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Still R70-35T LPG Fork Truck Service Repair Manual

service repair manual

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Still R70-35T LPG Fork Truck Service Repair Manual

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  1. 01 Workshop manual 7084 - 86 Chassis and counterweight Table of contents Page Chassis and counterweight Jacking up the fork truck 2 3 1

  2. 01 Workshop manual 7084 - 86 Chassis and counterweight Chassis The vehicle chassis is a welded construction with bolted on counterweight. The fuel tank is arranged in the right chassis half and the hydraulic tank in the left chassis half.. Counterweight The counterweight is fastened to the welded chassis construction with four bolts, see diagram. 1 - Hexagon bolt M24x130 / 8.8 Tightening torque = 710 Nm 2 - Spherical washer 3 - Cone pan Weight of counterweight: 2407 kg 2 1 3 2

  3. 01 Workshop manual 7084 - 86 Chassis and counterweight Jacking up the fork truck ATTENTION Before jacking up the fork truck, apply the parking brake. For various servicing routines, the fork truck must be jacked up. When jacking up the fork truck, suitable measures must be taken to prevent the fork truck slipping or tilting, e.g. using wooden blocks. Always ensure that only jacks with sufficient bearing capacity are used and that the fork truck is jacked up only on level ground and secured to prevent it rolling. Only jack up the vehicle at the points shown in the photos, i.e. at the mast on the left or right and at the chassis at the front or rear. Do not jack up the fork truck at the counterweight! When jacking up the fork truck at the mast, the safety regulations for working on the mast must be observed. 3

  4. 02 Workshop manual 7084 - 86 Steering axle Table of contents Page Technical service data 2 Design of the steering axle 3 Removing the steering axle 3 Fitting the steering axle 3 Removing the wheel hub 4 Fitting the wheel hub 4 Adjusting the steer angle 5 Checking the steer angle 5 Removing the stub axle 6 Fitting the stub axle 7 Greasing the axle 7 Removing the tie rods 8 Fitting the tie rods 8 Removing the steering cylinder 9 Fitting the steering cylinder 9 1

  5. 02 Steering axle Workshop manual 7084 - 86 Technical service data e t S n i r e g e l x a e t S e r a e l g n 8 0 - 8 2 ° n i - e o T 0 ± 1 m m W l e e h c a m r e b 0 ° C e t s a r 0 ° g i T e t h n i n g t o r q u e s W l e e h h u b MA = 4 7 0 N m W l e e h t u n MA = 6 4 0 N m e l x A n i r a e b g MA = 1 9 5 N m e t S n i r e g n i l y c r e d n i t n u o m g MA = 2 9 5 N m S K M o n n i k g n i p MA = 3 1 0 N m L u c i r b a n t G s e r p a a s e i f i n o e F a o t . c c D N I 5 1 - 5 2 8 K P 2 K u i h t t i l , 0 2 - m W l e e h h u b n i r a e b g s d G s e r p a s e i f i n o a e F a o t . c c D N I 5 1 - 5 2 8 K P 2 K u i h t t i l , 0 3 - m d G s e r p a s e i f i n o a e F L d a o t . c c D N I 5 1 8 2 5 K - P F 2 N u i h t i l , 0 2 - m S u b e l x a b n i r a e g s L I T S L d I - . t n e . o N 1 4 8 6 5 9 2

  6. 02 Workshop manual 7084 - 87 Steering axle Design of the steering axle The steering axle is mounted with 2 buffer elements on the counterweight. The stub axles are supported in taper roller bearings in the axle body. Steer angle limitation takes place via stop bolts on the stub axle 1 Axle body 2 Fixing plates 3 Hexagon bolt 4 Lockwasher 5 Buffer elements Removing the steering axle CAUTION: Only remove the steering axle with the mast mounted! Risk of tilting! - Apply the handbrake. - Place wooden blocks under the front wheels to prevent the vehicle rolling. - Loosen the steering axle wheel nuts. - Jack up the vehicle in the precribed manner. (See Group 01) - Remove the wheels. - Unscrew the hydraulic connections from the steering cylinder. CAUTION: hydraulic connections are unscrewed. Collect hydraulic oil and dispose of in a proper manner. Hydraulic oil will discharge when the - Place a hand pallet truck or similar with blocks of wood under the steering axle. - Unscrew the four cheese-head screws for fixing the steering axle. Fitting the steering axle - Fitting takes place in reverse order to removal. - Tightening torque of 4 cheese-head screws: MA = 195 Nm CAUTION: Do not interchange left and right hydraulic connections! STILL GmbH Stand: 3/00 (Replaces version: ) 03

  7. 02 Workshop manual 7084 - 86 Steering axle Removing the wheel hub 1 Axle body 2 Stub axle 3 Radial seal 4 Taper roller bearing 5 Wheel hub 6 Pin 7 Wheel cap 8 Hexagon nut 9 Washer 10 Taper roller bearing 11 Wheel bolt 12 Nut 3 4 5 10 6 7 1 2 11 - Loosen nuts (11) and remove wheel. - Remove dust cap (7). - Loosen hexagon nut (8). - Remove washer (9) with pin (6). - Remove wheel hub. - Remove taper roller bearings (4) and (10) from wheel hub; for this purpose, the radial seal (3) must be removed.. - If necessary, remove outer rings of taper roller bearings (4) and (10).Fitting the wheel hub - Thoroughly grease sealing lips of radial seal. - Fill taper roller bearings with grease F between inner ring and cage. - Fill bearing spaces at the points marked (x) with grease F. - Fitting takes place in reverse order to removal. - Tighten hexagon nut (8) constantly turning the wheel hub. Tightening torque: MA = 470 Nm 12 9 8 4

  8. 02 Workshop manual 7084 - 86 Steering axle Checking the steer angle The steer angle a must be 80° - 82°. To facilitate measurement, the supplementary angle b can be used. This must be 98° - 100°. ATTENTION:It must be ensured that the steer angle is definitely limited by the stop bolts (1). The stop must not take place in the steering cylinder. Rechtskurve turn right Adjusting the steer angle The steer angle is limited by one stop bolt (1) on each side respectively. - Adjust the left and right steer angles (1) to 80° - 82° with the stop bolts (1). - Check the opposite angle. - Check the free space at full steering wheel lock. - Check that the steer angle stop does not take place in the steering cylinder. Linkskurve turn left = 82° +0/-2Lenkeinschlag steering angles 1 5

  9. 02 Workshop manual 7084 - 86 Steering axle Removing the stub axle 1 1 2 3 4 5 6 7 8 9 10 Taper roller bearing 11 Spacer 12 Nipple 13 Taper roller bearing 14 Scraper ring 15 O-ring 16 Spacer Hexagon bolt Washer King pin Plug Stub axle Hexagon bolt Hexagon nut Spacer Scraper ring 2 16 3 15 4 14 13 5 12 11 6 10 7 9 8 - Remove wheel. - Press out bolt between tie rod and stub axle. - Loosen hexagon nut (1). - Remove washer (2). - Press out king pin (3) downwards. - Remove stub axle from axle. - Remove spacers, O-ring, scraper rings, taper roller bearings and spacers (8 - 16)from stub axle. 6

  10. 02 Workshop manual 7084 - 86 Steering axle Fitting the stub axle 1 2 1 Hexagon nut 2 Washer 3 King pin 4 Plug 5 Stub axle 6 Spacer 7 Scraper ring 8 Taper roller bearing 9 Spacer 10 Taper roller bearing 11 Scraper ring 12 O-ring 13 Spacer 14 Bolt 3 12 13 14 11 10 9 5 8 7 4 6 - Fit spacer (9) in stub axle. - Fit both taper roller bearings (8+10). Grease both bearings well with grease FL! - Thoroughly grease sealing lips of scraper rings (7+11) with grease FL. - Fit scraper rings (7+11), both spacers (13, 6 ) and O-ring (12). - Fit sub axle in axle. - Insert king pin (3) from below; lightly oil pin. - Fit washer (2). - Fit a new hexagon nut (1) and tighten with a torque of: MA = 310 Nm. - Press in bolt (14) of tie rod and secure with pins. - Fit wheel. - Grease steering axle with grease FL. Greasing the steering axle - Operate steering while greasing steering axle. - Grease eight nipples of steering axle with grease FL until fresh grease discharges at the bearing points (see diagram on page 8) 7

  11. 02 Workshop manual 7084 - 86 Steering axle Removing the tie rods 4 3 The steering axle has two tie rods seated between the steering cylinder and both stub axles. 1 Sub axle 2 Piston rod 3 Seals 4 Pins 5 Bolt 6 Tie rod 7 Ball socket 5 4 Remove pins (4) Press out bolt (5) Fitting the tie rods Fitting takes place in reverse order to removal. Bolt press-in force on cylinder side: max. 29 kN Bolt press-in force on stub axle side: max. 38 kN 8

  12. 02 Workshop manual 7084 - 86 Steering axle Removing the steering cylinder - Remove tie rods. - Unscrew hydraulic connections and mark. ATTENTION: Discharging hydraulic oil. - Loosen four bolts (1). Fitting the steering cylinder - Tighten bolts (1). Tightening torque: MA= 295 Nm - Screw on hydraulic connections. ATTENTION: Do not interchange hydraulic lines. - Fit tie rods. NOTE: Instructions for removing and fitting the steering cylinder are given under Group 06. Greasing the steering axle - Relieve the steering axle whilst greasing and operate the steering. - Grease the eight nipples (2) of the steering axle, starting from the upper nipples until fresh grease discharges at the bearing points. NOTE: When greasing the upper bearing, it is unnecessary for grease to discharge from the upper seal. It can also deviate downwards. 2 2 2 2 9

  13. 03 Workshop manual 7084 - 86 Table of contents Page Technical service data 2 Gear drive 3+4 Spur gearing with differential 5 Fitting the gear drive 6 Gear drive/tubular shaft 7 Axle shaft 8 Wheel hub 9 1

  14. 03 Workshop manual 7084 - 86 Technical service data G r o u p 0 3 G r a e v i r d e T y p e A E 4 0 - 0 2 g i T e t h n i n g q r o t u e / s i s s a h C v i r D e e l x a M A = 1 0 0 0 N m g i T e t h n i n g q r o t u e e l x A n i s u o h / g a r T o i s s i m s n n M A = 2 9 5 N m l a i x A e l c a r a n c e u t r a e G r a l u b s t f a h + 0 . 0 3 m m o t - 0 . 0 6 m m n i r e t n e C = A M g 5 a l f / e g n m N l e e h W h u b Z S M 8 x 1 8 9 . 0 1 g i T e t h n i n g q r o t u e 1 3 g i T e t h n i n g q r o t u e O l i n i a r d u l p g M A = 7 0 N m g i T e t h n i n g q r o t u e e l x A t f a h s Z S M 1 2 x 3 5 9 . 0 1 M A = 1 2 0 N m o i s s i m s n a r T n l i o y t i c a p a C = 5 . 9 e r t i l G e r a s e y t p e u i h t i L m s o a p e r g a s e h t i w E P v i t i d d a e 2

  15. 03 Workshop manual 7084 - 86 Gear drive Gear drive Description The gear drive consists of two-speed spur gearing with differential (1) and double supported drive pinion as well as flange-mounted d.c. motor (2), a long axle housing (3) and an axle housing (short side) integrated in the transmission case (1). The long axle housing (3) is bolted to the spur gearing. Both are bolted to the chassis and simultaneously serve for accommodating the mast bearing. 1 = Differential gear 2 = DC motor 3 = Right driving axle side with integral brake anchor plate 4 = Bolts 5 = Left driving axle side/gear half with integral brake anchor plate 6 = Mast bearing bracket 3

  16. 03 Workshop manual 7084 - 86 Gear drive drivemotor half-shaft half-shaft 4

  17. 03 Workshop manual 7084 - 86 Spur gearing with differential 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Transmission case 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 Seal Plug Cover Plug Catch Shaft seal Taper roller bearing Gear O-ring Washer 75 x 65 x 0.5 - 0.8 O-ring Shaft seal Cover Lock washer Hexagon bolt M8 x 20 8.8 Dowel pin Cheese-head screw Taper roller bearing Differential Gear Pin Hexagon bolt Washer 145 x 130 x 0.5 - 0.9 Taper roller bearing Gear with shaft Washer 160 x 85 x 0.5 - 0.9 Lock ring Reducing pipe 5

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  19. 03 Workshop manual 7084 - 86 Gear drive Removing the gear drive Remove mast Jack up vehicle Drain oil (2) and collect Loosen wheels/mounting Remove wheels Disconnect E-motor cables (mark!) Disconnect brake line at main brake cylinder Remove brake line from parking brake Support gear drive with a crane or rope winch Unscrew bolts (3) left and right Fitting the gear drive Position gear drive in chassis with a crane or rope winch Draw gear drive against chassis with 16 bolts and 16 washers Tighten all bolts (3) Tightenting torque MA =1000 Nm Remove crane or rope winch Connect E-motor cables Connect brake lines at main cylinder Fit brake lines in parking brake 1 = Oil filler neck with dipstick Fit wheels (see Group 04) 2 = Oil drain plug Mount mast (see Group 20) 3 = Bolts Measure oil level with dipstick 4 = Washers Oil capacity: 9.5 litre Transmission oil: SAE 90 EP - 51512 6

  20. 03 Workshop manual 7084 - 86 Gear drive/tubular shaft Housing = B Gear tubular shaft = A Cover = C mm Instructions for adjusting gear tubular shaft bearing 1. Measure both taper roller bearings complete on the gear tubular shaft up to the stop in the vertical position A over outer rings. 6. Both taper roller bearings must be fitted with 50% grease filling. Transmission oil SAE 140 EP can be used as a substitute. 2. Measure housing mounting dimension B 7. Prefit taper roller bearing outer ring (tacho) with fitting mandrel about 20 mm. 3. Measure centring collar length C on cover 8. Fit gear tubular shaft. 4. Packing thickness D=B-(A+C+0.06) 9. Prefit taper roller bearing outer ring (cover) with fitting mandrel about 20 mm. 5. Round packing thickness D up or down according to actual dimension = D + 0.03mm (initial tension) to 0.06mm (clearance). 10. Insert packing and bring taper roller bearing outer ring into its final position by evenly tightening the bolts. 7

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