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Hydraulic systems are pivotal in various industrial applications, and understanding how to troubleshoot issues with hydraulic pumps in low-flow, high-pressure circuits is essential for maintaining efficiency and reliability. This article outlines common problems, diagnostic techniques, and solutions to ensure optimal performance of hydraulic systems.
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One of the primary challenges in low-flow, high-pressure hydraulic circuits is the tendency for cavitation. Cavitation occurs when the local pressure in the hydraulic fluid drops below its vapor pressure, leading to the formation and collapse of vapor bubbles. This can cause significant damage to pump components, including impellers and casing. Symptoms of cavitation include unusual noise from the pump, fluctuating flow rates, and increased wear on components.

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To address cavitation, begin by checking the suction line for restrictions or leaks. Ensure that the fluid level in the reservoir is adequate, and verify that the suction strainer is clean and unobstructed. If the suction line is too long or convoluted, consider redesigning it to minimize losses. You may also need to adjust the system to reduce the demand for flow, thereby allowing the pump to operate within safer parameters.
Another issue that commonly arises in low-flow, high-pressure circuits is increased heat generation. When pumps operate outside of their optimal flow range—particularly at low flow—heat can build up, reducing efficiency and potentially damaging components. To combat overheating, ensure that the hydraulic fluid is at the proper viscosity for the operating temperature. Additionally, consider installing an external cooler or enhancing existing cooling systems to maintain optimal fluid temperatures.