Hydraulic Cylinder Repair and Overhaul

As Prime Hidrolik, we provide repair, maintenance and overhaul of hydraulic cylinders used in a wide range from industrial plants to mobile construction machinery.

Why Is Hydraulic Cylinder Repair Important?

Hydraulic cylinders are exposed to heavy loads and harsh operating conditions in press machines, injection lines, cranes, construction machinery, agricultural equipment, mining and industrial automation systems. Wear over time, sealing problems and performance losses directly affect your production efficiency and operating costs.

With professional hydraulic cylinder repair you can:

• Minimize unplanned downtime
• Save on new cylinder investment costs
• Increase system efficiency and operating speed
• Reduce occupational safety risks

Prime Hidrolik meticulously analyzes your faulty or underperforming cylinders and restores them to a safe and long-lasting solution in the shortest possible time.

Prime Hidrolik’s Professional Approach

At Prime Hidrolik, every hydraulic cylinder repair and overhaul job is handled within a systematic process. The goal is not only to eliminate the fault, but also to restore the cylinder to its original performance and, if possible, make it even more efficient with design improvements.

1. Preliminary Inspection and Fault Detection

When the cylinders arrive at our workshop, they undergo a detailed preliminary inspection process. At this stage:

• The outer body, rod, connections and clamps are checked visually and with measuring devices
• Leakage, impact, bending, corrosion and surface damages are detected
• The fault history is evaluated by taking into account customer feedback and operating conditions
• If necessary, on-site inspection is carried out in the field

After this preliminary evaluation, a comprehensive quotation and repair plan is prepared and presented to our customer. After approval, the detailed overhaul process begins.

2. Disassembly, Cleaning and Detailed Inspection

The cylinder is disassembled into all its components and cleaned of heavy dirt, oil, rust and residues. At this stage:

• Rod surfaces, piston, cylinder tube and connection elements are carefully examined
• Tolerance checks are performed with micrometers, calipers, dial indicators and special measuring fixtures
• Worn or out-of-tolerance parts are clearly identified

The detailed inspection stage is of critical importance for determining the correct repair strategy and cost optimization.

3. Mechanical Repair and Part Manufacturing

According to the detected damages, the necessary mechanical operations are carried out. These operations include:

• Rod surface grinding and polishing
• Chrome plating or hard chrome renewal
• Cylinder tube honing and inner surface correction
• Repair or replacement of broken or cracked connection elements
• Renewal of loosened bearings and bushings

In cases where the damage cannot be eliminated by repair, thanks to Prime Hidrolik’s extensive machine park, new rods, tubes, pistons and connection parts are manufactured with high precision. Thus, even parts that can no longer be supplied by the original manufacturer can be reproduced.

4. Renewal of Sealing Elements

One of the most common problems in hydraulic cylinders is oil leaks and power loss arising from wear of sealing elements. During the overhaul process:

• All seals, o-rings, rod seals, piston seals and wiper seals are renewed
• Sealing sets suitable for operating pressure, temperature, oil type and environmental conditions are selected
• If necessary, the existing design is improved and more durable materials are used

High-quality sealing elements are one of the fundamental factors that ensure long-term efficient and trouble-free operation of the cylinder.

5. Assembly, Testing and Adjustment

After all parts have undergone the necessary operations, the precision assembly stage begins. At this stage:

• All components are assembled in accordance with torque values
• Correct oil filling and air bleeding are performed to prevent possible air entrapment in the system
• Required stroke and limit adjustments are applied

After assembly, the cylinder is subjected on the Prime Hidrolik test bench to pressure and function tests under conditions close to real operating conditions. During the test:

• Leak checks are carried out
• Pressure resistance and end-of-stroke behavior are observed
• Measured values are compared with manufacturer standards and technical criteria

Each cylinder that successfully passes the tests is delivered to the customer with a detailed inspection form and report.

Which Hydraulic Cylinders Do We Repair?

Prime Hidrolik has the equipment to perform repair and overhaul of hydraulic cylinders of many different types and sizes. The main cylinder types we service are:

• Single-acting and double-acting cylinders
• Telescopic hydraulic cylinders
• Mining, steel, cement and heavy industry cylinders
• Press and injection machine cylinders
• Construction machinery and mobile hydraulic cylinders
• Agricultural and forestry equipment cylinders

In addition to standard sizes, we also offer special solutions for special design and large-diameter cylinders. All the overhaul processes you need are planned on a project basis and managed by our expert engineers.

A New Cylinder or Repair Instead of Overhaul?

Many businesses are undecided between purchasing a new product and repair when faced with a faulty cylinder. As Prime Hidrolik, we evaluate both options in detail from a technical and economic perspective