Hydraulic Cylinders

and Cylinder Systems

for Mobile Hydraulics

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HYDROSAAR, part of the global
HYDAC group, develops and
manufactures a broad range of
hydraulic cylinders and cylinder
systems for mobile applications.
Drawing on our knowledge base,
we develop the most appropriate
hydraulic cylinder solution for
your application. For example,
innovative position sensor
technology can be installed, or
the cylinder piston rods can be
supplied with special surface
coatings. Our cylinder engineering
includes design and calculations
performed with cutting-edge 3D
CAD and FE tools.
Each cylinder is optimised
individually to fulfil the customer’s
specific requirements.
Hydrosaar has been engaged
in mobile hydraulics for more
than a decade, supplying
global manufacturers of cranes,
construction machinery,
agricultural machines and special-
purpose vehicles.
Production capabilities:
z Cylinder strokes up to
12,000 mm
z Piston diameters
up to 600 mm
z Differential cylinders
z Synchronising cylinders
z Plunger cylinders
z Telescopic cylinders
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Your Partner for Expertise. Cylinder solutions for all
For cylinders and cylinder systems customer requirement
in mobile applications
Engineering expertise At a glance
Development / design / strength calculation / testing Telescopic systems
To fulfil the stringent requirements z Single-cylinder telescopic systems
required of the final product, we z Securing locking system
employ the latest technology: z Telescopic guide system
z 3D design
z Controller
z Finite element calculation for
optimised design
z Structural analysis
z Non-linear stability calculations
z Structural durability analysis
Boom, outrigger
and special cylinders
Surface treatment processes z Weight-optimised, space-saving
design
z Electroplating
z High-speed flame spraying and plasma z Integrated valve technology and
sensors
spraying (metallic and ceramic coatings)
z Induction melting of compound layers
z Laser-welded and plasma-welded layers
z Customised paint finishes (corrosivity
categories up to C5-M)
Mining and
excavator cylinders
z For high dynamic loads
Lightweight z Structurally durable design
z Weight-optimisation
z Use of high-strength steel materials
z Use of light metal and fibre-composite
materials
Functional safety – integrated sensors Suspension and
The technical requirements with regard to
functional safety are based on the
accumulator
standards IEC 61508 and EN 13849.
EN 954-1 EN 13849-1 IEC 62061 IEC 61508
cylinders
Machinery industry
HYDAC provides: (electronics, hydraulics, pneumatics, mechanics) z Cylinder-integrated accumulators
Controllers certified to
- IEC 61508, SIL 2 (3) - EN 13849, Pl d (c) z Combined cylinder/accumulator
Other components for applications with increased solution
functional safety z Self-supporting suspension struts
- Sensors - Valves
Support provided throughout, from risk analysis
to certified machine function
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 Cylinders
for mobile technology.
Light. Compact. System-based.

Production expertise

Manufacturing techniques
Cutting-edge machine equipment that can be
used for all kinds of machining work:
- Deep-hole boring
- Turning (CNC, NC and conventional)
- Honing
- Milling
- Grinding
- Welding CNC lathe (12 m turning length) Automated submerged-arc welding system

Assembly and test bench

z Cleaning and cylinder-assembly equipment
z PLC-controlled hydraulic test benches for test
pressures up to 1200 bar
z Function and fatigue test benches

Paint application
Cutting-edge paint technology for protection
against wear and corrosion.
z Sandblasting
z Cleaning
z Painting
z Drying

Quality assurance
Top quality is guaranteed by constantly
monitoring all processes (from design to
assembly), inspecting individual parts as well
as finished products, monitoring of measuring
equipment and contamination monitoring of the
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hydraulic oils used.
Consistent quality is the result of very close
collaborative relationships with customers and
suppliers.

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 Telescopic systems
for mobile cranes

Telescopic systems
In modern mobile cranes, the main boom is extended and retracted by a single-cylinder
telescopic system.
The systems are made up of the following main components:
z Double-acting hydraulic cylinder in lightweight design
z Guide frame
z Securing locking unit (SLU)
z Hydraulic accumulator unit including valve control Control and display
z Internal oil feed z Telescopic guide system adapted to suit specific cranes
z Telescopic boom and position detection z Reliable, flexible HY-TTC 90 controller, certified to
z Position sensor system (optional) ISO 13849
In addition to customised systems, a system with the in-house developed SLU is available. z Universal mobile display with integrated HY-eVision controller
Operating pressures: up to 350 bar z Customised control and visualisation software based on standard modules
Stroke: up to 12,000 mm

Advantages and features: Advantages and features:

z Complete hydraulic/mechanical/electric z Complete telescopic system package including control
system from a single source z Specific interface programming
z Flexible cylinder sizing z Customised visualisation
z Cylinder and SLU produced to customer z On-site commissioning support
specifications or our own design
z Minimal cylinder weight

Telescopic systems for mobile cranes

Securing locking unit – base mounted

Universal mobile display

with integrated HY-
eVision controller

Flexible HY-TTC 90
mobile controller

Flexible HY-TTC 500

mobile controller
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Functional Safety Functional Safety
PL d PL d
SIL 2 SIL 2

Telematic system
Controllers and visualisation

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 Boom, outrigger
and special cylinders
Boom cylinder
The boom cylinder alters the angle of main
booms and jib booms on cranes and construction
machinery. As the weight is generally restricted
by permissible axle loads, boom cylinders
are designed to be lightweight. High-strength
materials are used and modern calculation
methods are applied to optimise the design of
the cylinder components. The piston rods are
normally manufactured from hollow tubes.
Seal and guide systems ensure the cylinder
moves evenly with little friction and the load is
held leak-free over the entire operating-pressure
range.
Counterbalance valves or load-holding valves
can be integrated into the cylinder or into blocks
installed directly on the cylinder.
Hydrosaar manufactures boom cylinders with
piston diameters of up to 600 mm and strokes
of up to 9000 mm.
Special cylinders for cranes
Hydraulic cylinders are used for various special
purposes in cranes, for example to lift or move
counterweights, as mast fall-back prevention
cylinders or bolting cylinders, to extend or raise
masts or also to tension crawler tracks. The
cylinders are developed and produced in line with
customer requirements, as appropriate for the
particular task. Hydraulic valves, sensors and also
integral tanks are frequently integrated directly
into the cylinder.
Benefits and special features:
z Weight-optimised design
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z High-strength materials used
z Integrated valve technology
z Integrated anti-rotation piston rod
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Cylinders for vehicle outriggers
Mobile cranes and special-purpose vehicles
that support and move loads have outriggers
installed on the vehicle frame. Several cylinders
are normally used for extension, pivoting and
support. Like the boom cylinder, the cylinders are
lightweight and meet strict requirements regarding
leak-tightness. Hydrosaar provides solutions
with integrated sensors, particularly position and
pressure sensors, to satisfy the most stringent
requirements for comfort and safety (in line with
EN 13849).
Outrigger cylinder for mobile crane with special mounting
Lightweight boom cylinder for telescopic crane
Benefits and special features: Benefits and special features:
Boom, outrigger and special cylinders for cranes
z Lightweight design z Outrigger cylinder for static pressures of up
z High-strength materials used to 600 bar with integrated valve technology
z Special seals prevent any leakage z Extension cylinder, single- and multi-stage
z Integration of valve technology z Complete cylinder systems for special-
purpose vehicles and crane outriggers
z Structurally durable design
z Corrosion-resistant piston-rod coatings
Two-stage horizontal cylinder for outrigger
Steering and suspension cylinders
In the chassis of mobile cranes and construction
machinery, hydraulic cylinders are used in
steering and suspension functions.
Hydrosaar suspension cylinders and steering
cylinders boast low-friction guide & seal systems
and coatings tailored to suit the operating
conditions. Integrated position sensor systems
from the HYDAC HLT series and HYDAC
pressure sensors are available for the cylinders.
The suspension cylinders can be supplied with
Mast fall-back prevention cylinder with integrated valves, integral tanks and
accumulators integrated into the cylinder as well
anti-rotation as external accumulators.
Steering cylinder with integrated position sensors
In addition to offering cylinders as components,
HYDAC also manufactures complete suspension
and steering systems.
Benefits and special features:
z Integration of accumulator
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z Low-friction design
z Integrated end position damping
z Integrated position sensor technology
Counterweight cylinder with integrated valve technology
 Construction machinery
and mining

Excavator cylinders Road construction machinery

Cylinders used in excavators, particularly large Hydrosaar supplies cylinders for road construction
excavators and mining excavators, have to demonstrate machinery which meets the strictest standards for
a high degree of robustness and availability. durability and functional efficiency. The cylinders are
Hydrosaar supplies boom, stick, bucket, jaw and tailored to suit the construction machine to make the
track-tensioning cylinders. The cylinders are designed best use of the available space. If desired, the cylinders
for structural stability even at high cycle rates. A long can be fitted with integrated valves, position sensors and
service life is guaranteed, thanks to special piston rod pressure sensors, and also internal oil feed.
coatings, combined with seal and guide systems that
are designed specially for the particular application.

Jaw cylinder for mining excavator

Benefits and special features: Benefits and special features:

z Robust design for dynamic application z Vibration-resistant design
z Structurally durable design for high cycle rates z Special sealing systems
z Integrated position sensor technology z Integration of position sensor technology
z Integration of valve technology

Lift cylinder with integrated oil feed

Boom cylinder with integrated position sensor system

Construction machinery and mining

Rotary joints Mobile mining machines
For excavators, cranes and other construction Hydraulic cylinders for mobile machines used in surface
machinery, Hydrosaar offers customised rotary joints. mining and tunnelling are put under great strain as a
The rotary joints can be configured in terms of the result of contamination and temperature. To withstand
number of ports, port size and port design. such loads, the Hydrosaar cylinders designed for these
applications are extremely robust. Appropriate materials
To ensure long service life, the rotation pistons are
are used along with special piston-rod coatings, wipers
supplied with a special coating. If desired, the hydraulic
and seal and guide systems to guarantee a long service
ports can be supplemented with compressed-air ports
life.
and an electrical feed.

Benefits and special features:

z Robust design
Benefits and special features: z Special coatings
z Up to 16 ports z Special sealing systems
z Up to 420 bar z Integration of position sensor technology
z Piston coating for maximum service life z Integration of valve technology
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z Integration of compressed-air and electrical feed

Hydraulic rotary joint for large excavator, 16-port Expansion cylinder for tunnel boring machine

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 Suspension
and accumulator cylinders

Active heave compensation Real-world examples

Energy consumption is of increasing importance, particularly
in the machinery used in transshipment operations.
Hydraulic systems for energy recovery and active heave
compensation play a major role in reducing consumption.
HYDAC supplies machine builders with system solutions
Suspension-damper cylinders which include cylinders, accumulators and valve equipment
as primary components. In addition to cylinder/accumulator Working load
Cylinders provide suspension and damping during vehicle combinations, HYDAC provides cylinder-integrated
travel in many mobile machines, from large mining vehicles solutions.
to agricultural machinery. Hydrosaar supplies hydraulic
cylinders with integrated gas accumulators, developed Base load
specifically to take account of the customer’s requirements in
Compensation force
respect of suspension characteristics, forces and installation
space.

Force
Residual load

Stroke
Benefits and special features:
Active heave compensation: Material handler
z Cylinders with integrated or external hydraulic
accumulators Action/strategies:
z Open and closed hydraulic systems Benefits and special features:
z Energy recovery
z Adjustable damping characteristics z Combined cylinder/accumulator system for active
z Downsizing
heave compensation
z Designed according to Pressure Equipment Directive z Boost operation
z Reduced drive power and operating costs
z Self-supporting design possible
z Designed for specific application
z Piston-rod coating tailored to suit operating conditions Benefits:
z Low-temperature design (to -40 °C)
z Low-temperature design (to -40 °C) z Reduced fuel consumption

Suspension and accumulator cylinders

z Productivity increase
z Noise control

Quasi-statistical suspension characteristics, ∆z = ±35 mm, f = 0.5 Hz

275

250

225

200

175
Force in kN

150

125

100

75

50

25

0
0 10 20 30 40 50 60 70 80
Distance in mm

Suspension characteristics, suspension damper cylinder

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Suspension cylinder with integrated accumulator Cylinder for active heave compensation system

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Accumulator Technology 30.000
Global Presence.
Local Expertise.
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Process Technology 77.000
Fluid Service 79.000
Compact Hydraulics 53.000 www.hydac.com

HYDAC Headquarters
HYDAC Companies
HYDAC Sales and Service Partners
Accessories 61.000
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Contact Hirschbachstr. 7
HS-E 10.102.0/02.15

HYDAC INTERNATIONAL 66280 Sulzbach/Saar

GMBH Germany
Cooling Systems 5.700

Tel.: +49 6897 509-9700

Fax: +49 6897 509-9791
Email: info@hydrosaar.de
Internet: www.hydac.com