Brake performance is critical to forklift safety. Brake failure, soft braking, or unstable stopping often lead to collisions, rollovers, and cargo damage. This case analyzes a typical forklift braking fault and provides practical maintenance methods.
A diesel forklift used in a factory warehouse experienced poor braking effect: the braking distance was significantly longer, the brake pedal felt soft, and the braking force was insufficient, especially when carrying heavy loads. The driver reported that the problem became more obvious after long-term continuous operation.
Maintenance personnel first checked the brake fluid level and found it was below the minimum mark, with signs of fluid leakage at the wheel brake cylinders. Further inspection confirmed that the brake cylinder seals were aging and damaged, causing brake fluid leakage and air entering the brake pipeline, resulting in ineffective braking. In addition, the brake pads were severely worn, and the brake disc surface was uneven, which further reduced braking efficiency.
The repair process included replacing the damaged wheel brake cylinders and oil seals, replenishing qualified brake fluid, exhausting air from the entire brake pipeline to ensure no bubbles remained, replacing worn brake pads, and polishing or replacing the brake disc as needed. After adjustment, the forklift underwent multiple no-load and heavy-load braking tests.
The braking response returned to sensitivity, the braking distance was shortened to the standard range, and the fault was completely eliminated. To ensure long-term safe use, daily inspections should include checking brake fluid level, observing for oil leakage, monitoring brake pad wear, and regularly draining air from the brake system. Operators should report abnormal braking immediately to avoid safety accidents.
