The Hidden Costs of Ignoring Hydraulic Cylinder Maintenance in Mining
Mining operations rely on heavy-duty hydraulic cylinders to power essential machinery, such as excavators. These components endure extreme conditions, making regular maintenance crucial. However, many mining companies overlook hydraulic cylinder upkeep, leading to catastrophic failures, repairs, and unplanned downtime.
In this blog, we’ll explore the hidden costs of neglecting hydraulic cylinder maintenance and examine real-world case studies where better preventative care could have saved mining operations millions.
A mining operation in Western Australia suffered a complete hydraulic failure on a $5 million excavator due to a damaged seal in one of its boom cylinders. The issue went unnoticed for months as the team relied on temporary fixes instead of a proper overhaul.
The result?
The cylinder eventually failed during a major excavation, causing the arm to seize mid-operation.
The machine was out of commission for two weeks, leading to $800,000 in lost production.
The emergency repair and part replacement added another $250,000 to the bill.
A routine seal inspection and replacement (which costs less than $5,000) could have prevented this disaster.
A Queensland mining company experienced declining performance in one of its haul trucks but dismissed it as normal wear and tear. Over time, operators noticed the truck struggling to maintain lifting power, forcing them to limit its load capacity.
After months of inefficiency, an inspection revealed internal leakage in the hydraulic cylinder, reducing the system’s pressure and lifting ability. The lack of early detection meant:
The truck operated at only 60% efficiency for three months, leading to nearly $500,000 in lost productivity.
By the time the issue was addressed, the hydraulic system had sustained additional wear, requiring a full rebuild at a cost of $150,000.
A simple fluid analysis and pressure test (costing under $2,000) could have flagged the issue early, avoiding both downtime and unnecessary expenses.
At Rapid Rams, we understand that equipment reliability is everything in the mining industry. Our team specialises in high-performance hydraulic cylinders, repairs, and preventative maintenance to help you avoid costly downtime and maximise productivity.
Need an inspection or upgrade? Contact us today to keep your mining operations running at full strength.
Don’t wait for a breakdown—protect your investment with proactive maintenance!