Phase 1: Immediate Actions - Safe Shutdown & Site Securing
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Immediate Shutdown:
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Upon detecting any abnormality (unusual noises, smells, loss of control, fluid leaks, warning lights/alarms), immediately cease all operations.
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Position the machine on firm, level, and safe ground, away from hazards like slopes, trenches, or power lines.
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Securely lower all work equipment (bucket, arm, boom) to the ground; avoid leaving them suspended.
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Complete De-energization/Engine Shutdown:
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Shut off the engine, remove the key, and secure it.
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For electric excavators, disconnect the main power switch (typically located near the batteries).
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Depressurize Hydraulic System:
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After engine shutdown, slowly operate all control levers several times (e.g., bucket open/close, arm retract/extend) to release residual hydraulic pressure. This is crucial to prevent injury from high-pressure fluid injection.
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Establish Warning Zone:
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Place highly visible warning signs, barrier tape, or warning lights around the machine (recommended radius 5-10 meters), clearly marking "Equipment Failure - Do Not Operate".
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Activate the machine's warning beacon/lights during low visibility or nighttime conditions.
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Initial Risk Assessment:
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Observe Calmly: Without touching the machine, carefully observe the failure point (e.g., leak location, damaged component, smoke origin).
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Identify Hazards:
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High-Pressure Hydraulic Leaks: Extremely hazardous (pressures can exceed 35 MPa / 5000 psi, temperatures can reach 80°C / 176°F+), capable of penetrating skin or causing fire.
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Electrical System Faults: Risk of short circuits, arcing, or electrocution.
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Structural Failure/Loosening: Risk of falling components or machine instability.
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Undercarriage/Travel System Failure: Risk of unintended machine movement.
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Damaged Rotating Components: Risk of flying debris.
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Phase 2: Fault Diagnosis & Information Gathering
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Document Symptoms Precisely:
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Specific Manifestation: What action was the machine performing when the fault occurred? (e.g., slow/weak movement, jerking, stalling, unusual noise, vibration, smoke, engine shutdown, warning light/alarm).
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Instrumentation Data: Record all fault codes (e.g., engine warning light, hydraulic overheat light, electrical alarm) and gauge readings (coolant temp, oil pressure, hydraulic oil temp, fuel level, voltage).
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Operating Conditions: Workload, ambient temperature, and machine operating hours at the time of failure.
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Perform Basic Visual Inspection (Safely):
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Fluid Levels & Condition: Check engine oil, hydraulic fluid, coolant, and fuel levels. Look for contamination (milky emulsion, cloudiness, metal particles).
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Leak Inspection: Thoroughly check for leaks (oil, water, air) at the engine, hydraulic pump, control valves, cylinders, hose/pipeline connections, coolers, and radiator. Identify source and severity.
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Structural Inspection: Visually inspect major components (boom, arm, bucket, upper structure, undercarriage) for obvious deformation, cracks, weld failures, loose/missing bolts, or breaks.
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Belts & Hoses: Check for aging, cracks, abrasion, or looseness.
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Filter Status: Note condition of air, engine oil, hydraulic, and fuel filters if visible blockage is apparent.
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Consult Documentation:
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Locate the machine's Operation & Maintenance Manual (OMM) and Service Manual (SMM). These contain fault code definitions, system schematics, key specifications, and basic troubleshooting procedures.
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Phase 3: Engaging Professional Repair Support
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Contact Authorized Dealer or Qualified Technician:
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Clearly relay all documented symptoms, instrumentation data, initial inspection findings, and the machine Model/Serial Number to the service provider.
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Follow any remote guidance from the technician only if it can be performed safely. Do NOT attempt complex disassembly yourself.
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Repair Plan Communication:
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Discuss the diagnosis, proposed repair plan, required parts, estimated labor time, and costs in detail with the service provider.
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Clarify if the repair involves critical components (e.g., engine, main hydraulic pump, main control valve).
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Request clarification on warranty coverage implications, if applicable.
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Professional Repair Execution:
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Qualified Personnel Only: Repairs, especially involving hydraulics, high-voltage systems, or structural integrity, must be performed by certified technicians.
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Use Genuine/OEM-Equivalent Parts: Critical for reliability, performance, and safety. Avoid non-certified parts for core systems.
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Documentation & Testing: Ensure the service provider supplies a detailed repair report and conducts thorough post-repair functional and safety testing.
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Post-Repair Operation:
If you need it, you can contact us to help you check
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Review Repair Report: Understand the cause of failure and work performed.
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Initial Operation Monitoring: Closely observe machine performance during the first hours of operation after repair. Listen for noises, monitor gauges, and check for leaks.
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Adhere to Maintenance Schedule: Strictly follow the OMM's preventive maintenance schedule to minimize future breakdown risks.
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