Excavators rely heavily on hydraulic cylinders to perform various tasks like digging, lifting, and moving materials. When these cylinders malfunction, it can lead to significant downtime and increased operational costs. This guide provides a detailed process for removing, inspecting, and repairing the bucket cylinder of an excavator, including a rundown on the types of cylinders, their functions, basic hydraulics, necessary tools, and safety measures.
Types of Hydraulic Cylinders in Excavators and Their Functions
Before diving into the repair process, it's crucial to understand the different types of hydraulic cylinders found on an excavator and their specific functions:
Bucket Cylinder: Controls the angle and force of the bucket.
Boom Cylinder: Lifts and lowers the boom.
Arm (Stick) Cylinder: Moves the arm/stick in and out.
Swing Cylinder: Rotates the cab and the attached structure.
Each of these cylinders uses hydraulic fluid under pressure to create motion and force, allowing the excavator to perform its intended tasks.
Basic Description of How Hydraulics Work
Hydraulic systems use fluid to transmit power. In excavators, the hydraulic fluid is pumped under high pressure through hoses to the cylinders. As the fluid enters the cylinder, it pushes against a piston, which moves and extends the rod attached to the piston, creating movement in the corresponding part (bucket, boom, arm, swing).
Tools Needed
Wrench set
Screwdrivers
Allen keys
Hydraulic jack
Seal replacement kit
Cylinder hone (if needed for smoothing the barrel)
Chrome polish and rust remover
Safety glasses and gloves
Safety Measures
Ensure the excavator is turned off and stabilized.
Use proper lifting techniques and equipment to handle heavy parts.
Wear safety glasses and gloves to protect against hydraulic oil and debris.
Contain and dispose of hydraulic fluid properly to avoid environmental hazards.
Removing the Bucket Cylinder
Positioning: Lower the boom and bucket to a stable and flat surface. This reduces tension in the hydraulic lines and ensures safety during disassembly.
Draining Hydraulic Fluid: Place a drain pan under the cylinder. Carefully loosen the hydraulic hoses attached to the cylinder to allow the fluid to drain out, avoiding spills.
Detaching the Cylinder: Remove the pins that attach the cylinder to the boom and the bucket. You may need a hydraulic jack or a helper to safely manage the weight.
Removing the Cylinder: Once disconnected, carefully remove the cylinder from the excavator.
Inspecting and Repairing the Cylinder
Disassembling the Cylinder: Unscrew the cylinder head with the appropriate tools. Slide out the piston rod and inspect all components.
Inspecting the Rod and Barrel: Look for signs of wear like scratches or pits on the chrome of the rod and the inside of the barrel. Any damage can compromise the seals and the performance of the cylinder.
Fixing Chrome and Barrel Damage:
Divots in the Chrome: Use a chrome polish and a soft cloth to buff out minor scratches. For deeper divots, a re-chroming may be necessary.
Pitting in the Barrel: If the damage is minor, use a cylinder hone to smooth the surface. Severe pitting might require professional machining or replacement.
Replacing the Seals: Remove the old seals from the piston and the gland. Clean the grooves thoroughly before installing new seals from the kit.
Reinstalling the Cylinder
Reassembly: After the repairs, reassemble the cylinder by replacing the rod into the barrel and screwing the head back on.
Reattaching to the Excavator: Position the cylinder back into place, align the pins, and secure them.
Reconnecting Hydraulic Lines: Attach the hydraulic hoses and ensure they are tight to prevent leaks.
Testing: Refill the hydraulic fluid, start the excavator, and test the cylinder by operating the bucket. Check for any leaks or unusual noises.
Conclusion
Regular maintenance and prompt repair of hydraulic cylinders are crucial for the efficient operation of excavators. Understanding how these components work, and how to handle them safely, can save time and reduce costs related to equipment downtime. Always refer to the manufacturer's manual for specific procedures and torque specifications to ensure proper repair and reassembly.
Rechroming Your Shaft
Rechroming the shaft (or rod) of a hydraulic cylinder is a critical process used to restore the surface when it has been damaged by corrosion, wear, or scratches. This not only extends the life of the hydraulic cylinder but also ensures smooth operation and prevents seal damage. Here’s a detailed look at the rechroming process:
Step-by-Step Guide to Rechroming a Hydraulic Cylinder Shaft
Step 1: Disassembly and Cleaning
Remove the Cylinder: First, the hydraulic cylinder must be removed from the machinery.
Disassemble the Cylinder: The cylinder is then disassembled to separate the rod from the rest of the cylinder.
Cleaning: The rod needs to be thoroughly cleaned to remove any hydraulic fluid, dirt, and corrosion. This is usually done using chemical cleaners and mechanical brushing.
Step 2: Inspection and Measurement
Inspection: Examine the rod for any damage such as deep pits, scratches, or uneven wear patterns.
Measurement: Measure the thickness of the existing chrome plating and the diameter of the rod to ensure that the rechroming will bring it back to its original specifications.
Step 3: Grinding and Polishing
Grinding: The old chrome layer is ground down to remove the damaged layers completely. This is done using a cylindrical grinder that spins the rod while an abrasive wheel moves back and forth across its surface.
Polishing: After grinding, the rod is polished to achieve a smooth, clean surface that is free of any imperfections. This is crucial to ensure a good adhesion of the new chrome layer.
Step 4: Nickel Plating (if required)
Application: In some cases, a layer of nickel is applied before the new chrome layer. Nickel provides additional corrosion resistance and can help to smooth out any minor imperfections on the surface of the rod.
Step 5: Chrome Plating
Preparation: The rod is cleaned again to remove any contaminants from the grinding and polishing processes.
Chrome Plating Setup: The rod is placed in a chromic acid bath and connected to a cathode. The chrome plating solution contains chromium trioxide and other chemicals.
Electroplating: An electrical current is passed through the bath, causing chromium from the solution to deposit onto the rod. The thickness of the chrome layer can be controlled by adjusting the current and the time the rod spends in the bath.
Step 6: Final Polishing and Inspection
Polishing: Once the chrome layer has been applied, the rod is polished again to achieve the desired finish and smoothness.
Inspection: The final step involves inspecting the rod to ensure that the chrome layer is uniform and free of defects. Measurements are taken again to verify that the dimensions are within the specified tolerances.
Step 7: Reassembly and Testing
Reassembly: The rod is reassembled back into the cylinder, ensuring that all seals and parts are correctly installed.
Testing: The hydraulic cylinder is then tested under operating conditions to ensure that it functions properly with no leaks or mechanical failures.
Rechroming is an effective way to refurbish hydraulic cylinder rods that have suffered surface damage, restoring them to their original condition and performance specifications. This process not only saves costs by prolonging the equipment's life but also ensures optimal functioning and reliability of the hydraulic system. It's important that rechroming is done by professionals with the right skills and equipment to ensure high-quality results.