Customer Service 0232 479 15 50

The Most Common Causes of Hydraulic Cylinder Failures and Solutions

The Most Common Causes of Hydraulic Cylinder Failures and Solutions


The Most Common Causes of Hydraulic Cylinder Failures and Solutions

Hydraulic cylinders are one of the most critical parts of industrial machinery and mobile equipment. However, they can fail over time due to heavy use, improper maintenance, or environmental impacts. These failures not only lead to machine downtime but also to production losses, cost increases, and occupational safety risks.

As Hidroman, in this article, we discuss the most common causes of hydraulic cylinder failures and the measures that can be taken against these problems.

  1. Contamination in Hydraulic Oil

Dirt, water, or air mixed with hydraulic fluid; It causes wear of parts in the cylinder and deterioration of seals.

Solution:

  • To perform regular oil analysis,
  • Using high-quality filtration systems,
  • Paying attention to cleanliness during storage and filling.
  1. Gasket and Seal Failures

Incorrect material selection, high temperatures, or excessive pressure lead to premature failure of seals and seals.

Solution:

  • Choosing the appropriate gasket material,
  • Paying attention to tolerances during assembly,
  • Performing regular maintenance and leak checks.
  1. Side Load Effects

Non-linear loads placed on the roller shaft cause the shaft to warp and cause uneven wear on the inner surface.

Solution:

  • To make the cylinder assembly correctly,
  • To use load guidance systems,
  • To prevent misuse with operator training.
  1. Overpressure and Pressure Shocks

Pressure or sudden load changes that exceed the roller's design value can lead to significant damage.

Solution:

  • Using safety valves and pressure regulators,
  • To integrate shock-absorbing elements into the system,
  • Constantly monitoring pressure values.
  1. Temperature Problems

High temperature changes the viscosity of the oil, while low temperature can cause the system to slow down and damage the seals.

Solution:

  • Choosing hydraulic oil suitable for working conditions,
  • To provide temperature control with cooling and heating systems,
  • To take measures in design by analyzing environmental conditions.
  1. Damage to the Cylinder Body

Incorrect installation, impact or scratching of the surface by particles cause deformation of the cylinder body.

Solution:

  • Using high quality processing and coating techniques,
  • Working with protective equipment against impacts during assembly,
  • Conducting regular visual inspection.

Strategic Suggestions from Hidroman

As Hidroman, we offer not only product supply but  also consultancy and maintenance support for long-lasting and reliable systems. To extend the life of hydraulic cylinders and reduce costs:

  • Preventive maintenance programs should be implemented,
  • Operator and maintenance team should be trained,
  •  Malfunctions should be detected in advance with data-driven monitoring systems.

 

  • The Most Common Causes of Hydraulic Cylinder Failures and Solutions

 

  • Frequently Asked Questions (FAQs)
  • Why does a hydraulic cylinder fail?
    The most common causes are hydraulic oil contamination, seal and seal problems, side load effects, excessive pressure, temperature fluctuations and body damage.
  • How to prevent hydraulic cylinder failures?
    Breakdowns can be largely prevented with regular maintenance, oil analysis, quality filtration systems, proper installation, and operator training.
  • What does oil leaking from the cylinder mean?
    It is usually caused by gasket or seal failure. However, scratches or pressure problems in the cylinder body can also lead to oil leaks.
  • What should be the hydraulic cylinder maintenance period?
    Although it varies according to the intensity of use; monthly visual inspection and detailed maintenance at least once a year are recommended for industrial machines. Systems operating under severe conditions require more frequent maintenance.
  • Should a faulty cylinder be repaired or replaced with a new one?
    If the body and piston rod are not seriously damaged, repair and overhaul can be economical. However, refurbishing rollers that fail frequently or pose high safety risks is more advantageous in the long run.
  • What solutions does Hidroman offer?
    In addition to hydraulic cylinder manufacturing, Hidroman offers maintenance, revision, filtration solutions and technical consultancy services. Our goal is to operate our customers' systems in the most efficient and reliable way.

Hydraulic cylinder failures can be prevented to a great extent with the right precautions. With regular maintenance, quality equipment selection, and professional support, you can extend the lifespan of your machines and eliminate unexpected downtime.

For more information, you can contact the Hidroman expert team.