Still Truck RC40-16, RC40-17, RC40-18, RC40-20, RC40-25, RC40-30, RC40-33, RC40-35 Service Manual

Original Illustrated Factory Workshop Service Manual for Still IC Engined Forklift Truck Type RC40-16, RC40-17, RC40-18, RC40-20, RC40-25,  RC40-30, RC40-33, RC40-35.

Original factory manuals for Still Forklift Trucks, contains high quality images, circuit diagrams and instructions to help you to operate and repair your truck. All Manuals Printable and contains Searchable Text

Covered models:
    R4041
    R4042
    R4043
    R4044
    R4045
    R4046
    R4051
    R4052
    R4053
    R4054
    R4055
    R4056

Format: PDF, 362 Pages
Language: English

Contents:
00 Product information
    Foreword
    Information about the RC40
    Safety information
    To avoid accidents
    Jacking upthe front of the truck
    Jacking upthe rear of the truck
    Securing the fork carriage
    Safety regulations for handling consumables
    Oils
    Hydraulic fluid
    Diesel fuel
    Coolant
    Battery acid
    Disposal of consumables
    Diagnostics
    Tightening torques by units
    Standard torques
01 Service
    Maintenance
    Maintenance instructions
    Operations Preliminary to Maintenance
    Scheduled truck maintenance
    Summary table of maintenance operations
    Maintaining the KT20/KT 30 torque converter
    Changing the oil for the KT20/KT 30 torque converter
    Maintenance check lists
    Maintenance -400 hours
    Maintenance - 500 hours
    Maintenance- 1000 hours/annually
    Maintenance- 1500 hours or annually
    Maintenance -3000 hours/every two years
02 Diagnostics
    KT 20/KT 30 torque converter
    Troubleshooting
    Fault detection
    Kubota diesel engine 1.6/2.0 1- 2.5/3.5 1
    Checklist for engine overheating
    Troubleshooting
12 Internal combustion engine
    Kubota V 2403-M-DI-E3B diesel engine (1.6/2.0 1)
    Description
    Engine attachment parts
    General technical data
    Engine dimensions
    Engine identification
    Tightening torques for special screws
    Lubricating system specification
    Lubricating system specification, diesel version 1.6/2.0 1
    Forced circulation lubrication
    Kubota V 2607-DI-E3B diesel engine (2.5/3.5 1)
    Description
    Engine attachment parts
    General technical data
    Engine dimensions
    Engine identification
    Tightening torques for special screws
    Lubricating system specification
    Lubricating system specification, diesel version 2.5/3.5 1
    Forced circulation lubrication
    Start-up smoke elimination
    Start-up smoke elimination - Functionality
    Checking the speed sensor start-up smoke elimination
    Checking the start-up smoke elimination magnet
    Checking the start-up smoke elimination actuator
    Engine shut-off magnet
    Mounting the engine 2.5/3.5 1
    Mounting the torque converter and engine
    Kubota WG 2503 LPG engine (1.6/2.0 1- 2.5/3.5 1)
    Lubricating system specification
    Lubrication system specification, LPG version 1.6/3.5 1
13 Internal combustion engine - attachment parts
    Air intake/filter
    Cleaning the air filter
    Cooling system
    Radiator
    Cooling system specification, diesel version 1 .6/2.0 1
    Cooling system specification, diesel version 2.5/3.5 1
    Cooling system specification, LPG version 1 .6/3.5 1
    Checking and cleaning the radiatorfins
    Removing and installing the radiator
    Checking the coolant level
    Checking the coolant concentration
    Draining the coolant
    Topping up the coolant
    Fuel system
    Assembly overview: fuel system
    Air bleeding from the fuel feed circuit procedure
    Kubota diesel engine 1.6-2.0 1
    Fuel system specifications, diesel version 1.6/2.0 1
    Injector
    Injection pump
    Pump element
    Glow plug
    Glow plug continuity
    Kubota diesel engine 2.5-3.5 1
    Fuel system specifications, diesel version 2.5/3.5 1
    Injector
    Glow plug continuity measurement
    Injection pump unit
    Injector opening pressure
    Injection pump
    Pressure valve
    Engine speed regulator
    Fuel filter
    Draining water from the fuel filter
    LPG system
    LPG system
    Impco components
    Evaporator function- gas mixer
    0B6 MAP/MAT sensor
    Suction module
    Chassis module
    Gas shut-off valve unit
    Gas shut-off valve monitoring
    Shut-down due to lack of gas
    Maintenance and test specifications
    Testing CO level in exhaust gases
    Servicing the LPG filter
    Servicing the 30-bar excess pressure safety device
    Evaporator - Maintenance
    High-pressure relief valve- 1.7 bar
    LPG cylinder/tank
    LPG cylinder
    Changing the gas cylinder
    14 Internal combustion engine - exhaust system
    Exhaust system -diesel
    Removing and installing the exhaust system
    22 Mechanical drive axle
    Drive axle
    Lubricating system specification for drive axle
    Differences between axle KA 30 and KA 20
    Drive axle 2.5/3.5 1
    Removing and installing the drive axle
    Axle cooling system
    Gearbox oil cooling
    Checking the oil level in the axle cooling system
    Gearbox oil pump
    Cleaning the screen filter for gearbox oil
    Petrone double hydraulic pump, 1 9 cm3
    Petrone double hydraulic pump, 28 cm3
    Cardan shaft
    Cardan shaft
    Installing and removing the cardan shaft
    Torque converter
    Description
    Differences between KT 30 and KT 20 converter gears
    Functionality
    Sectional drawing
    Technical data
    Modes of operation (power flow)
    Lubricating system
    Lubricating system specification, KT 20 torque converter (1.6/2.0 1)
    Lubricating system specification, KT 30 torque converter (2.5/3.5 1)
    Dismantling and assembling the torque converter
    Mounting screws and pilot bearing
    Overview of gearbox assembly
    Overview of converter assembly
    Dismantling the torque converter
    Assembling the converter gear
    Dismantling the gearbox in assemblies
    Installing the gearbox units
    Dismantling the clutch drum unit
    Assembling the clutch drum unit
    Dismantling the forward gear clutch drum
    Assembling the forwards gear clutch drum
    Dismantling the reverse gear clutch drum
    Assembling the reverse gear clutch drum
    Dismantling the idling unit
    Assembling the idling assembly
    Dismantling the output pinion unit
    Assembling the output pinion unit
    Valve block
    Valve block
    Dismantling the valve block assembly
    Assembling the valve block assembly
    Converter gear pressure measurement
    Oil circulation
31 Chassis
    Counterweight
34 Driver's compartment
    Bonnet
    Installing and removing the bonnet
42 Steering system
    Steering axle 1 .6/2.0 1
    Steering axle
    Installing the steering axle
    Steering axle 2.5/3.0 1
    General technical data
    Swing axle
    Swing axle Removal and installation
    Wheel hub
    Steering angle
    Tie rod
    Axle stub
46 Wheels and tyres
    General information
    Filling the tyres
    Winter tyres
    Tyrewear check
    General information for changing tyres
    Changing the wheels 1.6/2. Ot
    Checking the tightening torque of the wheel nuts (1.6/2.0 1)
    Wheel replacement procedure
    Changing the wheels 2.5/3.5 1
    Checking the tightening torque of the wheel nuts (2.5/3.5 1)
    Wheel replacement procedure
    Disassembling a wheel
    Disassembly/assembly of tyres on rims with movable flange
    Quick tyres assembly/disassembly
49 Brake system
    Service brake
    Brake cylinder technical data
    Installing and removing the brake cylinder
    Stop lights microswitch
    Brake and inching pedal
    Brake system - General
    Function of the brake and inching pedal
    Installing and removing the inching cable
    Adjusting the inching pedal
    Adjusting the brake pedal
    Parking brake
    Installing and removing the handbrake cable
    Removing and installing the handbrake microswitch
    Adjusting the handbrake
    Maintenance
    Filling and bleeding the brake system (Iruna brake cylinder)
    Bleeding the brake system
50 Operating devices
    Accelerator pedal
    Adjusting the pedal travel
    Installing and removing the accelerator pedal
    Removing and installing the accelerator pedal cable
60 Electrics/electronics
    Electrical system
    Diesel version fuses
    Fuses for LPG version
    Wiring
    Power cables
    Maintenance guidelines for power cables
    Repair -Contact elements
    Other components
    SRO drive direction switch monitoring module
    ISO seat contact monitoring unit
69 Batteries and accessories
    Starter battery
70 Hydraulics
    Basic hydraulics
    Conical nipple fittings (CNF)
    Boltedjoint
71 Working hydraulics
    Tilt cylinder
    Tilt cylinder Removal and installation
    Dismantling the tilt cylinders
    Pump unit
    Petrone double hydraulic pump, 28 cm3
    Petrone double hydraulic pump, 19 cm3
    Hydraulic pump mounting
73 Hydraulic components
    Pump for axle cooling system
    Gearbox oil pump
76 Valves
    Safety valve
    Safety valve technical data
    Safety valve
81 Lift mast
    Lift mast
    General technical data
    Fork arm emergency lowering procedure
    Telescopic lift mast
    NiHo lift mast
    Triplex lift mast
    Lift mast - Removal
    Lift mast -installation
    Load chains
    Load chains Checking, cleaning
    Adjusting the load chains Telescopic lift mast (108/117/1 30)
    Adjusting the load chains NiHo lift mast (108/117/1 30)
    Middle load chain Triplex lift mast (108/117/1 30)
    Outer load chain Triplex lift mast
    Load chain locking device
    Run-out barrier
    End position damping
    Outer cylinder end position damping
    Middle cylinder end position damping
    Line break safety device
    Line break safety device
    Lift mast 1.6/1.8 1
    Telescopic lift mast 1.6/1.8 1
    NiHo lift mast 1.6/1.8 1
    Triplex lift mast 1.6/1.8 1
    Lift mast 2.0 1
    Telescopic lift mast 2.0 1
    NiHo lift mast 2.0 1
    Triplex lift mast 2.0 1
    Lift mast 2.5/3.0 1
    Telescopic lift mast 2.5/3.0 1
    NiHo lift mast 2.5/3.0 1
    Triplex lift mast 2.5/3.0 1
    Lift mast 3.5 1
    Telescopic lift mast 3.5 1
    NiHo lift mast 3.5 1
    Triplex lift mast 3.5 1
    Lift cylinder
    Lift cylinder
    Outer cylinder
    Centre cylinder
    Cylinder head
    Rollers/support rollers
    Support roller play
    Assembling the mast/carriage support rollers
    Check
    Fork carriage
    Fork carriage
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