Daewoo Doosan DX255LC-3 Excavator Service Repair Manual Instant Download

1
Shop Manual DX255LC-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.
950106-00374E April 2012
Original Instructions
Copyright DOOSAN 2012
2
Table of Contents
Safety Track Excavator Maintenance Safety
..................................................
. SP002322 Specifications Specifications for
DX255LC-3.........................................
...................... SP002547 General
Maintenance General Maintenance Instructions
..................................................
...... SP002454 Standard Torques
..................................................
............................... SP002404 Upper
Structure Cabin ..................................
..................................................
................ SP002324 Counterweight...........
..................................................
.......................... SP002548 Fuel
Tank..............................................
................................................
SP002549 Fuel Transfer Pump (Option)
..................................................
.............. SP002550 Swing Bearing.............
..................................................
........................ SP002329 Lower
Structure and Chassis Track Assembly
..................................................
..................................
SP002551 Engine and Drivetrain Engine Coolant
Heater (Option) ..................................
......................... SP002328 Drive Coupling
(Main Pump).......................................
.......................... SP002586 Hydraulics Hy
draulic System Troubleshooting, Testing and
Adjustment ............... SP002597
Accumulator.......................................
..................................................
. SP002455 Center Joint (Swivel)..................
..................................................
......... SP002456 Cylinders......................
..................................................
....................... SP002587
3
Swing Device .....................................
..................................................
. SP002588 Travel Device..........................
..................................................
............ SP002590 Main Pump...................
..................................................
....................... SP002591 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 Hydraulic
Schematic (DX255LC-3).............................
.......................... SP002589 Electrical
System Electrical System .........................
..................................................
....... SP002337 Electrical Schematic
..................................................
........................... SP002508 Attachments
Boom and Arm......................................
................................................
SP002592 Bucket...................................
..................................................
.............. SP002506
4
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Track Excavator Maintenance
Safety
SP002322
Edition 3
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 must 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.
Track Excavator Maintenance Safety Page 6
SP002322
8
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.
Other Signal Words In addition to safety signal
words, the following signal words are used to
indicate proper and effective use of machine.
IMPORTANT
This signal word identifies procedures which must be followed to avoid damage to machine.
The word "NOTE" identifies information for
effective use.
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.
SP002322 Page 7
Track Excavator Maintenance Safety
9
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 work site,
  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.
• 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

Track Excavator Maintenance Safety Page 8
SP002322
10
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 must be relieved before maintenance
is started. 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.
FG018457
Figure 1
SP002322 Page 9
Track Excavator Maintenance Safety
11
Track Assembly
SP002551
Edition 1
Track Assembly
SP002551 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
DX255LC-3 1001 and Up, 50001 and Up
SP002551 Page 5
Track Assembly
13

• GENERAL DESCRIPTION
• The track assembly is composed of the following
  major components
• Track
• Front Idler Roller
• Upper Roller
• Lower Roller
• Track Spring and Track Adjustment Cylinder

Track Assembly Page 6
SP002551
14
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 always. 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
SP002551 Page 7
Track Assembly
15
4. The increased clearance recommended for
muddy, sandy or snowy ground conditions is
between distance "C" in the below table.
Terrain Type Recommended Distance "A"
Normal "B" 320 - 340 mm (12.60 - 13.39 in)
Muddy, Sandy or Snowy "C" 340 - 370 mm (13.39 - 14.57 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 always. 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
SP002551
16
CLEANING AND INSPECTION (WEAR LIMITS AND
TOLERANCES)
CAUTION
AVOID INJURY Refer to "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.
SP002551 Page 9
Track Assembly
17
Track Shoe
8 2, 7
8 2, 7
9
11
1
3
6
4
5
FG025000
Figure 4
Track Assembly Page 10
SP002551
18
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 (1.024") 26 mm (1.024") 26 mm (1.024") 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") 0.074 0.0 0.32 - 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 0.162 37.8 mm (1.488") 0.062 0.0 0.3 - 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 -1.188 - -0.628
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") 0.280 0.250 37.8 mm (1.488") 0.062 0.0 0.188 - 0.28
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 38 mm (1.496") -0.150 -0.350 38.85 mm (1.530") 0.500 0.0 -1.7 - -1.0
SP002551 Page 11
Track Assembly
19
Lower Roller
3 4 FG024973 Figure 5
2
1
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 195 mm (7.677") 195 mm (7.677") 190 mm (7.48") 190 mm (7.48") 190 mm (7.48") 185 mm P (7.283")
2 Outside Diameter of Tread 160 mm (6.299") 160 mm (6.299") 154 mm (6.063") 154 mm (6.063") 154 mm (6.063") 150 mm P (5.906")
3 Width of Tread 49 mm (1.929") 49 mm (1.929") 55 mm (2.165") 55 mm (2.165") 55 mm (2.165")
4 Width of Flange 29 mm (1.142") 29 mm (1.142")
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 70 mm (2.756") -0.06 -0.09 70.2 mm (2.764") 0.18 0.13 -0.47 - -0.39 68.3 mm (R) (2.689")
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 77 mm (3.031") 0.14 - 0.09 77 mm (3.031") 0.03 -0.02 0.06 - 0.16
Track Assembly Page 12
SP002551
20
Upper Roller
4 3 FG024974 Figure 6
2 1
6 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 169 mm (6.654") 169 mm (6.654") 165 mm (6.496") 165 mm (6.496") 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 (5.118")
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") 0.05 0 -0.38 - -0.3
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") 0.15 - 0.1 61 mm (2.402") 0.04 -0.03 0.06 - 0.18
SP002551 Page 13
Track Assembly
21
Front Idler
4 3 5 FG024975 Figure 7
6
1 2
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 (21.323") 541.6 mm (21.323")
2 Outside Diameter of Tread 500 mm (19.685") 500 mm (19.685") 492 mm (19.370") 492 mm (19.370") 492 mm (19.370") 488 mm P (19.213")
3 Width of Protrusion 85 mm (3.346") 85 mm (3.346")
4 Total Width 160 mm (6.299") 160 mm (6.299")
5 Width of Tread 37.5 mm (1.476") 37.5 mm (1.476") 35 mm (1.378") 35 mm (1.378") 35 mm (1.378") 33 mm (1.299")
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 -0.03 75 mm (2.953") 0.415 0.37 -0.445 - -0.37
7 Interference between idler and bushing Standard Dimension (Idler) Tolerance Standard Dimension (Bushing) Tolerance Standard Interference Repair Limit
7 Interference between idler and bushing 85 mm (3.346") 0.12 0.09 85 mm (3.346") 0.035 - 0 0.055 - 0.12
Track Assembly Page 14
SP002551
22
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 always. 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.

SP002551 Page 15
Track Assembly
23
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 must 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
Track Assembly Page 16
SP002551
24
FRONT IDLER ROLLER Parts List
6
1
9
2
8
7 5
3
4 5
7
6
8
9 Figure 15
3
FG022507
Reference Number Description
1 Idler Assembly
2 Idler
3 Bearing
4 Shaft
5 Bushing
Reference Number Description
6 Pin
7 Floating Seal
8 O-ring
9 Plug
SP002551 Page 17
Track Assembly
25
Front Idler Roller Disassembly 1. Remove plug (9,
Figure 16) from idler assembly (1), and drain
oil into a suitable container.
9
FG022246
Figure 16 2. Separate the pin (6, Figure 17)
from the bearing (3).
6
3
FG022247
Figure 17
3. Use a press to remove bearing from the axle
(4). Separate the O-ring (8, Figure 18) from the
axle.
3 4

8
FG022507
Figure 18
4. Detach the floating seal (7, Figure 19) from
the idler (2) and bearing (3).
3
7 2
7
3 FG022508
Figure 19
Track Assembly Page 18
SP002551
26
5. Use a press to separate the axle (4, Figure
20), O-ring (8) and bearing (3).
8 3
4 FG022509
Figure 20 6. Remove bushing (5, Figure 21) with
the press and special tool (10, ST-1909).
10
5
2
FG022510
Figure 21
SP002551 Page 19
Track Assembly
27
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Front Idler Roller Reassembly
4 3 8

• Degrease, clean and dry all parts before
  reassembly. Insert bushing (5, Figure 21) into
  the idler (2).
• Grease O-ring (8, Figure 22) and insert it into
  the axle.
• Align the bearing (3, Figure 22) and axle (4)
  holes and pin
• (6) them together.

6
8 FG022511
Figure 22
4. Install floating seal (7, Figure 23) inside
the idler (2) and bearing (3).
3
7
NOTE
Apply clean gear oil (ISO VG 220EP) to the joint
side of the floating seal. Apply grease to the
floating seal O-ring.
2
7
3 FG022508

• Figure 23
• Install idler (2, Figure 24) on the axle.
• Install bearing (3, Figure 24) and pin (6) to the
  axle.

2
NOTE
Fill the idler assembly with new gear oil (ISO VG
220EP) with approximately 320 cc (10.8 oz).
6 3
7. Install plug (9, Figure 24) on the bearing.
9
FG022253
Figure 24
SP002551
Track Assembly Page 20
29
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friend! Thank you very much for reading. Enter
the link into your browser. The full manual is
available for immediate download. https//www.eb
ooklibonline.com