Still Diesel and LPG Forklift Truck Type RC40-15 RC40-18 RC40-20 RC40-25 RC40-30 (4011-4020) Service Repair Manual

Product information
Foreword
Information on RC40 15-30 1
Safety precautions
How to Consult the Manual
Operations Preliminary to Maintenance
To avoid accidents
General safety Regulations
Safety Regulations Relative to Operating Materials
12

Engine
Engine models 4TNE92 and 4TNE98
General service information
Component identification
Functions of the main engine components
Diesel fuel specifications
Priming the fuel supply system
Specifications
Main engine specifications
Engine processing
Tightening torques for standard bolts and nuts
Fuel system
Removal of the fuel injection pump
Installation of the fuel injection pump
Checking/adjusting the fuel injection timing
Maintenance of the fuel injectors
Fuel injectors inspection and testing
Servicing
Standard torques table
Engine oil level checking procedure
Checking / replacing the feed pipes and cooling hoses
Checking and adjusting the V-belt of the cooling fan
Changing the engine oil and oil filter
Checking and adjusting the regulator lever and engine speed control
Checking and adjusting the valve clearance
Changing the fuel filter
Troubleshooting
Troubleshooting information
Quick reference table for troubleshooting solutions
Troubleshooting solutions
Engine models Nissan K21 and K25
General service information
Main specifications
Engine plate
Standard data and repair limit
Tightening torque
Troubleshooting
Engine troubleshooting
LPG system troubleshooting
Onboard inspection and maintenance
Headed screw tightening
Retightening the manifold nut and screw
Adjusting the intake/exhaust valve clearance
Inspecting and adjusting the accessory belt
Changing the oil and oil filter
Engine casing inspection
Retightening the cylinder head screws
Retightening the manifold nuts
Adjusting the valve clearance
Changing the engine coolant
Cleaning the exterior of the radiator
Checking the cooling hoses and connections
Checking the compression pressure
Fuel supply system inspection
Cleaning and replacing the airfilter
Inspecting the mixer
Maintaining the mixer
Inspecting the FICD (fast idle control device)
Inspecting and changing the glow plugs
Inspecting the distributor
Inspecting the distributor cap and carbon terminals
Inspecting the rotor head
Inspecting the central signal rotor
Inspecting the vacuum control system
Inspection after refitting the distributor
Cleaning the interior of the distributor
Measuring the engine speed (carburettor model only)
Inspecting and adjusting the ignition timing idle speed and air-fuel mixture
Inspecting and adjusting the air-fuel mixture
Adjusting device
Adjusting the maximum RMP speed without load
Adjusting the maximum RMP speed with load
Inspecting the FICD (fast idle control device)
Special maintenance tools forthe model with carburettor
13

Engine accessory parts
Setup
Engine setup replacements
Mounting the engine 15/20 1
Engine
Engine reassembly
Mounting the engine 25/30 1
Reinstalling the engine
Air intake
Air filter
Cleaning the air filter
Cooling system
Radiator
Checking the coolant level 1

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Coolant level checking procedure
Checking the coolant level 25/30 1
Coolant level checking procedure
Checking and cleaning the radiatorfins
Draining rinsing and filling the cooling system with new coolant
Tank
Fuel tank
14

Exhaust gas system
Exhaust gas system
Silencer and exhaust
20 Transmission
Technical data for the TXL30
General transmission views (TXL30)
Transmission technical data (TXL30)
General transmission description (TXL 30)
Transmission sectional views for the TXL30
Transmission wiring diagram
Distributor technical data (TXL30)
Description of the hydraulic circuit
Transmission fastening for the TXL30
Engine-transmission coupling
Checking the engine-gearbox coupling
Maintenance for the TXL30
Transmission oil level inspection procedure
Check axle oil level
Troubleshooting
Troubleshooting
31

Truck
Truck
Counterweight
Reinstalling the counterweight 15/20 1
Counterweight reassembly
Reinstalling the counterweight 25/30 1
Reinstalling the counterweight
34

Drivers compartment
Drivers compartment
Drivers compartment central cross traverse
Drivers compartment
Drivers compartment reassembly
Drivers compartment spring supports
Covers
Drivers compartment covers and panelling
42

Steering
Hydraulically assisted steering
Hydraulically assisted steering technical data
Hydraulically assisted steering column unit
Hydraulically assisted steering -troubleshooting and corrective actions
Steering axle 1

5/2 Ot
Steering axle
Reinstalling the steering axle
Steering axle 25/30 1
Reinstalling the steering axle
46 Wheels and tyres
General information
Safety regulations for wheels and rims
General information for changing tyres
Tyrewear check
Changing the wheels 1

5/20 1
Wheel replacement procedure
Changing the wheels 25/30 1
Wheel replacement procedure
Disassembling a wheel
Disassembly/assembly of tyres on rims with movable flange
Quick tyres assembly/disassembly
Tightening torques 1

5/2 Ot
Wheel Tightening Check
Tightening torques 25/30 1
Wheel Tightening Check
49 Braking/inching system
Braking system operating characteristics
Braking system technical data
Braking system reassembly
Service brake
Brake pump
Brake shoes
Stop lights microswitch
Parking brake
Parking brake lever
Parking brake microswitch
Parking brake cables
Servicing
Brake fluid level check
Air bleeding from the brake pipes
50

Controls
Twin pedal
Accelerator pedal
Accelerator cable
56 Instruments
Instrument panel
60 Electrical and electronic system
Battery
Battery carrier
Checking the battery
Fuses
Fuse and relay location
Fuse replacement
71

Working hydraulic system
Service and lifting pump 15/2 0t
Service and lifting pump technical data
Service and lifting pump 25/30 1
Service and lifting pump technical data
71 Hydraulic components
Service and lifting pump
Service and lifting pump
Tank
Hydraulic oil tank technical data
Oil tank
Oil filter unit
Hydraulic tank oil level check procedure
76

Valves
Shut-off valves
Safety valve (load lowering block) (VBDC)
Safety valve
Safety valve
Safety valve technicaldata
Safety valve layout 15/20 1
Safety valve layout
Safety valve layout 2

5/30 1
Safety valve positioningon the simplex lift mast
Safety valve positioningon the duplex lift mast
Safety valve positioning on the triplex lift mast
Distributor valves
Lifting distributor technical data
80

Lift mast
Lift mast 15/20 1
Lift typologies
Simplex lift mast (Tele)
Simplex lift mast functional description
Hydraulic circuit for supplying the simplex lift mast cylinders
Adjusting the Simplex lift load chain
Simplex lifting diagram
Duplex lift mast (HiLo)
Duplex lift mast functional description
Hydraulic circuit for supplying the duplex lift mast cylinders
Adjusting the load chains of the duplex lift mast
Duplex lifting diagram
Triplex lift mast
Triplex lift mast functional description
Hydraulic circuit for supplying the triplex lift cylinders
Adjusting the lift chains on the triplex lift mast
Triplex lifting diagram