Atlas Copco Undercarriage of 700 Series Drilling Rigs

UNDERCARRIAGE
MODEL: ACGT/700
Read the instruction manual before operating this equipment.
This manual contains important safety information.

Do not destroy this manual.
This manual must be available to personnel who operate and maintain this machine.
CPN 57678203 LH, 57678211 RH 07/2004 REV 001

This page is intentionally blank.
Model: 700 Series Undercarriage
57678203 LH, 57678211 RH
Table of Contents
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1. SAFETY AND DANGER INSTRUCTIONS . . . . . . . . . . . . 3
1.1. To Be Observed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Manufacturer’s Declaration (only valid in Europe) . . . . . . . . . . . . . . . . 5
1.3. Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2. OPERATING AND SERVICE INTRUCTIONS . . . . . . . . . 9

2.1. General Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.2. Inspection Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.3. Tightening Torque Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.4. General Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3. DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.1. Drive – Function and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.2. Drive – Fitting and Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4. FRONT IDLER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

4.1. Front Idler Unit --- Function and Description . . . . . . . . . . . . . . . . . . . . 29
4.2. Front Idler Unit – Fitting and Removal . . . . . . . . . . . . . . . . . . . . . . . . . 33
5. CARRIER ROLLERS / SUPPORT RAILS . . . . . . . . . . . . . 37

5.1. Carrier Rollers/Support Rails – Function and Operation . . . . . . . . . . . 37
5.2. Carrier Rollers/Support Rails --- Fitting and Removal . . . . . . . . . . . . . 38
6. TRACK ROLLERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6.1. Track Rollers – Function and Operation . . . . . . . . . . . . . . . . . . . . . . . . . 39
6.2. Track Rollers – Fitting and Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7. CRAWLER TRACK AND GROUSER SHOE . . . . . . . . . . 41

7.1. Crawler Track and Grouser Shoe – Function and Operation . . . . . . . . 41
7.2. Crawler Track and Grouser Shoe – Fitting and Removal . . . . . . . . . . . 42
8. OTHER/SPECIAL COMPONENTS . . . . . . . . . . . . . . . . . . 67
8.1. Track Guide --- Function and Operation . . . . . . . . . . . . . . . . . . . . . . . . . 67
8.2. Track Guide – Fitting and Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
8.3. Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
9. UNDERCARRIAGE WEAR GUIDELINES / MEASUREMENT

TECHNIQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
9.1. Measurement Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
9.2. Front Idler Wear Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
9.3. Bottom Roller Wear Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
9.4. Top Roller Wear Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
9.5. Track Measurement - Link Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
9.6. Track Measurement - Chain Pitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
9.7. Track Measurement - Bushing Diameter . . . . . . . . . . . . . . . . . . . . . . . . 77
9.8. Sprocket Tooth Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
9.9. Track Wear Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
9.10. Estimating Remaining Wear Life and Service . . . . . . . . . . . . . . . . . . . . 80
WARNING: This manual contains data SPECIFIC to: 700 Series Undercarriage. page i
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Table of Contents
PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
57678203 TRACK,LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
57695611 IDLER UNIT,TRACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
57695629 ROLLER,TRACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
57695637 ROLLER,CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
52300654 FINAL DRIVE,TEIJIN SEIKI . . . . . . . . . . . . . . . . . . . . . 90
57713182 REDUCTION GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
57713497 MOTOR,HYDRAULIC . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
57695702 CHAIN,TRACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
page ii WARNING: This manual contains data SPECIFIC to: 700 Series Undercarriage.
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MAINTENANCE
SECTION
MAINTENANCE
WARNING: This manual contains data SPECIFIC to the 700 SERIES UNDERCARRIAGE page 1
57678203 LH, 57678211 RH
SECTION

MAINTENANCE
page 2 WARNING: This manual contains data SPECIFIC to the 700 SERIES UNDERCARRIAGE
57678203 LH, 57678211 RH
1. SAFETY AND DANGER INSTRUCTIONS
1.1. To Be Observed
1.1.1 Warnings
Throughout the manual, Dangers, Warnings, Cautions, Notices and Notes are used to designate
instructions of particular importance.
In this manual, these terms have the following significance:
DANGER Danger is used to indicate the presence of a hazard which will cause severe
personal injury, death, or substantial property damage if the warning is
ignored.
WARNING Warning is used to indicate the presence of a hazard which can cause severe
personal injury, death, or property damage if the warning is ignored.
CAUTION Caution is used to indicate the presence of a hazard which will or can cause
minor personal injury or property damage if the warning is ignored.
NOTICE Notice is used to notify people of installation, operation, or maintenance

information which is important but not hazard related. Hazard warnings
should never be included under the Notice signal word.
NOTE: Note is used for supplementary information not directly effecting safety or
damage to equipment.
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1.1.2 Forward
These operating instructions are a part of the scope of delivery. They are to be kept close at hand
and are to remain with the machine if being sold again.
All details, data and illustration contained in these operating instructions are subject to change as
result of technical developments. All rights reserved.
These operating instructions are not subject to any update service.
Information on latest developments can be obtained from:
Atlas Copcp Company

Drilling Solutions
2100 North First Street
PO Box 462288
Garland, Tx 75046 2288
Parts Customer Service

800 634 6410
The illustrations in this manual are only diagrammatic and may differ from the actually installed
components of the respective undercarriage. In addition, it is possible that there may also be other
components on the undercarriage that are not described in this manual. Conversely, there may also
be components and their functions are subject to technical change.
All components and their functions are subject to technical change.
1.1.3 Warranty
Applicable conditions of warranty are stipulated in the confirmation of order.
Warranty rights become void in the event of:
S Damage as a result of malfunctions caused by incorrect use or incorrect operation.

S Repairs or alterations carried out by persons who are neither trained nor authorized
to do so.
S Damage being caused by accessories or spare parts being used for which approval
has not been provided by the manufacturer.
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1.2 Manufacturer’s Declaration (only valid in Europe)
Manufacturer’s Declaration
in compliance with EC Directive
for Machinery 98/37/EC
Manufactured For:
Atlas Copcp Company
Drilling Solutions
2100 North First Street
PO Box 462288
Garland, Tx 75046 2288
Subject:
Manufacturer’s declaration by Atlas Copco in compliance with art. 4, par. 2 of the EC Directive for
Machinery.
The technical product described below in further detail is designed exclusively for installation in a
machine.
Starting up the porduct is forbidden until conformit;y has been established of the end product with
the directive 98/37/EWG. This declaration becomes void in the event of any alterations to the
technical product that have not been approved by the manufacturer.
Crawler undercarriage as described in the section Operating and Service Instructions.
Other applicable harmonized standards:
DIN EN 25817 for welding work

DIN EN 10029 for sheet steel used
Other applicable national standards and technical specifications:
See annex “Technical Description” to the order confirmation
1.3. Safety Instructions

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1.3.1 In General
This undercarriage has been constructed to “state of the art” standards and is operationally safe.
Nevertheless, machines can be the source of danger if they continue to be operated although a fault
is suspected or has already occured or it has been repaired incorrectly.
Under these circumstances there is
S Danger to life and limb

S Danger to the machine and other facilities and equipment, etc.
The machine must be shut down immediately if a fault is spected or has already occurred which could
endanger the safety of the operator, other persons on site or surrounding facilities and equipment,
etc.
All components have been carefully matched to each other. Fault free operation and a long service
life are only possible if original spare parts are used.
1.3.2 Regulations for Work Safety

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Personnel
Only properly trained and authorized personnel with appropriate specialist knowledge are to be ap-
pointed with maintenance and repair work.
Appropriate measures must be taken before commencing any work on the undercarriage to ensure
that the equipment cannot start up unintentionally or be started up inadvertently by others (e.g.
blocks). All switching on andoff procedures must be observed for this.
Protective equipment and clothing is mandatory for all work. Wear protective helments, shoes and
gloves. Close fitting clothes help to avoid injuries.
If assistants are required to help in carrying out work, responsibilities must be clarified beforehand
so that there is no possibility of unclear competence occuring with regard to safety aspects.
Tools and Equipment
Tools, lifting gear, fastening devices, jacks and other working equipment must be in a safe operation-
al and working conditions.
All lifting and fastening devices on the crawler undercarriage are only designed for the transporta-
tion of the undercarriage unless otherwise specified.
Metal splinters may break off and cause injuries when driving equipment bolts in or out. For this
reason, alsways wear safety goggles when driving bolts in or out.
Equipment or components which are being fitted or removed or where their installation position is
being changed must be secured against unintentional movement, slipping or falling over using suit-
able slifting gear of suspension/support devices.
Systems and units (i.e. tensioning units) must be depressurized in an appropriate manner before
opening.
Damaged hydraulic or mechanical pre tensioned spring elements must be exchanged as a complete
unit. Further information in this respect can be found in the respective component descriptions
and/or fitting and removal instructions.
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57678203 LH, 57678211 RH
2. OPERATING AND SERVICE INTRUCTIONS
2.1. General Maintenance Instructions
2.1.1 Handling Hydraulic Substances and Lubricants
The relevant applicable safety regulations for the respective products must be observed when han-
dling oil, grease or other chemical substances.
Suitable safety measures must be taken to avoid scalding and burning when the machine is warmed
up (i.e. at operating temperature), as operating media are then at least the same temperature.
Do not smoke if handling combustible fluids.
Caution with fire and naked flames. Not only fuel but also other operating media often have a low
flash point and ignite easily.
Lubricants that are not being reused must be disposed on in an environmentally friendly way.
2.1.2 Conversions or Changes to the Undercarriage
Unauthorized conversions or changes are not permitted for safety reasons. The rated pressure of con-
nected pressure relief valves and pressure tanks must not be altered.
Seals on units must not be removed.
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2.1.3 Before Starting Up
Before starting up:
S Lubricate all lubrication points

S Check all oil levels and adjust if necessary
S Check function of all repaired components
S Carry out visual inspection of all components
2.1.4 Wear Limits of Undercarriage Parts
Wear of the undercarriage is caused by movements, loads contact between parts of the undercarriage
and abrasive action of the ground.
This is increased by other factors including:
S Track resting on hard uneven rock bed during operation

S One sided undercarriage load during turning
S Driving long distances in reverse
S Driving over obstructions recklessly
S A track which is not tensioned according to operating conditions
S A large degree of dirt on complete undercarriage
Undercarriage components must be replaced by new parts if they are worn to 100 %. Otherwise ,
sudden machine failure is possible.
Careful and regular measurements are necessary in order to establish the extent of wear and when
replacements will be necessary.
The parts involved and measuring parts must be cleaned thoroughly when carrying out
measurements. If possible, carry out measurements at several points. The degree of wear is
determined by the maximum value, not the average value.
Wear limits are shown on the wear tables.

(Tables are not included with the manual. They can be ordered from the manufacturer).
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2.2. Inspection Intervals

Table (OH: = Operating Hours)
Component Interval Inspection Extent of Maintenance Work Description

Track Undercarriage Dai- Visual Extent of undercarriage dirtiness Chapter:
ly Track
General condition of the
undercarriage
undercarriage components
Fastening elements of frame
sections and undercarriage
fastenings
Monthly Visual Fastening elements of frame
sections and undercarriage
fastenings – grouser shoe
fastening (spot check)
Drive Dai- Visual Seal of gear – motor unit and Chapter:
ly possible hydraulic connections Drive
200 – 250 Check Gearbox oil level
OH
300 – 2000 Gearbox oil change

OH,
but less
than 1 year
Monthly Check Condition of and wear on
sprocket
Front Idler Unit Dai- Visual General state of spring and Chapter:
ly tension system Front idler unit
Weekly Seal of the front idler and the
tensioning system
Re–tensioning span of the
track (max. possible tensioning
span reached)
Check Condition of and wear on
front idler and sliding blocks
Track Rollers Dai- Visual Check for leakage Chapter:
ly
Monthly Check Condition of and wear on Track roller unit
track roller
Carrier Rollers and/or Dai- Visual Check for leakage Chapter:
Wearing Rails ly
Monthly Check Condition of and wear on Track roller unit
carrier roller
Crawler Track with Dai- Visual Check for leakage (only on oil or Chapter:
Grouser Shoes ly grease lubricated tracks) Crawler track with
Track pre-tensioning – track sag grouser shoes
Monthly Check Condition of and wear on track
link running surfaces, bushings
(outer diameter), and stretching
of track.
Condition of and wear on the
grouser shoes
Changes to intervals are possible depending on extent of use and operating conditions for the machine.
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2.3. Tightening Torque Tables
These tables do not apply for fastening the base plate to the track.
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2.4. General Instructions
2.4.1 Serial Number
All undercarriages or slide frames have a serial number for identification.
This number looks like the following example:
12345–1
The first part is the order number of the order confirmation.

The second part is the serial number for the undercarriage or side frame.
The number is embossed on the cover plate of the side section of the drive (design can vary according
to customer specification).
This number is always required when calling with inquiries or complaints.
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2.4.2 Structural Design of a Standard Crawler Undercarriage
The undercarriage is designed to meet universal demands. It consists of a central frame and two side
frames for mounting additional machine or undercarriage parts. The central frame can be welded
direct onto the side frames or bolted on the flange connection.
A simplification of the complete design has been achieved through using assemblies and/or
modules.
2.4.3 Operating Times

Standard designs –20ºC to +40ºC
Special designs –40ºC to +40ºC
Please contact the manufacturer for advice if intending to use the final drive or components in other
operating conditions (temperatures).
2.4.4 Function and Operation
The crawler undercarriages are supplied by the manufacturer without operating and drive units. The
operating instructions of the suppliers and the manufacturers must be observed for these parts.
2.4.5 General Assembly and Disassembly Instructions
Assembly Instructions
The crawler undercarriages are supplied as a complete unit.
All necessary assembly work on components to be exchanged is described in the respective
individual chapters.
Disassembly Instructions
Disassembling individual assemblies or components upon having reached their wear limits or in the
case of any failur occurrences is described separately for each component in the individual chapters.
We recommend not carrying out any repair work on the building site, but exchanging the component
instead.
We recommend getting in contact with Atlas Copco in the event of any major damage or repeated
failure of individual components.
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3. DRIVE
3.1. Drive – Function and Operation
3.1.1 General Danger Instructions
Danger can occur in particular under the following circumstances:
S Product is handled insufficiently trained personnel

S Incorrect installation, operation and maintenance/repair
S The product is not being used for its designated purpose
Alterations to the product are not permitted unless approved beforehand.
The transmission is designed exclusively for use as drive transmission for an undercarriage.
3.1.2 Instructions on Transport and Storage
S Please ensure that the crane or hoisting equipment has a sufficient load capacity
when lifting/transporting the transmission
S Only use approved transport elements
S Fasten the transmission carefully onto the crane hook and use suspension
devices according to the size of the transmission
S Make sure that no parts attached to the transmission can be damaged by
transport elements when lifting the transmission
S The transmission may only be stored in dry, heated rooms
S Make sure that the position of the transmission cannot change (tumble over, slip,
fall etc.) at point of storage
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3.1.3 Design of the Drive
The design of the track undercarriage consists of a complete unit

This unit consists of a fully encapsulated, multi–stage hi–performance planetary gear and the
sprocket. The gear is driven direct by hydraulic or electric flange–mounted motors.
The sprocket is available in standard, HD or special design with dirt pockets for packing ground
conditions.
Components adjoining the track are surpace hardened to minimise wear. The connection to the
driving wheel and transmission is established with HF bolt. The necessaryi torque levels for these
are shown in the attached tables.
The drive traction is transmitted to the track via the motor, transmission and sprocket.
1. Compact Transmission
2. Sprocket
3. Diagram of a Servo–Hydraulic Motor
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3.1.4 Description of the Transmission
The transmissions of the type series being used for the undercarriage have multi–stage planetary gear
depending on design.
A particular feature of the gear is its very compact and therefore space-saving design.
The gear can be fitted witrh an integrated multi-disc brake, which acts as parking brake. This is
activated by spring force and released hydraulically with pressure oil. The multi-disc brake must be
released without fail before switching on the hydraulic drive.
As a special design, the transmission can be supplied with a mechanical disengaging

mechanism enabling the transmission and hydraulic motor to be separated from each other,
e.g. if towing the machine following failure of the machine’s hydraulic system.
3.1.5 Commissioning
S Prevent the transmission from getting dirty

S Avoid pollution. Make sure not to spill any lubricant when filling
The transmission is supplied ready for installation without oil filling. Starting up or using the drive
without any lubricant would lead to rapid destruction of the transmission. See the chapter “Filling
with Transmission Oil” for checking and filling oil.
The transmission has been treated internally with a preservative agent that provides approximately
6 months of protection against corrosion, if stored in dry conditions. This internal preservative does
not have to be removed at start-up.
When fitting hydraulic lines for parking brakes abed hydraulic motor, make sure that no dirt or other
foreign bodies get into the transmission or hydraulic motor.
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3.1.6 Lubricants
Normal Operating Conditions (+10ºC to +30ºC)
Use only lubricants with viscosity ratings for ISO–VG 150 and ISO–VG 220 for normal operating
conditions from +10ºC to +30ºC.
Severe Operating Conditions (–30ºC to +50ºC)
Sever operating conditions indicate ambient temperature ranging from –30ºC to +50ºC.
Transmission oil with the appropriate viscosity is recommended. Fully synthetic lubricants can be
used.
For lower operating temperatures, use oil with a lower viscosity (SAE 80W–90). For higher
operating temperatures, use oil with a higher viscosity (SAE 85W–140).
3.1.7 Compact Transmission with Drive Motor
Connecting the locating flange of the side frame as well as the sprocket is achieved using adequately
dimensioned bolt connections. Transmission of torque is achieved by frictional locking.
Remove the protective caps when connecting the hydraulic hoses. Ensure no dirt or contaminants
enter the supply lines during the assembly process.
Observe and monitor:

S hydraulic pressure limits,
S maximum and minimum volume flow rates,
S allowance of oil leakage,
S brake air pressure.
If necessary, contact the manufacturer for permitted values.
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3.1.8 Parking Brake
The multi-disc brake incorporated into the transmission is a parking brake that is kept constantly
closed by pressure springs. The maintenance-free brake is designed as a separated compact unit and
should only be removed from the transmission and exchanged as a complete unit. This design
protects all individual componlents shuch as discs, springs, sealing elements etc. against outside
influences. Any repair work should only be carried out by a specialist workshop.
Feeding hydraulic oil either direct or via the drive brake valve and a connecting line to the brake
connection of the compoact unit opens the brake.
Pressure ranges within which the brakes can be vented must be observed. Only completely
vented brakes allow wear-free and fault free operation of the complete drive.
Use of separate hydraulic circuit for supplying the brakes is recommended of operating without a
parking brake valve.
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3.1.9 Unlocking the Parking Brake
The transmission is fitted with a disengaging gear. The disengaging gear is used to change the
transimission into neutral, i.e. the motor and transmission are disengaged without releasing the
brake. This neutral position is of special importance when the machine is to be towed:
S at higher speeds
S over longer distances
S without actuating the hydraulics.
The transmission must be protected from undue heating during travelling.
Undercarriages with drive units that are fitted with parking brakes cannot be moved when the
hydraulic system is not functioning. For this reason, it is possible to fit the undercarriage with an
unlocking mechanism.
DISCONNECT
COVER DISCONNECT
COVER
DISCONNECT
PIN DISCONNECT
PIN
ENGAGED DISENGAGED
Procedure for Disengagement of Gearing
The disconnect cover is secured with twp bolts (tightening torque 53 Nm).
To disengage both bolts have to be removed. Reverse and install the disconnect cover while pressing
the pin with it. Install and tighten the two bolts. Torque the bolts to 260 43 IN. LBS. (29.4 4.90
NSm).
ATTENTION! To avoid damage of gear teeth, it is absolutely necessary that disengagement

and re-- engagement is carried out with the machine at a standstill.
Re–engagement is carried out in the reverse steps.
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3.2. Drive – Fitting and Removal
Whenever working on the drive, always use suitable means to secure the machine against
starting up by itself or being started by others.
The undercarriage that is not connected with the track by the sprocket is not secured against
movement by the transmission brake. This means that the undercarriage must be secured separately
when removing the drive.
Opening the track first is a precondition for fitting/removing the drive (see “Track” chapter).
S Notes on transmission oil must be observed

S All parts being fitted must be clean and free of grease
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3.2.1 Connecting Frame--Transmission Sprocket
6
5
4
3
The transmission [1] must be inserted carefully into the side frame so that there is no damage to the
flange surfaces. Check transmission seating for correct installation. Fasten the transmission in place
by inserting bolts [5] and washer [6] in the frame. Screw into place by hand. Check again to ensure
that transmission seating is correct.
Pre–tighten all bolts by hand in a crosswise manner (see illustration below as an example).
30 1 5
29 6
28 7
27 8
26 9
25 10
24
3
4 11
23 12
22 13
21 14
20 15
19 16
18 17
2
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Further Instructions
S Clean all locating/joining surfaces thoroughly.

S Lift the transmission carefully into the locating flange of the
undercarriage using appropriate hoisting gear.
S Fasten the transmission securely onto the undercarriage frame, before
removing the hoisting attachments.
S Avoid any axial forces when installing
S Avoid any excessive force on the transmission housing.
S The transmission must not be tilted.
S Pay attention that no dirt or foreign particles get into the hydraulic
system.
S The musti–disc parking brake is a transmission safety device. Ensure no
dirt or foreign bodies get into the brake air connection.
S The brake air system must be carefully sealed.
S Do not allow any pressure build up in the brake line.
Connecting Sprocket – Transmission
Clean all locating/joining surfaces thoroughly. Hoist the sprocket with hoisting gear onto the
transmission and tighten onto the hub of the transmission without an;y heavy knocks.
Insert the bolts and washers for fastening the sprocket into the holes and screw into the thread in the
transmission by hand. Pre–tighten all bolts in the correct order and then to correct tension using a
torque wrench (see torque level table).
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3.2.2 Removing Sprocket
Slacken of track and undo track lock (see “Track” chapter).
Remove dirt from all parts and fastening elements. Use hoisting gear to secure the sprocket against
falling over. Undo the bolts on the driving wheel crosswise and remove completely.
Remove the driving wheel from transmission seat by tapping lightly with a rubber hammer. If
provided, insert pull–off bolts into provided threaded holes and tighten evenly. Push the sprocket
off the transmission seat in this way and lift out using the hoisting gear.
3.2.3 Removing Transmission
Remove dirt from all parts and fastening elements. Use hoisting gear to secure the
transmission against falling over. Undo the bolts on the frame crosswise and remove
completely.
Loosen the transmission from the frame seat by tapping lightly with a rubber hamer, then lift the
transmission out of the frame carefully using the hoisting gear.
S Catch any dripping/leaking oil in suitable containers.

S Only use approved transporting elements for transportation.
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3.2.4 Drive–Maintenance and Inspection
General Instructions
The complete drive unit consists of the following components:

S Motor
S Sprocket
S Transmission
S Integrated Brake (only on request)
S Disengaging Mechanism (only on request)
Always replace the component if it fails. Only use qualified mechanics for repairs.
3.2.5 Adding and Changing Transmission Oil
The transmission must be filled with fresh, clean oil before initial start–up (see details of
lubricants for types of oil).
See the “Inspection Intervals” table for intervals for oil checks or change.
Adding Transmission Oil:

Drive the machine onto a horizontal surface in a position where appropriate access to the drive
transmission is possible. Position the transmission so that the oil drain plug (2)
OIL LEVEL CHECK PORT OIL FILL PORT

1
DRAIN PORT
57678203 LH, 57678211 RH
Adding Transmission Oil(continued):

1
DRAIN PORT
DRAIN PORT
Position the transmission so that the oil drain plug (2) is positioned vertically at its lowest point
(about 6 o’clock). The oil filler plug (1) should then be on the left or right outside of the transmission
middle (about 10 or 2 o’clock).
Fill with oil until the level has reached the oil level check port. Insert filler plug, then tighten. Insert
the oil level check plug, then tighten.
57678203 LH, 57678211 RH
Draining Transmission Oil:
Danger of scalding or of burns from hot transmission oil. The transmission housing may also
be hot after running for longer periods. Always wear protective gloves and allow the
transmission to cool down first. Collect draining oil in appropriate containers and dispose of
in a environmentally safe manner.
DRAIN PORT
Place oil collection container underneath the transmission. Undo and remove oil filler plug, oil level
check plug, and oil drain plug . Drain oil completely. Insert drain plug with new washer and tighten.
Fill with oil, then insert oil level check plug and oil filler plug, then tighten.
3.2.6 Motor
The motor is maintenance free and only has to be checked visually for leaks during inspection.
57678203 LH, 57678211 RH
3.2.7 Multi–Disc Parking Brake
The multi–disc parking brake is integrated into the transmission on the motor side and is lubricated
by the transmission oil. Because of this design, the brake is maintenance free and consequently only
has to be checked for damage when carrying out a general overhaul of the complete transmission.
The brake circuit must be vented (bled) after working on the brake or the hydraulic
connections.
3.2.8 Disengaging Mechanism
The disengaging clutch is located on the rotor gear side (opposite the motor) and is not subject to
any special maintenance regulations.
57678203 LH, 57678211 RH
4. FRONT IDLER UNIT
4.1. Front Idler Unit - Function and Description
4.1.1 Design of Front Idler Units
Front Idler Units consist of the groups:
1 Front Idler with Sliding Blocks

2 Yoke
3 Spring Unit (Pre–Tensioned)
4 Track Tensioner
1 4
(Illustration indicates a standard front idler unit with spring unit and grease cylinder)
The Front Idler with Sliding Blocks (1) has a lifetime oil lubrication filling. The running surfaces
have been hardened to reduce wear. The Yoke (2) acts as a transmission element between the front
idler and the following components. The Spring Unit (3) acts as protection for the complete under-
carriage against overloads from outer influences (e.g. dirt) and is therefore an important component
of the undercarriage.
IMPORTANT! Any work on the pre–tensioned spring unit MUST be carried out by trained
and qualified personnel.
The Track Tensioner (4) is used for correct setting of track tension. The grease cylinder may be filled
with and operated by either grease or hydraulic oil.
57678203 LH, 57678211 RH
The following applies for pre–tensioned units:
All spring units can either be bolted, inserted or fastened onto the front idler yoke. This ensures easy
fitting removal. The pre–tensioned spring in the frame is an exception.
The pre–tensioned spring is first tensioned when in the undercarriage frame and then secured with
a locking system.
Dismantling the spring units may only be carried out by a qualified specialist. The following
applies to all spring units. REPLACE THE COMPLETE UNIT IF A REPAIR IS
NECESSARY.
Repairing spring units involves extensive safety measures and should only be carried out by
a qualified workshop.
4.1.2 Front Idler Complete with Sliding Blocks and Yoke
The Front Idler Unit fulfills the following functions:
S Deflection with simultaneous guidance of the track

S Positional adjustment via sliding blocks for setting track pre–tension and for
guidance during spring actions.
1 Front Idler
2 Sliding Block
3 Yoke
57678203 LH, 57678211 RH
4.1.2 Front Idler Complete with Sliding Blocks and Yoke (continued)
The Front Idler (1) runs in the Steel Mount (2) with its Sliding Blocks and can move in a longitudinal
direction.
The front idler guidance in the frame is greased at the factory duringi assembly to minimise wear.
Once assembled, the sliding blocks cannot be greased again
4.1.3 Track Tensioner
The track is provided with the necessary pre–tension by the Tensionioning Cylinder. The track’s
tension may need adjustment due to wear or changes in terrain conditions.
1
2
The Tensioning Cylinder (1) is supplied in standard design as a grease–tensioning cylinder. To

extend the cylinder, grease is applied through a special grease nipple (2) on the tensioning cylinder
To retract the cylinder, unscrew the grease nipple until grease starts exit the cylinder.
57678203 LH, 57678211 RH
4.1.3 Track Tensioner (continued)
ACCESS HOLE
STEEL FRAME
ACCESS COVER
Access to the grease tensioner is through the access holes that are located at the sides of the track
frames.
Attention must be spaid to the state of wear on the track in order to avoid damage to the track
tensioner.
Re–tensioning is not permitted after reaching the wear limits for the tracks as this would cause
excess strain on the undercarriage components beyond the permitted limits and there would
nbo longer be any safety against forced breakage
The tensioning cylinder requires a Lithium Grease NLGI Class 2 or 3.
Care must be taken to ensure that fluids are contained during performance of inspection,
maintenance, testing, adjusting and repair of the machine. Be prepared to collect the fluid
with suitable containers before opening any compartment or disassembling any component
containing fluids. Dispose fluids according to local regulations and mandates.
57678203 LH, 57678211 RH
4.2. Front Idler Unit – Fitting and Removal
4.2.1 Fitting Front Idler Unit – In General
Under all circumstances, appropriate steps must be taken whenever working on the front idler
unit to ensure that the device cannot start up of its own accord or through intervention by
others. The gear brake cannot hold a track at the sprocket if the track is unassembled or
broken. THE UNDERCARRIAGE MUST BE SAFELY SECURED BY MEANS OTHER
THAN THE GEAR BRAKE.
WHEN A TENSION ROD IS DAMAGED OR BROKEN, THERE IS A DANGER THAT A

COIL SPRING WILL NOT REMAIN IN ITS PRE--TENSIONED POSITION BUT WILL
FORCE THE FRONT IDLER OUT OF THE FRAME THROUGH SUDDEN
DE--TENSIONING WHEN THE TRACK IS REMOVED. BE AWARE OF THIS DANGER
WHEN RELEASING PRESSURE FROM THE PRE--TENSIONER, YET TENSION DOES
NOT RELIEVE FROM THE TRACKS.
When draining fluids, ensure that adequate sealable containers are available and that every
care is taken to prevent spillage. Always ensure waste fluids are disposed of in an
environmentally safe manner.
The crawler track must be opened prior to installing or removing the front idler unit.
57678203 LH, 57678211 RH
4.2.2 Front Idler Unit – Standard Design
The Front Idler consists of:
S Front Idler complete with Yoke (1 + 2)

S Pre–Tensioned Spring Unit (3)
S Track Tensioner (4)
1 4
(Illustration indicates a standard front idler unit with spring unit and grease cylinder)
Push the piston of the Trach Tensioner in as far as it will go. Screw the washer and grease nipple
into the Tensioner and tighten (shown below).
SCREW IN
PUSH PISTON IN GREASE NIPPLE
57678203 LH, 57678211 RH
4.2.2 Front Idler Unit – Standard Design (continued)
Insert the Track Tensioner from the bottom of the frame so that the grease nipple fits through the
appropriate hole in the plate in the frame. Bolt the tensioner in place and tighten.
Mount the yoke onto the sliding blocks and secure with bolts.
Mount the spring unit onto the yoke and secure with bolts.
57678203 LH, 57678211 RH
4.2.2 Front Idler Unit – Standard Design (continued)
Insert the assembled front idler unit carefully into the greased guide rails of the side sections using
the appropriate lifting device.
Push the front idler unit into place until the spring unit is against the piston of the track tensioner.
Ensure no obstructions exist.
SEAT THE FRONT IDLER UNIT ONTO

THE TRACK TENSIONER
57678203 LH, 57678211 RH
5. CARRIER ROLLERS / SUPPORT RAILS
5.1. Carrier Rollers/Support Rails – Function and Operation
5.1.1 In General
The Carrier Rollers are supplied as a complete unit.The complete unit has to be exchanged in the
event of any damage, repairs or upon reaching wear limits.
5.1.2 Function
The Carrier Rollers are used to guide the track in the upper strand and to support the track as to
minimize track sag, which prevents damage to neighbouring components.
The running surface of the Carrier Rollers have been hardened to prevent wear. The Carrier Rollers
are fitted with a “lifetime” seal to prevent dirt penetration and oil loss.
Carrier Rollers are fitted as a complete unit at the intended installation points above the steel bearers
and are ready for immediate use.
57678203 LH, 57678211 RH
5.2. Carrier Rollers/Support Rails - Fitting and Removal
Slacken the track and undo the track fastener as shown in the chapter covering Tracks. Undo the bolts
of the faulty Carrier Roller. Remove the roller with the proper lifting device. Dispose of the worn
roller properly.
Set the new roller in place using the proper lifting device. Use new bolts to secure the roller in
position.
Once roller is secured in place, re--mount the track as described in the chapter covering tracks.
57678203 LH, 57678211 RH
6. TRACK ROLLERS
6.1. Track Rollers – Function and Operation
6.1.1 In General
The Track Rollers are supplied as a complete unit.The complete unit has to be exchanged in the event
of any damage, repairs or upon reaching wear limits.
6.1.2 Function
The Track Rollers are used to guide the track so that the dynamic forces of the track are transmitted
to the ground as well as to endure the loads coming from the machine.
The running surface of the Track Rollers have been hardened to reduce wear. The Carrier Rollers
are fitted with “lifetime” seals to prevent dirt penetration and oil loss.
Track Rollers are fitted as a complete unit at the intended installation points under the rails and are
ready for immediate use.
57678203 LH, 57678211 RH
6.2. Track Rollers – Fitting and Removal
Slacken the track and undo the track fastener as shown in the chapter covering Tracks. Raise the track
undercarriage using a proper lifting device and clean the dirt off of all parts.
Undo the bolts of the faulty Track Roller. Remove the roller with the appropriate tools. Dispose of
the worn roller properly.
Set the new roller in place using the appropriate tools. Always use new bolts to secure the roller in
position.
Once roller is secured in place, re–mount the track as described in the chapter covering tracks.
57678203 LH, 57678211 RH
7. CRAWLER TRACK AND GROUSER SHOE
7.1. Crawler Track and Grouser Shoe – Function and Operation
7.1.1 Design of the Crawler Track
The Crawler Track consists of segments, which are divided into left and right links. The Grouser
Shoes are bolted onto the Crawler Track.
Master
Bushing
Track Washer Chain
Spacer
Seal RH Chain Master Master
Master Link Bushing Bushing
Spacer
RH Chain
Link
Chain Mas-
ter Pin
Chain
Pin
Left Hand
Master Link Master Pin
Chain Bush- Lock Pin
ing
LH Chain
Link Crawler Track
Segments Grouser
Shoes
The track links and the corresponding bushings are pressed together to form a unit. These units can
be linked to any required length. The shoes are then bolted onto the tracks.
The individual elements of the crawler track have been induction hardened making them extremely
wear resistant.
7.1.2 Function
The Crawler Tracks with Grouser Shoes support the loads of the machine and transmits the drive
output into drive movement. The running surface of the Crawler Track has been hardened to reduce
wear.
57678203 LH, 57678211 RH
7.2. Crawler Track and Grouser Shoe – Fitting and Removal
7.2.1 In General
These instructions describe the correct method of fastening the shoes onto the track. Incorrect
assembly is the most common cause for failure of the connection between grouser shoe and
crawler track.
S Remove all forms of foreign bodies and materials from the contact surfaces
of the links, which could interfere with the connection with the shoes and
bolts (e.g. paint, primer, rust, dirt etc.). Brushing or grinding lightly can
achieve this.
S Clean the contact surfaces and the nut seats of the track links.
S Coat the thread and contact surfaces underneath the bolt heads with thin
layer of oil (preferably) or grease.
Driving hardended pins in or out of the links by hammer involves considerable danger for
personnel as a result of material shearing off. Wear protective eyeware to prevent injuries.
If a pneumatic impact wrench is used to tighten or loosen bolts on grouser shoes, wear
protective appearal, especially eye protection (e.g. safety goggles).
57678203 LH, 57678211 RH
7.2. Crawler Track and Grouser Shoe – Fitting and Removal (Continued)
7.2.1 Assembling Links
Align two link units to each other. Place spacers and bushing as indicated in the illustration below.
Track Link
Bushing
Spacer Track Link
Pin
Set pin in place and tap in until knurled end has started. Place a guiding pipe over the pin and via
a driving pin, drive in pin completely until both ends show with equal lengths out of the links
7.2.2 Fitting Grouser Shoes
It is often underestimated how important it is to observe the correct procedure for fitting the Grouser
Shoes. Incorrect proceedure can result in bolts being over–stretched or worse, damage to the track
links
ALWAYS USE NEW BOLTS AND NUTS FOR FITTING GROUSER SHOES. USED BOLTS
CAN BE DEFORMED AND CAN NO LONGER GUARANTEE OPTIMUM CLAMPING
FORCE.
57678203 LH, 57678211 RH
7.2.2 Fitting Grouser Shoes (Continued)
Remove all forms of foreign material from the contact surfaces of the shoes that could interfere with
connection to the track links. Ensure the threaded areas of the links and the bolts are free from paint,
rust, primer or any other material.
Also clean the contact surfaces and nut seats on the track links.
Front Edge
of Shoe
Place the grouser shoes over the bolthole of the track links (note the direction of the front edge of
the shoe). Coat the thread and contact surfaces underneath the bolt heads with a thin layer of oil
(preferably) or grease.
Insert the bolts into the holes and screw into the nuts by a few turns (ensure the flatter side of the
nut is resting against the nut seat in the track link).
Tighten all bolts fully using a cross pattern as shown in the following illustration.
Do not over–tighten the bolts

57678203 LH, 57678211 RH
7.2.3 Torque Check/Re–Tightening
Due to normal settling occurrences, all bolts should be re–tightened after about 50 operating hours.
Use the same cross pattern tightening system as shown below without undoing the bolts
beforehand..
Do not over–tighten the bolts
Further checks must be made at regular intervals based on the experience on the machine
owner/operator and/or the recommendation of the machine manufacturer. If the bolts can be
tightened by more than a 90º turn at required torque setting during an inspection, have the
complete grouser shoe fitted again as new as described previously.
57678203 LH, 57678211 RH
7.2.4 Fitting Master Links and Master Shoes
The following list recommendations, especially for tracks with split master links, must be
observered in addition to the instructions for “Fitting Grouser Shoes”.
S Carefully clean the threaded holes of the master links.
S Ensure the bolts can be screwed in easily by hand.
S Clean the contact surfaces of the master links.
S Lubricate the cleaned threads and contact surfaces underneath the bolt
heads with a thin coat of oil. Avoid using grease wherever possible or only
use it very sparingly because otherwise it could settle at the base of the
threaded hole and prevent the bolts from being tightened properly.
S Close the master links and tighten the bolts as described earlier.
7.2.5 Tightening Procedure for Track Bolts
The necessary torque for each individual bolt is intended for two different tightening proceedures:
S Torque procedure
S Turning Angle Method
Torque Procedure
Tighten the bolts to the appropriate torque level in the above stated order. The torque level is to be
achieved using a torque wrench which requires a even turning movement (sudden jerking
movements will result in torque peaks and lead to incorrect torque values). Stop tightening as soon
as the required torque has been reached.
Turning Angle Procedure

With this process, the bolts are first tightened in a cross pattern to a pre–set torque according to the
table. Then turn the bolts an additional 120º (1/3 of a turn) to achieve the ideal pre–stress, as well
as a defined plastic deformation of the bolt
In both cases, tightening the bolts in excess of specifications leads to stress on the bolts beyond
the yield point combined with non–permitted plastic deformation and the danger of a
premature failure at the bolt connection.
57678203 LH, 57678211 RH
7.2.5 Tightening Procedure for Track Bolts (Continued)
Table of Torque Values for Track Bolts [Nm]

(Does not pertain to Master Track Bolts)
57678203 LH, 57678211 RH
Table of Torque Values for Track Bolts [ft lb]

(Does not pertain to Master Track Bolts)
57678203 LH, 57678211 RH
Table of Torque Values for Master Track Bolts [Nm / ft lb]

Only torque values for the Torque Procedure are specified in this table. Master Track Bolts should
only be tightened using the Torque Procedure.
57678203 LH, 57678211 RH
7.2.6 Fitting the Crawler Track
When laying out the track, ensure the track is straight and be aware of the track dimensions.
Place a wooden block under the end position of the track (front idler side, bushing side of the free
track upwards). Be aware of the correct position and directions of the track segments and grouser
shoes.
57678203 LH, 57678211 RH
7.2.6 Fitting the Crawler Track (Continued)
Once the track is laid out flat on the ground, place the assembled crawler side section with its track
rollers onto the track.
If left and right side running gears are to be positioned in sync with each other (or timed),
intermediately check to ensure the approprate alignment.
Once the trackside is properly aligned with the track, pull the track over the drive unit in the direction
of the front idler over the side section. Ensure the bushings of the track grip into the gaps between
the teeth of the sprocket.
57678203 LH, 57678211 RH
The position fo the track ends must be at the upper section of the front idler.
Put grease on the two spacers and insert into the counter bores (machined grooves) of the track links.
The purpose of the grease is to hold the spacers in place. If seal washers are used, apply them in the
same way.
57678203 LH, 57678211 RH
Grease the tips of the master pin. Align the ends of the tracks and insert the master pin into the hole.
Drive the pin in with a heavy hammer for smaller tracks. Larger tracks will require a hydraulic
pin–driving tool
Hammer Driving Pin Hydraulic Pin-- Driving Tool
Driving hardended pins in or out of the links by hammer involves considerable danger for
personnel as a result of material shearing off. Wear protective eyeware to prevent injuries.
If driving in the pins with a hammer, provide counter pressure behind the track link.
57678203 LH, 57678211 RH
After the track ends are properly connected, clean the threads of the master link halves. Apply bolt
grease to the master track bolts. Mount the grouser shoe and tighten the master track bolts with a
torque wrench using the Torque Procedure. Torque the master track bolts according to the Table of
Torque Values for Master Track Bolts.
57678203 LH, 57678211 RH
7.2.7 Tightening the Tracks
All of the components of the track must be assembled correctly.
A grease gun is required for tightening. Connect the grease gun onto the grease nipple of the
grease–tensioning valve. Pump the grease gun for as long as necessary to tension the track correctly.
A sag must be present in the chain. On a length of 1 to 1.5 meters,the sag must be 2 to 3 cm.
A sag must be present in the chain. Measure the extent of sag using a straight edge and a ruler as
shown below.
Measure the distance from the edge of the grouser shoe, in the middle of the sag, to the straight edge.
On a length of 1 to 1.5 meters, the sag must be 2 to 3 cm.
After completion of the tensioning process and measuring sag, remove the grease gun. Install the
protective cover, if equipped. Move the track on the undercarriage back and forth about one (1) turn
of the of the sprocket, then check the front idler and sprocket to ensure the track will ride them
properly.
57678203 LH, 57678211 RH
7.2.7 Tightening the Tracks (Continued)
Chains that are too loose do not fit properly on the front idler. They will slide especially when driving
forward or backward. The sliding will cause rapid wear at the chain links.Tracks that are too loose
can also slip out of the flanges of the rollers or off of the sprocket which will increase wear or cause
damage.
Tracks that are too tight will cause rapid wear at the idler bearings and drive bearings as well as at
the pins and bushings of the chain. This can also require greater motor output for track movement
which consequently requires a higher fuel comsumption.
57678203 LH, 57678211 RH
7.2.8 Removing the Crawler Track
Position the undercarriage so that the master pin is within the lower section of the front idler,
approximately under 45º from the middle downward. The mater pin has a hole in the facing side.
Do not drive the undercarriage off of the track arter laying it out. This causes an extreme
danger of non–braked undercarriages rolling. Secure the undercarriage against any
unintentional rolling.
57678203 LH, 57678211 RH
7.2.8 Removing the Crawler Track
First, the track must be de–tensioned. Using a wrench, twist the nipple just enough to allow grease
to seep out of the cross–hole. The nipple can be reached through an opening at the crawler
side–frame.
The grease in the tensioning element is under pressure. Undo the filling valve carefully and
slowly – but not too far!
The front idler should move in (back) automatically, but if it does not, the idler must be pushed back.
Observe the safety instructions for the spring elements of the Front Idler Unit. Refer to the
section of this manual covering the Front Idler Unit. The Front Idler Unit reset can occur as
a result of design or damage to the spring unit.
57678203 LH, 57678211 RH
7.2.8 Removing the Crawler Track (Continued)
Place a guide pipe with a drive mandrel over the master pin and knock the pin out. Provide a
counter–pressure behind the track link.
Guide Pipe
Drive Mandrel
Larger tracks may require a hydraulic pin remover to press the master pin out.
57678203 LH, 57678211 RH
7.2.8 Removing the Crawler Track (Continued)
Next, pull the track off in the drive direction using the proper lifting of device. Lay the track out,
then raise the machine so that the track can be removed.
Observe the safety instructions for the spring elements of the Front Idler Unit. Refer to the
section of this manual covering the Front Idler Unit. The Front Idler Unit reset can occur as
a result of design or damage to the spring unit.
The tracks are extremely heavy and can be hazardous to persons standing near the tracks
when they are being pulled off.
57678203 LH, 57678211 RH
7.2.9 Removal and Repair (Crawler Track/Grouser Shoe)
A broken track link must be replaced with a repair segment. The repair segment consists of a left
side, a right side and a master bushing, as seen below.
Right Track Link
Left Track Link
Master Bushing
Repair Segment
To get to the damaged link (or a damaged grouser shoe), remove the grouser shoe by removing its
bolts.
57678203 LH, 57678211 RH
7.2.9 Removal and Repair (Crawler Track/Grouser Shoe)
Before a broken link can be replaced, the damaged track link must be removed. Use a cutting torch
to cut through the broken link from above at point A. The torch cut section will fall out.
4 A
B
2
Next, cut through the pins and bushings at the marked points B using the cutting torch. Remove the
cut parts. (See the illustration below)
4 1
3 2
57678203 LH, 57678211 RH
7.2.9 Removal and Repair (Crawler Track/Grouser Shoe) (Continued)
Use the cutting torch to cut into the pins in the middle on sides 2 and 3 by about 20 – 40 mm
depending on track size.
4 1
3 2
Cut Into Pin Cut Into Pin
Drive the remaining piece of track link in until it falls loose. Also knock out any remaining pin.
4 1
Knock Out
3 2
57678203 LH, 57678211 RH
Knock the track link on side 3 out until the bushing emerges from the track seat and the track link
rotates around the hinge on side 4. If there is not enough play in the track to do this, remove the
residual pins first.
Then drive the track link with the residual pins on side 4 out.
4 1
Drive Remainder of
Link This Direction
3 2
Grind off the protruding bushing ends at the sides and grind flat any damage caused by cutting the
track link with the cutting torch.
Grind Off Grind Off
57678203 LH, 57678211 RH
Insert spacers (or seal washers, if applicable) and insert segments into track.
Grease the tips of the pins and insert into the holes.
Drive in the master pins with a heavy hammer. Provide a counter–pressure behind the track link.
Press in with a hydraulic pin–driving tool on larger tracks.
Hammer Driving Pin Hydraulic Pin-- Driving

Tool
After the track ends are properly connected, clean the threads of the master link halves. Apply bolt
grease to the master track bolts. Mount the grouser shoe and tighten the master track bolts with a
torque wrench using the Torque Procedure. Torque the master track bolts according to the Table of
Torque Values for Master Track Bolts.
57678203 LH, 57678211 RH
57678203 LH, 57678211 RH
8. OTHER/SPECIAL COMPONENTS
8.1. Track Guide - Function and Operation
8.1.1 In General
The Track Guides are used wherever track sag occurs on undercarriages while traveling over
obstructions. The result is that the track can run outside the flanges of the track rollers.
There are various types of track guides. Differentiation is made between welded and bolted designs.
There are also designs that cover the complete length of the undercarriage and others that are fitted
in sections.
8.1.2 Types of Track Guide
There are three types of track guides on Atlas Copco undercarriages, depending on size of tracks.
S Track guides welded to the unit require the undercarriage to be raised for fitting or
removal.
S Track guides bolted to the unit do not require the undercarriage to be raised for
fitting or removal.
S Track guides bolted to the unit over the complete frame do no require the
undercarriage to be raised for fitting or removal.
Track Guide Bolted Track Guide Bolted over Com-

onto the Unit plete Frame
57678203 LH, 57678211 RH
8.1.3 Function of Track Guide
Track guide acts as a “threading aid” for the track. If sagging occurs in the track, it comes away from
the track rollers. As the sag recedes, the track guide ensures that the track and the track roller are
properly aligned again.
8.2. Track Guide – Fitting and Removal
8.2.1 General Description
There are two fundamental designs of track guide. One is the welded guide and the other is the bolted
guide.
Welded Guides
The undercarriage has to be raised to fit the track guide as there is no possibility of fitting the chain
guide from the side. After the undercarriage is raised, the track guide is mounted onto the
undercarriage with bolts. Removal is done in the reverse.
Bolted Guides
The bolted guides can be fitted without raising the undercarriage as the track guide is in several parts.
In this case, one side of the track guide is bolted onto the undercarriage. The cross–link is then
connected to the first side of the track guide. The second side of track guide is then bolted onto the
cross–link. The second side is then bolted onto the undercarriage. Removal is done in the reverse.
Ensure there is no contact between the track guide and the track roller body and that there
is adequate play between and the track guide and the track (pin boss on the track).
57678203 LH, 57678211 RH
8.3. Covers
8.3.1 In General
Covers, shown in the following illustration, come equipped on all standard undercarriages.
Additional covers may come with some undercarriages, but are not shown in the illustration. Typical
covers are for the hydraulic motor or for the access for the lubrication point on the tensioning
element.
Cover
Cover
Handling cover plates can be very heavy depending on the size of the undercarriage, which
can cause serious injury.
8.3.2 Function
Covers on the undercarriage are made of sheet metal and are used for:
S Covering units and hydraulic lines
S Protection against dirt and contanimation
S Protecting persons from injury
57678203 LH, 57678211 RH
57678203 LH, 57678211 RH
9. UNDERCARRIAGE WEAR GUIDELINES AND MEASUREMENT TECHNIQUES
9.1. Measurement Cautions
To avoid measurement error, the following cautions must be observed:

S Before measuring wear, all component areas to be measured must be cleaned.
S Measuring tools must be perpendicular with component axis when obtaining
measurements.
S Over-tightening of measuring tools can result in measurement error.
S Measuring tools must be clean and free of damage to prevent measurement error.
57678203 LH, 57678211 RH
9.2. Front Idler Wear Limits
Measuring Tool: Depth Gauge
Measurement: Determine the distance between the center flange surface and the running
treads.
57678203 LH, 57678211 RH
9.3. Bottom Roller Wear Limits
Measuring Tool: Caliper

Measurement: Determine the diameter of the tread observing minimum reading to deter-
mine wear percentage
Optional Measurement: Use a Depth Gauge to measure the maximum distance from
flange to tread as a reference.
57678203 LH, 57678211 RH
9.4. Top Roller Wear Limits

Measurement: Determine the diameter of the tread observing minimum reading to deter-
mine wear percentage
Optional Measurement: Use a Depth Gauge to measure the maximum distance from
flange to tread as a reference.
57678203 LH, 57678211 RH
9.5. Track Measurement - Link Height
Measuring Tool: Depth Gauge
Measurement:
1. Measure from the link running surface to the track shoe plate to obtain the link height
(A).
2. The correct measurement location is next to the outer link surface in line with the pin
axis.
3. Reference the track wear table for resulting wear.
57678203 LH, 57678211 RH
9.6. Track Measurement - Chain Pitch
Measuring Tool: Tape Measure
Measurement: (Measure distance between 5 track pins)

1. Slowly tram machine to tension chain and stop without releasing tension (or
other tensioning method).
2. Connect the same points (pin edge) of 1st and 5th pin with a taut tape and obtain
measurement. Perform measurement in at least 2 locations of chain and retain
most significant value.
3. Reference the track wear table for resulting pitch increase.
57678203 LH, 57678211 RH
9.7. Track Measurement - Bushing Diameter
Measurement: Must be obtained from the bushing direction with the most significant wear
- regardless of forward or reverse.
Note that if the caliper is not passed over the maximum diameter opposite the wear being
measured, the measurement will be less. This mistake is typical when there is not enough
space between bushing and shoe to allow passage for the caliper tips. In such situations, the
shoe must be removed to allow accurate measurement.
57678203 LH, 57678211 RH
9.8. Sprocket Tooth Wear
Measuring Tool: Visual
Measurement: Sprockets are 100% worn when the tooth tip is sharp or tooth tip breakage
is beginning as a result of thin tooth tip condition.
Wear of the sprockets affects the entire tooth contour without leaving any reference point
for which a direct measurement can be based.
57678203 LH, 57678211 RH
9.9. Track Wear Limits
57678203 LH, 57678211 RH
9.10. Estimating Remaining Wear Life and Service
Having established the wear rates, estimates for potential service can be determined with the
following equation:
WH = Worked Hrs. – on component

AW = Actual Wear % (Example: 30 represents 30% wear)
PWL = Potential Wear Life – total wear life

PWL = (WH / AW) X 100
PRH = Potential Remaining Hours

PRH = PWL – WH
To allow estimation of component service, the following calculation can be used to identify the
potential service week.
PRH / Hrs Per Week operation = Service Week.
57678203 LH, 57678211 RH
PARTS
SECTION
PARTS
57678203 LH, 57678211 RH
57678203 TRACK,LH
12
13
6
TRACK,LH
10
10
13
24
36
35
34
23
32
30
29
33
31
13
19
22
4
20
23
9
13
21
22
15
16
17
14
16
57678203
1
26
25
27
28
13
18
8
7
2
Figure 1 :TRACK,LH
E57678211 REV 000
57678203 LH, 57678211 RH
57678203 TRACK,LH
REF. PART NO. QTY. UNIT DESCRIPTION
TRACK,LH
001 57695744 1 EA FRAME,TRACK.LH
002 57695611 1 EA IDLER UNIT,TRACK (See figure 2)
003 57695629 7 EA ROLLER,TRACK (See figure 3)
004 57695637 1 EA ROLLER,CARRIER (See figure 4)
005 57695645 1 EA SPROCKET,TRACK DRIVE
006 52300654 1 EA FINAL DRIVE,TEIJIN SEIKI (See figure 5)
007 57695652 1 EA GUARD,LH
008 57695660 1 EA GUARD,ROCK(RH)
009 57695678 1 EA PLATE,COVER
010 57695686 1 EA COVER,FINAL DRIVE
011 96744917 30 EA BOLT
012 96705520 21 EA BOLT,HEX HEAD
013 96702550 104 EA WASHER/10M5LC17AM4HR
014 96701503 28 EA BOLT/35M2AB522M3
015 96704721 1 EA BOLT/35M2AB472M3
017 96705652 1 EA NUT,LOCK
57678203
018 96703186 14 EA CAPSCREW/34M2AB513M3
019 96700893 2 EA SCREW,HEX/35M2AB518M3
020 57695694 7 EA SPACER,ROCK GUARD
021 57695736 7 EA BOLT
022 96727151 9 EA NUT
023 96727169 6 EA BOLT
024 96727250 5 EA BOLT
025 51236925 1 EA GASKET
026 51236933 1 EA FITTING
027 57695702 1 EA CHAIN,TRACK (See figure 9)
028 57687170 1 EA DECAL,UNDERCARRIAGE
029 57695728 1 EA PLATE,COVER
030 51952158 2 EA BUSHING,TRACK OSCILATION
031 95293403 1 EA ELBOW,90 DEG MALE
032 95201307 1 EA FITTING
033 95263380 1 EA FITTING,HYD---NPT/JIC
034 51028371 1 EA HOSE ASSY
035 96728480 1 EA BOLT,FLGD HEX HEAD
036 95368338 1 EA CLAMP, HOSE
57678203 LH, 57678211 RH
57695611 IDLER UNIT,TRACK

TRACK,LH
6
4
57678203
2
5
3
7
1
Figure 2 :IDLER UNIT,TRACK

C57695611 REV 000
57678203 LH, 57678211 RH
57695611 IDLER UNIT,TRACK
001 57695751 1 EA IDLER WITH BRACKETS
TRACK,LH
002 57695769 1 EA SPRING & TENSION DEVICE
003 57695777 1 EA FORK
005 96712187 4 EA BOLT
006 96706262 2 EA BOLT
57678203
57678203 LH, 57678211 RH
57695629 ROLLER,TRACK
TRACK,LH
8 6 2
5
57678203
Figure 3 :ROLLER,TRACK
C57695629 REV 000
57678203 LH, 57678211 RH
57695629 ROLLER,TRACK
001 57695785 1 EA SHELL,ROLLER
TRACK,LH
002 57695793 2 EA BUSHING
003 57695801 1 EA PLUG
004 57695819 1 EA SHAFT
005 57695827 4 EA O---RING
006 57695835 4 EA RING,SEAL
007 57695843 2 EA O---RING
008 57695850 2 EA BRACKET
009 57695868 2 EA PIN,DOWEL
57678203
57678203 LH, 57678211 RH
57695637 ROLLER,CARRIER
TRACK,LH
1 8
9
6 10
14 11
7 12
18
2
16
57678203
15
17
13
5
3
4
Figure 4 :ROLLER,CARRIER
C57695637 REV 000
57678203 LH, 57678211 RH
57695637 ROLLER,CARRIER
001 57695876 1 EA SHELL,ROLLER
TRACK,LH
002 57695884 1 EA SHAFT
003 57695892 2 EA BEARING
004 57700700 1 EA DISK,INTERNAL FACE
005 57700718 2 EA PIN
006 57700726 3 EA BOLT,SELF---LOCKING
007 57700734 1 EA O---RING
008 57700742 2 EA RING,SEAL
009 57700759 2 EA O---RING
010 57700767 1 EA COLLAR
011 57700775 1 EA RING,ELASTIC
012 57700783 1 EA O---RING
013 57700791 1 EA PLATE,SECURITY
014 57700809 3 EA WASHER,ELASTIC
015 57700817 1 EA O---RING
016 57700825 1 EA PLUG
017 57700833 2 EA BOLT,SELF---LOCKING
018 57700841 1 EA COVER
57678203
57678203 LH, 57678211 RH
52300654 FINAL DRIVE,TEIJIN SEIKI

TRACK,LH
57678203
Figure 5 :FINAL DRIVE,TEIJIN SEIKI

C52300654 REV 001
57678203 LH, 57678211 RH
TRACK,LH
57678203
Figure 6 :FINAL DRIVE,TEIJIN SEIKI

C52300654 REV 001
57678203 LH, 57678211 RH
001 52312659 1 EA HUB

TRACK,LH
001 57714206 1 EA SEAL KIT

006 52312667 1 EA GEAR,INPUT
015 52312675 1 EA COUPLING
021 52312683 2 EA BEARING,BALL
044 52312691 1 EA SHAFT
149 52312717 1 EA BEARING,ROLLER
150 52312725 1 EA BEARING,ROLLER
380 52312766 2 EA CONNECTOR
381 52312774 1 EA CONNECTOR
400 57713182 1 EA REDUCTION GEARS (See figure 7)
406 57713497 1 EA MOTOR,HYDRAULIC (See figure 8)
410 57713661 1 EA SRV2
57713679 2 EA D KIT,VALVE
57713687 1 EA D KIT,SLEEVE
57713695 1 EA D KIT,BODY
57713703 1 EA D KIT,PISTON BODY
415 57713711 1 EA VALVE,CONTROL
57678203
57713752 2 EA D PIN,PARALLEL
57713760 9 EA D BOLT,HEX SOCKET
57713729 1 EA D FLANGE ASM,REAR
57713737 1 EA D KIT,FLANGE REAR
57713745 1 EA D KIT,SPOOL
XXX 52312634 1 EA ASSY,RV GEAR
XXX 52312733 2 EA KIT,VALVE
XXX 52312741 1 EA KIT,BODY
XXX 52312758 1 EA VALVE,CONTROL
XXX 52312782 1 EA KIT,SEAL
XXX 52312816 1 EA KIT,SPUR GEAR
XXX 52312824 1 EA MOTOR,HYDRAULIC
57678203 LH, 57678211 RH
TRACK,LH
57678203
57678203 LH, 57678211 RH
57713182 REDUCTION GEARS

TRACK,LH
57678203
Figure 7 :REDUCTION GEARS

C52300654 REV 001
57678203 LH, 57678211 RH
57713182 REDUCTION GEARS
001 57713240 1 EA HUB
TRACK,LH
006 57713257 1 EA GEAR,INPUT
008 57713265 1 EA COVER
015 57713273 1 EA COUPLING
017 57713281 28 EA PIN
020 57713299 3 EA SNAP RING
021 57713307 2 EA BALL BEARING
025 57713315 3 EA RING,SNAP FOR SHAFT
027 57713323 2 EA O---RING
029 57713331 1 EA O---RING
030 57713349 1 EA O---RING
033 57713356 3 EA PLUG, SOCKET HEX
035 57713364 12 EA BOLT,SOCKET HEX
036 57713372 1 EA BALL,STEEL
042 57713380 2 EA PIN,PARALLEL
043 57713398 3 EA O---RING
044 57713406 1 EA SHAFT
045 57713414 1 EA PLATE
57678203
047 57713422 1 EA SPRING
048 57713430 1 EA SPRING GUIDE
049 57713448 1 EA COVER
050 57713455 1 EA PIN
051 57713463 2 EA BOLT,HEX HEAD
054 57713471 1 EA O---RING
059 57713489 1 EA SNAP RING
401 57713190 1 EA KIT,SPINDLE
57713208 1 EA D SPINDLE ASM
403 57713216 1 EA GEAR ASM,RV
404 57713224 1 EA KIT,SPUR GEAR
405 57713232 1 EA KIT,FLOATING SEAL
57678203 LH, 57678211 RH
57713497 MOTOR,HYDRAULIC
TRACK,LH
57678203
Figure 8 :MOTOR,HYDRAULIC
C52300654 REV 001
57678203 LH, 57678211 RH
57713497 MOTOR,HYDRAULIC
102 57713513 1 EA SHAFT
TRACK,LH
103 57713521 1 EA PLATE,SWASH
109 57713539 1 EA PLATE,TIMING
112 57713547 1 EA PISTON
113 57713554 10 EA SPRING
115 57713562 2 EA PLATE,FRICTION
116 57713570 2 EA PLATE,MATING
132 57713588 1 EA OIL SEAL
135 57713596 1 EA O---RING
139 57713604 1 EA O---RING
149 57713612 1 EA ROLLER BEARING
150 57713620 1 EA ROLLER BEARING
167 57713638 2 EA PIVOT
169 57713646 1 EA PLATE,MATING
171 57713653 2 EA PIN,PARALLEL
407 57713505 1 EA KIT,CYLINDER & PISTON
57678203
57678203 LH, 57678211 RH
57695702 CHAIN,TRACK
TRACK,LH
3
2
57678203
1 4
Figure 9 :CHAIN,TRACK
C57695702 REV 000
57678203 LH, 57678211 RH
57695702 CHAIN,TRACK
001 57700858 168 EA NUT
TRACK,LH
002 57700866 168 EA BOLT
003 57700874 42 EA SHOES
004 57700882 1 EA LINK WITHOUT SHOES
57678203
57678203 LH, 57678211 RH
57678203 LH, 57678211 RH
Index
A D
ASSY, RV GEAR, 52312634, 92 DECAL, UNDERCARRIAGE, 57687170, 83
DISK, INTERNAL FACE, 57700700, 89
B E
BALL, STEEL, 57713372, 95 ELBOW, 90 DEG MALE, 95293403, 83
BALL BEARING, 57713307, 95
BEARING
57695892, 89
F
BALL, 52312683, 92 FINAL DRIVE, TEIJIN SEIKI, 52300654, 83
ROLLER FITTING
52312717, 92 51236933, 83
52312725, 92 95201307, 83
BOLT HYD---NPT/JIC, 95263380, 83
57695736, 83 FLANGE ASM, REAR, 57713729, 92
57700866, 99 FORK, 57695777, 85
96706262, 85
96712187, 85 FRAME, TRACK.LH, 57695744, 83
96744917, 83
HEX HEAD, 57713463, 95
HEX SOCKET, 57713760, 92 G
SELF---LOCKING GASKET, 51236925, 83
57700726, 89
57700833, 89 GEAR, INPUT
SOCKET HEX, 57713364, 95 52312667, 92
57713257, 95
BRACKET, 57695850, 87
GEAR ASM, RV, 57713216, 95
BUSHING GUARD
57695793, 87 LH, 57695652, 83
TRACK OSCILATION, 51952158, 83 ROCK(RH), 57695660, 83
C H
HOSE ASSY, 51028371, 83
CHAIN, TRACK, 57695702, 83
HUB
CLAMP, HOSE, 95368338, 83 52312659, 92
COLLAR, 57700767, 89 57713240, 95
CONNECTOR
52312766, 92
52312774, 92
I
IDLER UNIT, TRACK, 57695611, 83
COUPLING
52312675, 92 IDLER WITH BRACKETS, 57695751, 85
57713273, 95
COVER
57700841, 89
K
57713265, 95 KIT
57713448, 95 BODY
FINAL DRIVE, 57695686, 83 52312741, 92
WARNING: This manual contains data SPECIFIC to: 700 Series Undercarriage. Index i
57678203 LH, 57678211 RH
Index
57713695, 92
CYLINDER & PISTON, 57713505, 97
P
FLANGE REAR, 57713737, 92 PIN
FLOATING SEAL, 57713232, 95 57700718, 89
PISTON BODY, 57713703, 92 57713281, 95
SEAL, 52312782, 92 57713455, 95
SLEEVE, 57713687, 92 DOWEL, 57695868, 87
SPINDLE, 57713190, 95 PARALLEL
SPOOL, 57713745, 92 57713380, 95
SPUR GEAR 57713653, 97
52312816, 92 57713752, 92
57713224, 95 PISTON, 57713547, 97
VALVE
52312733, 92 PIVOT, 57713638, 97
57713679, 92 PLATE
57713414, 95
COVER
57695678, 83
L 57695728, 83
FRICTION, 57713562, 97
LINK WITHOUT SHOES, 57700882, 99 MATING
57713570, 97
57713646, 97
SECURITY, 57700791, 89
M SWASH, 57713521, 97
TIMING, 57713539, 97
MOTOR, HYDRAULIC
PLUG
52312824, 92
57695801, 87
57713497, 92
57700825, 89
SOCKET HEX, 57713356, 95
N R
NUT, 57700858, 99
REDUCTION GEARS, 57713182, 92
RING
ELASTIC, 57700775, 89
O SEAL
57695835, 87
O---RING 57700742, 89
57695827, 87 SNAP FOR SHAFT, 57713315, 95
57695843, 87 ROLLER
57700734, 89 CARRIER, 57695637, 83
57700759, 89 TRACK, 57695629, 83
57700783, 89
ROLLER BEARING
57700817, 89
57713612, 97
57713323, 95 57713620, 97
57713331, 95
57713349, 95
57713398, 95
57713471, 95
S
57713596, 97 SEAL KIT, 57714206, 92
57713604, 97
SHAFT
OIL SEAL, 57713588, 97 52312691, 92
Index ii WARNING: This manual contains data SPECIFIC to: 700 Series Undercarriage.
57678203 LH, 57678211 RH
Index
57695819, 87 SPRING & TENSION DEVICE, 57695769, 85

57695884, 89 SPRING GUIDE, 57713430, 95
57713406, 95
57713513, 97 SPROCKET, TRACK DRIVE, 57695645, 83
SHELL, ROLLER SRV2, 57713661, 92
57695785, 87
57695876, 89
SHOES, 57700874, 99
V
SNAP RING VALVE, CONTROL
57713299, 95 52312758, 92
57713489, 95 57713711, 92
SPACER, ROCK GUARD, 57695694, 83
SPINDLE ASM, 57713208, 95 W
SPRING
57713422, 95 WASHER, ELASTIC, 57700809, 89
57713554, 97 WASHER/10M5LC17AM4HR, 96702550, 83, 85
WARNING: This manual contains data SPECIFIC to: 700 Series Undercarriage. Index iii
57678203 LH, 57678211 RH
Index
57695785, SHELL, ROLLER, 87

Numbers
57695793, BUSHING, 87
51028371, HOSE ASSY, 83
57695801, PLUG, 87
51236925, GASKET, 83
57695819, SHAFT, 87
51236933, FITTING, 83
57695827, O---RING, 87
51952158, BUSHING, TRACK OSCILATION, 83 57695835, RING, SEAL, 87
52300654, FINAL DRIVE, TEIJIN SEIKI, 83 57695843, O---RING, 87
52312634, ASSY, RV GEAR, 92 57695850, BRACKET, 87
52312659, HUB, 92 57695868, PIN, DOWEL, 87
52312667, GEAR, INPUT, 92 57695876, SHELL, ROLLER, 89
52312675, COUPLING, 92 57695884, SHAFT, 89
52312683, BEARING, BALL, 92 57695892, BEARING, 89
52312691, SHAFT, 92 57700700, DISK, INTERNAL FACE, 89
52312717, BEARING, ROLLER, 92 57700718, PIN, 89
52312725, BEARING, ROLLER, 92 57700726, BOLT, SELF---LOCKING, 89
52312733, KIT, VALVE, 92 57700734, O---RING, 89
52312741, KIT, BODY, 92 57700742, RING, SEAL, 89
52312758, VALVE, CONTROL, 92 57700759, O---RING, 89
52312766, CONNECTOR, 92 57700767, COLLAR, 89
52312774, CONNECTOR, 92 57700775, RING, ELASTIC, 89
52312782, KIT, SEAL, 92 57700783, O---RING, 89
52312816, KIT, SPUR GEAR, 92 57700791, PLATE, SECURITY, 89
52312824, MOTOR, HYDRAULIC, 92 57700809, WASHER, ELASTIC, 89
57687170, DECAL, UNDERCARRIAGE, 83 57700817, O---RING, 89
57695611, IDLER UNIT, TRACK, 83 57700825, PLUG, 89
57695629, ROLLER, TRACK, 83 57700833, BOLT, SELF---LOCKING, 89
57695637, ROLLER, CARRIER, 83 57700841, COVER, 89
57695645, SPROCKET, TRACK DRIVE, 83 57700858, NUT, 99
57695652, GUARD, LH, 83 57700866, BOLT, 99
57695660, GUARD, ROCK(RH), 83 57700874, SHOES, 99
57695678, PLATE, COVER, 83 57700882, LINK WITHOUT SHOES, 99
57695686, COVER, FINAL DRIVE, 83 57713182, REDUCTION GEARS, 92
57695694, SPACER, ROCK GUARD, 83 57713190, KIT, SPINDLE, 95
57695702, CHAIN, TRACK, 83 57713208, SPINDLE ASM, 95
57695728, PLATE, COVER, 83 57713216, GEAR ASM, RV, 95
57695736, BOLT, 83 57713224, KIT, SPUR GEAR, 95
57695744, FRAME, TRACK.LH, 83 57713232, KIT, FLOATING SEAL, 95
57695751, IDLER WITH BRACKETS, 85 57713240, HUB, 95
57695769, SPRING & TENSION DEVICE, 85 57713257, GEAR, INPUT, 95
57695777, FORK, 85 57713265, COVER, 95
Index iv WARNING: This manual contains data SPECIFIC to: 700 Series Undercarriage.
57678203 LH, 57678211 RH
Index
57713273, COUPLING, 95 57713570, PLATE, MATING, 97

57713281, PIN, 95 57713588, OIL SEAL, 97
57713299, SNAP RING, 95 57713596, O---RING, 97
57713307, BALL BEARING, 95 57713604, O---RING, 97
57713315, RING, SNAP FOR SHAFT, 95 57713612, ROLLER BEARING, 97
57713323, O---RING, 95 57713620, ROLLER BEARING, 97
57713331, O---RING, 95 57713638, PIVOT, 97
57713349, O---RING, 95 57713646, PLATE, MATING, 97
57713356, PLUG, SOCKET HEX, 95 57713653, PIN, PARALLEL, 97
57713364, BOLT, SOCKET HEX, 95
57713661, SRV2, 92
57713372, BALL, STEEL, 95
57713679, KIT, VALVE, 92
57713380, PIN, PARALLEL, 95
57713687, KIT, SLEEVE, 92
57713398, O---RING, 95
57713695, KIT, BODY, 92
57713406, SHAFT, 95
57713703, KIT, PISTON BODY, 92
57713414, PLATE, 95
57713711, VALVE, CONTROL, 92
57713422, SPRING, 95
57713729, FLANGE ASM, REAR, 92
57713430, SPRING GUIDE, 95
57713737, KIT, FLANGE REAR, 92
57713448, COVER, 95
57713745, KIT, SPOOL, 92
57713455, PIN, 95
57713752, PIN, PARALLEL, 92
57713463, BOLT, HEX HEAD, 95
57713760, BOLT, HEX SOCKET, 92
57713471, O---RING, 95
57713489, SNAP RING, 95 57714206, SEAL KIT, 92
57713497, MOTOR, HYDRAULIC, 92 95201307, FITTING, 83
57713505, KIT, CYLINDER & PISTON, 97 95263380, FITTING, HYD---NPT/JIC, 83

57713513, SHAFT, 97 95293403, ELBOW, 90 DEG MALE, 83
57713521, PLATE, SWASH, 97 95368338, CLAMP, HOSE, 83
57713539, PLATE, TIMING, 97 96702550, WASHER/10M5LC17AM4HR, 83, 85
57713547, PISTON, 97 96706262, BOLT, 85
57713554, SPRING, 97 96712187, BOLT, 85
57713562, PLATE, FRICTION, 97 96744917, BOLT, 83
WARNING: This manual contains data SPECIFIC to: 700 Series Undercarriage. Index v
Atlas Copco Drilling Solutions, Inc. A Company Within the Atlas Copco Group
P.O.Box 462288, 2100 North First Street
Garland, Texas 75046-2288
www.atlascopco.com/drillingsolutions

Atlas Copco Undercarriage of 700 Series Drilling Rigs

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UNDERCARRIAGE

Read the instruction manual before operating this equipment.

This manual contains important safety information.

CPN 57678203 LH, 57678211 RH 07/2004 REV 001

2. OPERATING AND SERVICE INTRUCTIONS . . . . . . . . . 9

4. FRONT IDLER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

5. CARRIER ROLLERS / SUPPORT RAILS . . . . . . . . . . . . . 37

7. CRAWLER TRACK AND GROUSER SHOE . . . . . . . . . . 41

9. UNDERCARRIAGE WEAR GUIDELINES / MEASUREMENT

This page is intentionally blank.

1. SAFETY AND DANGER INSTRUCTIONS

NOTICE Notice is used to notify people of installation, operation, or maintenance

These operating instructions are not subject to any update service.

Information on latest developments can be obtained from:

Atlas Copcp Company

Parts Customer Service

Applicable conditions of warranty are stipulated in the confirmation of order.

Warranty rights become void in the event of:

S Damage as a result of malfunctions caused by incorrect use or incorrect operation.

1.2 Manufacturer’s Declaration (only valid in Europe)

Crawler undercarriage as described in the section Operating and Service Instructions.

Other applicable harmonized standards:

DIN EN 25817 for welding work

Other applicable national standards and technical specifications:

See annex “Technical Description” to the order confirmation

1.3. Safety Instructions

Under these circumstances there is

S Danger to life and limb

1.3.2 Regulations for Work Safety

Tools and Equipment

This page is intentionally blank.

2. OPERATING AND SERVICE INTRUCTIONS

2.1. General Maintenance Instructions

2.1.1 Handling Hydraulic Substances and Lubricants

Do not smoke if handling combustible fluids.

2.1.2 Conversions or Changes to the Undercarriage

Seals on units must not be removed.

2.1.3 Before Starting Up

Before starting up:

S Lubricate all lubrication points

2.1.4 Wear Limits of Undercarriage Parts

S Track resting on hard uneven rock bed during operation

Wear limits are shown on the wear tables.

2.2. Inspection Intervals

Component Interval Inspection Extent of Maintenance Work Description

300 – 2000 Gearbox oil change

2.3. Tightening Torque Tables

2.4. General Instructions

2.4.1 Serial Number

All undercarriages or slide frames have a serial number for identification.

This number looks like the following example:

The first part is the order number of the order confirmation.

This number is always required when calling with inquiries or complaints.

2.4.2 Structural Design of a Standard Crawler Undercarriage

2.4.3 Operating Times

2.4.4 Function and Operation

2.4.5 General Assembly and Disassembly Instructions

3.1. Drive – Function and Operation

3.1.1 General Danger Instructions

Danger can occur in particular under the following circumstances:

S Product is handled insufficiently trained personnel

Alterations to the product are not permitted unless approved beforehand.

3.1.2 Instructions on Transport and Storage