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.
Introduction General information General information Operating on public roads The truck described in these operating instruc- tions corresponds to the applicable standards If the truck is to be operated on public roads, and safety regulations. the truck must conform to the national regu- The truck has been fitted with advanced tech- lations for the country in which it is being nology.
Introduction Intended use Intended use The industrial truck may be used only for its provided so that trucks can drive over these intended purpose. obstacles with as few bumps as possible. The industrial truck is intended for moving and Industrial trucks may only be used on road- lifting the loads specified on the capacity rat- ways that do not have curves that are too ing plate while observing the instructions given...
Introduction Improper use Attachments Mounting the attachment and connecting the energy supply for power-driven attachments Attachments may only be used for their inten- must only be performed by authorised person- ded purpose. Drivers must be taught how to nel in accordance with the information provi- operate the attachments.
Introduction Modifications to the truck Modifications to the truck Unauthorised truck modification is not per- – maintains a permanent record of the de- mitted. sign, test(s) and implementation of the mod- ification or alteration, Only in the event that the truck manufacturer is no longer in business and there is no suc- –...
Introduction Conformity marking Conformity marking The manufacturer uses the conformity mark- ing to document the conformity of the industri- al truck with the relevant directives at the time of placing on the market: CE: in the European Union (EU) ●...
Introduction EMC – Electromagnetic compatibility EMC – Electromagnetic compatibility Electromagnetic compatibility (EMC) is a key and secondly checks it for sufficient resistance quality feature of the truck. to 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-...
Declaration that reflects the content of the declaration of con- formity Declaration STILL GmbH Berzeliusstraße 10 22113 Hamburg Germany We declare that the specified machine conforms to the most recent valid version of the directives specified below: ...
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Introduction Declaration that reflects the content of the declaration of conformity handed over to the new owner if the industrial truck is sold on. 60128011601 EN - 04/20223 - 08 9...
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Introduction Declaration that reflects the content of the declaration of conformity 10 60128011601 EN - 04/20223 - 08...
Safety Regulations Regulations Regular safety inspection Periodic safety inspections are essential to keep your truck safe and in good working or- der. Europe: National laws based on Directives 95/63/EC, 99/92/EC and 2001/45/EC require that the truck is checked regularly by a com- petent person to ensure that it is in good con- dition.
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Safety Safety guidelines Working on the truck DANGER Risk of fire due to hot exhaust gases! DANGER Exhaust gases become so hot that materials in the Any additional bores or welding on the overhead immediate vicinity may smoulder or burn. guard will compromise its rigidity.
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Safety Safety guidelines Safety information for electromagnetic WARNING compatibility If a driver has active medical equipment such as a pace makers, defibrillator, cochlear implant, insulin WARNING pump or hearing aid, there is a possibility that the capabilities of the driver could be impaired. In operating areas with magnetic fields that have a magnetic flux density greater than 5 mT, unintention- The operating company must take drivers whose...
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 who operates the truck or on whose scheduling and correct performance of regular authority the truck is used.
Safety Definition of terms used for responsible persons Drivers Trucks must be driven only by persons who: safety shoes, safety helmet, protection gog- gles, gloves) Are at least 18 years of age ● Have read and understood the operating in- Have been trained in performing this task ●...
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...
Safety Carrying out regular inspections on the truck Carrying out regular inspec- tions on the truck The operating company must ensure that the truck is checked by a specialist at least once a year or after particular incidents. As part of this inspection, the technical condi- tion of the truck must be completely tested with regard to accident safety.
Safety Improper use plate). Overloading can affect braking distan- The truck and attachments must only be used ces, truck stability and the strength of the lift for authorised applications. mast. Follow the instructions in the user manual Do not pick up an off-centre load. when transporting loads.
Safety Hazard assessment Hazard assessment In accordance with health and safety regula- If the application conditions or the equipment tions, the employer is responsible for the safe- on industrial trucks change, the hazard as- ty and health of employees at work. sessment must be adjusted.
Safety Residual risks Residual risks Despite careful work and compliance with all Residual dangers can include: applicable standards and regulations, the pos- Escape of consumables due to leakages or ● sibility of other dangers when using the indus- the rupture of lines, hoses or containers, trial truck cannot be entirely excluded.
Safety In the case of tip-over If the industrial truck tips due to improper or incorrect operation: Do not release your seat belt ● Do not jump out ● Hold on tight ● Brace yourself with your feet ● Lean in the opposite direction to which the ●...
There is a risk of accident! – Do not use devices during travel or when handling loads. – Set the volume so that warning signals can still be heard. 60128011601 EN - 04/20223 - 08 23...
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.
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.
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- –...
Safety Safety regulations for handling consumables Hydraulic fluid WARNING ENVIRONMENT NOTE These fluids are pressurised during op- Hydraulic fluid is a water-polluting substance. eration of the truck and are hazardous to Always store hydraulic fluid in containers your health. ● that comply with regulations –...
Safety Safety regulations for handling consumables – Dispose of used battery acid in line with the ENVIRONMENT NOTE applicable regulations. Disposal of consumables – Soak up any spilt fluids such as hydraulic ENVIRONMENT NOTE oil, brake fluid or gearbox oil using an oil- binding agent.
Safety Environmental considerations Environmental considerations Handling consumables Comply with the statutory provisions ● ENVIRONMENT NOTE Before performing lubrication work, filter ● changes or any work on the hydraulic sys- Consumables must be handled properly and tem, carefully clean the area around the rel- in accordance with the manufacturer's instruc- evant part tions.
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 particular application conditions, sound reflec-...
Safety Fitting attachments than 2.5 m/s2. There are therefore no meas- as driving route, intensity of use etc. are con- urement guidelines for these measurements. 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-...
Safety Fitting attachments Class Load ca- Load As per pacity centre of Version Truck gravity 2328 8001 - 10999 Integrated attachments are made to match the installed lift mast. When retrofitting at- tachments, the correct attachment and all of the necessary parts from the industrial truck manufacturer—especially lift mast rollers and chain supports—must be available.
Safety Manually lowering the fork arms with ISO – Disconnect the hydraulic lines. – Connect the hydraulic lines to the attach- ment. Additional capacity rating plate Attachments alter the load capacity and stabil- ity of the truck. For each attachment, an addi- tional capacity rating plate must be mounted in the driver's field of vision to indicate the load capacity of the truck with the attachment;...
Safety Emergency exit from driver's cab with windows Emergency exit from driver's cab with windows CAUTION If the truck is equipped with a driver's cab with doors, DO NOT open the doors until the load is placed on the floor. NOTE If the truck has a driver's cab with a door, a window and glass, it is difficult for the driver...
Overview General view General view General front view Fork arms Tilt cylinder Mast Forward Front wheels Right Driver’s Seat Backwards Overhead guard Left 36 60128011601 EN - 04/20223 - 08...
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...
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 Serial number xx xxxx x xxxxx The serial number is used to identify the truck. The serial number is shown on the nameplate.
Overview Truck identification Variant 2: Industrial trucks built after 12/2021 Model Production number Year of manufacture Tare weight Max. battery weight/ Min. battery weight (only for electric trucks) Ballast weight (only for electric trucks) For more detailed information, refer to the technical data in the operating in- structions Conformity marking: CE mark for the...
Overview Truck identification 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. 42 60128011601 EN - 04/20223 - 08...
Overview Location of the decals Location of the decals 60128011601 EN - 04/20223 - 08 43...
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Overview Location of the decals Decal information: Lifting gear attachment if the truck is tipping over/Brace feet/Hold on point tight/Lean in the opposite direction to which Warning sign: Do not stand underneath the the truck is tipping fork/Do not stand on the fork/Do not enter Decal information: Hydraulic oil tank space behind the mast/ Injury to hand Warning sign: Danger due to overheating of...
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Overview Location of the decals Decal information: Capacity rating plate Manufacturer’s name Nameplate 60128011601 EN - 04/20223 - 08 45...
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Overview Location of the decals 46 60128011601 EN - 04/20223 - 08...
Use and operation Truck transport and lifting Truck transport and lifting Removing the mast CAUTION Mast removal and installation must be carried out by trained personnel. Contact your authorised dealer. Use a truck or flatbed trailer to carry the forklift truck The truck is normally transported by road and rail complete with lift mast.
Use and operation Truck transport and lifting – Fasten the forklift truck to the truck using ropes attached to the towing device and to the left and right outer profiles of the forklift truck's lift mast. CAUTION Damage may occur to the mast components. Stay clear of the ropes used for fastening, and do not tighten around hose lines, lift cylinders and mast chains.
Use and operation Truck transport and lifting Lifting the truck with a crane DANGER When lifting the truck with a crane, there is a risk of accident and fatal injury if personnel are in the working area of the crane. When using a crane to lift the truck, pay particular attention to ensure that no personnel are in the vicini- ty of the crane.
Use and operation Commissioning the truck DANGER The overhead guard will be damaged if it is con- tacted by lifting equipment that is under tension from lifting. This can result in later failure of the overhead guard and the risk of severe injury or death.
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 fork- lift truck in good condition. These checks are supplemental and do not replace periodic maintenance work.
Use and operation Remaining ready for operation Seat belt status and perform- ance 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.
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.
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 (M20X1.5) : 525 N.m±10% –...
Use and operation Remaining ready for operation Check the condition and opera- tion of chain – Check load chains for any distortion before operation. – Stop using the forklift immediately when the hinge pins of chain rotate before operation. –...
Use and operation Remaining ready for operation – Contact your authorised dealer 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.
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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 ...
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 –...
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.
Use and operation Remaining ready for operation Checking the hydraulic oil level ENVIRONMENT NOTE Please follow the instructions for handling/dis- posal of fluids and lubricants. NOTE The oil level should only be checked with the lift mast vertical and the fork carriage lowered. –...
Use and operation Refuelling Refuelling DANGER Turn off the engine before refuelling. Do not smoke or use naked flames while refuelling. – Remove the fuel tank cap (1) and refuel. – Close the fuel tank cap (1). CAUTION Risk of damage to injection system due to entering air.
Use and operation Mounting/dismounting system and cause operating faults. Winter die- NOTE sel fuel must be used at ambient temperatures below 0 °C (up to -20 °C) (this is offered at Special diesel fuels can be used for arctic cli- fuel stations in good time before the start of mates up to -44 C.
Use and operation Sealt and seat belt Sealt and seat belt Seat belt 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.
Use and operation Sealt and seat belt Adjusting the seat and seat belt CAUTION An incorrect seat setting may cause damage to the driver's back. The adjustment controls for the driver's seat should not be used during operation. Before starting the truck and whenever changing drivers, adjust the seat to correspond to the driver's weight and make sure that the settings have all en- gaged properly.
Use and operation Sealt and seat belt Fastening the seat belt DANGER Even when using an approved restraint system, there is some residual risk that the driver might be injured if the truck tips over. This risk of injury can be reduced through the combined use of the re- straint system and the seat belt.
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Use and operation Sealt and seat belt – Pull the seat belt (2) out of the belt retractor without jerking and fasten closely around the body over the thighs. NOTE Sit as far back as possible so that your back is leaning against the seat backrest.
Use and operation Sealt and seat belt Malfunction due to cold weather condi- tions – If the buckle or belt retractor is frozen, thaw them out and dry them thoroughly to pre- vent recurrence. CAUTION Do not subject buckle or belt retractor to excessive heat when thawing out.
Use and operation Sealt and seat belt Driver presence monitoring DANGER The driver must sit in the driver's seat when operat- ing the forklift truck. When starting a truck with a driver presence monitoring system, if the drive is not sitting in the driver's seat, the truck will behave as follows: –...
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;...
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. –...
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.
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 —...
Wait at least one minute between start attempts in order to 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. 74...
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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.
Use and operation Diesel Particulate Filter(DPF) Diesel Particulate Filter(DPF) Diesel oxidation catalytic converter The diesel oxidation catalytic converter has a water. In addition, the nitrogen monoxides are catalytic surface which is used to convert the converted to nitrogen dioxides. pollutants in the exhaust gas into harmless Temperature >...
Use and operation Diesel Particulate Filter(DPF) If the operating conditions of the engine do not permit any passive regeneration, the contami- nation of the diesel particle filter with soot will increase. A throttle valve controlled via the engine con- trol unit is located in the combustion air inlet. This is used to increase the exhaust gas tem- perature for regeneration of the diesel particle filter, if this is not reached during normal oper-...
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Every standstill regeneration slightly dilutes the engine oil with fuel. The number of stand- still regeneration is therefore monitored. Implementation of the standstill regen- eration The engine must be brought into a “safe state”...
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Use and operation Diesel Particulate Filter(DPF) – Pressing the regeneration switch(1). – The regeneration lamp(14) lights up contin- uously. – The HEST(high exhaust system tempera- ture)lamp(13) lights up during regeneration period. This light notifies the driver when hot exhaust gas is vented from the engine. Ensure that there is no combustible material around the exhaust pipe.
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Use and operation Diesel Particulate Filter(DPF) non-combustible residues accumulate in the filter so-called ash. If the ash loading goes beyond a certain level, this will be indicated by the ash lamp. The diesel particle filter needs to be replaced. The truck can operate normally until the re- placement is carried out by the authorization service.
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.
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.
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) . –...
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 appa- ratus when the forklift truck is not carrying a load. Operate the forklift truck slowly on an uncrowded road surface to test travelling func- tions.
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 –...
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.
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.).
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. –...
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. –...
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 neces- sarily located at the central point of the load itself.
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.
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!
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Use and operation Handling loads Impaired braking and steering movement ● Tipping over the load wheels or drive ● wheels Tipping the truck at right angles to the drive ● direction Risk of crushing of guide persons ● Reduced visibility ●...
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 dimensions 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.
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.
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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 slipping when the load is raised or lowered.
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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 entitled "Increasing the lifting speed". DANGER Risk of accident! –...
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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.
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.
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Use and operation Handling loads – Never drive with a load protruding to the side (e.g. with the sideshift)! 6210_800-014 Determining visibility conditions when driving with a load e3861567 Area that is not visible (max. 1085 mm) Load (varies depending on operator) Load height (in driving position) Driver's eye level 4000 mm (distance to the front from the rear...
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Use and operation Handling loads Procedure: The driver moves into position in his seat. ● The area that is not visible (A) is deter- ● mined based on the load (Y) and the length of the route (D). If the area that is not visible exceeds ●...
Use and operation Handling loads Driving on ascending and de- scending 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. –...
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.
Use and operation Handling loads Transport of swinging loads Before transporting suspended loads, consult the national regulatory authorities. National regulations may place restrictions on these operations. Contact the relevant authori- ties. DANGER Suspended loads that begin to swing can result in the following risks: Impaired braking and steering action ●...
Use and operation Handling loads DANGER Risk of accidents! When transporting hanging loads, never perform or end driving and load movements abruptly. Never drive on slopes with a suspended load. Transporting containers holding fluids as hanging loads is not permitted. Driving on loading bridges ...
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.
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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.
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.
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 exceed 2% of the daily operating time. If the truck is to be used for towing on a more reg- ular basis, the manufacturer should be consul- ted.
Use and operation Leaving the truck switched on, you must observe the following precautions: – Lower the fork carriage. Tilt the mast for- ward. – Ensure the direction control lever and all the operating levers in the neutral position. – Activate the parking brake. –...
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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.
Use and operation Truck storage Truck storage Truck Storage Before storage Long-term storage Before storing your forklift truck, clean it thor- If use of the truck will be suspended for more oughly and perform inspection as the following than 2 months, it should be parked in a well- procedures.
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Use and operation Truck storage – Add cooling fluid to specified level. NOTE – Perform pre-operation checks carefully. If the forklift truck will be out of use for a peri- od of over 12 months, check the quality of all –...
Use and operation Truck storage Disposal of old trucks smeared parts, as well as for tyres including The disposal of old trucks is regulated in di- fire protection measures. Suitable storage rective 2000/53/EC from the European Parlia- tanks for fluids such as fuel, AdBlue® (urea ment and Council.
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.
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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.
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. –...
Use and operation Cleaning – Clean the electrical system parts with a metal-free brush and blow the dust off with low-pressure compressed air. 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.
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 electri- cal system despite the precautionary measures taken, the system must first be dried using com- pressed air.
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: –...
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 longer periods, contact the authorised serv- ice centre to find out about additional meas- ures.
Use and operation Decommissioning Permanent decommissioning (scrapping) The forklift truck must be scrapped in com- pliance 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.
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Use and operation Decommissioning 124 60128011601 EN - 04/20223 - 08...
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 con- sumable material designed for the purpose. A written record must be kept of all work that has been carried out.
Maintenance Personnel qualifications Personnel qualifications Only qualified and authorised personnel are allowed to perform maintenance work. Regu- lar safety checks and checks after unusual incidents 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.
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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. 128 60128011601 EN - 04/20223 - 08...
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 ...
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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 ...
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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 ...
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.
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.
Maintenance Providing access to maintenance points Installing and removing the bot- tom 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.
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Maintenance Providing access to maintenance points – Carefully guide the bottom plate down and close. – Insert the rubber mat. – Close the bonnet. 60128011601 EN - 04/20223 - 08 141...
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.
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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 collect the used oil. – Remove the oil drain plug (2) and allow the oil to flow into the container.
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 ...
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 ...
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Maintenance Maintenance service – Carefully unscrew the drain plug (3) and allow 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. –...
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.
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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).
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.
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.
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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.
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. –...
Maintenance Maintenance service be 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.
Maintenance Maintenance service Cleaning the air filter Clogged filter inserts may have an adverse impact on engine performance. Make sure to periodically clean the air filter insert. – Open the buckle(1) and remove the air filter head cover(2). – Pull out the outer air filter(4). ...
Maintenance Maintenance service – Clean the inside of the air filter head cov- er(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 –...
Maintenance Maintenance service intake opening after the warning light illumi- nates. Changing the hydraulic trans- mission 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.
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). –...
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.
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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). –...
Maintenance Maintenance service Checking the drive axle gearbox – Unscrew the oil plug at the oil level aper- ture(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.
Maintenance Maintenance service NOTE The hydraulic oil will flow out. Place an oil pan under the filter. – Open the engine cover. – Remove the pedal pad and bracket. – Slacken off the fastening bolts and washers on the cover assembly, then remove the cover assembly.
Maintenance Maintenance service – Unscrew the breather filter (1) and dipstick and remove. – Remove the dipstick and balls on the dip- stick base from the breather filter and mount onto the new the breather filter. – Screw the breather filter and dipstick back into position.
Maintenance Maintenance service Fitting the forks – Loosen the centre stop bolt. – Tilt the mast forward until the fork is attach- ed to the centre groove of the carriage. – Apply the parking brake. – Tilt back the mast and raise the fork car- riage slowly with the fork located on the car- riage.
Maintenance Maintenance service – Check the thickness of the fork arm blade at a point between the end of the taper and heel of the fork arm. – Measure the sample section (ZC) as indica- ted in the drawing and compare it with sec- tions A, B, C.
Maintenance Maintenance service – Check the tightness of the elastic retaining rings at the piston rod connections on top of the lift mast. 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.
Maintenance Maintenance service Lubricating the lift mast and tilt cylinder bearings NOTE Lubricate using lubricating grease only. – Lower the fork carriage fully. – Using lubricating grease, lubricate the grease nipples (1)on the left and right tilt cylinder pivots at the drive axle from above. –...
Maintenance Maintenance service – Inject grease into the lift mast grease noz- zles on the left and right sides of the frame (3). – Lubricate using a grease gun until fresh grease comes out of the bearings. – Refit the floor plate and then the engine cover.
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Maintenance Maintenance service CAUTION For safety reasons, wear safety equipment while working at height. Adjusting the length of the lift chains* NOTE Use over time will cause the lift chains to stretch, therefore it is necessary to check and adjust their lengths.
Maintenance Maintenance service Checking the structure of the overhead guard NOTE Modification in overhead guard is not allowed without getting the approval from the manufac- turer. Check the structure of the overhead guard for no damage and transparent material forms the part of the overhead guard structure shall not exceed 20 mm vertical deformation.
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Maintenance Maintenance service 170 60128011601 EN - 04/20223 - 08...
Technical datasheet VDI Datasheet for RCD40 VDI Datasheet for 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.
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Technical datasheet VDI Datasheet for RCD40 Fork Carriage in Compliance with ISO 2328 Class/Form III A 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-...
Technical datasheet VDI Datasheet for RCD50 VDI Datasheet for 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)
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Technical datasheet VDI Datasheet for RCD50 Turning Radius Wa (mm) 2830 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...
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...
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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...
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Index Checking the structure of the overhead UMBERS AND YMBOLS guard......169 4T MAST SPECIFICATIONS..177 Checking the V-belt tension.
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Index EMC – Electromagnetic compatibility..Maintenance work without special qualifi- cations......127 Emergency exit from driver's cab with win- dows.
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Seat belt status and performance checks. VDI Datasheet for RCD40... . 173 Serial number..... .
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STILL GmbH 60128011601 EN - 04/20223 - 08...
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Original instructions Diesel forklift truck RCD40 RCD50 4231 4233 60128011601 EN - 04/20223 - 08...
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