Causes and Methods to Repair Cracked Hydraulic Boom

alamlawepopo, Hydraulic boom is an essential component of heavy equipment such as excavators, cranes, and loaders. This part is responsible for lifting and moving heavy loads using a hydraulic system.

Causes and Methods to Repair Cracked Hydraulic Boom
Repair Cracked Hydraulic Boom –

The boom, or arm, is typically made of strong metal materials and has a sturdy structure to withstand high pressures and heavy loads. Hydraulic booms have complex joints and welds to ensure strength and stability when used in various working conditions.

Cracks in hydraulic booms can pose a serious problem in the operation of heavy equipment such as excavators, cranes, or loaders. Cracks in hydraulic booms can be caused by various factors, ranging from overloading to imperfections in the manufacturing process. However, with proper understanding of the causes and appropriate repair techniques, cracks in hydraulic booms can be effectively addressed.

Causes of Cracks in Hydraulic Booms

  1. Overloading: One common cause of cracks in hydraulic booms is overloading during use. Operating equipment beyond the specified load limits can exert excessive pressure on the boom structure, eventually leading to the formation of cracks.
  2. Material Imperfections: Imperfections in the material or manufacturing process of hydraulic booms can also be a cause of cracks. This can occur if there are defects in the metal material or if the forming or welding process is not done correctly.
  3. Repeated Stress: Repeated and continuous use of heavy equipment can subject the hydraulic boom structure to repeated stress. This can accelerate the occurrence of cracks, especially if maintenance and upkeep are not carried out properly.

Repairing Cracked Hydraulic Booms

Here are some ways to repair cracked hydraulic booms:

  1. Welding: When there are small cracks in the hydraulic boom, one way to repair them is through welding. However, welding must be done by an experienced welder with appropriate certification. This is important to ensure that the welding is done correctly and safely to maintain the strength and stability of the boom.
  2. Replacement: If cracks in the hydraulic boom are considered large or severe enough that they cannot be repaired by welding, then the best option is to replace the damaged hydraulic boom with a new one. Replacing the damaged hydraulic boom will ensure that the performance of the heavy equipment remains optimal and reduce the risk of accidents or further damage.
  3. Maintenance: To keep hydraulic booms durable and free from cracks, it is important to perform regular maintenance. Some maintenance steps to be taken include:
  • Regularly inspecting hydraulic booms for signs of damage, including cracks or leaks.
  • Replacing hydraulic oil regularly as per manufacturer recommendations to maintain hydraulic system performance.
  • Performing routine servicing on hydraulic pumps and valves to ensure proper hydraulic system function.
  • Protecting hydraulic booms from corrosion by applying protective coatings or carrying out anti-corrosion maintenance regularly.
  • Avoiding operating hydraulic booms with loads exceeding the limits specified by the manufacturer.
  • Operating booms with excessive loads can cause undue stress on the structure and accelerate crack formation.

Repairing Hydraulic Booms by Welding

Before welding, proper preparation steps are crucial. The area to be welded must be cleaned of oil stains, paint, rust, and other dirt using a hand grinder. The crack in the weld must be cut using a planer, and the hardened base metal from previous welding must also be removed. After cutting, grooves must be ground on the inner interface to form a V-shaped groove. Then, the cleaned and prepared area must be inspected to ensure that all cracks have been detected and eliminated.

For welding, choose a welding rod model 5mm E5015 (J507) or E5016 (J506). The welding rod must be heated to a temperature of 350 degrees for 2 hours and then stored at a temperature of 100 degrees to prevent absorption of water vapor. The recommended welding current is 190-230A. Due to the large thickness of the excavator side plate, the welding area must be preheated to 150-250 degrees before welding. During the welding process, it is important to use segmented, symmetrical, and backward welding methods. During the cooling of the weld seam, the welded metal must be continuously hammered to remove stress. Additionally, when welding at the corner of the side plate, continuous welding must be performed to ensure good joint tension conditions and avoid early defects or falling.

By understanding the causes of cracks in hydraulic booms and following the correct repair procedures, crack problems can be effectively addressed, allowing heavy equipment to operate safely and efficiently. This is the article about repairing cracked hydraulic booms. Don’t forget to share it with your favorite social media. Hope this is useful!