Heavy-Duty Bar & Plate Heat Exchanger with Custom Flange Connection
Engineered for high-pressure hydraulic systems, our custom bar and plate oil cooler features heavy-duty welded flanges to ensure leak-free connections under extreme pressure pulses. This design is highly favored by European and American OEM machine builders for its robust structural integrity and superior thermal performance.
Made from high-grade aluminium and processed in our state-of-the-art vacuum brazing furnaces, these heat exchangers offer exceptional durability against hydraulic shocks. We provide full thermal design, simulation support, and ISO 9001 quality assurance. Partner with an OEM/ODM manufacturer that speaks your technical language - send us your drawings for a free feasibility review today!
Key Features & Benefits
- Heavy-duty welded flanges: leak-free connections under extreme pressure pulses.
- Vacuum brazed core: high-grade aluminum, processed in state-of-the-art furnaces.
- Shock resistant: exceptional durability against hydraulic shocks and vibration.
- Design support: full thermal design and simulation from your drawings or specs.
- ISO 9001 assurance: quality-controlled production with 100% pressure testing.
Product Specifications
| Parameter | Typical Range |
|---|---|
| Core type | Aluminum bar and plate, vacuum brazed |
| Connections | Heavy-duty welded flanges, custom ports |
| Maximum working pressure | up to 2.5 MPa (higher on request) |
| Cooling capacity | 5 - 200 kW (custom) |
| Oil flow rate | 20 - 500 L/min |
| Quality | ISO 9001, 100% pressure tested |
Compatibility / Fits Models
This flanged cooler is designed for heavy-duty hydraulic systems on excavators and industrial machines. We build custom flange and port designs to your drawing or sample, including OEM machine builder specifications.
| Application | Typical Machines |
|---|---|
| Construction | Excavators, wheel loaders, bulldozers |
| Industrial | Power units, hydraulic systems, gearboxes |
Exact fit confirmed from your drawing, sample or old part.
How It Works
- Hot hydraulic oil enters the cooler through the flange connection.
- Oil flows through the bar and plate core, and heat transfers to the fins.
- A fan blows air across the fins, carrying the heat away.
- The cooled oil returns to the hydraulic circuit at a safe working temperature.
Applications & Aftermarket
Custom flanged bar and plate oil coolers are used in high-pressure hydraulic systems on excavators and industrial machinery, where leak-free flange connections and robust structural integrity are essential.
We also supply cooling for related machines: excavator coolers, CAT excavator replacement radiators and plate-fin hydraulic oil coolers.
Custom & OEM Manufacturing
Send us your drawings, machine model or old part. We provide thermal design and simulation support, confirm the quotation within 24 hours, then produce with full testing. See our custom process or contact us.
Flange Design and Pressure Integrity
The flange is part of the pressure boundary, not a cosmetic connection. A reliable flange design must match the mating component and control the load path into the bar and plate core. Important variables include:
- Flange outside diameter and thickness
- Bolt circle or pitch-circle diameter
- Number, size and thread of bolts
- Flange face type and surface finish
- Gasket or O-ring groove
- Port bore and internal passage alignment
- Weld size, penetration and heat input
- Material and coating compatibility
A heavy-duty flange can reduce leakage risk, but incorrect bolt torque or pipe misalignment can still open the joint. For high-pressure hydraulic systems, the flange, gasket and fasteners must be evaluated as one connection.
Matching an Existing Flange Connection
To manufacture a drop-in or replacement cooler, send:
- A dimensioned drawing or accurate sketch
- Bolt-hole count and pitch-circle diameter
- Bolt size and thread
- Flange face type and gasket dimensions
- Port diameter and center position
- Angle of the flange relative to the mounting holes
- Tube or hose routing around the connection
- Working pressure, pressure spikes and flow direction
- Photos of the old part and the installation
If the original drawing is unavailable, we can reverse-engineer the connection from a sample or measured photos. The fit should be confirmed before production, especially when the cooler mounts to a frame, engine or hydraulic manifold.
Installation and Leak Prevention
Most flange leaks come from installation rather than the cooler itself. Use the following sequence:
- Confirm that the mating faces are clean and free from paint, burrs and old gasket material.
- Check that the pipes and hoses can align without forcing the flange.
- Install the correct gasket or O-ring for the fluid and pressure.
- Tighten fasteners in a crosswise sequence and use a calibrated torque wrench.
- Support the pipework so its weight does not hang from the cooler flange.
- Pressure-test the complete assembly before returning the machine to service.
Do not use bolt tension to pull a misaligned pipe into position. That introduces bending stress into the core, flange and mounting brackets. Flexible hose sections, proper clamps and vibration isolation can prevent the connection from being loaded during operation.
Inspection, Testing and Service
A flanged bar and plate cooler should be checked for:
- Pressure and leak integrity
- Weld and braze condition
- Flange flatness and face damage
- Thread condition and correct fastener engagement
- Core contamination or bent fins
- Mounting-bracket cracks
- Hose and pipe support condition
For critical hydraulic systems, we can complete pressure testing before shipment and provide the agreed inspection record. During service, inspect the flange for seepage, corrosion and loose fasteners, and check that oil temperature and pressure drop remain stable.
For related designs, review the bar and plate oil cooler assembly, plate-fin hydraulic oil cooler and CAT replacement radiator.
Need a custom flange connection for your hydraulic system? Send us your drawings - our engineers will review your feasibility for free within 24 hours.