The life expectancy of a hydraulic pump isn’t typically measured in years, but rather in hours. On average, the following tends to be true:
- Gear pump – 10,000 – 15,000 hours (equating to around 5-7 years of use)
- Vane pump – 12,000 – 18,000 hours (equating to around 6 to 9 years of use)
- Piston pump – 20,000+ hours (equating to around 10 years of use)
In this industry, the life expectancy of equipment from a hydraulic system is referred to as “service life.” But can you realistically expect your hydraulic pumps to reach the suggested number of hours? Our quick guide outlines some of the most common questions to help you get the most of the service life of your hydraulic pump equipment.
How often does a hydraulic pump break down?
Each particular pump type has a different rate of suffering issues and breaking down, almost always due to improper use or lack of maintenance. The following will break this down further, and later, we will go over how to maintain your equipment to prolong service life:
- Gear pumps – Gear pumps are susceptible to wear and tear due to their design. A study named “Selected Operational Problems of External Gear Pumps in Agricultural Machines” found that the following issues are the most common failures:
- Wearing seals – Seals breaking will cause an internal leak, and that leak will eventually destroy your system components. Degradation of seals mostly happens through inadequate lubrication causing constant friction within the system.
- Cavitation – When bubbles form within the hydraulic fluid, pitting and damage to internal surfaces.
- Contamination – Particle ingress can cause abrasion on the gears and bearings within the hydraulic system.
- Vane pumps – Vane pumps can be reliable, but they also experience issues in the first 500 hours of service if proper maintenance isn’t enforced. The following are examples of the most common faults:
- Vane wear – The wearing of vanes leads to decreased volumetric efficiency and increased internal leakage.
- Contamination – Particles can cause scoring of vane tips and housing, leading to failure.
- Overheating – When temperatures reach higher than what the system is designed for, it can lead to vane deforming and breaking.
- Piston pumps – Piston pumps have the highest reliability of these three pumps, meaning they have lower chances of experiencing failure. They are not immune, however:
- Oil contamination – Leads to abrasion on pistons and cylinders.
- Fatigue from pressure spikes – Pressure spikes can cause pistons to crack or break.
- Blocked inlets – Blocked inlets are the cause of cavitation in piston pumps, leading to pitting and surface erosion.
How best to maintain hydraulic pumps and ensure a long pump life?
The maintenance of your hydraulic pumps is the best way to ensure they will reach their maximum service life. The following tips revolve around hydraulic machinery:
- Use high-quality hydraulic fluid – Hydraulic fluid is a lubricant that facilitates pressure and heat transfer, and is the lifeblood of your system. Ensure that you use industrial-grade or special-purpose oil. Also, ensure oil cleanliness by filtering out contaminants that may cause wear.
- Maintain optimal operating conditions – Know your ideal operating temperature, and monitor it. Consider using fire-resistant fluids as a preventative measure, especially in high-temperature areas, but understand that it’s not a cure. Furthermore, you should also ensure that your hydraulic pressure is within reasonable parameters by maintaining fluid levels and/or installing pressure relief valves.
- Regularly inspect components – There are three main places to look:
- Shaft bearings – Replace worn bearings to prevent vibration, noise and component misalignment.
- Gaskets and seals – Check gaskets and seals. In the event of leaks, stop the use of the hydraulic machinery and replace it immediately. It’s a cheap fix compared to what the hydraulic system will eventually devolve into the longer the leaks go on.
- Filters – Change regularly. Keeping filters fresh means it does a better job of removing contaminants and protecting vital hydraulic system components.
- Track system performance – One of the best ways to identify problems is through tracking, which can lead to preventative measures:
- Track metrics – Monitor leakage rate, hydraulic pressure, and temperature for abnormalities.
- Utilise historical data – Schedule maintenance or replacements based on component wear patterns.
- Predictive maintenance: Adjust your maintenance schedule to perform more regular checks on the areas of the hydraulic system that suffer the most faults.
- Align duty cycle with pump capabilities – Optimise your duty cycle by matching it to your system’s pressure and load requirements. Going above the pump’s rated capacity with heavy use only risks premature failure.
- Control contamination – Use proper sealing to limit the amount of dirt and debris getting into the system, and ensure that you not only change hydraulic fluid often but also check for particles within the reservoirs. Investing in high-quality filters goes a long way in ensuring contamination is controlled.
- Ensure proper lubrication – Lubricate your system to ensure smooth operation of your pump’s performance, especially in shaft assemblies or piston pumps. This type of pump requires lubrication because it operates with metal-to-metal contact constantly, and shaft assemblies experience continuous rotation.
- Replace worn-out pumps and components on time – When your pump is coming to the end of its lifespan, which is between 7-10 years depending on the pump, your only choice is to replace them.
- Incorporate advanced monitoring systems – Use sensors to monitor pressures, flow and temperature in real time. Adding monitoring tech to your hydraulic systems not only makes maintenance that much easier, but it can alert you to problems early, increasing the overall efficiency of your machinery.
Is it better to repair or replace a hydraulic pump?
Repairing or replacing hydraulic pumps depends entirely on how old the pump is, how much it costs, and the repair options near you. The fact of the matter is, that a hydraulic pump repair job is likely to be the most cost-effective way to fix your hydraulic system. A replacement for a high-quality model will always come with the original hefty price tag, whereas repairs can range from minor to heavy.
Gear pump repair criteria
- Minor Repairs:
- Replacing seals, O-rings, and gaskets.
- Tightening or replacing fasteners.
- Cleaning internal components.
- Fixing small leaks.
- Moderate Repairs:
- Replacing worn shafts or bearings.
- Replacing components to prevent leaks.
- Polishing or replacing parts damaged by cavitation.
- Heavy Repairs:
- Full disassembly to replace heavily worn or damaged gears.
- Repairing or replacing housing damaged by cavitation or contamination.
- Extensive rework due to significant internal scoring or wear.
Vane pump repair criteria
- Minor Repairs:
- Replacing worn vanes or vane springs.
- Replacing seals and cleaning housing.
- Cleaning or replacing filters to address contamination.
- Tightening connections to stop small leaks.
- Moderate Repairs:
- Replacing worn shafts or bearings.
- Restoring efficiency by repairing internal leakage or replacing minor components.
- Heavy Repairs:
- Full overhaul, including replacing vanes, housing, and shafts.
- Addressing high heat or contamination damage.
- Replacing multiple worn components such as shafts, bearings, and the pump’s interior.
Piston pump repair criteria
- Minor Repairs:
- Replacing seals, O-rings, or washers.
- Cleaning pistons and swash plates to remove light contamination.
- Replacing minor external components, such as fasteners or covers.
- Moderate Repairs:
- Repairing or replacing damaged pistons or swash plates.
- Fixing internal leakage by addressing worn cylinders or surfaces.
- Repairing light cracks or fatigue-related issues in non-critical parts.
- Heavy Repairs:
- Complete disassembly to replace multiple pistons, swash plates, and cylinders.
- Addressing severe fatigue-related damage or structural failures.
- Restoring heavily scored or eroded components caused by pressure spikes or contamination.
Conclusion
Is your hydraulic pump faulty? If so, the most economical way to fix your problem is almost always through repair. When seeking maintenance help, you need a business that will treat your time with respect, offering speedy retrievals, diagnoses’ and accurate quotes. Remember, if you experience faults with your hydraulic pump, you can’t ignore it – it will only get worse and become more costly to repair or replace. Contact CJ Plant today.