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A bent rod from a hydraulic cylinder repaired by A1 Hydraulic Engineering reman rod re-rod

Top 4 Reasons Hydraulic Cylinder Rods Bend

A major failure for hydraulic cylinders is when the rod bends or buckles when in operation. Usually when a rod is bent it also damages the gland, and at times, the piston and bore too. Pretty much have the hydraulic cylinder to catastrophically fail. Why can the other parts fail? A hydraulic cylinder has specific engineered tolerances and clearances. The rod, gland, piston, and barrel bore are all ‘straight’ to each other. So when a rod has a bend in it, it’s centre axis is no longer inline or straight with the other component. This puts excessive loads to guide rings and bushes. The piston becomes ‘crooked’ and the gland gets damaged as it becomes a fulcrum for the bend. Retracting a bent rod into the cylinder does not straighten it again. The machine should be immediately stopped and the failed hydraulic cylinder repaired or replaced. So here they are… Top 4 Reasons Why Hydraulic Cylinder Rods Bend Rod diameter too small Inadequate rod material strength Improper cylinder mounting arrangement Machine misuse/abuse by the operator What You Can Do About It If there are loads greater than the rods ability to withstand bending or buckling, then a new rod should be manufactured with an increased diameter and/or higher material strength. For reason No.4, it just comes down to operator training and care for the machine or attachment. If they are being used outside the manufacturer’s original design and operational intent then don’t be surprised if the hydraulic cylinders fail and the overall machine uptime and life is drastically reduced. How to spot a possible bend in a rod Here are some way you can spot a possible bend in a hydraulic cylinder rod: ‘Juddering’ during operation An audible sound during operation Oil leakage from seals Rod scoring Irregular rod wear patten What You Need To Do If you suspect that your hydraulic cylinder has a bend or needs attention, contact us today. Getting the cylinder looked at now is far better than putting it off and having catastrophic failure. Contact us now on 07 3800 8721 and a friendly team member will help you get the best solution. Contact us today Written by The A1HE Team Date: 26.04.2024

hydraulic cylinder on an earthmoving machine excavator that may have dieseling which can damage hydraulic seals and piston so you need to contact A1 hydraulic engineering to reseal, reman, remanufacture, manufacture hydraulic cylinders

5 Steps To Remove Air Form Hydraulic Cylinders

Whenever you are installing a hydraulic cylinder to your machine, you should always assume that some air will be introduced in the hydraulic system. You can lose oil during the process of disconnecting and reconnecting hoses, fittings, burst/craning valves, or even when installing hydraulic cylinder that’s completely empty. All these situations are not a problem when you understand what dieseling is. What’s dieseling? Simply put it’s the detonation of trapped air in oil when compressed. Just think about how a diesel engine works. Dieseling can damage pistons and the seals. Shortening the life of the hydraulic cylinder. It also means it reduces machine uptime. That’s why it best practice to bleed or remove air after any hydraulic cylinder service, when getting a new cylinder, or when there’s a possibility of air that’s entered into the hydraulic cylinders, Before You Start Check the machine’s maintenance manual for the procedure that’s specific or recommended for you. The below procedure is general guideline. You need to keep the machines’ engine at a low RPM/idle throughout the whole procedure. And be patient. Don’t rush this important process. Don’t run the engine at full noise and sudden control movements to fill the hydraulic cylinder quicker. You are only promoting for dieseling to occur. The 5 Steps Keep the engine at low idle and then… Step 1: For 8 cycles, slowly extended and retracted the cylinder through approximately 3/4 of the full cylinder travel. Do this for 8 to 10 cycles. Don’t let the cylinders reach the stroke ends (bottom out), in both directions. Step 2: Pause before you change direction for a minimum of 5 seconds. Step 3: Then, slowly cycle the hydraulic cylinders to the full extend and retract travel, while keeping the hydraulic pressure low. Step 4: Pause before you change direction for a minimum of 5 seconds. Step 5: Finally, check the hydraulic oil level and top up as needed. Getting Your Hydraulic Cylinder Serviced If your machines’ hydraulic cylinders are leaking, loosing efficiency, or if you suspect that dieseling has occurred… Contact us now on 07 3800 8721 and a friendly team member will help you get the best solution. Contact us today Written by The A1HE Team Date: 14.03.2024

hydraulic cylinders on an Excavator with grab attachment that A1 Hydraulic Engineering does service and repair and manufacture reman remanufacturing in earthmoving mining quarry civil and industrial

Hydraulic Cylinders…But Green!

Big changes are happening in the earthmoving industry. This isn’t just a shift in fuel preferences; it’s a new way to make equipment cleaner and more sustainable, significantly altering how we power our heavy machinery. Major brands are already taking the lead, experimenting with hydrogen fuel cells and hydrogen-electric systems to bring about a greener era. To top it off, a brilliant team in the University Of NSW have patented a Hydrogen-Diesel Direct Injection Duel-Fuel System. This can make existing diesel engines use 90% hydrogen and have an 85% CO2 emission reduction! But here’s the twist – it’s not just about flashy new designs. A few industry giants are also revamping existing diesel-powered machines into hydrogen-electric powerhouses, trying out hydrogen-power on equipment. So Why All The Fuss? Unlike the traditional diesel and natural gas options, hydrogen is gaining popularity as a cleaner alternative. While electric machinery has been around, it’s not always the perfect fit for every job. Hydrogen steps in as a versatile option, delivering no emissions while maintaining the power, torque, and response time we’re used to with regular combustion engines. Here’s the amazing part – you don’t necessarily need an entirely new fleet to jump on the hydrogen bandwagon. Heavy machinery vehicles are being converted from diesel power to hydrogen-electric, showing that owners and managers can make a sustainable upgrade without a hefty price tag of an entire new fleet. And with the hydrogen market on the rise, earthmoving companies will have more options, from getting new equipment to tapping into the expanding hydrogen infrastructure. It’s not just about adopting a new method; it’s about reshaping how we look at progress in the heavy machinery industry. However, Here’s What You Should Know All these machines will still need to be serviced and maintained, including their hydraulic cylinders. Keeping your earthmoving machine’s hydraulic cylinders in top condition is vital to get the best efficiency and uptime. If your machine’s hydraulic cylinders are leaking, loosing power, or damaged, then don’t leave it any longer. For all your hydraulic cylinder enquiries and servicing call us on 07 3800 8721 and a friendly team member will help you get the best solution. Contact us today Written by The A1HE Team Date: 4.12.2023

An earthmoving machine cat caterpillar yellow grader in the minimg and earthmoving industry that A1 Hydraulic Engineering service and reseal and manufacture and reman and remanufacture hydraulic cylinders with electronic monitoring and service system

Will This Earthmoving Trend Take Off?

Ever wondered how you could enhance your machine’s performance and streamline your operations? Well, here’s the trend that’s growing with earthmoving machine manufacturers:  Electronic Machine Monitoring. In a nutshell, electronic monitoring allows you to keep a close eye on your machines in real time. You can use this technology the right way and change the way you operate, forever.  Or, will it end up like the app on your phone that’s rarely used but you know it does more stuff?    Imagine having the power to monitor fuel efficiency, track usage patterns, and even receive maintenance alerts, conveniently sent to your office or smartphone. It’s like having your own personal assistant. Now, you might be wondering, “Why should I look into machines with electronic monitoring?”  Game-Changer For Earthmoving Here’s why it can be a game-changer for earthmoving companies just like yours:  1. Earthmoving Efficiency: Know exactly how your machines are performing on the field. Find out the areas where you can better improve productivity, including the selection of attachment over another machine. 2. Maintenance Management: Never miss a beat by getting instant alerts about needed maintenance. Stay ahead of potential issues, minimise downtime and eliminate machine neglect.  3. Cost Efficiency: Monitor fuel usage and machine productivity. Get the extra help to cut down on operational costs and increase your overall profitability. 4. Safety Mindset : Monitor operator behavior and how the machine is treated. Build a safe working environment for your company.  5. Information In Real Time: Get all the data you need in real time. Manage your machines with ease. Improve your job site decision making. What It Means For You  At A1 Hydraulic Engineering, we understand the challenges faced by earthmoving companies. Whether you have an electronic monitoring feature in your machines or not, proper machine care should be your priority.  And the hydraulic cylinders are no exception. When your machine’s hydraulic cylinders are it top condition then your not going to get the unnecessary loss of energy that happens by decreasing efficiency. And with rising energy costs, having a mind set for machine care is as great company culture trait.   For all your hydraulic cylinder enquiries and servicing call us on 07 3800 8721 and a friendly team member will help you get the the best solution. Contact us today Written by The A1HE Team Date: 27.10.2023

resealing seals of various sizes and colours showing that A1 Hydraulic Engineering Hydraulic Cylinder Reseals Hydraulic Cylinder Repairs Hydraulic Cylinder Manufacturing

What You Should Know About Hydraulic Cylinder Seals

Hydraulic cylinder seals deteriorate over time due to many factors, and knowing the most common reasons behind this deterioration is vital for maintaining the performance and longevity of any hydraulic cylinder and the hydraulic system to your machine. Factors that contribute to seal deterioration include: environmental conditions, pressures, temperature exposure, and sealing materials. When a hydraulic cylinder is showing first signs of seal deterioration, such as leaks and loss of efficiency, then the best thing is to start planning to have it resealed. It is not uncommon for operators to ‘push’ the machine further and to work it longer – and even ignoring any signs altogether! Ways Hydraulic seals can deteriorate and fail 1. Extrusion: This occurs when high pressure forces the seal material to deform or extrude into gaps or clearances in the cylinder, compromising its integrity and sealing performance. 2. Compression Set: Over time, seals may lose their ability to return to their original shape after being compressed, ending up permanently deformed and loss of effectiveness. 3. Hardening and Cracking: Exposure to heat or extreme temperature, chemicals, or UV exposure can cause the seals to harden and become brittle, eventually leading to cracking or breakage. 4. Swelling: Some hydraulic fluids may cause seals to swell or expand, affecting its housing fit and sealing ability. 5. Contamination: Normal wear from repetitive motion is accelerated when contaminants, such as dust or abrasive particles, enter the hydraulic system and come into contact with the seals. When a hydraulic cylinder is showing first signs of seal deterioration, such as leaks and loss of efficiency, then the best thing is to start planning to have it resealed. Why You Shouldn’t Neglect These Signs Taking lightly any signs of hydraulic cylinder seal deterioration can have serious consequences. When seals start to deteriorate, they aren’t doing what their functions are for: sealing, guiding, wiping, and protecting. Leaking and bypassing seals leads to poor efficiency and the high risk of damage to the hydraulic system. The final result of neglect can be an expensive catastrophic failure to the hydraulic cylinder and system.   The best solution for hydraulic cylinder seal deterioration is to get it serviced. Inspect seals often for signs of leakage or damage. Seals must be replaced at the first sign of deterioration to prevent more problems. Use only high-quality seals that’s specific for the hydraulic system and following proper maintenance and operating practices, such as keeping hydraulic fluid clean and within recommended temperature and pressure limits, can help extend the life of seals.   What To Do Next For all your hydraulic cylinder enquiries and servicing call us on 07 3800 8721 and a friendly team member will help you get the the best solution. Contact us today Written by The A1HE Team Date: 5.10.2023


The Importance Of Regular Servicing

In the realm of industrial machinery and heavy equipment, hydraulic systems serve as the lifeblood that powers an array of operations. From construction machinery to manufacturing plants, hydraulics play a vital role in ensuring efficient and precise movements. However, like any complex system, hydraulic components require regular servicing and maintenance to operate at their best. The importance of having hydraulic parts regularly serviced cannot be overstated, as it directly impacts both the longevity of the machinery and the safety of the workers operating it. Enhancing Efficiency and Performance A well-maintained hydraulic system operates like a finely tuned orchestra, each component working in harmony to deliver seamless performance. Regular servicing ensures that hydraulic parts are free from contamination, such as dirt, debris, and moisture, which can lead to reduced efficiency and increased wear. Fluids need to be clean and at the right viscosity to ensure proper operation. Regular maintenance helps in identifying and rectifying potential issues before they escalate, thereby preventing costly breakdowns and downtime. Prolonging Lifespan Industrial machinery represents a significant investment, and extending the lifespan of these assets is of paramount importance. Neglecting hydraulic system maintenance can result in premature wear and tear, leading to component failures and the need for costly replacements. Regular servicing includes activities like fluid changes, filter replacements, and inspections to detect issues early. By addressing problems proactively, hydraulic systems can be kept in optimal condition, significantly extending their operational lifespan. Ensuring Safety Safety is paramount in any industrial environment. Hydraulic systems operating under high pressures can pose serious safety risks if not maintained properly. Leaks, ruptures, or component failures can result in hazardous situations for operators and those working in the vicinity. Regular servicing helps identify potential weak points in the system, ensuring that worn-out parts are replaced before they compromise safety. Adequate maintenance practices also reduce the risk of unexpected failures, protecting both personnel and equipment. Cost-Effectiveness While some might view regular servicing as an added expense, it is a sound investment in the long run. The cost of preventive maintenance is often significantly lower than the expenses incurred due to major breakdowns and repairs. Not only does regular servicing prevent unexpected downtime and production halts, but it also mitigates the need for emergency repairs that often come with a premium price tag. Furthermore, maintaining hydraulic parts reduces the risk of collateral damage to other components, translating into substantial cost savings over time. Environmental Responsibility Hydraulic systems rely on hydraulic fluids to function effectively. These fluids are susceptible to contamination and degradation over time. Neglected fluids can lead to leaks and spills that harm the environment. Regular servicing ensures proper fluid levels, reduces the likelihood of leaks, and promotes the responsible disposal of used fluids. By maintaining the integrity of hydraulic systems, businesses contribute to environmental sustainability and minimize their ecological footprint. Conclusion In the complex world of industrial machinery, hydraulic systems serve as the backbone of functionality. Regularly servicing hydraulic parts is not merely an option; it’s a necessity. Whether it’s maintaining efficiency, extending the lifespan of equipment, ensuring safety, or being environmentally responsible, the benefits of regular hydraulic parts servicing are multifaceted. By investing in proactive maintenance, businesses safeguard their operations, assets, and personnel, setting the foundation for sustained growth and success in a competitive landscape. Written by The A1HE Team Date: 13.8.2023