Hydraulic System Conversion for the Hitachi EX60-2: Enhancing Performance and Longevity

[MikePhua]

The Hitachi EX60-2 is a reliable and efficient mini excavator widely used in construction, landscaping, and small-scale excavation projects. Known for its solid hydraulic system and compact design, it remains a popular choice in the field of earthmoving. However, like any heavy machinery, over time, the need for upgrades and modifications can arise to keep it performing optimally.
One of the most common upgrades for the EX60-2 is a hydraulic system conversion. Hydraulic systems are essential to the functionality of any excavator, as they control key functions such as lifting, digging, and rotating. Over time, however, components can wear out, causing performance issues. In this article, we will explore the benefits and process of converting the hydraulic system on the Hitachi EX60-2 and discuss potential improvements to enhance machine efficiency and durability.
The Importance of Hydraulic Systems in Mini Excavators
The hydraulic system in mini excavators like the Hitachi EX60-2 is crucial for their operation. It powers the boom, arm, bucket, and rotation, allowing the operator to perform various tasks. The hydraulic pumps, valves, hoses, and cylinders are the backbone of the system, transmitting power from the engine to the working components.
As mini excavators are used in a variety of environments, including harsh and muddy conditions, it’s not uncommon for hydraulic systems to face issues like oil contamination, leaks, or loss of pressure. These problems can lead to decreased efficiency, poor performance, and even costly downtime. Therefore, maintaining and upgrading the hydraulic system is vital to ensuring the longevity of the machine and reducing operational costs.
Why Convert the Hydraulic System on the Hitachi EX60-2?
Hydraulic system conversions are often undertaken for several reasons, including:

1. Improved Performance
   As machines age, their original hydraulic systems may lose efficiency. A hydraulic conversion can boost performance by upgrading to newer, more advanced components. This can result in faster cycle times, improved lifting capacity, and better overall functionality.
   
2. Compatibility with Modern Attachments
   One of the main reasons for hydraulic conversions is to ensure that the excavator can handle modern, high-flow attachments. Newer attachments, such as advanced grapples, augers, or specialized buckets, may require a hydraulic system with higher flow rates or different pressure specifications than the original system could provide.
   
3. Preventative Maintenance
   Rather than waiting for the hydraulic system to fail, some owners opt for a hydraulic conversion as part of regular preventative maintenance. This approach can help avoid costly repairs and system failures down the line.
   
4. Increased Durability and Efficiency
   Upgrading to a more robust and efficient hydraulic system can significantly extend the lifespan of the excavator. Newer hydraulic components are typically more durable, energy-efficient, and less prone to wear and tear.
   

Common Issues with the Hitachi EX60-2 Hydraulic System
Before diving into the conversion process, it’s important to understand the common hydraulic issues that EX60-2 owners face:

• Loss of Hydraulic Power: As hydraulic pumps wear out, the system may lose pressure, leading to slower movements and reduced lifting capacity. This can affect the overall productivity of the machine.
  
• Leaks and Contamination: Hydraulic hoses and seals are prone to wear, and leaks can occur. Contamination from dirt and debris entering the system can lead to clogged filters, damaged components, and decreased efficiency.
  
• Inconsistent Operation: If the hydraulic system is not functioning properly, it can cause jerky or unpredictable movements. This may be due to issues with the pump, valves, or cylinders.
  

Steps to Convert the Hydraulic System on the Hitachi EX60-2
Converting the hydraulic system on the Hitachi EX60-2 is a technical process that involves several steps. The goal is to improve the system's flow, pressure, and efficiency. While the process can vary depending on the desired outcomes, here's a general overview of what the conversion involves:

1. Assess the Current Hydraulic System
   The first step is to assess the current hydraulic system to identify areas that need improvement. This includes checking the condition of the hydraulic pump, valves, hoses, and cylinders. If any parts are damaged or worn out, they should be replaced or upgraded.
   
2. Select the Right Hydraulic Components
   Once the system’s condition is assessed, the next step is to choose the components needed for the conversion. Upgrading the hydraulic pump to one with higher flow capacity is common in hydraulic conversions. Additionally, the valves, hoses, and cylinders may also need to be replaced or modified to handle the increased flow or pressure.
   
3. Install the New Hydraulic Pump
   The pump is the heart of the hydraulic system, so upgrading it is usually the first step in the conversion. A pump with a higher flow rate will increase the efficiency of the entire system. The installation process may involve removing the old pump, aligning the new one with the system, and ensuring that it is properly connected to the engine and hydraulic lines.
   
4. Upgrade the Hydraulic Hoses and Cylinders
   The next step is to replace the hydraulic hoses and cylinders. These parts should be able to handle the increased pressure and flow from the new hydraulic system. Using high-quality hoses and cylinders will improve the machine's performance and reduce the likelihood of leaks.
   
5. Replace or Upgrade the Control Valve
   The control valve is responsible for directing the flow of hydraulic fluid to the various components of the excavator. It may need to be replaced or adjusted to accommodate the new flow rates. A more advanced valve can offer smoother operation and more precise control over the machine’s movements.
   
6. Testing and Calibration
   Once all components are installed, the system should be thoroughly tested to ensure that it is functioning properly. This includes checking for leaks, verifying pressure levels, and testing the excavator’s hydraulics under load. If necessary, the system should be calibrated to ensure optimal performance.
   

Benefits of Hydraulic System Conversion for the Hitachi EX60-2

• Increased Productivity: The upgraded hydraulic system allows for faster cycle times and more powerful lifting and digging, resulting in improved efficiency on the job site.
  
• Enhanced Reliability: Newer hydraulic components are generally more reliable and less prone to wear, reducing the risk of unexpected breakdowns and downtime.
  
• Cost Savings: By avoiding costly repairs and increasing the machine’s efficiency, the hydraulic conversion can ultimately save money in the long run.
  
• Compatibility with Modern Attachments: After the conversion, the Hitachi EX60-2 can support newer, high-flow attachments, expanding the machine’s versatility and range of use.
  

Conclusion: Improving the Hitachi EX60-2 for Better Performance
The Hitachi EX60-2, with its robust design and dependable performance, remains a valuable asset for construction and excavation projects. However, upgrading the hydraulic system is a practical step for owners who want to improve the machine's efficiency, extend its lifespan, and ensure it can handle modern attachments.
Hydraulic system conversion is an effective way to boost the performance of the EX60-2, addressing common issues like loss of power, leaks, and slow operation. By upgrading components such as the pump, hoses, valves, and cylinders, operators can enjoy enhanced reliability and improved productivity on the job site.
Whether you are looking to upgrade for specific tasks or simply want to ensure that your mini excavator continues to perform at its best, a hydraulic system conversion is a worthwhile investment. With the right parts and expert installation, your Hitachi EX60-2 can continue to provide reliable service for years to come.