Welcome to the world of heavy machinery repair! In this blog post, we’ll delve into the intricate process of repairing the cracked spokes on a crawler crane track system.
This task is not only essential for the crane’s functionality but also a testament to the dedication and skill involved in maintaining such robust equipment.
The Urgency of Repairs Cracked Spokes
As we kick off this project, it’s essential to understand the urgency behind it. Personal projects often take a backseat to paying jobs.
As the owner of Topper Machine, I prioritize my shop’s paying jobs but have set aside time to focus on this crane repair.
The goal is to have this dragline crane operational by winter, allowing for a seamless transition into spring when more extensive work can be done.
Identifying the Problem
Upon removing the tracks from the crane, we discovered a significant issue: a broken wheel. Inspection of both wheels revealed numerous cracks, with some extending all the way across.
This indicated that not only was the wheel compromised, but it was also barely holding together.
With the situation assessed, our first step was to remove the damaged components and prepare for repairs.
It was clear that the bearings within the wheel assembly were also shot, necessitating replacement with Nilotron, a preferred material for its wear characteristics.
Disassembly Process
Disassembling the wheel assembly is crucial to address the damage effectively. After removing the wheel, I noticed that the shafts were in surprisingly good condition, with no noticeable wear.
However, the bushings were thinner than expected, indicating the need for new replacements.
To proceed, I planned to drive out the worn bushings and create new ones from Nilotron. This material is not only durable but has proven to outperform bronze in various applications.
Creating New Bushings
With the Nilotron tubing ready, I set up the lathe to cut the bushings to the correct dimensions.
The outer diameter needed to be three inches, with an inner diameter slightly oversized to ensure a snug fit once pressed in.
After successfully creating the bushings, I ensured they fit well on the shaft. With a small amount of slop, they were perfect for our application.
Preparing for Welding
Next, it was time to address the cracked wheel. I moved into the weld shop, where we began prepping the damaged areas for welding.
First, I had to determine the material type of the wheel. After some testing, it was confirmed to be cast steel, which is excellent for welding.
Welding the Wheel
With the area cleaned up and the material confirmed, I began the welding process. To ensure a strong bond, I used a carbon fiber welding blanket to maintain heat during the weld.
This method helps prevent thermal shock, which could lead to further cracking.
I employed a step-by-step approach to welding, allowing for cooling periods between passes. This technique helps manage thermal expansion and contraction, reducing the risk of future cracks.
Post-Welding Inspection
Once the welding was complete, I allowed the wheel to cool slowly while monitoring the temperature. The next day, I conducted a dye penetrant test to ensure no cracks were present after the repair.
The results were promising! No cracks were detected, and the welds appeared solid, confirming the repair’s success.
Final Thoughts
This project not only highlights the importance of routine maintenance and repairs on heavy machinery but also showcases the skills and techniques used to ensure these machines remain operational. The goal is to get the crane back on track, literally, by making all necessary repairs and adjustments before winter.
Thank you for joining me on this journey of repairing the crawler crane track system. If you have any questions or comments, feel free to reach out. Let’s keep pushing forward in our projects, and remember: always get it done right the first time!
Watch the full video here:
