Noblelift N Series Manual

FE3R16-SMS-001
Warning
Operators should read and understand
this manual and all warning labels on
the forklift before using the forklift!
Keep the manual for future reference!
Operation & Maintenance Manual
FE3R16 N/E SERIES
Battery Counterbalanced Forklift Truck
NOBLELIFT INTELLIGENT EQUIPMENT CO.,LTD.

1
Table of Contents
Introduction……………………………………………………………………………………………
4
Chapter 1 Precautions of using forklift……………………………………………………………
5
Ⅰ. Forklift transportation.......................................................................................................
5
Ⅱ. Forklift storage.................................................................................................................
5
Ⅲ. Pre-use preparation.........................................................................................................
5
Ⅳ. Operation of the forklift....................................................................................................
5
Ⅴ. Charging of accumulator cells.........................................................................................
6
Chapter 2 Structure and main performance parameters of the forklift…………………………
7
Ⅰ. Overall Dimension and Technical Parameters................................................................
7
1. Overall dimension..........................................................................................................
7
2 Technical Parameters.....................................................................................................
8
Ⅱ. Structure, principle and adjustment of the main components.........................................
9
1. Driving & Operation.......................................................................................................
9
1.1 Overview....................................................................................................................
9
1.2 Trouble shooting........................................................................................................
10
2. Braking system..............................................................................................................
10
2.1 Overview....................................................................................................................
10
2.2 Brake pedal ...............................................................................................................
10
2.3. Brake master cylinder...............................................................................................
11
2.4. Brake ........................................................................................................................
12
2.5 Device for parking brake control ...............................................................................
13
2.6 Technical points for brake disassembly and adjustment.........................................
14
2.7 Adjustment of brake pedal .......................................................................................
17
2.8 Troubleshooting.........................................................................................................
18
2.9. Maintenance.............................................................................................................
19
3 Steering system...........................................................................................................
20
3.1 Overview....................................................................................................................
20
3.2 Cycloid full hydraulic steering gear...........................................................................
20
3.3 hydraulic cycloid motor and rotary bearings .............................................................
21
3.4 Check of steering system after being re-installed.....................................................
22
3.5 Trouble shooting........................................................................................................
23
4 electrical system..........................................................................................................
23
4.1 Overview ..................................................................................................................
23
4.2 Electronic system ......................................................................................................
23
5．Accumulator……………………………………………………………………………………
28
5.1 Accumulator safety precautions…………………………………………………………
28
5.2 Accumulator use precautions……………………………………………………………
28
5.3 Charging of the accumulator………………………………………………………………
29
5.4 Installation and replacement of the accumulator………………………………………
31
6．Hydraulic system………………………………………………………………………………
32

2
6.1 Overview……………………………………………………………………………………
32
6.2 Oil pump……………………………………………………………………………………
32
6.3 Multi-way valve……………………………………………………………………………
32
6.4 Lifting cylinder and the lifting chain………………………………………………………
34
6.5 Governor valve……………………………………………………………………………
36
6.6 Tilt cylinder…………………………………………………………………………………
36
6.7 Hydraulic oil cylinder……………………………………………………………………
37
6.8 Maintenance and adjustment……………………………………………………………
37
6.9 Failure analysis…………………………………………………………………………
40
7．Lifting system…………………………………………………………………………………
41
7.1 Overview……………………………………………………………………………………
41
7.2 Inner and outer main frame………………………………………………………………
41
7.3 Fork frame…………………………………………………………………………………
42
7.4 Location of rollers…………………………………………………………………………
43
7.5 Maintenance and adjustment……………………………………………………………
44
7.6 Installation of accessories…………………………………………………………………
45
8．Removal and installation……………………………………………………………………
46
8.1 Precautions………………………………………………………………………………
46
8.2 Lifting points of the detached parts……………………………………………………
46
Chapter 3 0peration, use and safety of the forklift…………………………………………………
48
Ⅰ. Driving and operation......................................................................................................
48
1.Use of a new forklift........................................................................................................
48
2. The relationship between forklift stability and load.......................................................
48
3. Load centre and load curve...........................................................................................
48
4. Forklift stability...............................................................................................................
48
5.Transportation and handling of the forklift......................................................................
49
6. Preparation before driving.............................................................................................
49
7. Driving ...........................................................................................................................
50
8. Parking and temporary parking.....................................................................................
51
9. Use method of the accumulator....................................................................................
51
10. Stacking.......................................................................................................................
53
11. Un-stacking..................................................................................................................
53
12. Storage........................................................................................................................
54
Ⅱ. Operation device and use method ...............................................................................
55
1. Diagram on forklift parts and operation device .............................................................
55
2 Combination instrument.................................................................................................
55
3 Switches.......................................................................................................................
55
4 Controllers....................................................................................................................
56
5 Forklift body.................................................................................................................
59
Ⅲ.About safety.....................................................................................................................
60
1. Site and working environment of the forklift..................................................................
60

3
2. Safety rules....................................................................................................................
60
3 Handling of the forklift..................................................................................................
71
4 How to avoid rollover and how to protect yourself from accidents..............................
72
5 Safety issues during maintenance and protection......................................................
74
6 Safety during use of the accumulator..........................................................................
75
7 Signs............................................................................................................................
77
Chapter IV Periodic inspection and maintenance of forklift...................................................
78
Ⅰ. Check before operation...................................................................................................
78
1. Check points and contents............................................................................................
78
2. Check procedures.........................................................................................................
79
Ⅱ. Checking after operation ..............................................................................................
83
Ⅲ. Clean the forklift ..............................................................................................................
83
1. Clean the forklift surface ...............................................................................................
83
2. Clean the chain .............................................................................................................
83
3 Clean the electric system ............................................................................................
83
4 .After the cleaning..........................................................................................................
83
Ⅳ. Regular maintenance......................................................................................................
83
1. Regular maintenance schedule ....................................................................................
85
2. Replace critical safety components periodically...........................................................
93
Ⅴ. Lubricating parts and recommended oils........................................................................
94
1. Lubricating parts............................................................................................................
94
2. Recommended oils........................................................................................................
94
Ⅵ. Forklift noise and vibration parameters table................................................................
95

4
Introduction
This manual briefly describes the technical parameters of the counterbalanced accumulator
forklift made by our company, and the structure of its main components, working principle and
requirements on operation and maintenance. Please read this manual carefully before operation,
so as to achieve proper driving and maintenance, and to ensure safe and effective material
handling. Meanwhile, this manual aims to guide operators to use the forklift in an appropriate way
and to maximize its performance! We hope that operators and equipment managers could read it
carefully before use! Please strictly observe the provisions and cautions stipulated in this manual
and operate the forklift with caution and care, so that the forklift can be maintained in its best
status and optimal performance can be ensured. When you lease or transfer your forklift, always
keep this manual with it.
For highlighting purpose, the following icons are used in this manual:
1.----refers to a potential danger; if not avoided, it may cause serious human injury, vehicle
damage or fire.
2. ----refers to a potential danger; if not avoided，it may cause minor human injury, or local
damage to the vehicle.。
3. ----Refers to general cuations and instructions during use.
Most parts of the product are made from recyclable steel. The recycling and disposal of
cast-offs resulted during use, maintenance, cleaning and disassembling of the product has to
comply with local regulations without pollution to the environment. The recycling and disposal of
the cast-offs should only be operated by specialised personnel in the designated area. The
cast-offs, such as hydraulic oil, batteries and electronic units, if improperly disposed, may be
hazardous to the environment and human health.
Special Declaration:
1）This product is strictly prohibited for potentially explosive hazardous environments.
2）The Noise level of the normal use of this product is compliant with international
standards EN 12,053.
3）The vibration level of the normal use of the product is compliant with international
standards EN13059.
4）The normal use of the product's environmental requirements as follows: no more than
2000 meters above sea level and the temperature range of-5 °C—+40 °c, humidity should
no more than 90%, The wind speed is no more than 5m/s.
If you need to use in the freezer for a long time，Or in special environment, it is needed
to install special attachments. Please contact our technical staff.
5）Product recall serive is available when serial faulties occur.
Due to continuous product improvement, Nobleliftreserves the right to make changes in product
designs and specifications without prior notice. For the latest product parameters, please feel free
to contact us. All parameters provided herein are as of the publication date of the Instruction

5
Manual.

6
Chapter 1 Precautions of using forklift
Forklift drivers and managers must remember the principle of "safety first", and carefully read
this maintenance manual. Operators shall be in strict accordance with this manual to ensure safe
and normal operation.
Ⅰ. Forklift transportation
The following shall be noted when transporting forklift by container or trucks:
(1)Apply the parking brake;
(2) Fix the main frame and counterweight with steel wires, and use pads to wedge the
corresponding positions at the front and rear tires;
(3) Start lifting from the positions indicated by the "Craning Label" on the forklift.
ⅡStorage of the forklift
(1) Reduce the main frame to the lowest position;
(2) Turn off the electric lock, place the lever rod to the "Nertral" position and unplug the power
cord;
(3) Tighten the hand brake;
(4) Use pads to wedge the front and rear tires ;
(5) If the forklift is to be left unused for a long time, its wheels should be elevated. The
accumulator should be recharged once a month.
ⅢPre-use preparation
(1) Check if all instruments are normal;
(2) Check the tire pressure;
(3) Check the condition of the levers and pedals;
(4) Check if the accumulator voltage is within the working scope, and if the specific gracity of
the electrolyte and the height level of the liquid are appropriate;
(5) Check if the connectors and plug contacts of the electrical system are reliable;
(6) Check for leakage of the hydraulic fluid, electrolyte and brake fluid;
(7) Check the tightness of major fasteners;
(8) Check if the lighting and signal lamps are normal;
(9) Release the parking brake;
(10) Conduct test actions such as lifting and lowering the main frame, tilting forwards and
backwards, steering and braking;
(11) Contamination level of hydraulic oil shall not be greater than 12.
Ⅳ. Operation of the forklift
(1) Only trained and licensed drivers can drive the forklift;
(2) Operators shall wear security shoes, hats, clothing and gloves for protection purpose;
(3) Operators should note the performance and working conditions of mechanical, hydraulic,
electrical and MOSFET governor;
(4) Power on by switching on the key switch, choose the right position of direction switch, and
then rotate the steering wheel to see if the forklift can steer.
If ok, slowly depress the speed pedal and maintain an appropriate speed;
(5) Observe the voltage meter, if the voltage indicated by the voltage meter is below 41V
during working, immediately stop operation, and recharge the accumulator or replace with another
fully charged accumulator;
(6) Weight of loads handled should not exceed the specified value and fork spacing and
location should be appropriate. The fork should be fully inserted below all the goods, which shall
be uniformly distributed on the fork. Uneven loading shall be avoided;

7
(7) If the distance between loads‘ center of gravity and the fork arm is no more than 500mm, the
maximum load shall be the rated capacity. If the distance between loads‘ center of gravity and the fork
arm is more than 500mm, the maximum load shall be less than the rated capacity;
(8) When carrying loads, the main frame should tit backwards to the maximum extent and the
fork arm should be in contact with the goods. Raise the fork to about 200mm away from the
ground before driving;
(9) Standing under the fork and on the lifting fork are forbidden;
(10) The initial velocity should not be too fast when lifting and lowering goods;
(11) Never operate the forklift and accessories at places other than the driver's seat;
(12) When the main frame is moving forwards and backwards to the maximum extent, or
when the fork is lifted to its maximum height, the operator must rapidly set the lever to the neutral
position;
(13) When the main frame is lifting, driving or turning of the forklift is not allowed;
(14) When driving the forklift, drivers should pay attention to pedestrians, road obstacles and
potholes, and also note the gap above the forklift;
(15) Drivers should be very careful when driving on ramps. When driving on a ramp with slope
gradient more than one-tenth, do move forward for up-hilling and backward for down-hilling.
Never perform steering during up-hilling ad down-hilling process. And avoid loading and unloading
when the forklift is down-hilling;
(16) Slow down when steering on wet or slippery road surfaces; be very careful and drive
slowly when driving on docks or temporary boards;
(17) For forklifts with lifting height greater than 3 meters, users shall be careful to guard
against falling down of the goods overhead and take protective measures if necessary;
(18) Do not carry unfixed or loosely stacked goods and be careful when handling goods with
large size;
(19) When driving the forklift with load, emergency braking should be avoided;
(20) Before leaving the forklift, lower the fork down to the ground, set the lever at neutral
position and disconnect power. In case of parking on a ramp,
apply the parking brake. Use wedge pads to fix the wheels if you need to park for a long time;
(21) The safety valve pressures of multiple unit valve and steering device have been tuned up
before leaving the factory. During use, users
shall not adjust it, because excessive pressure may cause damage to the entire hydraulic system
or its components ,and the motor;
(22) Tire inflation pressure shall be in line with that stipulated on the "Air pressure" plate;
(23) When moving with no load, forklift with accessories shall be operated in a way as if
carrying a load.
Ⅴ. Charging of accumulator cells
(1) When charging the accumulator cells for the first time and further charging, users should
be in strict compliance with the instructions;
(2) When operating the forklift, if the accumulator voltage decreases to 41V, or that of its
single cell drops below l.7V , or the instrument alarms, users shall immediately stop using the
forklift and replace the accumulator or recharge it before further use;
(3) Check the specific gravity, liquid level and temperature of the electrolyte from time to time
during the charging process;
(4) Forklift must be recharged as soon as possible after use. Never leave the forklift
uncharged longer than 24 hours. When charging, pay attention to prevent
insufficient charging and over-charging, so as not to damage the battery;
(5) Users should conduct balanced recharging to the forklift in normal use once a month, so
as to adjust the proportion among the accumulator units.
Please refer to the relevant sections of this Mannual for detailed charging and maintenance
methods.

8
Chapter 2 Structure and main parameters of the forklift
Ⅰ. Overall size and performance parameters of the forklift
1. Overall dimensions (as shown in Figure 1-1 )

9
Figure 1-1 Overall dimension
2. Technical parameters (Table 1-1)
Features
1.2
Model No.
FE3R16E
FE3R16N
1.3
Driving Method: Electric (accumulator or power supply), diesel, petrol, LPG,
manual
Electric
Electric
1.4
Operation Method: Manual, travel, standing, seat, picking out
seat
seat
1.5
Nominal Load Capacity Q (kg)
1600
1600
1.6
Load Center Distance C (mm)
500
500
1.8
Fork Overhang x (mm)
340
340
1.9
Axial Distance y (mm)
1240
1240
Weight
2.1
Including accumulator (refer to 6.5) kg
2960
3000
2.2
Axle load with full load, front/rear kg
3980/580
4000/600
2.3
Axle load with empty load, front/rear kg
1260/1700
1280/1720
Body &
Wheel
3.2
Tires, front
18×7-8-14PR
457/178-308
3.3
Tires, rear
18×7-8
18×7-8
3.6
Tread, front b10 (mm)
822
822
3.7
Tread, rear b11(mm)
0
0
Basic Dimension
4.1
Mast/fork carriage tilt angle, forward/backward α/β(°)
3/5
3/5
4.2
Mast lowered height h1(mm)
1986
1986
4.3
Free lift height h2(mm)
105
105
4.4
Lift height h3(mm)
3000
3000
4.5
Mast extended height h4(mm)
3980
3980
4.7
Overhead guard height h6(mm)
2060
2060
4.8
Seat height h7(mm)
1050
1050
4.12
Towing pin height h10(mm)
570
570
4.19
Overall length l1(mm)
2785
2785
4.20
Body length (excluding fork) l2(mm)
1865
1865
4.21
Overall width b1/b2(mm)
1000
1000
4.22
Fork dimension s/e/l(mm)
35/100/920
35/100/920
4.24
Fork carriage width b3(mm)
980
980
4.31
Mast bottom ground clearance m1(mm)
92
92
4.32
Wheelbase center ground clearance m2(mm)
97
97
4.33
Aisle width, 1000X1200 tray (1200 across fork) Ast(mm)
3288
3288
4.35
Turning radius Wa(mm)
1520
1520
Performanc
e
Parameter
5.1
Traveling speed, full/empty km/h
10/11
10/11
5.2
Lifting speed, full/empty m/s
0.24/0.37
0.24/0.37
5.7
Gradeability, full/empty S230min %
10/13
10/13
Motor
6.1
Power of driving motor (S260 min) kw
5
5
6.2
Power of lifting motor (S3 15%) kw
8.6
8.6
6.4
Accumulator voltage/rated capacity K5 V/Ah
48/350
（48V/400）
48/350
（48V/400）
6.5
Accumulator weight kg
590
590
Others
8.1
Driving Control Type
AC
AC
8.2
Operation pressure for attachments MPa
16
16

10
Ⅱ.Structure, principle and adjustment of the forklift’s main components
1. Driving & Operation
1.1 Overview
The transmission system of forklift is composed of reduction gearbox assembly, differential
assembly and drive axle. 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. Gerotor motor
2. Motor
3.Pinion
4.Big gear wheel
5.Gear-box
6.Mounting panel
7. Plane bearing
8. Tyre
Figure 2-1 Driving & Operation
8.3
Attachment oil flow L/min
10
10
8.4
Noise level audible by driver, based on EN 12 053 db
70
70
1
2
5
3
4
6
7
8

11
This actuation steering axle has the structure compact reasonable, the operational performance
reliable, the transmission steady, the noise low status merit.The bridge shell uses the cast steel
material, the rigidity is good, bearing capacity is big, the main performance parameter (sees Table
2-1)
2. Technical parameters (Table 2-1)
Model
AC
Power of motor
kW
5
Motor voltage
V
48
Walking drive ratio
i
20.87
steering gear ratio
i
5.364
Tyre size
18X7-8
1.2 Failure Analysis
Table 2-2 Failure Diagnosis and Correction
Failures
Possible causes
Correction methods
High
vibration
Looseness of fastening bolts at the installation
and connection points
Tighten the bolts
Excessive
oil
temperature
Deterioration of gear oil
Replace
Abnormal oil level
Add or reduce oil
Jamming of moving parts
Adjustment
Oil leakage
Looseness of bolts at the combining surfaces
Tighten the bolts
Damaged seals
Replace
Noise
Damaged rotary gear
Replace
Damaged bearing
Replace
2. Braking system
2.1 Overview
The braking system consists of the brake pedal, brake master cylinder and wheel brakes. The
two wheel brakes in the front are hydraulic internal expansion brakes.
2.2 Brake pedal
The structure of brake pedal is shown in Figure 2-2. The pedal would transfer the pedal force
into brake oil pressure through the push rod on the brake master cylinder.

12
1 Brake oil cup
2. Brake pedal
3. Brake master cylinder
4. Brake sensor
5. Brake support
6. Spacing bolt
Figure 2-2 Brake pedal assembly
2.3 Brake master cylinder (Figure 2-3)
The master cylinder includes a valve seat, a check valve, a return spring, the main cup, piston
and auxiliary cup. Stop washer and stop steel wire are used to fix the ends of the cylinder and
rubber dust cover is applied to protect its external surface. Master cylinder piston works by
depressed the brake pedal to touch the push rod. When the brake pedal is depressed, the push
rod will push the piston forward, and the brake fluid in the cylinder will flow back to the storage tank
through the oil return hole until the main cup block the oil return hole. When the main cup block the
oil return hole, the brake fluid in front cavity of the master cylinder is compressed and the check
valve is opened. The fluid will flow to the wheel cylinder through the brake pipelines. Thus, each
wheel cylinder piston will protrude and the friction disk of the brake shoe will contact the brake
drum to achieve slowing down or braking. At this point, the back cavity of piston will be filled with
brake fluid from the oil return hole and the oil inlet. When the brake pedal is released, the piston
will be pressed backwards by the return spring, and at the same time the brake fluid in each brake
cylinder is also compressed by the return spring of the brake shoe, so that the brake fluid will flow
back to the master cylinder (front cavity of the piston ) through the check valve. Then the piston
will return to its normal position, while the brake fluid in the master cylinder flows back to the
storage tank through the oil returning hole. The pressure of the check valve will be adjusted to be
in certain proportional of the remaining pressures in the brake pipeline and the brake cylinder, so
that the cylinder cup will be correctly placed to prevent oil spilling and to eliminate air resistance
that may occur during emergency brake.
1. Locking nut
2. Pushing rod
3. Dust cover
4. Stop steel
wire
5. Stop washer
6. Auxiliary cup
7. Piston
8. Main cup
9. Spring
10. Check valve
11. Valve seat
12. Pump body
Figure 2-3 Brake Master Cylinder

13
2.4 Brake
The brake is a dual-shoe brake installed on both sides of the drive axle. The brake consists of
two groups of brake shoes, brake cylinders and regulators. One end of the brake shoe
contacts the fixed pin and the other end contacts the regulating device. The return spring and the
compression spring bar hold the parking brake. In addition, the parking brake mechanism and
automatic regulating device are also assembled onto the brake. See figure 2-4
1Brake cylinder
2. Brake cylinder
Piston
3. Cylinder sleeve
4. Brake cylinder spring
5. Brake cylinder shield
6. Piston rod of brake
cylinder
7 Oil plug of brake cylinder
8. Thread guard
9. Bleeder screw of brake
cylinder
10. Bleeder screw
shield
11. Brake shoes with
assembly （front）
12. Brake shoes with
assembly（back）
13. Brake backing plate
assembly
14. Clearance
adjuster
15. Spring farrowed device
16. Compression spring
bar
17. Compression spring
base
18. Spring
19. Rubber plug
20. Return spring
21. Guide plate
22. retainer spring
23. Orientation block
24. Spring
25 pallet
26. Pin
27. Hand braking
28. Spring
29. Hand braking bars
30. pin
31. spring washer
32. Stem pin block circle
33. Braking wiring
assembly
34.sring
35.Bolt
Figure 2-4 Brake
(1) Brake action
Brake cylinder exerts the same force to the main brake shoe and auxiliary brake shoe to
suppress the brake drum, until the upper end of auxiliary brake shoe contacts against the fixed pin.
Then the brake shoe will move towards the rotation direction of the brake drum. After contact
against the fixed pin, the friction between friction disk and brake drum will increase. The main
brake shoe will exert a pressure larger than the brake cylinder pressure on the auxiliary brake
shoe, resulting in a large braking force. See Figure 2-5
When moving backwards, the brake action is in reverse to that of moving forwards. See
Figure 2-6

14
Figure 2-5Action when moving forwards Figure 2-6 Action when moving backwards
(2) Parking brake
Mounted in the wheel brake, the parking brake consists of the lever and push lever. The lever
is mounted on side of the main brake shoe by a pin,
and the pulling action spread through the push lever to the auxiliary brake shoe. See figure 2-7
(3) Clearance self-adjusting mechanism
The clearance self-adjusting mechanism can maintain appropriate clearance between the
friction disk and the brake drum. See Figure 2-8 for its structure. Clearance self-adjusting
mechanism works only when the forklift is moving in reverse.
Figure 2-7 Parking brake Figure 2-8 Clearance self-adjusting mechanism
(4)Action of the automatic clearance adjusting mechanism
If braking during reversing of the forklift, the auxiliary and main brake shoes contact with each
other and rotate together, so that the lever will rotate rightwards aroundA point as shown in Figure
2-13, and B point is then elevated.After the brake is released, the lever will rotate leftwards by the
spring force to lower B point. When the clearance between brake hub and friction disk is enlarged,
the vertical distance of B point’s rotation will increase. The regulator will be toggled for one more
tooth and the regulating lever lengthens (see Figure 2-9), so that the clearance shrinks. Clearance
adjustment range falls within 0.40mm ~ 0.45mm.
2.5 Control device of parking brake (Figure 2-10)
The regulator located at the cam-type parking brake lever can be used to adjust the braking
force.
Braking force adjustment: Turn the regulator clockwise to increase the braking force; turn the
regulator counter-clockwise to reduce the braking force.
Pulling force：196N～294N
1. Pin
2. lever
3. Driving brake
shoe
1. Regulating
mechanism
2. Spring
3. Cable
4. Driven
brake shoe
5. Support rod
4. Guide groove
5. lever
Driving brake shoe
Driven brake shoe
Driving brake shoe
Driven brake shoe

15
Figure 2-9 Clearance Figure 2-10 Parking brake lever
self-adjusting mechanism
2.6 Technical points for brake disassembly and adjustment
Disassembly, assembly and adjustment of the brake and adjustment of brake pedal when the
wheel and wheel hub is removed.
2.6.1 Disassembly of the brake
(1) Remove the support pin, regulating bar, regulating device and spring on the auxiliary
brake shoe. See figure 2-11
(2) Remove the return spring on the shoe. See figure 2-12
Figure 2-11 Figure 2-12
(3) Remove the fixing spring on the main brake shoe. See figure 2-13
(4) Remove the main and auxiliary brake shoes. And also remove the regulator and the
regulator spring. See figure 2-14
Parking Brake
Wire rope
Along this direction elong elongtion

16
Figure 2-13 Figure 2-14
(5) Remove the brake pipe from the brake cylinder. Then remove the mounting bolt of the
brake cylinder, and remove the brake cylinder from the brake backing plate. See figure 2-15
6) Remove the E-shaped retaining ring used for fixing the brake cable on the brake backing
plate. Then remove the mounting bolt on the brake backing plate and dismount the brake backing
plate from the drive axle. See figure 2-16
Figure 2-15 Figure 2-16
(7) Disassemle the brake cylinder: Remove the dust-proof ring. Press on one end of the
piston to push out the other end and then press down the headed out end of piston with fingers.
See figure 2-17
Figure 2-17
2.6.2 Check of the brake
Inspect the parts and then repair or replace damaged ones.
(1) Check the surface of the brake cylinder and peripheral surface of the piston for rust; then
measure the clearance between the piston and the brake cylinder.
Standard size: 0.03mm-0.10mm; Maximum size: 0.15mm
(2) Conduct visual inspection of the piston cup for damage and deformation. Replace the cup
if there is any abnormality.
(3) Measure the free length of brake cylinder spring. Replace it if it exceeds the baseline.
(4) Measure the thickness of friction disk. Replace it if the wear degree exceeds limit. Figure
2-17 Standard thickness: 8.0mm; Minimum thickness: 2.0mm
(5) Conduct visual inspection on the inner surface of brake drum for damage and uneven
wear. Then grind the brake drum for correction purpose and replace it if it can’t be corrected.
Standard value: 314mm; Maximum value: 316mm. See Figure 2-19

17
Figure 2-18 Figure 2-19
2.6.3 Brake assembly
(1) Coat the cup and piston on the brake cylinder with brake fluid and assemble the spring,
piston cup, piston and protection loop in sequence.
(2) Mount brake cylinder on the brake backing plate.
(3) Mount the brake backing plate on the drive axle.
(4) Coat all the positions as shown in Figure 2-20
with heat-resistant grease,
and be careful not to smear any oil on the friction disk.
(a) Contact surface of the brake backing plate and
brake shoe;
(b) Fixed pin;
(c) Contact surface of the brake shoe and spring
compression base;
(d) Support pin of the hand brake lever;
(e)Threads on the regulating mechanism and other rotating parts. Figure 2-20
(5) Use a E-shape retaining ring to seize the parking brake cable.
(6) Mount the brake shoe with a fixed spring. See figure 2-21
(7) Mount the compression spring on the push lever of hand brake, and then mount the push
lever onto the brake shoe.
See figure 2-22
Figure 2-21 Figure 2-22
(8) Mount the brake shoe guide plate to the support pin, and then mount the return spring of
the brake shoe. First install the main shoe and then install the auxiliary shoe. See figure 2-23
(9) Mount the regulator, the regulator spring, ejector Pin, return spring of the ejector Pin. The
following points shall be noted:
(a) The screw direction and mounting direction of the regulator;
(b) The direction of spring in the regulator (contact between regulator gear and spring is not
allowed);
(c) The direction of return spring in the ejector pin (the spring hook at the support pin side
should be fixed at the side opposite to the ejector pin);
(d) The lower end of the adjustment lever must contact with the regulator gear.
(10) Connect the brake pipelines with the wheel cylinders.
(11) Measure the inner diameter of brake drum and outer diameter of brake shoe, and then
use the regulator to set the difference between inner diameter of brake drum and outer diameter of
brake shoe at 0.3mm-0.5mm. See figure 2-24

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Figure 2-23 Figure 2-24
2.6.4 Operation test of the automatic clearance regulator as shown in Figure 2-25
(1) First, adjust the diameter of brake shoe to be close to the stipulated installation size; pull
the lever to rotate the regulator. When letting the lever go, the regulator lever will return to its
original position and the regulator gear won’t rotate.
Note: Even if the regulator gear and the lever both return after the lever is let go, the regulator
still works properly.
(2) If the regulator can not finish the above actions when the lever is pulled, carry out the
following checks:
(a) Securely mount the adjustment lever, ejector pin, spring of the ejector pin and
compression spring base;
(b) Check the return spring on ejector pin and the regulator spring for damage,and then
check the rotation of its regulator gear and its meshing parts to see if there is excessive wear or
damage. Check whether the pin contacts with the gear. Replace damaged parts.
Figure 2-25
2.7 Adjusting the brake pedal as shown in Figure 2-26 (a)
(1) Shorten the push lever;
(2) Regulate the pedal spacing bolt and adjust the pedal height as shown in Figure 2-26 (b);
(3) Adjust the length of the push lever until its front end contacts with the piston of master
cylinder. Then turn back 1-2 circles to guarantee a free travel of the pedal between the
10mm-20mm;
(4) Lock the nuts of push lever and the pedal spacing bolt.
Inflation direction

19
a b
Figure 2-26
(5)Adjust the brake switch as shown in Figure 2-27
(a) After the height of the brake pedal has been adjusted,
release the brake switch and lock the nut;
(b) Disconnect the plug to separate the wires;
(c) Rotate the switch to set the gapA at 1mm;
(d) Make sure the brake light be lit when depressing the
brake pedal;
(e) Finally lock the nuts.
Figure 227 Brake light switch
2.8 Troubleshooting and FailureAnalysis(Table 2-3)
(Table 2-3)
Problems
Causes analysis
Solutions
Abnormal
braking
1.Oil leaks in the brake system
Repair it
2 The brake shoe clearance is not
well-tuned
Adjust the regulator
3 The brake is over-heated
Check if the brake is slipping
4 Brake drum and friction disk are not
appropriately contacted
Readjust it
5 There are foreign matters attached to the
friction disk.
Repair or replace it
6 The brake fluid is contaminated
Check the brake fluid
7 The brake pedal (micro-valve) hasn’t been
adjusted properly
Adjustment
Noise in
the brake
1 The friction surface is hardened or with
foreign matters attached on it
Repair or replace it
2 The baking plate is deformed or the bolts
are loosen
Repair or replace it
3 The brake shoe is deformed or is not
installed correctly
Repair or replace it
4 Worn friction disk
Replace
5 The wheel bearing is loosened
Repair or replace it
The
1 There are oil stain on the friction disk
Repair or replace it
Push lever
Spacing bolt
brake switch
Lock nut
Pedal
Break
Pedal