THE

COMPLETE
GUIDE

WHAT'S WRONG WITH

YOUR HYDRAULIC PUMP?

U N D E R S T A N D I N G N O I S E , H E A T,
F LO W A N D P R E S S U R E P R O B L E M S
 THE
COMPLETE
WHAT'S WRONG WITH YOUR HYDRAULIC PUMP? GUIDE

INTRODUCTION
UNDERSTANDING THE
4 MAIN PUMP PROBLEMS
This guide has been created to help you to pinpoint possible hydraulic pump
problems. In it, we outline the 4 most common pump issues and provide you
with more information about the contributing factors and underlying causes.
While this is not intended to be an exhaustive manual, it will help you to
narrow down pump problems so you can take the right steps to resolve your
issue.
The 4 main pump issues covered by this guide:

1. NOISE PROBLEMS

2. HEAT PROBLEMS

3. FLOW PROBLEMS

4. PRESSURE PROBLEMS
Berendsen Fluid Power is a nationwide hydraulics leader that stocks and
supplies a wide range of hydraulic pumps from major manufacturers
including Eaton and Danfoss. In addition, our repair centres across Australia
perform repairs and refurbishment to all hydraulic pump types. If you need
more information, or if you’d like to enquire about a pump repair, please
contact us.

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 THE
COMPLETE
CHAPTER 1 - NOISE PROBLEMS GUIDE

WHAT KIND OF NOISE ARE YOU POSSIBLE CAUSE

HEARING?

YOUR PUMP MAY BE

STEADY WHINE AND CAVITATING
RATTLING? Cavitation is a destructive condition whereby
excessively low inlet fluid pressure causes cavities
to form in the fluid and rapidly implode, leading to
metal erosion and damage to pump internal surfaces.
Cavitation is recognisable by the sound it produces.
If the cavitation is mild it will emit a steady high-
pitched whining sound. If more severe, a pronounced
rattling sound may be heard.

YOU MAY HAVE AIR IN YOUR

ERRATIC WHINE? FLUID
The whining noise caused by air leaks is more
erratic in nature. This is due to the uneven
distribution of the air in the hydraulic system.
Unlike cavitation, which forms vapour bubbles at
the pump inlet, air enters the pump along with the
fluid in an inconsistent manner through a loose
fitting in the suction line or from low oil level in
the reservoir. Thus, the sound often changes as the
machine operates.
Aerated oil causes many problems including:
 Sluggish or erratic actuator performance
 Reduced
 pump efficiency and accelerated
component wear.
 Damage to seals.
 Excessive heat and increased fluid
contamination.

YOU MAY HAVE MISALIGNED

MECHANICAL WHINE? COUPLING
A metallic or mechanical whine could be an
indication that the alignment between the pump
and motor is not concentric - leading to excessive
vibration, noise, temperature increases, and
increased wear on shafts and bearings. The pump
should be aligned in all orientations. Check that
the angle of alignment is correct in horizontal and
vertical planes. Also verify that the centrelines of
the pump and motor are aligned to avoid parallel
misalignment.

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 THE
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CHAPTER 1 - NOISE PROBLEMS GUIDE

WHAT KIND OF NOISE ARE POSSIBLE CAUSE

YOU HEARING?

YOUR PUMP MAIN BEARING MAY

MECHANICAL ROAR? BE WORN OR DAMAGED
A mechanical sound is usually an indication of
badly worn internal parts. Any grinding, scraping,
rough running pump sounds should be treated
as an indication of serious internal wear. In such
cases, the pump must be disassembled, inspected
and overhauled by a trained technician. Worn
components must be replaced and in some cases
machining work must be performed to restore the
pumps internal surfaces.

YOUR RELIEF VALVE MIGHT BE

STEADY HISSING? SET TOO LOW
Relief valves are designed to keep system pressure
from reaching dangerously high levels. Hydraulic
systems are not usually designed to dump flow
across their relief valves continuously. A hissing
sound and excessive localised heat is an indication
that a relief valve is bypassing flow at high
pressure.

YOUR RELIEF VALVE MAY BE

ERRATIC WHISTLING OR WORN OR DAMAGED
HISSING? A whistling sound or erratic hissing from a relief
valve often suggests that they are improperly
adjusted or stuck open. Slamming of actuators,
stalls and excessive heat generation are the early
symptoms of problems with these valves.

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 THE
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CHAPTER 2 - HEAT PROBLEMS GUIDE

POSSIBLE CAUSE

YOUR FLUID MAY BE TOO HOT

As hydraulic fluid circulates through your hydraulic

system it both produces heat by doing work
and transports that heat away from working
components. However, if the heat dissipation is
inadequate, or if the hydraulic oil does not have
PROBLEM the right heat dissipation properties, then it can
overheat. Build-up of dirt, debris and clogged
hydraulic filters can also affect a system’s ability to
dissipate heat and lead to hydraulic fluid becoming
too hot, leading to loss of fluid viscosity and

IS THE PUMP ITSELF

reduced lubrication and pump efficiency.

OVERHEATING?
Have you noticed a temperature YOUR PUMP
increase that is localised to the MAY BE CAVITATING
pump itself (without affecting
other parts of the circuit)? This Cavitation is the rapid formation and implosion
heat is likely related to the of air cavities in the hydraulic fluid which creates
a vast amount of heat. That is because the oil
mechanical condition or operation
implodes with such violence that it can generate
of the pump. Review the possible temperatures of up to 2700 degrees C at the
causes on the right. point of implosion! Cavitation compromises the
lubrication properties of the oil, and the excessive
heat is extremely damaging to hoses and seals and
metal components, which expand and wear.

YOU MAY HAVE

AIR IN YOUR FLUID
Aeration occurs when air makes its way into the
system via air leaks at points like pump seals,
pipe fittings and unions. Air generates heat when
compressed, so aeration increases the heat load
on the hydraulic system. Aeration accelerates
degradation of the fluid and causes damage to
system components through loss of lubrication,
overheating and burning of seals. High fluid
temperature can also cause damage from inadequate
lubrication as a result of excessive thinning of the oil.

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 THE
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CHAPTER 2 - HEAT PROBLEMS GUIDE

POSSIBLE CAUSE

YOUR RELIEF VALVE MAY BE SET

TOO HIGH
If the pump in use is too powerful for the demands
of the application, the relief valve may dump
the unused pressure continuously back into the
reservoir. This continuous unloading converts
PROBLEM pressure to heat, which inevitably results in
overheating of the pump. Check to ensure your
pressure relief valve is set at the correct level as
recommended by the manufacturer. If you cannot
achieve the correct setting without an increase
in pressure, the pump may be incorrect for the
IS THE PUMP ITSELF application.

OVERHEATING? THERE MIGHT BE EXCESSIVE

Have you noticed a temperature LOAD ON YOUR PUMP
increase that is localised to the When a load is lifted hydraulically, potential
pump itself (without affecting energy is stored in the load. Release of the load
other parts of the circuit)? This usually involves non-regenerative throttling, which
generates heat. If your pump is overheating, check
heat is likely related to the for work load in excess of circuit design.
mechanical condition or operation
of the pump. Review the possible
causes on the right. YOUR PUMP MAY BE WORN OR
DAMAGED
As pumps wear, the internal leakage or “slippage”
increases. On fixed displacement pumps this
leakage flows from the high-pressure outlet back
through the pump to the low-pressure inlet. In a
pressure compensated pump this flow is forced
out through the case drain. As this occurs fluid
is taken from a high pressure to a low pressure
without doing any mechanical work thereby
creating heat. In addition, as valves wear they
develop leakage paths that allow high-pressure oil
to leak to a low-pressure port creating heat. Keep
a log of the hours on your pump and be aware
of the service intervals. Inspect the pump and
overhaul or replace if necessary.

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CHAPTER 2 - HEAT PROBLEMS GUIDE

POSSIBLE CAUSE

YOUR SYSTEM PRESSURE MAY

BE TOO HIGH

System pressure is often adjusted to deal

with other hydraulic issues such as sluggish
performance. However, your hydraulic system is
designed with a specific pressure setting in mind.
PROBLEM Increasing the pressure may cause several negative
effects, including increased heat production.

YOUR RELIEF VALVE MAY BE SET

IS YOUR TOO HIGH
HYDRAULIC FLUID Pressure relief valves are there to ensure pressure

GETTING TOO HOT?

does not rise beyond prescribed limits. If your
relief valve is set incorrectly, it will not open soon
enough and pressure will increase, which generates
significant heat. This can have a detrimental effect
In some cases, a pump may on many parts of your system and contributes to
experience an increase in fluid degradation, loss of lubrication and lower
temperature as a result viscosity.
of hydraulic fluid that is
compromised or contaminated.
YOUR FLUID MAY BE DIRTY

Contaminated fluid has a reduced capacity for heat

dissipation and can also lead to blocked fluid filters
and strainers, which may allow low pressure leading
to cavitation and increased heat build-up.

YOUR FLUID MAY BE LOW

Low fluid levels can lead to oil starvation, which

leads to metal-on-metal friction, increased heat and
increased wear. If fluid levels in reservoirs are allowed
to drop, pump inlet ports can become exposed and
this presents an increased risk of aeration of the oil
leading to loss of lubrication, heat generation due to
air pressurization and depressurisation. Check fluid
levels for all stages of operation - ensure there is
sufficient fluid in the reservoir when the cylinders are
fully extended.

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 THE
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CHAPTER 2 - HEAT PROBLEMS GUIDE

SOLUTION

YOU MAY HAVE THE

INCORRECT FLUID VISCOSITY
Viscosity is the measure of a fluid’s resistance to flow.
It is commonly thought of as thickness, or resistance
to pouring. Hydraulic fluid viscosity influences
important performance parameters including power
transmission, lubrication and heat dissipation.
PROBLEM Low viscosity increases the risk of internal leakages
and negatively affects the efficiency of pumps and
motors. High viscosity can cause problems such as
sluggish movement, increased mechanical friction,
heat generation and cavitation. Ensure the hydraulic
fluid you use is correct for the operating conditions
IS YOUR and requirements of your system.

HYDRAULIC FLUID YOUR FLUID COOLING SYSTEM

MAY BE INADEQUATE OR FAULTY
GETTING TOO HOT?
The design of any hydraulic system must allow oil to
In some cases, a pump may dissipate heat in order to operate efficiently. Some
experience an increase in systems may do this with an oil reservoir or heat
exchanger or combination of both. If the system
temperature as a result design does not allow for sufficient heat dissipation
of hydraulic fluid that is or if the system is clogged or faulty, this will result in
compromised or contaminated. the fluid becoming overheated.
Assess the design of your hydraulic circuit and, if
necessary, install an oil cooler or increase the oil
reservoir capacity. Check for obstructions to airflow
around the reservoir, such as a build-up of dirt or
debris. Inspect the heat exchanger and ensure that
the core is not blocked. Check the performance of all
cooling circuit components and replace as necessary.

YOUR SYSTEM MAY BE TOO

WORN
Heating of hydraulic fluid in operation is caused
by inefficiencies. Inefficiencies result in losses of
performance, which means energy is lost as heat
instead of converted to force. That heat needs to go
somewhere. Worn pump, valve, motor, cylinder or
other components decrease efficiency and increase
internal friction, which all contributes to an increase
in oil temperature. Inspect overhaul and replace
components if necessary.

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 THE
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CHAPTER 3 - FLOW PROBLEMS GUIDE

POSSIBLE CAUSE

YOUR FLOW CONTROL COULD BE

SET TOO LOW
Flow control determines the amount of flow
delivered by the pump. Check this first to rule out
the most obvious cause of low flow. Check to see
that it is set to the correct level for the application.
PROBLEM
YOUR RELIEF VALVE MAY BE SET
TOO LOW
Relief valves control the pressure build-up in the
DOES YOUR PUMP pump. Should it be set too low it will open and
allow pressure to escape, reducing the flow from

HAVE LOW FLOW? the pump. Check to see your relief valve is set
within prescribed limits.

FLOW MAY BE BY-PASSING VIA A

PARTIALLY OPENED VALVE
Damaged or faulty valves may be creating relief
paths or unintentionally directing flow to other
parts of the system. Check the position of all your
system valves. Inspect for wear or damage. Replace
or overhaul damaged valves if necessary.

THERE MAY BE AN AIR LEAK IN

THE SYSTEM
As discussed elsewhere in this guide, air leaks cause
several performance issues including increased heat,
noise and erratic pressure. There are several ways that
air can make its way into your system. These include
loose connectors, air leaks in suction lines or an
insufficient supply of oil to pump from the reservoir
or as a result of lines and hoses that are too small.

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 THE
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CHAPTER 3 - FLOW PROBLEMS GUIDE

POSSIBLE CAUSE

YOUR MOTOR RPM MAY BE

TOO LOW
Pump flow is (in part) determined by the rate at
which the pump turns. If your motor is unable to
turn the pump at the required speed, the pump
will be unable to develop the required flow. Check
PROBLEM the motor specifications and replace it with the
correct unit if necessary.

DOES YOUR PUMP YOUR PUMP MAY HAVE EXCESSIVE

SLIPPAGE
HAVE LOW FLOW?
Slippage refers to internal leakage of hydraulic
fluid through the tiny gaps between pump
components such as vanes and gears. When a
pump is new the tolerances are very tight and
very little fluid can get between these moving
parts. As the pump wears, these gaps grow larger
and eventually more and more fluid is able to
pass through the gaps. This slippage reduces the
performance and efficiency of the pump, which
has an effect on its flow.

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 THE
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CHAPTER 4 - PRESSURE PROBLEMS GUIDE

POSSIBLE CAUSE

YOUR DIRECTIONAL CONTROL

COULD BE SET INCORRECTLY
You’d be surprised how often the directional
control is changed by other people or changed
inadvertently. Before you start unbolting things,
check the position of manually operated controls
and check the electrical circuit on solenoid
PROBLEM operated controls.

YOUR PUMP MAY NOT BE

RECEIVING FLUID
DOES YOUR Check to ensure adequate fluid flow to your pump.
PUMP HAVE There are many factors such as restrictions and
blockages which could contribute to poor fluid

NO PRESSURE? flow.
 Air leak in suction line
 Air present in the pump at start-up
 Insufficient supply of oil in pump
 Clogged or dirty fluid filters
 Clogged inlet lines or hoses
 Blocked reservoir breather vent
 Low oil in the reservoir

YOUR PUMP DRIVE MOTOR MAY

NOT BE OPERATING
Check to ensure that your pump drive motor is
turning over and is developing the required speed
and torque. In some cases, misalignment can cause
binding of the drive shaft, which can prevent the
motor from turning. If this is the case, correct the
misalignment and inspect the motor for damage.
If required, overhaul or replace motor.

YOUR PUMP COUPLING COULD

BE SHEARED
Check to ensure the pump to motor coupling
is undamaged. A sheared pump coupling is an
obvious cause of failure, however the location of
some pumps within hydraulic systems makes this
difficult to check so it may go overlooked.

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 THE
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CHAPTER 4 - PRESSURE PROBLEMS GUIDE

POSSIBLE CAUSE

YOUR PUMP DRIVE MOTOR

COULD BE REVERSED
In some cases, incorrect pipe routing between
control valve and the motor can reverse the
direction of flow from the drive motor. Check the
circuit to determine the piping is installed correctly.

PROBLEM
THE RELIEF VALVE COULD BE
SET INCORRECTLY
DOES YOUR It is possible that the entire flow could be passing
over the relief valve, preventing the pressure from
PUMP HAVE developing. Check that the relief valve is adjusted
properly for the pump specifications and the
NO PRESSURE? application.

THE RELIEF VALVE COULD BE

DAMAGED

If the pressure relief valve is set correctly, yet no

pressure is being produced, it is possible that the
valve itself may be at fault. Check to ensure the
relief valve is not sticking open and preventing
pressure development.

YOUR PUMP MAIN BEARING

MAY HAVE FAILED
Seized bearings, or pump shafts and other internal
damage may prevent the pump from operating all
together. If everything else checks out, uncouple
the pump and motor and check to see that the
pump shaft is able to turn. If not, overhaul or
replace the pump.

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 THE
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CHAPTER 4 - PRESSURE PROBLEMS GUIDE

POSSIBLE CAUSE

PRESSURE MIGHT BE ESCAPING

VIA A ‘RELIEF PATH’
Depending on the system design, some of your
flow may be unintentionally routing back to the
reservoir or another part of the system in such a
way as to reduce pressure build-up. Check your
system design to ensure correct routing.
PROBLEM
YOUR PRESSURE RELIEF VALVE
MAY BE SET INCORRECTLY
DOES YOUR If your pressure relief valve is set too low, it

PUMP HAVE may not allow the system to develop sufficient

pressure. Check that your pressure relief valve is
not set too low for the pump or the application.
LOW PRESSURE?
YOUR PRESSURE RELIEF VALVE
MAY BE DAMAGED
If your pressure relief valve is set correctly, but
there’s still no pressure, the relief valve may be
sticking open. Inspect the valve and replace or
overhaul if necessary.

YOUR PUMP, MOTOR OR

ACTUATOR COULD BE DAMAGED
Low pressure could be caused by general worn
components in all parts of the system. If you are
experiencing unexplained low pressure, it’s time to
consider a complete overhaul.

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 THE
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CHAPTER 4 - PRESSURE PROBLEMS GUIDE

POSSIBLE CAUSE

YOUR PRESSURE REDUCING

VALVE COULD BE SET TOO HIGH
Check the pressure reducing valve or unloading
valve to verify that it is set correctly for the pump
and the application.

PROBLEM

YOUR PRESSURE REDUCING

VALVE MAY BE DAMAGED
DOES YOUR PUMP
If your pressure reducing valve is set correctly and
HAVE EXCESSIVE you are still experiencing overpressure, the valve
may be damaged. Inspect the valve for wear or
PRESSURE? damage and overhaul or replace if necessary.

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 THE
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CHAPTER 4 - PRESSURE PROBLEMS GUIDE

POSSIBLE CAUSE

YOU MAY HAVE AIR IN YOUR

FLUID
Free air plays havoc in hydraulic systems. Air is a
compressible gas, while oil is an incompressible
liquid. As air bubbles circulate through a system
the pump will experience inconsistent pressure and
momentary instances of oil starvation, leading to
PROBLEM many problems.

YOUR PRESSURE RELIEF VALVE

MAY BE WORN
DOES YOUR
If your pressure relief valve is opening at the wrong
PUMP HAVE moment, or unable to contain the correct pressure,
it may result in pressure spikes followed by rapid
ERRATIC PRESSURE? pressure decrease. Inspect the pressure relief valve
and overhaul or replace if necessary.

YOUR HYDRAULIC FLUID MAY BE

CONTAMINATED
Contaminated fluid can block filters, cause
blockages in pipes and connectors and may
cause valves to stick or to become damaged.
Test your fluid contamination levels and follow
the prescribed filter changing schedule. Replace
contaminated fluid if necessary.

YOUR PUMP, MOTOR, ACTUATOR

OR OTHER SYSTEM COMPONENTS
COULD BE DAMAGED

General hydraulic system condition should be

considered at all times. Damage to hydraulic
motors, or hydraulic cylinders can cause internal
or external leakages that may compromise the
performance of the pump. External impact could
result in bent shafts, cylinder rods or misaligned
components - increasing friction. Sticking or
juddering cylinders may result in pressure spikes
that may appear as erratic pressure. Inspect the
entire system for damage and repair or overhaul
any components in need of attention.

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CHAPTER 4 - PRESSURE PROBLEMS GUIDE

POSSIBLE CAUSE

YOUR ACCUMULATOR COULD

BE FAULTY
The role of the hydraulic accumulator is to
absorb pressure ripples, and soften the impact
of directional control or actuation. If your
accumulator is defective or has lost charge, it may
not perform this task consistently, leading to erratic
PROBLEM delivery of pressure. Inspect the accumulator and
overhaul or replace if necessary.

DOES YOUR YOUR PUMP, MOTOR OR

PUMP HAVE ACTUATOR MAY BE WORN
ERRATIC PRESSURE? General system condition should always be
considered. All components have a lifespan and -
over time - components become less efficient, and
produce more heat and friction. Erratic pressure may
stem from a combination of different components
that are not working optimally, or it may be the
result of one worn bearing placing added load on the
pump or motor. If your system is aging, or if you’re
simply not sure how well it has been maintained,
then it may be time to consider a complete overhaul
if your system is experiencing erratic pressure.

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 THE
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CHAPTER 5 - PUMP MAINTENANCE GUIDE

PUMP MAINTENANCE RECOMMENDATIONS

AVOIDING CAVITATION AVOIDING AERATION

As we have discussed throughout this guide, Like cavitation, aeration is another damaging
cavitation is a major enemy to pump performance problem you will probably encounter in the life of
and lifespan. Here are some tips to reduce the your pump.
formation of these harmful cavities in your fluid. Here are some steps you can take to reduce the
1. Always ensure you maintain the correct oil level presence of air in your system:
in the reservoir at all times during operation. 1. Take care to bleed all the air from your system
Take into account the oil level drop when when filling or replacing fluid.
cylinders are extended.
2. Check for leaking connections and secure them
2. Make sure that all shut-off valves are open, if necessary.
are of the proper type, and are allowing
3. Fill the oil reservoir to the required level and
unrestricted flow.
ensure the reservoir level is sufficient at all
3. Ensure all hoses are of sufficient diameter times during operation - account for oil level
to allow adequate flow - so as to avoid oil drops as cylinders extend.
starvation and avoid pressure drops.
4. On mobile machines, pump reservoirs should
4. Ensure all filters are replaced according to the be designed to mitigate sloshing, which can
prescribed maintenance schedule. Clogged aerate your fluid.
filters will create an excessive pressure drop,
which leads to cavitation.
5. Ensure adequate fluid flow from the reservoir.
Pumps are designed to push fluid, not suck.

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CHAPTER 5 - PUMP MAINTENANCE GUIDE

PUMP MAINTENANCE RECOMMENDATIONS

AVOIDING AVOIDING FLUID

OVERPRESSURISATION CONTAMINATION

Excessive pressure generates heat, which is Fluid contamination is a major source of pump
damaging to hydraulic fluids. Keep in mind damage. Follow these recommendations to reduce
that pumps are designed to produce flow - not contamination and prolong the performance and life
pressure! If your system design is such that pumps of your pump.
are required to overcome too much pressure 1. Replace hydraulic filters according to the
to create the necessary flow, they will produce prescribed maintenance schedule.
excessive heat and eventually fail.
2. Check possible entry points such as breather
With this in mind, here are some tips for avoiding hoses or missing reservoir caps that may allow
this condition: dirt or water to enter.
1. Ensure the pump is appropriate for the 3. Make sure seals are in good condition so they do
application. Don’t turn up the pressure to not allow contaminants to get into cylinders or
compensate for a pump that is too small. motors.
2. Ensure pressure relief settings are adjusted 4. Clean new parts thoroughly before installation.
properly. In some cases, pumps are replaced New parts such as hoses sometimes contain
and the pressure settings are not changed rubber and metal particles from manufacturing.
accordingly. 5. Take fluid samples and keep a record of
3. Follow the correct maintenance procedures for contamination levels within your system so you
the rest of your machine or system. Don’t turn will be aware of the pattern of contamination
increases and can take preventative steps.
up the pressure to compensate for sticking
cylinders, or to overcome flow problems caused 6. When you sample hydraulic fluid, do so at the
by clogged lines or filters. same point each time to ensure consistency.
However, do not take samples from stagnant
points such as fluid reservoir drains or you will
encounter inaccurate readings.
7. Take care to store hydraulic fluid carefully. Fluid
will quickly become contaminated if containers
are left open.
8. Filter hydraulic oil through a fine mesh before
adding it to the hydraulic system to reduce
contaminants.

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