Daewoo Doosan DX225LC-3 Excavator Service Repair Manual Instant Download

1
Shop Manual DX225LC-3 Excavator
Serial Number 1001 and Up Serial Number 50001 and
Up (Europe Only)
DOOSAN and the DOOSAN logo are registered
trademarks of DOOSAN Corporation in the United
States and various other countries around the
world.
950106-00364E March 2012
Original Instructions
Copyright DOOSAN 2012
2
Table of Contents
Safety Track Excavator Maintenance Safety
..................................................
. SP002322 Specifications Specifications for
DX225LC-3.........................................
...................... SP002491 General
Maintenance General Maintenance Instructions
..................................................
...... SP002454 Standard Torques
..................................................
............................... SP002404 Upper
Structure Cabin ..................................
..................................................
................ SP002324 Counterweight...........
..................................................
.......................... SP002492 Fuel
Tank..............................................
................................................
SP002493 Fuel Transfer Pump (Option)
..................................................
.............. SP002534 Swing Bearing.............
..................................................
........................ SP002329 Lower
Structure and Chassis Track Assembly
..................................................
..................................
SP002494 Engine and Drivetrain Engine Coolant
Heater (Option) ..................................
......................... SP002328 Drive Coupling
(Main Pump).......................................
.......................... SP002495 Hydraulics Hy
draulic System Troubleshooting, Testing and
Adjustment ............... SP002535
Accumulator.......................................
..................................................
. SP002455 Center Joint (Swivel)..................
..................................................
......... SP002456 Cylinders......................
..................................................
....................... SP002497
3
Swing Device .....................................
..................................................
. SP002498 Travel Device..........................
..................................................
............ SP002499 Main Pump...................
..................................................
....................... SP002502 PTO
Server............................................
...............................................
SP002503 Gear Pump ...............................
..................................................
.......... SP002500 Main Control Valve
..................................................
............................. SP002403 Remote
Control Valve (Work Lever / Joystick)
..................................... SP002395
Travel Control Valve (with Damper)................
......................................
SP002381 Solenoid Valve Assembly
..................................................
................... SP002406 Breaker EPPR Valve
(Option) .........................................
..................... SP002458 Dozer Valve
..................................................
........................................ SP002529
Hydraulic Schematic (DX225LC-3)...................
....................................
SP002507 Electrical System Electrical System
..................................................
................................
SP002337 Electrical Schematic ....................
..................................................
....... SP002508 Attachments Boom and
Arm...............................................
.......................................
SP002505 Bucket...................................
..................................................
.............. SP002506
4
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Track Excavator Maintenance
Safety
SP002322
Edition 2
Track Excavator Maintenance Safety
SP002322 Page 1
6
SAFETY INSTRUCTIONS
WARNING
AVOID DEATH OR SERIOUS INJURY Instructions are necessary before operating or servicing machine. Read and understand the Operation and Maintenance Manual and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments repairs or service. Untrained operators and failure to follow instructions can cause death or serious injury.
APPLICABLE MODELS The contents of this section
apply to the following models and serial number
ranges.
MODEL SERIAL NUMBER RANGE
DX140LC-3 1001 and Up, 50001 and Up
DX180LC-3 1001 and Up, 50001 and Up
DX225LC-3 1001 and Up, 50001 and Up
DX255LC-3 1001 and Up, 50001 and Up
DX300LC-3 1001 and Up, 50001 and Up
DX340LC-3 1001 and Up, 10001 and Up
DX350LC-3 1001 and Up, 10001 and Up
DX380LC-3 10001 and Up
DX420LC-3 10001 and Up
DX490LC-3 10001 and Up
DX530LC-3 10001 and Up
SP002322 Page 5
Track Excavator Maintenance Safety
7
SAFETY MESSAGES Safety messages and safety decals
included in this manual and on the machine
provide instructions how to operate, service and
maintain the machine. Safety messages and safety
decals indicate potential hazards and describe
safety precautions required to avoid hazards.
Operator and maintenance personnel should read
and understand these safety messages and decals
before beginning operation or maintenance.
SAFETY ALERT SYMBOL
Be Prepared - Get to Know All Operating and Safety Instructions. This is a Safety Alert Symbol. Wherever it appears in this manual or on safety decals on the machine, you should be alert to the potential for personal injury or accidents. Always observe safety precautions and follow recommended procedures.
Signal Words The signal words "DANGER",
"WARNING", "CAUTION" are used throughout safety
messages and safety decals in this manual or on
the machine. They indicate an existence of, and
the relative seriousness of, a hazard. All three
indicate that a safety risk is involved. Observe
the precautions indicated whenever a Safety Alert
Symbol is present, no matter which signal word
appears next to it.
DANGER
DANGER - This signal word is used on safety messages and safety labels and indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
WARNING
WARNING - This signal word is used on safety messages and safety labels and indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION
CAUTION - This signal word is used on safety messages and safety labels and indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury.
Track Excavator Maintenance Safety Page 6
SP002322
8
SAFETY DECALS Location of safety labels (decals)
can vary from unit to unit. Refer to appropriate
Operation and Maintenance Manual, and parts
manual for your unit. Always replace damaged or
faded decals.
GENERAL

• Safe Operation is Operator's Responsibility
• Only trained and authorized personnel should
  operate and maintain the machine.
• Follow all safety rules, regulations and
  instructions when operating or performing
  maintenance on machine.
• Do not operate machine if you are under the
  influence of drugs or alcohol. An operator who
  is taking prescription drugs must get medical
  advice to determine if he or she can safely
  operate a machine.
• When working with other personnel on a worksite,
  be sure that all personnel know nature of work
  and understand all hand signals that are to be
  used.
• Be sure that all guards and shields are installed
  in their proper location. Have guards and
  shields repaired or replaced immediately if
  damaged.
• Be sure that you understand the use and
  maintenance of all safety features such as
  safety lock lever and seat belt. Use them
  properly.
• Never remove, modify or disable any safety
  features. Always keep them in good operating
  condition.
• Always check for and know the location of
  underground and overhead utility lines before
  excavating.
• Failure to use and maintain safety features
  according to instructions in this manual, Safety
  Manual and Shop Manual can result in death or
  serious injury.
• Know Your Machine
• Know how to operate your machine. Know the
  purpose of all controls, gauges, signals,
  indicators and monitor displays. Know the rated
  load capacity, speed range, braking and steering
  characteristics, turning radius and operating
  clearances. Keep in mind that rain, snow, ice,
  loose gravel, soft ground, slopes etc., can
  change operating capabilities of your machine.

SP002322 Page 7
Track Excavator Maintenance Safety
9
Proper Work Tools and Attachments Only use work
tools and attachments that are recommended by
DOOSAN for use on DOOSAN machines. When
installing and using optional attachments,
read instruction manual for attachment, and
general information related to attachments in
this manual. Because DOOSAN cannot anticipate,
identify or test all attachments that owners may
want to install on their machines, contact DOOSAN
for written authorization and approval of
attachments, and their compatibility with
optional kits. Attachments and attachment
control systems that are compatible with the
machine are required for safe and reliable
machine operation. Do not exceed maximum
operating weight (machine weight plus attachment)
that is listed on ROPS certification plate. Make
sure that all guards and shields are in place on
machine and on work tool. Depending on type or
combination of work equipment, there is a
potential that work equipment could interfere
with the cabin or other parts of machine. Before
using unfamiliar work equipment, check if there
is any potential of interference, and operate
with caution. While you are performing any
maintenance, testing, or adjustments to
attachments, stay clear of the following areas
cutting edges, pinch points, and crushing
surfaces. Never use attachment as a work platform
or manlift. Contact your DOOSAN distributor about
auxiliary hydraulic kits for attachments
installation. If you are in doubt about
compatibility of a particular attachment with a
machine, consult your DOOSAN distributor.
Pressurized Fluids Pressurized air or fluids can
cause debris and/or fluids to be blown out. This
could result in death or serious
injury. Immediately after operations are stopped,
coolant, engine oil, and hydraulic oil are at
their highest temperatures and the radiator and
hydraulic tank are still under pressure. Always
wait for temperature to cool down. Follow
specified procedures when attempting to remove
caps, drain oil or coolant, or replacing filters.
Always wait for temperature to cool down, and
follow specified procedures when performing these
operations. Failure to do so can result in death
or serious injury. When pressurized air and/or
pressurized water is used for cleaning, wear
protective clothing, protective shoes, and eye
protection. Eye protection includes goggles or a
protective face shield. Pressure can be trapped
in a hydraulic system and should be relieved
before maintenance is started.
FG018457
Figure 1
Track Excavator Maintenance Safety Page 8
SP002322
10
Releasing trapped pressure can cause sudden
machine movement or attachment movement. Use
caution if you disconnect hydraulic lines or
fittings. High-pressure oil that is released can
cause a hose to whip or oil to spray. Fluid
penetration can result in death or serious
injury. If fluid enters skin or eyes, get
immediate medical attention from a physician
familiar with this injury. Obey all local laws
and regulations for disposal of liquids. To
prevent hot coolant from spraying out, stop
engine and wait for coolant to cool. Using
gloves, slowly loosen cap to relieve pressure.
Flying or Falling Objects On work sites where
there is a potential hazard that flying or
falling objects can hit operator's cabin, select
and use a guard to match operating conditions for
additional operator protection. Working in mines,
tunnels, deep pits, and loose or wet surfaces,
could produce hazard of falling rocks or flying
objects. Additional protection for operator's
cabin could be required such as an Operator
Protection Guard (OPG) or window guards. Contact
your DOOSAN distributor for information on
available protective guards. To prevent personnel
from being struck by flying objects, keep
personnel out of work area.
HAOA110L
Figure 2
HAOA100L
Figure 3
SP002322 Page 9
Track Excavator Maintenance Safety
11
Swing Bearing
SP002329
Edition 2
Swing Bearing
SP002329 Page 1
12
SAFETY INSTRUCTIONS
WARNING
AVOID DEATH OR SERIOUS INJURY Instructions are necessary before operating or servicing machine. Read and understand the Operation and Maintenance Manual and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments repairs or service. Untrained operators and failure to follow instructions can cause death or serious injury.
APPLICABLE MODELS The contents of this section
apply to the following models and serial number
ranges.
MODEL SERIAL NUMBER RANGE
DX140LC-3 1001 and Up, 50001 and Up
DX180LC-3 1001 and Up, 50001 and Up
DX225LC-3 1001 and Up, 50001 and Up
DX255LC-3 1001 and Up, 50001 and Up
DX300LC-3 1001 and Up, 50001 and Up
DX340LC-3 1001 and Up, 10001 and Up
DX350LC-3 1001 and Up, 10001 and Up
DX380LC-3 10001 and Up
DX420LC-3 10001 and Up
DX490LC-3 10001 and Up
DX530LC-3 10001 and Up
SP002329 Page 5
Swing Bearing
13
SWING BEARING MAINTENANCE
Operating Recommendation The service life of the
swing bearing may be extended if a daily effort
is made to equalize usage over both ends of the
excavator. If the excavator is used in the same
operating configuration day in and day out (for
example, with the travel motors always under the
counterweight, or with the attachment over one
side of the machine more than the other), the
bearing's service life could be reduced.
Repositioning the excavator during the work
shift, to work the opposite end of the bearing,
will provide a more even and gradual rate of wear
and extended service life.
Measuring Swing Bearing Axial Play Regular checks
of bearing displacement should be made at least
twice a year. Use a dial indicator. Push the
attachment against the ground to lift up the
excavator above the ground and take measurements
at 4 points, 90 apart, around the
circumference of the bearing (Figure 1). Record
and keep all measurements. Play in the bearing
should increase minimally from one inspection to
the next. Eventually, however, as the bearing
begins to approach the limit of its service
life, clearance increases become much more
pronounced and the actual measured play in the
bearing could exceed twice the value that was
measured when the machine was new.
1
2
Measuring Bearing Lateral Play When vertical
checks are made, the side to side play in the
bearing can be checked by fully retracting the
arm and bucket cylinders and extending the tip of
the bucket as far forward as it will go. With the
excavator parked on a flat, level surface and the
bucket tip just off the ground, push against the
bucket sideways to take up all the lateral
clearance in the bearing. (Less than 100 lb of
force should be required to move the bucket over
all the way.) Check lateral play in both
directions and record the values. When the
bearing is beginning to approach the end of its
service life, measured lateral clearance should
start to show increase in value.
FG018734
Figure 1
Swing Bearing Page 6
SP002329
14
Swing Bearing Basic Operation The swing bearing,
which connects the upper structure with the lower
structure, consists of a inner ring, outer ring
and ball bearings. During swing movement, power
from the swing motor is transferred to the pinion
by planetary gears connected to gears on the
inner ring, which is fixed in the undercarriage.
Ball bearings turn the outer ring.
Reference Number Description
1 Outer Ring
2 Inner Ring
3 Tapered Pin
4 Plug
5 Ball
6 Retainer
7 Seal
Figure 2
Disassembly 1. Remove tip of tapered pin (3,
Figure 3) using grinder and tap lightly to remove
debris.
Figure 3 2. Remove plug (4, Figure 4) using a
M10 x P 1.5 bolt.
Figure 4
SP002329 Page 7
Swing Bearing
15
3. Lift outer ring and check that inner ring can
move freely. See Figure 5, if not, replace seal
(7, Figure 6).
Figure 5 4. Turn inner ring and use magnet bar
(C, Figure 6) to remove steel balls (5).
Figure 6 5. Turn inner ring and use wire (D,
Figure 7) to remove retainers (6).
Figure 7
Swing Bearing Page 8
SP002329
16
Assembly 1. Clean (degrease) the seal groove for
the outer and inner seals (7). Apply instant glue
to seal (7). Install both seals respectively into
position.
Figure 8 2. Hoist the outer race by crane
horizontally and match it with the inner race
coaxially. Rotating the outer race, insert balls
(5), support (6) into the plug (4) hole one by
one with a round bar.
Figure 9
Figure 10 3. Top plug (4) into outer race (1)
and then, drive pin (3) into the pinhole. Caulk
the head of pin (3) with a punch. Fill grease
through the grease fitting.
Figure 11
SP002329 Page 9
Swing Bearing
17
Track Assembly
SP002494
Edition 1
Track Assembly
SP002494 Page 1
18
TRACK TENSION
WARNING
AVOID DEATH OR SERIOUS INJURY Measuring track tension requires two people. One person must be in the operator's seat, operating the controls while the other person makes dimensional checks. Block frame to make sure the machine won't move or shift position during service. Warm up the engine to prevent stalls, park the excavator in an area that provides level, uniform ground support and/or use support blocks when necessary. The track adjusting mechanism is under very high-pressure. NEVER release grease pressure too fast. The track tension grease valve should never be loosened more than one (1) complete turn from the fully tightened down position. Bleed off grease pressure slowly. Keep your body away from the valve at all times. Always wear eye and face protection when adjusting track tension.
Track shoe link pins and bushings wear with
normal usage, reducing track tension. Periodic
adjustment is necessary to compensate for wear
and it may also be required by working
conditions. 1. Track tension is checked by
jacking up one side of the excavator. See Figure
1. Place blocking under frame while taking
measurement. Turn the track backward by 1 - 2
turns.
90 110
FG018383
Figure 1 2. Measuring the distance (A, Figure
2) between the bottom of the side frame and the
top of the lowest crawler shoe. Recommended
tension for operation over most types of terrain
is distance "B" in below table.
NOTE
Clean off the tracks before checking clearance
for accurate measurements.
A
3. Too little sag in the crawler track (less
than clearance distance "B" in below table)
can cause excessive component wear. The
recommended adjustment can also be too tight
causing accelerated stress and wear if ground
conditions are wet, marshy or muddy.
FG000223
Figure 2
SP002494 Page 7
Track Assembly
19
4. The increased clearance recommended for
muddy, sandy or snowy ground conditions is
between distance "C" on below table.
Terrain Type Recommended Distance "A"
Normal "B" 290 - 310 mm (11.40 - 12.20 in)
Muddy, Sandy or Snowy "C" 310 - 340 mm (12.20 - 13.40 in)
WARNING
AVOID DEATH OR SERIOUS INJURY The track adjusting mechanism is under very high- pressure. NEVER release grease pressure too fast. The track tension grease valve should never be loosened more than one (1) complete turn from the fully tightened down position. Bleed off grease pressure slowly. Keep your body away from the valve at all times. Always wear eye and face protection when adjusting track tension.

1. Track tension adjustments are made through the
   grease fitting (1, Figure 3) in the middle of
   each side frame. Adding grease increases the
   length of an adjustment cylinder (2). Extending
   the adjustment cylinder, increases the pressure
   on the tension spring pushing the track idler
   wheel outward.
2. If there is not enough slack or clearance in the
   tracks and the adjustment is too tight, the
   idler wheel and adjusting cylinder can be
   retracted by bleeding off grease through hole in
   adjustment cylinder (2, Figure 3).

2
1
3
FG018365
Figure 3
Track Assembly Page 8
SP002494
20
CLEANING AND INSPECTION (WEAR LIMITS AND
TOLERANCES)
CAUTION
AVOID INJURY Refer to the "Welding Precautions and Guidelines" information in "General Maintenance Procedures" section for general recommendations and specific safety precautions, before starting any lower travel frame component rebuilding procedure.
The tables that follow provide factory specified
dimensional limits (as new condition, recommended
service and replacement limit) for lower travel
frame components. Recommended maintenance to
replace most listed components requires welding
on additional material and grinding off excess.
Some components must be replaced before the
service limit is exceeded. No maintenance or
renewal is possible. Compare the values in the
tables with dimensions and profiles shown in the
adjacent figures.
SP002494 Page 9
Track Assembly
21
Track Shoe
8 2, 7
10
2, 7
9
11
1
3
6
5
4
FG023178
Figure 4
Track Assembly Page 10
SP002494
22
No. Check Item Standard Dimension Standard Dimension Standard Dimension Recommended Limit for Maintenance Recommended Limit for Maintenance Limit for Use (Repair - P or Replace - R)
1 Link Pitch 190 mm (7.48") 190 mm (7.48") 190 mm (7.48") 193 mm (7.598") 193 mm (7.598") 194.5 mm R (3.72")
2 Bushing Outside Diameter 59 mm (2.323") 59 mm (2.323") 59 mm (2.323") 57 mm (2.244") 57 mm (2.244") 54.0 mm R (2.126")
3 Link Height 105 mm (4.134") 105 mm (4.134") 105 mm (4.134") 100 mm (3.937") 100 mm (3.937") 96 mm P (3.78")
4 Length at Tip 21 mm (0.827") 21 mm (0.827") 21 mm (0.827")
5 Length at Tip 14 mm (0.551") 14 mm (0.551") 14 mm (0.551")
6 Height 26 mm (1.023") 26 mm (1.023") 26 mm (1.023") 20 mm (0.787") 20 mm (0.787") 20 mm (0.787")
7 Interference between bushing and link Standard Dimension (Bushing) Tolerance Standard Dimension (Link) Tolerance Standard Interference Repair Limit
7 Interference between bushing and link 59 mm (2.323") 0.434 0.394 59 mm (2.323") 0.072 0.0 0.322 - 0.434
8 Interference between regular pin and link Standard Dimension (Regular Pin) Tolerance Standard Dimension (Link) Tolerance Standard Interference Repair Limit
8 Interference between regular pin and link 38 mm (1.496") 0.222 0.165 37.8 mm (1.488") 0.062 0.0 0.300 - 0.422
9 Clearance between regular pin and bushing Standard Dimension (Regular Pin) Tolerance Standard Dimension (Bushing) Tolerance Standard Clearance Repair Limit
9 Clearance between regular pin and bushing 38 mm (1.496") 0.222 0.162 38.85 mm (1.530") 0.500 0.0 0.628 - 1.188
10 Interference between master pin and link Standard Dimension (Master Pin) Tolerance Standard Dimension (Link) Tolerance Standard Interference Repair Limit
10 Interference between master pin and link 37.8 mm (1.488") 0.28 0.25 37.8 mm (1.488") 0.062 0.0 0.188 - 0.280
11 Clearance between master pin and bushing Standard Dimension (Master Pin) Tolerance Standard Dimension (Bushing) Tolerance Standard Clearance Repair Limit
11 Clearance between master pin and bushing 37.8 mm (1.488") 0.28 0.25 38.85 mm (1.530") 0.500 0.0 0.770 - 1.300
SP002494 Page 11
Track Assembly
23
Lower Roller
3
4
6 5
1
2
FG022504
Figure 5
No. Check Item Standard Dimension Standard Dimension Recommended Limit for Maintenance Recommended Limit for Maintenance Recommended Limit for Maintenance Limit for Use (Repair - P or Replace - R)
1 Outside Diameter of Flange 185 mm (7.283") 185 mm (7.283")
2 Outside Diameter of Tread 154 mm (6.063") 154 mm (6.063") 150 mm (5.906") 150 mm (5.906") 150 mm (5.906") 166 mm (P) (6.535")
3 Width of Tread 49 mm (1.929") 49 mm (1.929") 55 mm (2.165") 55 mm (2.165") 55 mm (2.165") 145 mm P (5.709")
4 Width of Flange 29.5 mm (1.161") 29.5 mm (1.161")
5 Clearance between shaft and bushing Standard Dimension (Shaft) Tolerance Standard Dimension (Bushing) Tolerance Standard Clearance Repair Limit
5 Clearance between shaft and bushing Standard Dimension (Shaft) Shaft Standard Dimension (Bushing) Hole Standard Clearance Repair Limit
5 Clearance between shaft and bushing 65 mm (2.559") 0 -0.03 65.4 mm (2.575") 0.05 0 0.40 - 0.48 63.3 mm (R) (2.492")
6 Interference between roller and bushing Standard Dimension (Roller) Tolerance Standard Dimension (Bushing) Tolerance Standard Interference Repair Limit
6 Interference between roller and bushing Standard Dimension (Roller) Roller Standard Dimension (Bushing) Hole Standard Interference Repair Limit
6 Interference between roller and bushing 72 mm (2.835") 0.035 0 72 mm (2.835") 0.132 0.102 0.067 - 0.132
Track Assembly Page 12
SP002494
24
Upper Roller
4
3
2 1
6 5
FG022505
Figure 6
No. Check Item Standard Dimension Standard Dimension Recommended Limit for Maintenance Recommended Limit for Maintenance Recommended Limit for Maintenance Limit for Use (Repair - P or Replace - R)
1 Outside Diameter of Flange 169 mm (6.654") 169 mm (6.654") 165 mm (6.496")
2 Outside Diameter of Tread 142 mm (5.591") 142 mm (5.591") 136 mm (5.354") 136 mm (5.354") 136 mm (5.354") 130 mm (P) (5.276")
3 Width of Tread 51.5 mm (2.028") 51.5 mm (2.028") 56.5 mm (2.224") 56.5 mm (2.224") 56.5 mm (2.224")
4 Width of Flange 17 mm (0.669") 17 mm (0.669")
5 Clearance between shaft and bushing Standard Dimension (Shaft) Tolerance Standard Dimension (Bushing) Tolerance Standard Clearance Repair Limit
5 Clearance between shaft and bushing 54.5 mm (2.146") 0 -0.03 54.8 mm (2.157") 0.07 0.03 0.33 - 0.40
6 Interference between roller and bushing Standard Dimension (Roller) Tolerance Standard Dimension (Bushing) Tolerance Standard Interference Repair Limit
6 Interference between roller and bushing 61 mm (2.402") 0.04 0.03 61 mm (2.402") 0.12 0.09 0.05 - 0.09
SP002494 Page 13
Track Assembly
25
Front Idler
4 3 5
7
6
1 2
FG022506
Figure 7
No. Check Item Standard Dimension Standard Dimension Recommended Limit for Maintenance Recommended Limit for Maintenance Recommended Limit for Maintenance Limit for Use (Repair - P or Replace - R)
1 Outside Diameter of Flange 541.6 mm (21.322") 541.6 mm (21.322")
2 Outside Diameter of Tread 500 mm (19.685") 500 mm (19.685") 488 mm (19.213") 488 mm (19.213") 488 mm (19.213")
3 Width of Protrusion 85 mm (3.346") 85 mm (3.346") 75 mm (2.953") 75 mm (2.953") 75 mm (2.953") 65 mm (2.559")
4 Total Width 160 mm (6.299") 160 mm (6.299") 150 mm (5.906") 150 mm (5.906") 150 mm (5.906") 140 mm (5.512")
5 Width of Tread 37.5 mm (1.476") 37.5 mm (1.476") 43 mm (1.693") 43 mm (1.693") 43 mm (1.693")
6 Clearance between shaft and bushing Standard Dimension (Shaft) Tolerance Standard Dimension (Bushing) Tolerance Standard Clearance Repair Limit
6 Clearance between shaft and bushing 75 mm (2.953") -0.06 -0.09 75 mm (2.953") 0.415 0.37 0.430 - 0.505 76 mm R (2.992")
7 Interference between idler and bushing Standard Dimension (Idler) Tolerance Standard Dimension (Bushing) Tolerance Standard Interference Repair Limit
7 Interference between idler and bushing 83 mm (3.268") 0.035 0 83 mm (3.268") 0.12 0.09 0.055 - 0.120
Track Assembly Page 14
SP002494
26
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27
TRACK SHOES AND LINKS Track Removal
1. Position machine on a smooth level surface
with adequate room for forward and reverse travel.
FG019247
Figure 8

1. Release track tension. Refer to Track Tension
   on page -7 in this section for procedure.
2. Move machine until master link (4, Figure 9) is
   positioned at approximately 4 o'clock from top
   position on front idle roller.
3. Put a wooden block under track shoes, as shown.

2 1 4
FG004355
Figure 9 5. Loosen grease valve (1, Figure 10)
for track adjuster to drain grease out. Use
socket wrench 27 mm
WARNING
AVOID DEATH OR SERIOUS INJURY The track adjusting mechanism is under very high- pressure. NEVER release grease pressure too fast. The track tension grease valve should never be loosened more than one (1) complete turn from the fully tightened down position. Bleed off grease pressure slowly. Keep your body away from the valve at all times. Always wear eye and face protection when adjusting track tension.
1
FG004356
Figure 10

1. Remove four nuts and bolts (1 and 2, Figure 9)
   holding shoe to link. Remove enough shoes to
   make access to master pin.
2. Remove master pin from master link by hammer or
   press. Remove pin after detaching shoe.

SP002494 Page 15
Track Assembly
28
8. Move unit forward until entire track is laying
on ground. NOTE Do not drive unit off track.
FG003911

• Figure 11
• Rotate upper structure to 90 from track. Use
  bucket and boom to raise track frame off track.
• Position blocking under frame.

90 110
FG018383
Figure 12

• Track Installation
• Lay rebuilt or new track into position under
  track frame. End of track should be positioned
  under drive sprocket.
• With upper structure at 90 to track frame. Use
  bucket and boom to raise track frame off
  blocking.
• With blocking removed, lower track frame onto
  track. Make sure all rollers are properly
  positioned on track.

90 110
FG018383

• Figure 13
• Move unit forward while feeding track up over
  drive sprocket. Continue to pull track back
  until it engages front idle roller.
• Align master links and install master pin.
• Install four nuts and bolts (to fix track shoe).
• Apply track tension. Refer to Track Tension on
  page -7" in this section for procedure.

FG003912
Figure 14
SP002494
Track Assembly Page 16
29
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