Preventing Hydraulic Cylinder Failure:
Causes, Solutions & Maintenance Checklist
Hydraulic cylinders are the workhorses of countless machines across industries — powering lifting, pushing, pulling, and holding tasks with precision and strength. But even the most rugged cylinders are vulnerable to failure without proper care.
Understanding the potential causes of hydraulic cylinder failure, the proper care and maintenance schedule can help you extend service life, improve safety, and minimise costly downtime.
Common Causes of Hydraulic Cylinder Failure
Understanding why cylinders fail is the first step in prevention, and some of the most common causes include:
1. Seal Wear and Damage
- Cause: Excessive pressure, heat, contamination, or misalignment.
- Symptoms: External leaks, loss of pressure, rod drift.
- Solution: Use high-quality seals, matched to your application. Maintain clean hydraulic fluid and avoid overpressurising the system.
2. Rod or Barrel Scoring
- Cause: Contaminants in the fluid, poor lubrication, or misaligned components.
- Symptoms: Jerky movement, internal leakage, seal damage.
- Solution: Implement proper filtration and regularly inspect rod surfaces for damage.
3. Side Loading / Misalignment
- Cause: Improper mounting or structural misalignment.
- Symptoms: Uneven wear, seal failure, bent rods.
- Solution: Ensure correct mounting alignment and use clevis/trunnion mounts where lateral forces are present.
4. Fluid Contamination
- Cause: Dirt, water, or metal particles in the hydraulic fluid.
- Symptoms: Rapid wear of seals and internal components.
- Solution: Maintain clean fluid with regular filtration and scheduled oil changes. Use proper reservoir breathers and caps.
5. Overpressure or Shock Loading
- Cause: Pressure spikes, aggressive machine operation, or improper relief valve settings.
- Symptoms: Cracked end caps, seal blowouts, rod failure.
- Solution: Use correctly rated cylinders for the application. Fit overpressure protection, such as relief valves, where needed.
Hydraulic Cylinder Maintenance Checklist
Preventative maintenance is your best insurance policy against failure by including the following checks and measures in your maintenance routine. These checks are designed as a basic guide only, for general maintenance, as specific applications will require a custom maintenance schedule that is applicable to the usage of the cylinder.
Daily or Before-Use Checks
✔️ Visually inspect for leaks around the rod, ports, and barrel
✔️ Check for rod scoring, corrosion, or wear
✔️ Listen for unusual noises during operation
✔️ Confirm smooth cylinder movement under load
Weekly or Operational Maintenance
✔️ Check fluid levels and top up if needed
✔️ Inspect mounting hardware and alignment
✔️ Clean exposed surfaces and dust covers
✔️ Verify that hoses and connections are secure
Monthly / Quarterly Checks
✔️ Inspect and clean filters and breathers
✔️ Test cylinder for internal bypass (e.g. drifting under load)
✔️ Lubricate pivot points or mountings if applicable
✔️ Check hydraulic fluid for signs of contamination
Annual Maintenance
✔️ Perform a full fluid change and flush the system
✔️ Pressure-test cylinder if used in high-demand applications
✔️ Inspect and replace seals as needed
✔️ Review application pressures vs. cylinder specs
BOSS Hydraulic cylinders are built for power and durability and come with a lifetime warranty against manufacturing defects. Like any good industrial tools and equipment, hydraulic cylinders require regular inspection and maintenance for optimal performance. By understanding the causes of potential failure — from seal wear to misalignment — and implementing a routine maintenance strategy, you’ll extend equipment life, boost uptime, and enhance workplace safety.
Need help selecting or servicing your hydraulic cylinders?
Our team can provide the right advice, components, and support — no matter how tough the job so you can… let your BOSS do the hard work. Visit the BOSS Hydraulics website here