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Instandsetzungsservice

Bergbau HydraulikInformationsbroschüre

HeyTec 1000 ®

DURACHROM ®HeyTec 1000 ®

DURACHROM ®

Service for renewal and corrective maintenance of

Mining HydraulicsInformation Brochure

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HeyTec 1000® / DURACHROM®

Soaring prices and long delivery times of the materialsnecessary in tubes production have made it our businessto work out a solution to this situation.

With our patented procedures: HeyTec 1000® undDurachrom®

we are now able to refurbish your high-quality rams andcylinders classified as not repairable into almost like newcondition, offering even better quality than newlymanufactured parts.The procedures offered to our customers constitute a majorreorientation in a cost-saving planning of hydraulic plungersand cylinders.

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HeyTec 1000®

is a machining-procedure, developed and patented byus, where high quality, worn out parts, such as ramstages, are completely refurbished in a cost-savingfashion. With this machining the refurbished parts willhave a better corrosion protection and better glidingattributes than their brand new counterparts.

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-Processes of corrective maintenance for parts of rams -

During this process the defective parts of rams will be lathedinside and outside and subsequently welded on with aluminiumbronze.After the machining the refurbished parts retain their originaldimensions while, at the same time, feature a wear resistant andductile surface.Such surfaces are completely corrosion-resistant and offer majoradvantages due to their layer thickness, even in comparison withthe thin electroplated coating.During the process of surface mounting the parts are notmodified. By means of cooling of the tube wall the temperatureof the materials never exceeds 200 C and with this procedurethere are no changes in the structure or the stability of thematerial.The section modulus of the tube is identical with the originalvalues and the original elastic limit is preserved.In our security calculations the welded on material does notbelong to the tube material, and for that reason our calculationsare based on the values before the corrective maintenance of thelathed tubes.Only if the values of these calculations fully coincide with theoriginal values, the corrective maintenance may be carried out.

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-Auditing procedures for HeyTec 1000 -

For the protection of our comprehensive warranty-obligationwe have checked extensively on our test stand the insideand outside coated component parts.

Identical samples of our coated tubes and uncoated oneswere analyzed and checked by the company GLP –Germanischer Lloyd Prüflabor GmbH under the checknumber 4 10 662 HE. The elastic limit and expansion of thecoated tubes were identical with the values of the uncoatedtubes. The coating process doesn’t change the materials andstability. The bending-checks according to EN ISO 7438 withan angle of 180 C were carried out and defects of the coatedsurfaces were recorded.

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Coating on the inside after quality checking

Coating surfaces of a

ram

Coating on the inside after quality checked rams with 30.000 load alternations

Bending tests of the outer layer

According to EN ISO 7038 with 180°

before e.g. middle stage after

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Bronze restoration

Re-welding of bronze for rams and cylinders

HeyTec 1000As corrosion protection and wear-resistant coating

Qualified for production and all maintenance

before e.g. external stage after

Coating surfaces of aTelescopic ram

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DURACHROM ®

A more preferable alternative is the machining process“DURACHROM”. This machining process can only be usedfor outside coating. Refurbished 3 TS ram outside surface,DURACHROM inside surface HeyTec 1000

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The DOZUT - TAGOR PLC has been renderingservices in the field of DURACHROM protectivecoats applied to external working surfaces ofhydraulic cylinders (rams) for several years.

•How many DURACHROM - Z coats have been made?Within 5 years (2000 - 2005) 20 thousand hydraulic cylinders (rams)were coated. As there were two-stage legs among those cylindersthe number of coats made amounted in total to 25 thousand.

•Where has the DURACHROM - Z coat been utilised?The DURACHROM coat has successfully been applied in coal mineswhere very arduous conditions of operation exist. The DURACHROMcoat also finds its application in copper-ore mines and agriculturalmachines.

•What parameters characterize DURACHROM- Z coat?In view of the fact that DURACHROM coats have been developedrelatively not long ago, the DOZUT - TAGOR PLC in their work aimedat perfectioning the production technology and the improvement ofthe coat itself. There are some parameters which provide adequatecharacteristic of the DURACHROM coats.These are: - Mechanical strength Rm = 750 MPa - Hardness 230 ...250 HB

Thickness of protective layer g = 0. 75 - 1. 2 mm

•How much does the DURACHROM - Z coat cost?In spite of high labour-intensity of the manufacturing process thecost of the DURACHROM coat is comparable to or even lower thanthe cost of overhaul carried out with the use of electroplated coats.

•Is the DURACHROM - Z coat “approved for use”?The DURACHROM coats have been subjected to repeated tests inaccredited Laboratories for Certification.The DURACHROM coat has gained a certificate of approval forapplication in highly saline medium and in sea water.-The rams will be subjected to prototype tests and certified by DINPN-EN 1804-2:2004

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Coating surfaces of aTelescopic ram

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DURACHROM ®

High-grade steel covering for rams and cylinders

As corrosion protection and wear-resistant coating

Layer thickness 1000µm

Tensile strength Rm 800 N/mm2

Elongation at break A5 15 %

Brinell-hardness HB 10/1000 250Suitable for new products and all maintenance

Coating surfaces of aTelescopic ram before e.g. middle stage after

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The technological cutout for the lining of the mines

DURACHROM ®

New DURACHROM linings are used world-wide e.g. themining-fair in Katowice in the year 2005. The managingdirector Henryk Malyska (on the right), Kamex Z.o.o.presents his rams in the lining of Tagor.

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The safest way Complete corrective maintenance

Over the last years we have greatly influenced the market for correctivemaintenance. You can gain the most financially once you endow us withyour defective cylinders for complete corrective maintenance. They mustequal at least €3000,00 as per new product. The refurbished rams andcylinders comply with and exceed the requirements of newly manufacturedproducts.You will save more than 40% of the price for new products and you willobviously get an estimate of the costs for the corrective maintenance foreach cylinder after we have checked the degree of wear and tear of thedelivered products.Then you have to decide: Corrective maintenance yes or no!We offer a test order as a way to convince you!

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B. Heynck GmbH

Ruenhorst 3146395 Bocholt (Germany)

Telefon: +49 (0) 2871 - 72 46 Fax: +49 (0) 2871 - 184 222www.heynck-hydraulics.com

E-Mail:info@heynck-hydraulics.comGerd Petersmarketing & sales

Bernhard Heynckproduction

Our clients give feedback…

Reference letter to the product „hey Tec 1000 „In the Year 2004 the rams in our coal minesfailed after a short operating time due tocorrosion. We searched for a solution to thisproblem and found one presented by thecompany Heynck. The company Heynck offeredthe coating in bronze inside the rams.First units have been refurbished in thismanner. After that we tested the refurbishedunits in the coal mine.The result of this solution was more thansatisfactory. The rams regained their originaloperating time and didn’t have to scrappedprematurely.The bronze weldingsolution Hey Tec 1000offered by Heyncksaved our Companya lot of rams’ failuresas well as highmaintenance costs.

Yours sincerely,DSK Antrahzit

Ibbenbüren GmbH