Proper, consistent cylinder maintenance is necessary to keep your fluid power systems running smoothly and efficiently. Follow these FIVE steps to keep your cylinders in top shape.
1. Keep your oil clean. This should go without saying, but I wouldn’t have to say it if the majority of hydraulic failures weren’t still from contaminated oil. Dirt particles love to move back and forth inside a cylinder, so it’s especially important to ensure oil is clean the first time it makes its way into your cylinder.
2. Inspect your cylinder regularly. Have a look at the condition of the rod for corrosion, pitting, and uneven wear. Corrosion could signal excessive moisture, either ambient or within the fluid. The latter scenario is worse, as it spells disaster for your entire hydraulic system. Rod corrosion will accelerate seal wear, as friction damages the rod seal and wiper. Pitting on the rod can occur from corrosion, but also from physical damage, which will also lead to seal damage.
Uneven wear of the rod is often a result of misalignment. Sideload causes the rod to rub on one side of the bearing, which can prematurely wear the bearing, seal(s), and the rod itself. In most cases, a corroded and damaged rod can be re-chromed and/or polished to refinish it. If the rod can’t be repaired, it can be manufactured by any cylinder repair shop. Before re-installation, it would be wise to remedy the problem causing the damage in the first place, or you will find yourself in the business of changing the cylinder often.
3. Rotate your cylinders. If downtime is an absolute impossibility, you may want to keep a set of spare cylinders you rotate into service regularly. This will keep your cylinders fresh despite high-risk particle contamination or extreme operating conditions. Once one cylinder is removed from service, it can be disassembled, inspected, and repaired if required.
When a cylinder is in pieces, it’s a good idea to replace all seals, since they’re typically very economical. Inspecting the internals of your cylinders regularly also gives you clues about the condition of the rest of your hydraulic system. Also, a physical inspection of the piston and cap can tell you if particles have been trapped within the cylinder.
4. Service your accessories. The brackets, clevises, rod eyes, ball joints, or other connections to a hydraulic cylinder are nearly as important as the cylinder itself. When a pivot pin or clevis is worn, there is excessive slop and play in the joints of the cylinder. This will cause misalignment, which could lead to rapid wear or catastrophic damage in some cases.
5. Inspect your lube oil system. If you are running pneumatic cylinders, which often need their source of lubrication, inspect and service your lubrication system, as needed. A basic system will have a lubricator built into the filter/regulator assembly, which is fairly reliable. However, no lube oil can be provided when the reservoir is empty. Inspect the oil level regularly, and top off as needed.
When testing any lubrication system, check that excessive amounts of oil aren’t being introduced into the system. I’ve seen lube systems introducing so much oil as to hydro-lock a pneumatic cylinder, preventing it from cycling full stroke rapidly. Only a fine mist is required to help an air cylinder overcome friction.
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