Still RC-40 (4011 4012 4013 4014 4015 4016 4017 40148 4019 4020) Diesel/LPG Forklift Service Repair Workshop Manual

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Typ: Forklift

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Art.-Nr: 157142

Stichworte: 4011 4012 4013 4014 40148 4015 4016 4017 4019 4020 Diesel Featured Forklift Forklifts LPG Material Handling RC-40 RC40 Series Still

Produktvarianten

Beschreibung

The Still RC-40 Series Forklift Trucks, encompassing models with technical codes 4011 through 4020, represent a line of robust and reliable internal combustion engine-powered counterbalance forklift trucks designed for industrial material handling. These Diesel and LPG variants, with load capacities ranging from 1.5 to 3.0 metric tons, are built upon a heritage of German engineering quality and innovation, emphasizing durability and operational efficiency. The RC-40 series is engineered for demanding applications, incorporating features such as hydrostatic power steering, inching control for precise maneuvering, and operator safety systems like a Roll-Over Protective Structure. This comprehensive Factory Service Repair Workshop Manual provides detailed technical information and procedures for the Still RC-40 Series Forklift Trucks. It covers essential areas including product information, engine systems (Diesel variants like Yanmar 4TNE92/4TNE98 and LPG variants like Nissan K21/K25), transmission systems (TXL20/TXL30), truck structure, driver's compartment, steering, wheels and tires, braking and inching systems, controls, instruments, electrical and electronic systems, working hydraulic systems, hydraulic components, valves, and the lift mast. The manual offers step-by-step repair and service instructions, disassembly procedures, troubleshooting guidance, component diagnostics, and maintenance schedules, making it an indispensable resource for owners, mechanics, and technicians to ensure optimal performance and longevity of their equipment.

🏷️ Basic Information

Identification

Make:

Still

Model:

RC-40 Series Forklift Trucks

Product Name:

Still RC-40 (4011 4012 4013 4014 4015 4016 4017 40148 4019 4020) Diesel/LPG Forklift Trucks Service Repair Workshop Manual

Codes

Technical Codes:

4011, 4012, 4013, 4014, 4015, 4016, 4017, 40148, 4019, 4020

👋 Introduction

Market Position

Market Position:

The Still RC-40 series represents robust and reliable forklift trucks designed for industrial material handling applications. This manual positions itself as an essential resource for maintaining and repairing these specific models, emphasizing factory-level detail and accessibility for various skill levels.

Key Features

Key Features:

Highly detailed factory service repair manual, extensive coverage of Diesel and LPG variants, step-by-step instructions with hundreds of illustrations, comprehensive system coverage, printable PDF format, compatible with Windows and Mac.

📋 Manual Details

Coverage

Coverage Areas:

Product Information, Engine, Engine Accessory Parts, Exhaust Gas System, Transmission, Truck Structure, Driver's Compartment, Steering, Wheels and Tires, Braking/Inching System, Controls, Instruments, Electrical and Electronic System, Working Hydraulic System, Hydraulic Components, Valves, Lift Mast, Diagrams

Page Count

Page Count:

Not specified, but described as 'Highly Detailed' and '100 percents complete and intact' with 'hundreds of photos and illustrations'.

Manual Type

Manual Type:

Factory Service Repair Workshop Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Systems Covered:

Engine Systems (including fuel and exhaust), Transmission Systems (TXL20, TXL30), Hydraulic Systems (working and components), Steering, Braking, Electrical and Electronic Systems, Lift Mast Systems, Control Systems, Driver's Compartment Systems, Instruments.

Procedures Included

Procedures Included:

Detailed step-by-step repair and service instructions, complete disassembly procedures, troubleshooting guidance, component diagnostics, maintenance procedures, electrical system diagnostics, hydraulic system diagnostics.

Technical Depth

Technical Depth:

Comprehensive. Suitable for both DIY enthusiasts and experienced mechanics. Covers detailed illustrations and step-by-step instructions for complete disassembly and reassembly.

📊 Manual Specifications

File Format

File Format:

Compatibility

Compatibility:

All PC based Windows operating systems & Mac

Print Quality

Print Quality:

All pages are printable.

Requirements

Requirements:

Adobe PDF Reader & WinZip

⚙️ Engine Specifications

Primary Engine Diesel

Engine Diesel Variants:

Yanmar 4TNE92, Yanmar 4TNE98

Primary Engine Lpg

Engine Lpg Variants:

Nissan K21, Nissan K25

Performance Diesel 4Tne92

Engine Diesel 4Tne92 Specs:

Likely a 4-cylinder, naturally aspirated diesel engine. Specific HP/Torque not provided in product info, but typical for its class would be in the 35-50 HP range.

Performance Diesel 4Tne98

Engine Diesel 4Tne98 Specs:

Likely a 4-cylinder, naturally aspirated diesel engine with a larger displacement than the 4TNE92, offering increased power and torque for heavier duty cycles. Typical HP range might be 45-60 HP.

Performance Lpg K21

Engine Lpg K21 Specs:

Likely a 4-cylinder, overhead valve LPG engine. Known for smooth operation and lower emissions. Typical HP range around 40-55 HP.

Performance Lpg K25

Engine Lpg K25 Specs:

Likely a 4-cylinder, overhead valve LPG engine with a larger displacement than the K21, offering improved performance for heavier loads. Typical HP range around 50-65 HP.

Fuel System Diesel

Fuel System Diesel:

Direct Injection, Common Rail (likely for 4TNE98), or Indirect Injection diesel fuel system.

Fuel System Lpg

Fuel System Lpg:

Pressurized LPG (Liquefied Petroleum Gas) system with vapor withdrawal, regulator, and fuel mixer/injector.

🔧 Transmission

Standard

Transmission Type:

Automatic Transmission (model TXL20 for 1.5-2.0 ton variants, TXL30 for 2.5-3.0 ton variants).

Features

Transmission Features:

Designed for smooth power delivery and efficient operation in material handling. Likely features include torque converter for shock absorption and ease of operation, hydrostatic power steering integration.

📐 Dimensions

Model Variants

Model Variants Capacities:

RC40-15 (1.5 ton), RC40-18 (1.8 ton), RC40-20 (2.0 ton), RC40-25 (2.5 ton), RC40-30 (3.0 ton).

Weights Capacities

Weights Capacities:

Load capacities range from 1.5 to 3.0 metric tons (3,300 lbs to 6,600 lbs) depending on the specific model variant.

🛡️ Safety Features

Active Features

Active Safety Features:

Braking System (likely hydraulic drum or disc brakes with hydrostatic braking assist), Inching System (for precise low-speed maneuvering), Operator Presence System (prevents operation if operator is not seated).

Passive Features

Passive Safety Features:

Operator safety cage (ROPS - Roll-Over Protective Structure), Seatbelt, overhead guard for load protection, mast load backrest.

💡 Technology Features

Infotainment

Infotainment:

Basic. Typically limited to operational indicators and basic warning lights. No advanced infotainment systems are expected.

Driver Assistance

Driver Assistance:

Primarily focused on operational safety and efficiency: hydrostatic steering, inching control, operator presence system. Advanced electronic driver assistance features are unlikely for this product generation.

Diagnostics

Diagnostics Technology:

The manual provides detailed diagnostic procedures for electrical, hydraulic, and mechanical systems, enabling technicians to identify and resolve issues efficiently, likely using multimeter checks and visual inspection methods.

🔧 Maintenance

Service Intervals

Service Intervals:

The manual would detail specific intervals for engine oil changes, transmission fluid changes, hydraulic fluid changes, filter replacements (oil, fuel, air), brake inspections, and general lubrication points. Typical intervals are often 250-500 operating hours for major fluid services.

Fluid Specifications

Fluid Specifications:

The manual would specify required engine oil grades (e.g., API CF-4 or equivalent for diesel, specific grades for LPG), transmission fluid type (e.g., ATF Dexron III or similar), hydraulic fluid type (ISO VG 32 or 46), and coolant specifications (if applicable for diesel).

Known Issues

Common Issues:

Potential common issues with forklift trucks of this era and type can include wear on lift cylinders and seals, hydraulic pump wear, transmission control issues, brake system wear (shoes, drums/pads, rotors), electrical connection corrosion, and engine component wear (injectors, glow plugs, ignition components for LPG).

📚 Vehicle History

Brand Heritage

Brand Heritage:

Still GmbH is a German manufacturer of forklift trucks and warehouse equipment, known for its engineering quality, innovation, and reliability in the material handling industry. Established in 1920.

Model Evolution

Model Evolution:

The RC-40 series represents a line of internal combustion engine (ICE) powered counterbalance forklift trucks. These models typically incorporate advancements in engine technology for emissions and fuel efficiency, as well as ergonomic improvements for the operator.