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How to Disassemble and Reseal a Hydraulic Cylinder Rebuild North Carolina Hydraulic Cylinder:
Begin by thoroughly cleaning the cylinder in a wash bay to remove any oil, grease, and dirt.
• Before starting the disassembly process, have your mobile phone or digital camera ready. Take a picture at each step as you remove parts or components.
• Secure the Hydraulic Cylinder Rebuild North Carolina cylinder in a floor vice for clamping, except for small convertible-type cylinders. Avoid clamping cylinders on a bench-mounted vice. If necessary, clamp the cylinder on the flat section of the clevis. If not possible, use an appropriately sized rod or pin to clamp the pin in the vice and place the end of the barrel onto the pin.
• Level and support the gland nut/rod end of the Hydraulic Cylinder Rebuild North Carolina cylinder on sturdy wooden blocks.
• Whenever feasible, remove excess oil from both sides of the barrel by extending and retracting the rod. Collect all waste oil in suitable containers for future disposal by an approved registered waste collection company.
• Position an oil container beneath the gland nut to collect oil from the cylinder when dismantled. This step is crucial and requires careful preparation, selection of appropriate tools, and attention to detail.
• Identify the style of gland nut and use the suitable tool to remove it from the cylinder. Check for locking tabs or grub screws on the gland nut, as some cylinders have locking tabs (e.g., Yanmar) or grub screws (e.g., JCB).
• Threaded gland nuts can be tightly secured, so exercise caution and perseverance during their removal.
• Take a moment to check for grease nipples that lubricate the rod and barrel clevis pins. Always remove and clean grease points to ensure proper lubrication, as hardened bushes in swivel connections can block grease flow. Replace grease nipples with new ones.
• Remove the rod assembly from the barrel and collect any oil that drains out in an oil tray.
• Take the barrel out of the vice and set up the rod in the vice. Before attempting to remove the piston, take a picture with your phone or tablet to ensure proper orientation during reassembly.
• Check for grub screws or scotch keys in the piston or piston nut, as screws may be under seals. Identify the style of piston or piston nut and use the appropriate tool to remove the piston from the rod. Also, take a picture of the seal’s position and location on the gland and piston for reference during reassembly.
• After removing the gland nut and piston from the rod, start removing seals from both the gland nut and piston with care, as you’ll need samples for measurements and ordering. Ensure none of the seals are damaged during removal. Keep all old seals in a plastic bag to show the customer what has been replaced. Avoid assuming that two seemingly identical cylinders have the same seals.
• After removing all seals, wear bands, and bushes, use telescopic gauges (internal calipers) to check the barrel’s bore at various locations. Measure three places at the bottom, middle, and end of the barrel.
• Measure the rod’s dimensions and inspect it for damage, including rust marks, dents, scratches, and removed plating. Repair or replace either part with imperfections, or order a new Hydraulic Cylinder Rebuild North Carolina cylinder if necessary.
• Measure seals and wear band grooves for metal-to-metal contact only. Draw and label their sizes on grid paper, adding your name, date, and job details. Scan and email the measurements with the order number, avoiding faxing.
• Measure the seals and seal grooves, then order a new set from either the cylinder manufacturer or a reputable seal supplier. Ensure that the removed parts are correct for the job by comparing dimensions with part numbers and component sizing.
• Before reassembly, check all components for dimensions. Use emery paper to clean rust and marks from the gland nut and piston, paying attention to all surfaces.
• If applicable, use a wire wheel to remove imperfections from the parts. Reinstall seals in both the gland nut and piston. For one-piece Teflon seals, hold them tightly to the piston with a piston ring compressor or a hose clamp. Place the piston assembly in a plastic bag and freeze it for 20 minutes to shrink the Teflon seals, making them easier to install. Ensure the piston is oriented correctly to avoid damaging piston seals (refer to pictures taken during disassembly).
• Apply oil to the barrel and install the rod assembly into the barrel, tightening the gland nut. Place the cylinder on the test bench, pressurize it in both directions, retract the rod completely, and plug the piston side of the cylinder. Pump oil into the rod side and check for any bypass. If everything is in order, clean up, attach a Mobile Hose Fixers sticker to the cylinder, and bill the customer for a professional job, including clean-up time.
Load Holding Valves in Hydraulic Cylinder Rebuild North Carolina Hydraulic Cylinders: Enhancing Safety and Performance Load holding valves play a crucial role in numerous hydraulic system applications, offering several significant advantages:
• Load Holding: Load holding valves are indispensable when a hydraulic cylinder needs to maintain its position for an extended period without any undesired drift. Think of scenarios like a mobile crane’s outrigger that must stay level or a manlift extended for utility line work.
• Controlled Motion: When lowering a load, these valves prevent the actuators from advancing too quickly, preventing uncontrolled movement and potential pump cavitation.
• Pressure Relief: In specific situations, such as significant temperature fluctuations, load holding valves can provide pressure relief to prevent pressure intensification and potential system failure.
• Safety: Load holding valves are essential for safety. They can prevent hazardous situations, such as a falling boom caused by a ruptured hydraulic hose.
Load holding valves primarily come in two forms: pilot-operated check valves and counterbalance valves. While both valves serve to lock fluid within a cylinder and prevent drifting, they have distinct characteristics.
Pilot-Operated Check Valves: Pilot-operated check valves, also known as pilot-to-open check valves, are non-modulating valves that operate in either a fully open or fully closed state. These valves permit hydraulic fluid to enter a Hydraulic Cylinder Rebuild North Carolina cylinder while restricting the flow out of the cylinder unless pressurized fluid is supplied via a pilot line.