Excavator maintenance and upkeep

Excavators, also known as excavating machinery, are earth-moving machines that use buckets to dig materials above or below the machine's working surface and load them into transport vehicles or unload them into stockpiles. They have become one of the most important construction machinery in engineering projects. During use, reasonable maintenance is an effective means to extend the service life of the machine.

Daily inspection work is an important link to ensure that hydraulic excavators can maintain efficient operation for a long time. Especially for individual operators, doing a good job in daily inspection work can effectively reduce maintenance costs.

First, rotate the machine around twice to check for any abnormalities in its appearance and chassis, as well as whether there is any grease flowing out of the slewing bearing. Then, inspect the deceleration and braking device and the bolts and fasteners of the tracks. Tighten those that need to be tightened and replace those that need to be replaced in a timely manner. If it is a wheeled excavator, it is necessary to check whether the tires are abnormal and the stability of the air pressure.

Check whether the bucket teeth of the excavator are severely worn. It is understood that the wear of the bucket teeth will significantly increase the resistance during the construction process, which will seriously affect the work efficiency and increase the wear degree of the equipment components.

Check whether there are any cracks or oil leakage on the bucket rod and the cylinder. Check the electrolyte of the battery to avoid it being below the low level line.

The air filter element is an important component to prevent a large amount of dusty air from entering the excavator and should be inspected and cleaned frequently.

Regularly check fuel, lubricating oil, hydraulic oil, coolant, etc. to see if they need to be added. It is best to select the oil according to the requirements of the manual and keep it clean.

1. Fuel management

Different grades of diesel should be selected according to different ambient temperatures. Diesel must not be mixed with impurities, dust or water; otherwise, the fuel pump will wear out prematurely. Poor-quality fuel has a high content of paraffin and sulfur, which can cause damage to the engine. After each day's work, the fuel tank should be filled up to prevent water droplets from forming on the inner walls of the tank. Before starting work every day, open the water drain valve at the bottom of the fuel tank to release water. After the engine fuel is exhausted or the filter element is replaced, the air in the circuit must be discharged.

2. Management of other types of oil

Other oils include engine oil, hydraulic oil, gear oil, etc. Oils of different grades and grades must not be mixed. The additives that play a chemical or physical role are added during the production process of different types of excavator oil. It is necessary to ensure that the oil used is clean and prevent the mixture of impurities (such as water, dust, particles, etc.). Select the grade of oil based on the ambient temperature and application. When the ambient temperature is high, engine oil with high viscosity should be selected; when the ambient temperature is low, oil with low viscosity should be chosen. The viscosity of gear oil is relatively high to adapt to larger transmission loads, while the viscosity of hydraulic oil is relatively low to reduce the resistance of liquid flow.

3. Lubricating grease management

The use of lubricating oil (grease) can reduce the wear of moving surfaces and prevent noise. When storing and keeping grease, it must not be mixed with dust, sand particles, water or other impurities. It is recommended to use lithium-based grease g2-l1, which has good anti-wear performance and is suitable for heavy-duty working conditions. When refilling, try to squeeze out all the old oil and wipe it clean to prevent sand and soil from adhering.

4. Maintenance of filter elements

The filter element serves to filter impurities in the oil or gas circuit, preventing them from entering the system and causing malfunctions. All kinds of filter elements should be replaced regularly as required by the (Operation and Maintenance Manual). When replacing the filter element, it is necessary to check whether there are any metal particles adhering to the old filter element. If metal particles are found, timely diagnosis and improvement measures should be taken. Use pure filter elements that comply with the machine's specifications. The filtering capacity of inferior filter elements is poor. The surface and material quality of their filter layers do not meet the requirements, which will seriously affect the normal use of the machine.

5. Contents of regular maintenance

The fuel filter and additional fuel filter of the new machine should be replaced after 250 hours of operation. Check the clearance of the engine valves.

② Daily maintenance; Check, clean or replace the air filter element; Clean the interior of the cooling system; Check and tighten the track plate bolts; Check and adjust the reverse tension of the tracks; Check the intake heater; Replace the bucket teeth; Adjust the bucket gap; Check the liquid level of the front window washer fluid; Check and adjust the air conditioner; Clean the floor in the driver's cabin; Replace the filter element of the crusher (optional accessory). When cleaning the interior of the cooling system, after the engine has cooled down fully, slowly loosen the water inlet cover to release the internal pressure of the water tank, and then water can be released. Do not carry out cleaning work when the engine is running. The high-speed rotating fan can cause danger. When cleaning or replacing the coolant, the machine should be parked on a level ground.

③ Inspection items before starting the engine. Check the height of the coolant level (add water); Check the engine oil level and add engine oil. Check the fuel level (add fuel); Check the hydraulic oil level (add hydraulic oil); Check whether the air filter element is clogged. Check the wires; Check if the horn is functioning properly; Check the lubrication of the bucket; Check the water and sediment in the oil-water separator.

④ Every 100 maintenance items. Boom cylinder head pin shaft Arm foot pin The end of the boom cylinder arm; Cylinder head pin shaft of bucket rod cylinder Boom and boom connecting pins; The end of the cylinder rod of the bucket rod cylinder; Bucket cylinder head pin shaft Half-rod connecting pin The end of the bucket rod and the bucket cylinder rod; Bucket cylinder head pin shaft Bucket rod connecting pin Check the oil level in the slewing mechanism box (add engine oil); Drain water and sediment from the fuel tank.

⑤ Maintenance items every 250 hours. Check the oil level in the final transmission box (add gear oil); Check the electrolyte of the battery; Replace the oil in the engine oil pan and the engine filter element. Lubricate the slewing bearings (2 points); Check the tension of the fan belt and the tension of the air conditioner compressor belt, and make adjustments.

⑥ Maintenance items every 500 hours. Carry out maintenance items every 100 and 250 hours simultaneously; Replace the fuel filter element; Check the height of the grease on the rotating pinion (add grease); Inspect and clean the radiator fins, oil cooler fins and condenser fins. Replace the hydraulic oil filter element; Replace the oil in the final transmission box (only for the first time at 500 hours, and once every 1000 hours thereafter); Clean the air filters inside and outside the air conditioner system. Replace the filter element of the hydraulic oil vent port.

⑦ Maintenance items every 1000 hours. Carry out maintenance items every 100, 250 and 500 hours simultaneously; Replace the oil in the slewing mechanism box; Check the oil level of the shock absorber housing (return oil); Check all the fasteners of the turbocharger; Check the clearance of the turbocharger rotor; Inspection and replacement of generator belt tension; Replace the anti-corrosion filter element; Replace the oil in the final transmission box.

⑧ Maintenance items every 2000 hours. First, complete the maintenance items every 100, 250, 500 and 1000 hours; Clean the filter screen of the hydraulic oil tank; Clean and inspect the turbocharger; Check the generator and the starter motor; Check the engine valve clearance (and adjust it); Check the shock absorbers.

⑨ Maintenance after 4000 hours. Increase the inspection of the water pump every 4,000 hours. Add the item of changing the hydraulic oil every 5,000 hours.

⑩ Long-term storage. When the machine is stored for a long time, to prevent the piston rod of the hydraulic cylinder from rusting, the working device should be placed on the ground. After cleaning and drying the entire machine, store it in a dry indoor environment. If conditions limit that the machine can only be stored outdoors, it should be parked on a well-drained cement ground. Before storage, fill the fuel tank to the brim, lubricate all parts, replace the hydraulic oil and engine oil, apply a thin layer of grease to the exposed metal surface of the hydraulic cylinder piston rod, remove the negative terminal of the battery, or store the battery separately. Add an appropriate proportion of antifreeze to the cooling water according to the lowest ambient temperature. Start the engine and operate the machine once a month to lubricate all moving parts and charge the battery at the same time. Turn on the air conditioner and let it cool for 5 to 10 minutes.

As the saying goes, "A workman must first sharpen his tools if he is to do his job well." Effective maintenance can reduce the probability of machine malfunctions. The above are the maintenance methods for excavators. I hope they can be helpful to those in need.