why is my hydraulic pump overheating in stock

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.

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.

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.

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.

Based on polls I’ve conducted with my Hydraulics Pro Club members over the years, overheating ranks number two in the list of most common problems with hydraulic equipment. But unlike leaks, which rank number one, the causes of overheating and its remedies are often not as well understood. With the northern summer rapidly approaching, now is a good time for a little revision.

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 PLtotal = PLpump + PLvalves + PLconductors + PLactuators.

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 50% of continuous input power, depending on the type of hydraulic system and its application.

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

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% needs to be capable of dissipating a heat load of at least 20 kW. Assuming this system has an installed cooling capacity of 25kW, anything that increases heat load above 25 kW or reduces the cooling system’s capacity below 25kW will cause the system to overheat.

Consider this example. I was asked to investigate and solve an overheating problem in a mobile application. The hydraulic system comprised 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-ft 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 at the prevailing ambient conditions at the work site or 27% 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 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 3/4″ pressure hose at 24 gpm is 800 psi. The pressure drop across the same length of 1″ 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, albeit a relatively small amount, 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 build-up of dirt or debris.

As the long-umbilical story above illustrates, 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. So 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 (Fig. 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.

Brendan Casey is the founder of HydraulicSupermarket.com and the author of Insider Secrets to Hydraulics,Preventing Hydraulic Failures, HydraulicsMade Easy and Advanced Hydraulic Control.A fluid power specialist with an MBA, he has more than 20 years experience in the design, maintenance and repair of mobile and industrial hydraulic equipment. Visit his Web site: www.HydraulicSupermarket.com.

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.

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.

If one of your hydraulic pumps keeps overheating or wearing down, you should repair it soon. Your pump may potentially fail in the future if you don"t repair it fast. Learn why hydraulic pumps overheat or wear down quickly and how to repair your pump below.

Hydraulic pumps work exceptionally hard to keep your machines, cranes, and other equipment functional each day. But over time, pumps can experience issues that interfere with how well they perform each task. One of the main issues with hydraulic pumps is overheating.

Pumps can overheat if too much air enters the system during the day. Air can enter the pump"s housing or cavity through holes and other defects in the machine. Once air enters the system, it can contaminate the fluid inside your hydraulic pump.

A number of other things can trigger problems with your pump, including water, dirt, and debris. If you don"t remove the contaminants properly, they can damage your hydraulic pump before its time.

A contractor can examine your hydraulic pump to see why it overheats constantly. If air is the reason behind your pump"s problems, a contractor can inspect your machine for defects. A contractor may also check the hydraulic system itself for defects.

If a contractor does find defects in your machine or hydraulic system, they"ll seal or repair them for you. A contractor may need to take apart your machine or hydraulic system to make the necessary repairs.

If air isn"t the cause of your pump"s problems, a contractor will measure the temperature inside your machine"s hydraulic system. Hydraulic systems can run hot if they become too old to function well, or if the fluid inside the system is too thin to lubricate the pump and other parts. Using a thicker fluid for your hydraulic system should prevent it from overheating in the future.

A contractor will also check the fluid levels inside your system during the repairs. Low fluid levels can trigger a host of issues with hydraulic systems, including overheating and premature wear and tear. If you don"t maintain the correct fluid levels in your hydraulic system, it can cause the pump to overheat and fail.

It’s that time of year again and all over the country there are hydraulic systems overheating.  Some of them overheat every summer, but most of them usually just run a little warmer with increases in ambient temperature.  What is causing it?  Often a dirty or poorly placed heat exchanger can be the culprit.  Sometimes a bypassing check valve across the heat exchanger can make the system overheat.  Unless the design of the system has been changed in some way, it is very unlikely that adding a heat exchanger is the answer.  Systems that overheat are simply not operating efficiently and there is usually an easily corrected cause.  Here are four of the more common causes of overheating that we find.

By far the most common cause of overheating that we find is an improper adjustment.  On machines that usually do not overheat but are overheating now, this is the first thing we look for.  The most common component that gets out of adjustment is the pump compensator.  It is imperative that the compensator be set below the system relief valve.  But for whatever reason, someone decides that the system would run better at a higher pressure.  The compensator setting then gets increased, but the relief valve setting does not.  Once the compensator setting approaches the relief valve setting, the relief valve starts to crack open and dump oil flow to tank.  The more the compensator setting is increased, the more the relief valve opens and the more flow returns to tank.  Instead of varying its flow to meet the demands of the system as it is designed to do, the pressure compensating pump moves to full stroke behaving as a fixed displacement pump.  Any flow not used to move a load returns to tank through the relief valve.  At system idle, ALL of the pump flow returns to tank.  Since the resulting pressure drop doesn’t do any work, virtually all of the energy going into the system is converted to heat causing the fluid temperature to soar.

Changing the system pressure is usually a bad idea.  Most systems have designer recommendations for system pressure and a lot of design criteria are taken into consideration to determine the optimum system pressure.  Often the pressure is increased in an attempt to speed up the machine but this is a very inefficient way to accomplish this.  Flow rate, not system pressure, determines the speed of the actuator.  Yes, turning up the pressure will often also increase the flow, but the more efficient way is to open a flow control or raise the setting of the manual volume adjustment.  In the absence of designer recommendations, we usually recommend that the system relief valve be set approximately 250 PSI above the pump compensator.

In Figure 1 above, the system is adjusted correctly.  The pressure compensating pump is capable of delivering as much as 30 GPM.  With only the directional valve on the left open, the system uses 10 GPM so the pump will stroke only enough to maintain 1200 PSI in the system delivering 10 GPM.  When the second directional valve opens in Figure 2, the pump stroke increases to 20 GPM to maintain the 1200 PSI setting.  But in Figure 3, the compensator setting has been increased to 1600 PSI.  The relief valve however is set below that amount at 1450 PSI.  In an attempt to reach 1600 PSI in the system, the pump will stroke to its maximum 30 GPM.  The system only uses 10 GPM leaving 20 GPM to dump across the relief valve generating heat.  We can calculate the heat that is generated using the formula HP = PSI X GPM X .000583 and we see that an extra 17 HP is generated.  In Figure 4, the system is at idle.  The pump will remain at full stroke however dumping its full 30 GPM across the relief valve.  This generates a whopping 25 HP in excess heat!

This is one that we find most often in systems that have been modified from their original design.  One of the more common system upgrades is a higher flow pump to increase speed, but the system piping and hoses may not get the same upgrade.  The result is that it takes more pressure just to push the oil to the actuators to do the work.  For example, 20 GPM will flow through a #10 SAE hydraulic hose at a fluid velocity of 20 feet per second, but if the hose is replaced by a #12 SAE, the fluid velocity drops to only 15 feet per second.  This simple size increase reduces the restriction by 25%.  Tight radius bends in pipe will also increase turbulence in the lines.  Whenever the system flow rate is increased by installing a higher flow pump, check pipe and hose charts to ensure the system can withstand the greater flow rate without an excessive increase in fluid velocity.  In the absence of designer recommendations, we usually recommend that fluid velocity be kept between 2 – 5 fps in pump suction lines, 10 – 15 fps in return lines and 15 – 20 fps in pressure lines (for systems up to about 3000 PSI)  Above 3000 PSI, the system designer will usually specify how many bends can be in the system piping and what radius they must be.  This avoids the necessity of exceptionally large piping in higher pressure systems.

As components wear, internal bypassing increases.  Oil that bypasses across the tight tolerances of a component undergoes an immediate pressure drop that performs no work.  Heat is the inevitable result.  The more bypassing that occurs, the more heat is generated.  Some components are notorious heat generators even when brand new.  Servo valves,  proportional valves and flow controls all generate heat from the time they are new because they always have a pressure drop across them.  So how do we know if a component needs to be replaced in order to keep the temperature down?  The best way is to routinely measure the temperature gain at various components in the system.  Keep a record of these measurements and use them to help locate troublesome worn components.

One of the primary purposes of the reservoir is to radiate heat to atmosphere.  You may have wondered why your hydraulic reservoir is rectangular in shape while most other tanks you see are round.  The most efficient use of volume, i.e. the maximum volume with minimum surface area, is a sphere.  This may be desirable in some applications, but in a hydraulic system we want more surface area to radiate heat, not less.  When a system is designed, the reservoir is sized based on a number of factors such as how much the oil level will rise and lower with the operation of cylinders, how long oil should remain in the reservoir to allow contaminants to sink to the bottom and how much heat will need to radiate to atmosphere.  If a higher flow pump is installed, the oil will not stay in the reservoir long enough to dissipate heat.  Also, when a variable displacement pump is used, oil from the pump case drain is ported directly to tank.  A higher flow pump will also have a higher case drain flow.  Most variable displacement pumps will bypass approximately 1 – 3% of its maximum flow rate.  Case flow is very hot because it is oil that has just bypassed across the tight internal tolerances inside the pump.  A higher case flow will raise operating temperature if a larger reservoir is also not part of the upgrade.

This website or its third-party tools process personal data (e.g. browsing data or IP addresses) and use cookies or other identifiers, which are necessary for its functioning and required to achieve the purposes illustrated in the cookie policy. To learn more, please refer to the cookie policy. In case of sale of your personal information, you may opt out by sending us an email via our Contact Us page. To find out more about the categories of personal information collected and the purposes for which such information will be used, please refer to our privacy policy. You accept the use of cookies or other identifiers by closing or dismissing this notice, by scrolling this page, by clicking a link or button or by continuing to browse otherwise.

Learning what causes excessive heat, and how you can reduce its damaging effects on your hydraulic system, will extend your components" life expectancy far beyond its warranty period. Reducing heat can be as easy as adjusting a valve to performing a complete heat load analysis and adding the correct Air-Oil or Water-Oil cooling system.

This is a common complaint we hear from our customers. Normally 9 times out 10 “something” has changed in their systems and it is usually an adjustment. We find that in pressure compensated variable volume pump systems, “someone” felt the need for the system to use more pressure. They make the common mistake of adjusting the pump compensator to move past the main relief valve setting. This causes the pump to come on stroke and dump wasted flow at the max pressure setting, inducing HEAT into the system.

Pressure Drop is another heat generator when components are not sized properly. When it takes too much pressure just to push the oil through all the valves, pipes, hoses, elbows, bends, and filters, this wasted energy shows up as heat. You can avoid this by simply upsizing your components and reduce the bends in your plumbing. If radical bends are unavoidable, try increasing the size of your hoses and fittings. You increase your flow capacity dramatically by increasing only one hose size.

For example, 10 gallons per minute (GPM) through #10 SAE hydraulic hose flows at a velocity of 10 feet per second (fps), while the same 10 GPM flows at 7.5 fps through #12 SAE hose. That’s a 25% decrease in flow restriction!

When you hear this from your customers, the only thing you can do is add an external cooler to their system. Instead of reducing the cause, you just have to pull the excess heat out. You first determine the heat load and choose a cooler that will remove enough heat from the system to run at a normal temperature. Commonly, 120-140 degrees Fahrenheit (F) for industrial systems and 160-180 F for mobile applications are ideal. In heat removal, the general rule of thumb is to remove 1/3 of the input horsepower (or Prime Mover). Cooler selection is based on these factors and available flow. Proper selection can be made by any Cross Company account manager.

Heat is a hydraulic component killer and will indiscriminately attack each and every part of your system. Your oil can be as clean and pure as the wind driven snow, but if it gets hot, it will kill your machine. The mentioned methods, reduction tactics, or the addition of a oil cooler, will stave off this killer and help your components live a long and healthy life.

If you are having similar problems, or have questions about this topic, please do not hesitate to contact me or chat about your heat issues . Please have your system specifics on hand.

Everyone knows that contamination can be catastrophic to a hydraulic system. But heat can also be detrimental to hydraulic fluid and the components within that system.

Heat contamination reduces oil viscosity, which in turn reduces the fluid’s ability to lubricate components. This thinning of the oil causes surface-on-surface wear. Without proper viscosity levels, as components rub against each other — such as a wear plate and the slippers on a piston pump — they wear at accelerated rates.

This wearing also softens metals, which in turn increases the rate of wear. For example, anywhere there’s metal rubbing on and near to other pieces of metal (even if it’s two different materials such as bronze or stainless) as the metal heats up, it becomes softer and it wears away more quickly. This problem is exacerbated if other forms of contamination are present.

Heat enters a hydraulic system in multiple ways. One culprit is ambient heat. For example, you may have a blast furnace dipping molten metal into a ladle. It is imperative that the hydraulic actuators and the oil used within them are designed for that type of environment.

Another thing to be aware of is internally generated heat; this often is generated from piston pumps, inefficient gear pumps or friction created by other internal components. For example, while useful in specific applications, low-speed, high-torque motors may only have a 60-70% efficiency rating. This means 30 to 40% of the system energy is wasted as pure heat. This internal heat reduces lubrication, increasing friction and reducing lubricity. This may eventually cause the motor to wear out.

So how to do you filter out or remove heat from a system? First, you should try to design a system that doesn’t create it in the first place. Second, in regular maintenance, always keep an eye on the reservoir levels. You should have three times the pump capacity available in the reservoir. Ensure also that the reservoir is clean and not near heat sources (such as direct sunlight or machines that generate heat).

Finally, if there is any device that could be considered a heat filter, it would be a cooler or heat exchanger, which uses water or air to bring hydraulic fluid temperature down. Several types exist.

The first is a shell and tube heat exchanger, in which coolant water flows through internal system ports and tubing while the warmer hydraulic fluid circulates through others. The heat is transferred from one fluid to the other, thus bringing the overall fluid temperature down.

Air coolers can also be used. While not as effective, they are sufficient and often easier to use. These use a fan and radiator-type cooler, and often can be driven by hydraulic motors, simply to force cold air over the hot fluid inside.

Hyundai hydraulic pumps are integral parts of excavators. The company is the third largest manufacturer in the world. As one of the leading brands, Hyundai has been popularized after producing high quality and durable products over time.

An excavator Hyundai hydraulic pump can overheat for a variety of reasons. The most common cause is actually running the pump at too low of an RPM. When the pump is not turning fast enough, it can’t move the oil through the system quickly enough and it starts to overheat. Another common cause is a blockage in the system somewhere. This could be a blockage in the suction line, return line, or even in the pump itself. If there is a blockage, the oil can’t flow properly and it will start to overheat.

If your excavator Hyundai hydraulic pump is overheating, there are a few things you can do to try and fix the problem. First, check the RPM of the pump. If it is running too low, increase it until it is running at the proper speed. Next, check for any blockages in the system. If you find one, clean it out and see if that fixes the problem. Finally, if neither of those two things works, you may need to replace the pump itself.

There are many potential causes of an excavator Hyundai hydraulic pump overheating. The most common cause is a loss of hydraulic fluid due to a leak in the system. Other causes can include a build-up of dirt and debris in the system, or a problem with the pump itself.

If you suspect that your excavator’s hydraulic pump is overheating, the first step is to check for leaks. If you find a leak, make sure to repair it as soon as possible. If there is no leak, then you will need to clean out the system to remove any dirt or debris that may be causing the problem.

If you are still having problems with your excavator’s hydraulic pump overheating, it may be necessary to replace the pump itself. This is a more complex repair, so it is best to consult with a qualified mechanic or dealer before proceeding.

There are several potential causes of an excavator Hyundai hydraulic pump overheating, but the most common cause is simply because the pump isn’t getting enough oil. This can happen for a variety of reasons, such as a leaking oil line or an incorrect amount of oil being used. Another potential cause is that the pump isn’t getting enough cooling water, which can be caused by a clogged water filter or an insufficient water supply. Whatever the cause, it’s important to get the problem fixed as soon as possible to avoid damage to the pump.

The Hyundai hydraulic pump is located in the engine bay of the excavator. It is responsible for providing hydraulic pressure to the excavator’s hydraulic system. If the pump overheats, it can cause damage to the hydraulic system and potentially lead to a loss of excavator performance. There are a few things that you can do to prevent the pump from overheating:

– Inspect the pump regularly for any potential leaks. Leaks can cause the fluid level to drop and also allow air to enter the system, which can cause problems.

If you’re noticing that the Hyundai hydraulic pump on your excavator is overheating, there are a few things you can do to prevent it. First, make sure that the pump is getting enough oil. If the pump isn’t properly lubricated, it will overheat. You should also check the cooling system to make sure it’s working properly. If the pump is still overheating, you may need to replace the seals or bearings.

If you have an excavator Hyundai, you may have experienced your hydraulic pump overheating. This can be a major problem, as it can lead to damaged equipment and even injuries. However, there are a few things you can do to help prevent this from happening. make sure that your excavator is properly ventilated. Second, check the fluid levels in your hydraulic system regularly. Third, use aHydraulic Pump Overheating Prevention Kit. By following these simple tips, you can help ensure that your hydraulic pump doesn’t overheat and cause damage to your equipment or yourself.