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Common Hydraulic Cylinder Failures
Hydraulic cylinders are the driving force behind countless industrial, agricultural, and mobile machines. But even the toughest cylinders face wear and failure over time—especially under demanding conditions. At PSI Hydraulics, we see a range of recurring issues in the cylinders we repair and replace, including:
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Seal failures – Worn or damaged seals are a leading cause of internal and external leaks, resulting in loss of pressure, reduced performance, and fluid contamination. Seals can degrade due to age, improper materials, heat, or exposure to incompatible fluids.
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Bent rods or scored barrels – Side loading, improper alignment, or contamination can lead to bent rods and scored cylinder barrels, compromising sealing surfaces and causing premature wear or leaks. Left unaddressed, these issues often escalate into more extensive damage.
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Rod pitting and corrosion – Cylinders operating in outdoor or corrosive environments are vulnerable to pitting and rust on the rod surface. This weakens the rod and accelerates seal wear, increasing the risk of leaks and failure.
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Piston wear or misalignment - A misaligned cylinder or poor lubrication can cause piston wear, uneven loading, or internal scoring, leading to loss of efficiency, reduced stroke power, and shortened service life.
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Slow or erratic operation – If a cylinder is operating slower than usual—or moving unpredictably—the cause is often fluid contamination, low system pressure, or internal bypassing due to worn components.
Understanding the root cause of cylinder failure is critical to preventing costly downtime and ensuring long-term reliability. At PSI, we don’t just replace parts—we diagnose problems and rebuild your cylinder to meet or exceed original performance.
Our Cylinder Repair Capabilities
At PSI Hydraulics, we’re equipped to repair hydraulic cylinders of all sizes—from small bore cylinders on mobile equipment to large industrial cylinders used in heavy machinery. No matter the scale or complexity, we apply the same precision and attention to detail to every repair. Here’s how we restore your cylinder to peak performance:
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Disassembly and Inspection: We fully disassemble each cylinder and conduct a detailed inspection, documenting all points of wear, damage, or failure. This diagnostic approach ensures we identify not just the symptoms, but the root causes of cylinder problems.
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Precision Machining: Our in-house machine shop allows us to restore critical components with exacting tolerances. We perform rod reconditioning, barrel honing, rod straightening, and fabrication of replacement parts as needed to return your cylinder to like-new condition.
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Seal Replacement: We install high-quality seals selected for compatibility with your system’s hydraulic fluid, operating pressure, and temperature range—ensuring long-term leak resistance and reliability.
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Reassembly & Testing: Once rebuilt, each cylinder is carefully reassembled and pressure-tested under load to verify sealing integrity, smooth operation, and compliance with performance standards before it leaves our shop.
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Quick Turnaround: We know downtime costs you money. That’s why we offer quick turnaround times, with emergency repair services available to get your equipment back online as fast as possible without sacrificing quality.
When you trust PSI Hydraulics with your cylinder repair, you’re getting more than a fix—you’re getting a partner committed to keeping your operation running strong.
Repair vs. Replacement
When a hydraulic cylinder fails, you’re faced with a critical decision: repair it or replace it. The right choice depends on the severity of the damage, the urgency of your operation, and the availability of replacement parts. At PSI Hydraulics, we help you weigh the options with honesty and expertise. Here’s a general guide:
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Repair is often the best choice when:
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You’re dealing with minor seal leaks, rod pitting, or surface wear that can be resolved with reconditioning and new seals.
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Time is critical, and you need a quick turnaround—especially if we have parts in stock and can complete the rebuild within a day or two.
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Replacement may be necessary when:
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The cylinder has major barrel cracks, severe rod bending, or structural failure that compromises safety or can’t be reliably repaired.
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The cost of repair approaches or exceeds the cost of a new unit, making replacement the more economical long-term solution.
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In most cases, repair is faster and more cost-effective, especially when PSI can complete the rebuild in-house with quick turnaround. Whatever the situation, you can count on us to provide a transparent, expert recommendation—focused on getting you back to work with the best value and reliability possible.
Why Fast Repairs Reduce Downtime Costs
Every hour a machine sits idle is an hour of lost productivity—and lost revenue. While preventive maintenance is your first line of defense, PSI Hydraulics knows that unexpected failures still happen. Whether it’s a skid steer stalled on a construction site or a hydraulic press down in a fabrication plant, one thing is certain: speed matters.
At PSI, we help you minimize costly downtime by delivering fast, reliable hydraulic cylinder repairs through:
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In-Stock Components for Standard Cylinders: We maintain a supply of seals, rods, and other common replacement parts to eliminate delays waiting for standard components.
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In-House Machining and Honing: Our on-site machine shop handles critical services like rod reconditioning, barrel honing, and custom part fabrication—so you’re not stuck waiting on third-party vendors or outsourced work.
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Emergency Field Service: When time is critical and pulling equipment isn’t an option, we provide on-site repair, removal, and reinstallation services to get you back up and running directly in the field. By combining expertise, equipment, and fast turnaround, PSI Hydraulics helps you avoid prolonged outages and the costly ripple effects of downtime.
Want a quote? Just send us a photo and some basic dimensions — we’ll take it from there.
Quality Assurance & Pressure Testing
Hydraulic cylinders operate under extreme pressures — and one faulty component can bring an entire system down. That’s why PSI Hydraulics doesn’t just repair, we rebuild with precision.
What You Can Expect:
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Pressure Testing: Every repaired cylinder is tested to OEM or custom pressure specs to guarantee reliability.
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Micron-Grade Inspections: We inspect tolerances with dial-bore gauges, micrometers, and surface finish analyzers.
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Cleanroom Seal Installation: To minimize contamination, seals are handled in a controlled environment.
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Certification: Upon request, we provide a test report showing PSI pass/fail data and inspection notes.
We hold ourselves to higher-than-industry standards — because your safety and uptime depend on it.
Custom Solutions For Unique Cylinder Applications
Off-the-shelf parts don’t always cut it — and neither do generic repair shops. If your cylinder is custom-built, imported, or no longer manufactured, we’ve got you covered.
PSI specializes in:
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Reverse Engineering: We can recreate discontinued or OEM-exact parts from samples or prints.
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Upgrades: Need better performance? We can enhance materials, seal systems, or pressure specs.
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Prototype & Low-Volume Builds: From one-off builds to small-batch production, we serve niche applications.
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Application-Specific Rebuilds: From marine-grade corrosion resistance to high-temp seals for foundries — we adapt to your world.
This level of flexibility is what sets PSI apart — and why teams across Houston trust us for their most challenging rebuilds.
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