Proper Maintenance Practices for Hydraulic Cylinders in Construction Equipment

Hydraulic cylinders play a critical role in construction equipment like excavators, enabling smooth and efficient operation across various tasks. To extend their lifespan and prevent potential breakdowns, it's crucial to adopt proper maintenance techniques. Below are key guidelines to help maintain hydraulic cylinders and avoid common damage scenarios.

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Common Issues Leading to Hydraulic Cylinder Damage

1. Moving with Unretracted Attachments ?

When an excavator is moved with its attachments not fully retracted, the bucket is prone to collision with obstacles, such as rocks. This puts additional stress on the cylinder’s piston rod, which may lead to internal cylinder damage and cause cracks around the pin and pivot areas.

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2. Avoid Using Travel Force for Digging ?

Utilizing the excavator’s travel force for digging, especially when the arm cylinder is nearly retracted, can exceed the arm’s bending force, causing deformation or bending. Operations should strictly rely on the equipment's designed digging capabilities, not the travel force, to prevent damage.

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3. High Frequency of Hydraulic Breaker Operations ?

Continuous, high-frequency use of hydraulic breakers induces excessive vibration in the piston rod, which can lead to rod bending or even fractures due to over-stressing.

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4. Digging at Cylinder Limit Extension ?

Performing digging tasks when hydraulic cylinders are fully extended adds excessive load to the cylinder, machine frame, and the bucket teeth. The impact on these components increases, posing a risk of internal cylinder damage and adversely affecting other hydraulic components.

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5. Using Rear Track Lift Force for Digging ?

Some operators attempt to leverage the rear lift of the excavator body for digging. When the bucket separates from rocks, the sudden drop of the machine body increases the load on the bucket, counterweight, frame, and swing bearing. This practice can cause substantial damage to the equipment.

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Essential Maintenance and Care Techniques for Hydraulic Cylinders

To ensure optimal performance and longevity, the following practices should be observed:

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1. Protect the Piston Rod Surface ?

Avoid impacts and scratches on the piston rod to prevent seal damage. Regularly clean the dust seals and the exposed sections of the piston rod to prevent contaminants from entering the cylinder, which could damage the piston, cylinder bore, or seals.

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2. Inspect Connections Frequently ?

Regularly check threaded connections and bolts for looseness. Tighten any loose connections promptly to maintain stability and prevent unwanted vibrations.

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3. Lubricate All Connection Points ?

Ensure all linkage points are well-lubricated to prevent rust and abnormal wear that can result from operation in a dry state.

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4. Change Hydraulic Oil and Return Oil Filters Periodically ?

Clean hydraulic oil and filters are essential for cylinder longevity. Regularly replace the hydraulic oil and return oil filters to maintain cleanliness and prevent internal contamination.

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5. Purge Air Before Operation ?

Before starting operations, fully extend and retract the cylinder several times to release trapped air. Perform five cycles of full extension and retraction as a pre-operational test to avoid internal pressure buildup.

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6. Monitor Hydraulic Oil Temperature ?

Excessive oil temperatures can cause seals to degrade or deform, potentially leading to permanent damage or complete failure. Monitoring and maintaining a safe hydraulic oil temperature is crucial.

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7. Proper Storage Position After Operation ?

After completing work, park the excavator on level ground and retract the piston rod fully. This minimizes cylinder pressure by allowing hydraulic oil to return fully to the tank, reducing the risk of undue stress on the cylinder.

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Built for Mining and More

Origin Machinery provides hydraulic cylinders for mining machinery, including excavators, dump trucks, loaders, bulldozers and graders. Our advanced production line handles cylinders with diameters up to 800mm, rod diameters up to 600mm, and strokes up to 6000mm, with an annual output of 2,000 units.

Take on any challenge with Origin Machinery: [email protected]