Excavators operating in coastal ports, reclamation projects, aquaculture areas, and other environments face the threat of high salt mist, high humidity, and strong corrosion for a long time. Salt-containing moisture will accelerate the rust and corrosion of metal structural parts, engine parts, hydraulic components, electrical connectors, and chassis components, leading to paint peeling, component rust, thread seizure, circuit failure, and shortened service life. The corrosion damage in coastal environments is much more serious than that in inland areas, and targeted anti-corrosion maintenance is essential. This guide provides a special anti-corrosion maintenance scheme for coastal high-salt and high-humidity environments to reduce corrosion losses and ensure the reliability of excavators.
The body paint and structural parts are the first line of defense against salt spray corrosion. The salt mist in the coastal air contains a lot of chloride ions, which will penetrate the paint layer and cause rust and bulging on the metal surface. Clean the excavator body every day to remove salt dust and moisture attached to the surface. Use clean water to rinse the whole machine, especially the undercarriage, boom, arm, and frame, and then dry it with a rag or air gun. Regularly wax and seal the paint surface to form a protective film, isolate salt mist and moisture, and delay paint aging and rust.
Repair the damaged paint layer in time. Once the paint is scratched, peeled, or blistered, the internal metal will be directly exposed to salt spray and rust rapidly. Clean the rusted part with a rust remover, polish it smooth, apply anti-rust primer, and then spray the topcoat to restore the integrity of the paint surface. For welding spots and stress concentration parts with serious corrosion, additional anti-corrosion treatment can be carried out to prevent rust from expanding.
The undercarriage components have the most serious corrosion and need key protection. Track shoes, track chains, driving wheels, idlers, and supporting wheels are in direct contact with salt water and sediment, and rust and wear are accelerated. After each operation, thoroughly clean the undercarriage with high-pressure water to remove salt sediment and mud. Apply anti-rust grease or special anti-corrosion oil on the surface of undercarriage metal parts to form a corrosion-resistant layer. Check the floating oil seals of supporting wheels and idlers regularly to prevent salt water from entering and causing oil emulsification and bearing corrosion.
The engine and intake and exhaust systems are easily affected by salt spray. Salt mist entering the engine compartment will cause corrosion of valves, turbochargers, and exhaust pipes. Use a high-efficiency air filter with good sealing performance to prevent salt-containing air from entering the cylinder. Clean the air filter element frequently and replace it in time if damaged. Clean the engine surface, turbocharger, and exhaust pipe regularly to remove salt deposits. Check the engine oil for water and salt pollution, and replace the engine oil and filter element in advance if necessary.
The hydraulic system is highly sensitive to salt spray corrosion. Salt water entering the hydraulic system will cause corrosion of precision components such as hydraulic pumps, control valves, and cylinders, leading to internal leakage and action failure. Strengthen the sealing of the hydraulic oil tank respirator to prevent salt mist from entering. Check the hydraulic cylinder rod and oil seal regularly, clean the cylinder rod surface, and apply anti-rust grease. If the hydraulic oil is milky or contains impurities, it indicates that salt water has entered, and the hydraulic oil and filter elements must be replaced immediately.
Electrical connectors and electronic components are prone to short circuit and poor contact in high-salt and high-humidity environments. Salt corrosion will damage the connector terminals, leading to sensor signal failure and system abnormality. Clean the wiring harness, sensors, and controller connectors regularly, and apply waterproof and anti-corrosion connector grease to enhance the sealing and corrosion resistance. Check the wiring harness for wear and damage, and wrap the damaged part with waterproof tape to prevent salt moisture from entering. Ensure the drying of the cab electrical box and avoid the accumulation of condensed water.
Fasteners and threaded parts are easy to seize and rust. Salt spray corrosion makes bolts and nuts difficult to disassemble, causing trouble for maintenance. Apply anti-rust grease on the threads of important bolts before use. Check the tightness of fasteners regularly and reapply anti-rust grease during maintenance. For rusted bolts, use a rust remover to soak them before disassembly to avoid sliding and breaking.
Daily operation and parking precautions. Try to avoid the excavator from directly contacting with seawater and salt water. Park the excavator in a dry, ventilated, and covered garage as much as possible. If parked in the open air, use a waterproof and anti-corrosion car cover to wrap the whole machine to reduce the erosion of salt spray. After working in waterlogged coastal areas, carry out a thorough cleaning and anti-corrosion treatment immediately.
Regular anti-corrosion maintenance cycle. In coastal environments, shorten the maintenance cycle of hydraulic oil, engine oil, and filter elements. Conduct a comprehensive anti-corrosion inspection every month, focusing on checking the corrosion of structural parts, undercarriage, and electrical components. Conduct a thorough cleaning and anti-rust treatment every quarter to maintain the anti-corrosion performance of the equipment.
In summary, the anti-corrosion maintenance of excavators in coastal high-salt and high-humidity environments focuses on daily cleaning, paint protection, undercarriage anti-corrosion, and electrical system sealing. Strictly implementing targeted anti-corrosion measures can effectively slow down the corrosion rate, reduce failure rates, and ensure the long-term stable operation of excavators in harsh coastal environments.
