why is my hydraulic pump overheating for sale

Hydraulic pumps generate heat while they run. However, hydraulic fluid temperature should never exceed180 degreesF (82 degrees C) under normal working conditions. If your hydraulic pump temperature rises above this, then that is a sign that your pump is likely overheating. One of the most common causes of hydraulic system failure is a hydraulic pump that runs too hot or overheats.

When a hydraulic pump runs at a too-high temperature for too long, it can ultimately lead to pump failure. Once a hydraulic pump begins to fail, it can potentially damage the entire hydraulic system by sending contaminants and debris into the system that can damage its other components.

In addition, when some hydraulic fluids are subject to high temperatures, they can thin and lose their viscosity. When hydraulic fluid is too thin, it is much more likely to leak, and fluid that has lost its viscosity cannot lubricate your pump properly. Extremely hot fluid can also damage pump seals, further increasing the chance of a pump leak.

Some hydraulic fluids thicken and oxidize when exposed to high heat instead of thinning. When hydraulic fluids are too thick, they can restrict flow throughout the entire hydraulic system, which leads to your system heating up even further.

The sooner you determine why your hydraulic pump is running hot and repair the cause of the problem, the less likely your hydraulic system will develop irreversible damage or fail completely.

Hydraulic pumps overheat for many reasons. Just a few of the most common causes of hydraulic pump overheating include: Contaminated hydraulic fluid. When fluid has debris and dirt, contaminant particles can quickly build up on hydraulic system filters, leading to filter clogs. Your pump has to work harder to pump fluid through clogged filters, which leads to overheating.

Aeration. Air leaks at seals and fittings on your hydraulic system components can lead to air entering your system and forming bubbles in your fluid. Air bubbles generate heat when your system compresses them and then pass this heat into the surrounding fluid, overheating it.

Low reservoir fluid. Since your hydraulic system releases some of the heat it creates into reservoir fluid, a low reservoir fluid level can contribute to overheating.

Blocked or damaged heat exchanger. This component is also an important part of your hydraulic pump"s cooling system. If it is blocked or damaged, then it cannot help remove heat from your pump properly.

Once your hydraulic pump beings overheating, you need to find the cause of the problem and repair it. That way, your pump can begin operating within its ideal temperature range again.

If your pump overheats due to fluid contamination, then either remove all contaminants from existing fluid or remove the current contaminated fluid from the system and add fresh fluid. Be sure to filter all fresh hydraulic fluid before you add it to your system because even this fresh fluid can contain contaminants. Also, replace your fluid filters on a regular basis to prevent the overheating that can occur when these filters become blocked with debris.

If air has entered your system through leaky seals and fittings, then have a hydraulic system repair expert inspect and replace or tighten these fittings. Have a hydraulic system repair expert also look at heat exchanger damage to determine if the exchanger needs repairing or replacing.

Finally, be sure to check your system"s reservoir fluid level on a regular basis. Add new fluid when necessary to help this reservoir perform its important task of helping to keep your pump cool.

Your hydraulic pump should always operate within its ideal temperature range. If your pump is running hot, then contact the hydraulic pump experts at Quad Fluid Dynamics, Inc., forhydraulic pump diagnosis and repairtoday.

Is your hydraulic pump getting excessively hot during normal operation? Pumps do generate heat when running, however they are designed with specific heat parameters in mind. Overheating is an abnormal condition that leads to destructive issues such as thinning of hydraulic fluid, which leads to reduced lubrication, metal-on-metal contact of moving parts. And accelerated pump wear and failure.

Therefore it is never a good idea to ignore a pump that is exceeding its heat parameters under normal load. There are a number of factors that contribute to an excess buildup of heat and in this article, we’ll explain some of these issues.

Hydraulic fluid viscosity refers to the thickness or “resistance to pouring” of your hydraulic fluid. This is very important to the correct operation of your pump. The fluid not only transmits the power that moves your drives and actuators. It also lubricates internal components and removes heat from the system. Hydraulic fluid is designed to operate at a specific temperature range. As it heats, it becomes thinner and eventually it will lose the ability to lubricate moving parts. The increased friction may cause the pump to heat up, and naturally increased wear will be taking place when this is happening. On the other hand, hydraulic fluid that is too thick flows less efficiently within the system, which also results in heat buildup.

Fluid that is contaminated with dirt, debris, water and other impurities may cause heat build up in a few ways. Blocked fluid filters, pipes and strainers place undue load on the pump or even lead to pressure drops on the back side of filters that cause cavitation.

Low fluid levels can result in a condition in which not enough flow is reaching the critical hydraulic components and moving parts. This is known as oil starvation and just like running your car without oil, it will increase metal-on-metal friction and lead to increased heat and wear. Oil starvation can also be caused by clogged hydraulic filters, incorrect fluid reservoir design.

Cavitation is the rapid formation and implosion of air cavities in the hydraulic fluid. When these air cavities collapse under pressure, they generate a lot of heat. In fact, temperatures can reach up to 2700 degrees C at the point of implosion! Not only does cavitation compromise the lubrication properties of the oil, the excessive heat that is generated is extremely damaging to the hydraulic pump and the system as a whole. Attacking hoses and seals and causing metal components to expand and wear.

This happens when air makes its way into the system via air leaks at points like pump seals, and pipe fittings. And what happens next in a hydraulic system? Compression! Air generates heat when compressed, which naturally leads to an increase in temperature if left untreated. In extreme circumstances it can also lead to ‘hydraulic dieseling’ whereby compressed air bubbles actually explode in the same process that powers diesel engines. This is not good and leads to degradation of the fluid and damage to system components through loss of lubrication and burning of seals.

As pumps wear, the internal leakage or “slippage” increases. Essentially, fluid is able to make its way past tight fitting components, which reduces the efficiency of the pump, but in addition, as this occurs, fluid moves from a high pressure to a low pressure without doing any mechanical work, since according to the laws of physics energy cannot be destroyed, it is instead converted into heat.

A build-up of excessive heat is a symptom of hydraulic pump problems, but it is far from the only signal that there may be something wrong. There are other important warning signs that you should pay attention to. These include unusual noises, pressure problems and flow problems. Each of these symptoms provide clues about any potential pump problems that need to be addressed - so it’s important to familiarise yourself with all of these issues. To help, we’ve created a downloadable troubleshooting guide containing more information about each of these issues. So that you can keep your system up and running and avoid unplanned downtime. Download ithere.

Overheating ranks No. 2 in the list of most common problems with hydraulic equipment. Unlike leaks, which rank No. 1, the causes of overheating and its remedies are often not well understood by maintenance personnel

Heating of hydraulic fluid in operation is caused by inefficiencies. Inefficiencies result in losses of input power, which are converted to heat. A hydraulic system’s heat load is equal to the total power lost (PL) through inefficiencies and can be expressed as:

If the total input power lost to heat is greater than the heat dissipated, the hydraulic system will eventually overheat. Installed cooling capacity typically ranges between 25 and 40 percent of input power, depending on the type of hydraulic system.

How hot is too hot? Hydraulic fluid temperatures above 180°F (82°C) damage most seal compounds and accelerate degradation of the oil. While the operation of any hydraulic system at temperatures above 180°F should be avoided, fluid temperature is too high when viscosity falls below the optimum value for the hydraulic system’s components. This can occur well below 180°F, depending on the fluid’s viscosity grade.

To achieve stable fluid temperature, a hydraulic system’s capacity to dissipate heat must exceed its heat load. For example, a system with continuous input power of 100 kW and an efficiency of 80 percent needs to be capable of dissipating a heat load of at least 20 kW. Assuming this system has a designed cooling capacity of 25 kW, anything that increases heat load above 25 kW or reduces the cooling system’s capacity below 25 kW will cause the system to overheat.

Consider this example. I was recently asked to investigate and solve an overheating problem in a mobile application. The hydraulic system was comprised of a diesel-hydraulic power unit, which was being used to power a pipe-cutting saw. The saw was designed for sub-sea use and was connected to the hydraulic power unit on the surface via a 710-foot umbilical. The operating requirements for the saw were 24 GPM at 3,000 PSI.

The hydraulic power unit had a continuous power rating of 37 kW and was fitted with an air-blast heat exchanger. The exchanger was capable of dissipating 10 kW of heat under ambient conditions or 27 percent of available input power (10/37 x 100 = 27). The performance of all cooling circuit components were checked and found to be operating within design limits.

At this point it, was clear that the overheating problem was being caused by excessive heat load. Concerned about the length of the umbilical, I calculated its pressure drop. The theoretical pressure drop across 710 feet of ¾-inch pressure hose at 24 GPM is 800 PSI. The pressure drop across the same length of 1-inch return hose is 200 PSI. The theoretical heat load produced by the pressure drop across the umbilical of 1,000 PSI (800 + 200 = 1,000) was 10.35 kW. This meant that the heat load of the umbilical was 0.35 kW more than the heat dissipation capacity of the hydraulic system’s heat exchanger. This, when combined with the system’s normal heat load (inefficiencies) was causing the hydraulic system to overheat.

Hydraulic systems dissipate heat through the reservoir. Therefore, check the reservoir fluid level and if low, fill to the correct level. Check that there are no obstructions to airflow around the reservoir, such as a buildup of dirt or debris.

Inspect the heat exchanger and ensure that the core is not blocked. The ability of the heat exchanger to dissipate heat is dependent on the flow-rate and temperature of both the hydraulic fluid and the cooling air or water circulating through the exchanger. Check the performance of all cooling circuit components and replace as necessary.

An infrared thermometer can be used to check the performance of a heat exchanger, provided the design flow-rate of hydraulic fluid through the exchanger is known. To do this, measure the temperature of the oil entering and exiting the exchanger and substitute the values in the following formula:

For example, if the measured temperature drop across the exchanger is 4ºC and the design oil flow-rate is 90 L/min, the exchanger is dissipating 10 kW of heat. Relating this to a system with a continuous input power of 100 kW, the exchanger is dissipating 10 percent of input power. If the system is overheating, it means that either there is a problem in the cooling circuit or the capacity of the exchanger is insufficient for the ambient operating conditions.

On the other hand, if the measured temperature drop across the exchanger is 10ºC and the design oil flow-rate is 90 L/min, the exchanger is dissipating 26 kW of heat. Relating this to a system with a continuous input power of 100 kW, the exchanger is dissipating 26 percent of input power. If the system is overheating, this means that the efficiency of the system has fallen below 74 percent.

Where there is a pressure drop, heat is generated. This means that any component in the system that has abnormal, internal leakage will increase the heat load on the system and can cause the system to overheat. This could be anything from a cylinder that is leaking high-pressure fluid past its piston seal, to an incorrectly adjusted relief valve. Identify and change-out any heat-generating components.

A common cause of heat generation in closed center circuits is the setting of relief valves below, or too close to, the pressure setting of the variable-displacement pump’s pressure compensator. This prevents system pressure from reaching the setting of the pressure compensator. Instead of pump displacement reducing to zero, the pump continues to produce flow, which passes over the relief valve, generating heat. To prevent this problem in closed center circuits, the pressure setting of the relief valve(s) should be 250 PSI above the pressure setting of the pump’s pressure compensator (Figure 1).

Continuing to operate a hydraulic system when the fluid is over-temperature is similar to operating an internal combustion engine with high coolant temperature. Damage is guaranteed. Therefore, whenever a hydraulic system starts to overheat, shut it down, identify the cause and fix it.

When hydraulic oil is getting overheated, there could be several common causes that also cause the system to overheat. First, it is crucial to understand the type of hydraulic system you are using to begin troubleshooting why the system is overheating.

The first cause of hydraulic oil overheating is when the hydraulic equipment system parts and components are nearing the end of their useful lifespans. As they degrade, due to increased internal leakage, they have to work harder to maintain the desired system pressure.

For example, your hydraulic pump is wearing out and needs to be replaced. Due to internal wear pressurised fluid escapes from the high pressure side to the low pressure side generating heat increasing the temperature of the hydraulic fluid and causing circuit overheating.

It is understood that you may want to make system upgrades or changes to customize the system to reflect your specific needs. However, when you do not consider the entire system, it can cause the system to work hard, give off more heat, and increase hydraulic oil temperatures, leading to circuit overheating.

For instance, you may want to increase the fluid flow rate through the system. However, you did not account for the size of hoses and tubing to accommodate the higher flow rates. As a result, the system has to work hard to force the increased flow rates through incompatible hoses and tubes, resulting in more heat generation and fluid overheating.

Tweaking your hydraulic system is perfectly acceptable to optimize its performance. However, where many people go wrong is they only adjust one part of the system and fail to think about how the adjustment will impact other parts of the system.

For example, suppose you make an adjustment to the pump compensator and increase the pressure yet fail to also make a similar adjustment to the relief valve. In this instance the relief valve will blow off more frequently generating more heat and therefore increasing the circuit fluid temperature.

Every component in a hydraulic system imposes a load on the pump, this is referred to as the pressure drop across the particular component. The figure will vary depending upon the flow rate and the energy lost from the fluid due to the pressure drop is converted into heat. If the overall pressure drop across all the components in the circuit unexpectedly increases so the heat generated across the circuit will also increase.

If the fluid is not cooled to compensate for this the fluid temperature continues to increase as the other parts and components generate excessive heat.

If there is dirt, sludge, debris, or water in the hydraulic fluid, the system will generate more heat as it attempts to compensate for the contaminants and push the fluid through the system. Therefore, it is always vital to check your fluid for contamination and change it and or improve fluid filtration when required.

After troubleshooting overheating problems, if you have determined it is not due to the four common causes mentioned above, then there are two general ways you can resolve fluid overheating problems. You can either increase the reservoir capacity to dissipate heat or decrease the amount of heat being generated by the system.

Another way to increase the heat dissipation is to inspect the current heat exchangers, if they are being used, and make the appropriate adjustments. In some cases, you may want to install additional heat exchangers to help reduce the fluid temperature.

To find hydraulic parts, components, and accessories to help you resolve hydraulic oil overheating problems, or if you require assistance in troubleshooting system overheating, please feel free to contact White House Products, Ltd. at +44 (0) 1475 742500 today!

Hot hydraulic fluid can be one of the causes of an overheating final drive motor. If your hydraulic fluid is running at a higher than normal temperature then it can cause problems for your entire hydraulic system. In this Shop Talk Blog post, we are going to talk about what can cause hydraulic fluid to overheat.

Another potential source of problems is a relief valve. If a relief valve fails or is out of adjustment, it can affect the system pressure. Changes in system pressure, as we just discussed, can also affect the temperature of the hydraulic fluid.

If you use the wrong type of hydraulic fluid for your machine, that, too, can cause the fluid to overheat. If that’s the case, then you need to replace the hydraulic fluid to fully address the problem.

If the oil cooler gets dirty or becomes plugged, that can also cause hydraulic fluid to run too hot. The solution to this problem is to take some time to clean off the oil cooler fins. Another potential source of problems is the cooling fan. If it is damaged, or if the fan belt isn’t at a right tension, then it can be the source of hot hydraulic fluid.

Another source of overheating lies in the level of your hydraulic fluid. If your reservoir is low on hydraulic fluid, that can cause the fluid that is in the system to overheat. However, that points to another problem: a leak somewhere. Don’t just top off the hydraulic fluid level, but also check for leaks that could be responsible for a low level of fluid.

If your hydraulic system is running too hot, then you need to track down the source of the problem. Hot hydraulic fluid will lead to damage and is a sign that something is wrong and needs to be addressed. If left unaddressed, then expensive issues and unnecessary downtime are bound to be the results.

is your partner in providing new or remanufactured final drive hydraulic motors from a single mini-excavator to a fleet of heavy equipment. Call today so we can find the right final drive or hydraulic component for you, or check out our online store to.

Every hydraulic system is adversely affected by excessive heat. The impact of excessive heat in a hydraulic system can be particularly insidious because of the subtlety of its effects. Over time, excessive heat can lead to system damage due to seal failure as well as hydraulic fluid breakdown. It is important to remember that hydraulic fluid is critical to protection of the metal components in any system and its degradation will lead to shorter component life.

While good design techniques can be employed to reduce overall heat load in a system, it is generally a mistake to believe that good design alone can prevent overheating in the absence of a cooler. Learning what causes excessive heat, and how to reduce that heat, will extend your system components life expectancy. Reducing heat can be as easy as adjusting a relief valve, or as complex as performing a complete heat load analysis, and adding in the proper cooling system. There are many reasons for hydraulic overheating, but here are three that we see most often;

User improvisation: We often hear of systems that have been running smoothly for years, and now all of a sudden they begin running hot. In many cases this is caused by someone making a system adjustment. One of the more common adjustments made is to the pump compensator to achieve more pressure on pressure compensated variable volume pumps. If the adjustment is made, and it exceeds the main relief valve setting, the excess flow is dumped over the relief valve which induces heat into the system.

Improper system design: Pressure drop is another heat generator when components are not sized properly. When it takes too much pressure to allow flow through your valves, pipes, hoses, filters, and any other system components, this wasted energy generates excess heat.

Improper cooling selection: A cooler is almost always required regardless of your system design. This is especially true for mobile machines where reservoir space is limited so you have a smaller amount of available hydraulic oil along with rapid recirculating of that oil. Heat load and available flow are some of the things that have to be accounted when selecting an external cooler. In addition, there are many different types of coolers that fit different systems requirements.

Choosing the correct cooler for your system can be a complex and complicated process. Excessive heat in a hydraulic system will attack every part of that system, and shorten the life of every component. Here at Cross Company, and our Mobile Systems Integration Group, we have a team of engineers that specialize in complete hydraulic systems design to achieve maximum efficiency and proper cooling selection.

Whether you have a welded rod cylinder or telescopic cylinder, chances are you already know how destructive cylinder issues like fluid leaks can be. While leaks are known to cause cylinder issues, system overheating can be less obvious but just as pervasive. Hydraulic system overheating problems can be caused by different factors, including high heat hydraulic oil temperatures as well as system design pressure issues.

Hydraulic system heat contamination issues can be caused by different factors. With heat loading issues occurring from different sources, it is important to determine the correct cause of overheating for your hydraulic system. Common causes of hydraulic system overheating include:

Hydraulic fluid temperatures should stay within operating norms. Elevated or hot hydraulic oil can increase the chance of a system breakdown. High heat on hydraulic oil can increase oxidation, decreasing the oil’s performance and ability to maintain proper temperatures.

Higher hydraulic fluid temperatures can also create low viscosity issues. Maintaining normal viscosity levels allows your hydraulic system to function without added concerns about pump and valve wear and damage due to low viscosity.

Lack of fluid flow throughout your hydraulic system can cause motor issues as well as pump malfunctions and failure. Damage to your motor or pumps can require repair or component replacement.

Pressure issues can cause lack of fluid flow through your system. Pressure drop can occur due to lack of fluid flow through your system, resulting in higher operating temperatures and overheating.

While system damage from heat load can occur at any time, there are ways you can reduce and minimize system overheating. Troubleshooting tips for preventing hydraulic system overheating include:

Need performance-built replacement hydraulic cylinders or components? HCI stocks a wide inventory of high-performance hydraulic cylinders and component parts. We also design custom hydraulic cylinders manufactured with American-made machined parts.  Contact us to discuss your hydraulic requirements with us today.

You can use multiple different upgrades and tuning methods on hydraulic systems. Many users will invest in upgrades that promise more flow and speed. The issue with these upgrades is that they"re not always fit for the hydraulic systems they"re applied to.

Since everything needs to stay in balance, you must make sure your upgrades match the entirety of your hydraulic system. For example, a higher flow pump can help give increased capabilities to a hydraulic system, but did you also check to see if the system"s hoses and piping can handle that increase in flow?

The increased flow can hit your smaller hoses hard and require more pressure just to get through them. This goes for any part of the hydraulic system that isn"t readily capable of handling more flow.

When you make upgrades, also ascertain if you need to change other components. In the example of the higher flow pump, you can simply increase your hose size, and that makes all the difference.

If you have forklifts or other hydraulic equipment, you know how important it is to keep up on regular maintenance. However, even the most consistently-maintained machinery may eventually develop problems. One of the most common issues that arises in forklifts is overheating fluids. The overheating of hydraulic fluid can be caused by a number of things, and it can result in major issues for your machinery. It’s important to understand why fluid overheats, what kind of effects it can have on your machinery and what you can do to resolve this problem. Read on for more information from a forklift dealer in Abilene, TX.

Put simply, hydraulic systems overheat as a result of inefficient operation. When the power that is input in your system can’t be used to effectively promote mechanical function, that power is lost as heat. Your forklift’s hydraulic system is designed to dissipate much of this extra heat, but sometimes the heat that’s put off due to inefficient operation is greater than what the system is capable of handling. When this happens, you get overheated hydraulic fluid.

When hydraulic fluids reach temperatures of 180°F or more, they start to damage your system components. At this temperature, seal compounds start to break down and your oil will degrade at a much faster rate. There are short-term and long-term effects of a habitually overheating hydraulic system. Systems that frequently overheat have lower performance and decreased longevity.

The good news is that there are things that you can do to address an overheating hydraulic system. To solve the problem, you should focus either on increasing heat dissipation or decreasing the heat load, both of which will result in a decreased likelihood of overheating. To optimize heat dissipation, check the reservoir fluid level in your forklift. Top off this fluid level and then clean your system to clear away any obstructions that might be inhibiting proper airflow.

To decrease the heat load of your hydraulic system, you should inspect the condition of all of your system components. Any small leaks or inefficient parts could be contributing to a higher heat output that puts more strain on your hydraulic system. Identify leaks, aging and wear, and switch out old parts for new ones from a forklift dealer in Abilene, TX. You should also invest in regular service and maintenance for your forklift to promote effective operation. A forklift technician may be able to identify additional issues that might be contributing to overheating concerns.

Resolving issues with your forklift isn’t always easy, and that’s why the team at V-Bar Equipment Company is here to help. Our locally owned company has been serving the community since 1993 with forklift sales, rentals, repairs, maintenance and parts. We are proud to staff an expert team that has extensive knowledge, training and experience dealing with a wide variety of forklift models and mechanical issues. Regardless of your specific concerns, we would be more than happy to help. Simply give us a call today to find out more and to schedule an appointment.

Overheating isa frequent problemwithin hydraulic systems that may be determined by specific components. Thisinternal problem lies within the pump and causes a hydraulic system to overheat in the following ways:

Contaminated hydraulic fluid is a common cause for a Hydraulic system to overheat. This can occur when the container is not sealed properly which causes dust, dirt,debris,or moisture to contaminate the fluid.With hydraulic systems running at higher pressures and more efficiently than ever before, it is important tomonitorthe cleanliness of one’s hydraulic fluid. Reducing contamination can decrease damage andwillallowoneto get the most out oftheirequipment.

Wrong valve calibration could resultin pressure difficulties which can cause a hydraulic system to overheat. The main cause of this is when a facility’s plant design changes and maintenance recalibrate the pressure relief valves for the updated operating pressure. If maintenance adjusts the pressure,and it stilldoes notsolve the problem, the pressure relief valve may have to be replaced entirely. Erosion to a valve is a common occurrence as dirt and debris settle and collectthroughout time. Maintaining the correct pressure will help your system keep up with production and not slow down.

Aeration in a hydraulic system can bea common issueand is caused by an outside air leak in the suction line.The pressure used in the suction line of hydraulic systems is below atmospheric pressure, so oilcannotleak out, but air can leak in.This will occur when there are loose, leaky seals and fittings which will allowtheair to seep in.Aeration can have severalnegative effectson top of overheatingsuch as increasedpump cavitation, excessive noise, and loss of horsepower.Some symptoms of Aeration may include foaming of the fluid, irregular movements, and banging and or loud clicking noises as the hydraulic system compresses and decompresses.

A blocked heat exchanger is significant toheating one’s hydraulic system, while cooling it down is just as important.Aninfrared thermometer isan effective wayto checkthe temperatureof a heat exchanger. Theadjustments can be made according tothedesign of theflow rateof oil.Make sure to replace the fluid fitterslocatedin the pumpon a regular basis to ensure theywill not get blocked andoverheat.

Oil Type plays a critical role inany hydraulic system. The wrong oil will not only affect the performance of the system but also cut down the lifespan of the machine. Theoil Viscositydeterminesthe maximum and minimum temperatures in which a hydraulic system can safelyoperate.Thin oils have a lowviscosity andflow more easily at low temperaturesthanthicker oils that have a higherviscosity.If the oil is too thin it can cause internal friction whichcreates heat and cancausethe system to overheat.

Low reservoir fluid is a common cause ofoverheating in hydraulic systems as itreleasesbuilt-upheatfrom the machineintothe fluid. Not having enough reservoir fluid cancontribute tocavitation andultimate damage to the pump.

Hydraulic pump failure candamage the entire hydraulic system.When a pump fails,debris, dirt, and grime kick out downstreamand can affect theoil,filter,valves, fluid, and actuator.Contactour KICK@$$ hydraulic system repair professionalsat Allied Hydraulic to avoid these problems.

Hydraulic pumps convert mechanical energy into fluid flow, which powers hydraulic systems. Hydraulic systems are critical for everything from vehicles to industrial machinery to heavy-duty construction equipment.

No matter what you’re using your hydraulic system for, it’s important to know the signs that your pump is struggling. A simple check of these signs might be all that’s needed to prevent an expensive or dangerous pump failure later on.

One of the most serious signs of future pump failure is overheating. If heat exchanges and vents are obstructed or overwhelmed with airborne debris, it can reduce the pump’s ability to adequately dissipate heat. At temperatures of 180° F or higher, hydraulic fluid begins to lose viscosity, reducing its lifespan. Overheated fluid lowers the pump’s operating efficiency and puts additional strain on seals, valves and other parts.

Hydraulic fluid is also susceptible to contamination from external debris, chemicals or particles that have separated from the internal components like metal shavings or chips.

These particles will also increase heat by thinning the hydraulic fluid, clogging valves and fluid pathways and degrading the pump’s components. Another cause of excess heat is over-pressurization, which overworks the hydraulic fluid and increases friction and wear on the system.

Hydraulic pumps should be expected to produce some noise as a result of normal operation. However, new or unfamiliar noises like banging or a high-pitch whine are cause for concern. The most common cause for unusual sounds is contamination of the hydraulic fluid through aeration or cavitation.

As the aerated hydraulic fluid is put under pressure in the pumping process, these air bubbles destabilize the regular cycling of fluid, creating loud bangs or a high-pitched whine.

Leaks are a clear sign of problems with a hydraulic pump. Pump leaks are divided into internal and external leaks. External leaks are easier to find and may take the form of pools or puddles of hydraulic fluid underneath the machine, or a spray of fluid from a pressurized line. External leaks are usually caused by component issues like a hole or tear in a hose or pipe, loose connections, or damaged valves.

Internal leaks are harder to diagnose and are usually identified through secondary problems like low pressure, increased fluid demand, or slow performance. Internal leaks are tracked by closely monitoring fluid levels in different areas of the system or testing the pump with a trained technician. Internal failures are usually caused by the degradation of valves and other parts over time.

Slow or unreliable performance is an obvious sign that something is wrong with a hydraulic pump. Slow operation is symptomatic of a variety of other problems like overheating, contaminated fluid, or issues with pressurization. Another possible cause is that the pump’s components have simply degraded through regular use and are due to be changed. Problems with heat, fluid or pressurization will all put more stress on aging internal components and decrease the pump’s efficiency further.

With a little practice it’s easy to identify the common signs a hydraulic pump is starting to fail. Over time, common hydraulic pump problems will compound on one another to worsen overall performance, which makes early identification and repair important. However, even the best-maintained hydraulic pumps begin to show signs of wear and damage eventually. Many experts recommend a service check after every 10,000 hours of operation.

Servo Kinetics in Ann Arbor provides reliability centered maintenance checks to best serve your hydraulic pump and motor function. Our team of professionals and engineers are here to help address your industrial hydraulic repair needs in a timely manner with high quality work and at a low cost.

Our services include a large span of hydraulic pumps and motors as well asreverse engineering services and new pumps and motors. Every unit you send goes through a rigorous quality process that is trusted and used throughout the industry. Call us and experience the difference with a rapid response, fast turnaround, and ongoing cost savings.

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The pump is the heart of your hydraulic system, whether that system is on a small compact SSL or a massive hydraulic shovel. When that pump finally gives out, your machine does, also. Here are three key signs of impending pump failure to be on the lookout for!

One of the most common signs of impending pump failure is for it to start making excessive noise. In fact, when ball bearings or roller bearings have reached the end of their lifespan, you can expect to hear a significant amount of noise (along with vibration). When a bearing finally fails and is not replaced, it can do serious damage if you keep trying to use the pump. Banging and popping noises, in particular, are usually the result of aeration (air trapped within the hydraulic fluid) or cavitation.

Is your machine sluggish? Is it taking longer to complete work cycles than it used to? Does it just not react to control like it used to? These symptoms point to a loss of flow from your hydraulic pump, which is a natural result of a pump reaching the end of its useful life. As the internal components begin to wear, there will be an increase in internal losses within the pump. Those internal losses mean the pump can"t produce the same output it once did. That loss of output, in turn, will affect every system that depends on the pump.

Another sign of impending pump failure is overheating, and if you ignore an overheating pump it will lead to other problems. An increase in temperature is often tied to clogged hydraulic filters or a dirty heat exchanger. Also, overheating can lead to damaged seals and leaks, which result in their own set of problems. Overheating is also caused by either cavitation or aeration, both of which can lead to internal pump damage that is expensive to repair (assuming the damage is repairable).

If your pump is showing any of these signs -- noise, sluggishness, or overheating -- it might be a good time to think about getting it replaced. Here at Final Drive Parts, we offer both new and rebuilt hydraulic pumps for many different machines. Contact our sales team today to find out what your options are!

The hydraulic pumps on construction equipment are critical components of the machines and even though they are often designed to work under vigorous and intense conditions, no pump will last forever. Discovering a problematic pump can be complicated as the effects might seem to originate in other connected parts, and, if failures are gradual, the cascading effects of a pump failure can spread throughout a machine.

To help in your diagnosis — and with a small dash of preventive maintenance — we’ve put together this basic, short list of common pump problems and their causes.

Not every hydraulic pump on a machine is simple to inspect, but this Volvo main hydraulic pump on a EC220B-LC excavator sits behind a quick access door so an operator can check it often.

A failing hydraulic pump can be a long and subtle process, a sudden and catastrophic calamity, and all shades in-between, but often a perceptive operator will notice the signs of a pump failure in advance. It might take a few minutes of stopping and inspecting, but knowing what to watch for and taking the time to inspect your hydraulic pumps can often pay off in the long run and lead to fast and simple fixes, instead of prolonged and labor-intensive downtimes.

A hydraulic pump is often secured behind a door or guard or integrated deeply into the body of a machine, but taking the time to inspect the pump for the presence of oil (or oil and dirt clumping) can lead to the early discovery of problems. If the issue is simply a loose connection, a quick tightening can often stop a small issue from growing.

Since a hydraulic pump has both seals to prevent fluid from exiting the pump and also fluid from prematurely entering from one chamber to the next, failing seals can be both internal and external. Spotting an exterior leak is, of course, simpler, but being aware of where seals exist inside the pump can also help you diagnose a failing internal seal.

The most frequently noticed indication of a failing pump is often the start of a new sound coming from the hydraulic pump. An experienced operator will often immediately know and recognize a pump that is indicating issues through sounds, but for many it can be harder to pinpoint.

A problem with a pump can cause it to simply become louder in its operations, develop a whining sound, or even create a knocking sound. The sounds can indicate a number of problems, but often the cause is either cavitation or aeration in the pump.

Over long spans of work and under intense conditions, a hydraulic pump will often heat up, but excessive heating is often a sign of internal issues in the hydraulic pump. Checking a hydraulic pump for excess heat should always be done with safety in mind and with a secure machine and proper protective equipment. Periodically ensuring a hydraulic pump isn’t overheating allows an operator to discover if the pump is under undue strain and on a path to failure.

Overheating in a hydraulic pump can also cause fluid to thin, cause internal components to more rapidly degrade, and introduce dangerous working conditions to the machine. Overheating in a pump is both a sign of current trouble and a cause of other growing problems.

Unexpected and non-fluid movement of parts can be caused by issues with the hydraulic pump, but since the culprit can be a number of other parts in the system, diagnosing pump issues from these movements isn’t always simple. Still, if you do notice non-uniform movements in your machine, taking time to rule out the hydraulic pump is important.

A main hydraulic pump, like this one from a Komatsu PC400LC-6 excavator, comes with a working life and will need to be replaced or rebuilt at some time. This one is fresh from an H&R Recon and Rebuild shop and is headed to a customer.

Knowing some of the common causes of hydraulic pump failures is a proven way of proactively discovering developing issues and correcting them before they become disastrous to the pump and the machine.

The internals of a hydraulic pump are designed to work with fluid that meets exacting specifications. When hydraulic fluid is contaminated it can lead to issues developing in the pump, force the pump to work harder, and cause the pump to work erratically. One common culprit for contamination is water, and it can quickly lead to increased corrosion, changes in viscosity that lead to inefficiencies, and the inability to properly regulate heat in the pump.

Other debris, either introduced from outside or from the degradation of internal elements, can also lead to issues in the pump and signal failing seals or other parts.

A hydraulic pump is often containing a high level of pressure and as this pressure exerts force on seals in the pump, the seals can begin to leak or fail. Even minor leaks in seals can lead to loss of fluid and create issues in the system. Leaks can be both external and internal. For an internal leak, fluid will move from one part of the pump to another in unintended ways and force inefficiencies into the pump as it has to work harder to compensate.

While many hydraulic pumps are built to stand up to tough and continuous working conditions, every hydraulic pump is designed with an upper limit. Every time a hydraulic pump is subjected to overpressuring and overloading beyond what the manufacturer has specified, the pump is more prone to damage.

All hydraulic oil has a defined amount of air dissolved in it, but increases to this amount can lead to inefficiencies in the pump and force the pump to work harder or erratically. An increase in air can also happen inside the pump and create similar problems. Even though the pump and hydraulic system have mechanisms in place to regulate air in the system, if excess air is introduced the system should be returned to a balanced system before prolonged use of the pump.

The hydraulic system on a construction equipment machine is designed to work within defined parameters. Operating a machine with too little oil or too much oil for even the briefest amount of time can cause the pump to overwork, lead to increases in working temperatures, or create conditions for non-uniform movement. The exact type of oil used — matched to the machine and the working environment — can also impact how the hydraulic pump operates.

A simple and well-practiced maintenance plan can help prevent issues from developing and even discover issues early, leading to shorter and less costly downtimes.

The operator’s guide of your machine will define the hydraulic oil change schedule and adhering to that schedule can extend the life of your hydraulic pump. When oil is changed, take time to examine the spent oil for signs of debris

Keeping a pump on a hard-working machine looking new every day is nearly impossible, but routinely peeling back dirt, grime, and oil can help catch issues early.

No one wants to take a machine out of work for cleaning, but keeping the machine clean and ensuring pumps are not covered in mud, dirt, or other debris can allow them to be inspected more easily and avoid contamination and overheating.

The hydraulic hoses connected to a hydraulic pump can wear out over time and ensuring they are well-maintained can help you avoid the introduction of debris and even catastrophic issues in the case of sudden failures.

If a hydraulic pump fails on your machine, taking time to ensure you properly diagnose why and how the failure occurred will help you avoid repeating the failure with your replacement pump. Even if the pump failed simply from prolonged use and age, taking time to confirm that can lead to insights about how to extend the life of the next pump.

A hydraulic pump on an excavator, wheel loader, dozer, or articulated truck can be an often ignored component of the machine — until it starts to act up and cause issues. If problems have brought a pump to the forefront of your mind, hopefully, this short guide has helped simplify your pump problem solving.

If you find yourself in need of a replacement hydraulic pump, our Parts Specialists are always here to help. As a supplier of new, used, and rebuilt hydraulic pumps and with our deep inventory of parts, our Parts Specialists can often find the perfect solution to get a customer back up and running quickly. Simplify your search and give them a call.

Don"t see what you are looking for? With access to specialized search tools and our extensive vendor network, our parts specialists are here to search for you and to connect you to your parts, fast and simple.

The look and design of a hydraulic pump is customized to fit the machine and the available space. This main hydraulic pump is freshly reconditioned from a Kobelco SK160LC-VI excavator.

Hydraulic pumps come in a wide range of shapes and sizes. This large Volvo main hydraulic pump requires assistive overhead cranes and forklifts to move around the warehouse.

This article is part of the H&R Construction Equipment Parts How To series, designed to give readers and viewers a brief glimpse of the work of our Recon and Rebuild team or to provide basic maintenance and help tips. Whether you’re rolling up your sleeves and about to get your hands greasy or you’re just looking for a better understanding of a part, please practice proper safety protocols and understand this is only a basic guide. Consult a trained professional before performing any unfamiliar tasks.

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Over time and through repeated use, the hydraulic oil in your tools will degrade and become less effective. This is a normal process and happens for a few reasons.

The higher the pressure in a hydraulic system the more the oil will compress and degrade. But arguably, the most common reason is because of contamination. If you ignore the warning signs and do not replace the hydraulic oil the performance of your equipment may be affected, and the oil will lose its ability to defend against friction and corrosion.

Water enters the hydraulic system either through carelessness when handling the oil, via damaged seals, or by condensation. As you will be aware, oil and water don’t mix – and within a pressurized hydraulic system together they cause foaming and cavitation. The water will also result in clogged filters, reduced lubrication, and corrosion.

Aeration occurs when air gets into the system through seals and fittings, or maintenance. The air trapped inside the system can lead to cavitation causing a spongy or slow hydraulic response. Hydraulics depend on the fact that fluids can’t be compressed, and a system that contains air is more elastic. Furthermore, any resulting oxidation from the air can increase viscosity, create sludge, deplete additives, and increase the acidity of the oil.

Cavitation is when vapor bubbles are produced as a result of a rapid change in fluid pressure. These bubbles then collapse and cause small vibrations and shock waves. If this happens repeatedly, metal parts in the system may be damaged.

If you’re using an Enerpac hand pump with the correct grade of oil this is likely to be an amber color. The grade of Enerpac oil used with powered hydraulic pumps is more viscous and can be identified by blue color.

• The best way to extend the life of hydraulic oil is to minimize contamination. You can do this by working clean and taking extra care whenever you set up and connect your system. Before connecting your hydraulic hoses, make sure you remove any dirt and moisture from the connectors and other components.

An overheated electric motor will bring your equipment to a screeching halt. And while excessive heat may be the problem confronting you, knowing how and why your motor overheated is imperative. Until you get to the root of the problem, your motor will continue to reach peak temperatures, failing again and again.

The first step in dealing with an overheated motor is to make sure overheating is actually the problem. Unless you’re actively monitoring it when it fails, you may not suspect heat. To verify overheating, you’ll need to get the motor up and running again — this time with methods of monitoring it:

Any of these methods will qualify an overheat, so you can be sure that’s what you’re dealing with. Once confirmed, you’ll need to understand why your electric motor keeps exceeding safe operating temperatures.

As is the case with any electrical system, heat is a product of poor operating conditions. What happens when an electric motor overheats? Overheating is most generally traced back to one of these five core issues:

1. Electrical overload caused by excessive voltage supply or overwork by drawing more current will lead to overheating issues. As the motor works harder or under unusual load, heat will be the chief byproduct, leading to failure.

2. Low resistance is the most common reason behind electric motor failure. Degradation of motor windings by heat will pave the way for short-circuits and leakages, which leave the motor at risk for failure.

3. Contamination of dust and debris will raise the internal temperature of a motor and keep it from cooling, which leads to excessive heat over a longer period of time. This generally occurs without proper maintenance or venting for particles.

4. Start-stop frequency plays a big role in heat damage. Excessively starting, stopping, and starting your motor again won’t allow it to cool properly. The result is a high-heat environment that wears on the integrity of components.

5. Vibration from a condition like soft foot leads to excessive heat. If vibrations are severe enough, they’ll raise temperatures to unsafe levels and stress components beyond their capacity for heat.

The issue with heat-induced failures is that they’ll continue to happen until maintenance solves the core issue. Thankfully, there are ways to nip these problems in the bud without too much modification to a maintenance plan:

Thorough, routine maintenance ensures individual components within the electrical system get the attention they need to minimize overwork and overheating.

Alongside friction in mechanical equipment, heat is the bane of any factory’s electrical devices. Keeping heat in check starts with understanding what causes it and what you can do to minimize or eliminate those variables.

Issues with your electric motor overheating? You can always count on the professionals at Global Electronic Services. Contact us for all your industrial electronic, servo motor, AC and DC motor, hydraulic, and pneumatic needs — and don’t forget to like and follow us on Facebook!

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