How to Extend the Life of Your Pneumatic Cylinders

Pneumatic cylinders are widely known for their reliability, but like any mechanical component, they aren't immune to wear and tear. A failing pneumatic cylinder can disrupt operations, hinder productivity, and lead to significant delays and costs. Recognizing the warning signs early and knowing whether to repair or replace it can save you time and money. Pair this with routine maintenance to get the most out of your cylinder.

Faulty Pneumatic
Cylinder Symptoms

Common issues to watch for include sluggish actuation, hissing sounds, or intermittent startup. Sluggish motion often indicates inadequate actuation pressure, while hissing suggests a system leak caused by damaged seals or pistons. Regularly monitoring pressure levels and cylinder performance can prevent total system failure.

Other symptoms include unusually high actuation pressure, pulsing loads, or visible damage such as wear and corrosion. Faulty air lines or metering valves often lead to increased pressure needs, while load pulsing causes “chattering” motion which reduces accuracy and efficiency due to fluctuating air supply. Identifying these issues early can help maintain smooth system operation.

Common Causes of Pneumatic Cylinder Failures

Pneumatic cylinder failures are often linked to a few recurring causes, with side loading being one of the most common. Side loading happens when external forces or misaligned loads push against the piston rod, straining the cylinder’s axis. This usually results from improper installation. Addressing side loading quickly is critical to avoiding further equipment damage.

Contaminants such as oil, water, or dust can clog cylinder components, diminishing efficiency or causing outright failure. Additionally, insufficient lubrication can damage seals, while operating cylinders beyond their optimal range may overstress components, leading to breakdowns. Most brand-new pneumatic actuators are “lubed for life.” This means that no lubrication is required to operate the actuator. Once the actuator is subjected to lubrication, the internal grease will be flushed out. The actuator must be lubricated for the rest of its life. Clean, dry air is critical to long, maintenance-free operation.

Practical Tips for Fixing Issues

Maintaining your pneumatic cylinders ensures safe and efficient performance. Begin by following proper lockout/tagout procedures, turning off the power supply, and releasing any compressed air to minimize hazards. Inspect externally and internally, if possible, the cylinder rod, tube, and seals for rust, cracks, scoring of the ID wall of the actuator, or corrosion. Note that not all cylinders can be disassembled and are considered “throw away”. Clean accumulated debris and replace damaged parts as needed. For extensive damage, replacing the entire cylinder may be the best option. Follow the manufacturer’s lubrication recommendations, especially for tube gaskets, rod seals, piston seals, and inner surfaces, as this minimizes wear in extreme environments.

For seal replacements, secure the tube cover in a vice and remove the rod cover. Take apart the components, clean them thoroughly, and replace any worn seals, ensuring proper installation. Lubricate the internal bore of the cylinder per manufacturer specifications, typically a Lithium-based grease. Reassemble the cylinder and tighten the tube cover slightly more than before. Soapy water may be used to search for leaks by brushing it on over the nose of the cylinder by the rod wiper, and the connections of the head and body. Regular inspections and proper care will keep your cylinders operating smoothly for longer.

Preventative Maintenance Strategies

Proper installation is a key factor. Using incorrect tools or failing to secure components properly can compromise the cylinder’s functionality and durability. Ensuring fasteners are tightened to the correct torque level is especially important when installing tie rods.

Replace filters as recommended by the manufacturer to protect the system from harmful contaminants. Inspect fittings periodically for signs of rust or wear, as these can allow pollutants to enter the cylinder. By following these best practices, you can keep your pneumatic cylinders in top condition for an extended period.

Need a New Pneumatic Cylinder?

If you need a replacement pneumatic cylinder or help with installation, All World is here to assist. Our team of seasoned experts is well-versed in pneumatic systems and ready to recommend the perfect replacement. We’ll even cross-reference your current cylinder with other brands to guarantee compatibility.

Browse our extensive inventory of in-stock parts, available for next-day shipping, or reach out for personalized support. Keep your systems running smoothly—connect with All World today!