Excavators, as essential construction machinery, are widely used in various projects, including construction, mining, and road construction. Due to their complex operating environments and demanding workloads, prolonged high-load operation can easily lead to equipment failure, which in turn affects operational efficiency. Therefore, regular maintenance is crucial to extending the service life of excavators. This article, taking into account the characteristics and operating environment of excavators, will introduce key excavator maintenance tips to help users maintain optimal equipment operating condition, reduce repair costs, and extend service life.
1.1 Hydraulic System Inspection
The hydraulic system is one of the most core components of an excavator. Failure can lead to improper operation. To ensure the long-term stability of the hydraulic system, it is recommended to regularly perform the following operations:
Check the oil cleanliness and level: Oil deteriorates during use due to high temperatures and pressures. Prolonged oil replacement can affect system efficiency. Check the oil level monthly and refill or replace the hydraulic oil as necessary.
Check the pipes and fittings: Regularly inspect hydraulic pipes and fittings for leaks and replace worn or aged components promptly.
Hydraulic filter replacement: Regular replacement of hydraulic filters effectively prevents impurities from entering the hydraulic system, reduces component wear, and extends system life.
1.2 Cooling System Maintenance
Use a high-pressure air gun to reverse-blow the radiator fins daily to prevent dust accumulation (a blockage rate >30% will reduce cooling efficiency by 50%). Check the coolant level; the freezing point should be ≤ -25°C and the boiling point should be ≥110°C.
1.3 Lubrication System Maintenance
The lubrication system effectively reduces friction and wear on all components and is crucial for maintaining proper operation of the excavator. Regularly check the oil level and quality in the lubrication system to ensure that all components are properly lubricated. In particular, ensure sufficient lubrication in high-wear areas such as the bucket, arm, and transmission components.
Critical lubrication points (such as the slewing bearing and working device joints) should be regularly checked for grease sufficiency. In high-temperature environments, it is recommended to use NLGI grade 2 high-temperature grease and increase the relubrication frequency by 20%.
1.4 Track and Chassis Inspection
Regularly check the track tension. When operating in mountainous terrain, it is recommended to loosen the track slightly more than normal on flat ground. Check for loose track shoe bolts and wear on chassis components such as track rollers and carrier rollers.
Establish a regular inspection and maintenance system for your equipment. Strictly follow the manufacturer's maintenance manual and record every inspection and maintenance data. Regular maintenance not only identifies potential problems promptly but also ensures long-term stable operation of the equipment.
|
Maintenance Type |
Time period |
Main maintenance content |
|
Daily maintenance |
per class |
Check fluid level, clean radiator, and lubricate keyparts2 |
|
Level 1 maintenance |
200-250 hours |
Replace the engine oil and filter, check the hydraulic system and fasteners22 |
|
Secondary maintenance |
1000 hours |
Completely replace the hydraulic oil and fuel filters, clean the radiator22 |
|
Special maintenance |
According to the environment |
Dusty environment shortens air filter replacement cycle to 150hours8 |
Note: The specific maintenance cycle should be adjusted based on the operating environment and machine model.
3.1 Hydraulic System Optimization
In summer, it is recommended to use hydraulic oil with a viscosity grade of HV46 or higher.
Install a digital oil temperature sensor. During continuous operation, the oil temperature should be maintained below 85°C.
Shorten the filter element replacement interval by 30% to prevent oil oxidation and clogging of the valve block.
3.2 Engine Maintenance
Avoid overloading during the 100-hour run-in period for a new engine.
Check the turbocharger regularly for oil leaks.
Install a fuel prefilter to prevent diesel vaporization.
3.3 Electrical System Protection
Wrap wiring harness connectors with insulating tape to prevent oxidation at high temperatures.
The battery electrolyte level should be 10-15mm above the plate.
Regularly check the generator and starter motor connections for security.
4.1 Adding Oil Without Changing It
Many drivers only check the oil level and ignore the oil quality, causing engine components to operate in a poorly lubricated environment. Check the oil quality regularly and replace it if it becomes black, has an odor, or contains impurities.
4.2 Improper Bearing Treatment
Sanding the bearings with emery cloth instead of scraping them can cause abrasive particles to embed into the alloy, accelerating journal wear. Use a professional scraping process.
4.3 Heating the Piston with an Open Flame
Heating the piston with an open flame can cause local overheating and deformation. Use a uniform heating method such as an oil bath.
4.4 Neglecting Cylinder Clearance Measurement
Cylinder clearance should be measured perpendicular to the piston pin hole on the piston skirt. Measurements in other directions will be inaccurate.
5.1 High Temperature Environments
Check the coolant twice as often and replenish promptly if the level is low.
Appropriately shorten the hydraulic oil change interval.
Avoid refueling during the middle of the day to prevent thermal expansion and tank overflow.
5.2 Dusty Environments
Shorten the air filter replacement interval to 150 hours (normally 250 hours).
Clean the cab floor daily to prevent dust from entering the electrical system.
5.3 Working in Wet/Rainy Weather
Clean the equipment, especially the electrical system, promptly after operation.
Check components such as the control panel for moisture.
Use waterproof grease at lubrication points.
6.1 Daily Inspection Items
Hydraulic oil level and quality;
Cooling water level;
Engine oil level;
Track tension;
Working device pin lubrication.
6.2 Weekly Inspection Items
Air filter cleanliness;
Battery condition;
Lighting system function;
Hydraulic cylinder rod end cleanliness.
6.3 Monthly Inspection Items
Drive system gear oil;
Vehicle fasteners;
Hydraulic oil tank cleanliness;
Electrical circuit integrity.
The operator is an essential part of daily excavator maintenance. Proper operating habits can effectively extend the service life of the excavator. Operators should pay attention to the following points:
Avoid overloading: Overloading the excavator will increase equipment wear. Avoid operating at high loads for extended periods.
Warm and Cold Operation: Before starting, allow the engine to warm up for a while to ensure smooth operation of the hydraulic system and engine. When parking, the machine should be cold and should be stopped to avoid frequent restarts within a short period of time.
Keep the machine clean: During operation, prevent dirt and sand from entering the machine. Clean the exterior of the machine regularly to keep the cooling system unobstructed.
Strictly following the above maintenance measures can significantly extend the service life of the excavator, reduce failure rates, and improve operational efficiency. It is recommended to refer to the manufacturer's manual for specific models for adjustments and maintain a complete maintenance record.
Extending the service life of the excavator not only improves equipment efficiency and reduces failures, but also significantly reduces repair costs. By following these daily maintenance and inspection measures, operators can ensure that the excavator is in optimal condition, ensuring the smooth progress of projects. Long-term maintenance of an excavator requires meticulous attention to detail. Only through scientific maintenance and management can the equipment achieve long-term and efficient operation.
If you have any questions about excavator operation and maintenance, or would like to customize an excavator, please contact us. We offer custom excavator services.
