Gear Pumps & Motors Failure Analysis Guide

1
1. The heart of a hydraulic system is the

hydraulic pump. The pump is the component
FAI LURE AN ALYSI S/ that converts mechanical energy into fluid
energy. A healthy pump will allow the
TRO UBLESHO O TI N G hydraulic system on mobile equipment to
perform at its
its’ maximum level of effectiveness
effectiveness.
GEA R PUM PS & M O TO RS Without a healthy pump, the system will be less
responsive and rob the machine of performance
and productivity. A properly maintained
hydraulic system provides insurance that the
equipment will deliver the work it is designed to
do. A good preventative maintenance program
affords the operator hundreds of hours of
trouble free operation.
Unfortunately, the hydraulic system does not
always perform at its’ specified level. It is at
these times that we need to troubleshoot the
1 system and pinpoint the cause. A proper
© 1998 Commercial Intertech Corp.
diagnosis is critical to providing renewed

performance and extended life. This booklet is designed to help you properly identify the
cause of poor performance or component failure
failure. We will be taking an in-depth
in depth look at
Commercial Intertech’s gear pumps and motors.
Commercial Intertech is a worldwide manufacturer of fixed displacement hydraulic gear
pumps and motors. With facilities on four continents Commercial is positioned to provide
product and service to the global market place. For the past 75 years Commercial
Intertech has been the product of choice for meeting the needs of tough mobile
applications.
2. Th
2 The heart
h t off the
th hydraulic
h d li system,
t Commercial
C i l Intertech’s
I t t h’ external
t l spur gear pumps
are a fixed displacement design. For every complete revolution of the gear shaft the pump
displaces a fixed amount of oil. Pump output flow is proportional to the engine speed.
There are three casting components that make up the exterior pump capsule: shaft end,
gear housing, and port end cover. A tandem pump will have a fourth casting component,
the bearing carrier. Various casting materials are used including gray iron (the most
common), compacted graphite, ductile iron, and aluminum.
G and
Gear d ddrive
i shafts
h ft are cutt from
f alloy
ll steel
t l andd then
th case hardened.
h d d The Th mostt common
gear shaft is the integral, where the drive shaft and gear are one piece. The integral gear
shaft provides exceptional torque carrying capabilities. The other type is the “continental”
shaft and drive gear or the two piece. The “continental” shaft is machined with drive
extensions on both ends of the shaft; an
GEAR PUMP external drive (splined or keyed) and a smaller
Thrust splined end for internal drive. The drive
Plates Port End
Shaft Cover connection inside the pump is made by
End Cover Lip Seal
inserting the small end of the shaft into the hub
Mounting
of an internally splined drive gear.
Flange Roller
Bearings No matter what type of gear shaft used, the
gear journals must be supported by bearings or
Drive sleeve type bushings. The roller bearing
Spline
pumps require the use of ring seals to prevent
Drive Gear
g pressure
the high p oil that lubricates the
Idler Gear
bearings from traveling down the shaft.
Inlet Port Bushing pumps do not need ring seals as the
Out Board
bushings are lubricated with low pressure oil.
Bearing
To insure maximum pumping efficiency
Commercial Intertech’s pump and motor
Ring Seal Gear Housing
2 (High Pressure) products employ the use of pressure balance
thrust plates. ©1998 Commercial Intertech Corp
2
3. Tandem pumps are needed when there are

multiple functions, functions that require TANDEM GEAR PUMP
different flows and where a single section can Bearing carrier
Bushings
not provide adequate flow
flow. This P300 series
tandem pump shows the fourth casting
component, the bearing carrier.
4. Both pumps and motors employ a pressure

balanced thrust plate design
design. Oil pressure
hydraulically balances the thrust plates and
squeezes them against the two gear faces. The
squeeze provides a seal between the gear face
and the thrust plate surface preventing high
pressure oil from slipping back to the low Pumping Sections
3
pressure side of the pump. Mechanical seals © 1998 Commercial Intertech Corp.
are used behind the thrust plate to block oil

from slipping between the plate and adjoining
casting. GEAR PUMP CUTAWAY
In the roller bearing units these seals are called
OUT
pocket seals and are shown in the illustration.
The sleeve bearing (bushing) units use a
different kind of seal called a channel seal.
5. A cross sectional view of the pumping

chambers illustrates the flow path of the
hydraulic oil through the gear pump. As the
gears counter rotate the separating gear teeth IN
create a vacuum drawing oil into the inlet. Oil Pressure Balanced Thrust Plates
is picked up by each tooth and carried around
the outside of the gear, oil is not drawn
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through the center. The pockets between the © 1998 Commercial Intertech Corp.
gear teeth and the housing are referred to as

pumping chambers. As the gear teeth mesh on
the outlet side, oil is forced out of the pockets
and exits the pump. THRUST PLATE VIEW
Downstream resistance
D i to the
h output fl
flow
causes an increase in pressure. High pressure
on the outlet side of the housing forces the
gears to deflect into the low pressure (inlet)
OUTPUT
side. The tips of the gear teeth contact the
housing preventing high pressure output oil
from leaking back to the low pressure inlet. Force Force
Although necessary, this tooth to housing
contact can generate cast iron contaminant,
particularly in new units. Therefore,
Commercial Intertech 100% tests all units
before shipping, bringing them up to their OIL FLOW
operating pressure. Any contaminant
generated is filtered out by our test stands. 5 © 1998 Commercial Intertech Corp.
3
6. Contamination is the single largest

contributor to hydraulic component failures.
Contamination is considered to be any
substance found in the hydraulic oil not
specified by the oil producer. Water, dirt,
dust, air, etc.... System cleanliness and regular
preventative maintenance insure a long lasting,
responsive hydraulic system.
CO N TAM I N ATI O N
7. Particulate contamination is measured
across its largest diameter to determine size.
This chart shows some comparative sizes of
particles in microns (or micrometers).
Commercial suggests the use of a 25 micron
return line filter in systems with a pressure
6 © 1998 Commercial Intertech Corp.
rating of 2500 psi (172 bar) or less. In systems
rated between 2500 (172 bar) and 3000 psi
(207 bar) a 15 micron return line filter is
recommended. A 10 micron return line filter is
PARTICLE SIZES suggested for use with our P300 sleeve
bushing pumps.
SUBSTANCE MICRON INCH
Grain of salt 100 .0039
Human hair 70 .0027 8. Particle counting is the most common

method for determining cleanliness levels of
Lower limit of 40 .00158 hydraulic fluids. Powerful optical instruments
visibilty
are used to count the number of particles in a
White blood cell 25 .001
specified volume of fluid. There are several
Talcum powder 10 .00039 common cleanliness level standards, of these,
the International Standards Organization code
Red blood cell 8 .0003 has gained wide acceptance.
Bacteria 2 .000078 Th ISO code
The d consists
i off two index
i d numbersb
referring to the number of particles greater
than 5 micrometers and 15 micrometers found
in one milliliter of fluid.
Maximum recommended contamination levels
are a function of component clearances and
ISO CODES system operating pressure. As the system
pressure increases the oil film separating the
ISO CODE PARTICLES/ MILLILITER Fluid cleanliness working parts become thinner making the
> 5 micrometers > 15 micrometers required for components more susceptible to damage by
18/15 2,500 320 Flow control valves, contaminant. Microscopic particles streaming
cylinders
17/14 1,300 160 Gear pumps and
through the hydraulic components at high
motors velocities pound the wear surfaces weakening
16/13 640 80 Directional and and eroding material. Some particles get
pressure control
valves
wedged between the minute tolerances of the
15/12 320 40 Vane and piston new components and remove metallic material
pumps/motors from the wear surfaces. This wear generates
14/11 160 20 Servo control valves
additional contaminant in the system and leads
to leaks and a loss of component performance.
Commercial gear pumps require filtration of
8 © 1998 Commercial Intertech Corp. ISO 17/14 or better.
4
9. Read slide text.
CONTAMINATION
CAUSE Effect
• Improper filtration
• Accelerated wear
• Low oil level - concentration –bearings, thrust plates,
of contaminant housing
• Loose or lost breather cap • Bearing / bushing

failure
• Leaking fittings, seals, • Reduced pump
wipers
p efficiency
• Missing or collapsed inlet • Reduced life
strainer • Heat
• Poor fill practices • Internal leaks
• Clogged filter - by-pass • Failed pump
10. Nuts, bolts, screws, washers, plastic

closures, shop rags, pieces of hose, etc.... can
cause considerable damage to hydraulic pumps
and other hydraulic components. Many times
FO REI GN O BJECT
the failures caused by large foreign objects
occurs instantaneously as the pump ingests the
( N UTS & BO LTS)
debris and catastrophic failure results.
11. The damage that occurred to this gear set FOREIGN OBJECT
was caused by a hardened foreign object such as
a screw or nut. Additional debris has been DAMAGE
generated by the broken gear teeth and
component scoring. This type of failure can
contaminate the entire hydraulic system.

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12. Particles too large to fit between the tight

component tolerances will cause surface to
surface contact removing material from the
LARGE PARTI CLE softer thrust plate
plate. Damage to the thrust plate
surface, which provides a sealing surface
CO N TAM I N ATI O N between the high and low pressure oil leads to
leaks and a loss of performance.
Contamination in a hydraulic system is self
perpetuating. As damage to internal
Motion components continues additional debris is
Gear generated by the wearing of the components.
Large particle contaminant
Thrust plate
13. The pump thrust plate is one of the best

SCORED THRUST PLATE places to look for evidence contributing to the
pump failure. The thrust plate is sometimes
referred to as a wear plate. The score marks
on the above plate were caused by particles
being dragged across the plate surface by the
hardened gear face.
14. New components provide a smooth, even

SCORED THRUST PLATE surface allowing a continuous oil film to exist
between the thrust plate and gear face. When
these surfaces become scored the oil film
dissipates into the grooves interrupting the
film. Metal to metal contact occurs, resulting
in an increase in friction and heat. The
grooved plate surface can also provide an
escape route for high pressure oil to go back to
low pressure inlet, resulting in a loss of
pumping efficiency
efficiency.

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15. P300 series plate shows score marks from

large particle contaminant.
SCORED THRUST PLATE
15
16. Microscopic particles the size of airborne © 1998 Commercial Intertech Corp.
dust can accumulate in the tiny tolerances of

today's hydraulic components. The
accumulation can form a wedge between
moving parts, increasing friction and
accelerating wear. The velocity of the tiny
particles striking the wear surfaces can erode
FI N E PARTI CLE
material weakening the wear surface and
causing spalling. This erosion of metal leads
CO N TAM I N ATI O N
to internal leaks in critical components and
adds additional contamination to the hydraulic
system. All this adds up to a reduction of Fine particle contaminants
system efficiency causing the engine to work
harder, increasing fuel consumption.
Roller bearings are more susceptible to fine
particle contaminant than the bushing (sleeve
yp ) The bushingg units,, however,, are more
type).
susceptible to large contaminant than roller Th
Thrust
t plate
l t
bearings. 16 © 1998 Commercial Intertech Corp.
17. As the gear teeth mesh and oil is forced

out of the pump outlet, a small amount of the
oil is trapped by the meshing teeth in the tooth THRUST PLATE VIEW
space root area (circled). The trapped oil is
forced at right angles into the faces of the
thrust plates. Relieved areas on the plates
called trapping grooves allow the high
OUTPUT
pressure oil to escape. The high velocity of
the oil moving at a right angle to the thrust
plate will do serious damage to the thrust plate Force Force
in the trapping groove area if fine particle
contamination is being carried by the oil.
OIL FLOW

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18. The fine particles being carried by the

FINE PARTICLE hydraulic fluid erodes the thrust plate surface
CONTAMINATION in the trapping groove on the high pressure
side of the pump plate
plate. The erosion will be
heaviest where the teeth mesh and then
migrate towards the low pressure side of the
plate. Over time, the wear cuts a channel into
the plates’ surface allowing the oil to leak back
to the pump inlet. The volumetric efficiency of
the pump is reduced.
19. A closer inspection of the plate surface not

SCORED THRUST PLATE only reveals the damage in the center of the
plate but in the root seal area as well. A light
ring around the I.D. root seal area develops
due to the very tight clearances. Fine particles
wear the thrust plate surface leaving a polished
appearance
appearance.
20. This P300 thrust plate shows evidence of

fine particle contamination on the back side of
SCORED THRUST PLATE tthee thrust
t ust plate.
p ate. Finee erratic
e at c tracks
t ac s are
a e cut into
to
the plate surface around the balancing holes
and low pressure area.

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21. This thrust plate face shows erosion

damage in the areas of high oil velocity, such SCORED THRUST PLATE
as the trapping groove and balance holes.
Erosion of the wear surface has also occurred
just below the balance hole. The metal
removed from the wear surfaces adds to the
contaminated condition.
22. Internal leakage is the primary cause of a

loss of performance in a hydraulic system. Of
the three factors identified above, control of Leakage in Hydraulic Components
critical clearances have the most dramatic
impact. Wear, accelerated by contamination,
heat, or pressure, will act to increase these +
2 Control of clearance critical
critical clearances with disastrous results.
3
Q =flow
(leakage)
1
0
0 •Length
L th off Seal
S l 1 +
23. When contamination is present two wear •Clearance 2
bands will develop under the ring seals on the 22
•Pressure 3
gear shaft of the roller bearing pumps. These

bronze high pressure seals are designed to
reduce the high pressure oil lubricating the
bearings to low pressure before reaching the
shaft seal. Tiny particles, under high pressure WORN DRIVESHAFT
and velocity, progressively wear the gear
journal surface until the ring seal is no longer
effective. High pressure jets under the ring
seal pressurizing the shaft seal area.
The oil pressure on the shaft seal can force the
seal lip away from the journal or even dislodge
the seal from the bore. In both instances an
external leak would occur. Pump shaft seals
are typically rated for a maximum pressure of
15 to 20 psi. Shaft seals are sensitive to shaft
speed, an increase in speed can cause a
decrease in the maximum pressure rating of
the seal. 23
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24. When a seal leak is discovered the first

inclination for the maintenance staff can be to
DRIVE SHAFT RING SEAL replace the shaft seal. This will not solve the
problem. The ggear set and ringg seals may
p y also
have to be replaced. A rule of thumb for
determining excessive wear on the shaft is that
if you can feel the wear with your finger nail it
should be replaced.
Ring seals are not needed in the bushing
pumps as the bushings are lubricated with low
pressure inlet oil.
25. Contamination has caused wear bands to

MOTOR SHAFT develop on this roller bearing motor gear.
Closest to the spline end, the shaft has been
grooved by dirt trapped under the lip seal. As
the damage progresses external shaft seal leaks
will develop. Replacing the shaft seal at this
point will not correct the leak as the undercut
will prevent the proper squeeze of the seal on
the shaft.
Note: The contamination attacking the shaft
seal area could also been brought in from the
outside environment.
26. Excessive noise in a hydraulic system can

CAVI TATI O N & be caused by the presence of air in the
hydraulic oil. Air can be introduced into the
AERATI O N system two ways; through cavitation or
aeration. “Cavitation” occurs when the pump
inlet flow can no longer fill the pump
chambers created by the separation of the gear
teeth. The partial vacuum vaporizes some of
the oil causing air and or water to come out of
solution.
C it ti is
Cavitation i the
th formation
f ti off air,
i andd water
t
or oil vapor bubbles in the hydraulic oil.
Aeration is a form of cavitation that occurs
Thrust plate when outside air is drawn into the hydraulic
system due to a loose fitting or low oil level in
26 the reservoir.
10
27. As the bubbles, created by cavitation and

aeration, are carried around to the pump outlet,
the increase in pressure squeezes the bubbles.
CAVI TATI O N &
An implosion occurs when the pressure
becomes too great and the bubbles collapse
AERATI O N
inward.
Thrust plate
28. When the air bubbles implode intense

shock waves bombard the surface of the wear
plates. The shock waves erode the plates’
CAVI TATI O N &
surfaces on the high pressure side and trapping
groove area. The sealing capability of the
AERATI O N
plate is reduced resulting in a loss of output
flow.
The presence of air can also reduce the volume
of oil available to carry away heat that is
produced by mechanical friction. Vacuum
conditions created in the pump rob oil from the
bearing and thrust plate areas. The loss of oil
in bearing bore upsets the loading which can
result in premature bearing failure. Thrust
plates,
l t relying
l i on theth oil
il to
t maintain
i t i their
th i
Thrust p
plate
balance become unbalanced, resulting in a
28
milling of the plate surface. © 1998 Commercial Intertech Corp.
Physical damage can also be seen on the gear

housing bore in the form of a rough surface in
the gear wipe area.
CAVITATION DAMAGE
CAUSE - Inlet restriction Effect
29. Read slide text. • Clogged inlet strainer / • Noise
breather • Heat
• Inlet strainer too small • Accelerated wear
– thrust plates / housing
• Inlet line too long
• Internal leaks
• Inlet line bore too small
• Reduced
educed pupumpp
• Excessive engine speed
efficiency
• Collapsed inlet hose • Erratic actuator
• Suction head too great performance
• Oil too viscous (cold weather) • Failed pump

11
30. Read slide text.

AERATION DAMAGE
CAUSE - Air enters oil Effect
• Low oil level • Noise
• Vortexing of oil above • Heat
strainer - whirlpool • Accelerated wear
– thrust plates / housing
• Loose inlet fittings • Internal leaks
• Worn pump shaft seal • Erratic actuator
• Worn cylinder rod seal performance
p
• Foam suspended in oil due • Reduced pump
to sloshing in the reservoir efficiency
• Failed pump
31. This plate has been damaged by

cavitation. As the gear teeth come around to
CAVITATED THRUST PLATE the discharge side of the pump (outlet) the oil
is exposed to the outlet pressure collapsing the
large air bubbles.
OUTLET
INLET
32. A close up of the plate shows the severity

of the pitting. The damage is heaviest in the
CAVITATED THRUST PLATE root seal area where the clearance between the
plate and the gear face is the tightest. This
damage allows high pressure oil to escape
down the gear journal into the bearing or
bushing.

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33. Motor cavitation occurs when the CAVITATED MOTOR

supply pump cannot produce enough flow
to keep up with the speed of the motor. The THRUST PLATE
motor then begins to act as a pump. This
M75 series motor plate has cavitation
damage on both sides of the plate. This
condition occurs when a motor is cavitated
in both directions of rotation.
The damage to this plate is heaviest in the
trapping groove areas because the
cavitation
it ti bubbles
b bbl createdt d on th
the pump sideid
of the motor are carried to the outlet side
and are mechanically imploded by the
meshing of the gear teeth.
34. Again, a close up shows the severity of

the damage. CAVITATED MOTOR
THRUST PLATE
35. A loss of lubrication in the pump can

also cause rifling of the gears and thrust
plates. Air in the system creates an
imbalance in the thrust plate forcing it to
come in harder over one gear than the other.
The gears try to separate and walk towards 34 © 1998 Commercial Intertech Corp.
opposite ends of the pump. The effect is a

milling of the plates behind the idler gear at
one end of the pump and the drive gear on RIFLED GEAR
the other end. The torque needed to drive the
pump increases dramatically and the pump & THRUST PLATE
becomes heated. The removal of thrust plate
material will contaminate the hydraulic
system.
Note: The problem described above has been
largely eliminated in the P300 series bushing
pumps because of the new thrust plate
design. However, all pumps with an integral
d i shaft
drive h ft (including
(i l di the th P300 series)
i ) are
susceptible to rifling if an external force is
applied to the drive shaft (push or pulling
force). An example of this is an interference
fit between the drive shaft and its drive
coupling.
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36. Milling damage is evident at the center of

this thrust plate. Not as obvious is the
RIFLED THRUST PLATE cavitation erosion on the plate at three o’clock.
37. The milling has not erased the tell tale

erosion damaged caused by the cavitation.
When the damage has progressed to this point
the entire hydraulic system should be flushed
and the filters and strainers checked.
38. Pressure and hydraulic shock are also

causes of pump failure. Pumps operating
under a continuous heavy load, (high
36 © 1998 Commercial Intertech Corp. pressure), and extended duty cycle are
susceptible to premature wear and failure.
F
Forces generated
t d by
b th
the pump outlet
tl t pressure
and gear area causes a deflection of the gears.
RIFLED THRUST PLATE This stresses the bearings or bushings that
support the gear journals. The oil film needed
to lubricate and cushion the pump elements
becomes thinner and thinner with the increase
in pressure until direct contact is made.
In the roller bearing pump the repeated heavy
loading fractures the hardened surfaces of the
needle bearings, bearing race, and gear
journals. These fractures, over time, lead to a
breakdown of the surface material. Small
pieces of material break away leaving a rough
running surface. The rough surface can no
longer support the film of oil needed to
lubricate and cushion the pump components.
37
The damage quickly accelerates until a
catastrophic failure occurs spreading
contaminant throughout the hydraulic system.
The bushing pumps rely more heavily on the
film of oil to support the loaded gear journal.
Clearances between the journal and bushing
surface
f are greater than
h theh clearance
l in
i the
h
PRESSURE DAM AGE bearing pumps. This is necessary to support
the thicker oil film. When subjected to
repeated heavy loads a breakdown of the oil
film allows direct contact of the bushing and
journal. The PTFE coating, that protects the
REPEATED bushing I.D., wears away and an increase in
HEAVY
LOADING ct o and
friction a d heat
eat occurs.
occu s. Thee bushing
bus g susurface
ace
becomes rough and the oil film can no longer
be supported. Under continued operation and
friction becomes severe and the bushing may
start spinning in the bore. Again a catastrophic
failure results contaminating the entire
38 ©1998 Commercial Intertech Corp. hydraulic system.
14
PRESSURE DAMAGE
CAUSE EFFECT
• Accelerated wear
• Improper relief valve setting • Cracked housings
• Relief valve malfunctioned • Excessive housing cut-out
• Slow acting relief valve • Reduced efficiency
• Absence of a relief valve • Internal leakage
• Improper size elbow or fitting • Bearing / bushing failure
downstream of the valve • Thrust plates coined,
affecting the relief valve warped or cracked
performance • Broken drive / connecting
shaft
39 ©1998 Commercial Intertech Corp.
40. Extended operation under high pressures

has caused the spalling of the needle bearings BEARING FAILURE
in this bearing. Surface cracks have lead to a
fracturing of the needle bearing material. An
increase in system noise and heat could alert
the operator to this type of problem.
41. This slide shows the inner race of the

bearing and the damage caused by excessive
loading. BEARING FAILURE

15
42. As the bearing wears the gear journal

BEARING FAILURE becomes damaged by the direct contact of the
journal to the needle bearings.
43. The system pressure deflects the gears into

PRESSURE DAMAGED the low pressure inlet side of the pump. If the
system pressure increases above the pressure
GEAR HOUSING rating of the pump, then the gears deflect too far
and the gear housing cut-out becomes excessive.
Internal slip increases and the pump becomes
less efficient. The contaminant created by the
cut-out can foul relief valves and other system
components. If the housing cut-out exceeds
.005” (.007” for a bushing pump gear housing)
the gear housing should be replaced.
44. Hydraulic shock loads can cause an

immediate component failure in your hydraulic
PRESSURE DAMAGED system. Sudden pressure spikes that exceed the
GEAR HOUSING pressure rating of the pump can crack the
housing at the port location and bolt hole areas
of the casting. A slow acting or
malfunctioning relief valve can cause
excessive pressure spikes in the system.

16
45. Commercial Intertech’s engineering

department sets maximum pressure limits for PRESSURE DAMAGED
all pumps by calculating bearing loads and
housing stresses
stresses. However,
However the larger the port
GEAR HOUSING
size in the gear housing the weaker the casting.
The larger port requires the removal of a
greater percentage of casting material and a
reduction in the safety factor. Continuous
operating pressures above the pump rating can
lead to cracked housings due to fatigue.
46. Thrust plates can also be damaged by

excessive pressure. The above plate split
through the middle due to excessive loads. The PRESSURE DAMAGED
thrust plates used in the roller bearing product
are most susceptible to damage between the
THRUST PLATE
two gear bores. A small bleed hole, needed
for balancing pressures in the bearing bores, is
machined on the back side of the plate in this
area. Couple this with fact that the greatest
pressure in the pump occurs at the center of
the plate where the gear teeth mesh. The
oblong bores in the above plate are due to a
bearing failure.
47. Excessive pressures can also cause

coining damage to the thrust plate. This is a
deformation of material on the low pressure HEAVILY COINED THRUST
inlet side of the plate.
plate The heavy loading
pushes the plate into the gear housing with
PLATE
enough force to cause a bulging of material in
the relieved edge of the plate. The major O.D.
is flattened.
COINING

17
48. Hydraulic shock and excessive pressure

PRESSURE DAMAGED can also cause failures to the pump drive line.
DRIVE SHAFT Many times the drive coupling or pump drive
shaft will fail.
fail In the above example,
example the pump
drive shaft broke where the shaft diameter is
the smallest. The drive shaft was not strong
enough to withstand the torque load generated
by the high pressure.
Each section of a multiple pump or motor
should be regarded as a single unit with
p
corresponding g delivery
y and ppower input
p
requirements. Since the entire input
horsepower required to drive the pump is fed
through a common drive shaft, the power
delivered to or from the unit is limited by the
physical strength of the shaft. This limit is
48
defined as a “PL” factor; “P” being the
©1998 Commercial Intertech Corp.
maximum operating pressure and “L” the

summation of gear widths.
widths “PL”
PL for a single unit is calculated by multiplying the
maximum operating pressure by the gear width.
Each style or type of shaft has a unique “PL” rating. Tables are provided in each of the
pump/motor product catalogs defining the “PL” rating for each shaft type. If the “PL”
factor exceeds the catalog rating of your shaft choice select a new shaft type with an
adequate “PL” rating.
PL= Pressure X Total Gear Width
Torsional fatigue can also cause a shaft to fail, having a similar appearance to the above
shaft. With torsional fatigue failure, however, the core of the shaft across the break has a
smeared appearance caused by repeated forces and a gradual wearing out of the shaft. (A
sudden break is characterized by a rough granular shaft core.) Torsion forces acting on
the shaft in the same direction tend to cause a break at a 450 angle to the shaft axis.
PRESSURE DAMAGED 49. The connecting shaft in a tandem pump

has the smallest diameter in the pump drive
CONNECTING SHAFT line, many times making it the weak link.
In multiple units the “PL” must be calculated
g shaft as well as the
for the first connecting
drive shaft. When calculating the “PL” for the
connecting shafts, the drive gear is not
included. The calculation is made from the
first connecting shaft back.

18
50. Drive line misalignment can cause the

pump shaft to flex with each revolution, often
ROTATIONAL BENDING
resulting in a clean break at a 900 angle to the
shaft axis.
axis The fractures typically occur in
FATIGUE FAILURE
areas where stresses are concentrated, such as,
holes, grooves, and reduced diameters. A
rough spot on the
smooth shaft core is where the shaft finally
severed.
51. Heat is generated in a hydraulic system

whenever oil dumps from an area of high
pressure to low pressure without doing
mechanical work. Oil blowing over a relief
valve or flowing through piping, a valve, a
clogged filter or strainer all are examples of
sources of heat. Proper reservoir size can 50 ©1998 Commercial Intertech Corp.
dissipate much of the heat generated in a

system On some applications an oil cooler
system.
must be added to sufficiently cool the oil.
Other factors, such as, contamination,
cavitation/aeration, improper oil viscosity can
add to the heating problems of a hydraulic HEAT
system.
Heat build-up causes the hydraulic oil to loose
its viscosityy resulting
g in an oil that no longer
g
meets specification. This greatly reduces the • THINS THE SYSTEM OIL
lubricating effects of the oil on the close - increasing friction
tolerance parts. The heated oil oxidizes, • ACCELERATES THE BREAKDOWN OF THE OIL
encouraging corrosion, leakage, and the - causing sludge to form
development of sludge. Sludge can clog filters • CAN BE CAUSED BY WORN COMPONENTS
and strainers compounding system problems. • EVERY 18°F RISE IN OIL TEMPERATURE
leading to cavitation and additional heating of - doubles the rate of corrosion on exposed surfaces
th oil.
the il
The close running tolerances of the 51 ©1998 Commercial Intertech Corp.
pump/motor components makes them

susceptible to heat damage. Add the fact that
the thrust plates are being squeezed against the
gear faces with hydraulic pressure; a loss of
lubrication between the two surfaces can
HEAT DAMAGE
quickly lead to an increase in heat due to
friction.
CAUSE EFFECT
52. Read slide text. • Low oil level
• Cavitation / aeration / water • Breakdown of oil
• Contamination • Loss of lubricity
• Inlet restriction • Accelerated wear
• Relief valve • Reduced efficiency
• Incorrect fluid • Leakage
• Poor reservoir design • Varnish / sludge
• Undersized fittings, hoses, • Internal seal destruction
components • Seizure

19
53. With the loss of lubrication the thrust plate

becomes heated rapidly. If the condition persists
the plates will become so heated that lead in the
HEAT DAM AGE alloy will be drawn out of the plate.
Lead Motion
Motion
G
Gear
Gear
Thrust plate
54. As the lead comes to the surface the trailing

gear tooth smears the lead over the surface of the
plate. The plate will become blackened by the
lead oxidation.
HEAT DAM AGE
Motion
Gear
Thrust plate
55. The thrust plate in this slide has been

subjected to extreme heat causing the lead to be
HEAT DAMAGED THRUST drawn to the surface. A blackened surface and
PLATE thermal cracks in the plate can result.

20
56. Excessive heat can cause a thrust plate

material to become brittle and crack. HEAT DAMAGED THRUST
PLATE
57. This P300 series thrust plate has been

damaged by extreme heat due to a loss of HEAT DAMAGED THRUST
lubrication. The surface is blackened
PLATE
58. Temperatures of 400 degrees Fahrenheit

will melt the glass filled nylon channel seal HEAT DAMAGED THRUST
used in the P300 series
series. The buna element of
the two piece channel seal and the buna pocket
PLATE
seal will be damaged at a much lower
temperature.

21
59. With excessive heat the ends of the gear

teeth near the gear face become discolored.
HEAT DAMAGED GEAR The high heat causes a bluing of the teeth.
With continued operation the gear face and
thrust plate will start to weld together. The
continued motion of the gear tears thrust plate
material from the plates surface. The friction
can generate enough heat that the pump could
eventually seize up.
60. Welding between the gear face and the

thrust plate has occurred resulting in a ripping
HEAT DAMAGED THRUST of material from the plate surface.
PLATE
61. Fretting is a condition that occurs between

the drive shaft extension and the drive
coupling. These parts are commonly
lubricated with a heavy grease. Fretting
FRETTI N G DAM AGE damage occurs when the grease picks up grit
and the small amplitude vibration makes the
contaminated grease act like sandpaper. As
the wear progresses the clearance between the
parts becomes greater allowing more shaft
Coupling
Small amplitude coupling movement. The wear accelerates
vibration
until there is not enough engagement to carry
the torque load put on the shaft
shaft. At this point
the coupling will spin on the shaft stopping the
Drive spline
Contaminant revolution of the pump gears and thus pump
suspended
in grease flow. The coupling and the pump gear set
will have to be replaced.

22
62. This splined drive shaft has been worn by

fretting corrosion. To prevent this damage the
drive coupling should be cleaned regularly FRETTED DRIVESHAFT
followed with the application of a light coat of
synthetic grease.
63. Commercial Intertech performs a break-in

test on 100% of it’s factory built pumps. Any
pump repaired and rebuilt should also be
tested. This gives the unit a proper break-in
and insures that it is performing to
REBUI LD ERRO RS
specification. The unit should also be
inspected for external leaks at this time. The
recommended test/break-in procedure is
described in all the Commercial Intertech
pump service manuals. Fact, 99% of all
rebuild errors can be found at the test stand.
POTENTIAL ASSEMBLY
ERRORS
CAUSE EFFECT
• Improper bolt torque
• Nicked lip seal • Heat
• Pinched / fretted section • Extruded section seal
seal • External leak
• Improper
p p installation of • Internal leak
thrust plate • R d
Reduced d efficiency
ffi i
• Pinched pocket /
channel seal

23
65. Pinched or fretted section seals can lead to

PINCHED & FRETTED external leaks. If the section seal is not
SEALS properly installed the seal can be flattened
between the mating castings.
castings This provides a
leak path for oil to escape.
65 ©1998
©1998 CommercialIntertech
Commercial Intertech Corp.
Corp.
66. Your approach to system maintenance will

either give you a reliable, relatively trouble
SYSTEM MAINTENANCE free system or a system that is a constant
maintenance nightmare.
The best advise we can offer is to meet or
exceed the Original Equipment
SYSTEM M f t
Manufacturer’s
’ recommendations
d ti on
maintenance intervals, and follow his
recommendations when replacing critical
MAINTENANCE system components.
The OEM has engineered and assembled a
hydraulic system which has been thoroughly
tested and proven to give the best
performance possible.
possible
67. These are critical system components.
THE S
SYSTEM
S
INCLUDES:
• Hydraulic Oil • Hydraulic Pump
• Hoses/tubing • Directional Valve
• g
Fittings • Actuator
• Filters – motor
– cylinder

24
68. Careless substitution of any critical system

component with a substandard replacement
will lead to extended downtime and SUBSTITUTIONS
unnecessary expense.
expense
HYDRAULIC OIL
• Follow OEM recommendations as

closely as possible
• Unnecessary additives may be
detrimental
• Do not mix and match

WHEN REPLACING
HOSES LINES & FITTINGS
HOSES,
Use products with the same:

– Size
– Material
– Length
– Pressure rating
as the original equipment

25
71. Using “after market” hydraulic

HYDRAULIC components can be a dangerous proposition.
COMPONENTSS
After market substitutions may lack proper:

• Tolerances
• Testing
• Pressure rating
• Safety factor
• M t i l
Material
• Design
SUBSTITUTIONS CAN DEAL 72. SUBSTITUTES CAN COST

YOU BIG:
YOU A LOSING HAND • added downtime!
• additional repairs !!
• additional cost!!!
73. Replacing a worn or failed pump/motor

without taking the proper precautions can
lead to rapid failure of the new unit. The
tight factory tolerances of a new unit make it
more susceptible to the same conditions that
caused the first unit to fail. Flushing the
PUM P / M O TO R hydraulic system, changing filters, and
replacing used oil with new can insure proper
REPLACEM EN T component life. The relief valve and the
governor should be reset prior to resuming
normal operation
operation.
ALWAYS USE AN ACCURATE GAGE

WHEN ADJUSTING THE RELIEF
VALVE PRESSURE SETTING.
26
74. Before installing a new or rebuilt pump or

motor, back off the main relief valve until the
RECOMMENDED START-UP
spring tension on the adjusting screw is relieved.
This will avoid the possibility of immediate
FOR NEW OR REBUILT PUMP/
damage to the replacement unit in the event that MOTOR
the relief valve setting had been increased
beyond the recommended operating pressure • Insure system cleanliness
prior to removing the old unit. • Back-off relief valve pressure and reset governor
Before connecting any lines to the pump or • Fill unit with clean oil before connecting lines
motor, fill all ports with clean oil to provide • Connect the lines and mount unit
initial lubrication. This is p
particularlyy important
p • Operate the unit at zero pressure for a minimum of
where the unit is located above the oil reservoir. two minutes at low speed
• Gradually increase speed and pressure to normal
During the break-in period, the unit should run operating conditions - approximately 5 minutes
free and not develop an excessive amount of • Reset the main relief valve while the unit is operating
heat. Commercial’s pump/valve units should be at maximum operating speed
started up in the shift to raise position. This will
insure a good prime and prevent heat damage. 74 ©1998 Commercial Intertech Corp.
Commercial Intertech,
Intertech one of the world’s
world s largest
manufacturers of hydraulic components for the
mobile market, has brought you this training program
on Failure Analysis. If you have any further questions
on this subject or any of our hydraulic products,
please contact your Commercial Intertech Sales
Representative or your nearest Authorized
Distributor.

Gear Pumps &amp; Motors Failure Analysis Guide

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1

1. The heart of a hydraulic system is the

diagnosis is critical to providing renewed

3. Tandem pumps are needed when there are

4. Both pumps and motors employ a pressure

are used behind the thrust plate to block oil

5. A cross sectional view of the pumping

gear teeth and the housing are referred to as

6. Contamination is the single largest

Human hair 70 .0027 8. Particle counting is the most common

9. Read slide text.

• Loose or lost breather cap • Bearing / bushing

9 © 1998 Commercial Intertech Corp.

10. Nuts, bolts, screws, washers, plastic

10 © 1998 Commercial Intertech Corp.

11 © 1998 Commercial Intertech Corp.

12. Particles too large to fit between the tight

13. The pump thrust plate is one of the best

13 © 1998 Commercial Intertech Corp.

14. New components provide a smooth, even

14 © 1998 Commercial Intertech Corp.

15. P300 series plate shows score marks from

dust can accumulate in the tiny tolerances of

17. As the gear teeth mesh and oil is forced

17 © 1998 Commercial Intertech Corp.

18. The fine particles being carried by the

18 © 1998 Commercial Intertech Corp.

19. A closer inspection of the plate surface not

19 © 1998 Commercial Intertech Corp.

20. This P300 thrust plate shows evidence of

20 © 1998 Commercial Intertech Corp.

21. This thrust plate face shows erosion

21 © 1998 Commercial Intertech Corp.

22. Internal leakage is the primary cause of a

gear shaft of the roller bearing pumps. These

24. When a seal leak is discovered the first

24 © 1998 Commercial Intertech Corp.

25. Contamination has caused wear bands to

25 © 1998 Commercial Intertech Corp.

26. Excessive noise in a hydraulic system can

27. As the bubbles, created by cavitation and

27 © 1998 Commercial Intertech Corp.

28. When the air bubbles implode intense

Physical damage can also be seen on the gear

29 © 1998 Commercial Intertech Corp.

30. Read slide text.

30 © 1998 Commercial Intertech Corp.

31. This plate has been damaged by

31 © 1998 Commercial Intertech Corp.

32. A close up of the plate shows the severity

32 © 1998 Commercial Intertech Corp.

33. Motor cavitation occurs when the CAVITATED MOTOR

33 © 1998 Commercial Intertech Corp.

34. Again, a close up shows the severity of

35. A loss of lubrication in the pump can

opposite ends of the pump. The effect is a

36. Milling damage is evident at the center of

37. The milling has not erased the tell tale

38. Pressure and hydraulic shock are also

39. Read slide text.

39 ©1998 Commercial Intertech Corp.

40. Extended operation under high pressures

40 ©1998 Commercial Intertech Corp.

41. This slide shows the inner race of the

Gear Pumps & Motors Failure Analysis Guide

Gear Pumps & Motors Failure Analysis Guide