Acquaintance
The purpose of regular maintenance on excavators is to reduce machine failures, extend machine life, shorten machine downtime, improve work efficiency and reduce operating costs.
By managing fuel, lubricants, water and air, failures can be reduced by 70%. In fact, around 70% of failures are due to poor management.
1. Fuel management
Different grades of diesel oil should be selected according to different ambient temperatures (see Table 1); diesel oil should not be mixed with impurities, lime soil and water, otherwise the fuel pump will be worn prematurely;
The high content of paraffin and sulfur in inferior fuel oil will cause damage to the engine; the fuel tank should be filled with fuel after daily operation to prevent water droplets from forming on the inner wall of the fuel tank;
Open the drain valve at the bottom of the fuel tank to drain water before daily operation; after the engine fuel is used up or the filter element is replaced, the air in the road must be exhausted.
Minimum ambient temperature 0℃ -10℃ -20℃ -30℃
Diesel grade 0# -10# -20# -35#
2. Other oil management
Other oils include engine oil, hydraulic oil, gear oil, etc.; oils of different brands and grades cannot be mixed;
Different types of excavator oil have different chemical or physical additives in the production process;
It is necessary to ensure that the oil is clean and prevent the mixing of sundries (water, dust, particles, etc.); select the oil label according to the ambient temperature and use.
If the ambient temperature is high, the oil with high viscosity should be used; if the ambient temperature is low, the oil with low viscosity should be used;
The viscosity of gear oil is relatively large to accommodate large transmission loads, and the viscosity of hydraulic oil is relatively small to reduce fluid flow resistance.
Selection of oil for excavators
Container Outside temperature ℃ Oil type Replacement cycle h Replacement amount L
Engine Oil Pan -35-20 CD SAE 5W-30 250 24
Slewing Gear Box -20-40 CD SAE 30 1000 5.5
Damper housing CD SAE 30 6.8
Hydraulic tank CD SAE 10W 5000 PC200
Final Drive CD SAE90 1000 5.4
3. Grease management
Using lubricating oil (butter) can reduce the wear of moving surfaces and prevent noise. When the grease is stored, it should not be mixed with dust, sand, water and other impurities;
It is recommended to use lithium-based grease G2-L1, which has good anti-wear performance and is suitable for heavy-duty conditions; when filling, try to squeeze out all the old oil and wipe it clean to prevent sand from sticking.
4. Maintenance of filter element
The filter element plays the role of filtering impurities in the oil or gas path, preventing it from invading the system and causing failure; various filter elements should be replaced regularly according to the requirements of the (operation and maintenance manual);
When replacing the filter element, check whether there is metal attached to the old filter element. If metal particles are found, diagnose and take improvement measures in time; use the pure filter element that meets the requirements of the machine.
The filtering ability of the fake and inferior filter element is poor, and the surface and material quality of the filter layer do not meet the requirements, which will seriously affect the normal use of the machine.
5. Contents of regular maintenance
①After the new machine works for 250H, the fuel filter element and the additional fuel filter element should be replaced; check the clearance of the engine valve.
②Daily maintenance; check, clean or replace the air filter element;
Clean the inside of the cooling system; check and tighten the track shoe bolts;
Check and adjust track back tension; check intake heater; replace bucket teeth;
Adjust the bucket clearance; check the liquid level of the front window washer fluid; check and adjust the air conditioner;
Clean the cab floor; replace the crusher filter element (optional).
When cleaning the inside of the cooling system, after the engine is fully cooled, slowly loosen the water injection port cover to release the internal pressure of the water tank, and then water can be released;
Do not do cleaning work while the engine is working, the high-speed rotating fan will cause danger;
When cleaning or changing coolant, the machine should be parked on level ground;
The coolant and corrosion inhibitor should be replaced according to Table
3. The ratio of antifreeze to water is as required in Table
4.Coolant type Internal cleaning and replacement cycle of cooling system Anticorrosion device replacement cycle
AF-ACL antifreeze (super antifreeze) every 2 years or every 4000h every 1000h or when changing the coolant
AF-PTL antifreeze (long-lasting antifreeze) per year or 2000h
AF-PT antifreeze (winter type) every 6 months (only added in autumn)
Mixing ratio of antifreeze and water
Ambient temperature °C/capacity L -5 -10 -15 -20 -25 -30
Antifreeze PC200 5.1 6.7 8.0 9.1 10.2 11.10
③ Check items before starting the engine.
Check the height of the coolant level (add water);
Check the engine oil level and add oil;
Check the fuel level (add fuel);
Check the hydraulic oil level (add hydraulic oil);
Check if the air filter is clogged; check the wires;
Check whether the horn is normal; check the lubrication of the bucket;
Check for water and sediment in the oil-water separator.
④Every 100 maintenance items.
Boom cylinder cylinder head pin;
Boom foot pin;
Boom cylinder cylinder rod end;
Stick cylinder cylinder head pin;
Boom, stick connecting pin;
Stick cylinder cylinder rod end;
Bucket cylinder cylinder head pin;
Half-rod connecting pin;
Stick, bucket cylinder cylinder rod end;
Bucket cylinder cylinder head pin;
Stick connecting pin;
Check the oil level in the slewing gear box (add oil);
Drain water and sediment from the fuel tank.
⑤ Maintenance items every 250H.
Check the oil level in the final drive case (add gear oil);
Check battery electrolyte;
Change the oil in the engine oil pan, replace the engine filter element;
Lubricate slewing bearings (2 places);
Check the tension of the fan belt, and check the tension of the air conditioner compressor belt, and make adjustments.
⑥ Maintenance items every 500h.
Carry out maintenance items every 100 and 250H at the same time;
Replace the fuel filter;
Check the height of the rotary pinion grease (add grease);
Check and clean radiator fins, oil cooler fins and cooler fins;
Replace the hydraulic oil filter element; replace the oil in the final drive case (only at 500h for the first time, and once at 1000h after that);
Clean the air filter inside and outside the air conditioner system; replace the hydraulic oil breather filter.
⑦Maintenance items every 1000h.
Carry out maintenance items every 100, 250 and 500h at the same time;
Replace the oil in the slewing mechanism box; check the oil level of the shock absorber housing (return oil);
Check all fasteners of the turbocharger;
Check the clearance of the turbocharger rotor;
Inspection and replacement of generator belt tension;
Replace the anti-corrosion filter element;
Change the oil in the final drive case.
⑧ Maintenance items every 2000h.
Complete the maintenance items every 100, 250, 500 and 1000h first;
Clean the hydraulic oil tank filter; clean and check the turbocharger;
Check the generator, start the motor;
Check engine valve clearance (and adjust);
Check the shock absorber.
⑨Maintenance over 4000h.
Increase the inspection of the water pump every 4000h;
The item of replacing hydraulic oil is added every 5000h.
⑩ Long-term storage.
When the machine is stored for a long time, in order to prevent the piston rod of the hydraulic cylinder from rusting, the working device should be placed on the ground; the whole machine should be washed and dried and stored in a dry indoor environment
;If the conditions are limited and can only be stored outdoors, the machine should be parked on a well-drained cement floor;
Before storage, fill up the fuel tank, lubricate all parts, replace the hydraulic oil and oil, apply a thin layer of butter to the exposed metal surface of the piston rod of the hydraulic cylinder, remove the negative terminal of the battery, or remove the battery and store it separately;
Add an appropriate proportion of antifreeze to the cooling water according to the minimum ambient temperature;
Start the engine and operate the machine once a month to lubricate the moving parts and charge the battery;
Turn on the air conditioner and run for 5-10 minutes.
Post time: Jun-29-2022
