Hydraulic Cylinder Piston Seal Blowout: What Causes It and How to Prevent It

When a hydraulic cylinder suddenly starts leaking or loses force under load, the piston seal may have blown out. This failure isn’t random — it’s usually the result of pressure spikes, contamination, or improper assembly.

Common Causes of Piston Seal Blowout

  • Overpressure: Relief valve failure or shock load exceeds seal rating
  • Contaminated fluid: Dirt and debris score the bore and damage sealing surfaces
  • Improper installation: Twisted or cut seals from poor assembly technique
  • Rod misalignment: Off-center movement wears the piston seal unevenly

Warning Signs

  • Sudden loss of cylinder force under load
  • Hydraulic fluid leaking from both sides of the piston
  • Jerky movement or full stroke skip

Fixes and Prevention

  • Install high-pressure rated seals and check relief valve settings
  • Flush system and filter fluid before resealing
  • Use proper tools and techniques during seal installation
  • Check rod straightness and mounting alignment before reassembly

Conclusion

Piston seal blowouts take your equipment offline — fast. By maintaining clean fluid, managing system pressure, and installing seals correctly, you prevent repeat failures and keep your cylinders working under full load.

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