Hydraulic Cylinder Repair & Re-chroming
Complete rod re-surfacing, barrel honing & zero-bypass seal rebuild
Restoring single and double-acting hydraulic cylinders to OEM tolerances with internal barrel micro-honing up to Ø 400 mm and 4.5m stroke.
- ✓Internal barrel honing up to Ø 400 mm & 4.5 meters stroke
- ✓Hard chrome plating & induction hardening of piston rods
- ✓High-pressure polyurethane, PTFE & Viton seal kit installation
- ✓5,000 PSI hydrostatic internal bypass & external leakage testing
Hydraulic Pump & Motor Overhaul
Precision lapping, rotating group rebuilding & dynamic flow testing
Comprehensive overhaul of axial piston, bent axis, radial piston, and vane pumps with dynamic displacement test stand calibration.
- ✓Axial piston, bent axis, radial piston, and vane pump repair
- ✓Micro-lapping of cylinder blocks, valve plates, and slipper shoes
- ✓Shaft replacement and dynamic seal pressure calibration
- ✓Full-speed flow rate, volumetric efficiency & cavitation analysis
Hydraulic Valve Calibration & Repair
Spool micro-machining, solenoid testing & pressure relief setting
Precision reconditioning of directional control valves, proportional solenoids, relief valves, and modular subplate manifolds.
- ✓Digital current & response time testing on 12V/24V proportional coils
- ✓Internal spool cavity re-honing and zero-leak centering springs
- ✓Pilot-operated relief valve and counterbalance pressure calibration
- ✓Subplate DIN 24340 / ISO 4401 mounting interface verification
Custom Design & Hydraulic Engineering
3D SolidWorks fluid simulation, block milling & bespoke systems
Custom hydraulic circuit design, bespoke hydraulic power units (HPU), integrated manifold blocks, and thermal heat exchange calculations.
- ✓Integrated hydraulic manifold design reducing external hose runs
- ✓Bespoke electro-hydraulic power unit (HPU) fabrication
- ✓Custom oil reservoir sizing with heat exchanger & filtration calculation
- ✓Full circuit schematics and 3D STEP models provided for OEM approval
Turnkey System Integration
Electro-hydraulic controls, PLC automation & turnkey machinery sync
Seamless integration of hydraulic power with electronic PLC controllers, pressure transducer feedback, and automated industrial machinery.
- ✓PLC control panel synchronization with proportional valve logic
- ✓Pressure transducer, digital flow meter & safety interlock wiring
- ✓Multi-actuator sequencing and synchronized dynamic motion control
- ✓Turnkey factory acceptance testing (FAT) and commissioning
Prototype Development & Rapid Sizing
Fast-track custom fitting fabrication & proof-of-concept testing
Rapid turnaround fabrication of custom hydraulic adapters, non-standard threaded connectors, and prototype manifold blocks with CMM verification.
- ✓Rapid multi-axis CNC sample machining in 5 working days
- ✓Coordinate Measuring Machine (CMM) optical dimension verification
- ✓Extreme burst pressure margin testing before tooling commitment
- ✓First Article Inspection Reports (FAIR) provided for engineering approval
On-Site Installation Support & Piping
Rigid tube flanging, hose routing & flush cycle de-contamination
Experienced fluid power engineers deployed to your plant for rigid steel tube bending, non-skive hose routing, and on-site commissioning.
- ✓On-site rigid hydraulic steel tubing bending and 37° flare assembly
- ✓Anti-vibration hose clamping and friction-free routing inspection
- ✓High-velocity projectile tube cleaning & system oil de-contamination
- ✓Full on-site hydrostatic proof pressure testing and commissioning
Technical Training Programs & Workshops
Certified hydraulic safety, hose crimping & preventative maintenance
Practical, accredited workshops for maintenance personnel covering hydraulic safety, crimp diameter micrometer calibration, and contamination control.
- ✓High-pressure fluid injection injury hazard prevention & safety protocols
- ✓Computerized hose crimp micrometer calibration & swaging workshops
- ✓ISO 4406 fluid cleanliness standards and off-line filtration management
- ✓Hands-on troubleshooting for pumps, cylinders, and proportional valves
Diagnostic Troubleshooting & Oil Analysis
Laser particle counting, moisture analysis & preventative audits
Rapid diagnosis of high-frequency pressure spikes, cavitation, oil thermal breakdown, and seal degradation with digital data-logging.
- ✓ISO 4406 laser particle counter fluid cleanliness code diagnostic
- ✓High-frequency digital pressure transducer data-logging for shock spikes
- ✓System filtration upgrade and off-line kidney loop sizing calculation
- ✓On-site field engineer deployment for emergency machine fault audits
Standardized 4-Step Overhaul & Engineering Cycle
Every hydraulic component undergoes rigorous diagnostic inspection, micro-machining, automated pressure validation, and certified documentation.
Diagnostic & Teardown
Precision inspection, dimensional CMM check, and ultrasonic cleaning of all components.
CNC Machining & Sizing
Re-honing, hard-chroming, micro-lapping, and genuine certified seal kit fitting.
Hydrostatic Validation
100% automated pressure proof testing up to 2,800 Bar with flow rate data-logging.
Certified Dispatch
Detailed test certificate generation, seaworthy crating, and 12-month quality warranty.
Frequently Asked Questions
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