Hydraulic cylinders fail for a wide range of reasons, from poor specification and improper use to simple old age. Here are 10 reasons for failure and ways to repair a hydraulic cylinder.
1 - Regular seal leakage
This may be due to a number of reasons, the most common of which in the new cylinders are improper installation of seals, however, incorrect clearances for steel structures can also lead to failure at an early stage. Another physical reason for this malfunction after using the device is the corrosion or marking of the seal grooves. The oil itself can also be the cause either because it is polluted or because the air is trapped.
Corrective measures unsurprisingly include checking and, if necessary, replacing seals. Metal gaps should be checked in any case, and if the oil is considered contaminated, it should be replaced. There must be a clear reason established for oil pollution, as this may be a sign of less obvious balances - this is part of this process.
2 - Piston rod scored
Piston rod counting is often caused by oil contamination, but it can also be contaminated by the gland bearing. If this is not done in time, the gland bearing may fail completely.
The bearing of the gland must be checked and replaced if necessary. It will be necessary to flush the entire hydraulic system and change all filters before re-assembly and re-pressure.
3 - Cylinder clearance scored
Cylinder counting can also be caused by oil contamination, which in turn can be a sign of a failure of a piston engine bearing.
The piston head bearing will need to be checked and replaced if necessary. For any cause of failure, the entire hydraulic system must be flushed, and all filters are changed before reassembly and re-pressure.
4 - Internal corrosion of the barrel
The most likely cause of corrosion inside the barrel is water in the oil.
Correction may require disassembly and re-coating, but at a minimum, oil will need to be replaced. The cylinder must be protected from future water ingress, and this can also be a sign that it is either incorrectly specified or possibly used in an environment for which it was not designed.
5 - Piston rod pistol
To a large extent, the only cause of pitting corrosion of a piston rod is corrosion. It can also be a sign that the cylinder is either incorrectly specified, or possibly used in an environment for which it was not designed.
To start with the rod, and even the entire cylinder must be protected from weather conditions or any other reason for contact with water. Ideally, the rod should also be upgraded to marine specifications.
6 - Leakage around the outside diameter of the gland
The leakage around the outside diameter of the gland can be caused by a loose ring or the presence of a fractured gland, which, in turn, can be caused by bad gaps.
Clearances should be checked and glands checked for cracks. If the o-ring is damaged, you can often install a backup or replace the o-ring.
7 - bent piston rod
A bent piston rod may be a sign that the hydraulic cylinder is overloaded. This may be due to the fact that the cylinder and the associated piston work outside their specification, otherwise they are overloaded. It can also be caused by an external (side) impact of any kind — for example, a collision.
The first thing to check is the load and whether the cylinder works in the specification or not, since without this information any repairs will not last for a long time. The piston rod can be replaced, but it is also an opportunity to review the specification and, if necessary, update the rod.
8 - Separate weld seam on the basis and ports
A separate weld seam at the base and in the ports may be caused during initial manufacture (or recent repair repair) due to poor welding. It may also be caused by a shock load or a sudden impact on the total pressure (or beyond).
A cylinder usage check is necessary to ensure that it is not being used incorrectly or is not being used from its specification. This ensures that the problem does not recur after the repair.
Repair will include machining the welding and re-welding correctly.
9 - Eye damage is broken.
A broken eye bearing is usually caused by a cylinder working on a load on its specification, as well as a shock load or a sudden impact on the full pressure (or beyond).
As with the other problems above, before repairing it is necessary to check the operational use of the cylinder to make sure that it does not work from the specification. This investigation may result in a change in use as well as an update in the specification for repairs. For example, the specification of replacing an eye bearing may be improved, and the size of the pin may also increase.
10 - Rod on one side
A rod that is worn on one side is a sign of some kind of lateral movement due to the lack of support for the bearing (sometimes from bearing failure) or too much lateral load, which may be a result of misalignment or misuse. The rod itself can be defined for the load, so a cylinder should be used to ensure that it is used in the specification.
The repair will provide an opportunity not only to fix the problem, but also to increase the assembly specification by increasing the size of the rod, increasing the bearing area or turning on the outer rails. A combination of all three is also possible.
The above list, of course, is not exhaustive, but it is the most common failures. Often the repair of a hydraulic cylinder gives you the opportunity to familiarize yourself with the work practices or to raise the specification of the cylinder. This means that the problem is not only resolved, but also a preventive measure used to reduce the likelihood of recurrence in the future.
