Hydraulic Pump Maintenance and Repair: Why it’s Essential

In every setting where hydraulic power must be delivered, the pump is the system’s heart. If it goes down, so does the rest of the operation – and that means expensive downtime.

The only way to reliably avoid this is by investing time into regular pump maintenance. On-time maintenance is especially important for pumps exposed to high-contaminant environments, like those used in various dirt work and foundation repair settings.

How Poor Maintenance Affects Hydraulic Pump Systems

The majority of pump failures are the result of fluid contamination. Contaminants – whether solids or water – can infiltrate a hydraulic pump in a variety of way. Some examples include:

• Wear of internal components and/or seals
• Through poorly fitted hoses
• Through leaks
• Through the reservoir’s breather cap
• Due to an oversaturated filter
• Due to contaminated replacement components
• Due to poor fluid storage or transfer to the pump system

However solid particles enter the system, they can quickly bring down a pump. Hydraulic systems operate on extremely tight tolerances – even minor contamination is enough to degrade the fluid’s performance or cause severe corrosion or cavitation. Contamination can also cause valves to stick or other parts to take on damage.

On top of fluid contamination, component wear can cause a host of issues, including inconsistent pressure and overheating. If not addressed, component wear can result in total pump and equipment failure, which may be a safety issue in severe instances.

Seven Maintenance Tasks for Protecting a Hydraulic Pump’s Performance

Hydraulic pump maintenance is essential for system efficiency and life, as well as operator safety. Here are seven tips to ensure your pump remains in excellent operating condition:

1. Establish a consistent maintenance routine – Even the best-intentioned operating crew will miss critical maintenance tasks if there isn’t a plan in place. Consult the manufacturer’s guidance for the relevant pump model and schedule in cleanings, fluid changes and filter changes. Ideally, the system should be broken down a couple of times a year for a full inspection or if there are signs of distress (unusual noises, overheating, excessive vibration, etc.).

   When not in use, part of the company’s equipment maintenance plan should include proper pump and component storage. Storage areas should be well-maintained and free of excessive dust and other particulates.

2. Keep the pump body, hoses and fittings clean – As previously mentioned, avoiding fluid contamination is essential for hydraulic pump maintenance. Fundamental to this goal is cleaning the hydraulic pump and system components regularly – including hoses, fittings and all. Give these a good wipe down following operation.

   Occasionally, the pump will require a flush, and this should only be done with manufacturer-approved solvents. Flushes are recommended for new pumps, refurbished or acquired systems, and pumps that have recently recovered from a failure.

3. Replace the system’s filters on time – The pump’s filters are the first line of defense against solid contaminants, and water if your system features a desiccant breather. These filters have a finite useful life and must be replaced on time to avoid over-soiling and internal contamination.

   Filter changes must be scheduled, and operators should stick to the schedule for making those changes. Fortunately, hydraulic pump filters are designed for simple replacement, especially the spin-on suction filters typically found inside the pump’s reservoir. Most feature disposable cans that can be quickly removed and replaced.

4. Take the pump’s temperature regularly – Overheating is a general sign that something is wrong with the pump. It could signal contamination, a failing seal, excessive component wear, or pressure losses, among other signs of potential failure.

   Ideally, your pump will have built-in thermometers that simplify temperature readings, but hand-held infrared thermometers are also effective. Target the pump motor, heat exchanger and valves, in particular. If the motor or pump body are above recommended temperatures, the cooling system may need a check. With a little math, operators can calculate how much heat the exchanger is removing from the system, verifying whether the cooler is doing its job.

   If valves are overheating, they may be sticking. If that’s the case, further inspection of the valve is highly recommended to protect expensive downline components.

5. Sample the pump’s hydraulic fluid regularly – Some hydraulic pump systems are designed with test points that allow for quick fluid sampling. When sampling oil or hydraulic fluid, their visual state is key. If contamination is present, you may see sediment floating in the fluid. The fluid’s visual clarity is also a tell-tale indicator. Sometimes, contamination will produce a noticeable odor.

   Fluid samples can provide an early warning of problems to come, so consistent sampling is an important preventative measure.

6. Inspect the reservoir, fluid levels, hoses and filter indicators – Your eyes are the best tool for spotting system wear or early signs of damage. The pump’s reservoir, hoses and filters should be visually inspected with regularity. On the pump body, hoses, and connections, you’re looking for leaks. They’re unfortunately common and can adversely affect system pressure and temperature.

   Some filters come with indicators that trip an alert when it needs to be replaced. Give those an occasional look to ensure dirty filters are switched out promptly.
   Inside the reservoir, check for any signs of cavitation. During operation, if foaming or whirlpooling is present around the suction filter, the system may be taking on air. Cavitation is a serious threat to hydraulic pumps as those discrete air bubbles can score and pit internal parts.

7. Respond to any unusual noises the pump is making – Unusual sounds are a common sign of pump distress, and if something sounds off, it’s worth further inspection. Cavitation, for example, tends to produce a whining sound when present. If air is entering the fluid through the reservoir (aeration), it may sound like there are rocks rattling inside the pump.

   In general, if the pump is making sounds that it usually doesn’t, it could be a sign of imminent failure.

Hydraulic Pump Repair and Maintenance Should Be Handled by a Reputable Equipment Supplier

Consistent hydraulic pump maintenance will optimize system reliability and service life, but even the best-maintained pumps will eventually experience significant failure. When they do, it may be too difficult or too time-consuming to resolve the issue without expert assistance.

Hydraulic repair professionals are experienced in breaking down pumps, cylinders and other hydraulic equipment. By doing so, the technician can perform a full inspection of all components and recommend proper maintenance and repairs, and replacements if needed. If a part is needed, repair specialists can source those components quickly and get their clients’ equipment back in the field.