XCMG truck-mounted crane maintenance and repair is not simply a passive replacement of spare parts; rather, it involves a full-cycle management plan based on spare part characteristics. Appropriate selection and use of spare parts can reduce equipment failure rates by over 40%. The following analyzes the integration strategy between spare parts and maintenance from three perspectives: daily maintenance, scheduled repairs, and emergency response.

1. Daily Maintenance: Focusing on “Consumable Part Inspection” to Prevent Failures

The core of daily maintenance is to proactively identify potential problems by inspecting the condition of consumable parts, preventing minor failures from escalating. Specific procedures should be tailored to the specific characteristics of the spare parts:

Daily Inspection: Focus on checking the wire rope (for broken wires or excessive wear. If the number of broken wires reaches three per strand, replacement is required immediately); the hook (for deformation or cracks at the hook end; if wear exceeds 10% of the original size, replacement is required); the high-pressure oil pipe (for bulges or leaks. If leaks are detected, the seals or pipes must be replaced promptly); and the brake pads (if the thickness is less than 5mm, replacement is required).

Weekly Inspection: Refill special grease at each lubrication point (50-100g for each slewing bearing and 20-30g for each telescopic arm slider), check the hydraulic oil level (if below the lower limit, add XCMG special hydraulic oil), and clean the electrical system sensor probes to prevent dust from affecting detection accuracy.

Monthly Inspection: Replace the hydraulic oil filter (even if it is not yet due, if there is excessive impurities on the filter surface, replace it in advance). Check tire pressure (adjust according to the operating environment; maintain 0.8MPa for road operations and 0.6MPa for construction site operations). Test the emergency stop switch (ensure that the equipment stops immediately when triggered).

2. Regular Maintenance: Focus on “Replacement of Critical Spare Parts” to Extend Life

Regular maintenance requires preventive replacement of critical spare parts based on the equipment’s operating hours (or number of operations) to prevent sudden failures caused by aging. XCMG recommends the following replacement cycles for core spare parts:

Every 2000 operating hours (approximately 1 year): Replace the hydraulic oil (completely drain the old oil, clean the tank, and refill with new oil); slewing bearing grease (also check the slewing bearing clearance; if it exceeds 0.5mm, adjust or replace it); and the operating handle seal (to prevent oil leakage from affecting operation).

Every 5000 operating hours (approximately 2-3 years): Replace the hydraulic pump and motor seals (even if there is no leakage, seals will lose their elasticity due to aging); the torque limiter sensor (calibrate accuracy to ensure accurate load detection); and the boom pin (check the pin for wear; if it exceeds 0.2mm, replace it to prevent boom wobble).

10,000 operating hours (approximately 5 years): Replace the wire rope (even if there is no visible wear, fatigue damage may occur internally); outrigger cylinders (check the inner wall of the cylinder; if wear exceeds 0.1mm, replace to prevent leakage and outrigger sinking); PLC controller battery (to prevent parameter loss after a power outage).

3. Emergency Failure: Use genuine spare parts for rapid recovery

When equipment malfunctions, using genuine spare parts for repair minimizes downtime and prevents secondary failures. Common faults and spare part replacement solutions are as follows:

Hydraulic System Failure: If the boom is slow to extend or retract, first inspect the hydraulic filter (replace if clogged) and the hydraulic pump seals (replace if leaking). If the outriggers fail to lock, replace the counterbalance valves in the outrigger cylinders (original counterbalance valves have built-in one-way locks to ensure outrigger stability).

Electrical System Failure: If the display screen is blank, check the controller power harness (if poor contact, replace the plug) and the fuse (if blown, replace the original fuse with the same specification to prevent current mismatch and damage to the equipment). If the torque limiter alarm is abnormal, replace the angle sensor (the original sensor has high accuracy and can avoid false alarms).

Structural Component Failure: If the boom makes unusual noises, check the telescopic arm slider (if excessive wear, replace it and relubricate it). If the slewing mechanism is stuck, replace the slewing reducer gears (the original gears are carburized, with a tooth surface hardness of HRC58-62, for high wear resistance).

 If you need to purchase XCMG truck-mounted crane spare parts, please contact us directly. We will provide you with high-quality and affordable accessories!

You can also visit some of our websites

Click here to visit our spare parts web

Click here to visit our alibaba （There are more kinds of products）