Excavator high reaction will have these serious "symptoms"

Feb 12th,2025 181 Views

Excavator operation in plateau: problem analysis and response strategies

Excavator operation faces many challenges in plateau areas. The unique climate and geographical conditions of the plateau, such as low temperature and thin air, bring a series of problems to the normal operation of the excavator. Understanding these problems and mastering the response methods are crucial to ensure the efficient operation of the excavator.

I. Common problems of excavators in plateau environments

(I) Starting difficulties

1. Limited battery performance: The battery works best in an environment of 20℃ - 40℃. As the ambient temperature decreases, its output capacity decreases. When the temperature is below 30℃, the battery capacity decreases by 1% - 1.5% for every 1℃ drop. At 0℃, the capacity is only about 60% of the maximum value, resulting in a significant drop in voltage and failure to provide sufficient power for the engine to reach the rated starting speed.

2. Increased lubrication resistance: At low temperatures, the viscosity of the lubricating oil increases, and the resistance between the friction parts increases, causing the engine starting speed to decrease.

3. Combustion conditions deteriorate: The air is thin and the air pressure is low in high altitude areas, the compression end pressure and temperature are lower, the engine ignition delay time becomes longer, and the starting difficulty increases.

4. Diesel atomization is poor: At low temperatures, the viscosity and surface tension of diesel increase, the injection atomization quality deteriorates, affecting the combustion effect and increasing the difficulty of starting.

(ii) The engine is prone to "boiling"

The boiling point of water decreases as the atmospheric pressure decreases. At an altitude of 4,500 meters, the measured boiling point of water is 87°C, while the normal operating temperature of the engine is around 80-90°C, so it is easy to "boil".

(iii) Power reduction and fuel consumption increase

As the altitude increases, the air pressure decreases, and the air density and oxygen content decrease, which has a significant impact on diesel-powered excavators. For every 1,000 meters increase in altitude, the atmospheric pressure drops by about 11.5%, the air density decreases by about 9%, the power and torque of the internal combustion engine decrease by 8% - 13%, the fuel consumption increases by 6% - 9%, and the thermal intensity increases by 2% - 5%, resulting in a significant reduction in the engine's power and economy.

(IV) Other faults

1. Material aging: The low temperature and strong ultraviolet radiation on the plateau affect mechanical materials and electrical components. Rubber sealing materials are prone to aging, brittle cracking and wear, and their reliability is reduced.

2. Metal cold brittleness: Metal materials have low-temperature cold brittleness problems, which affects component performance.

3. Signal distortion: The signal measured by the sensor is prone to distortion, which affects the monitoring and control of the excavator's operating status.

2. Effective strategies for dealing with plateau operation problems

(I) Pay attention to battery life

When working on the plateau for a long time, the battery life of the excavator is shorter than that in the plains, and the replacement frequency should be appropriately increased.

(II) Frequent inspection of the intake system

The air pressure on the plateau is low, and the blockage of the intake channel will reduce the intake volume and seriously reduce the engine power. The intake system needs to be checked and cleaned regularly.

(III) Keep the radiator clean

Regularly clean the intercooler to reduce the intake temperature and increase the air density, which can greatly increase the engine power, improve the heat load, and reduce the maximum combustion temperature, the average cycle temperature, the exhaust temperature and the cylinder head temperature.

(IV) Adjust the fuel supply advance angle

Properly adjusting the fuel supply advance angle can improve the engine exhaust, but due to the low oxygen content in the plateau, there will still be a small amount of black smoke.

(V) Replace the plateau radiator cap

Replace the radiator cap suitable for the plateau environment to increase the boiling point of the cooling water and prevent the engine from "boiling".

(VI) Choose the right engine oil

Consider using multi-grade engine oil with better low-temperature performance to reduce lubrication resistance at low temperatures.

(VII) Shorten the maintenance cycle

Shorten the maintenance cycle from 250 hours to 200 hours to promptly discover and solve potential problems.

(VIII) Adjust the main pump power

When the equipment enters the plateau for construction, the engine power will decrease. The main pump power should be appropriately lowered to avoid the phenomenon of stalling.

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