7.

Brake System

Type Front Twin Wheel Brake, Internal Expansion, Hydraulic

Pedal Lever Ratio 5.66
Master Cylinder
19.05mm
Diameter
Wheel Brake 2-2.5t 3-3.5t
Type Dual Servo Type with Parking Brake
Wheel Cylinder
28.58
Diameter
Size of Brake Shoe
324×60×7mm 348×76×8mm
(L X W X T)
2 2
Area of Brake Shoe 194.4 cm ×4 264 cm ×4
Inner Diameter of
310mm 314mm
Brake Drum
Parking Brake Front Twin Wheel Brake, Internal Expansion, and Hydraulic Type

7.1 Overview
Brake system is in a front double-wheel brake type, and it is composed of brake master cylinder, brake,
and brake pedal mechanism.
7.2 Brake master cylinder includes one valve seat, one one-way valve, and one return spring, as well as
rubber cup, piston, and auxiliary rubber cup. The end part is fixed using thrust washer and stop steel wire,
while and external part is protected through rubber dust cap. The master cylinder piston acts through
push rod through operating brake pedal. When brake pedal is pushed down, the push rod pushes
forward the piston, and the brake fluid in the cylinder body flows back to oil tank through return oil port,
until the main rubber cup blocks the return oil hole. After main rubber cup has pushed the return oil port,
the brake fluid in front cavity of master cylinder is compressed and opens the one-way valve, thus to flow
to the wheel cylinder through bypass pipeline. In this way, the pistons of respective wheel cylinders
extend outwards, for the friction plate of brake shoe and the brake drum to get into contact with each
other, to achieve the effect of deceleration or brake. At this point, the rear cavity of piston is
supplemented with the brake fluid from return oil port and oil inlet port. When brake pedal is loosened,
the piston is pressed by return spring, and at the same time the brake fluid in respective brake cylinders
are likewise compressed by return spring of brake shoe, for brake fluid to return to the master cylinder
(the front cavity of piston) through one-way valve. The piston will return to original place, the brake fluid in
master cylinder will flow back to oil tank through return oil port, and the pressure of one-way valve is
adjusted to certain proportion to the remaining pressure in brake cylinders, so that the rubber cup of
wheel cylinder is correctly placed to prevent oil leak, and to eliminate the effect of choke that may
possibly arise during emergency brake.

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 Fig 7-1 Brake Master Cylinder

1. Clevis 5. Stop Steel Wire 9. Main Cup 13. Pump Body

2. Lock Nut 6. Stop Washer 10. Spring
3. Push Rod 7. Auxiliary Cup 11. One-way Valve
4. Dust Cap 8. Piston 12. Valve Seat

7.3 Wheel Brake

Wheel brake is in an internal expansion and hydraulic type, and it is composed of brake shoe, spring,
wheel cylinder, adjuster, and bottom plate. The two brakes are respectively mounted on the two ends of
front axle. One end of brake shoe is connected with support pin, while the other end is connected with
clearance adjuster, and bears down onto the bottom plate by spring and tension spring pull rod. Lever L
H Brake is mounted on primary brake shoe, while adjustment pull rod for automatic clearance adjuster is
fitted on secondary brake shoe. Refer to Fig 7-2, Fig 7-3.

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1. Spring
2. Rubber Cup
3. Piston
4. Cylinder Body
5. Piston Top Rod
6. Return Spring
7. Top Rod
8. Return Spring
9. Adjusting Lever
10. Auxiliary Brake Shoe
11. Clearance Adjuster
12. Spring
13. Brake Steel Cable Assembly
14. Pressure Spring Cap
15. Pin, shoe hold
16. Lever L H Brake E-Shaped Retainer Ring
17. Hand Brake Push Rod
18. Brake Cylinder Assembly
19. Return Spring
20. Primary Brake Shoe Fig 7-2 2t and 2.5t Wheel Brakes

1. Brake Cylinder Assembly

2. Spring
3. Rubber Cup
4. Piston Bolt Tightening Torque

5. Wheel Cylinder Shield

6. Piston Top Rod
7. Brake Shoe Return Spring
8. Brake Shoe
9. Spring
10. Hand Brake Push Rod Bolt Tightening
11. Spring Stay Wire Device Torque
12. Brake Shoe
13. Washer cup
14. Pin, shoe hold
15. Pressure Spring
16. Spring
17. Ratchet
18. Spring
19. Clearance Adjuster Assembly
20. Pin
21. Bottom Plate
22. Brake Shoe Return Spring
23. Lever L H Brake
24. Brake Steel Cable Assembly

Fig 7-3 3t and 3.5t Wheel Brakes

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 The brake action in forward movement is as follows
Support Pin
(as indicated in Fig 7-4). Through operating brake
wheel cylinder, the primary brake shoe and the F
secondary brake shoe are effected by two forces of i Working Force

Shoe
Secondary
equal size but reverse directions, respectively, for g

Primary
Shoe
brake shoe and brake drum to get into contact with
8
each other, while the primary brake shoe is pressed
-
onto the adjuster with support of friction force 5
between brake shoe and brake drum, thereby for
clearance adjuster to generate a larger force used to Adjuster
operate the wheel cylinder to push the secondary
Fig 7-4 Brake Actions during Forward
brake shoe, and to force the upper end of secondary
Running Process
brake shoe to bear down on the support pin, thus to
get a relatively large brake force. In another
connection, the reversing brake action is performed in
reverse direction, but the brake force is the same as Working Force

Shoe
Secondary
that during forward movement.

Primary
Shoe
Fig 7-5 Brake Actions during
Reversing Process

7.4 Automatic Clearance Regulator (with 2t brake mainly described, and the action principle of 1-4t
brakes is the same as that of 2t)
The automatic clearance adjuster is able to automatically maintain the clearance between brake shoe
and brake drum between 0.4-0.45mm (0.25-0.4mm for 3, 3.5). However this adjuster only acts during
reversing brake. During reverse movement, the brake shoe will disengage once the brake pedal is
pushed down, thereby, the secondary and the primarily brake shoes will begin to get into contact with
brake drum for rotation together, until the upper end of primarily brake shoe begins to get into contact
with support pin. Meanwhile when secondary brake shoe is released from the support pin, the A part of
adjusting lever (Refer to Fig 7-2.) is relatively in tension, thus for adjusting lever to rotate around the B
part, for C part to lower, and the D part of adjuster to rotate leftward, so as to achieve the objective of
automatic adjustment. When brake pedal is further pushed down, the pressure applied to both ends of
adjust is larger, which has increased the resistance to thread rotation, for the force of adjusting lever to
be unable to actuate rotation of part B.
7.5 Parking Brake
Parking brake is in mechanical, internal expansion type and built-in on wheel brake, and it shares the
brake shoe and the brake drum with foot brake. When the handle of parking brake is pulled, the brake
handle actuates the manual pull rod through brake cable (Refer to Fig 7-2 E), and this cable pushes the
manual brake push rod rightwards with the support of pin that plays the function of rotating shaft, for the
brake shoe to step towards the brake drum.
7.6 Adjustment of Brake Pedal (Mechanical Forklift Truck) (Refer to Fig 7-7.)
(1)Adjust short the push rod.
(2)Adjust the catch bolt, for the heights of pedals for 2-4t diesel forklift truck and LPG/Gasoline forklift
truck to be respectively 111mm and 113mm.
(3)Push down the brake pedal by 30-40mmt, and adjust long the push rod until the front end of push rod
begins to contact the piston of master cylinder.
(4)Screw down the lock nuts for push rod.
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 Parking Brake Handle
Brake Handle

Pin

Tension Plate

Brake Steel Cable

Fig 7-6 Parking Brake Device

Oil Tank

(Idle Stroke) (Idle Stroke)

Catch Bolt

Pedal

Fig 7-7 Adjustment of Brake Pedal (Mechanical Type)

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7.7 Adjustment of Brake
Pedal (Hydraulic Forklift Oil Tank
Truck) (Inching Pedal)
(1)Loosen the push rod and (Brake Pedal)
the interlock bolt. (Idle Stroke)

(2)Adjust the catch bolt, for Idle Stroke

the heights of pedals for
2-3.5t diesel forklift truck
and LPG/Gasoline truck to
be respectively 111mm and
113mm.
Catch Bolt
(3)Adjust the screw stem, for
the left pedal (inching pedal) Pedal
to get a 2-10mm idle stroke. Screw stem
Interlock Bolt
(4)Push down the right Connecting
pedal for 2-4t forklift truck by Shaft
60mm and adjust the length
of screw stem until the front
end of push rod begins to
contact the piston of master Brake Master
cylinder. Then tighten the Inching Valve
Pump
lock nut.
(5)Adjust the interlock bolt,
until the head of bolt begins
to contact the connecting
shaft, and lock it up.

Fig 7-8 Adjustment of Brake Pedal (Hydraulic Trucks)

7.8 Maintenance
This section covers brake disassembly, reassembly, and
adjustment (with mainly 2t brake described, while the
brakes for 3t are similar. Attention: The following ones
with are only the part drawings for 3t brake.).
7.8.1 Disassembly of Wheel Brake
(1)Remove the fixed spring of secondary brake shoe,
and take off the adjusting lever, top lever, and the top
lever return spring (Fig 7-9).

Fig 7-9

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(2) Remove the return springs for the two brake
shoes. (Fig 7-10)

Fig 7-10

(3) Remove the other three fixed springs. (Fig 7-11)

Fig 7-11

(4) Detach the primary brake shoe and the

secondary brake shoe, and at the same time remove
the spring for adjuster. (Fig 7-12)

Fig 7-12

(5) Demount the brake oil pip on the wheel Cylinder,

then remove the mounting bolts for wheel cylinder,
and separate the wheel cylinder from the bottom
plate. (Fig 7-13)

Fig 7-13
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 (6) Remove the E-shaped retainer ring that fastens the
brake cable onto the bottom plate, then remove the
mounting bolts on bottom plate, and detach the bottom
plate from the axle. (Fig 7-14)

Fig 7-14

(7) Remove the shield for wheel cylinder, and push out
all the parts inside the cylinder. (Fig 7-15).

Fig 7-15

7.8.2 Examination of Wheel Brake

Examine all the parts as to whether or not any of them is worn or damaged, and it shall be repaired or
replace, if incompliant.
(1)Examine whether or not the inner surface of wheel cylinder body and the surface of piston column are
rusted, and then measure the clearance between piston and cylinder body.
Specified Value: 0.065mm-0.150mm(2-3.5t Forklift Truck) Maximum Value: 0.15
(2)Visually check whether or not the pump rubber cup is damaged or distorted, and replace it if
incompliant.
Outer Diameter of Rubber Cup: 30.1-0.2(2-3.5t)
The standard value for interference of rubber cup is 1.52, and the minimum value is 0.42 (2-3.5t).
(3)Examine the free length of wheel cylinder spring, and replace it is improper.
It is specified that the free lengths of wheel cylinder springs for 3t, and 3.5t forklift trucks as well as 2t
forklift truck are respectively 58mm and 60mm.
(4)Examine the thickness of brake shoe, and replace it if it is found to be excessively worn out.
Specified Thickness: 7.2mm (2t) 8.0mm (3t, 3.5t)
Minimum Thickness: 2.0mm (2t) 1.0mm (3t, 3.5t)

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5) Examine the status of inner surface of brake drum, and it
shall be rehabilitated or replaced, if it is found to be
excessively worn out.
Standard Value: 310mm (2t, 2.5t), 314mm(3t, 3.5t)

Maximum Value after Rehabilitation: 312mm (2t, 2.5t), 316mm (3t, 3.5t) Fig 7-16

(6) Measure the free length and installation load of return

spring for brake shoe (Fig 7-16). Refer to Part 6 of Fig 7-2,
and Part 7 of Fig 7-3.)
Free Length: L= 106mm (2t, 2.5t), L=115.1mm (3t,3.5t)

Installation Length: 116mm (2t, 2.5t), 122mm (3, 3.5t)

Installation Load: 246N (2t, 2.5t), 225N (3t, 3.5t) Fig 7-17

(7) Measure the free length and installation load of return

spring for top rod (Fig 7-17). (Refer to Part 8 of Fig 7-2 and
Part 9 of Fig 7-3)

Fig 7-18
Free Length 124.5mm
Installation Length 130mm
Installation Load 245N
Forklift Truck Tonnage 2-3.5t

(8) Measure the free length and installation load of adjuster

spring (Fig 7-18 and Fig 7-19).
Free Length: 86mm (2t, 2.5t) 121mm (3t, 3.5t)

Installation Length: 97mm (2t, 2.5t) 137mm (3t, 3.5t)

Fig 7-19
Installation Load: 153N (2t, 2.5t) 71.5N (3t, 3.5t)

(9) Measure free length and installation load of ratchet spring

(Fig 7-20). Installation Load: 14.7N (3t, 3.5t)

Fig 7-20

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(10) Examine whether or not the adjusting mechanism is damaged, how the operating status is, and also
examine whether or not the contact of adjusting lever is out of order, and replace it when necessary.

7.8.3 Reassembly of Wheel Brake

(1) Firstly dip the wheel cylinder rubber cup and the piston with brake fluid, and then assemble spring,
rubber cup, piston, and shield in turn.
(2) Mount the wheel cylinder on bottom plate.
Attention: Ensure that respective parts are all at the correct position during installation, and the bolt
tightening torques are 14.7-19.6N.m (2t), 17.6 - 26.5N.m(3t and 3.5t).
(3) Mount the bottom plate onto the front axle. Bolt Tightening Torque: 120-140N.m
(4) Add #2 calcium base lubricating grease at a, b, c, d respective lubricating pints as indicated in Fig
7-21 and Fig 7-22, and be careful not to allow this grease to be adhibited on brake shoe.
(a) Support Face of Bottom Plate (b) Support Pin of Lever L H Brake
(c) Support Pin (d) Adjuster Thread and Other Rotating Parts
(e) Contact Face of Brake Shoe and Washer, Cup

Fig 7-21. 2t, 2.5t Forklift Truck Fig 7-22. 3t, 3.5t Forklift Trucks

(5) Mount the brake cable assembly onto the bottom plate using E-shaped retainer ring.

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(6) Mount the brake shoe onto the bottom plate using
fixing spring, but the bottom part of secondary brake
shoe shall be mounted with fixing spring after the
washer, cup and the adjusting lever have been properly
installed, to ensure that the pressure seat is fitted in the
holes of brake shoe and adjusting lever (Fig 7-23).

F
Fig 7-23

(7) Mount the compressed spring onto the hand brake

push rod, and then install the push rod onto the brake
shoe.
(8) Mount the guide plate of brake shoe onto the
support pin, and then install the return spring of brake
shoe (Fig 7-24).

Fig 7-24

(9) Install adjuster, adjuster spring, top rod, and return

spring for top rod (Fig 7-25).

Fig 7-25
Pay attention to the following respective items:
a) Adjuster Threat Direction and Its Installation Direction (In 2t, 2.5t forklift truck, right-hand threat is used
for left brake, while the left-hand thread is used for right brake. In 3t and 3.5t forklift trucks, left-hand
thread is used for left brake, while right-hand thread is used for right brake.)
b) Adjuster Spring Direction (It is not allowed for the tooth part of adjuster to contact the spring.
c) Top Rod Return Spring Direction (At the end of support pin, the spring hook shall be fixed on the
opposite side of top rod.)
d) Top rod and top rod return spring shall be fixed inside the sloth of support pin.
e) Make sure that the lower end of adjusting lever shall be in contact with the tooth part of adjuster.
(10) Connect the brake oil pip onto the wheel cylinder.
(11) Measure the inner diameter of brake drum, and adjust the adjuster for the differences between the
inner diameter of brake drum and the friction plate of brake shoe to be: 0.8-0.9mm (2t, 2.5t) , 0.5-0.8mm
(3t, 3.5t).

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7.9 Operating Test on Automatic Clearance Regulator
(1) Firstly allow the diameter of brake shoe to approach the installation size, and pull the adjusting lever
with hand in the direction as indicated by the arrow in Fig 7-26 for adjust to rotate. When hand is released,
the adjusting lever returns to its original place, while the gear of adjuster will not rotate.
Attention: Even if when hand is released, and the adjuster gear and the adjusting lever return together,
the adjuster is still able for normal work after being assembled.
(2) In the case when adjusting lever is pulled, and the adjuster cannot do the abovementioned action, the
following items shall be examined:
a) Mount the adjusting lever, the top rod, the top rod spring, and the washer, cup firmly.
b) Examine whether or not the relationship in arrangement between adjusting lever and adjusting gear is
correct. Refer to Fig 7-26 (2t, 2.5t), Fig 7-27 (3t, 3.5t), and replace the parts if not satisfactory. In addition,
examine whether or not lever and gear are in contact with each other.

Fig 7-26

Fig 7-27

c) Examine whether or not the return spring of top rod and the spring for adjuster are damaged, and then
examine the rotating status of adjuster gear and whether or not its engaged part is excessively worn out
or damaged.

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7.10 Failure Removal for Wheel Brake

Problem Analysis for Cause of Generation Removal Method

1. Oil leak with brake system To be repaired

Brake under Poor Condition

2. Clearance of brake shoe not properly Adjuster to be adjusted

adjusted
3. Brake too hot Examine whether or not
skidding exists
4. Contact between brake drum and brake shoe To be readjusted
under poor condition
5. Impurity attached on brake shoe To be repaired or replaced
6. Impurity blended into brake fluid Brake fluid to be examined
7. Brake pedal (inching valve) improperly To be adjusted
adjusted
1. Surface of brake shoe hardened or impurity To be repaired or replaced
Noise Present with Brake

attached on it
2. Bottom plate distorted or bolt loosened To be repaired or replaced
3. Brake shoe distorted or installation incorrect To be repaired or replaced
4. Brake shoe worn To be replaced
5. Bearing of wheel loosened To be repaired

1. Oil stain present on surface of brake shoe To be repaired or replaced

2. Clearance of brake shoe not properly Adjuster to be adjusted
Brake Un-uniform

adjusted
3. Wheel cylinder out of operation To be repaired or replaced
4. Brake shoe return spring damaged To be replaced
5. Brake drum deflected To be repaired or replaced

1. Oil leak with brake system To be repaired or replaced

2. Clearance of brake shoe not properly Adjuster to be adjusted
adjusted
Brake Weak

3. Air blended into brake system Air to be bled

4. Adjustment of brake pedal incorrect To be readjusted

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