A customer recently contacted us about a newly installed hydraulic guide rail lift. The lift was operating normally, but there was a noticeable humming “woo-woo” sound when the platform moved upward.
After analyzing the situation, we suspected the hydraulic cylinders, especially the piston rods and their sealing system.
For a two-cylinder guide rail lift, cylinder alignment and parallelism are very important. If the two cylinders are not working in a sufficiently parallel condition, additional friction can occur.
At the same time, new piston rod seals can be relatively tight during the initial operating period. The piston rod and seals need some time to run in, and this initial friction can sometimes create an unusual sound.
We recommended lubricating the exposed piston rods with suitable oil and adding about 10 liters of suitable hydraulic oil to the hydraulic tank according to the system requirements.
The noise did not disappear immediately. After several days of operation, however, the customer reported that the sound had become much quieter. A few more liters of hydraulic oil were then added.
For a newly installed hydraulic lift, this type of issue should be investigated step by step rather than immediately replacing the cylinder.
Important points to check include cylinder alignment, piston rod condition, seal tightness, lubrication, hydraulic oil level and the running-in period of the new cylinder.
Sometimes, a new hydraulic component simply needs proper lubrication and operating time for the sealing and sliding surfaces to settle into normal working conditions.
This case is a useful reminder that troubleshooting should start with the simplest possible causes before replacing major hydraulic components.
When working with large hydraulic cylinders, attention is often focused on pressure, lifting capacity, cylinder diameter and hydraulic power.
But sometimes, one of the smallest details deserves just as much attention: the breather port.
A good example is a 110/90 hydraulic cylinder.
The 110 mm dimension refers to the cylinder barrel inner diameter, while 90 mm refers to the piston/rod diameter.
Why does the breather matter?
During cylinder movement, the air inside the relevant cylinder chamber needs to move correctly.
If the breather port is incorrectly closed, internal air movement can be restricted and the cylinder may not operate normally.
This is why the breather should always be checked during installation and commissioning.
Can the breather be connected to a hose?
For suitable hydraulic lifting applications, a small flexible hose can be connected to the breather port and routed back toward the hydraulic oil tank.
One advantage is cleanliness.
If minor oil seepage occurs around the sealing area, the hose can help guide the oil back toward the tank instead of allowing it to spread around the equipment.
What about slight oil seepage?
A small amount of initial seepage does not necessarily mean that a new hydraulic cylinder has a failed seal.
Seal lubrication, friction and the initial running-in period can all affect cylinder behavior.
Where permitted by the cylinder design and seal specifications, suitable compatible lubricant can be applied through the designated lubrication point.
However, this should not be used to ignore a genuine leakage problem.
If leakage continues, increases or is accompanied by abnormal cylinder movement, the cylinder should be inspected.
The lesson
Hydraulic equipment reliability is often determined by details that are easy to overlook.
A correctly handled breather port, appropriate lubrication and regular inspection of seals can all contribute to cleaner and more reliable hydraulic cylinder operation.
When commissioning a hydraulic cylinder, don't just check the hydraulic connections. Check the small details too.
Guide rollers are an important part of a hydraulic home lift. They help guide the lift platform along the T-shaped guide rails and contribute to smooth and stable movement.
For many years, we used rubber-coated guide rollers.
Why rubber?
Because rubber is soft, flexible and relatively quiet during operation. For a home lift, where low running noise is important, this made rubber a very practical choice.
However, a customer installation in Nigeria gave us an unexpected troubleshooting case.
The rubber outer layer of the guide roller repeatedly came off during operation.
At first, we considered mechanical causes such as incorrect installation, roller alignment or contact with another component.
After discussing the situation with the customer, we identified the local high-temperature environment as a likely contributing factor.
In hot conditions, rubber can become softer. Continuous contact and friction between the roller and T-shaped guide rail can then accelerate wear over time.
We contacted the guide roller manufacturer and investigated an alternative.
The recommended solution was polyurethane.
The polyurethane material is firmly bonded to the steel roller body, creating a stronger and more durable construction.
We tested the new rollers and found that the running noise remained at a satisfactory level.
Based on the test results, we decided to make a permanent improvement.
Since the end of last year, newly produced home lifts have been equipped with polyurethane guide rollers.
This experience reminded us that troubleshooting is not only about fixing a failed component.
The better approach is:
Identify the problem → investigate the cause → test alternatives → improve the design → prevent recurrence.
A real-world installation can reveal things that are difficult to discover in a workshop.
That is why customer feedback and field experience are an important part of continuous product improvement.
A newly installed hydraulic lift should normally move smoothly and steadily.
But what happens when a newly installed lift begins to shake during operation?
Recently, we had a real troubleshooting case involving a two-rail, two-cylinder hydraulic guide rail lift.
The customer reported that the platform was shaking intermittently while going upward. It would not simply rise smoothly; instead, it moved with a noticeable “jerk, pause, jerk” motion.
There was also some shaking during lowering, but the problem was more obvious during upward movement.
Rather than immediately replacing any components, we decided to troubleshoot the lift step by step.
The First Check: Guide Rails and Rollers
Because the equipment uses guide rails, the first possibility we considered was mechanical friction.
A problem with guide rail alignment, guide roller adjustment, lubrication, or damage could potentially cause uneven platform movement.
The customer inspected the guide rails carefully.
There were no obvious scratches or abnormal wear marks.
The guide rollers were also checked and were rotating freely.
The rails were lubricated as an additional test.
Unfortunately, the platform still shook.
This made it less likely that the guide rail or roller system was responsible for the problem.
Checking the Chain and Safety Wire Rope
The next step was to inspect the chain and safety wire rope.
We considered whether the safety wire rope might have been adjusted too tightly and could be creating resistance during movement.
For the test, the customer was asked to disconnect the chain and safety wire rope and loosen the safety wire rope.
It is important to clarify that the safety wire rope is a safety protection component, not a component intended to carry the normal lifting load.
Even after the adjustment, however, the shaking remained.
So we continued.
Isolating the Hydraulic Cylinder
The next test was more important.
We wanted to know whether the shaking was actually being caused by the platform and mechanical system, or whether the hydraulic cylinder itself was behaving abnormally.
The customer disconnected the mechanical components and allowed the hydraulic cylinder to operate independently.
During this test, an interesting symptom appeared.
The cylinder itself produced an intermittent, segmented sound while operating.
This was a major clue.
If the platform is shaking, but the cylinder is also operating intermittently when isolated from the platform, the hydraulic system becomes a much stronger suspect.
Checking the Pump Station
We then checked the hydraulic power unit.
The pump station sounded normal.
There was no obvious abnormal noise from the pump station itself.
The unusual sound seemed to be coming from the cylinder.
At this point, we had already checked several possibilities:
So we began looking more closely at the hydraulic circuit.
Could There Be Air in the Hydraulic System?
One possibility was air trapped inside the hydraulic cylinder or hydraulic lines.
This can happen during installation or commissioning, especially when hydraulic piping is relatively long.
Unlike hydraulic oil, trapped air can be compressed. If air remains in the system, the cylinder may not move as smoothly as expected.
Depending on the system, trapped air can contribute to:
Jerky movement
Intermittent cylinder movement
Vibration
Unusual hydraulic noise
Uneven lifting
Uneven lowering
Based on the symptoms we observed, trapped air became the most likely explanation.
Bleeding the System
For this particular lift, we asked the customer to carry out a hydraulic bleeding procedure.
The cylinder was first returned to its fully closed position.
The manual lowering valve on the pump station was then opened so that oil could return.
The cylinder was raised again, but it was stopped before reaching the maximum position.
It was then lowered again.
This cycle was repeated approximately three or four times.
The purpose was to allow trapped air to escape from the cylinder and hydraulic lines.
After that, the cylinder was connected back to the platform.
The complete lift was then operated through several additional raising and lowering cycles.
The system was monitored during the process.
The Problem Was Basically Gone
After bleeding the hydraulic system, the customer tested the lift again.
The result was very different.
The previous intermittent shaking was basically gone.
The platform moved much more smoothly.
This confirmed that the hydraulic system was the most likely source of the problem, with trapped air being the likely cause.
The important point is that the cylinder itself was not necessarily defective.
The guide rails were not defective.
The rollers were not defective.
The safety wire rope was not the problem.
The pump station was also operating normally.
The problem was most likely related to air remaining in the hydraulic circuit after installation.
Why Systematic Troubleshooting Matters
This case is a good example of why hydraulic equipment should be diagnosed step by step.
When a lift shakes, it is easy to immediately suspect the mechanical structure.
But several different systems can produce similar symptoms.
For example:
Mechanical problems may cause:
Friction
Scratching
Abnormal roller movement
Uneven resistance
Hydraulic problems may cause:
Jerking
Intermittent cylinder movement
Hydraulic noise
Vibration
Uneven lifting
The symptoms can sometimes look similar.
That is why isolating individual components and systems can save a lot of unnecessary work.
A Useful Tip During Installation
For guide rail hydraulic lifts, we recommend paying particular attention to hydraulic bleeding during installation and commissioning.
This is especially important when the hydraulic lines are relatively long.
After the hydraulic system has been installed and connected, the system may require proper bleeding before the lift reaches its normal operating condition.
If a newly installed hydraulic lift shows abnormal shaking, don't immediately assume that a major component is damaged.
First check the basics.
Check the guide rails.
Check the rollers.
Check the mechanical connections.
Check the safety components.
Listen to the pump station.
Then, if the mechanical components appear normal, investigate the hydraulic system.
And don't forget one simple possibility:
There may still be air in the hydraulic circuit.
Final Thoughts
Every installation gives us another opportunity to learn.
This particular case started with a shaking platform and ended with a relatively simple solution.
The most valuable part was not simply finding the cause.
It was the troubleshooting process.
Instead of replacing parts based on assumptions, we isolated the different systems and tested them one by one.
That approach helped us determine that the problem was most likely caused by trapped air in the hydraulic cylinder and/or hydraulic lines.
For hydraulic lifting equipment, careful installation, commissioning, testing, and systematic troubleshooting are just as important as the equipment itself.
A smooth lift starts with a properly commissioned hydraulic system.
Electric roller shutter doors are a practical landing-door solution for hydraulic freight lifts.
When the lift arrives at a floor, the roller shutter door automatically opens. Before the platform leaves, the door closes first and then the lift begins to move.
One customer wanted the door to remain closed while the lift was parked.
Rather than simply accepting the standard operation, this smart customer modified the control program himself.
He changed the current-floor button logic:
Press once → Door closes.
Press again → Door opens.
The lift platform remains stationary during this operation.
The roller shutter door operates at approximately 0.2 m/s, allowing a door slightly over 2 meters high to open in around 10 seconds.
This project demonstrates how customer experience and customized PLC programming can make hydraulic freight lifts more flexible and practical for real-world applications.
A solenoid valve is one of the key components used in many hydraulic lifting systems. It may look like a relatively small component, but it plays an important role in controlling hydraulic oil flow.
In our hydraulic lift systems, solenoid valves are commonly used to control the lowering function of the lift.
How Does a Hydraulic Solenoid Valve Work?
The working principle of a solenoid valve is relatively simple.
When electrical power is supplied to the solenoid coil, the coil generates a magnetic field. This magnetic force moves the internal valve spool and changes the hydraulic oil passage.
When the electrical power is removed, the solenoid is de-energized and the valve returns to its normal position.
A typical sequence is:
24V DC ON → Solenoid energized → Valve spool moves → Oil passage opens
The voltage does not have to be 24V in every application. Different solenoid valves can use different coil voltages, so the coil voltage must always match the electrical control system and the manufacturer's specifications.
How Does the Solenoid Valve Make a Hydraulic Lift Descend?
On many hydraulic lift power units, the solenoid valve controls the hydraulic oil return circuit.
When the lift is holding its position, the corresponding oil passage remains closed.
When the operator presses the DOWN button, the control box sends an electrical signal to the solenoid valve.
The sequence is:
DOWN signal → 24V DC output → Solenoid valve operates → Return passage opens → Hydraulic oil flows back to the tank → Lift descends
Once the hydraulic oil can return to the tank, the platform can descend under the effect of gravity and the load acting on the lifting system.
When the DOWN signal is removed, the solenoid is de-energized and the valve returns to its normal position.
How Is a 24V Solenoid Valve Wired?
A commonly used 24V DC solenoid valve is relatively simple to connect.
The two coil terminals are connected to the corresponding control wires from the electrical control box.
For a solenoid connector with an indicator light, the light provides a useful visual indication of whether the coil is receiving electrical power.
When the DOWN command is activated:
24V ON → Indicator light ON → Solenoid energized
When the DOWN command stops:
24V OFF → Indicator light OFF → Solenoid de-energized
This simple indicator can be very useful during installation and troubleshooting.
What Is the Ground/Earth Terminal?
Some solenoid valve connectors also include a protective earth/ground terminal.
This terminal is different from the two coil terminals. The coil terminals supply power to operate the solenoid, while the protective earth connection is intended for electrical safety.
Whether the protective earth terminal should be connected depends on the specific valve, connector, electrical system, manufacturer instructions, and applicable electrical standards.
Therefore, the manufacturer's wiring diagram and applicable electrical regulations should always be followed.
How to Troubleshoot a Hydraulic Lift That Will Not Descend
If a hydraulic lift does not descend, the solenoid valve is one of the components worth checking.
First, check whether the DOWN command is being received by the control system.
Next, use a multimeter to check whether the expected voltage is being supplied to the solenoid coil when the DOWN command is active.
If the solenoid connector has an indicator light, check whether it turns on.
If there is no indicator light and no voltage, the problem may be related to the control signal, PLC output, relay, wiring, fuse, or power supply.
If the correct voltage is present but the solenoid does not operate, the solenoid coil or valve itself may need to be inspected.
If the solenoid operates normally but the lift still does not descend, the problem may be somewhere else in the hydraulic circuit, such as the valve spool, return passage, hydraulic pressure, or another hydraulic component.
Final Thoughts
A hydraulic solenoid valve is a small component with an important job.
By converting an electrical control signal into mechanical valve movement, it allows the electrical control system to control hydraulic oil flow.
For a typical hydraulic lift:
Electrical signal → Solenoid valve → Hydraulic oil passage → Oil returns to tank → Lift descends
Understanding this basic process makes installation, commissioning, and troubleshooting of hydraulic lifting equipment much easier.
For hydraulic lift manufacturers and users, knowing how to check the solenoid valve, its electrical signal, and the hydraulic circuit can significantly reduce troubleshooting time.
A lifting machine can contain hundreds of components.
Some are large and easy to notice, such as hydraulic cylinders and structural frames. Others are much smaller, but they are still critical to the movement of the machine.
Rollers are one of these components.
At Beacon Industries, we create 3D drawings and technical records for the rollers used in our lifting equipment projects.
Why Record Such a Small Component?
Because a roller is not just a simple wheel.
In many lifting mechanisms, rollers guide moving parts and help maintain smooth movement. We often think of them as the joints of the machine.
The roller needs to match the machine precisely.
Its diameter, width, shaft dimensions, bearing, and installation position all need to work together.
Even a small dimensional difference can affect the way a moving structure operates.
That is why we don't want to rely on memory when it comes to these parts.
We Create a 3D Model for Each Project
During the manufacturing process, the rollers and machined parts are documented with 3D drawings.
The project record can include:
Roller dimensions
Bearing model
Shaft dimensions
Matching parts
Special project requirements
This creates a digital reference for the components actually used in the machine.
It is particularly useful because different customers and different machines may require different roller sizes.
What Happens If a Roller Needs to Be Replaced?
This is where the records become especially valuable.
Suppose a lifting machine has been working for several years and one of its rollers eventually needs to be replaced.
Without the original technical information, the replacement process may require measuring the old part and identifying the bearing again.
With our project records, we can retrieve the original data.
The roller dimensions and bearing model are already documented.
This allows us to quickly determine what was originally used and prepare the correct replacement.
Small Details Can Make a Big Difference
When people look at a lifting machine, they usually focus on the overall structure.
But reliable operation is often the result of many small details working together.
A correctly sized roller.
A properly selected bearing.
The correct shaft dimensions.
The right fit between components.
All of these details contribute to smooth operation.
This is why we believe that engineering records are just as important as the manufacturing process itself.
Manufacturing Today, Maintenance Tomorrow
A machine may leave our factory today, but it can continue working for many years.
We therefore try to preserve important engineering information for the future.
The purpose of keeping 3D roller drawings is simple:
If a component needs to be replaced in the future, we want to have the correct information ready.
No guessing.
No unnecessary redesign.
No searching for old dimensions.
Just retrieve the project record and identify the original specification.
That is one of the small ways we try to make our lifting equipment easier to maintain over the long term.
Good manufacturing builds the machine. Good documentation helps keep it running.
