Repair FAILED Hydraulic Cylinder | Part 1 | Making a New Barrel
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- Опубликовано: 6 сен 2024
- This hydraulic cylinder failure is one of the WORST we have seen lately! The piston and seals are completely destroyed and the inside of the cylinder barrel is shredded from one end to the other. This is the stick cylinder off a Komatsu PC300 Excavator, it is a high cycle cylinder that gets a lot of use, so when things fail they can turn bad really quickly. The reason this hydraulic cylinder has failed is due to a number of reasons but it all started from the bad design of the OEM piston seals. The cast iron pressure seals are not a good idea! This video is Part 1 where we show step by step of making the new barrel. We need to remove the barrel end and head flange off the old barrel and machine up the new barrel. We also fit and weld on the ends to the new barrel using spray transfer MIG welding.
WATCH NEXT Part 2 - Making the new piston: • Repair FAILED Hydrauli...
In this video we are using:
- Hafco TM-26120G Centre Lathe
- WIA 500i Weldmatic Welder
- Hafco HPM-150T Hydraulic Press
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Our channel is all about showing you real life machining work from our workshop on the Gold Coast Australia. We specialize in manual machining, hydraulic repairs and heavy fabrication for the earth moving, mining and civil construction industries. So if you're a machinist that wants to see some big gear in action be sure to subscribe to our channel right now. We upload new videos every week that show lathe machining, milling, welding and all the good stuff that comes from a machining workshop. If that sounds like something that you would enjoy seeing, then make sure to join us by subscribing!
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I really laughed hard at the Alle-key scene!
Hi Kurtis! Do you ever feed back your findings to the manufacturers? As an ex Komatsu(Mining) employee I can certainly attest to their quest for quality.
@@dermozart80 glad you found that amusing 🥴😂
@@Churchill250267 hey mate nah, not sure they would appreciate the feedback I have to give 😂
@@CuttingEdgeEngineering You're probably as diplomatic as I am, then... Great video, as always!
At this point these Videos should be used as a teaching aid for students learning this trade in class. Outstanding production values and presentation! If you never made another video your body of work thus far cannot be overestimated for it's contribution to promoting the Millwright and industrial machining professions.
hey mate we've actually had a few trade schools reach out and ask to use the videos! 👍
@@CuttingEdgeEngineering Hope you made deal your skill is required learning!!!!
@@CuttingEdgeEngineering Hope you edited these for swearing? Don't want to give the yoof any bad habits now do we?????? Might scar the poor little darlings for life! Lol.
Or mechanical engineering of how not to design a cylinder.
Actually, what trade is it?
"At my own cost, I'm going to do this to make it look right: - and THAT, girls and boys, is called Pride of Workmanship. Nice one, Kurtis.
thanks mate
Absolutely. Cheers.
My dad used to say, right is right & wrong is nobody’s right
Plus it took off something like 24kg per meter of barrel length if I didn't totally mess up my math.
I was taught and have stuck with it the last 40 years " like it grew there".
This video is documented proof that professionalism isnt the words you say, its the standards you practice. Cant stop binge watching these!
Express your distaste and do a hell of a job anyways. Commendable.
I'm on my 63rd video in 21 hours...still can't stop!
There’s a lot of things to like about this channel, but an under appreciated one is The Giggler’s dedication to a strict upload schedule. That can’t be easy. Keep up the great work you two.
Thank you for noticing I appreciate that and at times it's not easy can definitely create some stress 😩🥴👍 Karen😁
@@CuttingEdgeEngineering That Giggler. She's not on the payroll mate, I hope...?
@@markneedham8726 'Fraid so, you see she is Karen's somewhat dippy but lovable twin sister who has the hots for Karl. (So the rumours go!)
@@markfryer9880 err who's Karl when he's at home? lol
Re: turning the barrel at your own expense: one of the things that keeps me coming back to this channel is the pride you take in quality work. Very well done.
everyone should take pride and have top notch quality like kurtis. sad to see that alot of ppl just dont care that much.
@@hannesblomqvist6954 to make people care... they have to be paid..right now machinist and other trades are one of the most underpaid out there
I’m amazed at your skills. What would a repair of this extent cost the customer?
@sikkingtruth7488 you can pay to the moon, if a person doesn't give a damn, money won't make them care any more. Giving a damn and going the extra comes from inside. They either have it or they don't.
1.7 million views absolutely amazing, I just love your processes and the clever skilled way you go about your work.
Coming from a life time helping design and installation of the electrical parts of machinery but would love to know who is watching you both with such enthusiasm of your skills??👍😁
Cheers mate! Viewers are from every part of the globe it feels like lol
@@CuttingEdgeEngineering I hope you’re receiving funds fm RUclips as are other Australians like LaVagabond etc if not would be worth contacting them you would be in the top Australians views wise👍😁
You know the old saying… “if you don’t schedule maintenance for your equipment, the equipment will schedule it for you”
Another great video guys can’t wait for part 2
That's a great saying very true
Whadya mean faulty maintenance??? We drove the wheels off, now we’re doing maintenance…
@@CuttingEdgeEngineering Actually, I don't think it's quite right...Close but not quite right...
I think the saying should be:
"If you don't schedule Cheap Preventative Maintenance for your Machines, your Machines WILL schedule EXPENSIVE Major Repairs for you"...
😄😁😆😅😂🤣
Your Technical Skills and Your commitment to “Total Integrity” to do the right thing for your customer! Looking forward to “Part-2” (also: nice clean shaving)…..
Cheers mate thanks for watching 😎👍
@Simon Sapot Thanks for the reminder.😂.
The pride you take in the work you do is second to none. The mindset of "If I were the customer, how would I want it to look?" Speaks volumes about how you run your business. I'm beyond impressed Kurtis. Your costumers are fortunate to have you doing their repair work. Kudos to you my friend. 😁👍
Agreed - new tech but old school values.That's a winning combination. Good on ya, Kurtis.
I think I will never get tired of seeing shavings spiral off the cutting head. It is like watching a fire. Thanks to Mrs. CEE for her great cinematography and filmmaking.
Glad it was enjoyed 😁
I’m glad none of these companies do preventative maintenance. Otherwise we wouldn’t have these killer videos.
haha this is true
@@CuttingEdgeEngineering We used to call these kind of jobs 'cash for life' jobs.
I always etimate that in my shop 80% of failures are caused. Only 20% is because of stuff being worn out or failed from natural causes.
For a short while I worked for a heavy equipment manufacturer. Our very expensive machines (Also very manitenance-heavy) needed some frame repair on-site due to abuse, but we sent an engineer and a technician to do the job. The jobsite secured a welding machine per our instruction, but literally had no other tools. None. They lifted the cab off the machine with rope they found at the local village. They found a breaker bar and a large adjustable wrench to do the rest of the disassembly. How you can buy a bunch of heavy mining equipment and not have a maintenance truck is beyond my comprehension. I don't even think they had tools to do oil changes. 😕
I think this situation was big $5M worth of machines and pay local peasants to drive them. Get paid $10M for job completion, and abandon all the machinery in the remote village.
This is absolutely masterful. While this may be another day in the life for you, it's a rare pleasure to see something large done so thoroughly and professionally with zero bullshit and helpful commentary. My experience is limited to what I did in metalwork in school on the lathe. This for me is genuinely terrific to see. Thank you kindly from Dublin. The outtakes are up there with Jackie Chans! :D
L
It is incredible that the lack of maintenance, and the replacement of a filter of no more than 100 dollars, produces the catastrophic deterioration that I have seen today. Great job guys!! Greetings from Argentina
Nah they are a chunk more than that, but compared to the cost of repairing... well replacing this cylender its absolutely nothing in comparison, especially when every other cyl in the machine, plus the hydraulic motors for slew and drive are probably going to need the same treatment before long... also maybe the pump... OH and the valves
The filter's just there to protect the pump and stop circulation of crap in the system, once that thing started galling up there was no saving it.... All but the most attentive operators just run their machines until they break.
Bosses don't care about preventative maintenance cos they don't see the advantage, why take a running machine out of service? That costs them money.
Problem is they end up spending more when the inevitable catastrophic failure happens........ so it's a double edged sword.
@@LuggageStardate I have to thank you for the answers, since I am ignorant in this matter and I am only subscribed because of the admiration that Kurtis causes me for his skill in what he does. For me his work is art, perhaps for others it is something normal.
I appreciate his comments because they help me understand a little more about the causes of these damages. A special greeting from Argentina, from an admirer of Kurtis who doesn't know how to put a nail in the wall!!
@@nickmaclachlan5178 Thank You Nick, I agree with you
Repairs sent out are a tax write off, in shop just overhead.
Makes me feel really good to see an honest, hard-working professional doing the right thing every time. I appreciate you and your work. Thanks man.
Cheers mate thanks for watching 😎👍
These videos are an absolute masterclass. Your work is superb and the videos are great to watch, even for someone only vicariously interested in machining. It's always a pleasure to watch a master at work!
When I was an equipment mechanic I'd use a stethoscope and listen to the hydraulic cylinders and predict the next one to fail. I'd mark them by stamping my initials into the barrel by a pressure port. When machines would come in with metal in the hydraulic oil the yard guys would look for my stamp to know which cylinder to pull. My boss hated it because I was right so often. 🤣
haha that's brilliant
note to self: Add a stethoscope to my field toolbox...
@@Hyratel if you do not have one in your pocket grab hard wood stick. Pressed against object of interest and base of your ear works well to transfer thing internal sounds to your hearing aparatus
I used that technique to check roller and ball bearings. It also worked on bearing problems in the Diesel Engines used in the river boats when I was on a repair ship in Vietnam in '66-'67. Better to pull an engine before it failed and left a boat up shits creek with only one paddle.
Well Kurtis, an ABSOLUTE masterclass in problem solving! With your skill and experience, do manufacturers actually listen to what you say?? Always look forward to friday and your latest revelations. I have learned ALOT by watching your videos and long may it continue nate!! Wilk have to visit your merch page!!
haha nah don't think they would like what I have to say
@@CuttingEdgeEngineering Such as that thread-lock on the piston head. Like... WTF was that
@@CuttingEdgeEngineering Btw, greetings from Brazil. I might be the oddest viewer you may have hahaha. Im a biologist, and I just finished my Master's in pathophysiology. But my hobby is metal and wood working on the weekends haha. One of my dreams is to have a shop that is 5% of what you have. I find very interesting watching your videos, and as Tarkers65 said, the problem solving. I LOVE to watch someone with experience do things that for me were unimaginable. And not only having the right tools, but the right approach. Btw, amazing collection of tools you have my friend.
Anyways... An outstanding machinist who is teaching a biologist across the world how to approach things in a more efficient and inteligent way.
HOW DID I FORGET ??
I need to say that I fucking LOVE your dog
One of the things I've most enjoyed watching and working with true professionals is the economy of motion they use to preform their tasks. You are a joy to watch Curtis! The absolute minimum of wasted motion, your obvious planning your motions three steps ahead, your getting the maximum benefit from you lifting aids. It's like a master class in great body mechanics.
I'm thinking of the 'economy of words' in the post above.- (making do with less) - bravo!
I love how the new barrel is wrapped in "Fragile" packing tape as if its not a tube of 1" wall thickness steel lol
Your a standup guy doing quality work. If I were a customer, I wouldn't expect or allow you to eat the cost of making it look right. I hope that your customers know what kind of person you are. It's rare to find someone who cares so much about the work they turn out.
it never ceases to amaze me how he runs that giant machine shop all by himself such big equipment he's got to be one of a very very few machine shops that are equipped with that kind of capability quite amazed excellent work my friend
3:00 am in Atlanta, Georgia...worth getting up to watch!
All that damage is incredible!
Love the video and great photography.
Dang mate that's dedication! Thanks for taking time to watch hope you enjoy it
5:10 AM here in Atlanta for me! 🤣
Yes, our Aussie Bloke is a hero of engineering. ;-) A very welded-on follower of these wonderful Aussies, bloke (engineer) & blokette (film-maker). Not in my city BTW.
An absolute joy to watch you work. Your expertise is exhibited in your clear and concise narration of what you are doing and why you are doing it. Great to see someone who knows his craft and is as humble as you.
That ceiling hoist has well and truly paid for itself I'd say, a well set up work shop Kurtis! Great work Karen, the video work competes with any professional channel on RUclips
A few other things on the wish list for the shop for it to be setup how I would really like. and Karen says THANKS!
Oh man, was looking forward to this! This looks properly destroyed.
😎👍 enjoy
@@CuttingEdgeEngineering After listening to your analysis of the design of the piston I was really looking forward to the end part for what you really thought of it. Was not disappointed 😌
I shudder to think about what the rest of the hydraulic system looks like if it doesn't have a filter! 🤮
@@PhilG999 Good bye pumps!
Absolutely f*cking munted. 😀
Im an amateur welder/fabricator. Watching your videos has sparked a desire to learn machine work. Even if its for my own personal use and knowledge base. Thanks for the great content!
Hi from Canada's East coast 4:00AM here. This one was well worth getting up early for. Kurtis your Knowledge and experience make these vids so educational. should be required viewing for operators and maintenance people everywhere. The operator of this machine should be sacked! no excuse for allowing this to get this bad. looking forward to part 2
Hey Mike seriously big thanks for taking time to watch so early! Glad you enjoyed it 😎👊
When all the movies out lately suck I watch CEE and am never disappointed. My inner childhood fascination with machines comes out. I become awe stricken by the amount of precision and care taken in this profession. keep up the good work
When l heard I'm going to turn the entire barrel because that's what l would expect to see if l were the customer, l thought YES! this man not only has the skills and knowhow, but he also knows how to treat his customers. It left a lot of chips on the floor, but you did one hell of a job. Thanks for sharing.
I was always told what meets the eye please the mind I like that you went the extra mile to true the cylinder it shows attention to detail , that I find lacking in new tradesmen keep up the videos 👍
Right on mate thanks for watching
Could not say it better!! Nice work Curtis always a pleasure to watch your videos. Keep up the the good work!
Curtis, I've watched a lot of your videos and each one your dedication in what you do astounds me. No shortcuts taken and proper pre-planning of each operation is clear to see. The motto measure twice and cut once probably sums up everything you do. You and your better half are a joy to watch and listen to - keep it up!
You have a very impressive skill set! I love listening to you explain what you are doing, and why you are doing it that way. Also, your thoughts on why the failure occurred is very interesting. You pull no punches in what you think, which is a sign of a good teacher. I can tell that not only do you sincerely love what you do, but that you take immense pride in your work! It shows. If I were a customer, I would not think twice about recommending you. Although you might cost more, your work is going to perform and last! Fantastic video! *Compliments to your videographer and editor!* 1st class content!
I'd say that's probably the world's fanciest cylinder barrel that large, being nearly 100% machined on all surfaces like that. 😂
My first reaction to the title was, "well this isn't new, he's done a lot of them", then I saw the damage and was very happy it's a new issue.
Thanks again for the work you both put into the videos
both of you do a masterful job in presenting this work, and demonstrating the best way to provide full "customer satisfaction". I really enjoy your work and the videos you produce.
Wow , with all the damage ...1st thing would be to rip the filter up and see what we'll see now thats a potentially scary proposition to be sure ...
I really appreciate you attention to detail Curtis you are a true craftsman who just happens to be an engineer to boot
Awesome work !
Hey mate thanks for watching glad you enjoyed it
Surprised the filter wasn't blocked with all the crap that came out of there?
@@nickmaclachlan5178
No kidding Nick
@@nickmaclachlan5178 Wonder if someone removed the filter? Can’t have that stupid thing always stopping up in the middle of a job!
@@ellieprice363 I've seen more stupid things done in the name of efficiency....... lol.
I actually just noticed that the steel from the shavings got to the point where they turned into "Blued steel" due to the heat. Always liked the look of blued steel, so it was a little interesting to see that happening right before my eyes!
ABSOLUTELY FASCINATING.
I am in trouble with my wife she wants to know WHY THE HELL I AM SPENDING HOURS WATCHING THIS, when I could be watching her weeding the garden.
If you have any USEFUL suggestions, KEEP THEM TO YOURSELF.
There is something satisfying about seeing someone who knows exactly what they are talking about doing an amazing job like this.
If I had a 1/3 of knowledge you have and Plus the 32 years I had I could have made a million dollars. Incredible how much you know and the constant work ethic you perform is outstanding.
when this man says " this is gonna be hard " you know that 80% of the other shops couldn't do it at all
I'm from the city of Campina Grande PB, Brazil! Congratulations my friend, excellent service. despite not being 100% working in the profession anymore, I learn a lot from your channel. "Knowledge that is not passed on is of no use to anyone!"👍👍👍
Every new video is an engineering lesson. So that this is my favourite fabrication/repair channel and also love the final part with the outtakes...good job. 😁
Cheers mate thanks for watching glad you enjoyed it! 😎👍
Very smart engineers who've never held a wrench making our lives miserable. Love your content and knowledge sharing. Keep it coming.
right. Like the Toyota "designers" who put the starter motor INSIDE the engine on V-8s. Or the Toyota designers who made the hatch 47" wide on the older Toyota vans.....when EVERY sheet material in the U.S. is 48" wide.
"Engineer" must be the most misused word in the world.
Do you understand how nice it is to see someone who actually using an impact gun correctly!!!??? Break the bolts with a socket or wrench and then use the gun.
Phenomenal work, a truly master at his craft!
Thank you for making parts and sharing the process in such a nice way. I'm in a machining program here in Seattle and while I'm learning a lot your centering holes are bigger than my finished holes so your work gives me an idea about large jobs.
Awesome mate all the best with it 😎👊
Hey Guys, thanks for another outstanding video! The production and editing is spot-on. If Kurtis ever got tired of machining and fabricating, he could be a first-rate instructor if he wanted! Especially liked the discussion about the manufacturer's design faults. I hope the manufacturer takes his advice to heart instead of sending a cease-and-desist letter. Greetings from the US, where that sort of thing happens all too often!
It's so refreshing to watch and listen to a guy that absolutely knows his stuff inside out. Top notch work Curtis!!
Good vídeo Kurtis 👏 I work to with lathe machines, and I like see your job. Greetings from Portugal
Cheers mate thanks for watching 😎👍
Senhor Manuel, outro bom torneiro é ruclips.net/user/Abom79
@@mongoose388 Abom needs to study editing from Karen and brevity from Kurtis.
@@asw19B100 I totally agree. Karen has professional quality skills that go beyond editing,which is a rarity on RUclips. Abom has gotten better recently and I cut him slack because he's a one man show and has time constraints. He seems a likeable guy that also loves his craft. Maybe his Abby can be like Karen for him.
@@mongoose388 Abom79 used to be good, but not so much lately.
\o/ Always look forward to the end of the week for a CEE vid! Tiny bit of damage there. Have a great weekend guys.
Cheers mate hope you enjoy this one and have a good weekend too 👍
I like that lil old school emoji \(°0°)/
I agree with all the engineery comments and praise... but Homeless and the bloopers @ the end make up for the Dumpster Fire that is the good ol' US of A currently ! Great entertainment and engineery stuff too ! Best wishes to all 3 of you on your future endeavors .... mate.
Hey ya'll Down Under...best wishes for a great weekend, give Homeless a big hug from the Other Sunshine State, Paul
Hey Paul you bet Homey always happy for extra cuddles haha
The sound of all that gravel in the piston would have been lovely to hear in operation
Still trying to figure out how you know how deep to part the rod end of that barrel. I don't think most people understand what mayhem would happen it it popped loose while you are machining it with the live center in it. But like magic you popped it off by hand after parting it just the right amount. Well done!
“That’s really a shit design.” 😂 oh the honesty. How many engineers have messed up something by making it over complicated. Thank you to those engineers that make things better.
Great video as always. And incredible camera work as usual 🤗
The engineers/designers were probably told by management to 'Find a solution that doesn't look like company XYZ's design, we don't want to be hit by a IP theft charge".
@@rgmolpus Maybe, usually it goes like this “that cost to much, find a cheaper way”.
T shirt 👍
I used to work on 18 wheelers and I believe every Ford engineer has to have at least a masters degree in "shit design". I absolutely hated working on their trucks.
I can't believe that was nearly a hour long, thank you Karen and Kurtis for producing such an engaging video. 😁👍
Hey mate that's really great feedback glad it was enjoyed, Karen is pretty conscious of viewer watch time and making a video that is 100% enjoyed
@@CuttingEdgeEngineering Then give her a pat on the back, as far as I am concerned she is doing a really great job. 😀👏
Dear Kurtis, I love the fact that your primary drive is to make your jobs look “right” rather than get them out of the door quickly. If only all manufacturers had the same attitude, the world would be a better place. Thanks.
Wow Kurtis how the hell could you not hear that happening on the machine, it must have been squealing like a banshee. Great informative video as always thanks to you both, oh and Karl. 👍
yeah they would have heard it and a good operator would have felt it
Between the sound of the engine, the hydraulic pump, the radio, the heater/AC, the bucket scraping on rocks, the other machinery around, not to mention the squealing, ungreased pins and I'm not surprised they didn't hear it.
@@CuttingEdgeEngineering Too right. The cylinder would be passing and losing power.
G'day! from the USA! Totally 'Munted" is a frikken understatement. I know you are up to the repair.The explanation behind the damage is perfect. The only thing I find questionable is running over the electric cord/welding/air hose at 26:05, learned a long time ago about the failure possiblity. Loyal weekly subscriber!
Cheers mate! Always good to see your comments 😎👊
What amazes me is the fact that Curt keeps in mind that he tries to make a happy satisfied customer and Curt is doing most of his work keeping the cost to the customer at a reasonable price! Customers reply to the job provided is the best advice one caan expect for future repair jobs if required. Love all his work and good luck to him and her!
Seems like just the other day I was using a ratchet strap to pull against my tailstock and I thought, “This isn’t what you should be doing” but after seeing CEE do it I am now certain that I was right and won’t doubt myself next time! As always, love y’all’s videos and appreciate you making my Fridays incredible!
I like to call that thinking outside the textbook, sometimes you gotta do what you gotta do 🤣👍
Hey Curtis, serious question mate: Why don't you elevate the welding rotisserie so you can stand at a comfortable height when you weld eyes on barrels, etc?
I think sometimes it's easier to sit on the floor to weld. Is for me anyways and your body is steadier too.
@@LawF250 Interesting. Thanks. He's certainly holding a fixed position for a long time during that operation.
I have the same thougt. And why not build a simple stand (seen one i personal) that holds the torch and weld by it "self" maby you activate the torch switch by a foot operated pedal?
@@fulf Sure - the lineboring welds are automated.
@from the dark side of the moon I'm interested in the reason he does it that way. Certainly he could elevate it if he wanted to.
My Dad always said "near enough isn't good enough, if it doesn't look right it isn't right" good to see a man take pride in his work, well done.
Curtis you’re a walking machine shop. Mad respect. I worked in super precision for centerline for years. It’s a whole different animal. Making things under 2”. You my friend are an amazing engineer! Btw have you ever checked out KT3406E before? I thought you might get a kick out of the content.
My Friday is complete. Greetings from Auckland, New Zealand (no so much in the future any more... daylight savings ended last weekend) to Kurtis, Karen (you do an amazing job with the camera and editing) and Homeless keeping you both under his paws :)
Hey Roger! So it must be only 2 hours ahead there now? Good time to be watching hope you enjoy this one 👍
Same here, Central Otago NZ
Yep. I recognise that pattern of damage & repair. Fascinating (tho not surprising) to see it at scale.
I was a nail & tool specialist, & repair tech. Pneumatic, standard & high press, & "gas" (air/fuel combustion), mainly Paslode. Saw this type of damage fairly regularly, but even for that this was extreme.
Deep respect for the ATD, standard of work & professional consideration you bring to what you do.
Brilliant as always guys . I'd say that was definitely mullered, good job they got you re manufacturing a new one . And careful or your gonna fill that swear jar in 1 blooper out take . Cheers guys
Absolutely terrific video, as usual! Kurtis, you are such a stickler for perfection, as you showed by machining the complete barrel to make that cylinder look correct, to fit the tube mounts.
Videography amazing, Karen. Love the slow-motion of machining chips flying! Swear jar gonna be full, soon😂
Hey mate! Yeah I have pretty high standards and been made even more aware of it over the years of fixing other peoples fuck ups 🤣
Amen to that!
When I saw that swear jar and it's fancy lid I thought there might be a speaker in it - drop a coin in and it would say "Thankyou" or "Good one" or "Scrooge" or ..... wait a minute! Just had a brainwave! I'm going out to my cave!!
Took up MIG welding recently, watching your stuff certainly helps.
When the allen key bent I chuckled, when the second broke I died laughing. 😝
I needed a moment down at the fence post again after that 😂
@@CuttingEdgeEngineering How much of the new swear jar contents came from that incident? If that was me, I'd probably half fill it when that Allen key broke =)
Looks like it twisted where the paint stopped, must be strong paint !
I always look forward to watching your video's. You and your wife are funny as heck in the bloopers part of the video. Keep the video's coming. Give your safety manager some good belly rubs for me please.
Cheers mate thanks for watching 😎👍
You are amazing.. You do what I call investigative repairs.. The opening of the hydraulic filter is a great way to start.. I wish I would of known this 55 years ago. We had a 966 Cat we used to contract plow snow with.. One of the rams got weak. We had it repaired and then kept changing the filters plus initial all new oil.. This worked but eventually another bucket ram started to get weak. We should of had all the rams inspected for contamination initially. But the big brute ran well after that and 5 years later my dad sold it. It seems that excavators just get abused.. I been watching on ic weld for the last few years …the many things the get broken on excavators. Great channel.... Well mate I like the coin jar too. I just can’t stop watch you repair things.. Great for old man to do …than watch anything on tv..Your out takes on this video are right on too.. Thanks..
put the turning machine for welding barrel's (dont know the name for it) higher on frames so you can sit that would be a big relief for your body
I was thinking the same thing
He wants to sit, read previous comments.
I've seen wheel bearing failures with less material than that. Incredible. 😳😳
yeah this one was a good effort
I went into business in 1996. From time to time, I do things "at my own expense" because it seems like the right thing to do. And yet, if I take a longer view, and little actions over a period of years add up to customers preferring my business over someone else's, it feels more like I was investing in the long-term success of my business.
I enjoy your videos quite a bit. I hope you all have a great business for as long as you enjoy running it.
Trying to imagine what a complete re-plumbing job on a machine of that size would entail....clearly it would cost an absolute flaming fortune.
Generally, the hardest part is removing hydraulic tank and getting it clean. Of course, removing the operating spools and spool; blocks, cleaning and checking them is a F****** horrible job. (it's fitted and plumbed before a lot of parts are assembled when machine is being built in factory) When I moved from 'workshop' fitter to 'Site Service Engineer' I made sure all the filters were checked instead of getting things sent back to workshop as I knew I would probably do a better job 'on site' than some of the people I was working with were capable of in a workshop. When a 'temporary' on site repair is still being hired out 2 years later it shows the 'quality' of work shop charge-hand was doing. I have no idea how he ever kept his job?
I've been turning wrenches on heavy equipment for 27 years, no way the operator didn't know something was going on with this machine.
Probably the boss saying, just finish the job and we will worry about it later.
It's usually:
"Well, it did start making a funny noise"
Nice job,
I’ve been doing this for 35 years, you do an excellent job explaining.
I’ve seen this same scenario many times, it’s hard to tell once the damage is so extensive. Normally this starts from contamination in the system and every stroke just makes it worse as you see. The cast iron piston rings are used normally when the piston passes over the port, although harder than the Teflon piston seal it’s still a good bearing surface against the honed tube. The unfortunate thing is that now all that metal is everywhere in the system, including most likely all the cylinders, valves, track motors ,rotary swivel and hoses.
One thing also to consider is the oil might have broke down in the heat and lost lubricity and started the whole process as well.again great job on your repair, it’s nice to see someone who knows how to do the job the right way.
Another fantastic job by the man, the myth, the legend! :) This has to be one of your best videos, Kurtis! Looking forward to part @!
Out of curiosity....are you self taught, or did you attend any kind of engineering school for what you do? My guess is self taught. :) Cheers from Alberta, Canada!
Hey mate thanks for watching glad you enjoyed it. Yeah mostly self taught and then went through the trade school used RPLs to get certified
A great demonstration of having pride in one's work - after the first pass it doesn't look right so re-think and do a much more aesthetically pleasing job. Nice work Kurtis 🙂
Have you overfilled and broken the swear jar yet?
The swear jar has some space left in it but I have been out on site, luckily the jar didn't come with me 🤣
@@CuttingEdgeEngineering I suppose that's your excuse and you're sticking with it ;-)
It's always a pleasure to watch, when somebody knows what to do and has the skills to do so.
Absolutely love this channel.
Glad you enjoy it!
Out of curiosity, how much weight do you guess, came off the full-length turn down of the barrel? Also, the outtakes were particularly golden, this time! ;-)
A quick calculation has it at about 50kg (assuming length 2m).
I respect that you machined the entire barrell at your own cost just for it to look better and to get to sleep at night. I do this myself when welding semi truck trailers. everyone says there is no point in doing this or that its gonna get painted etc Im happy knowing I left a good nice clean job after me even if it is going to get painted and full of dirt. it feels better when it looks atleast decent.
First, I’m amazed that grub screw didn’t come apart.
Second, in another video, you explained why you fly solo. Seeing your refusal to put out an item that wasn’t aesthetically pleasing as well as mechanically functional speaks to this ethic: bravo.
Love the look on your face when you said "NO, not doing this" -> i think that proud workmanship get you a lot of customers! Well done sir!
I was taught by a tool maker, (He was Aussie bloke) but I was taught in NZ. as a spring maker (when I left school as 14, for 30 years I had to learn the number 8 fencing wire way. Was a really good thing, I have since built cinemas all over the world, and because of the way we had to learn (back then) there is simply not much we cant do. You inspire people, I hope you can pass some of your ethic and skill onto our younger generation, who seem intent of expecting something for nothing. keep it going ..From an old guy who knows how hard it really is to do this sort of engineering. Back in my day we didn't have MIG or TIG we hard ARC, GAS old stuff. please do a school for the young ones, shit some one has to pass the real world stuff along.
Thank you for sharing your work.
We're in the same area together. 😅
I also do all the work so except the internal welding... I've just been doing it on the outside... this part of the video was very short and I did not realize how to achieve in the lathe a good internal cleaning in the welding and a perfect internal finish, not to spoil the seals.
You're a very good professional. Great hug from Portugal 🇵🇹
As someone just getting into machining, watching you parting that huge barrel with the live spindle set up filled my whole body with anxiety for what would happen if someone cut too deep (of course I knew you'd handle it safely, I was just putting my inexperienced self in your shoes). Having experienced the challenges/fear of parting but never having thought about having to do it at that large of a scale I wasn't sure what you were going to do, maybe you'd leave a good amount of material and saw the last bit?
When you got it down to the minimum amount of material and then separated it with one whack of your hammer (at 20:30) I literally cheered! The intuition you seem to have for the materials you work with, (like the amount required to keep the end from flying off the lathe or the balance point of a huge cylinder) is very inspiring!
Just watched both parts, absolutely enthralled. You are a real craftsman, amazing piece of repair work.
I do watch most of your videos. I am very impressed at your knowledge of the operations of all of the equipment. This, I imagine, comes with many rears of working with the products. I also have to believe that you have attended many classes on how thiese all work. Godd joj, John
I am an apprentice fitter/turner who works in the hydraulic industry and deal with these types of cylinders every day. We normally drill out the pin punches around the grub screw.
A very dedicated worker and very meticulous in all clearances makes him more than a good tutor.
I laughed when I saw giant, heavy duty steel tubes arriving with "Fragile - Handle with care" tape all over them 😄 Great video 👍
Are you the owner of this company? I like your videos. I started off as a machinist in 1981. Later went into multi skill industrial maintenance. Welding, fabrication, hydraulic, pneumatics and electrical. I would have loved to had a shop like you have. I’m retired now. Watching your videos bring back a lot of memories good memories. I loved what I did.
This guy has got to be one of the best welders I've ever seen. If not the best!
I cant overstate how immpressive this is, your entire channel is incredible. You are such a skilled craftsmen. Its hard to believe this is cost effective sometimes simply due to your incredible capabilities surely requiring no small fee. These cylinders must be incredibly expensive/hard to source.
Nothing more satisfying when your full pen welds passes the first time.👍
After 22 years of working on heavy machinery I will say that cylinder is better built now then it was new excellent work