EX‑60G Compact Excavator History Performance and Common Issues

[MikePhua]

The EX‑60G is a compact hydraulic excavator widely recognized in construction, landscaping, utility work, and property maintenance. Produced by Hitachi Construction Machinery, a company with roots going back to the early 20th century and a major global presence in excavators, cranes, and related heavy equipment, the EX‑60G represents a generation of 6‑ton class machines designed to balance power, maneuverability, and transportability. Hitachi excavators have been common in Europe, North America, and Asia, with legacy and used machines still in service decades after manufacture.
The EX‑60G sits comfortably between smaller entry‑level mini excavators and larger 8–10‑ton models. Typical operating weight for this class is around 13,500–14,000 lbs (6,100–6,400 kg), and engine power usually ranges from 55–65 hp (41–48 kW) depending on market emissions and configuration. The model has a standard digging depth around 12–13 ft (3.6–3.9 m) and bucket breakout forces that make it capable of medium‑duty trenching and grading. While generally reliable, these machines are subject to wear and typical issues that occur over extensive service life. Understanding common behaviors and maintenance needs helps operators keep the EX‑60G productive over thousands of hours.
Terminology Explained

• Operating Weight – Total machine weight ready to work, including full fuel tank, operator cab and standard attachments.
  
• Hydraulic Flow – Volume of hydraulic fluid pumped per minute, measured in gallons per minute (gpm) or liters per minute (L/min); higher flow typically yields faster implement action.
  
• Bucket Breakout Force – Measure of how much force the bucket can apply when ripping or lifting material, especially important for hard soils or loading.
  
• Swing Mechanism – The system allowing the upper structure to rotate, enabling digging and filling without repositioning the tracks.
  
• Track Tension – Manufacturer‑specified tightness of the track chain; incorrect tension accelerates wear and reduces traction.
  

Hitachi and the EX Series Evolution
Hitachi began building hydraulic excavators in the late 1960s and gained a solid reputation for robust hydraulic designs, smooth pilot controls, and durable undercarriages. By the early 2000s, models like the EX‑60G offered features such as pilot‑assisted control levers, adjustable auxiliary hydraulics for attachments, and operator comfort enhancements like improved seating and visibility. Sales for 5–7 ton excavators have been steady historically, reflecting their versatility on jobs requiring more capability than small mini‑excavators but without the transport and operating costs of larger machines.
Typical Use Cases and Strengths
The EX‑60G excels in a range of tasks:

• Utility trenching for water, gas, or electrical lines;
  
• Landscaping and irrigation ditching in tight spaces;
  
• Site cleanup and material handling with appropriate thumb or grapple attachments;
  
• Light demolition in urban environments.
  

Operators value its combination of reach, swing power, and track mobility, which generally gives a good balance of strength and nimbleness.
Performance Observations
Owners often report the following character traits from the EX‑60G series:

• Smooth hydraulic action – Even under varying load, pilot‑controlled hydraulics offer predictable response.
  
• Reliable engine torque – With engines optimized for low‑end torque, digging into loamy or mixed soils feels controlled.
  
• Compact travel footprint – The relatively short tail swing and narrow tracks make maneuvering around obstacles easier than with larger excavators.
  
• Serviceability – Access to routine service points such as filters, coolers, and fluid fill ports tends to be user‑friendly.
  

Common Issues and Maintenance Considerations
Like all machines that have accumulated significant hours, the EX‑60G exhibits some wear‑related themes:
Hydraulic Performance Decline
Over time, hydraulic pumps, control valves, and hoses can degrade. Symptoms include:

• Slowed bucket or boom speed under load
  
• Spongy or inconsistent joystick response
  
• Heat buildup in hydraulic oil during extended use
  

Periodic fluid changes with correct viscosity (as recommended by Hitachi service manuals) and filter replacements help maintain system longevity. For machines exceeding 5,000–7,000 hours, pump efficiency should be monitored; a drop in flow or pressure often precedes noticeable performance loss.
Track and Undercarriage Wear
Operating in abrasive soils accelerates undercarriage wear. Standard practices include:

• Checking track tension every 50–100 service hours
  
• Inspecting roller and idler wear patterns
  
• Replacing grouser pads if chipped or worn
  

Incorrect track tension — either too loose or too tight — contributes to premature wear and reduced traction. Ideal tension often leaves about 1.0–1.5 inches (25–37 mm) of sag on the bottom run under static weight.
Engine Fuel and Air System Needs
The diesel engines powering EX‑60G models require clean fuel and air for peak torque delivery. Clogged air filters can reduce engine breathing, leading to sluggish performance. Fuel filters overdue for replacement risk surface deposits on injectors, which can disturb spray patterns and efficiency. Regularly scheduled maintenance with quality fuel and periodic injector cleaning or testing helps maintain consistent performance.
Operator Comfort and Control Calibration
Older machines sometimes exhibit linkage wear that causes “slop” or delayed response in swing or auxiliary circuits. Technicians can mitigate this by checking:

• Control rod end play
  
• Pin and bushing wear
  
• Hydraulic pilot circuit pressures
  

Well‑tuned controls allow the operator to work more precisely — important when placing pipe or working near foundations.
Field Stories and Lessons
In one real‑world scenario, a contractor in the Southeast used a well‑maintained EX‑60G for utility work across several seasons. After about 6,000 hours, the operator noticed reduced bucket speed when digging clay. A pressure test revealed a small internal leakage in the main pump. Rather than replacing the entire pump, technicians installed a rebuild kit and replaced worn valves, restoring performance at a fraction of full replacement cost. This underscores how proactive fluid analysis and pressure testing can pinpoint issues before they become catastrophic.
Another example involved a landscaping team whose EX‑60G began “chattering” on uneven terrain. Inspection revealed track tension slightly below specification. After re‑tensioning and inspecting idlers, the vibration decreased significantly, improving both comfort and traction. These examples illustrate the value of regular, hands‑on checks rather than waiting for outright failures.
Suggested Best Practices
To keep an EX‑60G productive, consider these recommendations:

• Adhere to scheduled service intervals for hydraulic fluid, engine oil, and filters.
  
• Monitor hydraulic temperature; extended high‑temperature operation shortens fluid life.
  
• Check track tension and wear regularly, especially in abrasive environments.
  
• Inspect attachment hoses and couplers for leaks or swelling.
  
• Use quality fuel and clean air filtration to protect engine internals.
  

Owners often find that establishing a simple checklist — assessing fluid levels, track tension, and control responsiveness before each shift — prevents small issues from escalating.
Industry Trends and Market Position
Compact excavators like the EX‑60G have continued to grow in popularity because they hit a “sweet spot” between mobility and capability. With infrastructure upgrades and urban infill projects in many regions, demand for machines that can work in tight spaces with respectable digging performance remains strong. While newer models often feature advanced electronics, proportional auxiliary controls, and emissions‑compliant engines, the fundamental appeal of reliable hydraulics and simple service access keeps older models in use.
Conclusion
The Hitachi EX‑60G compact excavator stands as a reliable medium‑duty machine that can serve for many thousands of hours if maintained with diligence. Its balance of power, reach, and maneuverability makes it suitable for a variety of tasks, and common service practices — from hydraulic fluid changes to track tensioning — help sustain performance. By understanding the machine’s typical behaviors, terminology, and maintenance needs, operators and technicians can keep an EX‑60G productive and cost‑effective across long service lives. With practical care and attention to wear items, this class of excavator continues to be a valuable tool on varied job sites around the world.