The Ultimate Guide to Fluid Level Check

What is Fluid Level Check?

A fluid level check is an essential maintenance task that involves inspecting the various fluids in critical manufacturing vehicles, such as forklifts, industrial trucks, and side loaders, to ensure they are at optimal levels.

Regular fluid level checks are crucial because inadequate fluid levels can lead to serious mechanical issues, reduced vehicle performance, and potential safety hazards. Qualified mechanics or trained operators often perform this task as part of routine vehicle maintenance.

Benefits

Incorporating regular fluid level checks as part of your vehicle inspection routine offers multiple significant benefits, including:

• Prevention of Costly Repairs and Downtime: Routine checks help identify low or contaminated fluids early, preventing breakdowns and expensive repairs such as engine or transmission failures. For example, catching transmission fluid issues early can avoid some of the highest repair costs.

• Enhanced Equipment Longevity: Maintaining proper fluid levels ensures effective lubrication, cooling, and hydraulic functions, for they are key to reducing wear and tear on internal components and extending the lifespan of engines, transmissions, brakes, and other systems.

• Improved Safety: Keeping adequate brake and power steering fluid levels is critical for safe operation. Fluid level checks help avoid safety hazards caused by system failures, thereby protecting operators and cargo.

• Optimal Performance and Fuel Efficiency: Proper fluid levels ensure engines and mechanical systems run efficiently with less friction and heat, improving fuel economy and overall productivity.

• Early Problem Detection: Fluid analysis can detect contaminants like metal particles, water, or dirt that may indicate wear or leaks before visible symptoms appear. It enables proactive maintenance scheduling, reducing unexpected failures and downtime.

• Compliance with Regulations: The Occupational Safety and Health Administration (OSHA) requires daily inspections of all powered industrial trucks, such as forklifts, before they are placed in service. Meanwhile, forklifts working 24/7 should be checked at the end of each shift.

• Maintaining Resale Value: Well-documented fluid maintenance and analysis demonstrate good care to potential buyers, potentially increasing resale value.

7 Essential Fluids To Check in Your Vehicle

The list below highlights fluids you should regularly check and maintain to ensure safe and efficient vehicle operation.

Forklift Hydraulic Fluid

Hydraulic fluid is essential for operating a forklift’s lifting and steering mechanisms. It allows the forklift to lift, lower, and tilt loads smoothly and safely. Most forklift manufacturers recommend replacing hydraulic fluid every 1,000 hours of use.

Additionally, operators should have a pre-start and post-operation checklist to properly monitor oil levels.

How to Properly Check It:

1. Park the forklift on a level surface and lower the forks completely.

2. Turn off the engine and allow it to cool.

3. Locate the hydraulic fluid reservoir, which is often found near the mast or under the seat.

4. Remove the cap or dipstick to inspect the fluid level.

5. Ensure the level is within the marked range; top up with the manufacturer-recommended hydraulic fluid if needed.

6. Document fluid checks and conditions as part of regular maintenance records.

Transmission Fluid

Transmission fluid lubricates the internal components of the transmission system, ensuring smooth gear shifting and power transfer from the engine. Change it every 250 hours or annually, although manufacturer recommendations and operating conditions may vary.

How to Properly Check It:

1. Warm up the engine to normal operating temperature.

2. Park the vehicle on a level surface and shift it to neutral or park.

3. Locate and remove the transmission dipstick.

4. Wipe it clean, reinsert, then remove again to check the level and condition.

5. If the fluid is low or discolored, refill or replace using the recommended type.

Engine Oil

Engine oil lubricates engine components, minimizes friction, and helps control engine temperature. Check them frequently as part of your pre-trip and post-trip inspections.

Changing the engine oil differs per manufacturer, engine, application, and fuel type. So, follow the vehicle’s manual for proper procedures and regular service intervals.

How to Properly Check It:

1. Turn off the engine and allow it to cool.

2. Locate the engine oil dipstick and remove it.

3. Make sure to wipe it clean, insert it all the way back in, then remove again to verify the oil level.

4. If engine oil level remains below the recommended range, use the appropriate engine oil.

5. Inspect oil color—dark or gritty oil may indicate it’s time to change.

Brake Fluid

Brake fluid transfers pressure from the brake pedal to the braking system, enabling the vehicle to stop effectively. A low or contaminated brake fluid level can compromise safety.

Check your brake fluid every few months or during maintenance. If braking performance changes, inspect it immediately.

How to Properly Check It:

1. Find the brake fluid reservoir, typically on or near the master cylinder.

2. Check the level against the “MIN” and “MAX” indicators on the container.

3. Observe the fluid’s appearance—it should look either clear or a light yellow shade.

4. Refill with the correct brake fluid if the level is low or appears cloudy or dark.

Power Steering Fluid

Power steering fluid provides hydraulic assistance to the steering system, making maneuvering the vehicle easier and safer. Check the fluid every 100 hours of operation or once a month.

How to Properly Check It:

1. Find the power steering fluid reservoir, typically marked and located near the engine.

2. Check the fluid level using the dipstick or level indicators.

3. Inspect fluid condition—it should be clean and the proper color.

4. Add more fluid if it’s below the recommended level, using only the specified type.

Coolant

Coolant helps maintain engine temperature by absorbing excess heat and stopping the engine from overheating. It also protects engine components from corrosion and freezing.

Traditional coolants should be checked once it reaches either 500 hours or 4,000 km. However, it’s best to inspect regularly, especially before extreme winter or summer temperatures, as coolant properties can degrade, affecting pH, freezing, and boiling points..

How to Properly Check It:

1. Ensure the engine is completely cool before opening the radiator or coolant cap.

2. Locate the coolant reservoir or radiator.

3. The fluid level is between the “MIN” and “MAX” lines.

4. Refill with the correct coolant mixture if the level is low.

5. Do not open the cap when the engine is hot to avoid injury.

Windshield Washer Fluid

Washer fluid helps keep the windshield clear of dirt, dust, and debris, which is crucial for visibility and safety. This fluid should be checked weekly, especially in dirty or dusty working conditions.

How to Properly Check It:

1. Find the washer fluid reservoir, which is typically labeled and translucent.

2. Visually inspect the fluid level against the markings.

3. Open the cap and refill if the fluid is low.

4. Use proper washer fluid to avoid freezing or clogging.

Tips for Checking Fluid Levels Effectively

Effective fluid level checking in industrial vehicles involves a combination of routine, safety precautions, thorough inspection, and record keeping.

Here are key tips for checking fluid levels effectively:

1. Park on a Level Surface: Always park the vehicle on level ground for fluid checks to ensure accurate readings.

2. Follow Safety Procedures: Turn off the engine and let it cool when required, especially before checking fluids like engine oil and coolant; checking transmission fluid at operating temperature with the engine running is often recommended.

3. Consult the Owner’s Manual: The location of dipsticks, reservoir markings, and fluid type specifications varies by vehicle; the manual provides exact procedures and recommended fluids.

4. Use Proper Tools: Wipe dipsticks with clean rags or paper towels before rechecking fluid levels to avoid false readings. Add fluids using appropriate funnels to prevent spills and contamination.

5. Check Fluid Levels Regularly: Establish a routine schedule based on operating hours or mileage. Daily checks are advisable for critical systems like hydraulic fluid in industrial machinery, especially under heavy use or hot conditions.

6. Inspect Fluid Condition: Observe fluid color and clarity. Healthy fluid typically appears clearly (e.g., engine oil should be amber, transmission fluid red or pink). Dark, cloudy, milky, or burnt-smelling fluid indicates contamination, degradation, or potential mechanical problems.

7. Look for Leaks: Inspect under the vehicle and around reservoirs for any signs of fluid leakage, which can signal system faults.

8. Avoid Overfilling: Add fluids slowly and check levels frequently while topping up to maintain optimum levels without overfilling, which can cause damage.

9. Keep Detailed Records: Log all fluid checks, additions, and changes with dates and vehicle usage data to track maintenance history and identify abnormal fluid consumption or recurring issues.

10. Utilize Technology When Available: Some vehicles use electronic fluid sensors or monitoring systems for real-time alerts on fluid levels and conditions, improving accuracy and preventive maintenance.

11. Wear Protective Gear: Use gloves and protective eyewear, as some fluids can be hazardous.