Forklift hydraulic system – most common failures

Forklifts are made up of many complex components. Among them, we can distinguish those that create hydraulic system. They are responsible for the ability to raise and lower the forks. What are the most common failures of such elements?

Forklift Hydraulics - Oil Leaks

One of the most common faults hydraulic system in a forklift truck is a leak. Hydraulic oil plays an important role in the construction of the machine. It prevents friction, which could quickly lead to damage to important and expensive parts. Leaks most often occur when seals wear out, a hose is chafed, or there are leaks in other parts of the system, such as the oil tank.

Damage to the pump in the hydraulic system

Another important element of the hydraulic system is the pump. It is the pump that supplies oil to the other components. If it is damaged, the forklift will not be able to lift and lower loads. Repairing this element can be expensive, so it is worth taking care of it. The power pump drive and load lifting cylinders are particularly sensitive. This is where you need to be especially careful to prevent excessive pressure increase in the lifting mechanism and other dysfunctions.

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Oil contamination in the hydraulic system

The above-mentioned oil in the hydraulic system can only perform its function if it is sufficiently clean. Any contamination may damage important forklift components. Dust and chemical contamination most often get into the oil. 

To prevent serious failures of other vehicle components, it is necessary to change operating fluids regularly. This is the responsibility of the operator or the person responsible for the condition of the equipment. The hydraulic oil should be changed depending on how intensively the vehicle is used.

Damage to actuators in the hydraulic system 

Hydraulic system in a forklift truck, it relies on special actuators. They are responsible for driving the vehicle, lowering and raising the forks, and tilting the lifting mechanism mast. If the actuators are damaged, the device will become completely useless. 

They can be destroyed, for example, when the hydraulic oil pressure is too high and external leaks and leaks occur, or by lifting loads heavier than the maximum weight indicated by the manufacturer. For this reason, it is so important to follow the instructions in the manual. The latest models of forklifts are also equipped with special sensors that immediately detect overloading before important structural elements are damaged.

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Damage to valves in the hydraulic system

Hydraulic valves allow you to control the flow of oil throughout the system. If they are damaged, there may be a problem with the smooth lifting and lowering of loads. If you notice such symptoms, immediately repair the device. Failure can lead to damage to other, more expensive parts of the forklift.

Failure of hydraulic filters in a forklift

There are also filters in the hydraulic system of a forklift. These are elements that allow for the quick removal of any contamination from the oil. Over time, they wear out and stop working properly. This can lead to oil contamination, which will pose a threat to other components in combustion and electric forklifts.

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How to avoid a forklift breakdown?

Damage to some components is inevitable, especially in the case of intensively used machines. However, in order to avoid extensive breakdowns and reduce repair costs, it is worth replacing worn parts early enough. It is crucial to observe how the device works. When disturbing symptoms appear, it is a sign that the forklift should visit the workshop. 

Regular inspections and tests are also extremely important, for example of the mast tilt actuators, which are the responsibility of the hydraulic system and the hydraulic pump. Forklifts are devices subject to the control of the Office of Technical Inspection. This means that once every dozen or so months they must be checked by an employee designated by the UDT. Such an inspection is intended to detect any defects and order their repair. Only fully functional devices are intended for use.

Ongoing inspection of the forklift's hydraulic system

Its operator is usually responsible for the ongoing inspection of the technical condition of the forklift. Such a person must have appropriate qualifications obtained during an examination organized by the Office of Technical Inspection. During the course preparing for the test, future operators are taught how to build a forklift and what they need to remember to keep the device in proper condition. A qualified operator knows how to recognize hydraulic system faults and what to do if a vehicle breakdown occurs. Such a person is obliged to regularly check the parameters of the device before starting work, so he or she can quickly notice damage before it becomes serious and poses a threat.

Are you looking for parts that will help you repair faults in your forklift's hydraulic system? Check our offer and/ or contact us!