Chapter 16 - Undercarriage Mechanical: Service Manual

Service Manual
Chapter 16 - Undercarriage mechanical

Undercarriage - Mechanical ............................................................................................................................. 16-3
1 Travel................................................................................................................................................ 16-3
1.1 Technical data ........................................................................................................................ 16-3
1.2 Function / Operation ............................................................................................................... 16-4
1.3 Installation / removal............................................................................................................... 16-11
1.4 Travel brake............................................................................................................................ 16-13
2 Track components ............................................................................................................................ 16-15
2.1 Track pads.............................................................................................................................. 16-17
2.2 Track rollers............................................................................................................................ 16-18
2.3 Carrier rollers.......................................................................................................................... 16-20
2.4 Idler......................................................................................................................................... 16-22
2.5 Sprocket ................................................................................................................................. 16-24
2.6 Track guides ........................................................................................................................... 16-25
2.7 Tensioning cylinder and grease cylinder ................................................................................ 16-26
2.8 Monitoring............................................................................................................................... 16-28
2.9 Installation / removal of the track components ....................................................................... 16-35
3 Track tensioning (non hydraulic)....................................................................................................... 16-41
3.1 Function / operation................................................................................................................ 16-41
4 Preassembled modules .................................................................................................................... 16-43
4.1 Component location................................................................................................................ 16-43
4.2 Mounting / dismounting modules............................................................................................ 16-43
LFR/en/version: 09 / 2007
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Service Manual
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Service Manual Undercarriage - Mechanical
Travel
16 Undercarriage - Mechanical
16.1Travel
16.1.1Technical data
Gear type FAT 1000 / 102
Max. output speed min-1 12,9

Nominal output torque Nm 650 000
Gear ratio 249,8
Hydraulic motor Type 2xA6VE 250
Weight kg 3000
Oil quantity in gear l. 52
Oil quality API - GL - 5
Oil viscosity From -30°C to 10°C : SAE 80,
From -15°C to 30°C : SAE 80 W 90 or SAE 90,
From 0°C to 50°C : SAE 85 W 140.
Brake Disk brake / spring applied, pressure released

Brake torque static Nm 800 000
Oil pressure min. to release brake bar 30
Axial play :
A) roller bearing mm
B) roller bearing mm
C) roller bearing mm 0,5 - 1,1
D) Shaft mm 2,0 - 3,0
E) Planetary carrier mm 1,0 - 1,5
F) Oil channel mm 10 - 20
Torque :
L) Nm
M) Nm 295
N) Nm 120
O) Nm
P) Nm
Q) Nm
R) Nm 69
S) Nm 35
T) Nm 580
U) Nm 3200
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Undercarriage - Mechanical Service Manual
Travel
16.1.2Function / Operation
16.1.2.1Component location
Complete undercarriage
Hydraulic part of the travel system
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Travel
Travel gear with motors

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Travel
1 Planetary carrier 30 Internal geared wheel

2 Roller cage 31 Screw M12 x 35
3 Cylinder roller 35 Sun gear
5 Bearing ring 40 Planetary carrier
6 O-ring 45 Planet wheel
7 Screw M24 x 25 46 Planet wheel pin
10 Contact strip 47 Locking ring
11 Axial face seal 48 Supporting ring
12 Screw M36 x 200 50 Internal gear wheel
15 Holding disk 51 Screw M20 x 160
16 Screw M10 x 25 54 Locking ring
20 Planer wheel 55 Intermediate shaft

22 Locking ring
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Travel
56 Thrust washer 71 Screw M16 x 65

57 Screw M12 x 25 72 Lock washer
59 O-ring 73 Screw M8 x 45
60 Cover 74 Blanking plug
61 Screw M20 x 65 75 Spur wheel
62 Lock washer 76 Bearings
63 Screw plug 77 Bearings
70 Housing 78 Bearings
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Travel
79 Screw plug 88 Plate carrier

80 Primary shaft 89 Locking ring
81 Locking ring 90 Alu caps
82 Spring loaded multidisc brake 91 Hex. Head screw M12 x 30
83 O-ring 92 Lock washer
84 O-ring 93 O-ring
85 Motor flange 94 Taper plug
86 Allen head screw 95 Alu caps
87 Lock washer 96 Hex. Head screw M20 x 40
97 Washer
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Travel
16.1.2.2Functional description
Cinematic schematic
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Travel
Functioning
For the functional description of the travel gear see the preceding figures.
The primary shaft 80 is driven by the hydraulic motors. It meshes with the spur wheel 75 and permits the rota-
tion of the intermediate shaft 55. Bearings make the rotation between the intermediate shaft 55 and the assem-
bly (planetary carrier 1, contact strip 10, housing 70 and motor flange 85).
The intermediate shaft 55 meshes with the planetary wheel 45. On the other side, the planetary wheel 45
meshes with internal geared wheel 50. The planetary wheel 45 is mounted on the planetary carrier 40 with bea-
ring. The planetary carrier 40 is then driven in rotation.
The sun gear 35 meshes with the planetary carrier 40 and turns at the same speed.
The planet wheel 20 meshes with the sun gear 35. The planet wheel 20 is mounted in rotation on planetary
carrier 1 with a bearing. On the other side the planet wheel 20 meshes with the internal geared wheel 30. As
the assembly (planetary carrier 1, contact strip 10, housing 70 and motor flange 85) is fixed, the assembly com-
posed ( bearing ring 5, internal geared wheels 30 and 50) has a movement of rotation. A bearing makes the
rotation between these two assemblies.
The sprocket is bolted on the bearing ring 5 and then the rotation of the assembly (5, 30, 50) is tranferred to
the track and allows the travel movement of the excavator.
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Travel
16.1.3Installation / removal
16.1.3.1Installation and removal of the inner travelling mechanism

For first installation or reparation, which necessitates the opening of swing gear, see the manufacturer docu-
mentation : «Mounting instructions of FAT 1000-102».
16.1.3.2Installation and removal of the travel gear in the excavator
Component location
Pos. Component Pos. Component

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Travel
1 Side frame 25 Travel motor protection right

2 Travel drive FAT 1000 / 102 26 Travel motor protection left
3 Screw M30 x 2 1940 Nm 27 Washer
4 Washer 28 Screw M42 4810 Nm
6 Hydraulic motor 29 Sleeve
7 Bolt M20 560 Nm 30 Console
8 Washer 31 Console
10 O-ring 32 Washer
15 Lid 33 Screw M30 1900 Nm
16 Washer 40 Lid
17 Bolt M24 960 Nm 41 Bolt M16 280 Nm
18 Washer 42 Washer
20 Sprocket wheel 50 Split pin
21 Screw M30 x 2 1940 Nm 51 pin
22 Washer
For the installation and the removal of the travel gear in its housing, use an appropriate tools to carry this me-
chanism.
Installation description
• Lift the travel gear 2 and center it in the side frame 1.
• Fix the travel drive 2 to the side frame 1 by tightening the screws 3 to the prescribed torque.
• Lift the sprocket 20 and center it in the travel gear 2.
• Fix the sprocket 20 to the travel gear 2 by tightening the screws 21 to the prescribed torque.
• Lift the travel motors 6 and fix them to the travel gear 2 by tightening the bolts 7 to the prescribed torque.
• Lift the travel motors protection 25 or 26 and fix it to the side frame 1 by tightening the screws 28 to the
prescribed torque.
• Lift the lid 15 and fix it to the side frame 1 and to the central part by tightening the screws 17 or 41 to the
prescribed torque.
Removal description
• Remove the track (see § removal of track components).
• Lift the excavator and place it on supports.
• Remove rocks and debris.
• Remove the screws 28 and secure the lifting of the travel motors protection 25 or 26.
• Remove the travel motors protection 25 or 26.
• Remove the screws 17 or 41 and secure the lifting of the lid 15.
• Remove the lid 15.
• Remove the bolts 7 and secure the lifting of the travel motors 6.
• Remove the travel motors 6.
• Remove the screws 21 and secure the lifting of the sprocket 20.
• Remove the sprocket 20.
• Remove the screws 3 and secure the lifting of the travel gear 2.
• Remove the travel gear 2.
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Travel
16.1.4Travel brake
16.1.4.1Travel brake function / operation
Component location
1 Support ring 90 Motor flange

80 Drive shaft 101 Brake flange
85 Support 102 Brake
86 Multiple disc brake 103 Brake spring
87 Flange
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Travel
Functional description
When the travel motor is working, pressurised oil is feeding the travel brake. The pressurised oil is coming in
the brake through the hole, which is indicated with the arrow A. The ducts of pressurised oil cross the motor
flange 90 and the brake flange 101. The oil plates the brake 102 against the motor flange 90. So when the
travel motor is working the drive shaft 80 is in rotation.
For the braking operation the alimentation in pressurised oil is stopped. The force, which plates the brake 102
against the motor flange, has disappeared, so the brake springs 103 push the brake against the multiple disc
brake. A half of the disc brake are linked to the drive shaft 80 which is in rotation, and the other half is linked to
the support ring which is unmoved. The brake pressed the disc brake one against each other, so the rotation
of the drive shaft is stopped and the translation of the excavator.
The cinematic scheme explains how the travel brake is working.
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Track components
16.2Track components
1 Track drive sprocket and final drive 11 Rotary connection

2 Idler 12 Ladder
4 Track roller 14 Cover
5 Carrier roller 15 Cover
6 Track link 18 Hexagonal screw
7 Track pad 19 Hexagonal screw
8 Pin 21 Protection screw
9 Chain guide front 22 Chain guide

10 Chain guide back
Tightening torque :
13 Fixing side frame / central part M42 4810 Nm
18 Fixing track roller / track guide M30 1900 Nm
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Track components
Fixing sprocket / gear M30 x 2 1940 Nm
Fixing gear / support M30 x 2 1940 Nm
Track pad bolt M39 x 2 5590 - 6180
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Track components
16.2.1Track pads
1 Track link 5 Elastic washers

2 Track pad 6 Hexagonal head screw
3 Bushing 7 Nut
4 Pin
16.2.1.2Description of the track chain

One track chain is constiture of 49 track links (pos. 1). The links of the track chain are assembled to each other
with pins (pos. 4) mounted in bushings (pos. 3). Elastic washers (pos. 5) compensate the axial play. The pins
are mounted tightened on their extremities and sliding in the bushing. The pads are fixed on the links with hexa-
gonal head screws (pos. 6) which are bolted in the nuts (pos. 7). These nuts are inserted in the link holes.
Type of the hexagonal head screws : M39 x 2.
Tightening torque of the hexagonal head screws : 5590 - 6180 Nm.
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Track components
16.2.2Track rollers
2 Roller shaft 8 Screw plug

3 End part 9 Gasket ring
4 Bushing 10 Sealing
6 Roller pin 11 Track roller housing

7 O-ring 12 Lifetime seal
The track rollers make easier the rotation of the track chain, and permit the good alignment of the track chain.
Each track roller is fixed with 4 screws M30. The tightening torque of the screw is 1900 Nm. It must be checked
regularly (see Operation and Maintenance Manual).
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Track components
16.2.2.3Lubricant
Each track roller must be filled with 2700 cm3 of lubricant Agip Diesel Sigma S30 Pordoi - 30G. No other lubri-
cant is accepted.
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Track components
16.2.3Carrier rollers
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Track components
2 Axle 7 End part

3 Hinge 8 O-ring
4 Bushing 9 Roll pin
5 O-ring 10 Lifetime seal
6 Sealing 11 Carrier roller body
The carrier rollers (pos. 5) make easier the rotation of the track chains, permit the good alignment of the track
chains and allow to tighten the track chains. Two carrier rollers are mounted on each side of the excavator.
The four screws M24 (pos. 10) for the fixing of each carrier roller are tightened at 960 Nm. The tightening torque
must be checked regularly (see Operation and Maintenance Manual).
16.2.3.3Lubricant
Each carrier roller must be filled with 1820 cm3 of lubricant Agip Rotra LSX mixed with 202 cm3 of the additive
Agip Rocol ASO R. No other lubricant is accepted.
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Track components
16.2.4Idler
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Track components
2 Axle 10 Screw plug

3 Bushing 11 Roll pin
4 Thrust washer 12 Hex nut
5 Slider 13 Washer
6 Slide 14 Hexagon bolt
7 O-ring 15 Idler wheel
8 Sealing 20 Lifetime seal
9 Sealing
The idler is the second principal point of rolling of the track. It is also the intermediate part between the track
and the tension unit.
The idler is blocked thanks to the roll pin 11 and the nut 12. The tightening torque of the nut is 1900 Nm. It must
be checked regularly (see Operation and Maintenance Manual).
16.2.4.3Lubricant
Each idler wheel must be filled with 4000 cm3 of lubricant Total Fina transmission RS FE 80W90. No other lu-
bricant is accepted.
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Track components
16.2.5Sprocket
The sprockets mesh with the track chains, and allow the excavator to translate.
The sprocket (pos. 5) is fixed on the travel gear (pos. 1) thanks to the 45 screws M30 x 2.
The tightening torque of the screws 6 is 1940 Nm. It must be checked regularly (see Operation and Maintenan-
ce Manual).
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Track components
16.2.6Track guides
To permit to the track chains to be guided, three guides per side have been mounted :
– 1 : Chain guide front.
– 2 : Middle chain guide.
– 3 : Chain guide back.
Each guide is fixed to the side frame with screws M30.
The tightening torque of these screws is 1900 Nm.
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Track components
16.2.7Tensioning cylinder and grease cylinder
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Track components
For the tightening of the track chains, the system uses an hydraulic tensioning which pushes the idler via the
grease cylinder. The tensioning cylinder lays into the side frame, and it is guided in translation thanks to a guide
rail. The grease cylinder is used to adjust the track tension thanks to a grease gun (see Operation and Main-
tenance Manual).
The grease BP energrease LS EP2 (Ident Nr. 8501527 for a container of 180 kg) has to be used.
For the dismounting of the chain tracks, the hydraulic pressure which supplies the tensioning cylinder must be
stopped by closing the cylinder shut off valve (see §12 Track tensioning system).
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Track components
16.2.8Monitoring
Verify periodically that the maximal wear limits haven’t been reached. If the maximal wear limits have been rea-
ched, change the defective components.
16.2.8.1Track pads
New : Hn mm (inch) 65 (2.56)
Max. wear limit : Hv mm (inch) 40 (1.57)
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Track components
16.2.8.2Idler
New : Hn mm (inch) 48 (1,89)

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Track components
16.2.8.3Track roller
New : Dn mm (inch) 326 (12.93)
Max. wear limit : Dv mm (inch) 301 (11.81)
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Track components
16.2.8.4Carrier roller
New : Dn mm (inch) 270 (10.63)
Max. wear limit : Dv mm (inch) 254 (10)

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Track components
16.2.8.5Track chain link
New : Hn mm (inch) 245 (9.65)
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Track components
16.2.8.6Link pitch - four sections
New : Ln mm (inch) 1400 (55.12)
Max. wear limit : Lv mm (inch) 1425 (56.10)

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Track components
16.2.8.7Track chain bushing
New : Dn mm (inch) 133 (5.24)
Max. wear limit : Dv mm (inch) 128 (5.04)

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Track components
16.2.9Installation / removal of the track components

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Track components
16.2.9.1Installation and removal of the track pads and track-chains

See also SWP n°005 and n°011 in §2 Safe work procedure.
To change damaged track pads
The procedure to change a track pad is following :

– Park the excavator on a flat and solid ground. The pad, which has to be replaced, must be between the
carrier rollers.
– Carefully unscrew lubricating nipple 2 (see the figure before) by several thread pitches until the grease oo-
zes out of the nipples annular groove. Thus the pressure in the tensioning cylinder will be released.
– Remove the four fixing screws 6 of the damaged pad.
– Remove the pad and replace by a new one.

– Fix the pad on the track links by tightening the screws 6 on the bolts 7 at prescribed torque.
– Screw high pressure hose 1 onto the manual grease gun.
– Through the opening, connect the high pressure hose 1 with the special fitting 2 of the grease tension jack
(see figure before).
– Inject grease until the track is sufficiently tensioned.
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Track components
To remove the complete track-chain
– Park the machine on a flat and solid ground. Insert a wedge.

– Carefully unscrew lubricating nipple 2 (see the figure before) by several thread pitches until the grease oo-
zes out of the nipples annular groove. Thus the pressure in the tensioning cylinder will be released.
– Use the track press (see § Tooling) to remove the pin located over the sprocket.
Warning : the track could roll away quickly.
– To split the track-chain, start the machine up. Move the excavator slowly to roll the track-chain out.
– Lift the side of the machine and using a tractor, pull the track-chain out.
– Install supports under the machine, lower machine onto supports.
To install the complete track-chain

– The pressure in the tensioning cylinder must be released.
– Start the engine and lift the machine.
– Drag the track-chain under the excavator.
– Lower the excavator on track-chains and position correctly.
– By lifting its first extremity with an appropriate equipment, wind the track-chain round the idler and make it
lie on the carrier rollers.
– By lifting its second extremity with an appropriate equipment, wind the track-chain round the sprocket. Make
sure that the chain is mounted in the correct travel direction and that the track pads are correctly positioned.
– Position the two remaining links in alignment and insert joining pin (pos. 4) with the track press (see § Too-
ling).
– When the track-chains are mounted on each side of the excavator, retension the track-chain.
– Run the Diesel engine and actuate the travel movement to activate the track tension.
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Track components
16.2.9.2Track rollers
See also SWP n°010 in §2 Safe work procedure.
To remove and to install the track rollers
– Lift side of excavator until the track is far enough off the ground to accommodate safety stands.
– Remove the screws 4 and the track guide 2.
– Release the track tension corresponding to the side you want to work on. Thus the pressure in the tensio-
ning cylinder will be released.
– Place safety under rollers, so as the roller you are working on is free from obstruction.
– Lower machine back down onto stands. Making sure bucket stays on the ground. Turn machine off.
– Use Hy-torque to crack tension off every four bolts. Remove two bolts 3 on lower side of roller which become
inaccessible - due to lifting device.
– Use a lifting tool and lift apparatus and place it under roller. Take the weight of the roller.
– Remove the two remaining bolts 3 and remove the roller 1.
– Re-fit the new roller and install two bolts that are accessible and tighten most of the way up.
– Remove lifting tool and replace remaining bolts. Torque all bolts to prescribed tension.
– Re-fit the track guide and tighten it screws to prescribed torque.
– Lift machine and remove stands.
– Place machine back onto the ground and release the track tension.
– Run the diesel engine and actuate the travel movement to activate the track tension.
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Track components
16.2.9.3Carrier rollers
– Release the track tension corresponding to the side you want to work on. Thus the pressure in the tensio-
ning cylinder will be released.
– Using a loader or a jack, lift the track-chain into appropriate position and insert blockes between upper edge
of side frame and block up the track-chain.
– Remove screws 10 from roller 5. Using loader forks and remove roller 5 from the machine.
– Replace roller on machine and install screws. Jack or lift track-chains and remove the blocks. Lower track-
chains back onto rollers and remove jacks.
– Retension the track.
– Run the diesel engine and actuate the travel movement to activate the track tension.
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Track components
16.2.9.4Idler (idler wheel with the sliders)

– Remove the track-chain : lay out the chain, do not remove from under load rollers.
– Attach sling to idler 5 and use a loader or tractor to low the idler out on the track chain.
– Remove the screws 7 and the idler 5 and replace.
– Use a crane to hold up the rear section of the idler.
– Use loader to push the idler back into place.
– Reinstall the track-chain.
16.2.9.5Sprocket
For the installation and the removal of the sprocket see the part «Installation / Removal» in the subgroup «Tra-
vel gear».
16.2.9.6Installation and removal of the tensioning unit (tensioning cylinder and

grease cylinder)
Installation
– Put the tensioning cylinder and the grease cylinder in their housing in the side frame.
– Fix the oil induction hose and the return hose to the tensioning cylinder.
– Install the complete idler (see the part installation of the complete idler.
– Install the complete track-chain.
Removal
– Remove the complete track-chain.
– Remove the complete idler.
– Drain the tensioning cylinder.
– Dismount the oil induction hose and the return hose of the tensioning cylinder.
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Track tensioning (non hydraulic)
16.3Track tensioning (non hydraulic)
16.3.1Function / operation
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Track tensioning (non hydraulic)
2 Idler
4 Track roller
5 Carrier roller
The track tensioning is the system, which stretches the track chains. The functioning of this system is described
in the § Hydraulic track tensioning system.
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Preassembled modules
16.4Preassembled modules
16.4.1Component location
16.4.2Mounting / dismounting modules

For ease the transport, the undercarriage can be dismantled in 3 different parts :
– the center piece.
– Two side frames.
The side frames are fixed on the center piece thanks to hexagonal head screws M42 (see pos.1 and pos. 2).
The tightening torque necessary for the fixing of the side frame on the central part is 4810 Nm.
The tightening torque must be checked regularly (see Operation and Maintenance Manual).
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Preassembled modules
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Chapter 16 - Undercarriage Mechanical: Service Manual

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Service Manual

Chapter 16 - Undercarriage mechanical

R 9250 from 13466 16 - 1

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Gear type FAT 1000 / 102

Max. output speed min-1 12,9

Brake Disk brake / spring applied, pressure released

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Hydraulic part of the travel system

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Travel gear with motors

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1 Planetary carrier 30 Internal geared wheel

20 Planer wheel 55 Intermediate shaft

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56 Thrust washer 71 Screw M16 x 65

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79 Screw plug 88 Plate carrier

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16.1.3.1Installation and removal of the inner travelling mechanism

16.1.3.2Installation and removal of the travel gear in the excavator

Pos. Component Pos. Component

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1 Side frame 25 Travel motor protection right

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16.1.4.1Travel brake function / operation

1 Support ring 90 Motor flange

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1 Track drive sprocket and final drive 11 Rotary connection

9 Chain guide front 22 Chain guide

13 Fixing side frame / central part M42 4810 Nm

18 Fixing track roller / track guide M30 1900 Nm

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Fixing sprocket / gear M30 x 2 1940 Nm

Fixing gear / support M30 x 2 1940 Nm

Track pad bolt M39 x 2 5590 - 6180

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1 Track link 5 Elastic washers

16.2.1.2Description of the track chain

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2 Roller shaft 8 Screw plug

6 Roller pin 11 Track roller housing

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2 Axle 7 End part

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2 Axle 10 Screw plug

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16.2.7Tensioning cylinder and grease cylinder

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