Finding an EC for the Hitachi EX120-2 Excavator

[MikePhua]

When dealing with heavy equipment, particularly older models like the Hitachi EX120-2, sourcing specific parts like the Excavator Controller (EC) can be a daunting task. These machines, while highly reliable and durable, require consistent maintenance and sometimes parts replacement to keep them running efficiently. The EC, an essential electronic control unit, plays a crucial role in the functionality of the machine’s hydraulic and electrical systems. In this article, we will discuss the importance of the EC, challenges faced by owners in sourcing replacement parts, and how to navigate these challenges.
Understanding the Role of the Excavator Controller (EC)
The Excavator Controller, or EC, is the brain of an excavator’s electronic systems. It manages several key operations within the machine, including:

• Hydraulic Control: The EC regulates hydraulic functions, ensuring the correct flow of oil to the various parts of the machine. This ensures the smooth operation of the arm, boom, and bucket, as well as other hydraulic systems such as the swing and travel motors.
  
• Engine Control: The EC works closely with the engine control unit (ECU) to monitor and optimize the engine's performance. This includes controlling fuel injection timing, engine speed, and emissions.
  
• Monitoring Systems: It also houses diagnostic capabilities, allowing operators to troubleshoot issues related to hydraulic pressure, fluid levels, or engine performance through error codes or warning lights.
  

A malfunctioning EC can lead to several performance issues, including erratic behavior of the hydraulic system, engine misfiring, or, in the worst case, a complete breakdown of the machine. Therefore, sourcing a replacement EC is crucial for maintaining machine uptime and avoiding costly repairs.
Challenges in Sourcing an EC for the Hitachi EX120-2
The EX120-2 model, although still in use, is an older generation of the Hitachi excavators. As with many older models, parts can become difficult to source over time due to:

• Discontinuation of Parts: Manufacturers often discontinue parts for older models after a certain period, making it hard to find genuine replacements.
  
• Cost of New EC Units: New, OEM EC units can be expensive, and many owners of older models may not want to invest in a brand-new part if the machine still has other wear and tear.
  
• Compatibility Issues: Even if a replacement EC is available, there may be compatibility issues with the rest of the machine's electrical or hydraulic systems. It's essential to ensure that any replacement part integrates seamlessly with existing components.
  
• Finding Used Parts: Many excavator owners turn to the used market to find a more affordable EC. However, buying a used EC can be risky. Without the proper diagnostic tools, it's challenging to know whether a used part is in good working condition.
  

Where to Look for a Replacement EC
Finding a replacement EC for your Hitachi EX120-2 requires persistence and strategic searching. Here are several avenues that could help:

1. Authorized Dealers and Distributors:
   Reaching out to authorized Hitachi dealers is a great first step. While OEM parts for older models may no longer be in stock, dealers often have access to part catalogs and may offer alternatives or refurbished parts.
   
2. Online Marketplaces and Parts Suppliers:
   Websites like eBay, Alibaba, and specialized heavy equipment parts suppliers can be valuable resources. Some suppliers stock both new and refurbished EC units. When purchasing from these platforms, ensure that the seller provides a warranty or guarantee for the parts to avoid purchasing faulty items.
   
3. Aftermarket Parts Manufacturers:
   Some aftermarket manufacturers specialize in producing replacement parts for older excavators. These parts may be cheaper than OEM but must meet the required specifications to ensure they function correctly.
   
4. Forums and Online Communities:
   Engaging with other owners and operators of Hitachi machines in online forums, such as Heavy Equipment Forums or specialized excavator groups on social media, can provide valuable insights. Experienced operators often share parts sourcing tips, troubleshooting advice, and recommendations for trustworthy suppliers.
   
5. Salvage Yards and Equipment Scrappers:
   Excavator salvage yards can be a goldmine for used parts, including EC units. While these parts are used, many salvage yards test the equipment before selling it. This can be a more affordable option if you're willing to take a risk on used components.
   

Installing and Testing the New EC
Once a replacement EC is sourced, it's important to follow proper installation and testing procedures to ensure it functions correctly:

1. Installation:
   Installing the new EC requires basic knowledge of the electrical and hydraulic systems of the excavator. It's advisable to consult the machine's service manual or an experienced technician for guidance. Ensuring that the wiring connections are secure and that the ECU is correctly mounted is crucial for proper operation.
   
2. Calibration:
   After installation, the EC may need to be calibrated to match the specific characteristics of the EX120-2’s hydraulic and engine systems. Calibration helps the controller synchronize with other machine components and ensures optimal performance.
   
3. Diagnostics:
   Once the new EC is installed, running a diagnostic check is essential to verify that the system is functioning as expected. This includes checking for any error codes, hydraulic pressure issues, or engine performance abnormalities. Many modern machines come equipped with onboard diagnostic systems, which can quickly detect any issues with the new EC.
   
4. Test Run:
   Before using the excavator for full operation, perform a test run to check for smooth operation across all systems. Pay attention to any irregular sounds, vibrations, or loss of power, which could indicate a problem with the new EC or other components.
   

Potential Alternatives and Upgrades
If an EC for the Hitachi EX120-2 is impossible to find or prohibitively expensive, consider these alternatives:

1. Aftermarket ECU Systems: In some cases, aftermarket ECU systems designed for similar models of excavators may be compatible with the EX120-2. While they may require some modification, they can offer a more cost-effective solution.
   
2. Upgrading to a Newer Model: If repairs to the EC become too expensive or frequent, upgrading to a newer model may be a more practical solution in the long term. Newer models offer better fuel efficiency, lower emissions, and more advanced features.
   

Conclusion
Finding a replacement EC for the Hitachi EX120-2 can be challenging, but it is not impossible. By utilizing a combination of dealer support, aftermarket suppliers, salvage yards, and online resources, owners of the EX120-2 can often find affordable and functional replacement parts. Installation and calibration are critical to ensuring the new EC operates smoothly with the machine’s existing systems. Lastly, always consider the possibility of upgrades or newer models if the cost of repairs becomes excessive. With the right approach, you can extend the life of your Hitachi EX120-2 and keep it running for many more years.