On-site repair method for construction machinery - Solutions - Huaqiang Electronic Network

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As a construction equipment in the fields of urban construction, mining, road paving, water conservancy and hydropower, etc., it is also the main force in emergency rescue and disaster risk. To be such a heavy responsibility, it must be sturdy and durable, and it is not possible to drop the chain at a critical moment. If it is a failure to repair someone else, what should be done? Today, the editor of the Electrician Forum has compiled some repair methods for construction machinery for you. Regardless of the parts or the whole machine, I hope that everyone can help.

1, "planting silk" repair method

That is, it is screwed into the body or the body of the component to form a wire plugging function. For example, a 6135 engine block has cracks (length 30 mm). First, drill a crack stop at each end of the crack, then drill the tapping in the order of 1, 3, 5, 7... and screw in the copper screw, then drill the screw holes in order 2, 4, 6, 8... , screw in the copper screw in the same way. When drilling, ensure that the two adjacent screws have a 1/3 overlap. The screwing depth is preferably the same as the wall thickness. Finally, the head of the screw is tapped with a hammer to seal it. The diameter of the screw is 6~8mm. It is appropriate. Another ZL50 loader tank has a small hole leaking oil with a hole diameter of about 4mm. Find a steel with a diameter of 5mm to enlarge the hole, increase the thickness of the tank wall with the bead, tap the M6 ​​screw hole and screw in the screw to seal the hole.

2, "shift" repair method

That is, use your own parts to change positions or change the installation position and direction to restore the original function. For example: 1 There is a ZL40 type loader main hydraulic pump damaged, after decomposition, it is found that the front and rear side plate bronze wear layer and the passive gear tooth working surface have different degrees of wear. According to the wear of the front and rear side plates and the passive gear tooth surface, the front and rear side plates and the main and passive gears have the same structure and the same size, so the front and rear side plates are swapped. Installation, and the passive gear is flipped 180°, so that the frictional direction of the bronze wear layer of the front and rear side plates is opposite to the original one, so that the tooth surface of the passive gear that is not worn becomes the working surface, which restores the normal operation of the loader. The working pump of the 2W4-60C excavator and the steering pump of the ZL50 type loader are all CBG2 gear pumps with the same installation dimensions but opposite rotation directions. According to the CBG series gear pump, the pump body and the front and rear side plates can be rotated by 180° and then reassembled to realize the change of the rotating direction. It can be reassembled and exchanged. 3 When the engine flywheel ring gear is affected by the unilateral wear and the normal start, the ring gear can also be installed and reused.

3. "Alternative" repair method

That is, the local materials are taken to replace the damaged parts of the construction machinery. Mainly used for temporary replacement of gaskets, oil seals, tubing, radiators and wires. For example: 1 There is a W4-60C excavator. Because the hydraulic oil radiator is damaged and the oil leakage is serious, it is decided to change the hydraulic oil forced and natural integrated cooling method into a single natural cooling method. This will meet the cooling requirements of the system and restore the excavator work. 2 There is a ZL40 type loading arm hydraulic cylinder piston oil seal damaged, and the triangular oil tape is used instead of the piston oil seal, which makes it work quickly. The specific method is to first take a section of ordinary scrap triangle tape, the length of which is the same as the length of the outer circumference of the piston oil seal, and then shape the tip by grinding to make the top width wider than the piston oil seal ring groove by 10~10mm, and The joint is cut at an angle of 45° to increase the contact area and reduce leakage. 3 In the usual repair of the construction site, the following methods can be used: replacing the oil return hose of the fuel system with a common plastic pipe, replacing the low-pressure oil circuit sealing gasket with a plastic washer with a Coca-Cola beverage bottle, and replacing the ignition system of the gasoline engine with a cable wire. Separate the cylinder line, use the cigarette wire with 502 glue to stop the leak, use the rubber ring as the return spring.

4, "short circuit" repair method

Short-circuit the tubing, air pipe or circuit in the hydraulic system of the construction machinery, the pneumatic system, the fuel supply system and the electrical equipment, and connect the pipeline or the circuit directly over the parts that have already failed. For example: 1 There is a ZL50 loader because the driver does not let off the cooling water at night, causing the oil radiator to freeze. At this time, we remove the oil radiator, so that the oil pipe is directly connected to the oil passage of the machine, and the oil radiator The water pipe is shorted and the performance is restored. 2 There is a TL-180 fast bulldozer steering system relief valve failure, using the "open circuit method" to restore its work, that is, the overflow valve pilot valve spool oil hole is blocked, or directly make the overflow valve oil inlet Closed. It should be noted that the driver must keep the engine throttle in the middle position during operation, and should not work under large throttle conditions. 3 There is a W4-60C excavator in the work of the sudden loss of the pump, hydraulic system 瘫痪, we use a three-way joint to connect the pump A and the pump drain directly to the pump, so that the pump can supply oil to the hydraulic system separately, in time to recover The work of the hydraulic system. 4 There is a ZL50 loader flow distribution valve stem spring break, can not change parts at a time, decided to remove the valve stem, so that the valve body becomes a multi-channel joint, connecting the oil circuit. Although this makes the system lose the role of oil quantity adjustment and distribution, it can temporarily carry out the shovel loading operation. It should be specially stated that the short-disposal method is only an emergency repair method and cannot be used for a long time.

5, "Bone" repair method

That is, the damaged parts can be quickly repaired by means of bundling, welding, plywood, and glue. For example: 1 There is a W4-60C type excavator, and the rear axle wheel reducer axle housing bearing housing has a staggered fracture at the outer shoulder, and the outer spline of the wheel core support portion is torn (width 15mm). If the replacement cost is nearly 10,000 yuan, it is decided to take the "bone method" for the repair of the fracture. The annular tear portion of the fracture portion was cut off (the axial length was shortened by 455 mm), and then No. 45 high-quality carbon structural steel was selected as the bone material. Machining it, using high-strength E5016 (J506) welding rod, using double-sided V-shaped groove, DC reverse-segment segmentation multi-layer welding, completed the repair task in only 1h. 2 There is a hydraulic oil pipe of ZL40 loader ruptured, it is decided to saw it from the rupture. The steel pipe is used to form a “barb” at both ends of the steel pipe, inserted into the hydraulic oil pipe, the depth is about 100mm, and it is bundled with 8# wire. The wire ends of the two ends are twisted to prevent the steel pipe from falling off the oil pipe due to excessive oil pressure, which quickly restores the working performance of the machine.