Final Drive Issues on the Hitachi EX60URG Excavator

[MikePhua]

The Hitachi EX60URG and Its Legacy
The Hitachi EX60URG is a compact hydraulic excavator developed during the late 1990s as part of Hitachi’s push to expand its global footprint in the mid-size construction equipment market. With an operating weight of approximately 13,000 lbs and a bucket breakout force exceeding 9,000 lbs, the EX60URG was designed for urban excavation, utility trenching, and light demolition. Its compact tail swing and responsive hydraulics made it a favorite among contractors working in confined spaces.
Hitachi Construction Machinery, founded in 1970 as a division of Hitachi Ltd., quickly became a global leader in hydraulic excavator technology. By the early 2000s, the EX series had sold tens of thousands of units worldwide, with the EX60URG gaining particular traction in Asia and North America due to its reliability and ease of transport.
Understanding the Final Drive System
The final drive is the last stage in the power transmission system of a tracked excavator. It converts hydraulic energy into mechanical torque, propelling the tracks and enabling movement. On the EX60URG, each track is powered by a planetary gear reduction system coupled with a hydraulic motor. This configuration provides high torque at low speeds, essential for climbing, turning, and navigating uneven terrain.
Key components of the final drive include:

• Hydraulic motor
  
• Planetary gear set
  
• Bearings and seals
  
• Sprocket hub
  
• Case drain and pressure ports
  

The final drive is a sealed unit, designed to operate under high pressure and resist contamination. However, wear, improper maintenance, or fluid contamination can lead to failure.
Common Symptoms of Final Drive Failure
Operators may notice several warning signs when the final drive begins to fail:

• Loss of travel power on one side
  
• Grinding or clicking noises during movement
  
• Hydraulic fluid leaks near the sprocket
  
• Excessive heat buildup in the drive housing
  
• Jerky or uneven tracking
  

In one case from a construction site in British Columbia, an EX60URG began veering left during straight travel. After inspection, technicians found metal shavings in the final drive oil and a cracked planetary gear. The repair required a full teardown and replacement of the gear set and seals.
Troubleshooting and Diagnostic Tips
When diagnosing final drive issues, it’s important to isolate whether the problem is hydraulic or mechanical. Recommended steps include:

• Check hydraulic pressure at the travel motor ports
  
• Inspect case drain flow for excessive leakage
  
• Remove the sprocket and inspect the hub for play
  
• Drain final drive oil and check for metal debris
  
• Use infrared thermometers to compare drive temperatures
  

If the issue is hydraulic, the motor may need rebuilding or replacement. If mechanical, the planetary gears or bearings are likely compromised.
Repair and Replacement Considerations
Final drive repairs can be costly, ranging from $2,000 to $5,000 depending on parts and labor. Options include:

• Rebuilding the existing unit with OEM or aftermarket components
  
• Purchasing a remanufactured final drive
  
• Installing a new unit from Hitachi or third-party suppliers
  

When rebuilding, it’s critical to use high-quality seals and torque specifications. Improper assembly can lead to premature failure. Some operators opt for aftermarket drives, which can save up to 30% but may lack the longevity of OEM parts.
Preventive Maintenance Strategies
To extend the life of the final drive, operators should follow these practices:

• Change final drive oil every 500 hours or annually
  
• Use manufacturer-recommended gear oil (typically SAE 80W-90)
  
• Inspect seals and sprockets during routine service
  
• Avoid high-speed travel over rocky terrain
  
• Monitor case drain flow during hydraulic checks
  

A contractor in Texas shared how regular oil sampling helped detect early contamination in his fleet of EX60URG units. By catching the issue before gear damage occurred, he saved over $10,000 in potential repairs.
Final Drive Removal Procedure
Removing the final drive from an EX60URG requires careful planning and proper tools. Steps include:

• Park the machine on level ground and secure it
  
• Remove the track from the affected side
  
• Disconnect hydraulic lines and plug them to prevent contamination
  
• Unbolt the final drive from the frame using a torque wrench
  
• Use a hoist or jack to lift the unit safely
  

Always label hydraulic lines and ports to ensure correct reinstallation. Some drives weigh over 150 lbs, so lifting equipment is essential.
Industry Trends and Component Innovation
Modern excavators are increasingly equipped with electronically controlled final drives that adjust torque based on terrain and load. While the EX60URG predates these systems, retrofitting is possible with custom hydraulic controls. Manufacturers like Bonfiglioli and Nabtesco offer advanced drive units with integrated sensors and diagnostics.
In 2024, a Japanese startup unveiled a smart final drive system that uses vibration analysis to predict bearing failure. Though still in testing, such innovations may soon become standard in mid-size excavators.
Conclusion
The final drive on the Hitachi EX60URG is a critical component that demands attention and care. Whether diagnosing a travel issue or planning a rebuild, understanding the mechanics and maintenance requirements can save time and money. With proper upkeep and informed troubleshooting, the EX60URG continues to prove its worth decades after its release—digging, tracking, and turning with the reliability that built its reputation.