Having hydraulic cylinders repaired saves time and money
A hydraulic cylinder is always a relatively expensive component. The price of a new linear actuator is proportional to its size and the force it can exert.
At the same time, most damage that occurs is relatively easy to fix. It is therefore always advisable to inspect a defective cylinder before purchasing a new one. Often, even a heavily used linear actuator can be refurbished at a fraction of the cost of a new one. Furthermore, repairs are significantly faster. This is especially true if the hydraulic cylinder is a custom-made component.
Typical damage that can be resolved by repairing the hydraulic cylinder:
A hydraulically operated linear actuator consists of only a few components:
- Hydraulic line connections
- Housing with internal cylinder
- Extendable piston rod
- Seals
- Bushings
The primary weak point of any hydraulic cylinder is the seals. They are subject to the highest stress and must withstand high internal pressure. The sealing lips or rotary shaft seals in contact with the piston rod are under particularly high load. They are subjected to friction every time the rod extends or retracts.
Even the smallest impurities in the hydraulic oil or roughness on the piston rod are enough to damage the seal. The high internal pressure of the hydraulic system then does the rest, causing the entire hydraulic cylinder to leak.
Other common types of damage include rust spots on the piston rod or damage caused by external force.
Procedure for repairing hydraulic cylinders
A hydraulic cylinder can be effectively refurbished as long as the damage is not too advanced. The repair process involves the following steps:
- Dismantling the cylinder
- Disassembly
- Inspection
- Cleaning
- Replacement of all seals
- Refinishing the running surface and piston rod
- Reassembly
- Testing
When does a hydraulic cylinder need to be repaired?
A defective cylinder is noticeable through leaks or malfunctions. Significant pressure fluctuations in the hydraulic system can also indicate a faulty linear actuator.
However, more precise details are only known once the cylinder has been removed, disassembled, and inspected. It is important to be extremely thorough here. Every instance of damage to a hydraulic cylinder has a cause. A damaged chrome layer on the piston can indicate cavitation. If the piston is bent, this may suggest overloading. In both cases, the root cause must be addressed; otherwise, the repair will soon be in vain.
Cleanliness is crucial when working on hydraulic systems. Therefore, after disassembly, defective linear actuators are not only cleaned but usually also stripped of their coating. This ensures that no particles of paint or primer can enter the hydraulic oil during reassembly.
Most seals are standard items. However, any type of seal can also be custom-machined using lathes.
Repairs only become expensive if the piston rod and the cylinder running surface need to be refinished or replaced entirely. Whether this is necessary is decided after the inspection.
Finally, the cylinder is reassembled, painted, and tested. After a successful test run, it can be handed back to the customer or reinstalled in its original location.
How can hydraulic cylinder repairs be prevented?
For long-lasting repair success, it is recommended to replace the oil and all filters in the hydraulic system. This ensures that no old particles can damage the freshly overhauled hydraulic cylinder.
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