Service and repair of Hitachi machinery

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Put your machine in the hands of specialists

Professional service of Hitachi construction machinery at Wibako

Downtime on a construction site means huge financial losses, which is why at Wibako we provide express and uncompromising service for Hitachi machinery. We specialize in diagnostics, reconditioning, and repairs of fluid power systems and drive units for the ZX and EX crawler excavator series, as well as ZW wheel loaders. Our team of engineers and mechanics rapidly eliminates failures of main pumps, final drives, and swing motors, restoring full operational capability to the equipment and minimizing machine downtime. The key to our reliability is Wibako's powerful technical infrastructure, which includes an advanced diagnostic center and one of Europe's largest stocks of ready-to-install replacement components. We feature specialized test benches for load testing hydraulic pumps, allowing us to precisely calibrate systems after repair and guarantee factory-standard performance parameters. When purchasing reconditioned components from us or commissioning a repair of your own unit, you gain complete transaction security and the confidence that every part perfectly matches the technical specifications of your Hitachi model. Thanks to efficient logistics and a gigantic spare parts warehouse, we dispatch most key components within 24 hours, drastically cutting down wait times and letting your machine return to work without unnecessary delay.

Experienced mechanics

Specialized service for heavy-duty engines in Hitachi machinery

The maximum performance of Hitachi heavy construction and mining equipment directly depends on the condition of high-displacement diesel powertrains. For this reason, Wibako has established an elite team of mechanics specializing in advanced overhauls and major repairs of Isuzu internal combustion engines, which form the heart of powerful crawler excavators. Our workshop regularly restores full operational capability to demanding, six-cylinder Isuzu engines from the 6HK1 and 6WG1 series, which power flagship machines such as the Hitachi ZX290, ZX350, ZX490, and large-scale EX mining models. We fully understand the specifics of high-pressure Common Rail injection systems, advanced turbocharging setups, and DPF/SCR exhaust gas treatment systems installed in these massive engines. This enables us to flawlessly diagnose and resolve complex anomalies related to boost pressure drops, compression loss, or unstable operation of the piston-crank assembly under full working load. Every service operation is carried out using certified components from our own massive parts warehouse, guaranteeing complete purchasing security and eliminating long wait times for components. By choosing Wibako service, you gain assurance that your Hitachi's heavy engine will regain its full factory torque, permanently eliminating the risk of costly downtime on construction and mining contracts.

 

 

Advanced load testing of Isuzu engines

Engine dynamometer testing

Installing an untested engine after an overhaul risks another catastrophic failure on the job site. At Wibako, we completely eliminate this risk by subjecting every reconditioned Isuzu power unit to rigorous load testing on our professional, stationary engine dyno capable of handling units up to 700 HP. The purpose of this advanced process is the precise verification of operating parameters under full, real-world load conditions, allowing us to 100% replicate the extreme working environment of a Hitachi ZX350 or ZX490 crawler excavator prior to the physical installation of the engine in the machine. Our test station is equipped with an extensive telemetry sensor network that continuously monitors key technical parameters: power curves, torque, main gallery oil pressure and temperature, boost pressure generated by the turbocharger, and RPM stability under load. We also analyze cooling system parameters, including water pump performance and proper thermostat opening, as well as instantaneous and average fuel consumption, ensuring the engine is returned to the customer in pristine condition, fully compliant with Stage IV / Stage V factory specifications. Through hours of load testing, we can precisely fine-tune the high-pressure Common Rail injection systems of Isuzu 6HK1 and 6WG1 engines, detecting and eliminating any hidden assembly flaws. The culmination of the entire process is the generation of an official, detailed dynamometer report, providing technical proof of operational health and confirming the top quality of the work performed. By investing in engine service at Wibako, you gain uncompromising transaction security, complete operational reliability, and the certainty that your heavy Hitachi equipment will immediately take on the toughest excavation or earthmoving tasks after installation without the risk of costly and unexpected downtime.

 

When should you contact the service center?

Symptoms of engine failure in Hitachi machinery

Ignoring the early warning signs emitted by a heavy Isuzu engine in a Hitachi crawler excavator inevitably leads to catastrophic failure of the piston-crank mechanism and gigantic repair bills. An immediate response to any operational anomaly is vital. At Wibako, we most commonly diagnose and eliminate recurring symptoms that clearly indicate the need for intervention by our engineers and specialized workshop testing.


Pay close attention to the following alarming symptoms in your Hitachi ZX290, ZX350, or ZX490:


Sudden and noticeable drop in operating power - the machine visibly slows down during digging cycles, struggles to lift a full bucket in dense ground, or fails to respond properly to increased hydraulic load, which typically signals wear on the Common Rail injection system or compression loss in Isuzu 6HK1 and 6WG1 engine cylinders.


Unusual exhaust smoke color - dense black smoke from the exhaust indicates incomplete diesel combustion, blue smoke points to engine oil burning caused by worn piston rings, while white smoke signals coolant entering the combustion chamber.


Metallic knocking, noise, and excessive vibration - loud knocking originating from the engine block that changes in frequency with engine speed is a critical sign of worn rod or main bearings, play in piston pins, or timing gear failure, requiring immediate machine shutdown.


Cold and warm engine starting issues - prolonged cranking, hesitation right after firing up, or total inability to start the Isuzu engine in Hitachi ZX series machines directly points to a critical pressure drop in the CR fuel rail or wear in the high-pressure pump plunger elements.


Increased pressure in the cooling system and fluid loss - coolant blowing out through the expansion tank, oil present in the radiator, or hardened cooling hoses are clear indications of a cracked cylinder head or cylinder liner damage caused by thermal stress.


Error messages and emergency limp mode - regular display of fault codes on the operator panel related to oil pressure, engine temperature, or DPF/SCR system malfunctions, after which the system restricts engine RPM to prevent seizure.

Expert reconditioning

Advanced fluid power service in Hitachi machinery

The efficiency and precision of working movements in every Hitachi crawler excavator or wheel loader depend directly on the health of the high-pressure hydraulic system. That is why at Wibako we have created a specialized engineering department dedicated to comprehensive repairs, machining, and sealing of fluid power components. On a daily basis, our team of experts restores factory geometry and efficiency to key dynamic components, such as main dual axial piston pumps (including popular Hitachi/Kawasaki K3V112, K3V140, K5V140 series, and the latest K7V generations), swing motors, and travel motors responsible for driving final drives in machines ranging from the Hitachi ZX210 series to heavy ZX490 mining and demolition units. We thoroughly understand the specifics of Japanese HIOS and TRIAS hydraulic control systems, allowing us to accurately diagnose complex faults related to working pressure drops under load, lack of boom movement synchronization, or micro-cracks in housings. Wibako's in-house technical facilities enable us to perform the most precise reconditioning work, such as lapping cylinder block faces, replacing complete rotary groups, fitting pistons, and reconditioning control valves and regulators. Thanks to our massive internal inventory of ready-to-use components — from complete rotors, valve plates, and drive shafts to specialized Viton seal kits — we drastically eliminate costly machine downtime on job sites. Instead of searching for unverified aftermarket parts, you get guaranteed installation compatibility, perfect technical alignment with Hitachi specifications, and complete transaction safety for components restored to full mechanical operational capability.

 

Advanced hydraulic test bench

Professional dynamic testing and pump calibration on a stationary hydraulic test bench

Installing a reconditioned main pump without prior testing under real load conditions carries a massive risk of secondary failure across the entire system. At Wibako, we completely remove this margin for error by subjecting every hydraulic component to rigorous testing on our advanced stationary hydraulic test bench. Our high-power diagnostic station allows us to 100% recreate the extreme working conditions that dual axial piston Kawasaki K3V112, K3V140, or K5V140 pumps endure in Hitachi ZX210, ZX290, or ZX350 crawler excavators. During multi-hour dynamic testing, the test bench control system precisely monitors and logs critical technical parameters at operating pressures reaching up to 400 bar. Our engineers closely analyze geometric displacement, torque control regulator stability, response time to signals from Japanese HIOS and TRIAS systems, and oil temperature to detect any internal leakage. This procedure allows us to perfectly calibrate control valves and regulators before shipping the component to the customer, providing complete assurance that after machine installation, your Hitachi's booms and travel drives will operate synchronously, smoothly, and at full factory performance. The test on Wibako's bench concludes with the generation of an official, detailed report with efficiency charts, attached to every reconditioned unit upon request. By investing in fluid power service at Wibako, you gain uncompromising purchase safety, complete technical reliability, and the guarantee that your equipment will immediately return to heavy excavation work post-installation without the risk of further unexpected job site downtime.

 

When to react?

Symptoms of fluid power failure in Hitachi machinery

Prompt identification of the first signs of hydraulic efficiency loss in Hitachi construction machinery helps prevent complete seizure of main pumps and drastically reduces subsequent repair costs. Hitachi control systems, such as advanced HIOS or TRIAS setups, are extremely sensitive to oil quality, micro-contaminants, and internal leaks, which manifest in very specific ways during daily construction or quarry work.
Contact Wibako service if you notice the following symptoms in your Hitachi ZX210, ZX350, or ZW250 machine:


Weakening and noticeable slowing of machine movements after oil warms up - when the system is cold, the excavator operates correctly; however, as the hydraulic oil temperature rises, the speed of boom lifting, bucket curling, or upper structure swing drops drastically, which is a clear sign of internal leakage and wear in the main pump rotary group.


Lack of synchronization and smooth working movements - the machine arm moves jerkily, noticeable delay occurs when controlling multiple functions simultaneously, or one of the track drives pulls the machine to one side, indicating a fault in the main control valve sections or incorrect pilot pressure.


Loud operation, whining, and metallic noises near the pump - a characteristic harsh noise that intensifies under working resistance signals a drastic drop in piston efficiency, damage to the valve plate or drive shaft, or metallic debris in the system, which strictly requires an immediate machine shutdown.


Rapid and excessive hydraulic oil overheating - a constant system temperature exceeding operational norms, combined with a warning light on the Hitachi dashboard, indicates severe internal friction inside worn dynamic components or relief valve failure.


Travel and hill-climbing problems - the excavator lacks traction, struggles to pivot on a single track in soft soil, or completely locks up one drive, directly forewarning travel motor wear or seal damage in the swivel joint (center joint).


Arm or boom drift under load - after releasing the joysticks, a filled bucket automatically and slowly drops toward the ground, indicating leaks past hydraulic cylinder rod seals or worn seats in counterbalance/check valves.

Diagnostics in every corner of Poland

Hitachi Mobile Service

Our field teams operate fully equipped workshop vehicles, performing advanced repairs and diagnostics on construction sites, open-cast mines, and road projects from Silesia to Pomerania. We regularly eliminate critical equipment downtime in key industrial hubs and metropolitan areas, arriving swiftly to clients in cities such as Warsaw, Katowice, Wroclaw, Krakow, Poznan, Gdansk, Szczecin, Rzeszow, Bialystok, Lodz, and Lublin. The key to immediate on-site fault resolution is the implementation of diagnostic procedures using specialized software dedicated to Hitachi machine control systems, enabling flawless reading of fault codes, real-time verification of heavy Isuzu engine operating parameters, and precise physical pressure measurements in Japanese HIOS and TRIAS hydraulic systems. Directly on the construction site, our mechanics perform complex technical operations: from leak detection and replacement of damaged high-pressure hoses, through seal replacement in massive cylinders, to complete disassembly and assembly of entire components, such as two-section Kawasaki main pumps or slewing motors. We build the authority and reliability of Wibako's nationwide mobile service on the foundation of our vast logistical base - heading out, our engineers bring along certified components from our central warehouse, perfectly matched to the specific Hitachi model. This guarantees full purchase safety of parts and reduces intervention time to an absolute minimum, ensuring that whether your ZX series crawler excavator or ZW wheel loader is located in Lower Silesia, central Poland, or Masuria, we drastically reduce downtime costs and restore your equipment to work with full factory operating power.

 

Official Wibako partnership with Motorservice and Bosch

Hitachi parts warehouse

Eliminating costly downtime of construction and mining machinery requires immediate access to top-quality components, which is why the heart of our operations is Wibako's massive central warehouse, where over ten thousand catalog items dedicated to ZX, EX series crawler excavators and ZW wheel loaders are available off the shelf. We build our engineering authority and market leadership position on official, direct partnerships with global technology giants such as the Motorservice Group (distributor of Kolbenschmidt and Pierburg brands) and Bosch, allowing us to deliver uncompromising solutions and guarantee complete purchase safety. Thanks to our unique partner status, in the overhaul processes of heavy Isuzu 6HK1 or 6WG1 engines, we use exclusively certified, original Kolbenschmidt piston-crank assembly components, including precisely fitted pistons, cylinder liners, rings, and bearings with increased resistance to material fatigue. In turn, cooperation with the Bosch brand ensures constant and direct access to state-of-the-art technologies in Common Rail fuel injection systems, enabling our engineers to install brand-new or professionally remanufactured injectors, feed pumps, and high-pressure pumps while maintaining the strict standards of the Japanese manufacturer. In our huge warehouse, alongside advanced mechanical and fuel components, we store ready-for-immediate-dispatch Kawasaki two-section axial-piston main pumps, complete slewing motors, travel hydraulic motors, and extensive sets of technical seals matched to specific Hitachi machine models. Because we are not a middleman and hold most key elements on our own warehouse shelves, order packing and dispatch are executed within 24 hours of notification, drastically shortening the waiting time for components and allowing your Hitachi machine to return to work with full factory performance without the risk of contract delays.

 

 

 

 

 

 

Will I receive a warranty and test documentation after engine or hydraulics repair at Wibako?

Yes, every advanced service task performed at Wibako is covered by a full warranty, which provides our clients with maximum purchase safety and operational stability. Because we build our authority on hard engineering data, the culmination of a major Isuzu engine overhaul or axial-piston pump remanufacturing are rigorous load tests. Every client can receive, upon request, an official report and charts from our stationary engine or hydraulic dynamometer, serving as black-and-white technical proof that the unit achieves factory torque, proper geometric displacement, and maintains 100% tightness under full operating load.

In which regions of Poland does Wibako mobile service operate and how quickly does it reach Hitachi machines?

Our professional Wibako mobile service covers the entire territory of Poland, reaching every construction site, open-cast mine, and road project from Silesia to Pomerania. Our fully equipped workshop vehicles regularly operate in regions of cities such as Warsaw, Katowice, Wroclaw, Krakow, Poznan, Gdansk, Szczecin, Rzeszow, or Bialystok. Response and arrival time depends on the current location of our field engineering teams; however, thanks to excellent logistics and strategic team placement, we are able to arrive at the breakdown site in a satisfying period of time.

Do you also service older Hitachi machine models, e.g. the EX series?

Absolutely, at Wibako we have full technical facilities, engineering documentation, and many years of experience allowing for professional service and major overhauls of both the newest Hitachi ZX series models and older, extremely popular EX series machines. Our parts warehouse includes components for older generations of hydraulic systems and internal combustion engines, which allows us to effectively restore functionality to machines that theoretically have already been withdrawn from official manufacturer support.

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