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Professional Repair of Construction Machinery
Hitachi Machinery Service
Are you experiencing power loss issues in a Hitachi ZX210LC excavator, a damaged Kawasaki HPV118 pump, a smoking Isuzu 4HK1 engine, or do you need urgent mobile field service directly on the construction site? Our engineers are at your disposal.
Call us or send an inquiry - we will select the optimal solution and provide a repair quote within 24 hours.
Hitachi Service
Repair of Excavators, Wheel Loaders, and Power Hydraulics
Professional service for Hitachi construction machinery at WIBAKO includes comprehensive diagnostics, mobile field repairs, and major overhauls of hydraulic pumps as well as Isuzu/Yanmar internal combustion engines. We resolve issues with pressure drops in HIOS and TRIAS systems, leaks from final drives, or power loss under load in crawler excavators, wheeled excavators, and Zaxis and ZW series wheel loaders. Thanks to our own stationary hydraulic and engine test bench, every remanufactured pump and power unit is returned to the machine after strict verification of actual pressure and flow parameters under full operating load.
| Machine Category | Supported Hitachi Models | Key Components / Engines | Scope of WIBAKO Service Works |
| Minicavators and Compact Excavators | • Hitachi ZX17U-5 / ZX19U-6 • Hitachi ZX26U-5 / ZX33U-6 • Hitachi ZX48U-5 / ZX55U-6 • Hitachi ZX65USB-6 / ZX85USB-6 |
• Yanmar 3TNV / 4TNV engines • Kubota D902 / V1505 engines • Nachi / Kayaba piston pumps • Nabtesco final drives and travel motors |
• Pilot hydraulics calibration • Arm and kingpin play elimination • Major engine overhauls • Final drive and swing sealing |
| Wheeled Excavators | • Hitachi ZX140W-3 / ZX140W-6 • Hitachi ZX145W-6 / ZX155W-7 • Hitachi ZX170W-5 / ZX190W-6 • Hitachi ZX210W-3 / ZX210W-7 |
• Isuzu 4JJ1 / 4HK1 engines • Kawasaki K3V63 / K5V80 pumps • HIOS III / TRIAS hydraulic systems • Fast gearboxes and axles |
• HIOS system fault diagnostics • Travel pump remanufacturing • Axle and brake service • On-site mobile field service |
| Medium Crawler Excavators (13-25 tons) | • Hitachi ZX130-5 / ZX135US-6 • Hitachi ZX160LC-5 / ZX180LC-6 • Hitachi ZX210LC-3 / ZX210LC-6 / ZX210-7 • Hitachi ZX225US-5 / ZX250LC-6 |
• Isuzu 4HK1 / 6HK1 Common Rail engines • Hitachi / Kawasaki HPV118 / HPV102 pumps • TRIAS II main control valves • HMGF swing gearboxes and final drives |
• Dynamometer pump testing • Isuzu engine major overhaul • Undercarriage sealing • Power Boost pressure adjustment |
| Heavy and Demolition Crawler Excavators | • Hitachi ZX290LC-5 / ZX300LC-7 • Hitachi ZX350LC-5 / ZX390TC-6 • Hitachi ZX490LCH-6 / ZX690LCH-7 • Hitachi ZX890LCH-7 / EX1200 |
• Isuzu 6HK1 / 6WG1 Stage V engines • TRIAS III hydraulic system (3-pump) • Main pumps HPV145 / K5V200 • Heavy Duty crawler undercarriages |
• Drive motor remanufacturing • Main pump section replacement • Hydraulics audit and tuning • HD boom crack repair |
| Wheel Loaders (ZW Series) | • Hitachi ZW140-6 / ZW150-5 • Hitachi ZW180-6 / ZW220-7 • Hitachi ZW250-6 / ZW310-7 |
• Cummins / Isuzu 6HK1 engines • Torque converters & ZF gearboxes • Steering and piston work pumps • Variable displacement systems |
• ZF gearbox repair • Torque converter remanufacturing • Steering system service • Cylinder leak elimination |
| Older Excavator Series (EX Series) | • Hitachi EX120-2/3/5 • EX200-2/3/5 • Hitachi EX220-3/5 • EX300-3/5 • Hitachi EX400-3/5 |
• Isuzu 4BD1 / 6BD1 / 6BG1 engines • HPV091 / HPV116 / HPV125 pumps • PVC / EC computer controllers • Classic control valve systems |
• Hydraulic pump rebuilding • Electronics system modernization • Rigid pipe fabrication • Engine block and crankshaft grinding |
Pumps, Motors, and Control Valves
Comprehensive Hitachi Power Hydraulics Service
Comprehensive power hydraulics service for Hitachi machines at WIBAKO includes precise diagnostics, sealing, and complete remanufacturing of piston pumps, swing and travel motors, as well as multi-section main control valves. We repair TRIAS I/II/III and HIOS III/IV series hydraulic systems used in equipment ranging from ZX33U-5 mini-excavators to heavy-duty ZX490LCH-6 demolition excavators. Every reconditioned hydraulic pump and motor undergoes mandatory load testing on WIBAKO’s stationary load test bench, ensuring full recovery of nominal operating pressure (34.3–38.0 MPa) and factory displacement before component installation on the machine.
Comprehensive Hydraulic Pump Repair
Diagnostics and Remanufacturing of Kawasaki/Hitachi Main Pumps
The heart of the hydraulic system in Hitachi crawler and wheel excavators consists of dual- or triple-section variable displacement multi-piston pumps. In machines such as the Hitachi ZX210LC-5, ZX250LC-6, or ZX300LC-7, Kawasaki / Hitachi HPV118, HPV102, and HPV145 series units are most commonly used, along with K3V63, K3V112DTP, and K5V140 series pumps.
Progressive wear of rotating components caused by degraded oil, contamination, or system overheating leads to reduced efficiency, high-pressure line vibrations, and a characteristic loud whining noise from the pump under load.
At WIBAKO’s stationary workshop, the Hitachi main pump rebuilding process follows a strict technological regime:
Verification and Micro-Measurements: The removed component is disassembled and cleaned in ultrasonic cleaners. We measure the wear of the rotor (cylinder block), pistons, valve plate (control plate), piston shoes, and swashplate liner.
Replacement of Working Parts: Worn components are replaced with brand-new precision parts of the highest quality standard. We replace the complete set of Viton seals, main shaft bearings, and swashplate tilt control components.
Pressure and Flow Regulator Remanufacturing: We equip and calibrate LS control valves and torque limiters, which ensure smooth power division between hydraulics and the Isuzu 4HK1/6HK1 engine.
Mechanics with Many Years of Experience
Service and Relief Valves Repair
Multi-section main control valves installed in Hitachi excavators (responsible for controlling the boom, arm, bucket, and swing cylinders) are complex valve blocks working with very tight spool clearances. In TRIAS II and TRIAS III systems, even minimal internal spool leakage causes arm drift or an inability to perform compound movements.
We resolve issues with jerky attachment operation, lack of Power Boost function, and external leaks through:
Precision grinding and fitting of control spools to the valve body
Replacement and adjustment of main relief valves
Remanufacturing and calibration of holding and anti-shock valve sections, protecting cylinders against pressure spikes
Comprehensive Hydraulic Motor Repair
Repair of Swing Motors and Final Drives (Hydraulic Motors)
Problems with machine movement - e.g., drop in track pull force on Hitachi ZX130-5, machine pulling to one side, or inability to swing the upper structure with a full bucket on a slope - usually result from damaged travel or swing hydraulic motors.
At WIBAKO, we perform complete repairs of HMGF series piston hydraulic motors and travel motors with integrated planetary gearboxes (final drives) from Nabtesco, Kayaba, and Teijin Seiki:
Swing Motors: We replace valve plates, multi-disc brakes, and repair drive pinion shafts powering the swing gear ring.
Final Drives: We remanufacture two-speed piston motors, replace planet gears, planetary carriers, and Duo-Cone floating seals, preventing gear oil leaks and ingress of construction site dust.
Comprehensive Combustion Engine Overhauls
Overhauls and Service of Isuzu and Yanmar Internal Combustion Engines in Hitachi Machinery
Engine service at WIBAKO includes comprehensive diagnostics of Common Rail systems, routine maintenance of engine accessories, and major overhauls of Isuzu and Yanmar power units installed in Hitachi machinery. We service Isuzu 4HK1, 6HK1, 4JJ1, and Yanmar 3TNV/4TNV engines, found in excavators and loaders from the ZX19U-6 model to heavy ZX690LCH-7 machines. Every engine after repair undergoes mandatory startup and testing on a stationary engine dynamometer, where we verify actual power, torque, compression pressure, and exhaust emission parameters under full operating load.
Operational Specifics and Challenges
Isuzu Power Units in Hitachi Equipment
Japanese Isuzu diesel engines form the backbone of most medium and heavy Hitachi Zaxis crawler and wheel excavators (e.g., ZX140W-6, ZX210LC-6, ZX290LC-5, ZX350LC-6). These are structurally advanced units meeting strict emission standards, equipped with Common Rail injection systems, variable geometry turbochargers, EGR exhaust gas recirculation systems, and DPF/SCR particulate filters.
Comprehensive Overhaul of Internal Combustion Engines
Scope of Isuzu Engine Major Overhaul at WIBAKO
At the WIBAKO stationary workshop, the engine rebuilding process is carried out in strict compliance with the manufacturer’s original factory procedures and technical specifications:
Disassembly and Dimensional Inspection: The engine is completely disassembled down to individual components. We perform micrometric measurements of cylinder liner ovalization and wear, crankshaft journal wear, engine block alignment, and cylinder head mating surface flatness.
Machining: We perform engine block machining, crankshaft grinding combined with selecting the appropriate undersize main and con-rod bearings, as well as complete cylinder head reconditioning.
Fuel and Turbocharger System Reconditioning: We recondition or replace Denso high-pressure fuel pumps and injectors, generating new IMA/QR calibration codes. The turbocharger undergoes high-speed balancing and VGT actuator calibration.
Component Assembly: We reassemble the engine using brand-new pistons, rings, gaskets, and bearings, applying precise tightening torques for cylinder head bolts and connecting rod caps using torque and angle wrenches.
Comprehensive Hydraulic Motor Repair
Repair of Swing Motors and Final Drives (Hydraulic Motors)
Problems with machine movement - e.g., drop in track pull force on Hitachi ZX130-5, machine pulling to one side, or inability to swing the upper structure with a full bucket on a slope - usually result from damaged travel or swing hydraulic motors.
At WIBAKO, we perform complete repairs of HMGF series piston hydraulic motors and travel motors with integrated planetary gearboxes (final drives) from Nabtesco, Kayaba, and Teijin Seiki:
Swing Motors: We replace valve plates, multi-disc brakes, and repair drive pinion shafts powering the swing gear ring.
Final Drives: We remanufacture two-speed piston motors, replace planet gears, planetary carriers, and Duo-Cone floating seals, preventing gear oil leaks and ingress of construction site dust.
Comprehensive Internal Combustion Engine Overhauls
Overhaul and Service of Isuzu and Yanmar Engines in Hitachi Machinery
Engine servicing at WIBAKO includes comprehensive diagnostics of Common Rail systems, routine accessory repairs, and major overhauls of Isuzu and Yanmar power units installed in Hitachi machinery. We service Isuzu 4HK1, 6HK1, and 4JJ1 engines, as well as Yanmar 3TNV/4TNV models found in excavators and loaders ranging from the ZX19U-6 up to the heavy-duty ZX690LCH-7. Following any repair, every engine undergoes mandatory startup and testing on a stationary engine dynamometer, where we verify real-world power, torque, compression pressure, and emissions parameters under full operating load.
Operating Characteristics and Maintenance Challenges
Isuzu Power Units in Hitachi Equipment
Japanese Isuzu diesel engines form the core powerplants for the majority of mid-sized and heavy-duty Hitachi Zaxis tracked and wheeled excavators (including the ZX140W-6, ZX210LC-6, ZX290LC-5, and ZX350LC-6 models). These are advanced engineering units complying with strict emission standards, featuring Common Rail injection systems, variable-geometry turbochargers (VGT), EGR exhaust gas recirculation systems, and DPF/SCR particulate filters.
Comprehensive Internal Combustion Engine Overhauls
Scope of Isuzu Engine Major Overhaul at WIBAKO
At the WIBAKO stationary workshop, the engine rebuilding process is carried out in strict accordance with the manufacturer's factory technological procedures:
Disassembly and Precision Measurement: The engine is completely disassembled down to individual components. We perform micrometric measurements of cylinder liner ovality and wear, crankshaft journal wear, engine block alignment, and cylinder head mating surface flatness.
Machining: We handle engine block machining, crankshaft grinding with the selection of appropriate oversized main and rod bearings, as well as complete cylinder head reconditioning.
Fuel System and Turbocharger Reconditioning: We recondition or replace the Denso high-pressure fuel pump and injectors, generating new IMA/QR codes for them. The turbocharger undergoes high-speed balancing and VGT actuator calibration.
Component Assembly: We reassemble the engine using brand-new pistons, rings, gaskets, and bearings, adhering to precise torque specifications for head bolts and connecting rod caps using torque wrenches and angle gauges.
Performance Guarantee
Load Testing on a Stationary Hydraulic Test Bench
The biggest hallmark of our service is eliminating the risk of installing an untested component. No hydraulic pump or motor from Hitachi leaves our facility without a full inspection on a stationary test bench. During the bench test, we simulate real-world operating conditions, bringing the hydraulic oil up to an operating temperature of 50–60°C. We measure actual volumetric and mechanical efficiency, check the sensitivity of pressure regulators, and verify the absence of leaks at pressures reaching up to 40.0 MPa. Along with the reconditioned pump, the customer receives an official report complete with flow and pressure charts, guaranteeing that the equipment can immediately take on heavy-duty construction work right after installation.
Warning Table: Common Symptoms, Causes, and Risks of Continued Operation in Hitachi Machinery
| Hitachi Machine Symptom | Probable Technical Cause | Risk of Ignoring the Symptom |
| Loss of attachment power and slower operation after oil warms up (e.g. in ZX210LC-5) | Wear on valve plate, pistons, or cylinder block in the main pump (e.g. Kawasaki HPV118). Internal oil bypass due to viscosity drop | Hydraulic pump seizure, contamination of the entire system (valves and cylinders) with metal shavings |
| Loud, "whining" operation of the hydraulic pump under load | Hydraulic oil cavitation, suction line air leak, lack of pressure in the reservoir, or worn pump shaft bearings | Permanent damage to the pump swashplate and cylinder block, drive shaft breakage |
| Excavator pulls to one side during travel (e.g. in ZX140W / ZX210LC) | Damage to a section in the travel motor (HMGF hydromotor), relief valve leak, or damaged final drive seals | Planetary gearbox damage, oil leak, and total loss of machine mobility |
| Black exhaust smoke and power loss when raising the boom | Damaged or seized Denso Common Rail injectors in Isuzu 4HK1/6HK1 engines, VGT turbocharger malfunction | Piston crown burnout, melted injector, DPF filter damage, and necessity of a complete engine overhaul |
| Jerky/uneven operation or no response to joystick movements | Pilot control pressure drop below 3.9 MPa, gear pilot pump fault, or contaminated control valve solenoid valves | Uncontrolled attachment movements posing an immediate safety hazard to the operator and job site personnel |
| Oil leaks around the track sprocket wheel | Wear or damage to the floating seal (Duo-Cone seal) in the final drive | Gear oil loss, planetary gear seizure, and destruction of the hydraulic motor housing |
Fast Field Diagnostics and Repair
Hitachi Mobile Service
Hitachi mobile equipment service delivers full technical support directly to job sites, quarries, or machinery fleets. Operating nationwide - including major hubs like Warsaw, Poznań, Białystok, Szczecin, Łódź, Lublin, Wrocław, and Gdańsk, with a strong focus on southern Poland (Kraków, Katowice, Oświęcim, Nowy Targ, Zakopane, and Nowy Sącz) - our experienced technicians arrive with fully equipped mobile workshops to minimize equipment downtime. We perform advanced computer diagnostics, hydraulic load testing, and precise field repairs on Zaxis series wheeled and tracked excavators, as well as ZW series wheel loaders.
Dispatch Procedure and Response Time
Understanding the financial impact of a downed excavator on a job site, we treat emergency service calls as a top priority. Supported by our own in-house spare parts warehouse - stocked with replacement pumps, seal kits, filters, undercarriage components, and complete injectors for Isuzu engines - our mobile service team restores Hitachi machinery to full operation on the very first field visit in the majority of cases.
Over 30 Years of Industry Experience
Why Entrust Your Hitachi Machine to Us?
Choosing WIBAKO guarantees reduced operating costs, minimized downtime, and technical reliability backed by hard measurement data. We combine over twenty years of experience in heavy equipment repair with diagnostic facilities unique on a national scale. Rather than relying on guesswork and random component replacement, we deliver proven, specialized solutions for Hitachi excavators and loaders - from compact mini-excavators to heavy demolition and mining machinery.
In-House Stationary Engine and Hydraulic Test Benches: Every reconditioned Kawasaki/Hitachi main pump and Isuzu/Yanmar internal combustion engine is tested on-site at our headquarters in Kojszówka.
Experienced Specialists: Our team consists of mechanics who have specialized exclusively in heavy construction equipment for years. We know the ins and outs of TRIAS and HIOS hydraulic systems, as well as Denso and Isuzu control units.
In-Stock Spare Parts Inventory: We maintain an extensive inventory of genuine OEM parts and proven aftermarket alternatives. We also offer a hydraulic pump exchange program - turn in your damaged unit and receive a reconditioned one at a lower price.
Written Quality Guarantee: Every service performed, as well as every reconditioned hydraulic pump, travel motor, or overhauled engine, comes with a comprehensive warranty with no operating hour limits.
Which Hitachi machines do you service?
We service the full range of Hitachi construction and demolition equipment. In our stationary workshop and via our mobile service, we repair mini-excavators (including the ZX17U, ZX33U, and ZX55U), wheeled excavators (e.g., ZX140W-6, ZX190W-5, ZX210W-7), medium and heavy crawler excavators (from the ZX130 and ZX210LC up to the ZX490LCH and ZX890LCH), ZW-series wheel loaders, and older EX-series excavators (e.g., EX120, EX200, EX300).
How does hydraulic and engine testing on the WIBAKO dynamometer differ from a standard startup?
A load dynamometer test simulates real, heavy-duty machine operation under controlled workshop conditions. Simply starting an engine or running a pump "at idle" fails to reveal internal leaks and pressure drops that only occur once the oil reaches operating temperature. On the WIBAKO test bench, we measure actual volumetric flow rate, pressure, and system tightness, providing the customer with an official test report complete with performance charts.
Does the WIBAKO mobile service travel directly to a job site for a Hitachi excavator breakdown?
Yes, our fleet of mobile service units reaches machines directly on-site across the whole of Poland. Our field technicians are equipped with computerized diagnostic tools, high-pressure gauges, and field-repair equipment. They perform fault diagnostics, sealing repairs, pressure adjustments, and disassemble damaged pumps or engines for workshop overhaul.
