Hitachi Construction Machinery 110-135UR Workshop Manual 707 pages

Description

You ever try to rebuild a pump stack with aftermarket specs and end up with a regulator that leaks? I have. That’s why I only use factory documentation. This Hitachi Construction Machinery 110, 125US, 120, 135US, 135UR Workshop Manual is the real deal – 707 pages of OEM procedures straight from Hitachi Construction Machinery. No guesswork, no reprints, no third-party mistakes. Every torque value comes from the factory TORQUE CHART in Section 1. Every removal sequence is what the assembly line used.

Page 2 of this manual shows the safety alert symbol and the warning system. If you skip that page, you’re asking for a crushed hand. The manual is written for experienced technicians, but I’ve handed it to smart DIY guys who take their time. The difference between this and a generic manual is the depth. Want to know how to separate the 4-spool and 5-spool control valve? It’s in Section 2. Need the maintenance standard for the swing motor? It’s there too.

Torque Specs: Your Reference

Section 1 has a dedicated TIGHTENING TORQUE SPECIFICATION and a TORQUE CHART. Not a suggestion – a table with foot-pounds for every fastener. I’ve seen guys snap pump bolts using aftermarket values that were off by 15%. That’s not happening with this manual. Piping joint torque is also listed. And if you need periodic replacement intervals, that’s in the same section.

3 Major Sections Covered

Section 1 covers General precautions, tightening, and painting. Section 2 is the Upperstructure: cab removal, counterweight, main frame, pump device (with regulator and solenoid valve disassembly), control valve (4-spool and 5-spool), swing device, pilot valves, pilot shut-off valve, signal control valve, solenoid valve, holding valve. Section 3 dives into Undercarriage: swing bearing, travel device, center joint, track adjuster, front idler, upper and lower rollers. Each section contains MAINTENANCE STANDARD tables for each component.

That’s a lot of ground. If you’re working on a ZAXIS110, 120, 125US, 135US, or the 135UR with blade and offset, the manual separates those variants clearly. For instance, the blade control valve is only in the 135UR section. The pilot valve removal for the 135UR is different from the others.

Does This Manual Help with the ZAXIS135UR Blade Control Valve?

Yes. The manual includes REMOVE AND INSTALL BLADE CONTROL VALVE (ZAXIS135UR ONLY) and ASSEMBLE BLADE CONTROL VALVE (ZAXIS135UR ONLY). Also the offset pilot valve removal and assembly. If you have a 135UR with the emergency stop solenoid valve unit, that’s covered too. No need to guess – follow the factory procedure.

Get the Right Torque Data

I’ve already mentioned the torque chart. But I’ll say it again: don’t rely on memory. Look up the spec in the manual. The TORQUE CHART in Section 1 covers both SAE and metric fasteners. Also the MAINTENANCE STANDARD tables in each component section give you the acceptable clearance and wear limits. For the travel motor, the MAINTENANCE STANDARD tells you when to replace seals.

Why Factory Documentation Beats Aftermarket Reprints

Aftermarket manuals sometimes copy from the automotive industry and miss excavator-specific torque specs. That’s dangerous. This manual came from Hitachi Construction Machinery Co. Ltd. The PDF is scanned from the original print, not a third-party rewrite. You get the exact same content as a dealer technician. For background on why factory specs matter, see Automotive Industry Overview. Also, if you need other Hitachi models, check out Hitachi ZX210W Workshop Manual – 702-Page OEM Service Guide and Hitachi Construction Machinery 160LC, 180LC, 180LCN Workshop Manual | 666 Pages. For operator-level information, get Hitachi ZAX IS ZX130W-ZX210W Operator’s Manual.

On the travel device, the disassembly and assembly of the travel motor and brake valve requires understanding of gear reduction. If you’re new to that, the Manual Transmission article on Wikipedia provides background.

FAQ

Is this manual in English?

Yes.

What torque values are included?

The manual includes a dedicated TIGHTENING TORQUE SPECIFICATION and TORQUE CHART in Section 1 (GENERAL). It covers all standard fasteners, piping joints, and also references periodic replacement of parts. The values are from the OEM and are specific to each component group. For example, the pump device assembly uses specific torque for the regulator and solenoid valve. The control valve 4-spool and 5-spool sections have their own torque values. You won’t find a generic ‘tighten until snug’ – every fastener has a factory-specified ft-lb value. The MAINTENANCE STANDARD tables also list clearance limits and wear tolerances for swing bearing, travel motor, front idler, and more. That’s the kind of detail that saves your wallet and your job.

If you want to stop wasting time on bad data, Access the Factory Manual. Click the button above to get the PDF and put it on your tablet or print it out. Either way, you’ll have the same specs the factory uses.