technology

For a fully hydraulic excavator, it can be said that the hydraulic system is like the blood circulation system of the human body throughout the entire excavator, which includes the hydraulic tank, the main pump, the multi-way valve, the pipelines and the cylinders that perform each action, the motor and other components. These hydraulic components are precision machined, and they have higher requirements for the maintenance of the hydraulic system.

Improper maintenance or no maintenance will lead to failure, resulting in machine downtime, but also to your losses.

Three key points to keep the hydraulic system clean:

When hydraulic oil enters the hydraulic system operation, cleaning is the first problem.

Dirt and other impurities should be prevented from entering the system.

If small particles of impurities enter the hydraulic system, they will bruise the pump, jam the valve, block the oil port, and cause machine failure.

How to keep the hydraulic system clean?

A: There are three main points:

1, keep the hydraulic oil clean

Store the oil in a clean location and be careful when changing or refueling the oil.

Only use a clean funnel equipped with a fine mesh filter to transfer oil from the container to the tank.

Of course, the type of hydraulic oil you use must be genuine.

2. Keep the system clean

(1) Replace hydraulic oil and filter regularly

Good hydraulic oil contains a variety of additives that prevent oil deterioration.

However, these additives lose their effectiveness after a while.

Therefore, the oil should be changed regularly to ensure that the additives work.

The filter can only absorb a limited number of dirt particles and other impurities from the oil.

For various series (medium) machines, replace the hydraulic oil tank return filter every 1000 working hours, and clean the hydraulic oil tank suction filter when changing the hydraulic oil to keep the system clean.

When replacing the hydraulic oil filter, check the bottom of the filter for metal particles or debris;

The presence of copper or iron shavings indicates that the hydraulic pump, hydraulic motor or valve may be damaged or will be damaged, and the presence of rubber indicates that the hydraulic cylinder seal is damaged.

(2) Discharge tank dirt regularly

Regular discharge of water and sediment in the tank is very important to remove impurities from the oil, but it is also very important to regularly replace the hydraulic oil in the entire hydraulic system.

This is the only reliable way to completely remove system impurities, oxidized hydraulic oil and other harmful impurities.

Clean hydraulic oil should then be readded to the hydraulic system.

Please discharge hydraulic tank storage tank dirt every 250 working hours.

(3) Cleaning

If the hydraulic oil is contaminated, especially if the pump or cylinder or motor is damaged, all hydraulic oil must be replaced and the tank cleaned.

3. Keep the work area clean

(1) When adding hydraulic oil to the tank or re-adding hydraulic oil, ensure that the area around the filter box cover is clean.

(2) Only clean funnels or containers can be used.

Do not bring dirt into the system.

When maintaining the hydraulic system, only clean plastic plugs should be used to seal the end of the line.

When maintaining hydraulic components, the workbench must be absolutely clean.

Check the condition of the tools used, they should also be very clean.

First, excavator winter maintenance

The winter maintenance of excavators, I think, is not much different from that of ordinary diesel vehicles. First of all, we must replace -10 -30 diesel, which depends on the region in which you are located. The more northern the region is, we must add more diesel. In addition, we must replace the diesel filter, replace the oil with the locally applicable thickening machine oil, and replace the oil filter.

Conditional fuel tank should be well insulated.

The cooling system should carefully check whether the hose is aging and broken, and if there is a problem, it should be replaced in time because these places are more prone to problems in winter.

If there are conditions to provide hot water, the tank is best to heat the water every day so that it can better start the engine, but be careful not to forget to drain the water.

I do not advocate the use of antifreeze because it is more difficult to start the engine in particularly cold areas.

See your supplementary question, I would like to add that since it is a new car and the antifreeze with the original do not replace it, but pay attention to the insulation of the vehicle, I suggest that you still find the local old drivers to consult more suitable for the local situation, for reference only.

Maintenance of excavator

The purpose of regular maintenance of the excavator is to reduce the failure of the machine and extend the service life of the machine.

Reduce machine downtime;

Improve work efficiency and reduce operating costs.

As long as fuel, oil, water and air are well managed, failures can be reduced by 70%.

In fact, about 70% of failures are due to poor management.

1. Fuel management

Different grades of diesel should be selected according to different ambient temperatures (see Table 1);

Diesel oil can not be mixed with impurities, lime soil and water, otherwise it will cause premature wear of the fuel pump;

The high content of paraffin and sulfur in inferior fuel will cause damage to the engine.

The fuel tank should be filled with fuel after daily operation to prevent water droplets from the inner wall of the tank;

Open the water drain valve at the bottom of the fuel tank before daily operation;

After the engine fuel is used up or the filter element is replaced, the air in the road must be drained.

Minimum ambient temperature 0℃ -10℃ -20℃ -30℃ Diesel grade 0# -10# -20# -35#

2. Management of other oils

Other oils include engine oil, hydraulic oil, gear oil, etc.;

Different grades and grades of oil can not be mixed;

The chemical or physical additives added to different varieties of excavator oil in the production process are different;

To ensure that the oil is clean, to prevent sundries (water, dust, particles, etc.) mixed;

Select the oil label according to the ambient temperature and use.

When the ambient temperature is high, oil with large viscosity should be selected, and oil with small viscosity should be selected when the ambient temperature is low.

The viscosity of the gear oil is relatively large to adapt to the larger transmission load, and the viscosity of the hydraulic oil is relatively small to reduce the liquid flow resistance.

Table 2 Selection of excavator oil

Container external temperature ℃ Oil Type Replacement Period h Replacement amount L Engine oil sump -35-20 CD SAE 5W-30 250 24-20-10 CD SAE 10W-20-40 CD SAE 10W-30-15-50 CD SAE 15W-40

0-40 CD SAE 30 Rotary mechanism box -20-40 CD SAE 30 1000 5.5 Shock Absorber housing CD SAE 30 6.8 Hydraulic Fuel tank CD SAE 10W 5000 PC200 model :239 PC220 model :246 CD SAE

10W-30 CD SAE 15W-40 Final drive CD SAE90 1000 5.4

3. Lubricating oil management

The use of lubricating oil (butter) can reduce the wear of the moving surface and prevent noise.

Grease shall not be mixed with dust, sand, water and other impurities when stored.

It is recommended to use lithium grease G2-L1, which has good anti-wear performance and is suitable for heavy-duty working conditions.

When filling, try to squeeze out all the old oil and wipe it clean to prevent sand adhesion.

4. Maintenance of filter element

The filter element plays the role of filtering impurities in the oil or gas path to prevent it from intruding into 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 there are metal particles found in time to diagnose and take improvement measures;

Use pure filter element in accordance with the regulations of the machine.

The filtration capacity of the fake filter element is poor, and the surface of the filter layer and the quality of the material do not meet the requirements, which will seriously affect the normal use of the machine.

5, the content of regular maintenance

① The fuel filter and additional fuel filter should be replaced after the new machine works for 250H;

Check the clearance of the engine valve.

② Daily maintenance;

Check, clean or replace the air filter element;

Clean the inside of the cooling system;

Check and tighten the track plate bolts;

Check and adjust track tension;

Check the intake heater;

Replace the bucket teeth;

Adjusting bucket clearance;

Check the front window cleaning liquid level;

Check and adjust air conditioning;

Cleaning the cab floor;

Replace 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 the water can be released;

Do not clean while the engine is working, high-speed rotating fans will cause danger;

When cleaning or changing the coolant, the machine should be parked on a level ground;

Replace coolant and corrosion preventer according to Table 3.

The ratio of antifreeze to water is specified in Table 4.

Coolant type Cooling system internal cleaning and replacement cycle Anti-corrosion device replacement cycle AF-ACL antifreeze (super antifreeze) every 2 years or every 4000h every 1000h or replacement coolant AF-PTL antifreeze (long-acting antifreeze) annually or 2000h AF-PT antifreeze (winter type)

Every 6 months (added in autumn only)

Table 4 Mixing ratio of antifreeze and water

Ambient Temperature ° C/Capacity L-5-10-15 15-20-25-30 Antifreeze PC200 5.1 6.7 8.0 9.1 10.2 11.10 PC220 5.4 7.0 8.4 9.6 10.7 11.65 Water PC200 17.1 15.5

14.2 13.1 12.0 11.10 PC220 17.9 16.3 14.9 13.7 12.6 11.65

③ Check items before starting the engine.

Check the liquid level height of the coolant (add water);

Check engine oil level, add oil;

Check the fuel level (add fuel);

Check the hydraulic oil level (add hydraulic oil);

Check whether the air filter element is blocked;

Check the wires;

Check whether the horn is normal;

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;

Boom foot pin;

Boom cylinder rod end;

Bucket rod cylinder head pin shaft;

Boom, bucket rod connecting pin;

Bucket rod cylinder cylinder rod end;

Bucket cylinder head pin;

Half rod connecting pin;

Bucket rod, bucket cylinder rod end;

Bucket cylinder head pin;

Bucket rod connecting rod connecting pin;

Check the oil level in the box of the rotating mechanism (add oil);

Discharge water and sediment from the fuel tank.

⑤ Every 250H maintenance project.

Check the oil level in the final transmission box (add gear oil);

Check the battery electrolyte;

Replace the oil in the engine oil pan and replace the engine filter element;

Lubricate slewing supports (2 places);

Check the tension of the fan belt, and check the tension of the air conditioning compressor belt, and adjust.

⑥ Every 500h maintenance items.

Simultaneously carry out maintenance projects every 100 and 250H;

Replace the fuel filter element;

Check the height of the rotary pinion grease (add grease);

Check and clean radiator fins, oil cooler fins and cold cooler fins;

Replace the hydraulic oil filter element;

Change the oil in the final transmission box (only for the first time at 500h, and once after 1000h);

Clean the air filter elements inside and outside the air conditioner system;

Replace the hydraulic oil vent filter element.

⑦ Every 1000h maintenance project.

Simultaneous maintenance projects every 100, 250 and 500h;

Change the oil in the rotating mechanism box;

Check the oil level of the shock absorber housing (oil return);

Check all fasteners of the turbocharger;

Check the clearance of turbocharger rotor;

Generator belt tension check and replacement;

Replace the anti-corrosion filter element;

Replace the oil in the final transmission box.

⑧ Maintenance items per 2000h(h hours).

First complete maintenance projects every 100, 250, 500 and 1000h;

Cleaning hydraulic oil tank filter screen;

Clean and check the turbocharger;

Check the generator and start the motor;

Check engine valve clearance (and adjust);

Check the shock absorber.

⑨ More than 4000h maintenance.

Increase the inspection of the pump every 4000h;

Increase hydraulic oil replacement items every 5000h.

⑩ Long-term storage.

When the machine is stored for a long time, in order to prevent the hydraulic cylinder piston rod from rusting, the working device should be placed on the ground;

The whole machine is washed and dried and stored in a dry environment indoors;

If the conditions can only be stored outdoors, the machine should be parked on a well-drained cement floor;

Before storage, fill 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 for separate storage;

Add the appropriate proportion of antifreeze to the cooling water according to the lowest ambient temperature;

Start the engine once a month and operate the machine in order to lubricate the moving parts and charge the battery;

Turn on the air conditioner and run for 5-10min.

The winter maintenance of excavators, I think, is not much different from that of ordinary diesel vehicles. First of all, we must replace -10 -30 diesel, which depends on the region in which you are located. The more northern the region is, we must add more diesel. In addition, we must replace the diesel filter, replace the oil with the locally applicable thickening machine oil, and replace the oil filter.

Conditional fuel tank should be well insulated.

The cooling system should carefully check whether the hose is aging and broken, and if there is a problem, it should be replaced in time because these places are more prone to problems in winter.

If there are conditions to provide hot water, the tank is best to heat the water every day so that it can better start the engine, but be careful not to forget to drain the water.

I do not advocate the use of antifreeze because it is more difficult to start the engine in particularly cold areas.

Let's talk about that.

See your supplementary question, I would like to add that since it is a new car and the antifreeze with the original do not replace it, but pay attention to the insulation of the vehicle, I suggest that you still find the local old drivers to consult more suitable for the local situation, for reference only.

Excavator winter maintenance

First, the winter maintenance of the excavator, I think there is not much difference between the general diesel car and the first to replace -10 -30 diesel, which depends on the region you are in, the more northern the region will add more diesel, in addition to replace the diesel filter, the oil should be replaced by the local applicable thickening machine oil, the oil filter should also be replaced, and the hydraulic system should be replaced in time where there is oil leakage.

Conditional fuel tank should be well insulated.

The cooling system should carefully check whether the hose is aging and broken, and if there is a problem, it should be replaced in time because these places are more prone to problems in winter.

If there are conditions to provide hot water, the tank is best to heat the water every day so that it can better start the engine, but be careful not to forget to drain the water.

I do not advocate the use of antifreeze because it is more difficult to start the engine in particularly cold areas.

See your supplementary question, I would like to add that since it is a new car and the antifreeze with the original do not replace it, but pay attention to the insulation of the vehicle, I suggest that you still find the local old drivers to consult more suitable for the local situation, for reference only.

Maintenance of excavator

The purpose of regular maintenance of the excavator is to reduce the failure of the machine and extend the service life of the machine.

Reduce machine downtime;

Improve work efficiency and reduce operating costs.

As long as fuel, oil, water and air are well managed, failures can be reduced by 70%.

In fact, about 70% of failures are due to poor management.

1. Fuel management

Different grades of diesel should be selected according to different ambient temperatures (see Table 1);

Diesel oil can not be mixed with impurities, lime soil and water, otherwise it will cause premature wear of the fuel pump;

The high content of paraffin and sulfur in inferior fuel will cause damage to the engine.

The fuel tank should be filled with fuel after daily operation to prevent water droplets from the inner wall of the tank;

Open the water drain valve at the bottom of the fuel tank before daily operation;

After the engine fuel is used up or the filter element is replaced, the air in the road must be drained.

Minimum ambient temperature 0℃ -10℃ -20℃ -30℃ Diesel grade 0# -10# -20# -35#