Still RCD15 Original Instructions Manual

Diesel forklift truck

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Original instructions

Diesel forklift truck

RCD15

RCD18

RCD20

4211 4212 4213

60098011601 EN - 02/2024 - 08

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Page 1 Original instructions Diesel forklift truck RCD15 RCD18 RCD20 4211 4212 4213 60098011601 EN - 02/2024 - 08...
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 Introduction General information ........... 2 Truck data .
Page 6 Table of contents Safety regulations for handling consumables ....... 25 Permissible consumables .
Page 7 Table of contents Remaining ready for operation ......... . 52 Instructions for running-in .
Page 8 Table of contents Brake system ............ 86 Driving brake pedal and inching pedal .
Page 9 Table of contents Recommissioning after storage .......... 124 Permanent decommissioning (scrapping) .
Page 10 VDI Datasheet for RCD15 ........
Page 11 Introduction...
Page 12 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.
Page 13 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 bends that are too ing plate while observing the instructions given...
Page 14 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.
Page 15 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- –...
Page 16 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) ●...
Page 17 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-...
Page 18 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: ...
Page 19 Introduction Declaration that reflects the content of the declaration of conformity handed over to the new owner if the industrial truck is sold on. 60098011601 EN - 02/2024 - 08 9...
Page 20 Introduction Declaration that reflects the content of the declaration of conformity 10 60098011601 EN - 02/2024 - 08...
Page 21 Safety...
Page 22 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.
Page 23 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.
Page 24 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...
Page 25 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.
Page 26 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 ●...
Page 27 Safety Exhaust gases Exhaust gases CAUTION Risk to health from exhaust gases! Exhaust gases from internal combustion engines are harmful to your health. In particular, the soot particles contained in the diesel exhaust gas can cause cancer. Letting the combustion engine idle runs a risk of poisoning from the CO, CH and NO components contained in the exhaust gas...
Page 28 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.
Page 29 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.
Page 30 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.
Page 31 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.
Page 32 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 ●...
Page 33 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. 60098011601 EN - 02/2024 - 08 23...
Page 34 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 35 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 36 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 37 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 –...
Page 38 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.
Page 39 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.
Page 40 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-...
Page 41 Safety Fitting attachments accordance with Directive 2002/44/EC, in or- NOTE der to consider all additional influences, such as driving route, intensity of use etc. are con- Please note the definition of "operating com- sidered. pany" in the sense of responsible persons! Fitting attachments Only competent persons are permitted to fit the attachment and connect the energy supply...
Page 42 Safety Fitting attachments the necessary parts from the industrial truck manufacturer—especially lift mast rollers and chain supports—must be available. Contact your service partner. Hydraulic connection WARNING The hydraulic system is pressurised. Risk of injury. Wear protective equipment. CAUTION Risk of damage to the hydraulic system through con- tamination.
Page 43 Safety Manually lowering the fork arms with ISO capacity of the truck with the attachment; refer to the section entitled "Additional capacity rat- ing plate for attachments". Manually lowering the fork  arms with ISO The control valve is equipped with an emer- gency lowering screw (1) for manual lowering of the fork carriage.
Page 44 Safety Emergency exit from driver's cab with windows NOTE If the truck has a driver's cab with a door, a window and glass, it is difficult for the driver to open the door from the side when the truck encounters a fault in narrow passages. In the event of such dire danger, the driver can exit the truck via the rear window.
Page 45 Information about the truck...
Page 46 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 36 60098011601 EN - 02/2024 - 08...
Page 47 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 60098011601 EN - 02/2024 - 08 37...
Page 48 Information about the truck Instrumentation and controls Instrumentation and controls Overview of the driver’s compartment Steering wheel Direction selection lever Parking brake pedal A4 paper folder Accelerator pedal Lighting and direction indicator switch Driving brake pedal Operating lever Inching pedal Display unit Seat Cup holder...
Page 49 Information about the truck Instrumentation and controls Display unit “SCR error” indicator light “Battery charging” indicator light Seat indicator light "Engine error light" indicator light(Red light) Indicator light for "glow plug preheating" “DPF regeneration disabled” indicator Neutral Position indicator light(Red light) “Torque Converter Oil Temperature”...
Page 50 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 Serial number  xx xxxx x xxxxx The serial number is used to identify the truck. The serial number is shown on the nameplate.
Page 51 Information about the truck 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...
Page 52 Information about the truck Truck identification Engine serial number  The engine code and manufacturing number are engraved in the position(1) These num- bers are necessary to request quality assur- ance or to order parts. Product name Year of manufacture Serial Number After new representative specification 42...
Page 53 Information about the truck Location of the decals Location of the decals 60098011601 EN - 02/2024 - 08 43...
Page 54 Information about the truck Location of the decals Warning sign: Do not stand underneath the Warning sign: Danger due to overheating of fork/Do not stand on the fork/Do not enter radiator space behind the mast/ Injury to hand Warning sign: Danger due to shearing / Decal information: Capacity rating plate Danger to the driver’s head with engine Decal information: Filling in diesel...
Page 55 Information about the truck Location of the decals tight/Lean in the opposite direction to which Manufacturer’s name the truck is tipping 60098011601 EN - 02/2024 - 08 45...
Page 56 Information about the truck Location of the decals 46 60098011601 EN - 02/2024 - 08...
Page 57 Use and operation...
Page 58 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.
Page 59 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.
Page 60 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.
Page 61 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.
Page 62 Use and operation Remaining ready for operation Remaining ready for operation Instructions for running-in The truck can be operated immediately. ing hydraulics and the drive unit to high contin- uous loads. However, when driving during the first 50 op- erating hours, avoid subjecting both the work- Pre-shift checks Carrying out the following checks as part of your daily routine will help to keep the fork-...
Page 63 Use and operation Remaining ready for operation Check the structure of the overhead guard ● CAUTION for no damage and transparent material DO NOT use the truck, but call the technical service forms the part of the overhead guard struc- department, if you notice any malfunctions or if you ture shall not exceed 20 mm vertical defor- have any doubts about its correct operation.
Page 64 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.
Page 65 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 66 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 (M14X1.5) : 181 N.m±10% Rear tyres (M12X1.25): 113 N.m±10% –...
Page 67 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. –...
Page 68 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.
Page 69 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 70 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 71 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 neces- sary to avoid brake failure.
Page 72 Use and operation Remaining ready for operation DANGER Take care not to touch moving parts during this operation. 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).
Page 73 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 74 Use and operation Diesel fuel - Specifications CAUTION Use clean, specified, and qualified fuel only. Using irregular or unspecified fuel may cause critical damage and faults to the engine. When fuel needs to be added, be sure to add fuel with the engine stopped.
Page 75 Use and operation Engine coolant - specifications fatty acid methyl esters (FAME). Fuels accord- ing to ASTM D975 could contain other nonva- lidated FAAEs according to ASTM D6751. To maintain the optimum engine performance, refer to the following recommended fuel table to select the appropriate fuel.
Page 76 Use and operation Mounting/dismounting system and degrade the cooling performance, CAUTION so make sure to use tap water which satisfies By maintaining the coolant at the recommended mix- the following standards. ture ratio , you can effectively prevent corrosion in the engine and maintain long-term optimal engine performance.
Page 77 Use and operation Mounting/dismounting CAUTION Do not mount or dismount the truck from the right hand side unless it is an emergency. 60098011601 EN - 02/2024 - 08 67...
Page 78 Use and operation Seat and seat belt Seat 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.
Page 79 Use and operation Seat 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.
Page 80 Use and operation Seat 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.
Page 81 Use and operation Seat 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.
Page 82 Use and operation Seat 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.
Page 83 Use and operation Seat 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: –...
Page 84 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 85 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 86 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 87 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 88 Use and operation Diesel Particulate Filter (DPF) Diesel Particulate Filter (DPF) DPF Lamp and Switch The HEST (high exhaust system tem-  perature) light The HEST (high exhaust system temperature) light comes on up during regeneration periods. This light notifies the driver when hot exhaust gas is vented from the engine.
Page 89 Use and operation Diesel Particulate Filter (DPF) Forced regeneration (manual regenera-  tion) The driver can use these switches to activate or disable forced regeneration. DPF forced regeneration switch DPF regeneration disabled switch DPF Regeneration Methods Stage V engines are designed to perform pas- sive regeneration of soot accumulated in the DPF even under normal exhaust conditions without needing to be initiated by the driver.
Page 90 Use and operation Diesel Particulate Filter (DPF) At this time, normal operation is possible, al- though with caution for safety. Once regenera- tion is complete after 20 ~ 30 minutes, HEST lamp turn off. Forced regeneration (Manual Regener- ation) mode This regeneration mode is performed by the driver with the vehicle stopped in the event that DPF regeneration is not performed while...
Page 91 Use and operation Start the engine – The DPF lamp and HEST lamp turn on. – The engine rpm drops to an idling rpm. – The DPF lamp and HEST lamp turn off. – Place the forced regeneration (Manual Re- generation) switch in the OFF position.
Page 92 Wait at least one minute between start attempts in order to avoid running down the battery. If the engine still does not start after three attempts, do not try to start the engine again. Instead, contact your authorised service centre.
Page 93 Use and operation Driving Driving Driving CAUTION If the driver is distracted, there is a risk that accidents or injuries may occur. When the forklift truck is in operation, use of other electrical equipment (such as mobile phones) is prohibited. When using mirrors, ensure that the rear-view mirror is only used for monitoring the traffic behind the vehi- cle.
Page 94 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. NOTE For new CE truck, when you put forward or backward direction switch, the truck doesn’t work.
Page 95 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 direc- ...
Page 96 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.
Page 97 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 98 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 99 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 100 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 101 Use and operation Handling loads Handling loads Picking up a load DANGER DANGER Fall and crush hazard There is a risk of crushing as the lift mast or attachments may move. Standing on the forks is strictly prohibi- ted. For this reason, never reach into or enter the lift mast, or the area between the lift It is strictly prohibited to use the forks, mast and the forklift.
Page 102 Use and operation 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 103 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.
Page 104 Use and operation Handling loads Before lifting a load  Before lifting a load, check the load capacity chart on the engine cover. The maximum capacity is determined by the lifting height and the load centre distance. NOTE Check the load capacity limits and contact your authorised dealer before transporting: –...
Page 105 Use and operation Handling loads DANGER Risk of injury! – Do not step on the fork. DANGER Risk of injury! – Do not step under the raised forks. DANGER People may be injured in the danger area of the truck! The danger area of the truck must be completely clear of all personnel, except the driver in his normal operating position.
Page 106 Use and operation Handling loads Tipping the truck at right angles to the drive ● direction Risk of crushing of guide persons ● Reduced visibility ● DANGER Loss of stability! Slipping or swinging suspended loads can lead to a loss of stability and cause the truck to tip over. –...
Page 107 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.
Page 108 Use and operation Handling loads Picking up a load DANGER The truck may tip over if the load is too heavy. Before picking up the load, check that the dimen- sions and weight of the load lie within the permitted range for the truck.
Page 109 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.
Page 110 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! –...
Page 111 Use and operation Handling loads – Tilt the lift mast backwards. The load can  now be transported. 5060_003-101 Increasing the lifting speed – Fully depress the brake Inching pedal (1)  and hold it down. The drive wheels are now uncoupled from the engine.
Page 112 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 113 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 114 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 115 Use and operation Handling loads 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 corner of the load when it is positioned on the fork carriage in the driving position) The driver's field of vision can be severely...
Page 116 Use and operation Handling loads tions that may be encountered during opera- tion. The risks of poor visibility due to the load must be weighed against the risk of health-related consequences due to the upper body being twisted during reverse travel. A rotary seat can be used to assist the driver when reversing.
Page 117 Use and operation Handling loads – Do not drive downhill faster than the truck can drive uphill on the same gradient. – Determine the maximum permissible speed with a test drive uphill, if necessary. It is not permitted to drive on long ascending and descending gradients greater than 15% due to the specified minimum braking and sta- bility values.
Page 118 Use and operation Handling loads Determining the actual total weight  – Park the truck securely. – Determine the unit weights by reading the truck nameplate and, if necessary, the at- tachment (variant) nameplate and, if neces- sary, by weighing the load to be lifted. –...
Page 119 Use and operation Handling loads Risk of crushing of accompanying persons ● Poor visibility ● DANGER Loss of stability! Slipping or swinging suspended loads can lead to a loss of stability and cause the truck to tip over. – When transporting suspended loads, observe the following instructions.
Page 120 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 121 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 122 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.
Page 123 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. –...
Page 124 "0" and then pull out the ignition and stop key. DANGER Never switch the forklift truck off by turning the ig- nition and stop key while the forklift truck is still moving. DANGER NEVER leave the forklift truck without having first applied the parking brake(1) and removed the key.
Page 125 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.
Page 126 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 –...
Page 127 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.
Page 128 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 129 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 130 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 131 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.
Page 132 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.
Page 133 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 134 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.
Page 135 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.
Page 136 Use and operation Decommissioning 126 60098011601 EN - 02/2024 - 08...
Page 137 Maintenance...
Page 138 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.
Page 139 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.
Page 140 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. 130 60098011601 EN - 02/2024 - 08...
Page 141 Maintenance Scheduled truck maintenance Scheduled truck maintenance Maintenance — 500 hours At operating hours Carried 500 1500 2500 3500 4500 5500 6500 7500 8500 9500   Chassis, bodywork and fittings ...
Page 142 Maintenance Scheduled truck maintenance At operating hours Carried 500 1500 2500 3500 4500 5500 6500 7500 8500 9500   Check mast bearings for damage, and lubricate. Check the tightening torque ...
Page 143 Maintenance Scheduled truck maintenance Maintenance — 1000 hours At operating hours Carried 1000 2000 4000 5000 7000 8000   Chassis, bodywork and fittings ...
Page 144 Maintenance Scheduled truck maintenance At operating hours Carried 1000 2000 4000 5000 7000 8000   Check the fuel lines and clips ...
Page 145 Maintenance Scheduled truck maintenance At operating hours Carried 1000 2000 4000 5000 7000 8000   Check fork arms for wear and deformation ...
Page 146 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 ...
Page 147 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 ...
Page 148 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 ...
Page 149 Maintenance Scheduled truck maintenance Supply table Recommended Quan- Unit Operating material Specifications tity Engine 7.5L Engine oil CJ-4 15W-40 Hydraulic transmission Transmission oil Dexron Ⅲ 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) ing 4500mm mast Braking system...
Page 150 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 151 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 152 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.
Page 153 Maintenance Providing access to maintenance points – Carefully guide the bottom plate down and close. – Insert the rubber mat. – Close the bonnet. 60098011601 EN - 02/2024 - 08 143...
Page 154 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 155 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 ...
Page 156 Maintenance Maintenance service – Remove the oil cap(1).  – Add our recommended genuine oil by di- viding 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 157 Maintenance Maintenance service – 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. NOTE Please refer to the engine spare parts manual to find the part number of usable engine oil filters.
Page 158 Maintenance Maintenance service At this time, normal operation is possible, al- though with caution for safety. Once regenera- tion is complete after 20 ~ 30 minutes, HEST lamp turn off. CAUTION Turning the engine off during regeneration (i.e. while the HEST lamp is turned on) may have a severe impact on the DPF.
Page 159 Maintenance Maintenance service – Forced regeneration (Manual Regeneration) is performed for 30 ~ 40 minutes.(May take longer depending on the above-mentioned forced regeneration (Manual Regeneration) conditions). The DPF lamp and HEST lamp turn on. – The engine rpm drops to an idling rpm. –...
Page 160 Maintenance Maintenance service NOTE Please note the following while handling the DPF assembly. The muffler weighs approx. 13 kg and the ● DOC/DPF are weak against impacts, so be careful not to damage them during removal. When replacing the differential pressure ●...
Page 161 Maintenance Maintenance service – Clean the radiator (1).  – Clean the radiator fins using a suitable brush and blow them out using compressed air (max. 2 bar). – Check the radiator and coolant hoses for leaks and tighten the clips if necessary. CAUTION Risk of engine damage! If the cooling fluid level is low, this indicates a leak in...
Page 162 Maintenance Maintenance service – 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 pressure in order to avoiding damaging the insert. CAUTION Flying object hazard! Wear eye protection when carrying out maintenance on the engine and using compressed air or pressur-...
Page 163 Maintenance Maintenance service Change the air filter – Open the buckle(5) and remove the filter  cover(4). – 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 164 Maintenance Maintenance service Draining water from the fuel filter – Loosen 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. –...
Page 165 Maintenance Maintenance service Air bleeding in the fuel system  – Turn counterclockwise and loosen the air discharge valve (2) on top of the fuel filter. – Pump with the pump handle (3) until fuel is discharged through the air discharge valve (3).
Page 166 Maintenance Maintenance service – Tighten the fuel filter to 3/4.  – 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.
Page 167 – 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 168 Maintenance Maintenance service Number of Belt width Tension [N] Ribs 20.98~21.74 300~380 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.
Page 169 Maintenance Maintenance service Replacing the fine hydraulic  transmission oil filter ENVIRONMENT NOTE Please handle liquids and lubricating oil in ac- cordance with instructions. NOTE If transmission oil flows out, a collection con- tainer should be placed underneath the fine oil filter.
Page 170 Maintenance Maintenance service – Use the dipstick to check the transmission oil level, which should reach the upper mark on the dipstick. – Reinstall the floorplate. – Start the engine and run it in neutral for a while. After the engine stops running, recheck the oil level, which should be be- tween the upper and lower marks on the dipstick.
Page 171 Maintenance Maintenance service NOTE The high viscosity of gear oil means that ● it takes time for new oil to fill the gaps in the gearing. It is therefore preferable to use a pressurised filling tool; otherwise the fill- ing process will take a relatively long time. Even when oil flows out of the filler port, this does not mean that the oil level is full;...
Page 172 Maintenance Maintenance service – When changing wheels with tyres, inflate to the prescribed pressure. Front wheel change  – Lift the fork arms to at least 1 m above the ground. – Turn off the truck and perform the prelimi- nary maintenance operations.
Page 173 Maintenance Maintenance service Tightening the wheel nuts  Tighten the wheel fastenings before initial commissioning and whenever wheels are dis- mantled and installed or repairs are performed to the wheel fastenings. Then re-tighten the wheel fastenings at the latest after 100 operating hours. –...
Page 174 Maintenance Maintenance service Fill up the hydraulic oil – Unscrew the oil cap (1)assembly.  – Fill up with hydraulic oil through the oil inlet. – Use the dipstick to check the oil level. The oil level should reach the upper marking on the dipstick.
Page 175 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 176 Maintenance Maintenance service Removing the forks WARNING Manual handling risk. The forks are heavy. Care should be taken when removing the forks. – Apply parking brake. – Tilt the mast fully forward and lower the forks to approximately 150 mm from the ground.
Page 177 Maintenance Maintenance service – Release the fork latch (1) and slide the fork  to the required position. – Refit the knob by engaging it in one of the notches on the fork carriage. – Repeat the operation for the other fork and fit the centre stop bolt.
Page 178 Maintenance Maintenance service – Visually check that there are no cracks on the fork arms, especially in the fork heel and attachment areas. In case of doubt, check using a dye penetrant test. – Replace damaged parts if necessary. Checking the operation and in- ...
Page 179 Maintenance Maintenance service – Immediately blow the chain dry after clean- ing to remove water both on the chain sur- face and inside the hinge pins. Move the chain several times during the blow-drying process. – Immediately apply chain spray and keep the chain moving while doing so.
Page 180 Maintenance Maintenance service – Using lubricating grease, lubricate the  grease nipples (2)on the left and right tilt cylinder pivots at the chassis from above. – Inject grease into the lift mast grease noz-  zles on the left and right sides of the frame (3).
Page 181 Maintenance Maintenance service Adjusting the length of the lift chains, and lubricating using chain spray Adjusting the length of the lift chains*  NOTE As lift chains stretch with use, they must be adjusted, both on the left and right hand side. –...
Page 182 Maintenance Maintenance service 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. – Completely lower the mast. – Loosen the locknut (2). –...
Page 183 Maintenance Maintenance service exceed 20 mm vertical deformation. Otherwise it shall be replaced accordingly. The replace- ment shall be done by authorized service. 60098011601 EN - 02/2024 - 08 173...
Page 184 Maintenance Maintenance service 174 60098011601 EN - 02/2024 - 08...
Page 185 Technical datasheet...
Page 186 Technical datasheet Dimensions Dimensions 176 60098011601 EN - 02/2024 - 08...
Page 187 Technical datasheet VDI Datasheet for RCD15 VDI Datasheet for RCD15 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 188 Technical datasheet VDI Datasheet for RCD15 Fork Carriage in Compliance with ISO 2328 Class/ Form A,B 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-...
Page 189 Technical datasheet VDI Datasheet for RCD18 VDI Datasheet for RCD18 Characteristics Manufacturer STILL Model RCD18 Power type：Electric-Diesel-Petrol-LPG-Network Diesel Power (Electric) Operation Type:Hand-stand on-Driver seated Seated Load Capacity Q (kg) 1800 Load centre of gravity distance c (mm)
Page 190 Technical datasheet VDI Datasheet for RCD18 Working aisle width with pallet 800 x 1200 cross- Ast (mm) 4015 ways**** Turning Radius Wa (mm) 2180 Turning Point Minimum Distance from the Truck Cen- b13 (mm) ter Line Performance data Driving speed (with/without load) km/h 17/17 Lifting speed (with/without load)
Page 191 Technical datasheet VDI Datasheet for RCD20 VDI Datasheet for RCD20 Characteristics Manufacturer STILL Model RCD20 Power type：Electric-Diesel-Petrol-LPG-Network Diesel Power (Electric) Operation Type:Hand-stand on-Driver seated Seated Load Capacity Q (kg) 2000 Load centre of gravity distance c (mm)
Page 192 Technical datasheet VDI Datasheet for RCD20 Working aisle width with pallet 800 x 1200 cross- Ast (mm) 4035 ways**** Turning Radius Wa (mm) 2200 Turning Point Minimum Distance from the Truck Cen- b13 (mm) 601.5 ter Line Performance data16.3/16.3 Driving speed (with/without load) km/h 17/17 Lifting speed (with/without load)
Page 193 Technical datasheet Mast specifications Mast specifications Rated capacity height free-lift height mast an- mast max.hei load center 500mm height closed without with type with front/ height carriage carriage 1.5T 1.8T 2.0T carriage back 3000 1500 1800 2000 2002 4041 6/12 3300 1500 1800...
Page 194 Technical datasheet Mast specifications 184 60098011601 EN - 02/2024 - 08...
Page 195 Index Check the wheel nuts for correct condition. 56 Cleaning the air filter....Additional capacity rating plate for attach- Cleaning the electrical system..120 ments.
Page 196 Index Emergency exit from driver's cab with win- Maintenance work without special qualifi- dows......cations.
Page 197 Seat belt status and performance checks. VDI Datasheet for RCD15... . 177 Serial number..... .
Page 200 STILL GmbH 60098011601 EN - 02/2024 - 08...
Page 201 Original instructions Diesel forklift truck RCD15 RCD18 RCD20 4211 4212 4213 60098011601 EN - 02/2024 - 08...
Page 203 Diagrams...
Page 204 Diagrams Electric schematic diagram for DM02VB engine—with ISO3691 function Electric schematic diagram for DM02VB engine—with ISO3691 function 194 60098011601 EN - 02/2024 - 08...
Page 205 Diagrams Hydraulic diagram Hydraulic diagram 60098011601 EN - 02/2024 - 08 195...
Page 206 Diagrams Brake diagrams Brake diagrams 196 60098011601 EN - 02/2024 - 08...
Page 207 Diagrams Brake diagrams Parking brake Wheel brake Master cylinder Driving brake pedal Driving brake Wheel brake Wheel cylinder Parking brake lever/pedal Brake fluid tank Wheel cylinder 60098011601 EN - 02/2024 - 08 197...
Page 208 Diagrams Brake diagrams 198 60098011601 EN - 02/2024 - 08...
Page 210 STILL GmbH 60098011601 EN - 02/2024 - 08...

This manual is also suitable for:

Rcd18 Rcd20