Troubleshooting Guide for Lubrication Pumps

February 19, 2025 (updated February 19, 2025)

Lubrication pumps help maintain a machine’s ongoing performance, but when they malfunction, it ultimately leads to costly downtime, increased wear on machinery components, and even total equipment failure.

Common issues like irregular flow, overheating, corrosion, leaks, and cavitation can compromise an entire lubrication system and should be addressed as early as possible to prevent further damage to machinery.

In this article, we’ll discuss the issues highlighted above, focusing on symptoms, causes, and our recommended troubleshooting steps.

Issue #1 Irregular Flow

Irregular flow in pumps should be fairly obvious to identify because its main symptoms are inconsistent lubricant output. However, other symptoms you may notice could include erratic system pressure readings and unusual noises coming from the pump.

Causes

Clogged filters or lines.
Trapped air bubbles in the system.
Worn or damaged pump components (like seals, pistons, and gears).
Using lubricants that are too thick or too thin.
Incorrectly set or malfunctioning injectors and dividers.

Troubleshooting Steps

Inspect and clear any blockages in filters, lines, and nozzles.
Bleed air from the system.
Examine and potentially replace seals, pistons, or gears.
Ensure you’re using the manufacturer-recommended lubricant (e.g., the lubricant matches the manufacturer’s viscosity requirements).
Adjust or replace injectors, dividers, or controllers.

Issue #2: Overheating

If pumps are overheating, the motor or housing will be excessively hot, and you’ll definitely notice unusual smells similar to burning oil or electrical insulation, as well as burnt or degraded lubricant. In some situations, your entire system may shut down due to thermal overload.

Causes

Running the pump beyond its rated duty cycle.
Using a lubricant that’s too thick, which increases resistance and generates excess heat.
Clogged filters, lines, or nozzles that are forcing the pump to work overtime.
Poor ventilation or lack of cooling mechanisms within the lubrication system.
Worn bearings, misaligned components, or inconsistent lubrication, causing dry spots at certain lubrication points and increased mechanical friction.
Overvoltage, poor wiring, or motor inefficiencies.

Troubleshooting Steps

The easiest first step is checking for blockages within the system and then cleaning and/or replacing clogged filters, lines, and nozzles.
If it’s not caused by a blockage, then check the lubricant currently being used and replace it if it’s degraded or not the correct viscosity.
Verify that the pump isn’t being run beyond its rated duty cycle and adjust operating times if necessary.
Inspect bearings, seals, and other components for wear and misalignments.

If these steps don’t work, you need to improve the ventilation, install a cooling system, or check electrical connections. At this stage, we recommend seeking professional assistance.

Issue #3: Corrosion

Corrosion is characterized by visible rust or pitting on pump components. However, you may also notice discolored lubricant and reduced lubricant flow.

Causes

Water ingress, which is especially a problem in high-moisture environments.
Contact with corrosive lubricants, cleaning agents, or industrial chemicals.
Incompatible lubricant or pump materials.
Lack of protective coatings on metal surfaces.
Poor maintenance (e.g., not cleaning components).

Troubleshooting Steps

Immediately replace corroded parts, like seals and bearings.
Look for signs of moisture and chemical exposure and find ways to mitigate them.
Replace components with stainless steel or coated components when possible.

To prevent corrosion, ensure you store lubricants properly and use desiccant breathers to reduce any risk of moisture. You should also install enclosures or covers if your system is operating in high-humidity or chemical-exposed areas.

Issue #4: Leaks

Like irregular flow, leaks will be extremely noticeable. You’ll see visible oil or grease markings around the pump or fittings, and your lubricant levels are likely to remain low, even when operation is normal.

Causes

Worn or damaged seals and gaskets (most common).
Components that have been loosened over time from vibration or thermal expansion.
Physical damage (cracks and corrosion) to the pump housing (highly likely if your system is in a corrosive environment).
Overfilling the reservoir, which causes excess lubricant to leak through vents or seals forcefully.
Over pressurization within the system, which can cause seals and connections to fail.

Troubleshooting Steps

Check and adjust pressure systems if needed.
Inspect and replace any faulty seals and gaskets if needed.
Check connections and tighten them if they’re loose.
Upgrade/replace the pump housing if cracked or corroded.

Issue #5: Cavitation

Cavitation can lead to some pretty severe consequences (like total pump failure) if it’s not addressed. You should suspect cavitation as a potential issue if you’ve noticed unusual bubbling, rattling, or knocking sounds coming from the pump, decreased lubricant flow, fluctuating pressure, increased vibration, pitted or eroded surfaces in pump components, and/or overheating.

Causes

Leaks in the suction line that are introducing air into the system.
Low reservoir levels.
Clogged intake lines.
A restricted inlet or other excessive suction pressure that leads to vapor formation.
Using a lubricant that’s too thick and can’t flow properly within the system, which creates localized pressure drops and vapor formation.
Dirty or clogged filters.