Hydraulic cylinder piston rod after injury, if not handled in time, ranging from the impact of normal use, heavy hydraulic cylinder does not work. Our method of repair is to take a lighter part of the local grinding and polishing method to repair; for heavier pull marks are repaired by welding additional artificial grinding method. Crack formation: After the crane disintegration, found a luffing cylinder piston rod was severely injured, pull marks side by side 6. Caused by the main reason for the piston rod strain: dust ring embrittlement block was shedding, not only lost the role of dust, but also deposited here a lot of dust and magazines, the piston rod and hard impurities directly grinding, resulting in piston The rod is strained, the scars then scratch the cylinder rubber seal components, resulting in a serious hydraulic cylinder leakage. Repair requirements: filler and base metal must be combined with a solid, smooth; seasoning must be durable and easy to manual processing; manual processing must ensure that the piston rod diameter error of less than 0.06mm. After analysis, decided to use the filler for the J422 electrode. Because of the acidic electrode is not sensitive to rust, oil and moisture, it is not easy to produce hydrogenation holes; good processability, easy to operate; beautiful weld formation; moderate hardness of the material, easy to manual processing; arc stability, penetration depth larger, Combine firm. Repair process: (1) first to be welded parts clean, and then use wet mud will be around the pull marks. (2) Selection of 2.5mm diameter electrode, the current Welding Machine transferred to 120A, to take a straight line method of smooth welding. (3) After all the welding is finished, remove the mud and clinker cleanly, carry out filing along the circumference of the piston rod with a rasp and leave a machining allowance of 0.1-0.2mm. (4) A cylinder with an outer diameter of 185mm, an inner diameter of 125mm and a length of 150mm shall be sawed along the axis when the master cylinder (outer diameter of the piston rod is 125mm), one for the rough mold and the other for the fine mold. (5) Apply a thin layer of red ink to the inner wall of the coarse mold, and then press the coarse mold against the piston rod to be repaired for reciprocation along the axis several times. Then use a fine file to load the heavier red ink on the piston rod File away. So repeatedly filing, leaving the final 0.04-0.07mm allowance. (6) reuse 320 mesh sand dipped in kerosene with the fine mold to the piston rod grinding to the required size. (7) Finally with emery cloth dipped in kerosene for manual polishing. Measured, the maximum error of only 0.03mm. After the crane is repaired, after a year and a half of use, the luffing cylinder has never experienced any leakage and the piston rod is smooth and free from rust.
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