Still RCD 100 User manual

IC Truck
MTU Eu5
RCD 100
RCD 120
RCD 140
RCD 150
RCD 160
RCD 180
RCD 100 / 1200
RCD 120 / 1200
RCD 140 / 1200
RCD 150 / 1200
RCD 160 / 1200
RCD 180 / 900
Original instructions
5410 5411 5412 5413 5414 5415
5416 5417 5418 5419 5420 5421
5001 801 1625EN-05/2022 - 03

Address of manufacturer and
contact details
STILLGmbH
Berzeliusstraße10
22113 Hamburg, Germany
Tel. [phone]
Fax: [phone]
Email: [e-mail]
Website: http://www.still.de
Made in China
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.
This guide provides information for handling
industrial trucks:
●
Information on how to select suitable indus-
trial trucks for a particular area of applica-
tion
●
Prerequisites for the safe operation of in-
dustrial trucks
●
Information on the use of industrial trucks
●
Information on transport, initial commission-
ing and storage of industrial trucks
Internet address and QR code
The information can be accessed at any time
by pasting the address
https://m.still.de/vdma
in a web browser or by scanning the QR code.


Preface

 I5001 801 1625EN-05/2022 - 03

Abbreviations
Below is a list of abbreviations used in this
manual
ACM Aftertreatment Control Module
API American Petroleum Institute
BITA British Industrial Truck Association
CAN Controller Area Network
CPC Comon Powertrain Controler
ECM Engine Control Module
FDE Truck Data Acquisition Module
LED Light Emitting Diode
LFM Forklift Data Management
LTC Linde Truck Control
LVDT Linear Variable Displacement Transformer
MCM Motor Control Module
PIN Personal Identification Number
PPE Personal Protective Equipment
RPM Revolutions Per Minute
STVZO Straßenverkehrs-Zulassungs-Ordnung (Road Traffic Licensing
Regulations)
VDMA Verband Deutscher Maschinen- und Anlagenbau (German Engi-
neering Association)
LS Load Sensing
Preface

 II 5001 801 1625EN-05/2022 - 03

1 Introduction 
Truck data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Your industrial truck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Technical Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 5
Conformity marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 6
Declaration that reflects the content of the declaration of conformity . . . . . . . . . . . . . . .
 7
Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 8
Use of the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10
Improper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 10
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 10
Description of use and climatic conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 11
Information about documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Documentation scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  12
Supplementary documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 12
Issue date and topicality of the operating instructions. . . . . . . . . . . . . . . . . . . . . . . . . . .
 13
Copyright and trademark rights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 13
Explanation of information symbols used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 13
Date of edition and latest update of this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 15
List of abbreviations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 15
Environmental considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  18
Disposal of components and batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 18
EMC – Electromagnetic compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Servicing and spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Modifications and retrofitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Using attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Using working platforms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2 Safety 
Definition of terms used for responsible persons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Operating company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  24
Specialist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 24
Drivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 25
Basic principles for safe operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Insurance cover on company premises. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  27
Modifications and retrofitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 19
Table of contents

 III5001 801 1625EN-05/2022 - 03

Warning regarding non-original parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  29
Damage, faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 29
Medical devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 29
Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 29
Vibrations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 30
Wheels and tyres. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 30
Residual risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Residual dangers, residual risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  32
Special risks associated with using the truck and attachments. . . . . . . . . . . . . . . . . . . .
 33
Overview of hazards and countermeasures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 36
Danger to employees . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 38
Safety tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Carrying out regular inspections on the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  40
Insulation testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 40
Safety regulations for handling consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Exhaust gases. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  42
Safety Regulations Relative to Forklift Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 42
Safety regulations in case of accidental lateral tipping . . . . . . . . . . . . . . . . . . . . . . . . . .
 42
Safety regulations when driving. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 43
Permissible consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 45
Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 45
Hydraulic fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 46
Battery acid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 46
Non-ionising radiation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Medical equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3Overview 
General view of Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Safety devices and warning labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Switch panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
4 Operation 
Service plan before initial commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Pre-shift checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Regular maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Wheel removal — drive axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Table of contents

 IV 5001 801 1625EN-05/2022 - 03

Wheel refitting — drive axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Standard equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  67
Entering and exiting the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 67
Driver's cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 68
Tilt Cab_Face Lift. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 69
Standard driver's seat and comfort driver's seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 72
Adjusting the armrest. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 74
Adjusting the steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 75
Seat belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 75
Window heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 77
Heating system, air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 77
Display unit-Parker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 84
Starting and stopping the engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 87
Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 91
Joystick with single lever operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 94
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 98
Horn. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 99
Service brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 99
Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 100
Override Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 101
Battery access - opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 102
Trailer coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 102
To tow the truck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 103
Emergency exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 105
Optional equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Drive controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  106
5100 040 Multifunction Joystick. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 108
6240 005 load weight display (weight error (+/-100kg)) . . . . . . . . . . . . . . . . . . . . . . . . .
 109
Forklift Data Management (LFM). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 110
Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 120
Lighting options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 123
BlueSpot
TM
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  126
12v Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 127
24v Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 128
12/24v Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 128
4470 005 Cab vent fan 24v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 129
Mechless 1DIN truck radio with USB/AUX/Bluetooth . . . . . . . . . . . . . . . . . . . . . . . . . . .
 129
4460 005 Illuminated A4 clipboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 131
4210 010 Buddy seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 132
4480 005 Storage unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 132
4450 005 With cup holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 133
Table of contents

 V5001 801 1625EN-05/2022 - 03

Linde Forklift Data Management (LFM). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  134
Joystick with central lever operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 144
Adjusting the driver's seat with rotating device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 149
Safety equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 150
7109 005 Fire Extinguisher 2kg in Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 151
Fire suppression system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 152
6310 005 Tire pressure monitoring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 154
Tyre pressure detection system (new) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 164
7330 015 Reversing warning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 171
1390 010 Plastic wheel stud covers with movement indicator . . . . . . . . . . . . . . . . . . . .
 172
Operating optional attachments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 172
Coil boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 173
Cold Climate Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 175
Electrical steering function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 182
Fan functions in cleaning mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 184
7306 005 Central lubrication system – steer/mast/tilt . . . . . . . . . . . . . . . . . . . . . . . . . . .
 184
User instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 186
Indicator lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 187
Maintenance instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 189
Mounting instructions for lowering the lifting heads into the end beams of 178 series
spreaders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 193
Multifunctional handle _ 178 spreader. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 195
Working with a load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
Mast, lifting device and attachment controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  196
Load centre distance and load capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 196
Load rating plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 197
Before loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 198
Lifting a load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 199
Travelling with load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 200
Depositing the load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 201
Before leaving the truck unattended . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 202
Loading/transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Hoisting the truck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  203
Transporting the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 204
5 Maintenance 
General maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Safety information regarding servicing work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  210
Inspection and maintenance data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 211
Recommended consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 211
Table of contents

 VI 5001 801 1625EN-05/2022 - 03

Service plan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
Service plan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  217
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Check engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  222
Filling fuel and Adblue®. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 222
Air filter - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 225
Coolant level - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 226
Bleeding and draining the fuel system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
Transmission gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
Transmission oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  232
Chassis, bodywork and fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
Clean the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  233
Check seat belt for condition and correct operation (option). . . . . . . . . . . . . . . . . . . . . .
 234
Filling the windscreen washer bottle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 236
Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
Check the condition of structured components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  237
Tighten the wheel nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 237
Check the tyres for damage and foreign objects. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 237
Locations for jacks when changing wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 238
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
Check the parking brake for proper operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  239
Brake control mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 239
Driver’s seat switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 240
Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
Check the battery / batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  241
Check electric cables, connectors and connections for condition and tightness. . . . . . .
 241
Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
Hydraulic system: oil level check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  242
Hydraulic system: check for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 242
Hydraulic tank breather filter - check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 243
Load lifting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
Lubricate the mast and tilt cylinder pivots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  244
Lubricate fork carriage cylinder bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 245
Check the tension of double hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 246
Check and adjust mast chains, lubricate with chain spray . . . . . . . . . . . . . . . . . . . . . . .
 246
Table of contents

 VII5001 801 1625EN-05/2022 - 03

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
Troubleshooting of Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  248
Troubleshooting guide (Hydraulic system) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 251
Decommissioning the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
Measures before taking the truck out of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  253
Taking the truck out of service（note） . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 253
Putting the truck back into service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 254
Disposal of old trucks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 255
6 Technical data 
Truck dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
Overview of type sheets - 600mm load centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
Overview of type sheets - 1200 mm load centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
Table of contents

 VIII 5001 801 1625EN-05/2022 - 03

1
Introduction

Truck data
We recommend that you record all basic fork-
lift truck data in the following table so that it
is available if required by the sales network or
authorised service centre.
Type 
Serial number 
Date of delivery 
Introduction
1
Truck data
 2 5001 801 1625EN-05/2022 - 03

Your industrial truck
Technical Description
General
The 1411-02 range of fork trucks with MTU
engine offer the ability to lift capacities up
to 16 or 18tonnes, with lift capacities up to
16tonnes available at 1200mm load centre,
with lift capacities up to 18 tonnes available
at 600 mm. These products are based on
3 wheelbases and use modular components,
ensuring the final configured product delivers
the optimum balance between weight and ma-
noeuvrability.
Engine
The engine system is equipped with an elec-
tronic engine management system which com-
prises the following control units:
- Engine management control module (MCM)
- Drive control system unit (CPC)
- Exhaust gas aftertreatment control unit
(ACM)
The control units are connected in an electron-
ic network. Data is exchanged via CAN (Con-
troller Area Network).
In addition to the engine, the exhaust gas af-
tertreatment and the connection on the vehi-
cle/ device, the electronic engine management
system also monitors itself.
NOTE
It is not permitted to make changes to the
engine which affect exhaust and noise emis-
sions, contact your service partner if you are
in any doubt.
Electronic engine management
The engine system is equipped with an elec-
tronic engine management system which com-
prises the following control units: - Engine
control module (ECM). The control module is
connected with IFM system via CAN bus and
data is exchanged via CAN (Controller Area
Network).
The engine and drive control system are moni-
tored by the truck controller and status is dis-
played on the truck status display monitor.
In addition to the engine, the engine control
module also monitors itself. Depending on
the malfunctions/failures which occur, warning
and information displays are displayed on the
tuck status display monitor. The malfunction is
stored in the fault memory and if necessary a
safety and emergency mode is automatically
selected. If the electronic engine management
control detects a fault, the fault code is stored
in the control units. It can then be read by a
service partner.
Steering
The steering is a hydrostatic power system,
which operates the rear wheels with the steer-
ing wheel via the steering cylinder
Brake System
The truck park brake system is a spring ap-
plied, pressure release fail-safe system, con-
trolled by the operator via a switch located on
the arm rest. The park brake will not release
unless the operator has their foot on the serv-
ice brake pedal to ensure safe operation.
The service brake is a pressure applied,
spring release system, operated by connected
pedals located either side of the steering col-
umn.
Both park and service brake circuits are pow-
ered by a fixed displacement gear pump
mounted on the front of the main work hy-
draulic pump. This gear pump is fed by the hy-
draulic oil reservoir located on the right-hand
side of the truck, The oil passes through a
pressure filter before feeding the controlling
valves. The excess and return oil flow from
the brake circuits flushes and cools the oil
immersed wet disk brakes in the front drive
Introduction
1
Your industrial truck
 35001 801 1625EN-05/2022 - 03

axle before returning to the oil reservoir via the
return filter.
Using sensors, audible and visual warnings
will occur in the event of low brake pressure,
or if a fault is present in the brake system.
Hydraulic system
A single or tandem (depending on truck
variant) variable displacement, load sensing
work hydraulic pump is mounted directly to
the transmission. The back pump feeds both
steering and work hydraulic functions while
the front pump (if fitted) feeds the work hy-
draulic system. These pumps are fitted with
pressure compensators which act as safety
valves so that in the event of higher than
expected pressure flow is reduced to zero
and the maximum pressure is maintained at
310bar.
An externally mounted in-line priority valve en-
sures the steering function has priority over
work hydraulic functions.
The main hydraulic valve is a group of ad-
vanced CANbus controlled, load-independent
proportional valves and include primary and
secondary relief valves that prevent overload
of the hydraulic circuits.
To improve and enhance the safe design of
the hydraulic system the control valves are
fitted with LVDT spool position feedback sen-
sors which enable the valves to monitor their
own condition and broadcast any errors over
the CANbus.
The mast lift/lower section incorporate “leak
free” valves to eliminate the possibility of mast
creep when carrying heavy loads.
A combination cooler ensures that the temper-
atures are kept optimum for the transmission,
engine water and charge air. The cooling di-
rection and cooler location have been careful-
ly developed with the aim of minimising the
size of the cooling pack and maintaining best
in class cooling performance. The cooled air
direction pulls ambient clean air from above
the rear of the truck and drives warm air down
through the engine bay over the engine and
finally out at the front.
Lift mast
The standard mast is a double open centre
non-free lift type with twin lift and tilt cylinders,
lift chains mounted on each side and are at-
tached to the carriage.
Lift movement is achieved when the lift cyl-
inders extend and the lift chains pull on the
carriage, during this extension the inner mast
section slides inside channels of the outer
section.
The whole mast and carriage assembly is
mounted and pivots on two pins that are fixed
and located within the fabrications of the drive
axle and chassis, Hydraulic operated side
shifting is available with a choice of fork sec-
tion, style and attachment type.
Electrical system
The main truck`s electrical system is 24 volts,
this potential is delivered by two 12 v 95 AH
batteries connected in series, Charge is provi-
ded by the engine mounted alternator and the
charge current is controlled by a solid state
rectifier.
Electronic/electrical installation
Parker control system allow:
- sensitive, smooth driving and reversing,
- automatic engine speed control to match the
hydraulic power requirements,
- fast service due to self-diagnostics,
- greatest possible operational reliability.
Driving cab
The steel frame of the driver`s cab has been
constructed to function as the load guard and
has been tested to exceed the International
safety standards. Driver entry is provided via
the steps located to the left side of the truck.
Steps are also fitted to the right side of the
truck for access. The right cab door can to be
used as an emergency exit and is provided
for the use of a passenger where the optional
passenger seat is fitted and located to the rear
left of the cab floor.
Introduction
1
Your industrial truck
 4 5001 801 1625EN-05/2022 - 03

The cab and doors have large glazed areas
and allow the driver maximum all round visibil-
ity during driving and lifting operations.
Screen wiper and washers are fitted to the
front, top and rear screens with demist func-
tions as part of the cab heater or the optional
climate control system.
An optional passenger seat can be fitted in the
right rear corner of the cab.
An optional fire extinguisher can be fitted in
the cab if required.
The guard rails is the standard configuration if
the truck equipped with the ordinary glass.
Battery access
A compartment for battery access is located
on the left side of the truck, which allows you
to:
●
check the truck batteries
●
fill the windscreen washer reservoirs
General
The industrial truck described in these operat-
ing instructions conforms with the applicable
standards and safety regulations.
The industrial truck is fitted with state-of-the-
art technology. Following these operating in-
structions will allow the industrial truck to be
handled safely. By complying with the speci-
fications in these operating instructions, the
functionality and the approved features of the
industrial truck will be retained.
Get to know the technology, understand it and
use it safely - these operating instructions pro-
vide the necessary information and help to
avoid accidents and to keep the truck ready
for operation beyond the warranty period.
Therefore:
–Before commissioning the industrial truck,
read the operating instructions and follow
the instructions.
–Always follow all the safety information con-
tained in the operating instructions and on
the industrial truck.
Introduction
1
Your industrial truck
 55001 801 1625EN-05/2022 - 03

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)
●
UKCA: in the United Kingdom (UK)
●
EAC: in the Eurasian Economic Union
The conformity marking is applied to the
nameplate. A declaration of conformity is is-
sued for the EU and UK markets.
An unauthorised structural change or addition
to the industrial truck can compromise safety,
thus invalidating the declaration of conformity.
conformity symbols

Introduction
1
Your industrial truck
 6 5001 801 1625EN-05/2022 - 03

Declaration that reflects the content of the declaration of conformity




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:

Industrial truck type
corresponding to these operating instructions
Model corresponding to these operating instructions

− "Machinery Directive 2006/42/EC"
1)
− "Supply of Machinery Safety Regulations 2008, 2008 No. 1597"
2)


Personnel authorised to compile the technical documents:

See declaration of conformity


STILL GmbH


1)
For the markets of the European Union, the EU candidate countries, the EFTA States and
Switzerland.
2)
For the United Kingdom market.
The declaration of conformity document is
supplied with the industrial truck. The declara-
tion shown explains the conformity with the
provisions of the EC Machinery Directive and
the Supply of Machinery Safety Regulation
2008, 2008 No. 1597.
An unauthorised structural change or addition
to the industrial truck can compromise safety,
thus invalidating the declaration of conformity.
The declaration of conformity must be careful-
ly stored and made available to the responsi-
ble authorities if necessary. It must also be
handed over to the new owner if the industrial
truck is sold on.
Introduction
1
Your industrial truck
 75001 801 1625EN-05/2022 - 03

Nameplate
Nameplate, variant 1
1 Type
2  Serial number
3  Year of manufacture
4  Unladen mass in kg
5  Max. permissible battery weight in kg
(for electric trucks only)
6  Min. permissible battery weight in kg
(for electric trucks only)
7  Own mass (self weight) in kg without
battery
8  Manufacturer
9  Refer to technical data listed in this
operating instructions for more de-
tailed information
10  CE label
11  Rated drive power in kW
12  Battery voltage in V
13  Rated capacity
Nameplate, variant 2
1 Type
2  Serial number
3  Manufacturer
4  Year of manufacture
5  Unladen mass in kg
6  permissible battery weight in kg (for
electric trucks only) Max./Min.
7  Own mass (self weight) in kg without
battery
8  Data matrix code
9  Refer to technical data listed in this
operating instructions for more de-
tailed information
10  Conformity marking: CE mark for the
markets of the EU, the EU candidate
countries, the EFTA States and Swit-
zerland UKCA mark for the United
Kingdom market EAC mark for the
Eurasian Economic Union market
11  Rated drive power in kW


Introduction
1
Your industrial truck
 8 5001 801 1625EN-05/2022 - 03

12  Battery voltage in V
13  Rated capacity
NOTE
●
It is possible for there to be multiple con-
formity markings on the nameplate.
●
The EAC mark may also be located in the
immediate vicinity of the nameplate.
NOTE
Nameplate provided according to collocation
requirements.
Introduction
1
Your industrial truck
 95001 801 1625EN-05/2022 - 03

Use of the truck
Commissioning
Commissioning is the initial intended use of
the truck.
The necessary steps for the commissioning
vary depending on the model and equipment
of the truck. These steps require preparatory
work and adjustment work that cannot be per-
formed by the operating company. See also
the chapter entitled "Definition of responsible
persons".
–To commission the truck, contact the au-
thorised service centre.
Improper use
The operating company or driver, and not the
manufacturer, is liable for any hazards caused
by improper use.
NOTE
Please note the definition of the following re-
sponsible persons: "operating company" and
"driver".
Use for purposes other than those described
in these operating instructions is prohibited.
DANGER
There is a risk of fatal injury from falling
off the truck while it is moving!
–It is prohibited to carry passengers on
the truck.
The truck may not be operated in areas where
there is a risk of explosion, in areas that cause
corrosion or in areas that are particularly dus-
ty.
Stacking or unstacking on inclined surfaces or
ramps is not permitted.
Precautions
–Do not drive on steep slopes, to prevent the
load from slipping off.
–The truck must be switched off when left
unattended. Key (or key code) must be
Introduction
1
Use of the truck
 10 5001 801 1625EN-05/2022 - 03