Still RCD25 Original Instructions Manual
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Still RCD25 Original Instructions Manual

Diesel forklift truck
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Original instructions
Diesel forklift truck
RCD25
RCD30
RCD35
4221 4222 4223
60068011601 EN - 09/2020

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  • Page 1 Original instructions Diesel forklift truck RCD25 RCD30 RCD35 4221 4222 4223 60068011601 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 Information about the truck General forklift view ........... General front view .
  • Page 7 Table of contents Sealt belt ............Adjustment of the driver’s seat .
  • Page 8 Table of contents Cleaning............Cleaning the truck .
  • Page 9 VDI Datasheet for RCD25 ........

  • 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 60068011601 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 use...

  • Page 16: Ce Labelling

    Introduction CE labelling CE labelling  The manufacturer uses CE labelling to indi- cate that the truck complies with the standards and regulations valid at the time of marketing. This is confirmed by the issued EC declaration of conformity. The CE labelling is attached to the nameplate.

  • 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 General safety regulations Only allow qualified, trained and authorised safety distances established by the compe- ● personnel to operate the truck. tent authorities. Do not install any equipment on the truck Never raise loads using just one fork arm. ●...

  • Page 23: Exhaust Gases

    Safety Ground condition for using the truck 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...

  • 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. 60068011601 EN - 09/2020...

  • 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 ditions present (further sources of noise, par-...
  • Page 33 Safety Emissions The personal vibration load on the driver over NOTE a working day must be determined by the op- 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 60068011601 EN - 09/2020...

  • Page 35: Information About The Truck

    Information about the truck...

  • Page 36: 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 60068011601 EN - 09/2020...

  • Page 37: General Rear View

    Information about the truck General forklift 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 60068011601 EN - 09/2020...

  • Page 38: Instrumentation And Controls

    Information about the truck Instrumentation and controls Instrumentation and controls Control components Steering wheel Direction reverser Parking brake pedal A4 paper folder Accelerator pedal Light switch/direction indicator light switch Driving brake pedal Operating handle Inching pedal Display unit Seat Cup holder 60068011601 EN - 09/2020...

  • Page 39: Display Unit

    Information about the truck 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“...

  • Page 40: 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 41: 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 42: Engine Serial Number

    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 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.

  • Page 43: Location Of The Decals

    Information about the truck Location of the decals Location of the decals 60068011601 EN - 09/2020...
  • Page 44 Information about the truck Location of the decals Warning sign: Do not stand underneath the Warning sign: Danger due to shearing fork/Do not stand on the fork/Do not enter Warning sign: Danger due to overheating of space behind the mast/ Injury to hand radiator Decal information: Capacity rating plate Warning sign: Danger due to shearing /...
  • Page 45 Information about the truck Location of the decals if the truck is tipping over/Brace feet/Hold on Manufacturer’s name tight/Lean in the opposite direction to which the truck is tipping 60068011601 EN - 09/2020...
  • Page 46 Information about the truck Location of the decals 60068011601 EN - 09/2020...

  • 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 two open- ings 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% Rear tyres (M14X1.5): 181 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. ...

  • Page 58: 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 59: Check The Brake Fluid Level

    Use and operation Remaining ready for operation Check the brake fluid level  – Turn off the power to the forklift truck. – Check the brake oil container. The brake fluid level must be above the minimum mark. Unscrew the cap of the brake oil con- tainer and add more brake fluid as necessa- ry to avoid brake failure.

  • Page 60: Checking The Drive Axle Gearbox Oil

    Use and operation Remaining ready for operation DANGER Take care not to touch moving parts during this op- eration. 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.

  • 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.

  • 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 steering column 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 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. 60068011601 EN - 09/2020...
  • 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.

  • 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 30cm.
  • Page 76 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. 60068011601 EN - 09/2020...

  • Page 77: Changing Direction Of Travel

    Use and operation Driving Changing direction of travel – To change direction, release the accelerator  pedal (1) . – Press the service brake pedal (2) until the truck comes to a complete stop. – Move the lever (3) in the opposite direction ...

  • 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. –...

  • 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 Chart

    Before using attachments. ● Capacity Chart  For example: Truck model: RCD25 with single tyre Load centre: 500 mm Lift height: 5000 mm In this case, the maximum load capacity is: 2500 kg – Before loading, make sure that the dimen- sions and weight of the load are within the approved standard specified in the “Techni-...

  • Page 85: Transporting Pallets

    Use and operation Handling loads Transporting pallets  As a rule, loads (e.g. pallets) must be trans- ported individually. Transporting multiple loads at the same time is only permitted: when instructed by the supervisor and ● when the technical requirements have been ●...

  • Page 86: Transporting Suspended Loads

    Use and operation Handling loads DANGER Danger of death from falling loads! – Never walk or stand underneath suspended loads. Transporting suspended loads  Before transporting suspended loads, consult the national regulatory authorities (in Germa- ny, the employer's liability insurance associa- tions).

  • Page 87: Adjusting The Fork Arm Distance

    Use and operation Handling loads poles) must be available so that accompa- nying persons can guide suspended loads and prevent the loads from swinging Take particular care to ensure that there is ● no one in the drive direction in the driving lane If, despite this, the load begins to swing, en- ●...

  • Page 88: Picking Up A Load

    Use and operation Handling loads – 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 Use and operation Handling loads – Attach or secure the load to the lifting ac- cessory so that the load cannot move or fall. – Store the load so that the specified aisle width is not reduced by protruding parts. –...
  • Page 90 Use and operation Handling loads – Insert the fork as far under the load as pos-  sible using the brake Inching pedal. Stop the truck using the service brake as soon as the fork back is resting against the load. The load centre of gravity must be midway between the fork arms.
  • Page 91 Use and operation Handling loads – Lower the load while maintaining ground  clearance. 5060_003-102 – Tilt the lift mast backwards. The load can  now be transported. 5060_003-101 60068011601 EN - 09/2020...

  • Page 92: Transporting Loads

    Use and operation Handling loads Increasing the lifting speed – Fully depress the brake Inching pedal (1)  and hold it down. The drive wheels are now uncoupled from the engine. – Pull the "lift" operating lever as far back as possible.
  • Page 93 Use and operation Handling loads – Drive slowly and carefully round corners!  NOTE Observe the information in the chapter entitled "Steering". – Always accelerate and brake gently! NOTE Observe the information in the chapter entitled "Operating the service brake". 6210_800-013 –...

  • Page 94: Driving On Ascending And Descending Gradients

    Use and operation Handling loads Driving on ascending and descend-  ing gradients DANGER Danger to life! Driving on ascending and descending gradients car- ries special dangers! – Always follow the instructions below. – On ascending and descending gradients, the load must be carried facing uphill. –...

  • Page 95: Driving On Lifts

    Use and operation Handling loads Driving on lifts  The driver may only use this truck on lifts with a sufficient rated capacity and for which the operating company has been granted authori- sation. DANGER There is a risk to life if you are crushed or run over by the truck.

  • Page 96: Driving On Loading Bridges

    Use and operation Handling loads Driving on loading bridges  DANGER Risk of accident if the truck crashes! Steering movements can cause the tail end to veer off the loading bridge towards the edge. This may cause the truck to crash. The lorry driver and the truck driver must agree on the lorry's departure time.

  • Page 97: Setting Down Loads

    Use and operation Handling loads Setting down loads DANGER Risk of accident due to changed moment of tilt! Please note that the lift mast can be tilted far enough forwards with a raised load to cause the truck to tip over.
  • Page 98 Use and operation Handling loads – Lower the load until it rests securely on the  racking. – Look behind! – Move the truck back until the fork arms can be lowered without touching the stack. – Lower the fork to the ground clearance po- sition.

  • 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 "0" and then pull out the ignition and stop key. DANGER Never switch the forklift truck off by turning the igni- tion and stop key while the forklift truck is still mov- ing. DANGER NEVER leave the forklift truck without having first applied the parking brake(1) and removed the key.

  • 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.

  • 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 60068011601 EN - 09/2020...

  • 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. 60068011601 EN - 09/2020...

  • 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 60068011601 EN - 09/2020...

  • 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   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 Check the oil level of the brake system...
  • Page 119 Maintenance Scheduled truck maintenance At operating hours Carried 1000 2000 4000 5000 7000 8000   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;...

  • 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;...

  • Page 123: Supply Table

    Maintenance Scheduled truck maintenance Supply table Recommended Quan- Unit Operating material Specifications tity Engine 7.5L Engine oil API CJ-4 SAE15W-40 Hydraulic transmission Transmission oil Dexron Ⅲ/ Mobile ATF gear 38L for mast below ≥-5℃:L-HM46 4500mm mast Hydraulic system Hydraulic oil ≥-20℃:L-HV32(For cold 40L 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. 60068011601 EN - 09/2020...

  • Page 128: 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 129 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 130: Replacing The Engine Oil Filter

    Maintenance Maintenance service – Remove the oil cap(1).  – Add our recommended genuine oil by divid- ing it into several portions for replenish- ment. NOTE Ensure to refill the engine oil every 500 h. – Wait for about 1 ~ 2 minutes and then check the engine oil level.

  • Page 131: Replacement Of Coolant

    Maintenance Maintenance service – Lightly spread engine oil over the rubber packing (2) of the new oil filter (1). – Temporarily assemble the new oil filter by rotating it by hand. – Assemble the oil filter with the filter wrench at a torque of 16 ~ 20 N·m.
  • Page 132 Maintenance Maintenance service – Place a container in front of the coolant  drain plug ( as the arrow shows ). – Remove the radiator cap(1).  – Unplug the coolant drain plug of the radiator and then drain coolant. –...
  • Page 133 Maintenance Maintenance service at the specified mixing ratio to let the air be discharged from the radiator. NOTE Use recommended genuine antifreeze entitled "Engine coolant- Specifications" CAUTION – Do not mix antifreezes from different manufactur- ers. – Do not mix the coolant with different concentra- tions.

  • Page 134: Cleaning The Radiator, Checking For Leaks

    Maintenance Maintenance service ENVIRONMENT NOTE Discard exchanged coolant according to the regulations set forth by the relevant authori- ties. Disposing of exchanged coolant into the ground, sewers, drains, rivers, or the sea will cause serious environmental pollution. Viola- tion of regulations regarding discard of engine oil without observing the handling regulations, will be punished.
  • Page 135 Maintenance Maintenance service – Open the buckle(3) and remove the air filter  head cover(4). – Pull out the air filter(1).  – Remove dust from the filter by blowing out- ward through the filter using compressed air (2). Remove dust using minimum air pres- sure in order to avoiding damaging the in- sert.

  • Page 136: Change The Air Filter

    Maintenance Maintenance service – Clean the inside of the air filter head cover  (1). – Fit the filter(2)in the air filter housing(3). – Refit the air filter cover, and tighten the air filter head cover onto the air filter housing. Change the air filter –...

  • Page 137: Draining Water From The Fuel Filter

    Maintenance Maintenance service – Pull out the air filter (2)  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 138: Air Bleeding In The Fuel System

    Maintenance Maintenance service – Tighten the drain valve (1) at the bottom of the fuel filter. CAUTION Do not use tools to loosen the drain valve. Use of tools may damage the drain valve. Air bleeding in the fuel system ...
  • Page 139 Maintenance Maintenance service – Turn counterclockwise and loosen the fuel  filter. – Replace the fuel filter. CAUTION – Use the genuine fuel filters we recommend. Use of irregular or recycled parts may lead to critical failures in the engine. –...

  • Page 140: Check The Belt Tension

    Maintenance Maintenance service – Connect the WIFS (water in fuel sensor)  connector to the fuel filter. – Keep the fuel filter and the surroundings clean and out of foreign substances such as fuel. – Bleed air out of the fuel delivery line, as de- scribed in chapter entitled “Air bleeding in the fuel system”.

  • Page 141: 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 142: 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 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 floorplate. – Unscrew the oil drain plug (2). –...

  • Page 144: Changing The Drive Axle Gearbox Oil

    Maintenance Maintenance service Changing the drive axle gearbox oil  Emptying the gear oil – Ensure the forklift truck is stopped on a lev- el surface. – Unscrew the plug of the oil filler port(1) so that the gear oil is easier to discharge. –...

  • Page 145: 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 146 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). –...

  • Page 147: Change Brake System Liquid

    Maintenance Maintenance service 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. Capacity: approximately 0.3L. ● CAUTION Use a mistake and mixed with the brake liquid can cause the brake system seal unit rusty, even to the extent the brake out of order , serious consequences and so on.

  • Page 148: Changing The Suction 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. – Use a clean cloth to dry the dipstick(1) ...

  • Page 149: Replacing The Breather Filter

    Maintenance Maintenance service – Unscrew the suction filter (1) from the cover  assembly. – Screw in the new intake filter until tightened. – Refit the cover assembly to the frame using the fastening screws. – Refit the bracket and pedal pad. –...
  • Page 150 Maintenance Maintenance service 60068011601 EN - 09/2020...
  • Page 151 Technical datasheet...

  • Page 152: Technical Datasheet Dimensions

    Technical datasheet Dimensions Dimensions 60068011601 EN - 09/2020...

  • Page 153: Vdi Datasheet For Rcd25

    Technical datasheet VDI Datasheet for RCD25 VDI Datasheet for RCD25 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 154 Technical datasheet VDI Datasheet for RCD25 Fork Carriage Width b3 (mm) 1040 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) 4119 ways**** Working aisle width with pallet 800 x 1200 cross-...

  • Page 155: Vdi Datasheet For Rcd30

    Technical datasheet VDI Datasheet for RCD30 VDI Datasheet for RCD30 Characteristics Manufacturer STILL Model RCD30 Power type：Electric-Diesel-Petrol-LPG-Network Pow- Diesel er (Electric) Operation Type:Hand-stand on-Driver seated Seated Load Capacity Q (kg) 3000 Load centre of gravity distance c (mm) Axle centre to fork face...
  • Page 156 Technical datasheet VDI Datasheet for RCD30 Working aisle width with pallet 800 x 1200 cross- Ast (mm) 4344 ways**** Turning Radius Wa (mm) 2460 Turning Point Minimum Distance from the Truck Center b13 (mm) Line Performance data Driving speed (with/without load) km/h 18/18 Lifting speed (with/without load)

  • Page 157: Vdi Datasheet For Rcd35

    Technical datasheet VDI Datasheet for RCD35 VDI Datasheet for RCD35 Characteristics Manufacturer STILL Model RCD35 Power type：Electric-Diesel-Petrol-LPG-Network Pow- Diesel er (Electric) Operation Type:Hand-stand on-Driver seated Seated Load Capacity Q (kg) 3500 Load centre of gravity distance c (mm) Axle centre to fork face...
  • Page 158 Technical datasheet VDI Datasheet for RCD35 Working aisle width with pallet 800 x 1200 cross- Ast (mm) 4429 ways**** Turning Radius Wa (mm) 2540 Turning Point Minimum Distance from the Truck Center b13 (mm) Line Performance data Driving speed (with/without load) km/h 17/18 Lifting speed (with/without load)

  • Page 159: Mast Specifications

    Technical datasheet Mast specifications Mast specifications 2.5T MAST SPECIFICATIONS Rated capacity height free-lift height mast angle mast max.heig load center 500mm height closed without with car- type with car- double height carriage riage 2.5t front/ back riage tyres 3000 2500 2500 2080 4040...
  • Page 160 Technical datasheet Mast specifications 3.0T MAST SPECIFICATIONS Rated capacity height free-lift height mast an- mast max.heig load center 500mm height closed without with car- type with car- double front/ height carriage riage 3.0t riage tyres back 3000 3000 3000 2080 4273 3300 3000...
  • Page 161 Technical datasheet Mast specifications 3.5T MAST SPECIFICATIONS Rated capacity height free-lift height mast an- mast max.heig load center 500mm height closed without with car- type with car- double front/ height carriage riage 3.5t riage tyres back 3000 3500 3500 2230 4273 3300 3500...
  • Page 162 Technical datasheet Mast specifications 60068011601 EN - 09/2020...
  • Page 163 Index Control components....28 Address of manufacturer and contact details. I Adjusting the steering column..Daily checks before use.
  • Page 164 Parking brake..... . . 69 VDI Datasheet for RCD25... . 143 Personnel qualifications.
  • Page 165 Index Warnings......60068011601 EN - 09/2020...
  • Page 168 STILL GmbH 60068011601 EN - 09/2020...
  • Page 169 Original instructions Diesel forklift truck RCD25 RCD30 RCD35 4221 4222 4223 60068011601 EN - 09/2020...

  • Page 171: Diagrams

    Diagrams...

  • Page 172: Electric Schematic Diagram For Doosan D24 Engine-With Iso3691 Function

    Diagrams Electric schematic diagram for Doosan D24 engine—with ISO3691 function Electric schematic diagram for Doosan D24 engine—with ISO3691 function 60068011601 EN - 09/2020...

  • Page 173: Hydraulic Diagram

    Diagrams Hydraulic diagram Hydraulic diagram 60068011601 EN - 09/2020...
  • Page 174 Diagrams Hydraulic diagram 60068011601 EN - 09/2020...
  • Page 176 STILL GmbH 60068011601 EN - 09/2020...

This manual is also suitable for:

Rcd30Rcd35

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