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Join Date: Mar 2007
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Retrofitting of Hydraulic System

02/01/2012 1:26 AM

Hi,

I have a very old hydraulic system, almost 25 years old, which i need to retrofit bacuaise of inefficency and leakage.

As we cannot afford to go for completely replacing the system bcz of financial constraints, i need to do minimum modification.

Mainly i observe there is a continous leakage from manifold, even after we fix new Dc Valve and PR relief vale.

i dont have part number or drawing for the manifold to buy new or to modify.

is there anyway to replace this manifold and valve with any new system ?

i can afford change the valves according to new system.

Please propose me a better system for this retrofitting.

Ralish

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#1

Re: Retrofitting of hydraulic system

02/01/2012 3:32 AM

If you know who the manufacturer is, I would contact them for recommendations...If you don't, I would spend some time trying to figure out who the manufacturer is....It's hard to make specific recommendations on a generic piece of equipment...other than to say take it apart and refurbish or replace everything....In some cases this may not be practical....

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#2

Re: Retrofitting of hydraulic system

02/01/2012 7:57 AM

The porting on the control valve is it a industry standard? Porting has designations like DO3,DO5,DO8. The DO8 is the one for a hydraulic pilot activated valve. You can get the specs from for these standards and match it to the valve.http://www.magnaloy.com You can replace both control valve and manifolds with industry standards. There will be a change in the porting and mounting that you will have to deal with.

If the leak is not coming from between the valve and the manifold replacing them will not be the solution. Before this expense find the source of the leak. Steam clean or pressure wash it down. Then run it and locate the source. It maybe just a hose. After years of service the inner core on a hose gets brittle. Movement or vibration can crack this core. You will get minor seepage. Some of those fitting look like copper. Copper is soft and vibration will work the threads where they are screwed into the manifold. Replace them with steel. There are also hydraulic sealants that can be used to seal the threads to the adaptors in the block.

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#3

Re: Retrofitting of Hydraulic System

02/02/2012 12:17 AM

New gaskets, o-rings, seals, compression shims.....and a good quality "oil" resistant sealant applied only where permissible together with correct assembly practices should tidy that up.

New hoses too while you are at it.

Following the previous advice on cleaning prior to disassembly will make the job a lot easier and aid in successful leak amelioration.

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#4

Re: Retrofitting of Hydraulic System

02/02/2012 10:11 AM

You speak of inefficiencies, as well as leakage. As stated above, the leakages should be fairly easy to isolate. But if the leakage is from corrosion in the manifold, it may require replacement id severe. If that turns out to be the case, I would find a hydraulic repair facility that is well established, and local. Take some advice from the people that will be able to service it after instalation. There are packaged hydraulic systems that include pump with reliefe valve and reservoir that would connect to your existing motor, or engine. You would then need to add the specific valve system you are using to it. This is where the local hydraulic repair facility would be helpfull in determining the size requirements for you. Good luck.

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#5

Re: Retrofitting of Hydraulic System

02/03/2012 10:54 AM

Manifold part number or detail drawing may not necessary to make spare manifold. Any hydraulic system supplier can make manifold if schamatic diagram and valve model numbers are available. It seems to be simple one with one directional valve and pressure relief valve (position of relief valve is not clear from the description, it can be in P line or port line). Standard subplates and connecting piping can also replace this old manifold.

It will be helpful if you can give valve model number and functional details of application.

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