Still RCG40 Original Instructions Manual
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Still RCG40 Original Instructions Manual

Lpg forklift truck
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Original instructions
LPG forklift truck
RCG40
RCG50
4234 4236
60118011601 EN - 09/2020

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  • Page 1 Original instructions LPG forklift truck RCG40 RCG50 4234 4236 60118011601 EN - 09/2020...
  • Page 3 Tel. +49 (0) 40 7339-0 Fax: +49 (0) 40 7339-1622 Email: info@still.de Website: http://www.still.de Produced in China for STILL Rules for the operating com- pany of industrial trucks In addition to these operating instructions, a code of practice containing additional informa- tion for the operating companies of industrial trucks is also available.

  • Page 5: Table Of Contents

    Table of contents Introduction Truck data ............Intended use .
  • Page 6 Table of contents Environmental considerations ......... . . Disposal of components and batteries .
  • Page 7 Table of contents Check the engine oil level ..........Transmission oil level inspection procedure .
  • Page 8 Table of contents Adjusting the fork arm distance ..........Picking up a load .
  • Page 9 VDI Datasheet for RCG40 ........

  • Page 11: Introduction

    Introduction...

  • Page 12: Truck Data

    Introduction Truck data Truck data We recommend that you record all basic fork- lift truck data in the following table so that it is available if required by the sales network or authorised service centre. Type Serial number Date of delivery 60118011601 EN - 09/2020...

  • Page 13: Intended Use

    Introduction Intended use Intended use Driving routes The industrial truck may only be used as per- mitted. Driving routes shall be sufficiently paved, level The industrial truck is used for moving and lift- and free of objects. Drain channels and rail- ing the loads indicated on the capacity rating ways crossings, etc., shall be levelled and, if plate.

  • Page 14: Impermissible Use

    Introduction Impermissible use Attachments The permissible carrying capacity of the at- tachments and the permitted load of the indus- Attachments shall only be used as permitted. trial truck (carrying capacity and load moment) The driver shall be instructed in the handling combined with the attachments shall not be of attachments.

  • Page 15: Description Of Use And Climatic Conditions

    Introduction Description of use and climatic conditions The truck may not be operated in areas where there is a risk of fire, explosion or corrosion, or in areas that are particularly dusty. Stacking or unstacking is not permissible on inclined surfaces or ramps. Description of use and climatic conditions Normal use Special uses (applies to trucks with spe-...

  • Page 16: Ce Labelling

    Introduction CE labelling CAUTION NOTE This label is found on the truck in the This means that particular attention must be areas where particular care and atten- paid to the specific technical meaning be- tion are required from the operator. cause this may not be obvious, even to a spe- Refer to the appropriate section in these cialist.

  • Page 17: Emc - Electromagnetic Compatibility

    Introduction EMC – Electromagnetic compatibility EMC – Electromagnetic compatibility Electromagnetic compatibility (EMC) is a key secondly checks it for sufficient resistance to quality feature of the truck. electromagnetic interference with reference to the planned usage location . A number of EMC involves electrical measures are taken to ensure the limiting the emission of electromagnetic in-...

  • Page 18: Ec Declaration Of Conformity In Accordance With Machinery Directive

    EC declaration of conformity in accordance with Machinery Directive EC declaration of conformity in accordance with Machinery Di- rective EC / EU declaration of conformity STILL GmbH Berzeliusstraße 10 D-22113 Hamburg We declare herewith that the machine Industrial truck model:...

  • Page 19: Safety

    Safety...

  • Page 20: Definition Of Terms Used For Responsible Persons

    Safety Definition of terms used for responsible persons Definition of terms used for responsible persons Operating company The operating company is the natural or legal The operating company is responsible for the person or group who operates the truck or on scheduling and correct performance of regular whose authority the truck is used.
  • Page 21 Safety Definition of terms used for responsible persons The driver must: operating company or an authorised represen- tative, and have been specifically instructed to have read and understood the operating ● drive the truck. Specific knowledge of the truck manual to be operated is also required.

  • Page 22: Safety Regulations

    Safety Safety regulations Safety regulations Safety guidelines It is essential that operating personnel and re- DANGER pair personnel observe the" rules for the prop- Safety systems (e.g. the seat switch) are there for er use of industrial trucks" enclosed with these safety.

  • Page 23: Exhaust Gases

    Safety Safety regulations WARNING CAUTION Various pieces of special equipment are connected Depending on the duration of use and to the special "speed reduction" function. This is sim- operating time, components carrying ex- ply an assistance function, on which the driver must haust gases and exhaust air may be- not solely rely during operation.

  • Page 24: Ground Condition For Using The Truck

    Safety Ground condition for using the truck Ground condition for using the truck In order for the truck to be used, suitable ground must have the following characteris- tics: Even and level ● Hard ● Sturdy ● Free of obstacles ●...

  • Page 25: Residual Dangers, Residual Risks

    Safety Residual dangers, residual risks Residual dangers, residual risks Despite careful working and compliance with failure of the operating company to comply standards and regulations, the occurrence of with these regulations either intentionally or other risks when using the truck cannot be en- carelessly.

  • Page 26: Safety Regulations When Driving

    There is a risk of acci- dent! – Do not use devices during travel or when handling loads. – Set the volume so that warning signals can still be heard. 60118011601 EN - 09/2020...

  • Page 27: Safety Regulations In Case Of Accidental Lateral Tipping

    Safety Safety regulations in case of accidental lateral tipping Safety regulations in case of accidental lateral tipping If as a result of incorrect manoeuvring the c) Remain firmly seated, grip the steering truck appears to be tipping over sideways, wheel and dig your heels in. Wait until the carefully follow the instructions below: truck has reached a stable position before leaving the truck.

  • Page 28: General Safety Rules For Liquid Gas

    Safety General safety rules for liquid gas leaks it remains suspended near the ground, thus DANGER increasing the resulting hazard. It is prohibited to park or leave the truck in closed and/or under- LPG is highly flammable due to its volatility. Fur- ground environments.
  • Page 29 Safety General safety rules for liquid gas A - During use not airtight. To check the tightness of the system, use soapy water, Nekal solution or Before loosening the pipe fittings or hoses, other foaming agents. It is prohibited to in- ●...

  • Page 30: Exercise Caution When Handling Gas Springs And Accumulators

    Safety Exercise caution when handling gas springs and accumulators in the garages only when sufficient ventila- Garages, warehouses and repair shops ● tion is guaranteed (no hazardous concen- must be well-ventilated. It should be noted tration of explosive gases). that liquid gases are heavier than air and thus accumulate near the ground, in work pits and in other depressions in the ground, B —...

  • Page 31: Safety Regulations For Handling Consumables

    Safety Safety regulations for handling consumables Safety regulations for handling consumables Permissible consumables DANGER Failure to observe the safety regulations relating to consumables may result in a risk of injury, death or damage to the environment. – Observe the safety regulations when handling such materials.

  • Page 32: Oils

    Safety Safety regulations for handling consumables Oils DANGER WARNING Oils are flammable! There is a risk of slipping on spilled oil, particularly when combined with water! – Follow the statutory regulations. – Spilt oil should be removed immediately with oil- –...

  • Page 33: Hydraulic Fluid

    Safety Safety regulations for handling consumables Hydraulic fluid WARNING WARNING These fluids are pressurised during op- These fluids are pressurised during op- eration of the truck and are hazardous to eration of the truck and are hazardous to your health. your health.

  • Page 34: Battery Acid

    Safety Safety regulations for handling consumables Battery acid WARNING WARNING Battery acid contains dissolved sulphuric Battery acid contains dissolved sulphuric acid. This is toxic. acid. This is corrosive. – Avoid touching or swallowing the bat- – When working with battery acid, use tery acid at all costs.

  • Page 35: Environmental Considerations

    Safety Environmental considerations Environmental considerations Disposal of components and batter- The truck is composed of different materials. If components or batteries need to be replaced and disposed of, they must be: disposed of, ● treated or ● recycled in accordance with regional and ●...

  • Page 36: Packaging

    Safety Safety instructions for the LPG system Packaging During delivery of the truck, certain parts are packaged to provide protection during trans- port. This packaging must be removed com- pletely prior to initial start-up. ENVIRONMENT NOTE The packaging material must be disposed of properly after delivery of the truck.

  • Page 37: Safety Information On The Lpg System

    Safety Safety information on the LPG system Safety information on the LPG system DANGER DANGER In the event of an LPG leak, there is a Using twin LPG cylinders may carry a risk of explosion and fire at any time.If risk of explosion.
  • Page 38 Safety Emissions directly at the workplaces under the actual conditions present (further sources of noise, particular application conditions, sound reflec- tions) by the operating company. NOTE Please note the definition of "operating com- pany" in the sense of responsible persons! Vibrations The vibrations of the machine have been de- termined on an identical machine in accord-...

  • Page 39: Safety Tests

    Safety Safety tests Safety tests Carrying out regular safety inspec- tions on the LPG system Technical safety inspection of the LPG system The operating company must commission a competent person to check the LPG system. Observe the national regulations in the rele- vant country! In Germany, check the system in accordance with §...
  • Page 40 Safety Safety tests The operating company is responsible for en- suring any defects are remedied without de- lay. In the event of defects, notify the author- ised service centre. 60118011601 EN - 09/2020...

  • Page 41: Information About The Truck

    Information about the truck...

  • Page 42: General Forklift View

    Information about the truck General forklift view General forklift view General front view Fork arms Tilt cylinder Mast Forward Front wheels Right Driver’s Seat Backwards Overhead guard Left 60118011601 EN - 09/2020...

  • Page 43: General Rear View

    Information about the truck General forklift view General rear view Rear wheels Mast Rear weight Steering wheel Rear lights Control panel Trailer coupling Engine bonnet Overhead guard 60118011601 EN - 09/2020...

  • Page 44: Instrumentation And Controls

    Information about the truck Instrumentation and controls Instrumentation and controls Overview of the driver’s compartment Parking brake Lifting and lowering operating handle Speed switch Lighting and direction indicator switch Inching pedal Driver’s seat Brake pedal Steering wheel Accelerator pedal Horn button Display unit/Control panel Direction selection lever Side shifter operation lever...

  • Page 45: Display Unit

    Information about the truck Instrumentation and controls Display unit “SCR error” indicator light (not applied for “Water separator light” indicator light (not LPG truck) applied for LPG truck) Seat indicator light ”DPF regeneration disabled“ indicator Indicator light for "glow plug preheating" (not light(Red light) (not applied for LPG truck) applied for LPG truck) ”Battery charging“...

  • Page 46: Truck Identification

    Information about the truck Truck identification Truck identification Chassis number The truck serial number is stamped on the lower crossmember of the chassis at the driv- er's step plate Production number  xx xxxx x xxxxx NOTE The production number is used to identify the truck.

  • Page 47: Nameplate

    Information about the truck Truck identification Nameplate Type Refer to the technical data listed in these op- Production number erating instructions for more detailed infor- Year of manufacture mation Tare weight in kg CE labelling Max. permissible battery weight in kg (for Nominal drive power in kW electric forklift trucks only) Battery voltage in V...

  • Page 48: Engine Plate

    Information about the truck Truck identification The information for the battery weights (5，6) and the ballast weight(7)only applies to elec- tric forklift trucks. Engine plate Engine Model Name and Number Label  The engine model name and engine code number are written in this label(1). 60118011601 EN - 09/2020...
  • Page 49 Information about the truck Truck identification Engine Serial Number  The engine code and manufacturing number are engraved in the position(1) These num- bers are necessary to request quality assur- ance or to order parts. Product name Year of manufacture Serial Number After new representative specification 60118011601 EN - 09/2020...

  • Page 50: Location Of The Decals

    Information about the truck Location of the decals Location of the decals 60118011601 EN - 09/2020...
  • Page 51 Information about the truck Location of the decals Warning sign: Mast safety warning Warning sign: Danger due to overheating of Decal information: Capacity rating plate radiator Decal information: Filling in gasoline (option) Warning sign: Danger due to shearing / Manufacturer’s name Danger to the driver’s head with engine CE label hood not fully closed.
  • Page 52 Information about the truck Location of the decals 60118011601 EN - 09/2020...

  • Page 53: Use And Operation

    Use and Operation...

  • Page 54: Truck Transport And Lifting

    Use and Operation Truck transport and lifting Truck transport and lifting Use a truck or flatbed trailer to carry the forklift truck The truck is normally transported by road and rail complete with lift mast. If the truck's di- mensions exceed the max. clearance size al- lowed, it is transported with mast disassem- bled.

  • Page 55: Loading And Unloading The Truck

    Use and Operation Truck transport and lifting storage. In salty environments, appropriate protection must be provided. Loading and unloading the truck Use an inclined plane or a movable platform to load and unload the truck. If the truck is not operational, lift as described below.
  • Page 56 Use and Operation Truck transport and lifting Lifting the truck with a crane DANGER When lifting the truck with a crane, there is a risk of accident and fatal injury if personnel are in the working area of the crane. When using a crane to lift the truck, pay particular at- tention to ensure that no personnel are in the vicinity of the crane.

  • Page 57: Commissioning The Truck

    Use and Operation Truck transport and lifting CAUTION After hanging the slings from the lifting hook, the safety lock (4) must be fastened. The slings must not touch the overhead guard or any other installed equipment when the truck is being lifted. DANGER The overhead guard will be damaged if it is contac- ted by lifting equipment that is under tension from...

  • Page 58: Remaining Ready For Operation

    Use and Operation Remaining ready for operation Remaining ready for operation Pre-shift checks Carrying out the following checks as part of your daily routine will help to keep the forklift truck in good condition. These checks are supplemental and do not replace periodic maintenance work.
  • Page 59 Use and Operation Remaining ready for operation Make sure that the lights work correctly (if Check the shut off valve if L01 fault appears ● ● applicable). Check brake oil level. ● Visually check that the chains are taut. ● Check the fuel level and clips ●...

  • Page 60: Seat Belt Status And Performance Checks

    Use and Operation Remaining ready for operation Seat belt status and performance checks DANGER For safety reasons, the condition and protective ability of the seat belt must be checked on a daily basis. Do not operate the vehicle with the seat belt re- moved.

  • Page 61: Checking The Condition Of The Tyres

    Use and Operation Remaining ready for operation – Try to pull the belt. The automatic blocking  mechanism must not allow the belt (1) to come out of the retractor (2). CAUTION A warning sound will be activated when the operator leaves the seat without parking brake applied.

  • Page 62: Check The Wheel Nuts For Correct Condition

    Use and Operation Remaining ready for operation Check the wheel nuts for correct condition – Visually check the markings in the wheel  nuts and rims are correctly attached, re- tighten with torque spanner if necessary. Tightening torque: Front tyres (M20X1.5) : 525 N.m±10% Front tyres (M20X1.5) : 525 N.m±10% –...

  • Page 63: Check The Condition And Operation Of Chain

    Use and Operation Remaining ready for operation Check the condition and operation of chain – Check load chains for any distortion before  operation. – Stop using the forklift immediately when the  hinge pins of chain rotate before operation. –...

  • Page 64: Checking The Coolant Level

    Use and Operation Remaining ready for operation – Contact your service center if chains are  suffering abnormal force. – Keep the chains clean, ensure no excessive  dust exits; Immediately lubricate the chains with specified chain spay if chain surfaces are dry.
  • Page 65 Use and Operation Remaining ready for operation CAUTION Risk of engine damage! If there is cooling fluid miss- ing, this indicates leakages in the cooling system. Check the cooling system for leaks, such as from leaking hose clips. – Remove the radiator water tank cover. ...

  • Page 66: Check The Engine Oil Level

    Use and Operation Remaining ready for operation Check the engine oil level NOTE Check engine oil level with the engine cold and the forklift on level ground. Open the bonnet. – Extract the dipstick (1) and clean it with a ...

  • Page 67: Transmission Oil Level Inspection Procedure

    Use and Operation Remaining ready for operation Transmission oil level inspection procedure NOTE Check the transmission level with the trans- mission in neutral, the oil hot (at least 40°C) and with the truck on level ground. – Ensure the forklift truck is stopped on a lev- el surface.

  • Page 68: Checking The Drive Axle Gearbox Oil

    Use and Operation Remaining ready for operation Checking the drive axle gearbox oil  – Unscrew the oil plug at the oil level aperture (1). – Check the gear shaft oil level to ensure it is near the observation aperture posi- tion(around 15mm).

  • Page 69: Change The Lp Gas Tank

    Use and Operation Change the LP Gas tank – Use a clean cloth to dry the dipstick(1)  – The oil level should be between the upper and lower markings on the dipstick. WARNING The hydraulic oil must be checked while the engine is stopped and the forklift is in horizontal level, –...
  • Page 70 Use and Operation Change the LP Gas tank – Don't stop the engine. – Close the shut off valve (1) on the gas tank  tightly. – Until the engine nature stop without fuel and then stop engine by turn the switch key. –...
  • Page 71 Use and Operation Change the LP Gas tank – Hold the handle(5) and roll backward like  picture – Loosen the clip(6),and need two persons to  remove and change the gas bottle. NOTE Secure the LPG bottle in the holder so that the connecting fitting of the shutoff valve on the gas bottle faces towards the bottom.

  • Page 72: Fill The Lpg Tank

    NOTE We recommend to top up gas before begin- ning work, as long as the truck is still cold. If temperatures differ much between the supply tank in the open and the tank on the truck it...
  • Page 73 Use and Operation Fill the LPG tank* – Stop the engine and, if needed, the heater  and combustionchamber. – Put on protective gloves. – Close the shutoff valve (1). – Remove the cap from the filler valve (4). – Open the shutoff valve (3) –...

  • Page 74: Fuel-Specifications

    Use and Operation Fuel-Specifications Fuel-Specifications Fuel is flammable and can be dangerous. You should handle fuel with care. LP-gas containing 95 to 70 % propane with the remainder butane. Adjust the ignition sys- tem and the mixture control, if the LP-gas con- tains 70 to 20 % propane and the remainder butane.
  • Page 75 Use and Operation Engine coolant - Specifications Engine coolant specifications tilled, or demineralized water be used to mix with coolants. Use a Long Life Coolant (LLC) or an Extended NEVER mix extended or long life cool- Life Coolant (ELC) that meets or exceeds the ants and conventional (green) coolants.

  • Page 76: Using The Truck

    Use and Operation Using the truck Using the truck Opening the tap of the gas bottle or gas tank DANGER After the truck has been shut down in a closed room for a lengthy period, ventilate the room well before turning on the electrical system. Slowly and carefully open the tap of the gas bottle or gas tank.

  • Page 77: Climbing On/Off The Forklift

    Use and Operation Using the truck Climbing on/off the forklift After performing the daily checks, carry out  the following operations to use the truck. CAUTION Always face the vehicle when dismounting the fork- lift, in order to prevent injury to the legs and back. NOTE Do not grip the steering wheel or joysticks when climbing on /off the forklift.

  • Page 78: Fastening The Seat Belt

    Use and Operation Using the truck Moving the driver’s seat – Lift the lever(1)and hold. – Push the driver’s seat into the desired posi- tion. – Release the lever. – Ensure that the driver’s seat is securely en- gaged. Adjusting the seat backrest Do not put pressure on the seat backrest while engaging it.
  • Page 79 – Do not twist the seat belt when fastening it – Only use the seat belt to secure one person – Have any malfunctions repaired by the STILL service centre – Smoothly pull the seat belt out of the belt retractor(2) and fasten over the thighs with a close fit to the body.

  • Page 80: Adjusting The Position Of Steering Wheel

    Use and Operation Using the truck – Fasten the seat belt. Releasing the seat belt – Push the red button (4) on the buckle (1).  – Manually guide the belt tongue slowly back to the retractor. NOTE Do not allow the seat belt to retract too quick- ly.

  • Page 81: Ignition Device

    Use and Operation Using the truck Angle adjustment – Pull down the handle(1) clockwise.  – Move the steering column into the required position. – Pull back the handle anti-clockwise to its original position. Ignition device  NOTE The forklift can only be started if the reversing lever is in the centre position (neutral).

  • Page 82: Lighting And Turn Indicator Switch

    Use and Operation Using the truck Lighting and turn indicator switch  The turn indicator and the lighting are active if the ignition key is in position "Ⅰ". Direction indicators  – When the lever (1) is moved into position "R", the right indicator light lights up.

  • Page 83: Warning Horn

    Use and Operation Using the truck Lighting  – The lighting is switched on by turning knob (3) on the lever: Turning the knob to the first click switches ● on the clearance lights; Turning the knob until the second click ●...

  • Page 84: Direction Selection Lever

    Wait at least one minute between start attempts in order to avoid running down the battery. If the engine still does not start after three attempts, do not try to start the engine again. Instead, contact your authorised service centre.

  • Page 85: Driving

    Use and Operation Using the truck DANGER Risk to health from exhaust gases! Exhaust gases from internal combustion engines are harmful to your health. In particular, the soot particles con- tained in the diesel exhaust gas can cause cancer. Letting the engine idle poses a risk of poisoning from the CO, CH and NO components contained in the exhaust gas.
  • Page 86 Use and Operation Using the truck – Sit in the driver's seat and fasten the safety belt. – Start the engine. – Release the parking brake (1) , and the cor-  responding LED(2) will turn off. – Move direction selection lever (3) in the re- ...

  • Page 87: Forward

    Use and Operation Using the truck – Gently press the accelerator pedal(4) to set  off. Forward – Put the direction lever into the forward di- rection. – Smoothly press the accelerator pedal The speed of the forklift truck accelerates in relation to the increase in pedal travel.

  • Page 88: Speed Switch

    Use and Operation Using the truck Speed switch  Travel speed can be changed by pressing the speed switch on the control panel when the truck stops. If need to drive for a long distance , please press the HIGH gear(1). If need to drive with load, please choose the low speed, and press the LOW gear(2).

  • Page 89: Driving Brake Pedal And Inching Pedal

    Use and Operation Using the truck – Move the lever (3) in the opposite direction  of travel: (A) FORWARDS, (B) BACK- WARDS; then press the accelerator pedal (2) . The forklift truck will now accelerate in the new drive direction. DANGER Using operating lever to directly reverse the operat- ing direction of the forklift truck during operation is...

  • Page 90: Operating The Service Brake

    Use and Operation Using the truck Operating the service brake Braking and stopping DANGER At speeds that are too high, there is a danger that the truck could slip or overturn! The braking distance of the truck depends on the weather conditions and the level of contamination on the roadway.

  • Page 91: Parking Brake

    Use and Operation Using the truck Parking brake  The parking brake must be actuated every time the driver exits the truck. NOTE If the driver exits the truck without actuating the parking brake, a warning signal sounds. This signal even sounds if the truck has al- ready been switched off and the ignition and stop key has been removed.

  • Page 92: Closing The Gas Cylinder Or Lpg Tank* Shutoff Valve

    Use and Operation Using the truck Closing the gas cylinder or LPG tank* shutoff valve – Close the gas cylinder or LPGtank shut off  valve (1) tightly immediately after stopping the engine. – Remove the key when you leave the truck. –...

  • Page 93: Lifting System And Attachments

    Use and Operation Lifting system and attachments Lifting system and attachments Operating the lifting device DANGER When the lifting device or any attachments are moving, there is a danger the driver will be caught between the lifting device and the forklift truck. Therefore, the driver must not be located at or enter in between the lifting device and the forklift truck.

  • Page 94: Operating Attachments

    Use and Operation Lifting system and attachments Tilting the lift mast backward – Push the control lever (2) back. When transporting a load, tilt the lift mast backwards for better stability. Operating attachments Attachments are optional pieces of equipment installed on the forklift truck: (such as sideshift forks, rotators, clips, etc.).
  • Page 95 Use and Operation Lifting system and attachments Sideways movement  NOTE In order to prevent damage, do not operate in a sideways direction when the fork arms are on the ground. – Push the control lever (3) forwards and move to the left. –...

  • Page 96: Handling Loads

    Use and Operation Handling loads Handling loads Safety regulations when handing  loads The safety regulations for handling loads are shown in the following sections. DANGER There is a risk to life caused by falling loads or if parts of the truck are being lowered. –...

  • Page 97: Capacity Plate

    Use and Operation Handling loads Load centre distance refers to the distance be-  tween the vertical plane of the fork arms and the centre of gravity of the loads(1). NOTE The centre of gravity of a load is not necessa- rily located at the central point of the load it- self.

  • Page 98: Before Lifting A Load

    Use and Operation Handling loads Before lifting a load  Before lifting a load, check the load capacity diagram (1) on the engine cover. The maximum capacity is determined by the lifting height and the load centre distance. NOTE Check the load capacity limits and contact your authorised dealer before transporting: –...

  • Page 99: Transporting Suspended Loads

    Use and Operation Handling loads DANGER Risk of injury! – Do not step on the fork. DANGER Risk of injury! – Do not step under the raised forks. DANGER People may be injured in the danger area of the truck! The danger area of the truck must be completely clear of all personnel, except the driver in his normal operating position.
  • Page 100 Use and Operation Handling loads Risk of crushing of guide persons ● Reduced visibility. ● DANGER Loss of stability. Slipping or swinging suspended loads can lead to a loss of stability and cause the truck to tip over. – When transporting suspended loads, observe the following instructions Instructions for transporting suspended loads:...

  • Page 101: Adjusting The Fork Arm Distance

    Use and Operation Handling loads Adjusting the fork arm distance – Raise the knob (2) and rotate it by 90°.  – Adjust the fork arms (1) according to the di-  mensions of the load to be lifted. – Ensure that an equal distance is maintained from both fork arms to the centre line of the fork carriage.

  • Page 102: Picking Up A Load

    Use and Operation Handling loads Picking up a load DANGER The truck may tip over if the load is too heavy. Before picking up the load, check that the dimen- sions and weight of the load lie within the permitted range for the truck.
  • Page 103 Use and Operation Handling loads – Position the forks.  – Set the lift mast to vertical. – Lift the fork carriage to the stacking height. DANGER Risk of accident due to changed moment of tilt! If a truck is operated with a forwards tilt (variant) of more than 3°, there is a greater risk of the load slip- ping when the load is raised or lowered.
  • Page 104 Use and Operation Handling loads – Lift the fork carriage until the load is resting  entirely on the fork. NOTE The lifting speed can be increased by adjust- ing the engine speed. Refer to the chapter en- titled "Increasing the lifting speed". DANGER Risk of accident! –...
  • Page 105 Use and Operation Handling loads – Tilt the lift mast backwards. The load can  now be transported. 5060_003-101 Increasing the lifting speed  – Fully depress the brake Inching pedal (1) and hold it down. The drive wheels are now uncoupled from the engine.

  • Page 106: Transporting Loads

    Use and Operation Handling loads Transporting loads  NOTE Observe the information in the chapter entitled "Safety regulations when driving". DANGER The higher a load is lifted, the less stable it be- comes. The truck can tip over or the load can fall, increasing the risk of accident! Driving with a raised load and the lift mast tilted for- ward is not permitted.

  • Page 107: Driving On Ascending And Descending Gradients

    Use and Operation Handling loads – Never drive with a load protruding to the  side (e.g. with the sideshift)! 6210_800-014 Driving on ascending and descend-  ing gradients DANGER Danger to life! Driving on ascending and descending gradients car- ries special dangers! –...

  • Page 108: Driving On Lifts

    Use and Operation Handling loads – Reduce the driving speed on descending gradients. It is not permitted to drive on long ascending and descending gradients greater than 15% due to the specified minimum braking and sta- bility values. – Before driving on ascending and descend- ing gradients greater than 15%, consult the authorised service centre.

  • Page 109: Driving On Loading Bridges

    Use and Operation Handling loads Determining the actual total weight  – Park the truck securely. – Determine the unit weights by reading the truck nameplate and, if necessary, the at- tachment (variant) nameplate and, if neces- sary, by weighing the load to be lifted. –...

  • Page 110: Setting Down Loads

    Use and Operation Handling loads Determining the actual total weight  – Park the truck securely. – Determine the unit weights by reading the truck nameplate and, if necessary, the at- tachment (variant) nameplate and, if neces- sary, by weighing the load to be lifted. –...
  • Page 111 Use and Operation Handling loads WARNING Risk of accident from a falling load! If the fork or the load remains suspended during low- ering, the load may fall. – When removing a load from storage, move the truck far enough back so that the load and the fork can be lowered freely.

  • Page 112: Towed Load

    Use and Operation Towed load Towed load  DANGER There is an increased risk of accident when using a trailer. Using a trailer changes the truck handling character- istics. When towing, operate the truck such that the trailer train can be safely driven and braked at all times.

  • Page 113: Forklift Towing

    Use and Operation Forklift towing This truck is suitable for the occasional towing of trailers. If the truck is equipped with a tow- ing device, this occasional towing must not ex- ceed 2% of the daily operating time. If the truck is to be used for towing on a more regu- lar basis, the manufacturer should be consul- ted.
  • Page 114 Use and Operation Leaving the truck – Apply the parking brake (1).  – Switch off the truck by turning the key from “II” position to the “0” position. – Remove the ignition key. DANGER Do not switch off the truck by turning the key when the truck is moving.

  • Page 115: Cleaning

    Use and Operation Cleaning Cleaning Cleaning the truck – Park the truck securely. – Switch the electrical system off before cleaning. WARNING There is a risk of injury due to falling when climbing onto the truck! When climbing onto the truck, you can get stuck or slip on components and fall.
  • Page 116 Use and Operation Cleaning WARNING Excessive water pressure or water and steam that are too hot can damage truck components. – Strictly adhere to the following steps. – Only use high-pressure cleaners with a maximum output power of 50 bar and at a maximum temperature of 85°C.

  • Page 117: Cleaning The Electrical System

    Use and Operation Cleaning – Clean plastic parts only with cleaning mate- rials intended for plastic parts. – Observe the manufacturer's guidelines for working with cleaning materials CAUTION Excessive water pressure or water and steam that are too hot can damage truck components. –...

  • Page 118: Lubricate The Lift Mast And Chains With Chain Spray

    Use and Operation Cleaning Lubricate the lift mast and chains  with chain spray NOTE If there is excessive dust on the chain affect- ing the ability of the lubricant to permeate the chain, the lifting chain must be cleaned. –...

  • Page 119: After Washing

    Use and Operation Cleaning After washing  – Carefully dry the truck (e.g. with com- pressed air). – Sit in the driver's seat and start up the truck in accordance with the regulations. CAUTION Risk of short circuits! – If any moisture has penetrated into the electrical system despite the precautionary measures tak- en, the system must first be dried using com- pressed air.

  • Page 120: Decommissioning

    Use and Operation Decommissioning Decommissioning General information This chapter contains information about "tem- porary decommissioning" and "permanent decommissioning". Measures to be implemented when decommissioning The following tasks must be carried out if the truck is not used for an extended period: –...

  • Page 121: Recommissioning After Storage

    Use and Operation Decommissioning – Preserve the engine as specified by the en- gine manufacturer. – Cover the truck with a cover that is NOT made of plastic. – If the truck is to be decommissioned for lon- ger periods, contact the authorised service centre to find out about additional meas- ures.

  • Page 122: Permanent Decommissioning (Scrapping)

    Use and Operation Decommissioning Permanent decommissioning (scrapping) The forklift truck must be scrapped in compli- ance with local regulations. In the event of queries regarding the scrapping of forklift trucks in accordance with regulations, contact the authorised sales network or the recycling companies authorised for scrapping.

  • Page 123: Maintenance

    Maintenance...

  • Page 124: General Information

    Maintenance General information General information To keep the forklift truck in a good operating condition, the repair work specified on the fol- lowing pages must be carried out regularly, at the indicated intervals, and using the consum- able material designed for the purpose. A writ- ten record must be kept of all work that has been carried out.

  • Page 125: Personnel Qualifications

    Maintenance Personnel qualifications Personnel qualifications Only qualified and authorised personnel are allowed to perform maintenance work. Regu- lar safety checks and checks after unusual in- cidents must be performed by a competent person. The competent person must conduct their evaluation and assessment from a safety standpoint, unaffected by operational and eco- nomic conditions.
  • Page 126 Maintenance Preliminary maintenance operations DANGER Risk of severe electric shock. Disconnect the negative connecting terminal from the battery before performing any work on the electrical system. 60118011601 EN - 09/2020...

  • Page 127: Scheduled Truck Maintenance

    Maintenance Scheduled truck maintenance Scheduled truck maintenance Maintenance — 500 hours At operating hours Carried 1500 2500 3500 4500 5500 6500 7500 8500 9500   Chassis, bodywork and fittings Check the chassis for cracks Check the overhead guard/cab and panes of glass for damage Check the controls, switches and joints for damage, and apply grease and oil Check the driver’s seat for correct function and for damage Check that the seat belt is in good condition and functions correctly...
  • Page 128 Maintenance Scheduled truck maintenance At operating hours Carried 1500 2500 3500 4500 5500 6500 7500 8500 9500   Lift mast Check load chains for damage and wear, adjust and lubricate the load chains Check mast bearings for damage, and lubricate. Check the tightening torque Check mast profiles for damage and wear.

  • Page 129: Maintenance - 1000 Hours/Annually

    Maintenance Scheduled truck maintenance Maintenance — 1000 hours/annually At operating hours Carried 1000 2000 4000 5000 7000 8000 10000 11000 13000 14000   Chassis, bodywork and fittings Check chassis for cracks Check overhead guard/cab and panes of glass for damage Check controls, switches and joints for damage, and apply grease and oil Check driver's seat for correct function and for damage Variant: Check the dual pedal for damage and correct function, and lubricate...
  • Page 130 Maintenance Scheduled truck maintenance At operating hours Carried 1000 2000 4000 5000 7000 8000 10000 11000 13000 14000   Check the LPG system for damage, check that the screw joints are securely seated, and check for leaks using leak detection spray Check the high-pressure relief valves (1.7 bar) and solenoid shut-off valve Change the LPG filter Overhaul the evaporator/pressure regulator, replace the sticker...
  • Page 131 Maintenance Scheduled truck maintenance At operating hours Carried 1000 2000 4000 5000 7000 8000 10000 11000 13000 14000   Check the tilt cylinders and connections for damage and leaks Check the fork carriage for damage and wear Check the fork arm interlock for damage and that is working correctly Check that there is a safety screw on the fork carriage or on the attachment Check the fork arms for wear Lubricate the rolling tracks and fork carriage runners...

  • Page 132: Maintenance - 3000 Hours

    Maintenance Scheduled truck maintenance Maintenance - 3000 hours Carried At operating hours 3000 6000 9000 12000 15000   Chassis, bodywork and fittings Check chassis for cracks Check overhead guard/cab and panes of glass for damage Check controls, switches and joints for damage, and apply grease and oil Check driver's seat for correct function and for damage Variant: Check the dual pedal for damage and correct function, and lubricate Check that the seat belt is in good condition and functions correctly...
  • Page 133 Maintenance Scheduled truck maintenance Carried At operating hours 3000 6000 9000 12000 15000   Check the fuel lines and clips LPG system Check the LPG system for damage, check that the screw joints are securely seated, and check for leaks using leak detection spray Check the high-pressure relief valves (1.7 bar) and solenoid shut-off valve Change the LPG filter Overhaul the evaporator/pressure regulator, replace the sticker...
  • Page 134 Maintenance Scheduled truck maintenance Carried At operating hours 3000 6000 9000 12000 15000   Check support rollers and chain rollers for damage and wear Check tilt cylinders and connections for damage and leaks Check fork carriage for damage and wear Check fork arm interlock for damage and that it is working correctly Check that there is a safety screw on the fork carriage or on the attachment Check fork arms for wear and deformation...

  • Page 135: Supply Table

    Maintenance Scheduled truck maintenance Supply table Recommended Quan- Unit Operating material Specifications tity SAE 15W-40-API- Engine 10.5L Engine oil CJ-4-20ltr Hydraulic transmission Transmission oil Dexron Ⅲ/ Mobile ATF gear 90L for mast below (in- ≥-5℃:L-HM46 clude) 4500mm mast Hydraulic oil 95L for mast exceed- ≥-5℃:L-HM46 ing 4500mm mast...

  • Page 136: Providing Access To Maintenance Points

    Maintenance Providing access to maintenance points Providing access to maintenance points Opening the bonnet WARNING Risk of injury! Switch off the engine before opening the bonnet! CAUTION When opening the bonnet, the driver's seat may be damaged if it is not in its forward most position. Slide the driver's seat all the way forwards.

  • Page 137: Closing The Bonnet

    Maintenance Providing access to maintenance points – Push the lever (3)on the engine bonnet up-  wards with your left hand. WARNING Risk of injury from the bonnet low- The bonnet is fitted with a gas spring that ering! holds the bonnet in the open position. When addi- tional load is present, for example heavy objects, strong wind or other persons, the bonnet can lower suddenly.

  • Page 138: Installing And Removing The Bottom Plate

    Maintenance Providing access to maintenance points Installing and removing the bottom plate Removing the bottom plate CAUTION Risk of short circuit if cables are damaged! – Check the connection cables for damage. – When removing and reinstalling the bottom plate, make sure that the connecting cables are not damaged.
  • Page 139 Maintenance Providing access to maintenance points – Carefully guide the bottom plate down and close. – Insert the rubber mat. – Close the bonnet. 60118011601 EN - 09/2020...

  • Page 140: Maintenance Service

    Danger of burn injury! If it is necessary to bleed the engine oil when the oil is still hot, avoid contact with the oil and wear eye protection to avoid burn injuries. Failure to comply with regulations may result in death or serious injury.
  • Page 141 Maintenance Maintenance service – Remove the oil cap(1) to ventilate the  crankcase. This is beneficial for bleeding the oil. – Place an oil pan under the engine to collect the used oil. – Remove the oil drain plug(2) and allow the ...
  • Page 142 Maintenance Maintenance service – Remove the oil cap(1).  – Disassemble the oil level gauge. – Add our recommended genuine oil by divid- ing it into several portions for replenish- ment. NOTE Add specified oil and then wait for about 1 ~ 2 minutes and then check the engine oil level.

  • Page 143: Replacing The Engine Oil Filter

    Maintenance Maintenance service Replacing the engine oil filter  – Remove the oil filter (1). – Disassemble oil filter (1) with the filter wrench. CAUTION Oil in the filter may run down while detaching the oil filter. Be careful not to contaminate the other parts by using a cloth when detaching the filter.
  • Page 144 Maintenance Maintenance service K2234 J1034 DANGER – Never open the radiator cap while the engine is overheated. If the radiator cap is opened while the engine is overheated, hot water will spurt out and may cause serious burns. Open the radiator cap after ensuring that the engine has been cooled sufficiently.
  • Page 145 Maintenance Maintenance service – Remove the radiator cap(1).  – Unplug the coolant drain plug of the radiator and then drain coolant. – After completing coolant drain, connect the coolant drain plug again. – Drain the coolant from the coolant supple- mentary tank(2) and cleanse the tank.
  • Page 146 Maintenance Maintenance service CAUTION – Do not mix antifreezes from different manufactur- ers. – Do not mix the coolant with different concentra- tions. – Do not add antitrust which is not recommended by – As insufficient coolant concentration may cause corrosion or freezing, on the other hand, an ex- cessive concentration may degrade the cooling performance.

  • Page 147: Cleaning The Radiator, Checking For Leaks

    Maintenance Maintenance service Cleaning the radiator, checking for leaks – Park the truck securely. – Open the bonnet. – Clean the radiator (1).  – Clean the radiator fins using a suitable brush and blow them out using compressed air (max. 2 bar). –...

  • Page 148: Change The Air Filter

    Maintenance Maintenance service – Remove dust from the filter by blowing out-  ward through the filter using compressed air (5). Remove dust using minimum air pres- sure in order to avoiding damaging the in- sert. CAUTION Flying object hazard! Wear eye protection when carrying out maintenance on the engine and using compressed air or pressur- ised water jets, in order to prevent dust, flying debris,...

  • Page 149: Check The Belt Tension

    Maintenance Maintenance service – Pull out the air filter (3)  NOTE Clean the inside of the air filter head cover(1). – Ensure that the filter is not damaged during installation and that it is installed in the cor- rect direction. –...

  • Page 150: Changing The Hydraulic Transmission Crude Oil Filter

    – Press the pad (3) until unscrewing sound of the spring is heard. This force pushes the tension measuring instrument upwards. – If there is still tension left on the belt after removing the pad (3), the measurement re- sult is not accurate.

  • Page 151: Replacing The Fine Hydraulic Transmission Oil Filter

    Maintenance Maintenance service – Unscrew the fastening nut on the crude oil  filter; then remove the filter insert. – Replace it with a new crude oil filter insert. Fit the filter insert followed by the bottom cover onto the filter spindle; then tighten the nut.

  • Page 152: Changing The Oil Of The Hydraulic Transmission

    Maintenance Maintenance service Changing the oil of the hydraulic  transmission ENVIRONMENT NOTE Observe precautions for handling fuel and lu- bricants. – Place a container under the right side of the truck chassis. – Remove the floor plate. – Unscrew the oil drain plug (2). –...

  • Page 153: Checking The Drive Axle Gearbox Oil

    Maintenance Maintenance service Checking the drive axle gearbox oil  – Unscrew the oil plug at the oil level aperture (1). – Check the gear shaft oil level to ensure it is near the observation aperture posi- tion(around 15mm). – If necessary, fill the gearbox with gear oil until oil flows out of the oil level aperture.
  • Page 154 Maintenance Maintenance service – Lower the truck to the ground. – Tighten the wheel nuts to full torque (see corresponding paragraph). – When changing wheels with tyres, inflate to the prescribed pressure. Front wheel change  – Lift the fork arms to at least 1 m above the ground.

  • Page 155: Change Brake System Liquid

    Maintenance Maintenance service – Tighten the wheel nuts to full torque (see corresponding paragraph). – When changing wheels with tyres, inflate to the prescribed pressure. Change brake system liquid ENVIRONMENT NOTE Please handle liquids and lubricating oil in ac- cordance with instructions. NOTE please contact your authorised dealer for drain and change brake system liquid.

  • Page 156: Checking The Hydraulic Oil Level

    Maintenance Maintenance service Checking the hydraulic oil level ENVIRONMENT NOTE Please follow the instructions for handling/ disposal of fluids and lubricants. NOTE The oil level should only be checked with the lift mast vertical and the fork carriage lowered. – Apply the parking brake. –...

  • Page 157: Replacing The Breather Filter

    Maintenance Maintenance service – Slacken off the fastening bolts and washers on the cover assembly, then remove the cover assembly. – Slowly pull out the cover assembly so that the oil flows back into the tank. – Unscrew the suction filter (2) and return fil- ...
  • Page 158 Maintenance Maintenance service – Unscrew the breather filter (1) and dipstick  and remove. – Remove the dipstick and balls on the dip- stick base from the breather filter and mount onto the new the breather filter. – Screw the breather filter and dipstick back into position.
  • Page 159 Technical datasheet...

  • Page 160: Technical Datasheet Dimensions

    Technical datasheet Dimensions Dimensions 60118011601 EN - 09/2020...

  • Page 161: Vdi Datasheet For Rcg40

    Technical datasheet VDI Datasheet for RCG40 VDI Datasheet for RCG40 NOTE This VDI data sheet specifies only the techni- cal values of the truck version with standard equipment. Different tyres, lift masts, addition- al units etc. may produce different values.
  • Page 162 Technical datasheet VDI Datasheet for RCG40 Fork Carriage Width b3 (mm) 1480 Ground Clearance below Mast(laden) m1 (mm) Ground Clearance at Centre of Wheelbase(laden) m2 (mm) Working aisle width with pallet 1000 x 1200 cross- Ast (mm) 4557 ways**** Working aisle width with pallet 800 x 1200 cross-...

  • Page 163: Vdi Datasheet For Rcg50

    This VDI data sheet specifies only the techni- cal values of the truck version with standard equipment. Different tyres, lift masts, addition- al units etc. may produce different values. Characteristics Manufacturer STILL Model RCG50 Power type：Electric-Diesel-Petrol-LPG-Network Power (Electric) Operation Type: Hand-stand on-Driver seated...
  • Page 164 Technical datasheet VDI Datasheet for RCG50 Fork Carriage Width b3 (mm) 1480 Ground Clearance below Mast(laden) m1 (mm) Ground Clearance at Centre of Wheelbase(laden) m2 (mm) Working aisle width with pallet 1000 x 1200 cross- Ast (mm) 4597 ways**** Working aisle width with pallet 800 x 1200 cross- Ast (mm) 4797 ways****...

  • Page 165: Mast Specification

    Technical datasheet Mast specification Mast specification NOTE This data would be changed under different working condition. 4T MAST SPECIFICATIONS Rated capacity height free-lift height mast an- load center Mast Max. height 500mm closed without with car- type height with car- height carriage riage...
  • Page 166 Technical datasheet Mast specification 5T MAST SPECIFICATIONS Rated capacity height free-lift height mast an- load center Mast Max. height 500mm closed without with car- type height with car- height carriage riage double front/ riage tyres back 3000 5000 5000 2390 4275 3300 5000...
  • Page 167 Index Competent person....10 UMBERS AND YMBOLS Consumables 4T MAST SPECIFICATIONS..155 Disposal......5T MAST SPECIFICATIONS.
  • Page 168 Index General front view....Packaging......General rear view.
  • Page 169 Tension measurement....140 VDI Datasheet for RCG40... . 151 Towed load..... . .
  • Page 172 STILL GmbH 60118011601 EN - 09/2020...
  • Page 173 Original instructions LPG forklift truck RCG40 RCG50 4234 4236 60118011601 EN - 09/2020...

  • Page 175: Diagrams

    Diagrams...

  • Page 176: Electric Schematic Diagram For Doosan P34 Engine-With Iso3691 Function

    Diagrams Electric schematic diagram for Doosan P34 engine—with ISO3691 function Electric schematic diagram for Doosan P34 engine—with ISO3691 function 60118011601 EN - 09/2020...

  • Page 177: Hydraulic Diagram

    Diagrams Hydraulic diagram Hydraulic diagram 60118011601 EN - 09/2020...
  • Page 178 Diagrams Hydraulic diagram 60118011601 EN - 09/2020...
  • Page 180 STILL GmbH 60118011601 EN - 09/2020...

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Rcg50

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