Proper maintenance of machinery and equipment during the hot summer months can reduce repair costs and other unexpected expenses, lower operating costs, extend service life, and ultimately improve business efficiency. This article provides targeted maintenance suggestions based on common summer malfunctions in machinery and equipment.
1. Common mechanical equipment malfunctions in summer
1) Hydraulic system malfunction
Hydraulic systems frequently experience malfunctions such as pipe bursts, joint leaks, solenoid valve coil burnout, hydraulic valve jamming, and excessive noise in high-temperature environments. Systems using accumulators may suffer damage due to high hydraulic oil temperatures. In summer, aging circuits are more prone to insulation cracking due to thermal expansion and contraction of metals, leading to short circuits. Electrical components in control cabinets are also prone to failure in high-temperature seasons, and critical control components such as industrial control computers may experience malfunctions such as system crashes, slow operation, and control failures.
2) Lubrication system failure
Prolonged operation of construction machinery at high temperatures will lead to deterioration of the lubrication system, easy deterioration of the oil, and easy wear of various transmission systems such as the chassis. It will also affect the paint layer, braking system, clutch, throttle control system and metal structure.
3) Engine malfunction
The effects of high temperatures on engines are mainly manifested in the rapid temperature rise of the engine. Under conditions of high ambient temperature, the engine is prone to overheating, which reduces the viscosity of the engine oil and leads to mechanical failures such as cylinder scoring and bearing failure. At the same time, it also reduces the engine's output power. Sustained high temperatures place strict requirements on the permeability of the radiator, requiring the cooling system to operate under high load continuously, which reduces the lifespan of components such as the cooling system fan and water pump. The air conditioning compressor and fan are used particularly frequently, which can also easily lead to their failure.
4) Other faults
High temperatures and humidity in summer can cause batteries to explode if their vents are blocked due to increased internal pressure. Tires operate in high temperatures during the summer, leading to accelerated wear and a higher risk of blowouts due to increased internal pressure. Drive belts lengthen in summer, causing slippage, accelerated wear, and potential breakage if not adjusted promptly. Even small cracks in the driver's side window can widen or shatter in summer due to temperature differences or water splashes.
2. Summer maintenance and upkeep measures for mechanical equipment
1) On-site emergency handling of high temperature faults
(1) "Overheating" is one of the common faults of construction machinery caused by high temperature. When the water temperature is too high, do not rush to open the water radiator cover to dissipate heat. This can easily cause hot water to spray out and injure people. Water should be added after the water has cooled down naturally. According to operating experience and construction machinery operating specifications, when the operator finds that the engine has "overheated", he should stop the operation immediately and not turn off the engine. Let the engine idle and open all the louvers to increase the air flow so that the water temperature can slowly drop under the action of the cooling fan and release the large number of bubbles generated by the cooling system.
After the engine has been idling for a few minutes and the water temperature has dropped and stopped boiling, wrap the radiator cap with a wet towel or gauze, and carefully unscrew it partially to release the steam. Once you are sure that all the steam has been released from the radiator, unscrew the radiator cap completely. When unscrewing the radiator cap, remember not to expose your arms and keep your face away from the top of the filler neck to prevent hot water from scalding your face.
If the engine has stalled, start it quickly and let it idle. If the engine cannot be started after stalling, turn off the throttle and crank the crankshaft by hand. If there is no hand crank, use the starter motor intermittently to make the piston move up and down several times, dissipating the heat in the cylinder through the intake and exhaust air exchange.
(2) When adding coolant, it is best to add the same type of coolant as that in the water radiator. Do not add tap water unless it is an emergency. When adding coolant to the water radiator, you must wait until the water temperature drops to about 70°C before doing so. You should use the "gradual water addition method" to gradually cool down the water, and do not add water too quickly at once. That is, when adding water, let the engine idle while slowly adding water in a continuous stream to ensure the safety of the operators and equipment.
(3) When the brake or other parts are overheated, do not use water to cool them down, as this will reduce their lifespan and performance, and cause the parts to deform or even crack. Therefore, the machine must be stopped and allowed to cool down naturally.
2) Key points for daily maintenance and upkeep of mechanical equipment in summer
(1) Perform early maintenance and upkeep of construction machinery
With the arrival of summer, it is best to perform a comprehensive maintenance on construction machinery. This includes changing the engine's three filters and oil, replacing or adjusting belts, and checking the performance of the fan, water pump, generator, and compressor. If necessary, perform maintenance, repairs, or replacements.
For machinery operating in high-temperature areas, appropriately increase the viscosity grade of the engine oil. At the same time, check whether the cooling system and fuel system are unobstructed; replace aging wires, plugs, and hoses; check and tighten fuel lines to prevent fuel leaks; clean oil stains and dust from the engine body to ensure that the engine is "lightly loaded" and has good heat dissipation.
(2) Perform lubrication work properly.
Equipment lubrication is one of the important means to prevent wear and failure of equipment parts.
Lubrication plays a vital role in mechanical transmission and equipment maintenance, affecting equipment performance, precision, and lifespan. Effective lubrication requires adhering to the "five fixed points and three-stage filtration" principle: lubrication must be performed according to the prescribed lubrication time, operator, lubricant type, location, and quantity; and filtration must be maintained during the lubrication process (entry filtration, dispensing filtration, and refueling filtration). This reduces friction and wear, thereby ensuring the normal operation of the equipment.
During the hot summer months, the lubrication time should be adjusted by 0.5 to 1 times compared to spring and autumn. The condition of the oil should be closely monitored, as grease oils are prone to temperature fluctuations. If the temperature rises, add more oil (maximum three strokes with a grease gun). If the temperature remains slightly high after adding oil and then gradually drops, it indicates effective lubrication. The problem is that insufficient oil in the bearing is causing the temperature to rise.
If the temperature remains unchanged or only rises after adding oil, it indicates that the bearing is worn, severely lacking oil, or even that the oil inside is dry. Therefore, for grease lubrication, adjust the lubrication time, make a lubrication plan, and implement the lubrication schedule when it is due.
For liquid oils, special attention should be paid to emulsification. During the high temperatures of summer, lubricating oil operates in environments where temperatures are more than 20 degrees Celsius higher than in spring, autumn, and winter. The oil, being a hydrocarbon compound, experiences continuous temperature fluctuations, leading to the formation of water and emulsification. This emulsification significantly reduces viscosity, drastically decreasing the efficiency of the original lubricating film on the lubricated parts. Consequently, the frictional forces increase exponentially. Therefore, a proper lubrication plan, regular inspections, and proactive preventative maintenance are essential for liquid oils.
Summer maintenance of machinery and equipment should adhere to the principles of timeliness, rationality, and comprehensiveness to facilitate equipment operation and adaptation to external temperatures and working conditions. It is necessary to monitor equipment performance dynamics and develop maintenance plans that combine targeted and general approaches.
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