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UNDERSTANDING HYDRAULIC CYLINDERS AND THEIR MAINTENANCE
Hydraulic cylinder rebuild Oklahoma cylinders are actuators powered by hydraulic fluid, allowing for linear movement and unidirectional force. Commonly found in equipment like landing gears, harvesters, and manufacturing machinery, their widespread use demands regular upkeep. One crucial maintenance activity is repacking, which minimizes oil leaks, prolongs cylinder life, and minimizes machine downtime.
In this guide, we delve into the importance of repacking and walk you through the process, from preparation to post-maintenance testing, and where to source repacking kits.
THE IMPORTANCE OF REPACKING
Repacking is pivotal for hydraulic cylinder longevity. Oil leaks, if unchecked, can hasten the need for cylinder replacements and cause unexpected operational halts. Regular repacking ensures smooth operations, cost savings, and heightened efficiency.
For optimal maintenance, document each repacking session. If you observe oil leaks, reduced performance, or drifting in your cylinder, it’s time for a repack.
PREPARING AND TESTING THE CYLINDER
Before diving into repacking:
Confirm the cylinder rod is aligned.
Ensure the barrel’s inner surface has the correct cross-hatching.
Examine for any scarring or gouging.
Check the rod’s chrome plating for damage.
For pressure testing:
Fill the cylinder with hydraulic cylinder rebuild Oklahoma fluid.
Evacuate air by moving the cylinder through its full range repeatedly.
Pressurize the cylinder to extend it and inspect for internal leaks.
Retract the cylinder and check again for leaks.
Once these are done, you’re set for repacking.
Repacking is a simple yet essential process for maintenance:
Disconnect all lines or hoses to free the cylinder.
Seal all ports.
Decompress the cylinder, detach it, and clean.
Remove the gland, also remove the pin from the rod-end.
Extract the piston rod, handling it delicately to prevent damage.
Detach the piston from the rod with caution.
Replace seals and O-rings as necessary.
Ensure all parts are free from dust or debris.
Clean every component you’ve detached.
Reattach the piston to the rod.
Reconnect the hydraulic lines.
Test the cylinder for leaks as previously detailed.
Repacking, while straightforward, demands careful attention. Keep track of the disassembly order to ensure proper reassembly for hydraulic cylinder rebuild Oklahoma. Know your torque requirements to guarantee appropriate tightening. With these steps, your hydraulic cylinder’s performance and lifespan will be maximized.
Dating back to the late 18th Century, hydraulic cylinders leverage Pascal’s law, which highlights that fluid pressure, when applied, spreads equally in every direction. These cylinders gained prominence during the industrial revolution, supporting burgeoning factories. Today, their versatility finds them in industries like construction, mining, and offshore operations.
TYPES OF HYDRAULIC CYLINDERS
Single Acting Cylinders: These apply force in one direction, relying on another source (like gravity or a spring) for the reverse motion.
Double Acting Cylinders: This variant can exert force in both directions using hydraulic power.
Telescopic Cylinders: These have multiple stages, allowing for greater extension without increased space. They can vary in speed due to differing volume sizes between stages, but can be engineered to move uniformly.
Jack Cylinders: Portable and available in various sizes, these floor-based cylinders can lift weights ranging from 5 to 50 tonnes. Their versatility makes them popular rental choices for infrequent tasks.
Hydraulic cylinders operate on the formula:
Force = Pressure × Area
The force generated by a cylinder is a product of the pressure supplied by the Hydraulic Pumping Unit (HPU) and the cylinder’s piston size. Typically, pump pressures range from 210 to 690 Bar, with the average being around the lower limit. The pump’s capacity also determines the cylinder’s speed.
SIZING, DESIGN AND NEEDED CONSIDERATIONS
Designers must ensure that the hydraulic cylinder rebuild Oklahoma size is appropriate. Overextended cylinders risk buckling, necessitating sturdier builds, which could inadvertently increase force and weight.
Design Phase: Engineers craft the cylinder blueprint, taking into account its intended use and operating conditions. This process adheres to industry-specific standards, with a special focus on sectors with rigorous requirements, like offshore operations.
Machine Shop: Once designs are locked in, precision machinery creates the necessary components, ensuring exact dimensions and applying specialized coatings when needed.
Assembly: The fitting team must bring together all the parts, ensuring they select the best components for each build.
Quality Check: Before handing over to clients, every cylinder undergoes a comprehensive testing phase, including pressure, load, and pull tests. For offshore applications, third-party agencies, such as DNV-GL and Lloyds Register, may be involved.
Finishing Touch: The in-house painting team applies protective coatings, with offshore standards often dictating specific requirements. Customization, like company logos, can also be added at this stage.
Constructed primarily from carbon steel, the hydraulic cylinder rebuild Oklahoma barrel’s material choice varies based on application demands. For environments like food processing areas where painting is not feasible, stainless steel is preferred to combat corrosion. The barrel’s interior is typically left uncoated since hydraulic fluid offers inherent corrosion protection. Nonetheless, if corrosive fluids like water are used, internal coatings are applied.
The rod, being the only external unpaintable part, demands robust protection. It must resist wear, pitting, and corrosion. Any imperfections could damage seals, contaminating the hydraulic fluid and disrupting system performance. Standard rods are steel or stainless steel with a Hard Chrome Plating (HCP). Advanced coatings offer enhanced durability, while materials like Inconel may be used for extreme environments.
Connected to the rod, the piston oscillates within the cylinder bore due to hydraulic fluid’s push, generating the required force. It’s crucial to ensure hydraulic fluid doesn’t bypass the piston.
Predominantly oils, the choice of hydraulic fluid depends on system specifics, with viscosity being a key determinant. In flammable-risk environments, water-based fluids might be used.
Hydraulic cylinder rebuild Oklahoma cylinders have mounting points at both ends – the base and head. The mounting style is tailored to user needs and application. Options include pins, flanges, threaded connections, trunnions, spherical bearings, foot mounts, and more.
To maintain pressure and prevent oil leakage, the cylinder tube is sealed at both ends. While one end has a base, the other uses a neck gland to permit rod movement, which is sealed with appropriate materials.