Crawler cranes operate in complex environments (for example, wind turbine installation requires high-altitude, outdoor work, and bridge construction requires work on muddy roads). The maintenance of spare parts directly impacts the equipment’s service life and operational safety. Based on the characteristics of spare parts, XCMG has developed a full-cycle maintenance plan combining “preventive maintenance + emergency repair” to reduce equipment failure rates by over 50%.

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

Daily maintenance should be conducted in conjunction with the crawler crane’s operating conditions, with a focus on inspecting consumable parts and key areas to identify potential problems early:

Daily Inspection:

Wire rope: Check for broken wires, wear, and rust. Replace immediately if the number of broken wires exceeds five per strand. Check the wire rope tension. Too loose can cause rope skipping, while too tight accelerates wear and requires timely adjustment. Track System: Check the track shoes for cracks and deformation, and the track pins for looseness. If track shoe wear exceeds 10mm, replace them. Check the track rollers and carrier rollers for oil leaks. If leaks are present, replace the seals.

Braking System: Check the brake shoe thickness; if less than 6mm, replace them. Test the travel and slew braking performance. If the braking distance is excessive, adjust the brake clearance or replace the brake shoes.

Hydraulic System: Check the hydraulic oil level. If it is below the lower limit, add XCMG special hydraulic oil. Check the hydraulic lines for leaks. If leaks are present, replace the seals or high-pressure hoses.

Weekly Inspection:

Lubrication and Maintenance: Apply special grease to the track chain, slewing bearing, boom pin, and other parts (100-150g per track chain and 200-300g per slewing bearing) to ensure adequate lubrication.
Electrical System: Clean the torque limiter sensor and anemometer probe to prevent dust from affecting detection accuracy. Check the wiring harness connector for looseness. If so, reconnect and secure.
Counterweight: Check the counterweight connecting pin for looseness. Tighten if loose. Check the counterweight bracket for cracks. If cracked, repair by welding or replace.

Monthly Inspection:

Hydraulic Filter: Replace the hydraulic oil return filter and suction filter. Even if the replacement period is not due, replace them if excessive impurities on the filter surface (as determined by the differential pressure sensor) are present.
Tires (auxiliary tires): Check tire pressure (maintain 0.8-1.0 MPa) and tread wear. Replace if the tread depth is less than 3mm.
Safety Devices: Test the torque limiter, emergency stop button, and anemometer to ensure that the alarms and protective devices are functioning properly.

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

Regular maintenance requires preventive replacement of key spare parts based on the equipment’s operating hours (or number of operations) to prevent sudden failures due to aging. XCMG recommends the following replacement cycle for core spare parts for crawler cranes:

Every 3,000 operating hours (approximately 1.5 years):

Hydraulic System: Replace the hydraulic oil (completely drain the old oil, clean the oil tank, and refill with new oil). Seals in the hydraulic pump and motor (even if there are no leaks, seals lose their elasticity due to aging).

Travel System: Replace the track pins and bushings (check for wear; replace if wear exceeds 0.2mm). Bearings in the track rollers and carrier sprockets (replace if any noise or sticking occurs).

Electrical System: Replace the contacts of the contactor and relay (replace if burnt). Seals in the wiring harness connector (prevent water ingress).​

8,000 operating hours (approximately 4 years):

Crane structure: Inspect boom section welds; repair cracks by welding; replace boom pins (even if wear is within the specified range, preventative replacement is required to prevent breakage).

Slewing system: Replace the slewing bearing (check clearance; replace if greater than 0.5mm). Slewing motor gears (replace if abnormal noise or vibration is detected).

Braking system: Replace the master and slave cylinders (replace if braking performance is reduced). Brake fluid (use DOT4).

15,000 operating hours (approximately 7-8 years):

Core components: Replace the main hydraulic pump, multi-way valve (replace if pressure instability or leakage is detected). Track assembly (replace the entire track shoe or track chain if severely worn).

Electrical system: Replace the PLC controller battery (to prevent parameter loss after power failure). Torque limiter sensor (calibrate for accuracy to ensure accurate detection).

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