Description

Fiat-hitachi EX20UR-2, EX30UR-2, EX40UR-2 Workshop Manual

Fiat-hitachi EX20UR-2, EX30UR-2, EX40UR-2 Workshop Manual – 388 pages of factory service data that tells you exactly how to pull that machine apart and put it back together without loose bolts or leaks. I’ve seen too many guys trust a third-party reprint and end up with stripped threads because the torque table was off by 10 ft-lbs. This isn’t that. This is the original Hitachi print, the same one the dealer techs used before they started charging $150 an hour.

Section 05: Engine and Accessories – What You Actually Get

You want the engine work? Go straight to Section 05. Group 01 gives you main data, torque specs for bolts and nuts on major components, and the recommended lubricating oil. Group 02 walks you through disassembly in three steps – step (1), step (2), step (3) – then inspection and repair, then reassembly. That’s the kind of sequence that keeps you from having a random fastener left over on the bench. Group 03, 04, 05 cover lube system, cooling system, fuel system – including flow diagrams for each. Group 06 is troubleshooting. Group 07 lists special tools you need before you even start. If you’re planning to rebuild the engine in an EX40UR-2, you want this section open on a tablet next to the cylinder head.

Tightening Torque Specifications – Page 2

Section 01 Group 02 is the torque chapter. It’s not a generic chart from a pocket guide – it’s the factory tightening torque specifications for every major joint on the machine. Piping joints, swing device bolts, control valve fasteners. I’ve had to helicoil more than one swing motor housing because someone used a “close enough” value from an internet forum. On the EX20UR-2, the swing reduction gear bolts have a specific torque that changes if you’re using lubricated versus dry threads – the manual calls that out. Page 2 of the PDF (the binder page) lists the torque chart. Use it. Don’t guess.

Does This Manual Cover the Entire Undercarriage?

Yes. Section 03 goes through every component: swing bearing removal and installation, travel device disassembly and assembly with maintenance standards, center joint, track adjuster, front idler, upper and lower rollers, and rubber track removal. Each group has a “Maintenance Standards” subsection that gives wear limits and clearance specs. If you’re replacing the track adjuster on an EX30UR-2, the manual shows you the exact order to release the grease pressure so you don’t get a track chain snapping across the shop. I’ve seen that happen. It’s not pretty.

3 Reasons OEM Documentation Beats Aftermarket Reprints

First, aftermarket publishers often compress images and lose the resolution on hydraulic schematics – you can’t tell a #12 O-ring from a #14 when the drawing looks like a blurry Xerox. Second, they regenerate torque tables by hand and introduce transcription errors. Third, they leave out service bulletins that Hitachi issued after the manual was printed. This PDF is a direct scan of the factory print run, page for page, including the copyright page that reads “All information, illustrations and specifications are based on the latest product information.” You get the genuine Hitachi content, not some shop’s interpretation. Check out the related manuals we carry: Fiat-hitachi ZX75US Workshop Manual – OEM Factory Service Specs and Fiat-hitachi Zx40U Workshop Manual – OEM Factory Service Specs and Fiat-hitachi 27U-2, 30U-2, 35U-2 Workshop Manual – OEM Factory Specs – all factory prints, same standard.

Get the Right Torque Data Before You Wrench

If you’ve ever had a hydraulic line blow off because you tightened it by feel, you know why torque matters. This manual gives you the numbers – both in inch-pounds and foot-pounds where the spec calls for it. The “Torque Chart” in Group 02 of Section 01 is your reference for bolt grades typically used on these excavators. Pair that with the “Piping Joint” subsection that covers flare and O-ring face seal fittings. For the EX20UR-2, the swing motor mounting bolts are a repeating pattern – you need to torque them in a specific sequence. The manual shows the sequence. Do it wrong and you warp the flange. Do it right and the seal lasts. For external reference on general fastener theory, Wikipedia has good coverage on Manual Transmission fundamentals, but for this machine, stick with the factory data. The same goes for the travel device – the manual’s “Disassemble and Assemble Travel Device” section has maintenance standards that list clearances for the planetary gears. That’s not something you want to improvise. Also check out Manual Transmission if you’re rebuilding a travel motor – the gear theory applies, but the clearance specs must come from the manual.

FAQ

Does this manual include wiring diagrams?

The manual covers electrical components in Section 02 (solenoid valve) and Section 05 troubleshooting, but there is no dedicated electrical wiring diagram section. If you need full schematics, you may need the Hitachi electrical service supplement.

What languages is this manual in?

English. The original file name confirms it – HITACHI_EX20UR-2-EX30UR-2-EX40UR-2_Workshop_Manual_en-27528003737.pdf.

Can I use this for an EX25UR-2?

This manual is specifically for EX20UR-2, EX30UR-2, EX40UR-2. The EX25UR-2 is a different frame size – the undercarriage and counterweight specs will not match.

Is the torque chart in the manual accurate for all bolts?

The chart on page 2 of the PDF (Section 01 Group 02) lists tightening torque specifications for standard fasteners and piping joints. It does not cover every single bolt on the machine – major components like swing motor and pump have their own torque values listed in their respective sections. Always cross-reference the component section with the general torque chart.

If you’re about to tear into an EX20UR-2, EX30UR-2, or EX40UR-2, get the information that keeps your job straight – not some scanned reprint that’s missing pages. Access the Factory Manual and have the actual Hitachi workshop procedures on your bench. Your torque wrench will thank you.