Below is the standard procedure that is helpful for project maintenance team for maintenance and track replacement for bulldozers and excavators.
This instruction shall apply to all track replacement operations and other preventive maintenance actions for bulldozers, graders and excavators under the control of the contractor.
General Requirements
a) Clean the unit before service.
b) Park the unit on a flat and safe area.
c) Switch off the machine and release hydraulic system.
d) Lock-out facility in place.
e) Open track adjustment cap and release/loosen the track. Leave the plug on the loose position.
f) Put the master shoe at the back of the idler and loosen 4 bolts, release master shoe.
Procedure for Track Replacement on a Bulldozer
Place the new track at the back of the old track (underneath).
Connect the tip of the old track to the tip of the new track, make sure its securely tightened up.
Start the engine; jack up blade and ripper so that the unit lifts up.
Ensure the engine RPM remains in the low idle position.
Hang the old track above tip track with the help of crane. Ensure hook is inserted correctly.
Release parking brake and put the transmission lever into reverse speed 1 position.
Slowly let the final drive rotate so that the new track moves forward and the old track moves backward. Ensure the hook is inserted correctly and effectively.
Ensure that the crane follows the move of track backwards.
Make sure tip of the new track (above) remains in the middle of the idler.
After completion release the bolt between the tracks and remove the old track to a safe place.
Clean master link from paint and ensure the thread on the master link is clean.
Use crane to lift up the tip of the new track and support underneath so that the tip track in the middle of the idler and clean to the master link. Ensure hook is inserted correctly.
Connect 2 master links; make sure the link connector is tightened up.
Clean master shoe from paint and dirt and install master link.
Tighten the bolt in accordance with the service manual specifications (Lubricate with anti seize compound on the bolt).
Adjust track in accordance with the service manual specification.
Remove Lock-out of facility
Park unit in the appropriate area.
Report to the Field Supervisor that the unit is ready to use.
Track Replacement Process on a Excavator
Place the new track at the back of the old track (underneath).
Put the master shoe pin in the middle of the idler. Release 2 track shoes and master pin.
Connect the tip of the old track and new track with a temporary pin.
Start the engine, lift up boom and enter the unit into the new track, until both tips of the new track meet, release temporary pin and remove the old track to a safe place.
Ensure both tips of the new track are clean.
Install spacer and shim, install new pin.
Ensure the shoe is cleaned then install the shoe to the link.
Tighten bolt shoe in accordance with the service manual specification (lubricate with anti seize compound on the bolt).
Adjust track in accordance with service manual specification.
Remove Lock-out facility.
Park unit in the appropriate location.
Report to the Field Supervisor that the unit is ready to use.
Track Segment Replacement Method
Clean the unit before service.
Park the unit on the flat and safe area.
Lock-out facility in place.
Loosen bolts on the segment. If using impact wrench, wear safety glasses, gloves and earplugs.
Clean new segment from paint and clean final drive from dirt and mud.
Install new segment on final drive.
Lubricate with anti seize compound on the bolts and tighten the bolt in accordance with the service manual specifications.
For the next segment, start engine; lower the blade and ripper until the unit lifts up. Release parking brake, put the transmission on speed 1 position move forward or backward. Let the final drive rotate until the segment is in the free position.
Lift the blade and ripper and change the next segment.
Repeat for each additional segment.
Remove Lock-out Facility.
Park the unit on the appropriate location.
Report to the Field Supervisor that the unit is ready to use.
Cutting Edge Replacement of a Dozer or Grader
Place the unit on the flat and safe area.
Put the stand on the Push Arm (Dozer) and Draw Bar (Grader).
Switch off the machine, put on Lock-out Facility.
Clean the Bolt.
If using Impact Wrench, wear safety glasses, ear plug & gloves, while opening the bolt bind.
Try to use lifting tools to take down the old and new cutting edge and end bit.
Ask the Supervisor if the bolt is also to be replaced.
Ensure while tighten the bolt, it is appropriate with specification of the service manual.
Take off the stand on the push arm and draw bar.
Clean work area.
Take off the Lock-out Facility
Park the unit on a safe area.
Inform Supervisor that the unit ready to use.
Bucket Tip Replacement Procedure
Park the unit on a flat and safe area and switch off the engine. Use initiate Lock-out Facility.
Clean the Pin on the Bucket Tip.
Wear Safety Glasses while striking the Pin Lock.
Use a soft metal hammer for striking the Pin.
Wear Safety Gloves and use rags while lifting out worn out Bucket Tip to avoid cuts and burns.
Clean the Tip Adapter.
Install the new Bucket Tip. Ask the Supervisor if the Pin & Retainer are to be replaced.
Wear Safety Glasses while striking the Pin into place. Check surrounding area.
Ensure that all of the Pin Locks are correctly installed.
Remove Lock-out Facility (LOF)
Report to the Supervisor that the unit is ready to use.
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