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How to perform emergency repairs when construction machinery has issues?
2024-11-13
How to perform emergency repairs when construction machinery has problems? The following 8 emergency methods can be used when construction machinery has issues:
1. Simple Repair
A simple repair method to ensure reliable operation. For example, if a TY-220 bulldozer suddenly stalls during operation and inspection reveals that the connecting rod bearing is burnt out, and there are no replacement parts on site, soldering can be used to repair it. Then, use a knife to smooth the surface to the appropriate size, clean it, and reinstall it, allowing the diesel engine to resume operation.
2. Leak Sealing
With prolonged use of construction machinery, issues like oil, water, and air leaks can occur. The emergency methods for sealing leaks at the operation site include:
(1) Use tools to clean and wipe the leak point as much as possible.
(2) Use a pen or small brush to apply the prepared adhesive to the leak.
(3) Use pliers, tweezers, or other tools to apply sealing cotton to the adhesive and smooth it out, then apply another layer of adhesive.
(4) If there are leaks in deep holes or seams, first fill the holes or seams with the prepared adhesive, then insert the sealing cotton into the holes or seams. Alternatively, quickly insert the sealing cotton dipped in the prepared adhesive into the leak, but the prepared adhesive should be used up in one go.
3. Part Replacement
When operating construction machinery in the field, it is advisable to carry extra easily damaged spare parts for emergency replacements. For instance, if the seal of a diesel engine's water pump leaks due to wear and aging, replacing it with a new seal will restore normal operation. Additionally, replacing seals in hydraulic cylinders, hydraulic pumps, or hydraulic valves is also effective. If possible, replacing entire assemblies is simpler and more convenient, such as replacing a diesel filter or hydraulic oil filter. Otherwise, due to significant differences in part quality, wear levels, and dimensions, it may lead to unstable engine operation, hydraulic system oil leaks, severe load concentration, and early damage to replaced parts. It is important to conduct necessary inspections and tests before replacing new parts, including appearance and performance tests, to ensure the new parts are fault-free and avoid unnecessary troubles.
4. Bundling
When a bolt on construction machinery breaks or slips and cannot be tightened, consider using ropes, wires, and wooden sticks to temporarily restore operational status. For example, if the pneumatic mechanism of a 74-type excavator is damaged and the front axle cannot be engaged, reducing the machine's off-road performance and preventing the suspension hydraulic cylinder from locking, the fork shaft can be separated from the cylinder and pushed inward, then fixed around the fork shaft to ensure the front axle is driven. Similarly, if the suspension hydraulic cylinder or braking mechanism experiences reduced or no air pressure, this emergency method can also be applied.
5. Disassembly
Without affecting the operation of the construction machinery, temporarily remove damaged components that are not in use. For example, the generator of a damaged diesel engine can be removed, and a battery can be used to temporarily power the starting system. Some components can still be used in emergencies after simple repairs. For instance, if the diesel engine's intake valve is damaged, it can be removed and ground to restore sealing with the valve seat, allowing temporary use.
However, when disassembling, attention should be paid to:
(1) Avoid disassembling connections that are difficult to remove or that may reduce connection quality and damage some connecting parts, such as sealed connections, interference fits, riveted, and welded connections.
(2) When using impact methods to remove parts, ensure to use soft pads or hammers made of soft materials (like pure copper) to prevent damaging the surface of the parts.
(3) Apply appropriate force during disassembly, especially to protect major components from any damage. If it is necessary to damage one of two mating parts, preserve the part that is more valuable, difficult to manufacture, or of better quality.
(4) For long parts with a large diameter, such as precision slender shafts or screws, clean, oil, and hang them vertically immediately after disassembly. Heavy parts can be supported in a horizontal position using multiple points to avoid deformation.
(5) Clean disassembled parts as soon as possible and apply anti-rust oil. For precision parts, wrap them in oiled paper to prevent rust, corrosion, or surface damage. If there are many parts, categorize and label them before placing them.
(6) For small parts that are easy to lose, such as set screws, nuts, washers, and pins, after cleaning, try to reattach them to the main parts to prevent loss. For parts removed from shafts, it is best to temporarily reinstall them in the original order or string them together with wire for convenience in future assembly.
(7) For disassembled conduits, oil cups, and other lubrication or cooling pathways for oil, water, or air, as well as various hydraulic components, seal the inlets and outlets after cleaning to prevent dust and impurities from entering.
(8) When disassembling rotating components, try not to disrupt the original balance.
(9) For components that are prone to displacement and lack positioning devices or have directional mating parts, mark them before disassembly for easy identification during reassembly.
6. Short Circuit
If a component in the starting system or control circuit of construction machinery is damaged and cannot be repaired or replaced with spare parts, and if usage conditions allow, consider short-circuiting it for emergency use. However, this should not be used long-term, as short-circuiting often increases the heat in the circuit, potentially burning out other circuit components. The damaged component must be replaced immediately when conditions permit to prevent new faults.
After the low-pressure hydraulic oil pipe is damaged, other pipes can be used to restore its original length for emergency repairs. For example, in hydraulic excavators or fully hydraulic rock drilling vehicles produced by Nanjing Atlas, the oil pipes may age or wear out due to long-term use, leading to ruptures that cannot be sealed. In the absence of spare pipes for replacement, the damaged section can be cut off, and plastic or rubber pipes can be securely fitted to both ends of the oil pipe to ensure continuity. When construction machinery is operating or moving, if the electrical circuit or hydraulic system is damaged, the damaged section can be disconnected and temporarily not used. For instance, if a wire in the engine starting system is short-circuited and cannot be resolved immediately, the positive terminal can be left disconnected, supplying power only to the ignition system for emergency purposes. If a fault occurs in one of the parallel branches of the hydraulic system, the oil inlet pipe can be removed and sealed with a plug, allowing the other branches to continue functioning until repairs can be made after the work is completed.
8. Replacement
When a certain component of construction machinery is damaged and cannot work, and there are no spare parts available, other components on the vehicle that do not affect operation or locally sourced materials can be used as replacements. However, this repair method usually results in poor performance recovery of the machinery and is typically only used during unloaded operation. For example, the fan belt of a small excavator or a 6135 diesel engine can temporarily be replaced with tape or woven straps used for backpacks.
During the operation of construction machinery, unexpected failures are inevitable, so it is very important to prepare for emergency repairs.
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