Top 9 Causes of Hydraulic Cylinder Failure

A hydraulic cylinder is one of the most crucial hydraulic system components, which helps to generate mechanical force in a linear motion to push or pull a load or to lift something that requires exceptional force. It has a wide range of applications and is found almost everywhere around us: in forklifts, mining equipment, tractors, excavators, etc. From agriculture to ship-building, a myriad of industries relies heavily on hydraulic cylinders for the smooth operation of their systems and machining equipment.

As hydraulic systems are a fundamental part of all kinds of small and large industrial settings, regular maintenance of hydraulic cylinders is very important for their optimal performance and smooth functioning. Despite their inherent power and functionality, they will fail if they are not taken care of. From fluid contamination to piston damage, there are several causes of hydraulic cylinder failure. It is therefore wise to check for any leaks and contamination from time to time to ensure the effective operation of hydraulic cylinders. Of course, there can be some minor breakdowns but proper maintenance and repairs can prevent any major breakdowns.

How Does a Hydraulic Cylinder Operate?

The operation of a hydraulic cylinder is based on the working principle of Pascal’s law of fluid mechanics, which states that when pressure is applied to a confined fluid, it is transmitted uniformly throughout that fluid in all directions without a change in magnitude. In a hydraulic cylinder, an incompressible fluid such as oil or water transmits the forces from one area to another within the fluid. When pressure increases at any point in the confined fluid, there is an equal increase in pressure at every other point in the fluid.

When a power machine rotates the hydraulic pumping unit, a volume of hydraulic fluid passes through the cross-section per unit of time. The pressure in the fluid chamber equals the force applied divided by the area of the chamber. The pump can lift or push an infinite amount of weight depending on the pressure generated and the size of the cylinder.

What are the Most Common Causes of Hydraulic Cylinder Failure?

Now that we know how hydraulic cylinder functions, let us learn about the various reasons behind hydraulic failures. In this blog, we have outlined some of the most common causes of hydraulic cylinder failure.

• Damaged Seal

One of the most common causes of hydraulic cylinder failure is a damaged seal. There are various kinds of seals found inside a hydraulic cylinder namely rod seals, piston seals, buffer seals, etc. These seals can get damaged due to exposure to abuse, improper installation, excessive heat, pressure spikes, chemical corrosion, and fluid contamination. This, in turn, can have a negative impact on the efficiency of machinery operation and affect the overall life of the cylinder.

As seals play a crucial role in preventing the leakage of hydraulic fluid, it is important to replace the seals or get them repaired if they get damaged. If you want to avoid costly repairs and production downtime, be proactive and try to prevent cylinder failure by taking the necessary action.

• Fluid Contamination

If foreign particles get introduced into the hydraulic fluid, they can cause severe damage to the hydraulic cylinder. The participles trapped in the fluid can scratch and scrape the cylinder bore and degrade the piston rod, the surface of the seals, and other fittings. A faulty wiper seal generally causes fluid contamination. Due to oxidation caused by the contamination of fluid, all the metal parts of the cylinder can eventually corrode and this, in turn, can affect the operational efficiency of the hydraulic cylinder.

• Extreme Temperatures

When a hydraulic cylinder is subjected to extreme heat, the seals start to lose their effectiveness and shape. Likewise, extreme cold temperatures can make the seals brittle and reduce their elasticity. Both extremes can alter the viscosity of the hydraulic fluid and lead to hydraulic cylinder failure.

• Hydraulic Cylinder Side Loads

When hydraulic cylinders are not installed properly, it causes side loading and puts unintended pressure on various components of the cylinder. This, in turn, can cause uneven wearing and have catastrophic results, leading to hydraulic cylinder failure.

• Piston Damage

Piston damage is caused by a number of reasons. Pistons can get damaged over time due to normal wear and tear like any other piece of machinery or manufacturing equipment. Fluid contamination and side loading can also severely damage the pistons leading to the complete failure of the hydraulic system.

• Incorrect Cylinder Pressure

Hydraulic cylinders perform correctly when the hydraulic fluid is maintained at a precise operating pressure. However, when they are subjected to extreme pressure, it can cause dangerous operating conditions. It is thus important to regularly check the pressure and ensure that it complies with the designed specifications.

• Corrosion

Corrosion is one of the common hydraulic cylinder problems. Rust accumulates on the cylinder rod when equipment is stored outdoors with the cylinder extended. The specks of rust eventually develop into pits which damage the cylinder seal when the cylinder is retracted. You can prevent corrosion and protect your hydraulic cylinder by using micro oil film or any other lubricant.

• Cylinder Bore Scoring

Cylinder bore scoring may be caused by an improper mounting, alteration in alignment, or increased side load. It is found in the form of deep gouges or scuffs that appear on the inner side of the bore walls. It always starts at the bottom of the cylinder. Once bore scoring occurs, there is no way to reverse the damage. So, try to minimize the risk of having cylinder bore scoring by taking the necessary steps.

• Split Welds

When excessive force is applied to a hydraulic cylinder, cracks occur in welded surfaces and this, in turn, causes split welds. If a split weld is ignored, it can lead to critical consequences, causing damage to the equipment and severe injuries to workers.

Why Choose SabTech for Maintenance Purposes?

If you are having issues with your hydraulic cylinder, then SabTech is the one-stop solution for you. We are global leaders in the manufacturing, fabrication, and services of hydraulic solutions. Our well-seasoned team of technical experts provides hydraulic system repair services in Saudi Arabia of high excellence. Besides, our experienced professionals ensure that the machinery process in manufacturing our high-quality hydraulic cylinders is under careful control to prevent any damage.  

Conclusion

Now that you are familiar with the common causes of hydraulic cylinder failure, make sure that your hydraulic cylinder is examined regularly and properly maintained to avoid any hydraulic cylinder problems.

If you want a hydraulic cylinder repair or rebuild, contact us for complete satisfaction and peace of mind.