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Forklifts are indispensable equipment in modern warehousing and logistics industries, widely used in material handling, stacking, and transportation tasks. During forklift operation, the brakes, as one of its critical safety components, play a vital role. If the forklift brakes fail, it can lead to accidents, seriously threatening the safety of operators and the stability of the surrounding environment. Therefore, when encountering forklift brake failure, it is crucial to quickly identify the problem and take the correct countermeasures.
1. Causes of Forklift Brake System Failure
The causes of forklift brake system failure usually include the following:
(1) Brake fluid leakage
Most forklift brake systems use hydraulic systems. If there is a brake fluid leak or insufficient fluid, the brakes will not function properly. Brake fluid leaks can occur in pipes, joints, pumps, or cylinders.
(2) Brake pad wear
With increased use, brake pads gradually wear down. If the brake pads are severely worn, the braking force will be greatly reduced, ultimately leading to brake system failure.
(3) Air entering the brake system
If air enters the brake system, it will prevent the effective transmission of hydraulic pressure, causing the brakes to lose their braking effect. Air usually enters the system during brake fluid replacement or repair if the system is not thoroughly bled.
(4) Damaged brake disc or drum
Damage to the brake disc or drum (such as cracks, excessive wear, or deformation) will affect the normal operation of the brakes, leading to reduced braking performance or even complete failure.
(5) Brake pump failure
The brake pump is a crucial component that drives the hydraulic system. If the pump malfunctions or fails, the brakes will not operate normally.
(6) Electrical faults in the brake system
For electric forklifts, the brake system is closely related to the electrical system. Electrical system faults (such as sensor failure, broken wires, etc.) can also cause the brakes to malfunction.
2. Common Manifestations of Forklift Brake Failure
When a forklift's brakes fail, operators may encounter the following situations:
(1) Reduced braking effectiveness
If you notice that the brakes are slow to respond or the braking distance increases while using the forklift, it indicates a potential problem with the braking system. The operator may need to apply more force to the brake pedal to stop the forklift.
(2) Abnormal brake noise
When the brakes fail, they may emit unusual friction or metallic collision sounds. This is usually due to excessive wear of the brake pads or damage to the brake discs.
(3) Brake failure or inability to brake
The most serious situation is complete brake failure, resulting in the forklift being unable to stop. In this case, the operator must immediately stop operation and take emergency measures.
(4) Abnormal vibration or deviation
When the brakes are partially damaged, abnormal vibrations or deviations in the forklift's direction may occur during braking. This is due to uneven operation of the brakes.
3. Countermeasures for Forklift Brake Failure
When a forklift's brakes malfunction, operators should take the following measures:
(1) Stop and inspect
First, when you notice any abnormality in the forklift's brakes, immediately stop and ensure the forklift is in a safe state. Do not continue operating to avoid accidents. Find an open area to avoid endangering the safety of surrounding personnel.
(2) Check the brake fluid
If you suspect a brake fluid leak, check if the brake fluid level is sufficient. Check if the fluid level is below the specified safety line; if so, add an appropriate amount of brake fluid. If the fluid level is normal but there are signs of leakage, check the hydraulic lines and connectors for damage.
(3) Check the brake pads and discs
Check the wear of the brake pads and discs. If you find that the brake pads are excessively worn or the surface of the brake discs is damaged, replace the brake pads and discs immediately. Do not continue to use severely damaged brake components.
(4) Check the brake pump
A brake pump malfunction can lead to brake failure. Check the brake pump for signs of oil leaks or malfunctions. If a problem is found with the pump, it needs to be replaced or repaired.
