Maintenance of Excavators and Solutions to Common Problems

I. Importance of Excavator Maintenance

Excavators, as heavy-duty mechanical equipment, play a crucial role in engineering construction. However, with increasing usage time, various components of excavators may experience wear and tear, aging, and other issues, which not only affect the excavator's performance but also may lead to safety accidents. Therefore, regular maintenance of excavators and timely detection and resolution of potential problems are of great significance to ensure the normal operation of excavators and extend their service life.

II. Methods of Excavator Maintenance

Engine Maintenance
◆ Regularly replace oil and oil filters to ensure a clean engine interior and extend engine life.
◆ Check the engine coolant, fuel filter, etc., to ensure their normal operation.
◆ Regularly clean the engine radiator to prevent engine overheating due to poor heat dissipation.

Hydraulic System Maintenance
◆ Check the hydraulic oil level to ensure it is within the normal range.
◆ Regularly replace hydraulic oil and filters to keep the hydraulic system clean.
◆ Inspect hydraulic lines and fittings to prevent leaks and loosening.

Track and Tire Maintenance
◆ Check the wear condition of tracks and tires and replace severely worn parts promptly.
◆ Clean dirt, stones, and other debris from tracks and tires to prevent affecting driving performance.
◆ Check the tension of tracks and tires to ensure they are within the normal range.

Electrical System Maintenance
◆ Regularly inspect electrical components such as cables and plugs to prevent faults such as short circuits and open circuits.
◆ Check battery charge and electrolyte level to ensure the battery is working properly.
◆ Clean dust and debris from electrical components to prevent affecting electrical performance.

Lubrication System Maintenance
◆ Regularly check the lubrication condition of each lubrication point and add or replace lubricants promptly.
◆ Clean lubrication lines and filters to ensure smooth flow of lubricants.

III. Common Excavator Problems and Solutions

Difficulty Starting the Engine
◆ Check battery charge and electrolyte level, and replace or recharge promptly if there are issues.
◆ Check the fuel system to ensure normal fuel supply.
◆ Check for faults inside the engine and repair promptly if there are issues.

Slow or No Movement of the Excavator
◆ Check if the hydraulic system pressure is normal and inspect the hydraulic pump and valves if there are issues.
◆ Check if the electrical system is working properly and inspect cables, plugs, and other electrical components if there are issues.
◆ Check for faults or damage in the actuators (such as cylinders and motors).

Oil Leakage in the Excavator
◆ Check if the oil line fittings are loose or damaged and tighten or replace them promptly if there are issues.
◆ Check if the oil seals are aged or damaged and replace them promptly if there are issues.
◆ Check if the hydraulic lines are worn or aged and replace them promptly if there are issues.

The maintenance cycle of excavators is not fixed, but varies according to different parts and maintenance items. Here is a detailed summary of the excavator maintenance cycle:

Daily Maintenance
◆ Daily check the oil level in the hydraulic oil tank, clean the magnetic rod in the return oil filter and the magnetic cup in the servo loop filter, and inspect the hydraulic system for any leakage.
◆ Daily check the water accumulation in the air reservoir (for wheeled excavators) and drain it.
◆ Daily check if all instruments and alarm devices are working properly, and check for any abnormal sounds or temperatures in the moving parts.
◆ Daily check the diesel oil level in the sump, coolant level, drain the water separator, and inspect the condition of fans, belts, and other components.

Minor Maintenance Cycle
◆ Minor maintenance is typically performed between 250 to 500 hours.
◆ It mainly involves replacing engine oil, filters, fuel, checking fluid levels, etc.
◆ The specific cycle may vary slightly depending on the usage and load of the excavator.

Major Maintenance Cycle
◆ Major maintenance is typically performed between 500 to 1000 hours.
◆ It mainly involves replacing engine oil, hydraulic oil, cleaning the system, replacing the oil-water separator, and other more comprehensive inspections and maintenance tasks.

Maintenance Cycle for Special Components
◆ Air filter: Replace every 1000 hours.
◆ Return oil filter: Some models require replacement every 500 hours, while the initial maintenance time for new machines is 50 hours.
◆ Engine oil filter: Replace every 500 hours. The initial maintenance time for new machines is 100 hours or 50 hours, depending on the actual model.
◆ Diesel filter, oil suction filter, oil-water separator: The maintenance cycle depends on the specific model and usage.
◆ Seatbelt: Replace every 3 years.
◆ Cooling water: Replace every 2 years or 2000 hours.

Notes
◆ If the excavator is operating in an environment with a temperature below -13°C or above 38°C, the maintenance interval should be shortened.
◆ If the equipment is operating in harsh or dusty environments, the maintenance cycle must also be shortened.
◆ During maintenance, if any abnormalities are found, immediately report to the customer service center staff to avoid causing significant fault losses.

Please note that the above maintenance cycles are for reference only. Excavators with different models and working environments may have different maintenance cycles. In actual operation, refer to the maintenance manual and recommendations provided by the excavator manufacturer, and flexibly adjust the maintenance cycle based on actual conditions.