What are the emergency repair measures for construction machinery?

1. Simple revision

When construction machinery is in operation or in motion, if it suddenly malfunctions, simple repair methods should be adopted to ensure its reliable operation or function. This year, while guiding students on their graduation internship, I happened to come across a TY-220 bulldozer whose engine suddenly stalled during operation. After disassembling and inspecting it, it was found that the connecting rod bearing of the engine was burned out. As there were no replacement parts on site, solder was used for repair welding. Then, a small knife was used to smooth and flat the surface to the right size. After cleaning thoroughly, it was reinstalled and the diesel engine resumed operation.

2. Leak sealing

After long-term use, construction machinery may experience oil leakage, water leakage and air leakage. Emergency leak repair is more suitable for construction machinery that operates in tunnels for a long time. Due to the limited working space, it is easy for hydraulic or diesel fuel tanks to leak due to collision. In the event of this situation, you can apply epoxy resin adhesive or soap to patch up the leak in an emergency. If there is a perforation, it can be blocked with a wooden plug. If necessary, it should be securely fastened with iron wire or rope, etc. If oil leakage occurs due to loose pipe joints, you can wrap 3 to 5 turns of the raw tape provided randomly around the threaded part and then tighten it.

3. Replace parts

When working in the field with construction machinery, it is advisable to carry as many spare parts of vulnerable components as possible for emergency replacement. For instance, the sealing parts of the cooling water pump of a diesel engine may leak due to wear and aging of the water seal. After replacing the water seal with a new one, the operation of the water pump will return to normal. Of course, for hydraulic cylinders, hydraulic pumps or hydraulic valves, etc., replacing their seals for repair is quite effective. Also, it would be even simpler and more convenient if the machine parts and assemblies could be replaced, such as diesel filters or hydraulic oil filters, etc.

4. Binding

When a bolt on a construction machine breaks or slips and cannot be tightened, it is advisable to consider using ropes, iron wires and wooden sticks for binding and pasting to temporarily restore its operational state. When the pneumatic mechanism of the 74-type excavator is damaged, its front axle cannot be connected, and the off-road performance of the machine declines, causing the suspension hydraulic cylinder to fail to lock. When it is necessary to connect the front axle, the fork shaft can be separated from the cylinder and pushed inwards. Then, after one turn of the fork shaft, it should be fixed. This can ensure the drive of the front axle. Similarly, if the air pressure in the suspension hydraulic cylinder or braking mechanism drops or disappears, this first aid method can be adopted.

5. Disassembly

Under the premise of not affecting the operation of construction machinery, the temporarily unused and damaged parts can be disassembled and stretched. For instance, the generator of a damaged diesel engine can be removed, and a battery can be temporarily used to supply power to the starting system for a short period of time. Some machine parts, after being disassembled and simply repaired, can still be used in emergencies. If the gas generator of a diesel engine is damaged, it can be removed and ground to basically restore the seal with the valve seat ring, and then it can be used temporarily.

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, if the usage conditions permit, it can be considered to short-circuit and connect it for emergency use. However, it cannot be used for a long time because short-circuiting and connecting often increase the heat generation of the circuit, which may burn out other circuit components. When conditions permit, the damaged components must be replaced immediately to prevent new faults.

7. Supplement

After the low-pressure hydraulic oil pipe is damaged, other pipe materials can be used to restore its original length, which is convenient for emergency repair. For instance, for hydraulic excavators or fully hydraulic rock drilling jacks produced by Nanjing Atlas, if the oil pipes age or wear out due to long-term use, causing them to rupture and unable to be blocked, and there are no spare pipes to replace them, the damaged parts can be cut off, and plastic or rubber pipes can be placed over both ends of the oil pipes to secure and connect them firmly.

When construction machinery is in operation or in motion, if the circuit or hydraulic system is damaged, the damaged part can be disconnected and temporarily not used. If there is a grounding discharge in a certain part of the engine starting system and it cannot be eliminated for the time being, the positive terminal can be left suspended to cut off the power, and only the ignition system can be supplied with power for emergency treatment. If one of the several parallel branch circuits of the hydraulic system malfunctions, the oil inlet pipe can be removed and sealed with a plug at this time. In this way, the other branch circuits can still continue to work. When the operation is completed, it should be repaired in time.

8. Substitution

When a certain component of construction machinery is damaged and makes it unable to work, it can be replaced by other components on the vehicle that do not temporarily affect its operation or components made from local materials. However, this repair method leads to a poor recovery of the machinery's performance and is usually only adopted when it is running without load. For instance, the fan belts of small excavators or 6135 diesel engines can be replaced by adhesive tapes, woven belts for backpacks, etc. in a short period of time.