Noblelift Fe4p40n User manual

WARNING

Do not use the forklift before reading and understanding the operating

instructions as well as the waring decals on the truck.

Keep for future reference.

FE4P40N, FE4P45N, FE4P50N

Operation and maintenance manual

FEXP type

battery counterbalanced forklift truck

NOBLELIFT INTELLIGENT EQUIPMENT CO.,LTD.

Catalogue

Forward ………………………………………………………………………………………………………

Chapter one Attention when using the forklift truck …………………………………………………

1、Transportation for forklift………………………………………………………………………………

2、Deposit……………………………………………………………………………………………………

3、Preparation before use…………………………………………………………………………………

4、Operation of truck………………………………………………………………………………………

5、Battery charging…………………………………………………………………………………………

Chapter two The main performance parameters of forklift truck ……………………………………

Ⅰ、The truck’s outline dimension and performance parameters ………………………………………

1.The truck’s outline dimension …………………………………………………………………………

2. Technical data …………………………………………………………………………………………

Ⅱ、The construction，principle and adjustment of the truck’s main parts……………………………

1．Drive system …………………………………………………………………………………………

1.1 Drive system (single wheel drive)…………………………………………………………………

1.2 Drive system (double wheel drive)…………………………………………………………………

2．Brake system …………………………………………………………………………………………

2.1 Summarize …………………………………………………………………………………………

2.2 Brake paddle…………………………………………………………………………………………

2.3 Brake base pump ……………………………………………………………………………………

2.4 Brake staff……………………………………………………………………………………………

2.5 Parking brake operating device ……………………………………………………………………

2.6 Gist of dismantlement and regulating for brake staff ……………………………………………

2.7Adjusting for Brake pedal …………………………………………………………………………

2.8 Malfunction and cause .……………………………………………………………………………

2.9 Maintenance …………………………………………………………………………………………

3．Steering system ……………………………………………………………………………………

3.1 Summary ……………………………………………………………………………………………

3.2 Full Hydraulic cycloid redirector ……………………………………………………………………

3.3 Steering axle …………………………………………………………………………………………

3.4 Gist for adjustment and maintenance………………………………………………………………

3.5 Inspection after rebuilding of steering system ……………………………………………………

3.6 Diagnose of steering system ………………………………………………………………………

4．Electrical system ……………………………………………………………………………………

4.1 Electronic control assembly（Inmotion）…………………………………………………………

5．Battery …………………………………………………………………………………………………

5.1 Battery safety requirements ………………………………………………………………………

5.2 Battery use requirements …………………………………………………………………………

5.3 Battery charging ……………………………………………………………………………………

5.4 Installation and replacement of battery……………………………………………………

6．Hydraulic system ……………………………………………………………………………………

6.1 Sumarry ………………………………………………………………………………………………

6.2 Oil pump ………………………………………………………………………………………………

6.3 Multiway valve ………………………………………………………………………………………

6.4 Lift cylinder and lift chains …………………………………………………………………………

6.5 Tilt cylinder …………………………………………………………………………………………

6.6 Hydraulic cylinder …………………………………………………………………………………

6.7 Hydraulic hose ………………………………………………………………………………………

6.8Maintenance and adjustment ………………………………………………………………………

6.9 Fault analysis…………………………………………………………………………………………

7．Lifting system…………………………………………………………………………………………

7.1 Summarize……………………………………………………………………………………………

7.2 Inner and outer mast ………………………………………………………………………………

7.3 Fork carriage …………………………………………………………………………………………

7.4 Roller position ………………………………………………………………………………………

7.5 Maintenanceandregulation …………………………………………………………………………

7.6 Instructionsofinstallingaccessaries ………………………………………………………………

8．Disassemblingandinstallation………………………………………………………………………

8.1 Attentions……………………………………………………………………………………………

8.2Hoistinglocationforpartsdisassembled……………………………………………………………

Chapter Three Operation,use and safety for forklift ……………………………………………………

Ⅰ、Driving and operation……………………………………………………………………………………

1．Usage of new vehicle…………………………………………………………………………………

2．Connection between load and stability ………………………………………………………………

3．Load center and load curve …………………………………………………………………………

4．Forklift stability …………………………………………………………………………………………

5．Transportingandloadingforforklift ……………………………………………………………………

6．Preparation before driving ……………………………………………………………………………

7．Steer……………………………………………………………………………………………………

8．Parking and temporary parking………………………………………………………………………

9．Usage of battery ………………………………………………………………………………………

10．Stacking………………………………………………………………………………………………

11．Unstacking……………………………………………………………………………………………

12．Deposit………………………………………………………………………………………………

Ⅱ、Using instruction ofoperatingdevices…………………………………………………………………

1．Components,schematicdiagramforoperatingdevices ………………………………………………

2．Instrument unit …………………………………………………………………………………………

3．Switches ………………………………………………………………………………………………

4．Control …………………………………………………………………………………………………

5．Bodywork ………………………………………………………………………………………………

Ⅲ、Safety issues……………………………………………………………………………………………

1Operation place and working environment ……………………………………………………………

2．Safety rules ……………………………………………………………………………………………

3．Truck’ s transportation …………………………………………………………………………………

4．Howtoavoidoverturning,howtoprotectyourself ………………………………………………………

5. Safety problem in Maintenance ………………………………………………………………………

6．Safety problem in battery usage ………………………………………………………………………

7．Plate ……………………………………………………………………………………………………

Chapter four Truck’s regular check and maintenance …………………………………………………

Ⅰ、The check before operation……………………………………………………………………………

1.Checkingpointandcheckingcontent ……………………………………………………………………

2. Checking procedure ……………………………………………………………………………………

Ⅱ、Check after operation…………………………………………………………………………………

Ⅲ、Truck cleaning……………………………………………………………………………………………

1. Truck surface cleaning ………………………………………………………………………………

2. Chains cleaning…………………………………………………………………………………………

3. Electric system cleaning ………………………………………………………………………………

4.After cleaning …………………………………………………………………………………………

Ⅳ、Regular maintenance……………………………………………………………………………………

1.Regularmaintenanceschedule …………………………………………………………………………

2.Regular replacement of key safety parts ……………………………………………………………

103

Ⅴ、Area lubricated and lubricant recommended…………………………………………………………

104

1.Area lubricated …………………………………………………………………………………………

104

2.Lubricant recommended………………………………………………………………………………

104

Forward

This manual briefly introduces the technical parameters as well as the construction,working

principle and the requirements in operation and the maintenance of each main part of the

four-wheel battery counter-balanced forklift truck of our company.Before operation,please read the

manual carefully to ensure safe and efficient load portage by correct operation and

maintenance,and to help the operator to use the battery forklift truck properly so as to make full

use of it.It is hoped that the operator and the facility manager read the manual carefully before

operation!Please perform strictly according to the attention matters in this manual,drive

coutiously,operate carefully,use meticulously.Always make your forklift truck be in the best

situation and make full use of it,When lending or assigning the forklift,please bind this manual with

it. To illuminate particularly,the following titles are used in this manual:

1. ---- Regulations that you need to pay attention and have to comply with before operation,if

not do so,it should lead to injury on human or damage on equipments and fire.

2. ---- Regulations that you need to pay attention and have to comply with before

operation,if not do so,it should lead to damage on equipments or some sort of injury on human.

3. ---- Something that you have to pay attention before operation.

The majority of materials that consists of the equipment can be completely recycled. During

working,repairing,maintenance and cleaning,there are waste materials have to be collecting and

disposing in friendly-environment way under the rules of local government.professional experts

must be necessary for dealing with these waste materials（such as hydraulic fluid,old battery

andelectronic devices ）at a specified area,otherwise,the negative effect may harm the

environment and human health.

Considering the demands of constantly developing and renewing the products.Manufacturer

reserves the right to modify our own products at any moment without notice or incurring in any

sanction.It is suggested to get contact with us if users want to know the up to date information of

the products.All the information reported herein is based on data at the moment of the publication

of the manual.

Chapter one Attentions when using the forklift truck

The operator mast always keep in mind the principle of safety first.Conscientiously and

cautiously read the maintenance manual.Undergo safe operate and canonical operate strictly

following the demand in this manual

1 Transportation for forklift

Pay attention to the following particulars when using container or automobile to convey forklift

truck

(1) Enable parking brake

(2) Fasten mast and counterweight with steel wire in both two sides;Chock with wedge the

front and rear wheels at propor site

(3) Hoist Lift the forklift according to indication on lifting plate

2 Deposit

(1) Lower the mast to the lowest position

(2) Switch off power,Push all the operating rod to vacancy;Pull out power plug

(3) Stretch hand brake rod

(4) Chock with wedge front and rear wheels

(5)When truck is in long-term non-use.Wheels should be overhead.And battery should be

boost charged once a month

3 Preparation before use

(1) Check up all the meters

(2) Check up tire pressure

(3) Check up the state of each handle and pedal

(4) Check up if the voltage of battery is in operating range;and weather the specific density of

electrolyte and the altitude of liquid surface are in order

(5) Check up if the contact of each connector and plug of electrical system is ok

(6) Check up if the hydraulic liquid,electrolyte or brake fluid is leaking

(7) Check up the condition of each main fastener

(8) Check up if the illuminators,signal lamps are in order

(9) Loosen parking brake

(10) Try to lift and lower the mast,tilt forward and backward the mast,turn and brake the truck

(11) Be sure that the polluting level of hydraulic oil is less than 12grade

4 Operation of truck

(1) Only can the person operate the truck who has been trained and got driver’s license

(2) Operator should wear safe protective shoes,cap,costume in his operation

(3) Pay attention to the performance and working conditions of mechanics,hydraulic,electrical

and MOSFET governor when operating

(4) Switch on the power,turn on the key,select the position of direction switch,roll the steering

wheel to see if the truck is in order,step down the governor pedal slowly,keeping a proper starting

acceleration

(5) Check the voltage meter when the truck is in working,if the value stated in the meter is less

than 41V（72V）,stop working immediately,charge the battery or change another fully charged

battery

(6) When conveying,the load should not exceed the rated capacity.The separation and

position of forks should be appropriate,insert the forks absolutely downside the load,make the load

uniformly distributed on the forks;to prevent load from deviation

(7) When the distance between the load’ gravity center and yoke is equal or less than

500mm.The maximum load capacity should be the rated capacity,and when the distance between

the load’ gravity center and yoke is more than 500mm;the maximum load capacity should be less

than the rated capacity

(8) When forks is bearing load,tilt backwards mast mostly,the yoke should always contact with

load;lift forks upto 200mm high from ground before driving

(9) No standing under forks,no standing on forks when lifting

(10) The starting speed should not be too fast when starting to lift and lower the load

(11) No operation of truck and it’s additions without sitting on the driver’s seat

(12) Push handle immediately to middle position when the mast has tilted forward or

backward to the extreme position

(13) No driving or turning when the mast is lifting

(14) When travelling,pay attention to passers by,obstacles,irregular road and the clearance of

upper side of forklift

(15) Be careful of travelling on slope,when the angle of slope is more than10%,travel forward

upslope and travel backward downslope. no turning on slope,no loading or unloading when

travelling downslope

（16）Reduce speedwhen turning on the damp or slick road,take special care and drive slowly

when travelling on dock or on temporary board

(17) Operating high lift range truck of which the lifting height is more than 3m,pay attention to

the dropping of the load,and take measures to prevent it when necessary

(18) Don’t convey unfastened or loosely stacked load,be caref when conveying large-size

load(19) When travelling with load,avoid emergency brake

(20) When leaving the truck,lower the forks to ground;push lever to free position,switch off

power,when parking on the slope,pull tight the brake apparatus and plug the wheels with wedge if

the parking time is long

(21) The protection valves on multiway valve and on steering device are already regulated,so

the users shouldn’t regulate randomly when using to prevent that the excessively high oil pressure

leads to the damage of the whole hydraulic system and the burnout of the electric motor

(22) Charge the tyres according to the pressure value stated in “tire pressure” indication

(23) Treat the operation of non-load truck with additional apparatus as the operation load

truck

5 Battery charging

(1) In the first time of charging or boost charging of battery,act strictly according to the rules

stated in battery specification

(2) When the truck is in working,and when the battery voltage drops to 41V（72V）or any one

of the cells voltage drops to 1.7V or the meter alarms,stop working immediately,charge the battery

or change another fully charged battery

(3) Inspect at any moment the density,the level and the temperature of electrolyte when

charge the battery

(4) Charge the battery at once after use of the truck,the storage period should be less than

24h;in order not to damage the battery,prevent under charging or over charging of the battery

(5) In order to adjust the density of each cell,make a equalizing charge of the battery in

regular service once a month,please refer to the related chapter to get the details of the charging

method and usage maintenance

Chapter two The main performance parameters of forklift truck

Ⅰ、The truck’s outline dimension and performance parameters

1. The truck’s outline dimension see figure 1-1

Figure 1-1 outline

2.Technical data

2.1 FE4D40-50 Technical data(Single wheel drive)（list 1-1）

Model number

FE4D40

FE4D45

FE4D50

specifications

Drive mode:

Electromotion

Operation mode:

Seat-driving pattern

Rated capacity Q(kg)

4000

4500

5000

Load center distance C(mm)

500

Load distance x(mm)

563

Wheelbase y(mm)

1900

Service weight including battery kg

6680

6950

7290

Axle loading,laden front/rear kg

9420/1260

10210/1240

11060/1230

Axle loading,unladen front/rear kg

3080/3600

3140/3810

3240/4050

Tyres size,front

250-15

Tyres size,rear

21X8-9

Track width,front b10(mm)

1200

Track width,rear b11(mm)

1040

Mask/fork carriage tilt foreward/backward

α/β(°)

6/10

Lowered mast height h1(mm)

2260

Freelift height h2(mm)

150

Lift height h3(mm)

3000

Extended mast height h4(mm)

4117

Overhead load guard height h6(mm)

2265

Seat height h7(mm)

1200

Traction pin height h10(mm)

490

Overall length l1(mm)

3962

Length to face of forks l2(mm)

2892

Overall width b1(mm)

1450

Fork dimensions s/e/l(mm)

50/150/1070

Fork carriage width b3(mm)

1380

Ground distance,centre of wheelbase

m2(mm)

165

Turning radius Wa(mm)

2560

Travel speed,laden/unladen km/h

14/15

13/14

Lift speed,laden/unladen m/s

0.32/0.48

0.29/0.44

0.25/0.44

lowering speed,laden/unladen m/s

0.40/0.35

0.42/0.35

0.45/0.35

Drawbar pull,laden/unladen S2

5minute %

16/20

15/20

Drive motor rating S260min kw

16.6

lift motor rating S3 15% kw

13.5X2

battery voltage,nominal capacity K5

v/A.h

80/630

80/650

battery weight kg

1740

1840

working pressure of attachments

MPa

14.5

oil volume for attachment l/m

2.2 FE4D40-50 Technical data (Double wheel drive)（list 1-2）

Model number

FE4D40

FE4D45

FE4D50

specifications

Drive mode:

Electromotion

Operation mode:

Seat-driving pattern

Seat-driving

pattern

Rated capacity Q(kg)

4000

4500

5000

Load center distance C(mm)

500

Load distance x(mm)

563

Wheelbase y(mm)

1900

Service weight including battery kg

6680

6950

7290

Axle loading,laden front/rear kg

9420/1260

10210/1240

11060/1230

Axle loading,unladen front/rear kg

3080/3600

3140/3810

3240/4050

Tyres size,front

250-15

Tyres size,rear

21X8-9

Track width,front b10(mm)

1200

Track width,rear b11(mm)

1040

Mask/fork carriage tilt foreward/backward

α/β(°)

6/10

Lowered mast height h1(mm)

2260

Freelift height h2(mm)

150

Lift height h3(mm)

3000

Extended mast height h4(mm)

4117

Overhead load guard height h6(mm)

2265

Seat height h7(mm)

1200

Traction pin height h10(mm)

490

Overall length l1(mm)

3962

Length to face of forks l2(mm)

2892

Overall width b1(mm)

1450

Fork dimensions s/e/l(mm)

50/150/1070

Fork carriage width b3(mm)

1380

Ground distance,centre of wheelbase

m2(mm)

165

Turning radius Wa(mm)

2560

Travel speed,laden/unladen km/h

14/15

13/14

Lift speed,laden/unladen m/s

0.32/0.48

0.29/0.44

0.25/0.44

lowering speed,laden/unladen m/s

0.40/0.35

0.42/0.35

0.45/0.35

Drawbar pull,laden/unladen S2 5

minute %

16/20

15/20

Drive motor rating S260min kw

11X2

lift motor rating S3 15% kw

13.5X2

battery voltage,nominal capacity K5

v/A.h

80/630

80/650

battery weight kg

1740

1840

working pressure of attachments

MPa

14.5

oil volume for attachment l/m

Ⅱ、The construction,principle and adjustment of the truck’s main parts

1. Drive system :There are two configurations for the drive system: the front single-wheel drive

and the front two-wheel drive.

1.1 Drive system(Single wheel drive)

1.1.1 Summarize

The drive system consists of gear box assembly, differential mechanism assembly and drive

axle, the reducer drive gear connects directly to drive motor.The travel speed increases with the

increment of rotational speed of drive motor, And when the rotational direction of the motor

changes, the travel direction changes too.

1.1.2 Reducer casing and differential mechanism

Reducer,of which the two pairs of column screw gear make the rotational speed decline of the

output axis of travel motor and make the twist moment rise from travel motor,and then send the

twist moment to differential,lies between drive axle and travel motor,see figure 2-1

1. differential assembly

2.bolt

3. locking plate

4. bearing block

5. bearing

6. Adjusting pad

7. O-ring

8. bolt

9. spring washer

10. bearing cap

11. grease seal

12. bead flange

13. taper bolt

14. bearing

15. bearing

16. input axis

17. bearing

18. duplicate gear

19. bearing

20. paper washer

21. tank cover

22. bolt

23. spring washer

24. bolt

25. stop dog

26. bolt

27. O-ring

28. axle

29. gear shaft

30. box

Figure 2-1 Reducer

Differential mechanism, of which the front connects to axle shell,is installed on the front-half

shell by the bearing block in on two sides. The shell of the differential is left-right subdivision in

construction,and there are two half axle gears and four planet gears in it.see figure 2-2

1. bearing

2. bolt

3. Right differential housing

4. cushion ring

5. half axle gear

6. thrust washer

7. epicyclic gear

8. cross axle

9. Gasket or washer

10. nut

11. Left differential case

12. lock washer

13. gear ring

14. bolt

Figure 2-2 Differential mechanism

1.1.3 Drive axle

The drive axle consists of axle shell,wheel hub and arrester. It is installed in the front of

framework

The shell is unit casted in construction,the tyres are fastened on wheel hub with studs and

nuts,wheel hub is supported on axle shell by conical roller bearing,power is delivered by

differential to differential axle by differential,wheel hub which drives front wheel to rotate is drived

by differential axle.Differential shaft only bears the twisted moment delivered to wheel hub.There

are seals inside left wheel hub to prevent water and dust or oil leakage installed in wheel hub.

see figure 2-3

1. Half shaft bolt

2. left half axle

3. gland

5. lockwasher 80

6. Bridge housing assembly

7. breather plug

4. nut M80X2

8. stop up

9. Right half axis

10. Right brake assembly

11. hub nut

12. Bolted post

13. nut M20X1.5

14. gasket

15. grease seal

16. bearing

17. wheel boss

18. bearing

19. oil seal collar

20. oil seal

21. brake drum

22. Left brake assembly

23. Brake hexagonal bolt

24. Brake hexagonal bolt

Figure 2-3 Drive axle

1.1.4 Installation of wheel hub

(1) Fill the wheel hub with 100ml grease,and then fix it on the axle.see figure 2-4.

(2) Screw up adjust nuts with 9.8N.m of twist moment,then reverse them 1/2 coil

(3) Hang the weighter on the bolt to measure the starting moment of the wheel hub,when it

reachs the defined value,start to screw up the nut.

starting moment:：49N·m－147N·m。（ figure 2-5）

fgure 2-4 injection of grease figure 2-5 measurement of starting moment

(4) Install lock plate and lock nut, and cock up lock plate to stop nut

(5) Tyre assembly（figure 2-6）

Fix gas pole and nut cap upon tyre,and assemble wheel rib pay attention to the following

items:

Attention:

(a) Gas pole lies in the gap of the wheel rib

(b) Wheel rib bolts should be installed toward outside

1.rim

2. tyre

figure 2-6 tyre assemble

1.1.5 Malfunction analysis

List 2-2 malfunction diagnose and adjustment

malfunction

items

possible reason

adjusting method

shake a lot

the fastening bolts loosen

Tighten

Too high of

oil

temperature

gear oil deteriorates

replacing

Un usual Oil level

Supplying or reducing

Clamping stagnation of moving parts

adjustment

oil leak

Contacting surface bolts loose

tighten

seal packing rings worn

replacing

noise

gear damages

replacing

bearing damages

replacing

1.2 Transmission system(Double wheel drive)

1.2.1 Overview

The transmission system of forklift is composed of two reduction gearbox assembly and two

travel motors. Driving gear of decelerator is connected directly with the travel motor, so the driving

speed of forklift increases with the increase of motor speed and the driving direction can be

changed by changing the direction of motor rotation.

1.2-1 Reduction gearbox assembly

Located at frame, One end of Transmission is linked with travel motor, the other end

installation tire. See figure 2-1

1. Wheel hub

2. Wheel fixing screw

3. Needle cage

4. Shaft seal

5. Taper Roll. Bearing

6. Set-Right Spacer

7. Spacer

8. Breather plug

9. Socket head cap screw

10. Socket head cap screw

11. Socket head cap screw

12. Housing

13. Screw Plug

14. Magnetic Screw Plug

15. Locking pin

16. Needle cage

17. Taper Roll. Bearing

18. Retaining ring

19. Ring-gear carrier disc

20. Ring gear

21. Stud

22. Washer

23. Hexnut

24. Planet carrier

25. Retaining ring

26. Planet gear

27. Roller bearing

28. Retaining ring

29. Locknut

30. Retaining ring

31. Helix gear

32. Retaining ring

33. Ball bearing

34. Cover

35. Helix pinion

36. Ball bearing

37. Retaining ring

38. Retaining ring

39. Locking pin

40. Sun pinion

41. Feather key

42. Lever

43. Elastic pin

44. Pin

45. Socket head cap screw

46. Screw Plug

47. Cover

48. Seal

49. Washer

50. Connection

51. Bleeding valve cap

52. Bleeding valve

53. Basket

54. Basket

55. Piston

56. Elastic disc

57. Disk Pusher

58. Friction disk

59. Steel disk

60. Support disk

61. Retaining ring

62. Locking pin

63. Spring

64. Stud

65. Spring

Figure 2-7 Decelerator

1.2.2 Care and maintenance

○,1 Before conducting running-in test of the gear box, users shall fill in gear oil (gear oil

shall be selected in accordance with the instructions. Please refer to Table 2-1 for the specific

requirements). Fill oil into the hole at top of the axle shell until oil is spilled out of the oil level hole

in central axle.

○,2 It is necessary to check every 2000 working hours that the stroke of the brake piston is

not over 3.5 mm, otherwise it is necessary to replace the brake disk to avoid accidents.

○,3 Check all the fasteners each 50 working hours . If any looseness is found, tighten it

immediately.

○,4 Check the wheel axle and wheel hub connection each 50 working hours for any oil

leakage. Re-apply sealant if any leakage is found.

○,5Check if the oil level in the gear box meets standards. If the oil level reduces, users

should promptly fill up

○,6 Oil in the gear box should be changed every 1000 working hours.

○,7 Annual technical maintenance: Disassemble the drive axle for inspection every year.

○,8Check and debug requirements during the installation process:

2. Brake system

2.1 Summarize

Brake system,Being Two-front-wheel internal expansion oil pump type,consists of brake

paddle,brake base pump and wheel brake staff

2.2 Brake paddle

The construction of brake paddle is illustrated in figure 2-7.The paddle transfers the stamp

force exerted by the pushing rod of brake base pump into the pressure of brake oil

1. brake oil cup

2. brake support

3. brake sensor

4. bolt

5. brake pedal

6. brake pump

figure 2-7 brake paddle assembly

2.3 Brake base pump（figure 2-8）

Base pump consists of a valve support,a one-way-valve,a rebound spring and base leather

cup,piston,assistant leather cup.The end of the base pump is fixed with lock washer and lock steel

wire,And the outside of it is protected with rubber dust preventing cover.The base pump works

under the assistance of pushing rod by operating brake paddle,Step down the brake paddle,the

rod pushs the piston,the brake fluid flow back to oilcan through oil return hole until the base leather

cup plugs the oil return hole.After the base leather cup push over the oil return hole,the brake fluid

of the front cavity of base pump is compressed and open the one way valve and through brake

pipeline flow into subsidiary pump.Then,the piston of each subsidiary pump pushes out to make

the brake shoe wearing piece get contact with the brake drum,and finally stop the truck or make it

slowdown. Now,the back cavity is supplied with the fluid by the brake fluid from oil return hole and

oil-in hole.Release the brake paddle,the piston is push backward by the brake shoe rebound

spring,at the same time,the brake fluid in each subsidiary brake pump is compressed by the

rebound spring.Which makes the brake fluid flow back to base pump through one way valve,the

piston returns back to initial position,the brake fluid in base pump flow back to oilcan through oil

return hole,one way valve pressure is adjusted in proportion to the residual pressure in brake

pipeline and subsidiary brake pump,the leather cups in subsidiary pump should be placed

correctly to prevent oil leaking and the case of air resistance which possibly occurs in emergency

brake.

1.latch nut

2.pushing rod

3.antidust cover

4.locking steel

wire

5.locking

washer

6.assistant

leather cup

7.piston

8.base leather

cup

9.spring

10.cheak valve

11.valve

supporter

12.pump body

figure 2-8 base brake pump

2.4 Brake

The brake staff adopted is two shoe brake installed in the two sides of drive axle.The brake

staff consists of two groups of brake shoes,subsidiary brake pumps and regulators,one end of the

brake shoe,which holds back the parking brake parts through rebound spring and Pressure

spring,contacts with fixing pin and another end of it contacts with regulator,In addition,there are

brake packing device and automatic regulating device assembled on brake staff. See figure 2-9

1.brake baseplate

assembly

2.clearance

adjuster

3.friction plate

assembly

4.washer

5.pull rod

6. spring

7.washer

8.push rod

9. spring

10.push rod

11.spring

12.adjusting lever

13. spring seat

14. spring

15. spring cap

16. spring

17. spring seat

18.pull rod

19.pin

20. washer

21.rubber plug

22.brake cable

assembly

23.bolt M8×16

24.washer 8

25.cylinder

26. protective

cover

27.piston rod

28.piston

29.ceal cup

30.spring

31.oil plug

32.screw

33.protective cover

34.dust cover

figure 2-9 brake stuff

(1) Motion of brake stuff

The brake drum is pressed by the leading brake shoe and the secondary brake shoe with the

same force from subsidiary brake pump,when the top side of the brake shoe is stopped by the

fixed pin,the brake shoe will move toward brake drum until being stopped by the fixed pin,then the

friction between wearing piece and brake drum will increase. As the pressure the leading brake

shoe exerted on the secondary brake shoe is much larger than the subsidiary pump

pressure.Tthere will occur a quite large brake force. see figure 2-10

When driving backward,the brake stuff works in reverse to it when drives forward.

see figure 2-11

figure 2-10 motion when driving forward figure 2-11 motion when driving backward

(2) parking brake

The parking brake device which consists of pulling rod and pushing rod is assembled in wheel

brake stuff. The pulling rod,of which the action is transported to the side of secondary brake

shoe,is installed on the side of leading brake shoe.See figure2-12

(3) gap-self-regulating device

Gap-self-regulating device can keep a proper gap between wearing piece and brake drum,it

works only when driving backward.see figure 2-13.

figure 2-12 parking brake figure 2-13 gap-self-regulating device

(4) Motion of gap-self-regulating device

Brake the truck when driving backward,the secondary brake shoe gets contact to and roll

together with the leading brake shoe,making pulling rod rotating rightward around point A,see

figure 2-13,and B point rises. After the release of brake,pulling rod turns left under the force of

spring,Bpoint descending.with the increasing of the gap between wearing piece and brake

1.pin

2.pull rod

3.active

hoof

1.adjusting

mechanism

2.spring

3.dragline

4.driven

hoof

5.jackstay

4.guide alot

5.pull

rod

Active hoof

Driven hoof

Active hoof

Driven hoof

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