Applied Failure Analysis Hydraulic Cylinder Seal Failure Analysis

Other Repair Process Information - REHS2811 - Hydraulic Cylinder Seal Failure Ana...
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Applied Failure Analysis

Hydraulic Cylinder Seal Failure Analysis{7562}
Media Number -REHS2811-00
Publication Date -01/11/2005
Date Updated -29/11/2005
i02405885
Hydraulic Cylinder Seal Failure Analysis{7562}

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Introduction
Careful inspection of the hydraulic cylinder seals after a failure can give indications of the root
cause. Document the complaint of the customer and determine if the problem is drift, leakage, or
noise. Leakage can occur at the rod seals between the cylinder head and rod or at the head seals
between the head and the tube. Leakage can also occur internally at the piston seals, between the
piston and the tube. At disassembly, all seals should be inspected for any change in appearance in
comparison to new seals. All scratches, nicks, cuts, foreign particles, dimensional changes, or
color changes should be noted. The following sections describe most common problems,
indications of the root causes, and remedies.
Cleanliness of hydraulic components during assembly is critical. Before assembly, all parts must
be properly cleaned. All parts that will be stored prior to assembly must be stored in a way to
protect them from contamination. Refer to Cleaning Guide Equipment and Chemical
Recommendations Reference Manual, SEBF8354 for complete cleaning instructions of all dealer
areas. Refer to Spec Shop Cleaning Guideline, SEBF8360 for specifics on spec shop parts
cleaning.
Nomenclature
The following illustration shows the position of all the seals, rings and bands that will be
discussed in this document. A bolted head cylinder is shown, but threaded gland and threaded
crown cylinders have the same basic seal positioning.
Illustration 1
(1) head o-ring seal

(2) head seal backup ring
(3) wear band
(4) buffer seal
(5) u-cup seal
(6) wiper seal
(7) nut
(8) piston
(9) head
(10) rod
(11) piston seal expander ring
(12) piston seal ring
(13) wear band
Rod Seal Leakage

Assembly Damage
1. Assembly Cone Not Used
Indications
A small section of the material is found to be clipped out of the buffer seal, U-cup
seal, or wiper seal ID lip.
Steel backed PTFE wear ring (used on HEX machines) is heavily scratched in one or
more discrete areas.
Possible Root Causes
A sharp edge, usually at the end of the cylinder rod, has clipped or scratched the seals as the
head is pushed over the rod.
Remedy
It is recommended that a seal guide be used when reassembling the head to the rod. Any
metal part that comes in contact with a seal during assembly or operation must be free of
sharp edges.
Comments
The wiper seal is most commonly clipped when a guide is not used. The head lands pilot the
head after the wiper goes over the rod. An attempt to assemble the head over the rod in one
motion should be made, because it is possible for the wiper lip to be caught between the
edge of the sealguide and the rod chamfer if a jerking motion is used. All burrs and sharp
edges should be removed from the end of the rod prior to reassembly.
Illustration 2
g01202321
Steel backed PTFE wear band heavily scratched by the edge of the rod.
2. Wiper Seal Not Installed Properly

Indications
The wiper seals' metal shell is dented, or deformed.
Dirt enters the cylinder through the wiper seal because the lip is not in close contact
with the rod.
The wiper seal is dislodged from the counterbore.
The contacting band of the wiper seal is not uniform in width around the
circumference of the seal.
The wiper seal was not installed properly or the seal was damaged during installation.
Remedy
A piloting, wiper seal driver should be used to install wiper seals that have a metal shell. If
necessary, use a rubber mallet to tap around the edges of the seal. This will ensure proper
seating of the seal against the counterbore. Do not dent the metal shell.
Comments
An uneven contact band on the ID of the wiper indicates that the seal was not properly
seated against the back of the counterbore, or that the rod was bent. Always use bearing
adhesive on the OD of the metal shell to aid in retention and eliminate the seal OD as a
possible leak path. However, adhesive on any other surface of the seal, rod, or head is not
allowed.
3. Damage to the Head
Indications
Upon removal of the seals, scratches or gouges are found in the seal grooves of the
head.
The seals were removed in a manner that was too aggressive. Gouges were left in the
grooves by screwdrivers, chisels, or other hardened tools. The groove's surface finish was
degraded beyond the ability of the seals to properly function. Refer to Illustration 3.
Remedy
Care should be taken in order to prevent damage to the groove when removing rod seals.
Use a seal pick or other tools of low hardness to remove the seals.
Illustration 3
g01202423
Buffer groove damage by removing a seal with a screwdriver.
Contamination
1. Paint Contamination
Indications
The front face of the wiper seal is painted to the wiper lip edge. Paint overspray is
found on the rod in a location that will enter the seals during operation. Refer to
Illustration 5.
Other indications are pieces of paint adhering to the inner diameter of the rod seals.
Refer to Illustration 4.
The wiper seal and/or rod was not properly masked during painting of the cylinder.
Remedy
Before painting, protect the entire front face of the wiper seal and the section of the rod that
will make contact with the seal.
Comments
Small paint chips cause leakage by getting between the sealing lip of the U-cup seal and the
rod. The U-cup lip edge must be clean of any contaminant to function at maximum
efficiency.
Illustration 4
g01202426
Paint of front face of wiper seals. Paint on the lip edge indicates that the rod was probably painted.
Illustration 5
g01202568
Strut in which the wiper seal and the rod just outboard of the seal was not masked prior to painting.
2. Metallic Contamination
Indications
Small, medium sized axial scratches are found across the sealing lip of the U-cup.
Scratches that match are often found on the buffer and wiper seals. Refer to
Illustration 7 and 8.
Shiny metal flakes and chips are embedded in the wear bands, and in the sides of the
plastic piston seal ring. Refer to Illustration 6.
The rod is scratched in one or more places. The scratches are straight running the
length of the rod stroke.
Metal contaminants were not removed from the system before the contaminants migrated to
the cylinders. The contaminants may have been the by-product of the manufacturing
process, wear or the result of repairs. The contaminants damage the rod seals.
Remedy
Replace wearing components. Always replace the wear bands and piston seal during
resealing because these components act as particle traps. The systems' cleanliness may
improve after a cylinder reseal if the contamination was the result of manufacturing
cleanliness instead of system wear. Replace any rod with scoring or a nick deep enough to
be felt with a fingernail.
Comments
There is nothing in the rod seals that can scratch a rod. However, rod seals and wear bands
can hold hard particles against the rod resulting in long axial scratches. These scratches may
then damage the U-cup seal. A single fine scratch on the ID of the U-cup seal can result in a
noticeable leak.
Illustration 6
g01202384
Metallic particles are shown embedded in the piston seal ring. These particles cause leakage by scratching the
U-cup sealing lip.
Illustration 7
g01202571
The scratches in the U-cup lip were caused by metallic contamination.
Illustration 8
g01202573
Fine scratches are shown on the sealing lip of the U-cup. Very small scratches will result in noticeable
leakage.
3. Dirt Contamination
Indications
Heavy scratches or wear is found on the ID of the rod seals.
Large amounts of dirt are found between the seals and around the wear bands.
The rod is scored to varying degree.
The wiper seal was damaged or improperly assembled, and dirt is entering the
cylinder.
The head was not properly cleaned prior to resealing.
Other Repair Process Information - REHS2811 - Hydraulic Cylinder Seal Failure A... Page 10 of 22
Bent cylinder rods cause uneven wear of the wiper seal or a loss of lip to rod contact
pressure on one side of the seal.
Nonmetallic contaminants were built into the cylinder or other hydraulic components.
Remedy
Ensure proper assembly of the wiper seal. Thoroughly clean the head and pay close
attention to the inside of the seal grooves prior to resealing. Straighten or replace any bent
rod according to the guidelines in the Special Instruction, SEBF8072, "Inspection and
Salvage of Hydraulic Cylinder Components" .
Comments
A small amount of very fine dirt or dust behind the wiper seal is to be expected after long
service. The area behind the wiper is dead space and system contamination will not result
unless the buildup is heavy. The U-cup or buffer seal may have black oil around the OD
after a period of service. This material is a combination of extremely small wear particles
from the head wear band and chrome from the rod. This does not contribute to seal failures.
Illustration 9
g01202672
The cylinder rod was lightly scored by aluminum oxide contaminants that were trapped by the head wear
band.
4. Water Contamination (Hydrolysis)

Indications
Any of the rod seals, but especially the buffer, is cracked and brittle.
The seal has large pieces missing from the sealing edge.
Material can be scratched off the seal with a fingernail.
Water or coolant has contaminated the hydraulic oil. Cooler failure is possible if the
machine is water to oil cooled. Water can condense on tank walls. Water may also reach
higher concentrations around the rod seals. The higher concentration of water is due to low
oil flow around the seals.
Remedy
If the oil sample indicates water in the oil, change the oil. Use hydrolysis resistant rod seals.
Always use special carboxylated nitrile (black) U-cup and wiper seals, and a PTFE step
buffer seal when using water/glycol hydraulic fluids.
Comments
A very small amount of water or coolant can quickly damage rod seals at elevated
temperatures. At moderate temperatures, the breakdown occurs more slowly.
Illustration 10
g01202682
Buffer seal destroyed by hydrolysis. Note the leathery "skin" on the outside of the part.
Illustration 11
g01203199
Head oval seal destroyed by hydrolysis.
Damage to Mating Iron

1. Rod Damage
Indications
There may be scratches on the ID of the rod seals and uneven wear patterns on the rod
seals and on the wear band.
Nicks or scratches on the surface of the cylinder rod that are not completely straight
and axial are other indications.
Pits or cracks can be found on the chrome surface of the rod.
The rod is bent.
The rod has been scratched or abraded the working environment.
The chrome surface on the rod is of low quality or was improperly polished.
Remedy
Straighten or replace any bent rod according to the guidelines in Special Instruction,
SEBF8072, "Inspection and Salvage of Hydraulic Cylinder Components". Re-chrome,
polish, or re-rod any damaged rod according to the guidelines in Special Instruction,
SEBF8072, "Inspection and Salvage of Hydraulic Cylinder Components".
Illustration 12
g01202435
Rod scuffed by poor handling.
2. Head Groove Damaged or not Made to Standards

Indications
Seal grooves are corroded and pitted.
Tool drag marks are evident, surface finish does not meet standards.
Water has entered the head, or the head was left exposed to the environment. The head
grooves were not properly machined.
Remedy
Obtain a new head. The grooves cannot be machined to a larger diameter in order to remove
pitting or tool marks without reducing the efficiency of the rod seals.
Illustration 13
g01202436
Step incorrectly machined into the wall of the buffer seal groove.
Illustration 14
g01202760
U-cup and buffer seal grooves with poor surface finish.
U-cup Extrusion
1. U-cup Extrusion
Indications
The buffer seal is worn flat or ribbons of material are coming off the back of the seal.
The ID of the U-cup seal closest to the wiper seal has small chunks removed from it
or it has a melted appearance.
Ribbons of material have flowed in between the rod and the head land behind the Ucup.
High pressure spikes have occurred in the cylinder.
The relief pressure setting may be set too high.
The buffer seal has been damaged. This exposes the U-cup to full system pressure.
If extrusion is seen on truck struts, overloading or overcharging may have occurred.
Remedy
Use a backup ring behind the U-cup seal that closes the clearance between the land and the
rod. Lower pressure relief settings. Replace damaged buffer seals.
Comments
Extrusion is not related to melting. The melting temperature of polyurethane is much higher
than the temperatures that can be generated in a normal operating hydraulic system.
Illustration 15
g01202765
A moderately extruded U-cup.
Illustration 16
g01202437
A heavily extruded U-cup seal.
Heat Damage
1. Heat Damage
Indications
The buffer and U-cup seals may appear very dark in color.
The U-cup has taken a heavy compression set.
The seals are cracked and brittle.
The hydraulic system temperature is too high for standard rod seals. Standard rod seals are
rated to 93 C (199.4 F) continuous operating temperature.
Remedy
Check cooling components for efficiency and fix any problems. Modify machine operation
in order to avoid overheating. Use high temperature rod seals. Use appropriate hydraulic oil
for the your specific operating conditions for good lubricity.
Illustration 17
g01203287
A buffer seal destroyed by oil temperatures higher than the rated operating temperature of the seal material.
Illustration 18
g01203288
U-cup seal destroyed by hydraulic system temperatures higher than the rated operating temperature of the seal
material.
Note: Rod Seal Assembly Tips

Push the U-cup to the back of the groove toward the wiper. The U-cup will remain in that
position during operation after the first pressure cycle.
Lubricate the rod and rod guide lightly before pushing the head over the rod. Do not
lubricate the seals excessively. Any oil between the U-cup and wiper seals will leak. The
leak will occur during the first hours of operation.
For optimum rod seal performance, the rod surface finish should be 0.40 micrometers (16
microinches).
Head Seal Leakage

O-ring seal or Backup Ring clipped during Assembly
Indications
A small section of the O-ring or backup ring appears "bitten" out of the part. This is most
common of the ends of split backup rings.
The backup ring was in a "sprung out" condition, and the ends of the ring did not remain in the
seal groove prior to the mating of the head with the cylinder tube. The ends of the seal outside the
groove were clipped.
Remedy
Make sure that the head seal O-ring and the backup ring grip the head tightly before mating the
head with the tube. If the backup ring does not grip the head tightly, assembly compound can be
used to prevent the ends from extending outside the seal groove in some cases.
Comments
Screw in the threaded gland head slowly in order to avoid pinching and stretching the Oring head seal.
Lubricate the OD of the seals lightly before assembly.
Many threaded gland head seal O-rings have a blue PTFE coating in order to reduce friction
during assembly.
The head seal O-ring on the threaded gland cylinder is often cut during disassembly by the
threads.
Illustration 19
g01202471
Head seal Backup Ring Clipped during Assembly.
Illustration 20
g01203751
Head seal Backup Rings Clipped during Assembly.
Head Seal and/or Backup Ring Extrusion

Indications
Ribbons of material that flowed into the clearance between the head and the cylinder tube
are present at disassembly.
Large amounts of material are missing on the low pressure side of the head seal O-ring.
Head seal extrusion is usually caused by oil pressures that are too high.
Head seal extrusion failures can also occur if the tube bore is too large or if the diameter of
the land behind the seal is too small (extrusion gap is too high).
Some failures have been attributed to the stretch of head bolts on the bolted cylinders.
Threaded gland cylinders have had failures because of the expansion of the tube at very
high pressures.
Remedy
If the backup ring is extruding use one of a harder material. The pressure around the head seal
may need to be reduced. Always tighten threaded gland cylinder heads to the proper torque after
resealing.
Piston Seal Drift

Dieseling
Indications
The cylinder drifts at a high rate.
Oil temperatures are elevated due to flow of oil through small clearances at high pressure.
The piston seal ring or rubber expander ring is eroded in a finger-like pattern. The area
around the erosion is blackened and sometimes smells burnt.
When air or other entrained gases that are saturated with oil vapors form in the hydraulic oil
dieseling occurs. When these bubbles are compressed at a high rate the gases ignite due to
adiabatic heating. The resulting explosion erodes adjacent components, especially nonmetallic
parts.
Remedy
All efforts should be made in order to remove air or other entrained combustible gases from the
system after resealing a cylinder before using the machine. Extend and retract the cylinders several
times before heavy work is done in order to force air back to the tank.
Illustration 21
g01202475
Piston Seal Ring damaged by Dieseling.
Illustration 22
g01202479
Piston Seal Ring Damaged by Dieseling at the Step Cut.
Explosive Decompression
Indications
The cylinder drifts at a high rate.
The rubber expander ring has large chunks of material missing.
There is no smell of burning or damage to the seal ring.
Explosive decompression (ED) occurs when gases that have penetrated into a rubber expander
ring suddenly expand due to a very rapid drop in hydraulic oil pressure, or when voiding occurs in
the cylinder. The rapid expansion of the entrained gas bubble pops a chunk of material out of the
rubber ring. If the damage accumulates the ring can no longer properly seal.
Remedy
All efforts should be made in order to remove air or other entrained gases from the system after
resealing a cylinder before using the machine. Extend and retract the cylinders several times
before heavy work is done in order to force air back to the tank. Refer to the cylinder removal and
install procedure for the specific model for more specific instructions. Use dieseling/ED resistant
piston seals. These seals are made of a rubber material designed to be less permeable to gases in
the hydraulic oil. Use protection piston seal backup rings. These rings reduce the area of the
rubber expander ring that is exposed to the oil and therefore reduce the amount of gases that
penetrate the rubber.
Comments
ED and dieseling are very similar. The root cause of ED and dieseling is air in the hydraulic
system.
Illustration 23
g01202522
Piston seal expander ring heavily damaged by explosive decompression.
Scratched Piston Seal Ring

Indications
The cylinder drifts slowly.
The split plastic seal ring has heavy axial scratches on it that run from one side of the seal to
the other.
Bore damage
Contamination
Remedy
If a damaged bore is the root cause of a scratched seal ring the bore will need to be lightly honed
or oversized in order to remove the damaged areas. Follow the recommendations found in the
Special Instruction, SEBF8072, "Guideline for Reusable Parts and Salvage Operations". If
contamination is the cause of the scratches all components must be thoroughly washed during
reseal of the cylinder.
Illustration 24
g01203311
Cylinder heavily scored by metallic contamination.
Illustration 25
g01203314
Piston seal ring scored by a cylinder bore with a poor surface finish.
Note: Other Information

Do not apply excessive heat to the cylinder with the seals in place. Heat can be conducted
into the seals and the seals may be damaged.
Excessively high pressure spikes will damage the rod seals. PTFE step seals do not last as
long as a backed polyurethane buffer seal at pressures above 24 MPa (3500 psi). Any
increase in the line relief pressure settings will reduce the life of the rod seals.
A head wear band should spring out when in the groove. A piston wear band should grip the
piston in order to avoid damage to the parts when the head is assembled to the rod and when
the rod assembly is mated with the cylinder assembly.
Oversized piston seals and wear bands should be used if the bore is honed 0.25 mm (0.010
inch)past nominal.
Note: Assembly Tips
After resealing a cylinder be sure to torque the piston nut properly. If the nut or the bolt is
not torqued properly the cylinder may drift due to leakage between the piston and the rod
mating surface.
The step cut on the piston seal can be slightly open before the rod assembly is mated with
the cylinder assembly. The gap will close completely when the assemblies are mated.
If the cylinder pressure test shows cylinder drift it may be necessary to rotate the rod eye
while slowly stroking the cylinder to help seat the piston seal in the groove.
Slight scuffing of the piston seal ring with a fine grit sandpaper or emery cloth in a
circumferential direction can help seat the ring to the cylinder bore.
Copyright 1993 - 2011 Caterpillar Inc.
Mon Nov 21 17:57:54 UTC+0200 2011
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Other Repair Process Information - REHS2811 - Hydraulic Cylinder Seal Failure Ana...

Applied Failure Analysis

Publication Date -01/11/2005

Date Updated -29/11/2005

Hydraulic Cylinder Seal Failure Analysis{7562}

(1) head o-ring seal

Rod Seal Leakage

2. Wiper Seal Not Installed Properly

Buffer groove damage by removing a seal with a screwdriver.

The scratches in the U-cup lip were caused by metallic contamination.

4. Water Contamination (Hydrolysis)

Head oval seal destroyed by hydrolysis.

Damage to Mating Iron

Rod scuffed by poor handling.

2. Head Groove Damaged or not Made to Standards

U-cup and buffer seal grooves with poor surface finish.

A moderately extruded U-cup.

A heavily extruded U-cup seal.

Note: Rod Seal Assembly Tips

Head Seal Leakage

Head seal Backup Ring Clipped during Assembly.

Head seal Backup Rings Clipped during Assembly.

Head Seal and/or Backup Ring Extrusion

Piston Seal Drift

Piston Seal Ring damaged by Dieseling.

Piston Seal Ring Damaged by Dieseling at the Step Cut.

Piston seal expander ring heavily damaged by explosive decompression.

Scratched Piston Seal Ring

Cylinder heavily scored by metallic contamination.

Note: Other Information

Mon Nov 21 17:57:54 UTC+0200 2011

All Rights Reserved.

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