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Wheeled multifunctional motorized crossing frames represent a new type of crossing equipment for high-voltage transmission line construction. The initial design is too conservative, having a large safety margin and high material redundancy. Therefore, it is necessary to study a lightweight design version. However, as the structure constitutes an assembly consisting of multiple components, it also exhibits relatively high complexity. In a lightweight design, optimizing multi-component and multi-size parameters can lead to structural interference and separation, seriously affecting the smooth progress of design optimization. Therefore, an optimization design method of a multi-parameter complex assembly structure is proposed to solve this problem. Firstly, the typical stress conditions of the wheeled multifunctional motorized crossing frame were analyzed using its structural model. Then, a finite element model of the beam was established in ANSYS 2021 R1 Workbench, and the mechanical characteristics were analyzed. The results show that the arm support is the key load-bearing component and has significant optimization potential. Subsequently, functional mapping relationships were established among the 14 dimension parameters of the arm support, reducing the number of design variables to six and successfully avoiding component separation or interference during optimization. Through global sensitivity analysis, the height, thickness, and length of the arm body were screened out as the core optimization parameters from six initial design variables. Then, 29 groups of sample points were generated via central composite design (CCD), and a response surface model reflecting the relationships among the arm body’s dimensional parameters, total mass, maximum stress, and maximum deformation was established using the Kriging method. Leave-one-out cross-validation (LOOCV) was performed, and the coefficients of determination (R2) for model fitting were all higher than 0.995, indicating extremely high prediction accuracy. Taking mass and deformation minimization as the optimization objectives, the MOGA algorithm was adopted to perform multi-objective optimization and determine the optimal engineering parameters. Simulation verification was conducted on the optimized arm support, and an eigenvalue buckling analysis was performed simultaneously to verify structural stability. Finally, the proposed optimization method was experimentally verified through mechanical performance tests of the full-scale prototype under symmetric and eccentric loads. The results show that the mass of the optimized arm support is reduced from 217.73 kg to 189.8 kg, with a weight reduction rate of 12.8%. Under an eccentric load of 70,000 N, the maximum deformation of the arm support is 8.9763 mm, the maximum equivalent stress is 314.86 MPa, and the buckling load factor is 6.08, all of which meet the requirements for structural stiffness, strength, and buckling stability. The maximum error between the experimental and finite element results is only 4.64%, verifying the accuracy and reliability of the proposed method. The proposed optimization methodology, validated on a wheeled multifunctional motorized crossing frame, serves as a transferable paradigm for the lightweight design of complex assemblies with coupled dimensional constraints, thereby offering a general reference for the structural optimization of multi-component transmission line equipment, construction machinery, and other multi-component engineering systems.