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Hitachi Excavators and Cold Climate Adaptation
Hitachi Construction Machinery, a division of Hitachi Ltd. founded in 1970, has long been recognized for its robust hydraulic excavators. The ZX series, often powered by Isuzu diesel engines, is widely used in Canada, Russia, and northern Europe—regions where winter temperatures routinely drop below −30°C. To ensure reliable cold starts and cabin comfort, many operators retrofit these machines with auxiliary diesel heaters such as Webasto or Proheat systems.
Terminology Note
The most effective installation method on Hitachi excavators involves tapping into the cab heater lines, which typically draw coolant from the top of the engine block and return it to the bottom. This configuration allows the diesel heater to circulate warm coolant through the block without affecting the radiator circuit, thanks to thermostat isolation. This approach minimizes heat loss and ensures efficient engine preheating.
For machines requiring hydraulic fluid warming, a Skully flange must be welded into the hydraulic tank to accommodate the heat exchanger. This step requires draining the tank, cleaning the weld zone, and pressure testing the flange after installation.
Comparing Webasto and Proheat Systems
Webasto’s TSL 17 model is popular for its compact design and affordability, often retailing around $900–$1,000. Proheat units, while more expensive, offer advanced features such as programmable timers, temperature sensors, and directional valves to isolate the engine from hydraulic circuits. However, these added complexities increase the risk of failure and complicate troubleshooting.
One mechanic reported installing Proheat systems with full automation on Hitachi 300-series machines. While the performance was excellent initially, the complexity led to frequent service calls. In contrast, simpler Webasto setups on service trucks and semi tractors proved more reliable over time.
Field Experience and Reliability Concerns
A farmer-operator in Saskatchewan shared his experience with a Webasto TSL 17 installed on a Volvo loader. The unit worked flawlessly for two years, then failed twice—once due to internal wiring and once due to a control module fault. Repairs cost over $300 each time, leading to frustration and a shift toward portable propane-fired heaters.
Alternative Heating Solutions
For infrequently used machines, some operators prefer portable water-circulating heaters powered by propane. These units, often referred to as “hot box heaters,” rely on thermal convection to circulate heated coolant through the engine block. While slower than diesel-fired systems, they offer flexibility and lower upfront cost. Adding a 12V circulating pump can significantly improve performance, especially on larger machines like skidders or dozers.
Installation Tips and Recommendations
Retrofitting diesel heaters on Hitachi excavators is a practical solution for cold climate operations. Whether using Webasto for simplicity or Proheat for automation, success depends on thoughtful plumbing, electrical integrity, and realistic expectations. For seasonal use, portable heaters offer a viable alternative. As winter conditions grow harsher and uptime becomes critical, auxiliary heating systems remain a key investment in machine reliability and operator comfort.
Hitachi Construction Machinery, a division of Hitachi Ltd. founded in 1970, has long been recognized for its robust hydraulic excavators. The ZX series, often powered by Isuzu diesel engines, is widely used in Canada, Russia, and northern Europe—regions where winter temperatures routinely drop below −30°C. To ensure reliable cold starts and cabin comfort, many operators retrofit these machines with auxiliary diesel heaters such as Webasto or Proheat systems.
Terminology Note
- Diesel Heater: A self-contained unit that burns diesel fuel to heat coolant or air, enabling pre-warming of engines and cabins.
- Cab Heater Lines: Coolant lines that circulate through the operator’s cabin heater core, often used as tap-in points for auxiliary heating systems.
- Hydraulic Tank Heat Exchanger: A device installed in the hydraulic reservoir to warm fluid using engine coolant or an external heat source.
The most effective installation method on Hitachi excavators involves tapping into the cab heater lines, which typically draw coolant from the top of the engine block and return it to the bottom. This configuration allows the diesel heater to circulate warm coolant through the block without affecting the radiator circuit, thanks to thermostat isolation. This approach minimizes heat loss and ensures efficient engine preheating.
For machines requiring hydraulic fluid warming, a Skully flange must be welded into the hydraulic tank to accommodate the heat exchanger. This step requires draining the tank, cleaning the weld zone, and pressure testing the flange after installation.
Comparing Webasto and Proheat Systems
Webasto’s TSL 17 model is popular for its compact design and affordability, often retailing around $900–$1,000. Proheat units, while more expensive, offer advanced features such as programmable timers, temperature sensors, and directional valves to isolate the engine from hydraulic circuits. However, these added complexities increase the risk of failure and complicate troubleshooting.
One mechanic reported installing Proheat systems with full automation on Hitachi 300-series machines. While the performance was excellent initially, the complexity led to frequent service calls. In contrast, simpler Webasto setups on service trucks and semi tractors proved more reliable over time.
Field Experience and Reliability Concerns
A farmer-operator in Saskatchewan shared his experience with a Webasto TSL 17 installed on a Volvo loader. The unit worked flawlessly for two years, then failed twice—once due to internal wiring and once due to a control module fault. Repairs cost over $300 each time, leading to frustration and a shift toward portable propane-fired heaters.
Alternative Heating Solutions
For infrequently used machines, some operators prefer portable water-circulating heaters powered by propane. These units, often referred to as “hot box heaters,” rely on thermal convection to circulate heated coolant through the engine block. While slower than diesel-fired systems, they offer flexibility and lower upfront cost. Adding a 12V circulating pump can significantly improve performance, especially on larger machines like skidders or dozers.
Installation Tips and Recommendations
- Use weather-sealed connectors and heat-resistant wiring to prevent electrical failures.
- Mount the heater unit in a location shielded from road spray and debris.
- Install quick-connect couplers for service truck integration, allowing external heating during extreme cold.
- Test the system after installation by monitoring coolant flow and heater startup cycles.
- Keep spare fuses, relays, and diagnostic tools on hand for field troubleshooting.
Retrofitting diesel heaters on Hitachi excavators is a practical solution for cold climate operations. Whether using Webasto for simplicity or Proheat for automation, success depends on thoughtful plumbing, electrical integrity, and realistic expectations. For seasonal use, portable heaters offer a viable alternative. As winter conditions grow harsher and uptime becomes critical, auxiliary heating systems remain a key investment in machine reliability and operator comfort.
