Excavators undertake high-intensity,
extended-duration tasks in earthmoving construction, mining operations, and
infrastructure development. Under complex working conditions and frequent
operation, equipment inevitably experiences various malfunctions. Timely and
accurate diagnosis of fault causes, coupled with standardized corrective
actions, is crucial for ensuring stable equipment operation and minimizing
downtime risks. This article categorizes and analyzes common excavator faults
based on practical usage scenarios, providing users with valuable technical
guidance.
I. Common Mechanical Failures
· Abnormal Noise Issues
Unusual noises occurring during excavator
rotation, boom extension/retraction, working device operation, or near engine
cylinder liners are typically linked to insufficient lubrication or localized
wear. Accurately pinpoint the noise source first, then promptly replenish
grease at relevant hinge points and friction areas to prevent further component
damage from dry friction.
· Track Breakage or Derailment
Prolonged operation on rough terrain, improper turning maneuvers, or failure to clear debris from tracks can cause excessive wear or derailment. Inspect track tension, the condition of welded areas beneath track guards and idler wheels. Replace worn or deformed components promptly to prevent secondary damage.
II. Engine System Failures
· Failure to Start (No Ignition)
If the excavator fails to restart after
stalling during operation, common causes involve issues with the fuel pump or
injectors. On-site troubleshooting can involve cooling the fuel pump with water
for preliminary assessment. If the engine starts successfully after cooling,
calibrate the fuel pump and inspect the injector functionality.
· Hot Engine Stalling
When the machine experiences power loss or
stalls while hot, accompanied by black smoke, this is often due to clogged fuel
system, intake system, or engine “three filters” (air, fuel, oil). If caused by
increased internal leakage in the high-pressure fuel pump, professionally
calibrate the pump and inspect the regulator, valve assembly pressure, and
internal component wear.
· Exhaust Valve Malfunction
If the exhaust system exhibits abnormalities, prioritize inspecting the exhaust valve assembly for damage. If the assembly is intact, examine the condition of the exhaust valve filter element. This filter element is typically recommended for replacement every 1000 hours to ensure unobstructed exhaust flow.
III. Electrical System Failures
· Lighting System Failure
Non-functioning lights are often caused by
a blown high-voltage fuse or wiring faults. If a blown fuse is detected, replace
it with an identical specification to prevent secondary failures from
mismatched components.
· Air Conditioning System Not Cooling
If refrigerant leakage occurs due to wear
on the expansion valve's temperature sensor, replace the expansion valve.
Follow standard procedures for vacuum extraction, pressure retention testing,
and precise refrigerant charging to restore normal cooling performance.
· Engine Shutdown Warning Displayed
Upon this warning, first verify that engine
oil has been changed at scheduled intervals and that oil levels are adequate.
Simultaneously inspect the oil pressure sensor and its wiring harness for open
circuits or short circuits.
IV. Hydraulic System Malfunctions
· Sluggish Vehicle Operation
Slow response typically relates to abnormal
pressure in the main relief valve. Inspect the relief valve for blockages or
wear, then adjust or replace based on findings.
· Complete System Inactivity
This fault requires starting with the pilot
system. Check pilot pressure and main pump pressure. The troubleshooting
sequence should include the electrical system (e.g., safety lock switches,
solenoid valves, fuses) and the hydraulic system (pilot pressure, main relief
valve, hydraulic pump, return filter, etc.) to accurately pinpoint the source
of the fault.
· Isolated Movement Malfunction
When a specific movement significantly
slows down or fails completely while others function normally, focus on
inspecting the spool valve. Verify its sealing integrity, disassemble to check
for scratches or wear, and ensure the ball bearing moves freely within the
valve body. If abnormalities are found, repair or replace the valve immediately.
Excavator malfunctions rarely stem from a
single cause but result from the combined effects of prolonged operating
conditions, maintenance practices, and operating methods. Systematic
inspections and standardized maintenance of mechanical, engine, electrical, and
hydraulic systems not only promptly eliminate potential hazards but also
effectively extend equipment lifespan and enhance overall construction
efficiency. Users are advised to establish regular inspection and maintenance
logs. For complex faults, promptly engage professional technicians to ensure
the equipment remains in optimal operating condition.
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