LiftSmart LS-RT50 User manual

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.
©7/2019

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

1
Ⅰ. Power System
1.Engine for Forklift
Engine
Parameter
Diesel
QSF3.8t3TC112(Cummins)
Rated power
kw
86
Rated rotate
r/min
2200
Max Torque
N·m/speed r/min
470/1100-1700
Forklift truck
model
LS-RT50
LS-RT50-4

2
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

3
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

4
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

5
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.

6
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.