Common Fault Analysis and Improvement Suggestions for Pneumatic Balance Device (Pneumatic Shock Absorber System) of Hydraulic Forklift

1、 Common fault types and cause analysis

Lifting failure (unable to lift or lifting slowly)

Equipment aging: Long term use can cause wear and tear on internal parts of the lifting equipment (such as oil seals and piston rings), or hydraulic oil leakage, which can hinder power transmission.

Collaborative failure of components: spring elasticity attenuation, top rubber aging, dust cover damage, resulting in obstructed expansion and contraction of shock absorbers or sealing failure.

Poor system coordination: The overall performance of the pneumatic shock absorption system decreases, such as failure of air pressure control or electronic control system, which affects the dynamic adjustment ability.

Oil leakage and abnormal noise

Sealing failure: Wear or improper installation of oil seals and gaskets can cause hydraulic oil leakage, accompanied by "tear like" oil stains.

Damping reduction: The internal valve body of the shock absorber is worn or the hydraulic oil is insufficient, resulting in a metallic impact sound or "thud" sound during movement.

Loose components: Loose nuts at the end of the piston rod and aging support rubber pads can cause abnormal noise and potentially damage other components.

Performance degradation (poor shock absorption effect)

Hydraulic oil contamination: Oil deterioration or impurities entering the system can cause damping force attenuation and increase the frequency of vehicle vibration.

Abnormal tire pressure: High or low tire pressure affects the shock absorption effect, and the tire cushioning capacity decreases in a state of low air pressure.

Suspension system wear: components such as springs and swing arms are aging, with insufficient support, exacerbating body vibration.

2、 Improvement suggestions and solutions

Targeted maintenance and component replacement

Oil leakage treatment: Check the wear of oil seals and gaskets, replace seals and replenish hydraulic oil; If the oil leakage is severe, repair the damping valve or replace the shock absorber assembly.

Eliminating abnormal noise: tighten the piston rod nut and replace the aging support rubber gasket; Check if the top glue and dust cover are damaged and replace them in a timely manner.

Performance recovery: For shock absorbers with spring elastic attenuation, match new springs or replace high-performance shock absorbers (such as adjustable damping type).

System upgrade and optimization

Replace high-quality assemblies: Choose shock absorber assemblies from brands such as LEACREE to solve oil leakage and abnormal noise problems, and improve driving stability.

Maintenance of air pressure control system: Regularly check the sealing of air pressure sensors and air storage tanks to ensure normal dynamic adjustment function.

Calibration of electronic control system: Software upgrade or parameter adjustment of intelligent electronic control system to optimize shock absorption response speed.

Operation and maintenance standards

Regular inspection: Check the appearance and oil leakage of the shock absorber every 20000 kilometers, and conduct professional performance tests (such as damping curve testing) every 50000 kilometers.

Adjustment of driving habits: Avoid passing through deep pits or speed bumps at high speeds, and reduce the impact load of shock absorbers under extreme working conditions.

Environmental protection: Vehicles driving in saline alkali areas should undergo chassis rust prevention treatment every 3 years to extend the lifespan of rubber components.

Cost benefit optimization

Graded maintenance strategy:

Mild malfunction (such as minor oil leakage): Replace the oil seal, replenish the oil, and temporarily postpone the replacement of the assembly.

Moderate faults (such as obvious oil leakage and body vibration): Replace the shock absorbers within 6 months and check the suspension system synchronously.

Severe faults (such as complete oil leakage, brake nodding): Immediately replace the shock absorber and collaborative components (such as springs, top rubber).

Component selection: Prioritize the use of original factory accessories (such as Toyota TRD, KYB) or internationally certified parts (such as Muno, Sachs) to balance performance and cost.

3、 Preventive maintenance recommendations

Establish a maintenance loop: Through the process of "symptom recognition (such as continuous vibration, oil leakage) → regular self inspection (such as observing rebound by pressing the car body) → professional inspection", potential problems can be detected in advance.

Technical upgrade: Consider installing shock-absorbing buffer adhesive or upgrading to adjustable damping shock absorbers (such as BILSTEIN B12 series) to balance comfort and handling.

Training and recording: Train operators on fault phenomena and handling methods, establish maintenance records, track the service life and fault patterns of shock absorbers.

The main equipment produced by Hebei Makita: stage electric hoist, electric chian hoist, wire rope electric hoist，Hand chain hoist, lever hoist, pneumatic hoist and other lifting equipment