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Part of the Hitachi Repair Manuals.
This 388-page Hitachi excavator workshop manual pdf (OEM #KM-584E-00) covers the EX20UR-2, EX30UR-2, and EX40UR-2 family from upperstructure down to undercarriage. Open it and you get full exploded views of the pump device, control valve, swing device, and travel device, plus a dedicated clearances section for bearings and rollers you'd otherwise be eyeballing with a feeler gauge and a guess. Inside: a complete Engine and Accessories section covering lubrication, cooling, and fuel systems, backed by a troubleshooting chart for chasing engine faults instead of throwing parts at the problem. Torque the 19 mm pipe union to 29 N-m and set the pump mounting bolts to 88 N-m before you seal the housing back up. Nobody wants to strip a fitting because a forum post guessed wrong. Bookmarked by section and searchable by keyword, so you jump straight to Group 03 or Group 06 without flipping through 388 pages by hand.
What's Inside This Hitachi EX20/30/40 UR-2 Series Manual
| System | Pages | Key Topics |
|---|---|---|
| General Information | 6-19 | Precautions for Disassembly and Assembly, Tightening Torques |
| Upperstructure | 20-156 | Canopy, Counterweight, Pump Device, Control Valve, Swing Device, Pilot Valve, Shockless Valve |
| Undercarriage | 157-254 | Swing Bearing, Travel Device, Center Joint, Track Adjuster, Front Idler, Upper and Lower Rollers |
| Front Attachment | 255-296 | Boom and Arm Assembly, Cylinders |
| Engine and Accessories | 297-388 | Engine, Lubricating System, Cooling System, Fuel System, Troubleshooting |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| All Models | ||
| Pipe Thread Connection / Union Joint Tightening Torque Specifications | 19 mm: 29 N-m (3.0 kgf-m, 22 lbf·ft) | p. 17 |
| O-ring Seal Joint Tightening Torque | 27 mm: 93 N-m (9.5 kgf-m, 69 lbf·ft) | p. 17 |
| Pump mounting bolts torque | 88 N-m (9 kgf-m, 65 lbf·ft) | p. 13 |
| Main pump delivery hoses torque | 39 N·m (4 kgf·m, 29 lbf·ft) | p. 12 |
| Air bleed plug tightening torque | 64 N·m (6.5 kgf·m, 47 lbf·ft) | p. 72 |
| Control valve mounting bolts torque | 49 N·m (5 kgf·m, 36 lbf·ft) | p. 71 |
| Hose connection tightening torque (19 mm) | 29 N·m (3 kgf·m, 22 lbf·ft) | p. 71 |
| Hose connection tightening torque (22 mm) | 39 N·m (4 kgf·m, 29 lbf·ft) | p. 71 |
| Tighten plug (30) into body (1) (EX30UR-2, EX40UR-2) | 34+4.9 N-m (3.5+0.5 kgf·m, 25+3.6 lbf·ft) | p. 82 |
| EX30UR-2 | ||
| Hydraulic oil capacity | 42 L (11.1 US gal) | p. 95 |
| 3KC1 | ||
| Clearance between small end pin hole and piston pin (3KC1) | 0.020~0.041 (mm) | p. 344 |
| 3KR2 | ||
| Clearance between small end pin hole and piston pin (3KR2) | 0.008~0.020 (mm) | p. 344 |
Hitachi EX20/30/40 UR-2 Series Common Problems This Manual Covers
Hitachi EX30UR-2 engine overheats rapidly under load and stalls out during heavy operation
Drain the cooling system and remove the thermostat housing. Inspect the radiator fins for clogging. Test the thermostat in heated water. Replace the unit if it fails to open between 75 - 78 °C as specified on page 374. Torque the inlet manifold to 1.5~2.5 kg·m.
Manual Section: Overheat p. 374Sluggish hydraulic response with slow boom lift and stick cylinder delays during lifting operations
Check the hydraulic tank level and inspect main pump delivery hoses for leaks. Tighten loose hose connections to 39 N·m as directed on page 12. If sluggishness continues, remove the pump and verify the clearance between the cylinder block bore and plunger is 0.5 mm or less.
Manual Section: Low hydraulic pressure p. 12Machine entering limp mode unexpectedly with loose bottom plate on the flow control valve
Inspect the flow control valve bottom plate and check for missing plugs. Tighten the control valve mounting bolts to 49 N·m as outlined on page 71. Secure the main flow valve plugs into the body to 34+4.9 N-m to seal the system and restore normal hydraulic function.
Manual Section: Control Valve p. 71Loud engine knocking noise accompanied by excessive white smoke pouring from the exhaust stack
Remove the valve cover and inspect the valvetrain components. Measure the cold inlet valve clearance and adjust it to exactly 0.25 mm as detailed on page 313. Check the fuel piping for leaks and verify injection timing to eliminate the knocking sound and clear up the exhaust.
Manual Section: Engine knocking p. 313Frequently Asked Questions
What are the torque specs for the Hitachi EX30UR-2 main pump bolts?
For the Hitachi EX30UR-2, the pump mounting bolts (12 mm, Qty 2) should be tightened to a torque of 88 N-m (9 kgf-m, 65 lbf-ft). The wrench size required is 19 mm. p. 11
How to reset the hydraulic pressure on Hitachi EX20UR-2?
To reset the hydraulic pressure after pump installation on the Hitachi EX20UR-2, remove plug (3) from the top of the main pump casing, fill the pump casing with hydraulic oil, then lightly retighten plug (3). Operate the engine at slow idle speed to bleed air until hydraulic oil oozes out of the plug hole, then stop the engine and tighten plug (3) to 64 N-m (6.5 kgf-m, 47 lbf-ft). p. 39
What are the replacement specifications for Thermostat?
The thermostat should be replaced if there is wear, damage, or other defects. For inspection, the opening temperature should be 75 - 78°C, and the valve lift should be 8 mm or more at 90°C.
What is the lubricating oil capacity for the 3KC1 engine, including the filter?
The lubricating oil capacity for the 3KC1 engine, including the filter, is approximately 4.5 liters. The recommended oil is Idemitsu "Apolloil Superwide 15W-40" (API service classification: class CD). p. 316
What are the tightening torque specifications for the cylinder head bolts on a 3KC1 engine?
For a 3KC1 engine, new cylinder head bolts should be tightened to 9.5 - 10.5 kg-m. If reusing bolts, the torque should be 11.0 - 12.0 kg-m. Engine oil should be applied to the threads before tightening. p. 308
How quickly can I access this Hitachi EX20UR-2, EX30UR-2, EX40UR-2, Excavator?
Immediate download of the complete 388-page searchable Workshop Manual. Access it on any device, from a laptop at your desk to a phone in the field.
Is this Hitachi EX20UR-2, EX30UR-2, EX40UR-2, Excavator manual printable?
Yes, print as many copies as you want, and there are no restrictions. Many mechanics print the section they need and bring it to the shop floor.
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