Prices for just about everything are rocketing up ever higher and faster. So, when essential pieces of machinery either stop working efficiently or stop working altogether it’s an extra financial burden that no one needs.
Hydraulic cylinders are such a key component in a huge variety of machinery and across many industries, this is one of those pieces of machinery you need to be running well. Regular checks including daily, weekly and monthly checks with an annual service are essential to help you avoid expensive hydraulic cylinder repairs and keep your machinery in tiptop condition for years.
However, what if you spot something during your hydraulic ram maintenance checks that needs repairing?
This simple and easy-to-follow guide will help you and your team to undertake hydraulic cylinder repairs and rebuilds to keep your machinery and your business running smoothly.
Preparing To Repair A Hydraulic Cylinder
An essential first move when preparing for ANY hydraulic ram repair that might be tempting to skip is giving it a thorough clean.
Please, please, please don’t skip this step. By first cleaning the hydraulic cylinder you are avoiding getting debris, dirt and grime into your hydraulic system, which will spell more trouble than you might have already.
Also, ensure you can do the repairs in a relatively clean and dust/debris-free area.
Things To Check First
The most common problems are:<
- Contamination of air, debris, or water.
- Incorrect fluid levels.
- Excessive loads (over what is recommended for the machine).
- Dirty or clogged filters.
- Worn out parts such as seals, hoses and valves.
The Process Of Repair
Daily, Weekly & Monthly Checks / Annual Servicing
Regular maintenance checks will help prevent many of the common problems listed above and many of which lead to each other.
Worn pipes, valves and seals lead to contamination. Incorrect fluid levels lead to overheating, air contamination and loss of power. Dirty filters lead to contaminated fluid, overheating and poor performance.
Prevent Excessive Loads
Ensure everyone working with hydraulic equipment knows the load-bearing capabilities of each piece of equipment, double checks load weights and does not take risks.
Removing Air From A Hydraulic System
Extend the cylinder and leave it for a while to allow the air to rise to the top then partially retract the cylinder.
Open the bleed valve and allow all the air to escape until the hydraulic fluid starts to flow.
Ensure the hydraulic fluid is topped up to the right levels so it does not allow air to enter the system.
Removing Water & Debris From A Hydraulic System
To do this, it is best to flush the system.
- Begin by draining the oil
- Clean the reservoir, and remove and replace the filters.
- Use a low viscosity oil to fill the reservoir and prime the system to get the oil heated to operating temperature.
- Turn the hydraulic system off and drain the flushing oil.
- Replace with the right oil for your hydraulic system.
Replacing Hoses & Seals
Ensure you have the right size replacements before you begin. Inaccurate measurements, even of the lowly O ring, can cause major problems.
Dissembling The Hydraulic Cylinder
Before any of these replacements you will need to follow these steps:
- Ensure you have the correct set of replacements for your system.
- Gather equipment: rubber mallet, pliers, and a wrench.
- Remove the steel wire rings, both internal and external on a wire ring cylinder.
- On a threaded gland cylinder remove the end cap.
- Remove rod seals, rod, and piston seals. Remember where they come from, taking photos if required, to help you with reassembling the hydraulic cylinder.
Replacing Seals
- Remove the cylinder seals and clean the area.
- Before replacing the new seals lubricate them and the other parts before reassembling the cylinder.
Replacing Hoses
- Identify the hose that is worn or damaged.
- Clean the area, cut out the hose and clean again.
- Double-check the length.
- Using an adapter carefully root in the hose.
- Tighten.
- Double-check for gaps and that seals are tight.
- Run the system at low pressure while you check for leaks.
More Complicated Repairs
For more complicated repairs or just to be 100% sure that the repair job is done fast and done well, hiring professionals is always going to be money well spent. Investing in expert hydraulic repair services like our team at MCH Hydraulics, not only gets you back up and running fast but helps to ensure the longevity of your hydraulic machinery.