hot & Cool Box)

17- Cigar Lighter
18- Rear Switch Panel
16
19- Engine Stop Knob

15

M1GF-01-005

17

18

M1SE-01-002
19

M1CC-01-015

1-2
 OPERATOR'S STATION
CAB FEATURES
15 2 3 4 5 6 7
K model
1- Left Control Lever/Horn Switch
(On Top of Lever)
2- Left Travel Pedal 8
3- Left Travel Lever
1
4- Right Travel Lever
9
5- Right Travel Pedal
14
6- Attachment Pedal (ZAXIS135USK) 10

7- Right Control Lever/Power Boost Switch 13

11
(On Top of Lever: ZAXIS225US, 225USLC)
8- Monitor Panel
9- Switch Panel 12

10- Key Switch

11- Air Conditioner Panel --- If Equipped
12- Operator’s Seat
13- Radio
14- Cab Door Release Lever M1SE-01-103

15- Pilot Control Shut-Off Lever

16- Fuse Box
17- Glove Compartment (Hot & Cool Box)
17
18- Cigar Lighter
19- Rear Switch Panel 16

20- Engine Stop Knob

21- Switch Panel 2 (ZAXIS135USK)

M1GF-01-005

18

M1SE-01-002
20
19
21

M1CC-01-015

M157-01-183

1-3
 OPERATOR'S STATION
MONITOR PANEL
1 2
1- Coolant Temperature Gauge
2- Fuel Gauge
3- Display Selection Switch
4- Set Switch 17

5- Work Mode Switch 16

6- Fuel Level Indicator
15
7- Air Filter Restriction Indicator
8- Alternator Indicator 14
3
9- Hydraulic Oil Filter Restriction Indicator 13
(K and L Model)
10- Engine Oil Pressure Indicator 4

11- Preheat Indicator

5
12- Overheat Indicator
13- Digging Mode Indicator 6
12
14- Attachment Mode Indicator 7
11
8
15- Liquid Crystal Display (LCD) (Hour Meter, etc.) 10
16- Auto-Idle Indicator
9
17- Auto-Acceleration Indicator

M1SE-01-005

1-4
 OPERATOR'S STATION
COOLANT TEMPERATURE GAUGE

Engine coolant temperature is indicated. Coolant tem-

perature is normal when the needle stays in the middle
zone while operating.

M178-01-104

FUEL GAUGE

Fuel machine before needle reaches “E”.

M178-01-105

AUTO-IDLE INDICATOR

Green indicator will light when the auto-idle/acceleration

selector is turned to the A/I position.

M178-01-092

AUTO-ACCELERATION INDICATOR

Green indicator will light when the auto-idle/acceleration

selector is turned to the A/A position.

M178-01-093

1-5
 OPERATOR'S STATION
FUEL LEVEL INDICATOR

When red fuel indicator lights, approximately A liters of fuel

remain.

A: ZAXIS125US, 135US, 135USK, 135USL

30L (7.9 US gal)
ZAXIS225US, 225USLC 40L (10.0 US gal) M178-01-034

AIR FILTER RESTRICTION INDICATOR

Red indicator will light when the air filter elements are
clogged. Clean or replace outer element.

M178-01-035

OVERHEAT INDICATOR

IMPORTANT: Prevent possible engine damage. Do not

stop engine while this red indicator is
ON. Instead, reduce load and run engine
at slow idle. If overheat indicator con-
tinues to stay ON, shut engine off.
M178-01-036
Red indicator will light and buzzer will sound when the en-
gine coolant overheats. Reduce the load immediately and
run engine at slow idle. Inspect for debris around radiator.
Also, check for low coolant level in the reserve tank.

ENGINE OIL PRESSURE INDICATOR

IMPORTANT: Prevent possible engine damage.

If engine oil pressure indicator comes
on while operating, stop the engine im-
mediately.

Red indicator will light and buzzer will sound when engine M178-01-037
oil pressure is low. Stop the engine immediately. Check the
engine/hydraulic systems and oil levels for any abnormality.

NOTE: Cold oil, low oil level, or operating on a steep

slope may cause indicator to light.

ALTERNATOR INDICATOR

Red indicator will light with low alternator output. Check

electrical system. M178-01-038

1-6
 OPERATOR'S STATION
PREHEAT INDICATOR

Orange indicator will light when the key switch is turned to

ON position in cold weather. Light will turn off after a few
seconds, indicating that the preheat is completed.

M178-01-041

HYDRAULIC OIL FILTER RESTRICTION

INDICATOR (K Model)

Red indicator will light when the hydraulic oil filter element
is clogged. Clean or replace the filter element.
M1CC-01-039

1-7
 OPERATOR'S STATION
LIQUID CRYSTAL DISPLAY (LCD), DISPLAY
SELECTION SWITCH, SET SWITCH

LCD (15) displays 5 kinds of information such as Hour

Meter, Trip Meter 1, Trip Meter 2, Engine Speed, and Hy-
draulic Oil Temperature.

NOTE: Immediately after the key switch is turned “ON”,

the LCD always displays the Hour Meter. When 3
15
the machine is shipped from the factory, the
LCD is set not to display the Engine Speed and
the Hydraulic Oil Temperature. Contact your 4
nearest Hitachi Dealer if required to display
these kinds of information.

Selecting Display

Each time display selection switch (3) is pressed, the LCD

displays the Hour Meter, Trip Meter 1, and Trip Meter 2 in
that order. In case the LCD has been set to display the En-
gine Speed, and Hydraulic Oil Temperature, these kinds of
information will be displayed after the Trip Meter 2 is dis-
played.

M1G6-01-011

Hour Meter Mark

HOUR METER

The LCD displays the total hours of operation [accumu-

lated hours of operation] since the machine started working
in hour [h]. The tenth of an hour (6 minutes) is displayed by
one digit beyond decimal point. During the Hour Meter dis-
play, the hour meter mark lights on the display screen.
While the machine is operating, the decimal point flashes. M178-01-006
When Hour Meter is Displayed:

NOTE: The hour meter reading can be checked by de-

pressing display selection switch (3) for longer
than 0.5 seconds even though the key switch is
“OFF”. The LCD continues to display the hour
meter reading as long as display selection
switch (3) is kept depressed. When the switch
is released, the LCD stops displaying.

1-8
 OPERATOR'S STATION
TRIP METER
(TRIP METER 1 AND TRIP METER 2)

The remaining hours [h] of operation before the trip mark

start flashing is displayed. (Refer to page 1-9.) During Trip
Meter display, the trip mark (either [TRIP 1] or [TRIP 2]) is 3
indicated on the screen.
15
4

M1G6-01-011

ENGINE SPEED Trip Mark

-1
The LCD displays the engine speed in min . During En-
-1
gine Speed display, the engine speed mark and unit [min ]
are indicated at the bottom of the screen.

HYDRAULIC OIL TEMPERATURE

M178-01-007

The LCD displays the hydraulic oil temperature in !C. Dur- When Trip Meter 1 is displayed: Trip Mark
ing Hydraulic Oil Temperature display, unit [!C] is indicated
at the bottom of the screen.

NOTE: While displaying either ENGINE SPEED or

HYDRAULIC OIL TEMPERATURE, the letters
of “USER” is indicated on the screen. This is
not trouble but shows the current monitor con- M178-01-008

trol mode of the LCD. When Trip Meter 2 is displayed: Control Mode
Engine Indication
Speed
Mark

M1G6-01-009
When Engine Speed is displayed:
Control Mode Indication

Hydraulic Oil
Temperature
Mark

M1G6-01-010
When Hydraulic Oil Temperature is displayed:

1-9
 OPERATOR'S STATION
TRIP METER FUNCTION
When the hours of machine operation accumulates up to
the preparatorily set-hour, the trip meter advises the op-
erator that the remaining hours from the set-hour become
zero by flashing the trip mark either “TRIP 1” or “TRIP 2.” 3
The trip mark keeps flashing for 30 seconds when the
hours of machine operation accumulates up to the prepa- 15
ratorily set-hour. Until the trip meter is reset, the trip mark 4
flashes for 30 seconds each time the key switch is turned
“ON” afterward.
IMPORTANT: The hours of operation indicated on the
trip meter is the hours of machine opera-
tion counted after the trip meter is set, be-
ing different from the accumulated hours
of operation displayed by the hour meter.
NOTE: Regardless of the type of information the LCD
indicates, the trip meter function is kept acti-
vated once it is set. Therefore, whenever the
hours of operation accumulates to the set-hour, M1G6-01-011
the trip mark flashes irrespective of the cur-
rently displayed information.
When the trip mark flashes with the trip meter
displayed on the LCD, the trip mark stays “ON”
after flashing. In case information other than the
trip meter is display when the trip mark flashes,
the trip mark is deleted after flashing.
Trip Meter Setting
1. Turn the key switch “ON”. Display “Trip Meter 1” of Trip Mark
“Trip Meter 2” by operating display selection switch (3).

NOTE: Different hour setting can be made independ-

ently to “ Trip Meter 1” and “Trip Meter 2.”

2. Select the hour desired to set by pressing SET switch

(4). The set-hour shifts as follows each time SET M178-01-007
switch (4) is pressed. When Trip Meter 1 is displayed: Trip Mark
50 " 100 " 150 " 200 " 250 " 300 " 400 " 500 " 750
" 1000 " 1250 " 1500 " 2000 " 2500 " 3000 " 3500
" 4000 " 4500 " 5000
When the SET switch is kept depressed for 2 seconds, the
set-hour will shift in the fast forward (FF) mode.

3. When the hour desired to set is displayed, press dis- M178-01-008

play selection switch (3) to set the trip meter. When Trip Meter 2 is displayed:

NOTE: After the trip meter is set, the LCD (when the
trip meter is displayed) displays how many
hours are remaining before the hours of ma-
chine operation accumulates to the set-hour.
Accordingly, when trip mark flashes, the trip
meter indicates “0 hr.” Until the trip meter is re-
set, the excess hours (with mark “-“) of opera-
tion is displayed on the trip meter afterward.

1-10
 OPERATOR'S STATION
Resetting Set-Hour
1. Turn the key switch ON. Press display selection
switch (3) to display the trip meter desired to reset.
The trip meter will display the hours remaining before
the trip mark starts flashing at this time.
2. Each time SET switch (4) is pressed, the currently
remaining hours can be changed as shown below. 3

Currently Remaining Set-hour after Resetting

Time 4
35.2 # 50
184.7 # 200.0

3. Each time SET switch (4) is pressed further, the

set-hour will change as follows:
50 " 100 " 150 " 200 " 250 " 300 " 400 " 500 " 750
" 1000 " 1250 " 1500 " 2000 " 2500 " 3000 " 3500
" 4000 " 4500 " 5000
When the SET switch is kept depressed for 2 sec-
onds, the set-hour will shift in the fast forward (FF)
mode.
4. When the hour desired to set is displayed, press dis-
play selection switch (3) to reset the trip meter.
M1G6-01-011
IMPORTANT: When the set-hour is changed, the trip
meter starts counting the hours from the
Trip Mark
beginning. Accordingly, note that the
hours displayed after resetting differs
from the hours of operation accumu-
lated from the first setting of the trip
meter.

$% When the trip meter is not used: M178-01-007

When the trip meter is not used, set the sufficiently long When Trip Meter 1 is displayed: Trip Mark
hours of operation by following the procedure mentioned
above. (Example: 5000 hrs)

NOTE: The set-hour of the trip meter is 10000 hrs

when the machine is shipped from the factory.

M178-01-008
When Trip Meter 2 is displayed:

1-11
 OPERATOR'S STATION
WORK MODE SWITCH

Work mode either “Digging Mode” or “Attachment Mode”

can be selected by pressing work mode switch (5).

$% Digging Mode
Select when the machine is engaged in normal digging
works. Digging mode indicator (13) is ON while the dig-
ging mode is selected.
14
$% Attachment Mode
Select this mode when the machine is equipped with an
optional attachment. Attachment mode indicator (14) is 13
ON while the attachment mode is selected.
5

M1SE-01-005

1-12
 OPERATOR'S STATION
SWITCH PANEL
1
1- Engine Control Dial
2- Auto-Idle/Acceleration Selector
3- Power Mode Switch
4- Travel Mode Switch
5- Work Light Switch 2
6- Wiper/Washer Switch
3

M178-01-091

ENGINE CONTROL DIAL

Use engine control dial (1) to adjust engine speed.

Turn it clockwise to increase engine speed or counter-
Fast Idle
clockwise to decrease engine speed.

• The fully clockwise position : Fast idle 1

• The fully counterclockwise position : Slow idle Slow Idle

M178-01-011

1-13
 OPERATOR'S STATION
AUTO-IDLE/ACCELERATION SELECTOR

The auto-idle/acceleration selector sets the engine speed

control mode to either Auto-Idle or Auto-Acceleration.

!" Auto-Idle Mode

When the auto-idle/acceleration selector is turned to the
A/I position, the engine speed is reduced to slow idle
M178-01-094
speed 4 seconds after releaving all control levers (neu-
tral), reducing the fuel consumption. When the auto-idle
mode is selected, auto-idle indicator (1) on the monitor
panel lights.
!" Auto-Acceleration Mode
When the auto-idle/acceleration selector is turned to the 2
A/A position, the engine speed is controlled in response
to the control lever stroke. In addition, the engine speed
is reduced to slow idle speed 4 seconds after releasing 1
all control levers (neutral). Thereby, fuel consumption is
reduced more than in the auto-idle mode. When the
auto-acceleration mode is selected, auto-acceleration
indicator (2) on the monitor panel lights.

M1SE-01-005

1-14
 OPERATOR'S STATION
POWER MODE SWITCH

Three engine speed modes, E, P, and H/P modes, are se-

lected by operating the power mode switch.

!" E (Economy) Mode

Although production is slightly reduced more than in the
P mode, the fuel consumption and noise levels are re-
duced, allowing the machine to operate efficiently. M178-01-095

!" P Mode
Use the P mode when general digging work is needed.

!" H/P (High Power) Mode

Use the H/P mode when extra horsepower is needed, i.e.
when rolling in the arm in excavation work, etc.

TRAVEL MODE SWITCH

Two travel modes, FAST and SLOW, are selected by turn-

ing the travel mode switch to either position.

Mark (Fast Speed Mode)

Mark (Slow Speed Mode)
M178-01-096

1-15
 OPERATOR'S STATION
WORK LIGHT SWITCH

Work light switch has the following positions:

• 1 Position
Work light (1) on the base machine will light. Also, the
instrument panel illumination will light.
• 2 Position
M178-01-097
Work light (2) will light in addition.
• OFF Position
Work lights (1) and (2) and the instrument panel illu-
mination will turn off. 2

M1SE-01-003

1-16
 OPERATOR'S STATION
WIPER/WASHER SWITCH Fast

The wiper and the window washer are operated using the
wiper/washer switch.
Mid

!" Wiper
Slow
Turn the wiper/washer switch to the specified position to
operate the wiper.

OFF Position: The wiper stops and is retracted.

INT Position: The wiper operates intermittently at the
M178-01-098
interval selected by the switch position
as described below.
INT (Slow): The wiper operates at 8-second interval.
INT (Mid): The wiper operates at 6-second interval.
INT (Fast): The wiper operates at 3-second interval. Wiper
ON Position: The wiper operates continuously.

NOTE: When the front window (upper) is opened, the

wiper will not operate. If the front window is
opened while during operating the wiper, the
wiper will stop.

!" Washer
Press and hold the wiper/washer switch to squirt washer
fluid onto the front window. When the wiper/washer
switch is pressed for more than 2 seconds, the wiper
operates until the switch is released. When the
wiper/washer switch is released, the wiper automatically
retracts. While operating the wiper in the INT mode,
when the wiper/washer switch is pressed, the wiper op-
eration mode is changed to the continuous operation
mode.
M1CC-01-107

IMPORTANT: Washer motor may be damaged if

wiper/washer switch is held for more
than 20 seconds, or continually operated
with no fluid in the washer tank.

1-17
 OPERATOR'S STATION
!" Washer (K Model)
As long as the wiper washer switch is held down,
washer fluid will be squirted from the nozzles on the
front window and overhead window. Continue holding
the wiper washer switch for more than 2 seconds to
automatically operate the front window wiper. Release
the wiper washer switch to stop fluid from being squirted
from the nozzles and to automatically stop and retract
the wipers. While the wiper is operating in the INT posi-
tion, when the wiper washer switch is pushed, the wiper
will change to operate continuously.

IMPORTANT: The washer motor in the washer fluid

tank may be damaged if washer fluid is
kept squirted for more than 20 seconds
or the motor is continuously operated
with the washer fluid tank empty. Moni-
tor the washer fluid squirting time and
the fluid level in the washer reservoir.

Wiper Switch (K Model) (Overhead Window)

Wiper switch (1) has two positions as follows:

ON Position ## Overhead window wiper (2) operates.

OFF Position ## Overhead window wiper (2) stops.

M178-13-001

M157-01-183

M157-01-081

1-18
 OPERATOR'S STATION
Switch Pannel 2 (K Model)

1- Attachment Select Switch (Optional)

2- Crusher (Optional)
3- Pulverizer (Optional)
4- Breaker (Optional)
5- Wiper (Overhead Window)

M178-13-001

4 2 3

M157-01-182

1-19
 OPERATOR'S STATION
SWITCH PANEL (Optional)

NOTE: The optional switch locations differ depending

on the kinds of optional devices are equipped.
Before using the switches on the switch panel,
make sure what kind of optional devices are
equipped. All available optional devices are
shown below.

• Travel Alarm Deactivation Switch

• Swing Alarm Deactivation Switch
• Rear Light Switch Optional Switch
M1CC-01-015

Travel Alarm Deactivation Switch (Optional)

The travel alarm buzzer sounds during travel operation.
When push the travel alarm deactivation switch, the
travel alarm buzzer function is deactivated.

Swing Alarm Switch (Optional)

The swing alarm system sounds the buzzer and turns
the beacon light ON during swing operation. When the
swing alarm deactivation switch is set to the OFF posi-
tion, the swing alarm buzzer function is deactivated.

1-20
 OPERATOR'S STATION
KEY SWITCH 2 3
1- OFF (Engine Off) 1 4

2- ACC (Horn, Radio etc.)

3- ON (Engine On)
4- START (Engine Start)

M178-01-049

POWER BOOST SWITCH

ZAXIS225US, 225USLC 5

Power boost switch (5) is used to gain maximum digging

power, and is located on the top of the right control lever.

HORN SWITCH M1GF-01-004

Horn switch (6) is provided on the top of the left control

lever. The horn continuously sounds as long as the switch
is pressed.
6

M1GF-01-004

1-21
 OPERATOR'S STATION
CIGAR LIGHTER

Operation
1
IMPORTANT: In case cigar lighter (2) doesn’t pop out
automatically 30 seconds after pushing
cigar lighter (2) in, pull out cigar lighter
(2) manually. Then, consult the your
nearest Hitachi dealer.

1. Turn key switch (1) to the ACC or ON position.

2. Press and release cigar lighter (2) knob.
3. Cigar lighter (2) knob will return to the original posi- M178-01-049

tion when cigar lighter (2) becomes usable. Pull the

cigar lighter out to use.
2
4. After using cigar lighter (2), insert cigar lighter (2) into
the panel until the knob is seated in the original posi-
tion.

Using Cigar lighter (2) Port as External Power

Source
Use cigar lighter (2) port to supply power to lighting
equipment for servicing the machine.

IMPORTANT: Only 24 V electric power is available

from the cigar lighter port on this ma-
M1CC-01-015
chine. Never connect accessories that
use power other than 24 V. Damage to
the batteries and accessories may result.
Don’t supply power to accessories for a
long time without running the engine.
Failure to do so may discharge the bat-
teries.

1. Pull cigar lighter (2) knob out.

2. Correctly insert the accessory socket into cigar lighter
(2) port.
3. Turn key switch (1) to the ACC or ON position. Power
is supplied to the connected accessory.
4. After using the accessory, disconnect the accessory
socket and insert cigar lighter (2) into the port.

1-22
 OPERATOR'S STATION
CAB LIGHT

Turn the cab light ON or OFF by using switch (1).

INSTALLING FIRE EXTINGUISHER

A fire extinguisher can be installed at the right rear corner M1CC-01-016

inside the cab. Consult your nearest HITACHI dealer to in-
stall a fire extinguisher.
Fire Extinguisher

M1CC-01-042

1-23
 OPERATOR'S STATION
PILOT CONTROL SHUT-OFF LEVER

Pilot control shut-off lever (1) functions to prevent the ma-

chine from being mistakenly operated when the operator is
getting on or off the machine.
The pilot control shut-off lever is moves backward together 1
with the console spring back mechanism, making mount-
ing/dismounting the machine and maintenance work eas-
ier.

CAUTION:
1. Pilot control will not be shut-off unless pilot
control shut-off lever (1) is completely
pulled-up to the LOCK position.
LOCK Position M1CC-01-017

2. Before leaving the operator's seat, always

stop the engine and pull the pilot control
shut-off lever up to the LOCK position.
3. Also, pull the pilot control shut-off lever up to
the LOCK position when transporting the
machine or when the day's work is complete. 1

4. Confirm that the pilot control shut-off lever is

in the LOCK position before starting the en-
gine.
5. When moving the pilot control shut-off lever
to the UNLOCK position, take care not to ac-
tivate other control levers by mistake. The
machine may be unexpectedly operated, pos-
sibly causing an accident or personal injury. UNLOCK Position M1CC-00-009

ENGINE STOP KNOB

If the engine does not stop when the key switch is turned to
the OFF position, (due to a machine or key switch malfunc-
tion), pull engine stop knob (2) all the way to the stop. The
engine will stop. M1SE-01-002
2

NOTE: If the knob is pulled halfway, the engine may

not start or may stall during operation. Be sure
to push the knob to the fully retracted position
before restarting the engine.

1-24
 OPERATOR'S STATION
FUSE BOX

10- OPTION 3 20- SPARE

5A
9- OPTION 2 19- GLOW. R
10A 5A
8- OPTION 1 18- AUXILIARY
5A 10A
7- AIRCON 17- ROOM LAMP
5A 5A
6- POW. ON 16- LIGHTER
5A 10A
5- SWBOX 15- RADIO
5A 5A M1CC-01-018

4- SOLENOID 14- HORN

10A 10A 20 19 18 17 16 15 14 13 12 11
3- EC. MOTOR 13- HEATER
10A 20A
2- CONTROLLER 12- WIPER
5A 10A
1- BACKUP 11- LAMP
5A 20A

10 9 8 7 6 5 4 3 2 1

M1CC-01-007

1-25
 OPERATOR'S STATION
AIR CONDITIONER (OPTIONAL)

Features:

!" Full-Automatic Control

Regardless of variations in atmospheric temperature
and whether sun light is intense or not, the air tempera-
ture at the vent, blower speed, and air in/out vent loca-
tions are automatically controlled so that air temperature
in the cab is maintained at the temperature set by the
temperature control switch.

!" Highest and Lowest Temperature Control

Highest or lowest air temperature in the cab is set by
turning either the FH (Full-Heat) or FC (Full-Cool) indi-
cator ON using the temperature control switch.

!" Heater Start-Operation Control System

In winter or in cold weather, when starting the engine,
the engine coolant is cool and air temperature inside the
cab is low. Then, cool air is restricted not to flow in the
cab to the minimum (LO) until the coolant is warmed
when the front foot vent and /or foot vent is selected.

1-26
 OPERATOR'S STATION
Part Name 1

1- Front Vent
2- Foot Vent
3- Defroster Vent
4- Rear Vent
5- Control Panel
6- Blower Switch
7- Liquid Crystal Display (LCD)
8- Air Conditioner Switch
9- AUTO Switch
3 2 M1CC-01-017
10- OFF Switch 4

11- Temperature Control Switch

12- Circulation Mode Switch
13- Fresh Air Mode Switch
14- MODE Switch

NOTE: Except for the foot vent, all vents are provided
with louvers to adjust the air flow direction. In
addition, the louvers on the front vent and de-
froster vent can be completely opened and
closed by hand. M1CC-01-018

5 6 7 8 9

14 13 12 11 10
M178-01-073

1-27
 OPERATOR'S STATION
Control Panel Designation and Function 7 9

• Mode Switch (14):

Selects the air vent. The selected air vent is indicated
on LCD (7).

Air flows out of front vent and the defroster

vents. 14 M178-01-074

Air flows out of the front and rear vents and

the defroster vents. Display when AUTO switch (9) is pressed:
Air flows out of the front and foot vents and
the defroster vents.
Air flows out of the foot vents.
Each time mode switch (14) is pressed, the vent location
can be changed in four stages as illustrated below.

AUTO# # # #

• When AUTO switch (9) is selected the AUTO, the air

7 11
vent location is automatically selected.
!" Temperature Control Switch (11):
Sets temperature in the cab from 18.0 to 32.0$C or 63 to
91$F by 0.5$C or 1$F step. The set-temperature is dis-
played on LCD (7).
• FC (Full-Cool)
Push the button after setting air temperature to M178-01-075

18$C (65$F). Air flow temperature is set to the lowest Display when the button is pressed
and the “FC” symbol is displayed on LCD (7). after displaying 25.0$C (77$F).
• FH (Full-Heat)
Push the button after setting air temperature to
32$C (90$F). Air flow temperature is set to the highest
and the “FH” symbol is displayed on LCD (7).
• When the AUTO indicator is ON, air temperature at
the vents is automatically set together with the blower
speed and vent locations.
AUTO Indicator
• When the AUTO indicator is OFF, only air temperature 7
at the vents is automatically set.
• When the “FC” symbol is displayed on LCD (7), air
temperature at the vent, air vent (front and rear vents)
locations, recirculation air suction port, and blower
speed are maintained at the lowest cooling conditions.
However, in case the circulation indicator is ON before
the “FC” symbol is displayed, circulation operation is M178-01-076
maintained. 9 11
Display when the LCD displays %FC& symbol.

1-28
 OPERATOR'S STATION
• When the “FH” symbol is displayed on LCD (7), air
flow-in temperature at the vent, air vent (front and rear 7 8
vents) locations, fresh air suction port, and blower
speed are maintained at the highest heating condi-
tions. However, in case the circulation indicator is ON
before the “FH” symbol is displayed, circulation opera-
tion is maintained.
Selecting Display Between Celsius And Fahrenheit
1. While depressing both (8) A/C and mode (15) switches, 15 13 M178-01-077
turn the key switch “ON”.
Display when the LCD displays %FH& symbol.
2. The LCD will display “Sd” for approx. 5 seconds.
3. After display “Sd” is deleted, all LED will come ON.
4. After all LED come ON, repeat to press the blower switch
(6) four times.
5. Sequentially, press the A/C (8) and blower (6) switches at
the same time.
6. Then, the selection mode between celsius and fahrenheit
starts.
Each time the fresh air mode switch (13) is pressed, the
display is shifted between celsius and fahrenheit.
When celsius is displayed, the LED displays “C.”
When fahrenheit is displayed, the LED displays “F.”
Select either one to be preferred.
7. After selection is complete, end by turning the key switch
“OFF”.
The LED will display in the selected mode when the
machine is operated next time.
6 AUTO Indicator
Display on LCD
Celsius ($C) 18.0 to 32.0
Fahrenheit ($F) 63 to 91
!" Blower Switch (6)
• When the AUTO indicator is ON, the blower speed is
automatically controlled.
• When the AUTO indicator is OFF, the blower speed is con-
trolled in 4 steps. When the button is pressed with M178-01-075

the blower OFF, the blower starts running in the HI mode.

Then, each time the button is pressed, the blower
speed is reduced by one step. The LCD indicates the
blower fan speed. When the button is pressed with
the blower OFF, the blower starts running in the LO mode.
Then, each time the button is pressed, the blower
speed is increased by one step. The LCD indicates the
corresponding blower fan speed.
!" Circulation Mode Switch (12):
!" Fresh Air Mode Switch (13):
Changes the air circulation mode and automatically selects
the air vent. When fresh air mode switch (13) is pressed,
the indicator comes ON and the fresh air circulation mode
is selected, allowing fresh air to flow in. When fresh air
mode switch (13) is pressed again, the indicator goes OFF M178-01-078
13 12
and the fresh air suction port is closed. When circulation
mode switch (12) is pressed, the indicator comes ON and
the circulation mode is selected. When circulation mode Display when fresh air vent switch (13) is pressed.
switch (12) is pressed again, the indicator goes OFF and
the fresh air suction port is opened.
NOTE: Operating the above switches controls the fresh air
suction port manually or automatically. Therefore,
even if the AUTO switch is turned ON, the fresh air
suction port status will not be changed.

1-29
 OPERATOR'S STATION
!" Air Conditioner (A/C) Switch (8)
A/C Indicator
Press A/C switch (8) to turn the cooler and the A/C indi- 8
cator ON. However, unless the blower is running (the fan
display of blower switch (6) is lit), the cooler will not be
turned ON.

!" OFF Switch (10)

Press OFF switch (10) to turn the blower and the air
conditioner OFF.
6 10
M178-01-075
!" AUTO Switch (9) Display when Air Conditioner Switch (8) is pressed:
Press AUTO switch (9) to turn the AUTO and the A/C AUTO Indicator
indicators ON so that the air flow-in temperature at the 9
vent, blower speed, vent locations, and fresh air suction
port are automatically controlled.

M178-01-075
Display when AUTO Switch (9) is pressed:

CAB HEATER OPERATION

1. Operate the AUTO switch.

According to signals sent from various sensors, the
air conditioner amplifier automatically selects the air
flow-in vents, air suction ports, and air flow-in tem-
perature at the vent, and controls the blower speed.
7 8 9
2. Operate Temperature Control Switch (11).
Set temperature control switch (11) so that %25.0& is
indicated on LCD (7). Control air temperature inside
cab using this switch as necessary.
3. As Necessary:
• Operate MODE switch (14) to manually select the air
M178-01-079
vent.
6 14 13 12 11
• Operate blower switch (6) to manually control the
blower speed.
• Operate fresh air mode switch (13) to maintain the air
vent in the fresh air circulation mode.
• Operate circulation mode switch (12) to maintain the
air suction port in the circulation mode.

When the A/C indicator is ON, the air conditioner functions

dehumidifier. Press A/C switch (8) to turn OFF the dehu-
midifier function.

1-30
 OPERATOR'S STATION
COOLING OPERATION
7 8 9
1. Press AUTO Switch (9)
The AUTO and the A/C indicators come ON. Then,
the air temperature at the vent, blower speed, vent
locations, and air suction ports are automatically con-
trolled by the air conditioner amplifier according to
signals sent from various sensors.
2. Operate Temperature Control Switch (11). M178-01-075
6 14 13 12 11
Set temperature control switch (11) so that %25.0& is
indicated on LCD (7). Control air temperature inside
the cab using this switch as necessary.
3. As Necessary:
• Operate MODE switch (14) to manually select the air
vent.
• Operate blower switch (6) to manually control the
blower speed.
• Operate fresh air mode switch (13) to maintain the air
vent in the fresh air circulation mode.
• Operate circulation mode switch (12) to maintain the
air suction port in the circulation mode.
In case the front window (lower) becomes clouded, manu- 3 M1CC-01-017

ally close the defroster vent (3).

DEFROSTER OPERATION 7 8 9
1. Press AUTO Switch (9). Temperature-controlled air
blows out. During cold weather season when starting
the engine, the engine coolant temperature and air
temperature in the cab are low. Then, cool air is re-
stricted not to flow in the cab to the minimum (LO) by
the Heater Start-Operation Control System.
2. Set temperature control switch (11) so that %25.0& is
M178-01-074
14 13 11
indicated on LCD (7). Set fresh air vent switch (13) in
the fresh air circulation mode. 1

3. Select the front vents or the front and rear

vents using MODE switch (14).

Control air flow direction by adjusting the louvers at the

front vent (1) and the defroster vent (3).

Control air temperature in the cab by operating tempera-

ture control switch (11). If the windowpanes become
clouded in rainy season or when dehumidifying, turn the
indicator of A/C switch (8) ON.

3 M1CC-01-017

1-31
 OPERATOR'S STATION
Cool Head / Warm Feet Operation
6
Cool and warm air is simultaneously supplied to the 8
head vents and feet vents respectively.

1. Press blower switch (6) to adjust the blower speed.

2. Press MODE switch (14) to display the front and rear
vent mark on the liquid crystal panel. Then,
M178-01-080
turn A/C switch (8) ON (indicator lights). 14 11

Control air temperature inside the cab by operating tem-

perature control switch (11).

1-32
 OPERATOR'S STATION
TIPS FOR OPTIMAL AIR CONDITIONER US-
AGE
7 9
For Rapid Cooling
Temperature in the cab may rise over 80$C (176$F)
when the machine is exposed to sun light in the sum-
mer.
In this case, ventilate air in the cab first by opening the
windows for rapid cooling. After starting the engine,
M178-01-081
press AUTO switch (9). Set temperature to %18.0& on 11
12
LCD (7) using temperature control switch (11). Turn cir-
culation mode switch (12) ON.

When Windows Become Clouded

If the insides of the windows become clouded during
rainy weather or on humid days, operate the air condi-
tioner to aid in keeping the windows clear. When the
atmosphere is very damp, and if the air conditioner has
run excessively, the outside of the windows may become
clouded. If this happens, turn off the air conditioner to
adjust the temperature in the cab.

Off-Season Air Conditioner Maintenance

To protect each part of the compressor from a lack of
lubricant, operate the air conditioner at least once a
month for several minutes with the engine running at a
slow speed during off-season. When the cab tempera-
ture is lower than 15$C (59$F), the air conditioner may
not operate. If this happens, warm the cab using the Air Conditioner Sensor
heater first.

IMPORTANT: ! Do not suddenly increase the engine

speed.
! Refer to the item “Check Air Condi-
tioner Filter” in the Maintenance Sec-
tion for maintenance of the air condi-
tioner filters.
! Always clean the auto air conditioner
sensor for effective air conditioner
performance. Avoid placing any ob-
structions around the sensor.

M178-01-082

1-33
 OPERATOR'S STATION
CAB HEATER (OPTIONAL) 1

Part Name and Location

1- Front Vent
2- Foot Vent
3- Defroster Vent
4- Rear Vent
5- Control Panel
6- Mode Switch
7- Fresh Air Vent Switch
8- Temperature Control Switch 3 2 M1CC-01-017
4
9- Blower Switch
10- OFF Switch

NOTE: Air flow direction can be changed by controlling

the louvers at all air vents except for the foot
vents. The louvers at the front and defroster
vents can be manually opened or closed.

Control Panel Designation and Function

• Mode Switch (6):
Selects the air vent. M1CC-01-018

Air flows out of the front vents and the

5 6 7
defroster vents.
Air flows out of the front and rear vents
and the defroster vents.

Air flows out of the foot vents.

Temperature Control Switch (8)

One of 8 indicators is lit. The air flow temperature at the M178-01-072
vent is lower or higher as the indicator closer to the left or 10 9 8
right end is lit respectively. Both warmed and cooled air
flow out of the same air vent.

1-34
 OPERATOR'S STATION

• Blower Switch (9)

The blower speed is controlled from Lo to Hi in 4
steps. When the button is pressed first, the
blower starts running in the HI mode. Then, each time
the button is pressed, the blower speed is re-
duced by one step. The blower speed indicator corre-
sponding to the blower speed is lit. When the
button is pressed first, the blower starts running in the
LO mode. Then, each time the button is M178-01-072
10 9
pressed, the blower speed is increased by one step.
Press OFF switch (10) to stop the blower operation.

7
• Fresh Air Mode Switch (7):
Changes the air circulation mode. When fresh air vent
switch (7) is pressed, the indicator comes ON and the
fresh air circulation mode is selected, allowing fresh
air to flow in. When fresh air mode switch (7) is
pressed again, the indicator goes OFF and the circu-
lation mode is selected.
M178-01-072

1-35
 OPERATOR'S STATION
CAB HEATER OPERATION
6
When any mode switches (6) are pressed ( , ,
), warm air will flow out from the corresponding vent.
However, the foot vent mode is commonly used for
cab heating.

Press foot mode switch (6). Set temperature control

switch (8) to the right end position.
M178-01-072
Press blower switch (9) to blow warm air out of the foot 9 8
vents. Adjust the air temperature in the cab by operating
temperature control switch (8) and blower switch (9). When
required to quickly increase air temperature in the cab, se-
lect the air recirculation mode. However, if air recirculation
mode is used for a long time, the windowpanes will be-
come clouded due to a difference in temperature between
outside and inside the cab. Occasionally ventilate the cab.
(When the fresh air circulation mode is selected, the win-
dowpanes will be prevented from becoming clouded.)

M1CC-01-017

1-36
 OPERATOR'S STATION
DEFROSTER OPERATION
6 7
Press mode switch (6) (either the front or front/rear
vent mode switch). Set temperature control switch (8)
to the heat operation position. Press fresh air mode switch
(7).

Press blower switch (9). Warm air will blow out from the
front or front/ rear vents.
M178-01-072
Adjust air flow direction from front vent (1) and defroster 9 8
vent (3) by controlling the louver direction.
1
Use temperature control switch (8) and blower switch (9) to
adjust air temperature in the cab.

M1CC-01-017
3

1-37
 OPERATOR'S STATION
AM/FM RADIO OPERATION 7 6 5 2

Controls on the radio

1- Power Switch/Volume Control Knob
2- Tone Adjustment Ring
3- AM/FM Switch
4- Station Presets
5- Tuning Switches 8 9 4 3 1
6- Display Mode Change Switch M157-01-027

7- Digital Display
8- Time Set Switches
9- Set Switch

Tuning Procedure
• Manual Tuning Procedure
Repeatedly tap one of tuning switches (5) until the de-
sired station is reached.
Each time the tuning switch is pressed, the frequency
changes at an interval.
Tap the tuning switch ( ) to increase the fre-
quency.
Tap the tuning switch ( ) to decrease the fre-
quency.

Digital display (7) will return to the setting (the clock or

the frequency, whichever one is set by the display
mode change switch) approximately 5 seconds after
tuning switches (5) are no longer tapped or pressed.

• Automatic Search Function

Press and hold one tuning switch (5) for more than
half a second until an electronic tone is heard, then
release. The frequency display will move up to the
next higher frequency station.
To go up to the next higher frequency station, press
and hold the tuning switch ( ).
To go down to the next lower frequency station,
press and hold the tuning switch ( ).

After displaying the next frequency station, digital dis-

play (7) will return to the setting (the clock or the fre-
quency, whichever one is set by the display mode
change switch) in approximately 5 seconds.
In order to deactivate the automatic search function
while it is operating (while searching the next available
frequency station), simply tap tuning switch (5) again.
If the receiving radio waves are weak, i. e. such as
when the machine is located between high rising
buildings, etc., use the manual tuning procedure to
select the desired station.

1-38
 OPERATOR'S STATION
Station Presetting Procedure 7 5
1. Select the desired station using tuning switches (5).
(Refer to the “Tuning Procedure” section.)
2. Press and hold one station preset (4) for more than 2
seconds until an electronic tone is heard. Now, the
selected station is preset for the selected station
preset. The frequency of the preset station will be in-
dicated on digital display (7).

Once the presetting is complete for a station preset (4), 4

the radio will be tuned to the preset station when station M157-01-027
preset (4) is pressed (for less than 2 seconds).

DIGITAL CLOCK SETTING PROCEDURE

7 6
NOTE: In order to set the clock, digital display (7) must
be in the time display mode.

1. Press and hold display mode change switch (6).

While holding display mode change switch (6), use
time set switches (8) and/or set switch (9) to set the
clock.
The functions of time set switches (8) and set switch
(9) are as follows: 8 9

• Time Set Switch (H): Each time set switch (H) is M157-01-027
pressed, the hour display will increase by one.
• Time Set Switch (M): Each time set switch (M) is
pressed, the minute display will increase by one.
(The time is displayed in 12 hour standard.)

If either of the switches (H) or (M) is pressed and

held, the hour or minute display will change continu-
ously until the switch is released.
• Set Switch (SET) (9): If set switch (SET) (9) is
pressed, the minute display will be reset to “00.”
• If the minute display is “29” or smaller when set
switch (SET) (9) is pressed, the display will be reset
to “00” without changing the hour display.
• If the minute display is “30” or larger when set
switch (SET) (9) is pressed, the hour display will be
increased by one and the minute display will be re-
set to “00.”

For example, if set switch (SET) (9) is pressed when

the clock display is “10:29” and “10:30”, the clock dis-
play will change to “10:00” and “11:00” respectively.

1-39
 OPERATOR'S STATION
AM/FM RADIO OPERATION
4 7 5 2
Controls on the radio
1- Power Switch/Volume Control Knob
2- Tone Adjustment Ring
3- AM/FM Switch
4- Station Presets
5- Tuning Switches
3 6 8 1
6- Display Mode Change Switch
M1G6-01-026
7- Digital Display
8- Time Set Switches

Tuning Procedure
• Manual Tuning Procedure
Repeatedly tap one of tuning switches (5) until the de-
sired station is reached.
Each time the tuning switch is pressed, the frequency
changes at an interval.
Tap the tuning switch [UP] ( ) to increase the fre-
quency.
Tap the tuning switch [DOWN] ( ) to decrease the
frequency.

• Automatic Search Function

Press and hold one tuning switch (5) for more than
half a second, then release. The frequency display will
move up to the next higher frequency station.
To go up to the next higher frequency station, press
and hold the tuning switch [UP] ( ).
To go down to the next lower frequency station,
press and hold the tuning switch [DOWN] ( ).

In order to deactivate the automatic search function

while it is operating (while searching the next available
frequency station), simply tap tuning switch (5) again.
If the receiving radio waves are weak, i. e. such as
when the machine is located between high rising
buildings, etc., use the manual tuning procedure to
select the desired station.

1-40
 OPERATOR'S STATION
Station Presetting Procedure
4
1. Select the desired station using tuning switches (5). 7
(Refer to the “Tuning Procedure” section.)
2. Press and hold one station preset (4) for more than
1 second until an electronic tone is heard. Now, the
selected station is preset for the selected station
preset. The frequency of the preset station will be in-
dicated on digital display (7).

M1G6-01-026
Once the presetting is complete for a station preset (4), 5
the radio will be tuned to the preset station when station
preset (4) is pressed (for less than 1 second).

DIGITAL CLOCK SETTING PROCEDURE 7

NOTE: In order to set the clock, digital display (7) must

be in the time display mode.

1. Press display mode button (6) to indicate the hour

display on digital display (7).
2. Press and hold time set button (RST) (8) for longer
than 1 second. The hour display will start flashing and 6 8 M1G6-01-026

the time set mode will be selected.

3. Press time set button (H or M) (8) to set the clock.
Each time time set button (H or M) (8) is pressed, the
time display will increase by one. If time set button (H
or M) (8) is pressed and held, the time display will
change continuously.
• When setting the hour, pres time set button (H) (8).
• When setting the minute, press time set button (M)
(8).
The time is displayed in 12 hour standard.
If either of the switches (H) or (M) is pressed and
held, the hour or minute display will change continu-
ously until the switch is released.
4. When the hour display is “12,” if time set button (H)
(8) is pressed, the hour display will be reset to “1.”
When the minute display is “59,” if time set button
(M)(8) is pressed, the minute display will be reset to
“00.” However, the hour display remains unchanged
in this case.
5. After the clock setting is complete, press and hold
time set button (RST)(8) again for longer than 1 sec-
ond, or turn the radio switch OFF to end the clock
time setting procedure. Digital display (7) stops
flashing and changes to stay ON.

1-41
 OPERATOR'S STATION
CAB DOOR RELEASE LEVER
1

CAUTION: Open the cab door all the way until it

securely locks in the latch on the side of the cab.

To unlock the door from this position, push down on lever

(1).

M1CC-01-019

OPENING UPPER FRONT WINDOW

1. Push down lock release lever (2) at the upper center

to release the upper front window lock.

2. Holding the upper and lower handles (one each) on

the upper front window, pull the upper front window 2
up and back until it securely catches into auto lock
(4).

CAUTION: Always secure lock pin (3) in the lock M1CC-01-021

position after the upper front window is opened.

3. After confirming that the window securely catches

into auto lock (4), slide lock pin (3) into the left
bracket boss hole to lock the window in position.

NOTE: When the upper front window is opened, the

wiper and washer are inoperable.

M1CC-01-020

3
2

M1CC-01-031

1-42
 OPERATOR'S STATION
CLOSING UPPER FRONT WINDOW

CAUTION: Avoid possible injury while closing

window. 3
2
Upper front window comes down very forcefully.
Close window only when sitting in the operator's
seat. Guide window down slowly.

1. Pull out lock pin (3) to unlock window.

2. Slightly move the window forward while pushing lock 4
release lever (2) to release auto lock (4).
3. Pull window down slowly until it securely catches into M1CC-01-031
auto lock (5).

NOTE: The wiper and washer won’t operate until the

upper front window is completely closed.

M1CC-01-020

5 5

M1CC-01-021

1-43
 OPERATOR'S STATION
REMOVING AND STORING LOWER FRONT
WINDOW

CAUTION: Take care not to pinch yours fingers

when handling the lower front window.

1. Open the upper front window beforehand when re-

moving the lower front window.
2. While pulling the lower front widow upward, remove
it.
3. Store the removed windowpane in the storing position.
After inserting the windowpane into rubbers (2 and 3),
slide it sideways securely into rubber (1). Then, push
fastener (4) to lock. M1CC-01-022

1
4

3
2

M1CC-01-023

1-44
 OPERATOR'S STATION
OPENING SIDE WINDOWS

Opening Cab Door Window

Slide rear pane to the front.

Cab Door Window M1CC-01-026

1-45
 OPERATOR'S STATION
OPENING/CLOSING OVERHEAD WINDOW 1

Opening
1. Move lock levers (1) toward center of window.
2. Hold handle (2) and lift window until it rises upright.
With the window positioned upright, it will be secured
in position by dampers (3).

Closing
1. Hold handle (2) and pull window down until “click”
sound is heard from locks (1).
M1CC-01-027
2
Note that the overhead window can be used as an 3
emergency exit.

OPENING/CLOSING OVERHEAD WINDOW M1CC-01-028

(Clear Hatch: If Equipped)
1
Opening
1. Move lock levers (1) toward center of window.
2. Hold handle (2) and lift window until it rises upright.
With the window positioned upright, it will be secured
in position by dampers (3).

Closing
1. Hold handle (2) and pull window down until “click”
sound is heard from locks (1).

Note that the overhead window can be used as an M1CC-01-027

2
emergency exit.
3

IMPORTANT:
1. Replace the clear hatch with a new one every 5
years even if undamaged. In case it was remarka-
bly damaged or has received severe shock loads,
replace it even if it has been not in use for 5
years.
2. When cleaning the clear hatch, use a neutral de-
tergent. If acidic or alkaline detergent is used, the M1CC-01-028
clear hatch may become discolored or crack.
3. Keep organic solvent away from the clear hatch.
Failure to do so may cause the clear hatch to be-
come discolored or crack.

1-46
 OPERATOR'S STATION
EMERGENCY EXIT

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.
1

NOTE: See page 1-38 “OPENING UPPER FRONT

WINDOWS” for the opening method of the front
windows.

CAUTION: Take care not to be injured with

pieces of broken glass .

2. If the front window is difficult to open, break the front

window glass using the emergency evacuation tool
(1). Then, escape through the broken window.
3. If the front window is not available for escaping, break
M1CC-01-016
the rear window glass using the emergency evacua-
tion tool. Then, escape through the broken window.

NOTE: Emergency exit decals (2) are affixed to the

front and rear windows..

4. If neither of front and rear windows are available for

emergency exit, open the overhead window to es-
cape from the cab.
2

M1CC-01-032

M1CC-01-033

1-47
 OPERATOR'S STATION
ADJUSTING THE SEAT

Seat height and angle adjustment

Seat height adjustment range is 60 mm (2.4 in) with
steps every 15 mm (0.6 in) (5 positions in total). More-
over, the height of the front part and the rear part of the
seat are adjusted independently, thus allowing the angle
of the seat to be adjusted.

CAUTION: Avoid possible injury while operating

lever (1). When pushing down lever (1), do not
grab it. Fingers may be pinched between lever (1)
and the seat stand. Be sure to push on the upper Caution: Possibility of Push down with the
face of lever (1). pinched fingers palm.
SS-747
Use lever (1) to adjust the seat height and/or seat angle
as follows:
• To adjust the front part of the seat
Push down lever (1) while sitting on the seat, and ap- 1
4 3
ply or remove body weight to obtain the desired height.
When the desired height is obtained, release lever (1).
• To adjust the rear part of the seat
Pull up lever (1) while sitting on the seat, and apply or
remove body weight to obtain the desired height.
When the desired height is obtained, release lever (1).
Console and seat fore-aft adjustment 2

Pull lever (2) to the right to adjust the seat and both right
and left consoles to the desired distance from the travel
pedals and levers. Release lever to lock seat and con-
soles into position.

NOTE: Seat and console fore-aft adjustment range is

120 mm (4.7 in) with steps every 20 mm (0.8
in). M1SE-01-002

CAUTION: In case the control levers are pulled

fully backward with the seat in the forward most
position, the control levers may come in contact
with the arm rest. Always check that the levers 5
can be fully stroked before starting operation.
Seat fore-aft adjustment
6
Pull lever (3) to the right to unlock the seat from both
consoles. With lever held to the right, slide the seat to
the desired distance from pilot control levers. Release
the lever.

NOTE: Seat fore-aft adjustment range is 160 mm (6.3

in) with steps every 16mm (0.8 in). M1G6-01-017

Backrest adjustment
Push lever (4) forward to release backrest lock. Move
backrest to the desired position and release lever.
Armrest adjustment
Armrest (5) can be pulled upright by hand for easy get-
ting on and off the machine.
The angle of armrest (5) can be adjusted in the desired
position by turning adjusting dial (6) located on the bot-
tom of armrest (5).

1-48
 OPERATOR'S STATION
Headrest Adjustment 60 degrees 7
Headrest height and angle can be adjusted.
Pull headrest (7) upward or push downward to the de-
sired position. (Height adjustment range: 50 mm (2.0 in))
Headrest (7) can be adjusted 60 degrees forward from
the upright position. Move headrest by hands to the de-
sired angle.

M1G6-01-017

1-49
 OPERATOR'S STATION
ADJUSTING THE SEAT --- IF EQUIPPED

Seat Height and Angle Adjustment

Seat height adjustment range is 60 mm (2.4 in) with
steps every 15 mm (0.6 in) (5 positions in total). More-
over, the height of the front part and the rear part of the
seat are adjusted independently, thus allowing the angle
of the seat to be adjusted.
CAUTION: Avoid possible injury while operating
lever (1). When pushing down lever (1), do not
grab it. Fingers may be pinched between lever (1)
and the seat stand. Be sure to push on the upper
Caution: Possibility Push down with SS-747
face of lever (1). of pinched fingers the palm.
Use lever (1) to adjust the seat height and/or seat angle
as follows:
• To adjust the front part of the seat:
Push down lever (1) while sitting on the seat, and ap-
ply or remove body weight to obtain the desired height.
When the desired height is obtained, release lever (1).
• To adjust the rear part of the seat:
Pull up lever (1) while sitting on the seat, and apply or
remove body weight to obtain the desired height.
When the desired height is obtained, release lever (1). 1

Console and Seat Fore-aft Adjustment

5
Pull lever (2) to the right to adjust the seat and both right
and left consoles to desired distance from the travel
pedals and levers. Release lever to lock seat and con-
soles into position.
NOTE: Seat and console fore-aft adjustment range is
2
60 mm (2.4 in) with steps every 20 mm (0.8 in).
CAUTION: In case the control levers are pulled 4 3 M1GF-01-006

fully backward with the seat in the forward most

position, the control levers may come in contact
with the arm rest. Always check that the levers
can be fully stroked before starting operation.
Seat Fore-Aft Adjustment
Pull lever (3) to the right to unlock the seat from both
consoles. With lever held to the right, slide the seat to
the desired distance from pilot control levers. Release
the lever.
NOTE: Seat fore-aft adjustment range is 160 mm (6.3
in) with steps every 16 mm (0.8 in).
Suspension Adjustment
Turn knob (4) clockwise to increase suspension stiff-
ness.
Turn knob counterclockwise to decrease suspension
stiffness.
Backrest Adjustment
Pull up lever (5) to release backrest lock. Move backrest
to the desired position and release the lever.

1-50
 OPERATOR'S STATION
Armrest Adjustment 60 degrees
8
Armrest (6) can be pulled upright by hand to get on and
off the machine easily.
The angle of armrest (6) can be adjusted to the desired 6
position by turning adjusting dial (7) located on the bot-
tom of armrest (6).

Headrest
Headrest height and angle can be adjusted. 7
Pull headrest (8) upward or push downward to the de-
sired position. (Height adjustment range: 50 mm (2.0 in))
Headrest (8) can be adjusted 60 degrees forward from
the upright position. Move headrest by hands to the de-
sired angle. M1G6-01-017

1-51
 OPERATOR'S STATION
ADJUSTING CONSOLE HEIGHT 2 2

Adjust the console height to the operator’s comfort and/or

work conditions. Adjusting console height can be achieved
using three positions provided vertically at 20 mm intervals.

CAUTION: Before loosening the console, sup-

port the console. Otherwise, the console may
suddenly drop, possibly causing personal injury.

Adjusting Procedures
1. Lower the bucket to the ground. Stop the engine.
2. Move the pilot control shut-off lever to the LOCK po-
M1CC-01-040
sition.
4
3. Remove right console holding bolt (1). Loosen bolts
(2) to adjust the console height.
4. Remove left console holding bolts (3). Loosen bolt (4)
to adjust the console height.
5. After adjusting, tighten bolts (1, 2, 3, and 4).
Tightening Torque: 49N!m (5 kgf!m)

M1CC-01-041

1-52
 OPERATOR'S STATION
SEAT BELT
1 2

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), and attaching hard-
ware. Replace seat belt (1), buckle (2), or attach-
ing hardware if they are damaged, or worn.
Replace seat belt (1) every three years, regard-
less of appearance.

Seat Belt
1. Confirm that seat belt (1) is not twisted. Securely in-
sert the end of seat belt (1) into buckle (2). M157-01-168

Lightly pull on the belt to confirm that the buckle 1

latches securely.
2. Adjust seat belt (1) so that the belt is snug but com-
fortable.
3. Push button (3) on buckle (2) to unfasten seat belt
(1).

M157-01-169

1 2

3
M157-01-170

1-53
 OPERATOR'S STATION
MEMO
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1-54
 BREAK-IN
OBSERVE ENGINE OPERATION CLOSELY

IMPORTANT: Be extra cautious during the first 50

hours, until you become thoroughly fa-
miliar with the sound and feel of your
new machine.

1. Operate the machine only in economy (E) mode and

limit the engine horsepower up to about 80 % of full
load.
2. Avoid excess engine idling.
3. Check indicator lights and gauges frequently during
operation.

EVERY 8 HOURS OR DAILY

1. Perform 8-hour or daily service. (See Maintenance

guide -- 8 hours.)
2. Watch for fluid leaks.
3. Lubricate working tool pivots every 8 hours for the
first 50 hours, and every 8 hours when working in
mud and water.

AFTER THE FIRST 50 HOURS

1. Perform 50-hour service. (See Maintenance guide --

50 hours.)
2. Check accessible hardware torque. (See Hardware
Torque Specifications in Maintenance chapter.)

AFTER THE FIRST 100 HOURS

Perform 50-hour and 100-hour service. (See Maintenance

Guide -- 50 hours and 100 hours.)

2-1
 BREAK-IN
MEMO
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2-2
 OPERATING THE ENGINE
INSPECT MACHINE DAILY BEFORE STARTING

ELECTRICAL SYSTEM HYDRAULIC SYSTEM

Check for worn or frayed wires and loose connections. Check for leaks, kinked hoses, and lines or hoses that
rub against each other or other parts.

BOOM, BUCKET, SHEET METAL, TRACKS

LUBRICATION
Check for bent, broken or missing parts.
Check lubrication points on the Periodic Service Chart.

HARDWARE
PROTECTIVE DEVICES
Check for loose or missing parts.
Check guards, fenders.

FUEL SYSTEM
SAFETY
Drain water and deposits from fuel tank.
Walk around machine to clear all bystanders/obstacles
from machine area.

3-1
 OPERATING THE ENGINE
BEFORE STARTING ENGINE 1

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 (2) to ON position. All indicator lights
and warning lamps will come on. They will stay on for
approximately 3 seconds, except for alternator (3)
and engine oil pressure (4) indicator, which will con-
tinue to stay on further. If any lamp fails to light, the
bulb may be burned out.
Only when the machine is equipped with the high per- LOCK Position M1CC-01-017
formance full-flow filter (optional), hydraulic oil filter
restriction indicator (5) bulb is checked.
2

IMPORTANT: The monitor panel indicates the machine

operating conditions. In case the ma-
chine is operated with indicator bulbs
burnt, even if any abnormality occurs,
the panel will not indicate warnings cor-
rectly. Accordingly, if any indicator bulbs
are burnt, immediately consult your
nearest HITACHI dealer for repair. After
the indicator bulb check is complete, if
alternator indicator (3) and/or engine oil
pressure indicator (4) stays OFF, the M1CC-01-005

machine is abnormal. Immediately con-

sult your nearest HITACHI dealer for re-
pair.

4. Adjust the seat to allow full pedal and control levers

stroke with operator’s back against the backrest. Fas-
ten the seat belt.

NOTE: Use a wet cloth when wiping dust off monitor or

switch panels to prevent damaging the panel
face.
Rubber is used on the switch parts. Take care
not to tear the rubber-made parts with
sharp-edged tool, such as a screwdriver.
3

M1SE-01-005
5

3-2
 OPERATING THE ENGINE
STARTING THE ENGINE IN ORDINARY TEM- 1
PERATURE

1. Pull the pilot control shut-off lever (1) up to the LOCK

position.
2. Turn engine control dial (3) to the slow idle position.
3. Insert key switch (2). Turn it ON position. Check that
preheat indicator (4) is OFF at this time.
4. Sound horn to alert bystanders.
5. Turn key switch (2) to start engine.

IMPORTANT: Prevent starter damage.

Never operate starter motor for more LOCK Position M1CC-01-017

than 10 seconds at a time. If engine fails

to start, return key switch to OFF. Wait 2
for more than 30 seconds, then try again.
After a false start, do not turn key switch
until engine stops or starter may be
damaged.

6. Release key switch (2) immediately after the engine

has started. It will return to ON position.

M1CC-01-005

Slow Idle

3 M178-01-011

M1SE-01-005

3-3
 OPERATING THE ENGINE
STARTING IN COLD WEATHER

Preheating
1. Pull the pilot control shut-off lever up to the LOCK
position.
2. Turn engine control dial (1) to around the middle be-
tween the L and H positions.
3. Insert key switch (2). Turn key switch (2) ON.
4. The machine will automatically check if preheating is
required or not. When preheating is required, preheat 1
indicator (3) is lit for approx. 8 seconds. M178-03-002

2
NOTE: In case, preheat indicator (3) doesn’t come ON,
preheating is not required.

5. Sound horn to alert bystanders.

6. As soon as preheat indicator (3) goes OFF, turn the
key switch (2) to the START position to rotate the
starter.
M178-01-049

IMPORTANT: Prevent starter damage.

Never operate starter motor for more
than 10 seconds at a time. If engine fails
to start, return key switch to OFF. Wait
for more than 30 seconds, then try again.
After a false start, do not turn key switch
until engine stops or starter may be
damaged.

7. Release the key switch (2) immediately after the en-

gine has started. It will return to ON position.

M1SE-01-005

3-4
 OPERATING THE ENGINE
CHECK INSTRUMENTS AFTER STARTING

Checking lnstruments through Monitor Functions.

After starting the engine, check the following points
through the monitor functions.

Check that
1. Alternator indicator (1) is off.
2. Engine oil pressure indicator (2) is off.
3. Engine noise and exhaust gas are normal.
IMPORTANT: Prevent possible damage to engine.
If indicator lights do not go out after
starting engine, IMMEDIATELY STOP
THE ENGINE and correct the cause.
Operate machine at less-than-normal 1
loads and speeds until engine is at nor-
mal operating temperature.

M1SE-01-005

3-5
 OPERATING THE ENGINE
USING BOOSTER BATTERIES

CAUTION:
1. An explosive gas is produced while batteries
are in use or being charged. Keep flames or
sparks away from the battery area. Charge the
batteries in a well ventilated area.
Do not continue to use or charge the battery
when electrolyte level is lower than specified.
Explosion of the battery may result.
Park the machine on a dry, firm or concrete
surface, not on steel plates, if the machine is
parked on steel plates, dangerous sparks may SA-032
be unexpectedly created on the machine.
Never connect a positive terminal to a nega-
tive terminal, as a dangerous short circuit will
occur.
2. The operator must be in the operator’s seat so
that the machine will be under control when
the engine starts. Jump starting is a
two-person operation.

IMPORTANT: The machine electrical system is a 24

volt negative (–) ground. Use only 24
volt booster batteries.

When the machine batteries are exhausted, start the en- 1

gine using booster batteries as shown below.

Connecting the booster batteries (Red)

1. Stop the engine of the machine on which booster
batteries are mounted.
2. Connect one end of red cable (1) to the positive (+)
terminal of the machine batteries, and the other end
to the positive (+) terminal of the booster batteries.
3. Connect one end of black cable (2) to the negative Booster Batteries Machine Batteries
(–) terminal of the booster batteries, and then make (Black)
ground connection to the frame of the machine to be To Upperstructure of the Machine
started with the other end of black (–) cable (2). In the
M104-03-002
last connection to frame, be sure to connect the cable 2 Connecting the Booster Batteries
end as far away from the machine batteries as possi-
ble.
4. Start the engine of the machine on which booster bat-
teries are mounted.
5. Start the engine of the troubling machine.
6. After the engine starts, disconnect cables (2) and (1),
following the procedure below.

3-6
 OPERATING THE ENGINE
Disconnecting the booster batteries 1
1. Disconnect black negative (–) cable (2) from the ma-
chine frame first.
(Red)
2. Disconnect the other end of black negative (–) cable
(2) from the booster batteries.
3. Disconnect red positive (+) cable (1) from the booster
batteries.
4. Disconnect red positive (+) cable (1) from the ma-
chine batteries. Booster Batteries Machine Batteries
(Black)
To Upperstructure of the Machine
M104-03-002
2 Disconnecting the Booster Batteries

3-7
 OPERATING THE ENGINE
STOPPING THE ENGINE

Engine stop procedure

1. Park the machine on a level surface.
2. Lower the bucket to the ground.
3. Turn engine control dial (1) to the slow idle position
and run the engine for 5 minuets to cool the engine.
SA-390
3
IMPORTANT: Turbocharger may be damaged if the
engine is not properly shut down.

4. Turn key switch (2) OFF. Remove the key from the
key switch.
5. Pull pilot control shut-off lever (3) to the LOCK posi-
tion.

If the engine does not stop with the key switch

turned in the OFF position
M1CC-01-017
If the engine does not stop when the key switch is turned
to the OFF position (due to a machine or key switch mal-
function), pull engine stop knob (4) all the way to the
stop. The engine will stop.
1
Slow Idle
NOTE: If the knob is pulled halfway, the engine may
not start or may stall during operation. Be sure
to push the knob to the fully retracted position
before restarting the engine.

M178-01-011

M178-01-049

4 M1SE-01-002

3-8
 DRIVING THE MACHINE
DRIVE THE MACHINE CAREFULLY

IMPORTANT: During freezing weather, park machine

on a hard surface to prevent tracks from
freezing to the ground. Clean debris
from tracks and track frame.

If tracks are frozen to the ground, raise

tracks using boom, move machine care-
fully to prevent damage to drive train
and tracks.

Select a route that is as flat as possible. Steer machine as

straight as possible making small, gradual changes in di-
rection.

When driving over rough terrain, reduce engine speed to

lessen possibility of undercarriage damage.

NOTE: An arrow-mark seal is stuck on the inside sur-

face of the side frame to indicate the machine
front direction.

M178-03-001
Arrow-mark

4-1
 DRIVING THE MACHINE
STEERING THE MACHINE USING PEDALS

CAUTION: In the standard travel position, the

front idlers are positioned at the front of the ma- Front Idler
chine and the travel motors at the rear. If the Cab
travel motors are positioned at the front of the
machine, the control actions of the travel pedals
will be reversed. Be sure to confirm the position
of the travel motors before traveling.

• FORWARD TRAVEL
Push down on front (A) of both pedals.
Travel Motor
• REVERSE TRAVEL
Push down on rear (B) of both pedals. M104-01-038

• NEUTRAL POSITION (C)

When the travel pedals are placed in neutral, travel
brakes automatically will stop and/or hold the ma-
chine.
A
• RIGHT TURN D
Push down on front of left pedal. A C
B
• LEFT TURN D
Push down on front of right pedal. C
B
• SHORT TURN (Spin turn)
Push down the front of one pedal and the rear of the
Forward and Reverse
other.
M104-04-009
M104-04-003

NOTE: For long-term traveling, push down on pedal

tabs (D) and rest feet on footrests.

Pivot Turn M104-04-010

M104-04-003

Spin Turn
M104-04-011
M104-04-007

4-2
 DRIVING THE MACHINE
STEERING THE MACHINE USING LEVERS

CAUTION: In the standard travel position, the

front idlers are positioned at the front of the ma- Front Idler
chine and the travel motors at the rear. If the Cab
travel motors are positioned at the front of the
machine, the control actions of the travel levers
will be reversed. Be sure to confirm the position
of the travel motors before traveling.

• FORWARD TRAVEL
Push both levers forward (A).
Travel Motor
• REVERSE TRAVEL A
Pull both levers rearward (B). A M104-01-038
C
• NEUTRAL POSITION (C)
When the travel levers are placed in neutral, travel C
brakes automatically will stop and/or hold the ma- B
chine. B

• RIGHT TURN D
Push left lever forward.
• LEFT TURN D
Push right lever forward.
• SHORT TURN (Spin turn)
Push one lever forward and pull the other rearward.
Forward and Reverse
M104-04-009
NOTE: For long-term traveling, push down on pedal M104-04-003

tabs (D) and rest feet on footrests.

Pivot Turn M104-04-010

M104-04-003

Spin Turn
M104-04-011
M104-04-007

4-3
 DRIVING THE MACHINE
TRAVEL MODE SWITCH

CAUTION: Tipping-over accidents can cause se-

rious personal injury. Do not change travel mode
while traveling; especially, changing to the fast
mode when descending slopes will create a very
dangerous situation. Always stop the machine
before changing the travel speed mode.

Turn travel mode switch (1) on the switch panel to the

specified position to select the travel mode (Fast/Slow).
2
!" Fast Mode: Turn travel mode switch (1) to mark (2) 1
position.
!" Slow Mode: Turn travel mode switch (1) to mark
3
(1) position.

Mark (Fast Speed Mode)

Mark (Slow Speed Mode)

NOTE: Traction force and gradeability in the fast mode

will be reduced more than in the slow mode.
When more traction force is required, select the
slow mode.

M1CC-01-101
TRAVEL ALARM (Optional)

During travel operation, the travel alarm sounds the buzzer

to warn the people near the machine that the machine is
traveling.

Deactivating Travel Alarm

More than 12 seconds after starting to travel the ma-
chine, push the travel alarm deactivation switch to stop
the travel alarm. (Within 12 seconds, the travel alarm
deactivation switch is inoperable.)
Once the machine stops traveling and when restarting to
travel, the travel alarm will sound again. If desired to
stop the alarm, operate the deactivation switch once Optional Switch Location
M1CC-01-015
more.

NOTE: The optional switch locations differ depending

on what kinds of optional devices are equipped.
Before using the switches, make sure what
kinds of optional devices are equipped.

4-4
 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.

• Before moving machine, determine which way to

move travel pedals/levers for the direction you want to
go. When the travel motors are in the rear, pushing Travel Motor
down on the front of the travel pedals or pushing the
levers forward moves the machine forward, towards
the idlers. M104-05-008

An arrow-mark seal is stuck on the inside surface of

the side frame to indicate the machine front direction.
• Select a travel route that is as flat as possible. Steer
the machine as straight as possible, making small
gradual changes in direction.
• Before traveling on them, check the strengths of
bridges and road shoulders, and reinforce if neces-
sary.
• Use wood plates in order not to damage the road sur-
M178-03-001
face. Be careful of steering when operating on asphalt Arrow-mark
roads in summer.
• When crossing train tracks, use wood plates in order
not to damage them.
• Do not make contact with electric wires or bridges.
• When crossing a river, measure the depth of the river
using the bucket, and cross slowly. Do not cross the
river when the depth of the river is deeper than the
upper edge of the upper roller.
• When traveling on rough terrain, reduce engine speed.
Select slow travel speed. Slower speed will reduce
possible damage to the machine.
• Avoid operations that may damage the track and un- SA-011
dercarriage components.
• During freezing weather, always clean snow and ice
from track shoes before loading and unloading ma-
chine, to prevent the machine from slipping.

4-5
 DRIVING THE MACHINE
OPERATING ON SOFT GROUND

• Avoid traveling on very soft ground that does not have

sufficient strength to firmly support the machine.
• If the machine is operated on very soft ground or be-
comes stuck, it may be necessary to clean the track
frame area.
• Swing the upperstructure 90° and lower the bucket to
raise one track off the ground. Make sure to keep the
angle between the boom and arm 90 to 110° and posi-
tion the bucket’s round side on the ground.
• Rotate the raised track back and forth to remove mud
and dirt.
• After lowering the track to the ground, select slow
travel speed. Carefully move the machine to firm
M104-05-012
ground.
• Utilize the boom and arm functions to pull the machine
toward firm ground.
• Tow the machine if the machine becomes stuck but
only if the engine is still operating. Be sure to attach a
tow line correctly. (Refer to the “TOWING MACHINE A
SHORT DISTANCE” section on the next page.)

RAISE ONE TRACK USING BOOM AND ARM

CAUTION: Keep the angle between boom and

arm 90 to 110° and position the bucket’s round
side on the ground.
to
Swing the upperstructure 90° and lower the bucket to raise
track off ground. Do not dig bucket teeth into the ground
when using the hoe bucket reversed.

Place blocks under machine frame to support the machine.

IMPORTANT: When the machine is modified as a face

shovel by installing the hoe bucket in to
reverse, avoid raising the machine
above the ground using the front at-
tachment with the bucket cylinder fully
extended. Excessive loads will be ap- M104-05-013

plied to the pins around the bucket and WRONG

the bucket cylinder, resulting in break-
age of the pins.

SA-817

4-6
 DRIVING THE MACHINE
TOWING MACHINE A SHORT DISTANCE

CAUTION: Cables, straps, or ropes can break RIGHT

causing serious injury. Do not tow machine with
damaged chains, frayed cables, slings, straps, or
wire ropes.
Always wear gloves when handling cable, straps
or wire ropes.

When your machine becomes struck but the engine is still

operational, attach wire rop tow lines as illustrated at right, Wire Rope
and slowly tow your machine to firm ground using another
machine.
Be sure to attach the wire ropes around the track frames of M104-05-010

both machines as illustrated.

To prevent the wire ropes from being damaged, place
some protective material between the track frame and the WRONG
wire ropes.

IMPORTANT: Do not use the shackle hole on the track

frame for towing the machine.
A shackle hole is provided to pull only Wire Rope
light weight objects. Refer to page 5-17
for instructions for using the shackle
hole properly. Shackle

M104-05-011

4-7
 DRIVING THE MACHINE
OPERATING IN WATER OR MUD

The machine can be operated in water up to the upper

edge of the upper rollers only if worksite footing has suffi-
cient strength to prevent the machine from sinking past the
upper edge of the upper roller, and only if the water is flow-
ing slowly.

When operating in such conditions, check the machine’s A

position often. Reposition the machine if necessary.
M104-05-009
Avoid submerging the swing bearing, swing gears and cen-
ter joint.
ZAXIS125US, ZAXIS135USL,
135US, 135USK 225US, 225USLC
If the swing bearing, swing gears and center joint are sub-
A 660 mm 770 mm
merged, remove the drain plug to drain mud and water.
(2# 2$) (2# 6$)
Clean swing area. Install plug. Lubricate swing internal
gear and swing bearing.

Swing Internal Gear Capacity:

ZAXIS125US, 135US, 135USK, 135USL: 9L (2.4 US gal)
ZAXIS225US, 225USLC: 14L (3.7 US gal)

Lubricate swing bearing. (See Maintenance Guide, 500

hours)

4-8
 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 A
slopes with the bucket loaded or any load sus-
pended by the bucket.

• Never attempt to ascend or descend 30 degrees or SA-657

steeper slopes.
• Be sure to fasten the seat belt.
• Keep the bucket pointed in the direction of travel, ap-
proximately 0.5 to 1.0 m (1 ft 8 in to 3 ft 3 in) (A)
above the ground. If the machine starts to skid or be-
comes unstable, lower the bucket immediately.
• Driving across the face of a slope or steering on a
slope may cause the machine to skid or turnover. If A
the direction must be changed, move the machine to SA-658
level ground, then, change the direction to ensure
safe operation.
• Avoid swinging the upperstructure on slopes. Never
attempt to swing the upperstructure downhill. The
machine may tip over. If swinging uphill is unavoidable,
carefully operate the upperstructure and boom at slow
speed.
• If the engine stalls on a slope, immediately lower the
bucket to the ground. Return the control levers to neu-
tral. Then, restart the engine.
• Be sure to thoroughly warm up the machine before
SA-441

ascending steep slopes. If hydraulic oil has not WRONG

warmed up sufficiently, sufficient performance may not
be obtained.

SA-442

4-9
 DRIVING THE MACHINE
PARKING THE MACHINE ON SLOPES

CAUTION: Avoid parking machine on slopes.

The machine may tip over, possibly resulting in
personal injury.

If parking the machine on a slope is unavoidable:

• Thrust the bucket teeth into the ground.
• Return the control levers to neutral and pull the pilot M1CC-04-005
control shut-off lever to the LOCK position.
• Block both tracks.

PARKING THE MACHINE

1. Park the machine on a level surface.

2. Lower the bucket to the ground.
3. Turn the auto-idle switch off.
1
Slow Idle
IMPORTANT: Turbocharger may be damaged if the
engine is not properly shut down.

4. Turn engine control dial (1) counterclockwise to the

stop (the slow idle position).
Run the engine approximately 5 minutes to cool the
engine. M178-01-011

5. Turn the key switch to OFF. Remove the key from the 2
key switch.
6. Pull pilot control shut-off lever (2) to the LOCK posi-
tion.

IMPORTANT: Protect cab electrical components from

bad weather. Always close windows,
roof vent and cab door when parking the
machine.

7. Close windows, roof vent, and cab door.

8. Lock all access doors and compartments.

LOCK Position M1CC-01-017

4-10
 OPERATING THE MACHINE
CONTROL LEVER (ISO PATTERN)

1 5
CAUTION: Never place any part of body beyond
window frame. It could be crushed by the boom if
boom control lever is accidentally bumped or 7
otherwise engaged. If window is missing or bro- 4 8
3
ken, replace immediately.
Prevent possible injury from unexpected ma-
chine movement. 2 6
Make sure you know the location and function of
each control before operating.

The machine is equipped with a label showing the control

patterns of the levers and pedals.

IMPORTANT: When digging, avoid hitting tracks with

boom cylinders.
When digging over the end of the tracks,
travel motors should be at the rear to
maximize machine stability and lift ca- M1CC-01-010

pacity.
3
1
When a lever is released, it will automatically return to neu-
tral, and that machine function will stop.
4
1- Arm Roll-Out 2
2- Arm Roll-In
3- Swing Right
4- Swing Left
5- Boom Lower M104-05-001

6- Boom Raise
7- Bucket Roll-In.
8- Bucket Roll-Out.
6

8 7
5

M104-05-002

5-1
 OPERATING THE MACHINE
CONTROL LEVER (HITACHI PATTERN)

CAUTION: Never place any part of body beyond

1 5
window frame. It could be crushed by the boom if
boom control lever is accidentally bumped or
otherwise engaged. If window is missing or bro- 7
ken, replace immediately. 4 8
3
Prevent possible injury from unexpected ma-
chine movement.
Make sure you know the location and function of 2 6
each control before operating.

The machine is equipped with a label showing the control

patterns of the levers and pedals.

IMPORTANT: When digging, avoid hitting tracks with

boom cylinders.
When digging over the end of the tracks,
travel motors should be at the rear to
maximize machine stability and lift ca-
pacity. M1CC-01-010

When a lever is released, it will automatically return to neu- 1

4
tral, and that machine function will stop.

1- Swing Right 2

2- Swing Left 3

3- Arm Roll-In
4- Arm Roll-Out
5- Boom Lower
M104-05-001
6- Boom Raise
7- Bucket Roll-In.
8- Bucket Roll-Out.
6

8 7 5

M104-05-002

5-2
 OPERATING THE MACHINE
ATTACHMENT PEDAL (BREAKER) 1

(K Model)
The breaker can be operated using attachment pedal (1)
located on the right front of the seat, as illustrated.

CAUTION: Be sure to lock attachment pedal (1)

with pedal lock (2) when the attachment pedal is
not in use.

1. Select the attachment mode using work mode switch

(3). Attachment mode indicator (4) will light when se-
lected. M178-13-001

2. Move pedal lock (2) forward to unlock attachment

pedal (1).
3. Push down on attachment pedal (1) to operate the
breaker. 4
4. Remove foot from attachment pedal (1) to stop the
breaker. 3

5. Always keep attachment pedal (1) locked with pedal

lock (2) when the attachment pedal is not in use.

When operating a hydraulic breaker, set the stopper bolt

height to approx. 24 mm (0.94 in) so that the pedal cannot
be accidentally pressed into the reverse position.

IMPORTANT: When operating a hydraulic breaker,

M1SE-01-005
don’t step on attachment pedal (1) rear-
ward. Damage to the hydraulic breaker 1
may result. UNLOCK
LOCK
2

Stopper Bolt

M1G6-13-004

Adjust to Approx.24 mm M1G6-13-003

(0.94 in)

5-3
 OPERATING THE MACHINE
ATTACHMENT PEDAL 1
(HYDRAULIC CRUSHER)

(K Model)
Machine stability, applicable hydraulic oil pressure and oil
quantity for crusher, etc. must be examined when selecting
a crusher.
Be sure to consult your authorized dealer when selecting a
crusher.

For operational instructions, refer to the crusher instruction

manual.

M178-13-001
Operation
The crusher can be operated using attachment pedal (1)
located on the right front of the seat, as illustrated.
5
CAUTION: Be sure to lock attachment pedal (1)
with pedal lock (2) when the attachment pedal is
not in use.

Crusher with Two Speed Modes: (Optional)

1. Select the attachment mode using work mode switch
(3). Attachment indicator (4) will light.
Turn attachment select switch (5) to the CRUSHER
(L) or to the CRUSHER (S) position
2. Move pedal lock (2) forward to unlock attachment M157-01-182

pedal (1). 1
UNLOCK
3. Push down on attachment pedal (1) either forward or
backward to open or close the crusher. LOCK
2
4. Remove foot from attachment pedal (1) to stop the
crusher.
5. Always keep attachment pedal (1) locked with pedal
lock (2) when attachment pedal (1) is not in use.

Crusher without Two Speed Modes: Tighten the

Stopper Bolt M1G6-05-011
1. Select the general purpose mode with work mode
switch (3). General purpose mode indicator (6) will
light.
2. Move pedal lock (2) forward to unlock attachment
pedal (1). 4
Note that if the attachment mode is selected, 6
open/close speed of the crusher may become slow.
3

M1SE-01-005

5-4
 OPERATING THE MACHINE
PILOT CONTROL SHUT-OFF LEVER

Pilot control shut-off lever (1) functions to prevent

misoperation of the machine from occurring if the control
levers are accidentally moved when leaving the operator's
seat or when entering the cab.
CAUTION:
1. Always pull pilot control shut-off lever (1) into
the full LOCK position. The pilot control
shut-off function will not be activated
otherwise.
2. When leaving the machine:
• Stop the engine.
• Then, pull the pilot control shut-off lever up to
the LOCK position.
3. Always check to be sure that the pilot control
lever is pulled up to the LOCK position
before:
• Transporting the machine.
• Leaving the machine at the end of the shift.
4. When moving the pilot control shut-off lever
1
to the UNLOCK position, take care not to
activate other control levers by mistake. The
machine may be unexpectedly operated,
possibly causing an accident or personal
injyry.
Pilot Control Shut-Off Lever Operation
Before Leaving the Machine:
1. Park the machine on a firm, level surface. Lower the
bucket to the ground. Return all control levers to neu-
tral. Properly shut down the engine.
2. Pull pilot control shut-off lever (1) up into the full
LOCK position.
Before Starting Operation:
LOCK Position M1CC-01-017
1. Confirm that pilot control shut-off lever (1) is pulled
up to the LOCK position.
After starting the engine:
1. Confirm that all control levers and pedals are in
neutral and that no part of the machine is in motion.
1
2. Lower pilot control shut-off lever (1) to the UNLOCK
position.
If any part of the machine (any actuator) moves when
the pilot control shut-off lever is lowered to the UNLOCK
position despite the fact that all controls are placed in
neutral, the machine is malfuntioning. Immediately pull
the pilot control shut-off lever back to the LOCK position,
and stop the engine. Then, see your authorized dealer.
UNLOCK Position M1CC-01-009

5-5
 OPERATING THE MACHINE
Warming-up Operation
Warm up the engine coolant as follows:

1. Run the engine with engine control dial (1) turned to

the slow idle position. 1
2. When the needle of coolant temperature gauge (2) Slow Idle
indicates the arrow position, warm up operation is
complete.

M178-01-011

M178-01-104

Hydraulic Oil Warm-Up Operation

IMPORTANT: Hydraulic components may be seriously

damaged if the machine is operated with
hydraulic oil temperature below 30°C
(86°F). Always warm hydraulic oil to
specifications before operating the ma-
chine.

In case the hydraulic oil temperature is lower than 0 !C

when starting the engine, the engine speed is automati-
cally increased for approx. 15 minutes to quickly warm
up the hydraulic oil.

NOTE: As soon as the hydraulic oil is warmed upto 0

!C even though it is still shorter than 15 minutes,
the warm-up operation is automatically com-
plete so that the engine runs at an idle speed.

During auto warm-up operation, if the engine

speed is increased more than that of the auto
warm-up operation by operating engine control
dial (1), the engine runs at the speed set by en-
gine control dial (1).

5-6
 OPERATING THE MACHINE
Warming-up the Motor and the Cylinders

IMPORTANT: • In cold weather, be sure to thoroughly

warm-up the motors and cylinders.
• If the hydraulic circuit is continuously
relieved for a certain amount of time,
the temperature in the control valve
would rise excessively. Never operate
to stroke end more than 15 seconds.
After relieving any function, up to 15
seconds, be sure to have a 5–10 sec-
ond intermission.

1. Check that the needle of coolant temperature gauge

(2) starts moving so that engine coolant warm-up
operation is complete.
2. Turn engine control dial (1) to the medium position.
1
3. Operate the boom, arm and bucket cylinders slowly
to each stroke end several times.
4. Operate travel and swing functions slowly, initially
moving only short distances.
5. Continue to repeat steps 3 and 4 until bucket cycle
time is normal.
M178-01-011

M178-01-104

5-7
 OPERATING THE MACHINE
ENGINE SPEED CONTROL
1
Increase and decrease the engine speed using engine
control dial (1) located on the right console, as illustrated.

• Turn engine control dial (1) clockwise to increase the

engine speed. Turn engine control dial (1) counter-
clockwise to decrease the engine speed.
• Note that the auto-idle function will be deactivated if
engine control dial (1) is operated while the engine is
running at the auto-idle setting.
• Before stopping the engine, always turn engine control
dial (1) counterclockwise to the stop (to the slow idle
setting). Run the engine five minutes to cool the en-
gine. Then, turn key switch (2) to OFF position to stop
the engine.

M178-01-091

High Idle

1
Slow Idle

M178-01-011

5-8
 OPERATING THE MACHINE
AUTO-IDLE

With auto-ilde/acceleration selector (3) turned to the A/I

position, approximately 4 seconds after all control levers
are returned to neutral, the engine speed decreases to the
1
auto-idle setting to save fuel consumption. The engine
speed will immediately increase to the speed set by engine
control dial (2) when any control lever is operated.

CAUTION:
"# Always check if auto-idle indicator (1) is turned
on or off before starting operation. If the indi-
cator is on, the auto-idle function will be acti-
vated.
"# Always be aware of engine control dial setting
when auto-idle/acceleration selector (1) turned
to the A/I position. If the engine speed is set
high with engine control dial (2), and if the op-
erator is not aware of the high engine speed
setting, the engine speed will unexpectedly in-
crease when any control lever is operated,
causing unexpected machine movement, thus
possibly resulting in serious personal injury.
"# Prevent the machine from unexpected move-
ment. Be sure to turn off auto-idle/acceleration M1SE-01-005

selector (3) when unexpected machine move-

ment is undesirable, especially when load-
ing/unloading the machine for transportation. 2

Note that auto-idle function can be turned on or off only

when the key switch is in ON position. Always check if the
auto-idle function is turned on or off with auto-idle indicator
(1).
3
Auto-Idle Function ON : Auto-Idle Indicator (1) ON
Auto-Idle Function OFF : Auto-Idle Indicator (1) OFF

• When auto-idle/acceleration selector (3) is turned

OFF with auto-idle indicator (1) ON, indicator (1) will
go OFF and the auto-idle system is deactivated.
• Even if the engine is stopped by turning the key switch
with auto/acceleration selector (3) in the AUTO-IDLE
position $indicator (1) ON%, the auto-idle system is not
deactivated. When the engine is restarted, the
auto-idle system remains activated, allowing auto-idle
indicator (1) to flash for 5 seconds and stay ON later.

M178-01-091

5-9
 OPERATING THE MACHINE
AUTO ACCELERATION
4
Auto-Acceleration Function
When auto-idle/acceleration selector (3) is turned in the
A/A position, the engine speed can be varied in propor- 1
tion to the stroke of the control levers. In addition, the
engine speed is reduced to the auto-idle speed approx.
4 seconds after releasing the control levers. Thereby,
fuel consumption is reduced more than when operating
in the auto-idle mode.
When auto-idle/acceleration selector (3) is turned in the
A/A position, both auto-idle indicator (1) and
auto-acceleration indicator (4) are lit.

CAUTION: Be sure to check whether

auto-acceleration indicator (4) is ON or OFF be-
fore operating the control levers. When the indi-
cator is ON, the auto-acceleration system func-
tions.

When a control lever is operated with

auto-idle/acceleration selector (3) turned to the
A/A position, the engine speed is increased in
proportion to the stroke of the control lever up to
the engine speed set by engine control dial (2). M1SE-01-005
Therefore, beware that the engine speed will
suddenly increase, after moving a control lever if
high engine speed is set by engine control dial
(2). 2

Be sure to turn auto-idle/acceleration selector (3)

OFF before starting works such as when loading
the machine on or off a trailer or lifting a load
with the front attachment, which may result in
personal accidents if the engine speed is sud- 3
denly changed.

M178-01-091

5-10
 OPERATING THE MACHINE
Changing Auto-Acceleration Mode
When changing the auto-acceleration mode, turn 4
auto-idle/acceleration selector (3) with the key switch ON.
Check the selected mode by referring to auto acceleration
indicator (4). 1

Indicator ON: Auto-Acceleration system is activated.

Indicator OFF: Auto-Acceleration system is deactivated.

• When auto-idle/acceleration selector (3) is turned to the

A/I position or OFF position with auto-acceleration indi-
cator (4) ON, indicator (4) will go OFF and the
auto-acceleration system is deactivated.
Even if the engine is stopped by turning the key switch with
auto-idle/acceleration selector (3) in the A/A position $indi-
cator (4) ON%, the auto-acceleration system is not deacti-
vated. When the engine is restarted, the auto-acceleration
system remains activated, allowing auto-idle indicator (1)
and auto-acceleration indicator (4) to flash for 5 seconds
and stay ON later.

M1SE-01-005

M178-01-091

5-11
 OPERATING THE MACHINE
WORK MODE

Two work modes can be selected for most appropriate

front and swing speeds for the work to be performed.

When the engine is started, the digging mode is automati-

cally set. Each time work mode switch (1) is pressed, the
two following modes are selected alternately.
2
• Digging Mode
• Attachment Mode

The selected work mode is indicated by attachment mode

indicator (2) or digging mode indicator (3). Select the work 1
3
mode corresponding to the work in which the machine is
engaged while referring to the table below.

M1SE-01-005

Work Mode Description

General Purpose
Designed for general digging and truck loading.
Mode
Select this mode when using attachments other than
Attachment Mode
bucket.

POWER BOOST
ZAXIS225US, 225USLC

The power boost switch (4) is used to gain maximum

digging power, and is located on the top of the right control
lever.
4
When the power boost switch (4) is pushed, increased
front attachment power will be supplied for about 8
seconds.

M178-05-002

5-12
 OPERATING THE MACHINE
POWER MODE

One of three engine speed modes, E, P or H/P mode, can

be selected using power mode switch (1).

!" E (Economy) Mode

Even if the engine speed is reduced in the E mode, dig- 1

ging force remains unchanged from that in the P mode.
Although production is reduced slightly more than in the
P mode, the fuel consumption and noise levels are re-
duced, allowing the machine to operate most efficiently.

!" P Mode

Operate the machine in this mode when performing

normal work.

!" H/P (High Power) Mode

M178-01-091

CAUTION: In the H/P mode, the engine speed

will change quickly. To ensure safety, be sure to
turn power mode switch (1) to the P or E mode
position before starting such works as loading
the machine on or off a trailer or lifting a load
with the front attachment, which may result in
personal accidents if the engine speed is sud-
denly changed.

When rolling in the arm while digging deep trenches for

example, more power may be required. In such cases,
use the H/P mode. The maximum power of the machine
can be utilized in this mode, increasing work efficiency
when more power is required than in the P mode.

The H/P mode is activated and the engine speed is in-

creased when the boom raise or the arm rolled-in opera-
tion is made with the engine fast idle speed set at faster
-1
than approx. 1700 min .

NOTE: In the H/P mode, the engine speed changes

depending on load applied to the machine.

5-13
 OPERATING THE MACHINE
PRECAUTIONS FOR OPERATION USING
A BUCKET

(K Model)
This machine is specially modified to perform demolition
work efficiently :
When the bucket is attached to the front, this machine
should be used only for light-duty operations such as han-
dling scraps.
Avoid using this machine for heavy-duty digging.

Increased counterweight :

The counterweight of this machine is A kg more than the Model A: Additional Weight
standard counterweight, so as to maintain machine stability ZAXIS135USK 800 kg (1760 lb)
when heavy demolition attachment are installed.
As the standard bucket is lighter in weight, heavy digging
work may cause the machine to excessively pitch back-
wards, possibly causing the machine to become unstable.
Be sure to avoid heavy digging work with this machine.

Modified bucket link :

The entire length of a breaker or crusher is usually longer

than that of the standard bucket. Then, if one of these at- Demolition work wrist
angle Standard work
tachments is attached to the standard arm without reduc- Wrist redaction angle
Wrist angle
ing the wrist angle at the arm top end, the tip end of the
attachment will easily come into contact with the bottom M104-05-051
face of the arm when the bucket cylinder is extended, re-
sulting in the arm damage. Therefore, a modified bucket
link to reduce the wrist angle is employed on this machine, Wrist reduction angle
by which the arm is protected from damage. (degree)
(Refer to the right illustration.) ZAXIS135USK 7
Reduction in the wrist angle will decreases the actual mov-
able load capacity of the bucket, so that this machine with
the modified bucket link cannot provide efficient digging
work.

Machine remodification required for exclusive digging

use :

Follow these remodefication procedures when the machine

is to be exclusively used for digging. (Consult your nearest
authorized Dealer for details.)

!" Replace the counterweight with that for the standard

machine
!" Replace front link B With that for the standard machine.
!" In case by-pass pipings are provided on the arm, be
sure to remove them.

5-14
 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.

• Be sure to wear close fitting clothing and safety

equipment appropriate for the job, such as a hard hat,
etc. when operating the machine.
• Clear all persons and obstacles from area of opera-
tion and machine movement.
Always beware of the surroundings while operating.
When working in a small area surrounded by obsta-
cles, take care not to hit the upperstructure against
obstacles.
• When loading onto trucks, bring the bucket over the M104-05-015

truck beds from the rear side. Take care not to swing
the bucket over the cab or over any person.

5-15
 OPERATING THE MACHINE
OPERATE THE MACHINE SAFELY

CAUTION: Prevent the machine from tipping

over and from being involved in a ground
collapse. Take the necessary precautions as
follows:
1. Make sure the worksite has sufficient strength
to firmly support the machine.
When working close to an excavation or at
road shoulders, operate the machine with the
tracks positioned perpendicular to the cliff
face with travel motors at the rear, so that the
machine can more easily evacuate if the cliff
face collapses.
2. If working on the bottom of a cliff or a high
bank is required, be sure to investigate the
M104-05-016
area first and confirm that no danger of the
cliff or bank collapsing exists. If any possibil-
ity of cliff or bank collapsing exists, do not
work on the area.
3. Soft ground may collapse when operating the
machine on it, possibly causing the machine
to tip over. When working on a soft ground is
required, be sure to reinforce the ground first
using large pieces of steel plates strong and
firm enough to easily support the machine.
4. Note that there is always a possibility of ma-
chine tipping over when working on rough
terrain or on slopes. Prevent machine tipping
over from occurring. When operating on
rough terrain or on slopes:
• Reduce the engine speed.
• Select slow travel speed mode.
• Operate the machine slowly and be
cautious with machine movements.

5-16
 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. When soil sticks to the bucket, remove it by moving
the arm and/or bucket rapidly back and forth.
4. When trenching a straight line, position the tracks
parallel to the trench. After digging to the desired
M107-05-037
depth, move the machine as required to continue the
trench.

IMPORTANT: When lowering the boom, avoid sudden

stops that may cause shock load dam-
age to the machine.

When operating the arm, avoid bottom-

ing the cylinder to prevent cylinder dam-
age.

When digging at an angle, avoid striking

the tracks with the bucket teeth.

When digging a deep excavation, avoid

striking the boom or bucket cylinder
hoses against the ground.

GRADING OPERATION

IMPORTANT: Do not pull or push dirt with the bucket

when traveling.

Select grading mode when finishing work is required.

Position the arm slightly forward of the vertical position with

bucket rolled back, as shown.

Operate arm roll-in function while slowly raising the boom.

Once the arm moves past, the vertical position slowly lower M104-05-017

the boom to allow the bucket to maintain a smooth surface.

Grading operation can be more precisely done by operat-

ing the boom, arm and bucket simultaneously.

5-17
 OPERATING THE MACHINE
FACE SHOVEL OPERATION
WRONG
CAUTION: Take care not to hit the cab when roll-
ing in the arm with the reversed-installed bucket.

• For face shovel operation, dig the ground using the

arm cylinder in a scraping motion.
• When underground water is expected, make a slope Watch out!
(Take care not to hit the
angle of 2 to 3° to drain this water as shown. cab with bucket)

M107-05-045

2 to 3°

M104-05-020

WRONG
AVOID ABUSIVE OPERATION

Do not use travel as an additional digging force. Severe

machine damage may result.

Do not raise rear of machine to use the machine’s weight

as additional digging force. Severe machine damage may
result.
WRONG

WRONG

M104-05-018

5-18
 OPERATING THE MACHINE
OPERATING TIPS WRONG
Do not hit the track with the bucket when digging.
Whenever possible, position your machine on a level sur-
face.
Do not use the bucket as a hammer or pile driver. Do not
attempt to shift rocks and break walls using swing motion.

IMPORTANT: To avoid damaging cylinders, do not

strike the ground with the bucket nor
use the bucket for tamping with the
bucket cylinder fully extended (the
bucket completely curled under).
M104-05-019

Adjust the length and depth of each cut to produce a full

bucket with every pass.
Full loads on every pass is more productive than a faster
cycle with a partially filled bucket.
Full load should be the first objective, followed by speed, to
increase productivity.

IMPORTANT: Do not attempt to break ledge rock by

extending the arm to maximum reach
and dropping the front of the bucket on
the bucket teeth for penetration. Serious
damage to the machine can result.
M161-05-006

Once the trench is open, ledge rock can be broken by pull-

ing the bucket up under the layers. The top layers are
pulled out first, with one or two layers being lifted at a time.
Do not side load the bucket. For example, do not swing the
bucket to level material or do not strike objects from the
side with the bucket.

SELECT CORRECT TRACK SHOES

IMPORTANT: Using wide track shoes on rough ground

may result in shoe bending and/or
loosening, and may damage other un-
dercarriage components.

Never use wide track shoes on rough ground such as

rocks, sand or gravel. Wide track shoes are designed for
soft ground.

Track shoe bolts should be checked periodically for tight-

ness.

5-19
 OPERATING THE MACHINE
HYDRAULIC BREAKER AND HYDRAULIC
CRUSHER

Select a breaker or crusher that is the correct size and

weight for your machine. See your authorized dealer for
correct breaker information.

Carefully study the operation manuals of the machine,

breaker and crusher, and perform the required checks
and/or inspection before connecting the breaker or the
crusher to the arm.

IMPORTANT: Precautions for connecting breaker or

crusher piping.
• Do not allow impurities to enter into the system
when switching the breaker or the crusher with
the bucket.
• When the breaker or crusher is not used, apply
the cover to the pipe opening on the arm top and
install the plug into the hose end of the breaker or
the crusher to prevent impurities from entering
the system.
Be sure to provide spare covers and plugs in the
tool box so that they will be available when
needed.
• After connecting, check the connecting seal fitting
for oil leakage, and pipe clamp bolts for loose-
ness.

5-20
 OPERATING THE MACHINE
PIPINGS FOR BREAKER AND CRUSHER

(ZAXIS125US, 135US, 135USK, 135USL)

Close
Operational procedures for stop valves and selection valve.

A, B
Stop
Valves Open

when using breaker

A TO TANK

B C
A C FRONT REAR
Selection
when using crusher
Valves
TO VALVE

FRONT REAR

M105-05-006
Stop Valves A Stop Valves B Stop Valves C
Close : When not using
Close : When using crusher
attachment or is detached.
Refer to the right table
Open : When using
Open : When using breaker
attachment

ATTACHMENT ARM ATTACHMENT PEDAL

BOOM MAIN BODY

CONTROL VALVE

PUMP
LEFT SIDE OF THE FRONT

CLOSE : CRUSHER
CLOSE : NPK BREAKER STOP RELIEF
OPEN : :OTHER BREAKER VALVES B VALVE

RIGHT SIDE OF THE FRONT

OPEN : BREAKER STOP

CLOSE : CRUSHER VALVES DRAIN OIL TANK

STOP CLOSE : WHEN NOT USING ATTACHMENT SELECTION

; BREAKER : TO TANK
VALVES A OPEN : WHEN USING ATTACHMENT VALVE C
; CRUSHER : TO VALVE
M105-05-007

5-21
 OPERATING THE MACHINE
PIPINGS FOR BREAKER AND CRUSHER

(ZAXIS225US, 225USLC)
Close
Operational procedures for stop valves and selection valve.

A, B
Stop
Valves Open

B
C
A Close

B D

A C
Stop
Open
Valves

when using breaker

TO TANK

D FRONT REAR
M107-05-003 Selection
when using crusher
Stop Valves A Stop Valves B Stop Valves C Valves
TO VALVE
Close : When not using Close : When using crusher Close : When using crusher
attachment or is detached. or NPK breaker or breaker except NPK
Open : When using Open : When using breaker Open : When Using NPK
attachment (except NPK) breaker FRONT REAR

ATTACHMENT ARM ATTACHMENT PEDAL

BOOM MAIN BODY

HIGH PRESSURE
ACCUMULATOR
PUMP
LEFT SIDE OF THE FRONT

CLOSE : CRUSHER
CLOSE : NPK BREAKER STOP
VALVES B
OPEN : :OTHER BREAKER RELIEF VALVE

RIGHT SIDE OF THE FRONT

OPEN : BREAKER STOP

CLOSE : CRUSHER VALVES C DRAIN OIL TANK
CLOSE : WHEN NOT USING
STOP ATTACHMENT SELECTION ; BREAKER : TO TANK
VALVES A OPEN : WHEN USING VALVE D
ATTACHMENT LOW PRESSURE ; CRUSHER : TO VALVE
ACCUMULATOR M107-05-004

IMPORTANT: Be sure to close stop valve (B) for the Using the crusher with stop valve
low pressure accumulator when using (B) for the low pressure accumu-
the crusher. lator open will result damages to
the accumulator.

5-22
 OPERATING THE MACHINE
SECONDARY RELIEF PRESSURE
ADJUSTMENT

When attaching the breaker other than the NPK, it is nec- Two methods are available to measure the pressure.
essary to install the secondary relief valve in line. For this Measure the pressure as follows.
purpose, the boom piping for the attachment is provided
with a part to which the secondary relief valve is con- 1. Measuring the pressure at the relief valve :
nected.
(1) Attach a pressure gauge to the pressure
Pressure is set to A when shipped from HITACH.
gauge connection port (see the figure be-
low)
Model Set Pressure A (2) Close the stop valves at the arm end.
ZX125US, 135US, 135USK, 2 Depress the attachment pedal to pressure
17.6MPa (180 kgf/cm )
135USL, 225US, 225USLC the line.
(3) Adjust the pressure to 1 to 1.5MPa (10 to
After completing piping, reset this pressure to the specified 2
15 kgf/cm ) higher the setting pressure.
level of each breaker.

Adjust the pressure as follows :

1. Attach the pressure gauge to the pressure gauge

port.
2. Loosen the lock nut, then gradually turn the pres-
sure-adjust screw clockwise to increase the pressure,
or counterclockwise to reduce the pressure.
One turn of the screw changes about 4.9MPa (50
2
kgf/cm ) in pressure.
3. After adjusting the pressure, make sure to tighten the
lock nut.

PRESSURE DECREASE PRESSURE INCREASE

PRESSURE-ADJUST
BOLT

(WIDTH ACROSS FLAT : 14)

LOCK NUT
(WIDTH ACROSS FLAT : 14)

PRESSURE GAUGE
CONNECTION PORT

(PT 1/4) M107-05-005

2. Measuring the pressure at the arm end.

(1) Remove the attachment connection horse and
connect a pressure gauge to the connection fit-
ting at the arm end.

(2) Adjust the pressure to the setting pressure.

5-23
 OPERATING THE MACHINE

PRECAUTIONS FOR BREAKER OPERATION

CAUTION: Machine stability is reduced as the WRONG

breaker is much heavier than the bucket.
When using a breaker, the machine is more apt to
tip over. Also, flying objects may hit the cab or
other part of the machine. Observe the following
precautions and take any other precautions nec-
essary to prevent accidents and machine damage
from occurring.

• Avoid hitting objects with breaker.

M104-05-055

The breaker is heavier than the bucket, causing the

breaker to lower faster.
Take care not to hit any objects with breaker. Doing so
will result in damage to the breaker, the front attach- WRONG
ment, and/or the upperstructure. Always move (lower)
the breaker slowly to position the tip of the chisel on
the object to be broken before starting breaker opera-
tion.

• Do not use the breaker and/or the swing function to

move objects. Damage to the boom, arm, and/or
M104-05-056
breaker may result.

WRONG

• To prevent cylinder/machine damage, do not operate

the breaker with the hydraulic cylinder rod fully re-
tracted or fully extended.

M104-05-057

Hose jumping abnormally

Accumulator

• Stop operation if breaker hydraulic hoses jump ab-

normally. Change in breaker accumulator pressure or
a damaged accumulator will cause abnormal hose
jumping and may cause breaker and/or machine dam-
age.
Immediately contact your authorized dealer if this Hose jumping
abnormally
happens.

M104-05-058

5-24
 OPERATING THE MACHINE
• Do not operate the breaker in water. Doing so will
cause rust and seal damage, resulting in damage to
the hydraulic system components. WRONG

Rod

M104-05-059

• Do not use breaker for lifting operation. The machine

tipping over and/or breaker damage may result. WRONG

M104-05-060

• Do not operate the breaker to the side of the machine. WRONG

The machine may become unstable and undercar-
riage component life may shorten as a result from op-
erating the breaker to the side of the machine.

RIGHT RIGHT

WRONG M104-05-061

• Operate the hydraulic excavator carefully to avoid hit-

ting the boom.
WRONG

Watch Out!
Take care not to hit the
boom with the breaker

M104-05-062

5-25
 OPERATING THE MACHINE
• Do not operate breaker with the arm positioned verti-
cally. Excessive vibration to the arm cylinder will occur,
causing oil leakage. WRONG

M147-05-013

• Press the breaker so that the chisel (the axis) is posi-

tioned and thrusted perpendicular to the object.
RIGHT WRONG

M147-05-014

• Do not operate the breaker continuously longer than

one minute. Excessive chisel wear will result. If an
object could not be broken within one minute, apply
the chisel to other locations, less than one minute for
each location.

If an object could not be

broken within one min-
ute, apply the chisel to
other locations, less
than one minute for
each location.

M147-05-015

• Raising the front part of the undercarriage by pressing

down the breaker may cause damage to the front at-
tachment. Although raising the front edge of the un-
dercarriage up to 150 mm (6 in) is tolerable, do not Pressing
practice this method more than necessary. Never Down
raise the front edge of the undercarriage higher than Raising 100 to
150 mm (6 in) by pressing the breaker down. 150 mm

M147-05-016

5-26
 OPERATING THE MACHINE
BREAKER MAINTENANCE

Change Hydraulic Oil and Replace Hydraulic Oil Tank Filter
Hydraulic breaker operation subjects the hydraulic system
to become contaminated faster and to quickly deteriorate
the hydraulic oil. For this reason, hydraulic oil must be
changed and the hydraulic oil tank filter must be replaced
more often than the machine equipped with a bucket.
Failure to do so may result in damage to the breaker,
hydraulic oil pump, and other related hydraulic sys-
tem components. Recommended changing intervals
are shown below. (For filter replacement and oil
changing intervals are shown below.(For filter re-
placement and oil changing procedures, refer to the
“Hydraulic System” in the “MAINTENANCE” Sec-
tion.)

Changing intervals (Hours)

Full Flow Filter

Attachment Availability *Hydraulic Oil **Element Type
Element

1500
Standard Filter Paper
Bucket 100% 2500 1000
High Performance Element
4000
Hydraulic 600 100 Standard Filter Paper
100%
Breaker 1000 300 High Performance Element
* : Replacement intervals differ depending on the brand of hydraulic oil used. Refer to the Hydraulic System
in the MAINTENANCE section.
** : Use the high performance element (micro-glass) on K/L Model.

Replacement Intervals (Hours) of Hydraulic Oil and Full Flow Filter Element

Hours to Replace Hours to Replace Hy-

Element draulic Oil

100
: When using high performance ele-
ment (micro-glass)
Replacement Interval when us-
ing1500-hour life time hydraulic oil : When using filter-paper element
80

Average 60 Replacement Interval when using

Breaker 2500-hour life time hydraulic oil
Operating
Availability
(%) 40 Replacement Interval when using
4000-hour life time hydraulic oil

20

0 500 1000 1500 2000 2500 3000 3500 4000

M178-13-004
Excavator Operating Hours

IMPORTANT: Use a high performance element (mi-
cro-glass) on K/L Model. In case using a
filter-paper element is unavoidable, re-
place hydraulic oil and the filter element
at the intervals as illustrated with dotted
lines.
NOTE: K Model is equipped with a full-flow filter
restriction indicator. However, if a fil-
ter-paper element is used, this indicator
doesn’t operate. (Refer to the Hydraulic
System in the Maintenance section.)

5-27
 OPERATING THE MACHINE
PRECAUTIONS FOR CRUSHER OPERATION

Prevent machine tipping over and damage to the front at-

tachment. Observe the following precautions for crusher
operation.

CAUTION: Machine stability is reduced as

crusher is much heavier than bucket.
When operating with a crusher, the machine is
more apt to tip over. Also, falling or flying objects
may hit the cab or other part of the machine. Ob-
serve the following precautions and take any
other precautions necessary to prevent accidents
and machine damage from occurring.

• Do not allow the machine’s weight to be supported by WRONG

the crusher or bucket cylinder with the bucket cylinder
fully extended or retracted. Doing so may damage the
front attachment. In particular, avoid doing so with the
bucket cylinder fully extended, as the front attachment
will be easily damaged.
Take care to prevent this from happening when dis-
mantling foundation structures using the crusher.
• Using the front attachment, don’t raise the base ma-
chine off the ground with the arm cylinder fully ex- M107-05-046
tended. Failure to do so may result in damage to the
arm cylinder.
• When a heavyweight attachment such as a crusher is
installed, avoid quickly starting or stopping the front
attachment. Failure to do so may result in damage to
the front attachment.
• Do not attempt to perform crushing on either side of
the machine. Always perform crushing operations to
the fore or rear, parallel with the tracks. Otherwise, WRONG
tipping over may occur.

• Operate the hydraulic excavator carefully to avoid hit- M107-05-047

ting the room, and cab.

WRONG

M1G6-05-009

5-28
 OPERATING THE MACHINE
When operating the crusher up high with the boom fully
raised, be careful of falling objects.
WRONG

M107-05-048

• When operating the crusher on a floor in a building,

first confirm that the floor has sufficient strength to WRONG
support the load caused by crushing, in addition to the
machine weight.
• Always operate the crusher on a stable, level surface,
not on a slope or on crushed scraps.
• Do not use the crusher to haul or load crushed scraps.
• If a multiple number of attachments, such as crusher
and bucket, or crusher and breaker, are used, replac-
ing them with each other at intervals, impurities are
more apt to enter the hydraulic system and the hy-
draulic oil deteriorates quickly. For this reason, replace
the hydraulic oil tank filter and change the hydraulic oil
at the intervals specified in the breaker time sharing
diagram in the previous section. Read the breaker M107-05-049
time sharing diagram supposing that time sharing
percentage of attachment (s) other than the crusher is
that of the breaker.
• Always remove the crusher from the excavator before
transporting the machine. Do not fully extend the
bucket cylinder when transporting, as this may dam-
age the front attachment, when vibrations arise during
transportation.

5-29
 OPERATING THE MACHINE
ATTACHMENT

Allowable Weight Limits of Installed Attachment

!" When an attachment other than the standard bucket is

installed on the machine, the machine stability will be
different. If a heavy attachment is used, not only will con-
trollability be affected but also machine stability will be
reduced, possibly causing safety hazard.

!" Before installing attachments such as hydraulic breaker,

crusher (concrete crusher), or pulverizer, take machine
controllability into account when selecting the weight of
the attachment by referring to the table below.

Unit: kg (lb)
Speci- Base Machine Breaker Crusher/Pulverizer
fica-tion Model Arm Std. Weight Max. Weight Std. Weight Max. Weight
Demoli-
ZX135USK Std. 1050 (2310) 1250 (2750) 1350 (2970) 1600 (3520)
tion Type
ZX125US Std. 950 (2090) 1050 (2310) 1150 (2530) 1350 (2970)
Standard ZX135US Std. 1000 (2200) 1100 (2420) 1200 (2640) 1400 (3080)
Type ZX225US Std. 1650 (3630) 1800 (3960) 2000 (4400) 2300 (5060)
ZX225USLC Std. 1850 (4070) 2050 (4510) 2250 (4950) 2600 (5720)
Logging
ZX135USL Std. 1000 (2200) 1100 (2420) 1200 (2640) 1400 (3080)
Type

!" Breaker operation speed is faster than crusher operation

so that the recommended breaker max. weights are re-
duced more than those of the crushers.

!" The weight is not the only factor to be considered when

selecting a breaker. Select proper manufacturers’
breaker models while referring to the table on the next
page.

!" Avoid installing an attachment with a long overall length.

Damage to the front attachment may result.

!" When an attachment of the max. weight is installed, al-

ways operate the attachment over the front or rear side
of the machine. In addition, avoid operating the attach-
ment at the maximum reach.

!" Crushers are heavier than breakers. Slowly move the

control lever when operating a crusher.

5-30
 OPERATING THE MACHINE
Attachments

Example commercial attachment models (breakers and When the machine is operated with an attachment
crushers) for excavators are shown in the following table. other than bucket, generally heavier loads are ap-
Among the crusher models, some models are heavier than plied to the base machine comparing with bucket
the recommended weight on the previous page. Before in- only operation. Therefore, unless the machine is
stalling them, sufficiently coordinate with the attachment properly operated, damage not only the attachment
manufacture. but to the base machine may result. Thoroughly
read and understand the base machine operator’s
manual and the attachment manual to prevent acci-
dents.
Breaker (ZAXIS125US, 135US, 135USK, 135USL)
MONTA GERMANY
Maker HITACHI NPK Okada Furukawa Mitsubishi Toukuu Matuda STK Ranma
BERT KRUPP

Model HSB29 HSB29S H-7XB OUB308 HB10G MKB900 TNB7E THBB801 BRH625 SIB215 E64 HM560CS

820 920 940 810 790 870 910 740 1000 900 1000 870
Weight kg (lb)
(1810) (2030) (2070) (1790) (1740) (1920) (2010) (1630) (2200) (1980) (2200) (1920)

Flow Rate (L/min) 60～120 60～120 90～140 90～120 70～90 65～110 70～140 80～110 80～130 80～130 70～130 50～110

Operating Pressure 12.3～14.7 12.3～14.7 11.8～13.7 11.8～15.7 13.7～15.7 13.7～16.7 11.8～16.7 13.7～18.6 ～113 13.7～15.7 13.2～14.2 11.8～13.7
MPa (kgf/cm2) (125～150) (125～150) (120～140) (120～160) (140～160) (140～170) (120～170) (140～190) (～115) (140～160) (135～145) (120～140)

Secondary Relief
21.6 21.6 17.6 17.6 17.6 17.6 19.6 11.8 17.6 15.7 16.7
Valve Set Pressure －
(220) (220) (180) (180) (180) (180) (200) (120) (180) (160) (170)
MPa (kgf/cm2)

Breaker (ZAXIS225US, 225USLC)

MONTA GERMANY
Maker HITACHI NPK NPK Okada Furukawa Mitsubishi Toukuu Matuda STK Ranma
BERT KRUPP

Model HSB66 HSB66S H-10XB E-12X OUB312 HB20G MKB1400 TNB14E THBB1400 BRH501 SIB221 E-66 HM960CS

1510 1520 1450 1550 1400 1480 1480 1487 1480 1350 1400 1300 1500
Weight kg (lb)
(3330) (3350) (3200) (3420) (3090) (3260) (3260) (3280) (3260) (2980) (3090) (2870) (3310)

Flow Rate (L/min) 110～160 110～160 160～200 165～210 140～180 125～150 110～160 130～170 120～170 110～140 160～210 100～160 130～170

Operating Pressure 11.8～13.7 15.7～17.7 13.7～16.7 15.7～17.6 14.7～17.6 12.7～16.7 9.8～12.7 7.8～10.8 15.7～17.6 13.2～14.2 11.8～13.7
MPa (kgf/cm2) (125～135) (125～135) (120～140) (160～180) (140～170) (160～180) (150～180) (130～170) (100～130) (80～110) (160～180) (135～145) (120～140)

Secondary Relief
21.6 21.6 17.6 17.6 17.6 17.6 12.7 10.8 19.6 15.9 16.7
Valve Set Pressure － －
(220) (220) (180) (180) (180) (180) (130) (110) (200) (160) (170)
MPa (kgf/cm2)

5-31
 OPERATING THE MACHINE

Crusher (ZAXIS125US, 135US, 135USK, 135USL)

Maker SANGO JYUKI NPK※ Sakado Oosumi STK※

Model TS700RCD S-15X SPAC70R-3 MR800 CX750

1200 1410 1300 1400 1250
Weight kg (lb)
(2650) (3110) (2870) (3090) (2760)
1980 2230 1620 1900 2000
Overall Length mm (ft·in)
(6’6’’) (7’4’’) (5’4’’) (6’3’’) (6’7’’)
Rated Pressure Mpa 24.5 20.6 27.4 ～31.4 27.4
(kgf/cm2) (250) (210) (280) (～320) (280)

Maximum Opening Width 700 750 750 800 750

mm (ft·in) (2’4’’) (2’6’’) (2’6’’) (2’8’’) (2’6’’)

Swing Method Free Free － Free Free

Crusher (ZAXIS 225US, 225USLC)

Maker HITACHI SANGO JYUKI NPK※ Sakado Oosumi STK※

Model HSK100 HSC160 TS850RCD S-22XA SPAC80R-3 MR1 100-2 CX1 100
2430 2300 2000 2000 1640 2100 2350
Weight kg (lb)
(5360) (5070) (4410) (4410) (3620) (4630) (5180)
2340 2600 2500 2500 1810 2100 2450
Overall Length mm (ft·in)
(7’8’’) (8’6’’) (8’2’’) (8’2’’) (5’11’’) (6’11’’) (8’0’’)
Rated Pressure Mpa 27.9 27.9 27.4 24.5 27.4 27.4 27.4
(kgf/cm2) (285) (285) (280) (250) (280) (280) (280)
Maximum Opening Width 900 850 850 850 850 1000 1100
mm (ft·in) (2’11’’) (2’9”) (2’9”) (2’9”) (2’9”) (3’3”) (3’7”)

Swing Method Hydraulic Hydraulic Free Free Free Free Free

Jaw Tip Crushing Kn 640 980 970 630 590

Force (ton) (65) (100) (99) (64) (60)
Jaw Center Kn 980 1570 1570 780 1540 880
Crushing Force (ton) (100) (160) (160) (80) (157) (90)
Always contact your nearest HITACHI dealer before installing attachments shown with this mark ※.

5-32
 OPERATING THE MACHINE
ATTACHMENT CONNECTION PARTS

The attachment hydraulic line and connection parts are lo-

cated as illustrated below. When the attachment is dis-
connected, be sure to install caps or plugs to the ends of
both the arm and attachment side hydraulic lines to pre-
vent dust from entering or from sticking.

Plug Thread Size: JIS B2351 O-Type PF1

Plug
Adapter

Hose

Cap
M178-05-005
When the attachment is disconnected:

Part No. List (Fill attachment manufacturer’s part Nos. in the blank spaces.)
Maker Adapter Size Adapter Cap Plug Hose

Male-Type
Form / Size
PF-UNF

ZAXIS125US, 135US,
PF1-1-1/16UN 4456399 4222711 4222264
135USK, 135USL
ZAXIS 225US,
PF1-1-5/16UN 4214444 4222712 4222265
225USLC

Female-Type
Form / Size
PF-PF30!

ZAXIS125US, 135US,
PF1-PF3/4 4129457 9718916 4222047
135USK, 135USL
ZAXIS225US,
PF1-PF1 4042034 9718917 4168177
225USLC

Male-Type
Form / Size
PF-PF30!

ZAXIS125US, 135US,
PF1-PF3/4 4456120 4222715 4222044
135USK, 135USL
ZAXIS225US,
PF1-1-5/16UN 4456118 4222716 4222045
225USLC

5-33
 OPERATING THE MACHINE
PRECAUTION FOR ARM ROLL-IN/BUCKET
ROLL-IN COMBINED OPERATION
--- If Headguard-Integrated Cab is Equipped

CAUTION: The bucket teeth will hit the head-

guard if the bucket is rolled in with the arm fully
rolled in, as illustrated, when the 4 m long arm
(13 ft 2 in) is attached. When performing com-
bined operation of long arm roll-in/bucket roll-in
or when rolling in the bucket with the long arm
fully retracted, be careful not to hit the headguard
with the bucket teeth.

WHEN INSTALLING AN ATTACHMENT

LONGER THAN STANDARD BUCKET M107-05-072

CAUTION: When an attachment (such as a hy-

draulic breaker or crusher), the overall length of
which is longer than that of the bucket, is in-
stalled, the attachment may come in contact with
the cab and/or the boom. Operate the machine
with care not to allow the tip of the front attach-
ment to hit the cab and/or the boom while rolling
in the front attachment.
M1G6-05-009

5-34
 OPERATING THE MACHINE
SHACKLE HOLE USAGE Shackle hole for towing light
weight objects.
A shackle hole is provided on the track frame to tow light
weight objects as specified below. Track Frame

IMPORTANT: Be sure to conform to the restrictions

and precautions stated below when tow-
ing a light weight object using the
shackle hole provided on the track frame.
The track frame and/or the shackle hole Wire Rope
may be damaged otherwise.

• The maximum drawbar pull is A. Shackle

ZAXIS125US : 39200 N (4000 kgf) M104-05-011

ZAXIS135US, 135USK : 44100 N (4500 kgf)
ZAXIS135USL : 53900 N (5500 kgf)
ZAXIS225US, 225USLC : 73600 N (7500 Kgf)
• Be sure to use a shackle.
• Keep the tow line horizontal, straight, and parallel to
the tracks.
• Select the slow travel mode. Slowly drive the machine
when towing.

OVERNIGHT STORAGE INSTRUCTIONS

1. After finishing the day’s operation, drive the machine

to a firm, level ground where no possibility of falling
stones, ground collapse, or floods.
Park the machine referring to the
“PARKING THE MACHINE” in the “DRIVING THE
MACHINE” section.
2. Fill the fuel tank with fuel.
3. Clean the machine.
4. If anti-freeze or long life coolant is not used in cold
weather, be sure to drain coolant from the radiator
M1SE-05-109
and the engine jacket. Also, be sure to put a tag in a
visible place if the coolant has been drained.

5-35
 OPERATING THE MACHINE
EMERGENCY BOOM LOWERING
PROCEDURE (Without hose-rupture safety
1 Boom I
valve) Front
ZAXIS125US, 135US, 135USK, 135USL

CAUTION: Never allow anyone to come under

the front attachment while performing the 2
emergency boom lowering procedure.

If the engine stalls and cannot be restarted, lower the

boom and the bucket to the ground referring to the
emergency boom lowering procedure stated below.

1. Remove rubber caps (1) and (2) from the boom I

section of the 4-spool control valve.

2. Remove lock nut (8) using a wrench (17 mm). Be

sure to turn the wrench counterclockwise to remove M175-05-001
Control Valve
lock nut (8).

6
3. Turn socket-head screw (7) clockwise to the stop 3
using an allen wrench (4 mm). 4

1
4. Turn lock nut (5) counterclockwise to loosen it, using
5
a wrench (17 mm).

5. Loosen socket-head screw (6) clockwise using an 7

allen wrench (4 mm) while closely watching the boom 2
lower. Note that the loosened degree of screw (6)
determines the boom lowering speed. Adjust the
8
boom lowering speed with the allen wrench as
required.
Take care not to remove snap ring (3) and washer (4)
at this time. Also, do not loosen screw (6) excessively
or cause washer (4) to be deformed.
M154-05-001

6. After the bucket is lowered to the ground, turn screws

(6) and (7) counterclockwise to the stop. Loosen
screw (7) 1/8 of a turn clockwise. Tighten lock nuts
(5) and (8).
Tightening Torque: 20 N!m (2 kgf!m)

7. Re-install rubber caps (1) and (2). Be sure to return

them to their original positions.

NOTE: Be sure to work on screw (7) first, then, on

screw (6), as stated above.

5-36
 OPERATING THE MACHINE
EMERGENCY BOOM LOWERING
PROCEDURE (Without hose-rupture safety
valve)
ZAXIS225US, 225USLC
2
CAUTION: Prevent personal injury. Confirm that 1
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.

1. Loosen lock nut (1). Loosen screw (2) one half of a

turn. The boom will start to lower. The boom lowering
speed can be somewhat adjusted by loosening screw
(2) more.

Front-attachment
NOTE: Never loosen screw (2) more than 2 turns. side
Screw (2) may come off.
M178-05-003

2. After the bucket is lowered to the ground, retighten

screw (2), then lock nut (1) to the specifications be-
low.
Lock Nut (1)
Tool : 13 mm
Torque : 13 N!m (1.3 kgf!m, 9.4 lbf!ft)
Screw (2)
Tool : 4 mm (Hexagonal wrench) Emergency Valve
Torque : 6.9 N!m (0.7 kgf!m, 5.0 lbf!ft)

1
NOTE: Excessive leakage may result if the screw and
the lock nut are tightened insufficiently. Be sure 2
to retighten the screw and the lock nut to speci-
fications.

M178-05-011

5-37
 OPERATING THE MACHINE
EMERGENCY BOOM LOWERING PROCE-
DURE (With hose-rupture safety valve)

CAUTION: Prevent personal injury. Confirm that

no one is under the front attachment before
starting 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.

1. Loosen the lock nut (1).

M1G6-05-017
2. Loosen very slowly the adjusting screw (2) in order to 1
lower the Front Attachment till to ground. 2

NOTE: Never loosen screw (2) more than 1.5 turns.

Screw (2) may come off.
3. After the Front Attachment is lowered to the ground,
retighten adjusting screw (2), then lock nut (1) to the
specifications below.
Lock Nut (1)
Tool : 17 mm
Torque : 30 ± 2 N!m (3.1 kgf·m)
Screw (2) M1G6-05-013

1
Tool : 6 mm (Hexagonal wrench) 2

NOTE: It is enough to perform the above procedure

only on one of the hose-rupture safety valve.

M1G6-05-014

5-38
 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. Do not use damaged chains, frayed
cables, slings, straps, or ropes to crane.

Never move the load quickly. Never move load

over a person’s head. Do not allow any persons
near load.

Keep all persons away from wire-rope-attached

load, lifted or sitting on the ground unless it is
securely sitting on blocks or on the ground.

Position upperstructure so that the travel motors

are at the rear.
SA-014
Do not attach sling/chain to the bucket teeth.

• Secure sling/chain tightly to the load to be lifted. Wear

gloves when securing sling/chain.
• Fasten sling/chain to bucket loop, with the bucket
curled and arm retracted.
• Coordinate hand signals with your signal man before
starting.
• Be aware of the location of all persons in the working
area.
• Attach a hand line to load and make sure person hold-
ing it is well away from load.
• Before lifting, test your load.
1. Park your machine close to load.
2. Attach load to the machine.
3. Raise load 50 mm (2 in) above the ground.
4. Swing the load all the way to one side.
5. While keeping load close to the ground, move it
away from machine.
6. If there is any indication of reduced stability of your
machine, lower load to the ground.
• Lift load only as high as necessary.

5-39
 OPERATING THE MACHINE
LONG ARM OPERATION --- IF EQUIPPED

1. The optional [ZAXIS125US: 2.81 m (9" 2#)]

[ZAXIS135US, 135USK: 3.01 m (9" 11#)] long arm is
only for light works such as loam loading, sludge
handling,etc.. Do not use it for heavy works such as
digging gravel. When the arm is used for digging,
apply shallow cut to the ground to avoid tough
digging, or arm damage may result.

2. When the machine is equipped with the

[ZAXIS125US: 2.81 m (9" 2#)]
[ZAXIS135US, 135USK: 3.01 m (9" 11#)]
long arm, the hoe-bucket size must be limited to
the followings due to stability and strength of the
machine;
3 3
ZAXIS125US PCSA 0.40 m (0.52 yd )
with 700 mm (28 in) shoe
3 3
PCSA 0.45 m (0.59 yd )
3 3
ZAXIS135US, 135USK PCSA 0.45 m (0.59 yd )
with 700 mm (28 in) shoe
3 3
PCSA 0.50 m (0.65 yd )

3. When the machine is equipped with the long arm,

connect the arm cylinder end to:
Pin bore A (when the machine is in operation)
Pin bore B (when the machine is transported)

IMPORTANT: Connect the arm cylinder rod end to pin

bore B only when the machine is
transported.
Do not operate the digging or loading
function with the arm cylinder
connected to pin bore B as the bucket
may hit the cab accidentally with this
connection.

When transporting the machine, follow the procedure

shown below to convert it into the transporting posture.
(a) Position the bucket cylinder with rod retracted a
little from the fully extended position.
(b) Position the arm cylinder with rod retracted a little T105-01-02-002
from the fully extended position.
(c) Lower the boom until the arm top comes into
contact with the ground.
mm (ft. in)

Arm Cylinder Height of Front Attachment (H)

Rod End ZAXIS125US ZAXIS135US, 135USK
Connected To: Without Bucket With Bucket Without Bucket With Bucket
Pin Bore A 2870 (9" 5#) 3120 (10" 3#) 2990 (9" 10#) 3220 (10" 7#)
Pin Bore B 2520 (8" 3#) 2720 (8" 11#) 2620 (8" 7#) 2840 (9" 4#)
Dimensions include shoe-lug height.

5-40
 TRANSPORTING
TRANSPORTING BY ROAD

When transporting the machine on public roads, be

sure to first understand and follow all local regulations.

• When transporting using a trailer, check the width,

height, length and weight of the trailer with the ma-
chine loaded.
Note that transporting the weight and dimensions may M107-06-013
vary depending on the type of shoe or front attach-
ments installed.
• Investigate beforehand the conditions of the route to
be traveled, such as dimensional limits, weight limits,
and traffic regulations.

In some cases, disassemble the machine to bring it within

dimensional limits or weight limits of local regulations.

LOADING/UNLOADING ON A TRAILER

Always load and unload the machine on a firm, level sur-

face.

CAUTION: Be sure to use a loading dock or a

ramp for loading/unloading.

Ramp/Loading Dock:
1. Before loading, thoroughly clean the ramp and flat-
bed. Dirty ramps or flatbeds with oil, mud, or ice on
them are slippery and dangerous.
2. Place blocks against the truck and trailer wheels
while using a ramp or loading dock.
3. Ramps must be sufficient in width, length, and
strength. Be sure that the incline of the ramp is less
than 15 degrees.
4. Loading docks must be sufficient in width and
strength to support the machine and have an incline
of less than 15 degrees.

6-1
 TRANSPORTING
Loading/Unloading

CAUTION:
!" Always turn the auto-idle/acceleration switch
OFF and the power mode switch P or E when
loading or unloading the machine, to avoid
unexpected speed increase due to uninten-
tional operation of a control lever.
!" Always select the slow speed mode with the
travel mode switch. In the fast speed mode,
travel speed may automatically increase.
!" NEVER steer while driving up or down a ramp
as it is extremely dangerous. If repositioning
is necessary, first move back to the ground or
flatbed, modify traveling direction, and begin
to drive again.
!" The top end of the ramp where it meets the
flatbed is a sudden bump. Take care when
traveling over it.
!" Prevent possible injury from machine tipping
while the upperstructure is rotating. Keep the
arm tucked under and rotate the upperstruc-
ture slowly for best stability.

Loading
1. The machine direction should be as follows:
With the front attachment: Travel forward with the
front attachment at the front.
Without the front attachment: Travel in reverse, as il-
lustrated.
2. The centerline of the machine should be over the
centerline of the trailer.
3. Drive the machine onto the ramp slowly.
With the front attachment:
M107-06-021
• Position the bucket with its flat surface resting on
the trailer. Angle of the arm to boom should be 90 to
110°.
• Rest the bucket on the trailer just before the ma-
Less than 15°
chine begins to tip forward onto the trailer. Slowly
travel forward until the tracks are firmly on the
trailer.
M107-06-018
• Slightly raise the bucket. Keeping the arm tucked
under, slowly rotate the upperstructure 180°.
• Lower the bucket onto blocks.

M107-06-013

6-2
 TRANSPORTING

4. Stop the engine. Remove key from switch.

5. Move the control levers several times until hydraulic
pressure in the cylinders is released.
6. Pull pilot control shut-off lever to LOCK position.
7. Close cab windows, roof vent and door, and cover the
exhaust opening, to prevent entry of wind and water.

NOTE: In cold weather, be sure to warm up the ma-

chine before loading or unloading it.

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 at-
tachment to the trailer with a chain or cable.
M107-06-013

6-3
 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. Unloading the machine with
the arm tucked in may cause machine
damage.

1. To move the machine over end of the trailer onto the

ramp, rest the flat surface of the bucket on the
ground. Angle of the arm to the boom should be 90
to 110°.

IMPORTANT: Prevent possible damage to the hydrau-

lic cylinders. Do not allow the machine
to hit the ground hard with the bucket.

2. The bucket must be on the ground before the ma- M107-06-023

chine begins to tip forward.
3. As the machine moves forward, raise the boom and
extend the arm until the machine is completely off the
ramp.

M107-06-015

6-4
 TRANSPORTING
MACHINE LIFTING PROCEDURE

CAUTION:
!" Lifting wire ropes and other lifting tools can
break, possibly causing serious personal in-
jury. Do not use damaged or deteriorated wire
ropes or lifting tools.
!" Be sure to contact your authorized dealer for
correct lifting procedure, and size and kinds
of lifting wire ropes and lifting tools.
!" Pull the pilot control shut-off lever to the
LOCK position so that the machine does not
accidentally move while being lifted.
!" Incorrect lifting procedure and/or incorrect
wire rope attachment will cause the machine
to move (shift) while being lifted, resulting in
machine damage and/or personal injury.
!" Do not lift the machine quickly. Excessive
load will be applied to the lifting wire ropes
and/or lifting tools, possibly causing them to
break.
!" Do not allow anyone to come close to or un-
der the lifted machine.
!" The indicated gravity center is for the stan-
dard specification machine. The gravity center
will vary depending on the kinds of attach-
ments and/or optional equipment to be in-
stalled or their position to be taken. Therefore,
take care not to lose the balance of the ma-
chine while lifting.

Support
1. Fully extend the arm and bucket cylinders. Lower the Bar
boom until the bucket comes in contact with the Center of
ground. Gravity

2. Pull the pilot control shut-off lever to the LOCK posi-

tion.
3. Stop the engine. Remove the key from the key
switch. M1G6-06-001

4. Use wire ropes and support bar of sufficient length so

that they do not come in contact with the machine
while lifting.
Wrap some protectors around wire ropes and/or
support bar as required to prevent the machine from
being damaged.
5. Drive a crane to an appropriate position for lifting.
6. Thread the wire rope through and under both sides of
the track frames as illustrated. Attach the wire ropes
to the crane.

6-5
 TRANSPORTING
MEMO
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6-6
 MAINTENANCE
CORRECT MAINTENANCE AND INSPECTION
PROCEDURES

Learn how to service your machine correctly. Follow the

correct maintenance and inspection procedures shown in
this manual.

Inspect machine daily before starting.

• Check controls and instruments.
• Check coolant, fuel and oil levels.
• Check for leaks, kinked, frayed or damaged hoses
and lines. SA-005

• Walk around machine checking general appearance,

noise, heat, etc.
• Check for loose or missing parts.

If there is any problem with your machine, repair it before

operating or contact your authorized dealer.

IMPORTANT: ! Use only recommended fuel and lu-

bricants.
! Use only genuine HITACHI parts.
! Be sure to use only genuine Hitachi
parts. Failure to do so may result in
serious injury or death and/or ma-
chine breakdown.
! 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.
! Never disassemble electrical compo-
nents such as main controller, sen-
sors, etc.

7-1
 MAINTENANCE
CHECK THE HOUR METER REGULARLY

• Lubricate, make service checks and adjustments at

intervals shown on periodic maintenance chart at-
tached the machine (and on the following pages).
• Intervals on the periodic maintenance chart are for
operating in normal conditions. If you operate your
machine in more adverse conditions, you should ser-
vice it at SHORTER INTERVALS.

USE CORRECT FUELS AND LUBRICANTS

IMPORTANT: Always use recommended fuels and lu-

bricants.
Failure to do so will result in machine
damage and loss of Hitachi product war-
ranty.

7-2
 MAINTENANCE
LAYOUT

Arm Cylinder
Arm Boom

Bucket Cylinder Center Joint

Link B Swing Bearing

Link A Control Valve

Swing Device

Bucket Work Light Hydraulic Oil Tank

Fuel Tank
Boom Cylinder
Side Cutter
Cab Muffler
Tooth

Pilot Filter

Pump
Control Lever Counterweight
Washer Tank Engine
Inter Cooler (Except ZAXIS125US),
Front Idler Radiator, Oil Cooler,
Track Adjuster Air Cleaner
Upper Roller
Reserve Tank
Track Frame Battery
Lower Roller
Track Link
Track
Travel Device Track Shoe

M1SE-01-004

7-3
 MAINTENANCE
MAINTENANCE GUIDE TABLE

The maintenance guide table is affixed to the reverse side

of the tool box cover. Lubricate and/or service the parts at
the intervals as instructed in the table so that all necessary
maintenance can be performed regularly.

!" Symbol Marks

The following marks are used in the maintenance guide
table.

Grease Hydraulic Oil Filter

(Front Joint Pin, Swing Bearing, Swing (Pilot Filter, Hydraulic Oil Tank Filter,
Gear) Suction Filter)
Gear Oil
(Travel Reduction Device, Swing Re- Air Cleaner Element
duction Device)
Coolant
Engine Oil
(Long-Life Coolant)

Fuel Filter
Engine Oil Filter
(Fuel Filter Cartridge)

Hydraulic Oil

Item Page Item Page

1 Engine Oil 7-19 9 Hydraulic Oil Filter (Main) 7-32
2 Coolant 7-51 10 Hydraulic Oil Filter (Pilot) 7-34
3 Grease 7-17 11 Hydraulic Oil Filter (Air Breather) 7-35
4 Grease 7-15 12 Engine Oil Filter 7-19
5 Grease 7-18 13 Gear Oil (Pump Transmission) 7-21
6 Hydraulic Oil 7-27 14 Fuel Filter 7-46
7 Gear Oil (Travel Device) 7-23 15 Gear Oil (Swing Device) 7-22
8 Hydraulic Oil Filter (Suction) 7-29 16 Air Cleaner Element 7-49
ZAXIS225US, 225USLC

7-4
 MAINTENANCE
Maintenance Guide Table
Sample : ZAXIS225US, 225USLC

14 13 11 4 16

12

2
10

6 4 4 5 3
SS2047294

7-5
 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.

M104-07-021
2. Lower the bucket to the ground.
1
3. Turn the auto-idle/auto acceleration selector switch
off.

IMPORTANT: The turbocharger may be damaged if the

engine is not properly shut down.

4. Run the engine at slow idle speed without load for

five minutes.
5. Turn the key switch OFF. Remove key from switch.
2
(If maintenance must be performed with engine run-
ning, do not leave machine unattended.)
6. Pull the pilot control shut-off lever (1) to the LOCK
M1CC-07-003
position.
7. Before performing any work on the machine, attach a
“Do Not Operate” tag on the right control lever.

SA-287 SS2045102

7-6
 MAINTENANCE
HOOD AND ACCESS COVERS 1
2
ZAXIS125US, 135US, 135USK, 135USL

CAUTION:
1. Do not keep the hood and access covers open
when the machine is parked on a slope, or
while the wind is blowing hard. The hood or
access covers may close accidentally, possi-
bly resulting in personal injury.
2. When opening or closing the hood and ac-
M1SE-07-010
cess covers, take extra care not to catch fin-
Engine Cover
gers between the base machine and the hood
or access covers. 2
1
• Remove locks (2 used) to open the engine access
cover. Holding the handle on the access cover, raise
the cover until rod (2) is secured with catch (1).
• After opening the right and/or left access cover, be
sure to insert rod (2) into cover lock hole (3) to hold
the cover.

M1SE-07-011
Radiator Cover

M1SE-07-013
2 Front Right Cover
3 2

Left Cover M1SE-07-014

Rear Right Cover M1SE-07-012

7-7
 MAINTENANCE
ZAXIS225US, 225USLC 1

CAUTION:
1. Do not keep the hood and access covers open 2
when the machine is parked on a slope, or
while the wind is blowing hard. The hood or
access covers may close accidentally, possi-
bly resulting in personal injury.
2. When opening or closing the hood and ac-
cess covers, take extra care not to catch fin-
gers between the base machine and the hood
or access covers.

• Remove locks to open the engine and/or front access Engine Cover M1GF-07-001

cover. Holding the handle on the access cover, raise 2

the cover until rod (2) is secured with catch (1). 1

• After opening the right and/or left access cover, be

sure to insert rod (2) into cover lock hole (3) to hold
the cover.

Front Cover M1GF-07-021

2 3
Front Right Cover M1GF-07-022

Left Cover M1GF-07-023

Rear Right Cover M1GF-07-024

7-8
 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. For this reason, replace these parts at the
intervals shown in the table below. However, if any of these
parts are found to be defective, replace before starting op-
eration, regardless of the interval.
Also, when replacing hoses, check the clamps for defor-
mation, cracks, or other deterioration, and replace as nec-
essary.
Be sure to perform periodic inspection of all hoses, as
shown below, and replace or retighten any defective parts
found, as necessary.
Consult your authorized dealer for correct replacement.

Replacement
Periodic Replacement Parts
Intervals
Fuel hose (Fuel tank to filter) Every 2 years
Fuel hose (Fuel tank to injection pump) Every 2 years
Engine
Oil filter hose (Engine to oil filter) Every 2 years
Heater hose (Heater to engine) Every 2 years
Pump suction hose Every 2 years
Base Machine
Pump delivery hose Every 2 years
Hydraulic Swing hose Every 2 years
System Boom cylinder line hose Every 2 years
Front Arm cylinder line hose Every 2 years
Attachment Bucket cylinder line hose Every 2 years
Pilot hose Every 2 years

NOTE: Be sure to replace seals, such as O-rings and

gaskets, when replacing hoses.

7-9
 MAINTENANCE
MAINTENANCE GUIDE

A. GREASING (See Page 7-15)

Interval (hours)
Parts Quantity
8 50 100 250 500 1000 2000
1. Front Joint ZAXIS125US, 135US, 135USK,
Bucket and 8 " ""
Pins 135USL
Link Pins
ZAXIS225US, 225USLC 9 " ""
Others 11 " ""
2. Swing Bearing 2
3. Swing Internal Gear 1 """

NOTE: " Maintenance required when operating in water or mud and under extreamely severe condition.
"" Maintenance required only during first time check.
""" Check and add grease.

IMPORTANT: Grease bucket and link pivots every day until break-in operation (50 hours) is complete.
When any bucket other than the one with play adjustment devices provided exclusively for
Zaxis series is used, grease the two bucket connecting pins every 250 hours.

B. ENGINE (See Page 7-19)

Interval (hours)
Parts Quantity
8 50 100 250 500 1000 2000
1. Engine Oil Oil Level Check 1
ZAXIS125US,
135US, 135USK, 15.8 L (4.2 US gal)
2. Engine Oil Change 135USL
ZAXIS225US,
25.0 L (6.6 US gal)
225USLC
3. Engine Oil Filter Replacement 1

C. TRANSMISSION (See Page 7-21)

Interval (hours)
Parts Quantity
8 50 100 250 500 1000 2000
1. Pump Transmission Oil Level Check 1
ZAXIS225US,
Change 1.0 L (1.0 US qt)
225USLC
Oil Level Check 1
ZAXIS125US,
2. Swing 135US, 135USK, 3.2 L (3.4 US qt)
Reduction Gear Change 135USL
ZAXIS225US,
6.7 L(1.8 US gal)
225USLC
Oil Level Check 2
ZAXIS125US,
4.0 L#2 (4.2 US qt)
135USL
3. Travel
ZAXIS135US,
Reduction Gear Change 4.2L#2 (1.1 US gal)
135USK
ZAXIS225US,
7.2 L#2 (1.9 US gal)
225USLC

7-10
 MAINTENANCE
D. HYDRAULIC SYSTEM (See Page 7-25)
Interval (hours)
Parts Quantity
8 50 250 300 500 1000 1500 2500 4000
1. Check Hydraulic Oil Level 1
2. Drain Hydraulic Oil Tank Sump 1
ZAXIS125US, 135US,
3. Change 120 L (31.7 US gal) # # # #
135USK, 135USL
Hydraulic Oil
ZAXIS225US, 225USLC 200 L (52.8 US gal) # # # #
4. Suction Filter Cleaning 1 When changing hydraulic oil
ZAXIS125US, 135US 1 # #
5. Replace
ZAXIS135USK, 135USL 1
Full-Flow Filter
ZAXIS225US, 225USLC 1 # #
6. Replace Pilot Oil Filter 1
7. Replace Air Breather Element 1
8. Check Hoses for leaks -
and Lines for cracks, bend, etc. -
NOTE: # Hydraulic oil changing interval differs according to the kind of hydraulic oil used.
See recommended oil chart.

E. FUEL SYSTEM (See Page 7-41) Tank capacity ZAXIS125US, 135US, 135USK, 135USL 250 liter (66 US gal)
ZAXIS225US, 225USLC 270 liter (71 US gal)
Interval (hours)
Parts Quantity
8 50 100 250 500 1000 2000
1. Drain Fuel Tank Sump 1
2. Check Water Separator 1
3. Replace Fuel Filter 1
4. Clean Feed Pump Strainer 1
5. Check Fuel for leaks, cracks, etc. —
Hoses for cracks, bend, etc. —

F. AIR CLEANER (See Page 7-49)

Interval (hours)
Parts Quantity
8 50 100 250 500 1000 2000
1. Air Cleaner Cleaning 1 (Or when indicator lit)
Outer Element Replacement 1 After cleaning 6 times or 1 year
2. Air Cleaner In-
Replacement 1 When outer element is replaced
ner Element

7-11
 MAINTENANCE
G. COOLING SYSTEM (See Page 7-51)
Interval (hours)
Parts Quantity
8 50 100 250 500 1000 2000
1. Check Coolant Level 1
2. Check and Adjust Fan Belt Tension 1 ""
ZAXIS125US, 135US,
19 L (5.0 US gal) Twice a year #1
3. Change Coolant 135USK, 135USL
ZAXIS225US, 225USLC 23 L (6.1 US gal) Twice a year #1
4. Clean Inter Cooler (Except ZAXIS Outside 1 #2
125US), Oil Cooler and Radiator Core Inside 1 When changing coolant
5. Clean Oil Cooler Front Screen 1 #2
6. Clean Air Conditioner Condenser (Opt.) 1 #2
7. Clean Inter Cooler Front Screen (Opt.) 1 #2
Clean Air Conditioner Front Screen (Opt.) 1 #2
NOTE: "" Maintenance required only during first time check.
#1 Change every two years or 4000 operating hours, whichever comes first.
#2 Shorten the maintenance interval when the machine is operated in dusty areas.
IMPORTANT: Use fresh water or normal tap water as a coolant. Don’t use strong acid or alkaline water.
Use the coolant with genuine Hitachi Long-Life Coolant (LLC) mixed by 30 to 50 %.

H. ELECTRICAL SYSTEM (See Page 7-57)

I. MISCELLANEOUS (See Page 7-62)

Parts
1. Check Bucket Teeth for Wear and
Looseness
2. Change Bucket
3. Convert Bucket Connection Into Face
Shovel
4. Adjust Bucket Linkage
5. Remove Travel Levers
6. Check and Replace Seat Belt
7. Check Windshield Fluid Level
8. Check Track Sag
Circulating Air Cleaning
9. Check Air
Filter Replacement
Conditioner
Cleaning
Filter (Opt.) Fresh Air Filter
Replacement
10. Check Air Conditioner (Opt.)
11. Check Injection Nozzle
12. Retighten Cylinder Head Bolt
13. Inspect and Adjust Valve Clearance
14. Check Fuel Injection Timing
15. Measure Engine Compression Pressure
16. Check Starter and Alternator
17. Change Water Pump Grease
18. Check Tightening Torque of Bolts and
Nuts
Interval (hours)
Quantity
8 50 100 250 500 1000 2000 4000
—
— As required
— As required
1 As required
2 As required
1 Every 3 years (Replace)
1 As required
2
1
1 After cleaning 6 times or so
1
1 After cleaning 6 times or so
—
— #
— #As required
— #
— #As required
— #
— #
— #
— ""

NOTE: "" Maintenance required only during first time check.

# Contract your authorized dealer for maintenance.

7-12
 MAINTENANCE
Brand Names of Recommended Grease
Where to be Bucket, Arm and Boom, Swing Gear,
applied Swing Bearing, etc.
Manufacturer –20 to 40 °C (–4 to 104 °F)
Nippon Koyu SEP 2 #1
British Petroleum BP Energrease LS-EP2
Caltex Oil Multifax EP2
Esso Beacon EP2
Idemitsu Kosan Daphne Coronex Grease EP2
Mobil Oil Mobilux EP2
Nippon Oil Epinoc Grease AP2
Shell Oil Shell Alvania EP2 #2
NOTE: The machine shipped from the factory is filled
with lubricants marked with .
#1 Swing Gear
#2 Front Joint Pin and Swing Bearing

Recommended Engine Oil

Depending upon the expected air temperature
range between oil changes, use the oil viscosity
shown on the temperature chart below.

API CD Class
SAE 30 or equivalent (both summer and winter)
High temperature areas, SAE 40 or equivalent
Low temperature areas, SAE 10W or equivalent

Brand Names of Recommended Engine Oil

Kind of Oil Engine Oil
Application Engine Crank Case Fuel Injection Pump and
Air Governor
Temp. –20 to 0 °C –10 to 35 °C 25 to 40 °C
Manufacturer (–4 to 32 °F) (14 to 95 °F) (77 to 104 °F)
British Petro- BP Vanellus C3
leum 10W 30 40
RPM DELO 300 Oil
Caltex Oil
10W 30 40
Essolube D-3
Esso
10W 30 40
Apolloil diesel motive
S-310 S-330 S-340
Idemitsu Kosan –15 to 40 °C (5 to 104 °F)
Apolloil custom wide 15W-40
Apolloil super wide 15W-40
Mobil Delvac
Mobil Oil
1310 1330 1340
Hidiesel S 3
Nippon Oil –20 to 35 °C (–4 to 95 °F) –10 to 40 °C (14 to 104 °F)
10W-30 15W-40
Rymla D
Shell Oil
10W 30 40
NOTE: The machine shipped from the factory is filled with lubricants marked
with .

7-13
 MAINTENANCE
Brand Names of Recommended Oil
Application Swing and Travel Reduction Gear Pump Transmission
Kind of Oil Gear oil Engine Oil or Gear Oil (shown in left column)
Air Temp. –20 to 40 °C –10 to 35 °C –25 to 40 °C
–20 to 40 °C (–4 to 104 °F) (–4 to 104 °F) (14 to 95 °F) (77 to 104 °F)
Manufacturer BP Vanellus C3
British Petroleum BP Gear oil SAE90EP
30 40
RPM DELO 300 Oil
Caltex Oil Universal Thuban SAE 90
30 40
Essolube D-3
Esso Esso Gear Oil 80W-90, 85W-90
30 40
Apolloil super wide Apolloil diesel motive
Idemitsu Kosan Apollo Gear HE90
15W-40 S-330 S-340
Mobil Delvac
Mobil Oil Mobilube GX90
1330 1340
Gear Lube SP90 (Swing and travel Hidiesel S3
reduction device) #2 –20 to 35 °C
Nippon Oil
SP80W-90 (Pump Transmission ‘only’) 15W-40 #1 (–4 to 95 °F)
#1 10W-30
Rymla zoil white pilot super
Shell Oil Shell Spirax EP90
30 40
Remarks API GL 4 Class API CD Class

NOTE: The machine shipped from the factory is filled with oil marked .
#1 Engine oil or gear oil for pump transmission
#2 Gear oil for swing and travel reduction device
Engine/gear oil can be used for pump transmission.
Brand Names of Recommended Hydraulic Oil
Kind of Lubricant Hydraulic Oil
Where to be applied Hydraulic System
Change Interval 4000 hours 2500 hours 1500 hours
Environmental
–20 to 40°C –10 to 40°C –20 to 40°C –10 to 40°C –20 to 40°C –10 to 40°C
Temp.
(–4 to 104°F) (14 to 104°F) (–4 to 104°F) (14 to 104°F) (–4 to 104°F) (14 to 104°F)
Manufacturer
Hitachi Super EX 46HN
Idemitsu Kosan Super Hydro 46 WRHU
British Petroleum Bartran HV46
Rando Oil
Caltex Oil
HD46
Rando Oil
Texaco INC.
HD46
Chevron U.S.A INC. Chevron AW46
Esso NUTO H46
Mobil Oil DTE 25
Shell Oil Tellus Oil S46 Tellus Oil 46
Remarks Anti-wear type hydraulic oil

NOTE: Use proper hydraulic oil in accordance with the atmospheric temperature.
The machine shipped from the factory is filled with oil marked .
When the atmospheric temperature is between -40°C and +20°C: Use the proper hydraulic oil having
high and low temperture characteristics by referring to the values shown below.
Low Temerture Viscosity: Less than 4000cSt at -40°C
High Temerture Viscosity: More than 6.5cSt at +80°C
The above values are approximately equivalent to ISO viscosity grade #22. However, low temperature
viscosity will differ depending on each product. Contact each hydraulic oil manufacture directly.
When the atmospheric temperature is below -40°C: Contact your authorized dealer

7-14
 MAINTENANCE
A. GREASING

Front Joint Pins

Bucket and Link Pins --- every 500 hours

ZAXIS125US, 135US, 135USK M178-07-007

135USL ZAXIS225US, 225USLC

Others --- every 500 hours

• Boom Foot

ZAXIS125US, 135US, 135USK, 135USL M1SE-07-003

ZAXIS225US, 225USLC M1GF-07-019

• Boom Cylinder Bottom

M104-07-002

7-15
 MAINTENANCE
• Boom and Arm Joint Pin, Arm Cylinder Rod Pin and
Bucket Cylinder Bottom Pin.

ZAXIS125US, 135US, 135USK, ZAXIS225US, 225USLC

135USL M157-07-157 M154-07-003

• Boom Cylinder Rod Pins and Arm Cylinder Bottom Pin.

(Centralized greasing system)

M1GF-07-019
ZAXIS125US, 135US, 135USK, 135USL

M1SE-07-003
ZAXIS225US, 225USLC

7-16
 MAINTENANCE

Swing Bearing --- every 500 hours

CAUTION: Lubricating both the swing bearing

and gear and rotating the upperstructure must be
done by one person. Before you lubricate the
swing bearing, clear the area of all persons.

Each time you leave the cab

! Lower the bucket to the ground.
! Stop the engine.
! Pull the pilot control shut-off lever to the
LOCK position.
! Use handrails. 1 M157-07-159

1. Park the machine on a level surface.

2. Lower the bucket to the ground.
3. Turn the auto-idle switch off.
IMPORTANT: The turbocharger may be damaged if the
engine is not properly shut down.

4. Run the engine at slow idle speed without load for

five minutes.
5. Turn the key switch OFF. Remove the key from the
key switch.
6. Pull the pilot control shut-off lever to the LOCK posi-
tion.
7. With the upperstructure stationary, apply grease via
the two grease fittings.
8. Start the engine. Raise the bucket several inches off
the ground and rotate the upperstructure 45! (1/8
turn).
9. Lower the bucket to the ground.
10. Repeat the procedure three times, beginning with
step 3.
11. Apply grease to the swing bearing until grease can
be seen escaping from the swing bearing seals.
Grease capacity:
ZAXIS125US, 135US, 135USK, 135USL
0.25 L (0.27 US qt)
ZAXIS225US, 225USLC 0.30 L (0.32 US qt)

12. Take care not to supply excessive grease.

7-17
 MAINTENANCE

Swing Internal Gear --- every 500 hours

CAUTION: Adding or changing swing internal

gear grease and rotating the upperstructure must
be done by one person. Before you start, clear
the area of all persons.

Each time you leave the cab

! Lower the bucket to the ground. 1
! Stop the engine.
! Pull the pilot control shut-off lever to the
LOCK position.
! Use handrails.

1. Park the machine on a level surface.

2. Lower the bucket to the ground.
3. Turn the auto-idle switch off.
IMPORTANT: The turbocharger may be damaged if the
engine is not properly shut down. ZAXIS125US, 135US, 135USK, 135USL M154-07-012

4. Run the engine at slow idle speed without load for 1

five minutes.
5. Turn the key switch OFF. Remove the key from the
key switch.
6. Pull the pilot control shut-off lever to the LOCK posi-
tion.
7. Open the tool box cover on the upperstructure and
remove cover (1).
8. Grease must be to the top of all internal gear teeth of
the swing bearing and be free of contamination.
Add approximately 0.5 kg (1.1 lb) of grease, if re-
quired. If the grease is contaminated, remove grease
and replace with clean grease. ZAXIS225US, 225USLC M178-07-008

IMPORTANT: If water or mud is found in the swing

gear area, see Operating in Water or Mud
in the “Driving the Machine” section.

9. Install the cover.

10. If grease shows any sign of water or mud, replace all
the grease on the internal gear.
Remove cover (2) from the bottom of the swing gear
housing, located near the center joint.

2
Grease capacity:
ZAXIS125US, 135US, 135USK, 135USL
9 L (2.4 US gal) M154-07-011

ZAXIS225US, 225USLC 14 L (3.7 US gal)

7-18
 MAINTENANCE
B. ENGINE

Engine Oil Level --- check daily

1

IMPORTANT: For most accurate readings, check the 2

oil level every day before starting the
machine. Be sure the machine is on a
level surface.

1. Remove dipstick (1). Wipe oil off with a clean cloth.

Reinsert dipstick (1).
2. Remove dipstick (1) again. Read level. Oil level must
be between the circle marks. SS-2092

3. If necessary, add oil via oil filler cap (2). ZAXIS125US, 135US, 135USK, 135USL
Be sure to use only recommended oil (see Recom-
mended Engine Oil Chart). 1
2

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.

CAUTION: The ZAXIS 125US engine is not

equipped with an intercooler.

ZAXIS225US, 225USLC SS-2110

Change Engine Oil --- every 500 hours

Replace Engine Oil Filter

--- every 500 hours

1. Run the engine to warm oil. Max.

DO NOT run the engine until oil is hot. Min.

2. Park the machine on a level surface. M178-07-011

3. Lower the bucket to the ground.

4. Turn the auto-idle switch off.

IMPORTANT: The turbocharger may be damaged if the

engine is not properly shut down.

5. Run the engine at slow idle speed without load for

five minutes.
6. Turn the key switch OFF. Remove the key from the
key switch.
7. Pull the pilot control shut-off lever to the LOCK posi-
tion.

7-19
 MAINTENANCE

CAUTION: Engine oil may be hot. Take extra care

to avoid burns.
3
8. Remove oil filler cap (2). Remove drain plug (4). Al-
low oil to drain through a clean cloth into a 50 liter (13
4
US gal) container.
9. After all oil has drained, inspect cloth for any debris
such as small pieces of metal.

10. Install and tighten drain plug (4).

ZAXIS125US, 135US, 135USK, 135USL M1SE-07-019
ZAXIS125US, 135US, 135USK, 135USL
11. Engine oil filter cartridge element (5) is located next
to the pump device. Open the right access cover and 3
secure the cover with rod (6).
12. Remove the filter cartridges of engine oil filter (5) by 4
turning it counterclockwise with the filter wrench.
13. Clean the filter gasket contact area on the engine.
14. Apply a thin film of clean oil to the gasket of the new
filter. ZAXIS225US, 225USLC M1GF-07-007

15. Install new filter. Turn the filter cartridge clockwise by

hand until the gasket touches the contact area. Be
sure not to damage the gasket when installing the fil-
Oil Pan
ter.
16. Tighten engine oil filter (5) 3/4 to 1 turn more using Clean Cloth
the filter wrench. Container
Be careful not to overtighten.
17. Remove the oil filler cap. Fill the engine with recom- 6
M104-07-010
mended oil. Check that oil level is between the circle
marks on the dipstick after 15 minutes.

Engine oil capacity:

ZAXIS125US, 135US, 135USK, 135USL
15.8 L (4.2 US gal)
ZAXIS225US, 225USLC 25.0 L (6.6 US gal)

18. Install the oil filler cap.

5
19. Start the engine. Run the engine at slow idle for 5
minutes. ZAXIS125US, 135US, 135USK, 135USL M1SE-07-015

20. Check that the engine oil pressure indicator on the

monitor panel goes out immediately. If not, stop the
engine immediately and find the cause.
21. Stop the engine. Remove the key from the key
switch.
5
22. Check for any leakage at the drain plug.
23. Check oil level on the dipstick.

NOTE: Don’t re-use the cartridge element.

ZAXIS225US, 225USLC M1GF-07-007

7-20
 MAINTENANCE
C. TRANSMISSION

Pump Transmission
ZAXIS225US, 225USLC
Check Oil Level --- every 250 hours
1. Park the machine on a level surface.
M104-07-021
2. Lower the bucket to the ground.
3. Turn the auto-idle switch off.
IMPORTANT: The turbocharger may be damaged if the 2
engine is not properly shut down.
1
4. Run the engine at slow idle speed without load for
five minutes.
3
5. Stop the engine. Remove the key from the key
switch.
6. Pull the pilot control shut-off lever to the LOCK posi-
tion.
7. Remove dipstick (1). Oil must be within the specified
range.
8. If necessary, remove filler plug (2) and add oil. (See
M178-07-085
gear oil chart)
9. Recheck oil level.

Change Oil --- every 1000 hours

1. Park the machine on a level surface.
2. Lower the bucket to the ground.
Clean Cloth
3. Turn the auto-idle switch off.
Container
IMPORTANT: The turbocharger may be damaged if the
engine is not properly shut down.

4. Run the engine at slow idle speed without load for

M104-07-010
five minutes.
5. Stop the engine. Remove the key from the key
switch.
6. Pull the pilot control shut-off lever to the LOCK posi-
Specified Range
tion.

CAUTION: Oil may be hot. Wait for oil to cool 1

before starting work.

7. Remove filler plug (2).

8. Remove drain plug (3). Allow oil to drain through a
clean cloth into a 2 liter (0.52 US gal) container.
M110-07-016
9. After all oil has drained, inspect cloth for any debris
such as small pieces of metal.
10. Reinstall the drain plug (3).
11. Add oil via filler plug (2) until it is within the specified
range on dipstick (1).
12. Reinstall filler plug (2).

7-21
 MAINTENANCE

Swing Reduction Gear 1

Check Oil Level --- every 250 hours

1. Park the machine on a level surface.
2. Lower the bucket to the ground.
3. Turn the auto-idle switch off.
IMPORTANT: The turbocharger may be damaged if the
engine is not properly shut down.

4. Run the engine at slow idle speed without load for

five minutes. 2 M1SE-07-020
ZAXIS125US, 135US, 135USK, 135USL
5. Stop the engine. Remove the key from the key
switch.
1
6. Pull the pilot control shut-off lever to the LOCK posi-
tion.
7. Remove dipstick (1). Oil must be between marks.
8. If necessary, remove oil filler cap (2) and add oil.
(See gear oil chart) 2
9. Recheck oil level.

Change Gear Oil --- every 1000 hours

1. Park the machine on a level surface. ZAXIS225US, 225USLC M1GF-07-002

2. Lower the bucket to the ground.

3. Turn the auto-idle switch off.
IMPORTANT: The turbocharger may be damaged if the
engine is not properly shut down.

4. Run the engine at slow idle speed without load for Specified Range
five minutes.
5. Stop the engine. Remove the key from the key M104-07-017
switch.
6. Pull the pilot control shut-off lever to the LOCK posi-
tion.

CAUTION: Gear oil may be hot. Wait for gear oil

to cool before starting work.

7. Remove the drain plug mounted on the end of drain

pipe to drain oil.
8. Reinstall the drain plug.
9. Remove oil filler cap (2) and add oil until it is between
the marks on dipstick (1).
10. Reinstall the oil filler cap.

7-22
 MAINTENANCE
Air Release Plug 1
Travel Reduction Gear (Oil Supply Plug)

Check Oil Level --- every 250 hours Oil Level Check
Plug 2
1. Park the machine on a level surface. Horizontal Oil Level
2. Rotate the travel motor until the imaginary line
through plug (1) and plug (3) is vertical.
3. Lower the bucket to the ground.
4. Turn the auto-idle switch off. Drain Plug 3
IMPORTANT: The turbocharger may be damaged if the M107-07-096
engine is not properly shut down.
1
5. Run the engine at slow idle speed without load for
five minutes.
6. Stop the engine. Remove the key from the key
2
switch.
7. Pull the pilot control shut-off lever to the LOCK posi-
tion.
3
CAUTION: Keep body and face away from the air
release plug. Gear oil is hot. Wait for gear oil to
cool and then gradually loosen the air release
plug to release pressure. M157-07-170

8. After gear oil has cooled, slowly loosen air release

plug (1) to release pressure.
9. Remove air release plug (1) and oil level check plug
(2). Oil must be up to the bottom of hole.
10. If necessary, add oil until oil flows out of the oil level
check plug hole. (See gear oil chart)
11. Wrap the plug threads with sealing-type tape. Install
plugs (1) and (2).
Tighten plugs (1) and (2) to 50 N"m (5.1 kgf"m, 37
lbf"ft).
12. Check the gear oil level in the other travel reduction
gear.

7-23
 MAINTENANCE
Change Gear Oil --- every 2000 hours

1. Park the machine on a level surface. 1

2. Rotate the travel motor until the imaginary line

through plug (1) and plug (3) is vertical.
2
3. Lower the bucket to the ground.
4. Turn the auto-idle switch off.
3

IMPORTANT: The turbocharger may be damaged if the

engine is not properly shut down.
M157-07-170
5. Run the engine at slow idle speed without load for
five minutes.
6. Stop the engine. Remove the key from the key
switch.
7. Pull the pilot control shut-off lever to the LOCK posi-
tion.

CAUTION: Keep body and face away from the air

release plug. Gear oil is hot. Wait for gear oil to
cool and then gradually loosen the air release
plug to release pressure.

8. After gear oil has cooled, slowly loosen air release

plug (1) to release pressure, and temporarily re-
tighten plug (1).
9. Remove drain plug (3) and plug (1), in that order, to
drain oil.
10. Clean drain plug (3). Wrap the threads of the drain
plug with sealing-type tape. Install the plug.
Tighten the plug to 50 N!m (5.1 kgf!m, 37 lbf!ft).
11. Remove oil level check plug (2).
12. Add oil until oil flows out of the oil level check plug
hole. (See gear oil chart)
13. Clean plugs (1) and (2). Wrap the threads of oil level
check plug (2) and air release plug (1) with seal-
ing-type tape. Reinstall the plugs.
Tighten the plugs to 50 N!m (5.1 kgf!m, 37 lbf!ft).
14. Repeat steps 8. to 13. for the other travel reduction
gear.

7-24
 MAINTENANCE
D. HYDRAULIC SYSTEM

INSPECTION AND MAINTENANCE OF HY-

DRAULIC 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, firm

surface before servicing hydraulic equipment.
2. Lower the bucket to the ground and stop the engine.
3. Begin servicing hydraulic components only after
components, hydraulic oil and lubricants are com-
pletely cooled, and after releasing residual pressure.
3.1 Bleed air from the hydraulic oil tank to release in-
ternal pressure.
3.2 Allow the machine to cool down.
Note that servicing heated and pressurized hydrau-
lic components may cause hot parts and/or oil to fly
off or escape suddenly, possibly resulting in per-
sonal injury.
3.3 Keep body parts and face away from plugs or
screws when removing them.
Hydraulic components may be pressurized even
when cooled.
3.4 Never attempt to service or inspect the travel and
swing motor circuits on slopes. They are highly
pressurized due to self-weight.

4. When connecting hydraulic hoses and pipes, take

special care to keep seal surfaces free from dirt and
to avoid damaging them. Keep these precautions in
mind:
4.1 Wash hoses, pipes, and the tank interior with a
washing liquid and thoroughly wipe it out before re-
connecting them.
4.2 Only use O-rings that are free of damage or defects.
Be careful not to damage them during reassembly.
4.3 Do not allow high pressure hoses to twist when
connecting them. The life of twisted hoses will be
shortened considerably.
4.4 Carefully tighten low pressure hose clamps.
Do not overtighten them.
5. When adding hydraulic oil, always use the same
brand of oil; do not mix brands of oil. As the machine
is filled with Super EX 46HN when it is shipped from
the factory, use it as a general rule. When selecting
to use another brand of oil listed in the table “Brand
names of recommended hydraulic oil”, be sure to
completely replace the oil in the system.
6. Do not use hydraulic oils other than those listed in the
table “Brand names of recommended hydraulic oil”.
7. Never run the engine without oil in the hydraulic oil
tank.

7-25
 MAINTENANCE
REPLACEMENT OF HYDRAULIC OIL AND
FILTER

Change Hydraulic Oil and Replace Hydraulic Oil Tank Filter
Hydraulic breaker operation subjects the hydraulic system
to become contaminated faster and to quickly deteriorate
the hydraulic oil. For this reason, hydraulic oil must be
changed and the hydraulic oil tank filter must be replaced
more often than the machine equipped with a bucket. Fail
ure to do so may result in damage to the breaker,
hydraulic oil pump, and other related hydraulic sys-
tem components. Recommended changing intervals
are shown below. (For filter replacement and oil
changing intervals are shown below.(For filter re-
placement and oil changing procedures, refer to the
“Hydraulic System” in the “MAINTENANCE” Sec-
tion.)

Changing intervals (Hours)

Full Flow Filter

Attachments Availability Hydraulic Oil
Element
Element Type

1500
Standard Filter Paper
Bucket 100% 2500 1000
High Performance Element
4000
Hydraulic 600 100 Standard Filter Paper
100%
Breaker 1000 300 High Performance Element
: Replacement intervals differ depending on the brand of hydraulic oil used. Refer to the Hydraulic System in the
MAINTENANCE section.
: Use the high performance element (micro-glass) on K/L Model.

Replacement Intervals (Hours) of Hydraulic Oil and Full Flow Filter Element

Hours to Replace Hours to Replace Hy-

Element draulic Oil

100
: When using high performance ele-
ment (micro-glass)
Replacement Interval when us-
ing1500-hour life time hydraulic oil : When using filter-paper element
80

Average 60 Replacement Interval when using

Breaker 2500-hour life time hydraulic oil
Operating
Availability
(%) 40 Replacement Interval when using
4000-hour life time hydraulic oil

20

0 500 1000 1500 2000 2500 3000 3500 4000

M178-13-004
Excavator Operating Hours

IMPORTANT: Use a high performance element (mi-
cro-glass) on K/L Model. In case using a
filter-paper element is unavoidable, re-
place hydraulic oil and the filter element
at the intervals as illustrated with dotted
lines.
NOTE: K Model is equipped with a full-flow filter
restriction indicator. However, if a fil-
ter-paper element is used, this indicator
doesn’t operate. (Refer to the Hydraulic
System in the Maintenance section.)

7-26
 MAINTENANCE

Check Hydraulic Oil Level --- daily

IMPORTANT: Never run the engine without oil in hy-

draulic oil tank.

1. Park the machine on a level surface.

M104-07-021
2. Position the machine with the arm cylinder fully re-
tracted and the bucket cylinder fully extended.
3. Lower the bucket to the ground.
4. Turn the auto-idle switch off.
IMPORTANT: The turbocharger may be damaged if the
engine is not properly shut down.
1
5. Run the engine at slow idle speed without load for
five minutes.
6. Turn the key switch OFF. Remove the key from the
key switch.
7. Pull the pilot control shut-off lever to the LOCK posi-
tion.
8. Check oil level with level gauge (1) on hydraulic oil
tank. Oil must be between marks on the gauge. If
necessary, add oil. ZAXIS125US, 135US, 135USK, 135USL M1SE-07-004

CAUTION: The hydraulic oil tank is pressurized.

Push the pressure release button on the tank cap 1
to release pressure, and carefully remove the
cap.

To add oil:
9. Push the pressure release button on the air breather
to release pressure. Remove the cover.
10. Add oil. Recheck oil level with level gauge (1).
11. Install the cover. Make sure the filter and rod assem-
bly is in correct position.

ZAXIS225US, 225USLC M1GF-07-003

7-27
 MAINTENANCE

Drain Hydraulic Tank Sump

--- every 250 hours

IMPORTANT: Never run the engine without oil in hy-

draulic oil tank.

1. Park the machine on a level surface with the upper- 1 M104-07-117

structure rotated 90! for easier access.

2. Lower the bucket to the ground.
3. Turn the auto-idle switch off.
IMPORTANT: The turbocharger may be damaged if the
engine is not properly shut down.

4. Run the engine at slow idle speed without load for

five minutes.
5. Turn the key switch OFF. Remove the key from the
key switch. ZAXIS125US, 135US, 135USK, 135USL SS-2096

6. Pull the pilot control shut-off lever to the LOCK posi-

tion.

CAUTION: The hydraulic oil tank is pressurized.

2
Push the pressure release button on the air
breather to release pressure.

7. Push the pressure release button (1) on the air

breather to release pressure.

CAUTION: Do not loosen the drain plug until oil ZAXIS125US, 135US, 135USK, 135USL M1SE-07-021
is cool. Hydraulic oil may be hot, potentially
causing serious injury. 1

8. After oil is cool, loosen drain plug (2) to drain water

and sediment. Do not remove the plug completely,
only loosen it enough to drain water and sediment.
9. After draining water and sediment, retighten the plug.

ZAXIS225US, 225USLC SS-2086

ZAXIS225US, 225USLC M1GF-07-011

7-28
 MAINTENANCE

Change Hydraulic Oil

Suction Filter Cleaning

--- every 4000 hours, 2500 hours
or 1500 hours
K/L model: 1000 hours
M104-07-117
CAUTION: Hydraulic oil may be hot. Wait for oil 1
2
to cool before starting work.
Level Gauge
IMPORTANT: Hydraulic oil changing intervals differ
according to kind of hydraulic oils used.
(See Recommended Oil Chart in this
group)

1. Park the machine on a level surface with the upper-

structure rotated 90! for easier access. High
2. Position the machine with the arm cylinder fully re- Low
tracted and the bucket cylinder fully extended.
3. Lower the bucket to the ground. M157-07-016

4. Turn the auto-idle switch off. 2 1

IMPORTANT: The turbocharger may be damaged if the

engine is not properly shut down.

5. Run the engine at slow idle speed without load for

five minutes.
6. Stop the engine. Remove the key from the key
switch.
7. Pull the pilot control shut-off lever to the LOCK posi-
tion.
8. Clean the top of the hydraulic oil tank to keep dirt out ZAXIS125US, 135US, 135USK, 135USL SS-2096
of the hydraulic system.

CAUTION: The hydraulic oil tank is pressurized. 1

Push the pressure release button on the air
breather before removing the air breather.
2
9. Push pressure release button (1) on the air breather.
10. Remove cover (2).
11. Remove oil using a suction pump. The hydraulic oil
tank capacity, up to specified oil level, is approxi- SS-2086
mately 200 liters (53 US gal).
ZAXIS225US, 225USLC

7-29
 MAINTENANCE
12. Remove drain plug (3). Allow oil to drain.
13. Remove suction filter and rod assembly (4).
2
14. Clean the filter and tank interior. If the filter is to be
replaced, install new filter on the rod as shown.
Tighten nut to 14.5 to 19.5 N!m (1.5 to 2.0 kgf!m,
11.0 to 14.5 lbf!ft).

3
M157-07-062

ZAXIS125US, 135US, 135USK, 135USL M1SE-07-021

3
ZAXIS225US, 225USLC M1GF-07-011

7-30
 MAINTENANCE
15. Install filter and rod assembly (4). Make sure the filter
is positioned correctly on the outlet.
ZAXIS125US, 135US, 135USK, 135USL: 732 mm (28.8 in)
16. Replace the hydraulic tank oil filter. (See “Mainte- ZAXIS225US, 225USLC: 931 mm (36.6 in)
nance Every 500 Hours” Section)
17. Clean, install and tighten drain plug (3).
20 mm (0.79 in)
18. Add oil until it is between the marks on the oil level
gauge.
19. Install cover (2). Make sure filter and rod assembly
(4) are in correct positions. Tighten the bolts to 50
N!m (5.1 kgf!m, 37 lbf!ft).

4
IMPORTANT: If the hydraulic pump is not filled with oil,
M107-07-070
it will be damaged when the engine is 5
started.

20. Remove air bleed plug (5) from the top of the pump.
21. Fill the pump with oil through air bleed plug (5) port.
22. Reinstall the plug.
23. Start the engine and run at slow idle. Put a “Do Not
Operate” tag on the pilot control shut-off lever.
Make sure the pilot control shut-off lever is in the
LOCK position.
24. Slowly loosen air bleed plug (5) to release trapped air.
Retighten the plug when air stops and oil flows from
the plug port. ZAXIS125US, 135US, 135USK, 135USL M1SE-07-005

25. Purge air from the hydraulic system by running the 5

engine at slow idle and operating all control levers
slowly and smoothly for 15 minutes.
Note that an air bleeding device is equipped in the
pilot circuit. For this reason, air in the pilot circuit has
been purged with the completion of this step.
26. Position the machine with the arm cylinder fully re-
tracted and the bucket cylinder fully extended.
27. Lower the bucket to the ground.
28. Turn the auto-idle switch off.
29. Stop the engine. Remove the key from the key
switch.
30. Pull the pilot control shut-off lever to the LOCK posi- ZAXIS225US, 225USLC M1GF-07-005

tion.
31. Check the hydraulic oil tank gauge. Remove cover
(2) to add oil if necessary.

7-31
 MAINTENANCE

Replace Full-Flow Filter --- every 1000 hours

1. Park the machine on a level surface.

2. Lower the bucket to the ground.
3. Turn the auto-idle switch off.
IMPORTANT: The turbocharger may be damaged if the
engine is not properly shut down.

4. Run the engine at slow idle speed without load for

five minutes.
SA-039
5. Stop the engine. Remove the key from the key
switch.
1 2 3
6. Pull the pilot control shut-off lever to the LOCK posi-
tion.

CAUTION: The hydraulic oil tank is pressurized.

Push the pressure release button on the air
breather before removing the air breather. 4

7. Push the pressure release button on the hydraulic oil

tank to release pressure.

NOTE: There is spring tension under the cover. Hold

down the cover when removing last two bolts.

8. Hold down filter cover (2) against light spring load

when removing the last two bolts (1). Remove filter
cover (2).
9. Remove spring (4) and element (5). 5

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. A rubber type of
material can indicate cylinder packing failure.

10. Discard element (5) and O-ring (3).

11. Install a spring (4) and new element (5).
12. Install filter cover (2) with a new O-ring (3). M178-07-069

13. Install and tighten bolts (1) to 50 N!m (5.1 kgf!m, 37

lbf!ft).

7-32
 MAINTENANCE

Replace Full-Flow Filter (K/L Model)

--- every 300 hours
In case the hydraulic oil filter indicator on the monitor panel
comes ON, immediately replace the filter even if operation
hours are shorter than 300 hours after replacing the filter
previously.
M104-07-021

CAUTION: :Immediately after operating the ma-

chine if hydraulic system or line is openned, hot
and high pressure hydraulic oil may spout, pos-
sibly causing severe burns. Wait for the hydrau-
lic oil to cool before starting any maintenance
work.
7
IMPORTANT: Replacement intervals differ according
to the brand of hydraulic oil used and
the kind of the filter element used, as
well as the operating hour ratio of the
installed attachment.
1
IMPORTANT: Precautions for Using Element
1. High performance element (mi-
cro-glass) is used in the full-flow filter
element on Excavators for Demolition
Work (K/L Model). Be sure to replace
the filter with the same type of high
performance element. In case using a
filter-paper element is unavoidable,
refer to the descriptions for replacing
hydraulic oil and full-flow filter ele-
ment in the MAINTENANCE section.
2. In case the same filter paper element 4 2 3 1
as used on Std. Model, the filter re-
striction indicator will not operate.
Insulate the harness to indicator (7).

Replacement
1. Park the machine on solid and level ground. After
extending the bucket cylinder, retracting the arm cyl-
inder, and lowering the bucket on the ground, as il-
lustrated to the right, stop the engine. 5
2. Be sure to push the air vent valve to release any air
pressure from the hydraulic oil tank before replacing
the element.
3. Remove bolts (1) (6 used) to remove cover (2) and
O-ring (3). When removing cover (2), slowly remove it
while pressing the cover downward so that spring (4)
doesn’t fly out.
4. Remove spring (4) and element (5).
5. Replace element (5) and O-ring (3) with new ones.
Install them into the hydraulic oil tank.
6. Install cover (2). Tighten bolts (1) (6 used) to specifi-
cation. M175-07-035

Tightening Torque: 50 N-m (5.1 kgf·m 37 lbf·ft)

7-33
 MAINTENANCE

Replace Pilot Oil Filter

--- every 1 000 hours

1. Park the machine on a level surface.

2. Lower the bucket to the ground.
3. Turn the auto-idle switch off. M104-07-021

IMPORTANT: The turbocharger may be damaged if the

engine is not properly shut down.

4. Run the engine at slow idle speed without load for

1
five minutes.
2
5. Stop the engine. Remove the key from the key
switch. 3
6. Pull the pilot control shut-off lever to the LOCK posi-
tion. 4

CAUTION: The hydraulic oil tank is pressurized.

Push the pressure release button on the air
breather before removing the air breather.

7. Use a wrench to remove filter case (4) from filter

M178-07-068
head (1) by turning it counterclockwise.
8. Remove filter element (2) by turning it.
9. Remove and discard O-ring (3) and filter element (2).
10. Clean filter head (1) O-ring (3) and the element area.
11. Apply a thin film of clean oil to a new O-ring (3) and Pilot
install it in filter head (1). Be sure O-ring (3) is cor- Filter
rectly positioned.
12. Apply a thin film of clean oil to the ring of new filter
element (2), that fits into filter head (1). Slowly install
filter element (2) by turning it.
13. Clean filter case (4).
ZAXIS125US, 135US, 135USK, 135USL M1SE-07-018
14. Install filter case (4) onto filter head (1) by turning it
clockwise. Tighten case 39 N!m (4 kgf!m, 28.9 lbf!ft).

Pilot Filter

ZAXIS225US, 225USLC M178-07-065

7-34
 MAINTENANCE

Replace Air Breather Element

--- every 4000 hours

CAUTION: Hydraulic oil may be hot just after

operation. Hot hydraulic oil may spout, possibly
causing severe burns. Be sure to wait for oil to
cool before starting work. M104-07-021

Replacement Procedures
1. Park the machine on solid and level ground. Fully
extend the bucket cylinder, fully retract the arm cylin-
der, and lower the bucket to the ground as illustrated
to the right. Stop the engine.
2. Before replacing the element, be sure to bleed air
pressure from the hydraulic oil tank by pressing the
air bleed valve on the hydraulic oil tank.
3. Turn cover (2) clockwise about 1/4 turn. Turn cap (1)
counterclockwise to remove it.
4. Turn cover (2) counterclockwise to remove it. Then, M157-07-185

remove element (3).

5. Install new element (3). Tighten to install cover (2)
1
until cover (2) comes in contact with the element.
Then, further tighten the cover 1/4 turn.
6. Securely tighten cap (1) clockwise by hand. While
holding cap (1) by hand so that cap (1) doesn’t rotate, 2
securely tighten cover (2) by rotating counterclock-
wise 5 to 10! by hand.
7. Take care never to allow water and/or contaminant to 3
stay between cover (2) and body (4) (air breathing
port).
8. Replace the element periodically to keep hydraulic oil
4
clean and to extend hydraulic components service
life.

M1G6-07-001

7-35
 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.
If an accident occurs, see a doctor familiar with
this type of injury immediately. SA-031
Any fluid injected into the skin must be surgically
removed within a few hours or gangrene may re-
sult.

CAUTION: Hydraulic oil and lubricant leaks can

lead to fire that may result in serious injury.
To avoid this hazard :
1. Park the machine on a firm, level surface.
Lower the bucket to the ground.
Stop the engine. Remove key from the key
switch. Pull the pilot control shut-off lever to
the LOCK position.
2. Check for missing or loose clamps, kinked SA-292

hoses, lines or hoses that rub against each

other, damaged oil cooler, and loose oil cooler
flange bolts, for leaks.
Check hoses, lines and oil cooler at the check
points indicated below for leaks and other
damage that may result in future leaks.
If any abnormalities are found, replace or re-
tighten them, as shown in Tables 1-3.
3. Tighten, repair or replace any missing, loose SA-044
or damaged clamps, hoses, lines, oil cooler,
and loose oil cooler flange bolts.
Do not bend or strike high-pressure lines.
Never install bent or damaged hoses or lines.

7-36
 MAINTENANCE

Table 1. Hoses 3 2
Interval(hours) Check Points Abnormalities Remedies 1
Daily Hose covers Leak (1) Replace 2
Hose ends Leak (2) Replace
3
Fittings Leak (3) Retighten or replace
hose or O-ring
Every 250 Hose covers Crack (4) Replace M137-07-008

hours Hose ends Crack (5) Replace 3 2

1

2
Hose covers Exposed reinforcement (6) Replace
3
Hose covers Blister (7) Replace

M115-07-145

Hose Bend (8) Replace 5

M115-07-146

Hose Collapse (9) Replace 6

(Use proper bend
radius)

Hose ends and Deformation or Replace M115-07-147

fittings Corrosion (10)
8
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

10
M115-07-149

Fig.1

7-37
 MAINTENANCE
Table 2. Lines
Interval(hours) Check Points Abnormalities Remedies 12
13
Daily Contact surfaces of Leak (11) Replace
flange joints O-ring 11
and/or
retighten bolts
M137-07-001
Welded surfaces on Leak (12) Replace
joints
Every 250 hours Joint neck Crack (13) Replace 13 12
Welded surfaces Crack (12) Replace
on joints
Clamps Missing Replace
Deformation Replace M137-07-007
Loose Retighten
NOTE: Refer to the illustrations in Fig.2 for each check point location or for a descrip- Fig.2
tion of the abnormality. Use genuine Hitachi parts.

Table 3. Oil cooler 15

Interval(hours) Check Points Abnormalities Remedies
Every 250 hours Contact surfaces of Leak (14) Replace
16
flange joints O-ring
and/or
retighten bolts

Oil cooler Leak (15) Replace

Coupling and Leak (16) Retighten or
rubber hose replace 14
NOTE: Refer to the illustrations in Fig.3 for each check point location . M137-07-002
Fig.3

7-38
 MAINTENANCE
SERVICE RECOMMENDATIONS FOR HY-
DRAULIC FITTINGS
2 6 1 4 5
Two hydraulic fitting designs are used on this machine.

Flat Face O-ring Seal Fitting (ORS Fitting)

An O-ring is used on the sealing surfaces to prevent oil
6
leakage.
3
M104-07-033
1. Inspect fitting sealing surfaces (6). They must be free
of dirt or defects.
2. Replace O-ring (1) with a new one when assembling
fittings.
3. Lubricate O-ring (1) and install it into groove (3) using
petroleum jelly to hold it in place.
4. Tighten fitting (2) by hand, pressing the fitting joint
together to ensure O-ring (1) remains in place and is
not damaged.
5. Tighten fitting (2) or nut (4) to the torque values
shown. Do not allow hose (5) to twist when tightening
fittings.
6. Check for leaks. If oil leaks from a loose connection,
do not tighten fitting (2). Open the connection, re-
place O-ring (1) and check for correct O-ring position
before tightening the connection.
Torque specifications ±10%
Width across flats (mm) 27 32 36 41,46
N!m 93 137 175 205
Fastening
(kgf!m) (9.5) (14) (18) (21)
torque
(lbf!ft) (69) (101) (130) (152)

7-39
 MAINTENANCE
Metal Face Seal Fittings
7 9 8 10 5
Fittings are used on smaller hoses and consist of a
metal flare and a metal flare seat.

1. Inspect flare (10) and flare seat (9). They must be

free of dirt or obvious defects.

IMPORTANT: Defects in the tube flare cannot be re-

paired. Overtightening a defective flare M202-07-051
fitting will not stop a leak.

2. Tighten fitting (7) by hand.

3. Tighten fitting (7) or nut (8) to the torque values
shown. Do not allow hose (5) to twist when tightening
fittings.

Width across flats

17 19 22 27
(mm)
N!m 24.5 29.5 39 78
Fastening
(kg!m) (2.5) (3) (4) (8.0)
torque
(lbf!ft) (18) (21.5) (29) (58)

Pilot Piping Fittings (For shuttle valve)

Width across flats (mm) 19

N!m 34.3
Fastening torque
(kg!m) (3.5)
(lbf!ft) (25.3)

7-40
 MAINTENANCE
E. FUEL SYSTEM 1

Recommended Fuel
Use high quality DIESEL FUEL only (JIS K-2204) (ASTM
2-D). Kerosene must NOT be used.

Refueling
1. Park the machine on a level surface.
2. Lower the bucket to the ground.
3. Turn the auto-idle switch off.

IMPORTANT: The turbocharger may be damaged if the

engine is not properly shut down.

4. Run the engine at slow idle speed without load for

five minutes.
5. Stop the engine. Remove the key from the key
switch.
M1SE-01-005
6. Pull the pilot control shut-off lever to the LOCK posi-
tion.
2
CAUTION: Handle fuel carefully. Shut the engine
off before fueling. Do not smoke while you fill the
fuel tank or work on fuel system.

7. Check fuel level gauge (3) or fuel gauge (1) of the

monitor panel. Add fuel if necessary.

IMPORTANT: Keep all dirt, dust, water and other for-

eign materials out of the fuel system.
ZAXIS 125US, 135US, 135USK, 135USL
SS-2094

ZAXIS 225US, 225USLC

M1GF-13-001

7-41
 MAINTENANCE
8. To avoid condensation, fill the tank at the end of each
day’s operation. Take care not to spill fuel on the
machine or ground. Fuel tank capacity is 200 liters 3
(53 US gal).
Do not fill the tank more than specified. Stop filling Yellow
Mark
when a yellow mark on fuel level gauge (3) becomes
visible. Be sure to position the fuel service nozzle so
that any part of the nozzle does not obstruct rising of
the float-type fuel level gauge (3).
9. Reinstall filter cap (2) on the filler tube. Be sure to
lock filter cap (2) with the key to prevent the cap from
being lost as well as to prevent vandalism.
M157-07-060
NOTE: Take precautions for Fueling with Automatic
Fueling Device (Optional).
Avoid overfilling. Never fail to remove filler cap
(2) when refueling with the automatic fueling
device and be sure to stop fueling when the yel-
low mark on the float becomes visible.

7-42
 MAINTENANCE

Drain Fuel Tank Sump --- daily

1. Park the machine on a level surface with the upper-

structure rotated 90° for easier access.
2. Lower the bucket to the ground.
3. Turn the auto-idle off. M104-07-117

IMPORTANT: The turbocharger may be damaged if the

engine is not properly shut down.

4. Run the engine at slow idle speed without load for

five minutes. 1
5. Turn the key switch OFF. Remove the key from the 2
key switch.
6. Pull the pilot control shut-off lever to the LOCK posi-
tion. ZAXIS 125US, 135US, 135USK, 135USL M1SE-07-021
1
7. Open drain cock (1) for several seconds to drain wa-
ter and sediment. Close the drain cock.

Check Water Separator

--- every 50 hours
Water separator (4) separates any water that may get
mixed with the fuel. Water separator (4) contains a float
which rises as water accumulates.
Be sure to drain the sediment when the float rises up to the M1GF-07-010
ZAXIS 225US, 225USLC
“Drain Water” mark written on the outside of water separa-
tor (4).
3
IMPORTANT: If the fuel contains an excessive amount 4
of water, shorten the interval between
water separator checks. 5

Draining Coolant
1. Water separator (4) is located on the back of the hy-
draulic oil tank. Open the right access cover and hold
the cover with the rod.
2. Close fuel cock (2) under the fuel tank to stop the fuel ZAXIS 125US, 135US, 135USK, 135USL M1SE-07-017

supply.
3
3. Loosen plug (3) on water separator (4). Loosen drain
plug (5) on the bottom of the separator case to drain
water deposited in the case.
4
4. After draining water, be sure to tighten plugs (3 and 5
5).
5. Return fuel cock (2) to the original position.

NOTE: After draining, be sure to bleed air from the fuel

system.
ZAXIS 225US, 225USLC M1GF-07-008

7-43
 MAINTENANCE
Bleed Air from Fuel System
ZAXIS125US, 135US, 135USK, 135USL
1
IMPORTANT: Air in the fuel system may make the en-
gine hard to start or make it run irregu- 2
larly. After draining water and sediment
from the water separator, replacing the 3
fuel filter, cleaning the feed pump
strainer or running the fuel tank dry, be
sure to bleed the air from the fuel sys-
tem.

1. Confirm that drain plug (3) and air bleed plug (1) on
water separator (2) are tight. If air bleed plug (1) is M1SE-07-017

not tight, air will not bleed from the fuel system.
2. Confirm that fuel cock (4) is opened.
3. Loosen air bleed plug (5) on the fuel filter.
4. Loosen fuel feed pump (6) knob, raise and lower the
plunger until no more air bubbles can be seen in the
fuel.
5. Tighten air bleed plug (5) on the fuel filter. Raise and
lower the fuel feed pump plunger until the load be-
4
comes heavy.
6. Push fuel feed pump (6) knob down and tighten.
7. Start the engine and run at slow idle.
M1SE-07-021

8. Put a “Do Not Operate” tag on the right control lever.

9. Pull the pilot control shut-off lever to the LOCK posi-
tion.
5
10. Inspect the fuel system for leaks.

M175-07-007

7-44
 MAINTENANCE
Bleed Air from Fuel System
1
ZAXIS225US, 225USLC
IMPORTANT: Air in the fuel system may make the en-
gine hard to start or make it run irregu- 2
larly. After draining water and sediment
from the water separator, replacing the 3
fuel filter, cleaning the feed pump
strainer or running the fuel tank dry, be
sure to bleed the air from the fuel sys-
tem.
M1GF-07-008
1. Confirm that drain plug (3) and air bleed plug (1) on
water separator (2) are tight. If air bleed plug (1) is
not tight, air will not bleed from the fuel system.
2. Confirm that fuel cock (4) is opened.
3. Loosen air bleed plug (5) on the fuel filter.
4
4. Loosen fuel feed pump (6) knob, raise and lower the
plunger until no more air bubbles can be seen in the
fuel.
5. Tighten air bleed plug (5) on the fuel filter. Raise and
lower the fuel feed pump plunger until the load be-
comes heavy. M1GF-07-010

6. Push fuel feed pump (6) knob down and tighten.

7. Start the engine and run at slow idle.
8. Put a “Do Not Operate” tag on the right control lever.
9. Pull the pilot control shut-off lever to the LOCK posi-
tion.
10. Inspect the fuel system for leaks.

5
SS-2110

M178-07-025

7-45
 MAINTENANCE

Replace Fuel Filter

--- every 500 hours
1
1. For safety and to protect the environment, always
use proper containers when draining fuel. Do not
pour fuel onto the ground, down a drain or into a
stream, pond or lake. Dispose of waste fuel properly.
2. Remove cartridge filter (1) using the filter wrench.
3. Apply a thin film of clean fuel to the gasket of new
cartridge filter (1).
4. Tighten cartridge filter (1) by hand until the gasket
makes contact with the sealing surface.
5. Using the filter wrench, tighten cartridge filter (1)
about 2/3 turn more. Do not overtighten cartridge fil-
ter (1).
ZAXIS125US, 135US, 135USK, 135USL M175-07-007
6. After replacing cartridge filter (1), bleed air from the
fuel system.

ZAXIS225US, 225USLC SS-2110

7-46
 MAINTENANCE

Clean Feed Pump Strainer

--- every 1000 hours,

1. Confirm drain cock (1) is the close position.

2. Remove the feed pump inlet hose joint bolt, located
at water separator (2) inlet.
3. Remove strainer (4) from joint bolt (3) using a screw 1
driver.
4. Clean strainer (4) using diesel fuel.
M1SE-07-021
5. Install strainer (4) and plug (5) in joint bolt (3). ZAXIS125US, 135US, 135USK, 135USL

6. Install and tighten joint bolt (3). Then, bleed air from
the fuel system. 1

ZAXIS225US, 225USLC M1GF-07-0110

5 4 3

M178-07-102
3

M1SE-07-017

ZAXIS125US, 135US, 135USK, 135USL

M1GF-07-008
ZAXIS225US, 225USLC

7-47
 MAINTENANCE

Check Fuel Hoses

--- daily
--- every 250 hours

CAUTION: Fuel leaks can lead to fires that may

result in serious injury.
To avoid this hazard :

1. Park the machine on a firm, level surface. Lower the

bucket to the ground. Stop the engine. Remove key
from the key switch. Pull the pilot control shut-off
lever to the LOCK position.
2. Check for kinked hoses, and hoses that rub against
each other parts for leaks.
Check hoses at the check points indicated below for
leaks and other damage that may result in future
leaks. If any abnormalities are found, replace or re-
tighten them, as shown in Table 4.
3. Repair or replace any loose or damaged hoses.
Never install bent or damaged hoses.
Table 4. Hoses
Interval(hours) Check Points Abnormalities Remedies 1 2
Daily Hose ends Leak (1) Retighten or
replace
Soutache braid Friction (2) Replace
hose Crack (2) Replace
Every 250 Soutache braid Crack (3) Replace
hours hose 1
Hose ends Crack (4) Replace M137-07-003

4
Hose Bend (5) Replace
M137-07-004

Hose Collapse (6) Replace

(Use proper bend radius)
M137-07-005

Hose ends and fittings Deformation or Replace 6

Corrosion (7)
NOTE: Refer to the illustrations in Fig.1 for each check point location or for
a description of the abnormality. Use genuine Hitachi parts.
7
M137-07-006

Fig.1

7-48
 MAINTENANCE
F. AIR CLEANER

Clean the Air Cleaner Outer Element

--- every 250 hours or when the restriction in-
dicator comes ON 2

Replace the Air Cleaner Outer and Inner

Elements
--- after cleaning six times or after one year M1SM-07-015

1. Park the machine on a level surface.

2. Lower the bucket to the ground.
3. Turn the auto-idle switch off.

IMPORTANT: The turbocharger may be damaged if the

engine is not properly shut down.
M1SE-07-016
1
4. Run the engine at slow idle speed without load for 2
ZAXIS125US, 135US, 135USK, 135USL
five minutes.
5. Stop the engine. Remove the key from the key
switch.
6. Pull the pilot control shut-off lever to the LOCK posi-
tion.
7. Loosen clamps (2) to remove the cover.
8. Remove outer element (1).
M1GF-07-026
9. Tap outer element (1) with the palm of your hand,
NOT ON A HARD SURFACE.
1

M1GF-07-025
ZAXIS225US, 225USLC

7-49
 MAINTENANCE

CAUTION: Use reduced compressed air pres-

2
sure. (Less than 0.2 MPa, 2 kgf/cm ). Clear area of 4
bystanders, guard against flying chips, and wear 1 2
personal protection equipment including goggles
or safety glasses. cover

10. Clean outer element (1) using compressed air. Direct

the air to the inside of the filter element, blowing out.
11. Clean the filter interior before installing outer element
(1).
12. Install outer element (1). 3 valve M157-07-061

13. Install cover and tighten wing nut (2).

14. Start the engine and run at slow idle.
15. Check the air filter restriction indicator on the monitor
panel. If the air filter restriction indicator comes ON,
stop the engine and replace the outer element (1).
16. When replacing the air cleaner filter element, replace
both outer (1) and inner (3) elements together. Re-
move outer element (1). Clean the filter interior be-
fore removing inner element (3). Remove inner ele-
ment (3). First install inner element (3) and then in-
stall outer element (1).

7-50
 MAINTENANCE
G. COOLING SYSTEM

Coolant
Use fresh water or normal tap water as a coolant. Don’t
use strong acid or alkaline water. Use the coolant with
genuine Hitachi Long-Life Coolant (LLC) mixed by 30 to
50 %.

If the air temperature is expected to fall below 0!C

(32!F), fill the cooling system with an genuine Hitachi
Long-Life Coolant (LLC) and soft water mix. As a gen-
eral rule, the ratio of LLC should range between 30%
and 50% as shown in the table below. If the ratio is be-
low 30%, the system may develop rust, and if it is above
50%, the engine may overheat.

LLC Mixing Table

ZAXIS125US, 135US, 135USK,
Mixing ZAXIS225US, 225USLC
Air temperature 135USL
ratio
LLC Soft water LLC Soft water
!C !F % liters US gal liters US gal liters US gal liters US gal
－1 30 30 5.7 1.51 13.3 3.51 6.9 1.82 16.1 4.25
－15 5 35 6.7 1.77 12.3 3.25 8.05 2.13 14.95 3.96
－20 －4 40 7.6 2.01 11.4 3.01 9.2 2.43 13.8 3.65
－25 －13 45 8.6 2.27 10.4 2.75 10.35 2.73 12.65 3.35
－30 －22 50 9.5 2.51 9.5 2.51 11.5 3.04 11.5 3.04

CAUTION:
1. Antifreeze is poisonous; if ingested, it can
cause serious injury or death. Induce vomiting
and get emergency medical attention immedi-
ately.
2. When storing antifreeze, be sure to keep it in
a clearly marked container with a tight lid. Al-
ways keep antifreeze out of the reach of chil-
dren.
3. If antifreeze is accidentally splashed into eyes,
flush with water for 10 to 15 minutes and get
emergency medical attention.
4. When storing or disposing of antifreeze, be
sure to comply with all local regulations.

7-51
 MAINTENANCE

Check Coolant Level --- daily

CAUTION: Do not loosen radiator filler cap (1)

unless the system is cool. Loosen the cap slowly
to the stop. Release all pressure before removing
the cap.

With the engine cold, the coolant level must be between

the FULL and LOW marks on coolant reservoir (2), located
behind the radiator access door. If the coolant level is be-
low the low mark, add coolant to coolant reservoir (2).
1
If coolant reservoir (2) is empty, add coolant to the radiator SS-2092

and then to coolant reservoir (2).

FULL
LOW

ZAXIS125US, 135US, 135USK, 135USL M1SE-07-028

SS-2110

FULL

LOW

ZAXIS225US, 225USLC M1GF-07-014

7-52
 MAINTENANCE

Check and Adjust Fan Belt Tension

--- every 100 hours (first time after 50 hours)
8 to 12 mm
IMPORTANT: Loose fan belt may result in insufficient
battery charging, engine overheating as 3
Deflection
well as a rapid, abnormal belt wear. Belts
that are too tight, however, can damage Fan Pulley
both bearings and belts.

Visually check the belt for wear. Replace if necessary.

Check fan belt tension by depressing the midpoint between
fan pulley (3) and crank pulley (4) with the thumb. Deflec-
tion must be 8 to 12 mm (0.32 to 0.47 in) with a depressing
4
force of approximately 98 N (10 kgf, 22 lbf). Crank Pulley M1CD-07-022

If tension is not within specifications, loosen nuts (5) and

(7) for the adjusting plate and alternator bracket. Move the 5
alternator by bolt (6) until tension is correct. Tighten the
6
adjusting plate and nuts (5) and (7).

NOTE: When a new belt is installed, be sure to

re-adjust the tension after operating the engine
for 3 to 5 minutes at slow idle speed to be sure
that the new belt is seated correctly.

7 M197-07-072

7-53
 MAINTENANCE

Change Coolant
--- every two years or 4000 hours whichever
comes first.

Clean Radiator Interior

--- when changing coolant

CAUTION: Do not loosen the radiator cap until

the system is cool. Loosen the cap slowly to the
stop. Release all pressure before removing the
cap.

IMPORTANT: Use fresh water or normal tap water as a

coolant. Don’t use strong acid or alka-
1
line water. Use the coolant with genuine
Hitachi Long-Life Coolant (LLC) mixed
by 30 to 50 %.

1. Remove the radiator cap. Open drain cocks (1) and

(2) on the radiator and engine block to allow the cool-
ant to drain completely.
2. Close drain cocks (1) and (2). Fill the radiator with tap
water and a radiator cleaner agent. Start the engine
and run at a speed slightly higher than slow idle;
when the needle of the temperature gauge reaches
the green zone, run the engine for about ten more
M1SE-07-024
minutes.
3. Stop the engine and open drain cock (1). Flush out
the cooling system with tap water, until draining water
is clear. This helps remove rust and sediment.
4. Close drain cock (1). Fill the radiator with tap water
and LLC at the specified mixing ratio. When adding
coolant, do so slowly to avoid mixing air bubbles in
the system.
5. Run the engine to sufficiently bleed the air from the 2
cooling system.
6. After adding coolant, operate the engine for several
minutes. Check the coolant level again, and add
ZAXIS125US, 135US, 135USK, 135USL
coolant if necessary. M175-07-011

ZAXIS225US, 225USLC M178-05-025

7-54
 MAINTENANCE

Clean Intercooler Core Intercooler

(ZAXIS135US, 135USK, 135USL 225US,
225USLC),
Radiator, and Oil Cooler Core

Clean Oil Cooler Front Screen

--- every 500 hours

CAUTION: Use reduced compressed air pres-

2
sure (Less than 0.2 MPa, 2 kgf/cm ) for cleaning
purposes. Clear the area of bystanders, guard
against flying chips, and wear personal protec- M1SE-07-028
ZAXIS125US, 135US, 135USK, 135USL
tion equipment including eye protection.
Intercooler
IMPORTANT: When operating the machine in a dusty
environment, check the screen every
day for dirt and clogging. If clogged,
remove, clean and reinstall the screen.

1. Open the radiator access door and hood.

2. Clean the air conditioner condenser.
3. Remove the oil cooler front screen and clean it.
4. Clean both the radiator and oil cooler using com-
2
pressed air (Less than 0.2 MPa, 2 kgf/cm ) or water. Oil Cooler
M1GF-07-015
ZAXIS225US, 225USLC

Oil Cooler Front Screen

ZAXIS125US, 135US, 135USK, 135USL M1SE-07-028

Oil Cooler
Front
Screen

M1GF-07-015
ZAXIS225US, 225USLC

7-55
 MAINTENANCE

Air Conditioner Condenser

Clean Air Conditioner Condenser
(If equipped) --- every 500 hours
--- every 500 hours

Clean Inter Cooler Front Screen

(Opt.) --- every 500 hours
Clean Air Conditioner Front Screen
(Opt.) --- every 500 hours

CAUTION: Use reduced compressed air pres-

2
sure (Less than 0.2 MPa, 2 kgf/cm ) for cleaning
purposes. Clear the area of bystanders, guard
against flying chips, and wear personal protec-
tion equipment including eye protection.

IMPORTANT: When operating the machine in a dusty ZAXIS125US, 135US, 135USK, 135USL M1SE-07-028
environment, check the screen every
day for dirt and clogging. If clogged, Air Conditioner Condenser
remove, clean and reinstall the screen.

ZAXIS225US, 225USLC M1GF-07-015

7-56
 MAINTENANCE
H. ELECTRICAL SYSTEM

IMPORTANT: Improper radio communication equip-

ment and associated parts, and/or im-
proper installation of radio communica-
tion equipment effects the machine's
electronic parts, causing involuntary
movement of the machine.
Also, improper installation of electrical
equipment’s may cause machine failure
and/or a fire on the machine.
Be sure to consult your authorized
dealer when installing a radio commu-
nication equipment or additional elec-
trical parts, or when replacing electrical SA-032
parts.

Never attempt to disassemble or modify

the electrical/electronic components. If
replacement or modification of such
components is required, contact your
authorized dealer.
BATTERIES

CAUTION: Battery gas can explode. Keep sparks

and flames away from batteries. Use a flashlight
to check the battery electrolyte level.

Do not continue to use or charge the battery

when electrolyte level is lower than specified.
Explosion of the battery may result.
SA-036
Sulfuric acid in battery electrolyte is poisonous. It
is strong enough to burn skin, eat holes in cloth-
ing, and cause blindness if splashed into the
eyes.

Avoid hazard by:

1. Filling batteries in a well-ventilated area.
2. Wearing eye protection and rubber gloves.
3. Avoiding breathing fumes when electrolyte is
added.
4. Avoiding spilling or dripping electrolyte.
5. Using proper booster battery starting proce-
dures.

If you spill acid on yourself:

1. Flush your skin with water.
Battery Location M1SE-07-028
2. Apply baking soda or lime to help neutralize
the acid. ZAXIS125US，135US, 135USK, 135USL
3. If splashed in eyes, flush with water for 10 to
15 minutes. Get medical attention immediately.

7-57
 MAINTENANCE

If acid is swallowed:
1. Drink large amounts of water or milk.
2. Then drink milk of magnesia, beaten eggs, or
vegetable oil.
3. Get medical attention immediately.

IMPORTANT: Add water to batteries in freezing

weather before you begin operating your
machine for the day, or else charge the
batteries.
Battery Location
IMPORTANT: If the battery is used with the electrolyte M1GF-07-015

level lower than the specified lower level, ZAXIS225US, 225USLC

the battery may deteriorate quickly.

IMPORTANT: Don’t refill electrolyte more than the

specified upper level. Electrolyte may
spill, damaging the painted surfaces
and/or corroding other machine parts.

NOTE: In case electrolyte is refilled more than the

specified upper level line or beyond the bottom
end of the sleeve, remove the excess electro-
lyte until the electrolyte level is down to the
bottom end of the sleeve using a pipette. After
neutralizing the removed electrolyte with so-
dium bicarbonate, flush it with plenty of water,
otherwise, consult the battery manufacturer.

7-58
 MAINTENANCE
Electrolyte Level Check --- every one month
1. Check the electrolyte level at least once a month.
2. Park the machine on level ground and stop the en-
gine.
3. Check the electrolyte level.
3.1 When checking the level from the battery side:
Clean around the level check lines with a wet towel.
Don’t use a dry towel. Static electricity may be de-
veloped, causing the battery gas to explode. Check U.L (Upper Level)
if the electrolyte level is between U.L (Upper Level)
L.L (Lower Level)
and L.L (Lower Level). In case the electrolyte level
M146-07-109
is lower than the middle level between the U.L and
L.L, immediately refill distilled water or commercial
battery fluid. Be sure to refill with distilled water be- Filler Port
fore recharging (operating the machine). After re-
filling, securely tighten the filler plug.
3.2 When impossible to check the level from the battery Sleeve
side or no level check mark is indicated on the side: Upper Level
After removing the filler plug from the top of the bat- Lower Level
tery. Check the electrolyte level by viewing through Separator Top
the filler port. It is difficult to judge the accurate Proper
M146-07-110

electrolyte level in this case. Therefore, when the Since the electrolyte surface touches the bottom end of
electrolyte level is flush with the U.L, the level is the sleeve, the electrolyte surface is raised due to surface
judged to be proper. Then, referring to the right il- tension so that the electrode ends are seen curved.
lustrations, check the level. When the electrolyte M146-07-111
level is lower than the bottom end of the sleeve, re- Lower
fill with distilled water or commercial battery fluid up When the electrolyte surface is lower than the bottom end
of the sleeve, the electrode ends are seen straight.
to the bottom end of the sleeve. Be sure to refill with
distilled water before recharging (operating the
M146-07-112
machine). After refilling, securely tighten the filler
plug.
3.3 When an indicator is available to check the level,
follow its check result.
4. Always keep around the battery terminals clean to
prevent battery discharge. Check terminals for loose
and/or rust. Coat terminals with grease or petroleum
jelly to prevent corrosion build up.

M409-07-072

7-59
 MAINTENANCE
Check electrolyte specific gravity

CAUTION: Battery gas can explode. Keep sparks
and flames away from batteries. Use a flashlight
to check the battery electrolyte level.
Sulfuric acid in battery electrolyte is poisonous. It
is strong enough to burn skin, eat holes in cloth-
ing, and cause blindness if splashed into the
eyes.
Never check the battery charge by placing a
metal object across the posts. Use a voltmeter or
hydrometer.
!) battery clamp
Always remove the grounded (!
first and replace it last.
Avoid hazard by:
1. Filling batteries in a well-ventilated area.
2. Wearing eye protection and rubber gloves.
3. Avoiding breathing fumes when electrolyte is
added.
4. Avoiding spilling or dripping electrolyte.
5. Using proper booster battery starting proce-
dures.
If you spill acid on yourself:
1. Flush your skin with water.
2. Apply baking soda or lime to help neu-
tralize the acid.
3. If splashed in eyes, flush with water for
10 to 15 minutes. Get medical attention
immediately.
If acid is swallowed:
1. Drink large amounts of water or milk.
2. Then drink milk of magnesia, beaten
eggs, or vegetable oil.
3. Get medical attention immediately.
IMPORTANT: Check the specific gravity of the
electrolyte after it is cooled, not
immediately after operation.
Check the electrolyte specific gravity in each bat-
tery cell.
The lowest limit of the specific gravity for the elec-
trolyte varies depending on electrolyte tempera-
ture. The specific gravity should be kept within the
range shown below. Charge the battery if the spe-
cific gravity is below the limit.

Recommended range of specific gravity by electrolyte temperature

104°F 40°C

68°F 20°C Working range

Fluid temp.
32°F 0°C

–4°F –20°C

–40°F –40°C
1.21 1.22 1.23 1.24 1.25 1.26 1.27 1.28 1.29 1.30 1.31 1.32

Specific gravity of battery fluid

7-60
 MAINTENANCE
REPLACE BATTERIES
Your machine has two 12-volt batteries with negative (!)
ground.
If one battery in a 24-volt system has failed but the other is
still good, replace the failed battery with one of the same
type. For example, replace a failed maintenance-free bat-
tery with a new maintenance-free battery. Different types of
batteries may have different rates of charge. This differ-
ence could overload one of the batteries and cause it to
fail.

REPLACING FUSES
M1CC-01-018
If any electrical equipment fails to operate, first check the
20 19 18 17 16 15 14 13 12 11
fuses. Fuse box is located behind the operator’s seat. A
fuse location/specification decal is attached to the fuse box
cover.
Remove the fuse box cover by lifting it upward. Spare Spare
Fuse
fuses are located on the underside of the cover.
IMPORTANT: Be sure to install fuses with correct Tool
M1CC-01-007
amperage ratings to prevent electrical
system damage due to overload. 10 9 8 7 6 5 4 3 2 1

1- BACKUP 11. LAMP Reservoir

5A 20A 21 22
2- CONTROLLER 12. WIPER
5A 10A
3- EC. MOTOR 13. HEATER
10A 20A
4- SOLENOID 14. HORN
10A 10A
5- SWBOX 15. RADIO
5A 5A
6- POW. ON 16. LIGHTER
5A 10A
7- AIRCON 17. ROOM LAMP
5A 5A
8- OPTION 1 18. AUXILIARY
5A 10A ZAXIS125US, 135US, 135USK, 135USL M1SE-07-022

9- OPTION 2 19. GLOW. R

Intercooler
10A 5A
10. OPTION 3 20. SPARE
5A
"# Fusible Link (Main Fuse)
In case the starter won’t rotate even if the key switch is
turned to the START position, fusible link may the cause
of the trouble. Remove the cover next to the engine
coolant reservoir to check the fuse. Replace it if blown.

21- + Side (Red) 45A

22- ! Side (Black) 65A
21 22

ZAXIS225US, 225USLC M1GF-07-013

7-61
 MAINTENANCE
I. MISCELLANEOUS
1 4 5

Check Bucket Teeth --- daily

Check the bucket teeth for wear and looseness

Replace teeth (1) if tooth wear exceeds the designated
service limit shown below.

M104-07-056
Dimension A in mm (in)
Model New Limit of Use
2
ZAXIS125US, 135US,
166 (6.5) 85 (3.4)
135USK, 135USL
ZAXIS225US, 225USLC 200 (7.9) 95 (3.7)
3

Replacing procedure

CAUTION: Guard against injury from flying

pieces of metal. Wear goggles or safety glasses,
and safety equipment appropriate to the job.

1. Use hammer (2) and drift (3) to drive out locking pin
M104-07-116
(5). Be careful not to damage rubber pin lock (4)
while removing locking pin (5). RIGHT WRONG
2. Remove tooth (1). Inspect locking pin (5) and rubber
pin lock (4) for damage, replace if necessary. Short
5
locking pins and damaged rubber pin locks must be
replaced with new ones.

Flush one end of the locking pin

to evaluate. In this instance, the
locking pin is too short.
M104-07-118

M104-07-058

WRONG WRONG

M104-07-059

7-62
 MAINTENANCE
3. Clean shank (6) surface.
4. Install rubber pin lock (4) into shank (6) hole as shown.

RIGHT WRONG WRONG

6 4
M104-07-060

5. Position new tooth (1) over shank (6).

RIGHT WRONG WRONG

M104-07-061
6 1

6. Drive locking pin (5) fully into the hole as shown.

WRONG
RIGHT

1 5 M104-07-062

NOTE: Check the bucket teeth periodically to

ensure that wear does not exceed the
designed service limit.

7-63
 MAINTENANCE

Change 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 to 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. Be sure the bucket will
not roll when the pins are removed.
Link
2. Slide the O-rings out of the way, as shown.
B
3. Remove bucket pins A and B to separate the arm
and bucket. Clean the pins and pin bores. Apply suf- A
ficient grease to the pins and pin bores.
4. Align the arm and alternate bucket. Be sure the
bucket will not roll.
5. Install bucket pins A and B.
6. Install the locking pins and snap ring on pins A and B. M104-07-063

7. Adjust bucket linkage clearance for pins A. See ad-

justing bucket linkage clearance procedure.
8. Apply grease to pin joints A and B.
9. Start the engine and run at slow idle. Slowly operate
the bucket in both directions to check for any inter-
ference in bucket movement. Do not operate a ma-
chine that has any movement interference. Correct
interference problem.

7-64
 MAINTENANCE

Convert Bucket Connection Into Face Shovel

CAUTION: When driving the connecting pins in O-Ring Shift

or out, guard against injury from flying pieces of
metal or debris; wear goggles or safety glasses,
and safety equipment appropriate to the job.

IMPORTANT: Provide ample space for turning the

bucket 180$$. Before starting converting
work, keep bystanders clear of the ma- Bucket Boss
chine. When using a signal person, co-
ordinate hand signals before starting.
Link

B
1. Park the machine on a level surface. Lower the
bucket to the ground and position it with the flat sur- A
face resting on the ground. Be sure the bucket will
not roll when the pins are removed.
2. Slide the O-rings out of the way, as shown.
3. Remove bucket pins A and B to separate the arm
and bucket. Clean the pins and pin bores. Apply suf-
ficient grease to the pins and pin bores.
4. Turn the bucket 180$. Be sure the bucket will not roll.
5. Align the arm and bucket. Install bucket pins A and B,
then install the locking pins and snap rings on pins A
and B.
6. Apply grease to pin joints A and B.
7. Start the engine and run at slow idle. Slowly operate
the bucket in both directions and check for any inter-
ference in bucket movement. Do not operate a ma-
chine that has any movement interference. Correct
interference problem. Link

M104-07-064

7-65
 MAINTENANCE

Adjust the Bucket Linkage

The machine is provided with a bucket adjustment system
to take up play in the linkage. When play in the linkage
increases, remove and install shims as follows:

1. Park the machine on a level surface. Lower the

bucket to the ground with the flat side down so that
the bucket will not roll.

2. Run the engine at slow idle. With the bucket on the

ground, slowly swing counterclockwise slightly until
the top of the left bucket boss contacts the arm.

3. Stop the engine. Pull the pilot control shut-off lever to

the LOCK position.

NOTE: Bolt (1) does not need to be removed to remove

shims. Shims are of a split type that can be
easily pushed off with a screwdriver after bolts
(1) have been loosened.
Clearance
Adjust Part
4. Slightly loosen three (M14) bolts (1) using a 22 mm
wrench. Remove all shims (2) from clearance (c)
between plate (3) and bucket.

5. Push and hold bolts (1) to remove all clearance (a)

M503-07-056
between arm and boss (4). Holding boss (4) against
arm increases clearance (b). Measure distance (b)
using a feeler gauge. This distance should not be II 4 Bucket

adjusted below 0.5 mm (0.02 in). Bucket Pin Arm 2

d

3
6. Install as many shims (2) into clearance (b) as
possible.

NOTE: Remaining shims (2) must be installed in

clearance (c) to prevent arm end face or bolt 1
damage.
a
7. Install remaining shims (2) into clearance (c) and b c
tighten bolts (1) to 140 N!m (14.3 kgf!m, 103 lbf!ft).
II
NOTE: The total number of shims (2) used is A.
A : 12 (6 pairs)

8. Replace boss (4) if measurement (d) is 5 mm (0.2 in)

or less.

SECTION II
M104-07-066

7-66
 MAINTENANCE

Remove the Travel Levers

The travel levers may be removed if desired.

1. Park the machine on a level surface. 4

3
2. Lower the bucket to the ground.
3. Turn the auto-idle switch off.
4. Turn the key switch OFF. Remove the key. 2

5. Pull the pilot control shut-off lever to the LOCK

position.
1
6. Remove bolts (1) and (2) to remove levers (3) and (4)
from brackets.

NOTE: Wrench size 17 mm

Tightening torque 50 N!m (5.1 kgf!m, 37
M178-07-077
lbf!ft)

7-67
 MAINTENANCE

Check and Replace Seat Belt

1
Check --- daily
Replace --- every 3 years

Always maintain the seat belt in a functional condition and 2

replace when necessary to ensure proper performance.
1
Prior to operating the machine, thoroughly examine belt (1),
buckle (2) and attaching hardware (3). If any item is dam- 3 3
aged or materially worn, replace the seat belt or compo-
nent before operating the machine.

We recommend that the seat belt be replaced every three

years regardless of its apparent condition.

M1CC-017-036

Check Windshield Washer Fluid Level

--- as required.
4

Check fluid in windshield washer tank (5).

If the fluid level is low, remove cap (4) and add fluid via the 5
opening.
During winter season, use all season windshield washer
which will not freeze.

ZAXIS125US, 135US, 135USK, 135USL M1SE-07-016

5 4

ZAXIS225US, 225USLC M1GF-07-004

7-68
 MAINTENANCE

Check Track Sag --- every 50 hours

Swing the upperstructure 90° and lower the bucket to raise

the track off the ground as shown.

Keep the angle between the boom and arm 90 to 110!

and position the bucket’s round side on the ground. Place
blocks under the machine frame to support the machine.
Rotate the raised track in reverse two full rotations and
then forward two full rotations.

Measure distance (A) at the middle of the track frame from

the bottom of the track frame to the back face of the track
shoe.

ZAXIS125US, SA-283
ZAXIS225US,
135US, ZAXIS135USL
225USLC
135USK
Track sag 250 to 280 mm 265 to 295 mm 300 to 335 mm
specifications (9.9 to 11.0 in) (10.4 to 11.6 in) (11.8 to 13.2 in)

NOTE: Check track sag after thoroughly removing soil

stuck on the track area by washing.

Adjust Track Sag

Precautions for Adjusting Track Sag
1. If track sag is not within specifications, loosen or
tighten the track following the procedures shown on
M107-07-068
the next page.
2. When adjusting track sag, lower the bucket to the
ground to raise one track off the ground.
Repeat this procedure to raise the other track.
Each time, be sure to place blocks under the ma-
chine frame to support the machine.
3. After adjusting track sag of both tracks, move the
machine back and forth several times.
4. Check track sag again. If track sag is not within
specifications, repeat adjustment until correct sag is
obtained.

7-69
 MAINTENANCE
Loosen the 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.
M107-07-075
1. To loosen the track, slowly turn valve (1) counter-
clockwise using long socket 24; grease will escape 1
from the grease outlet.
2
2. Between 1 to 1.5 turns of valve (1) is sufficient to
loosen the track.
3. If grease does not drain smoothly, slowly rotate the
raised track.
4. When proper track sag is obtained, turn valve (1)
clockwise and tighten valve (1).
ZAXIS125, 135US, 135USK, 135USL:
90 N!m (9.2 kgf!m, 66 lbf!ft)
ZAXIS225US, 225USLC: Grease Outlet
147 N!m (15 kgf!m, 108 lbf!ft) M104-07-119

Tighten the Track

CAUTION: It is abnormal if the track remains

tight after turning valve (1) counterclockwise or if
the track is still loose after charging grease to fit-
ting (2). In such cases, NEVER ATTEMPT TO DIS-
ASSEMBLE the track or track adjuster, because
of dangerous high-pressure grease inside the
track adjuster. See your authorized dealer imme-
diately.

To tighten the track, connect a grease gun to grease fitting

(2) and add grease until the sag is within specifications.

7-70
 MAINTENANCE

Clean and Replace Air Conditioner Filter

Clean Filter
Circulating Air Filter --- every 500 hours
2
Fresh Air Filter --- every 500 hours

Replace Filter
Circulating Air Filter --- After cleaning 6 times
or so
Fresh Air Filter --- After cleaning 6 times or so
M1SE-07-006

Removing Fresh Air Filter 4

ZAXIS125US, 135US, 135USK, 135USL
1. From the cab outside, pull the upper section of filter
cover (2) located at the rear of the cab to remove the
cover.
2. Pull the grip on fresh air filter (4) through the opening
for filter cover (2) to remove fresh air filter (4).
ZAXIS225US, 225USLC
1. From the cab outside, remove bolts (1) to remove ZAXIS125US, 135US, 135USK, 135USL M1SE-07-007
cover (2).
2. Pull the upper section of filter cover (3) to remove the
cover. 1

3. Pull the grip on fresh air filter (4) through the opening
for filter cover (3) to remove fresh air filter (4). 2

M1GF-07-018

M1GF-07-017

M1GF-07-016

ZAXIS225US, 225USLC

7-71
 MAINTENANCE
Removing Circulating Air Filter (Outside)
1. Circulating air filter (outside) (5) is located beside the
seat stand.
2. Remove screw (6). While pulling toward the cab front,
unlatch air filter (outside) (5) from the seat stand to
remove air filter (outside) (5).

Removing Circulating Air Filter (Inside)

1. Hold the center of circulating air filter (inside) (7)
(front half section in two pieces) to remove it through
opening for circulating air filter (outside) (5). 5
6
2. Slide circulating air filter (inside) (7) (rear half section
in two pieces) toward the cab front. Remove it in the M1CC-07-011
same method as the front section.

CAUTION: Use reduced compressed air pres-

2
sure (less than 0.2 MPa, 2 kgf/cm ) for cleaning
purposes. Clear the area of bystanders, guard
against flying chips, and wear personal protec-
tion equipment including eye protection.
7
Cleaning
Clean both the external and internal filters by blowing M1CC-07-012
compressed air or washing with water.

When washing the filters with water, follow the proce-

dures below:

1. Wash with tap water.

2. Soak the filters in neutral detergent-mixed water for
approx. 5 minutes.
3. Wash the filters with water again.
4. Dry the filters.

7-72
 MAINTENANCE
Installation
When installing the cleaned recirculation and/or ventila-
tion filter or new filters, follow the reverse order of the 4
Removing Filter procedures described on the front page.
Notch
• Fresh Air Filter (4)
ZAXIS125US, 135US, 135USK, 135USL
Set fresh air filter (4) so that the notched side faces
toward the cab left side. After setting, install the filter
cover so that it aligns with the duct.
ZAXIS225US, 225USLC ZAXIS125US, 135US, 135USK, 135USL M1SE-07-007

Set fresh air filter (4) so that the notched side faces
toward the cab left side. After setting, install the cover
so that it aligns with the duct. Install the cover ant 1
tighten bolts.
Notch
• Circulating Air Filter (Inside) (7)
Install the filter (rear section in two pieces) (7) into the
groove and slide it toward the cab rear side. Then, in-
stall filter (front section in two pieces) (7) into the
groove.

ZAXIS225US, 225USLC M1GF-07-016

• Latch circulating air filter (outside) (5) into the seat

stand. Slide it toward the cab rear side and secure it
with screw (6).
7

M1CC-07-013

M1CC-07-012

6
5
M1CC-07-011

7-73
 MAINTENANCE

2
Check the Air Conditioner --- daily
Oil Seepage

1. Check pipe connections for refrigerant gas leakage.

If oil seepage is found around pipe connections, as
illustrated, it indicates possible gas leakage.
2. Check refrigerant quantity.
1
After running the engine at 1500 min－ (rpm) for 2 to Detail
M1CD-07-038
3 minutes, check refrigerant quantity through the 1
sight glass on the receiver tank.
3. Check the condenser.
If the condenser fins become clogged with dirt or in- M1SE-07-028

sects, the cooling effect will be decreased. Be sure to

keep it clean at all times.(Refer to “Clean Radiator ZAXIS125US, 135US, 135USK, 135USL
Core” in Maintenance Section.)
2
4. Check the compressor Oil Seepage
After operating the air conditioner for 5 to 10 minutes,
touch the high-pressure side and low-pressure side
pipes with your hand. If normal, the high-pressure
side pipe will be hot, and the low-pressure side cold.
5. Check mounting bolts for looseness.
Confirm that the compressor mounting bolts and Detail
other mounting/fastening bolts are securely tightened. M107-01-047
1
6. Inspect belt, check and adjust tension. ZAXIS225US, 225USLC
Visually check the compressor belt for wear. Check
and adjust belt tension, referring to the illustration
(right).

Compressor belts
Depressing Force: approximately 98 N (10 kgf, 22 lbf) No Refrigerant Insufficient
Empty Quantity
Deflection: 9 to 12 mm (0.35 to 0.47 in)

Almost clear. A few

If any abnormalities are found in air conditioner opera- bubbles may appear
tion, see your authorized dealer for inspection. Sufficient when the engine
Quantity speed is raised or
lowered.

M107-01-050
Fan Pulley

Alternator Pulley

Deflection
8 to 12 mm
98 N (10 kgf)
Push

Crank Pulley Compressor Pulley

Tension Pulley
M178-07-039

7-74
 MAINTENANCE
Adjust Compressor Belt Tension
Visually check the belt for wear. Replace if necessary.
Check compressor belt tension by depressing the midpoint
between compressor pulley and crank pulley with the
thumb. Deflection must be 9 to 12 mm (0.35 to 0.47 in)
with a depressing force of approximately 98 N (10 kgf, 22
lbf).

If tension is not within specifications, loosen bolt 1. Move

Crank Pulley
the tension pulley by bolt (2) until tension is correct.
Tighten bolt (1). Tension Pulley

NOTE: When a new belt is installed, be sure to

re-adjust the tension after operating the engine Compressor
1
for 3 to 5 minutes at slow idle speed to be sure 2 Compressor Pulley
M1G6-07-013

that the new belt is seated correctly.

7-75
 MAINTENANCE

Cleaning Cab Floor --- as necessary

IMPORTANT: When cleaning the cab floor with tap

water, spray the floor only. Take care not
to splash the surrounding area. Don’t
increase water spray speed by restrict-
ing the hose end, and don’t use high
pressure steam for cleaning. Be sure to
completely remove any moisture from
the surrounding area.

1. Park the machine on solid and level surface. Lower D

the bucket to the ground. Before cleaning, stop the
engine and the air conditioner, and protect the air A
conditioner in-cab air suction port and the foot air
vent with covers (A and B) stored in the pocket be-
hind the backrest.
2. Turn over the floor mat. Remove bolt ( C ) to remove
the air conditioner circulating air filter. Install cover (A)
in the position where the circulating air filter was in- E
stalled. Secure cover (A) with bolt (C). Remove foot
air vent holding bolt (D). Attach cover (B) onto the B C M1CC-07-038
foot air vent and secure cover (B) with bolt (D). E

IMPORTANT: Never fail to do this preparation work.

Failure to do so may result in damage/
failure of the air conditioner.

3. Sweep the cab floor clean using a brush, and brush

dust from the cab floor while spraying water.
4. When cleaning the floor mat, sweep dust (water)
along the grooves on the floor mat.
5. When cleaning after removing the floor mat, remove
two caps (E) plugging the cleaning holes on the floor
plate. Sweep dust (water) through these cleaning
holes.
6. After cleaning, remove covers (A and B) from the air
conditioner in-cab suction hole and the foot air vent
while following the above steps in reverse. Install the
circulating air filter. (Refer to the descriptions for
Clean and Replace Circulating Air Filter and Fresh Air
Filter.) Store covers (A and B) in the pocket behind
the backrest.
IMPORTANT: If the A/C is operated without removing
the cover, the A/C will not operate effi-
ciently so that its cooling ability is re-
duced.

7-76
 MAINTENANCE

Check Injection Nozzle

--- every 500 hours

See your authorized dealer.

Retighten Cylinder Head Bolt

--- daily

See your authorized dealer.

Inspect and Adjust Valve Clearance

--- every 1 000 hours

See your authorized dealer.

Check Fuel Injection Timing

--- daily

See your authorized dealer.

Measure Engine Compression Pressure

--- every 1 000 hours

See your authorized dealer.

Check Starter and Alternator

--- every 1 000 hours

See your authorized dealer.

Change Water Pump Grease

--- every 4 000 hours

See your authorized dealer.

7-77
 MAINTENANCE

19 Check Tightening Torque of Bolts and Nuts

--- every 250 hours (first time after 50 hours)
Check tightness after the first 50 hours then every 250
hours. Tighten to torque shown if any are loose. Bolts and
nuts should be replaced with those of the same or higher
grade.
For tightening nuts and bolts other than specified in the ta-
ble below, refer to the Tightening Torque Chart at the end
of this section.

IMPORTANT: Check and tighten bolts and nuts using

a torque wrench.

ZAXIS125US, 135US, 135USK

Bolt Dia Wrench Torque
No. Descriptions Q’ty
mm Size (mm) N!m (kgf!m) (lbf!ft)
Engine cushion rubber mounting nut (Fan side) 14 4 22 140 (14.3) (101)
1
Engine cushion rubber mounting bolt (Pump side) 16 2 24 235 (24) (175)
Engine bracket mounting bolt 10 7 17 50 (5.1) (37)
2
Engine bracket mounting nut 10 1 17 50 (5.1) (37)
3 Hydraulic oil tank mounting bolt 16 4 24 210 (21.5) (155)
4 Fuel tank mounting bolt 16 4 24 210 (21.5) (155)
17 24.5 (2.5) (18)
3 19 30 (3.1) (22)
1" "12UNF
16 22 40 (4.1) (30)
5 ORS fittings for hydraulic hoses and piping 27 95 (9.7) (70)
7 32 140 (14.3) (105)
1" "12UNF 36 175 (17.8) (130)
16
41 210 (21.5) (155)
6 Pump mounting bolt 10 8 17 50 (5.1) (37)
7 Control valve mounting bolt 14 6 22 140 (14.3) (105)
8 Control valve bracket mounting bolt 16 4 24 210 (21.5) (155)
9 Swing device mounting bolt 20 10 30 500 (51) (370)
10 Swing motor mounting bolt 10
7 8 64 (6.5) (47)
(Hex.Wrench)
11 Battery mounting nut 10 2 17 20 (2.0) (14.5)
12 Cab mounting nut 16 4 24 210 (21.5) (155)
Swing bearing mounting bolt to upperstructure 18 30 27 400 (41) (295)
13
Swing bearing mounting bolt to undercarriage 16 36 24 270 (27.5) (200)
Travel device mounting bolt 16 28 24 300 (30.5) (220)
14
Travel reduction device cover mounting bolt 14 4 22 140 (14.3) (103)
15 Sprocket mounting bolt 16 32 24 270 (27.5) (200)
16 Upper roller mounting bolt 12 8 19 100 (10) (70)
17 Lower roller mounting bolt 16 56 24 300 (30.5) (220)
18 Track shoe bolt 16 352 24 410 (42) (300)
20 Cover mounting bolt 6 － 10 10 (1) (7.4)
10 － 17 50 (5.1) (37)
12 － 19 90 (9.2) (66)
21 Flexible master coupling of piping 8 － 13 (1.05 to
10.3 to 12.4 (7.59 to 9.11)
1.26)
22 Jubilee Clamp of low pressure piping － 7 5.9 (0.6) (4.3)
T-bolt clamp of low pressure piping 11 5.9 (0.6) (4.3)

7-78
 MAINTENANCE

ZAXIS135USL
Bolt Dia Wrench Torque
No. Descriptions Q’ty
mm Size (mm) N!m (kgf!m) (lbf!ft)
Engine cushion rubber mounting nut (Fan side) 14 4 22 140 (14.3) (101)
1
Engine cushion rubber mounting bolt (Pump side) 16 2 24 235 (24) (175)
Engine bracket mounting bolt 10 7 17 50 (5.1) (37)
2
Engine bracket mounting nut 10 1 17 50 (5.1) (37)
3 Hydraulic oil tank mounting bolt 16 4 24 210 (21.5) (155)
4 Fuel tank mounting bolt 16 4 24 210 (21.5) (155)
17 24.5 (2.5) (18)
3 19 30 (3.1) (22)
1" "12UNF
16 22 40 (4.1) (30)
5 ORS fittings for hydraulic hoses and piping 27 95 (9.7) (70)
7 32 140 (14.3) (105)
1" "12UNF 36 175 (17.8) (130)
16
41 210 (21.5) (155)
6 Pump mounting bolt 10 8 17 50 (5.1) (37)
7 Control valve mounting bolt 14 6 22 140 (14.3) (105)
8 Control valve bracket mounting bolt 16 4 24 210 (21.5) (155)
9 Swing device mounting bolt 20 10 30 500 (51) (370)
10 Swing motor mounting bolt 10
7 8 64 (6.5) (47)
(Hex.Wrench)
11 Battery mounting nut 10 2 17 20 (2.0) (14.5)
12 Cab mounting nut 16 4 24 210 (21.5) (155)
Swing bearing mounting bolt to upperstructure 18 30 27 400 (41) (295)
13
Swing bearing mounting bolt to undercarriage 16 36 24 270 (27.5) (200)
Travel device mounting bolt 16 32 24 300 (30.5) (220)
14
Travel reduction device cover mounting bolt 14 6 22 180 (18.4) (135)
15 Sprocket mounting bolt 20 32 30 460 (47) (340)
16 Upper roller mounting bolt 16 16 24 270 (27.5) (200)
Lower roller and track guard Lower roller 18 － 27 450 (46) (330)
17
mounting bolt Track guard 18 8 27 500 (51) (370)
18 Track shoe bolt 18 336 27 560 (57) (410)
19 Track guard mounting bolt 18 8 27 500 (51) (370)
20 Cover mounting bolt 6 － 10 10 (1) (7.4)
10 － 17 50 (6.1) (37)
12 － 19 90 (9.2) (66)
21 Flexible master coupling of piping 8 － 13 (1.05 to
10.3 to 12.4 (7.59 to 9.11)
1.26)
22 Jubilee Clamp of low pressure piping － 7 5.9 (0.6) (4.3)
T-bolt clamp of low pressure piping 11 5.9 (0.6) (4.3)

7-79
 MAINTENANCE
IMPORTANT: Check and tighten bolts and nuts using
a torque wrench.

ZAXIS225US, 225USLC
Bolt Dia Wrench Torque
No. Descriptions Q’ty
mm Size (mm) N!m (kgf!m) (lbf!ft)
Engine cushion rubber mounting bolt Upper (Pump Side) 18 2 27 360 (37) (265)
1 Engine cushion rubber mounting nut Lower (Pump Side) 16 4 24 210 (21.5) (155)
Fan Side 14 4 22 140 (14.5) (103)
2 Engine bracket mounting bolt and nut 10 8 17 50 (5.1) (37)
3 Hydraulic oil tank mounting bolt 16 4 24 210 (21.5) (155)
4 Fuel tank mounting bolt 16 4 24 205 (21) (151)
1" 3 "12UN 17 24.5 (2.5) (18)
16 F 19 30 (3.1) (22)
22 40 (4.1) (30)
5 ORS fittings for hydraulic hoses and piping 1" 7 27 95 (9.7) (70)
16 "12UN 32 140 (14.3) (105)
F 36 175 (17.8) (130)
41 210 (21.5) (155)
6 Pump mounting bolt 10 8 17 50 (5.1) (37)
7 Control valve mounting bolt 16 4 24 210 (21.5) (155)
8 Control valve bracket mounting bolt 16 4 24 210 (21.5) (155)
9 Swing device mounting bolt 20 12 30 500 (51) (370)
10 Swing motor mounting bolt 12 8 10 90 (9.2) (66)
11 Battery mounting nut 10 2 17 50 (5.1) (37)
12 Cab mounting nut 16 4 24 205 (21) (151)
Swing bearing mounting bolt to upperstructure 20 32 30 510 (52) (380)
13
Swing bearing mounting bolt to undercarriage 20 36 30 490 (50) (360)
14 Travel device mounting bolt 20 32 30 630 (64) (460)
Travel reduction device cover mounting bolt 14 12 22 175 (18) (130)
15 Sprocket mounting bolt 20 32 30 470 (48) (350)
16 Upper roller mounting bolt 16 16 24 270 (27.5) (200)
Lower roller ZAXIS225US 18 56 27 460 (47) (340)
17
mounting bolt ZAXIS225USLC 18 64 27 460 (47) (340)
ZAXIS225US 20 368 27 840 (86) (620)
18 Track shoe bolt
ZAXIS225USLC 20 392 27 840 (86) (620)
19 Track guard mounting bolt 18 16 27 500 (51) (370)
6 － 10 10 (1) (7.4)
20 Cover mounting bolt 10 － 17 50 (5.1) (37)
12 － 19 90 (9.2) (66)
21 Flexible master coupling of piping 8 － 13 10.3 to 12.4 (1.05 to 1.26) (7.59 to 9.11)
Jubilee Clamp of low pressure piping 5 － 7 5.9 (0.6) (4.3)
22
T-bolt clamp of low pressure piping 6 － 11 5.9 (0.6) (4.3)

7-80
 MAINTENANCE
Tightening Torque Chart

Hexagon
Wrench
Bolt Dia. Wrench
Size
Size M552-07-091 M552-07-090 M157-07-225
Socket Bolt
N!m (kgf!m) (lbf!ft) N!m (kgf!m) (lbf!ft) N!m (kgf!m) (lbf!ft)
M8 13 6 30 (3.1) (22) 20 (2.0) (15.0) 10 (1.0) (7.4)
M10 17 8 65 (6.6) (48) 50 (5.1) (37) 20 (2.0) (15.0)
M12 19 10 110 (11.0) (81) 90 (9.2) (66) 35 (3.6) (26.0)
M14 22 12 180 (18.5) (135) 140 (14.3) (103) 55 (5.6) (41)
M16 24 14 270 (27.5) (200) 210 (21.5) (155) 80 (8.2) (59)
M18 27 14 400 (41.0) (295) 300 (30.5) (220) 120 (12.0) (89)
M20 30 17 550 (56.0) (410) 400 (41.0) (295) 170 (17.0) (125)
M22 32 17 750 (76.5) (550) 550 (56.0) (410) 220 (22.5) (162)
M24 36 19 950 (97.0) (700) 700 (71.5) (520) 280 (28.5) (205)
M27 41 19 1400 (143) (1030) 1050 (107) (770) 400 (41.0) (295)
M30 46 22 1950 (200) (1440) 1450 (148) (1070) 550 (56.0) (410)
M33 50 24 2600 (265) (1920) 1950 (200) (1440) 750 (76.5) (550)
M36 55 27 3200 (325) (2360) 2450 (250) (1810) 950 (97.0) (700)

CAUTION: If fixing bolts for counterweight are

loosened, consult your nearest authorized dealer.

IMPORTANT: Make sure bolt and nut threads are clean

before installing.
Apply lubricant (e. g. white zinc B solved
into spindle oil) to bolts and nuts to sta-
bilize their friction coefficient.
NOTE: Tightening torque required is shown in N!m.
For example, when tightening a bolt or nut with
a wrench of 1 m length, turning the end of it
with a force of 120 N, the torque produced will
be:

1 m ×120 N = 120 N!m

To produce the same torque with a wrench of

0.25 m:
0.25 m # N = 120 N!m

Necessary force will be:

120 N!m $ 0.25 m = 480 N

7-81
 MAINTENANCE
1. Retighten the engine insulation
rubber mounting bolts and
nuts.
Nut (Fan Side)

ZAXIS125US, 135US, 135USK, MSE-07-026 ZAXIS225US, 225USLCM1GF-07-007

Bolt and Nut (Pump Side) 135USL

ZAXIS125US, 135US, 135USK, M1SE-07-027

2. Retighten the engine bracket 135USL
mounting bolts and nuts. ZAXIS225US, 225USLCM178-07-048

ZAXIS125US, 135US, 135USK, M1SE-07-026

135USL ZAXIS225US, 225USLCM1GF-07-007

3. Retighten the hydraulic oil tank
mounting bolts.

ZAXIS125US, 135US, 135USK, M1SE-07-021

135USL ZAXIS225US, 225USLC M1GF-07-011
4. Retighten the fuel tank
mounting bolts.

ZAXIS125US, 135US, 135USK, M1SE-07-021 ZAXIS225US, 225USLC M1GF-07-030

135USL

7-82
 MAINTENANCE
5. Retighten the ORS fittings for hydraulic hoses and
piping.

M104-07-079
6. Retighten the pump mounting
bolts.

M1GF-07-005

ZAXIS125US, 135US, 135USK, 135USL ZAXIS225US, 225USLC

M1SE-07-015

7. Retighten the control valve

mounting bolts.

ZAXIS125US, 135US, 135USK, 135USL

M1SE-07-025
ZAXIS225US, 225USLC
M1GF-07-028

8. Retighten the control valve

bracket mounting bolts.

M1GF-07-029
ZAXIS125US, 135US, 135USK, 135USL ZAXIS125US, 135US
M1SE-07-025
9. Retighten the swing device
mounting bolts.

M1GF-07-002

M1SE-07-020
ZAXIS125US, 135US, 135USK,135USL ZAXIS125US, 135US

7-83
 MAINTENANCE
10. Retighten the swing motor
mounting bolts.

ZAXIS125US, 135US, 135USK, 135USL M1SE-07-020 ZAXIS225 US, 225USLC M1GF-07-002

11. Retighten the battery mounting

nuts.

ZAXIS125US, 135US, 135USK, 135USL M1SE-07-023 M1GF-07-012

ZAXIS225US, 225USLC

12. Retighten the cab mounting nuts.

M157-07-219
13. Retighten the swing bearing
mounting bolts to the
upperstructure.

ZAXIS125US, 135US, 135USK, 135USL M104-07-086 ZAXIS225US, 225USLC M107-07-088

Retighten the swing bearing

mounting bolts to the
undercarriage.

ZAXIS225US, 225USLC M107-07-089

7-84
 MAINTENANCE
14. Retighten the travel device mounting bolts.

M154-12-002
Retighten the travel reduction device cover mounting
bolts.

M1G6-07-007
15. Retighten the sprocket mounting bolts.

16. Retighten the upper roller mounting bolts. M154-07-050

M154-07-051

17. Retighten the lower roller mounting bolts.

M104-07-090

7-85
 MAINTENANCE
18. Retighten the shoe mounting bolts.

M104-07-091
19. Retighten the track guard mounting bolts.

M107-07-094

20. Retighten the cover mounting bolts.

SS-2095

21. Retighten flexible master

coupling.

M1G6-07-008

22. Retighten jubilee and T-bolt

cramp

Jubilee
Clamp
M1SE-07-029 Jubilee Clamp T-Bolt Clamp
M1GF-07-009
ZAXIS125US, 135US, 135USK, 135USL
ZAXIS225US, 225USLC

7-86
 MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS
MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS

Operating Conditions Precautions for Maintenance

Muddy Soil, Rainy or Before Operation: Check the tightness of plugs and all drain cocks.
Snowy Weather After Operation: Clean the machine and check for cracks, damaged,
loose or missing bolts and nuts. Lubricate all necessary
parts without delay.
Near the Ocean Before Operation: Check tightness of plugs and all drain cocks.
After Operation: Thoroughly clean the machine with fresh water to wash
off salt. Service electrical equipment often to prevent
corrosion.
Dusty Atmosphere Air Cleaner: Clean the element regularly at shorter service intervals.
Radiator: Clean the oil cooler screen to prevent clogging of the
radiator core.
Fuel System: Clean the filter element and strainer regularly at shorter
service intervals.
Electrical Equipment: Clean them regularly, in particular, the commutator
surface of the alternator and starter.
Rocky Ground Tracks: Carefully operate while checking for cracks, damage and
loose bolts and nuts. Loosen the tracks a little more
than usual.
Front Attachment: Standard attachment may be damaged when digging
rocky ground. Reinforce the bucket before using it, or
use a heavy duty bucket.
Freezing Weather Fuel: Use high quality fuel suitable for low temperature.
Lubricant: Use high quality low viscosity hydraulic oil and engine oil.
Engine Coolant: Be sure to use antifreeze.
Battery: Fully charge the batteries regularly at shorter service
intervals. If not fully charged, electrolyte may freeze.
Tracks: Keep the tracks clean. Park the machine on a hard
surface to prevent the tracks from freezing to the ground.
Falling Stones Cab: Provide a cab guard to protect the machine from falling
stones when necessary.

9-1
 MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS
MEMO
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9-2
 STORAGE
STORING THE MACHINE

1. Inspect the machine. Repair worn or damaged parts.

Install new parts if necessary.
2. Clean the primary air cleaner element.
3. Retract all hydraulic cylinders, if possible. If not, coat
exposed cylinder rods with grease.
4. Lubricate all grease points.
5. Park the tracks on long stable blocks.
6. Wash the machine.
7. Remove the batteries and store them in a dry pro-
tected place after charging fully. If not removed, dis-
connect the negative battery cable from the (!) ter-
minal.
8. Add an antirust agent to the coolant. In cold weather,
add an antifreeze, or drain the coolant completely. Be
sure to attach a “No Water in Radiator” tag on a
clearly visible location if the system is drained.
9. Loosen the alternator belt and fan belt.
10. Paint necessary areas to prevent rust.
11. Store the machine in a dry, protected place. If stored
outside, cover with a waterproof cover.
12. If the machine is stored for a long time, operate hy-
draulic functions for travel, swing and digging two to
three times for lubrication, at least once a month.
Be sure to check the coolant level and lubrication
conditions before operating.

Precautions for Disconnecting or Connecting

Batteries
In case the batteries are kept disconnected for more
than one month or when the batteries are reconnected,
contact your nearest Hitachi dealer. Resetting of the ICX
(Information Controller) may be required.

10-1
 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.
4. Start the engine.
Run the engine at half speed for several minutes be-
fore full load operation.
5. Cycle all hydraulic functions several times.
6. Carefully check all systems before operating the ma-
chine at full load.

NOTE: When the machine has been stored for a long

time, be sure to perform the following steps as
well:
(a) Check condition of all hoses and connec-
tions.
(b) Warm up the engine.
(c) Stop the engine.
(d) Install new fuel filters. Replace the engine
oil filter and fill the engine with oil.

IMPORTANT: If the machine has not been used for a

long time, oil films on sliding surfaces
may have broken down. Cycling hydrau-
lic functions for travel, swing and dig-
ging two to three times is necessary to
lubricate the sliding surfaces.

10-2
 TROUBLESHOOTING

ENGINE
Problem Cause
Engine Cranks But Will No fuel
Not Start or Hard to Start
Wrong fuel
Contaminated fuel
Low battery power
Injection pump
Wrong preheat line or glow plugs
Poor electrical connection
Starter motor failure
Wrong engine oil
Air filter plugged
Fuel filter plugged
Engine compression low
Injection nozzles dirty or not working
correctly
Fuel shut-off linkage
Leaks in fuel system
Air in fuel system
Fuel feed pump plunger up
Feed pump strainer dirty
Engine Knocks, Runs Ir- Engine oil level low
regularly or Stops
Plugged air intake system
Feed pump strainer dirty
Injection pump out of time
Plugged fuel filters
Low coolant temperature
Water, dirt or air in fuel system
Injection nozzles dirty or faulty
Fuel shut-off linkage
Solution
Add fuel.
Bleed air.
Drain tank. Use correct fuel.
Drain tank and add clean fuel.
Charge or install new battery.
See your authorized dealer.
See your authorized dealer.
Clean and tighten battery and starter
motor connections.
Replace starter.
Drain oil. Use correct oil.
Replace elements.
Remove air from fuel system.
Clean fuel tank strainer.
See your authorized dealer.
See your authorized dealer.
Adjust or repair linkage.
Check fuel system connections.
Bleed air.
Push down and tighten knob.
Clean or replace.
Add oil.
Clean filter and system.
Clean or replace.
See your authorized dealer.
Install new filters.
Thermostat not working correctly or too
“cool”.
Bleed air from fuel system.
Clean fuel tank outlet screen.
See your authorized dealer.
Adjust or repair linkage.

11-1
 TROUBLESHOOTING
ENGINE
Problem Cause
Engine Not Developing Full Air filters plugged
Power Fuel line restricted
Contaminated fuel
Fuel filters plugged
Plugged vent in fuel tank cap
Injection nozzles dirty or
malfunctioning
Injection pump linkage adjustment
Wrong fuel
Wrong oil
Turbocharger failure
Injection pump out of timing
Exhaust restriction
Engine is too hot or cold
Engine failure
Valve clearance
Intake or exhaust system leakage
Engine Overheats Low coolant level
Thermostat
Engine overloaded
Radiator cap faulty
Radiator core or oil cooler core
plugged
Radiator screen plugged
Injection pump out of timing
Fan damaged
Air cleaner plugged
Alternator and fan belt loose
Pulley grooves worn
Cooling system passages dirty
Temperature gauge or sending unit See your authorized dealer.
11-2
Solution
Replace filter elements.
Repair or replace fuel line.
Drain fuel tank and clean outlet screen.
Refill.
Change filters.
Clean or install new cap.
See your authorized dealer.
See your authorized dealer.
Use correct fuel.
Use correct oil.
See your authorized dealer.
See your authorized dealer.
Remove muffler and run engine.
See below.
See your authorized dealer.
Check and adjust valves.
See your authorized dealer.
Add coolant.
See your authorized dealer.
Check hydraulic relief valves.
Install new cap.
Clean radiator and oil cooler.
Clean screen.
See your authorized dealer.
Replace fan.
Clean air cleaner.
Tighten or install new belt.
Replace pulleys.
Flush cooling system.
 TROUBLESHOOTING
ENGINE
Problem Cause
Coolant Temperature Too Low Thermostat
Temperature gauge or sending unit
Low Engine Oil Pressure Engine oil pump or pump drive
Low oil level
Engine oil pressure regulation valve
Plugged oil pump intake screen
Plugged oil filter
Oil leaks
Oil diluted with fuel or coolant
Engine temperature too high
Wrong oil
Engine Uses Too Much Oil Wrong oil
Oil leaks
Engine temperature too high
Plugged air cleaner
Internal engine component wear
Engine Uses Too Much Fuel Plugged or dirty air intake system
Wrong fuel
Fuel injection nozzles
Injection pump out of time
Excessive Black or Gray Wrong fuel
Exhaust Smoke
Plugged or dirty air intake or exhaust
system
Injection pump out of timing
Injection nozzles dirty or faulty
Basic engine failures
11-3
Solution
See your authorized dealer.
See your authorized dealer.
See your authorized dealer.
Add oil.
See your authorized dealer.
See your authorized dealer.
Install a new oil filter.
Check for leaks.
See your authorized dealer.
Check cooling system.
Drain oil. Use correct oil.
Drain oil.Use correct oil.
Check engine oil drain plug.
Check cooling system.
Clean element or install new element.
See your authorized dealer.
Clean air intake system.
Use correct fuel.
See your authorized dealer.
See your authorized dealer.
Drain tank. Use correct fuel.
Clean air intake and exhaust system.
See your authorized dealer.
See your authorized dealer.
See your authorized dealer.

Problem
Nothing Works
Nothing Works
(Except clock)
Batteries Undercharged
Starting Motor Will Not Turn
Starter Solenoid Chatters
Starter Motor Turns but Will
Not Crank Engine
Engine Cranks Slowly
TROUBLESHOOTING
ENGINE
Cause Solution
Battery Recharge or replace.
Battery relay Replace relay.
Loose or corroded connections Clean and tighten or replace batteries.
Alternator belt loose Tighten or install new belt.
Alternator not charging See your authorized dealer.
Fuse Replace fuse.
Key switch failure Replace key switch.
Battery undercharged or dead Recharge or replace battery.
Battery cables making poor Clean connections.
connections
Fusible link Replace fusible link.
Key switch See your authorized dealer.
Start relay See your authorized dealer.
Starter solenoid See your authorized dealer.
Starter Repair or replace start motor.
Starter pinion jammed in flywheel Repair or replace starter.
gear
Major engine failure See your authorized dealer.
Poor connections at batteries or Clean connections.
starter
Low battery charge Recharge or replace batteries.
Starter solenoid “hold-in” windings See your authorized dealer.
open
Starter pinion gear not engaging See your authorized dealer.
flywheel ring gear
Pinion shift mechanism jammed or See your authorized dealer.
malfunctioning
Pinion gear teeth broken See your authorized dealer.
Flywheel gear teeth broken See your authorized dealer.
Battery cables damaged or broken Inspect and replace cables.
internally
Battery or starter cable Clean and tighten connections.
connections loose or corroded
11-4
 TROUBLESHOOTING
ENGINE
Problem Cause
Exhaust Gas is White Wrong fuel
Cold engine
Thermostat faulty or too “cool”
Injection pump out of time
Coolant leakage into engine cylinder
Turbocharger Excessively Bearings not lubricated
Noisy or Vibrates
Worn bearings
Air leak in engine, intake or exhaust
manifold
Improper clearance between turbine
wheel and turbine housing
Broken blades on turbine
Oil Dripping from Damaged or worn bearings and/or
Turbocharger Adapter worn seals
Excessive crankcase pressure
Turbocharger oil return line carbon
build up where line passes exhaust
manifold
Excessive Drag in Carbon build-up behind turbine wheel
Turbo-charger Rotating caused by combustion deposits
Members
Dirt build-up behind compressor
wheel caused by air intake leaks
Bearing seizure or dirty or worn
bearings, caused by excessive
temperature, unbalanced wheel, dirty
oil, oil starvation, or insufficient
lubrication
11-5
Solution
Drain tank. Use correct fuel.
Run engine until warm.
See your authorized dealer.
See your authorized dealer.
See your authorized dealer.
Insufficient oil pressure.
Check for restricted turbocharger oil
line.
See your authorized dealer.
Inspect, repair.
See your authorized dealer.
Remove exhaust elbow and air inlet
hose and inspect.
See your authorized dealer.
Inspect and clean air cleaner.
Check for proper engine service
intervals or dirt enter into engine.
Check vent tube to ensure tube is not
plugged.
Clean.
Remove line.
Inspect, clean.
Inspect, clean.
Inspect, clean.
See your authorized dealer.

Problem
Engine Cranks Slowly
Starter Motor Continues to
Run After Engine Starts
Charging Indicator Light
On-Engine Running
Noisy Alternator
No Monitor Panel Indicators
Work
Individual Light in Monitor
Panel is Not Working
TROUBLESHOOTING
ELECTRICAL SYSTEM
Cause Solution
Battery discharged or will not hold a Replace battery.
charge
Starter “dragging” See your authorized dealer.
Low battery voltage Recharge or replace battery.
Start relay stuck See your authorized dealer.
Starter solenoid stuck See your authorized dealer.
Starter not disengaging See your authorized dealer.
Key switch See your authorized dealer.
Loose or glazed alternator belt Check belt.
Replace if glazed, tighten if loose.
Engine rpm low Adjust rpm to specification.
Excessive electrical load from added Remove accessories or install higher
accessories output alternator.
Loose or corroded electrical Inspect, clean, or tighten electrical
connections on battery, ground strap, connections.
starter, or alternator
Battery voltage low Change or replace battery.
Alternator or regulator See your authorized dealer.
Indicator circuit See your authorized dealer.
Worn drive belt Replace belt.
Worn pulleys Replace pulleys and belt.
Pulley misaligned Adjust alternator mount.
Alternator bearing Loosen alternator belts.
Turn pulley by hand.
If any roughness is felt, repair
alternator.
Fuse Replace fuse.
Wiring harness See your authorized dealer.
Bulb Replace bulb.
Fuse Replace fuse.
Wiring harness See your authorized dealer.
11-6
 TROUBLESHOOTING

ELECTRICAL SYSTEM
Problem Cause Solution
No Indicators in Gauge Panel Circuit board See your authorized dealer.
Operate Wiring harness See your authorized dealer.
Fuse Replace fuse.
Indicator Light in Gauge Panel Bulb Replace bulb.
is Inoperative Fuse Replace fuse.
Sender Do sender check.
Wiring harness failure See your authorized dealer.
Coolant Temperature Gauge Fuse Replace fuse.
Does Not Work Gauge See your authorized dealer.
Gauge sender Do coolant temperature gauge sender
check.
Wiring harness See your authorized dealer.
Indicator Lights Do Not Fuse Replace fuse.
Operate Auto-idle Bulb Replace bulb.
Auto-idle switch See your authorized dealer.
Fuel Gauge Does Not Work Fuse Replace fuse.
Gauge See your authorized dealer.
Wiring harness See your authorized dealer.

11-7
 TROUBLESHOOTING

MODE SELECTION
Problem Cause Solution
Work Mode Selector Mode switches See your authorized dealer.
Does Not Work Electrical connector See your authorized dealer.
Failed pilot pressure switch wire See your authorized dealer.
harness
Main controller See your authorized dealer.
Solenoid valve unit See your authorized dealer.
Fast/Slow Travel Speed Travel mode switches See your authorized dealer.
Does Not Function Pilot pressure switch (Travel) See your authorized dealer.
Pump delivery pressure sensor wire See your authorized dealer.
harness
Main controller See your authorized dealer.
Solenoid valve unit See your authorized dealer.
Damaged travel motor See your authorized dealer.
Auto-Idle Does Not Work Fuse Replace fuse.
Switch panel See your authorized dealer.
Electrical connector See your authorized dealer.
Wire harness See your authorized dealer.
EC motor See your authorized dealer.
Pressure switches (Travel, Front) See your authorized dealer.
Main controller See your authorized dealer.

11-8
 TROUBLESHOOTING

CONTROL LEVERS
Problem Cause Solution
Moves Hard Corroded joint See your authorized dealer.
Worn out pusher See your authorized dealer.
Does Nothing Worn out pusher See your authorized dealer.
Pilot valve See your authorized dealer.
Does Not Return to Neutral Pilot valve See your authorized dealer.
Too Much Play Worn out pivot joint See your authorized dealer.
Lever is Not Vertical In Neutral Pilot valve See your authorized dealer.

Problem
Hydraulic Functions are Slow
Hydraulic Oil Overheats
HYDRAULIC SYSTEM
Cause Solution
Low oil level Fill reservoir to full mark.
Cold oil Push hydraulic warm up switch.
Wrong oil Drain tank. Use correct oil.
Engine speed too low Increase speed or see your authorized
dealer.
Pilot circuit See your authorized dealer.
Worn pump See your authorized dealer.
Restricted pump suction line See your authorized dealer.
Wrong oil Use correct oil.
Air leak in pump suction line See your authorized dealer.
Oil lines restricted See your authorized dealer.
Low oil level Fill reservoir to full mark.
Plugged filters Install new filters.
Worn pump See your authorized dealer.
Plugged radiator or oil cooler Clean and straighten fins.
Oil cooler bypass See your authorized dealer.

11-9
 TROUBLESHOOTING

Problem
Hydraulic Oil Overheats
Oil Foams
Low or No Oil Pressure
No Hydraulic Functions
(Noise from pumps)
Hydraulic Cylinders Operate
but Cannot Lift Load
HYDRAULIC SYSTEM
Cause
Relief valve
Contaminated oil
Travel motors
Improperly adjusted hydraulic
components
Air leak in line from reservoir to pump
Kinks or dents in oil lines
Wrong oil
Water in oil
High or low oil level
Wrong oil
Improperly adjusted hydraulic
components
No oil in system
Worn cylinder packings
Relief valve
Hydraulic pump
Decreased set-pressure of main relief
valve in control valve
Lack of hydraulic oil
Damaged suction line or hose
Clogged suction filter
Sucked air from oil suction port
Hydraulic pump worn
Main relief valve pressure low
Hydraulic oil level low
Suction screen plugged
Pump suction line leaking
Solution
See your authorized dealer.
Drain oil and refill.
See your authorized dealer.
See your authorized dealer.
Repair leak or see your authorized
dealer.
Check lines.
Use correct oil.
Change oil.
Correct level.
Use correct oil.
See your authorized dealer.
Fill with correct oil.
See your authorized dealer.
See your authorized dealer.
See your authorized dealer.
Add oil.
See your authorized dealer.
Clean.
See your authorized dealer.
See your authorized dealer.
Add oil.
Clean strainer and system.
Inspect suction line.

11-10
 TROUBLESHOOTING
HYDRAULIC SYSTEM
Problem Cause
One Control Lever Does Not Relief valve pressure low
Work Tube or hose damaged
Hydraulic fittings loose
Damaged O-rings in fittings
Hydraulic Pump
Pilot valve
Pilot lines
One Cylinder Does Not Work Control valve spool damaged or
contaminated with dirt
Hydraulic lines damaged
Fittings loose
O-ring in fitting damaged
Pilot valve
Pilot lines
One Cylinder Does Not Work Piston seals leaking
or Has Little Power Cylinder rod damaged
Pilot lines
Pilot valve
Failed wiring harness
Both Travel Motors Do Not Center joint failure
Work
One Travel Motor Does Not Travel motor
Work Parking brake not releasing
Pilot valve
Pilot lines
Travel is Not Smooth Track adjustment
Track idler or rollers damaged
Track frame bent
11-11
Solution
See your authorized dealer.
Repair or replace.
Tighten.
Install new O-ring.
See your authorized dealer.
See your authorized dealer.
Repair or replace.
See your authorized dealer.
Repair or replace.
Tighten.
Install new O-ring.
See your authorized dealer.
Repair or replace.
See your authorized dealer.
See your authorized dealer.
Repair or replace.
See your authorized dealer.
See your authorized dealer.
See your authorized dealer.
See your authorized dealer.
See your authorized dealer.
See your authorized dealer.
Repair or replace.
Adjust tension.
See your authorized dealer.
See your authorized dealer.
 TROUBLESHOOTING

HYDRAULIC SYSTEM
Problem Cause Solution
Travel is Not Smooth Rocks or mud “jammed” in track frame Remove and repair.
Travel brake not releasing See your authorized dealer.
Swing Does Not Work Swing brake release valve See your authorized dealer.
Swing motor See your authorized dealer.
Pilot valve See your authorized dealer.
Swing is Not Smooth Swing gear See your authorized dealer.
Swing bearing See your authorized dealer.
Lack of grease Apply grease.
Engine Stops When Travel Failure of connector contact Repair or replace.
or/and Control Lever Moved Failed wiring harness See your authorized dealer.
Failed Main controller See your authorized dealer.

11-12
 SPECIFICATIONS
SPECIFICATIONS

ZAXIS125US

T1SE-01-01-001

Model ZAXIS125US
Type of Front-End Attachment 2.26 m (7 ft 5 in) Arm
3 3 3 3 3
Bucket Capacity (Heaped) m (yd ) PCSA 0.45 m (0.59 yd ), CECE 0.4 m
Operating Weight kg (lb) 12400 (27300)
Basic Machine Weight kg (lb) 9900 (21800)
ISUZU BB-4BG1T, 59 kW (80 PS)/1950 min! (rpm)
1
Engine
－1
!63 kW (85 PS)/2150 min (rpm)
A : Overall Width
(Excluding Rearview Mirrors) mm (ft"in) 2490 (8" 2#)
B : Cab Height mm (ft"in) 2740 (9" 0#)
C : Rear End Swing Radius mm (ft"in) 1465 (4" 10#)
D : Minimum Ground Clearance mm (ft"in) * 440 (1" 5#)
E : Counterweight Clearance mm (ft"in) * 890 (2" 11#)
F : Engine Cover Height mm (ft"in) * 2020 (6" 7#)
G : Overall Width of
Upperstructure mm (ft"in) 2470 (8" 1#)
H : Undercarriage Length mm (ft"in) 3580 (11" 9#)
I : Undercarriage Width mm (ft"in) 2490 (8" 2#)
J : Sprocket Center to Idle Center mm (ft"in) 2880 (9" 5#)
K : Track Shoe Width mm 500 (Iron Crawler)
(ft"in) (20#)
2
Ground Pressure kPa (kgf/cm ) (psi) 39 (0.40) (5.7)
!1
Swing Speed min (rpm) 13.9 (13.9)
Travel Speed (fast/slow) km/h 5.3/3.2
(mph) (3.3/2.0)
Gradeability degree (%) 35 (70)

NOTE: ! H/P mode

* The dimensions do not include the height of the shoe lug.

12-1
 SPECIFICATIONS
WORKING RANGES

ZAXIS125US

G
G

C C
D
D

E
E

F
F
F

A
B
B A

M1SE-12-001

Backhoe Shovel
T1SE-01-01-002

Model ZAXIS125US
Category 1.96 m (6" 5#) Arm 2.26 m (7" 5#) Arm 2.81 m (9" 3#) Arm
Item Backhoe Shovel Backhoe Shovel Backhoe Shovel
A : Maximum Digging Reach mm 7790 7930 8060 8200 8530 8680
(ft"in) (25" 6#) (26" 0#) (26" 5#) (26" 11#) (28" 0#) (28" 6#)
*1 B : Maximum Digging Depth mm 4970 5120 5270 5420 5820 5970
(ft"in) (16" 4#) (16" 10#) (17" 3#) (17" 9#) (19" 1#) (19" 7#)
*1 C : Maximum Cutting Height mm 8800 8900 9020 9180 9370 9530
(ft"in) (28" 10#) (29" 2#) (29" 7#) (30" 1#) (30" 9#) (31" 3#)
*1 D : Maximum Dumping Height mm 6350 6600 6570 6830 6920 7180
(ft"in) (20" 10#) (21" 8#) (21" 7#) (22" 5#) (22" 8#) (23" 7#)
E : Transport Height mm 2780 2780 2780 2780 *2 2740 *2 2740
(ft"in) (9" 1#) (9" 1#) (9" 1#) (9" 1#) (9" 0#) (9" 0#)
F : Overall Transport Length mm 7240 7240 7240 7240 *2 7150 *2 7150
(ft"in) (23" 9#) (23" 9#) (23" 9#) (23" 9#) (23" 5#) (23" 9#)
G : Minimum Swing Radius mm 1940 1940 2030 2030 2370 2370
(ft"in) (6" 4#) (6" 4#) (6" 8#) (6" 8#) (7" 9#) (7" 9#)

NOTE: *1 The dimensions do not include the height of the shoe lug.
*2 The dimensions asterisked are for transport pin position.

12-2
 SPECIFICATIONS
SHOE TYPES AND APPLICATIONS

ZAXIS125US
500 mm (20#) 600 mm (24#) 700 mm (28#) 510 mm (20#) 700 mm (28#)
Shoe Width
Grouser Shoe Grouser Shoe Grouser Shoe Flat Shoe Triangular Shoe
For Ordinary For Ordinary For Weak For Paved For Weak
Application Ground Ground Footing Road Footing
(Standard) (Option) (Option) (Option) (Option)
Operating Weight kg 12400 12700 12900 12900 12700
(lb) (27300) (28000) (28400) (28400) (28000)
Basic Machine Weight kg 9900 10200 10400 10400 10200
(lb) (21800) (22500) (22900) (22900) (22500)
Cab Height mm 2740 2740 2740 2750 2790
(ft"in) (9" 0#) (9" 0#) (9" 0#) (9" 0#) (9" 2#)
Minimum Ground ! 440 ! 440 ! 440 470 490
Clearance (mm) (17#) (17#) (17#) (19#) (17#)
Undercarriage mm 3580 3580 3580 3600 3680
Length (ft"in) (11" 9#) (11" 9#) (11" 9#) (11" 10#) (12" 1#)
Undercarriage Width mm 2490 2590 2690 2500 2690
(ft"in) (8" 2#) (8" 6#) (8" 10#) (8" 2#) (8" 10#)
39 kPa 33 kPa 28 kPa 39 kPa 28 kPa
2 2 2 2 2
Ground Pressure (0.40 kgf/cm , (0.34 kgf/cm , (0.29 kgf/cm , (0.40 kgf/cm , (0.29 kgf/cm ,
5.7 psi) 4.8 psi) 4.1 psi) 5.7 psi) 4.1 psi)

500 mm (20#) 500 mm (20#) 500 mm

Shoe Width
Single Grouser Shoe Pad Crawle Shoe Rubber Pad Shoe

Application For Paved Road (Option) For Paved Road (Option) For Paved Road (Option)

Operating Weight kg 12700 12500 12900

(lb) (28000) (27600) (28400)
Basic Machine Weight kg 10200 10000 10400
(lb) (22500) (22000) (22900)
Cab Height mm 2770 2790 2780
(ft"in) (9" 1#) (9" 2#) (9" 1#)
Minimum Ground 470 500 480
Clearance (mm) (19#) (20#) (19#)
Undercarriage mm 3650 3660 3620
Length (ft"in) (12" 0#) (12" 0#) (11" 11#)
Undercarriage Width mm 2490 2490 2490
(ft"in) (8" 2#) (8" 2#) (8" 2#)
39 kPa 39 kPa 40 kPa
Ground Pressure 2 2 2
(0.40 kgf/cm , 5.7 psi) (0.40 kgf/cm , 5.7 psi) (0.41 kgf/cm , 5.8 psi)

NOTE: • The specifications for the front-end attachment are for 2.26 m (7 ft 5 in) arm with PCSA 0.46 m (0.6
3
3
yd ) standard bucket.
• 600 mm (24 in), 700 mm (28 in) grouser shoe, 510 mm (20 in) flat shoe and 700 mm (28 in) triangular
shoe not be used on gravel or rocky ground.
• ! The dimensions do not include the height of the shoe lug.

12-3
 SPECIFICATIONS
BUCKET TYPES AND APPLICATIONS

ZAXIS125US
Bucket Capacity Bucket Width
3 3 Front-End Attachment
m (yd ) mm (in)
Bucket
PCSA CECE With Side Without Side 1.96 m 2.26 m 2.81 m
Heaped Heaped Cutters Cutters (6" 5#) Arm (7" 5#) Arm (9" 3#) Arm
0.19 (0.25) 0.17 550 (22#) 450 (18#) # # #
0.30 (0.39) 0.25 700 (28#) 580 (23#) # # #
0.40 (0.52) 0.33 800 (31#) 680 (27#) # # #
Hoe Bucket
0.45 (0.59) 0.4 970 (38#) 850 (33#) # # * ○
0.50 (0.65) 0.45 1010 (40#) 890 (35#) # ○ !
0.59 (0.77) 0.5 1070 (42#) 950 (37#) ○ □ !
0.45 (0.59) 0.4 970 (38#) 850 (33#) # # * ○
0.50 (0.65)
Reinforced Bucket (Side Pin 0.45 1010 (40#) 890 (35#) ○ ! !
Type)
0.50 (0.65) 0.45 1010 (40#) 890 (35#) ○ ! !
V-Type Bucket ! Angle 90° ○ ○ ○
One Point Ripper ! ! $ $ !
Slope-Finishing
! 1000 (39#)x1600 (63#) ◇ ◇ ◇
Blade

NOTE: • Symbols in the above table have the following meanings.

#: General excavating
%: Light duty excavating
$: Rock digging
&: Loading work
$: Slope-finishing work
!: Not applicable (not warrantable)

• Hoe bucket is applicable to the following types of work.

General excavating:
For digging and loading operation of sand, gravel, clay, ordinary earth and so on.
Light duty excavating:
For digging and loading operation of dry, loosened earth, sand, mud and so on.
3 3
Their bulk density shall be less than 1.60 t/m (2700 lbf/yd ) as a standard.
Loading:
For loading operation of dry, loosened earth and sand.
3 3
Their bulk density shall be less than 1.10 t/m (1850 lbf/yd ) as a standard.
Rock digging:
For digging/loading operation of mountain gravels, blasted rock, hard clay, soft rock and so on.
• * : Applicable only to 700 mm (28 in) grouser shoe.

12-4
 SPECIFICATIONS
SPECIFICATIONS

ZAXIS135US

T1SE-01-01-001

Model ZAXIS135US
Type of Front-End Attachment 2.52 m (8 ft 3 in) Arm
3 3 3 3 3
Bucket Capacity (Heaped) m (yd ) PCSA 0.50 m (0.65 yd ), CECE 0.45 m
Operating Weight kg (lb) 13200 (29100)
Basic Machine Weight kg (lb) 10600 (23400)
ISUZU CC-4BG1TC, 63 kW (85 PS)/1950 min! (rpm)
1
Engine
－1
!66 kW (90 PS)/2150 min (rpm)
A : Overall Width
(Excluding Rearview Mirrors) mm (ft"in) 2490 (8" 2#)
B : Cab Height mm (ft"in) 2740 (9" 0#)
C : Rear End Swing Radius mm (ft"in) 1465 (4" 10#)
D : Minimum Ground Clearance mm (ft"in) * 440 (1" 5#)
E : Counterweight Clearance mm (ft"in) * 890 (2" 11#)
F : Engine Cover Height mm (ft"in) * 2020 (6" 8#)
G : Overall Width of Upperstructure mm (ft"in) 2470 (8" 1#)
H : Undercarriage Length mm (ft"in) 3580 (11" 9#)
I : Undercarriage Width mm (ft"in) 2490 (8" 2#)
J : Sprocket Center to Idle Center mm (ft"in) 2880 (9" 5#)
K : Track Shoe Width mm 500 (Grouser Shoe)
(ft"in) (20#)
2
Ground Pressure kPa (kgf/cm ) (psi) 41 (0.42) (5.4)
!1
Swing Speed min (rpm) 13.7 (13.7)
Travel Speed (fast/slow) km/h 5.0/3.0
(mph) (3.4/2.1)
Gradeability degree (%) 35 (70)

NOTE: ! H/P mode

* The dimensions do not include the height of the shoe lug.

12-5
 SPECIFICATIONS
WORKING RANGES

ZAXIS135US

G
G

C C
D
D

E E

F
F
F F
A
B B
A

M1SE-12-001
Backhoe T1SE-01-01-002 Shovel

Model ZAXIS135US
Category 2.10 m (6" 11#) Arm 2.52 m (8" 3#) Arm 3.01 m (9" 11#) Arm
Item Backhoe Shovel Backhoe Shovel Backhoe Shovel
A : Maximum Digging Reach mm 7930 8080 8300 8440 8760 8910
(ft"in) (26" 0#) (26" 6#) (27" 3#) (27" 8#) (28" 9#) (29" 3#)
*1 B : Maximum Digging Depth mm 5120 5270 5530 5680 6020 6170
(ft"in) (16" 10#) (17" 3#) (18" 2#) (18" 8#) (19" 9#) (20" 3#)
*1 C : Maximum Cutting Height mm 8950 9100 9220 9370 9610 9760
(ft"in) (29" 4#) (29" 10#) (30" 3#) (30" 9#) (31" 6#) (32" 0#)
*1 D : Maximum Dumping Height mm 6490 6790 6760 7030 7150 7400
(ft"in) (21" 4#) (22" 3#) (22" 2#) (23" 1#) (23" 5#) (24" 3#)
E : Transport Height mm 2840 2840 2840 2840 *2 2840 *2 2840
(ft"in) (9" 4#) (9" 4#) (9" 4#) (9" 4#) (9" 4#) (9" 4#)
F : Overall Transport Length mm 7290 7290 7290 7290 *2 7310 *2 7310
(ft"in) (23" 11#) (23" 11#) (23" 11#) (23" 11#) (24" 0#) (24" 0#)
G : Minimum Swing Radius mm 1940 1940 2060 2060 2400 2400
(ft"in) (6" 4#) (6" 4#) (6" 9#) (6" 9#) (7" 10#) (7" 10#)

NOTE: *1 The dimensions do not include the height of the shoe lug.
*2 The dimensions asterisked are for transport pin position.

12-6
 SPECIFICATIONS
SHOE TYPES AND APPLICATIONS

ZAXIS135US
500 mm (20#) 600 mm (24#) 700 mm (28#) 510 mm (20#) 700 mm (28#)
Shoe Width
Grouser Shoe Grouser Shoe Grouser Shoe Flat Shoe Triangular Shoe
For Ordinary For Ordinary For Weak For Paved For Weak
Application Ground Ground Footing Road Footing
(Standard) (Option) (Option) (Option) (Option)
Operating Weight kg 13200 13500 13700 13700 13500
(lb) (29100) (29800) (30200) (30200) (29800)
Basic Machine Weight kg 10600 10900 11100 11100 10900
(lb) (23400) (24000) (24500) (24500) (24000)
Cab Height mm 2740 2740 2740 2750 2790
(ft"in) (9" 0#) (9" 0#) (9" 0#) (9" 0#) (9" 2#)
Minimum Ground ! 440 ! 440 ! 440 470 490
Clearance (mm) (1" 5#) (1" 5#) (1" 5#) (1" 7#) (1" 7#)
Undercarriage mm 3580 3580 3580 3600 3680
Length (ft"in) (11" 9#) (11" 9#) (11" 9#) (11" 10#) (12" 1#)
Undercarriage Width mm 2490 2590 2690 2500 2690
(ft"in) (8" 2#) (8" 6#) (8" 10#) (8" 3#) (8" 10#)
41 kPa 35 kPa 30 kPa 42 kPa 30 kPa
2 2 2 2 2
Ground Pressure (0.42 kgf/cm , (0.36 kgf/cm , (0.31 kgf/cm , (0.43 kgf/cm , (0.31 kgf/cm ,
6.0 psi) 5.1 psi) 4.4 psi) 6.1 psi) 4.4 psi)

500 mm (20#) 500 mm (20#) 500 mm

Shoe Width
Single Grouse Shoe Pad Crawler Shoe Rubber Pad Shoe
Application For Paved Road (Option) For Paved Road (Option) For Paved Road (Option)
Operating Weight kg 13500 13300 13700
(lb) (29800) (29300) (30200)
Basic Machine Weight kg 10900 10700 11100
(lb) (24000) (23600) (24500)
Cab Height mm 2770 2790 2780
(ft"in) (9" 1#) (9" 2#) (9" 1#)
Minimum Ground 470 500 480
Clearance (mm) (1"7#) (1" 8#) (1" 7#)
Undercarriage mm 3650 3660 3620
Length (ft"in) (12" 0#) (12" 0#) (11" 11#)
Undercarriage Width mm 2490 2490 2490
(ft"in) (8" 2#) (8" 2#) (8" 2#)
42 kPa 41 kPa 43 kPa
Ground Pressure 2 2 2
(0.43 kgf/cm , 6.1 psi) (0.42 kgf/cm , 6.0 psi) (0.44 kgf/cm , 6.3 psi)
NOTE: • The specifications for the front-end attachment are for 2.52 m (8 ft 3 in) arm with PCSA 0.50 m (0.65
3
3
yd ) standard bucket.
• 600 mm (24 in), 700 mm (28 in) grouser shoe, 510 mm (20 in) flat shoe, 700 mm (28 in) triangular
shoe and 500 mm (20 in) rubber crawler not be used on gravel or rocky ground.
• ! The dimensions do not include the height of the shoe lug.

12-7
 SPECIFICATIONS
BUCKET TYPES AND APPLICATIONS

ZAXIS135US
Bucket Capacity Bucket Width
3 3 Front-End Attachment
m (yd ) mm (in)
Bucket
PCSA CECE With Side Without Side 2.10 m 2.52 m 3.01 m
Heaped Heaped Cutters Cutters (6" 11#) Arm (8" 3#) Arm (9" 11#) Arm
0.19 (0.25) 0.17 550 (22#) 450 (18#) # # #
0.30 (0.39) 0.25 700 (28#) 580 (23#) # # #
0.40 (0.52) 0.33 800 (31#) 680 (27#) # # #
Hoe Bucket 0.45 (0.59) 0.4 970 (38#) 850 (33#) # # ○
0.50 (0.65) 0.45 1010 (40#) 890 (35#) # # * ○
0.59 (0.77) 0.5 1070 (42#) 950 (37#) # ○ !
0.66 (0.86) 0.55 ! 1030 (41#) □ ! !
0.50 (0.65) 0.45 1010# (40#) 890 (35#) # # * ○
0.50 (0.65)
(Side Pin 0.45 1010 (40#) 890 (35#) # # * ○
Reinforced Bucket Type)
0.50 (0.65)
0.45 1010 (40#) 890 (35#) # # * ○
(H Type)
0.59 (0.77 0.50 1070 (42#) 950 (37#) # ○ !
V-Type Bucket ! Angle 90° ○ ○ ○
One Point Ripper ! ! $ $ !
Slope-Finishing
! 1000 (39#)x1600 (63#) ◇ ◇ ◇
Blade

NOTE: • Symbols in the above table have the following meanings.

#: General excavating
%: Light duty excavating
$: Rock digging
&: Loading work
$: Slope-finishing work
!: Not applicable (not warrantable)

• Hoe bucket is applicable to the following types of work.

General excavating:
For digging and loading operation of sand, gravel, clay, ordinary earth and so on.
Light duty excavating:
For digging and loading operation of dry, loosened earth, sand, mud and so on.
3 3
Their bulk density shall be less than 1.60 t/m (2700 lbf/yd ) as a standard.
Loading:
For loading operation of dry, loosened earth and sand.
3 3
Their bulk density shall be less than 1.10 t/m (1850 lbf/yd ) as a standard.
Rock digging:
For digging/loading operation of mountain gravels, blasted rock, hard clay, soft rock and so on.
• * : Applicable only to 700 mm (28 in) grouser shoe.

12-8
 SPECIFICATIONS
SPECIFICATIONS

ZAXIS135USK

M1SE-12-005

Model ZAXIS135USK
Type of Front-End Attachment 2.52 m (8 ft 3 in) Arm
3 3 3 3 3
Bucket Capacity (Heaped) m (yd ) PCSA 0.50 m (0.65 yd ), CECE 0.45 m
Operating Weight kg (lb) 14400 (31700)
Basic Machine Weight kg (lb) 11600 (25600)
ISUZU CC-4BG1TC, 63 kW (85 PS)/1950 min! (rpm)
1
Engine
－1
!66 kW (90 PS)/2150 min (rpm)
A : Overall Width
(Excluding Rearview Mirrors) mm (ft"in) 2490 (8" 2#)
B : Cab Height mm (ft"in) 2740 (9" 0#)
C : Rear End Swing Radius mm (ft"in) 1510 (4" 11#)
D : Minimum Ground Clearance mm (ft"in) * 440 (1" 5#)
E : Counterweight Clearance mm (ft"in) * 890 (2" 11#)
F : Engine Cover Height mm (ft"in) * 2020 (6" 8#)
G : Overall Width of Upperstructure mm (ft"in) 2470 (8" 1#)
H : Undercarriage Length mm (ft"in) 3580 (11" 9#)
I : Undercarriage Width mm (ft"in) 2490 (8" 2#)
J : Sprocket Center to Idle Center mm (ft"in) 2880 (9" 5#)
K : Track Shoe Width mm 500 (Grouser Shoe)
(ft"in) (20#)
2
Ground Pressure kPa (kgf/cm ) (psi) 45 (0.46) (6.5)
!1
Swing Speed min (rpm) 13.7 (13.7)
Travel Speed (fast/slow) km/h 5.0/3.0
(mph) (3.4/2.1)
Gradeability degree (%) 35 (70)

NOTE: ! H/P mode

* The dimensions do not include the height of the shoe lug.

12-9
 SPECIFICATIONS
WORKING RANGES

ZAXIS135USK

G
G

C C
D
D

E E

F
F
F F
A
B B
A

M1SE-12-001
Backhoe T1SE-01-01-002 Shovel

Model ZAXIS135USK
Category 2.52 m (8" 3#) Arm
Item Backhoe Shovel
A : Maximum Digging Reach mm 8300 8440
(ft"in) (27" 3#) (27" 8#)
*1 B : Maximum Digging Depth mm 5530 5680
(ft"in) (18" 2#) (18" 8#)
*1 C : Maximum Cutting Height mm 9220 9370
(ft"in) (30" 3#) (30" 9#)
*1 D : Maximum Dumping Height mm 6760 7030
(ft"in) (22" 2#) (23" 1#)
E : Transport Height mm 2870 2870
(ft"in) (9" 5#) (9" 5#)
F : Overall Transport Length mm 7290 7290
(ft"in) (23" 11#) (23" 11#)
G : Minimum Swing Radius mm 2060 2060
(ft"in) (6" 9#) (6" 9#)

NOTE: *1 The dimensions do not include the height of the shoe lug.
*2 The dimensions asterisked are for transport pin position.

12-10
 SPECIFICATIONS
SHOE TYPES AND APPLICATIONS

ZAXIS135USK
500 mm (20#) 600 mm (24#) 700 mm (28#) 510 mm (20#)
Shoe Width
Grouser Shoe Grouser Shoe Grouser Shoe Flat Shoe
For Ordinary For Ordinary For Weak For Paved
Application Ground Ground Footing Road
(Standard) (Option) (Option) (Option)
Operating Weight kg 14400 14700 14900 14900
(lb) (31700) (32400) (32800) (32800)
Basic Machine Weight kg 11600 11900 12100 12100
(lb) (25600) (26200) (26700) (26700)
Cab Height mm 2870 2870 2870 2880
(ft"in) (9" 5#) (9" 5#) (9" 5#) (9" 5#)
Minimum Ground ! 440 ! 440 ! 440 470
Clearance (mm) (1" 5#) (1" 5#) (1" 5#) (1" 7#)
Undercarriage mm 3580 3580 3580 3600
Length (ft"in) (11" 9#) (11" 9#) (11" 9#) (11" 10#)
Undercarriage Width mm 2490 2590 2690 2500
(ft"in) (8" 2#) (8" 6#) (8" 10#) (8" 3#)
45 kPa 38 kPa 33 kPa 46 kPa
2 2 2 2
Ground Pressure (0.46 kgf/cm , (0.39 kgf/cm , (0.34 kgf/cm , (0.47 kgf/cm ,
6.5 psi) 5.5 psi) 4.8 psi) 6.7 psi)

500 mm (20#) 500 mm

Shoe Width
Pad Crawler Shoe Rubber Shoe
Application For Paved Road (Option) For Paved Road (Option)
Operating Weight kg 14500 14900
(lb) (32000) (32800)
Basic Machine Weight kg 11700 12100
(lb) (25800) (26700)
Cab Height mm 2920 2890
(ft"in) (9" 7#) (9" 6#)
Minimum Ground 500 480
Clearance (mm) (1" 8#) (1" 7#)
Undercarriage mm 3660 3620
Length (ft"in) (12" 0#) (11" 11#)
Undercarriage Width mm 2490 2490
(ft"in) (8" 2#) (8" 2#)
45 kPa 46 kPa
Ground Pressure 2 2
(0.46 kgf/cm , 6.5 psi) (0.47 kgf/cm , 6.7 psi)
NOTE: • The specifications for the front-end attachment are for 2.52 m (8 ft 3 in) arm with PCSA 0.50 m (0.65
3
3
yd ) standard bucket.
• 600 mm (24 in), 700 mm (28 in) grouser shoe, 510 mm (20 in) flat shoe and 500 mm (20 in) rubber
crawler not be used on gravel or rocky ground.
• ! The dimensions do not include the height of the shoe lug.

12-11
 SPECIFICATIONS
BUCKET TYPES AND APPLICATIONS

ZAXIS135USK
Bucket Capacity Bucket Width
3 3 Front-End Attachment
m (yd ) mm (in)
Bucket
PCSA CECE With Side Without Side 2.52 m
Heaped Heaped Cutters Cutters (8" 3#) Arm
0.19 (0.25) 0.17 550 (22#) 450 (18#) #
0.30 (0.39) 0.25 700 (28#) 580 (23#) #
0.40 (0.52) 0.33 800 (31#) 680 (27#) #
Hoe Bucket
0.45 (0.59) 0.40 970 (38#) 850 (33#) #
0.50 (0.65) 0.45 1010 (40#) 890 (35#) #
0.59 (0.77) 0.50 1070 (42#) 950 (37#) ○
0.50 (0.65) 0.45 1010# (40#) 890 (35#) #
0.50 (0.65)
(Side Pin 0.45 1010 (40#) 890 (35#) #
Reinforced Bucket Type)
0.50 (0.65)
0.45 1010 (40#) 890 (35#) #
(H Type)
0.59 (0.77) 0.50 1070 (42#) 950 (37#) ○
Clamshell Bucket 0.30 (0.40) #
560 (22#)
(Center-pull)
Clamshell Bucket
0.30 (0.40) 590 (23#) #
(Shell-push)

NOTE: • Symbols in the above table have the following meanings.

#: General excavating
%: Light duty excavating

• Hoe bucket is applicable to the following types of work.

General excavating:
For digging and loading operation of sand, gravel, clay, ordinary earth and so on.
Light duty excavating:
For digging and loading operation of dry, loosened earth, sand, mud and so on.
3 3
Their bulk density shall be less than 1.60 t/m (2700 lbf/yd ) as a standard.

IMPORTANT: The ZX135USK base machines must be modified when being applied exclusively to
excavation work. (Refer to “Precautions for Operation Using a Bucket” in the OPERATING
THE MACHINE section.)

12-12
 SPECIFICATIONS
SPECIFICATIONS

ZAXIS135USL

T1SE-01-01-001

Model ZAXIS135USL
Type of Front-End Attachment 2.52 m (8 ft 3 in) Arm
3 3 3 3 3
Bucket Capacity (Heaped) m (yd ) PCSA 0.50 m (0.65 yd ), CECE 0.45 m
Operating Weight kg (lb) 14700 (32410)
Basic Machine Weight kg (lb) 12100 (26680)
ISUZU CC-4BG1TC, 63 kW (85 PS)/1950 min! (rpm)
1
Engine
－1
!66 kW (90 PS)/2150 min (rpm)
A : Overall Width
(Excluding Rearview Mirrors) mm (ft"in) 2490 (8" 2#)
B : Cab Height mm (ft"in) 2950 (9" 8#)
C : Rear End Swing Radius mm (ft"in) 1465 (4" 10#)
D : Minimum Ground Clearance mm (ft"in) * 595 (1" 11#)
E : Counterweight Clearance mm (ft"in) * 1100 (3" 7#)
F : Engine Cover Height mm (ft"in) * 2230 (7" 4#)
G : Overall Width of Upperstructure mm (ft"in) 2470 (8" 1#)
H : Undercarriage Length mm (ft"in) 3790 (12" 5#)
I : Undercarriage Width mm (ft"in) 2490 (8" 2#)
J : Sprocket Center to Idle Center mm (ft"in) 2990 (9" 10#)
K : Track Shoe Width mm 500 (Grouser Shoe)
(ft"in) (20#)
2
Ground Pressure kPa (kgf/cm ) (psi) 44 (0.45) (6.4)
!1
Swing Speed min (rpm) 13.7 (13.7)
Travel Speed (fast/slow) km/h 4.9/2.7
(mph) (3.0/1.7)
Gradeability degree (%) 35 (70)

NOTE: ! H/P mode

* The dimensions do not include the height of the shoe lug.

12-13
 SPECIFICATIONS
WORKING RANGES

ZAXIS135USL

G
G

C C
D
D

E E

F
F
F F
A
B B
A

M1SE-12-001
Backhoe T1SE-01-01-002 Shovel

Model ZAXIS135USL
Category 2.52 m (8" 3#) Arm
Item Backhoe Shovel
A : Maximum Digging Reach mm 8300 8440
(ft"in) (27" 3#) (29" 8#)
* B : Maximum Digging Depth mm 5320 5290
(ft"in) (17" 5#) (17" 4#)
* C : Maximum Cutting Height mm 9430 9580
(ft"in) (30" 11#) (31" 5#)
* D : Maximum Dumping Height mm 6970 7240
(ft"in) (22" 10#) (23" 9#)
E : Transport Height mm 2950 2950
(ft"in) (9" 8#) (9" 8#)
F : Overall Transport Length mm 7390 7390
(ft"in) (24" 3#) (24" 3#)
G : Minimum Swing Radius mm 2060 2060
(ft"in) (6" 9#) (6" 9#)
NOTE: * The dimensions do not include the height of the shoe lug.

12-14
 SPECIFICATIONS
SHOE TYPES AND APPLICATIONS

ZAXIS135USL
500 mm (20#) 700 mm (28#) 800 mm (32#) 500 mm (20#) 760 mm (30#)
Shoe Width
Grouser Shoe Grouser Shoe Grouser Shoe HighGouser Shoe Triangular Shoe
For Ordinary For Weak For Weak For Weak For Weak
Application Ground Footing Footing Footing Footing
(Standard) (Option) (Option) (Option) (Option)
Operating Weight kg 14700 15200 15500 14800 16000
(lb) (32410) (33510) (34170) (32630) (35270)
Basic Machine Weight kg 12100 12600 12900 12200 13400
(lb) (26680) (27780) (28440) (26900) (29540)
Cab Height mm 2950 2950 2950 2990 3010
(ft"in) (9" 8#) (9" 8#) (9" 8#) (9" 10#) (9" 11#)
Minimum Ground ! 595 ! 595 ! 595 ! 600 ! 660
Clearance (mm) (1" 11#) (1" 11#) (1" 11#) (2" 0#) (2" 2#)
Undercarriage mm 3790 3790 3790 3860 3920
Length (ft"in) (11" 9#) (11" 9#) (11" 9#) (11" 10#) (12" 1#)
Undercarriage Width mm 2490 2690 2790 2490 2750
(ft"in) (8" 2#) (8" 10#) (9" 2#) (8" 2#) (9" 0#)
44 kPa 32 kPa 29 kPa 44 kPa 31 kPa
2 2 2 2 2
Ground Pressure (0.45 kgf/cm , (0.33 kgf/cm , (0.30 kgf/cm , (0.45 kgf/cm , (0.32 kgf/cm ,
6.4 psi) 4.7 psi) 4.3 psi) 6.4 psi) 4.6 psi)

NOTE: • The specifications for the front-end attachment are for 2.52 m (8 ft 3 in) arm with PCSA 0.50 m (0.65
3
3
yd ) standard bucket.
• 700 mm (28 in), 800 mm (32 in) grouser shoe, 500 mm (20 in) high grouser shoe, 760 mm (30 in)
triangular shoe not be used on gravel or rocky ground.
• ! The dimensions do not include the height of the shoe lug.

12-15
 SPECIFICATIONS
BUCKET TYPES AND APPLICATIONS

ZAXIS135USL
Bucket Capacity Bucket Width Front-End
3 3
m (yd ) mm (in) Attachment
Bucket
PCSA CECE With Side Without Side 2.52 m
Heaped Heaped Cutters Cutters (8" 3#) Arm
0.19 (0.25) 0.17 550 (22#) 450 (18#) #
0.30 (0.39) 0.25 700 (28#) 580 (23#) #
0.40 (0.52) 0.33 800 (31#) 680 (27#) #
Hoe Bucket
0.45 (0.59) 0.4 970 (38#) 850 (33#) #
0.50 (0.65) 0.45 1010 (40#) 890 (35#) #
0.59 (0.77) 0.5 1070 (42#) 950 (37#) ○
0.50 (0.65) 0.45 1010# (40#) 890 (35#) #
0.50 (0.65)
(Side Pin 0.45 1010 (40#) 890 (35#) #
Reinforced Bucket Type)
0.50 (0.65)
0.45 1010 (40#) 890 (35#) #
(H Type)
0.59 (0.77) 0.50 1070 (42#) 950 (37#) ○

NOTE: • Symbols in the above table have the following meanings.

#: General excavating
$: Light duty excavating

• Hoe bucket is applicable to the following types of work.

General excavating:
For digging and loading operation of sand, gravel, clay, ordinary earth and so on.
Light duty excavating:
For digging and loading operation of dry, loosened earth, sand, mud and so on.
3 3
Their bulk density shall be less than 1.60 t/m (2700 lbf/yd ) as a standard.

12-16
 SPECIFICATIONS
SPECIFICATIONS

ZAXIS225US, 225USLC

A C
G

E
D

K J
I H

M1GF-012-001

Model ZAXIS225US ZAXIS225USLC

Type of Front-End Attachment 2.91 m (9 ft 7 in) Arm
3 3 3
Bucket Capacity (Heaped) PCSA 0.8 m (1.05 yd ), CECE 0.7 m
Operating Weight 23000 kg (50700 lb) 23500 kg (51800 lb)
Basic Machine Weight 18800 kg (41400 lb) 19300 kg (42500 lb)
–1
Isuzu AA-6BG1T 103 kW/1900 min (140 PS/1900 rpm)
Engine –1
!110 kW/2100 min (150 PS/2100 rpm)
A: Overall Width
2810 mm (9 ft 3 in) 2990 mm (9 ft 10 in)
(Excluding back mirrors)
B: Cab Height 2950 mm (9 ft 8 in) 2950 mm (9 ft 8 in)
C: Rear End Swing Radius 1680 mm (5 ft 6 in) 1680 mm (5 ft 6 in)
D: Minimum Ground Clearance *450 mm (18 in) (Excluding shoe lug)
E: Counterweight Clearance * 980 mm (3 ft 3 in) (Excluding shoe lug)
F: Engine Cover Height * 2220 mm (7 ft 3 in) (Excluding shoe lug)
G: Overall Width of Upperstructure 2810 mm (9 ft 3 in) 2810 mm (9 ft 3 in)
H: Undercarriage Length 4170 mm (13 ft 8 in) 4460 mm (14 ft 8 in)
I: Undercarriage Width 2800 mm (9 ft 2 in) 2990 mm (9 ft 10 in)
J: Sprocket Center to Idler Center 3370 mm (11 ft 1 in) 3660 mm (12 ft 0 in)
K: Track Shoe Width 600 mm (24 in) (Grouser shoe)
2 2
Ground Pressure 52 kPa (0.53 kgf/cm , 7.1 psi) 49 kPa (0.50 kgf/cm , 6.8 psi)
–1 –1
Swing Speed 13.3 min (rpm) 13.3 min (rpm)
Travel Speed (fast/slow) 5.5/3.3 km/h (3.4 mph)
Gradeability 35° (tan! = 0.70)
NOTE: ! H/P mode
* The dimensions do not include the height of the shoe lug.

12-17
 SPECIFICATIONS
WORKING RANGES

ZAXIS225US, ZAXIS225USLC

G G

C C
D
D

E E

F F
B

A A

Shovel M1GF-12-009
Backhoe

Model ZAXIS225US, 225USLC

2.22 m (7 ft 3 in) Arm 2.91 m (9 ft 7 in) Arm
Category
Backhoe Shovel Backhoe Shovel
Item
mm ft"in mm ft"in mm ft"in mm ft"in
A: Maximum Digging Reach 9350 30’8” 9490 31’2” 10010 32’10” 10150 33’3”

B: Maximum Digging Depth *6100 *20’0” *6240 *20’6” *6790 *22’3” *6930 *22’9”

C: Maximum Cutting Height *10550 *34’7” *10710 *35’2” *11100 *36’5” *11250 *36’11”

D: Maximum Dumping Height *7640 *25’1” *7730 *25’4” *8190 *26’10” *8340 *27’4”

E: Transport Height 3160 10’4” 3100 10’2” 2990 9’10” 2950 9’8”

Std 9040 29’8” 9030 29’8” 8920 29’3” 8910 29’3”

F: Overall Transport Length
LC 9180 30’1” 9170 30’1” 9060 29’9” 9050 29’8”

G: Minimum Swing Radius 2590 8’6” 2590 8’6” 2300 7’7” 2300 7’7”

NOTE: * The dimensions do not include the height of the shoe lug.

12-18
 SPECIFICATIONS
SHOE TYPES AND APPLICATIONS

ZAXIS225US
760 mm (30”) 900 mm (35”)
600 mm (24”) 700 mm (28”) 800 mm (31”) 600 mm (24”)
Shoe Width Triangular Triangular
Grouser Shoe Grouser Shoe Grouser Shoe Flat Shoe
Shoe Shoe
For Ordinary For Weak For Weak For Paved For Weak For Weak
Application Ground Footing Footing Road Footing Footing
(Standard) (Option) (Option) (Option) (Option) (Option)
Operating Weight kg 23000 23400 23700 23800 24000 25000
(lb) (50700) (51600) (52200) (52500) (52900) (55100)
Basic Machine Weight kg 18800 19200 19400 19500 19700 20800
(lb) (41400) (42300) (42800) (43000) (43400) (45900)
Cab Height mm 2950 2950 2950 2960 3020 3020
(ft"in) (9’8”) (9’8”) (9’8”) (9’9”) (9’11”) (9’11”)
Minimum Ground ! 450 ! 450 ! 450 ! 490 ! 460 ! 460
Clearance (mm) (18”) (18”) (18”) (19”) (18”) (18”)
Undercarriage mm 4170 4170 4170 4200 4300 4300
Length (ft"in) (13’8”) (13’8”) (13’8”) (13’9”) (14’1”) (14’1”)
Undercarriage Width mm 2800 2900 3000 2800 2960 3100
(ft"in) (9’2”) (9’6”) (9’10”) (9’2”) (9’9”) (10’2”)
52 kPa 45 kPa 40 kPa 53 kPa 42 kPa 37 kPa
2 2 2 2 2 2
Ground Pressure (0.53 kgf/cm , (0.46 kgf/cm , (0.41 kgf/cm , (0.54 kgf/cm , (0.43 kgf/cm , (0.38 kgf/cm ,
7.1 psi) 6.3 psi) 5.5 psi) 7.4 psi) 5.8 psi) 5.1 psi)

NOTE: • The specifications for the front-end attachment is for 2.91 m (9 ft 7 in) arm with PCSA 0.8 m (1.05
3
3
yd ) bucket.
• 700, 800 mm (28, 31 in) grouser shoe, 600 mm (24 in) flat shoe and 900 mm (35 in) triangular shoe
should not be used on gravel or rocky ground.
• ! The dimensions do not include the height of the shoe lug.

12-19
 SPECIFICATIONS

ZAXIS225USLC
760 mm (30”) 900 mm (35”)
600 mm (24”) 700 mm (28”) 800 mm (31”) 600 mm (24”)
Shoe Width Triangular Triangular
Grouser Shoe Grouser Shoe Grouser Shoe Flat Shoe
Shoe Shoe
For Ordinary For Weak For Weak For Paved For Weak For Weak
Application Ground Footing Footing Road Footing Footing
(Standard) (Option) (Option) (Option) (Option) (Option)
Operating Weight kg 23500 23900 24200 24300 24500 25600
(lb) (51800) (52700) (53400) (53600) (54000) (56400)
Basic Machine Weight kg 19300 19700 19900 20100 20300 21400
(lb) (42500) (43400) (43900) (44300) (44800) (47200)
Cab Height mm 2950 2950 2950 2960 3020 3020
(ft"in) (9’8”) (9’8”) (9’8”) (9’9”) (9’11”) (9’11”)
Minimum Ground !450 !450 !450 !490 !460 !460
Clearance (mm) (18”) (18”) (18”) (19”) (18”) (18”)
Undercarriage mm 4460 4460 4460 4490 4590 4590
Length (ft"in) (14’8”) (14’8”) (14’8”) (14’9”) (15’1”) (15’1”)
Undercarriage Width mm 2990 3090 3190 2990 3150 3290
(ft"in) (9’10”) (10’2”) (10’6”) (9’10”) (10’4”) (10’10”)
49 kPa 42 kPa 37 kPa 50 kPa 39 kPa 35 kPa
2 2 2 2 2 2
Ground Pressure (0.50 kgf/cm , (0.43 kgf/cm , (0.38 kgf/cm , (0.51 kgf/cm , (0.40 kgf/cm , (0.36 kgf/cm ,
6.8 psi) 6.0 psi) 5.3 psi) 7.0 psi) 5.5 psi) 4.8 psi)

NOTE: • The specifications for the front-end attachment is for 2.91 m (9 ft 7 in) arm with PCSA 0.8 m (1.05
3
3
yd ) bucket.
• 700, 800 mm (28, 31 in) grouser shoe, 600 mm (24 in) flat shoe and 900 mm (35 in) triangular shoe
should not be used on gravel or rocky ground.
• ! The dimensions do not include the height of the shoe lug.

12-20
 SPECIFICATIONS
BUCKET TYPES AND APPLICATIONS

ZAXIS225USR, ZAXIS225USRLC
Bucket Width
Bucket Capacity (in)
Bucket 3 3
(With side Application Front-End Attachment
m (yd )
cutter)
PCSA CECE ZAXIX225US ZAXIX225USLC
1.22. m (7’3”) 2.91 m (9’7”) 2.22 m (7’3”) 2.91 m (9’7”)
(Heaped) (Heaped)
Arm Arm Arm Arm
0.51 (0.67) 0.45 850 (33”) # # # #
0.80 (1.05) 1.7 1140 (45”) # # # #
0.91 (1.19) 2.8 1280 (50”) # % # #
Hoe Bucket 1.10 (1.44) 3.9 1460 (58”) $ " % $
1.20 (1.57) 1.0 1450 (58”) $ " $ "
(Without side
cutter)
Reinforced Hoe
Bucket
0.80 (1.05) 0.70 1140 (45’) # # # #
Reinforced Hoe
Bucket
(Transverse-Type-
0.80 (1.05) 0.70 1140 (45’) # # # #
Pin-Used Type)
Reinforced Hoe
Bucket (HD Type)
0.80 (1.05) 0.70 1140 (45’) # # # #
Reinforced Hoe
Bucket
0.91 (1.19) 0.80 1280 (50”) # % # #
V-Type Bucket " 90°
Excavating % % % %
V-trenches
0.6 0.5
800 (31.5”) & " & "
Ripper Bucket (Without side
(0.78) (0.65)
cutter)
One Point Ripper " — & " & "
Slope-Finishing
" 1800 Bank cutting # # # #
Blade (70”) finish
NOTE: • Symbols in the above table have the following meanings.
#: General excavating
%: Light duty excavating
&: Rock digging
$: Loading work
#: Slope-finishing work
": Not applicable (not warrantable)
• Hoe bucket is applicable to the following types of work.
General excavating:
For digging and loading operation of sand, gravel, clay, ordinary earth and so on.
Light duty excavating:
For digging and loading operation of dry, loosened
3
earth, sand,
3
mud and so on.
Their bulk density shall be less than 1.60 t/m (2700 lbf/yd ) as a standard.
Loading:
For loading operation of dry, loosened earth and
3
sand. 3
Their bulk density shall be less than 1.10 t/m (1850 lbf/yd ) as a standard.
Rock digging:
For digging/loading operation of mountain gravels, blasted rock, hard clay, soft rock and so on.
IMPORTANT: Using inapplicable buckets may cause serious damage to the front structure such as boom,
arm and hydraulic cylinders.

12-21
 SPECIFICATIONS
MEMO
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12-22
 OPTIONAL ATTACHMENTS AND DEVICES
BUCKET TEETH (Transverse-Type-Pin-Used
Type)

Replacement Procedure

CAUTION: Guard against injury from flying

pieces of metal. Wear goggles or safety glasses.

1. Securely lower the bucket to the ground.

2. Use hammer (3) and drift (2) to drive out trans- 5 1 2 3
verse-type locking pin (1) to remove tooth (4).

NOTE: Be sure to use a drift (2) thinner than pin (1).

3. Clean shank (5) surface. Attach a new tooth (4) onto

shank (5). Insert pin (1) as deep as it goes. Then,
drive pin (1) using hammer (3) and drift (2) to se-
curely lock tooth (4).

4
M157-14-013

13-1
 OPTIONAL ATTACHMENTS AND DEVICES
BLADE LEVER

ZAXIS125US, ZAXIS135US, 135USL

Use blade lever (1) on the operator!s right to raise and

lower the blade. 4 1

When the lever is released, it automatically returns to

neutral, keeping the blade in its position until the lever is 3
operated again.
2
1- Blade Lever
2- Blade Raise
3- Neutral
4- Blade Lower

M1CC-01-010

PRECAUTIONS FOR BLADE OPERATION 4

This blade is designed as a light service attachment for the M155-14-008

hydraulic excavator. Please keep the following points in

mind:

1. This blade is designed to be used for dozing work

only. Do not attempt to dig deeply with the blade.
Doing so will damage not only the blade but the
undercarriage as well.
2. Do not apply intensive or uneven loads. Never apply
high-speed impact to the blade by running the
machine into a load.
3. Jacking up the machine with this blade, the surface
beneath the blade comes under high pressure,
increasing the risk of surface collapse.
Always be sure that the surface is strong enough to
support the weight of the machine during operation.
Avoid dangerously uneven distribution of weight on
the blade by maintaining even contact between the
blade and the ground.
4. Never use this blade as an outrigger.
5. Avoid contact between the bucket and the blade while
digging.

13-2
 OPTIONAL ATTACHMENTS AND DEVICES
AVOID HITTING BLADE WITH FRONT-END
ATTACHMENT WRONG

When operating the machine with the blade positioned

towards 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.

M155-14-009

WRONG

M155-14-010

AVOID HITTING BLADE WITH BUCKET WRONG

When crowding the arm into a traveling or transporting

position, be careful not to let the bucket hit the blade.

M155-14-010

AVOID STRIKING THE BLADE INTO A ROCK WRONG

Do not attempt to strike large rocks with the lade, as doing

so will damage the blade and the blade cylinders,
shortening their operating lives.

M155-14-011

13-3
 OPTIONAL ATTACHMENTS AND DEVICES
BLADE MAINTENANCE

Greasing . . . . every 250 hours

Lubricate all fittings shown in the figure.

• Blade Joint Pins (6 points)

• Blade Cylinder Rod (2 points)
• Blade Cylinder Bottom (2 points)

M175-13-002

M198-07-017

Transportation Figure for Machine Equipped with

Blade
When transporting the machine equipped with a blade
and a long arm front attachment on a trailer, place the
blade in the opposite position toward the front
attachment. Otherwise, the bucket may come in contact
M175-13-005
with the blade.

13-4
 OPTIONAL ATTACHMENTS AND DEVICES
Specifications (ZAXIS125US)

T1SE-01-01-001

Model ZAXIS125US with Blade

Type of Front-End Attachment 2.26 m (7 ft 5 in) Arm
3 3 3 3 3
Bucket Capacity (Heaped) m (yd ) PCSA 0.45 m (0.59 yd ), CECE 0.4 m
Operating Weight kg (lb) 13400 (29500)
Basic Machine Weight kg (lb) 10900 (24000)
-1
Engine ISUZU BB-4BG1T, 59 kW (80 PS)/1950 min (rpm)
-1
! 63 kW (85 PS)/2150 min (rpm)
A : Overall Width
(Excluding Rearview Mirrors) mm (ft"in) 2490 (8!2")
B : Cab Height mm (ft"in) 2740 (9!0")
C : Rear End Swing Radius mm (ft"in) 1465 (4!10")
D : Minimum Ground Clearance mm (ft"in) * 440 (1!5")
E : Counterweight Clearance mm (ft"in) * 890 (2!11")
F : Engine Cover Height mm (ft"in) * 2020 (6!8")
G : Overall Width of Upperstructure mm (ft"in) 2470 (8!1")
H : Undercarriage Length mm (ft"in) 3580 (11!9")
I : Undercarriage Width mm (ft"in) 2490 (8!2")
J : Sprocket Center to Idle Center mm (ft"in) 2880 (9!5")
K : Track Shoe Width mm 500 (Grouser Shoe)
(ft"in) (20")
2
Ground Pressure kPa (kgf/cm ) (psi) 42 (0.43) (6.1)
-1
Swing Speed min (rpm) 13.9 (13.9)
Travel Speed (fast/slow) km/h 5.3/3.2
(mph) (3.3/2.0)
Gradeability degree (%) 35 (70)

NOTE: ! H/P mode

* The dimensions do not include the height of the shoe lug.

13-5
 OPTIONAL ATTACHMENTS AND DEVICES
Working Ranges (ZAXIS125US)

J
H
F I

M1SE-12-006

Model ZAXIS125US with Blade

Category
1.96 m (6!5") Arm 2.26 m (7!5") Arm 2.81 m (9!3") Arm
Item
A : Maximum Digging Reach mm (ft"in) 7790 (25!7") 8060 (26!5") 8530 (28!0")
*1
B: Maximum Digging Depth mm (ft"in) 4970 (16!4") 5270 (17!3") 5820 (19!1")
*1
C: Maximum Cutting Height mm (ft"in) 8800 (28!10") 9020 (29!7") 9370 (30!9")
*1
D: Maximum Dumping Height mm (ft"in) 6350 (20!10") 6570 (21!7") 6920 (22!8")
*2
E : Transport Height mm (ft"in) 2780 (9!1") 2780 (9!1") 2740 (9!0")
*2
F : Overall Transport Length mm (ft"in) 7780 (25!6") 7780 (25!6") 7690 (25!3")
G : Minimum Swing Radius mm (ft"in) 1940 (6!4") 2030 (6!8") 2370 (7!9")
H : Max. Raising Height mm (ft"in) 480 (1!7")
I : Max. Digging Depth mm (ft"in) 520 (1!8")
J : Blade Angle degree 25

NOTE: *1 The dimensions do not include the height of the shoe lug.
*2 The dimensions asterisked are for transport pin position.

13-6
 OPTIONAL ATTACHMENTS AND DEVICES
Shoe Types and Applications (ZAXIS125US)

Shoe Width mm 500 (20") 600 (24") 700 (28") 510 (20") 700 (28")
(in) Grouser Shoe Grouser Shoe Grouser Shoe Flat Shoe Triangular Shoe
For Ordinary For Ordinary For Weak For Paved For Weak
Application Ground Ground Footing Road Footing
(Standard) (Option) (Option) (Option) (Option)
Operating Weight kg 13400 13700 13900 13900 13700
(lb) (29500) (30200) (30600) (30600) (30200)
Basic Machine Weight kg 10900 11200 11400 11400 11200
(lb) (24000) (24700) (25100) (25100) (24700)
Cab Height mm 2740 2740 2740 2750 2790
(ft"in) (9!0") (9!0") (9!0") (9!0") (9!2")
* Minimum Ground mm *440 *440 *440 470 490
Clearance (ft"in) (17") (17") (17") (19") (19")
Undercarriage Length mm 3580 3580 3580 3600 3680
(ft"in) (11!9") (11!9") (11!9") (11!10") (12!1")
Undercarriage Width mm 2490 2590 2690 2500 2690
(ft"in) (8!2") (8!6") (8!10") (8!2") (8!10")
42 kPa 36 kPa 31 kPa 43 kPa 30 kPa
2 2 2 2 2
Ground Pressure (0.43 kgf/cm , (0.37 kgf/cm , (0.32 kgf/cm , (0.44 kgf/cm , (0.31 kgf/cm ,
6.1 psi) 5.3 psi) 4.6 psi) 6.3 psi) 4.4 psi)

Shoe Width mm 500 mm (20") 500 mm (20") 500 mm

(in) Single Grouser Shoe Pad Crawler Shoe Rubber Pad Shoe
Application For Paved Road (Option) For Paved Road (Option) For Paved Road (Option)
Operating Weight kg 13700 13500 13900
(lb) (30200) (30000) (30600)
Basic Machine Weight kg 11200 11000 11400
(lb) (24700) (24300) (25100)
Cab Height mm 2770 2790 2780
(ft"in) (9! 1") (9! 2") (9! 1")
* Minimum Ground mm 470 500 480
Clearance (ft"in) (19") (20") (19")
Undercarriage Length mm 3650 3660 3620
(ft"in) (12! 0") (12! 0") (11! 11")
Undercarriage Width mm 2490 2490 2490
(ft"in) (8! 2") (8! 2") (8! 2")
42 kPa 42 kPa 43 kPa
Ground Pressure 2 2 2
(0.43 kgf/cm , 6.1 psi) (0.43 kgf/cm , 6.1 psi) (0.44 kgf/cm , 6.3 psi)
NOTE: • The specifications for the front-end attachment are for 2.26 m (7 ft 5 in) arm with PCSA 0.45 m (0.59
3
3
yd ) standard bucket.
• 600 mm (24 in), 700 mm (28 in) grouser shoe, 510 mm (20 in) flat shoe and 700mm (28 in) triangular
shoe not be used on gravel or rocky ground.
• * The dimensions do not include the height of the shoe lug.

13-7
 OPTIONAL ATTACHMENTS AND DEVICES
Specifications (ZAXIS135US)

T1SE-01-01-001

Model ZAXIS135US with Blade

Type of Front-End Attachment 2.52 m (8 ft 3 in) Arm
3 3 3 3 3
Bucket Capacity (Heaped) m (yd ) PCSA 0.50 m (0.65 yd ), CECE 0.45 m
Operating Weight kg (lb) 14200 (31300)
Basic Machine Weight kg (lb) 11600 (25600)
ISUZU CC-4BG1TC, 63 kW (85 PS)/1950 min# (rpm)
1
Engine
－1
!66 kW (90 PS)/2150 min (rpm)
A : Overall Width
(Excluding Rearview Mirrors) mm (ft"in) 2490 (8! 2")
B : Cab Height mm (ft"in) 2740 (9.0)
C : Rear End Swing Radius mm (ft"in) 1465 (4! 10")
D : Minimum Ground Clearance mm (ft"in) * 440 (1! 5")
E : Counterweight Clearance mm (ft"in) * 890 (2! 11")
F : Engine Cover Height mm (ft"in) * 2020 (6! 8")
G : Overall Width of
Upperstructure mm (ft"in) 2470 (8! 1")
H : Undercarriage Length mm (ft"in) 3580 (11! 9")
I : Undercarriage Width mm (ft"in) 2490 (8! 2")
J : Sprocket Center to Idle Center mm (ft"in) 2880 (9! 5")
K : Track Shoe Width mm 500 (Grouser Shoe)
(ft"in) (20")
2
Ground Pressure kPa (kgf/cm ) (psi) 44 (0.45) (6.4)
#1
Swing Speed min (rpm) 13.7 (13.7)
Travel Speed (fast/slow) km/h 5.0/3.0
(mph) (3.1/1.9)
Gradeability degree (%) 35 (70)

NOTE: ! H/P mode

* The dimensions do not include the height of the shoe lug.

13-8
 OPTIONAL ATTACHMENTS AND DEVICES
Working Ranges (ZAXIS135US)

J
H
F I

M1SE-12-006

Model ZAXIS135US with Blade

Category
2.10 m (6!11") Arm 2.52 m (8!3") Arm 3.01 m (9!11") Arm
Item
A : Maximum Digging Reach mm (ft"in) 7930 (26!0") 8300 (27!3") 8760 (28!9")
*1
B: Maximum Digging Depth mm (ft"in) 5120 (16!10") 5530 (18!2") 6020 (19!9")
*1
C: Maximum Cutting Height mm (ft"in) 8950 (29!4") 9220 (30!3") 9610 (31!6")
*1
D: Maximum Dumping Height mm (ft"in) 6490 (21!4") 6760 (22!2") 7150 (23!5")
*2
E : Transport Height mm (ft"in) 2840 (9!4") 2840 (9!4") 2840 (9!4")
*2
F : Overall Transport Length mm (ft"in) 7830 (25!8") 7830 (25!8") 7850 (25!9")
G : Minimum Swing Radius mm (ft"in) 1940 (6!4") 2060 (6!9") 2400 (7!10")
H : Max. Raising Height mm (ft"in) 480 (1!7")
I : Max. Digging Depth mm (ft"in) 520 (1!8")
J : Blade Angle Degree 25

NOTE: *1 The dimensions do not include the height of the shoe lug.
*2 The dimensions asterisked are for transport pin position.

13-9
 OPTIONAL ATTACHMENTS AND DEVICES
Shoe Types and Applications (ZAXIS135US)

Shoe Width mm 500 (20") 600 (24") 700 (28") 510 (20") 700 (28")
(in) Grouser Shoe Grouser Shoe Grouser Shoe Flat Shoe Triangular Shoe
For Ordinary For Ordinary For Weak For Paved For Weak
Application Ground Ground Footing Road Footing
(Standard) (Option) (Option) (Option) (Option)
Operating Weight kg 14200 14500 14700 14700 14500
(lb) (31300) (32000) (32400) (32400) (32000)
Basic Machine Weight kg 11600 11900 12100 12100 11900
(lb) (25600) (26200) (26700) (26700) (26200)
Cab Height mm 2740 2740 2740 2750 2790
(ft"in) (9!0") (9!0") (9!0") (9!0") (9!2")
* Minimum Ground mm *440 *440 *440 470 490
Clearance (ft"in) (1!5") (1!5") (1!5") (1!7") (1!7")
Undercarriage Length mm 3580 3580 3580 3600 3680
(ft"in) (11!9") (11!9") (11!9") (11!10") (12!1")
Undercarriage Width mm 2490 2590 2690 2500 2690
(ft"in) (8!2") (8!6") (8!10") (8!3") (8!10")
44 kPa 38 kPa 33 kPa 45 kPa 32 kPa
2 2 2 2 2
Ground Pressure (0.45 kgf/cm , (0.39 kgf/cm , (0.34 kgf/cm , (0.46 kgf/cm , (0.33 kgf/cm ,
6.4 psi) 5.5 psi) 4.8 psi) 6.5 psi) 4.7 psi)

Shoe Width mm 500 mm (20") 500 mm (20") 500 mm (20")

(in) Single Grouser Shoe Pad Crawler Shoe Rubber Pad Shoe
Application For Paved Road (Option) For Paved Road (Option) For Paved Road (Option)
Operating Weight kg 14500 14300 14700
(lb) (32000) (31500) (32400)
Basic Machine Weight kg 11900 11700 12100
(lb) (26200) (25800) (26700)
Cab Height mm 2770 2790 2780
(ft"in) (9! 1") (9! 2") (9! 1")
* Minimum Ground mm 470 500 480
Clearance (ft"in) (19") (20") (19")
Undercarriage Length mm 3650 3660 3620
(ft"in) (12! 0") (12! 0") (11! 11")
Undercarriage Width mm 2490 2490 2490
(ft"in) (8! 2") (8! 2") (8! 2")
Ground Pressure 45 kPa 44 kPa 46 kPa
2 2 2
(0.46 kgf/cm , 6.5 psi) (0.45 kgf/cm , 6.4 psi) (0.47 kgf/cm , 6.7 psi)
NOTE: • The specifications for the front-end attachment
are for a 2.52 m (8 ft 3 in) arm with PCSA 0.50
3 3
m (0.59 yd ) standard bucket.
• 600 mm (24 in), 700 mm (28 in) grouser shoe,
510 mm (20 in) flat shoe, 700mm (28 in)
triangular shoe and 500 mm (20 in) rubber
crawler not be used on gravel or rocky ground.
• * The dimensions do not include the height of
the shoe lug.

13-10
 OPTIONAL ATTACHMENTS AND DEVICES
Specifications (With Blade) (ZAXIS135USL)

M1SE-12-008

Model ZAXIS135USL
Type of Front-End Attachment 2.52 m (8 ft 3 in) Arm
3 3 3 3 3
Bucket Capacity (Heaped) m (yd ) PCSA 0.50 m (0.65 yd ), CECE 0.45 m
Operating Weight kg (lb) 15800 (34830)
Basic Machine Weight kg (lb) 13100 (28880)
ISUZU CC-4BG1TC, 63 kW (85 PS)/1950 min! (rpm)
1
Engine
－1
!66 kW (90 PS)/2150 min (rpm)
A : Overall Width
(Excluding Rearview Mirrors) mm (ft"in) 2490 (8" 2#)
B : Cab Height mm (ft"in) 2950 (9" 8#)
C : Rear End Swing Radius mm (ft"in) 1465 (4" 10#)
D : Minimum Ground Clearance mm (ft"in) * 595 (1" 11#)
E : Counterweight Clearance mm (ft"in) * 1100 (3" 7#)
F : Engine Cover Height mm (ft"in) * 2230 (7" 4#)
G : Overall Width of Upperstructure mm (ft"in) 2470 (8" 1#)
H : Undercarriage Length mm (ft"in) 3790 (12" 5#)
I : Undercarriage Width mm (ft"in) 2490 (8" 2#)
J : Sprocket Center to Idle Center mm (ft"in) 2990 (9" 10#)
K : Track Shoe Width mm 500 (Grouser Shoe)
(ft"in) (20#)
2
Ground Pressure kPa (kgf/cm ) (psi) 44 (0.45) (6.4)
!1
Swing Speed min (rpm) 13.7 (13.7)
Travel Speed (fast/slow) km/h 4.9/2.7
(mph) (3.0/1.7)
Gradeability degree (%) 35 (70)

NOTE: ! H/P mode

* The dimensions do not include the height of the shoe lug.

13-11
 OPTIONAL ATTACHMENTS AND DEVICES
Working Ranges (Grouser Shoe) (ZAXIS135USL)

G
G

C C
D
D

E E
H
F
F I
F
A
B B
A

M1SE-12-007
Backhoe T1SE-01-01-002 Shovel

Model ZAXIS135USL
Category 2.52 m (8" 3#) Arm
Item Backhoe Shovel
A : Maximum Digging Reach mm 8300 8440
(ft"in) (27" 3#) (29" 8#)
* B: Maximum Digging Depth mm 5320 5290
(ft"in) (17" 5#) (17" 4#)
* C: Maximum Cutting Height mm 9430 9580
(ft"in) (30" 11#) (31" 5#)
* D: Maximum Dumping Height mm 6970 7240
(ft"in) (22" 10#) (23" 9#)
E: Transport Height mm 2950 2950
(ft"in) (9" 8#) (9" 8#)
F: Overall Transport Length mm 7390 7390
(ft"in) (24" 3#) (24" 3#)
G: Minimum Swing Radius mm 2060 2060
(ft"in) (6" 9#) (6" 9#)
H: Blade Bottom Highest Position 490
(adovegroumd level) (1" 7#)
I: Blade Bottom Lowest Position 500
(adovegroumd level) (1" 8#)

NOTE: * The dimensions do not include the height of the shoe lug.

13-12
 OPTIONAL ATTACHMENTS AND DEVICES
Shoe Types and Applications (ZAXIS135USL)

500 mm (20#) 700 mm (28#) 800 mm (32#) 500 mm (20#) 760 mm (30#)
Shoe Width
Grouser Shoe Grouser Shoe Grouser Shoe HighGouser Shoe Triangular Shoe
For Ordinary For Weak For Weak For Weak For Weak
Application Ground Footing Footing Footing Footing
(Standard) (Option) (Option) (Option) (Option)
Operating Weight kg
15800 16200 16600 15900 17100
(lb)
Basic Machine Weight kg
13100 13600 14000 13300 14500
(lb)
Cab Height mm 2950 2950 2950 2990 3010
(ft"in) (9" 8#) (9" 8#) (9" 8#) (9" 10#) (9" 11#)
Minimum Ground ! 595 ! 595 ! 595 ! 600 ! 660
Clearance (mm) (1" 11#) (1" 11#) (1" 11#) (2" 0#) (2" 2#)
Undercarriage mm 3790 3790 3790 3860 3920
Length (ft"in) (11" 9#) (11" 9#) (11" 9#) (11" 10#) (12" 1#)
Undercarriage Width mm 2490 2690 2790 2490 2750
(ft"in) (8" 2#) (8" 10#) (9" 2#) (8" 2#) (9" 0#)
47 kPa 34 kPa 31 kPa 47 kPa 37 kPa
2 2 2 2 2
Ground Pressure (0.48 kgf/cm , (0.35 kgf/cm , (0.32 kgf/cm , (0.48 kgf/cm , (0.38 kgf/cm ,
6.8 psi) 4.0 psi) 4.6 psi) 6.8 psi) 5.4 psi)

NOTE: • The specifications for the front-end attachment are for 2.52 m (8 ft 3 in) arm with PCSA 0.50 m (0.65
3
3
yd ) standard bucket.
• 700 mm (28 in), 800 mm (32 in) grouser shoe, 500 mm (20 in) high grouser shoe, 760 mm (30 in)
triangular shoe not be used on gravel or rocky ground.
• ! The dimensions do not include the height of the shoe lug.

13-13
 OPTIONAL ATTACHMENTS AND DEVICES
USING RUBBER PAD SHOE

ZAXIS125US,135US
Pad crawler is a tract link on which a rubber pad is installed WRONG
so the machine doesn’t damage road surfaces when trav-
eling. Be sure to observe all precautions for handling pad
crawler. Avoid operating the machine in the following con-
ditions:

Forbidden Operations

Do not operate on sharp, rocky, uneven surfaces, such as

river rock, gravel, etc.

Do not allow engine oil, gasoline, etc. to remain on the

track, and avoid traveling in oil in order to reduce the dan- M107-05-051
ger of slipping.

While raising the machine using the front attachment don’t

allow the other side track to drive., possibly causing per-
sonal injury, damaging or displacing pad crawler.

13-14
 OPTIONAL ATTACHMENTS AND DEVICES
TRAVELING AND OTHER CAUTIONS

Do not keep the rubber pad shoe under direct sunlight for
more than three months.

Avoid reckless steering operations on concrete road to the

extent possible, as this will cause wear to the shoe lug.
Also, avoid running on asphalt road of more than 60°C
(140°F) in temperature, as this will cause wear to the shoe
as well as damage to the road surface.

Ease the machine down from the jacked-up position.

Do not let it drop.
M175-0-13-003

Pad crawler has large friction force. Therefore to avoid

damaging the pad crawler slowly operate the control levers
to gradually turn the machine.

After raising one side track with the front attachment,

slowly lower the pad crawler equipped machine.

If the pad crawler becomes severely damaged, contact

your nearest Hitachi Dealer for replacement.

13-15
 OPTIONAL ATTACHMENTS AND DEVICES
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. M175-13-004

2. Fasten each corner of the machine and front attach-

ment to the trailer with a chain or cable.

PRECAUTIONS FOR TRANSPORTING MA-

CHINES WITH RUBBER-PAD SHOES

When transporting a machine with rubber pad shoes, be

sure to fasten the right and left track frames securely to the
flatbed with wire ropes and soft protectors, as shown. Do
not allow wire ropes to come into direct contact with rub-
ber-covered shoes.

Wire Rope

Soft Protector
Side Frame
Lower Roller
Rubber-Pad Shoe

Flatbed M102-06-004

13-16
 OPTIONAL ATTACHMENTS AND DEVICES
Check Track Sag --- every 50 hours

Swing the upperstructure 90° and lower the bucket to raise

the track off the ground as shown.

Keep the angle between the boom and arm 90 to 110!

and position the bucket’s round side on the ground. Place
blocks under the machine frame to support the machine.
Rotate the raised track in reverse two full rotations and
then forward two full rotations. M1CC-07-014

Measure distance (A) at the middle of the track frame from

the bottom of the track frame to the back face of the track
shoe.

ZAXIS125US, ZAXIS225US,
ZAXIS135USL
135US, 135USK 225USLC
Track sag 250 to 280 mm 265 to 295 mm 300 to 335 mm
specifications (9.9 to 11.0 in) (10.4 to 11.6 in) (11.8 to 13.2 in)

NOTE: Check track sag after thoroughly removing soil

stuck on the track area by washing.
M102-07-045

Adjust Track Sag

Precautions for Adjusting Track Sag
1. If track sag is not within specifications, loosen or
tighten the track following the procedures shown on
the next page.
2. When adjusting track sag, lower the bucket to the
ground to raise one track off the ground.
Repeat this procedure to raise the other track.
Each time, be sure to place blocks under the ma-
chine frame to support the machine.
3. After adjusting track sag of both tracks, move the
machine back and forth several times.
4. Check track sag again. If track sag is not within
specifications, repeat adjustment until correct sag is
obtained.

13-17
 OPTIONAL ATTACHMENTS AND DEVICES
Loosen the 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.
M107-07-075
1. To loosen the track, slowly turn valve (1) counter-
clockwise using long socket 19; grease will escape 1
from the grease outlet.
2
2. Between 1 to 1.5 turns of valve (1) is sufficient to
loosen the track.
3. If grease does not drain smoothly, slowly rotate the
raised track.
4. When proper track sag is obtained, turn valve (1)
clockwise and tighten to 90 N!m (9.2 kgf!m, 66 lbf!ft).

Grease Outlet
Tighten the Track
M104-07-119

CAUTION: It is abnormal if the track remains

tight after turning valve (1) counterclockwise or if
the track is still loose after charging grease to fit-
ting (2). In such cases, NEVER ATTEMPT TO DIS-
ASSEMBLE the track or track adjuster, because
of dangerous high-pressure grease inside the
track adjuster. See your authorized dealer imme-
diately.

To tighten the track, connect a grease gun to grease fitting

(2) and add grease until the sag is within specifications.

13-18
 OPTIONAL ATTACHMENTS AND DEVICES
ELECTRONIC KEY LOCK OPERATION
MANUAL

Electronic key lock

The controller exclusively designed to read the data
stored in the IC chip built in the key judges whether or
not to start the engine and to operate the hydraulic sys-
tem. To the contrary that usual keys are identified by the
difference in groove pattern curved on the key, the IC
chip allows the key to identify using electrical signals,
patterns of which can be made in trillions, resulting in
copying the key is very difficult.
IC Chip Built-in Key
Electronic key lock system
The controller equipped in the cab reads the data stored
in the IC chip built in the key and checks electrically
whether the key used is a correct one or not to the cor-
responding machine serial No. The controller reads the
IC data when the key switch is turned ACC. When the
correct key is used, the engine is started in due course.
If an incorrect key is used, the engine will not start even
if the key is turned to the START position.
NOTE: If the start switch is turned ON two to three
times with an incorrect key, the horn will sound
to inform abnormality. Once the horn sounds, it
continues to sound for about 4 minutes even
though the key switch is turned OFF. Turn the
M1G6-13-014
switch ON with the correct key to stop the horn
sounding.

Precautions for handling of electronic key lock

1. Precautions for Handling of Registration key Lock
and Ordinary Operation Key

Use the electronic key in the same way as the usual

key to start the engine. One registration key (gray)
and two registered ordinary operation keys (black)
are included in the electronic key lock kit. Be sure to
use the ordinary operation key (black) in normal ma-
chine operation. Refer to the following pages for han-
dling the electronic key lock other than normal opera-
tion.

13-19
 OPTIONAL ATTACHMENTS AND DEVICES
2. Handling of Registration Key (Gray)

Registration key (gray) is used to register the ordinary

operation keys (black). Thereby, if the registration key
is lost, not only cancellation / additional registration of
the ordinary operation keys becomes impractical but
also possibly the registration key function may be
misused by a third person. Therefore, replacement of
both the key and the controller is recommended in
this case. As long as one ordinary operation key is
held at hand, the engine can be started. However, in
case both the registration and ordinary operation
keys are lost, the keys and the controller unit must be
Controller
replaced.
IMPORTANT: As mentioned above, the registration
key helps the customer to correctly op-
erate and service the machine. Accord- Registration Key (Gray)
ingly, the registration key should be kept
in a secure place such as the customer
‘s office under strict superintendence.

Necessary replacing parts when the registration key is

lost:
Key Assembly (P/N 4477011): A set of the IC chip Loop Antenna
Ordinary Operation Key (Black) M1G6-13-015
built-in keys and controller unit

After the registration key and the controller are replaced,

the ordinary operation keys become unusable. Re-register
them to make them available.

3. Ordinary Operation Key

The ordinary operation keys (black) become available

after registered using the registration key and the
controller. Two ordinary operation keys in the elec-
tronic key lock attached to the delivered machine
have already been registered. In case the ordinary
operation key is lost, get genuine Hitachi spare ordi-
nary operation key (P/N 4484755). Then, use it after
registration is performed. Normally, up to 5 ordinary
operation keys can be registered to make them us-
able. Refer to the following pages for registration
procedure.
1

(1) Registration Key (Gray): 1

(2) Ordinary Operation Keys (Black): Max. 5

M1G6-13-016

13-20
 OPTIONAL ATTACHMENTS AND DEVICES
If more than one ordinary operation keys are lost after reg-
istration is complete and when new spare ordinary opera-
tion keys are obtained, re-perform registration of the new
keys together with the old ordinary operation key. (Refer to
the following pages for the registration cancellation proce-
dure.)

IMPORTANT: In case an ordinary operation key is lost,

cancel the registration of the ordinary
operation keys to make them unusable
so that the machine may not be misused
with the lost key. (Refer to the following
pages for the registration cancellation
procedure.)

4. In case both the registration and ordinary operation

keys are lost:
In case both the registration and ordinary operation
keys are lost, the keys and the controller assembly
must be replaced. Please contact your nearest Hi-
tachi dealer.
5. When reselling the machine:
Resell the machine together with the registration and
ordinary operation keys.

13-21
 OPTIONAL ATTACHMENTS AND DEVICES
REGISTRATION/REGISTRATION
CANCELLATION OF ORDINARY OPERATION
KEY

Be sure to read the following description beforehand.

Registration: Makes the machine controller acknowl-

edge the new ordinary operation keys
(black) are correctly set to the corre-
sponding registration key.
Registration Cancellation:
Makes the registration of the ordinary op-
eration key unavailable in case an ordinary
operation key is lost, preventing the lost
key from being misused. The remaining
ordinary operation keys are re-registered
so that the lost key registration becomes
null.

Preparation for Registration

Check that the engine can be started using the registra-
tion key (gray). If not, the key used to start the engine
might be the one for another machine. Check whether it
is correct one.
NOTE: Registration cannot be performed if the regis-
tration key arranged for the machine is not
used.

Check that the engine can be started with the ordinary

operation key having been used. In case the engine
doesn’t start, the key used to start the engine might be
the one for another machine. Check whether it is correct
one.
NOTE: Don’t attempt to re-register the ordinary opera-
tion key having been registered for another
machine.

NOTE:
• The engine cannot be started with an ordinary opera-
tion key newly obtained as a service part unless it is
registered.
• If the engine is attempted to start more than 5 times
per 3 minutes with an incorrect key, the security sys-
tem is activated, causing the horn to sound.
• Turn either the registration key (gray) or the ordinary
operation key (black) ON to stop the horn.

13-22
 OPTIONAL ATTACHMENTS AND DEVICES

ADDITIONAL REGISTRATION
PROCEDURE
[To increase the numbers of the ordinary opera-
tion keys (black):]
In case an ordinary operation key was lost, make
the lost key unavailable by following the procedure
described on next page before performing this reg-
istration procedure.

To increase numbers of the key

Get Genuine Hitachi Service Part. Contact your nearest Hi-

Ordinary Operation Key tachi dealer.
(P/N 4484755)

Insert the registration key into the key switch. Turn the key OFF to ACC.

Hold the key switch ACC for 10 seconds.

Turn the key switch OFF. Remove the registration key.

Within 10 seconds after the key is turned OFF.

Using an ordinary operation key to be registered, turn the

key switch OFF to ACC.

Arrange the old ordinary op-

eration keys and all the keys to Within 10 sec-
be registered at hand. Perform Hold the key switch ACC for 10 seconds. onds after the key
this process to all keys. is turned OFF.

Turn the key switch OFF. Remove the ordinary operation key.
Wait more than 30
seconds after the
Repeat the above two steps to all ordinary operation keys to be reg- key is turned OFF.
istered. Are all keys registered?
No.

Insert the registered key into the key switch. Turn the key OFF to
ACC.

Hold the key switch ACC for 10 seconds.

Turn the key switch OFF. Remove the registered key.

Check that the engine can be started with the Registration has failed.
registration key and all the ordinary operation Retry.
keys. No.

Yes.

Registration Key: Gray

Registration is complete. Ordinary Operation Key: Black

13-23
 OPTIONAL ATTACHMENTS AND DEVICES
REGISTRATION CANCELLATION PROCE-
DURE
(To make the lost key unavailable)

To make the lost key unavailable. Arrange all remaining ordinary

operation keys at hand before-
hand.

Insert the registration key into the key switch. Turn the key OFF to ACC.

Hold the key switch ACC for 10 seconds.

Turn the key switch OFF. Remove the registration key.

Within 10 seconds after the key is turned OFF.

Using a remaining ordinary operation key, turn the key switch OFF
to ACC.

Within 10 seconds
Hold the key switch ACC for 10 seconds. Wait more than 30
after the key is
seconds after the key
Perform this process to turned OFF.
is turned OFF.
all remaining ordinary
operation keys.
Turn the key switch OFF. Remove the registration key.

Repeat the above two steps to all ordinary operation keys to be reg-
istered. Are all keys registered?

Insert the registration key into the key switch. Turn the key OFF to
ACC.
No.

Hold the key switch ACC for 10 seconds.

Turn the key switch OFF. Remove the registration key.

Check that the engine can be started with Registration has failed.
the registration key and all the ordinary op- Retry.
eration keys.
No.
Yes.

Registration Key: Gray

Registration is complete. Ordinary Operation Key: Black

13-24
 INDEX
A Control Lever (HITACHI Pattern) .......................5-2
AM/FM Radio Operation.............................. 1-38, 40
Additional Registration Procedure................... 13-23
Adjusting Console Height .................................. 1-52
Adjust the Operator’s Seat .................................. S-5
Adjusting the Seat ............................................. 1-48
Adjusting the Seat --- If Equipped ..................... 1-50
After the First 100 Hours ..................................... 2-1
After the First 50 Hours ....................................... 2-1
Air Cleaner ........................................................ 7-49
Air Conditioner (Optional).................................. 1-26
Air Filter Restriction Indicator .............................. 1-6
Alternator Indicator .............................................. 1-6
Attachment ........................................................ 5-30
Attachment Connection Parts ........................... 5-33
Attachment Pedal (Breaker)................................ 5-3
Attachment Pedal (Hydraulic Crusher)................ 5-4
Auto Acceleration .............................................. 5-10
Auto-Acceleration Indicator ................................. 1-5
Auto-Idle .............................................................. 5-9
Auto-Idle Indicator ............................................... 1-5
Auto-Idle/Acceleration Selector ......................... 1-14
Avoic Hitting Blade with Bucket......................... 13-3
Avoid Abusive Operation................................... 5-18
Avoid Applying Heat to Lines Containing
Flammable Fluids........................................ S-27
Avoid Heating Near Pressurized Fluid Lines ..... S-27
Avoid High-Pressure Fluids............................... S-23
Avoid Hitting Blade with Front-End Attachment .... 13-3
Avoid Injury from Back-Over
and Swing Accidents ................................... S-12
Avoid Injury from Rollaway Accidents ............... S-11
Avoid Power Lines............................................. S-15
Avoid Striking the Blade into a Rock ................. 13-3
Avoid Tipping..................................................... S-14
Avoid Undercutting ............................................ S-13
B Fuel System .......................................................7-41
BREAK-IN ........................................................... 2-1
Before Starting Engine ........................................ 3-2
Beware of Exhaust Fumes ................................ S-25
Blade Lever ....................................................... 13-2
Blade Maintenance............................................ 13-4
Breaker Maintenance ........................................ 5-27
Bucket Teeth (Transverse-Type-Pin-Used Type) ... 13-1
C Handle Chemical Products Safely .................... S-29
COMPONENTS NAME ....................................... 1-1
Cab Door Release Lever................................... 1-42
Cab Features....................................................... 1-2
Cab Heater (Optional) ....................................... 1-34
Cab Heater Operation ................................. 1-30, 36
Cab Light ........................................................... 1-23
Check Instruments After Starting ........................ 3-5
Check the Hour Meter Regularly ......................... 7-2
Cigar Lighter...................................................... 1-22
Closing Upper Front Window ............................ 1-43
Confirm Direction of Machine to be Driven ......... S-9
14-1
Control Lever (ISO Pattern) ...............................5-1
Control Levers ...................................................11-9
Coolant Temperature Gauge .............................1-5
Cooling Operation ..............................................1-31
Cooling System..................................................7-51
Correct Maintenance and Inspection Procedures ...7-1
D
DRIVING THE MACHINE ....................................4-1
Defroster Operation .....................................1-31, 37
Dig with Caution................................................ S-15
Digital Clock Setting Procedure ...................1-39, 41
Dispose of Waste Properly ............................... S-29
Drive Machine Safely ........................................ S-10
Drive the Machine Carefully.................................4-1
E
Electrical System ......................................7-57, 11-6
Electronic Key Lock Operation Manual............13-19
Emergency Boom Lowering Procedure .............5-36
Emergency Exit..................................................1-47
Engine ......................................................7-19, 11-1
Engine Control Dial ............................................1-13
Engine Oil Pressure Indicator ..............................1-6
Engine Speed ......................................................1-9
Engine Speed Control..........................................5-8
Engine Stop Knob ..............................................1-24
Evacuating in Case of Fire................................ S-25
Every 8 Hours or Daily .........................................2-1
F
Face Shovel Operation ......................................5-18
Fasten Your Seat Belt......................................... S-6
Follow Safety Instructions ................................... S-2
Fuel Gauge ........................................................1-5
Fuel Level Indicator..............................................1-6
Fuse Box............................................................1-25
G
General Precautions for Cab .............................. S-4
Grading Operation .............................................5-17
Greasing ..........................................................7-15
H
Handle Fluids Safely --- Avoid Fires ................. S-17
Hood and Access Covers ....................................7-7
Horn Switch........................................................1-21
Hour Meter ...........................................................1-8
Hydraulic Breaker and Hydraulic Crusher..........5-20
Hydraulic Oil Filter Restriction Indicator (K Model)...1-7
Hydraulic Oil Temperature...................................1-9
Hydraulic System ......................................7-25, 11-9
I
INDEX ................................................................14-1
 INDEX
Inspect Machine .................................................. S-3 P
Inspect Machine Daily Before Starting ................ 3-1 Park Machine Safely......................................... S-17
Installing Fire Extinguisher ................................ 1-23 Parking the Machine ..........................................4-10
Investigate Job Site Beforehand ......................... S-8 Parking the Machine on Slopes .........................4-10
Periodic Replacement of Parts ............................7-9
J Pilot Control Shut-Off Lever........................1-24, 5-5
Jump Starting ...................................................... S-7 Pipings for Breaker and Crusher .......................5-21
Power Boost.......................................................5-12
K Power Boost Switch ...........................................1-21
Keep Person Clear from Working Area............. S-13 Power Mode.......................................................5-13
Keep Riders Off Machine .................................... S-7 Power Mode Switch ...........................................1-15
Key Switch......................................................... 1-21 Practice Safe Maintenance............................... S-19
Precaution for Arm Roll-In/Bucket Roll-In
L Combined Operation ...................................5-34
Layout ................................................................ 7-3 Precautions for Blade Operation........................13-2
Liquid Crystal Display (LCD), Display Precautions for Breaker Operation ....................5-24
Selection Switch, Set Switch ......................... 1-8 Precautions for Crusher Operation ....................5-28
Loading/Unloading on a Trailer ........................... 6-1 Precautions for Operation Using a Bucket ........5-14
Long Arm Operation --- If Equipped .................. 5-40 Precautions for Operations ................................5-15
Precautions for Transporting Machines
M with Rubber-Pad Shoes.............................13-16
MAINTENANCE .................................................. 7-1 Precautions for Traveling on Slopes....................4-9
MAINTENANCE UNDER SPECIAL Precautions for Welding and Grinding.............. S-26
ENVIRONMENTAL CONDITIONS ................ 9-1 Preheat Indicator .................................................1-7
Machine Lifting Procedure................................... 6-5 Prepare Machine for Maintenance.......................7-6
Maintenance Guide ........................................... 7-10 Prepare for Emergencies.................................... S-2
Maintenance Guide Table ................................... 7-4 Prevent Battery Explosions............................... S-28
Maintenance Under Special Prevent Burns ................................................... S-22
Environmental Conditions ............................. 9-1 Prevent Fires .................................................... S-24
Miscellaneous .................................................. 7-62 Prevent Parts from Flying ............................... S-21
Mode Selection.................................................. 11-8 Protect Against Falling Stones and Debris ......... S-8
Monitor Panel ...................................................... 1-4 Protect Against Flying Debris............................ S-16
Move and Operate Machine Safely ..................... S-6 Protect Against Noise ......................................... S-3
Provide Signals for Jobs Involving Multiple
N Numbers of Machines................................... S-9
Never Position Bucket Over Anyone ................. S-13
Never Undercut a High Bank............................. S-14 R
Raise One Track Using Boom and Arm ..............4-6
O Recognize Safety Information............................. S-1
OPERATING THE ENGINE ................................ 3-1 Registration Cancellation Procedure ...............13-24
Registration/Registration Cancellation
OPERATING THE MACHINE ............................. 5-1
of Ordinary Operation Key .........................13-22
OPERATOR’S STATION .................................... 1-2
Remove Paint Before Welding or Heating........ S-27
OPTIONAL ATTACHMENTS AND DEVICES... 13-1
Removing and Storing Lower Front Window .....1-44
Object Handling................................................. S-16
Removing the Machine from Storage ................10-2
Object Handling --- If Equipped ......................... 5-39
Replace Rubber Hoses Periodically ................. S-22
Observe Engine Operation Closely ..................... 2-1
Opening Side Windows ..................................... 1-45
Opening Upper Front Window........................... 1-42
S
SAFETY.............................................................. S-1
Opening/Closing Overhead Window ................. 1-46
Operate Only from Operator’s Seat .................... S-7 SAFETY SIGNS................................................ S-31
Operate the Machine Safely.............................. 5-16 SPECIFICATIONS.............................................12-1
Operate with Caution......................................... S-15 STORAGE .........................................................10-1
Operating Backhoe............................................ 5-17 Safety Transporting .......................................... S-18
Operating Tips................................................... 5-19 Seat Belt ............................................................1-53
Operating in Water or Mud.................................. 4-8 Secondary Relief Pressure Adjustment .............5-23
Operating on Soft Ground ................................... 4-6 Select Correct Track Shoes...............................5-19
Overheat Indicator............................................... 1-6 Service Air Conditioning System Safely............ S-28
Overnight Storage Instructions.......................... 5-35 Shackle Hole Usage ..........................................5-35

14-2
 INDEX
Starting in Cold Weather ..................................... 3-4 Specifications .............................................12-9
Starting the Engine in Ordinary Temperature...... 3-3 Working Ranges........................................12-10
Stay Clear of Moving Parts................................ S-20 ZAXIS135USL
Steering the Machine Using Levers ................ 4-2, 3 Bucket Types and Applications .................12-16
Stopping the Engine ............................................ 3-8 Shoe Types and Applications .........12-15, 13-13
Store Attachments Safely.................................. S-21 Specifications ...........................................12-13
Storing the Machine .......................................... 10-1 Specifications (With Blade) .......................13-11
Support Machine Properly................................. S-20 Working Ranges........................................12-14
Switch Panel .................................................... 1-13 Working Ranges (Groser Shoe) ................13-12
Switch Panel (K Model) ..................................... 1-19 ZAXIS225US, ZAXIS225USLC
Switch Panel (Optional) ..................................... 1-20 Bucket Types and Applications .................12-21
Shoe Types and Applications ....................12-19
T Specifications ...........................................12-17
TRANSPORTING................................................ 6-1 Working Ranges........................................12-18
TROUBLESHOOTING ...................................... 11-1
Tips for Optimal Air Conditioner Usage............. 1-33
Towing Machine a Short Distance....................... 4-7
Transmission ................................................... 7-21
Transporting .................................................... 13-16
Transporting by Road.......................................... 6-1
Travel Alarm (Optional) ....................................... 4-4
Travel Mode Switch.................................... 1-15, 4-4
Traveling.............................................................. 4-5
Traveling and Other Cautions ......................... 13-15
Trip Meter (Trip Meter1 and Trip Meter 2)........... 1-9
Trip Meter Function ........................................... 1-10

U
Understand Signal Words ................................... S-1
Use Correct Fuels and Lubricants....................... 7-2
Use Handholds and Steps................................... S-5
Using Booster Batteries....................................... 3-6
Using Rubber Pad Shoe.................................. 13-14

W
Warn Others of Service Work ........................... S-20
Wear Protective Clothing .................................... S-3
When Installing an Attachment Longer than
Standard Bucket.......................................... 5-34
Wiper/Washer Switch........................................ 1-17
Work Light Switch ............................................. 1-16
Work Mode........................................................ 5-12
Work Mode Switch ............................................ 1-12

Z
ZAXIS125US
Bucket Types and Applications ................... 12-4
Shoe Types and Applications............. 12-3, 13-7
Specifications ................................... 12-1, 13-5
Working Ranges ................................ 12-2, 13-6
ZAXIS135US
Bucket Types and Applications ................... 12-8
Shoe Types and Applications........... 12-7, 13-10
Specifications ................................... 12-5, 13-8
Working Ranges ................................ 12-6, 13-9
ZAXIS135USK
Bucket Types and Applications ................. 12-12
Shoe Types and Applications.................... 12-11

14-3