As the “core workhorse” in engineering construction, excavators—from crawler-type to wheeled, small to large—have core component wear that directly affects construction efficiency regardless of model. Many operators believe “no failure means no maintenance,” but overlook that minor issues like dust intrusion, oil deterioration, and insufficient lubrication will quietly accelerate the wear of key components such as hydraulic pumps. Eventually, this leads to downtime for repairs, with costs often exceeding 10 times that of daily maintenance. Scientific daily maintenance is the key to extending equipment lifespan at the lowest cost.
(I) Hydraulic System: The “Key Guardian” of Smooth Operation
The hydraulic system is the “muscle” of an excavator, consisting of core components such as hydraulic pumps, hydraulic cylinders, and pipelines. Its maintenance focus is “impurity prevention and leakage prevention,” directly determining the precision and efficiency of equipment operations.
Hydraulic Oil Management: Strictly use the hydraulic oil grade specified by the equipment. Mixing oils of different brands or models is strictly prohibited to avoid chemical reactions causing oil deterioration. Check the fuel tank oil level daily to ensure it is between the scale marks. Test oil contamination every 500 hours (professional test strips are recommended), filter or replace immediately if exceeding standards. For long-term stored equipment, replace with new hydraulic oil in advance.
Filters and Seals: Replace suction filters, return oil filters, and pilot filters every 250 hours. Clean the filter seat with a clean cloth during replacement to prevent contaminants from entering the hydraulic circuit. Wipe the hydraulic cylinder piston rod clean after daily operation to remove dirt and impurities, apply anti-rust oil when parked, and replace original seals immediately if leakage is detected to prevent hydraulic oil leakage from affecting pressure stability.
Fault Warning and Handling: If slow operation or weak digging occurs, it may be due to insufficient pressure of the main relief valve or internal leakage of the hydraulic pump, requiring timely inspection and commissioning. For excessive oil temperature, first check if the hydraulic radiator is blocked or the check valve malfunctions. If abnormalities persist after cleaning the radiator fins, test the hydraulic pump condition.
Safety Taboos: Never over-tighten bolts on hydraulic pipelines to avoid bolt breakage or pipeline deformation; do not mix seals of different specifications to prevent seal failure and leakage.
(II) Traveling and Working Equipment: Periodic Maintenance of Wear-Resistant Components
The traveling mechanism and working equipment are core parts of excavators directly contacting the working surface, with high component wear rates. Focus on “cleaning, tightening, and lubrication.”
Traveling Mechanism: For crawler excavators, clean soil and stones between track shoes daily to avoid track deformation caused by extrusion of hard impurities. Check track tension (general standard: 280-320mm)—excessive looseness easily leads to derailment, while excessive tightness accelerates wear. Tighten track bolts to 75 kgf.m torque, re-tighten promptly if loose, and replace with original bolts of the same specification if lost. For wheeled excavators, check tire pressure daily to meet load requirements, ensure the outrigger support surface is flat, and lock the suspension hydraulic cylinder firmly before operation to prevent displacement during work.
Pins and Bushings: The connecting pins of the boom, arm, and bucket are high-frequency moving parts. Inject lithium-based No. 3 grease every 8 hours until new grease overflows from the gaps to ensure sufficient lubrication and avoid dry friction jamming. Regularly inspect bushing wear, replace immediately if excessive clearance or abnormal noise occurs, and re-inject grease after replacement.
Working Equipment Components: Regularly check bucket tooth wear and replace immediately when wear exceeds 1/3 to prevent bucket body deformation due to uneven force. Overlay weld or replace severely worn bucket wear plates to extend service life. If equipped with a hydraulic breaker (hammer), check chisel wear and nitrogen pressure daily, replace the breaker filter every 250 hours, and inject special grease to avoid chisel jamming or piston wear.
Travel Safety Tips: When transferring equipment over short distances, keep the drive wheel at the rear and the bucket 1m above the ground. Inspect the traveling mechanism and supplement lubrication every 500-1000m traveled. Avoid colliding the bucket with the frame or hard objects during operation to prevent cracks in structural welds.
(III) Auxiliary Components: Easily Overlooked “Maintenance Blind Spots”
In addition to core systems, some auxiliary components, though not directly involved in power transmission, affect the overall operational stability of the equipment and require simultaneous maintenance.
Filter Components: Air filters (non-engine use) and various hydraulic system filters must be replaced strictly according to the cycle. Use genuine filters that meet machine specifications—shoddy filters have poor filtration capacity and easily cause system failures due to impurity intrusion.
Electrical and Brake Components: Check the performance of travel brakes and parking brakes daily to ensure sensitivity. Inspect wire connections for looseness and aging, clean dust and oil from connections to prevent short circuits or poor contact. Test safety components such as horns and warning lights regularly to ensure proper operation.
Grease Management: Store maintenance grease in sealed containers to avoid mixing with dust, sand, and other impurities. Ensure grease fittings are clean during injection to prevent impurities from entering the gaps of moving parts with the grease.
Pitfall Avoidance Guide: 4 Common Maintenance Mistakes to Never Make
Over-Maintenance: Frequent disassembly of precision components such as hydraulic valves and pumps will damage sealing performance and assembly accuracy, ultimately accelerating wear.
Shoddy Components: Using non-genuine filters, seals, or track bolts may cause hydraulic system contamination, seal failure, and traveling mechanism malfunctions, increasing maintenance costs.
Improper Lubrication: Insufficient grease injection or use of low-quality grease will cause dry friction of pins and bushings, shortening service life. Randomly mixing different types of grease may trigger chemical reactions leading to lubrication failure.
Operational Violations: Colliding the bucket with the frame during operation or turning without braking the tracks will accelerate the wear of structural parts and traveling components. Operating wheeled excavators without locking the suspension hydraulic cylinder may cause outrigger deformation or equipment displacement.
Universal Maintenance Schedule: Flexible Adjustment by Working Conditions
| Maintenance Cycle | Core Maintenance Content | Applicable Scenarios |
| Daily | Check hydraulic oil level and wipe hydraulic cylinder piston rod; clean impurities from tracks/tires and inspect traveling mechanism tightness; check bucket tooth and chisel wear; test brake performance | Universal for all working conditions |
| 8 Hours | Inject grease into pins, slewing bearings, and hydraulic breakers | Continuous operation scenarios |
| 100 Hours | Inspect track/tire bolt tightness; clean hydraulic radiator fins; check hydraulic breaker nitrogen pressure | New equipment and regular working conditions |
| 250 Hours | Replace hydraulic oil filters and pilot filters; inspect seal leakage; replace hydraulic breaker filters | Regular working conditions |
| 300 Hours | Enhance hydraulic system cleaning; inspect bushing wear; tighten key bolts of traveling mechanism | Harsh working conditions with dust, sand, and humidity |
| 500 Hours | Test hydraulic oil contamination and replace if necessary; lubricate slewing motor output shaft; fully inspect structural welds | Universal for all working conditions |
| Annually | Fully inspect structural welds; replace aging seals; overhaul brake system; comprehensive hydraulic system cleaning | Universal for all working conditions, with priority implementation before winter |
Daily Maintenance = Cost Savings + High Efficiency
Whether it’s precision work with small excavators or heavy-duty construction with large equipment, the lifespan of core components such as hydraulic systems and traveling devices lies in daily maintenance. Following the principles of “prevention first, genuine components, and standardized operation” can not only extend the lifespan of key components by 50% but also reduce downtime for failures, allowing excavators to continuously create value at construction sites. Remember: proper maintenance is the most cost-effective investment.
