Skytrak Loss of Hydraulics: Troubleshooting and Solutions

[MikePhua]

Skytrak telehandlers are widely used in construction and material handling due to their powerful hydraulics, versatility, and all-terrain capabilities. However, like all hydraulic-powered equipment, they can occasionally experience issues related to hydraulic performance, such as a complete loss of hydraulics. These problems can lead to significant downtime and operational disruption if not properly addressed. In this article, we will explore the common causes of hydraulic loss in Skytrak telehandlers and provide troubleshooting tips and solutions.
Common Causes of Hydraulic Loss in Skytrak Telehandlers
1. Low Hydraulic Fluid Levels
One of the most common causes of hydraulic loss is simply low hydraulic fluid levels. A decrease in fluid levels can cause a drop in hydraulic pressure, resulting in sluggish or non-functional hydraulics. It is essential to regularly check fluid levels to ensure that they are within the recommended range.
Industry Insight: A construction company once encountered a hydraulic issue with their Skytrak telehandler where the boom wouldn’t lift properly. After checking the hydraulic fluid, they discovered that it was below the recommended level. A fluid top-up immediately restored full hydraulic function.
2. Hydraulic Fluid Contamination
Contaminated hydraulic fluid can cause internal damage to the hydraulic components, leading to a loss of pressure and reduced system functionality. Dirt, debris, and moisture can enter the hydraulic system through worn seals or vents. This contamination can damage hydraulic pumps, valves, and seals, leading to leaks or loss of power.
Real-World Case: In an agricultural setting, a Skytrak telehandler experienced intermittent hydraulic failure. Upon inspecting the system, it was found that the hydraulic fluid was contaminated with dirt and water. A thorough flushing of the system and replacement of the fluid solved the issue, preventing further damage to the hydraulic components.
3. Hydraulic Pump Failure
A malfunction or failure in the hydraulic pump is another common cause of hydraulic loss in Skytrak telehandlers. The pump is responsible for pressurizing the hydraulic fluid, and if it becomes worn or damaged, the entire hydraulic system can fail to function. Pump failure can occur due to prolonged use, improper maintenance, or contamination in the system.
Expert Tip: A noticeable sign of pump failure is inconsistent or weak hydraulic movement. If the pump has failed, it will likely need to be replaced. Always use high-quality replacement parts to ensure the longevity of the hydraulic system.
4. Leaks in the Hydraulic System
Hydraulic systems are susceptible to leaks, especially in high-pressure areas. Leaks in hoses, fittings, or seals can lead to a significant loss of hydraulic fluid, resulting in a failure of hydraulic operations. Leaks can be difficult to detect without proper inspection, as they may be small or hidden in less accessible areas of the machine.
Maintenance Story: A Skytrak operator noticed a loss of hydraulic performance and, after a thorough inspection, found a small leak in one of the hydraulic hoses. Replacing the hose restored full hydraulic power to the system, ensuring smooth operation.
5. Faulty Hydraulic Valves
Hydraulic valves regulate the flow of fluid throughout the system. If a valve becomes stuck or malfunctions, it can prevent fluid from reaching the necessary components, leading to hydraulic failure. This is more likely to occur in older machines or those subjected to heavy usage.
Industry Example: A contractor working on a large construction project faced repeated hydraulic failures with their Skytrak telehandler. After troubleshooting, they discovered that a valve in the control system was faulty. Replacing the valve immediately solved the issue and restored normal operation.
Troubleshooting and Solutions for Hydraulic Loss
1. Check Hydraulic Fluid Levels and Quality
The first step in troubleshooting hydraulic issues is to check the hydraulic fluid levels. If the fluid is low, top it up with the recommended type of hydraulic oil. It’s also essential to check the quality of the fluid. If the fluid appears dirty, contaminated, or discolored, it may need to be replaced. Regular fluid maintenance is crucial to the health of the hydraulic system.
Pro Tip: Keep track of the fluid replacement schedule and follow the manufacturer's guidelines on fluid types and intervals to ensure smooth system operation.
2. Inspect for Leaks
Inspect the hydraulic system thoroughly for leaks. Pay close attention to hoses, seals, and fittings, especially in high-pressure areas. If a leak is found, replace the damaged components and refill the system with the proper hydraulic fluid.
Maintenance Insight: Use hydraulic leak detection dye for harder-to-find leaks, especially in high-pressure or hard-to-reach areas. This dye can make locating the source of the leak much easier.
3. Flush the Hydraulic System
If you suspect contamination, it’s important to flush the hydraulic system. Drain the old fluid, clean the system thoroughly, and replace it with fresh, high-quality fluid. Additionally, replace the filters to ensure that no contaminants remain in the system.
Real-Life Example: After encountering hydraulic power issues, a maintenance team performed a complete hydraulic system flush on their Skytrak telehandler, eliminating the contamination problem. This proactive measure extended the lifespan of the hydraulic components and ensured optimal performance.
4. Test the Hydraulic Pump
If fluid levels and leaks are not the issue, the hydraulic pump should be tested. A failing pump may exhibit symptoms such as weak or erratic hydraulic performance. If necessary, replace the pump with an OEM (Original Equipment Manufacturer) part to ensure that the system functions correctly.
Expert Tip: If the hydraulic pump is suspected of being the issue, use a flow meter to measure the output and compare it to the manufacturer’s specifications. If the flow is below the specified level, the pump is likely failing.
5. Check Hydraulic Valves and Controls
Inspect the hydraulic valves and controls for proper function. If valves are found to be stuck or malfunctioning, replace them as needed. Valves are critical for directing fluid flow, and a malfunction can disrupt the entire hydraulic system.
Industry Insight: A faulty hydraulic valve in a Skytrak telehandler once caused a construction project delay. The valve was replaced, and the telehandler was back in action the same day, avoiding additional downtime.
Conclusion
A loss of hydraulics in a Skytrak telehandler can result in significant downtime and operational disruption, but with the right troubleshooting steps, most issues can be resolved quickly. Regular maintenance, including fluid checks, leak inspections, and pump tests, is key to preventing hydraulic system failures. By staying on top of these common issues and performing routine maintenance, operators can keep their Skytrak telehandlers running smoothly and efficiently.