Embarking on the task of rebuilding a hydraulic cylinder without giving due attention to safety precautions is a critical mistake. The process, though technical and intricate, involves handling heavy components and dealing with high-pressure systems, where the margin for error is slim, and the consequences of negligence can be severe.

With competitive price and timely delivery, EOOE sincerely hope to be your supplier and partner.

The first step in ensuring safety is equipping oneself with the appropriate gear. This includes sturdy gloves to protect against hydraulic oil, which can be harmful to skin, safety goggles to guard against any flying debris or oil splashes, and steel-toed boots to prevent injuries from heavy parts. Remember, hydraulic fluid can be slippery, creating a hazard in the work area.

Another often overlooked aspect is the lockout/tagout procedure. This is essential to ensure that the equipment is properly shut down and de-energized before any service or maintenance begins, thereby preventing accidental activation of the system. 

Additionally, when disassembling and reassembling the cylinder, be mindful of the potential for stored energy in the form of compressed springs or pressurized fluid. Releasing this energy unexpectedly can lead to parts moving suddenly and forcefully, posing a significant risk.

Moreover, the use of proper tools and techniques during the rebuild process is part of safety too. Using inappropriate tools or methods can not only damage the cylinder but also increase the risk of personal injury.

A common misstep in the process of hydraulic cylinder rebuilding, which often goes unnoticed, is inadequate cleaning before disassembly. This oversight can lead to significant issues, as the presence of dirt, grime, and old hydraulic fluid can contaminate the internal components during the rebuilding process. Such contamination can cause abrasion, accelerate component wear, and compromise the integrity of seals, leading to inefficiencies and potential failures.

The role of thorough cleaning in preventing contamination is paramount. Before any disassembly begins, it’s crucial to remove all surface contaminants. This involves using a degreaser and a non-abrasive brush to meticulously scrub the cylinder’s exterior, paying particular attention to crevices and joints where contaminants tend to accumulate. 

Once the external cleaning is complete, the focus shifts to the interior. Flushing the interior with a suitable cleaning fluid is essential to remove old hydraulic fluid, which often contains metal particles, rubber from degraded seals, and other debris. After disassembly, each component should be individually cleaned. For metallic parts, ultrasonic cleaning can be highly effective in removing even the most stubborn contaminants. Non-metallic parts, such as seals and O-rings, should be gently cleaned with a solvent that doesn’t degrade the material.

How to identify a Hydraulic Cylinder?

One of the biggest questions asked in the hydraulic cylinder industry is how to identify what cylinder you have. The answer is a lot simpler than you would think. There are two ways to identify a cylinder.

The first way is by the part number. Typically, there will be a stamp or a plate on the cylinder with a 5 to 10 digit part number on the cylinder. Also, finding out the manufacturer will help a great deal. Xtreme Cylinders references over 60,000 part numbers so if you’re able to find a part number, feel free to give us a call.

Want more information on Multi Stage Hydraulic Cylinder? Feel free to contact us.

The second way to identify a cylinder is by dimensions. This is obviously more time consuming than finding a part number but by no mean is it difficult. In America, dimensions for cylinders are broken down in the standard system so you will want to use the unit of inches when measuring the cylinder. When getting dimensions for a cylinder, the first thing you have to do is find out if your cylinder is a single stage cylinder or a multi staged cylinder. If the cylinder is single stage cylinder the rod will stay the same size as the cylinder extends. If the cylinder is a multi-stage cylinder, the rod will decrease in size as the cylinder extends. Review the pictures below for examples of both types of cylinders.

*example of a single stage cylinder

*example of a multi-stage cylinder

If you find out you have single stage cylinder more commonly referred to as a standard cylinder, there are certain dimensions you will need. The first dimension you will need is the bore. The bore is the inside diameter of the cylinder. To measure the bore, you will want to measure the outside barrel of the cylinder with a caliper. With standard cylinders, typically the bore is about half an inch bigger than the outside diameter. For example, if the outside diameter of your cylinder 4.5 inches, you can assume the bore is 4 inches. While this way doesn’t always give you the exact inside diameter9da2, this is the closest you can get to figuring out the bore without knowing the thickness of the walls inside the cylinder.

Once you have the bore of the cylinder, you now need to find out what the rod diameter is. To do this, all you have to do is take the caliper and measure the diameter of the rod.

The next measurement you will need is the closed dimension. This dimension is measuring the center of the base pin to center of the rod pin when the cylinder is completely closed.

Once you have the closed dimension, it is now time to get the open dimension. The open dimension is measured the same way the closed dimension is, but the cylinder needs to be completely extended. The open dimension is the meaaba0surement of the center of the base pin to center of the rod pin when the cylinder is completely extended.

The next dimensions you will need are the pin-hole diameters. Many cylinders have rod pin and base pin holes with different diameters so make sure you measure both the base and rod pin.

Once you are finished getting all of these dimensions the next step is to find out what kind of mounting the cylinder has. There are a couple different mounting style but the main two with standard cylinders are clevis and cross tube mounting. Clevis Mounting looks the letter U and is often referred to as bunny ears.

If you want to learn more, please visit our website dual hydraulic cylinder.