Hydraulic and pneumatic cylinders are designed to deliver years of dependable performance—but when a failure happens, it can halt production, reduce efficiency, and create costly downtime. Understanding the most common cylinder issues and how to troubleshoot them is essential for keeping your equipment running smoothly.

Below is a guide to identifying common hydraulic and pneumatic cylinder problems—and the steps you can take to prevent them.

1. External Leaks  

One of the most frequent issues operators face is fluid leaking around the rod, ports, or tube.

Possible causes:

• Worn or damaged seals

• Contamination in the fluid

• Misalignment between the rod and load

• Excessive pressure or side loading

How to troubleshoot:

• Inspect seals and replace if worn

• Verify rod alignment and mounting stability

• Confirm system pressure matches design specifications

How to avoid:
Regular maintenance and proper mounting dramatically reduce seal-related failures.

2. Rod Bending or Scoring  

A bent, scratched, or scored rod often leads to premature seal failure and poor cylinder performance.

Possible causes:

• Side loading from incorrect mounting

• Shock loads or impact

• Contaminants wearing down rod coating

How to troubleshoot:

• Check for proper mounting support

• Inspect rod alignment through full stroke

• Replace the rod or cylinder if structural damage is present

How to avoid:
Use proper mount styles and consider specialty coatings, especially in abrasive environments.

3. Seal Wear & Premature Failure

When seals break down, the cylinder quickly loses efficiency.

Possible causes:

• High temperatures

• Incorrect seal material

• Contaminated hydraulic fluid

• Excessive cycle rates

How to troubleshoot:

• Identify whether heat, pressure, or contaminants are responsible

• Replace seals with the correct material blend

How to avoid:
Work with your cylinder supplier to match seal packages to your specific application.

4. Slow or Erratic Movement

If a cylinder becomes sluggish or inconsistent, the root cause is usually inside the system.

Possible causes:

• Air in the hydraulic system

• Internal leaks

• Low fluid levels

• Valve malfunction

How to troubleshoot:

• Bleed the system to remove air

• Check for bypassing across piston seals

• Inspect valves and ensure full flow

How to avoid:
Maintain clean hydraulic fluid and follow OEM service intervals.

5. Internal Corrosion

Cylinders exposed to moisture, harsh chemicals, or lack of lubrication can corrode from the inside out.

Possible causes:

• Water contamination in fluid

• Inadequate protective coatings

• Harsh operating environments

How to troubleshoot:

• Inspect fluid samples

• Check for pitting inside the barrel or on the rod

How to avoid:
Choose stainless steel components or specialty finishes for corrosive applications.

Preventing Cylinder Failures Starts With Proper Design & Maintenance

Most hydraulic cylinder problems and pneumatic cylinder issues can be traced back to improper mounting, incorrect seal material, contamination, or environments that exceed standard design specs. The good news? These issues are preventable with the right engineering support.

Sheffer has been diagnosing and solving cylinder failures for more than 70 years. If you're experiencing ongoing problems or want help identifying the root cause, our team is here to help.

 Need help troubleshooting a cylinder issue?

Contact Sheffer today for expert support.
Let us help you diagnose, repair, or redesign the right solution for your application.