Bucket shaft manufacturers have observed that the recent large-scale renovations of heating pipes in various regions have put excavator operators to the test, with the workload almost laying the foundation for the entire year's harvest. However, this requires the bucket shaft to operate without malfunctions, especially serious issues like overheating and black smoke. Unfortunately, many machine owners have recently encountered this problem and are urgently seeking help from engineers regarding the issue of black smoke emanating from their machines under load. Below, the bucket shaft manufacturer will guide you through accurately diagnosing the fault and how to quickly resolve it.
Regarding the symptoms and causes of excavator parts malfunctions:
The bucket shaft manufacturer first investigated the specific situations described by the owners. One owner described how their machine had been idle for almost a quarter of a year before being put into operation. With a large-scale operation recently underway and a tight schedule, the machine developed a malfunction, emitting black smoke under load, shortly after restarting. This caused the owner considerable anxiety.
The owners contacted the excavator parts factory's repair technicians to see if there were any solutions. After understanding the overall situation through the technicians' assessment and drawing on past experience with similar malfunctions, the bucket shaft manufacturer determined that the problem was caused by poor combustion. The specific causes are as follows:
1. Check all excavator parts for insufficient air intake.
2. Poor fuel injector atomization is the primary concern.
3. Ignition timing errors are also a crucial factor and must be thoroughly checked.
Based on the machine model and operating data of all excavator parts provided by the owner, the bucket shaft manufacturer, along with the repair technicians, used big data and past experience to determine the most easily inspectable factor: the air intake. The inspection revealed that the air intake pressure was only 180 kPa when the machine was under load, significantly lower than the normal value of 230 kPa. Therefore, all potential fault points were initially identified.
Regarding the troubleshooting methods:
1. Based on the above, the mechanic immediately inspected the excavator's air filter, turbocharger, and all intake pipes from the air filter to the engine, but found nothing abnormal.
2. Due to the slight peculiarity of this model (Type 8), if air enters the diesel fuel system through the fuel lines, it will cause a drop in common rail pressure, which will also cause a decrease in the control injector and intake pressure. However, no air was found in the fuel lines after inspection.
3. After the above inspection, the only remaining issue with the intake system was the intercooler. Since the intercooler cannot be visually inspected or tested, the mechanic chose the most direct method: replacement. After replacing it with a known working intercooler and testing the machine, the fault disappeared!
The excavator's fault was finally resolved. The root cause was a problem with the intercooler, leading to insufficient intake pressure, which caused the black smoke emanating under load as described by the owner. Simply replacing the faulty component resolved the issue, and the machine functioned normally!
During periods of tight deadlines and heavy workloads, machine owners face the most challenging times when malfunctions occur. They must balance meeting deadlines with maintaining the machine's condition. If problems aren't addressed promptly, they can lead to more serious issues with excavator parts. Therefore, bucket shaft manufacturers advise owners to remember two points: first, don't delay when encountering a malfunction; second, act quickly and decisively when necessary. Otherwise, procrastination will only result in expensive replacement parts, which is ultimately a losing proposition!
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