How to repair hydraulic cylinders?

Hydraulic cylinders take a significant part of the entire hydraulic system. They are mechanical actuators that provide the unidirectional force. Integration of hydraulic cylinders will eliminate the presence of levers and gears. Both mobile (front end loaders, hydraulic lifts, construction vehicles, tractors, auto cranes,) and industrial systems (hydraulic presses, agricultural machines, marine equipment, forges, and packing machines) utilize hydraulic systems. Among them, most of the applications use hydraulic cylinders for lifting, sliding, picking and gripping.

Before performing the repairs, clean the surface properly and disconnect the hoses and plugs attached to it. Make sure that you work area is clean and neat. After disconnecting the parts, drain all the fluid present inside the cylinders and hoses. For repair of the hydraulic cylinder, we need some tools. Proper hydraulic cylinder seal kit, rubber mallet, screwdriver, punch, pliers, emery cloth, and torque wrench are the tools required for repairing. Leaking hydraulic cylinder is the most common issue that results in a cylinder repair. Disassembly of the cylinder, diagnosing the cause of failure, repairing or replacing faulty components, and rebuilding the cylinder are the steps involved in cylinder repair. During the process of hydraulic cylinder repair, always consider the below-mentioned cylinder repair tips.

• If you disassemble the hydraulic cylinder as a part of repair, inspect not only the failed part but also perform a thorough inspection of all other hydraulic cylinder components.
• Hydraulic wear bands (also called wear ring or guide ring) are used for guiding pistons. So, don’t forget to assemble the wear band because this will eliminate the metal-to-metal contact.
• Premature failure of rod seals indicates the bend or scratch on the hydraulic rod.
• Metal tools will scratch the surface of the cylinder rod or cylinder barrel and will create problems like corrosion. So always choose the best-fit tools for repairs.
• Larger hydraulic cylinders use high tension springs. Therefore, if you are an inexperienced hydraulic technician, be careful while handling such cylinders.
• For hydraulic cylinder seals replacement, don’t measure the existing size of the seal. It will expand or compress according to the environmental condition. The best option to replace seals is to contact your hydraulic equipment manufacturer and order a proper seal kit for the particular cylinder you need.

As a part of the scheduled hydraulic cylinder maintenance process, always check the chrome plated rod, cylinder seals, hydraulic cylinder tubing, cylinder gland and piston. During the inspection, if you found the hydraulic rod being damaged, remember that your system is under danger. The rough rod surface will increase friction. Therefore, the rod must be polished to lower the friction. These maintenance procedures will reduce failures to a greater extent.