Hydraulic Cylinder Failures in Construction Machines

It is hydraulic power, which makes construction machines lift, dig, push, and haul with apparent ease. Hydraulic cylinders are the components that convert fluid pressure into actual work on the job site.

 Since they operate continuously and under pressure, along with the fact that they are usually the first components to fail, cylinders often fail because they see dirty fluid, are maintained poorly, or are operated under extreme conditions. In this article, we will look at five types of heavy equipment where we see cylinder issues most frequently and how proper service can extend their life.

Here are the five heavy machines most prone to hydraulic cylinder failure—and what makes them especially vulnerable.

 1. Excavators – High Duty Cycles and Side Loading

Excavators are constantly working their boom, stick, and bucket cylinders. Unlike other machines, excavators often operate at awkward angles or with uneven loads, which causes side loading on the cylinder rods. This side pressure bends or scores the rod over time, eventually damaging the seals. Add in abrasive soil and rocks, and the risk of contamination multiplies.

Tip: Operators should avoid digging with the bucket at sharp side angles and inspect rods for scratches before they turn into leaks.

Suggested Read: A Complete Guide for Fixing Excavator Issues

 2. Backhoe Loaders – Dual Function Stress

Backhoe loaders are special because they provide both loader and excavator capabilities. This results in the cylinders continuously changing from raising to digging. Consequently, you may overheat and seal wear due to continuous hydraulic pressure changes. The loader arm cylinders are more susceptible to bending of the rods when they have unbalanced loads. 

 Tip: Allow cooling time for hydraulics during extended shifts, and do not "overload" the loader bucket, causing uneven loading of dig/dump cylinders.

 3. Bulldozers – Exposure to Abrasive Materials

Bulldozer blade cylinders live in some of the harshest conditions. They’re always pushing abrasive materials, soil, gravel, or even rock. This environment causes rod pitting and damages the protective chrome layer on the rod. Once that happens, dirt sticks easily and tears the seals apart.

Tip: Daily cleaning of rods and checking wiper seals dramatically increases cylinder life. Small maintenance here prevents costly rebuilds later.

Suggested Read: Bulldozer Hydraulic Maintenance

 4. Wheel Loaders –

Risks of overextension of wheel loaders available speed, making it easy for operators to overload the bucket or over-tilt it, overextending the cylinder, thus putting excess strain on the rods and seals. Another cause for premature failure that is not obvious is contaminated fluid from a filter that has not been maintained, thus causing damage to internal surfaces.

Tip: you should never operate the loader by exceeding the rated capacity, and while inexpensive, fluid samples or replacing filters regularly is cheap insurance against a potential breakdown. 

 5. Cranes – 

Pressure and Safety Considerations Cranes that use hydraulic cylinders are especially challenged by the need for precise control combined with extreme pressures. When a seal blows or if there is some form of internal leakage, the crane will lose lifting power, causing a direct safety issue. Cylinders for cranes are also at risk from thermal expansion when hydraulic oil is heated to high temperatures due to long lifts. 

Tip: always check the load charts and schedule hydraulic professionals to inspect the equipment. In crane maintenance, not maintaining equipment is not only costly, but it is also dangerous.

Final Thoughts

While hydraulic cylinder failures can happen in any machine, excavators, backhoes, bulldozers, wheel loaders, and cranes face the highest risk because of the extreme conditions they operate under. The good news is that most failures are preventable. Routine activities such as cleaning, checking hydraulic fluid levels, not overloading your mini-excavator and scheduling regular hydraulic cylinder repairs for construction equipment will only help to maintain these machines at a peak operating level.

If you include hydraulic system maintenance as part of your routine operations, rather than an afterthought, you will not only take better care of your machines, but you will also take care of the project deadlines, reducing downtime, operator safety, and your bottom line.