How are Hitachi excavators assembled?

From parts to power units: Witness the incredible assembly process of the EX8000 mining excavator

Bigger than your average excavator, the Hitachi EX8000 is a monster in the excavator world. Powered by two Tier 4 Final engines, it offers excellent fuel economy.

But before we get to the point where we can really appreciate all the details, let’s take a look at the actual assembly process captured in this amazing video we created.

Why is Proper Assembly Important?

Proper assembly is crucial when dealing with any type of heavy equipment, and the Hitachi EX8000 mining excavator takes this concept to a new level. Once the excavator’s many large components arrive on site, it typically takes 45-90 days (depending on local conditions) to be assembled and ready for use. However, that’s not the end of the process, as commissioning and testing phases are required next.

What are EX8000 assembly best practices?

As we mentioned before, proper assembly is essential if you want to get the most out of your Hitachi EX8000.

Step 1: Follow Safety Precautions

Of course, the first thing to consider is to ensure that all necessary safety precautions are followed. Therefore, you should take the following steps:
• Ensure that all technicians and operators are trained and qualified to operate the required tools and machinery
• Check that all personnel in the area are wearing appropriate personal protective equipment (PPE), including steel-toed boots, gloves, goggles, and hard hats
• Review assembly instructions and machine specifications before beginning the assembly process to ensure familiarity with the task at hand
• Follow all safety regulations and guidelines for your location
• Ensure that project-specific safety plans, job hazard assessments, pre-job hazard assessments, and other required safety documents are prepared and in place

Step 2: Prepare the Assembly Area

The assembly area must meet several key criteria to ensure that there are no unnecessary delays during the assembly process. This means:
• Find a level, stable surface that provides ample space for assembly
• Clear the area of ​​any debris or obstructions
• Control access to/exit the build platform
• Set up office trailers, car wash carts, and tool boxes
• Install build platform signage
Lay out all structures and components for easy access during the assembly process.

Step 3: Assemble the Substructure

Now we start assembling the major components and see how the machine comes together. In the next steps you will:
• Assemble the substructure by attaching the side frames to the body
• Assemble the track pad sections and wrap around the side frames
• Install the slew bearing to the body
• Make sure all connections are properly torqued

Step 4: Assemble the Mainframe and Counterweight

Next is to assemble the mainframe, which is usually done at the same time as installing the chassis, or before installing the chassis. Here are the steps:
• Attach the mainframe to the body
• Connect all hydraulic hoses and lines
• Install the side modules (contains the engine, pump drive, pump, etc.)
• Add counterweight to the mainframe
• Attach the cab to the mainframe

Step 5: Install the boom, arm, and bucket

Now we have almost all of the major components assembled, leaving only the boom, stick, and bucket to be installed. Once completed, you will need to focus on the following:
• Connect the remaining pipes, hoses and hydraulic cylinders
• Ensure all pins and covers are installed as per Hitachi’s instructions
• Install the bucket, ensuring all teeth, cutting edges and additional wear parts are installed

Step 6: Local Options Installation

The final step in assembly is to install all customer and region specific options to ensure the EX8000 will operate smoothly for local conditions. Local options installed may include but are not limited to:
• Cold Weather Kit (with machine oil heater for easier starting in winter)
• Fire Suppression System
• Radio, Communication System and Mine Dispatch System
• Additional Lighting
• Customer Logo and/or Unit Number Signage
• Additional Emergency Disconnect Switch

Step 7: Final Checks and Adjustments

Now that the EX8000 is fully assembled, it’s time to make sure everything is functioning properly. Final inspection and testing includes:
• Fluid level check and refill
• Check for loose or missing connections
• Functional test of all systems (e.g. engine, electrical and hydraulic)
• Consult the operator's manual for proper run-in and maintenance procedures
• Production study to prove machine capacity (tons per hour)

Helping you get the most out of your Hitachi EX8000

As you can see, the Hitachi EX8000 is a powerful excavator that takes time and expertise to assemble correctly.

To learn more about this giant mining excavator, contact Kyotechs experts. We have a deep understanding of the excavator industry and we have the expertise to help you solve any problems you may encounter with your excavator.