What happens when a hydraulic cylinder fails?

When a hydraulic cylinder fails, it can lead to several operational issues, ranging from reduced efficiency to complete system failure. The consequences depend on the type and severity of the failure. Here are the most common outcomes:  

1. Loss of Power or Movement  

- The cylinder may stop extending or retracting due to internal or external damage.  

- This can lead to equipment downtime, causing production delays.  

2. Hydraulic Fluid Leaks  

- External leaks occur due to worn seals, cracked cylinder walls, or damaged hoses.  

- Internal leaks (seal failure) cause reduced pressure, leading to weak or slow cylinder movement.  

3. Overheating and Pressure Loss  

- A failing cylinder may cause excessive heat buildup, affecting hydraulic fluid performance.  

- Loss of pressure can reduce force output, making the system inefficient.  

4. Uncontrolled Movements or Jerky Operation  

- A damaged cylinder may cause uneven or erratic motion, which can be dangerous in industrial machinery.  

- This could be due to air contamination, worn seals, or bent rods.  

5. Structural Damage  

- Bent or broken piston rods can make the cylinder inoperable.  

- If ignored, this can lead to damage in connected components, including pumps and valves.  

Common Causes of Hydraulic Cylinder Failure  

- Seal wear and tear due to high pressure or temperature.  

- Contaminated hydraulic fluid (dirt, water, or air bubbles).  

- Overloading or excessive side loading beyond design capacity.  

- Corrosion or pitting from moisture or chemical exposure.  

Preventing Hydraulic Cylinder Failures  

- Regular maintenance (seal inspection, fluid replacement, rod alignment checks).  

- Using high-quality hydraulic fluid to avoid contamination.  

- Monitoring for leaks and abnormal sounds to catch issues early.  

If a hydraulic cylinder fails, it’s crucial to diagnose the issue quickly and repair or replace the affected components to prevent further system damage.