Daewoo Doosan DX490LC-3 and DX530LC-3 Excavator Service Repair Manual Instant Download (Serial Number 10001 and Up)

1
Shop Manual
DX490LC-3/DX530LC-3 Excavator
Serial Number 10001 and Up
DOOSAN and the DOOSAN logo are registered
trademarks of DOOSAN Corporation in the United
States and various other countries around the
world.
950106-00259E May 2012
Original Instructions
Copyright DOOSAN 2012
2
Table of Contents
Safety Track Excavator Maintenance Safety
..................................................
. SP002618 Specifications Specification for
DX490LC-3/DX530LC-3...............................
.............. SP002557 General
Maintenance General Maintenance Instructions
..................................................
...... SP002454 Standard Torques
..................................................
............................... SP002404 Upper
Structure Cabin ..................................
..................................................
................ SP002324 Counterweight...........
..................................................
.......................... SP002558 Fuel
Tank..............................................
................................................
SP002559 Fuel Transfer Pump (Option)
..................................................
.............. SP002560 Swing Bearing.............
..................................................
........................ SP002329 Lower
Structure and Chassis Track Assembly
..................................................
..................................
SP002561 Engine and Drivetrain
Engine............................................
..................................................
..... SP002540 Engine Coolant Heater (Option)
..................................................
......... SP002328 Drive Coupling (Main
Pump).............................................
.................... SP002562 Hydraulics Hydrauli
c System Troubleshooting, Testing and Adjustment
............... SP002563 Accumulator.............
..................................................
........................... SP002455 Center Joint
(Swivel)..........................................
................................... SP002545
3
Cylinders.........................................
..................................................
.... SP002564 Swing Device .......................
..................................................
............... SP002565 Travel
Device............................................
............................................
SP002566 Main Pump................................
..................................................
.......... SP002567 Gear Pump ....................
..................................................
..................... SP002568 Main Control Valve
..................................................
............................. SP002569 Fan Motor
for Oil Cooler ...................................
.................................... SP002576 Fan
Motor for Radiator................................
..........................................
SP002577 Fan Pump ................................
..................................................
........... SP002583 Remote Control Valve (Work
Lever / Joystick) ................................
..... SP002578 Travel Control Valve (with
Damper)...........................................
........... SP002381 Solenoid Valve Assembly
..................................................
................... SP002406 Breaker EPPR Valve
(Option) .........................................
..................... SP002458 Hydraulic
Schematic.........................................
....................................
SP002570 Electrical System Electrical System
..................................................
................................
SP002571 Electrical Schematic ....................
..................................................
....... SP002572 Attachments Boom and
Arm...............................................
.......................................
SP002573 Bucket...................................
..................................................
.............. SP002574
4
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Track Excavator Maintenance
Safety
SP002618
Edition 1
Track Excavator Maintenance Safety
SP002618 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
DX490LC-3 10001 and Up
DX530LC-3 10001 and Up
SP002618 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.
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
SP002618
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 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.

SP002618 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 must be relieved before maintenance
is started. Releasing trapped pressure can cause
sudden machine movement or attachment movement.
Use caution if you
FG018457
Figure 1
Track Excavator Maintenance Safety Page 8
SP002618
10
disconnect hydraulic lines or fittings. High-press
ure 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
SP002618 Page 9
Track Excavator Maintenance Safety
11
Track Assembly
SP002561
Edition 1
Track Assembly
SP002561 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
DX490LC-3 10001 and Up
DX530LC-3 10001 and Up
SP002561 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
SP002561
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
SP002561 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" 380 - 410 mm (14.96 - 16.14 in)
Muddy, Sandy or Snowy "C" 410 - 460 mm (16.14 - 18.11 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
SP002561
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 or
no maintenance or renewal is possible. Compare
the values in the tables with dimensions and
profiles shown in the adjacent figures.
SP002561 Page 9
Track Assembly
17
Track Shoe
8 7
10
7
2
2
9
11
1
3
6
4
5
FG018732
Figure 4
Track Assembly Page 10
SP002561
18
No. Check Item Standard Dimension 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 215.9 mm (8.50") 215.9 mm (8.50") 215.9 mm (8.50") 215.9 mm (8.50")
2 Bushing Outside Diameter 71.0 mm (2.80") 71.0 mm (2.80") 71.0 mm (2.80") 71.0 mm (2.80") 68.0 mm (2.68") 68.0 mm (2.68") 66.0 mm (R) (2.60")
3 Link Height 129 mm (5.08") 129 mm (5.08") 129 mm (5.08") 129 mm (5.08") 126 mm (4.96") 126 mm (4.96") 122 mm (P) (4.80")
4 Length at Tip 24 mm (0.94") 24 mm (0.94") 24 mm (0.94") 24 mm (0.94")
5 Length at Tip 18 mm (0.71") 18 mm (0.71") 18 mm (0.71") 18 mm (0.71")
6 Height 36 mm (1.42") 36 mm (1.42") 36 mm (1.42") 36 mm (1.42") 32 mm (1.26") 32 mm (1.26") 30 mm (1.18")
7 Interference between bushing and link Standard Dimension Tolerance Standard Dimension Tolerance Tolerance Standard Interference Repair Limit
7 Interference between bushing and link Standard Dimension Shaft Standard Dimension Hole Tolerance Standard Interference Repair Limit
7 Interference between bushing and link 71.4 mm (2.81") 0.05 0.0 71.0 mm (2.80") 0.074 0.0 0.45 0.326 0.326 - 0.45
8 Interference between regular pin and link Standard Dimension Tolerance Standard Dimension Tolerance Tolerance Standard Interference Repair Limit
8 Interference between regular pin and link Standard Dimension Shaft Standard Dimension Hole Tolerance Standard Interference Repair Limit
8 Interference between regular pin and link 47.0 mm (1.85") 0.285 0.135 46.8 mm (1.84") 0.062 0.0 0.485 0.273 0.273 - 0.485
9 Clearance between regular pin and bushing Standard Dimension Tolerance Standard Dimension Tolerance Tolerance Standard Interference Repair Limit
9 Clearance between regular pin and bushing Standard Dimension Shaft Standard Dimension Hole Tolerance Standard Interference Repair Limit
9 Clearance between regular pin and bushing 47.0 mm (1.85") 0.285 0.135 47.9 mm (1.89") 0.5 0.0 1.265 0.615 0.615 - 1.265
10 Interference between master pin and link Standard Dimension Tolerance Standard Dimension Tolerance Tolerance Standard Interference Repair Limit
10 Interference between master pin and link Standard Dimension Shaft Standard Dimension Hole Tolerance Standard Interference Repair Limit
10 Interference between master pin and link 47.0 mm (1.85") 0.11 0.08 46.8 mm (1.84") 0.062 0 0.31 0.218 0.218 - 0.31
11 Clearance between master pin and bushing Standard Dimension Tolerance Standard Dimension Tolerance Tolerance Standard Interference Repair Limit
11 Clearance between master pin and bushing Standard Dimension Shaft Standard Dimension Hole Tolerance Standard Interference Repair Limit
11 Clearance between master pin and bushing 47.0 mm (1.85") 0.11 0.08 47.9 mm (1.89") 0.5 0.0 1.32 0.79 0.79 - 1.32
SP002561 Page 11
Track Assembly
19
Lower Roller
3
4
5
6
2
1
FG018733
Figure 5
No. Check Item Standard Dimension Standard Dimension Standard Dimension Standard Dimension Recommended Limit for Maintenance Recommended Limit for Maintenance Limit for Use (Repair - P or Replace - R)
1 Outside Diameter of Flange 250 mm (9.84") 250 mm (9.84") 250 mm (9.84") 250 mm (9.84")
2 Outside Diameter of Tread 200 mm (7.87") 200 mm (7.87") 200 mm (7.87") 200 mm (7.87") 194 mm (7.64") 194 mm (7.64") 175 mm (R) (6.89")
3 Width of Tread 54.6 mm (2.15") 54.6 mm (2.15") 54.6 mm (2.15") 54.6 mm (2.15") 64 mm (2.52") 64 mm (2.52") 71 mm (P) (2.80")
4 Width of Flange 34.4 mm (1.35") 34.4 mm (1.35") 34.4 mm (1.35") 34.4 mm (1.35")
5 Clearance between shaft and bushing Standard Dimension Tolerance Standard Dimension Tolerance Tolerance Standard Interference Repair Limit
5 Clearance between shaft and bushing Standard Dimension Shaft Standard Dimension Hole Tolerance Standard Interference Repair Limit
5 Clearance between shaft and bushing 85 mm (3.35") -0.08 -0.13 85 mm (3.35") 0.5 0.45 0.63 0.53 0.53 - 0.63
6 Interference between roller and bushing Standard Dimension Tolerance Standard Dimension Tolerance Tolerance Standard Interference Repair Limit
6 Interference between roller and bushing Standard Dimension Shaft Standard Dimension Hole Tolerance Standard Interference Repair Limit
6 Interference between roller and bushing 92 mm (3.62") 0.23 0.18 92 mm (3.62") 0.03 -0.02 0.25 0.15 0.15 - 0.25
Track Assembly Page 12
SP002561
20
Upper Roller
4 3
2
6
1
5
FG019393
Figure 6
No. Check Item Standard Dimension Standard Dimension Standard Dimension Standard Dimension Recommended Limit for Maintenance Recommended Limit for Maintenance Limit for Use (Repair - P or Replace - R)
1 Outside Diameter of Flange 210 mm (8.27") 210 mm (8.27") 210 mm (8.27") 210 mm (8.27")
2 Outside Diameter of Tread 180 mm (7.09") 180 mm (7.09") 180 mm (7.09") 180 mm (7.09") 171 mm (6.73") 171 mm (6.73") 162.5 mm (R) (6.40")
3 Width of Tread 47.5 mm (1.87") 47.5 mm (1.87") 47.5 mm (1.87") 47.5 mm (1.87")
4 Width of Flange 17.5 mm (0.69") 17.5 mm (0.69") 17.5 mm (0.69") 17.5 mm (0.69") 11.5 mm (0.45")
5 Clearance between shaft and bushing Standard Dimension Tolerance Standard Dimension Tolerance Tolerance Standard Interference Repair Limit
5 Clearance between shaft and bushing Standard Dimension Shaft Standard Dimension Hole Tolerance Standard Interference Repair Limit
5 Clearance between shaft and bushing 68 mm (2.68") -0.05 -0.1 68 mm (2.68") 0.19 0.13 0.29 0.18 0.18 - 0.29
6 Interference between roller and bushing Standard Dimension Tolerance Standard Dimension Tolerance Tolerance Standard Interference Repair Limit
6 Interference between roller and bushing Standard Dimension Shaft Standard Dimension Hole Tolerance Standard Interference Repair Limit
6 Interference between roller and bushing 68 mm (2.68") 0.19 0.13 68 mm (2.68") 0.03 -0.02 0.17 0.1 0.1 - 0.17
SP002561 Page 13
Track Assembly
21
Front Idler
4 3 5
7
6
1 2
FG019394
Figure 7
No. Check Item Standard Dimension Standard Dimension Standard Dimension Standard Dimension Recommended Limit for Maintenance Recommended Limit for Maintenance Limit for Use (Repair - P or Replace - R)
1 Outside Diameter of Flange 682 mm (26.9") 682 mm (26.9") 682 mm (26.9") 682 mm (26.9")
2 Outside Diameter of Tread 680 mm (26.8") 680 mm (26.8") 680 mm (26.8") 680 mm (26.8") 610 mm (24.02") 610 mm (24.02") 605 mm (R) (23.82")
3 Width of Protrusion 102 mm (4.02") 102 mm (4.02") 102 mm (4.02") 102 mm (4.02")
4 Total Width 203 mm (7.99") 203 mm (7.99") 203 mm (7.99") 203 mm (7.99")
5 Width of Tread 50.5 mm (1.99") 50.5 mm (1.99") 50.5 mm (1.99") 50.5 mm (1.99") 53.5 mm (2.11") 53.5 mm (2.11") 55.5 mm (2.19")
6 Clearance between shaft and bushing Standard Dimension Tolerance Standard Dimension Tolerance Tolerance Standard Interference Repair Limit
6 Clearance between shaft and bushing Standard Dimension Shaft Standard Dimension Hole Tolerance Standard Interference Repair Limit
6 Clearance between shaft and bushing 110 mm (4.33") 0.15 0.1 110 mm (4.33") 0.5 0.43 0.4 0.28 0.28 - 0.4
7 Interference between roller and bushing Standard Dimension Tolerance Standard Dimension Tolerance Tolerance Standard Interference Repair Limit
7 Interference between roller and bushing Standard Dimension Shaft Standard Dimension Hole Tolerance Standard Interference Repair Limit
7 Interference between roller and bushing 117 mm (4.61") 0.24 0.17 117 mm (4.61") 0.09 -0.05 0.19 0.08 0.08 - 0.19
Track Assembly Page 14
SP002561
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
• Move machine until master link (4, Figure 9) is
  positioned at approximately 4 o'clock from top
  position on front idle roller.
• Put a wooden block under track shoes, as shown.

2 1 4 FG004355
Figure 9 4. 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.

SP002561 Page 15
Track Assembly
23
7. 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
SP002561
24
FRONT IDLER ROLLER Parts List
6
9
1
2
8
7 4
3
4 5
6
7
8
9
3
FG003913
Figure 15
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
Track Assembly Page 18
SP002561
25
Front Idler Roller Disassembly 1. Remove plug (9,
Figure 16) from idler assembly (1), and drain
oil into a suitable container.
9
FG003914
Figure 16 2. Separate the pin (6, Figure 17)
from the bearing (3).
6
3
FG003915
Figure 17
3. Use a press to remove bearing from the axle
(4). Separate the O-ring (8, Figure 18) from the
axle.
4
3
8
FG001482
Figure 18
4. Remove the floating seal (7, Figure 19) from
the idler (2) and bearing (3).
3
7 2 7
3
FG001483
Figure 19
SP002561 Page 19
Track Assembly
26
5. Use a press to separate the axle (4, Figure
20), O-ring (8) and bearing (3).
8 3
4 FG001484
Figure 20 6. Remove bushing (5, Figure 21) with
the press and special tool (10, ST-1909). 10
5
2
FG001485
Figure 21
Track Assembly Page 20
SP002561
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 FG001486
Figure 22
4. Install floating seal (7, Figure 23) inside
the idler (2) and bearing (3).
3
7
NOTE
Apply clean engine oil to the joint side of the
floating seal. Apply grease to the floating seal
O-ring.
2
7
3
FG001483

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

NOTE
Fill the idler assembly with new gear oil (ISO VG
220 EP/VI 130) with approximately 420 cc (14.2
oz).
6
2
3
7. Install plug (9, Figure 29) on the bearing.
9
FG001488
Figure 24
SP002561 Page 21
Track Assembly
29
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