How to extend the service life of construction machinery

1. Machinery Procurement

When making a purchase, it is essential to conduct on-site inspections, compare prices among different sellers, and buy products with reasonable designs, high manufacturing technology content, and good after-sales service. Excellent design is the primary step in extending the service life of machinery. It can be planned from aspects such as simplifying disassembly and assembly, modulating components, centralizing oiling, monitoring inspection, extending the lubrication cycle, generalizing wear parts, and having complete random tools. As much as possible, maintenance items can be reduced in design to gradually achieve maintenance-free operation. The service life can also be prolonged by choosing new materials that are wear-resistant, vibration-resistant, impact-resistant and corrosion-resistant.

2. Mechanical Use

Based on nearly a decade of practice in mechanical usage and management, the author believes that the service life of machinery can be prolonged through the following five aspects of management.

1. Always provide safety production education to drivers and operators. Safety is the guarantee of efficiency, and the responsibility for safety is heavier than Mount Tai. Always keep in mind the ten key points of safety work (the key to safety lies in attention, the key to attention lies in guidance, the key to leadership lies in management, the key to management lies in the site, the key to the site lies in implementation, the key to implementation lies in inspection, the key to inspection lies in rectification, and the key to rectification lies in prevention) and the "Ten Don 'ts" of safe driving (drive civilly, don't drive heroic cars; Respect and give way to each other, and do not drive vehicles with blocked air. Be courteous and give way first, and do not drive vehicles that cut in line. Skilled in technology and never drive a paralyzed vehicle. Take timely breaks and don't drive aimlessly. Honk the horn and drive slowly. Do not drive risky vehicles. Drive carefully and don't drive recklessly. Timely repair and do not drive a makeshift car. Stay calm and cautious, and don't drive in a hurry. Keep this in mind to avoid traffic accidents and mechanical accidents and extend the service life of machinery.

2. Formulate and implement various rules and regulations

Over the past decade of practical exploration, we have formulated safety production systems, job responsibilities for drivers and operators, operation procedures for mechanical equipment, management, maintenance and repair systems for mechanical equipment, etc. We have consistently implemented the "Two Determinations and three Guarantees" system (determining personnel and machines; Mechanical operators should achieve "three understandings" (understanding structure, principle and performance) and "four abilities" (being able to use, maintain, inspect and troubleshoot), use machinery correctly, strictly follow safety technical operation procedures, and implement target cost management for mechanical equipment. The economic benefits of the operator are linked to the mechanical usage fees (such as fuel costs, maintenance costs, upkeep costs, tool costs, etc.) for purchase, and the operator receives performance-based wages.

3. Regularly and irregularly conduct technical condition checks on the equipment and promptly repair any problems identified. Formulate a winter maintenance and repair plan, inspect and repair the costs of each vehicle and item one by one, and lay a foundation for smooth construction in the coming year.

4. Strengthen the professional ethics education, safety production and business technical training for machine management personnel, drivers and operators. Through training, not only have their operation and maintenance skills been improved, but also their professional dedication has been transformed from passive execution to active participation. Especially for the temporary workers hired, they must receive short-term training in safety and business knowledge. Those who pass the examination will have their labor contracts signed and be covered by personal insurance to prevent potential problems before they occur.

5. The influence of environmental factors on usage

Most construction mechanization is carried out in the open air, and the operation sites frequently change. Therefore, its performance is greatly affected by factors such as temperature, air pressure, pollution, road conditions and weather at the operation site. Many construction units have overlooked the impact of environmental factors on the use of machinery and failed to take corresponding protective or adaptive measures, resulting in a decline in the performance of the machinery, a shortened service life, and even accidents. If effective measures are taken at the construction site, such as keeping the construction access roads flat frequently and maintaining them in a timely manner; On rainy days, fill in the puddles on the sidewalks in time. On sunny days, water them frequently to reduce dust. When maintaining and repairing construction access roads, reducing the slope and other factors in accordance with local conditions are all beneficial to extending the service life of machinery. For instance, during the construction of Bin Gu Road in 1998, due to the dry air, the 18/21 roller used a dry air filter. Excessive dust accelerated the wear of the piston and piston rings. Within a month, the piston and cylinder liner were replaced twice. Countermeasures were considered, and the air filter was replaced with the wet filter of the Dongfanghong bulldozer, which greatly reduced the wear and extended the service life.

3 Maintenance and upkeep

Regular maintenance of machinery is the key to extending its service life. However, many units have numerous regulations on the maintenance forms of machinery, but they focus more on usage than maintenance. Especially when the schedule is tight and the tasks are heavy, they often neglect maintenance work, believing that the machinery is operating normally without faults and does not need to be stopped for maintenance. This often leads to major malfunctions of the mechanical equipment and even accidents, which not only increases the maintenance costs It also delays the project schedule. During the 6.9-kilometer water-stabilized crushed stone and asphalt concrete paving on Xinhe Road in 2004, we used the evening time to maintain the ABG423 paver. From May 4th to November 12th, 2004, the machine was in operation for a total of 1,800 hours, with zero faults, which extended the service life of the machinery. This included changing the hydraulic oil, the oil pump's transmission gearbox, the driving gearbox's gear oil, and changing the engine oil, oil filter element, and diesel filter (coarse and fine) elements every 150-200 hours. The air filter was also cleaned regularly.