Six Signs Hydraulic Cylinder Repairs are Needed
If hydraulic cylinder repairs are needed, they will likely show signs of distress before failure is imminent. Six of the most common signs include:
- A long lapse between maintenance intervals
- Issues with power delivery – either inconsistent force application or loss of power
- Unusual noises during operation
- Overheating hydraulic cylinder components or fluid
- Visual signs of hydraulic fluid contamination
- Excessive wear to the hydraulic cylinder rod, barrel or seals
If any of the above signs are present, shut down the hydraulic cylinder and schedule a detailed inspection before operating it again. Minor problems can lead to catastrophic, expensive failures, and every cycle is a risk when troubling signs of distress are present. An expert hydraulic equipment technician can quickly assess the cylinder’s condition and troubleshoot any problems before correcting them.
Sign 1) It Has Been a While Since the Hydraulic Cylinder was Serviced
Hydraulic cylinders and pumps are most reliable when they’re kept on a consistent maintenance schedule. Hydraulic equipment manufacturers recommend ideal service intervals (printed in the operator’s manual), and sticking to these intervals will avert most preventable failures.
To ensure your company stays on pace with these service intervals, consider implementing a maintenance tracking system for your hydraulic cylinders and pumps. A maintenance tracking system is used to keep a record of the equipment’s service history, its next service interval and if there are any specific concerns about the equipment’s condition. With a maintenance tracking system in place, your crews won’t be caught off-guard by an impending round of maintenance – or a preventable hydraulic cylinder failure.
Sign 2) The Hydraulic Cylinder isn’t Delivering Power Like it Should
Poor power delivery is often the first sign that something is wrong with the hydraulic cylinder. If the cylinder isn’t generating enough power or if it is handling roughly, it could be a sign of fluid resistance somewhere in the hydraulic circuit. Leaks, malfunctioning valves, contamination and overheating are all potential causes. And because there are a variety of potential causes behind power failure, the equipment should be inspected by a knowledgeable hydraulic equipment expert.
Sign 3) Unusual Sounds While the Hydraulic Cylinder is Operating
Hydraulic equipment makes plenty of noise while it’s operating, and your crews will soon become familiar with these typical operating sounds. If, however, there are unaccounted for sounds while the hydraulic system is operating, it could indicate serious issues like aeration or cavitation. Sounds like rattling, whining or “sizzling” are major concerns and may indicate impending failure.
Sign 4) Hydraulic Cylinder Components or Fluid are Overheating
Optimal hydraulic system function depends on optimal temperature settings. When hydraulic fluid exceeds these optimal temperatures, the fluid’s characteristics will be adversely affected – such as viscosity. To check the hydraulic fluid’s temperature, target a test point on the hydraulic cylinder and take multiple readings over multiple days and in different settings – to establish a baseline for the cylinder’s temperatures.
If temperatures exceed its baseline range, it could be a sign of flow issues, overly soiled filters, excessive component wear or something worse.
Sign 5) There are Signs of Contamination in the Hydraulic Fluid
Hydraulic fluid contamination is the number one cause of hydraulic system failure, and it can lead to catastrophic failures if not addressed right away. Hydraulic fluid contamination can be caused by many factors, including clumsy hydraulic system maintenance, excessive component wear, overly soiled filters, hydraulic fluid leaks and many other potential causes.
Catching contamination early is key to heading off severe hydraulic system failures. This means occasionally taking a hydraulic fluid sample from a test point connected to the system. Look for any visible signs of sediment in the fluid, which will appear as cloudiness or a milky quality.
In its early stages, hydraulic fluid contamination is typically invisible to the naked eye. To catch this subtle degree of contamination, a fluid sample will need to be sent off to a lab for chemical analysis. This should be done every few months or so.
Sign 6) There is Excessive Wear to the Hydraulic Cylinder’s Components
Excessive component wear can shed contamination into the system or cause significant vulnerabilities during operating. For hydraulic cylinders, it’s the cylinder’s rod, barrel or seals that require special attention. If there are signs of scoring or abrasion inside the cylinder barrel, it could be a sign of rod misalignment or other calibration issues.
The hydraulic cylinder seals are one of the most common failure points when a cylinder does experience issues. Deteriorating seals may allow hydraulic fluid to bypass or may allow contamination to ingress into the system. As such, the hydraulic cylinder seals must be inspected and replaced regularly.
Dealing with the Above Troubling Signs? A Hydraulic System Technician Can Provide the Needed Expertise
Power delivery problems, unusual noises, elevated temperatures, excessive component wear – any of these signs may portend potentially expensive failures. To prevent that expensive downtime from sidelining your operations, consider partnering with an expert hydraulic equipment technician. A hydraulic equipment expert can quickly troubleshoot the problem, perform a full system inspection, and resolve the underlying issue. That way, your hydraulic cylinders will provide optimal reliability and value.