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LiftSmart LS-RT50 Operation And Maintenance Manual

5t rough terrain forklift truck
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LS-RT50
5T rough terrain forklift truck
OPERATION AND MAINTENANCE MANUAL
Original Instruction
LS-RT50
LS-RT50-4
01/2020

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  • Page 1 LS-RT50 5T rough terrain forklift truck OPERATION AND MAINTENANCE MANUAL Original Instruction LS-RT50 LS-RT50-4 01/2020...
  • Page 2 Please contact Adaptalift Group or your sales agent if you have any questions regarding this manual. Rated lifting Hydraulic weight (t)/ Model Engine transmission Load Center (mm), Remarks LS-RT50 RTE500-120000-G00 5/600 Cummins QSF3.8t3TC112 Diesel Engine LS-RT50-4 RTC500-120000-G00 5/600 © 07/2019...

  • Page 3: Table Of Contents

    Content Content ..........................3 I. General rules ........................5 II. Name of main parts or component ................7 1、 Instruments ..........................8 CAN Bus Instrument ........................12 2、Control and Switches ......................18 3. Truck body and others ......................... 22 三、Safety rules ....................... 27 IV.
  • Page 4 XIV.Description of OPS System ..................82 XV.Relevant safety command and standard ............... 84 XVI.Maintenance record ....................86...

  • Page 5: General Rules

    I. General rules To keep the truck and you safe, obey these rules below: 1. Only trained and authorized operators shall be permitted to operate the truck. 2. Before starting truck you should check all control and alarm devices; if any are damaged, DO NOT operate until it is repaired.
  • Page 6 approves a modification or alteration, the manufacturer or successor shall also make and approve appropriate changes to the capacity plate, decals, tags and operation and maintenance handbooks. 27. In the event 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 manufacturer and the user shall: (1) Arrange for the modification or alteration to be designed, tested and implemented by an...

  • Page 7: Name Of Main Parts Or Component

    II. Name of main parts or component 1. Fork 2. Load backrest 3. Tilt cylinder 4.Mast 5. Lift cylinder 6. Steering wheel 7. Overhead guard 8. Seat 9. Cover hood 10. Counter balance 11. Rear wheel 12. Truck frame 13. Front wheel...

  • Page 8: 1、 Instruments

    1、 Instruments...
  • Page 9 Water temperature gauge maintenance to the forklift. Refer to monthly maintenance after first flash. Refer periodical maintenance schedule for per period. Take the actual This gauge indicates flashing time as standard. temperature in the torque converter transmission box when the key is at Charging indicator ┃(ON) position.
  • Page 10 the indicator lights up for a moment. Engine fault indicator After the indicator goes out, turn the [Electronic-controlled engine] key to . “Start” position Sedimentor indicator [Diesel truck] When the engine gets out of order, this Indicator will be on. then it must immediately stop, according to an engine fault table troubleshooting.
  • Page 11 the parking indicator will shows off. needs to be stopped for repair. Warning will damage engine transmission, etc. when indicated. Severe warning indicator [Electronic-controlled engine] Only Cummins engine forklift truck: When this light is on, it indicates the engine is in severe work condition and the engine power reduced severely.

  • Page 12: Can Bus Instrument

    CAN Bus Instrument New Murphy instrument is applied in a new generation of Liftsmart forklift truck, which can display the monitored engine and other machine data on the readable 3.8 inch QVGA black-and-white LCD. This display can not only handle complex engine diagnosis, but also realize the basic engine alarm and stop control.
  • Page 13 Engine general fault It is used to indicate the engine exhaust temperature. When this indicator lights up, When this indicator lights up, it indicates the it indicates that the engine exhaust truck trouble, stop the truck immediately temperature is too high, stop the truck and troubleshoot the fault according to fault immediately, check the engine exhaust table.
  • Page 14 △ Caution： If the light continues to stay lit or flashes Parking indicator shows on means during operation, the charging rate is low brake is applied. Please loosen the parking and should be checked immediately handle (hand brake handle), and then the Oil pressure indicator parking indicator will show off △...
  • Page 15 cursor position values, move cursor, return to previous menu, confirm password. Enter transmission calibration page if password is correct. Adjust display parameter in this page, choose to set different parameters, adjust different parameter values or definitions of the display, return to previous menu.
  • Page 16 Press YES, and enter regeneration mode. Press CANCEL, and return to previous menu. Press INHIBIT in the regeneration process can prohibit regeneration mode. 2.3 After entering engine fault page, interface displays as the following figure: REGEN MODE stands engine regeneration mode, in this mode, there will be the following conditions: AUTO：...
  • Page 17 Top left corner displays engine catalyst level. Top right displays smoke load percentage. Bottom left displays exhaust filter inlet temperature. Bottom right displays exhaust filter outlet temperature. Continue page turn, the third interface displays as the following figure Top left displays current speed load. right displays accelerator...

  • Page 18: 2、Control And Switches

    2、Control and Switches 1.Steering wheel 2.Horn 3.Combination switch 4. Key switch 4. Key switch 4. Key switch 7.Display 8.Instrument 9.Rocker switch 10. Accelerator pedal 10. Accelerator pedal 10. Accelerator pedal 13. Wiper spray lid 13. Wiper spray lid 13. Wiper spray lid 16.Steering wheel adjustable...
  • Page 19 Steering wheel [1] Turn on the headlamp and small lamp, turn this switch, and aim the position line on the switch knob to the relevant marking on the Turn right Turn left switch subject. It controls the movement direction of truck.
  • Page 20 When the engine is running, do Caution turn to” ” Cause multiway valve equips with position to avoid starter motor being tilt lock valve, when the engine misses, damaged. even push forward the tilting handle When starting, do not rotate the can not tilt forward the mast.
  • Page 21 differential lock quickly lock Step the brake pedal, the vehicle differential, so that the left and right wheels traveling speed decreases, step to the end, become rigid connection. In this way, most or the truck stops. Releasing the pedal, the even all of the torque can be transmitted to truck starts to move.

  • Page 22: Truck Body And Others

    After adjustment, pull the steering Loosen Button wheel to make sure it being locked. Block Reversing lever[17] It‟s installed on the left of the steering column. These series forklift trucks are electronic reversing, push or pull this lever to realize the following functions： Pull backward the lever, that is to pull tight;...
  • Page 23 without the load backrest. no seat adjustment is allowed in the process of travelling seat  Make sure the lever is moved completely to separate the seat structure before forward and rearward adjustment of th e seat and angle adjustment of seat backrest.
  • Page 24 WARNING To lock the hood, press the red button on Use left pollex to press the red button (with the air spring pipe. The lock button is unstuck the word PRESS) in the socket, it‟s untied. this time, then push down the button on the ·...
  • Page 25 Caution Reinstall the radiator cover hood and tighten the bolt by hand. Fix up this part by inner hexagon bolts for truck exported to Europe. Use socket spanner to loose before remove; reinstall and tighten the bolt by socket spanner Warning Radiator cap and coolant reservoir forks...
  • Page 26 Fuel reservoir cap without lock The fuel reservoir cap is located on the rear left side of the truck body. The fuel reservoir cap has a breather inside it to allow air to enter the reservoir. Check to see that the breather is in good condition every time Disassembly and assembly of the head fuel is added.

  • Page 27: 三、Safety Rules

    三、Safety rules 7. Never mount or dismount a moving truck. Use the safety step(s) and safety grip when mounting or dismounting the truck. 1. Only trained and authorized operators should operate the truck. 2. Inspect the truck at periodic intervals for oil or water leaks, deformation, defects, etc.
  • Page 28 20. Keep fluid cans, row cotton, paper or chemicals away from the truck during operation since they may catch fire or 15. Before driving over a dock-board or explode due to exhaust gas from the bridge-plate, be sure that it is properly muffler.
  • Page 29 if equipped, when the forks are raised and DO NOT operate the truck when the loaded, since this will cause the truck to weather is inclement, such as wind storms, become unbalanced. thunder storms, snow and etc. A truck with attachments should be considered the same as a loaded truck.
  • Page 30 Caution Make sure the fork does not protrude from under load. The protruding fork tips may damage or turn over an adjacent load. 30. Know the rated capacity of your lift truck place hands into and its attachment, if any, and never exceed it.
  • Page 31 Replace damaged or missing decals operate the truck in reverse or have a guide and name plate. Liftsmart provides various attachments to the user, like rotating clamp, side shifter, jib and so on, which are for special use.

  • Page 32: Maintenance

    IV. Maintenance See Preventive maintenance schedule for further information. 1. Daily maintenance（8hours） It is also used as check before operation. 1. Check leaks： electrolyte, hydraulic oil, brake fluid, coolant, and oil in hydraulic transmission gear box. Warning Check engine coolant DO NOT operate truck if leaked fuel is Inspect the small reservoir tank to see if the found following pre-operational checks.
  • Page 33 Hydraulic oil level check Check the oil level in the hydraulic oil tank. The oil level should be in the place between two limits. Square oil gauge, top with ring number to indicate applicable tonnage of vehicle type (see figure): ○...
  • Page 34 Inspect the shift lever to see if loose and shift 7、 Brake fluid level check change is smooth. Check the fluid level in the brake fluid Lifting lever, tilting lever and reservoir. The level should be between the attachment lever check two seams of the reservoir.
  • Page 35 Tire pressure adopts new standard GB/T2982-2001: Driving wheel Steering wheel Truck type （Front （Rear wheel） wheel） 4t-5t 830kPa 860kPa...

  • Page 36: Weekly Maintenance（40Hours

    2. Weekly maintenance（40hours） Warning 1、 Dust will blow into your eyes, so please wear protective glasses. Increase the following content based on daily 2、 Do not maintain and replace element maintenance. filter time according 1. Air cleaner maintenance requirement will lead to the damage of General condition：...
  • Page 37 4. Mast and forks 6. Lubrication of mast Check the mast and forks to make sure: Lubricate the following parts periodically ① There is no crack and bend on the forks, according to the requirements of lubrication and the forks are installed on the fork sheet bracket strongly;...
  • Page 38 ： Tightening torque N.m Warning 4.0t-5.0t When painting lubrication grease; stop the 441～558 truck on a smooth road, engine off and pull hand brake. Avoid injury to hand or body, Rear wheel and avoid falling off from high place. Keep safe.
  • Page 39 4.0t-5.0t Height and free clearance：mm Height Free clearance Brake 145± 5 pedal Inching pedal Inching connected 145± 5 pedal bolt-brake pedal: 12. Hand brake Make sure that the hand brake lever, after pulled up, still has good function when return. the required tension when pulled up ：...

  • Page 40: Every One And A Half Months Maintenance（250Hours

    3. Every One and a half months maintenance（250hours） Increase the below content based upon weekly maintenance 1. Change engine oil and oil filter（The first 100h replacement, after every 250 hours to replace.） ⑨ Start the engine, check for oil leaks around ①...
  • Page 41 completely drained. Warning Hot hydraulic oil and parts will cause injury. DO NOT touch the hot hydraulic oil and parts ① Put one case (volume is over 20 liters) under the transmission. ② Remove oil plug and drain oil. ③ Clean oil plug then install.
  • Page 42 Abnormal: water in White combustion chamber Warning Don‟t start the lift truck in bad ventilation space. There is carbon monoxide in the exhaust gas, it is very dangerous 9. Check battery and electrolyte Refer to Operational method of lead acid battery.

  • Page 43: Every Half Year Maintenance (1000 Hours)

    ① Put one container (cubage is over 60 L) 4.Every half year maintenance under the hydraulic oil box. Dismantle the (1000 hours) hydraulic oil tank drain plug, and discharge the oil to the container. Increase the following content based on ②...
  • Page 44 ③ Before installing new one, install sensor articles in hand, put a little fuel on the filter airproof. Notice Before installation, it is prohibited to add fuel to filter, otherwise it will accelerate the abrasion of fuel system parts. ④ Install new filter component.

  • Page 45: Annual Maintenance (2000 Hours)

    See “Re-add amount”. 5.Annual maintenance (2000 hours) ④ Install level plug and curved-shaped plug adapter Increase the following content based on ⑤ Start-up forklift. Run engine at idle and semiannual maintenance. place the steering wheel control handle at 1. Replace the engine coolant neutral.

  • Page 46: 6、Others

    6、Others 1. Fuse, relay Front whee ① Please first find out the reason before ① Park forklift truck on level concrete. replace damaged fuse or relay. ② Start engine and raise mast about 100mm ②Replace with regulated standard fuse height. The Control box of forklifts are placed on ③...
  • Page 47 Warning Do not remove wheel nuts until rear tires are raised from ground. ⑤ Raise the forklift with jack until rear wheels off the ground. Support forklift truck by putting additional wooden blocks under both sides of the front truck frame as shown below. ⑥...
  • Page 48 5. The operation of too hot engine If the engine is too hot, DO NOT stop it at once, do as follows: ① Reduce speed; ② Open the engine cover; ③ Stop engine when water temperature drops ④ Check coolant, add water, if need. 3.

  • Page 49: Structure And Stability Of Truck

    V. Structure and stability of truck It is very important for operator to know the truck‟s structure and relationship between load and stability. The structure of the truck Caution The basic structure of the truck is mast (include mast and forks) and body (include tire).
  • Page 50 Caution the stability zone of the barycenter In order to make the truck stable, the combined center must be within the triangle which is made up of the two points where the two front wheels touch the ground and the midpoint of the back driving axle.

  • Page 51: Operation

    VI. Operation the controls, lightly putting it on the wheel. ② Set the bottom of the fork 15 to 20 cm above the ground and fully tilt back the upright. Warning Before operating the truck, check all controls and warning devices for proper operation.

  • Page 52: Pick Up

    好。 it with you. Caution: · Be careful to get off,Never jump off the truck. · Do not park the truck on travelling route. 3. Pick up · The forks should be adjusted sidewise to maintain proper balance of load. ·...

  • Page 53: Remove Load

    the load is raised high. 5. Remove load · Slow down when approaching the area where the load is to be retrieved. · Stop the truck about 30cm away from the loads. · Check the condition of the loads. · Tilt the mast forward until forks become horizontal.

  • Page 54: Parking

    VII. Parking 1. Parking daily Warning The block must be single and hard ① Park your truck to desired place and block enough to support the truck. the wheels. Don‟t blocks higher than ② Make sure the shift level is in the neutral 300 mm（11.81 inch）.
  • Page 55 ②Drain the gear oil of the crankcase, driving axle, hydraulic transmission box (torque converter type) clear it and add with new gear oil. ③Clean the hydraulic oil reservoir and fuel reservoir (removing any dirt or water) and add with new hydraulic oil/fuel.

  • Page 56: Maintenance

    The problems may be corrected by adjusting the diesel nozzle pressure and fuel atomization. ⑦ Dispose of waste oil or electrolyte liquid according to local environmental protection laws and regulations. ⑧ Follow the maintenance schedule. ⑨ After performing maintenance, keep a record. Only use Liftsmart parts ⑩...

  • Page 57: Preventive Maintenance Schedule

    1. Preventive maintenance schedule ○——Check, revise, adjust ×——Replace Caution： （1） If the work place has a lot of dirt or other pollutants, time between maintenance intervals should be decreased. （2）If problems like loss of engine power, sudden increase in truck noise, or black smoke occur, check the truck immediately.
  • Page 58 Semi-annu One and a Check Daily 3months Annual Service required Tool half Monthly Item (8 hrs) (500hrs) (2000hrs) (250hrs) (1000hrs) Check for the oil ○ ○ ○ ○ ○ leakage of engine Check oil capacity and ○ ○ ○ ○ ○...
  • Page 59 Drive system periodical maintenance schedule One and a Semi-annu Check Daily 3months Annual half Service required Tool Item (8 hrs) Monthly (500hrs) (2000hrs) (1000hrs) (250hrs) Replacement × oil-absorbing filter × × First time element (200h) ○ ○ ○ ○ ○ Leakage condition ×...
  • Page 60 ○ ○ ○ ○ ○ Rim damage condition Split-type rim bolt Test ○ ○ ○ ○ ○ looseness hammer Steering system periodical maintenance schedule One and a Semi-annu Check Daily 3months Annual half Service required Tool Item (8 hrs) Monthly (500hrs) (2000hrs) (1000hrs)
  • Page 61 Brake system periodical maintenance schedule One and a Semi-annu Check Daily half 3months Annual Service required Tool Item (8 hrs) Monthly (500hrs) (2000hrs) (1000hrs) (250hrs) Dividing ○ ○ ○ ○ ○ Idle stroke scale ○ ○ ○ ○ ○ Pedal travel Brake pedal ○...
  • Page 62 Brake drum abrasion, ○ damage condition Check baseboard ○ deforms Flaw Brake ○ Check if crack detectio baseboa Check if loosen during Test ○ installation hammer Hydraulic system periodical maintenance schedule One and a Semi-annu Check Daily 3months Annual half Service required Tool Item...
  • Page 63 Wire harness damage ○ ○ ○ ○ loosen Wire condition Circuit joint looseness ○ ○ ○ condition Steerin Work and installation ○ ○ ○ ○ ○ indicato condition r light Work and installation ○ ○ ○ ○ ○ Horn condition Light Work and installation ○...
  • Page 64 Fork root hook welded ○ ○ ○ ○ part crack wear condition. welded part between Inner and outer ○ ○ ○ ○ mast beam crack or damage. welded part between mast and tilting ○ ○ ○ ○ cylinder has bad welding, crack or damage.

  • Page 65: Torque Specifications

    Check chassis lubrication ○ ○ ○ ○ lubricate condition after clean grease or change oil Check oil in the ○ oil tank Working ○ ○ ○ ○ ○ system condition 2. Torque Specifications ： Unit N · m Grade Bolt‟s diameter 4～5 5～7 7～9...

  • Page 66: Periodic Replacement Of Key Safe Parts

    3. Periodic replacement of key safe parts Some parts are not checked during routine maintenance. Please refer to the table below for the average service life of these parts Replace them when their service life has expired, sooner if they damaged. Name of key safe part service life (years) 1～2...
  • Page 67 4. Table for the oil used in the truck all-terrain forklift used oil Description Shop sign, Code name Capacity(L) Remark 0#（Summer） Diesel -10#∽-35#（Winter） fueling General season：CH-4 grade capacity 15W／40 see engine Diesel vehicle use Diesel engine oil winter：CH-4 grade 10W／30 manual or Arctic-alpine: CH-4...

  • Page 68: Lubrication System Drawing

    5.Lubrication system drawing Notice: 1. The detail of lubricating oil for different trucks can refer to List of forklift oil. 2. Lubrication for mast guide and chain, please see the mast lubrication of Weekly Maintenance (every 40 hours). Environment protection 1.Clean, maintain, repair truck at the appointed place.

  • Page 69: Labels：stick Various Nameplate And Mark At Different Position Of The Truck

    IX. Labels：Stick various nameplate and mark at different position of the truck 2.CE Danger label labe Hang label Hang label Hand injury risk Safety belt label Load curve label Hydraulic oil label label Antifreeze label 10.Text label Tie down label Diesel label 16.
  • Page 70 ： Danger Label on the outside of mast Truck can Hold TIP OVER! Don‟t stand on or under fork, otherwise the life Risk of serious Tight INHURY Lean Away Brace may be in danger. or DEATH! WARNING Faste Seatblet Do Not Jump! From Impact Feet 6：...
  • Page 71 closed, the steering wheel and seat back are restored to their original Tie down label position. Hand brake label 12.Gasoline label：it shows that oil filter position, which on the rear left outrigger of overhead guard Operate label Hydrodynamic truck Tonnage label INCHING BRAKE ACCELERATOR...
  • Page 72 Lubrication system label LUBRICATION SYSTEM CHART 24.Four-wheel drive label Print position of serial number Each car corresponds only to a serial （ ） 22、 Danger label No entering mast label number, which is printed on the front right Warning： It is dangerous of your life. If the side of the frame.

  • Page 73: Truck Transporting, Lifting, Towing

    X. Truck transporting, lifting, towing Hoist the truck Use steel wire ropes through the holes in the two sides of the outside mast‟s beam and the hook of the counter balance, then use the lifting device to hoist the truck. Warning •...

  • Page 74: Xi.main Technical Performance Parameter

    XI.Main technical performance parameter LS-RT50-XW70E-RT2 LS-RT50-XW70C-RT4 Model Rated capacity 5000 5000 Load centre distance Overall maximum lift height 3000 3000 Free lift height Maximum lift speed (with load) mm/s Tilt of the mast 15° /15° 15° /15° Max travel speed...
  • Page 75 Ⅻ.Operational method of lead acid battery I. Maintenance-free Lead-acid Battery and the usage Maintenance-free battery serves as power starting engine, and also use as substitute power for voltage stabilizing and overloaded engine. It owns characteristics like small internal resistance, stable terminal voltage, large supply current, little water consumption, high capacity, good cold-starting performance, light terminal etching, small volume, light quality, low fault rate and easy maintenance.
  • Page 76 Check of maintenance-less battery Cause the environment of forklift use is very high, water consumed easily, you should pay attention to electrolyte height. There is fluid adding mouth at the battery cover, once the electrolyte level is lower than LOWER LEVEL, please add pure water to highest level UPPER LEVEL.
  • Page 77 III. Notice to battery use Battery will produce explosive gas, the electrolyte is corrosive, and the current generated from the battery is enough to burn the skin. During the operation or work around it, please obey the following item: · During work around the battery, you should wear safety goggles; ·...

  • Page 78: Xiii.use, Installation And Safety Rules Of Attachment

    XIII.Use, installation and safety rules of attachment The attachment is in accordance to International standard ISO2328 Hook-on type fork arms and carriages - mounting dimensions, such as clamp, rotator, paper roll clamp, carrying ram, side-shifter etc. Sideshifter Fork positioner Rotator Push/pull Coil boom Bar arm clamp...
  • Page 79 2. Attachment assembly Warning Any change to safety or capability of attachment without authorization is strictly prohibited Actual load capacity should be the least of rated load capacity, attachment load capacity, combined load capacity of truck and attachment, combined load capacity of truck. Generally speaking, the combined load capacity of truck is the least.
  • Page 80 XIV.Description of OPS System OPS System（For hydraulic electronic shifting truck only） The OPS (Operator Presence Sensing) System is developed to assure the safety and prevent the operators from travelling or handling operation when the operator is not seated or not in the proper position, helping to decrease or prevent the accidents due to the maloperation.
  • Page 81 If it happens to encounter the following situations, please park the forklift truck in a safe place and contact the local agency of Liftsmart forklift for inspection. a) Shift the gear switch to first gear of forward or reverse, but the neutral indicator light flashes when ready to start.
  • Page 82 XV.Relevant safety command and standard The model by CE certification which according to the follow instruction and standard: DIRECTIVE 2006/42/EC OF THE EUROPEAN PAMENT AND OF THE COUNCIL, DIRECTIVE 2000/14/EC OF THE EUROPEAN PAMENT AND OF THE COUNCIL, EN ISO 3691-1:2015,EN ISO 3691-1:2015/AC:2016 ISO/TS 3691-7:2011, EN1175-2:1998+A1:2010,...
  • Page 83 XVI.Maintenance record Date Item of maintenance Signature Remark...
  • Page 84 13 22 54 www.adaptalift.com.au...

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