PISTON PUMP

FAILURE ANALYSIS
A Guide to Analyzing Axial
Piston Pump Failures

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CONTAMINATION
TYPICAL FAILURE MODES
l PISTON SEIZED IN BORE, PULLS SHOE OFF.

l PISTONS SHOW FINE SCRATCHES,DULL FINISH.

• Contamination
l EXCESSIVE WEAR ON SWASHBLOCK FACE,
• Fluid Issue SHOE FACE AND VALVE PLATE FACE.
• Over Pressurization
l EXCESSIVE WEAR ON SADDLE BEARINGS.
• Improper Inlet Condition
l HYDRO-DYNAMIC BEARING WORN.
• Case To Inlet Differential
• Miscellaneous l CONTROL UNSTABLE: PISTON STICKING,
COMPENSATOR SPOOL STUCK OR WORN,
ORIFICE IN CONTROL PISTON PLUGGED.
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CONTAMINATION EXAMPLES A Clear Indication of Contamination

Vertical scratches on the

piston barrel.

Note Metal Transfer

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SHOE WEAR PLATE SHOWING

Dull and scratchy finish SIGNS OF WEAR DUE TO DIRT

Normal Appearance:
A Mirror Finish
Scratchy Uneven
Wear
Abnormal Appearance:
A Steel Wool Look

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 VALVE PLATE RUN ON A BAD
FLUID ISSUE
FLUID
Viscosity too Low, Operating Temperature too High,
Not a Hydraulic Fluid, Fluid Breaking Down

l PISTON SEIZED IN BORE, PULLS PISTON SHOE

l SHOE FACES AND OR VALVE PLATE FACE
SMEARED Note the
l BALL WORN THROUGH SHOE RETAINER Smeared
l SHAFT SEAL LEAKS Running
l CAVITATION, AIR ENTRAINMENT Surface
l EXCESSIVE SADDLE BEARING WEAR

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WORN FULCRUM BALL WORN SADDLE BEARING

Typical Failure on
Low Lubricity
Fluid
The fulcrum ball
is between the
rotating group and
the shoe retainer
plate. Note the material has delaminated

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OVER PRESSURIZATION/SPIKES EXCESSIVEWEAR ON CYLINDER
Spike Relief Always Recommended FACE
l Excessive swashblock face, cylinder to valve plate wear
l Pistons broken at necks
l Broken shaft where cylinder rides
l Broken tail shaft (dual)
l Control pin broken Cracks
l Cylinder cracked between kidneys Would
Appear
l Control O-ring, gasket failure (PVW) Between
Kidneys
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TORSIONAL FATIGUE: BENDING FATIGUE FAILURE

Note Cone Shaped Failure Note Straight Break

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 CAVITATION ON COMPRESSION
IMPROPER INLET CONDITIONS BRIDGE

What are the improper inlet conditions for piston pumps?

l CAVITATION ON VALVE PLATE FACE

l NOISE (MARBLE SOUND)

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DIFFERENTIAL CANNOT
CASE TO INLET DIFFERENTIAL EXCEED 10 PSI
Case to inlet differential refers to the pressure difference
between the inlet pressure (vacuum) and the case drain Examples of high case pressure differential:
pressure.
l SHOE EDGES ROUNDED
The pressure in the case has to be vented back to the reservoir
l SHOES LOOSE ON BALLS
below fluid level. As the pump creates flow the inefficiencies
are drained into the case. If the case drain line or fittings are l SWASHBLOCK WEAR, HALF MOON SHAPE
undersized this will cause the case pressure to increase.
l EXCESSIVE WEAR ON BACK OF SHOE
FLANGES
l SEAL RETAINER BENT

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 STAGES OF DAMAGE DUE TO
SHOE LOOSE ON BALL SHOE LIFT

This is an example of a
shoe that became loose
on the ball and with
repeated high case
pressure fatigued the
slipper and finally
cracked . This is called
Shoe Lift, the sound 3rd Stage
associated with it would 2nd Stage
be constant machine gun 1st Stage
noise typically worse at
full stroke.
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THE FINAL STAGE OF SHOE LIFT HALF MOON SHAPED MARKS

A sure sign of shoe

lift

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 WEAR ON SHOE RETAINER FROM
ROLLED SHOES: THE TELL
SHOE FLANGES
TALE OF SHOE LIFT

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BENT SEAL RETAINER SEAL RETAINER

As can be seen in the picture the retainer is clearly bent, that After removal of the shaft assembly, the seal retainer is
is from the case pressure pushing the seal against retainer. accessible. The seal retainer is placed between the outboard
The surface on the shaft where the seal rides will have a side of the pump and behind the bearing.
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 SEAL RETAINER SEAL RETAINER REMOVED

Seal retainer in position

on the pump shaft.

Once the seal retainer has been removed the shaft seal is
exposed for removal. Investigate the seal closely and you
probably notice that it has been pushed out of the pump
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housing a little distance. 30
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MISCELLANEOUS FRETTED DRIVESHAFT

l INPUT SHAFT BROKEN

MISALIGNMENT

l CONTROL INSTABILITY
AIR
62 ©1998 Commercial Intertech Corp.

l PUMP VIBRATES
MISALIGNMENT 62. This splined drive shaft has been worn by fretting
corrosion. To prevent this damage the drive coupling should be
cleaned regularly followed with the application of a light coat of
synthetic grease.
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 HELPFUL HINTS FOR
ANALYZING BASKET CASES KEYS TO FAILURE ANALYSIS
l The last piece to fail will have the least amount of damage.
l Try to piece together the broken parts. This may seem like a l Don’t go into a problem with a preconceived
waste of time but many times you will observe things which idea about the cause.
can help you determine the original cause of failure. l Don’t assume anything, verify everything.
l Get the history of events:
l Don’t overlook the obvious.
What recently changed ?
What was going on just prior to failure ?
How long was pump running for?
Talk to the operators.
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