Forklift hydraulic maintenance is an important aspect of forklift upkeep.
Forklift hydraulic systems are responsible for the machine’s lifting and steering capabilities, so changing its fluid is necessary to keep the machine functional.
Routine maintenance, including the occasional forklift hydraulic fluid change, can help avoid errors and mistakes that cause forklift failures and malfunctions.
In this article, we will discuss the importance of hydraulic maintenance and how to implement a solid plan to avoid costly breakdowns and headaches.
Let’s dive in!
Why Hydraulic Maintenance Matters
Taking care of your hydraulic systems is like going for regular checkups at the doctor. A little effort goes a long way.
When you maintain your equipment properly, it lasts longer, works better, and saves you time and money.
Avoiding Big Problems with Small Fixes
Reactive maintenance (waiting until something breaks to fix it) causes unexpected downtime, disrupting your operations, and ultimately impacting your bottom line.
It’s like waiting until your phone dies to charge it—inconvenient and disruptive.
However, scheduling regular maintenance lets you choose when to pause and take care of your equipment instead of dealing with sudden breakdowns.
Plus, keeping your hydraulic parts in good shape helps them last longer, expanding its useful life.
Making Your Equipment Work Smarter
A well-maintained hydraulic system uses less energy and works more efficiently.
Regular checkups, like testing the oil, can catch small problems before they become major issues.
For example, if the oil contains tiny metal particles, it might mean parts inside the system are grinding against each other.
Keeping everything clean also helps avoid pressure-related issues that slow you down.
Pressure is a key part of how hydraulics work—they use pressurized fluid to generate power. But if dirt, debris, or other contaminants get into the system, they can block or damage components, leading to pressure spikes. These spikes can strain the system, causing leaks, equipment wear, or even complete failure. Keeping the system clean helps avoid these problems and ensures smooth operation.
Staying Reliable and Ready
Nobody likes surprises when it comes to their equipment.
Maintaining your hydraulic components like keeping hydraulic cylinders clean ensures they’re doing their job properly.
Taking the time to plan ahead means your equipment stays reliable and lasts longer.
Dodging Emergency Repairs
Fixing something at the last minute usually costs more and takes longer.
Catching small issues early—like noticing a squeaky hinge before it breaks—can save you a ton of trouble.
Simple steps, like checking for wear and tear after each use, go a long way in keeping everything working.
Meeting Compliance Standards
Regular maintenance keeps your equipment compliant with industry standards, like OSHA, ensures workplace safety, and avoids potential fines.
Adhering to regulations is a responsible approach to maintenance.
Staying on top of maintenance such as inspecting hoses, motors, and pumps and regularly changing out old hydraulic fluid helps you meet these standards.
By giving your hydraulic systems a little extra attention, you’ll save money, avoid stress, and keep everything working as it should.
Creating a Hydraulic Maintenance Plan
A well-structured hydraulic maintenance plan is essential for keeping your equipment operating efficiently.
Here’s how to build one that works.
Setting the Right Schedule
The frequency of maintenance tasks depends on your equipment.
Always consult your manual or dealer for specific guidelines.
Keep detailed maintenance logs to track your progress, or hire an experienced company for assistance.
Prioritizing the Hydraulic Filter
Hydraulic filters remove contaminants that can damage your system.
The first filter change at around 250 hours (or whatever interval specified by the manufacturer) is especially critical as it removes debris from the system’s break-in period and lays the groundwork for long-term reliability.
Replacement filters should always be part of your maintenance plan.
| Maintenance Task | Frequency |
|---|---|
| Initial Filter Change | 250 hours |
| Regular Filter Change | 2000 hours/annually |
Keeping your hydraulic reservoir clean and free of contaminated fluid is just as important.
Regular inspections, cleaning, and timely filter replacements help ensure the longevity of your system.
Maintaining Optimal Fluid Levels
Checking hydraulic fluid levels regularly is key to preventing performance issues.
Correct fluid levels maintain proper system function and maximize your machine’s lifespan.
Inspect hydraulic lines for oil leaks and keep them clear of debris.
Conducting Visual Inspections
Leaks or strange noises? Don’t ignore them. A quick visual inspection can uncover hidden problems, helping you address issues early.
Make visual inspections a regular part of your maintenance routine.
Look for signs like fluid discoloration, a bubbly appearance, or a burnt oil smell.
These could indicate bigger problems and should be addressed immediately.
Fluid Analysis
Fluid analysis detects contaminants in hydraulic fluids, oils, coolants, and fuels.
Regularly sampling and testing ensure optimal machinery conditions offering early warning of performance issues.
This gives managers time to address issues.
Fluid analysis identifies problems, helping implement corrective measures and reducing operating costs.
Regularly scheduled testing improves productivity and workplace safety.
Contaminated fluid can cause catastrophic failure in hydraulic cylinders and other hydraulic components.
Keep an eye out for signs of built-in contamination like liquid pooling in the storage tank.
Who Can Perform A Hydraulic Fluid Change On A Forklift?
A forklift hydraulic oil change cannot be performed by anybody.
So, while changing a forklift’s hydraulic oil is relatively simple it needs accuracy and knowing what to do.
That skill can be performed by the following people:
- The operator
- A mechanic
- A service technician
The operator can perform the hydraulic fluid change on a forklift if they know how to do it.
In most cases, operator training also includes inspection and maintenance activities like forklift hydraulic oil changes.
Otherwise, it can be completed by any in-house mechanic if available.
Most warehouses and forklift operator sites have mechanics for forklift inspection and maintenance.
Let the mechanic perform the oil change during a scheduled or pre-operation inspection.
If the site has no mechanic available, we recommend a professionally certified forklift technician to complete the hydraulic fluid change.
You can use a mobile service technician or go to a dealership like Conger.
A trained and experienced service technician knows what fluids to use on different forklift models and the different forklift fluids.
They’ll safely and efficiently complete the hydraulic oil change, often as part of general forklift maintenance and servicing.
If you have questions about forklift hydraulic fluid changes and are located in Green Bay, Wausau, Neenah, Richfield, Madison, or the surrounding areas, Conger is here to help!
How to Change Forklift Hydraulic Fluid
Most manufacturers suggest a forklift hydraulic oil change every 1,000 hours of operation, but before you change the fluid, you’ll want to check your hydraulic fluid levels.
So, here are the steps and processes involved in changing a forklift’s hydraulic fluid:
Step 1: Park your forklift on level ground and lower the forks
First, you must ensure that your forklift is parked in a safe work area on a level surface.
You’ll also need to lower the forks to the ground and ensure the tynes are completely reduced to the ground.
This will both ensure the forklift is at rest and support the weight.
Finally, set the parking brake and turn the ignition off!
Step 2: Check Hydraulic Fluid Level
Once the forklift is parked and the ignition is turned off, your next step is to check the hydraulic fluid level.
To check the forklift hydraulic fluid, do the following:
- Open the hood to find the forklift hydraulic fluid reservoir in the engine bay.
- Remove the cap from the forklift hydraulic fluid reservoir.
- Use a dipstick to check the fluid level.
- Dry the dipstick and dip it in again to double-check the hydraulic oil reservoir just to be sure.
Otherwise, refer to the manual to find the interval for changes.
To monitor hydraulic fluid levels properly, we recommend operators check oil levels daily as part of their pre-start checklists.
This keeps you informed about the oil level and to top up or change the fluid before damage is caused by running a machine with insufficient hydraulic oil levels of contaminated oil.
Step 3: Collect all the Materials and Items you Need to Perform the Hydraulic Fluid Change
If you decide to proceed with the hydraulic fluid change, you need to prepare the right tools and items.
- You’ll need to know what kind of fluid to use from the different hydraulic oil types — water-based fluids, petroleum-based fluids, and synthetic fluids. Consult the forklift manual to determine which type of fluid you need.
- Drain pan with enough capacity.
- A new oil filter.
- Other tools are necessary to open and close the reservoir tank and plug.
Step 4: Remove the Drain Plug and Drain out all the old hydraulic fluid
The next step is to drain out the old hydraulic oil from the forklift.
- Place a drain pan under the drain plug. Make sure the container has enough capacity to hold the full contents of the oil reservoir.
- Check the drain plug at the bottom of the reservoir but this can depend on the forklift model.
- Remove the drain plug that protects the hydraulic fluid from spilling.
- Drain out all the old hydraulic oil.
Ensure all the fluid is drained out of the reservoir tank so that it doesn’t mix with the new hydraulic fluid you’ll add.
Step 5: Inspect the condition of the empty hydraulic oil reservoir tank
While the reservoir tank is empty, inspect its condition (physical) for any wear and tear. Also, inspect for any foreign matter.
- Inspect the bottom layer of the tank.
- Inspect the “insides” of the tank.
An inspection ensures that the tank has no damage and that the fluid will be safe from leakage or impurities.
Next, clean the tank if necessary. For instance, if it has any sludge.
This will help ensure that the tank is fresh and clean for the new hydraulic oil free from any impurities that can cause a malfunction or damage.
Step 6: Re-install the drain plug
Remember you removed the drain plug and you need to re-install the drain plug before you pour the new hydraulic fluid into the forklift.
Step 7: Replace oil filters
Remember, rydraulic fluids systems have hydraulic filters that protect the engine from any solids and impurities.
When changing the hydraulic fluid, you also need to replace the oil filter.
Make sure you select the right oil filter for the forklift model.
Only use high-quality oil filters to protect your hydraulic pump and other components.
You can consult with the forklift’s operator manual, a dealer, or the manufacturer.
Once you replace the filter, you can proceed to add the hydraulic oil.
Step 8: Add Hydraulic Fluid to the Fill Tube and Pump Fluid Into the Reservoir
Since you have already selected the hydraulic fluid you want to add, it’s time to add it to the forklift.
Now, remove the vented cap that directs oil into the tank.
You can now add the fluid reservoir tank.
You’ll want to constantly check the gauge as you are filling the oil so as not to overfill.
Slow down as it nears the fill line and stop when the tank is full.
Once the fluid level reaches the maximum line (max line) stop pouring.
Don’t pass the max line.
Step 9: Remove the Pump Nozzle
Slowly remove the nozzle from the vented cap.
Then clean up any spills or residual fluid on the surface of the pump and tank.
You want your forklift machine to remain clean and free from spills.
Next replace the vented cap and close the lid
Step 10: Close the Engine Bay
You’re done replacing the hydraulic fluid of your forklift.
If it was part of the routine (scheduled) maintenance, you can proceed to other maintenance requirements.
Otherwise, you can now close the engine bay and start your engine.
Test that all hydraulic system functions are working correctly.
If so, continue with your operations of the day.
Ensure you maintain your hydraulic system well for perfect performance.
Common Questions about Hydraulic Maintenance
What is the maintenance of a hydraulic system?
Hydraulic system maintenance involves keeping the system functioning optimally.
This includes fluid and filter changes, inspections for leaks, and performance checks.
Hydraulic maintenance ensures the system operates with pressurized fluid as intended, delivering the necessary hydraulic energy.
Proactive maintenance includes regularly scheduled inspections and routine maintenance to identify potential problems before they arise.
This comprehensive approach to maintenance helps prevent premature failure of hydraulic equipment.
How often do you need to change hydraulic fluid?
Change hydraulic fluid annually or every 2,000 operating hours, depending on the equipment and operating conditions.
Regularly changing hydraulic fluid helps maintain a healthy hydraulic system.
Sticking to a preventive maintenance schedule for changing hydraulic fluid is vital to keeping the hydraulic system working at its peak.
By keeping the hydraulic hoses, the hydraulic motor, and other main parts of the system clean you’ll be on your way to maintaining an efficient system.
This will reduce your overall repair costs and extend the life of the hydraulic components.
Remember that the hydraulic pump relies on clean fluid to properly pressurize the hydraulic system.
How often should hydraulic oil be checked?
Check hydraulic oil levels daily or before each use.
This catches leaks and fluid loss from extended use.
Schedule inspections as a part of a larger hydraulic maintenance plan.
Identifying potential leaks early can prevent more significant issues.
Low fluid can also indicate other problems requiring corrective maintenance measures.
By ensuring your equipment operating properly and maintaining a clean service for pressurized hydraulic fluid, you can ensure the longevity and efficiency of your machinery.
What are the 4 requirements of hydraulic oil?
Hydraulic oil needs these properties:
- Good viscosity for lubrication.
- High viscosity index for minimal temperature-related viscosity changes.
- Demulsibility to prevent water mixing.
- Anti-wear properties to reduce wear.
These properties maintain efficient operation and prevent catastrophic failure from occurring.
Regularly checking and changing your oil helps to maximize its service life.
Keeping hydraulic systems clean through maintenance measures, such as regular inspections, helps prevent costly downtime from major failures.
Conclusion
Proper hydraulic maintenance is essential for ensuring your forklift operates efficiently, reliably, and safely.
By following a proactive maintenance plan, including regular fluid checks, timely hydraulic oil changes, and thorough inspections, you can minimize downtime, extend the lifespan of your equipment, and avoid costly repairs.
Remember, a well-maintained hydraulic system not only improves performance but also protects your investment and ensures compliance with safety standards.
Whether you handle maintenance in-house or rely on professionals, staying consistent with these best practices will keep your forklifts running smoothly and your operations stress-free.
Take the time to prioritize hydraulic maintenance—your equipment, team, and bottom line will thank you!