Excavator Maintenance Matters: Are You Maintaining Your Machine the Right Way?

Excavators operate intensively on construction sites, yet many failures are caused by insufficient daily maintenance. Clogged air filters, contaminated engine oil, or hydraulic oil can reduce engine efficiency, accelerate component wear, and even lead to hydraulic system failure. For users, whether operating a crawler excavator or a wheel excavator, proper maintenance is crucial to ensure stable equipment performance.

Regular and standardized maintenance not only extends the service life of excavators but also ensures construction efficiency and personnel safety. Good maintenance habits can prevent unexpected downtime, reduce repair costs, and improve the overall economic performance of the equipment.

This article combines TDER’s experience and systematically analyzes daily inspections, periodic maintenance, seasonal and long-term storage care, as well as the selection of oils and parts, explaining how to keep excavators in optimal condition and achieve efficient and safe operation.

I. Daily Inspection and Routine Maintenance

Daily inspection and maintenance are the first line of defense for ensuring stable excavator performance. Conducting systematic checks on key components before and after each workday not only helps detect potential risks early but also maintains consistent output under heavy-duty conditions. Following the daily maintenance items below can significantly reduce the likelihood of failures:

1. Fluid Level Check: Confirm that engine oil, coolant, and hydraulic oil levels are within the recommended range, ensuring no abnormal leakage or rapid consumption.

2. Fuel System Maintenance: Inspect the fuel system and water separator. Drain accumulated water when necessary to prevent moisture or impurities from entering the fuel system, which can cause injection or power issues.

3. Inspection of Key Components: Check the machine for oil leaks, looseness, or wear—especially in high-movement areas.

4. Lubrication Maintenance: Add grease to pins and lubrication points as required to ensure smooth joint movement and reduce wear on working components.

5. Good Operating Habits: Allow the engine to idle for 3–5 minutes before starting work and before shutdown. This ensures proper lubrication and cooling of the turbocharger and allows the hydraulic system to reach a stable working state.

Through careful daily inspections and correct operating habits, early failures can be effectively prevented, laying a solid foundation for long-term, efficient excavator operation.

II. Periodic Maintenance Planning

The long-term stable operation of an excavator relies on a scientific and well-structured periodic maintenance plan. Scheduling maintenance based on operating hours not only extends the machine’s lifespan but also minimizes downtime caused by unexpected failures. According to industry experience and real-world usage, the following maintenance intervals are recommended:

1. Every 50 hours: In addition to daily maintenance, inspect and clean the battery; check and adjust the track tension to ensure the electrical system and travel mechanism remain in good working condition.

2. Every 250 hours: Replace the engine oil, engine oil filter, and air filter. Inspect the fan belt for wear and adjust its tension if necessary to maintain stable engine performance.

3. Every 500 hours: Replace the fuel filter and hydraulic return/suction filters; clean the radiator and oil cooler fins to prevent overheating caused by poor heat dissipation; inspect and replace travel and swing gear oil. For new machines, the first 500-hour maintenance is especially important.

4. Every 1000 hours: Replace the hydraulic oil and swing mechanism oil; check turbocharger fasteners for looseness and confirm proper rotor clearance to ensure stable and reliable engine performance.

5. Every 2000 hours: Clean the hydraulic tank filter screen; inspect the alternator and starter motor performance; adjust engine valve clearance based on wear conditions to maintain smooth power output.

6. Environmental Load Adjustment: In harsh working environments—such as high dust, heavy-duty, or continuous operation—the maintenance intervals should be shortened. This is especially important for air filter and engine oil filter replacement to prevent reduced filtration efficiency from affecting the engine and hydraulic system.

By following a scientific periodic maintenance schedule and adjusting intervals according to real working conditions, excavators can maintain stable and efficient performance in all job environments.

III. Seasonal Maintenance and Special Working Conditions Configuration

Industry experience shows that excavators operating under special conditions can easily encounter issues such as shutdowns in low temperatures or severe component wear in high temperatures. This highlights the importance of adjusting maintenance plans according to the seasonal environment.

In summer, the focus should be on checking the radiator and cooling system for blockages to prevent engine overheating. In high-temperature regions, it is recommended to install an enlarged radiator, optimize the cooling system, and use automatic lubrication or scheduled lubrication checks to reduce wear on key components. In winter, low-temperature engine oil and antifreeze should be used; in extremely cold areas, a lower-temperature grade of antifreeze is required to ensure smooth engine starting and to protect the hydraulic system.

By combining seasonal maintenance with proper configuration for special working conditions, the excavator can maintain stable operation, reduce failure rates, extend service life, and ensure both productivity and operational safety.

IV. Long-Term Storage Maintenance

Many customers are concerned about how to properly maintain their equipment during long-term storage to ensure it remains in good condition when returned to operation. To address this, we recommend a systematic storage maintenance plan covering cleaning, lubrication, protection, and energy management to minimize component aging, corrosion, and performance degradation.

1. Full Machine Cleaning: Thoroughly clean the entire machine, focusing on the working attachment, undercarriage, and hydraulic connections to remove all dirt, dust, and debris. Place the working attachment on the ground to avoid uneven stress or additional strain caused by prolonged suspension.

2. Lubrication and Anti-Rust Treatment: Fully grease all critical lubrication points; apply a thin layer of grease or anti-rust oil to hydraulic cylinder rods to prevent oxidation or pitting during long-term exposure.

3. Energy System Management: Disconnect the negative terminal of the battery and store it separately. Start the machine or recharge the battery monthly to maintain battery activity and prevent damage from discharge.

4. Oil Replacement and Protection: Replace hydraulic oil and engine oil before storage to prevent internal residues or moisture from causing corrosion, deposits, or performance deterioration during downtime.

By following standardized long-term storage maintenance, aging and performance decline can be effectively prevented, ensuring that the excavator remains safe and efficient when put back into service, providing reliable support for subsequent construction work.

TDER 9 Tonne Crawler Excavator

V. Oil and Parts Selection

Choosing the right oil and parts is crucial for both daily maintenance and long-term upkeep. Many customers may try cheaper non-original oils or filters during use, but over time, these products can accelerate wear on the engine and hydraulic system and may even cause failures. To ensure equipment performance and extend service life, it is recommended to consistently use original or certified oils and filters recommended by the equipment manufacturer.

Additionally, for equipment meeting National IV emission standard (or higher), special attention must be paid to urea usage. Only use urea from reputable brands and avoid mixing in impurities to prevent damage to the urea pump or SCR system, which could affect emission performance and equipment reliability. Proper oil and parts selection not only ensures reliable operation but also provides a solid foundation for both daily maintenance and long-term use, serving as a critical guarantee for the safe and efficient operation of every excavator.

VI. Conclusion

Proper maintenance is the core guarantee for the efficient operation of an excavator. Through scientific and regular inspection and maintenance, not only can equipment failure rates be significantly reduced, but construction efficiency can also be improved and the overall service life of the machine extended. Operators should develop good habits in daily operation — such as idling the engine before and after startup, using genuine oils and urea, and performing all maintenance tasks according to the scheduled intervals — to ensure the excavator always remains in optimal working condition.

Consistently following this principle over time not only reduces maintenance costs and the risk of unplanned downtime but also provides reliable productivity support for construction projects. In short, proper excavator maintenance safeguards efficient construction and allows each machine to deliver its maximum value.