Hydraulic Pump Overheating: Hazards, Causes, and ...

Author: Alice

Jan. 13, 2025

Hydraulic Pump Overheating: Hazards, Causes, and ...

Hydraulic pumps generate heat while they run. However, hydraulic fluid temperature should never exceed 180 degrees F (82 degrees C) under normal working conditions. If your hydraulic pump temperature rises above this, then that is a sign that your pump is likely overheating. One of the most common causes of hydraulic system failure is a hydraulic pump that runs too hot or overheats. 

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Learn about the hazards of a hydraulic pump that runs too hot, the most common causes of this problem, and the ways to remedy this common pump issue. 

Overheating Hazards

When a hydraulic pump runs at a too-high temperature for too long, it can ultimately lead to pump failure. Once a hydraulic pump begins to fail, it can potentially damage the entire hydraulic system by sending contaminants and debris into the system that can damage its other components. 

In addition, when some hydraulic fluids are subject to high temperatures, they can thin and lose their viscosity. When hydraulic fluid is too thin, it is much more likely to leak, and fluid that has lost its viscosity cannot lubricate your pump properly. Extremely hot fluid can also damage pump seals, further increasing the chance of a pump leak. 

Some hydraulic fluids thicken and oxidize when exposed to high heat instead of thinning. When hydraulic fluids are too thick, they can restrict flow throughout the entire hydraulic system, which leads to your system heating up even further. 

The sooner you determine why your hydraulic pump is running hot and repair the cause of the problem, the less likely your hydraulic system will develop irreversible damage or fail completely.

Overheating Causes

Hydraulic pumps overheat for many reasons. Just a few of the most common causes of hydraulic pump overheating include: 

  • Contaminated hydraulic fluid. When fluid has debris and dirt, contaminant particles can quickly build up on hydraulic system filters, leading to filter clogs. Your pump has to work harder to pump fluid through clogged filters, which leads to overheating. 
  • Aeration. Air leaks at seals and fittings on your hydraulic system components can lead to air entering your system and forming bubbles in your fluid. Air bubbles generate heat when your system compresses them and then pass this heat into the surrounding fluid, overheating it. 
  • Low reservoir fluid. Since your hydraulic system releases some of the heat it creates into reservoir fluid, a low reservoir fluid level can contribute to overheating. 
  • Blocked or damaged heat exchanger. This component is also an important part of your hydraulic pump's cooling system. If it is blocked or damaged, then it cannot help remove heat from your pump properly. 

While these problems are common causes of hydraulic pump overheating, pumps can overheat for numerous additional reasons.

Overheating Solutions

Once your hydraulic pump beings overheating, you need to find the cause of the problem and repair it. That way, your pump can begin operating within its ideal temperature range again.

If your pump overheats due to fluid contamination, then either remove all contaminants from existing fluid or remove the current contaminated fluid from the system and add fresh fluid. Be sure to filter all fresh hydraulic fluid before you add it to your system because even this fresh fluid can contain contaminants. Also, replace your fluid filters on a regular basis to prevent the overheating that can occur when these filters become blocked with debris.

If air has entered your system through leaky seals and fittings, then have a hydraulic system repair expert inspect and replace or tighten these fittings. Have a hydraulic system repair expert also look at heat exchanger damage to determine if the exchanger needs repairing or replacing. 

Finally, be sure to check your system's reservoir fluid level on a regular basis. Add new fluid when necessary to help this reservoir perform its important task of helping to keep your pump cool. 

High temperature problem of vacuum pump

High temperature problem of vacuum pump

(1) The motor power and the working current is so large, which causes the vacuum pump have a high temperature.

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(2) The number of fan blades is small, thus the wind is also small.

(3) The fan speed is low, thus the wind pressure and the air volume is small.

(4) The bus voltage of the vacuum pump motor is 380V. Due to the cable voltage drop and uneven load distribution, the actual voltage applied by the motor is only 365V. The low voltage causes the operating current to be large.

(5) The motor is attached with dust and oil, which reduces the heat dissipation capacity and causes the vacuum pump to have a high temperature.

Rotary Vane Vacuum Pump

Vacuum pump high temperature problem countermeasure

The motor power and speed are matched to the vacuum pump and cannot be changed. The fan is mounted on the motor spindle. The motor speed determines the fan speed and cannot be replaced. Although increasing the number of fan blades can play a certain role, but after the number of blades increases, the dynamic balance is not easy to find. If the alignment is not good, the vibration of the motor will increase.

(1) Lengthen the original vacuum pump fan cover by 40cm, and install an axial fan with the same diameter as the fan cover. The axial fan motor power is 850W, the speed is r/min, and the voltage is 380V. The original fan continues to be retained. The axial flow fan is additionally provided with one power supply control, and the axial flow fan is not interlocked with the main motor. After the vacuum pump is started, the axial flow fan is started in time, and the axial flow fan is stopped 30 minutes after the vacuum pump is stopped, so that the main motor is fully cooled;

(2) Regularly remove dust from the vacuum pump motor, keep the heat sink of the motor clean, and increase its heat dissipation capacity;

(3) Adjust the bus voltage of the vacuum pump to 400V.

Vacuum pump high temperature solution effect

(1) Due to the high speed of the axial fan, the wind pressure is large, and the cooling effect is greatly enhanced. Under the same ambient temperature and load current, the temperature of the main motor of the vacuum pump drops by 12 °C. The main motor temperature in summer is no longer exceeded.

(2) Slow down the insulation aging speed of the main motor and prolong its service life.

(3) The axial flow fan can be artificially controlled. After the main motor is stopped, the axial flow fan can still operate, and the main motor can be fully cooled.

(4) After the voltage is adjusted, the diaphragm pump operating current is reduced to 210A, and the heat generation is relatively reduced.

(5) Try to balance the load distribution of the two busbars as much as possible to prevent the voltage drop of a certain busbar from being overloaded due to excessive load.

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