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The Rise of Hitachi’s Compact Excavators
Hitachi Construction Machinery, established in 1970 as a division of Hitachi Ltd., quickly became a global leader in hydraulic excavator technology. The EX series, launched in the late 1980s, marked a turning point in compact excavator design. The EX60, introduced in the early 1990s, was engineered for urban construction, utility work, and precision excavation. With an operating weight of approximately 13,000 pounds and a bucket breakout force exceeding 9,000 pounds, the EX60 offered a powerful yet nimble solution for contractors.
By the end of the 1990s, Hitachi had sold tens of thousands of EX60 units worldwide. Its popularity stemmed from its hydraulic precision, durable undercarriage, and compatibility with tight job sites. The EX60 was often seen in municipal fleets, landscaping operations, and infrastructure projects across Asia, Europe, and North America.
Core Specifications and Travel System Design
The EX60 is powered by a four-cylinder Isuzu 4JB1 diesel engine, producing around 55 horsepower. Its travel system consists of two hydraulic motors mounted on each track, fed by a variable displacement pump. The machine uses a center rotary joint to distribute hydraulic flow between upper and lower structures, allowing 360-degree rotation while maintaining travel power.
Terminology Note: A “rotary joint” (also called a swivel joint) is a hydraulic component that enables fluid transfer between rotating and stationary parts. “Variable displacement pump” adjusts flow rate based on demand, improving efficiency.
The travel motors are equipped with planetary gear reduction and spring-applied, hydraulically released brakes. This configuration ensures smooth movement and automatic braking when hydraulic pressure drops.
Symptoms of Travel Issues
Operators have reported several travel-related problems in aging EX60 units:
Hydraulic Motor and Rotary Joint Failures
One of the most common culprits is internal leakage in the travel motors. Over time, seals degrade, allowing hydraulic fluid to bypass internal components, reducing torque. Testing case drain flow can reveal excessive leakage.
Another frequent issue is rotary joint seal failure. When seals degrade, hydraulic pressure drops, especially during travel. This can cause one side of the machine to lose power or both tracks to behave erratically.
A contractor in British Columbia shared how his EX60 labored on slopes and refused to turn sharply. After inspecting the rotary joint, he discovered a torn seal and scored shaft. Replacing the joint restored full travel function.
Track Frame Interference and Terrain Effects
On compact excavators like the EX60, rubber tracks can catch on the track frame, especially on uneven ground. This mechanical interference mimics hydraulic failure, causing the machine to jerk or stall during turns.
Operators should inspect:
Engine and Pump Considerations
While travel issues often stem from hydraulic or mechanical faults, engine performance can also play a role. A weak engine may struggle to supply adequate power to the hydraulic pump, especially under load.
Signs of engine-related travel problems include:
Diagnostic Strategy and Field Testing
To isolate travel faults, operators can perform the following tests:
Preventive Maintenance and Upgrade Tips
To extend the life of the EX60 travel system:
Operator Stories and Real-World Adaptations
In 2022, a flood response team in Thailand used an EX60 to clear debris from a canal. The machine struggled on muddy slopes until the team replaced the rotary joint and upgraded to reinforced rubber tracks. The excavator then performed flawlessly for the remainder of the season.
Another operator in New Zealand added a pressure gauge to his travel circuit, allowing real-time monitoring of hydraulic output. This helped him detect early signs of motor wear and schedule repairs before failure.
Conclusion
The Hitachi EX60 remains a trusted compact excavator, but its travel system demands attention as the machine ages. From hydraulic motor leakage to track interference, a range of issues can affect movement. With careful diagnostics, preventive maintenance, and field-tested solutions, operators can restore full mobility and extend the life of their machines. The EX60’s legacy is built not just on engineering, but on the ingenuity of those who keep it moving.
Hitachi Construction Machinery, established in 1970 as a division of Hitachi Ltd., quickly became a global leader in hydraulic excavator technology. The EX series, launched in the late 1980s, marked a turning point in compact excavator design. The EX60, introduced in the early 1990s, was engineered for urban construction, utility work, and precision excavation. With an operating weight of approximately 13,000 pounds and a bucket breakout force exceeding 9,000 pounds, the EX60 offered a powerful yet nimble solution for contractors.
By the end of the 1990s, Hitachi had sold tens of thousands of EX60 units worldwide. Its popularity stemmed from its hydraulic precision, durable undercarriage, and compatibility with tight job sites. The EX60 was often seen in municipal fleets, landscaping operations, and infrastructure projects across Asia, Europe, and North America.
Core Specifications and Travel System Design
The EX60 is powered by a four-cylinder Isuzu 4JB1 diesel engine, producing around 55 horsepower. Its travel system consists of two hydraulic motors mounted on each track, fed by a variable displacement pump. The machine uses a center rotary joint to distribute hydraulic flow between upper and lower structures, allowing 360-degree rotation while maintaining travel power.
Terminology Note: A “rotary joint” (also called a swivel joint) is a hydraulic component that enables fluid transfer between rotating and stationary parts. “Variable displacement pump” adjusts flow rate based on demand, improving efficiency.
The travel motors are equipped with planetary gear reduction and spring-applied, hydraulically released brakes. This configuration ensures smooth movement and automatic braking when hydraulic pressure drops.
Symptoms of Travel Issues
Operators have reported several travel-related problems in aging EX60 units:
- Machine struggles to climb inclines
- Travel speed is inconsistent or sluggish
- Turning with one track is difficult or impossible
- Sudden jerks or resistance during movement
- Audible banging or catching sensation from tracks
Hydraulic Motor and Rotary Joint Failures
One of the most common culprits is internal leakage in the travel motors. Over time, seals degrade, allowing hydraulic fluid to bypass internal components, reducing torque. Testing case drain flow can reveal excessive leakage.
Another frequent issue is rotary joint seal failure. When seals degrade, hydraulic pressure drops, especially during travel. This can cause one side of the machine to lose power or both tracks to behave erratically.
A contractor in British Columbia shared how his EX60 labored on slopes and refused to turn sharply. After inspecting the rotary joint, he discovered a torn seal and scored shaft. Replacing the joint restored full travel function.
Track Frame Interference and Terrain Effects
On compact excavators like the EX60, rubber tracks can catch on the track frame, especially on uneven ground. This mechanical interference mimics hydraulic failure, causing the machine to jerk or stall during turns.
Operators should inspect:
- Track tension and alignment
- Wear on track rollers and idlers
- Clearance between track shoes and frame
Engine and Pump Considerations
While travel issues often stem from hydraulic or mechanical faults, engine performance can also play a role. A weak engine may struggle to supply adequate power to the hydraulic pump, especially under load.
Signs of engine-related travel problems include:
- Excessive smoke during movement
- Engine bogging when tracks engage
- Poor response when switching directions
- Fuel filter condition
- Air intake restrictions
- Engine compression and injector performance
Diagnostic Strategy and Field Testing
To isolate travel faults, operators can perform the following tests:
- Case drain flow test on each travel motor
- Pressure test at the pump outlet and motor inlet
- Visual inspection of rotary joint seals
- Track movement test on level and inclined surfaces
Preventive Maintenance and Upgrade Tips
To extend the life of the EX60 travel system:
- Replace hydraulic filters every 500 hours
- Use high-quality ISO VG 46 hydraulic oil
- Grease track rollers and idlers weekly
- Inspect rotary joint seals annually
- Maintain engine performance with regular servicing
Operator Stories and Real-World Adaptations
In 2022, a flood response team in Thailand used an EX60 to clear debris from a canal. The machine struggled on muddy slopes until the team replaced the rotary joint and upgraded to reinforced rubber tracks. The excavator then performed flawlessly for the remainder of the season.
Another operator in New Zealand added a pressure gauge to his travel circuit, allowing real-time monitoring of hydraulic output. This helped him detect early signs of motor wear and schedule repairs before failure.
Conclusion
The Hitachi EX60 remains a trusted compact excavator, but its travel system demands attention as the machine ages. From hydraulic motor leakage to track interference, a range of issues can affect movement. With careful diagnostics, preventive maintenance, and field-tested solutions, operators can restore full mobility and extend the life of their machines. The EX60’s legacy is built not just on engineering, but on the ingenuity of those who keep it moving.
