As the core equipment for road maintenance and asphalt removal, the efficient operation of milling machines/fraiseuse is directly related to project progress and cost control. However, long-term high-load operation, complex working conditions and improper maintenance can easily lead to frequent equipment failures, especially abnormalities in the power system, hydraulic system and transmission system, which may cause downtime losses.
This article will deeply analyze the common fault types, diagnostic methods and maintenance solutions of milling machines to help you quickly restore construction efficiency and reduce maintenance costs. motor grader cat new motor grader for sale
1. Common fault types and symptoms of milling machines
Types de défauts et symptômes courants des fraiseuses**
(1). Power system failure**
- **Engine will not start or power drops**
- Symptoms: No response when starting, black smoke, insufficient output power.
- Potential causes: fuel filter blockage, turbocharger failure, electronic control sensor (such as crankshaft position sensor) failure.
- **Hydraulic system abnormality**
- Symptoms: unstable milling drum speed, slow movement, and high hydraulic oil temperature (＞80℃).
- Key causes: hydraulic pump wear, overflow valve sticking, oil contamination (excessive particulate matter).
(2). Milling operation failure**
- **Uneven milling depth or abnormal wear of the cutter head**
- Symptoms: Waves appear on the road surface and the frequency of blade breakage increases.
- Common causes: loose toolholder installation, automatic leveling sensor failure, rotor bearing wear.
- **Conveyor system blocked**
- Symptoms: Waste buildup, conveyor belt slipping or stopping.
- Diagnostic focus: Check the scraper chain tension, pulley wear, and whether the hydraulic motor is overloaded.
(3). Electrical control system failure**
- **Control panel alarm or malfunction**
- Typical codes: overload protection (E102), oil temperature is too high (E205), sensor signal loss (E301).
- Troubleshooting direction: line short circuit, PLC module failure, poor grounding.
2. Efficient fault diagnosis process – quickly locate the root cause of the problem
Processus de diagnostic de panne efficace – localisez rapidement la cause première du problème**
(1). Preliminary inspection**
- **Visual Inspection**: Check for obvious problems such as oil leaks, broken belts, missing blades, etc.
- **Running test**: Start without load to observe abnormal noise, and gradually load to test the response of each function.
(2). Professional tools to assist diagnosis**
- **Hydraulic pressure test**: Use a pressure gauge to detect the pressure value of the main pump and motor (standard range: 20-35MPa).
- **Fault code reading**: Connect to the OBD diagnostic instrument to analyze the fault codes recorded by the ECU/PLC.
- **Oil Analysis**: Detect the hydraulic oil contamination level (NAS level 9 and below is a safe value) and determine the internal wear condition.
(3) Module-by-module troubleshooting method**
- **Power module**: Check fuel supply, intake system, exhaust back pressure.
- **Hydraulic module**: Test pump valve group response and cylinder sealing.
- **Transmission module**: disassemble and inspect the gearbox, chain tension and bearing condition.
3. Targeted maintenance solutions – accurate troubleshooting
Solutions de maintenance ciblées – dépannage précis**
(1). Engine maintenance**
- **Fuel system maintenance**: clean the fuel tank and replace the diesel filter (recommended every 500 hours).
- **Turbocharger maintenance**: clean carbon deposits, replace sealing rings, and ensure smooth air intake.
- **Electronic control system repair**: Replace damaged sensors (such as water temperature sensor, oxygen sensor) and recalibrate ECU parameters.
(2). Hydraulic system repair**
- **High-pressure pump replacement**: If the test pressure is 15% lower than the rated value, the plunger pump or gear pump needs to be replaced.
- **Oil circuit cleaning**: Use professional flushing equipment to remove impurities in the pipeline and replace high temperature resistant seals.
- **Heat dissipation optimization**: clean the hydraulic oil radiator fins and install an auxiliary cooling fan (suitable for high temperature environment).
(3). Milling system maintenance**
- **Cutter management**: Use the “symmetrical replacement method” to avoid rotor imbalance (check the cutter wear every 50 hours).
- **Bearing maintenance**: Lubricate rotor bearings (use high temperature lithium grease), replace worn cages.
- **Automatic leveling calibration**: recalibrate the ultrasonic sensor and adjust the hydraulic cylinder stroke.
4. Preventive maintenance strategy – the key to extending equipment life
Stratégie de maintenance préventive – la clé pour prolonger la durée de vie des équipements**
(1). **Daily maintenance checklist**
- Check oil levels (engine oil, hydraulic oil, gear oil).
- Clean the radiator and air filter (dusty environment requires daily cleaning).
- Tighten any loose bolts, especially on the tool holder and transmission parts.
(2). **Periodic deep maintenance**
- **Every 250 hours**: Replace hydraulic oil filter and check belt tension.
- **Every 1000 hours**: Clean the fuel tank, calibrate the sensors, and lubricate the joint bearings of the entire vehicle.
- **Annual overhaul**: dismantle and inspect the engine block, hydraulic pump, transmission gearbox, and replace aging parts.
Through systematic fault diagnosis and standardized maintenance, the service life of the milling machine can be significantly extended, work efficiency can be improved and the risk of downtime can be reduced.
Grâce à un diagnostic systématique des pannes et à une maintenance standardisée, la durée de vie de la fraiseuse peut être considérablement prolongée, l’efficacité du travail peut être améliorée et le risque de temps d’arrêt peut être réduit.
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Post time: Apr-20-2025