Our HYDRAULIC Cylinder Repair Process – A Closer Look

The End-To End Hydraulic Cylinder Repair Process To OEM Standards

Decades of experience in hydraulic cylinder repair has shaped an OEM-quality process built for demanding industrial applications. Below is our end-to-end hydraulic cylinder repair workflow, showing why Berendsen Fluid Power is trusted across Australian industry for precision workmanship, reliable performance, and consistent turnaround.

Cylinder Disassembly

Our facilities feature heavy overhead cranes and special purpose disassembly equipment including hydraulic nut tensioning devices to handle very long, large bore cylinders. Our special purpose cylinder disassembly benches can accommodate cylinders up to 12,000mm in length and 600mm bore and can develop up to 90,000Nm nut tensioning torque and 20 tonne pull apart force.

Inspection / Evaluation

Cylinder condition is evaluated down to the micrometre through digital and manual measuring and testing equipment to assess tolerances, bore concentricity, rod straightness, crack detection, chrome hardness and thickness, and surface finish. Our extensive experience in cylinder failure diagnosis enables us to identify the underlying cause of wear or catastrophic failure.

Reliability Engineering

Through sophisticated simulation software, our in-house engineering department is capable of analysing stress concentrations in cylinder components to determine whether the material and component design is optimal for the application. Berendsen’s in-house engineers can then redesign components to significantly improve the reliability and longevity of cylinder components. New designs are tested and verified by computer simulation prior to manufacture, ensuring the long-term performance of every component.

Replacement Parts and Seals

Where original spare parts are not readily available Berendsen employs high-speed CNC machines and other devices to rapidly manufacture cylinder components in-house at our ISO 9001 certified manufacturing facility. Our engineering department utilises CAD design to ensure all manufacturing details conform to specifications and we have an extensive library of component designs for a wide range of equipment types. In addition, our close working relationship with seal manufacturer Hallite gives us access to a complete range of high quality standard seals. Where required, Hallite will design and machine seals to our exact specifications immediately, from a wide range of materials.

Machining and Reconditioning

Our knowledge of OEM specs and cylinder tolerances gives us the ability to accurately assess those parts that may be reused or reconditioned, and those that must be re-manufactured. Berendsen has the equipment and expertise on site to perform all machining operations to properly recondition cylinder components. Where possible, we may reclaim worn surfaces through welding processes utilising specialised jigs and rotators.

Hard Chrome Plating and Surface Engineering

As part of our comprehensive hydraulic cylinder repair process, Berendsen offers a range of in-house surface treatments designed to restore and enhance the performance of piston rods. Depending on customer requirements and the condition of the component, piston rods are reconditioned using specialised techniques to improve wear resistance and corrosion protection.

These treatments include:

• Hard chrome plating
• Nickel plating
• Thermal spraying
• Laser cladding
• Heat treatments

Key capabilities include:

• World‑class stripping and preparation lines with caustic and acid baths for thorough cleaning
• Custom 360‑degree horizontal rotation chrome plating tanks for hydraulic cylinder rods up to 12 metres
• Precision cylindrical grinding and linishing for surface preparation and finishing

With these advanced facilities, we ensure your hydraulic components are repaired to the highest standards of durability and performance.

Assembly

Our industry specific experience in longwall mining, heavy mobile equipment, mineral processing and manufacturing applications, combined with in-depth knowledge of precise cylinder assembly procedures, special purpose cylinder assembly benches and calibrated nut tensioning tools, ensure correct torque specifications are achieved.

Testing

Our facilities are equipped to test cylinders using a range of fluid mediums, including mineral oil, water glycol and solcenic fluid. Our testing facilities have the capacity to verify cylinder performance up to 600 bar static pressure. Berendsen is also capable of developing customer-specific testing procedures to verify cylinder performance under specified conditions, such as induced loads, using purpose-built cylinder test frames.

Painting and Finishing

Technician applying a protective, corrosion-resistant coating as the final step in our hydraulic cylinder repair process, delivering an OEM-quality finish ready for service.