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