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Autonomous troubleshooting and solutions for brake failures of electric forklifts

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Update time : 2021-11-25 16:56:01
In the electric forklift that has been used for a period of time, the brake system often has problems such as brake failure and brake deviation, which affect the normal use of the electric forklift. As a professional manufacturer of electric forklifts, HITOP forklifts have unique solutions in the face of brake failures of electric forklifts. Troubleshooting and solutions for common problems of electric forklift brake system:

1. Brake failure
The performance is that the electric forklift cannot achieve deceleration or parking during braking. The solution is as follows:
If you step on the brake pedal several times in succession, the pedal does not rise and you feel no resistance, you should first check whether the brake master cylinder is short of brake fluid. If it is short, the same type of brake fluid should be added and the pipeline air should be purged; if it is not short, check whether each brake pipeline is leaking or damaged, and correct or replace it as appropriate.

Step on the brake pedal, if there is no sense of linkage, it may be that the connection between the pedal and the master cylinder is disconnected, and the connection organization should be checked and connected.
brake of electric forklifts

If you step on the brake pedal, although you feel a certain resistance, the pedal position cannot be maintained, it sinks significantly, and the master cylinder leaks or sprays. The cause is mostly the brake master cylinder seal. The brake master cylinder should be differentiated and the master cylinder seal should be replaced.

If the above checks are normal, it may be that the master cylinder seal is out of position. At this moment, the brake master cylinder should be differentiated and the master cylinder seal of the same type should be replaced.

2. Poor braking
This problem has three manifestations: one is that the electric forklift cannot decelerate and park when the pedal is trampled several times; the second is that the pedal height is normal when trampled, but the pedal is weak and cannot be parked immediately; the third is that the pedal is high when trampling the pedal. , Hard or even rebound, but the braking effect is not good. The solution is as follows:

If you step on the brake pedal several times in succession, the pedal will gradually rise, and you can feel the elasticity of the pedal without lifting your foot after it rises. You can release the pedal and stop for a moment and then step on it. There is air in the dynamic system and should be exhausted.

The sequence of air discharge should start from the brake master cylinder and then to the brake cylinders. The air discharge sequence of each sub-cylinder should start with the sub-cylinder closest to the brake master cylinder and discharge one by one. Exhaust method: One person acts as the brake pedal, and the other person acts as the exhaust. First step on the brake pedal and do not loosen it, then loosen the vent screw. After the brake fluid mixed with air is sprayed out and the pressure is reduced, tighten the bleed screw to relax the brake pedal. After the brake pedal is completely returned, depress the brake pedal fully and continue to deflate. Repeat this several times to completely exhaust the air.

If the brake does not work when you step on the brake pedal, the position of the brake pedal will gradually increase after several steps, and the braking effect is outstanding, indicating that the pedal free stroke is too large or the gap between the friction plate and the brake hub is too large. At this moment, you should first check and adjust the pedal free stroke to make it within the regular scale, and then check and adjust the gap between the friction plate and the brake hub.

If you step on the brake pedal one after another, the position of the pedal can be gradually increased. If you continue to step on the pedal without raising your foot, you will not feel the pedal elasticity, but you will feel sinking, indicating that there is a leak in the brake system or the oil from the master cylinder. The valve is not tightly closed. At this moment, check whether there is any leakage in the pipeline joints. If there is leakage, it should be handled by fastening, welding or replacement.

If the position of the pedal is very low when the pedal is stepped on, the position still cannot be raised after a few more steps on the pedal. Usually, the vent hole of the brake master cylinder or the brake fluid compensation hole is blocked, which should be checked and dredged. If the pedal height meets the requirements, it is not fragile and sinks when stepping on, but the braking effect is poor, it is a wheel brake problem, and the wheel brake should be repaired.

If the brake pedal is high, hard or rebounds when using the foot brake, it may be a problem with the vacuum booster. You should first check whether the vacuum tubes are intact and whether the joints are firmly connected, and then check the vacuum booster. When checking, you can first step on the brake pedal, then start the engine, and work at idle speed for a few seconds. If you feel the brake pedal lowers by a small amount, it indicates that the vacuum booster is outstanding; if the brake pedal does not lower by itself, it indicates that the vacuum booster The vacuum booster should be replaced due to poor operation of the device.

3. Braking deviation
The problem is that the two wheels cannot work together or the braking force is not equal when braking, which makes the electric forklift deflect to one side when braking. The solution is as follows:

During the road test, if the electric forklift travels to the right when braking, it indicates that the left wheel is braking slowly or lacks braking force; on the contrary, it indicates that the right wheel is braking slowly or lacks braking force.

If it is determined that a wheel is slow to brake or lack of braking force, check whether the brake pipeline of the wheel is collided or leaked. If so, the reason should be found and removed. If the wheel pipeline is intact, the wheel pump can be exhausted. If the phenomenon of braking deviation is eliminated after exhaust, it indicates that there is air resistance in the wheel cylinder or pipeline. If there is no air resistance, you should check and adjust the gap between the wheel friction plate and the brake hub.

If there is no doubt about the above check, it is stated that the problem is inside the wheel brake, the wheel brake should be disassembled and inspected, and the wear of the brake pads and the operation of the brake cylinder should be checked, and repaired or replaced if necessary.

4. Brake drag
This problem is manifested in that after the brake pedal is raised, the braking of all or a single wheel cannot be completely eliminated immediately, which affects the electric forklift from starting or moving from the beginning. The diagnosis and solutions to this problem are as follows:

After operating the electric forklift for a period of time, touch the brake hub of each wheel by hand. If the brake hubs of all wheels are hot, it means that the problem is in the brake master cylinder; if a single wheel is hot, it means that the problem is in the wheel brake.
If it is judged that the problem part is in the master cylinder, the free stroke of the pedal should be checked first. If the free stroke does not meet the requirements, the pedal free stroke should be adjusted according to the rules; if the free stroke meets the requirements, the cover of the oil storage chamber of the master cylinder can be opened to investigate the oil return of the master cylinder, if the oil cannot be returned or the oil return is slow , The master cylinder should be disassembled for maintenance and replaced if necessary.
If the problem is with the wheel brakes, loosen the vent screw first. If the brake fluid is sprayed out quickly and the brake shoes return, the pipeline is blocked and the pipeline should be cleared; if the brake shoes cannot return, the gap between the brake pads and brake hubs should be adjusted.

If none of the above inspections and adjustments have any effect, the brake hub should be removed, and the condition of the cylinder piston seal, return spring and brake shoe pin should be checked, and repair and replacement should be carried out if necessary.

HITOP forklift is a high-tech enterprise specializing in manufacturing safety forklifts and transportation equipment. Main business: electric forklifts, diesel forklifts, pallet trucks, stackers, etc. The annual output of forklifts is as high as 20,000, the introduction of international advanced production equipment, and the factory inspection process is as high as hundreds of times.
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