Replacing BROKEN Eye & Repair CRACKED Cylinder for D10 Dozer | Machining, Welding, Milling

how you going guys Kurtis from cutting edge  engineering today's job we have a d10 ripper   lift cylinder that's come in for repair on a dozer  especially the bigger machines they do have two   ripper lift cylinders one on each side which lifts  and lowers the ripper frame while the machine is   in operation they also have tilt cylinders on  top of them to tilt the pitch of the rippers   depending what ground they're working in these  are a very very common component to get damaged or   completely destroyed thankfully someone was kind  enough to point out the issue with this because   i would not have seen it it's come in because it  has torn the eye completely out of the end of the   cylinder barrel one of the main reasons why these  fail is the grease port that was put in from the   oem it is pretty much a dotted line to where it is  going to fail so another reason these can actually   fail is there is a lack of maintenance these do  a lot of movement while they are in operation if   these aren't greased of a morning or an afternoon  start or finish of a shift they tend to dry out   and sooner or later the bush and the pins start  to wear each other out when they start to wear out   there starts to become movement between the two  and then finally they start to hammer each other   and the result is cracks in the eye judging by the  look of the way this has failed the grease port   has caused the crack and it has been cracked there  for a very long period of time because the other   side it has got the cleanest surface so it was the  last thing to break it was working for a period of   time not sure how long with the crack through the  greaseport finally it stretches the eye out and   elongates the hole after it does that it finally  breaks the eye completely off the cylinder barrel   however that is not the only problem so when the  customer disassembled this cylinder it was sitting   upright on their ram bench they didn't bother  to turn it over and have a look underneath   and they would have found multiple cracks  forming in the base of the cylinder barrel   if the eye didn't break and this had kept working  sooner or later it would have pulled the complete   eye out of the base of the barrel so i wasn't  notified about these cracks and the customer   didn't know about them either i didn't plan to  have to try and repair the whole bottom end of   this barrel so what we need to do is set it up  in the saw we'll cut the old eye off and we will   grind those cracks out to see how far they go and  if they go too far it's pretty much a write-off right oh so i've gone and cut the bulk of the  material off around where those cracked areas   are i did grind one of them out i didn't find  the bottom of the crack so what i'm going to   do now rather than remove excess amounts of  material with a grinder i'm going to grab the   die grinder and i'm just going to try and find  the base of the cracks to see whether this is   at all salvageable if the cracks go all the way  through into the barrel it's not really worthwhile   trying to repair that because it's pretty much  guaranteed to fail when we do run into situations   like that we do have a second option and the  second option is we completely replace the barrel   end we do keep one of those in stock we  get them pre-machined from another company   but that is a massive expense because they do  start out as a really big piece of solid material   so we're just going to see if we  can find the base of these cracks i got it now another one to get so i was able to chase out all of those cracks the  good news is they didn't go all the way through   the barrel if there was any chance they were  going through the barrel there would have been   oil and smoke coming back through the cracks as  i was grinding it out we didn't see any of that   i have checked the inside the cracks didn't  make it through so we are ready to continue   the repair on the ripper barrel the next thing i  need to do i need to weld up what i've ground out   and i'm not going to use a mig welder for  that i am going to use a stick welder the   material i'm going to put back in there they're  called an austarc 77 that is the WIA equivalent   of a 7018 and the reason i'm going to use that  is when i was working in the field they were   the only rods we would use when we would repair  such jobs like this i know mig wires have come a   long way in the last 10 or so years but i'm  just going to stick with what i know works right so that repair went really really well i  am very confident that there will be no further   cracks in that so while i'm waiting for that to  cool down i'm going to take the eye over to the   lathe and start machining the material we're  going to use to replace the eye it is a flame   cut blank of a hundred mil high tensile plate  we keep these in stock because these are a very   very high turnover component the shape and  the thickness of the eyes throughout the   dozer series do vary and change so the eye  we have here that will suit a d8 and a d9   and the eye beside it is for our d10  and d11 i need to get this eye cleaned   up just give it a quick grind then we'll  take it over and set it up in the lathe so the first thing i'm going to do i'm going to  face it just to clean up the surface i'm then   going to rough bore the id to within a mil of  its finished size the welding process will pull   the eye out of round so i don't want to machine it  to it's finish size because it will end up being oval once the welding process is complete we'll  put it in the milling machine and we'll finish bore   the id to the size required the reason i don't  do all the boring on the milling machine because   this is a high tensile plate and it is flame cut  that flame cut edge is very very hard if i was to   attempt to do that on the milling machine using  the baby boring bars and the boring head they run   a tcmt insert which are quite small it would  just tear up inserts where on the lathe i can   put a big boring bar in there and i can chew that  material out this is far quicker and easier for me right oh so we've got that bored to  within a mil of our finished size   so now that that's done we're  going to take it over the saw right oh so we got the eye prepped up  now we've cut the bevels on that the   barrel end has cooled down enough  now that we can quickly grind this   and then do a dye penetrant test just  to make sure there are no more cracks so the dye penetration test  showed there are no cracks   in our repair so now we can  get onto fitting the new eye righto guys so it was a bit of  fiddling around to get this set   up but we've done enough of these in  the past that we know the combination   of the v blocks on a standard barrel with  the multiple blocks underneath the eye   holds the eye up to the right height to get  it back on the center line of the barrel right so we've got the eye tacked on we've got  our support plates tacked on which will also be   used as runoff plates the first thing i'm going to  do i'm going to do a couple of passes on each side   just to lock that eye in position so it doesn't  want to move on me when i go to fully weld it   after i do that i can then take it off the bench  put it down on the turning rollers because it's   just going to save me from manually flipping this  on the bench the welding wire we're going to be using   will be hobart xl525 and the gas we're going to  be using will be argo shield heavy which is 80 percent argon 20 percent co2 the reason i'm going to be  using mig and not stick to weld the eye   onto the barrel is because mig is a lot faster  it's a little bit more controllable that's   the process that has never let me down  before so i'm not going to change today what you got what you got righto guys so that's been cooling down for  the past couple of hours what i did after   the welding process i used a nine inch grinder to  remove the bulk of the material then i went in with the sanding pad to blend everything in really  nicely really happy with how that turned out so what we need to do now we need to take  it over to the mill i'm going to finish bore the   eye to spec and then i need to  drill a hole for the grease port right oh guys so we've just taken our  first cleanup cut i have measured the bore the bore size we are shooting for is four inches  which is 101.6 at the moment it is sitting at   101.49 so we have 0.11 to come out so we divide  that by two and that's how far we advance the   dial on the boring head so we shot pretty close  there uh usually i don't try and get that close   but we've still got material to  remove so we're still in good shape right oh so we are about to drill  the grease hole for the grease port   we are not going to put it back in the standard  location because that becomes a dotted line for   a crack to occur what we are going to do  is move the grease hole toward the barrel   get it away from this really thin area put  it through a more substantial area of the eye   and that helps eliminate any  cracks forming in the future there it goes righto guys so the job is now complete everything  went really really well considering we weren't   expecting the cracks in the barrel end this  is about a day's work for us to do so it's   very economical to do a repair like this if the  customer was to go and try and replace the barrel   he could be looking in the vicinity of  six to ten thousand dollars depending on   if it's available and whether you're buying  genuine after-market or a second-hand part   so the customer customer's going  to be really happy with the repair   job's done we're going to get it back  to our customer thanks for watching you ready sure woah what we are going to moo is [ __ ] i lost what you said oh my gawd    [ __ ] how did you start that oh wait where are we going because be caught oh wait what's the reason i don't know right   so what we're going to do we're going to  make a new eye and then we're going to [ __ ] giggle we do a lot of [ __ ] in here apparently right so on a d10 or a d9 uh [ __ ] me ah you may remember oh   there was oh [ __ ] me  [ __ ] me english dude    so what i'm going to do i'm going to face the eye i'm then going to rough bore it to within a mil of its finished oh [ __ ] i didn't say id    right so what i'm going to do i'm going to face the eye [ __ ] oh my god let's do it sentence by sentence   right so the first thing i'm going to do i'm going to face it and then i'm going to rough bore it oh fffuuu right so what i'm going to do i'm going to face the eye off   oh [ __ ] hang on    it's not funny Karen [giggle] ready yep are you sure yessss are you ready i'm not ready ever so i'm gonna bore it to within a mil of it's finished size [ __ ] off train i was smashing that [giggle] [ __ ] off train that looks like [ __ ] bull [ __ ] what is that right where it needs to be 87.4 yup 874   wow that's a fluke and a half hell yeah got it strapped down we're going  to get it back to our customer thanks for watching [Laughter] i forgot that bit ahhh get it ow

Channel: Cutting Edge Engineering Australia

Views: 5,549,121

Keywords: cutting edge engineering australia, machinist in australia, machininst, abom79, cee australia, Replacing BROKEN Eye & Repair CRACKED Cylinder for D10 Dozer, hydraulic cylinder repair, caterpillar wrenching, caterpillar bulldozer, machining, milling machine, boring in milling machine, caterpillar d10, stick welding, mig welding, boring head milling machine, crack repair, crack repair welding, replacing broken eye on a cylinder, Repair Cracked Cylinder, stick weld, cylinder repair

Id: zwBPb-WjwWc

Length: 45min 23sec (2723 seconds)

Published: Fri Jul 01 2022