LiftSmart LS-RT50 User manual

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

Foreword
5.0t all-terrain forklift is a new developed forklift of Adaptalift Group, it
owns characteristics as energy conservation and environment protection, novel
structure and superior performance.
This manual introduces safety, operation, transportation, lubrication, brief structure
and maintenance method of trucks. Driver, maintenance personnel and equipment
manager must read and comprehend this manual before use.
Because of the update and improvements of our products, there may be some
differences between this operation manual contents and your forklift truck.
Illustration adopted by this manual may vary from your truck structure.
This manual is also available for container forklift and forklift equipped with
attachment.
Please contact Adaptalift Group or your sales agent if you have any
questions regarding this manual.
©07/2019
Model Engine Hydraulic
transmission
Rated lifting
weight (t)/
Load Center
(mm), Remarks
LS-RT50 Cummins
QSF3.8t3TC112
Diesel Engine
RTE500-120000-G00 5/600
LS-RT50-4 RTC500-120000-G00 5/600

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. Maintenance ............................................................................................................... 32
1. Daily maintenance（8hours）...............................................................................................32
2. Weekly maintenance（40hours）...............................................................................................36
3. Every One and a half months maintenance（250hours）................................................40
4.Every half year maintenance (1000 hours)...........................................................................43
5.Annual maintenance (2000 hours)...............................................................................................45
6、Others......................................................................................................................................46
V. Structure and stability of truck................................................................................... 49
VI. Operation.....................................................................................................................51
1. Start-up......................................................................................................................................51
2. Travel.........................................................................................................................................51
3. Pick up.......................................................................................................................................52
4. Stacking load............................................................................................................................52
5. Remove load.............................................................................................................................53
VII. Parking........................................................................................................................ 54
1. Parking daily.............................................................................................................................54
2. Park the truck for a long time.................................................................................................54
3. Running after storing for a long time.....................................................................................54
VIII. Maintenance.............................................................................................................56
1. Preventive maintenance schedule........................................................................................57
2. Torque Specifications ..............................................................................................................65
3. Periodic replacement of key safe parts.................................................................................66
4. Table for the oil used in the truck...........................................................................................67
5.Lubrication system drawing.....................................................................................................68
IX. Labels：Stick various nameplate and mark at different position of the truck .. 69
X. Truck transporting, lifting, towing.............................................................................. 73
XI.Main technical performance parameter................................................................... 74
XIII.Use, installation and safety rules of attachment.................................................. 80

XIV.Description of OPS System....................................................................................82
XV.Relevant safety command and standard............................................................... 84
XVI.Maintenance record .................................................................................................86

5
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.
3. When carrying a load, do not overload. The forks should insert in the load completely and
evenly. It is not permitted use only one fork to load.
4. You should operate the truck smoothly when starting, turning, traveling, braking and parking.
On a slick or wet road, decrease speed when turning.
5. Lower the forks and tilt the mast backwards when traveling with a load.
6. If the slope angle is bigger than 10%, travel forward up slope and backward down slope.
Never turn sideways or stack load on an incline.
7. Be aware of bystanders, barriers, potholes and overhead clearances.
8. DO NOT allow passengers or persons to stand on the fork.
9. DO NOT stand or walk under the fork.
10. DO NOT operate the truck or attachment from any position except the operator‟s seat.
11. DO NOT carry the load unpackaged. Be careful when carrying large loads.
12. Take care not to lose load when lift height is higher than 3 meters, take protective
measures if necessary.
13. Travel with load as low as possible and tilt back the mast.
14. When driving over a dock-board or bridge-plate, be careful and drive slowly.
15. Make sure that there is no naked flame near the area, never smoke. The driver should not
remain seated when adding fuel.
16. Treat the truck with attachments as a loaded truck
17. When leave the truck, you should put the forks down, make the shift lever in neutral, shut
down the engine and cut the power. When parking on a grade, make sure to tighten the
brake lever. If necessary, use a block when parking on a grade for a long time.
18. If the truck suddenly gets out of order, or for leakage of electrolyte, hydraulic oil or brake oil
when lifting goods or grade climbing, leave truck in safe state and contact service technician
immediately.
19. During installation and assembly, there will be noise and vibration. Please choose the right
tool and assembly method. Minimize the noise and vibration as soon as possible to reduce
noise pollution.
20. The work road surface for forklift should be stable and free of litter, preferably cement,
blacktop or concrete. If there is snow, ice, water or other eye irritants, protect against these
and resume work.
21. Move the truck to the place where respects traffic when it anchors. If the reason is brake or
turn system, move it by a suitable truck (Refer to the part of truck carrying); other reasons,
use a suitable truck to move, tie the cord outside of truck. Please abide by the traffic
regulations when moving the truck on roads.
22. DO NOT operate the truck or load cargo after removing the hood, water tank cover board,
overhead guard, or load backrest of mast.
23. Make sure there is enough light around the work area.At night, use the head lamps.
24. Handle with automatic pitch fork of the forklift when the load must not make lateral
operation, so as not to lose balance and forklift components of the damage caused.
25. Before hydraulic oil temperature rises, do not tilt the mast forward, backward or lift the mast
to the limit when in idling.
26. No modifications or alterations to a powered industrial truck, which could affect, for
example, capacity, stability or safety requirements of the truck, shall be made without the
prior written approval of the original truck manufacturer, its authorized representative, or a
successor thereof. This includes changes affecting, for example, braking, steering, visibility
and the addition of removable attachments. When the manufacturer or his successor

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
engineer(s) expert in industrial trucks and their safety;
(2) Maintain a permanent record of the design, test(s) and implementation of the
modification or alteration;
(3) Approve and make appropriate changes to the capacity plate(s),decals, tags and
instruction handbook;
(4) 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 the organization that made the modification or alteration.

7
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

8
1、Instruments

9
Water temperature gauge
This gauge indicates the oil
temperature in the torque converter
transmission box when the key is at
┃(ON) position. In normal status, LED
Displayed in the range of 60 ℃-110 ℃
Caution
If LCD display in the red zone ,
please stop the truck at once.
Decrease the engine speed to make
the engine cool. Check the cooling
fluid if enough and the fan belt‟s
elasticity if fit.
Fuel gauge
The gauge indicates the fuel level in
the tank when the key is at ┃(ON)
position.
Suggest filling up the fuel tank after
work every day.
Hourmeter
This meter measures working time of
engine when the key is at ┃(ON)
position. The meter increase one
number every working hour.
Use meter to schedule lubrication and
maintenance periods.
Caution
When reaching the first 100h, the
spanner logo will flash one hour at
regular intervals to reminder of the
maintenance to the forklift. Refer to
monthly maintenance after first flash.
Refer to periodical maintenance
schedule for per period. Take the actual
flashing time as standard.
Charging indicator
This lamp indicates the battery
condition of charge. The lamp comes
on when the ignition switch is set at
┃“ON”, but it goes out as the engine
starts and accelerator pedal is pressed
Caution
If the light continues to stay lit or lights
up during operation, the charging rate is low
and should be checked immediately.
Engine oil pressure alert lamp
This lamp indicates the pressure
condition of engine lube oil. Although it
lights up when the engine switch is set
at “ON”, once the engine starts up and
the accelerator pedal is pressed, this
lamp goes out.
Caution
If this light continues to stay lit or lights
up during operation, the pressure is lower
than 0.05Mpa and should be checked
immediately.
Glow indicator [Diesel truck]
Turn the key to “ON” position and

10
the indicator lights up for a moment.
After the indicator goes out, turn the
key to . “Start” position
Sedimentor indicator [Diesel truck]
In normal state, once the starter is set
to “ON” position, this lamp lights
up. After the engine is started up, it
goes out.
This lamp lights up when water in
sedimentor reaches to a certain level,
while the engine is running.
注意
如果灯亮时继续操作，燃油喷射泵就有
可能被损坏。
Transmission oil temperature
warning light（Hydraulic Forklift）
In normal state, once the starter is set
to “ON” position, this lamp lights
up. After the engine is started up, it
goes out.
During work time if the oil
temperature exceed the normal
rang(60~120。C) the indicator light on
Caution
If the pointer enters the red range, stop
the operation instantly and slow down
engine speed to cool the coolant and wait
until the pointer goes into the green range,
and have a check then.
Engine fault indicator
[Electronic-controlled engine]
When the engine gets out of order,
this Indicator will be on. then it must
immediately stop, according to an
engine fault table troubleshooting.
Can be judged according to the
fault indicator lamp (flash code), Can
be based on the fault indicator (flash
code) judgment, or ECU diagnostics
port connected to diagnostic
equipment, read the fault code
information stored in the ECU.
For more information, see engine
manual
Neutral position start-up indicator
[Electric-switch]
Put the steering handle in the neutral
position when truck on the temporarily
stop, the light will indicated on
The truck can be started up only in the
neutral position.
It‟s prohibited for truck in the neutral
position sliping when it‟s on the slope.
OPS indicator [Optional]
When this light is on, it means
driver leave the seats or not sitting on
the seat correctly.
Parking indicator
Parking indicator shows on means
brake is affected, Please loosen the
parking handle (hand brake handle),

11
the parking indicator will shows off.
Warning
It will damage the engine and
transmission, etc. when indicated.
Severe warning indicator
[Electronic-controlled engine]
OnlyCummins engine forklift truck:
When this light is on, it indicates the
engine is in severe work condition and
the engine power reduced severely. If
condition stays and starts engine
protection shut-down, then this
indicator will flash 30 seconds before
engine shut down to warn the
impending shut-down.
Air filter indicator
When the light is on, it indicates the air
inlet system is blocked, stop the truck
and clean the air filter.
Seat belt warning indicator
[Optional]
Whenthislight is on,it means not
wearing a seatbelt or not locked.
Accumulator warning indicator
The light is on, indicating that
the braking pressure is too low and
needs to be stopped for repair.

12
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. Technical specification：
Display screen：3.8 inch/97mm, QVGA, 320×240pixel; black-white transflective
LCD, with LED backlight and built-in heater.
Visual angle：Horizontal visual±55°, vertical visual +45°/-60°.
Button: Five touch mode buttons.
Alarm: PV380 display has two alarm lights in the button area,Yellow LED
represents for general fault alarm, red LED represents for stop fault alarm;After
fault occurred, PV380 will display different indicator according to fault level, the
indicator stay lit even the fault page is hidden;Trigger the output by setting the
alarm point, and then connect with buzzer or stop relay.
Mean time between failures: 50000hrs.
1. Main interface display as follows：

13
Engine general fault
When this indicator lights up, it indicates the
truck trouble, stop the truck immediately
and troubleshoot the fault according to fault
table.
Engine stop fault
When this indicator lights up, it indicates
severe engine fault, stop the truck
immediately and troubleshoot according to
fault table.
Glow indicator
The light comes on when the switch is set
to┃(ON). After the indicator goes out,
turn the switch to the (Start) position.
Engine exhaust treatment fluid (DEF)
level indicator
It is used to indicator the level, when this
indicator lights up, it indicates the DEF level
is too low, stop the truck, add diesel
particulate filter oil, start the engine after the
light goes out.
Caution
Please select the engine exhaust
treatment fluid that meets the standard
requirements, otherwise it will damage the
DEF tank and other related original parts.
Air filter indicator
When this indicator lights up, it indicates air
filter element blockage and needs clean.
Exhaust temperature indicator
It is used to indicate the engine exhaust
temperature. When this indicator lights up,
it indicates that the engine exhaust
temperature is too high, stop the truck
immediately, check the engine exhaust
device and reduce the temperature.
Static regeneration
This light indicates the static regeneration
condition of engine
Low brake pressure indicator
This light indicates the pressure state of the
accumulator. This indicator lights up when
the starting switch places in the “travel”
position, but goes out after the engine
starts.
Caution
If the light continues to stay lit or
flashes during operation, the accumulator
pressure is lower than normal value and
should be checked immediately.
Transmission oil temperature
It is used to display transmission oil
temperature, when ! is displayed after
,it means the transmission oil
temperature is too high, stop working,
reduce engine speed to cool down until !
disappears. Otherwise, check oil or do
other checks.
Battery voltage and charging indicator
This light indicates the battery charging
status, it lights up when the switch is set
to┃(ON), but goes out after the engine
starts.

14
△
! Caution：
If the light continues to stay lit or flashes
during operation, the charging rate is low
and should be checked immediately
Oil pressure indicator
This light indicates the pressure of the
engine lube oil. The lamp comes on when
the ignition switch is set to ┃(ON), but goes
out after the engine starts.
△
! Caution：
If the light continues to stay lit or flashes
during operation, the pressure is lower
than 0.05Mpa and should be checked
immediately.
Hour meter
When the key switch is set to ┃(ON), hour
meter works. Hour meter will add one
number for working per hour.
Hour meter reading displays forklift
accumulated actual working time.
Coolant temperature indicator
This light indicates engine coolant
temperature.
△
! Caution:
If the light continues to stay lit or flashes
during operation, engine coolant
temperature is too high and should be
checked immediately.
Fuel gauge
When the key in ┃(ON) position, the gauge
indicates the fuel level in the tank.
It‟s suggested to fill up the tank after work.
Parking Indicator
Parking indicator shows on means
brake is applied. Please loosen the parking
handle (hand brake handle), and then the
parking indicator will show off
△
! Warning：
Running the truck when the indicator is on
will damage the engine and transmission etc.
2. Press any button at the bottom of
home page and other parameter display
page, the system bottom will pop-up the
following menu:
Buttons are defined as follows：
：Enter display setting page。
：Enter post-processing request
page.
：Enter engine fault page.
：Page turn.
2.1 After entering display setting page,
interface displays as the following
figure:

15
Adjust display parameter in this page,
choose to set different parameters,
adjust different parameter values
or definitions of the display, return to
previous menu.
When the cursor points at
Transmission Calibration, press Enter, and
enter transmission calibration password
input page
Input transmission calibration
password at this page, set
cursor position values, move
cursor, return to previous menu,
confirm password.
Enter transmission calibration page if
password is correct.
AEB Req means the request for
transmission calibration, make transmission
calibration after entering this page. IP page
means entering inching switch calibration
page, as shown below
IP Rep means the request for inching
switch calibration. AEB page means
entering transmission calibration page.
Transmission and inching switch calibration
refer to “III. ZF Transmission”.
2.2 After entering post-processing
request page, interface displays as the
following figure:

16
REGEN MODE stands for engine
regeneration mode, in this mode, there will
be the following conditions:
AUTO：Engine completes regeneration
mode normally.
INHIBIT: Engine suddenly stopped in
regeneration process.
If engine does not broadcast any
messages about regeneration mode, it
displays N/A.
Press OK, and system prompt:
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:
When the cursor points at ACTIVE
FAULTS-ECU, press OK and enter current
fault display page.
Check current fault information by
moving the cursor up and down,ADDRESS
00 means engine, 03 means transmission.
According to the displayed address
information to confirm if it is caused by
engine fault or transmission fault, and find
out corresponding fault code and
information through SPN and FMI numbers.
2.4 Press Page Turn on the main
interface, the second interface displays
as the following figure:

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.
Top right displays accelerator pedal
position.
Bottom left displays engine intake
temperature.
Bottom right displays machine working
hours.

18
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
switch
16.Steering wheel adjustable
switch
16.Steering wheel
adjustable switch

19
Steering wheel [1]
Turn left Turn right
It controls the movement direction of
truck. Rotate counterclockwise, the truck
moves to the left; rotate clockwise, then
moves to the right
Warning:
The truck adopts all hydraulic steering,
so when the engine is flameout, it’s
difficult to steer. The engine should be
started immediately to steer again.
Horn button [2]
Press the button in the center of
steering wheel, the horn will sound.
Combination switch（Turn signal switch/light
switch）[3]
Use this lever which is at the right side of
steering column to indicate the turning
direction of the truck.
Push the switch lever forward when turning
left, and pull it backward when turning right.
The appropriate turn signal will blink.
Forward-left turn light, N-neutral, Backward-right
turn light
The turn signal lever does not automatically
return to the neutral position unlike general
passenger cars. It must be returned to the
neutral position manually.
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
switch subject.
Key switch [4]
O(OFF)
This is the position where the key is
inserted or removed, and engine stop at
this position.
┃(ON)
The electric circuit is connected
when the starter switch at “┃”. After the
engine starts, the key keeps at this
position.
(START)
When the key is placed in the
“START” position, then engine starts.
When loosening the hand, the key will be
automatically returned to the “┃”
position by resilience force.
Diesel engine
When starting, the key is at “┃” position
and the preheat indicator lights (I) will be
on for a moment. After the light goes out,
turn the key to “ ” position.
Caution
1.Do not keep the key in the
“┃”position when the engine is shut
down to avoid battery discharge.

20
2.When the engine is running, do
not turn the key to” ”
position to avoid starter motor being
damaged.
3.When starting, do not rotate the
starter motor for more than 5 seconds at
a time. There should be 120 seconds
between two start.
Lift lever [5]
Control the lifting and downing of the
forks.
Push-- down pull--lift
Lifting speed is controlled by tilting
backwards angle of lever and accelerator
pedal. The downing speed can be
controlled by tilting forwards angle of the
lever.
Tilt lever [6]
It is used for forward and backward
tilting of mast.
Push—tilt forward
Pull---tilt backward
The tilting speed is controlled by
tilting angle of the lever and accelerator
pedal effort
Caution
Cause multiway valve equips with
tilt lock valve, when the engine misses,
even push forward the tilting handle
can not tilt forward the mast.
Cup holder[7]
It is in the right side of the instrument. It‟s
designed for the operator to put the cup.
1 Warning light.：Press backward, the warning
light is on; press forward, the warning light is
off.
2 Rear headlamp switch：Press backward,
the rear headlamp is on; press forward, the
rear headlamp is off.
3 2-4 drive switch: press down, convert to
4 drive; press up, convert to 2 drive.
Caution
Four-wheel drive is only used in bad road
conditions or extreme conditions.Use
2-wheel drive when driving normally.
Forklift trucks should be driven by two
wheels when turning on roads, sand,
snow and ice.
4 Differential lock switch: press down,
differential lock; press up, differential
works.
Differential lock is a locking mechanism
installed on the central differential for
four-wheel drive vehicle. Its function is to
improve the passing capacity of forklift in bad
road conditions or extreme conditions, that is,
when a wheel of the forklift idles, the