CAT 963 Full Hydraulic Build
 

Well many of you guys may remember the Cat tracked loader that Brian had built. I recently acquired it and have started to do some fiddling with it. When I received it the genius people at the post office couldn't read every single side of the box that said which way was up and the model was left upside down to let all the hydraulic fluid leak out. Brian did and excellent job of packing it but there was still a good amount of leakage. Anyways I started to tear into it like a kid at christmas and found all the inner workings were in tact and about ready to go. First things first I cleaned it up and got all the fluid off of the electronics and dried everything out for the night and then broke into it again the next day.

Well in the process a couple of lines were pulled off so I got them back on and fired up the motor with my new esc installed and decided to see what this loader could do. Well to my surprise the bucket worked flawlessly dumping but was a little slow going up so I bled it both directions and it helped it out. Next was onto the arm rams. Now here is where I started to hit a problem.

I began lifting the arm and it got almost all the way up then stalled. I figured I had some air in them as well so I cracked the return lines at the time and got the arms all the way up. I rehooked up the lines and started to send the arm down when all of a sudden I realized it had stopped and all the fluid was pouring out the front seal of the right arm. :eek: I couldn't believe it. I didn't have that much pressure behind it and it started leaking. So I tinkered with the pressure and no matter how low I set it through my esc I still had a leak. :(

Well anyways after spending a few days thinking about it I decided instead of contacting the original mfg of the hydraulic cylinders I would just take time and build my own. So now that we are caught up to today I finally got some time to start on my own setup. Anyways here are a few pics of todays progress on one of the arm cylinders. Now I'm not sure how many seals other models have in their cylinders but I decided to go with four simply to have insurance that I would have no leaks.

I started out by simply making the new cylinder cap and creating o-ring grooves by building multiple layers with offsetting sizes to press fit in and seal up tight on the shaft.

http://i90.photobucket.com/albums/k2...r/IMG_1266.jpg

http://i90.photobucket.com/albums/k2...r/IMG_1269.jpg

I then took a small c-clamp and mounted it into a small vise and used it as a small arbor press. I am pressing all five pieces together to build the cap in this picture.

http://i90.photobucket.com/albums/k2...r/IMG_1270.jpg

Once all the pieces were pressed together I installed the two o-rings in the end cap. There is an inner oil seal and an outer dust seal just inside the front face to keep debris out of the cylinder itself and to help protect the shaft a bit better.

http://i90.photobucket.com/albums/k2...r/IMG_1271.jpg

I then turned out a shaft for the cylinder and over sized it by just a few thousandths so I was guaranteed a good seal.

http://i90.photobucket.com/albums/k2...r/IMG_1268.jpg

http://i90.photobucket.com/albums/k2...r/IMG_1272.jpg

http://i90.photobucket.com/albums/k2...r/IMG_1273.jpg

Once I polished up the ram itself and threaded both ends I started making the inner sealing rings and mounted the assembly up to the ram.

http://i90.photobucket.com/albums/k2...r/IMG_1275.jpg

My final part for today was cutting the body of the cylinder and honing and polishing the inside so I get a good seal all the way and make sure that the ram slides smoothly while still sealing both directions. I added a little oil to both sides of the ram and pulled it both directions to find out that my seals were holding up and I had no leaks.

http://i90.photobucket.com/albums/k2...r/IMG_1276.jpg

http://i90.photobucket.com/albums/k2...r/IMG_1277.jpg

Now all I have left to do is build the back cap and assemble the cylinder and hook lines to it. I hope to be able to run these rams up to the 165psi I was getting out of the pump without having anything blow out.:confused:

Hope you guys like the progress so far and I hope to have some more updates soon. I really plan on having this done and running good by St. Louis so if all goes well I believe that it may be possible to have it working by next weekend.:D

Thanks for looking.

Tyler

Re: CAT 963 Full Hydraulic Build
 

Looks good! Wish I had the tools and equipment to make stuff like that!

Re: CAT 963 Full Hydraulic Build
 

Got a little time to work on the loader lastnight so here are some new pics. I cut the back out to make room for a cooling fan to keep the pump and electronics cool inside the closed model. I also got the front trimmed out some more to stuff as much in the small space as I can. This little guy will be loaded when it's all done.

Heres some of my latest pics.

http://i90.photobucket.com/albums/k2...r/100_2799.jpg

http://i90.photobucket.com/albums/k2...r/100_2800.jpg

http://i90.photobucket.com/albums/k2...r/100_2801.jpg

And here are a couple of the hydraulics that are gonna be powering this little machine.

http://i90.photobucket.com/albums/k2...r/100_2802.jpg

http://i90.photobucket.com/albums/k2...r/100_2803.jpg

Hope you guys like the progress.

Tyler

Re: CAT 963 Full Hydraulic Build
 

looks great Tyler!! Your making me wish I wouldn't have sold it!;);) nice job on the cylinder mods.

Re: CAT 963 Full Hydraulic Build
 

Hey Brian, I thank you for selling it and I'll keep it in good hands. Maybe if I ever get up to Indy or you make it to St. Louis you will get to operate it. I'm really hoping right now that I can get the new seals in that I need and get these cylinders done by next week and get it fully operational before St. Louis.

Tyler

Re: CAT 963 Full Hydraulic Build
 

Hey Tyler, any info on the hydraulic pump? Keep up the great work!

Cheer's, Neil.

Re: CAT 963 Full Hydraulic Build
 

Hey Neil, the pump is made my a guy in spain. I haven't run it yet to get the cylinders to work but hopefully when my new ones are done I will be able to get some pressure readings off of it and let you know what kind of power output it has.

Now that I've got my radio setup to where the pump only runs when I actuate the servo's for the valves I'm not too worried about prolonged wear on the motor or excessive heat.

I can currently run the loader around on the floor with just the track drives and when I want to operate the pump I flip a switch and start toggling the right stick for the hydraulics and the pump runs.

I'm hoping to see about 140-160psi out of the pump at full power but that will be dictated a little later once everything is built.

Tyler

Re: CAT 963 Full Hydraulic Build
 

One thing I would like some input on is what should I use for hydraulic fluid?

I know the manufacturer of the pump and hydraulics recommends using antifreeze with this system but that is what was run in it before and it really made everything sticky and gummed up so I will not be going back with it for those two reasons alone.

I'm thinking I will probably just buy a quart of iso 32 hydraulic fluid due to the sheer fact that it is considered a 10wt oil and is should flow nicely and lubricate everything very well.

I was wondering what most of the hydraulic guys use around here and if I'm on the right track.

I also know I have some Lucas brand synthetic fork oil that is used for motorcycles at work and thought maybe that would be the way to go but I have no idea of it's properties or how it breaks down under high pressure and being forced through the hydraulic system and small valve ports.

Any advice or help on this would be greatly appreciated.

Tyler

Re: CAT 963 Full Hydraulic Build
 

i use this http://www.halfords.com/webapp/wcs/s...Id_255207#tab1

works well enough
[edit] its iso32

Re: CAT 963 Full Hydraulic Build
 

10wt should be just fine, that's what my full size Cat equipment run's.
Cheer's, Neil.

Re: CAT 963 Full Hydraulic Build
 

Working on micro hydraulics looks so cool! I've worked on massive shovels and loaders which have huge cylinders, I wish at home , I could build and work on what you have :). ..... I guess I can leave my 2 1/4 wrench at work for this stuff eh?

I have no kids, no college fund to worry bout. My plan was retire at 55 .......:eek: now I got the RC truck bug and because of my career, it's only a matter of time before I have a shovel, dozer or loader of my own :D
My new plan is retire ?........someday....:). Lol

Mario

Re: CAT 963 Full Hydraulic Build
 

Re-Tire-Ment, I go to the tire store, I buy New, I buy Used, I get flat's fixed, I buy recap's!:p Retirement:eek::eek::eek: It's a proven system:D:D:D
Cheer's, Neil.

Re: CAT 963 Full Hydraulic Build
 

It's time for an daily update with some progress. I got my new seals in today and decided I would spend some time assembling one of the cylinders and getting it built. I got everything buttoned up on it and stuck it in the loader just to see what I had and here are some pics of the results. Now only one more identical to this one and then on to the bucket ram then hopefully they all hold good pressure and operate smoothly and handle the pressure better than the original ones that came with this unit.

Anyways here are a few teaser pics from tonights progress.

Fully collapsed:

http://i90.photobucket.com/albums/k2...r/IMG_1289.jpg

Fully extended:

http://i90.photobucket.com/albums/k2...r/IMG_1290.jpg

And here are a few close ups of the attachment points.

http://i90.photobucket.com/albums/k2...r/IMG_1291.jpg

http://i90.photobucket.com/albums/k2...r/IMG_1292.jpg

I hope I can get the other one built sometime this weekend and have the model back together next week.

Lemme know what you guys think.

Tyler

Re: CAT 963 Full Hydraulic Build
 

:eek::eek: Looks great Tyler! Maybe you should start building cylinder kits?

Re: CAT 963 Full Hydraulic Build
 

They look great!

Re: CAT 963 Full Hydraulic Build
 

They look great! If it works well you've come up with an easy way to make cylinders without a lot of tooling! What did you use for tubing and are the end caps soldered on?

Thanks, Reg

Re: CAT 963 Full Hydraulic Build
 

Nice Job as usual Tyler. Making it look easy.

Re: CAT 963 Full Hydraulic Build
 

Brian if these cylinders hold up and work out I may just be able to replicate some of them for others if there was enought intrest.

Tyler

Re: CAT 963 Full Hydraulic Build
 

Thanks for the compliments guys. It keeps me goin even when these things take forever to build.

Tyler

Re: CAT 963 Full Hydraulic Build
 

Everything on these cylinders are out of aluminum and the final product is pressed together for a tight seal. I have nothing soldered on but we will see how they hold up against the pressure that the pump is puttin out.

Thanks for the compliment.

Tyler

Re: CAT 963 Full Hydraulic Build
 

Looking good Tyler ,awesome job on the cylinders ,hope it works out for you.:)

Re: CAT 963 Full Hydraulic Build
 

It's gonna be a heck of mess, not if, but when it blows apart! :eek: :D

Red lock tite might hold it all together for a while.

The Leimbach cyl ends are screwed on & glued.

You might want to try the cyls in a tuppaware container to contain the fluid explosion! ;)

Re: CAT 963 Full Hydraulic Build
 

Joe is right Ty . Trust me ;) I tried it :o I was lucky to do an air test of about 60 PSI 1st . otherwise they look good .

Re: CAT 963 Full Hydraulic Build
 

Ok, coming from you two I know I have a problem already. I am going to design cylinder number three now and make some ends that will thread on so I don't have to worry. I'd rather do it right the first time then clean up a mess. I'll get to cracking on some new cylinders later and make them threaded. I hooked up air to the cylinder and I was able to push it to 100lbs of pressure but my pump on a full battery is pushing 165psi. :eek:

I'll try to get some more ideas but thanks for the heads up. :)

Tyler

Re: CAT 963 Full Hydraulic Build
 

Well just a little update for the evening. I haven't gotten any more done on the loader the last couple nights with the hydraulics but I have gotten some new wiring done and made some other parts for it. I'm currently waiting on some material to come in to make the new cylinders and hopefully get started on them later this week.

I decided to follow what Steve and Joe said about creating threaded on caps and have everything sealed up tight and no way of blowing out a pressed on cap. I will be building the new ones out of brass as well since I can get a smoother finish, it's a softer yet more convenient material and should also hold up to the fluid great.

I did do some testing on the pump yesterday as well and found out that while using some universal hydraulic fluid it was quickly apparent that it was way too thick. I did do some research and found out that it is approximately a 30wt oil so I know that is now out of the question.

I did however pick up a small container of Lucas brand fully synthetic fork oil made for motorcycles at work today for a couple of bucks that says specifically on it that it is a 10wt and is great for high pressure applications up to 280psi and has a great viscosity rating making it essential in small orifice applications; which as small as my hoses and valves are should make this a great oil to use.

Now the only thing I have left to do before I can get started on the new hydraulics is mount the pump/motor assembly to the new plate and also flush the hydraulic tank and pump then fill it all back up and test it with the lighter weight oil.

Thats all I have for tonight but I will be starting on the rest of the auxiliary wiring within the next couple of days and installing some new switches and led's so this machine can work at night and see what's going on around it.

Thanks guys,

Tyler

Re: CAT 963 Full Hydraulic Build
 

Well I have a little bit of progress from the afternoon today. I got around to getting my hydraulic filter housing made and installed the filter and screen. I hope to get the cylinders done this evening if possible and possibly get the loader working this week.

Anyways here are a few pics of the new filter housing.
http://i90.photobucket.com/albums/k2...r/IMG_1435.jpg

http://i90.photobucket.com/albums/k2...r/IMG_1436.jpg

http://i90.photobucket.com/albums/k2...r/IMG_1437.jpg

Hope to have some more updated for you all soon.

Tyler

Re: CAT 963 Full Hydraulic Build
 

looking good!

Is that a bruder? will the plastic hold up from the strain that the hydraulics will put on it?

Admire the work needed to build your own hydraulics :)

Re: CAT 963 Full Hydraulic Build
 

Well after finally finding this project a ways back on page two I decided it's time for a resurrection and to bring this project back to life.

I have been tinkering off and on with this loader for a while and I think I'm getting close enough to have it running and operating before long. Maybe next week it'll be moving again and have working hydraulics. :confused:

Anyways here are some quick pics from the progress of the machine so far. I've built a new hydraulic tank for it and also trying to figure out where to locate everything. I will be making a plate to mount the battery and speed control on for the pump this weekend when I get time and after the new esc's I need for this and the tractor come in.

Everything is still in the mock up stages in these pics but it'll give everyone an idea of what goes inside one of these little machines.

Enough jibberish and here are some new pics.

http://i90.photobucket.com/albums/k2...psabe0bb2b.jpg

http://i90.photobucket.com/albums/k2...psc7de2d23.jpg

http://i90.photobucket.com/albums/k2...psef001f45.jpg

http://i90.photobucket.com/albums/k2...ps4ac2f6ea.jpg

That's about all I have for tonight on updates but like I said I should have movement by the end of the weekend and hopefully operation of the loader by next week sometime.

Tyler

Re: CAT 963 Full Hydraulic Build
 

Tyler,

What scale is the loader and what motors are you using?...lookin good! Colin

Re: CAT 963 Full Hydraulic Build
 

Looking good! When you finish yours you can help me finish mine...... I just gotta re figure the bucket arm mount..... mine is screw drive not hyd....

Re: CAT 963 Full Hydraulic Build
 

I almost forgot about the loader Aaron you need to get that up and running too.

Re: CAT 963 Full Hydraulic Build
 

Colin the loader is said to be 1:16 scale, some parts are a little off but it fits good with the Tamiya scale trucks and trailers.

The drive motors are Beetle motors from robotmarketplace.

Tyler

Re: CAT 963 Full Hydraulic Build
 

You two have way too many projects going on anymore. Trucks, tractors, loaders, what next a working circus? I can see Aaron being the ring master in this situation. Anyways Aaron lemme know what you need help with and I'll do my best. I got my speed controls in today so I should have pressure and movement tomorrow in the tractor and have this pump running again.:D

Tyler

New Drive Hubs & Motor Mounts
 

Time for a new update since we had a company wide snow day today that gave me plenty of time to work on the loader. I spent most all day inside out of the 14 inches of snow we got and slaved away making new parts and pieces for the loader. I've almost got this loader up and running for good this time. Fitting all the new goodies in it has been fun and quite a challenge considering the minimal space I've got and what I'm trying to stick in it such as the hydraulic system, two gear motors for the track drives, a hydraulic pump fan, two batteries, and hopefully if I can get ones sometime a servonaut SMX to make this machine come alive.

Anyways I got to whittling away at some fresh metal today and thought I should post up some pics of the new pieces I made.

I started out making new motor mounts for the drive motors so I can easily switch them out if need be. I didn't want to go too light on the mounts so they got about 4 hours of attention. Here are a few pics of what I did.

http://i90.photobucket.com/albums/k2...ps0192d776.jpg

http://i90.photobucket.com/albums/k2...ps3217f561.jpg

http://i90.photobucket.com/albums/k2...ps4e40b865.jpg

http://i90.photobucket.com/albums/k2...ps8a78c13b.jpg

http://i90.photobucket.com/albums/k2...ps2341c1cf.jpg

http://i90.photobucket.com/albums/k2...ps08a5f1c3.jpg

I wanted something removable and strong so these are what I was able to come up with.

Tyler

New Interior Setup
 

My next task up for the day was getting everything fitted inside the model and having a little room to spare. Very little room to spare I might add.

I made a new motor mount for the hydraulic pump as well today so that it will be solid mounted and still be able to have plenty of air flow over it from the fan blowing on it. I also added a battery plate inside as well to elevate them just enough to let air circulate around everything inside the model so I don't get too hot while operating. I made a plugin for the dual batteries as well out of a couple of deans plugs so that I can easily lift the rear and access the batteries and plugs. These also help keep things in place and wires out of the way.

Under the black plate is the hydraulic tank and the esc for the hydraulic pump in the back. I will also have a new sabertooth underneath to run the two drive motors so everything should be a close fit when finished.

All I have left to mount is the receiver and valve block in the front once my new Hitec servos get in.

Enough talking and here are some more pics of todays progress coming together.

http://i90.photobucket.com/albums/k2...psbb4c3c56.jpg

http://i90.photobucket.com/albums/k2...psabb7520c.jpg

http://i90.photobucket.com/albums/k2...ps683c3b4b.jpg

Well hope you guys enjoy the new pics and I hope to get some more parts in this weekend and have a video for everyone next week possibly.

Thanks for looking,
Tyler

Mock Up Pictures
 

Oh I almost forgot the shots of all the hydraulics on the front. Here are a couple of mock up shots of what I'm aiming for.

http://i90.photobucket.com/albums/k2...ps66a9b379.jpg

http://i90.photobucket.com/albums/k2...psc6b32e56.jpg

http://i90.photobucket.com/albums/k2...psa4a565a5.jpg

http://i90.photobucket.com/albums/k2...ps4823002e.jpg

http://i90.photobucket.com/albums/k2...psa6deee3c.jpg

http://i90.photobucket.com/albums/k2...ps40d69eea.jpg

http://i90.photobucket.com/albums/k2...pscb6f9ab5.jpg

http://i90.photobucket.com/albums/k2...pscf39290b.jpg

http://i90.photobucket.com/albums/k2...psf0f47b7b.jpg

http://i90.photobucket.com/albums/k2...ps5454800f.jpg

Ok, that's all the pictures I have for now for new updates but I will have more to follow in the next few days along with a video or two as well.

Thanks for looking,
Tyler

Re: CAT 963 Full Hydraulic Build
 

Looks awesome! Nice job cramming all that stuff in there too.

Re: CAT 963 Full Hydraulic Build
 

Looking Great!!!! You should have it up and running in no time!

Re: CAT 963 Full Hydraulic Build
 

I like your final drive setup "rear sprocket"
Cheer's, Neil.

Time for lights!!!
 

Time for some more updates. I finally have the track drives mounted up with the new hubs and everything is starting to really come together. I have the electronics plate almost finished and mounted (just waiting for the Sabertooth to come in) into the chassis and I should be able to get things up and running this week. I have to finish wiring up my switches for the Sabertooth and the pump esc then tie the fan in and all my wiring should be about done.

I got a wild hair up my rear end tonight and decided that there were simply not enough wires in the mess so I needed to add more. :p Anyways I decided to add some lights to the front of this loader so I can do some work at night and not have to worry about not seeing what I'm going to hit.

Anyways I was able to stuff the interior back into the model with no visible signs of modification other than the new lights out front. Hope you guys like the new pics and updates.

Here are the new hubs installed in the chassis.

http://i90.photobucket.com/albums/k2...ps4de30e0a.jpg

http://i90.photobucket.com/albums/k2...psb3d8ebb3.jpg

http://i90.photobucket.com/albums/k2...ps865a8837.jpg

Also a shot of the hydraulic tank I have with the fitting and breather on the top

http://i90.photobucket.com/albums/k2...ps7baa7124.jpg

Now some shots people have wondered about for the electronics plate.

http://i90.photobucket.com/albums/k2...ps84f6ebc3.jpg

Underneath side.

http://i90.photobucket.com/albums/k2...psa942f7f4.jpg

http://i90.photobucket.com/albums/k2...psff9a61c7.jpg

And now for some shots of the new cab lights.

http://i90.photobucket.com/albums/k2...ps6dedca63.jpg

http://i90.photobucket.com/albums/k2...ps92c75067.jpg

http://i90.photobucket.com/albums/k2...ps7c3e0977.jpg

What good are lights without a night shot?

http://i90.photobucket.com/albums/k2...psc6722ff4.jpg

Note that the carpet line you see in front of the loader cab is just shy of 3 feet in front of it. That should give some distance to how far the light goes from the model.

Thats all I have for tonight for updates but I will keep more coming as the build progresses. If I get the Sabertooth in this week I should have it back together and running by the weekend hopefully. Just a few more little tweaks and tunes here and there and it should be good.

Thanks for looking and lemme know what you guys think.:rolleyes:

Tyler