Before your machine’s hydraulic pump fails, it may exhibit some warning signs. Here are some of the most common symptoms of hydraulic pump failure you should watch out for.
This symptom could be a sign that the hydraulic pump is not operating at its optimal capacity, leading to slower work cycles and reduced overall efficiency. If you’ve noticed that your machine struggles to lift heavy loads or seems sluggish, the hydraulic pump may be failing.
A loss of power can significantly disrupt operations, as it affects the equipment's ability to perform its intended tasks. This symptom can range from a slow decline to an abrupt failure, indicating serious internal issues within the pump that require immediate attention.
When hydraulic equipment operates more slowly than usual, it may suggest that the hydraulic system is not receiving enough power from the pump. This inefficiency can delay projects and increase operational costs.
This indicates a lack of smooth flow in the hydraulic fluid, possibly due to air entrapment or fluctuations in pump pressure. Such inconsistency can lead to precision tasks being performed poorly, raising safety concerns on the job site.
Noise often precedes other more tangible symptoms of failure. It can indicate various issues, from cavitation to mechanical wear, signaling that the pump requires inspection.
These sounds are more serious than general noise and often suggest severe internal wear or failure. Such conditions usually demand immediate pump repair or replacement to prevent further damage.
Problems with the hydraulic fluid, including contamination and improper levels, can lead to a host of issues, from decreased performance to complete system failure. Regular fluid checks and maintenance are crucial.
Hydraulic leaks not only lead to fluid loss but also reduce the system's pressure and efficiency. They can also pose environmental and safety risks, making prompt detection and repair essential.
Visible damage to the pump, such as wear and tear or cracks, can compromise the system's integrity and lead to leaks or failure. Regular inspections can help identify and address these issues early.
Overheating can degrade hydraulic fluid and damage system components, indicating that the pump is operating beyond its limits or that there is insufficient cooling.
If the pump is working inefficiently, the equipment may require more power to perform the same tasks, leading to increased fuel consumption and operational costs.
Hydraulic pumps offer advantages over many other types of pumps, both for industry and home use. Three main types of hydraulic pumps are commonly employed, including rotary vane-, screw type-, and gear pumps. All three have wide industrial, automotive, and marine applications.
All pumps need an external power source, but hydraulic pumps offer the advantage of using the kinetic power of water for most of their energy. For the external source, hydraulic pumps utilize petrol-, diesel-, gas- or electricity to generate momentum.
Others make use of natural elements. These are continuously running pumps seen frequently on farms. For example, a windmill uses a hydraulic pump to lift water from deep in the ground, using the wind for natural power.
But hydraulic systems have uses in many industries outside of agriculture. They are in demand across the board from automotive and manufacturing to aerospace and construction and even healthcare.
Safety should always be paramount in all applications when operating a hydraulic system, including both pumps and motors. To ensure against a potentially painful, devastating, and expensive injury, consider the following safety tips:
Operate the system for its intended purposes only
As with all machinery, hydraulic pumps have an intended purpose. Unfortunately, one of the shortest routes to catastrophe is operating the system for another reason. When designers consider safety, they engineer the machine with a particular set of uses in mind. Departing from this endangers you and absolves the manufacturer from product liability claims.
Perform a detailed inspection before starting the system
Inspections allow you to identify hazards before the parts start moving. Be sure to check hydraulic hoses, connectors, fluid reservoirs, and other components for signs of the following:
● Leaks
● Loose fittings
● Cracked hoses
● Low hydraulic oil fluid level
● Other signs of disrepair
Shut down the system for fluid leaks
If you discover a fluid leak, suspend system operations. Before restarting, you should find the source of the leak and repair it. If you operate while the system is losing fluid, you may have difficulty keeping the system going because of excessive pressure on the components. This can also cause blowouts, particularly in the vicinity of the leak.
Shut down systems right away if they overheat or lose pressure
Continuing operations while the system is overheating or losing pressure can lead to damages and costly repairs. Also, overheated components may seize up, increasing the potential for accidents and injuries.
Always wear the proper personal protection equipment (PPE)
Manufacturers recommend wearing PPR while operating some hydraulic machines. Disregarding PPE can lead to dreadful consequences.
Never put your hands, face, arms, or other body parts into or near moving components.
Be careful of the system’s moving parts, such as fan blades, belts, and other components. Contact with moving parts may result in bruises, cuts, and other serious injuries.
Sometimes, troubleshooting requires observing the system in operation. Keeping a safe distance allows you to look and listen to the machine’s movements without risk of injury.
Employ lockout-tagout procedures before starting system maintenance
Using lockout-tagout procedures prevents someone from starting the machine while you are conducting maintenance. In addition, it’s important to release the hydraulic pressure before servicing the pumps, motors, and cylinders.
Get the proper training
System operators need the training to run systems safely. Inexperience and limited knowledge of machine operation may result in injury.
Never leave the system running unattended
A hydraulic system running unattended is a disaster in the making. When something goes awry, immediate system shutdown is often required. Failure to do so can harm the machine and endanger anyone in close contact.
Pay attention
Being focused and vigilant is crucial in maintaining a safe environment. A slip in attention or relaxation of safety principles can place you and others in jeopardy. So stay alert around heavy machinery.
Following these tips and manufacturer-recommended safety procedures can keep yourself and others safe. This ensures against costly, painful workplace injuries. In addition, you safeguard the system itself, preventing unnecessary breakdowns, blowouts, and shredded components.
Hydraulic systems provide valuable efficiencies and make many industrial processes possible. But like all machines, they can cause injury and breakdown without proper maintenance and precautions.
Have you scheduled a hydraulic system inspection?
If your hydraulic pump or motor is due for an inspection or maintenance, Servo Kinetics in Ann Arbor provides the services you need. Our industrial hydraulic repair solutions are efficient and accurate as we make sure to deliver on time at a competitive price. Call and speak to an engineer about our quality hydraulic repair services and our Special Offers.