Making a Hydraulic Cylinder Piston Hitachi Zaxis 670 Excavator Part 1

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Homey what's this what's this so we had a delivery  from one of our local viewers from north Brisbane dropped us off some dog stuff and a  six pack of beer for carl thanks for the gifts good boy who's dat how you going guys Kurtis from cutting edge engineering  today's job is going to be part one of two   we have two lift cylinder barrels off a zx670  to be repaired and two pistons to manufacture   the boom lift cylinders are what lift and  lower the boom when the machine's in operation what we've got here today we've got the left and  the right barrel and we've also got the left and   right piston the left barrel seems to be in  worse shape than the right hand side it seems   there's been a foreign material of some nature  make its way into the cylinder and because the   cylinders share oil it has gone through both of  them we're not exactly sure where this foreign   material has come from we can't pinpoint what  it was so the customer is going to have to   strip all the hydraulic system off the machine  pumps hoses pipe work tank the lot and try and   clean out as much as they can get it back to  a suitable stage as you can see by the damage   in the barrels we are going to have to re-barrel  the two lift rams because there is a material   shortage at the moment on home cylinder tube in  that particular size we're waiting on material   for our barrels so we'll get onto them when it  gets here and the pistons are pretty well dead   there's no fixing these at all so for today we're  going to start doing the piston so the two pieces   of material it's a piece of 38 mmvs6 very close  to a 4140 but machine's a lot like a 1045   it's not a nicer surface finish but that's no  problem considering what they're doing this   is a slug of 200 diameter by 95 mil thick we  couldn't get a hollow bar anywhere near close   to the size we needed so we're going to start  with a solid bore out the inside start machining [music] righto guys so we've bored out the the new piston  we've left about one and a half mil inside there   to clean up i need to machine a recess down  the inside of the piston here for the nut   so the nut has got a relieved area on it that  shoulder there this nut's not actually off this   machine this is off a much much larger excavator  but they all seem to run exactly the same sort   of configuration everything just gets larger  or smaller so we'll get that machined in there   then we're going to flip it around in the  machine and we'll start doing the other side righto guys so now that now that the recess has  been machined i can flip it over in the chuck i'm   going to grab it from the id of the recess that  way i can do all of the other machining or 99 percent   of it with the one set up that then allows me  to finish bore the id to suit the rod face it   off so that's going up against the end of the  rod or up against a cushion bearing and then   do the outside then i know everything is nice  clean and straight parallel with each other   there won't be any interference in the barrel  there won't be any interference on the rod   everything will just go together  100 perfect so there's probably   other ways you could do it you could create a  spigot machine a spigot that the piston slips   on and a nut that tightens up against that there's  been cases where we've had to do it that way   but when you've got a recess to use and  you can grip the part quick easy simple [music] one point 7 mil to come off exactly a mil to come out spot on the money is that for me no no this one's not for you well it could be coarse and fine cool very cool very handy thanks tristan  from perth yeah thank you very much perfect got to flip the part to grab the other side [music] right so that's piston number one  done let's get cracking on number two [music] righto guys we've completed the machining on  our two pistons they're both 100 percent finished now   we're going to give them back to the customer  they're going to do the assembly so put these   back on the rods seals so on and so  forth for those who might be wondering   to buy a brand new piston from the oem is about  3700 dollars australian we can well and properly make   these cheaper customers decide to go down  that path save themselves some money so once the material arrives for the re-barrels we'll  get stuck into that so stay tuned for part two we're going to go into the cause yeees just just get the intro done right or ready yup how you going guys Kurtis from cutting edge  engineering so [ __ ] train righto guys so we've bored out the the new piston we're left about one uh we've lift righto guys so we've we've uh righto guys so i've finished machining up that re uh [ __ ] righto guys uh [ __ ] how did i start the last one i can't remember [ __ ] it righto righto guys so oh [ __ ] i totally lost it oh [ __ ] i lost it starting again yeah so we do have [ __ ] so the  cylinders [ __ ] me so the cylinders are   off a uh [ __ ] they're the boom lifts oh [ __ ] they're the boom lift rams oh [ __ ] me i'm having a moment [Laughter] one word at a time um so using oh [ __ ] me it's not funny [giggle] so yeah yuh [giggle] so as you can see by the damage um so wait what the [ __ ] oh my god so [Laughter] and that's it we're going to do it you're going to get wet pfft hang on oh bull [ __ ] tight i just blew a big hole through it it ain't tight no more i'm going to clamp this thing into [ __ ] something so I don't have to try and hold it   the inserts [ __ ] [ __ ] i'm just going to change it go away you little bastard homeless shush meanwhile where's my gift [Laughter] oh my god [Laughter] you are crazy hey did you have fun lay down lay down no lay down spin around good boy yum yum yum yum good boy oh my goodness hey oi oi oi clean it up  oi what's all homeless eat them up of course

2021-10-31

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