While electric forklifts often get attention for their battery requirements, the hydraulic system is equally critical to every forklift’s operation. Whether you’re running electric, gas, or diesel machinery, the hydraulics are what allow your forklift to lift, tilt, and move loads efficiently. Neglecting hydraulic maintenance can lead to costly breakdowns, unexpected downtime, and safety risks.
Understanding how to maintain and troubleshoot forklift hydraulics is essential for keeping your operations running smoothly. Our guide covers the key aspects of forklift hydraulics maintenance, helping you identify potential issues before they become significant problems.
What Does a Forklift Hydraulic System Do?
The hydraulic system is the muscle behind your forklift’s lifting capabilities. It uses pressurised hydraulic fluid to power the lift mechanism, enabling the forks to raise and lower heavy loads with precision.
A typical forklift hydraulic system includes several key components:
- The hydraulic pump generates pressure by moving fluid from the reservoir through the system.
- The hydraulic cylinder converts this pressure into mechanical force, pushing the forks up or down.
- Valves control the flow and direction of hydraulic oil.
- Hoses connect all the components together.
- The reservoir stores the hydraulic fluid when it’s not in use.
When all these hydraulic components work together properly, your forklift operates well. Problems with any single part can affect the entyre system’s performance.
Why Is Regular Forklift Hydraulics Maintenance Essential?
A well-maintained system uses less energy, performs more consistently, and lasts longer – saving you money over the machine’s lifetime.
It’s also vital for safety and productivity. Hydraulic failures can lead to sudden load drops or unexpected breakdowns, disrupting operations and endangering workers. Routine inspections and servicing help detect wear before it becomes a hazard, reducing downtime and keeping your equipment and team safe.
How Often Should You Check Hydraulic Fluid Levels?
Checking hydraulic fluid levels should be part of your daily forklift inspection routine. Low fluid levels can cause the hydraulic pump to run dry, leading to overheating and premature failure.
To check the fluid level, locate the reservoir on your forklift. Most models have a sight glass or dipstick that allows you to see the current level. The fluid should be within the marked range when the forks are lowered. If it’s consistently low, there may be a leak in the system that needs attention.
The colour and clarity of hydraulic oil can tell you a lot about its condition. Fresh hydraulic fluid is typically amber or light brown and clear. If the oil appears dark, cloudy, or contains particles, it may be contaminated and needs replacing.
What Are the Signs of Hydraulic System Problems?
Recognising early warning signs can help you address issues before they cause a complete breakdown. Here are some common symptoms:
- Slow or jerky movements – If the forks lift or lower more slowly than usual, or move in jerks rather than smoothly, this often indicates low fluid levels or contaminated oil.
- Unusual noises – Whining, grinding, or squealing sounds from the hydraulic pump suggest air in the system or worn components.
- Visible leaks – Puddles of fluid under the forklift or wet spots on hoses and cylinders indicate leaks that need immediate attention.
- Reduced lifting capacity – If your forklift struggles to lift loads it previously handled easily, the hydraulic system may not be generating sufficient pressure.
- Overheating – Excessive heat in hydraulic components indicates problems with fluid levels, contamination, or component wear.
How Do You Inspect Hydraulic Hoses and Connections?
Hydraulic hoses are under constant pressure and subject to wear and tear from regular use. They require careful inspection to prevent sudden failures.
Check for Visible Signs of Damage
Check hoses for cracks, abrasions, bulges, or signs of rubbing against other components. Pay particular attention to areas near connections and bends, where stress is greatest. Even small cracks can lead to complete hose failure under pressure.
Inspect Connections and Fittings
Examine all connections and fittings for signs of leakage. Hydraulic fluid leaks often show up as damp or oily areas around fittings. Loose connections should be tightened carefully, but over-tightening can damage threads and create more problems.
Replace Damaged Hoses Promptly
Replace any hose that shows signs of damage. The cost of a replacement hose is minimal compared to the damage that can result from a sudden failure during operation.
What’s Involved in Hydraulic Cylinder Maintenance?
The hydraulic cylinder does the heavy lifting in your forklift, converting fluid pressure into the force needed to raise loads. Proper cylinder maintenance ensures reliable operation.
- Inspect the cylinder rod for scratches, pitting, or corrosion. Damage to the rod can tear the seals, allowing fluid to leak and contaminants to enter the cylinder. Keep the exposed portion of the rod clean and free from debris.
- Check the seals regularly for signs of wear. Leaking seals are a common cause of hydraulic problems. If you notice fluid weeping from around the rod, the seals likely need replacement.
- The cylinder mounting points also require inspection. Loose mounting bolts can cause misalignment and accelerated wear. Ensure all fasteners are secure and properly torqued.
How Do You Maintain the Hydraulic Pump and Reservoir?
The hydraulic pump is the heart of the system, and the reservoir keeps it supplied with clean fluid. Both require regular attention.
Reservoir
Keep the reservoir clean and check for contamination. Remove the fill cap periodically and inspect the fluid for water, dirt, or metal particles. Contaminated hydraulic oil should be drained and replaced immediately to prevent damage to the pump and other hydraulic components.
Check the breather cap on the reservoir to ensure it’s not clogged. A blocked breather creates a vacuum as fluid is drawn out, which can cause pump cavitation and damage.
Pump
Listen to the pump during operation. Unusual noises or excessive heat indicate problems that need professional diagnosis. The hydraulic pump is a complex component best serviced by qualified technicians.
When Should You Replace Hydraulic Oil?
Hydraulic fluid doesn’t last forever. Over time, it breaks down and becomes contaminated, losing its ability to lubricate and protect components.
Most manufacturers recommend changing hydraulic oil based on operating hours, typically every 1,000 to 2,000 hours. However, operating conditions can affect this interval. Forklifts working in dusty environments or extreme temperatures may need more frequent oil changes.
When changing hydraulic oil, drain the old fluid completely and inspect it for contamination. Replace the filter at the same time. Using the manufacturer-specified grade of hydraulic fluid is essential for proper system performance.
Professional Forklift Hydraulic Servicing with TAG
While daily checks and basic maintenance can be handled in-house, comprehensive hydraulic servicing requires specialist knowledge and equipment. TAG Forklift Truck Services offers professional maintenance and repair services for all types of forklifts.
We also offer forklift refurbishment services to extend the lifespan of older machinery, including hydraulic system overhauls. If you’re experiencing persistent hydraulic problems with an ageing forklift, refurbishment can be more cost-effective than purchasing new equipment.
For businesses looking to hire forklifts rather than purchase them, our hire fleet is maintained to the highest standards. All servicing and maintenance is included in the hire agreement, giving you peace of mind.
Get in Touch
Contact us to discuss your forklift maintenance requirements. Our team is here to keep your operations running smoothly.