Failure Analysis

At Royal, we work with our customers to review their failures and use that information to provide a solution.

Understanding failure mode of your cylinder is the first step towards developing a solution.

You can use the list below to diagnose what type of failure your cylinder is up against and possible solutions. Or send your cylinder to us and our engineering team will review the cylinder and go over the application with you to develop a custom cylinder solution.

Avoid costly downtime.
Contact Royal for assistance.

Troubleshooting Guide

LOCATION Symptoms Possible Causes Remedies
PISTON ROD Scored or Scratched
  • Oil Contamination
  • Inspect Gland Bushings and Rod Seals. Replace if necessary
  • Modify to add rod wear rings.
Bent or Broken
  • Side Load
  • Misalignment
  • Consider Piston Stop or external rod supports
  • Review the range of motion for the cylinder. Cylinder rod and mounts need to be aligned.
Worn on one side or spot
  • Excessive side load
  • Rod Undersized
  • Change range of motion
  • Increase rod size
  • Add external supports
  • Corrosion
  • Review rod material
  • Consider external rod protection
  • Scored or Scratched
  • Oil Contamination
  • Inspect Piston and piston seals. Replace if necessary
  • Replace Barrel
  • Rod Eye Elongated
  • Shock Load/Slamming
  • Undersized
  • Check cylinder cushioning and operating conditions
  • Review size of pin and forces
  • Trunnion Pins Breaking
  • Undersized
  • Misalignment
  • Review size of pin and forces
  • Review the range of motion for the cylinder. Cylinder rod and mount need to be aligned.
  • Cylinder Slipping or Chattering
  • Lubrication
  • Internal Leakage
  • Air in System
  • Review lubrication delivery system
  • Piston seals worn, replace with new
  • Bleed system
  • Leakage
  • Incorrect Seals
  • Seal Grooves compromised
  • Tolerance mistake in Grooves
  • Air in Oil
  • Contamination of Oil
  • Check seal compatibility
  • Check grooves for scratches or correction
  • Inspect groove size
  • Bleed System
  • Replace oil and replace seals



Chris McGregor