A forklift is essential for material handling in warehouses, construction sites, and industrial operations. If it stops lifting or struggles to lift heavy loads, it can lead to operational delays and safety hazards. The issue could be due to hydraulic system failures, low fluid levels, clogged filters, or mechanical damage.
In this blog, we will explore the most common reasons why a forklift fails to lift properly, how to diagnose the issue, and the best solutions to fix it.
1. Low Hydraulic Fluid Levels
Why Does It Affect Lifting?
Hydraulic fluid generates pressure to lift the forks. If the fluid is too low, the system won’t produce enough power to lift heavy loads.
How to Diagnose:
- The forklift lifts slower than usual.
- The forks stop mid-lift or struggle to lift heavier loads.
- You hear whining or hissing noises from the hydraulic system.
How to Fix:
- Check and refill hydraulic fluid to the correct level (refer to your forklift service manual).
- Inspect for leaks in hydraulic lines and fittings.
- Use the correct hydraulic fluid recommended by the manufacturer.
2. Clogged Hydraulic Filters
Why Does It Cause Lifting Issues?
Filters prevent dirt and contaminants from entering the hydraulic system. A clogged filter restricts fluid flow, reducing lifting power.
How to Diagnose:
- The forks move sluggishly or stop midway.
- The hydraulic system overheats.
- Unusual noises from the hydraulic pump.
How to Fix:
- Replace clogged hydraulic filters regularly (check the Case Construction Equipment Manuals for the recommended maintenance schedule).
- Keep hydraulic fluid clean by storing it properly and replacing it at regular intervals.
3. Worn or Failing Hydraulic Pump
Why Does It Affect Lifting?
The hydraulic pump generates pressure to lift the forks. Over time, wear and tear can cause it to lose efficiency.
How to Diagnose:
- The forklift operates normally when empty but struggles with heavy loads.
- The hydraulic system makes a whining noise.
- The pump fails to maintain pressure.
How to Fix:
- Use a pressure gauge to test the hydraulic pump.
- Replace the pump if it’s not generating enough pressure.
- Refer to Case IH Equipment Service Manuals for proper pump replacement procedures.
4. Air in the Hydraulic System
Why Does It Affect Lifting?
Air trapped in hydraulic lines reduces pressure, leading to weak or inconsistent lifting.
How to Diagnose:
- The forklift lifts erratically or loses power mid-lift.
- Bubbles in the hydraulic fluid reservoir.
- Spongy or delayed response when lifting.
How to Fix:
- Bleed the hydraulic system to remove trapped air.
- Ensure all hydraulic connections are sealed properly.
- Follow air removal steps in John Deere Machinery Manuals.
5. Bent or Damaged Mast Components
Why Does It Affect Lifting?
If the forklift’s mast, chains, or rollers are damaged, they can obstruct movement and prevent smooth lifting.
How to Diagnose:
- The mast tilts unevenly or binds when lifting.
- Visible wear or bending on the mast chains.
- Forks move erratically or get stuck mid-lift.
How to Fix:
- Inspect the mast and chains for damage.
- Lubricate rollers and replace worn-out components.
- Check Volvo Equipment Service Manuals for proper mast maintenance guidelines.
How to Prevent Forklift Lifting Issues
✔ Regularly check and maintain hydraulic fluid levels.
✔ Replace hydraulic filters at recommended intervals.
✔ Monitor hydraulic pump performance and replace worn-out components.
✔ Inspect the mast and chains for wear and lubrication.
✔ Follow manufacturer-recommended service schedules from heavy equipment service manuals.
If your forklift is struggling to lift properly, having a detailed service and repair manual can help with troubleshooting and repairs.
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