What Causes Hydraulic Cylinder Failures — And How to Prevent Them

When failure strikes, PSI responds: From seal degradation to full rod wear, we diagnose and resolve critical cylinder issues fast.

When a hydraulic cylinder fails, it’s never convenient. From stalled construction equipment to unexpected plant shutdowns, the impact of a cylinder failure can be immediate and expensive. Fortunately, many of these failures are preventable.

This article breaks down the most common causes of hydraulic cylinder failure, what warning signs to watch for, and how PSI Hydraulics helps you prevent downtime with better design, fabrication, and service practices.

---

The Most Common Causes of Hydraulic Cylinder Failure

1. Contamination in the Hydraulic Fluid

Dirt, water, or metal particles in your fluid can destroy seals, scratch cylinder walls, and reduce lubrication. Contamination is the number 1 enemy of hydraulic systems.

Prevention Tips:

• Use high-quality filters and replace them regularly

• Sample and test your hydraulic fluid as part of routine maintenance

• Keep fill ports and fluid containers clean and sealed

2. Seal Damage or Wear

Seals are critical to cylinder performance. Damage can occur from heat, incorrect installation, or poor-quality materials.

Prevention Tips:

• Always use the correct seal type for your pressure and temperature range

• Inspect for leaks or scoring regularly

• Choose premium-grade seals designed for your specific application

3. Improper Cylinder Alignment

Side loading happens when the cylinder isn’t perfectly aligned with the load it’s moving. This puts uneven pressure on the rod and internal components, leading to premature wear or bending.

Prevention Tips:

• Make sure cylinder mounting points are properly aligned

• Avoid bending or twisting forces during operation

• Use clevis or spherical rod-end mounts where misalignment is expected

4. Corrosion or Environmental Exposure

Humidity, saltwater, and chemicals can attack cylinder rods and seals, especially in coastal or chemical plant environments.

Prevention Tips:

• Use stainless or coated rods for harsh environments

• Apply rod bellows or wipers to keep contaminants away

• Choose seals with chemical resistance for exposed systems

5. Overloading and Pressure Spikes

Operating outside a cylinder’s pressure range can cause seal blowouts, rod deformation, or barrel expansion.

Prevention Tips:

• Know your system’s operating pressure and ensure components are rated above it

• Add relief valves to control pressure spikes

• Specify cylinders with the right safety factor for load and cycle frequency

6. Inadequate Lubrication

Friction inside the cylinder’s moving parts can cause scarring, overheating, and seal damage if not properly lubricated.

Prevention Tips:

• Ensure proper fluid levels and fluid type

• Regularly check for unusual heat or noise during operation

• Use cylinders with internal lubrication grooves when appropriate

---

Warning Signs Your Hydraulic Cylinder May Be Failing

Don’t wait for a complete failure. Watch for these early indicators that your cylinder needs repairing:

• Sluggish or uneven movement

• Visible fluid leaks or weeping

• Unusual noises under load

• Rod scoring or discoloration

• Loss of pressure or reduced extension

If you catch these signs early, you can often avoid a full replacement.

---

How PSI Hydraulics Prevents Cylinder Failures Before They Happen

Custom-Built Cylinders, Engineered Right the First Time

We fabricate cylinders to match your exact application—not just "close enough." That means precision-fit components, proper materials, and engineering support.

Seal and Rod Material Matching

We select seals and rods based on your specific operating conditions, including temperature, fluid type, and environmental exposure. No guesswork.

In-House Pressure Testing and Inspection

Every custom cylinder we build is tested for leaks, pressure handling, and stroke integrity before it leaves our facility.

Preventive Maintenance Programs

For high-use equipment or critical systems, we offer:

• Onsite inspection and rebuilds

• Seal replacement and rod resurfacing

• Fluid condition checks and filter assessments

---

Frequently Asked Questions (FAQ)

Q: How often should hydraulic cylinders be inspected?

A: For high-use systems, a monthly inspection is ideal. For moderate-use systems, quarterly checks can help catch early signs of wear or leakage.

Q: Can a damaged rod be repaired or does it require full replacement?

A: Minor rod scoring can often be resurfaced. Severe pitting or bending usually requires a full rod replacement. PSI can assess this in-house.

Q: Are all cylinder failures caused by poor maintenance?

A: Not necessarily. Design flaws, environmental exposure, or using the wrong type of cylinder for an application can also cause failure.

Q: What types of seals work best in high-temperature applications?

A: Viton, PTFE, and other high-temp-rated materials are commonly used in cylinders exposed to elevated temperatures.

Q: What’s the average lifespan of a well-maintained hydraulic cylinder?

A: With proper maintenance and correct usage, cylinders can last 5–10 years or more, depending on the environment and duty cycle.

---

Rebuild or Replace? How to Decide

Not every cylinder failure requires a brand-new build. Here are some guidelines:

Choose to Rebuild When:

• The barrel and end caps are intact

• Rod scoring is minor and repairable

• The cylinder size or specs are non-standard and hard to source

• Lead time for a replacement is longer than repair

Choose to Replace When:

• The rod is bent or fractured

• Barrel is cracked or expanded

• You need a system redesign or upgraded specs

• Downtime costs outweigh repair value

PSI offers both services, and we’re happy to inspect and quote both options side by side so you can make the right call.

---

Types of Hydraulic Cylinders and Their Failure Tendencies

Understanding your cylinder type can help predict and prevent the most common failures:

Tie-Rod Cylinders

Common in industrial applications. Failures often occur at the tie rod threads or due to misalignment.

Welded-Body Cylinders

Stronger and more compact than tie-rod types. Failures often result from side loads or inadequate seal material.

Telescopic Cylinders

Used in dump trucks and lifting platforms. Prone to overextension and contamination in multi-stage designs.

Ram-Type Cylinders

Single-acting and often found in lifting/lowering setups. Most failures stem from rod corrosion or base leaks.

At PSI, we build, repair, and stock components for all cylinder types.

---

Precision starts at design: PSI custom-builds cylinders to fit your system’s pressure, environment, and duty cycle—down to the last micron.

Need Help Diagnosing or Replacing a Problem Cylinder?

Hydraulic cylinders fail for a reason. But with the right planning, design, and support, most failures can be prevented long before they interrupt your operations.

Contact PSI Hydraulics today for a cylinder inspection, rebuild quote, or new custom fabrication. We’ll help you solve the issue—and make sure it doesn’t happen again.