Still RC40-16, RC40-17, RC40-18, RC40-20, RC40-25, RC40-30, RC40-33, RC40-35 Diesel / LPG Forklift Trucks Service Repair Worksho

Workshop literature STILL ELECTRONIC DOCUMENTATION SYSTEM Diesel/LPG forklift trucks RC40-16 RC40-17 RC40-18 RC40-20 RC40-25 RC40-30 RC40-33 RC40-35 4041 4042 4043 4044 4045 4046 r. . 4051 4052 4053 4054 4055 4056 tlfSt I D IfltralOglStlCS 50988012021 EN -11/2013

History of changes Edition 01/2013 • Chapter 01 - Maintenance • Chapter 02- Diagnostics • Chapter 12 - Internal combustion engine • Chapter 13 - Internal combustion engine - attachment parts • Chapter 14 - Internal combustion engine - exhaust system • Chapter 22- Mechanical drive axle • Chapter 22 -Torque converter Chapter 31 - Chassis Chapter 42 - Steering system Chapter 46 - Wheels and tyres Chapter 49 - Brake system Chapter 50 - Operating devices Chapter 60 - Electrics Chapter 69 - Batteries and accessories Chapter 70 - Hydraulics Chapter 71 - Working hydraulics Chapter 73 - Hydraulic components Chapter 81 - Lift mast 50988012021 [EN]

Header r Documentation This workshop manual contains all the informa¬ tion required to assist the trained service engi¬ neers with all work, repairs and maintenance on this truck. In addition, some of the components have been deliberately excluded from this work¬ shop manual and are explained elsewhere to ensure a clear and complete overview. Changes may be made at short notice and at any time, and are communicated via Service Information docu¬ ments. The additional documentation comprises work¬ shop manuals and special documentation. Workshop manuals • Kubota V-2403-M-DI-E3B internal combustion engine (1.6/2.0 1) • Kubota V-2607-DI-E3B internal combustion engine (2.5/3.5 1) • Kubota WG-2503 LPG engine (1.6/3.5 1) Special documentation • Overview of consumables • FEM 4.004 test log book Operating circuit diagrams • See the circuit diagram overview Symbols Used The signal terms Danger, Warning, Caution, Note and Environment note are used in this document as hazard warnings or for unusual information that requires special identification: A DANGER means that failure to comply involves risk to life and/or major damage to property can occur. A WARNING means that failure to comply involves risk of serious injury and/or major damage to property can occur. A CAUTION means that failure to comply involves risk of material damage or destruction. [fl NOTE means that particular attention is drawn to com¬ binations of technical factors which may not be evident even to a specialist. 50988012021 [EN] III

Header ENVIRONMENT NOTE The instructions listedhere must be complied with as otherwise environmental damage may result. For your safety, additional symbols are also used. Please heed the various symbols. Changes and retrofitting Warnings before making changes to the truck If the truck is used for work not listed in the guidelines or truck-specific original operating instructions and has to be converted or retrofitted accordingly, you should be aware of the following: • Any structural modification can affect the handling and stability of the truck, and can result in accidents. • Without authorisation from STILL, no changes that affect the stability, the load capacity and the safety systems may be carried out. • Operation of the truck without an overhead guard at a lift height of over 1 800 mm is prohibited. • It is prohibited to install and use restraint systems that are not approved by STILL. • It is prohibited to drill holes in the overhead guard or to perform welding on it. • When carrying out welding on other parts of the truck, it is essential that the battery and all connections to the electronic controls are disconnected. • Only for electric forklift trucks: It is prohibited to drill holes in the area of the driver's seat into the battery hood because hydrogen can enter through the bores into the driver's cab. IV 50988012021 [EN]

Header r CE conformity i> With the CE declaration of conformity, STILL con¬ firms that the truck complies with the standards and regulations valid at the time of marketing. The CE conformity mark is shown on the name- plate and indicates compliance with the above regulations. A subsequent structural change or addition to the truck can compromise safety, thus invalidating the CE declaration of conformity. In this case, a new CE declaration of conformity is essential for the structural changes. The company that was instructed by the truck operating company to carry out the change is responsible for issuing a new CE declaration of conformity. The contractor of the operating company must also fulfil the following prerequisites: • Construction documents, test documents and assembly instructions associated with the change must be archived and remain accessible at all times. • Check that the capacity rating plate, decal in¬ formation, hazard warnings and the operating instructions are consistent with regard to the changes and modify if necessary. The change must be processed by a design office that specialises in the area of industrial trucks. The change must be planned, checked and implemented in accordance with the standards and directives valid at the time. Specialist A qualified person is defined as a service engin¬ eer or a person who fulfils the following require¬ ments: • A completed vocational qualification that demonstrably proves their professional exper¬ tise. This proof should consist of a vocational qualification or a similar document. • Professional experience indicating that the qualified person has gained practical expe¬ rience of trucks over a proven period during their career. During this time, they have be¬ come familiar with a wide range of symptoms that require checks to be carried out, for exam¬ ple from the results of a hazard assessment or from a daily inspection. • Recent professional involvement in the field of the truck test in question and an appropriate further qualification are essential. The quali¬ fied person must have experience of carrying out the test in question or of carrying out sim- 50988012021 [EN] V

1 Header ilar tests. Moreover, such a person must also be aware of the latest technological develop¬ ments regarding the truck to be tested and the risk being assessed. Working with spare parts Warning regarding non-original parts Original parts, attachments and accessories are specially designed for this truck. We specifi¬ cally draw your attention to the fact that parts, attachments and accessories supplied by other companies have not been tested and approved by STILL A CAUTION Installation and/or use of such products may therefore have a negative impact on the design features of the truck and thus impair active and/or passive driving safety. We recommend that you obtain approval from the manufacturer and, if necessary, from the relevant regulatory authorities before installing such parts. STILL accepts no liability for any damage caused by the use of non-original parts and accessories without approval. Working with electronic controls It is not generally permitted to open controls. STILL's liability and the warranty are no longer applicable once the seal has been damaged. In exceptional cases, personnel authorised by STILL are allowed to open the controls. VI 50988012021 [EN]

Table of contents 00 Product information Foreword 00-1 Information about the RC40 00-1 Safety information 00-2 To avoid accidents 00-2 Jacking up the front of the truck 00-2 Jacking up the rear of the truck 00-3 Securing the fork carriage 00-4 Safety regulations for handling consumables 00-5 Oils 00-5 Hydraulic fluid 00-6 Diesel fuel 00-7 Coolant 00-8 Battery acid 00-9 Disposal of consumables 00-9 50988012021 [EN] VII

Table of contents Diagnostics 00-10 Tightening torques by units 00-10 Standard torques 00-10 01 Service Maintenance 01-1 Maintenance instructions 01-1 Operations Preliminary to Maintenance 01-1 Scheduled truck maintenance 01-2 Summary table of maintenance operations 01-2 Maintaining the KT20/KT 30 torque converter 01-4 Changing the oil for the KT20/KT 30 torque converter 01-4 Maintenance check lists 01-5 Maintenance -400 hours 01-5 Maintenance - 500 hours 01-5 Maintenance- 1000 hours/annually 01-7 Maintenance- 1500 hours or annually 01-9 Maintenance -3000 hours/every two years 01-12 02 Diagnostics KT 20/KT 30 torque converter 02-1 Troubleshooting 02-1 Fault detection 02-2 Kubota diesel engine 1.6/2.0 1- 2.5/3.5 1 02-5 Checklist for engine overheating 02-5 Troubleshooting 02-7 1 2 Internal combustion engine Kubota V 2403-M-DI-E3B diesel engine (1.6/2.0 1) 12-1 Description 12-1 Engine attachment parts 12-1 General technical data 12-2 Engine dimensions 12-3 Engine identification 12-4 Tightening torques for special screws 12-4 Lubricating system specification 12-4 Lubricating system specification, diesel version 1.6/2.0 1 12-4 Forced circulation lubrication 12-5 VIII 50988012021 [EN]

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Still RC40-16, RC40-17, RC40-18, RC40-20, RC40-25, RC40-30, RC40-33, RC40-35 Diesel / LPG Forklift Trucks Service Repair Worksho

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