Hydraulic Cylinder Failure: Common Causes, Symptoms, and Solutions

Modern machinery relies on a hydraulic system for its operations. However, this hydraulic system is incomplete if its hydraulic cylinder is not working properly. In some cases, this cylinder can fail, causing the hydraulic system to malfunction. It is worth noting that hydraulic cylinder failure is uncommon.

However, nothing is perfect, so neither are hydraulic cylinders. If the hydraulic system remains ignored over time or has aged enough, its hydraulic cylinder can develop issues. However, the good news is that the common issue with hydraulic cylinders can be fixed. In this article, I will discuss common hydraulic cylinder failures, their causes, symptoms, and solutions. Let’s get started.

The hydraulic cylinder in the machinery is just like the heart in the entire system. It forms the actual work of lifting, pushing, pulling, and so on. First, the hydraulic pump generates pressure, and the hydraulic oil transmits it. However, none of them is as important as hydraulic cylinders. Its job is to use hydraulic pressure to move the piston rod to perform actions such as pushing, pulling, lifting, etc.

Without the hydraulic cylinder, the machinery cannot perform its function. Even if all other parts of the machine are perfect, it still won’t work. That’s the reason we can also call hydraulic cylinders the muscle of the hydraulic system. If the cylinder is in good condition, the hydraulic system will help the machine perform its function perfectly. But if there is even a slight problem with the cylinder, the entire system will not operate.

Hydraulic systems undoubtedly work effectively for many years. However, it does not mean they are free of problems throughout their entire lifespan. Over time, due to continuous use, several problems arise. If you know their causes, you can address them promptly and prevent serious issues later. So let’s dive in and discuss the common problems a hydraulic cylinder faces and how to fix them.

The most common cause of hydraulic cylinder failure is oil contamination. Actually, clean oil is crucial to the efficient operation of the entire system. If there are small dirt or dust particles, they circulate in the cylinder, block oil movement, and damage the entire system. These tiny particles can also scratch internal surfaces and wear out seals.

Solution: To fix this issue, regularly check the oil condition. If you find it is dirty, quickly replace it with new oil. Also, use the oil that manufacturers recommend and replace oil filters on time.

Seals in hydraulic cylinders keep the oil inside the tank and prevent it from leaking. As the hydraulic system is used repeatedly, these seals naturally wear out because of friction. As a result, the oil starts to leak, and fluid pressure inside the pump decreases. If this continues, all the fluid might flow away, and the hydraulic system won’t work at all.

Solution: To cope with this issue, inspect the sealing system regularly. If you notice oil leakage near the pump, it is a clear sign that the seal is worn out. So immediately replace those seals and reinstall the high-quality seals properly.

Every hydraulic cylinder has a specific maximum load capacity. If you put a load beyond that safe limit, the cylinder has to work much harder than it was designed to. This load increases stress on other parts, such as the piston, seals, rod, and pumps. This stress leads to faster wear, oil leaks, bent parts, or complete cylinder failure.

Solution: To resolve this issue, you should always operate the machine within its rated load capacity. Make sure your workers understand the maximum limit of your hydraulic machine and don’t exceed it. As a best practice, you can follow the recommended load capacity listed in the user manual for your specific machinery.

Like any other machine or operating system, the hydraulic system also needs proper maintenance. But if you overlook this maintenance, the dirt builds up in the internal parts. When the fluid gets dirty, it cannot move and create pressure properly. Also, the seal wears out, and oil starts leaking. These problems might not be noticeable at first. But over time, they grow larger and stop the entire system from working.

Solution: Create a preventive maintenance schedule and inspect the hydraulic system regularly. In this schedule, check the cylinder, hydraulic oil, hoses, seals, and fittings for signs of wear or damage. If you find anything wrong, fix it quickly at this early stage.

The piston rod moves in and out of the hydraulic cylinder every time the machine operates. But sometimes, due to uneven load and sudden impact, this piston bends, causing the hydraulic cylinder to fail. Corrosion can also be the reason for the piston bending. Remember, a slight bend in this part creates stress on other parts and affects the smooth operation.

Solution: You should not overload the hydraulic machinery. This way, the hydraulic system operates within its limits, ensuring the piston rods move smoothly. Also, regularly check the rod for bends or any other damage. If there is corrosion or rust on it, replace the piston or coat it with paint.

The good thing about a hydraulic cylinder is that it does not fail without warning. In many cases, it starts showing small signs that something is wrong. These signs warn you that if you don’t cope with them at this stage, they will grow into big failures. Here are some symptoms a hydraulic cylinder shows before it finally fails.

• Hydraulic Oil Leaks: The first, most common sign of hydraulic cylinder failure is oil leaking. You will see oil outside the cylinder, piston rod, or hydraulic hoses. This usually happens when seals become worn, damaged, or loose.
• Slow or Weak Performance: If the hydraulic machine takes longer than usual to operate, it is a sign that something is wrong. This can happen because of low hydraulic pressure, worn seals, or internal cylinder wear.
• Decrease in Machine’s Potential: A healthy hydraulic cylinder typically enables the hydraulic system to operate at its best. The machines complete their job perfectly at their full potential. If the hydraulic cylinder is weak, the machines fail to work properly. You’ll notice machines getting slower in their work. It indicates pressure loss inside the cylinder or damage to an internal part.
• Jerky or Uneven Movement: As you know, hydraulic machines work smoothly without jerks. However, if it starts shaking, jerking, or moving unevenly, it means the hydraulic cylinder is not operating correctly
• Unusual Noises: Generally, hydraulic machinery operates quietly. But if you hear knocking, grinding, squealing, or other unusual noises, the machine is not working well. These noises are clear signs that there is trapped air in the cylinder or that the cylinder needs lubrication.

Manufacturers build hydraulic cylinders to be robust enough to handle heavy work every day. But still, they sometimes fail over time. There can be several reasons for this failure, such as poor maintenance, incorrect operation, or harsh conditions. Some of these problems affect the cylinder from the outside, and you can easily notice them.

But the big issue arises when the problem occurs inside the cylinder, which is difficult to notice. To help you understand better, here is the list of hydraulic cylinder failures you must know about.

• Corrosion and Rust
• Hydraulic Oil Leakage
• Internal Seal Failure
• Cylinder Scoring and Surface Damage
• Hydraulic Cylinder Cavitation
• Hydraulic Cylinder Drift
• Hydraulic Cylinder Overheating
• Mechanical Fatigue Cracking

In conclusion, hydraulic cylinders are of utmost value for the smooth working of hydraulic systems. It won’t be wrong to say that these cylinders are the heart of any hydraulic system. If it malfunctions, the hydraulic system will collapse. As I said above, hydraulic cylinders are generally durable and do not fail immediately. However, when these cylinders are left without maintenance, they can develop issues. In this article, I discuss the causes of hydraulic cylinder failure and practical solutions. You’ll also learn about the symptoms and common failure types of these cylinders.