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Summary of Contents for Still RCD40
- Page 1 Original instructions Diesel forklift truck RCD40-50 4231 4233 60128011601 EN - 03/2020...
- 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.
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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 Diesel fuel - Specifications..........Engine coolant - Specifications .
- Page 8 Table of contents Driving on loading bridges ..........Setting down loads .
- Page 9 Data sheet RCD40........
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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 60128011601 EN - 03/2020... -
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 Description of use and climatic conditions Normal use Special uses (applies to trucks with spe- cial equipment) – Indoor and outdoor use. – Ambient temperature in tropical regions up – Ambient temperature in tropical and Nordic to +40°C. -
Page 16: Ce Labelling
Introduction CE labelling For your safety, additional symbols are also CAUTION used. Please take these different symbols into This label is found on the truck in the consideration. areas where particular care and atten- tion are required from the operator. Refer to the appropriate section in these operating instructions. -
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 Guidelines
Safety Safety guidelines 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. have familiarised himself with safe opera- ●... - Page 22 Safety Safety guidelines Safety information WARNING DANGER Depending on the duration of use and operating time, components carrying ex- The industrial truck must not be used by unauthor- haust gases and exhaust air may be- ised persons. come hot. Only trained persons and those authorised for opera- Protective equipment must therefore be tion may have access to the industrial truck.
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Page 23: Exhaust Gases
Safety Exhaust gases Exhaust gases CAUTION Risk to health from exhaust gases! Exhaust gases from internal combustion engines are harmful to your health. In particular, the soot particles contained in the diesel exhaust gas can cause cancer. Letting the combustion engine idle runs a risk of poisoning from the CO, CH and NO components contained in the exhaust gas... -
Page 24: 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 25: 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. 60128011601 EN - 03/2020... -
Page 26: 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 27: 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 28: 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 29: 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 30: 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 31: 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 32: Packaging
Safety Emissions 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. Emissions The values specified apply to a standard truck ticular application conditions, sound reflec-... - Page 33 Safety Emissions measurement guidelines for these measure- as driving route, intensity of use etc. are con- ments. sidered. The personal vibration load on the driver over a working day must be determined by the op- NOTE erating company at the actual place of use in Please note the definition of "operating com- accordance with Directive 2002/44/EC, in or- pany"...
- Page 34 Safety Emissions 60128011601 EN - 03/2020...
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Page 35: Overview
Overview... -
Page 36: General View
Overview General view General view General front view Fork arms Tilt cylinder Mast Forward Front wheels Right Driver’s Seat Backwards Overhead guard Left 60128011601 EN - 03/2020... -
Page 37: General Rear View
Overview General view General rear view Rear wheels Steering wheel Rear weight Control panel Rear lights Engine bonnet Trailer coupling Exhaust pipe Overhead guard Filler cap for fuel tank Mast 60128011601 EN - 03/2020... -
Page 38: Instrumentation And Controls
Overview 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 Cup holder... -
Page 39: Display Unit
Overview Instrumentation and controls Display unit “SCR error” indicator light “Water separator light” indicator light Seat indicator light ”DPF regeneration disabled“ indicator Indicator light for "glow plug preheating" light(Red light) Neutral Position indicator ”Battery charging“ indicator light ”Torque Converter Oil Temperature“ indica- "Engine error light"... -
Page 40: Truck Identification
Overview 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 41: Nameplate
Overview 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 Min. -
Page 42: Engine Plate
Overview Truck identification The information for the battery weights (5，6) and the ballast weight(7)only applies to elec- tric forklift trucks. Engine plate The engine plate(1) is fixed to the cylinder head cover or the crankcase. The type(2),engine no.(3) and performance data are attached to the engine plate. -
Page 43: Location Of The Decals
Overview Location of the decals Location of the decals 60128011601 EN - 03/2020... - Page 44 Overview Location of the decals Decal information: Lifting gear attachment Passengers are not allowed/Do not jump off point if the truck is tipping over/Brace feet/Hold on Warning sign: Do not stand underneath the tight/Lean in the opposite direction to which fork/Do not stand on the fork/Do not enter the truck is tipping space behind the mast/ Injury to hand...
- Page 45 Overview Location of the decals Decal information: Caution / Read the oper- Nameplate ating instruction Manufacturer’s name Decal information: Capacity rating plate 60128011601 EN - 03/2020...
- Page 46 Overview Location of the decals 60128011601 EN - 03/2020...
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Page 47: Use And Operation
Use and operation... -
Page 48: 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 49: Lifting The Truck With A Crane
Use and operation Truck transport and lifting storage. In salty environments, appropriate protection must be provided. 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. -
Page 50: Commissioning The Truck
Use and operation Commissioning the truck – Attach a sling (2) (able to at least bear the weight of the forklift truck ) to the openings in the counterweight. – Attach two shackles (5) to the two openings in the upper beam of the outer lift mast. –... -
Page 51: 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 52: 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 53: 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 54: 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 55: 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 56: 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 57 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 by ...
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Page 58: Checking The Engine Oil Level
Use and operation Remaining ready for operation The radiator is assembled with coolant level sensor. The corresponding light in the display will illuminate while the coolant is too low, fill in the radiator with specified coolant accordingly. – Screw the radiator cap back on securely. Checking the engine oil level –... -
Page 59: 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 60: 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 61: Refuelling
Use and operation Refuelling – 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 62 Use and operation Diesel fuel - Specifications Carbon residue content not to exceed Diesel Fuel Specifi- ● Location 0.35% by volume. Less than 0.1% is prefer- cation red. ASTM D975 Total aromatics content should not exceed ● No.1D S15,S500 35% by volume. Less than 30% is prefer- No.2D S15,S500 red.
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Page 63: Engine Coolant - Specifications
Use and operation Engine coolant - Specifications Engine coolant - Specifications Engine coolant specifications DANGER Scald hazard ! Use a Long Life Coolant (LLC) or an Extended Life Coolant (ELC) that meets or exceeds the – NEVER remove the radiator cap if the engine is following guidelines and specifications. -
Page 64: Mounting/Dismounting
Use and operation Mounting/dismounting Mounting/dismounting 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 mounting/dismounting the forklift. – First place your left foot on the step. Grip the handrail or overhead guard beam and mount the truck from the left-hand side. -
Page 65: Sealt Belt
Use and operation Sealt belt Sealt belt Adjustment of the driver’s seat CAUTION Slide the driver’s seat to find the best operating posi- tion relative to the steering wheel, the accelerator and braking pedals, and the joystick. Before starting the truck and whenever changing drivers, adjust the seat to match the driver’s weight and make sure that the settings have all engaged properly. -
Page 66: Fastening The Seat Belt
Use and operation Sealt belt Adjusting the seat suspension NOTE The driver’s seat can be adjusted to suit the weight of the individual driver. In order to ach- ieve the best seat suspension setting, the driv- er should perform the adjustment whilst sitting on the seat. - Page 67 – 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 68 Use and operation Sealt 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.
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Page 69: Switches
Use and operation Switches Switches Ignition device NOTE The forklift can only be started if the reversing lever is in the centre position (neutral). The ignition key has three positions: Position "0" Key removal position (no circuit powered ● except for horn, stop lights;... -
Page 70: Lighting And Turn Indicator Switch
Use and operation Switches 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 71: Warning Horn
Use and operation Switches 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 ● switches on the clearance lights, front head- lights, and also rear lights. -
Page 72: Direction Selection Lever
Use and operation Adjusting the position of steering wheel Direction selection lever Direction selection lever (1) is used to select the required drive direction of the truck or to switch the drive mode to idling. The direction selection lever offers three different positions: FORWARDS —... -
Page 73: Start The Engine
OM1826 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. 60128011601 EN - 03/2020... - Page 74 Use and operation Start the engine 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.
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Page 75: Driving
Use and operation Driving Driving Driving CAUTION When using mirrors, ensure that the rear-view mirror is only used for monitoring the traffic behind the vehi- cle. Reverse travel is therefore only permitted when looking directly behind you. CAUTION Always tilt the mast backwards and lower the fork arms to the ground around 300mm. -
Page 76: Forward
Use and operation Driving – Move direction selection lever (3) in the re- quired drive direction: (A) FORWARDS, (B) BACKWARDS. – Gently press the accelerator pedal(4) to set off. Forward – Put the direction lever into the forward di- rection. -
Page 77: Changing Direction Of Travel
Use and operation Driving – Steadily press the accelerator pedal The speed of the forklift truck accelerates in relation to the increase in pedal travel. Changing direction of travel – To change direction, release the accelerator pedal (2) . –... -
Page 78: Brake System
Use and operation Brake system Brake system Driving brake pedal and inching pedal NOTE We recommend that the driver familiarizes himself with the efficacy of the braking appara- tus when the forklift truck is not carrying a load. Operate the forklift truck slowly on an un- crowded road surface to test travelling func- tions. -
Page 79: Parking Brake
Use and operation Brake system – Take the foot off the accelerator pedal (1). – Press the brake pedal (2) until the truck is stationary. – Actuate the parking brake to keep the fork- lift truck braked. Procedure in the event of failure of the service brake –... -
Page 80: 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 81: 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 82 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. –...
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Page 83: 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 84: 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 85: Before Lifting A Load
Use and operation Handling loads – Before operating an attachment, read the load capacity data plate on the attachment. 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. -
Page 86: Transporting Suspended Loads
Use and operation Handling loads included are the areas where loads could fall or working equipment could fall or be lowered. 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! - Page 87 Use and operation Handling loads Tipping the truck at right angles to the direc- ● tion of travel 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.
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Page 88: 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 89: 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 90 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 91 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 92 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.
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Page 93: 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 94: 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 95: 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 96: 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 97: 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 98 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.
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Page 99: 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 100: 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 101 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.
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Page 102: 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 103 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.
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Page 104: 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 105: 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 106: 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 107: 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 108: 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 109: 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 110 Use and operation Decommissioning 60128011601 EN - 03/2020...
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Page 111: Maintenance
Maintenance... -
Page 112: 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 113: 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 114 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. 60128011601 EN - 03/2020...
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Page 115: 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 116 Maintenance Scheduled truck maintenance At operating hours Carried 1500 2500 3500 4500 5500 6500 7500 8500 9500 Check mast profiles for damage and wear. Lubricate the mast profiles 60128011601 EN - 03/2020...
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Page 117: Maintenance - 1000 Hours
Maintenance Scheduled truck maintenance Maintenance — 1000 hours At operating hours Carried 1000 2000 4000 5000 7000 8000 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 118 Maintenance Scheduled truck maintenance At operating hours Carried 1000 2000 4000 5000 7000 8000 Steering and steering axle Lubricate the rear wheel bearings Lubricate the steering axle and check for leaks Brake Check and adjust the service brake Check and adjust parking brake Check the oil level of the brake system Change the brake oil...
- Page 119 Maintenance Scheduled truck maintenance At operating hours Carried 1000 2000 4000 5000 7000 8000 Special equipment Heating system: Check the fresh air filter Heating system: Check for damage; observe the manufacturer’s maintenance in- structions Check attachments for wear and damage; observe manufacturer's maintenance in- structions Check trailer coupling for wear and damage;...
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Page 120: 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 121 Maintenance Scheduled truck maintenance Carried At operating hours 3000 6000 9000 12000 15000 Change the fuel filter Check the fuel lines and clips Steering and steering axle Lubricate the rear wheel bearings Lubricate the steering axle and check for leaks Brake Check and adjust the service brake Check and adjust parking brake...
- Page 122 Maintenance Scheduled truck maintenance Carried At operating hours 3000 6000 9000 12000 15000 Lubricate the rolling tracks and fork carriage runners Special equipment Heating system: Check the fresh air filter Heating system: Check for damage; observe the manufacturer’s maintenance in- structions Check attachments for wear and damage;...
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Page 123: Supply Table
Maintenance Scheduled truck maintenance Supply table Recommended Quan- Unit Operating material Specifications tity Engine Engine oil APICJ-4 SAE 15W-40 Hydraulic transmission Dexron Ⅲ/Mobile ATF Transmission oil gear transmission oil 90L for mast below ≥-5℃:L-HM46 4500mm mast Hydraulic system Hydraulic oil ≥-20℃:L-HV32(For cold 95L for mast exceed- storage use) -
Page 124: 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 125: 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 126: 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 127 Maintenance Providing access to maintenance points – Carefully guide the bottom plate down and close. – Insert the rubber mat. – Close the bonnet. 60128011601 EN - 03/2020...
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Page 128: Maintenance Service
Risk of burn injury! If it is necessary to discharge the engine oil when the oil is still hot, avoid contact with the oil in order to avoid burn injuries. Wear eye protection. Failure to comply with regulations may result in death or serious injury. - Page 129 Maintenance Maintenance service – Remove the oil filler cap (1) to ventilate the crankcase. This is beneficial for bleeding the oil. – Place an oil pan (3) under the engine to col- lect the used oil. – Remove the oil drain plug (2) and allow the oil to flow into the container.
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Page 130: Changing The Engine Oil Filter
Maintenance Maintenance service Changing the engine oil filter ENVIRONMENT NOTE Be environmentally responsible. Dispose of used oil in accordance with applicable laws and regulations. Failure to comply with laws and regulations will result in serious damage to the environment. – Rotate the engine oil filter (1) anticlockwise ... -
Page 131: Changing The Fuel Filter Cartridge
Maintenance Maintenance service Changing the fuel filter cartridge – Loosen and unscrew filter with tool. – Collect escaping fuel. – Clean the sealing surface of the filter carrier with a clean, lint-free cloth. – Oil the seal of the new original spare filter ... - Page 132 Maintenance Maintenance service – Carefully unscrew the drain plug (3) and al- low the fuel to flow out. – Remove the water trap (2) from the mount- ing surface (1) by turning it to the left. Wipe up any spilled fuel. –...
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Page 133: Draining Water In The Water Trap
Maintenance Maintenance service Draining water in the water trap DANGER Risk of fire and explosion! Diesel fuel is highly flammable and explosive under certain conditions. When removing and carrying out maintenance on fuel system components (such as when changing the fuel filter), place an oil pan under the engine oil port. - Page 134 Maintenance Maintenance service CAUTION Be environmentally responsible. Dispose of used oil in accordance with applicable laws and regulations. Failure to comply with laws and regulations will result in serious damage to the environment. Comply with EPA guidelines or government meas- ures for the correct handling of hazardous materials (such as oil, diesel and engine coolant).
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Page 135: Fuel System Air Bleeding
Maintenance Maintenance service Fuel system air bleeding WARNING Risk of fire and explosion! Diesel fuel is highly flammable and explosive under certain conditions. When venting the fuel system, place an oil pan un- derneath the vent port. Avoid using workshop rags to collect fuel. -
Page 136: Changing The Coolant
Maintenance Maintenance service – Loosen the vent port (2) by rotating 2-3 turns. – Turn the key to the ON position and fill the electronic fuel pump (1) for 10-15 seconds or until fuel flows from the vent port with no air bubbles. - Page 137 Maintenance Maintenance service ENVIRONMENT NOTE Be environmentally responsible. Please follow this procedure to dispose of hazardous waste. Failure to follow this procedure will severely damage the environment. Handle hazardous waste such as engine ● oil, diesel or engine coolant appropriately according to guidelines from the Environ- mental Protection Agency or other govern- ment organizations.
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Page 138: Checking The V-Belt Tensioning
Maintenance Maintenance service – Open the drain plug (2) on the engine block and drain the coolant. – After draining the engine coolant, flush the radiator and engine block to remove any rust, scale and contaminants. Reinstall and tighten the engine block drain plug. –... -
Page 139: Replacing The V-Belt
Maintenance Maintenance service conducted as chapter entitled “Tension measurement The fixed lower part of the auto tensioner ● has a minimum/maximum indicator. If the indicator is found to be beyond the ● minimum/maximum range upon visual in- spection, the belt layout components must be checked. -
Page 140: Cleaning The Air Filter
Maintenance Maintenance service Cleaning the air filter Clogged filter inserts may have an adverse im- pact on engine performance. Make sure to pe- riodically clean the air filter insert. – Open the buckle(1) and remove the air filter head cover(2). –... -
Page 141: Changing The Air Filter
Maintenance Maintenance service – Clean the inside of the air filter head cover (2). – Fit the filter(4)in the air filter housing(3). – Refit the air filter cover, and tighten the air filter head cover onto the air filter housing. Changing the air filter –... -
Page 142: Changing The Hydraulic Transmission Crude Oil Filter
Maintenance Maintenance service intake opening after the warning light illumi- nates. Changing the hydraulic transmis- sion crude oil filter ENVIRONMENT NOTE Please follow the instructions for disposal of fluids and lubricants. NOTE Place a container under the crude oil filter to collect oil flowing out of the transmission. -
Page 143: 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 144: Wheel Replacement Procedure
Maintenance Maintenance service Wheel replacement procedure Rear wheel replacement procedure – Turn off the truck and perform the prelimi- nary maintenance operations. – Partially loosen the wheel fastening nuts (1). – Raise the back of the truck by jack and ar- range supports (2) under the ballast. - Page 145 Maintenance Maintenance service Front wheel change – Lift the fork arms to at least 1 m above the ground. – Turn off the truck and perform the prelimi- nary maintenance operations. – Partially loosen the wheel fastening nuts (1). –...
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Page 146: 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 147: Changing The Suction Filter And Return Filter
Maintenance Maintenance service NOTE The oil level should only be checked with the lift mast vertical and the fork carriage lowered. – Apply the parking brake. – Open the engine cover. – Screw the oil cap with dipstick(1). – Use a clean cloth to dry the dipstick. –... -
Page 148: Replacing The Breather Filter
Maintenance Maintenance service – Unscrew the suction filter (2) and return fil- ter (3) from the cover assembly. – Screw in the new intake filter until tightened. – Refit the cover assembly to the frame using the fastening screws. –... - Page 149 Technical datasheet...
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Page 150: Technical Datasheet Dimensions
Technical datasheet Dimensions Dimensions 60128011601 EN - 03/2020... -
Page 151: Data Sheet Rcd40
Technical datasheet Data sheet RCD40 Data sheet RCD40 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. Characteristics Manufacturer... - Page 152 Technical datasheet Data sheet RCD40 Fork Carriage Width b3 (mm) 1380 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) 4552 ways**** Working aisle width with pallet 800 x 1200 crossways****...
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Page 153: Data Sheet Rcd50
Technical datasheet Data sheet RCD50 Data sheet RCD50 Characteristics Manufacturer STILL Model RCD50 Power type：Electric-Diesel-Petrol-LPG-Network Power Diesel (Electric) Operation Type:Hand-stand on-Driver seated Seated Load Capacity Q (kg) 5000 Load centre of gravity distance c (mm) Axle centre to fork face... - Page 154 Technical datasheet Data sheet RCD50 Turning Point Minimum Distance from the Truck Center Line b13 (mm) Performance data Driving speed (with/without load) km/h 24/25 Lifting speed (with/without load) 0.44/0.53 Lowering speed (with/without load) 0.44/0.53 Drawbar Pull Tractive Effort (at 2km/h) with/without load 25/23 Gradeability (at 2km/h) laden/unladen Service Brake...
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Page 155: 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 156 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 157 Danger area......75 Data sheet RCD40....141 Data sheet RCD50.
- Page 158 Index Forward......Operating the service brake... . 68 Front wheel change.
- Page 159 Index Tension measurement....129 Use a truck or flatbed trailer to carry the forklift truck..... . . Towed load.
- Page 162 STILL GmbH 60128011601 EN - 03/2020...
- Page 163 Original instructions Diesel forklift truck RCD40-50 4231 4233 60128011601 EN - 03/2020...
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Page 165: Diagrams
Diagrams... -
Page 166: Electric Schematic Diagram
Diagrams Electric schematic diagram Electric schematic diagram 60128011601 EN - 03/2020... -
Page 167: Hydraulic Diagram
Diagrams Hydraulic diagram Hydraulic diagram 60128011601 EN - 03/2020... - Page 168 Diagrams Hydraulic diagram 60128011601 EN - 03/2020...
- Page 170 STILL GmbH 60128011601 EN - 03/2020...
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