Typical Hydraulic Cylinder Failures and Solutions

Typical Hydraulic Cylinder Failures and Solutions

Typical Hydraulic Cylinder Failures and Solutions

Like any mechanical system, hydraulic systems have a risk of failure over time. In some cases, these problems can be fixed with repairs, while others may require replacement of the unit or the entire system. Therefore, it is of great importance to understand the factors that affect the healthy functioning of the system. General condition of the hydraulic system; The quality of the oil used is directly related to the purity of the system and the meticulousness of maintenance services.

Remember: Failure is only a consequence. The main thing is to find the reason behind this result and eliminate it permanently.

In this article, the most common types of malfunctions in hydraulic cylinders, their symptoms, causes and solutions are discussed in detail.

Why Are Hydraulic Cylinders Critical?

Hydraulic cylinders; They are the basic components that undertake the task of carrying loads in many applications from industrial facilities to mobile construction machines. They work just like human muscles: they handle heavy lifting by converting pressurized fluid into a linear motion.

But even the most robust systems can wear out over time. Irregular maintenance, installation errors or design deficiencies can lead to serious problems. Many failures are manifested by some symptoms before a complete system failure. These symptoms should not be ignored.

Common Symptoms That Indicate a Malfunction

• Air ingress, cavitation or dirty liquid: Pulsating movements and abnormal noises may occur inside the cylinder.
• Insufficient lubrication and wear on seals: Causes jerky, intermittent movement of the rod.
• Increased energy consumption: Leaks or internal friction reduce system efficiency.
• Overheating of the cylinder: It is a sign of problems in the cooling system.
• Coaxiality disorders, side loads: Causes accelerated wear on rods and bushings.

1. Physical Failures in a Hydraulic Cylinder: Symptoms, Causes, and Solutions

Symptom	Probable Cause	Solution
Loud pulses	Air, cavitation, oil contamination in the system	Bleed the air, check the pump and filters, clean or change the oil
Jerky stick movement	Excessive friction, damage to seals, lack of oil	Replace gaskets, check lubrication, ensure surface cleanliness
Oil leaks	Damaged seals, excessive pressure, faulty assembly	Refresh gaskets, check pressure settings and assembly accuracy
Overheating	Long-term load, dirty oil, internal friction	Change oil, review cooling, analyze load conditions
Rapid bushing wear	Side loads, misalignment, rod tilt	Correct coaxiality, replace bushings and guides
Reduced positioning accuracy	Rod tilt, guide clearance	Check the rod, remove the deformation
Metal particles in oil	Wearing surfaces	Clean the system, replace damaged parts
Weak/not fast stick movement	Lack of pressure, internal leakage	Check the system, replace the piston seal
Leakage when stopped (drift)	Microcracks, gasket or piston wear	Disassemble the system, repair or replace parts
Damage to chrome plating	Pollution, improper oil, poor filtration	Re-chrome coating by grinding, renew the filter system

2. Malfunctions Due to Liquid Contamination

Dirty liquid is the worst enemy of the hydraulic system. Water, dust, rust and microparticles can damage all components of the system.

Symptom	Reason	Solution
Ringing, crushing sounds	Water/solids ingress into the oil	Install a filtration + water separator system
Gasket/bushing/rod damages	Abrasive particles	Filtration down to 3 microns, oil test, use of protective oil
Cylinder wear	Mechanical friction and contamination	Refurbish or repair parts
Low pressure/leaks	Clogged ducts	Replace gaskets, check pressure settings
Overheating	Friction due to pollution	Improve the cooling system, increase filtration
Falling productivity, jolts	Valve and cylinder problems	Apply 3–5 micron filtration
Positioning issues	Adhesive contaminants	Adjust gap settings, use microparticle counter
Burning smell/oil blackening	High temperature, oxidation	Change the oil, eliminate the causes of overheating
Malfunctions after oil change	Dirty equipment/tanks	Clean tools, apply filter filling
Pump and motor wear	Old oil, particle accumulation	Periodic oil change, filter check, oil analysis

Most Common Causes of Failure (MDPI, 2021)

Reason	Share (%)	Explanation
Liquid contamination	41,1	The most common reason. Particles damage seals and surfaces.
Inadequate care	12,6	Filter, oil and system checks are not carried out on time.
Use of sub-industry parts	10,0	Poor quality parts reduce system life.
Physical damage	6,5	External impacts, bumps, twists.
Unsuitable oil viscosity	5,2	Excessive thick/liquid oil disrupts the system balance.
Wrong filter selection	1,7	Low filtration capacity results in particle ingress.
Excessive vibration	1,7	It spoils the joints, tires the seals.
Unknown cause	9,1	Factors that could not be determined during diagnosis.

Conclusion and Recommendation

Reliability in hydraulic systems is directly dependent on fluid cleaning and correct maintenance habits. Thanks to appropriate filtration solutions, more than 50% of failures can be prevented.

An important note: Simply changing the oil is often not enough. Contaminants accumulate inside system components; Even if the oil changes, these harmful deposits continue to damage your system.

Take precautions, avoid costly repairs.
Modern Seide Hydraulics deep filtration systems are not just an expense, but an investment that extends the life of your equipment.

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