Hitachi EX60-5 Track Retention Issues and Undercarriage Solutions

[MikePhua]

The EX60-5 and Hitachi’s Compact Excavator Legacy
The Hitachi EX60-5 is a compact hydraulic excavator designed for precision digging, trenching, and utility work. Introduced in the late 1990s, it was part of Hitachi’s fifth-generation EX series, offering improved cab ergonomics, hydraulic efficiency, and electronic monitoring systems. With an operating weight around 13,000 pounds and powered by a four-cylinder Isuzu diesel engine, the EX60-5 became a popular choice for contractors working in urban environments and confined spaces.
Hitachi, founded in 1910, has long been a global leader in construction machinery. The EX series helped solidify its reputation for reliability and smooth hydraulic control. The EX60-5, in particular, was widely exported across Asia, Europe, and North America, with thousands of units still in operation today.
Terminology Notes

• Track Tensioner: A hydraulic or spring-loaded mechanism that maintains proper tension in the excavator’s track chain.
  
• Carrier Roller: A roller mounted on the top of the track frame that supports the upper portion of the track.
  
• Idler Wheel: A non-powered wheel at the front of the track frame that guides and supports the track chain.
  

Symptoms of Track Displacement
Operators may encounter:

• Track slipping off the sprocket or idler during turns or uneven terrain
  
• Visible sagging or slack in the track chain
  
• Loud popping or grinding noises from the undercarriage
  
• Track binding or jamming during travel
  
• Uneven wear on sprockets, rollers, or track pads
  

A crew in Queensland reported that their EX60-5 track came off twice during slope work. After inspection, they discovered a failed tensioner seal and a worn idler bearing, both contributing to the instability.
Root Causes and Diagnostic Strategy
Track derailment typically results from:

• Insufficient Track Tension
  • Hydraulic tensioner may leak or lose pressure over time
    
  • Diagnosed by measuring track sag and inspecting grease fitting
    
• Worn or Misaligned Rollers
  • Carrier or bottom rollers may seize or wear unevenly
    
  • Confirmed by rotating rollers manually and checking for play
    
• Damaged Idler or Sprocket Teeth
  • Sharp edges or missing teeth cause poor engagement
    
  • Detected by visual inspection and wear pattern analysis
    
• Track Chain Stretch or Pad Misalignment
  • Over time, chains elongate and pads may shift
    
  • Measured by comparing pitch length and pad alignment
    
• Foreign Material in Undercarriage
  

• Mud, rocks, or debris can force the track off
  
• Identified during cleaning and inspection
  

Inspection steps:

• Park machine on level ground and relieve track tension
  
• Measure track sag between carrier roller and idler
  
• Inspect tensioner cylinder and grease fitting for leaks
  
• Rotate rollers and idler to check for bearing wear
  
• Clean undercarriage and inspect for foreign objects
  

Repair Procedure and Component Recommendations
To restore track stability:

• Remove track using pry bars and excavator boom for leverage
  
• Inspect and replace damaged rollers, idler, or sprocket
  
• Rebuild or replace hydraulic tensioner and refill with grease
  
• Install track and adjust tension to manufacturer spec
  
• Test machine on flat and sloped terrain to verify alignment
  

Recommended components:

• Hitachi EX60-5 track tensioner rebuild kit
  
• Carrier and bottom roller set with sealed bearings
  
• Idler wheel with bushings and seals
  
• Sprocket segment kit with hardened teeth
  
• Track chain with matched pitch and pad spacing
  

A technician in Alberta rebuilt an EX60-5 undercarriage after repeated derailments. By replacing the tensioner and aligning the rollers, the machine operated through a full season of trenching without further track issues.
Preventive Maintenance and Long-Term Solutions
To prevent future derailments:

• Inspect track tension weekly during active use
  
• Clean undercarriage daily in muddy or rocky conditions
  
• Replace rollers and idlers every 2,000 hours or as needed
  
• Monitor sprocket wear and replace segments before tooth loss
  
• Use track guards or guides in high-slope or demolition environments
  

Some fleet managers retrofit older EX60-5 units with upgraded tensioners and reinforced track frames. Others install undercarriage monitoring sensors to detect misalignment or excessive wear.
Recommendations for Operators and Technicians

• Maintain an undercarriage service log with tension readings and component replacements
  
• Train operators to avoid sharp turns on uneven terrain
  
• Stock spare rollers, seals, and grease for field repairs
  
• Partner with Hitachi dealers for updated service bulletins and retrofit kits
  
• Consider full undercarriage inspection during seasonal downtime
  

For machines operating in trenching, forestry, or demolition, track integrity is essential for mobility and safety.
Conclusion
Track derailment on the Hitachi EX60-5 is a solvable issue rooted in tension, alignment, and wear. With disciplined inspection, quality repairs, and preventive care, the undercarriage can be restored to full reliability. In the rhythm of excavation, the track is the foundation—and when it holds true, the machine moves with confidence.