Still Diesel LPG forklift trucks RC40-16 RC40-18 RC40-20 RC40-25 RC40-30 RC40-35 Workshop Manual- PDF DOWNLOAD
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Still Diesel LPG forklift trucks RC40-16 RC40-18 RC40-20 RC40-25 RC40-30 RC40-35 Workshop Manual- PDF DOWNLOAD
Language : English
Pages : 504
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Still Diesel LPG forklift trucks RC40-16 RC40-18 RC40-20 RC40-25 RC40-30 RC40-35 Workshop Manual- PDF DOWNLOAD
00 Product information
Foreword
Product overview
Safety information
Jacking up the front of the truck
Jacking up the rear of the truck
Securing the fork carriage
Maintenance 01
Maintenance instructions 01
Operations Preliminary to Maintenance 01
Maintenance – 500 hours 01
Maintenance – 1000 hours/annually 01
Maintenance – 1500 hours 01
Maintenance – 3000 hours/every two years 01
Operating materials 01
Harnesses and hoists 01
Tightening torques by units 01
Standardised tightening torques for standard-pitch threads and fine-pitch threads 01
Standardised tightening torques for hose fittings 01
12 Internal combustion engine
Kubota V 2403-M-DI-E3B diesel engine for 1 6 to 2 0-t trucks
General technical data
Engine attachment parts
Engine dimensions
Engine identification
Tightening torques for special screws
Lubricating system specification, diesel version 1 6/2 0 t
Forced circulation lubrication
Checklist for engine overheating
Troubleshooting
Kubota V 2607-DI-E3B diesel engine for 2 5 to 3 5-t trucks
General technical data
Engine attachment parts
Engine dimensions
Table of contents
Engine identification 12
Tightening torques for special screws 12
Lubricating system specification, diesel version 2 5/3 5 t 12
Forced circulation lubrication 12
Start-up smoke suppression system – General 12
Start-up smoke elimination – Functionality 12
Checking the start-up smoke elimination magnet 12
Checking the start-up smoke elimination actuator 12
Checking the speed sensor start-up smoke elimination 12
Engine shut-off magnet 12
Checklist for engine overheating 12
Troubleshooting 12
Installing the engine on 2 5 to 3 5-t trucks 12
Mounting the torque converter and engine 12
Kubota WG 2503 LPG engine for 1 6 to 2 0-t trucks/2 5 to 3 5-t trucks 12
Lubrication system specification, LPG version 1 6/3 5 t 12
Checklist for engine overheating 12
Troubleshooting 12
13 Internal combustion engine – attachment parts
Air filter 13
Cleaning the air filter 13
Cooling system 13
Radiator 13
Cooling system specification, diesel version 1 6/2 0 t 13
Cooling system specification, diesel version 2 5/3 5 t 13
Cooling system specification, LPG version 1 6/3 5 t 13
Checking and cleaning the radiator fins 13
Checking the coolant concentration 13
Removing and installing the radiator {heat exchanger) 13
Checking the coolant level 13
Draining the coolant 13
Topping up the coolant 13
Diesel fuel system, 1 6 t-2 0 t 13
Fuel system specifications, diesel version 1 6/2 0 t 13
Assembly overview: fuel system 13
Draining water from the fuel filter 13
Table of contents
Air bleeding from the fuel feed circuit procedure
Pre-heating time control unit
Injector
Injection pump
Pump element
Glow plug
Glow plug continuity
Diesel fuel system, 2 5 t-3 5 t
Fuel system specifications, diesel version 2 5/3 5 t
Assembly overview: fuel system
Draining water from the fuel filter
Air bleeding from the fuel feed circuit procedure
Pre-heating time control unit
Injector
Injector opening pressure
Injection pump unit
Injection pump
Glow plug continuity measurement
Pressure valve
Engine speed regulator
LPG system
LPG system
lmpco components
Evaporator function – gas mixer
Suction module
MAP/MAT sensor 0B6
Chassis module
Gas shut-off valve unit
Gas shut-off valve monitoring
Shut-down due to lack of gas
Maintenance and test specifications
Testing for leaks in the LPG system
Testing CO level in exhaust gases
Servicing the LPG filter
Servicing the 30-bar high-pressure relief valve
Evaporator – maintenance
Safety valve – 1 7 bar
X 50988012021 EN – 02/2015
Table of contents
LPG cylinder/tank
LPG cylinder
Changing the gas cylinder
14 Internal combustion engine- exhaust system
Exhaust system
Bottom exhaust pipe, 1 6-2 0 t
Bottom exhaust pipe, 2 5-3 5 t
Top exhaust pipe and variants, 1 6-2 0 t
Top exhaust pipe and variants, 2 5-3 5 t
Particle filter for exhaust pipe, 1 6-2 0/2 5-3 5 t
Removing and installing the exhaust system
22 Mechanical drive axle
Drive axle
Drive axle MSP KA 20
MSP KA 30 drive axle
Lubricating system specification for drive axle
Differences between axle KA 30 and KA 20
Structure and operation of the drive axle
Drive axle – General
Carrier subassembly comprising the differential and the parking brake
Removing the hub
Disassembling the service brake and brake package
Disassembling the hub
Disassembling the parking brake
Assembling the parking brake
Axle housing cover
Assembling the hub
Assembling the service brake with the multi-disc brake pack
Installing the hub
Checking and changing the gearbox oil
Removing and installing the drive axle
Function of the gearbox oil cooling system
Thermostat for the gearbox oil cooling system
Cooling circuit for the gearbox oil cooling system
Gearbox oil pump
Checking the oil level in the axle cooling system
Cleaning the screen filter for gearbox oil
Differences between KT 30 and KT 20 converter gears -37
Functionality -38
Sectional drawing -39
Technical data -40
Modes of operation (power ow) -41
Lubricating system specication, KT 20 torque converter (1 6/2 0 t) -42
Lubricating system specication, KT 30 torque converter (2 5/3 5 t) -43
Changing the oil for the KT20/KT 30 torque converter -43
Mounting screws and pilot bearing -44
Overview of gearbox assembly -45
Overview of converter assembly -47
Dismantling the torque converter -48
Assembling the converter gear -57
Dismantling the gearbox in assemblies -65
Installing the gearbox units -67
Dismantling the clutch drum unit -69
Assembling the clutch drum unit -71
Dismantling the forward gear clutch drum -73
Assembling the forwards gear clutch drum -76
Dismantling the reverse gear clutch drum -79
Assembling the reverse gear clutch drum -82
Dismantling the idling unit -85
Assembling the idling assembly -86
Dismantling the output pinion unit -87
Assembling the output pinion unit -88
Valve block -91
Dismantling the valve block assembly -92
Assembling the valve block assembly -95
Converter gear pressure measurement -98
Oil circulation -99
-100
Troubleshooting -100
Fault detection -101
-104
-104
-104
50988012021 EN – 02/2015 XI
Table of contents
Torque converter
Description
Lubricating system
Dismantling and assembling the torque converter
Valve block
Troubleshooting
Universal drive shaft
Cardan shaft
Installing and removing the cardan shaft
STILL
XII 50988012021 EN – 02/2015
Table of contents
31 Chassis
Counterweight 31
Counterweight 31
34 Driver’s compartment
Bonnet 34
Installing and removing the bonnet 34
42 Steering system
Hydraulic steering 42
General technical data 42
Steering hydraulics 42
Priority valve 42
Error detection 42
Steering wheel and steering column 42
Steering wheel and steering column 42
Installing and removing the steering wheel 42
Removing and installing the steering column 42
Steering axle for 1 6 to 2 0-t trucks 42
Steering axle 42
Installing the steering axle 42
Steering axle for 2 5 to 3 5-t trucks 42
General technical data 42
Swing axle 42
Swing axle Removal and installation 42
Wheel hub 42
Steering angle 42
Tie rod 42
Axle stub 42
46 Wheels and tyres
General information 46
Filling the tyres 46
Winter tyres 46
Tyrewear check 46
Changing the wheels on 1 6 to 2 0-t trucks 46
Checking the tightening torque of the wheel nuts (1 6/2 0 t) 46
50988012021 EN – 02/2015 XIII
Table of contents
Wheel replacement procedure 46
Changing the wheels on 2 5 to 3 5-t trucks 46
Checking the tightening torque of the wheel nuts (2 5/3 5 t) 46
Wheel replacement procedure 46
Disassembling a wheel 46
Pulling a new tyre onto a rim 46
Quick tyres assembly/disassembly 46
49 Braking and inching system
Service brake 49
Hydraulic operating brake/mechanical parking brake 49
Brake system – General 49
Function of the inching and brake pedal 49
Brake cylinder technical data 49
Installing and removing the brake cylinder 49
Stop lights microswitch 49
Brake and inching pedal 49
Checking and adjusting the inching pedal (combi pedal) 49
Installing and removing the inching cable 49
Adjusting the brake pedal 49
Combi pedal/separate pedal 49
Components of the separate brake and inching pedal 49
Removing the combi pedal/installing the separate pedal (Continental brake cylinder)
49
Checking and adjusting the inching and brake pedal (separate pedal) 49
Parking brake 49
Installing and removing the handbrake cable 49
Removing and installing the handbrake microswitch 49
Adjusting the handbrake 49
Maintenance 49
Filling and bleeding the brake system (lruna brake cylinder) 49
Bleeding the brake system 49
50 Operating devices
Accelerator pedal 50
Adjusting the pedal travel 50
Accelerator pedal switch 50
XIV 50988012021 EN – 02/2015
Table of contents
Potentiometer 50
Installing and removing the accelerator pedal 50
Removing and installing the accelerator pedal cable 50
60 Electrics/electronics
Electrical system 60
Fuse assignment (diesel) 60
Fuse assignment (LPG) 60
Wiring 60
Power cables 60
Maintenance guidelines for power cables 60
Repair – Contact elements 60
Other components 60
SRO drive direction switch monitoring module 60
Potentiometer 60
ISO seat contact monitoring unit 60
69 Batteries and accessories
Starter battery 69
Starter battery 69
Working with batteries 69
70 Hydraulics
General 70
General technical data 70
Operating speeds for lowering 70
Operating speeds for lifting 70
Operating speeds for tilting 70
Emergency lowering 70
Releasing the pressure from the hydraulics 70
Safety check 70
Lowering safety test 70
Forward tilt safety test 70
Safety checks of hose assembly 70
Basic hydraulics 70
Basic hydraulics 70
Torque converter 70
Lift cylinders 70
50988012021 EN – 02/2015 XV
Table of contents
Steering hydraulics 70
Intake filter and return line filter cycles 70
Intake filter 70
Return line filter 70
Breather filter 70
Hydraulic tank 70
Checking the hydraulic oil level 70
Hydraulic oil 70
Replacing the return line filter 70
Removing and installing the return line filter and the intake filter 70
Additional means of securing the hydraulic hoses 70
Operating levers 70
Bolted joint 70
Screw joints on the basic hydraulics 70
Conical nipple fittings (CNF) 70
Pressure test 70
71 Working hydraulics
Tilt cylinder 71
Tilt cylinder Removal and installation 71
Changing the set of seals ( 1500 – 2000 kg) 71
Elbow unions on the 1 6-2 0-t variant 71
Hydraulic pump 71
Hydraulic pump 71
Double hydraulic pump ( 19 cm3) on the 1 6-2 0-t variant 71
Double hydraulic pump (28 cm3) on the 2 5-3 5-t variant 71
Auxiliary hydraulics 71
Auxiliary hydraulics 71
76 Valves
Basic hydraulics 76
General technical data 76
Four-way directional control valve block 76
Safety valve 76
General technical data 76
Safety valve/pressure control valve 76
Emergency lowering 76
Removing and installing the safety valve/pressure control valve 76
XVI 50988012021 EN – 02/2015
Table of contents
80 Load lift system
Mast bearings 80
Mast bearings, 1 0 t- 2 0 t 80
Mast bearings, 2 5 t- 3 5 t 80
81 Lift mast
Lift mast 81
General technical data 81
General technical data 81
Hose safety valve of triplex mast 81
Support roller play ( 108/117 /130) 81
Load chains – Checking and cleaning 81
Run-out barrier 81
Working on lift masts 81
Lift mast- removal 81
Lift mast – installation 81
Telescopic lift mast 81
Telescopic lift mast (108/117/130) 81
Adjusting the load chains Telescopic lift mast ( 108/117 /130) 81
Telescopic lift mast- Line break safety valve 81
Telescopic lift mast 1 6/1 8 t 81
Telescopic lift mast 2 0 t 81
Telescopic lift mast 2 5/3 0 t 81
Telescopic lift mast 3 5 t 81
Ni Ho lift mast 81
NiHo lift mast (108/117/130) 81
Adjusting the load chains NiHo lift mast (108/117/130) 81
Ni Ho lift mast- Line break safety valve 81
NiHo lift mast 1 6/1 8 t 81
NiHo lift mast 2 0 t 81
NiHo lift mast 2 5/3 0 t 81
Ni Ho lift mast 3 5 t 81
Triplex lift mast 81
Triple lift mast ( 108/117 /130) 81
Removing the support rollers in the lift mast 81
Assembling the lift mast after replacing the support rollers 81
Outer load chains and chain rollers 81
Table of contents
Middle load chain and chain roller
Adjusting the outer load chains Triple lift mast ( 108/117 /130)
Adjusting the middle load chain Triple lift mast ( 108/117 /130)
Triplex lift mast – Line break safety valve
Triplex lift mast 1 6/1 8 t
Triplex lift mast 2 0 t
Triplex lift mast 2 5/3 0 t
Triplex lift mast 3 5 t
Lift cylinder
Lift jack
Working on lift cylinders
Outer cylinder
Disassembling/assembling the outer cylinder
Centre cylinder
Disassembling/assembling the middle cylinder
End position damping of outer cylinder
Middle cylinder end dampener
84 Load support
Fork carriage
Fork carriage
Annex
X Circuit diagrams
Hydraulics
Hydraulic circuit diagram
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