LiftSmart LS-RT50 Manuale utente

LS-RT50

5T rough terrain forklift truck

SERVICE MANUAL

7/2019

13 22 54

www.adaptalift.com.au

Foreword

5T Rough terrain forklift truck is a new developed forklift of Adaptalift Group.

It owns characteristics as High vehicle capacity, novel structure and superior

performance.

The manual is the introduction of structure, working principle and serving of

forklift truck.

For safety and performance of truck, all in charge of operation, maintenance

and management must read and comprehend this manual well.

The manual also applies to container fork-lift trucks.

It is forbidden anybody without training and qualification to maintain.

Only in the event that the truck manufacturer is no longer in business and

there is no successor in the interest to the business, the user may arrange for a

modification or alteration to a powered industrial truck provided, however, that

the user shall:

a) Arrange for the modification or alteration to be designed, tested and

implemented by an engineer(s) expert in industrial trucks and their safety;

b) Maintain a permanent record of the design, test(s) and implementation of

the modification or alteration;

c) Approve and make appropriate changes to the capacity plate(s), decals,

tags and instruction handbook;

Affix a permanent and readily visible label to the truck stating the manner in

which the truck has been modified or altered together with the date of the

modification or alteration, and the name and address of theorganisation that

accomplished the tasks.

CONTENT

Ⅰ.Power System ..................................................................................................................... 1

1.Engine for Forklift........................................................................................................... 1

Ⅱ.Drive system ....................................................................................................................... 2

1.Summarize..................................................................................................................... 2

2. Hydrodynamic power transmission gear-box ................................................................ 4

3. Driving axle..................................................................................................................... 6

ⅢSteering system.................................................................................................................. 13

1 Structure introduction ................................................................................................. 13

Ⅳ.Brake system...................................................................................................................... 26

1.Data............................................................................................................................... 26

2.Fault diagnoses and corrections................................................................................... 27

3.Brake inching pedal adjustment.................................................................................... 29

4.Brake valve and accumulator........................................................................................ 30

5.Hand brake.................................................................................................................... 32

6.Service brake................................................................................................................ 38

7.Hydraulic brake malfunction diagnosis......................................................................... 40

8.Exhaust of air in the hydraulic system.......................................................................... 40

Ⅴ.Hydraulic system ................................................................................................................ 40

1.Oil pump........................................................................................................................ 40

2.Multiple directional control valve................................................................................... 42

3.Rotary type piping filter ................................................................................................. 50

4.One-way governor valve............................................................................................... 50

5.Lifting cylinder............................................................................................................... 50

6.Tilting cylinder ............................................................................................................... 51

7.Air exhaust in hydraulic system .................................................................................... 51

8.Hydraulic system fault diagnosis and corrections......................................................... 52

9.Hydraulic system schematic diagram........................................................................... 53

Ⅵ. Lifting system..................................................................................................................... 54

1.Assemble debugging data ............................................................................................ 55

2.Fault diagnosis and corrections.................................................................................... 56

3.Summary....................................................................................................................... 61

4.Mast dismantle and install adjustment.......................................................................... 62

5.Disassembly and installation of lifting cylinder ............................................................. 67

6.Disassembly and installation of tilting cylinder ............................................................. 68

7.Noticing proceeding of debugging................................................................................ 69

Ⅶ.Electrical system ................................................................................................................ 70

1.Control box assembly.................................................................................................... 70

2.Instrument,sensor and relay ......................................................................................... 71

3.Lighting system............................................................................................................. 74

4.Electrical system diagram............................................................................................. 80

Ⅰ. Power System

1.Engine for Forklift

Engine

Parameter

Diesel

QSF3.8t3TC112(Cummins)

Rated power

Rated rotate

r/min

2200

Max Torque

N·m/speed r/min

470/1100-1700

Forklift truck

model

LS-RT50

LS-RT50-4

Ⅱ.Drive system

1. Summarize

Fig2-1 Drive system（Two-wheel drive）

1.Drive axle

2.Drive ShaftAssembly

3.Hydraulic

transmission

gearbox

4.Gearbox bracket

5.Hand Brake Bracket

6.Tyre Assembly

Fig. 2-2 Drive system（Four-wheel drive）

1.Drive axle assembly

2.Drive Shaft

Assembly

3.Hydraulic

transmission gearbox

4.Rear Drive Shaft

Assembly

5.Gearbox bracket

6.Hand Brake Bracket

7Tyre Assembly

2.Hydraulic transmission gearbox (four-wheel drive)

1.Summary

4F35 hydraulic transmission gearbox is a new type gearbox for four-wheel drive rough terrain

forklift truck, with total 4 shifts (three forward and one reverse)and PTO interface, and time

sharing four-wheel drive can be realized based on the actual requirement.

Torque converter for 4F35 hydraulic transmission gearbox is comprehensive with signal

stage two phase and three working wheel, thus it owns automatic adaptability of hydraulic

transmission output, which can change its output torque and speed as the change of external

load, and absorb and remove the shock vibration from engine and external load to the drive

system; the adopted electronic-hydraulic shift with inching valve and cushion valve makes

operation simple, easy and smooth starting, and greatly reduces the fatigue strength of the

operation.

Axle disengaging mechanism is controlled by solenoid valve, and conversion between

two-wheel drive and four-wheel drive through hydraulic clutch can be carried out at any time

according to the condition of the road, thereby greatly improves the cross-country capacity of the

forklift

2.Main technical parameters

Product model

4F50

Rated output of matched engine Kw

55~74

Rated speed of matched engine r/min

2200~2400

Direction of rotation（face input end）

Clockwise

Drive ratio on

front axle

F1 gear

3.77

F2 gear

1.737

F3 gear

0.86

R gear

1.737

Drive ratio on

rear axle

F1 gear

4.188

F2 gear

1. 93

F3 gear

0.955

R gear

1.93

PTO transmission ratio

0.7838

Torque converter model

YJH315

Work oil temperature of gearbox

L-TSA32GB11120 turbine oil or 6#,

8# hydraulic transmission oil

3.Installment and use notice

3.1 The main oil pressure of gearbox is 1.0-1.3 MPa, and the oil pressure of converter is 0.5-0.7

MPa.

3.2 Normal working oil temperature is 70℃～95℃, maximum working oil temperature should not

exceed 120℃or last over 5 minutes.

3.3 Working oil should keep clean, have no other impurity. Replace oil after being used for 100

hours for the first time, and then replace oil per 1000hours or use after stopping for a long time.

3.4 Check the working oil level in the gearbox after the engine starts for 3 minutes, and the oil

level should be within the dipstick regulated scale.

3.5 When the vehicle need shift, first close inching valve and then shift. When braking, first close

inching valve, and then brake to avoid damage clutch or brake malfunction.

4.Fault reason and corrections

Item

Fault reason and corrections

Efficiency

decline and

over high oil

temperature

1 Friction lining stuck or damage. Check if friction lining has gluing,

uneven contact or warpage;

2 Insufficient torque converter oil supply. Check if oil pump wear or

oil level is in normal position;

3 Bearing failure. Replace bearing;

4 Check if lubricating oil line blocks;

5 Torque converter one-way wheel stuck.

Oil leakage

1 Sealing gasket damage; Replace sealing gasket;

2 Rubber parts age or damage; Replace parts;

3 Parts damage. Replace.

Low clutch

pressure or

over large

swing

1 Low oil level. Check oil level and add oil to normal oil level;

2 Input shaft assembly and piston sealing ring wear or the joint is

wedged when assembling. Replace sealing ring or be careful when

assembling.

3 Oil pump wear; Replace oil pump.

4 Inching valve rod not reset.

3.Drive axle

1. Structure and Working Principle

1.1 Structure and Working Principle

The basic structure of the driving axle is shown in Fig. 2-5. It is mainly composed of axle

housing assembly, main drive, half axle, wheel-side reducer and wet multi-disc brake.Its working

principle is shown in Fig. 1. The driving moment is input into the main drive, and the direction of

power is changed by the vertical installation of active bevel gears and driven bevel gears.The

speed is reduced and the transmitted torque is increased. Then the power is transmitted to the

wheel edge through differential and half axle. After further deceleration by the wheel edge

deceleration mechanism, the motion and moment are transmitted to the two driving wheels.

Fig. 1 Working schematic diagram

1.2.Wheel Edge Reducer and Bridge Shell Structure

The wheel side reducer is a planetary deceleration mechanism, mainly composed of

planetary gear frame, internal gear, planetary gear, solar gear, etc. The internal gear is fixed on

the wheel support axle by spline, and the planetary gear frame and hub are fixed in one. Details

are shown in Figure 2, Figure 3 and Detailed Table 1.

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