Hydraulic cylinders are used in a wide range of machinery—from mining equipment to cranes. Their primary purpose is to generate force and motion. When working with or around hydraulic systems, it’s crucial to understand the power and speed of the cylinder to maintain a safe working environment.
A cylinder’s force depends on its size and the system pressure. Even a small cylinder—about the size of a banana—can generate 900 kilograms of force at 180 bar. At the same pressure, a large cylinder with a one-meter diameter can produce a lifting force of 1,441,000 kilograms. With forces this powerful, safety protocols and working methods must be taken seriously at all times.
Hydraulic cylinder power and things to consider
The report was prepared on January 8, 2024.
Machine and Cylinder Maintenance
Hydraulic cylinders are primarily used in heavy machinery and production lines, where their role is to lift and move heavy loads. That’s why it’s critical that the machines function properly—any failure can lead to loads tipping or falling. For example, if a crane’s outrigger has surface damage and worn seals, the cylinder could fail, causing the entire crane to collapse. With heavy loads, the consequences can be severe.
This makes cylinder maintenance and refurbishment essential for safe working conditions. Understanding the force a hydraulic cylinder can produce is key to working safely around it.
Extra Caution Required
When working with heavy machinery and powerful hydraulic cylinders, you can never be too careful. When attaching a cylinder to a machine, always make sure nothing—like your fingers or clothing—can get caught or pinched. Always be mindful of your coworkers’ safety as well.
Keep in mind that removing a cylinder requires the use of a lifting aid, as cylinders are often very heavy. Put simply—if you’re detaching a cylinder or bucket, make sure it’s properly supported to prevent anything from falling on you or your coworkers.
If you’re ever unsure about something—such as the condition of the cylinder or the machine—it’s always better to check before starting work.
Safe Distances and Avoiding Unnecessary Risks
Avoid unnecessary risks while working—never stand under the boom of an excavator or forestry machine, and don’t move out of the operator’s line of sight.
Maintaining a safe distance is essential. Many machines have clearly defined working zones that must be respected. For example, cranes may have a safety sector of 10 to 40 meters—entering this area is not recommended. The same applies to excavators, where flying debris can pose a serious hazard when digging with high force.
Fittings and Hoses
When working with hydraulic systems, it’s important to remember that high system pressure is also present inside the fittings and hoses, as they are responsible for delivering hydraulic oil to the cylinder. Over time, hoses may develop scratches or cracks, which can lead to oil spraying out. Due to the high pressure, the oil can spray with enough force to penetrate the skin.
To prevent such incidents, hose condition must be inspected regularly, and necessary maintenance carried out promptly. Old hoses should be routed to follow the movement of the boom and must never be pulled or yanked during operation.
Proper Training
Proper training and orientation are essential for safe working practices. Anyone working with hydraulic cylinders and heavy machinery must understand how the equipment functions and what factors affect its performance. Employees must also be aware of the potential risks involved—and how to prevent them.
