Still RC40-16, RC40-17, RC40-18, RC40-20, RC40-25, RC40-30, RC40-33,RC40-35 Forklift Workshop Manual

Original Illustrated Factory Workshop Service Manual for Still IC Engined Forklift Trucks Models RC40-16, RC40-17, RC40-18, RC40-20, RC40-25, RC40-30, RC40-33, RC40-35 Series R4041, R4042, R4043, R4044, R4045, R4046, R4051, R4052, R4053, R4054, R4055, R4056

Electrical Circuit Diagrams Included!!!

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:
   RC40-16
   RC40-17
   RC40-18
   RC40-20
   RC40-25
   RC40-30
   RC40-33
   RC40-35
Format: PDF, 374 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