Here is everything you want to know about hydraulic lifts.
You will learn:
A hydraulic lift is a mechanism designed to elevate objects by using force generated through liquid pressure within a cylinder, prompting the piston to move upward. Incompressible oil is introduced into the cylinder, elevating the piston. When a valve opens, allowing the oil to exit, the piston lowers due to the pull of gravity.
The concept behind hydraulic lifts is governed by Pascal's Law. This principle asserts that any alteration in pressure applied to an incompressible fluid within a confined space is evenly transferred throughout the liquid in every direction.
Pascal’s Law, applied to hydraulic systems, can be exemplified by a scenario where a minimum force applied to an incompressible liquid on one end results in a significant force on the opposing end.
Hydraulic systems are advantageous for providing precise control in high-force applications, are economically beneficial, and make efficient use of energy resources.
A hydraulic lift operates on the foundational principles of hydraulics, utilizing Pascal’s Law to magnify force. In a hydraulic system, force is applied at one point to an incompressible hydraulic fluid (often high-grade oil), which transfers that force through piping to a second point, allowing for efficient lifting or movement. The core mechanism consists of two interlinked pistons—commonly called the master and slave cylinders—connected via strong, reinforced hydraulic lines filled with oil or hydraulic fluid.
The image below illustrates the two pistons and their connection via a pipe.
The diagram below depicts a basic hydraulic device mechanism. The handle on the right pumps incompressible oil from the reservoir into the high-pressure chamber in the center. As the oil is pumped in, the ram rises.
The force generated in a hydraulic lift system is directly related to the surface area of the pistons involved. According to Pascal’s Principle, when force is applied to the smaller (input) piston, it creates pressure which is transmitted undiminished through the hydraulic fluid to the larger (output) piston. For example, if the smaller piston has a diameter of two inches and the larger piston is six inches across—three times as large—the resulting force is magnified by a factor of nine. In practical terms, applying just 100 pounds of force to the small piston allows the lifting of 900 pounds on the large piston. This multiplication of force is why hydraulic lifts are so valuable in car repair shops, industrial manufacturing, and material handling facilities.
In the diagram below, observe how a downward movement of the smaller piston can lift a significantly heavier load with minimal effort. The piston on the left, carrying a one-pound load and having a surface area of one square inch, travels down ten inches to raise a ten-pound load on the right-side piston.
This combination of high lifting capacity and precise control makes hydraulic lifts essential in applications ranging from automotive lifts and wheelchair lifts to heavy-duty industrial elevators and material handling equipment.
Hydraulic lift systems—whether used in elevators, forklifts, scissor lifts, or automotive lifts—all operate on the same basic principles using similar components. To understand how hydraulic lifts work, it’s important to know the role and function of each part of the hydraulic system. Below is a comprehensive overview of these components that ensure optimal performance, safety, and durability of hydraulic machinery.
Hydraulic circuits are specialized pathways that manage fluid flow, hydraulic pressure, and directional control within a closed hydraulic system. These circuits include valves (directional, relief, and check valves), pressure switches, and flow controllers, all of which collaborate to ensure safe and efficient movement of hydraulic actuators such as lift tables and jacks. The image below helps visualize the key features and flow paths in a typical hydraulic circuit.
A hydraulic pump, often rotary or reciprocating in design, converts mechanical power from an electric motor or internal combustion engine into a steady flow of hydraulic energy. The pump generates a vacuum at the inlet to draw hydraulic oil from a reservoir, then forces the pressurized fluid through the system’s pipes and hoses to power actuators and lift mechanisms. Choosing the correct hydraulic pump—gear pump, vane pump, or piston pump—ensures system efficiency and longevity for a given lift application.
The hydraulic motor serves as an essential actuator in hydraulic equipment, converting fluid pressure and flow into rotational force and torque. This enables rotary motion for various industrial machines and tools. Compared to linear actuators, hydraulic motors are ideal for applications where continuous rotation is required. These motors work alongside hydraulic pumps, providing the dynamic movement needed for conveyor belts, winches, and high-capacity lifts.
The hydraulic cylinder, often called a linear actuator or ram, is key to converting hydraulic fluid pressure into powerful linear motion. This is the component responsible for the vertical movement in hydraulic jacks, scissor lifts, and lift tables. Hydraulic cylinders come in single-acting or double-acting designs, and their capacity depends on bore size, stroke length, and fluid pressure rating.
Hydraulic pistons operate within cylinders under immense fluid pressure to produce precise linear displacement. In advanced piston designs, such as axial piston pumps and bent-axis motors, multiple pistons are arranged to boost flow rates and system responsiveness, enabling smooth and reliable operation even under heavy-duty cycles.
Hydraulic fluids play a crucial role in system efficiency, wear protection, and heat dissipation for hydraulic lifts and machinery. The most common fluids are mineral oils, but water-based and synthetic options (such as glycol ether, organophosphate esters, polyalphaolefins, propylene glycol, and silicone oil) are chosen for specialized needs, such as high temperature resistance, fire safety, and environmental considerations. Choosing the right hydraulic fluid—considering viscosity, lubricity, and anti-wear additives—greatly impacts the reliability and service life of hydraulic equipment.
Reliable hydraulic lifts depend on advanced control valves and integrated safety devices. Directional control valves manage the movement of hydraulic actuators, while pressure relief valves protect equipment from dangerous overpressure events. Modern hydraulic lift systems also incorporate load holding valves and emergency lowering mechanisms, ensuring user safety in industrial and commercial settings.
Hydraulic lifts offer several key benefits over traditional mechanical lifting devices. These advantages include precise load control, high lifting capacity, smooth and quiet operation, low maintenance requirements, and adaptability to various layout configurations. Hydraulic lifts are widely used for vehicle lifts in auto shops, industrial scissor lifts, wheelchair lifts for accessibility, and freight elevators in warehouses due to their versatility and reliability.
Hydraulic lifts and hydraulic lift systems have become essential machinery across a wide range of industries, including manufacturing, warehousing, healthcare, logistics, and public transportation. From enabling safe patient mobility in hospitals to facilitating efficient material handling in factories to improving accessibility for public transit, modern hydraulic lifts are engineered to enhance productivity, safety, and ergonomics. As the applications of industrial lifting equipment continue to expand, it is critical for facilities and end-users to understand the various types of hydraulic lifts available, their core functions, and the unique benefits they offer for specific lifting, transport, or access needs.
Below are descriptions of several major types of hydraulic lifts, each designed to meet distinct operational requirements for vertical lifting, personnel elevation, and specialized material handling.
Table lifts are versatile hydraulic lifting platforms engineered to move materials from floor level to ergonomic work heights. Commonly used in automotive, warehousing, manufacturing, and logistics sectors, these hydraulic lift tables provide safe, stable vertical movement for tasks such as loading pallets onto conveyor belts, positioning heavy objects for assembly, or lifting equipment onto packaging lines. Transportation companies frequently utilize table lifts to load cargo onto truck beds or warehouse docks, reducing manual lifting injuries and boosting workflow efficiency.
Personnel lifts, also known as hydraulic man lifts or vertical mast lifts, are designed to safely elevate workers to variable heights for inspection, facility maintenance, electrical repair, warehouse stocking, and more. These industrial lifts feature guardrails and secure platforms, supporting occupational safety in settings such as gyms, production facilities, theaters, and convention centers—ideal for accessing lighting systems, ceilings, HVAC units, or overhead inventory. Their compact footprint and ease of maneuvering on job sites make personnel lifts indispensable for elevated work in both commercial and industrial environments.
Forklifts—sometimes referred to as forklift trucks or industrial lift trucks—are robust hydraulic-powered vehicles engineered for the efficient transportation and stacking of heavy materials. Found in construction sites, warehouses, shipping yards, and distribution centers, forklifts utilize precision hydraulic lift cylinders, masts, and forks to handle palletized goods, containers, drums, and other oversized loads. They play a crucial role in streamlining material movement, loading and unloading shipments, and optimizing warehouse organization for increased throughput and supply chain efficiency.
Medical lifts—sometimes called patient lifts or hospital bed lifts—leverage hydraulic lift mechanisms to adjust the position of surgical tables, hospital beds, diagnostic equipment, and mobility aids. Reliable and ergonomic, these lifts allow healthcare professionals to transport patients from rooms to surgical suites with ease, and enable safe transfer and positioning for both patients and staff. Integrated hydraulic bed adjustment systems also facilitate optimal patient accessibility, comfort, and care, meeting rigorous healthcare safety and hygiene standards.
Automotive lifts, or vehicle lifts, are high-capacity hydraulic lifting systems designed to raise cars, trucks, and commercial vehicles for repair, inspection, and detailing. Found in garages, automotive service centers, body shops, and car dealerships, automotive lifts are engineered to handle substantial loads using reinforced steel arms and locking safety features. Their vertical lifting motion allows unimpeded access to the vehicle’s undercarriage, streamlining tire replacement, brake repairs, engine diagnostics, and maintenance operations.
Post car lifts represent a specialized automotive lift solution, featuring two hydraulic posts and four support arms for balanced vehicle elevation. Favored in professional automotive repair shops and commercial garages, post car lifts support a wide range of vehicle types—from sedans and SUVs to pickup trucks. Advanced safety locks, adjustable arm placements, and hydraulic synchronization ensure stability and precision for major repairs requiring wheel and axle access, suspension work, or engine removal.
Platform lifts—sometimes referred to as elevated work platforms, aerial lifts, or scissor lift tables—offer a spacious and stable base for workers, equipment, or materials at elevated heights. Frequently used in facilities maintenance, warehousing, theater production, and large-scale construction projects, these hydraulic platform lifts support safe overhead work, cleaning, staging, and complex installations. Their large lifting capacity, smooth vertical travel, and customizable platform sizes make them ideal for jobs requiring multiple personnel or oversized loads.
Pallet lifts, also known as pallet stackers or pallet jacks with hydraulic lift systems, are essential for logistics, shipping, and warehousing operations. These hydraulic lifting devices facilitate efficient movement of palletized goods for forklift-free loading, unloading, shelf stacking, and transporting materials onto production lines. They increase workflow speed, minimize workplace injuries, and optimize storage density by allowing access to higher racking levels and tight warehouse aisles.
Hand-pumped lifts, or manual hydraulic lifts, operate through user-powered hydraulic hand pumps, offering robust lifting performance in environments without electricity or for portable use. With a sturdy design and reliable release lever, they are capable of hoisting loads up to one ton to heights exceeding six feet. Popular in fieldwork, small workshops, repair environments, and temporary job sites, these lifts offer cost-effective, low-maintenance solutions where simple, powerful vertical lifting is required without complex machinery.
Because no two industrial lifting challenges are exactly the same, many hydraulic lift manufacturers offer custom hydraulic lift solutions tailored for unique, unconventional, or demanding environments. Customization may address space constraints, unusual loads, safety compliance, or integration with automated systems. Engineering teams work closely with clients to design and build hydraulic lifts that feature:
Leading manufacturers employ skilled engineers to consult on project-specific requirements, redefining lift parameters and adapting mechanical designs to match diverse industrial, commercial, or manufacturing environments. As technology evolves and new industry standards emerge, customized hydraulic lift systems help businesses stay flexible and responsive to changing production and operational needs, ensuring both efficiency and compliance.
Vertical Reciprocating Conveyors (VRCs)—sometimes called vertical material lifts, freight lifts, or goods lifts—are industrial lifting solutions designed to transport heavy materials vertically between multiple building levels. According to ASME B20.1 standards, VRCs are classified as conveyors and material lifts, not for use in passenger transport. These hydraulic lift systems can be installed in warehouses, distribution centers, mezzanines, factories, and even exterior building spaces to move cartons, pallets, parts, and other bulk goods between floors in a safe and efficient manner.
Unlike traditional freight elevators, VRCs typically offer greater placement flexibility, reduced installation costs, and minimal space requirements (no separate machine rooms or deep pits). Their structural supports, enclosed carriages, and advanced safety mechanisms prevent load shifting during transit, reducing workplace accidents. VRCs also serve as a safer, more effective alternative to forklifts or scissor lifts for routine vertical material handling tasks.
Hydraulic VRCs are valued for their smooth, controlled vertical movement and ability to handle loads between 3,000 and 6,000 pounds. Compared to mechanical VRCs, they offer faster installation and lower upfront costs, making them ideal for two-level lift applications up to 25 feet in height where non-continuous or low-cycle operation is required. VRCs are a preferred solution for businesses seeking to optimize vertical transport, streamline workflow between levels, and reduce manual labor throughout the facility.
Lift tables have gained popularity as work surfaces that can be adjusted to the precise height needed for tasks such as packaging, assembly, organization, or positioning items. Unlike adjustable tables, lift tables are distinguished by their higher lifting capacities.
A standard lift table can handle loads ranging from 2,000 to 6,000 pounds and can be adjusted from as low as 7 inches to as high as 60 inches, with a workspace that typically ranges from 24 to 72 inches. Available in various shapes and sizes to suit different applications, lift tables offer versatile solutions for many industrial needs. Below is a description of some of the different types of lift tables.
Mobile lift tables, also known as lift carts, are a type of push cart that can be raised using a manual foot pump. They are commonly used for light assembly operations and offer the convenience of mobility.
Rotating hydraulic lift tables are specialized lift tables featuring a turntable recessed into the surface, allowing access to a load from all four sides. The turntable operates on anti-friction bearings, enabling smooth and effortless rotation. When not in use, it can be locked in place. These lift tables often have a low profile, allowing them to be lowered to just a few inches off the floor for easy access with a pallet jack or forklift.
Like all hydraulic tables, rotating hydraulic lift tables are constructed from highly durable materials and are capable of lifting nearly a ton of products. They are designed to precisely position loads, reducing the need for manual lifting by workers and enhancing operational efficiency.
Low-profile lift tables have a collapsed height of just a few inches, allowing them to be loaded with a hand truck or forklift. Because they do not require a pit or floor indentation, they are suitable for use on upper floors as well as the main floor. The hydraulic lift is activated via a foot switch or push-button remote, enabling operators to raise or lower the table to an optimal working height.
Low-profile tables are designed to ergonomically position loads for easy handling or unloading, reducing worker fatigue, boosting productivity, and improving overall worker satisfaction. Their flexibility makes them adaptable to a wide range of applications.
Stainless steel lift tables are commonly utilized in the food and pharmaceutical industries due to their adherence to strict hygiene and sanitary requirements. Their resistance to corrosion and rust allows for easy cleaning with solvents and water, making them ideal for maintaining high standards of cleanliness.
High-capacity hydraulic lift tables are heavy-duty tools capable of lifting loads up to 60 tons, with lifting heights ranging from 52 to 92 inches. They feature platforms varying from 4' by 6' to 10' by 22', with options for custom larger platforms. Equipped with scissor legs and torque tubes, these tables provide exceptional stability and support, minimizing load deflection and shifting.
The number of scissor legs and hydraulic cylinders can vary based on the table's design and manufacturer. Like other hydraulic tables, high-capacity models can be operated using a handheld pendant or foot switch, and often include an upper travel limit switch. Additional features may include tilt tops, powered turntables, V-cradles, and corrosion-resistant finishes, among others.
High-capacity hydraulic lift tables are built to endure the rigorous demands and continuous use of heavy-duty machinery, making them the robust workhorses of the lift table category.
Ground entry lift tables are designed with ground-level access to the platform to address concerns about tripping hazards and space constraints. They feature a cut-out section in the shape of a "U" or "E," allowing for easy loading with open-bottom pallets or skids.
Tilting lift tables are designed for handling containers with loose parts. They raise to an ergonomic height and tilt toward the operator, reducing the need for bending and stretching. These tables can be adjusted to tilt up to 90 degrees, enhancing accessibility and ease of use.
Tandem lift tables integrate standard lifting functions with additional lifts to extend the length or width of the platform. This design provides the added benefit of increased platform size, allowing for the accommodation of larger loads and enhanced edge and side load capacity.
Multi-stage lift tables use stacked pairs of scissor arms, with one lift table mounted on top of another. This configuration allows for increased vertical travel while maintaining a compact platform size.
Hydraulic lifts are built from steel and offer precise accuracy, making them both sturdy and durable. Their robust design has led to their widespread use across various industries. Below are a few industries that depend on hydraulic lifts for their efficiency and powerful performance.
Electro-hydraulics is a widely used application of hydraulic technology in various industrial settings. Key advantages of hydraulics include rapid response times and high precision. Hydraulic systems are employed in a range of industries, including plastic processing, metal extraction, automated production, machine tools, paper manufacturing, loaders, crushers, presses, and textiles. The image below showcases a hydraulic press used in the plastics industry.
Mobile hydraulics offer the flexibility to adapt to various conditions and scenarios. They are particularly valuable in the construction and building industries, where they are utilized in cranes, excavators, backhoes, and earth-moving equipment. The image below shows a concrete boom truck equipped with a hydraulic arm for unloading concrete.
The automotive industry is the largest consumer of hydraulic technology. Hydraulics are extensively used in production, repair, and various internal components of vehicles. The image below illustrates the application of hydraulic automation in truck manufacturing.
Marine hydraulics deliver linear and rotary force and torque rapidly and efficiently. The three types of marine hydraulic systems are open, closed, and semi-closed. They are used for cranes, mooring and anchor winches, stabilizers, steering, thrusters, propellers, and platforms.
Aircraft components must adhere to stringent standards before they are approved for use. Hydraulic pumps and valves are crucial in meeting these regulations and play a vital role in aircraft design and production. Hydraulics are used for various functions, including wing adjustments, landing gear retraction and extension, door operations, brakes, and steering. The image below highlights some of the key applications of hydraulics in aircraft.
Hydraulics are well-suited for mining due to their power, controllability, reliability, and ease of maintenance—qualities that are essential in this high-risk environment. Mining operations, which involve large-scale equipment and operations, benefit from the significant power and force provided by hydraulic systems, making them an ideal choice for handling the demanding conditions of the industry.
Hydraulic lifts are robust pieces of equipment designed to exert significant force. Both the Occupational Safety and Health Administration (OSHA) and the American National Standards Institute (ANSI) set stringent guidelines for their use. A fundamental requirement is that operators must be at least 18 years old and have undergone thorough training on the safe operation and potential risks associated with hydraulic lifts.
Below is a summary of the key regulations and safety tips for operating hydraulic lifts.
OSHA regulations for lifts broadly apply to any work performed on elevated platforms.
Standard 1926.451 – Safety and Health Regulations for Construction – Although primarily focused on construction, this standard outlines requirements for guardrails and fall protection. Originally designed for scaffolds, it has been extended to include lift systems as well.
Standard 1910.29 – Walking-Working Surfaces – This standard addresses fall protection systems and measures to prevent falling objects, including specifications for guardrails and railings.
Aerial lifts are classified as mobile elevating work platforms (MEWPs). According to ANSI A92, these lifts must be equipped with two types of sensors: one that sounds an alarm and prevents operation when the load exceeds safety limits, and another that triggers an alarm and halts movement if the slope becomes too steep.
Gates on aerial lifts must be equipped with toe guards and cannot be chains. For outdoor use, wind speed sensors are mandatory. Platform railings must be at least 43.5 inches high. When operating on uneven ground, the tires must be solid or foam-filled. Additionally, ANSI A92 includes expanded training requirements for operators.
MH29.1 provides updated guidelines for operating and using industrial-sized scissor lifts for personnel. It outlines the distinctions and similarities between dock lifts, access lifts, and lift tables. This standard includes comprehensive details on the responsibilities of manufacturers, users, owners, and operators, along with a clearer explanation of the requirements for scissor lifts.
B20.1 sets the safety standards for conveyors and related equipment, including vertical reciprocating conveyors (VRCs), which function similarly to elevators for transporting large materials between floors in a building. These standards cover the design, construction, installation, maintenance, inspection, and operation of VRCs, addressing potential hazards and risks. Initially published in 1947, B20.1 has been updated several times to reflect advancements in technology, with the latest revisions in 2021 focusing on gates and enclosures.
To be OSHA certified for operating aerial and scissor lift equipment, an operator must complete an OSHA-approved training course. This course is designed to teach workers how to safely operate lift equipment. Regulations mandate that employers must provide certification training to ensure legal compliance.
The training includes:
Here below is a sample daily checklist for hydraulic lifts.
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