Hydraulic jack has become a staple tool in various industrial projects—from heavy construction to equipment maintenance in the mining and manufacturing sectors. This tool is known for its ability to lift heavy loads with minimal effort. However, no matter how advanced the equipment is, a single small mistake can be fatal—ranging from equipment damage, project delays, to workplace accidents.
For this reason, it is crucial for field operators to understand not only how a hydraulic jack works but also the common mistakes to avoid. Here are five fatal mistakes that often occur in the use of hydraulic jacks in the industrial world, along with preventive solutions.
1. Lifting Loads Beyond the Jack’s Capacity
This is the most common and also the most dangerous mistake. Every hydraulic jack is designed with a maximum load limit that must be respected. Forcing a load beyond its capacity can:
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Permanently damage the hydraulic system
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Cause the jack to break or slip
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Increase the risk of injury to the operator
Solution:
Always check the jack’s technical specifications before use, and ensure the working load does not exceed the maximum number indicated on the tool.
2. Using the Jack on an Unstable Surface
Hydraulic jacks require a flat, hard, and stable surface to operate safely. Using it on soft, sloped, or uneven ground can cause:
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The jack to slip while lifting
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The load to fall suddenly
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Damage to the jack’s structure
Solution:
Always use a steel plate base or stable platform as the jack’s foundation, especially when working in outdoor project areas with less-than-ideal surfaces.
3. Not Using Additional Support Tools (Jack Stand)
Many technicians and operators make the mistake of relying on the hydraulic jack as a long-term load support. In fact, jacks are designed only for lifting, not holding loads for extended periods.
Risks:
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The jack can lose pressure and slowly lower
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Sudden collapse while the load is still on top
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Serious threat to workplace safety
Solution:
After lifting the load, always use a jack stand or mechanical support to hold the load, then release the pressure from the jack.
4. Not Performing “Bleeding” After Refilling Oil
When the hydraulic jack is refilled with oil or has not been used for a long time, air often gets trapped inside the system. If not removed (bleeding process), the jack will not function optimally and may feel “weak.”
Consequences:
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The jack cannot lift the load
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Piston movement becomes unstable
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Hydraulic system operates under uneven pressure
Solution:
Perform manual bleeding according to the manufacturer’s instructions after oil refill or major servicing. This is usually done by opening the valve and pumping several times without a load.
Read also: Hydraulic Jack vs Pneumatic Jack – Which is More Suitable for Your Industrial Needs?
5. Ignoring Routine Inspections and Signs of Damage
One of the main causes of jack failure is neglecting routine inspections. Many operators overlook signs such as:
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Oil leaks around the cylinder
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Stuck piston or piston not fully rising
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Hissing sounds during operation
Risks:
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Drastic reduction in jack performance
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Functional failure during work
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Potential accidents on site
Solution:
Implement daily and weekly inspection schedules, especially for large projects. Immediately service or replace worn components before using again.
Conclusion
Hydraulic jacks are indeed very helpful tools, but careless use or lack of technical understanding can lead to equipment damage and endanger safety. By avoiding the five fatal mistakes above—from overload to neglecting inspections—you can ensure the tool works optimally and the project runs smoothly.
To ensure you are using quality tools that meet industry standards, entrust your lifting equipment needs to PT. Karya Setia Jaya. We provide certified hydraulic jacks with reliable after-sales service to support the smooth operation of your projects. Contact our technical team today and get product recommendations that best suit your industrial needs.