Project Information
Project Name: Hydraulic Jack for Rail Equipment
Applied Equipment: Urban Rail Construction & Maintenance Equipment
Date: May 26, 2026
Order Code: HJ-S-15
Product Type: High-Pressure Hydraulic Jack
Operating Pressure: 70 MPa
Bore: 70 mm
Rod Diameter: 50 mm
Stroke: 300 mm
Rated Lifting Capacity: 15 Tons
Project Background & Requirements Overview
This project involved the development of a customized 15-ton high-pressure hydraulic jack for urban rail construction and maintenance equipment.
Initial Customer Request
The customer provided photos and functional information for the existing hydraulic jack and specified several critical requirements:
- 70 MPa operating pressure
- 15-ton rated lifting capacity
- High-pressure valve integrated with the hydraulic jack
- Load-holding and locking function after lifting
- Customized hydraulic connection
- Customized thread dimensions
- Customized mounting and port dimensions
- Reliable operation under high-pressure working conditions
- Functional compatibility with the customer’s existing equipment
Because this hydraulic jack operates at pressures up to 70 MPa, component selection, sealing reliability, dimensional accuracy and high-pressure safety were especially important.
Engineering Goal
Our engineering goal was not simply to reproduce the appearance of the original hydraulic jack.
The key objective was to understand the actual working function of each component from the customer’s photos and technical descriptions and then develop a technically equivalent solution.
After reviewing the application, our engineers identified the required valve function as a high-pressure one-way shut-off/check valve arrangement, which allows hydraulic oil to enter during lifting while helping maintain pressure and lock the load in position.
At the same time, we evaluated alternative valve components with equivalent performance to help the customer reduce procurement costs without compromising the required working pressure or functional reliability.
Customer’s Special Requirements – Customization
Unlike a standard industrial hydraulic cylinder, this hydraulic jack required extensive customization because it operates in a 70 MPa high-pressure hydraulic system.
The main customization requirements included:
70 MPa High-Pressure Design
The hydraulic jack needed to operate reliably at pressures up to 70 MPa.
This required appropriate design consideration for:
- Cylinder body strength
- Piston and rod dimensions
- Sealing system
- High-pressure hydraulic ports
- Thread strength
- Valve pressure rating
- Hydraulic fittings and connections
All pressure-related components were selected according to the operating conditions of the hydraulic jack.
Chrome-Plated Piston Rod
The piston rod was designed with a chrome-plated surface to provide improved:
- Wear resistance
- Surface hardness
- Corrosion resistance
- Sealing performance
- Service life
This is particularly important for hydraulic jacks used in demanding rail construction and maintenance environments.
Customized Hydraulic Connections
The hydraulic connection dimensions could not be replaced directly with standard ports.
Therefore, the following dimensions were customized according to the customer’s existing equipment:
- Hydraulic port dimensions
- Connection threads
- Port hole dimensions
- Quick coupling interface
This allows the new hydraulic jack to connect directly with the customer’s existing hydraulic equipment without requiring major changes to the original system.
Load Holding and Locking Function
One of the most important functional requirements was that the hydraulic jack needed to maintain pressure and hold the load after lifting.
Based on the customer’s description and reference product, our engineering team selected a suitable high-pressure one-way shut-off/check valve solution.
The valve arrangement helps:
- Allow hydraulic pressure to enter the jack during lifting
- Prevent unintended reverse oil flow
- Maintain hydraulic pressure
- Hold the lifted load in position
- Improve operational stability
High-Pressure Quick Coupling
A compatible high-pressure quick coupling was also supplied as part of the complete solution.
This allows easier connection between the hydraulic jack and the customer’s hydraulic power source while ensuring compatibility with the required pressure level.
AiSoar Solution & Design Description
Based on the customer’s physical product photos, functional description and dimensional information, our engineers developed a complete customized solution consisting of:
Hydraulic Jack + High-Pressure Valve + High-Pressure Quick Coupling
Final Hydraulic Jack Configuration
| Item | Specification |
|---|---|
| Product | Hydraulic Jack |
| Rated Lifting Capacity | 15 Tons |
| Operating Pressure | 70 MPa |
| Bore Diameter | 70 mm |
| Rod Diameter | 50 mm |
| Stroke | 300 mm |
| Piston Rod | Chrome-plated |
| Valve | High-pressure one-way shut-off / check valve |
| Main Function | Lifting + Pressure Holding + Load Locking |
Key Design Highlights
Reverse Engineering from Customer Reference
The customer did not initially provide a complete manufacturing drawing.
Therefore, our engineers first analyzed:
- Reference product photos
- Valve configuration
- Hydraulic connection position
- Thread dimensions
- Port dimensions
- Overall structure
- Customer’s description of the operating process
This allowed us to understand the function of the existing product before determining the final hydraulic solution.
Correct High-Pressure Valve Selection
Selecting the correct valve was critical to this project.
From the customer’s functional description, our engineers determined that the hydraulic jack required a valve capable of controlling reverse flow while maintaining pressure after lifting.
A suitable 70 MPa-rated high-pressure one-way shut-off/check valve was therefore selected to provide the required pressure-holding and locking function.
Customized Interface for Direct Replacement
The hydraulic jack was designed according to the customer’s existing connection and installation dimensions.
Customized threads, hydraulic connections and port dimensions allow the new jack to match the customer’s original equipment as closely as possible.
The goal was to provide a direct replacement solution without changing the customer’s existing operating system.
Complete Hydraulic Jack Package
Instead of supplying only the cylinder body, we provided the customer with the required matching hydraulic components, including:
- Hydraulic jack
- High-pressure valve
- High-pressure quick coupling
- Customized hydraulic connections
This reduces the customer’s effort in sourcing and matching high-pressure components separately.
Cost Optimization Without Sacrificing Required Performance
Another important objective of the project was to reduce procurement costs.
After confirming the required valve functions and pressure rating, we selected an equivalent high-quality valve solution that could meet the required operating conditions while offering a more competitive cost compared with the customer’s previous configuration.
The optimization focused on component sourcing rather than reducing critical technical specifications, allowing the customer to maintain the required performance while controlling purchasing costs.
Project Result & Application Effect
After completing the customized design and production, the hydraulic jack was tested according to the required high-pressure operating conditions.
The completed solution matched the customer’s main technical and functional requirements.
Achieved Results
- 70 MPa high-pressure working capability
- 15-ton rated lifting capacity
- Reliable lifting operation
- Stable pressure-holding performance
- Load-locking function through the high-pressure valve
- Customized hydraulic connections matched to the customer’s equipment
- Customized threads and port dimensions
- High-pressure quick coupling supplied as part of the solution
- Chrome-plated piston rod for improved durability
- Functional configuration consistent with the customer’s original hydraulic jack
- Reduced procurement cost through optimized component selection
The project demonstrates how a hydraulic jack can be customized not only according to basic parameters such as bore, rod and stroke, but also according to the complete operating requirements of the equipment, including valve function, connection interfaces, pressure rating and accessories.
Customer Feedback
Feedback Content:
Customer feedback can be added after installation and actual operation of the hydraulic jack on the rail equipment.
If available, this section can include:
- Customer confirmation after receiving the hydraulic jack
- Installation photos
- On-site application photos
- WhatsApp or email feedback
- Repeat order information
- Feedback regarding pressure holding, lifting performance or installation compatibility
For replacement projects, our engineering team can also work from existing product photos, samples, drawings or dimensional information to develop a suitable customized solution.
