EX120-2 Excavator Conversion Kit: A Comprehensive Guide

[MikePhua]

The EX120-2 is a popular model of hydraulic excavator, manufactured by Hitachi. Over time, as machinery ages or specific requirements evolve, equipment owners may seek ways to upgrade or convert their machines to better suit their needs. A conversion kit is an efficient solution that allows an excavator to be upgraded or modified without the need for a complete machine overhaul. In this article, we explore the EX120-2 conversion kit, detailing its purpose, installation, and benefits, as well as offering insights into the decision-making process for using such kits.
What is an Excavator Conversion Kit?
An excavator conversion kit is a set of components designed to modify or upgrade an existing excavator. This can involve changes to the engine, hydraulics, electrical systems, or attachments, allowing the machine to perform new tasks, meet updated regulations, or extend its operational life. For the EX120-2, a conversion kit typically aims to improve machine performance, fuel efficiency, or add new capabilities such as different bucket attachments or increased lifting capacity.
While the EX120-2 is a solid machine with a reliable reputation, owners may seek to modernize it with a conversion kit to enhance its capabilities, reduce maintenance costs, or improve fuel efficiency. Such upgrades are usually more cost-effective than purchasing a brand-new machine, making them a popular choice for owners who want to get more out of their equipment.
Key Components of the EX120-2 Conversion Kit
When it comes to upgrading the EX120-2, the conversion kit can include various components depending on the intended improvement. These components typically focus on improving hydraulic efficiency, increasing power output, or adapting the machine for new tasks. Below are the typical components that might be part of a conversion kit for this model:

1. Engine Upgrade or Replacement
   A common modification is upgrading or replacing the engine to improve fuel efficiency or meet emissions standards. Conversion kits often include a new engine that integrates seamlessly with the EX120-2’s existing structure.
   
2. Hydraulic System Modifications
   Upgrading the hydraulic system may involve replacing pumps, motors, or valves. Enhanced hydraulic components can provide greater lifting capacity, improved cycle times, and better overall performance, especially when dealing with demanding tasks such as heavy lifting or handling specialized attachments.
   
3. Control System Updates
   Modernizing the excavator’s control system can lead to better precision and smoother operation. Kits may include updated control panels or electronic systems that offer better integration with modern attachments, increased accuracy, or easier operation for the operator.
   
4. Attachment Compatibility
   As part of a conversion, new attachment systems may be introduced, allowing the machine to handle a wider range of tools such as grapples, hammers, or augers. This can drastically increase the versatility of the EX120-2.
   
5. Structural Modifications
   Some conversion kits include structural upgrades to handle increased loads or new attachments. This may include reinforcement of the boom, arm, or undercarriage to support the added demands.
   
6. Cooling System Enhancements
   A more efficient cooling system may be included in the conversion kit, especially if the engine or hydraulic system is being upgraded to generate more heat. The new system would help prevent overheating, extending the lifespan of critical components.
   

Why Choose a Conversion Kit for the EX120-2?
There are several reasons why an owner might choose to use a conversion kit for their EX120-2 excavator:

1. Cost-Effective Upgrade
   Upgrading a machine with a conversion kit is often much cheaper than purchasing a new model. It allows the machine to perform like a newer model while avoiding the hefty cost of replacement.
   
2. Improved Performance
   By upgrading key components such as the engine, hydraulics, and controls, the conversion kit can improve overall machine performance, making it more capable in various applications such as digging, lifting, and material handling.
   
3. Increased Efficiency
   Upgraded engines and hydraulics can enhance fuel efficiency, reduce downtime, and improve operational speed. These improvements can lead to lower operating costs and higher productivity on the job site.
   
4. Compliance with Regulations
   Conversion kits can help older machines meet modern emissions standards or safety regulations. This is important for companies that need to adhere to environmental and industry regulations to remain competitive and compliant.
   
5. Extended Equipment Life
   With the right upgrades, the EX120-2 can be given a second life, extending its operational life and providing more value for the investment.
   

Challenges and Considerations When Using a Conversion Kit
While conversion kits provide numerous benefits, there are also several challenges and considerations that owners must keep in mind:

1. Compatibility Issues
   The conversion kit must be compatible with the EX120-2’s existing components. Some kits may require additional modifications to ensure that all components work together seamlessly.
   
2. Installation Complexity
   Installing a conversion kit is not always a simple process. Depending on the kit, the installation may require technical expertise and specialized equipment. It’s crucial to work with professionals or certified technicians who are experienced with the machine and the specific kit being used.
   
3. Cost vs. Benefit
   While conversion kits are generally cost-effective, they still represent an investment. It’s important for owners to weigh the cost of the conversion against the expected benefits, such as improved efficiency or increased versatility. If the upgrades don’t significantly improve productivity, the conversion may not be worthwhile.
   
4. Warranty and Support
   Before proceeding with a conversion, it’s essential to check with the manufacturer or the kit supplier about warranty and support. Some conversions may void existing warranties or require separate service agreements.
   

Real-World Example: The Conversion of an EX120-2 Excavator
One real-world example of a successful conversion involved a construction company that owned a fleet of EX120-2 machines. The company was facing rising fuel costs and increased downtime due to aging hydraulic systems. After upgrading several of their EX120-2 machines with conversion kits, they saw a marked improvement in fuel efficiency and reduced maintenance costs. The hydraulic system modifications allowed for faster cycle times, and the engine upgrade helped cut fuel consumption by 15%.
The conversion also allowed the machines to support a wider variety of attachments, including a hammer for breaking concrete and a grapple for handling debris. This increased the versatility of their fleet, allowing the company to take on a wider range of projects without needing to invest in additional equipment.
Conclusion: The Benefits of an EX120-2 Conversion Kit
The EX120-2 is a durable and capable excavator, but like all machinery, it can benefit from upgrades to keep up with changing demands and newer technologies. A conversion kit offers a cost-effective way to enhance performance, increase efficiency, and extend the life of the machine. Whether it’s upgrading the engine, improving the hydraulics, or expanding attachment compatibility, a well-chosen conversion kit can provide significant returns in terms of productivity, cost savings, and versatility.
For owners looking to extend the life of their EX120-2 excavator, a conversion kit is an excellent option. However, it’s essential to carefully assess the compatibility, installation requirements, and potential benefits before proceeding. With the right kit, the EX120-2 can continue to be a valuable asset on the job site for many more years to come.