Hydraulic Cylinder Repair and Overhaul
Hydraulic Cylinder Repair and Overhaul is a professional maintenance and repair process performed to improve the performance of hydraulic systems, prevent leaks and extend their life. This process includes examining the mechanical parts and repair kits of the cylinder, repairing or replacing damaged parts.
Hydraulic Cylinder Repair and Overhaul Process
1. Fault Detection
The cylinder is tested while connected to the system. The following situations are analyzed:
Whether there is a leak.
Loss of performance in carrying loads.
Noises or vibrations during operation.
The cylinder is disassembled and a more detailed examination is performed.
2. Disassembly
The cylinder is disassembled into its parts (piston, cap, rod, sleeve (liner)).
Damaged, worn or deformed parts are determined.
Generally, damages on the shaft surface and bending on the shaft, damages or out of tolerance in the places where the repair kits of the cap and piston are installed, scratches or out of tolerance on the pipe are detected.
3. Cleaning and Inspection
Hydraulic oil and dirt deposits are cleaned.
The inner surface of the pipe and the piston rod are checked for wear and roughness.
Bolts and sealing elements are examined.
4. Part Replacement or Repair
Shaft Repair: The bent shaft is straightened with a press or replaced with a new one if necessary.
Bolt Replacement: Worn bolts are replaced with new ones.
Surface Treatment: If there are scratches on the inner surface of the pipe and they are of a salvageable size, a honing process is applied. This process smooths the inner surface of the cylinder.
5. Assembly and Testing
The cylinder is reassembled.
Load and leakage tests are performed by connecting it to the system. In these tests, the maximum pressure resistance and performance of the cylinder are measured.
6. Revision and Development
If there are problems in the cylinder due to design or manufacturing errors, engineering improvements are made.
The life of the cylinder is extended by using more durable materials or advanced sealing systems.
Repaired and Overhauled Parts
Piston Rod: Often deformed or worn.
Bolts and Sealing Elements: These are the most frequently replaced parts.
Cylinder Tube: Internal surface smoothness is eliminated by honing.
Connecting Elements: If there is damage to bolts, nuts or clamps, they are renewed.
Piston and Cap: If there is a deviation from tolerance in the places where the seals are installed, they are replaced with a new part to prevent leaks.
Advantages of Hydraulic Cylinder Repair
Cost Savings: It is more economical than buying a new cylinder.
Increased Performance: Overhaul ensures that the cylinder returns to its first-day performance.
Longer Life: The repaired cylinder can be used for many years with proper maintenance.
Uninterrupted Operation: Overhaul ensures long-term operation of the machine.
Things to Consider in Repair and Overhaul
Professional Service: Due to the complexity of hydraulic systems, it should be done in a specialized workshop.
Original Spare Parts Usage: Poor quality parts can shorten the life of the repair.
Periodic Maintenance: After the overhaul, the system's oil level and leakage checks should be done regularly.
Test Certificate: Tests performed after the overhaul should be approved with a document.
Hydraulic cylinder repair not only solves problems, but also supports operational continuity by increasing the reliability and work power of your equipment.
