FLUID POWER SEALING SOLUTIONS

TROUBLESHOOTING GUIDE
POLYMER SEALS
Technical Information — troubleshooting guide Engineered Polymer Solutions

This section provides troubleshooting criteria for Chesterton’s hydraulic and pneumatic sealing devices. It should be
used only as a general reference guide when repacking, rebuilding, or redesigning any cylinder or press and specific
guidance can be provided by your Chesterton representative. By installing superior, longer lasting seals and
components in a properly designed cylinder, one can expect greatly extended, leak-free service.

SEAL CONDITION No visible damage, but leaking

Probable Cause Possible Solution
Incorrect size seal not sealing dynamically Check seal and equipment dimensions.
or statically. Check for additional causes of leak such as
static O-ring or gasket leak.

Hydroplaning due to low sealing pressure Check fluid pressure on return to tank cycle.
with high viscosity fluid and too smooth Check dynamic surface finish. Check cycle
surface finish. speed. Consider alternate seal design with
higher pre-load.

SEAL CONDITION Rolled or twisted seal may have permanent creases from twisting in seal cavity and
may be severely rolled
Probable Cause Possible Solution

A variety of conditions may cause rolling of a Check dimensions of seal and equipment.
seal. Drag due to sizing problem, vacuuming, Check system and application for operating
extrusion, or swelling may all cause seals to condition. Look for other types of damage to
roll. In addition, side loading and shock help troubleshoot this problem.
loading could be contributing factors.

SEAL CONDITION Seal lips are crushed, crimped or creased

Probable Cause Possible Solution

Seal too tall for groove. Remachine seal groove or choose

shorter seal.

Loose bottom bushing under seal hits seal Secure and vent bottom bushing.
when pressurized.

Seal is being mechanically loaded by a Remove device if not necessary or re-work

metallic or elastomeric retaining device. device to prevent contact with seal lip(s).

Seal is being dragged to bottom of groove or Correct vacuum condition or secure seal
box by vacuum or by missizing of seal. with retaining device. Check seal dimensions
and correct application of piston and rod
designed seals.

Piston cup lip is jammed by hold down plate Correct inside (“d2” dimension) of piston
on piston or is acting as stop at end or stroke. cup relative to diameter of hold down plate.
Provide mechanical stop on stroke or
choose cup with shorter lip.

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Technical Information — troubleshooting guide Engineered Polymer Solutions

SEAL CONDITION Extrusion of inside diameter heel

Probable Cause Possible Solution
If extrusion is evident all around Rework or replace gland or bushing
circumference of inside diameter heel, rod to achieve recommended clearance.
or ram to gland or bushing clearance is Use rigid back-up ring.
excessive for pressure.
If extrusion is evident on half of the Rework or replace gland or bushing. Replace
circumference of the inside diameter heel, bearings. Use backup ring. Check gland
rod or ram is side loading. Gland may not be for centering.
centered or cylinder head may be cocked.

SEAL CONDITION Extrusion of outside diameter heel

Probable Cause Possible Solution
A1: If extrusion is evident all around A1: Rework or replace piston head or retube
circumference of outside diameter to achieve recommended clearance. Use
heel, piston head-to-bore clearance non-metallic bearing band(s) to prevent
is excessive. May be due to poor design, wear. Check cylinder integrity relative
wear, or pressure swelling or to maximum pressure. Use back-up rings
“ballooning.” under extreme shock loads.

A. Piston Application A2: If extrusion is evident on half of the A2: R

 ework piston head for non-metallic
circumference of the outside diameter bearing band thus centering piston.
heel, piston is side loading or cylinder Check cylinder bore for possible ovality.
is out-of-round.

B: Excessive clearance between gland and B: R

 ework or replace gland or use
stuffing box bore. back-up ring.

B. Rod Seal Application

SEAL CONDITION U-cup split through center of its cross-section

Probable Cause Possible Solution
If splitting or separation is apparent over Check equipment dimensions and compare
most or all of seal’s circumference, the cause to seal dimension.
is a dial oversizing or incorrect seal size.

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Technical Information — troubleshooting guide Engineered Polymer Solutions

SEAL CONDITION U-cup or piston cup lip is separated from heel

Probable Cause Possible Solution
If splitting or separation is apparent over a Rework or replace bearing support to
small portion of seal’s circumference, the achieve concentricity of rod and piston.
cause is a lack of concentricity or ovality of Check stuffing box and cylinder bores for
equipment. roundness.

SEAL CONDITION Crescent shaped section missing from dynamic sealing lip
Probable Cause Possible Solution
Piston seal lip is passing over port either Chamfer sharp internal port edges, alter
during installation or actual use. stroke or piston design to avoid port. If
caused during installation, use shim or
otherwise protect seal from sharp edges.

Seal lip was kinked, jammed, or curled back Use care when installing. Don’t use sharp
during installation. tools. Check lip before pushing into bore.

SEAL CONDITION Excessive abrasion or grooving of dynamic sealing lip

Probable Cause Possible Solution
A1: Excessive wear on inside diameter A1: Rework or replace rod or ram to achieve
indicates poor rod finish. finish of 8 – 24 R.M.S (Ra).

A2: Excessive wear on inside diameter indi- A2: Install sharp lip, abrasion resistant wiper.
cates abrasive particles in the system. Consider an externally mounted, easily
replaceable wiper. May require a custom
A. Rod Seal Application
wiper in excessively wet/dirty
environments.

B1: Excessive wear on outside diameter B1: R

 ework or replace cylinder tube to a
indicates poor bore finish. bore finish of 8 – 24 R.M.S (Ra).

B2: Excessive wear on outside diameter B2: Check condition of fluid. Filter system
indicates abrasive particles in the system. with portable filtration or drain and
flush system.
B. Piston Application

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Technical Information — troubleshooting guide Engineered Polymer Solutions

SEAL CONDITION Excessive wear, misshaping, darkening of V-ring sets in stacked sets
Probable Cause Possible Solution

Undercompression of stacked V-ring set can Check split if applicable, check alignment
cause rings to roll or twist and bind causing of each ring before installing next ring.
leakage and excessive friction.

Overcompression of stacked V-ring Measure equipment and seal set carefully;

set can cause binding and excessive friction shim and adjust properly. If ram or rod
due to lack of lubricating barrier and is binding, loosening of load on set may
additional drag. ease binding. May need to remove and
re-pack V-rings properly.

SEAL CONDITION Wear on dynamic heel 360˚ of seal’s circumference

Probable Cause Possible Solution

Misapplication of rod or piston designed seal Use rod seals for rod applications and piston
or wrong seal size. mounted seals on pistons. Check equipment
and seal dimensions.

SEAL CONDITION Excessive wear on dynamic heel and lip of 180˚ of seal’s circumference. May also
show extrusion of dynamic heel 180˚ opposite of the worn side of the seal
Probable Cause Possible Solution
Side loading due to misalignment, mounting Re-work or replace bearing or bushing
and clevis design or application and design to achieve concentricity. Check for
causing bushing and bearing wear and misalignment or cause of side loading.
excessive seal wear. Also increases clearances Increase bearing area with strong,
resulting in possible extrusion. non-metallic bearings. Check diametral
clearances for adequate seal support.
A. Rod Seal Application

B. Piston Application

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Technical Information — troubleshooting guide Engineered Polymer Solutions

SEAL CONDITION Excessive wear on heel 360˚ of circumference of piston cup, often the seal lip
will not show wear
Probable Cause Possible Solution

Overcompression of the piston cup due to Compress flange thickness (H2)10%. Check
overtightening of the hold down plate or base thickness relative to space available.
base thickness too great for the available Do not overtighten. Check cup visually after
space causes the heel to squeeze-out. tightening for heel squeeze-out.

SEAL CONDITION Vertical/Axial scratches on static lip may be associated with other damage
Probable Cause Possible Solution
Incorrect sizing of rod or piston seal will Check dimensions of seal groove/stuffing
cause seal to move axially in the seal groove/ box and rod or bore diameter. Check for seal
stuffing box. Axial movement is evident due fit and correct application of rod seal or
to scratches on static lip. piston mounted seal.

Vacuuming due to inability of fluid to fill Correct shock-loading if possible. Check

cylinder to make up for increasing system for pipe flow volume. Consider
volumetric area. alternate seal design.
A. Piston Application

A: Excessive wear or “pock-marked” A: R

 e-work to achieve a static finish
appearance on outside diameter 32 – 45 R.M.S. (Ra).
indicates a poor static finish on box
bore or seal groove.

B: Excessive wear or “pock-marked” appear- B: R

 e-work to achieve a static finish
ance on inside diameter indicates a poor 32 – 45 R.M.S. (Ra).
B. Rod Seal Application static finish on piston seal groove.

SEAL CONDITION Discoloration, swelling, softening, or hardening of seal compound

Probable Cause Possible Solution

Fluid incompatibility with hydraulic fluid, Check compatibility of seal compound.

lubricating oil, installation grease, or Change fluid type or substitute seal
cleaning solvent. compound.

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Technical Information — troubleshooting guide Engineered Polymer Solutions

SEAL CONDITION Black, tar-like deposits and/or burned spots, possibly burned completely through
the heel of the seal. This damage will appear in the crotch area between the seal lips.
Probable Cause Possible Solution
Dieseling, due to auto ignition of hydraulic Bleed all air from hydraulic system. Caution
fluid causing intense heat at the damaged should be used to bleed system after any
area. Dieseling results from trapped air work is done to pump, valves, lines, or
bubbles in the fluid rising to settle between actuators.
the seal lips where, under pressure, the
bubbles are compressed. Rapid decompres-
sion of compressed air bubble results in
energy released as heat.

SEAL CONDITION Seal is dark or black in color, has lost flair or is drastically misshaped
Probable Cause Possible Solution
Darkening of entire seal indicates excessive Protect against environmental heat source.
fluid temperatures or environmental heat Maintain or utilize cooling system. Use high
exposure. temperature seal compound.

Darkening of dynamic lip only indicates Check reciprocating or rotating speed. Check
excessive friction due to speed, lack of lubric- lubrication of pneumatic system or lubricity
ity, or jamming of dynamic lip or heel. of hydraulic fluid. Look for evidence of
jamming of lip or extrusion of heel.

Drastically misshaped seal indicates Use high temperature seal compound.

prolonged exposure to heat or extremely Check seal groove dimensions.
high heat. May be caused by continual rolling
of seal in groove.

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 GLOBAL SOLUTIONS, LOCAL SERVICE
Since its founding in 1884, A.W. Chesterton Company has successfully
met the critical needs of its diverse customer base. Today, as always,
customers count on Chesterton solutions to increase equipment re-
liability, optimize energy consumption, and provide local technical
support and service wherever they are in the world.

Chesterton’s global capabilities include:

n
Servicing plants in over 100 countries
n
Global manufacturing operations
n
More than 500 Service Centers and Sales Offices worldwide
n
Over 1200 trained local Service Specialists and Technicians

Visit our website at

www.chesterton.com

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Technical data reflects results of laboratory tests and is intended to indicate general characteristics only.
A.W. CHESTERTON COMPANY DISCLAIMS ALL WARRANTIES EXPRESSED, OR IMPLIED, INCLUDING WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE OR USE. LIABILITY, IF ANY, IS LIMITED TO PRODUCT REPLACEMENT ONLY.
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EQUIPMENT. PLEASE REFER TO RELEVANT MATERIAL SAFETY DATA SHEETS, PRODUCT DATA SHEETS AND/OR PRODUCT LABELS FOR SAFE USE, STORAGE, HANDLING AND DISPOSAL OF PRODUCTS OR CONSULT WITH YOUR LOCAL CHESTERTON REPRESENTATIVE.

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