Crane Remanufacturing: Disassembly, Cleaning, Repair & Assembly
Remanufacturing cranes for construction machinery are configured around four stages: disassembly, cleaning, reconditioning, and final assembly. The disassembly stage uses a QD Type 10–30t crane to turn the complete machine; the cleaning stage uses KBK/LD 0.5–3t cranes for component transfer; the reconditioning stage uses a QD Type 10–30t crane for component assembly; and the final assembly stage uses a QD Type 10–30t crane for complete machine assembly. Complete plant investment ranges from $30,000 to $90,000.
Disassembly Stage: Machine Tipping and Component Sorting
Complete construction machines (excavators and wheel loaders) weigh between 10 and 30 tons. During disassembly, the machine must be tipped 90° to access the undercarriage and traveling components. A QD Type 10–30t crane is recommended. Kelude's disassembly-area cranes come standard with dual braking and anti-sway control.
To disassemble the excavator's slewing platform and undercarriage frame, the crane tips the complete machine 90° and holds it in position. Hydraulic cylinders (boom, arm, and bucket cylinders) weigh 100–300 kg each and require dedicated storage racks after removal.
Cleaning Stage: KBK System for Component Flow
Disassembled components (engines, hydraulic parts, and structural components) weigh 50–500 kg. A KBK 0.5–2t or LD Type 3t crane is recommended. In the cleaning area, KBK rails run along the cleaning line, covering the spray-wash and drying stations.
Hydraulic pumps, motors, and valve groups are cleaned in ultrasonic washing machines, with individual parts weighing 50–200 kg. Cleaned components are then transferred to the inspection area (dimensional, hardness, and flaw detection). The KBK rail covers the full process from cleaning through inspection and reconditioning.
Reconditioning Stage: Remanufacturing and Assembly
Remanufacturing and assembly of engines, gearboxes, and hydraulic pumps involves components weighing 500–2,000 kg. A QD Type 10–30t crane is recommended (shared with the disassembly area). Workbenches in the reconditioning area feature adjustable heights, and the crane supports the assembly workflow.
Remanufacturing of engine blocks, cylinder heads, and crankshafts includes build-up welding, machining, and assembly. Crankshafts weigh 50–200 kg, and main bearing bush clearance must be held within 0.05–0.10 mm during assembly.
Final Assembly Stage: Complete Machine Assembly and Commissioning
Reconditioned components are assembled into complete machines on the final assembly line. A QD Type 10–30t crane is recommended (shared with the disassembly area). The commissioning area requires hoisting test loads for functional testing.
Functional testing after final assembly (hydraulic system pressure, travel speed, and slewing speed) requires hoisting test loads. Kelude's QD Type cranes in the remanufacturing area cover the full process from final assembly through testing.
Disassembly QD Type10-30t Tilting | Cleaning KBK/LD 0.5-3t | Refurbishment QD Type10-30t |
Final Assembly QD Type10-30t | Complete Machine Tilting 90°Tilting | complete plant 20-6010k |
Crane Configuration Table for the Four Remanufacturing Stages
| Process Stage | Crane Model | tonnage | Component | Allocation | investment |
|---|---|---|---|---|---|
| Disassembly | QD Type | 10-30t | Complete Machine | Shared | 20-5010k |
| Cleaning | KBK/LD | 0.5-3t | Component | Dedicated | 5-1510k |
| Refurbishment | QD Type | 10-30t | engine | Shared | - |
| Final Assembly | QD Type | 10-30t | Complete Machine | Shared | - |
Kelude Heavy Industry delivers a full-process solution for construction machinery remanufacturing. The disassembly bay features QD Type turnover units for complete machines, the cleaning bay uses KBK component flow systems, and the repair/Final Assembly bay shares QD Type cranes.
Complete Machine Tilting QD Type10-30t+Dual Brake | Cleaning Flow KBKMulti-Station Along Cleaning Line | Shared Solution Disassembly & Refurbishment Final Assembly Shared QD |
Frequently Asked Questions
Q: What lifting capacity is required for turning over a complete engine during disassembly?
A: 10–30 t for the complete unit. The QD Type crane provides a lifting height of ≥10 m and is equipped with a dual braking system.
Q: How long is the KBK crane rail in the cleaning area?
A: It can be assembled in sections to match the cleaning line length, typically 15–30 m.
Q: What setup do you recommend for a remanufacturing workshop?
A: A single QD Type crane (10–30 t) can handle disassembly, repair, and final assembly, while the cleaning area uses a separate KBK system.
Q: What accuracy requirements apply to engine remanufacturing?
A: The crankshaft-to-bearing-bush clearance must be 0.05–0.10 mm. The QD Type crane's variable-frequency drive with creep speed control supports precise assembly.
