Do-it-yourself old jack repair

In detail: do-it-yourself repair of an old jack from a real master for the site my.housecope.com.

The jack is quite widespread. They are in the arsenal of almost every motorist, they can be useful when carrying out various work in the workshop. There are several types of such a mechanism, in this case we will pay attention to the hydraulic one. Such a tool transmits force by compressing the fluid. The complexity of the mechanism and its application in difficult operating conditions determines the need for repairs. You can repair the hydraulic structure with your own hands, but all the features of this process should be taken into account. Consider how to repair a hydraulic jack and what the features of this process may be.

Repair of a hydraulic jack

The design of a hydraulic jack can vary significantly. Many professional models can last for a long time, but certain reasons can lead to a serious defect.

Hydraulic trolley jack

Faults in the hydraulic jack can be attributed to the following problems:

Many causes of hoist failure are the result of improper use of the device. In addition, some hydraulic jack models require periodic oil changes. These and many other points are taken into account when reviewing the operating instructions.

Do-it-yourself repair of a hydraulic jack can be done in your own workshop if you have the required materials and tools. It should be borne in mind that some versions of the lifting mechanism are represented by non-separable structures, and it will be rather difficult to carry out repair work. The hydraulic jack should be disassembled taking into account the peculiarities of its design. This may require the following tools:

Video (click to play).

Hammer and chisel.
Pliers.
Screwdrivers with different diameters.
Hacksaw.
A set of keys and a gas wrench.

Necessary repair tools

There are just a huge number of varieties of hydraulic jacks, so it's difficult to say exactly which tools you may need to get the job done. In some cases, the possibility of easy access to the internal mechanism for maintenance or repair is provided, in others it will take quite a lot of free time to sort it out.

As for the materials, it all depends on what kind of malfunction in the structure. very often seals that are made of plastic or rubber fail. Quite a lot of difficulties can arise with their selection, since even a small gap can lead to the passage of the working fluid into the upper chamber (leading to a drop in pressure). If we consider damage to the rod or glass, then such malfunctions are solved only by replacing the entire element.

When considering how to disassemble a hydraulic jack, consideration must be given to design features. The force in all cases is transmitted through oil, which has a low compression ratio. As previously noted, in order to ensure the long service life of the device under conditions of frequent use, an oil change should be carried out, as it can lose its performance over time.

Hydraulic jack device

The device of a rolling jack does not differ significantly from the usual persistent one.The working part is done using similar principles. It should be borne in mind that the design largely depends on what the carrying capacity is. Some models are equipped with a threaded extension that allows the initial lifting height to be initially adjusted.

A hydraulic jack with your own hands can be repaired in the event of a malfunction of the auxiliary elements or the main working part. In most cases, problems arise precisely with the working part. The classic version is represented by a combination of the following elements:

A piston that has O-rings. It is on him that the pressure is exerted by the liquid. Due to the combination of a huge number of seals made of different materials, the piston does not allow oil to pass through, even when high pressure occurs. In addition, the structure itself is designed for high loads. The use of rubber seals allows the element to be movable.
Cylinder with seals. It is the cylinder that creates the working cavity in which pressure is exerted on the rod. In order to reduce friction during the stroke of the moving element, the surface is polished to a mirror-like state. In the manufacture of this element, materials with high corrosive properties are used. The appearance of even insignificant rust leads to the fact that the moving part begins to wear out quickly. The outside of the cylinder is cast iron, which is highly susceptible to shock loading. Therefore, you should handle the tool in question carefully.
Power rod. This element is connected to the piston and is set in motion. It is the rod that perceives the load that occurs between the lifted object and the piston. High-quality steel is used in the manufacture, designed for high load. To extend its service life, the surface is chemically treated to provide corrosion resistance. It should be borne in mind that when using a hydraulic jack in violation of operating recommendations related to permissible loads, the rod is curved. Such a malfunction is extremely common.
Passage channel systems. In order to supply and remove oil from the working chamber, passageways are required. They are small and can become clogged over time.
A plunger pump that provides pressure. Most of the mechanical-type devices provide for manual pumping of liquid into the working area. The plunger pump device is characterized by high reliability, rarely fails.
A bleed valve is used to remove liquid from the working chamber. Such a structural element can be implemented in different ways. As a rule, this is a small screw, when turned, due to the pressure exerted on the stem, all the liquid is removed from the working chamber.
Cuffs and seals. These elements provide insulation for the working chamber and other structural elements. They also provide mobility of the piston rod. In the manufacture of cuffs and seals, plastic materials are used that are highly resistant to mechanical stress or the effect of the applied oil. Important indicators of seals are their outer and bore diameters, as well as rigidity and wear resistance. Finding a suitable replacement option is in many cases quite difficult.
Filler hole to maintain the required oil level in the system. From time to time it is necessary to add oil to maintain the required level. As a rule, when the hydraulic jack is used intensively or when it is transported in the wrong position, the hydraulic fluid level drops. Some device models have an oil level indicator.

Rolling jack device

In general, we can say that the design is quite simple, but it has many rubbing elements. Many manufacturers create collapsible designs when the seals on the stem are fixed with a nut or other fastener. It should be borne in mind that there are also non-collapsible versions, the repair of which is several times more complicated.

Repairing a jack in most cases is quite simple, provided you have the necessary consumables. It should be borne in mind that the appearance of corrosion on the surface can significantly complicate the task. Therefore, you need to purchase a special liquid for removing corrosion and oxidation.

Do-it-yourself repair of a sliding hydraulic jack can be conditionally divided into several main stages:

The essence of the problem is determined. If the structure does not hold pressure, then there is a high probability of wear on the seals. In the case when the lift occurs with difficulty, that is, the possibility of deformation of the stem or the occurrence of other problems.
A complete analysis of the structure is carried out. At this stage, the main thing is not to damage the fasteners. It is worth remembering that during the supply of pressure, the working cavity must contain it. Even a minor defect can cause leakage and pressure drop.
An inspection of the integrity of the main elements is carried out. In most cases, the cause of the problem can be determined by visual inspection of the structure. For example, seals can have recesses, grooves and other deformations, a slight bend in the stem, low flow channels due to the accumulation of soot and dirt.
After determining the cause of the malfunction, you can repair the rolling jack.

In most cases, the hydraulic jack can be repaired as follows:

After disassembling the structure, the internal cavity is cleaned from various debris. In addition, the oil used will have to be completely replaced.

The seals can be removed in various ways. As a rule, there is a fixing element, due to which the immobility of the elastic bands is ensured during the operation of the device. It is worth considering the sequence of the arrangement of rubber bands and seals of various types. Incorrect installation may result in the device not holding pressure.

As previously noted, stem curvature and damage to the mirror surface cannot be corrected on your own. Too much wear and tear leads to the fact that it is necessary to replace the entire element or the lifting mechanism itself.The bottle-type hydraulic jack has an even simpler design. As a rule, it does not require any adjustments. Therefore, after assembling it, you can start testing and subsequent operation, provided there are no problems. Some manufacturers of lifting mechanisms provide instructions on how to disassemble the device and carry out repairs. Its use can significantly simplify the task. Image - Do-it-yourself repair of an old jack

The repaired hydraulic jack must first be checked for proper operation. This is due to the fact that frequent use with improper installation of seals or other mistakes will lead to rapid wear of the main elements. Therefore, you should provide for the presence of insurance in the event of lifting the car or other mechanisms. With the correct repair work, you can significantly extend the life of the hydraulic jack.

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In order to repair the hydraulic jack as little as possible, you need to monitor the product and operate it correctly. Maintain the correct level of fluid that seeps through the seals. Often, due to the ingress of air, the load is jammed while it is being lifted. Then difficulties arise when it is lowered. In these cases, the jack needs to be disassembled and repaired.Carry out it really on your own, observing a certain sequence of actions.

The hydraulic jack consists of 3 parts:

At the beginning of operation, the mechanism is placed on a flat surface, the valve closes and, due to the movement of the lever, the stem is lifted. On descent, the valve opens and the pressure of the weight returns the stem to its place.

When the lever is pressed, fluid is pumped from the housing into the cylinder, pushing it up. The suction and discharge valves prevent it from returning.

When the valve in the pump opens, the fluid returns to the housing space.

Bottle jacks have the ability to lift loads ranging from 3 to 200 tons. This is ensured by the presence of a large support plane.There are 2 types of bottle machines:

Single-stem. Due to their ease of use, they are used in mechanical engineering and construction. The jack is adopted by motorists - for lifting cars. Used as a knot in a pipe bender or press.

Double-headed. Works both vertically and horizontally. The device includes 2 rods. They are lifted up by a cylinder.

Externally, it is a cart mounted on wheels. Before work, it rolls up under the load being lifted.The design is large in size, so it is used in tire shops. Lifting is done by pressing the lever. When the valve is opened, the stem is lowered.If a slight lowering is required, a tubular handle is used. It fits onto the valve screw and rotates it around its axis. A slight decrease in the stock begins.

This type of product has disadvantages:

Large dimensions and heavy weight of the product.

The presence of a concrete or asphalt site.

Do-it-yourself repair of a hydraulic jack. For this, all possible malfunctions and the rules for their elimination are studied. Parts are prepared in advance - to replace those that have failed. The main causes of breakdowns and the rules for their elimination are known. To do this, you need to have a suitable tool at hand.

Before filling with new oil, the old one is completely removed. If flushing liquid is present, it is also removed.

Before filling in a new one, all the air present is eliminated. The outlet valve opens and the device goes down. Then you should carry out at least 5 pumping. The bolt is removed from the filler neck and oil is poured through the nozzle to the required level. Then the pumping is repeated, and the oil is poured again. It is important to bleed all air from the system. As soon as the oil surface stops bubbling and reaches the desired mark, the jack is ready for use.

If the jack is properly operated, the number of breakdowns will dramatically decrease.

To do this, you need to adhere to the following rules:

It is forbidden to lift a load exceeding the permissible one.
The work is carried out smoothly, without jerking.
Installation can only be carried out on a flat surface.
Before work, all movable joints are lubricated.
An external examination of the device is carried out in order to detect cracks or oil leaks.
The oil level is checked and must be brought up to normal.

A monthly maintenance is required to keep the hydraulic jack running smoothly. Since the product is constantly subjected to heavy loads, all parts require the presence of lubricant. It is important to avoid the presence of dirt, which leads to jamming of the apparatus. The device is stored in a lowered state.

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Today, it is impossible to imagine carrying out a car repair, whether it be changing a wheel or repairing a suspension, without the use of jacks - special devices that are designed to lift the load and fix it at a certain height. And today, the most popular are hydraulic jacks, in which the force is created using a piston and a working fluid.

The main elements in the design of a hydraulic jack are:

metal case;
hydraulic piston;
working fluid.

The hydraulic jack can have a regular body or an extended body made of hardened metal. The body performs the following functions: it is a reservoir for working oil and acts as a guide cylinder for the piston.

This type of unit is equipped with an air, foot or hand operated hydraulic pump. The design of the jack contains safety valves and other devices to maintain trouble-free and long-term operation.

Retractable hydraulic cylinder and lifting mechanism, which raises a special platform, are located in the holes of the case. Lowering is done by turning the T-handle. The design has built-in wheels that provide the device with mobility. The extended body of the shooting gallery is usually used to work with heavy vehicles and buses.

Any hydraulic lifting mechanism works using a fluid on the principle of communicating vessels. Before work, you need to install the unit on a solid and level surface under the machine and, with the valve closed, hold down the lever until the car reaches the required height. The descent of the machine occurs by opening the valve located on the jack body.

Working hydraulic oil pumped by the drive pump using a lever. The fluid moves into the cylinder through the valve, squeezing it out. The oil return outlet is prevented by two valves - suction and discharge. In order to lower the jack, you need to open the valve on the pump, in this case, the liquid from the cylinder goes back into the housing.

The presence of threads on the body, protected by a special casing, threaded holes in the base and threads on the stem, guarantees unlimited work of the jacks and the possibility of using it for bending, clamping and crimping.A reliable support made of hardened metal and mounted on the stem protects the hoist from damage. The grooved part of the base prevents the vehicle from slipping.

Hydraulic jacks considered the most unpretentious... The main feature of hydraulics is an incompressible working fluid. As a result, the load is lifted smoothly, braking accuracy and fixation at the required height. Hydraulic jacks have excellent efficiency - up to 85% and high lifting capacity - over 250 tons with little effort, thanks to the high gear ratio between the surfaces of the cylinder and the pump plunger.

But hydraulic hoists have a much higher initial lift than mechanical hoists. Another difficulty is the impossibility of precise adjustment of the lowering height. To support the jack in the working position, it is necessary to constantly monitor the tightness of the oil seals and valves, as well as monitor the oil level. Store and transport these units only in an upright state, otherwise liquid may spill out of the case.

Disadvantages of hydraulic jacks:

They are rather slow.
They are large and heavy.
High price.
Small travel for single piston jacks.

The construction of the hydraulic vertical jack is the simplest. The area of use of these jacks is quite extensive due to the significant range of the lifted load - from 3 to 200 tons. Bottle jacks are used in trucks. In addition to the main advantages of a hydraulic jack, bottle models have a few more - a large support area, compactness and versatility of use.

Vertical jacks can be double-stem and single-stem. The single-stem device is characterized by ease of use and simplicity of design, which expands the scope of its use and makes it possible to perform work of varying complexity:

dismantling and installation in construction and mechanical engineering;
repair of wheels of cars and cars;
use of a pipe cutter, pipe bender, press and similar tool as a power unit.

The double-rod telescopic jack has a similar structure with the vertical one, the principle of the bottle mechanism is based on the installation of several rods. The piston is located at the base of the telescopic device. It can be used vertically and horizontally. It fits most cars and has a small size. Lifting takes place using a lifting lever, which is brought to the working position by a cylinder.

This type of jack works on the same principle as a vertical jack, but with the difference that the cylinder is not in a vertical position, and the piston is not directly aligned with the pickup. This device is called trolley due to the fact that it is a cart on wheels that can be rolled over the surface. The jack moves while lifting the lever and picking up or "Rolls up" under the load.

This jack is set in motion, like bottle machines, by swinging the lever, and also lowered by unscrewing the valve screw. If it is necessary to lower the weight, then it is necessary to put the tubular handle on the valve screw, then the partition enters the groove of this screw. By turning the handle around the axis, the operator also rotates the screw, thus reducing the pressure in the cylinder and lowering the car to the required height.

As a rule, a rolling jack is used at a tire station, since it is ideal for lifting one side of a car, it is quite quick to install and work. The disadvantages of this design stem from the name - for the trolley hoist to operate, a firm and level surface, asphalt or concrete is required. In addition, the large weight and size make it difficult to transport the device in the car.

Rolling jacks are divided by purpose:

For personal use of passenger cars with a carrying capacity of up to three tons.
For tire and car services, with a lifting capacity of up to four tons and with the installation of pre-lift arms to quickly reach the required lift height.
For special vehicles and for the maintenance of heavy vehicles with a lifting capacity of up to twenty tons and with the installation of pre-lift levers.

Hydraulic lifting devices need periodic maintenance, therefore, oil must be added to the working cylinder, which flows out during operation through all kinds of seals and oil seals. In addition to the question of how to pump a hydraulic jack with your own hands, problems can also consist in jamming while lifting the car to the required height, as well as the inability to lift even a light load or the inability to lower the piston after lifting.

To test or repair the jack with your own hands, you must purchase the required repair kit... Before repairing, you must first disassemble the unit. To do this, you may need a key extension to get more leverage and more force. Also, be sure to prepare a container for used oil and prepare a new one.

Then you need to get the pistons and check them for corrosion. All corrosion and dirt must be removed. Make sure the stem is not bent. If the deformation still occurs, then it is unlikely that you will be able to align it again, so you can finish the repair with your own hands on this.

It is also worth checking the valve that transfers the oil. Why it is unscrewed and checked for dirt or deformation. If the valve is broken due to mechanical deformation, then it simply needs to be replaced. In this case, it can simply clog up, and the ball begins to sit loosely in its place. This is the reason for the oil leak.

Pour out the old working fluid completely. This is a fairly simple procedure, although it will take you a long time as the liquid flows through the cylinders. The oil is drained by bleeding the system by moving the lever up and down. Thoroughly wash all elements from oil and dust residues. Fully replace all seals and cuffs.

Another reason for jack breakage is dirt that gets into the working mechanism. To remove it, you need to unscrew the head of the case, pour kerosene into the base and pump the jack with the shut-off needle unscrewed. At the end of the operation, kerosene must be removed and new oil must be poured into the working part.

During prolonged operation, air bubbles accumulate in the working part of the jack, significantly reducing its operation. The repair of this breakdown occurs in this way.

First unscrew the bypass valve and the oil tank cap, and then at a fast pace pump the pump several times... Thus, the air will escape from the working part into the oil tank. After that, you can close the hole that leads to the oil tank and the bypass valve. If everything is done correctly, the air will escape, and the device will work normally again. If the attempt is unsuccessful, repeat these steps.

So, you got acquainted with the device of a hydraulic jack, studied its advantages and disadvantages, figured out the classification and know how to repair a hydraulic jack with your own hands. The main thing is to remember during its operation about periodic filling of working fluid and maintenance.

The jack is one of the most important tools in the arsenal, it will help everywhere: repairing a machine or equipment, carrying out a variety of construction and repair work. And if suddenly your device is out of order for some reason, you need to learn how to repair a hydraulic jack with your own hands!A wide variety of jacks will also please, each of which has its own characteristics and distinctive features. Image - Do-it-yourself repair of an old jack

Like any equipment that carries huge loads, devices can often break down, and therefore you always need to know how to repair the jack yourself. To be fully armed at the time of a breakdown!