Hydraulic Cylinder Repair

Most of the heavy machinery or your car for that matter works on the principle of hydraulics. Heavy bulldozers, excavators and forklifts also have these hydraulic cylinders as an integral part of their machinery. It plays a major role in domestic applications like automotive parts, elevators and door stoppers. The concept of a hydraulic system is based on the principle that a force which is applied at one point is transmitted to the destination via an incompressible fluid (say, oil).

The best example of this application is the brakes of your car, which is basically a piston driven hydraulic system. When you press the brake pedal in your car, a push is exerted on the brake's master hydraulic cylinder, thereafter the force which is applied is multiplied by the four slave pistons (each at the wheel). The hydraulic fluid is compressed and a linear motion is produced which actuates to press the brake pads against the brake rotor to stop the car.

Hydraulic Cylinder Problems

Before going about problems concerning hydraulic cylinder, let me first brief you about hydraulic cylinder parts and working. The entire hydraulic cylinder assembly comprises a hydraulic pump (generates pressure) and a hydraulic cylinder (delivers the linear motion). The cylinder is fitted into a cylindrical barrel with a piston and the whole barrel is sealed at both ends. Now, the piston's movement is driven by the hydraulic fluid that is regulated by the hydraulic pump. So when the pump generates pressure on the incompressible fluid, the piston is pushed up, causing the linear motion as stated. If the pump sucks back the fluid, the piston is forced down. Now for a greater force, a greater surface area of the piston would suffice, which adheres to the theory of multiplying the force.

For hydraulic cylinder repair, there are certain causes which can lead to its malfunctioning. Scroll through the below reasons and solutions to get a better idea.

• A crack in a hydraulic cylinder indicates that the cylinder needs to be replaced at the earliest, as there is no way you would want to repair it, considering it to be a tough procedure with uncertain results. A bent piston rod can also hamper the performance of this hydraulic system.
• Over a period of time due to persistent wear and tear, there is a chance that the seal of the hydraulic cylinder might break.Yes, all you have to do is have a graphical layout of the entire assembly (say, a printout) and order for a repair kit from the manufacturer. Now how to repair a broken seal? Locate the seal which can be found around the piston shaft on one end. Unscrew the lid from the shaft entry and loosen the pump to reduce the hydraulic pressure. Now detach the piston from the shaft and replace the broken seal with the newly obtained seal from the repair kit. Once you are done, run a thorough check on the seal alignment. Oil the parts well and reassemble the entire assembly.
• Similarly, if the piston rings get damaged, follow the above procedure of disassembling the parts and when completing the reassembly, do not forget to oil, once the repair is done.

Hydraulic Cylinder Repair Tools

Whenever you indulge in the repair of any machinery, a checklist must be prepared first. What you should repair, must be your first priority. Here are the requisites needed before you go about the task of repairing the cylinder.

• Get a graphical layout of the hydraulic cylinder assembly in hand before commencing with the repair.
• Now get your repair kit ready. It will have new shaft seals which are nothing but O-shaped rings that cover the inside of the cylinder when the piston shaft pushes into the cylinder.
• Lubrication is a very important aspect as far as any machinery is concerned. The piston shaft must be well-lubricated, but remember, there is a specific level of lubrication defined in the manufacturer's manual. Any amount of lubrication more than or less than the desired level can hamper the life of the piston shaft.
• Last but not the least, quality of the hydraulic cylinder matters the most. If the cylinder rod is unable to withstand pressure exerted by the fluid, then it might succumb to bending, which in turn will cost you a fortune, spending on the entire replacement thing.

Whenever you try your hand at repairing assemblies and all, make sure you have the manufacturer's manual or the guidance of an experienced mechanic, so that the repairing goes smoothly for you! Good luck!