Do you know about the 20 classic faults that excavators may encounter during operation and their repair methods?
Excavators, as representatives of heavy machinery, play an important role in various engineering projects due to their complexity and efficiency. However, like any mechanical equipment, excavators may also encounter various malfunctions. Below, we will analyze in detail the 20 common classic faults of excavators and their maintenance methods.
1. Difficulty starting in winter: This is mainly due to increased oil viscosity, reduced battery capacity, and increased compressed air leakage. The solutions include preheating the engine, using low viscosity engine oil, and checking the battery condition.
2. Poor starting performance: The reasons may include low starting speed, poor cylinder sealing, improper clearance between engine components, etc. During maintenance, relevant components should be inspected and adjusted.
3. The crankshaft cannot rotate: This is usually caused by mechanical faults such as poor meshing between the starter and flywheel teeth, cylinder sticking, or crankshaft locking. The engine needs to be disassembled for maintenance.
4. Can rotate but cannot start: The exhaust pipe emits no smoke, which may be due to oil circuit problems such as no oil in the tank or clogged filters. The oil circuit should be inspected and cleaned.
5. Difficulty or inability to start, white smoke emission: It may be due to water in the diesel or a damaged cylinder gasket causing cooling water to enter the cylinder. The diesel should be replaced and the cylinder gasket checked.
6. Difficulty or inability to start, emitting gray and white smoke: The reason is that the engine temperature is too low or the fuel supply time is too late. The engine should be preheated and the fuel supply time adjusted.
7. Difficulty or inability to start, black smoke emission: The result of incomplete diesel combustion may be poor diesel quality, poor intake, or fuel injector leakage. Diesel should be replaced, air filters should be cleaned, and fuel injectors should be inspected.
8. Difficulty in hot start: caused by severe wear of the plunger pair of the fuel injection pump and the needle valve pair of the fuel injector. The fuel injection pump and injector should be disassembled for maintenance or replacement.
9. Normal low speed but no high speed, insufficient smoke exhaust: caused by insufficient circulating oil supply or blocked oil circuit. Adjust the fuel injection pump and clean the oil circuit.
10. Insufficient power, gray and white smoke emission: caused by delayed fuel injection time or low engine temperature. The fuel injection time should be adjusted and the engine should be warmed up.
11. Insufficient power and thick black smoke emissions: caused by excessive engine fuel supply or dirty air filter. Adjust the fuel injection pump and clean the air filter.
12. Insufficient power, blue smoke emission: caused by engine oil entering the cylinder for combustion or turbocharger failure. Oil consumption should be checked and the turbocharger should be repaired.
13. Turbocharger prone to malfunction: Due to the harsh working conditions of the turbocharger, it requires high lubrication and cooling. When using, attention should be paid to the cleanliness of the lubricating oil and the cooling condition of the turbocharger.
14. No idle or unstable idle: caused by governor malfunction or wear of fuel injection pump plunger. The governor and fuel injection pump should be inspected and repaired.
15. Sudden engine shutdown during operation: caused by reasons such as broken driving teeth of the fuel injection pump or stuck internal moving parts of the engine. Immediate shutdown for maintenance is required.
16. Slow shutdown during operation: caused by untimely or interrupted fuel supply. The fuel level in the fuel tank and the fuel supply pipeline should be checked.
17-20. Other faults: including electrical system faults, hydraulic system faults, and structural component damage. These faults require maintenance and handling based on specific circumstances.
In short, understanding the common faults and maintenance methods of excavators is of great significance for ensuring the smooth progress of the project. In practical operation, corresponding maintenance measures should be taken based on the fault symptoms and causes to ensure that the excavator can safely and efficiently complete the task.
