Why Hydraulic Pumps Fail (And How to Prevent It)

Like any mechanical component, hydraulic pumps are prone to failure if not carefully maintained. With proper understanding and attention, you can not only prevent these failures but also extend the life of your hydraulic system significantly.

The Common Causes of Hydraulic Pump Failure

Despite their robust design, hydraulic pumps are vulnerable to specific challenges. Improper system maintenance or design issues can lead to one or more of the following problems:

1. Excess Heat

One of the most common culprits of hydraulic pump failure is heat. Hydraulic systems naturally generate heat during operation. While some heat is normal, too much can be detrimental. If left unaddressed, excess heat can cause significant damage to seals, valves, and other system components.

Why Is Heat an Issue?

High oil temperatures break down hydraulic fluids, reducing their viscosity and causing inadequate lubrication. Over time, this leads to increased wear and tear on the pump and other components. Additionally, heat can cause seals to harden or deteriorate, leading to oil leaks and eventual system failures.

How to Prevent Excess Heat

• Proper Reservoir Size: Ensure the oil reservoir is adequately sized for the system’s operating conditions. A well-sized reservoir allows for better heat dissipation.

• Install Oil Coolers: Adding an oil cooler to your system can help keep hydraulic fluid temperatures within acceptable levels.

• Monitor Fluid Levels Regularly: Insufficient oil levels can cause the system to overheat. Always maintain adequate oil levels and top off when necessary.

2. Contamination

Contamination within the hydraulic system is another leading cause of pump failure. This can occur when dirt, debris, or other foreign particles enter the system.

Why Is Contamination Dangerous?

Contaminants can damage the pump's internal components, such as pistons and gears, reducing efficiency and causing wear. They can also block vital system pathways, further straining the pump and other hydraulic components.

How to Prevent Contamination

• Regularly Change Filters: Use proper filtration systems and change filters at regular intervals to keep the hydraulic fluid clean.

• Use High-Quality Hydraulic Fluids: Poor-quality or incompatible hydraulic fluids can introduce foreign substances. Always use the recommended fluid type for your system.

• Inspect and Maintain Seals: Worn-out seals can allow contaminants to enter the system. Regular inspection and replacement of seals help prevent this issue.

3. Cavitation

Cavitation occurs when there is insufficient flow of hydraulic fluid to the pump’s inlet. This creates voids or air bubbles within the fluid, which collapse under pressure, damaging pump components.

Signs of Cavitation

One telltale sign of cavitation is foamy hydraulic oil. This indicates air is entering the system. Other symptoms include unusual noise during operation or a decrease in pump efficiency.

How to Prevent Cavitation

• Increase the Size of the Inlet Line: A larger inlet line can improve the flow of hydraulic fluid to the pump.

• Avoid Elbows and Bends: Remove any unnecessary elbows, bends, or filters on the inlet line to ensure a smoother flow of hydraulic oil.

• Position the Reservoir Above the Pump: Having the oil reservoir located above the pump helps maintain a steady flow and reduces the likelihood of cavitation.

Prolonging the Life of Your Hydraulic Pump

Preventing pump failure starts with proper system design and consistent maintenance practices. Here are additional tips to maximize the lifespan of your hydraulic pump:

• Monitor Oil Quality and Temperature: Regularly check the oil temperature and quality to detect early signs of heat-related issues or contamination.

• Schedule Routine Inspections: Periodically inspect the system components for wear, leaks, and signs of damage. Early detection can save you thousands in repairs and downtime.

• Implement Predictive Maintenance: Use advanced diagnostic tools to identify potential issues before they escalate. Many modern hydraulic systems now include sensors that monitor performance in real-time.

Partnering with a Reliable Source for Hydraulic Components

When it comes to maintaining and repairing hydraulic systems, the quality of your components matters. Low-quality parts not only wear out quickly but can also introduce new vulnerabilities to your system. That’s where trusted experts like Bailey International can make a difference.

With over 40 years of expertise in hydraulic components, Bailey International provides reliable, high-quality solutions tailored to your industry’s needs. From hydraulic pumps to filters, their extensive range of products and expert support ensures your system operates at its best.

Why Choose Bailey International?

• Experience You Can Trust: With decades of experience, Bailey has become a trusted partner for construction professionals, hydraulic engineers, and mechanics.

• Custom Solutions: For unique operational needs, Bailey offers customized components through its MVP program.

• Comprehensive Support: Bailey provides expert guidance every step of the way, from design to maintenance.

Looking to optimize your hydraulic systems even further? Take advantage of Bailey International’s vast catalog of hydraulic components and extensive expertise. Whether you need routine maintenance supplies or custom solutions, they’ve got you covered. Visit our digital catalog today and discover how Bailey can power your progress.