349 1 en 2009-04-06

CRAWLER BASE:
DX500/DX680/DX700/DX780/DX800/DQ500
Table of Contents

1. SAFETY . 3

2. LOCATION OF COMPONENTS ............................................................................................ 4

3. ENGINE AND COMPRESSOR .............................................................................................. 5

3.1. Engine ......................... 5
3.1.1. Engine oil, oil filter and crankcase breather ................................................................................ 6
3.1.2. Bleeding the fuel system ................................................................................................................ 7
3.1.3. Water separator/filter ...................................................................................................................... 8
3.1.4. Engine cooling system ................................................................................................................... 9
3.1.5. Radiator core ... 10
3.2. Engine and compressor air filters ....................................................................................................... 11
3.2.1. Service and replacement of air filters ........................................................................................... 12
3.3. Checking and changing oil of Stiebel transfer gear ....................................................................... 13
3.3.1. Oil recommendation of Stiebel transfer gear .............................................................................. 14

4. UPPER FRAME ..................................................................................................................... 15

4.1. Receivers .................... 15
4.1.1. Hydraulic oil receiver ...................................................................................................................... 15
4.1.2. Fuel receiver .... 16
4.2. Upper frame swing cylinder .................................................................................................................. 17
4.2.1. Adjusting the double pressure-relief valve (194) ........................................................................ 18
4.2.2. Removing the cylinder .................................................................................................................... 18
4.3. Upper frame extra swing cylinder (optional) .................................................................................... 19
4.4. Upper frame swing joint ......................................................................................................................... 19
4.4.1. Removal of upper frame from lower frame ................................................................................. 20

5. COMPONENTS OF TRAMMING HYDRAULICS .................................................................. 21

5.1. Rexroth final drive hydraulic schema ................................................................................................. 22
5.2. Trasmital final drive hydraulic schema .............................................................................................. 23
5.3. Mottrol final drive hydraulic schema .................................................................................................. 24
5.4. Operation .................... 25
5.4.1. Tramming from cabin ...................................................................................................................... 25
5.4.2. Slow speed ....... 25
5.4.3. Fast speed ........ 25
5.4.4. Stopping ............ 25
5.4.5. Remote control 26

6. OSCILLATION ....................................................................................................................... 27
6.1. Components of oscillation ..................................................................................................................... 27
6.2. Operation .................... 28
6.2.1. Operation of oscillation hydraulics ................................................................................................ 29
6.3. Oscillation cylinders 29
6.3.1. Removing the cylinders .................................................................................................................. 29

7. TRACKS AND DRIVE GEAR ................................................................................................ 30

7.1. Adjusting tracks ....... 30

Copyright © Sandvik Mining and Construction 1 (38)

ID: 349 1 en 2009-04-06
 7.2. Checking and adding final drive oil ..................................................................................................... 31
7.2.1. Draining final drive oil ..................................................................................................................... 31
7.3. Trasmital final drive checking and adding oil .................................................................................. 32
7.3.1. Trasmital final drive changing oil .................................................................................................. 33
7.4. Mottrol final drive checking and adding oil ....................................................................................... 34
7.4.1. Mottrol final drive changing oil ....................................................................................................... 35
7.5. Removing of the track chain ................................................................................................................. 35
7.5.1. Assembling the track chain ............................................................................................................ 35
7.6. Removing the final drive ........................................................................................................................ 36

2 (38) Copyright © Sandvik Mining and Construction

ID: 349 1 en 2009-04-06
 CRAWLER BASE:
DX500/DX680/DX700/DX780/DX800/DQ500

1. SAFETY ID: 15240

Always follow safety instructions and be careful in your work.

Servicing, adjusting, or repairing the rig is only allowed to per-
sons with special service training for the rig in question. Read
the instructions carefully before servicing, adjusting, or repair-
ing the rig.

Pressurized hydraulic hoses must no be touched by hand. The

hoses may have unnoticeable hairline cracks that let out high--
pressure oil sprays that may penetrate the skin.

Watch out for rotating parts of the rig. Service or repair the rig
only with the engine stopped. Make sure that the rig cannot be
started without cause during the service.

Do not stay under a rig that has not been supported properly.
Do not disconnect hydraulic hoses or valves before having sup-
ported the rig. Before service, support the rigmechanically or
by running a cylinder into its extreme position.

OBSERVE ABSOLUTE CLEANNESS WHEN DISMANTLING AND

REASSEMBLING HYDRAULIC EQUIPMENT. Whenever a cylin-
der has been removed, the hydraulic circuit must be vented and
flushed. This is done to prevent dirt and air in the cylinder from
causing functional disturbances.

Copyright © Sandvik Mining and Construction 3 (38)

ID: 349 1 en 2009-04-06
CRAWLER BASE:
DX500/DX680/DX700/DX780/DX800/DQ500

2. LOCATION OF COMPONENTS ID: 15241

1 2 8 3

10 9 7 6

ID: 25372

1. Fuel receiver
2. Compressor oil / air receiver
3. Engine cooler
4. Engine air filter
5. Compressor air filter
6. Compressor
7. Hydraulic pumps
8. Side pump
9. Transfer gear
10. Hydraulic oil receiver

4 (38) Copyright © Sandvik Mining and Construction

ID: 349 1 en 2009-04-06
 CRAWLER BASE:
DX500/DX680/DX700/DX780/DX800/DQ500

3. ENGINE AND COMPRESSOR ID: 15242

3.1. Engine ID: 15243

Refer to your engine operation and maintenance manual to get the detailed instructions.

4 2 3 1

ID: 25591

1. Dipstick
2. Oil drain plug
3. Oil filter
4. Oil filling plug
5. Crankcase breather
6. Fuel filter
7. Water separator / filter

Copyright © Sandvik Mining and Construction 5 (38)

ID: 349 1 en 2009-04-06
CRAWLER BASE:
DX500/DX680/DX700/DX780/DX800/DQ500

3.1.1. Engine oil, oil filter and crankcase breather ID: 15244

• Check engine oil level daily with the dipstick. The oil level must be between ”add” and ”full” marks.
• Change both engine oil and oil filter every 200 operating hours.
• At the same time clean the crankcase breather (5).

ID: 25605

6 (38) Copyright © Sandvik Mining and Construction

ID: 349 1 en 2009-04-06
 CRAWLER BASE:
DX500/DX680/DX700/DX780/DX800/DQ500

3.1.2. Bleeding the fuel system ID: 15245

The fuel system can be bled with a pump (1). Refer to your engine operation and maintenance manual
to get the detailed instructions.

ID: 25618

Copyright © Sandvik Mining and Construction 7 (38)

ID: 349 1 en 2009-04-06
CRAWLER BASE:
DX500/DX680/DX700/DX780/DX800/DQ500

3.1.3. Water separator/filter ID: 15246

Frequency of water draining is determined by the amount of impurities in the fuel. Water is heavier
than fuel and will settle to the bottom of the bowl (D). The bowl must be drained before the water level
reaches the bottom of the filter element (E). Check the water amount in the bowl every day; drain the
bowl of water by opening the drain valve (F).
As the filter element slowly gets blocked by impurities, the fuel flow to the engine becomes restricted,
resulting in noticeable power loss and/or troubles in starting the engine.
Vacuum gauge (H) monitors the condition of the filter. When the reading of the gauge is between 7
and 8, the filter must be replaced. Check the reading of the gauge every day; note that the engine
must be running at full speed during the checking.
Never let the engine run when the gauge reading is over 9!

Replace the filter element every 200 engine hours or if you notice any power loss in the engine.
1. Drain off some fuel from the bowl by opening drain valve (F).
2. Spin element (E) and bowl (D) off together.
3. Remove the bowl from the element and replace o-ring (G).
4. Apply a coating of clean fuel or engine oil to the o-ring and element seal.
5. Spin the bowl onto the new element and spin them onto the filter head manually.Do not use any
tools for the tightening!
Do not pre-fill the filter with fuel!

F G

ID: 21015

Water separator/ fuel filter

• check the reading of the gauge when the engine is running at full speed
• replace the filter element when the needle is between 7 and 8 (inHG)
• never let the engine run when the reading is over 9!

8 (38) Copyright © Sandvik Mining and Construction

ID: 349 1 en 2009-04-06
 CRAWLER BASE:
DX500/DX680/DX700/DX780/DX800/DQ500

3.1.4. Engine cooling system ID: 15247

At the upper part of the engine there is an inlet air intercooler and at the lower part a water cooler.
Expansion vessel is located beside the cooler.
Always use antifreeze solution or cooling system conditioner to protect the cooling system from cor-
rosion. Check the proper concentration from engine instruction booklet.

OK

ID: 21026

Check the amount of cooling liquid daily when the engine is cold. The amount of cooling liquid is
correct when the liquid level reaches the bottom of the expansion vessel filling pipe.
Engine revolution speed drops first to idle and stops after a delay if the amount of cooling liquid drops
too low. At the same time the control display displays a notice.
Hot fluid and steam can cause severe injuries. Never open the
radiator cap when the engine is hot or running.

Never add cold coolant to hot engine as this may damage the
cylinder head.

Change antifreeze solution every 1800 operating hours. Drain both engine and radiator. Mix the
antifreeze solution and refill cooling system slowly to avoid air pockets. Start the engine with expan-
sion vessel cap off and let the coolant level stabilize. Add coolant if necessary. Check the cooling
system for leaks at the same time.

Copyright © Sandvik Mining and Construction 9 (38)

ID: 349 1 en 2009-04-06
CRAWLER BASE:
DX500/DX680/DX700/DX780/DX800/DQ500

3.1.5. Radiator core ID: 15248

• Clean the radiator core every 50 hours for impurities. Always inspect/clean the radiator core with
the engine stopped.
• If you use a high pressure washer for the cleaning, be careful not to damage the radiator core.
• Normal impurities, such as dust, can also be removed with pressurized air. Do not use a higher air
pressure than 4 bar.
The engine is equipped with a suction fan. Blow the radiator
clean from the fan side.

10 (38) Copyright © Sandvik Mining and Construction

ID: 349 1 en 2009-04-06
 CRAWLER BASE:
DX500/DX680/DX700/DX780/DX800/DQ500

3.2. Engine and compressor air filters ID: 15249

The engine and the compressor have separate air filters that are located in the rear of the rig on top
of the engine. The air filter unit includes a pre-separator and a filter element.

2
4 1
1
3
4
3

ID: 25659

Air is drawn in the filter through the hole (1). The intake air gets into a whirling motion which separates
the heavier particles from the air. The engine exhaust gases create suction that draws the particles
out through the ejector tube (2). The pre-cleaned air is then drawn through the air filter (3) and the
safety filter (4) into the engine and the compressor.

3 4 1 5

ID: 25660

1. Intake holes
2. Ejector tube
3. Filter element
4. Safety filter element

Copyright © Sandvik Mining and Construction 11 (38)

ID: 349 1 en 2009-04-06
CRAWLER BASE:
DX500/DX680/DX700/DX780/DX800/DQ500

5. Service indicator

The purpose of the safety filter element is to prevent impurities from entering the intake holes while
the filter element is removed or in case the filter element breaks down.

3.2.1. Service and replacement of air filters ID: 15251

The air filter units are equipped with a service indicator (5). When the engine or compressor air supply
is disturbed because the air filter is blocked, the service indicator shows red colour.
The function of the service indicator is must be checked daily by pressing the button at the end of the
indicator. The red float should move freely.
The filter element must be cleaned or replaced when the service indicator shows red. The filter ele-
ment must be replaced at least every 600 hours or every 6 months.
The filter element can be cleaned max. six times. Note that the
filtering capacity and structure of the element are weakened af-
ter every cleaning.

When the filter element is cleaned or changed the safety filter

element must be kept in place.

The safety filter element must not be cleaned.

The safety filter element must be replaced when the filter element has been replaced three times, or
at least every 1200 hours.
Cleaning the filter element
• Outwards from the clean side.
• With pressurized air: max 6 bar from over 5 cm distance.
• With water without a nozzle: max 2.5 bar.
• The filter element can also be cleaned with a washing agent recommended by the producer, see
instructions of the producer.
• Dry the element after having cleaned it with water. The drying temperature must be below 82_C.

After cleaning, put a bright light inside the filter element to

check any possible damage. Turn the filter around slowly; if you
notice any luminous points or other damage, replace the filter
immediately.

When changing the filters, always check the seals and the seal-
ing surfaces. Carefully install the seals in their correct places.
When changing the filters, also check the engine and the com-
pressor intake lines and their connections.

12 (38) Copyright © Sandvik Mining and Construction

ID: 349 1 en 2009-04-06
 CRAWLER BASE:
DX500/DX680/DX700/DX780/DX800/DQ500

3.3. Checking and changing oil of Stiebel transfer gear ID: 15252

• Check the transfer gear oil level (1) daily.

• Change the transfer gear oil after first 200 engine hours and then after every 1200 engine hours.
• Oil capacity is about 3,2 litres. Always check the oil level by the dipstick.
• Drain plug (2) and filling plug (3).
• Open air plug (4) to help oil filling.
• Clean the breather (5) during every oil change by compressed air.
Only use the oils according to the oil recommendation next page.

4
1

max 2

min

ID: 25702

Copyright © Sandvik Mining and Construction 13 (38)

ID: 349 1 en 2009-04-06
CRAWLER BASE:
DX500/DX680/DX700/DX780/DX800/DQ500

3.3.1. Oil recommendation of Stiebel transfer gear ID: 15253

Lubricant typer Synthetic oil PAO

Kine. viscosity mm2/s 40° C 220 100

Ambient temperature -25 ... 80° C -35 ... 60° C
ARAL Degol PAS 220
BP Enersyn HTX 220
Castrol Alphasyn T 220 Alphasyn T 100
Elf Reductelf Synthese 220
DEA Intor HCLP 220
Esso Spartan Synthetic EP 220
FUCHS Renolin Unisyn CLP HC 220 Renolin Unisyn CLP HC 100
Mobil Mobilgear SHC XMP 220 Mobilgear SHC XMP 100
KLÜBER Klübersynth EG-4-220
Agip Agip Blasia SX 220 Agip Blasia SX 100
Chevron Tugra Synthetic Gear Lubricant
220
Shell Shell Omala Oil HD 220
Optimal Synthetic A 220 Synthetic A 100

Factory filling: Shell Gear HDS 150 Synthetic gear oil.

14 (38) Copyright © Sandvik Mining and Construction

ID: 349 1 en 2009-04-06
 CRAWLER BASE:
DX500/DX680/DX700/DX780/DX800/DQ500

4. UPPER FRAME ID: 15254

4.1. Receivers ID: 15255

4.1.1. Hydraulic oil receiver ID: 15256

Hydraulic oil receiver is located on the left side of the rig.

1 3

ID: 25713

1. Breather filter
2. Oil level sight glass
3. Hydraulic oil return filter
4. Collecting piece

Hydraulic oil level is checked in the level indicator on the left side of the receiver. The oil level should
be half way up the sight glass. A hand pump is used for filling the hydraulic and the compressor oil
receivers. Choose the receiver to be filled with a 3--way valve on the top of the hand pump.
The hydraulic oil receiver breather filter is located on the top of the receiver (changing interval 600
h).
The hydraulic oil return filter is inside the receiver. To change the return filter the cover on top of the
receiver must be opened. Before the cover is removed, the top of the receiver must be carefully
cleaned to prevent dirt from entering the receiver. The sealing surfaces of the filter element must
always be checked and carefully pressed into the grooves.
The hydraulic system pressure filter is located at the rear of the control panel. The filter is equipped
with an electric device that indicates when the filter element should be replaced.
The filter indicator light may go on for a while when the engine
is started and the hydraulic oil is still cold. This does not, how-
ever, mean that the filter is clogged.

Copyright © Sandvik Mining and Construction 15 (38)

ID: 349 1 en 2009-04-06
CRAWLER BASE:
DX500/DX680/DX700/DX780/DX800/DQ500

4.1.2. Fuel receiver ID: 15257

Fuel receiver is located in the front right-hand corner.

1 3

ID: 25718

1. Breather filter
2. Drainage plug
3. Filling cap

• Use only clean fuel for refilling the receiver; it is extremely important to keep fuel containers clean
and drained of water.
• Clean the area around the filling tube carefully before opening the fuel receiver filling cap. This
prevents dust and other impurities from entering the receiver.
• Keep the filling pump valve clean; when using a hand pump take care that the pump inlet hose and
the fuel container intake hole are clean.
• Clean the electric filling pump valve and protect it from impurities before filling the tank.
• Do not keep the tank filling cap open when using the electric pump.
• Drain water from the fuel tank regularly (every 50 hours or once a week). Clean the tank every 1200
engine hours.
• Replace the breather every 600 engine hours or if it is moistened by fuel (overfilled).
• Fill the fuel tank at the end of each day of operation to drive out moist air and to prevent
condensation. Do not fill the tank to the top. Fuel expands as it gets warm and may overflow.

16 (38) Copyright © Sandvik Mining and Construction

ID: 349 1 en 2009-04-06
 CRAWLER BASE:
DX500/DX680/DX700/DX780/DX800/DQ500

4.2. Upper frame swing cylinder ID: 15258

The upper frame swing cylinder is equipped with end-position damping and a manifold-mounted
double overcenter valve. The manifold must not be replaced with hydraulic hoses. Double pressure-
relief valve (194) of the cylinder.

182

B2 A2

194
B1 A1

181

ID: 25730

Copyright © Sandvik Mining and Construction 17 (38)

ID: 349 1 en 2009-04-06
CRAWLER BASE:
DX500/DX680/DX700/DX780/DX800/DQ500

4.2.1. Adjusting the double pressure-relief valve (194) ID: 15259

A2 B2

A1 MA B1 MB

ID: 25732

1. Plug the hoses leading to the swing cylinder (valve ports A2 and B2).
2. Connect a pressure gauge to the measuring point (MA) at the port (A1).
3. While the engine is running at full speed, pressurise the port (A2) by turning the upper carriage
to the left.
4. Adjust the pressure to 130 bar.
5. Connect the pressure gauge to the measuring point (MB) at the port (B1).
6. While the engine is running at full speed, pressurise the port (B2) by turning the upper carriage
to the right.
7. Adjust the pressure to 180 bar.
8. Lock the adjustments.

4.2.2. Removing the cylinder ID: 15260

1. Drive the rig onto level ground.

2. Support the upper frame immovable in relation to the lower frame by, for instance, pressing the
feed stinger firmly against the ground.
3. Operate the cylinder hydraulically to find the point where the cylinder pins are not under load.
4. Loosen the overcenter valves just enough to release the cylinder pressures.
5. Disconnect the hydraulic hoses of the cylinder. Plug and mark the connections.
6. Support the cylinder and remove the pins.

18 (38) Copyright © Sandvik Mining and Construction

ID: 349 1 en 2009-04-06
 CRAWLER BASE:
DX500/DX680/DX700/DX780/DX800/DQ500

4.3. Upper frame extra swing cylinder (optional) ID: 15261

The upper frame extra swing cylinder is equipped with a manifold-mounted double overcenter valve.
The manifold must not be replaced with hydraulic hoses.
Removing the cylinder
1. Drive the rig onto level ground.
2. Support the upper frame immovable in relation to the lower frame by, for instance, pressing the
feed stinger firmly against the ground.
3. Operate the cylinder hydraulically to find the point where the cylinder pins are not under load.
4. Loosen the overcenter valves just enough to release the cylinder pressures.
5. Disconnect the hydraulic hoses of the cylinder. Plug and mark the connections.
6. Support the cylinder and remove the pins.

ID: 17045
1. Upper frame swing cylinder
2. Upper frame extra swing cylinder

4.4. Upper frame swing joint ID: 15263

Two radial bearings and one axial bearing are used at the swing joint between the upper frame and
the lower frame. Regular lubrication of the bearings significantly lengthens their operational life.

Copyright © Sandvik Mining and Construction 19 (38)

ID: 349 1 en 2009-04-06
CRAWLER BASE:
DX500/DX680/DX700/DX780/DX800/DQ500

4.4.1.
Removal of upper frame from lower frame ID: 15264

1. With the boom in the transport position, move the rig onto level ground.
2. Connect the lifting hooks (Cf. Fig.) and lift the upper frame enough to keep it steady.

ID: 25400

Lifting points on the rig; 1, 2 and 3

3. Remove the upper frame swing cylinder (don’t remove the upper frame extra swing cylinder).
4. Disconnect the hydraulic hoses between the upper frame and lower frame. Plug and mark the
connections.
5. Remove the swing joint locking cover.
6. Lift the upper frame off the lower frame as straight as possible.
7. Lower the upper frame onto a strong and steady base for repairs.
DANGER
Never stay under a load that is hanging from lifting ropes.

20 (38) Copyright © Sandvik Mining and Construction

ID: 349 1 en 2009-04-06
 CRAWLER BASE:
DX500/DX680/DX700/DX780/DX800/DQ500

5. COMPONENTS OF TRAMMING HYDRAULICS ID: 15266

1. Variable displacement pump.

130. Pilot control valve for the tramming valve 135; the valve is used for controlling the right and
left track of the rig.
131. Remote control tramming valve (optional); the valve is used for controlling the left track of the
rig.
133. Tramming mode selector valve (optional); the valve is used for selecting either tramming from
cabin or using remote control for tramming.
134. Remote control tramming valve (optional); the valve is used for controlling the right track of
the rig.
135. Tramming valve; divides oil flow to the left and the right tramming motor. The valve includes
main pressure relief valve 138 and pressure compensators 139 and 140, and inlet valves 152
and 153.
136. Right tramming valve spool; determines the volume of the oil flow to the right tramming motor.
137. Left tramming valve spool; determines the volume of the oil flow to the left tramming motor.
138. Main pressure relief valve for the operation of pump 1. Set value 320 bar.
139. Tramming spool pressure compensators. A pressure compensator ensures that the tramming
140. speed remains unchanged despite changes in load.
143. Right tramming brake valve; acts as a hydrostatic brake preventing the motor from rotating by
keeping the return line closed. Also prevents the rig from rushing when tramming downhill.
144. Left tramming brake valve; acts as a hydrostatic brake preventing the motor from rotating by
keeping the return line closed. Also prevents the rig from rushing when tramming downhill.
145. Right brake.
146. Left brake.
147. Right tramming motor.
148. Left tramming motor.
149. Tramming speed selector valve; used for selecting slow/fast tramming speed. The valve is
controlled by the selector switch in the cabin.
150. Control cylinder for swash plate angle (RH).
151. Control cylinder for swash plate angle (LH).
152. Inlet valves; prevent motor cavitation.
153.
154. Pressure switch; switches on back-up alarm when reversing.

Copyright © Sandvik Mining and Construction 21 (38)

ID: 349 1 en 2009-04-06
CRAWLER BASE:
DX500/DX680/DX700/DX780/DX800/DQ500

5.1. Rexroth final drive hydraulic schema ID: 32568

146 145

151 148 150 147

144 143

149

X5
153 152

137 136
133
135

138

140 320 139

130
154

134 131

132

80 50 1 90

ID: 25521

22 (38) Copyright © Sandvik Mining and Construction

ID: 349 1 en 2009-04-06
 CRAWLER BASE:
DX500/DX680/DX700/DX780/DX800/DQ500

5.2. Trasmital final drive hydraulic schema ID: 32569

ID: 32571

Copyright © Sandvik Mining and Construction 23 (38)

ID: 349 1 en 2009-04-06
CRAWLER BASE:
DX500/DX680/DX700/DX780/DX800/DQ500

5.3. Mottrol final drive hydraulic schema ID: 32570

ID: 32572

24 (38) Copyright © Sandvik Mining and Construction

ID: 349 1 en 2009-04-06
 CRAWLER BASE:
DX500/DX680/DX700/DX780/DX800/DQ500

5.4. Operation ID: 15267

The rig is equipped with piston motors (hub gear). Two tramming speed ranges are available. Max.
tramming speed is 3.5 km/h.

5.4.1. Tramming from cabin ID: 15268

The pilot control valve (130) levers are used for moving the tramming valve (135) spools hydraulically.
Pilot pressure comes from the energized tramming mode selector valve (133).
The idling pressure of the pump (1) affects the spools through the pressure compensators of the
tramming valve (135). When the pilot control levers are moved, control pressure moves the spools
accordingly. When the spools are deviated from neutral position, the load sensing line to the pump
regulator is opened. The pump is adjusted to an output corresponding the load of the tramming motor.
Oil flows through the tramming valve into the tramming motor and opens the tramming brake valves
(143 and 144) in the return line. At the same time oil pressure opens the tramming motor brakes (145
and 146) through the shuttle valve.
The return oil from the tramming motor flows through the tramming brake valve and the tramming
valve into the receiver.

5.4.2. Slow speed ID: 15269

When the tramming speed selector valve (149) is without voltage, the control cylinders (150 and 151)
move the tramming motor swash plate to maximum angle to gain slow tramming speed and high
torque.

5.4.3. Fast speed ID: 15270

When the tramming speed selector valve (149) gets voltage, tramming circuit pressure affects the
piston side of the control cylinders (150 and 151) moving them against the spring to extreme positions.
This, in turn, gives a smaller angle to the tramming motor swash plate and results in high tramming
speed and less torque.

5.4.4. Stopping ID: 15271

The rig is stopped by returning the pilot control levers to neutral position. The pilot pressure is released
through the control valve into the receiver; the tramming valve spools (136 and 137) return to neutral
position. The tramming circuit pressure is released through the tramming valve spools into the re-
ceiver. The springs now push the tramming motor brakes on.
When the rig is stopped, or when the tramming speed gets too high (e.g. when tramming downhill),
the tramming motor tends to act as a pump due to external load. Since the pressure in the line to the
tramming motors drops, the control pressure in the tramming brake valves (143 and 144) drops as
well. The valve moves towards neutral position restricting the return flow and that way the motor
speed. Thus the valve operates as a hydraulic brake preventing the rig from rushing downhill.
When the rig has stopped, the spools of the tramming brake valves return in neutral position. Together
with the mechanical brakes this ensures that the rig stands still.

Copyright © Sandvik Mining and Construction 25 (38)

ID: 349 1 en 2009-04-06
CRAWLER BASE:
DX500/DX680/DX700/DX780/DX800/DQ500

5.4.5. Remote control ID: 15272

Pilot control pressure comes from the drilling block through the unenergized tramming mode selector
valve (133).
The remote control valve block contains electrical remote control tramming valves (131 and 134) for
both tramming motors. The block also includes a pressure reducing valve (132), which is used for
selecting maximum tramming speed. Control pressure affects the position of the spools and the oil
flow to the tramming motors through the shuttle valve.

26 (38) Copyright © Sandvik Mining and Construction

ID: 349 1 en 2009-04-06
 CRAWLER BASE:
DX500/DX680/DX700/DX780/DX800/DQ500

6. OSCILLATION ID: 15273

6.1. Components of oscillation ID: 15274

50. Variable displacement pump.

159. Control valve for left oscillation lock-up valves (162 and 168). The valve is used for locking
and unlocking the left oscillation cylinder. It is operated electrically by switch S25 in the cabin
(not shown here). A light in the panel indicates the valve being energized (oscillation unlocked).
160. Control valve for right oscillation lock-up valves (161 and 167). The valve is used for locking
and unlocking the right oscillation cylinder. It is operated electrically by switch S25 in the cabin
(not shown here). A light in the panel indicates the valve being energized (oscillation unlocked).
161. Lock-up valve of the right oscillation cylinder; when closed, the valve prevents oil from flowing
from the piston side of the oscillation cylinder. When needed, the valve locks the right-side
cylinder together with the valve (167)
162. Lock-up valve of the left oscillation cylinder; when closed, prevents oil from flowing from the
piston side of the oscillation cylinder. When needed, the valve locks the left-side cylinder
together with the valve (168).
163. Right oscillation cylinder.
164. Left oscillation cylinder.
165. Oscillation control valve; the valve is used for oscillating the rig. It is operated electrically by
switch S26 in the cabin (not shown here).
166. Oscillation cylinder main lock-up valve; closes the oscillation circuit during tramming when the
lock-up valves (161, 162, 167 and 168) are open.
167. Lock-up valve of the right oscillation cylinder; when closed, prevents oil from flowing from the
piston-rod side. When needed, the valve locks the right-side cylinder together with the valve
(161).
168. Lock-up valve of the left oscillation cylinder; when closed, prevents oil from flowing from the
piston-rod side. When needed, the valve locks the left-side cylinder together with the valve
(162).
169. Flow control valves for the oscillation cylinders; the valves are used for adjusting oscillation
speed.
246. Shuttle valve.

Copyright © Sandvik Mining and Construction 27 (38)

ID: 349 1 en 2009-04-06
CRAWLER BASE:
DX500/DX680/DX700/DX780/DX800/DQ500

168
165

162 164
246 159
166
169
167
X5

160
163
161

80 50 1 90

ID: 17048

6.2. Operation ID: 15275

During tramming the track oscillation must be open; the cylinders are then connected to each other
through cylinder lock-up valves.
Free movement of the tracks ensures good maneuverability and reduces stress in the frame struc-
tures.
After tramming oscillation is locked. This gives good support to chain feed during alignment and
drilling.

28 (38) Copyright © Sandvik Mining and Construction

ID: 349 1 en 2009-04-06
 CRAWLER BASE:
DX500/DX680/DX700/DX780/DX800/DQ500

6.2.1. Operation of oscillation hydraulics ID: 15276

When the rig is oscillated, the hydraulically operated lock-up valves (161, 162, 167 and 168) are open,
provided that the control valves (159 and 160) are open (energized).
The oscillation valve (165) is used for directing oil either to the piston-rod side or the piston side of
the cylinders, depending on the desired oscillation angle.
In case only one track is oscillated, choose first the desired track with an oscillation lock-up control
valve (159 or 160) by using switch S25. The oscillation valve (165) is used for directing oil either to
the piston side or the piston-rod side of the cylinder.
Oil flow is restricted with one way restrictor (169) during oscillation. The movement will be smooth
regardless of the position of the boom and the feed.
Pilot controlled non-return valve (166) ensures that the oscillation will not creep.

6.3. Oscillation cylinders ID: 15277

6.3.1. Removing the cylinders ID: 15278

When removing the cylinders, make sure that the rig is properly
supported.

1. Run the rig onto level ground.

2. Support the rig immovable by, for instance, pressing the feed stinger firmly against the ground as
far to the front as possible.
3. Support the rear end of the upper frame firmly against the ground.
4. By operating the cylinder hydraulically, search the point where the cylinder pins are not under
load.
Do not disconnect hydraulic hoses or valves before having sup-
ported the rig.

5. Disconnect the hydraulic hoses and plug and mark the connections.
6. Support the cylinder and remove the pins (see instructions in boom section).

Copyright © Sandvik Mining and Construction 29 (38)

ID: 349 1 en 2009-04-06
CRAWLER BASE:
DX500/DX680/DX700/DX780/DX800/DQ500

7. TRACKS AND DRIVE GEAR ID: 15279

7.1. Adjusting tracks ID: 15280

15...35 mm

1 2

ID: 25750

Both of the tracks are equipped with a grease-filled tensioning cylinder (1). To tension the track,
grease is pressed into the cylinder with the grease press provided for this purpose.
The track is correctly adjusted when the upper stretch slack is 15–35 mm. If the track needs to be
slackened, open the grease nipple (2) cautiously 2–3 turns, whereby grease will squeeze out of the
cylinder along the groove in the thread of the nipple.

30 (38) Copyright © Sandvik Mining and Construction

ID: 349 1 en 2009-04-06
 CRAWLER BASE:
DX500/DX680/DX700/DX780/DX800/DQ500

7.2. Checking and adding final drive oil ID: 15281

1 2 3

ID: 15622

1. Oil filling plug

2. Oil checking and drainage plug
3. Oil level

• Check oil level every 200 operating hours, and change oil every 600 operating hours.
• When oil level is checked, or oil is added, the gear must be in such a position that the drain plug is
upwards and below the gear centre line (ref. fig.).
• When you are adding oil, open both plugs. Oil filling capacity is 2,0 l. Ref. Oil recommendation for
the quality of oil.
If the amount of oil in the drive gear has increased, it is probable
that the shaft seal of the hydraulic motor is damaged.

7.2.1. Draining final drive oil ID: 15282

ID: 15624

1. Oil filling plug

2. Oil checking and drainage plug

• Drive the gear in a position in which the drain plug points downwards.
• Open both plugs.

Copyright © Sandvik Mining and Construction 31 (38)

ID: 349 1 en 2009-04-06
CRAWLER BASE:
DX500/DX680/DX700/DX780/DX800/DQ500

7.3. Trasmital final drive checking and adding oil ID: 32562

ID: 32566

1 Oil checking and filling plug

2 Oil drain plug
3 Oil level
1. Check oil level every 200 operating hours, and change oil every 600 operating hours.
When oil level is checked, or oil is added, the gear must be in such a position that the drain plug
(2) is downwards (ref. fig.).
When you are adding oil, open checking and filling plug (1). Oil filling capacity is 2,0 l. Ref. Oil
recommendation for the quality of oil.
If the amount of oil in the drive gear has increased, it is probable
that the shaft seal of the hydraulic motor is damaged.

32 (38) Copyright © Sandvik Mining and Construction

ID: 349 1 en 2009-04-06
 CRAWLER BASE:
DX500/DX680/DX700/DX780/DX800/DQ500

7.3.1. Trasmital final drive changing oil ID: 32563

ID: 32566

1 Oil checking and filling plug

2 Oil drain plug
3 Oil level
1. Drive the gear in a position in which the drain plug (2) points downwards.
2. Open both plugs.
3. Close drain plug (2).
Oil filling capacity is 2,0 l. Ref. Oil recommendation for the quality of oil.

Copyright © Sandvik Mining and Construction 33 (38)

ID: 349 1 en 2009-04-06
CRAWLER BASE:
DX500/DX680/DX700/DX780/DX800/DQ500

7.4. Mottrol final drive checking and adding oil ID: 32564

1
3

ID: 32567

1 Oil checking and filling plug

2 Oil drain plug
3 Oil level
1. Check oil level every 200 operating hours, and change oil every 600 operating hours.
When oil level is checked, or oil is added, the gear must be in such a position that the drain plug
(2) is downwards (ref. fig.).
When you are adding oil, open checking and filling plugs (1). Oil filling capacity is 2,2 l. Ref. Oil
recommendation for the quality of oil.
If the amount of oil in the drive gear has increased, it is probable
that the shaft seal of the hydraulic motor is damaged.

34 (38) Copyright © Sandvik Mining and Construction

ID: 349 1 en 2009-04-06
 CRAWLER BASE:
DX500/DX680/DX700/DX780/DX800/DQ500

7.4.1. Mottrol final drive changing oil ID: 32565

1
3

ID: 32567

1 Oil checking and filling plug

2 Oil drain plug
3 Oil level
1. Drive the gear in a position in which the drain plug (2) points downwards.
2. Open all plugs.
3. Close drain plug (2).
Oil filling capacity is 2,2 l. Ref. Oil recommendation for the quality of oil.

7.5. Removing of the track chain ID: 15283

1. Drive track chain so that the masterpin is in

center line of the idler wheel. The masterpin
is marked with a 10 mm drilling in the center
of the pin.
2. Slacken the track chain by loosening the
adapter in end of the track tensioning
cylinder.
3. Hit the masterpin out from the chain link.
4. Drive the rig backwards so that the chain
straightens on the ground. Take care that the
chain will not stick to the track frame. Note the
need of space when driving the rig. ID: 15625

7.5.1. Assembling the track chain ID: 15284

1. Lift the end of the chain on the drive wheel. Drive the rig forwards and at the same time pull the
chain e.g. with iron bar so it comes tight enough on the track frame.
2. Drive the chain to the center line of the idler wheel. Support the under end of the chain with e.g.
plank.
3. Install the washers and hit the masterpin back to the chain link.

Copyright © Sandvik Mining and Construction 35 (38)

ID: 349 1 en 2009-04-06
CRAWLER BASE:
DX500/DX680/DX700/DX780/DX800/DQ500

7.6. Removing the final drive ID: 15285

1. Turn the upper frame to lateral position.

2. Cut the track.
3. Jack up the track from oscillation axle so that the drive sprocket is free.
4. Clean the final drive and the hose connections carefully.
5. Remove cover of the final drive.
6. Disconnect the hoses of tramming, pilot pressure and drain case lines. Dismantle also the flange
connections of the tramming hoses from the drive gear. Mark and plug the hoses and connections.
7. Support the final drive unit.

ID: 15626

8. Loosen final drive mounting bolts inside the track frame.

9. Pull the final drive out.
See separate instructions on how to change the tramming motor shaft seal.

36 (38) Copyright © Sandvik Mining and Construction

ID: 349 1 en 2009-04-06
 CRAWLER BASE:
DX500/DX680/DX700/DX780/DX800/DQ500

Copyright © Sandvik Mining and Construction 37 (38)

ID: 349 1 en 2009-04-06
www.sandvik.com
 350 0 en 2009-02-16

FINAL DRIVE
Table of Contents

1. PARTS OF THE FINAL DRIVE ............................................................................................. 3

Copyright © Sandvik Mining and Construction 1 (4)

ID: 350 0 en 2009-02-16
2 (4) Copyright © Sandvik Mining and Construction
ID: 350 0 en 2009-02-16
 FINAL DRIVE

1. PARTS OF THE FINAL DRIVE ID: 15286

1 2 3 3 4

5 6

ID: 15628

1. Valve group
2. Hydraulic motor
3. Brake
4. Planet gear
5. Motor adjustment
6. Brake release

Copyright © Sandvik Mining and Construction 3 (4)

ID: 350 0 en 2009-02-16
www.sandvik.com