Still Forklift R70-80 Series Service Repair Manual

WORKSHOP - MANUAL R 70-60 / 70 / 80

R 7044 - 46 Ident-No.: 164 732(ex146 592)

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Workshop Manual R 7044 - 46

Chassis Frame Constructed of electrically welded steel plate, the chassis frame consists of a right-hand and lefthand section.

At the rear, both frame sections are bolted to the counterweight, whereas at the front an upper cross member(l) and a lower transverse web (2) are bolted dirctly on the frame.

The fuel tank is positioned within the right-hand frame section, whereas the hydraulic tank is housed within the left-hand frame section. Made of plastics, both tanks are slid in place into the frame section from the counterweight end.

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Workshop Manual R 7044 - 46

Chassis Frame

1 = frame, RH side 2 = frame, LH side 3 = hex hd screw M 24x70 8.8 MA = 660 Nm 4 = tension washer 5 = hex nut M24 6 = hex hd screw M27x170 10.9 MA = 940 Nm 7 = washer 8 = hex hd screw M24x85 8.8 MA = 660 Nm 9 = tension washer

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10 = cross member 11 = hex hd screw M24x50 10.9 MA = 940 Nm 12 = tension washer 13 = lower transverse web 14 = hex hd screw M24xl 80 8.8 MA = 660 Nm 15 = split lockwasher 16 = counterweight 70 - 60, 3759 kgs 70 - 80, 5340 kgs

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Workshop Manual R 7044 - 46

Chassis Frame

Should one or both of the frame sections have been removed, replacing must be effected in the sequence shown below.

1 Fit the intermediate flange into position on the frame and tighten the retaining screws by hand 2 Bolt the counterweight on the frame. Do not fully tighten the bolts at this stage 3 Assemble the lower transverse web onto the frame and intermediate flange 4 Fit the upper cross member into position. Tighten the retaining screws by hand 5 Align the frame sections 6 Tighten the counterweight retaining bolts to a torque of MA= 660 N m 7 Check spacing between both frame sections. should be 1080 Âą 1 mm 8 To replace the electric drive motors with their respective reduction gear remove cross member 9 Assemble the lower transverse web with intermediate flange and cross member to the frame.

Torque retaining screws to requirements 1 = cross member 2 = hex hd screws M 24x 180 8.8 MA = 660 Nm 3 = lower transverse web 4 = hex hd screws M24x50 10.9 MA = 940 Nm 5 = hex hd screws M 24x 180 8.8 MA = 660 Nm 6 = RH frame section 7 = LH frame section

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Workshop Manual R 7044 - 46

Technical Data for Maintenance Service Steer axle Wheel lock angle

80-82°

Toe-in

0±1 mm

Wheel camber

0°

Trail

0°

Torque loading Steer axle fitted with a single acting steer cylinder Wheel hub

MA= 170 Nm

Axle bearings

MA = 385 Nm

Track rod

MA = 140 Nm

Eyebolt (bearing socket) for steer cylinder piston rod

MA = 80 Nm

Steer axle fitted with a double acting steer cylinder Wheel hub

MA= 150 Nm

Wheel nuts

MA = 640 Nm

Axle bearings

MA = 385 Nm

Steer cylinder fixing

MA =1050 Nm

Nut on king pin

MA = 600 Nm

Lubricants Wheel hub bearings

Grease F to DIN 51825-KP2K-20, lithium soap based Grease F to DIN 51825-KP2K-30, lithium soap based Grease FL,DIN 51825-KPF2N-20, lithium soap based STILL Ident. No. 148659

Stub axle bearings

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Workshop Manual R 7044 - 46

Steer axle Mechanical configuration of steer axle The articulating steer axle suspended from the rear counterweight is mounted in a self-aligning bearing.

The stub axles are supported in the axle beam on bushings and thrust bearings. Sleering is limited by stop screws on the axle beam right and left. Articulation is limited by stops on the counterweight.

1 = axle bearing 2 = roll pin 3 = split lockwasher 4 = hex hd bolt M20 X 120 torque loading: 385 Nm 5 = axle beam Steer axle removal - Jack up rear of the truck by approx. 460 mm and place wooden blocks under the counterweight in front of the axle. Chock front wheels securely to prevent rolling of the truck. Apply the handbrake.

- Disconnect hydraulic lines at steer cylinder.

CAUTION: prepare for oil spillage.

- Remove the 4 hex hd bolts (4) M20 x 120 which retain the axle bearing (1) in place.

- Slide a hand pallet truck under the steer axle with approx. 130 mm high wooden blocks placed on the fork ends of the hand pallet truck. Using a 1500 mm long lever rod, drive axle bearing (1) out of the 4 roll pins (2) and lower the axle onto the hand pallet truck.

Steer axle installation - Install steer axle by reversing the removal procedure.

Torque hex hd bolts (4) to MA = 385 Nm

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Workshop Manual R 7044 - 46

Steer Axle Axle bearing - Dismantling 1 =hex hd screw M6x16 2 = split lockwasher 3 = washer 4 = bushing 5 = axle bolt 6 = bearing support or bracket 7 = shim 8 = grease nipple 9 = axle arm 10 = hex hd screw AM 14x45 - Y564-8G 11 = hex nut M14 - 934 M65 Before dismantling the bearing axle, it will be necessary to remove the steer axle - see Functional Group 02: Steer axle removal.

- Slacken hex nut (11) - Remove hex hd screw (10) - Remove hex hd screws (1) - Remove washers (3) - Drive out axle bolt (5) - Drive out bushings (4) if necessary - Remove bearing support (6) Axle bearing - Reassembling - Reverse the dismantling procedure - If necessary, compensate for end play in bearing support by adding shims (7) (three different thicknesses are available as per parts cataloque).

- Make sure the bushings are installed in the correct position. * the slot of the bushing may alternatively point in one or the other of the directios, as illustrated

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Workshop Manual R 7044 - 46

Steer Axle Trail wheel hub - Dismantling 1 = stub axle 2 = washer 3 = chevron seal 4 = tapered roller bearing 5 = wheel hub 6 = tapered roller bearing 7 = washer 8 = castle nut; torque loading = 170 Nm 9 = cotter pin 10 = hubcap 11 = ball seat nut 12 = bolt - Slacken ball seat nut (11) and remove wheel - Remove hub cap (10) - Remove cotter pin (9) - Remove castle nut (8) -- Remove wheel hub (5) If necessary, drive out of wheel hub outer races of tapered roller bearings (4) and (6) Withdraw tapered rollers (4) and chevron seal (3) from the stub axle Trail wheel hub - Reassembling - Reverse the dismantling procedure - Before reassembling the wheel hub, first fill cavity of tapered roller bearing and bearing cage with grease. Cavities should be repacked with grease at places identified by an Y on the drawing - Carefully apply a smear of grease to the sealing lips of the chevron seal (3).

- Ensure the chevron seal is positioned correctly the lips side should face towards the axle baem - Torque crown nut (8) to 170 Nm, then back off the nut until the next cotter pin hole appears - Install cotter pin and lock

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Workshop Manual R 7044 - 46

Steer Axle Track rod removal 1 =cap 2 = COTTER PIN 3 = castle nut; torque loading = 140 Nm 4 = washer 5 = circlip 6 = ball joint 7 = cylinder rod eyebolt 8 = steer cylinder 10 = stub axle 13 = track rod 13a= pin 14 = steering arm 1. Dismantling at stub axle: -

Remove cap (1) Remove cotter pin (2) Remove castle nut (3) Remove washer (4) Withdraw eyebolt (7) Drive pin (13a) out of stub axle (10) (protect threads)

2. Dismantling at steering arm - Remove cotter pin (2) - Remove castle nut (3) - Drive pin of track rod (13) out of steering arm (14) Track rod installation - Reverse the removal procedure - Torque both castle nuts (3) to 140 Nm 02

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Workshop Manual R 7044 - 46

Steer Axle Stub Axles - Dismantling 9 = thrust bearing 10 = stub axle 11 = grub screw (secured with Loctite 242) 12 = shim 14 = conical head lubricating nipple 15 = hollow screw 16 = cap 17 = bushing 18 = king pin 19 = conical head lubricating nipple 20 = axle beam - Before dismantling the stub axle, dismount the-track rod bearing as well as the cylinder rod eyebolt located on the LH side (see 7rack rod removal ) - Remove hollow cap - Remove grub screw (11) (secured with Loctite) - Drive king pin (18) out of steer axle - Remove stub axle (10) from steer axle - Drive out bushings (17)

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Workshop Manual R 7044 - 46

Steer Axle Stub Axles - Reassembling - Tap bushings (17) in place with an installer. Make certain bushings are installed in their orginal position.The slot of the bushings must point either forward or backward as shown in the lower drawing - Insert stub axle (10) with thrust bearing (9) and shim (12) (which must first be lubricated with grease) into the axle beam (20) - Compensate for end play by adding shims (12) (seven different thicknesses are available as per parts cataloque) Maximum permissable endplay =< 0. 1 mm - Press in the king pin (18) from below - Refit cap (16) - Install hallow screw (15) - Apply Loctite 242 to grub screw (11) with which the king pin is secured and install grub screw 9 = thrust bearing 10 = stub axle 11 = grub screw (secured with Loctite 242) 12 = shim 15 = hollow screw 17 = bushing 18 = king pin 20 = axle beam Fitting position of bushings (17) * the slot of the bushings (17) may alternatively point in one or the other of the directions, as illustrated

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Workshop Manual R 7044 - 46

Steer Axle Steering arm - Dismantling 1 = steering arm 2 = axle beam 3 = track rod 4 = hex hd bolt M 12x30 secured with Loctite 242 5 = washer 6 = tapered roller bearing 7 = tapered roller bearing 8 = washer 9 = sealing ring 10 = pin - Remove hex hd bolt (4) - Remove washer (5) - Withdraw bearings (6) + (7) if necessary Steering arm - Reassembling - Reverse the dismantling procedure - Clean hex hd bolt (4) in a degreasing agent, apply Loctite 242 and tighten to a torque of 86 Nm

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Workshop Manual R 7044 - 46

Steer Axle Steer cylinder removal

1 = steer cylider 2 = pin 3 = hex hd bolt M 1 0x20 4 = washer 5 = taphole (1 6xl.5) 6 = eyebolt 7 = piston rod 8 = hex hd bolt M 1 2x55 Torque loading = 80 Nm

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Remove from the stub axle:

1.1

the eyebolt (6) - for disassembly see page 5 of Functional Group 02 Track rod removal Removing the piston rod (7) from the eyebolt (6) - slacken hex hd bolt (8) - screw off piston rod (7) from eyebolt

1.2

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Workshop Manual R 7044 - 46

Steer Axle 2. Removing the cylinder from the axle beam - remove hex hd bolt (3) - remove washer (4) - screw a screw* (1 6xl.5 thread) into the existimg taphole (5) of the pin (2) and, by exerting pressure against the screw head with an appropiate lever, press out the pin.

Steer cylinder installation - Reinstall the steer cylinder in the reverse order of removal

Detail Z

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Workshop Manual R 7044 - 46

Steer Axle Checking the steering angles The steering angle must amount to 80° - 82°. To facilitate the measurement use the complomentary angle for the setting. It should amount to 98° - 100°.

IMPORTANT: Ensure that the wheel lock is limited by the stop screws (1) and (2) resp. and not by the cylinder stroke.

Wheel angle stop adjustment Right-hand bend

The wheel stop angle is limited by the stop screws (1) and (2) respectively.

- By operating on stop screws (1) and (2) respectively, set both steering angles to 80° - 82° - Check opposite angles.

- Check for adequate clearance between wheels and truck frame.

Left-hand bend

- Check that the wheel lock is not limited by the cylinder stroke.

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Workshop Manual R 7044 - 46

Steer axle fitted with a double acting steer cylinder Configuration of steer axle The articulating steer axle suspended from the counterweight is mounted in 2 neoprene blocks. The stub axles are supported in the axle beam on tapered roller bearings. Steering is limited by stop screws on the stub axles.

1 = axle beam 2 = fixing plates 3 = hex. hd. bolt 4 = spring washer 5 = neoprene blocks Steer axle removal CAUTION:

Remove steer axle only with mast in position on the truck!

Risk of tipping!

- Apply the parking brake - Securely chock the front wheels to prevent rolling of the truck.

- Slacken steer wheel nuts.

- Jack up rear of the truck at counterweight (x) and place wooden blocks under the counterweight in front of the axle.

- Remove wheels - Disconnect the hydraulic connections at steer cylinder.

- Remove the four socket head screws which retain the steer axle in place.

CAUTION: Prepare for oil spillage when disconnecting the hydraulic connectionsI Catch oil in a Pan of adequate capacity and dispose of the used oil in accordance with laws and regulations.

- Remove the four socket head screws which retain the steer axle in place.

- Slide a hand pallet truck under the steer axle with wooden blocks placed on the fork ends of the hand pallet truck.

- Using a lever, drive steer axle out of roll pins and lower the axle onto the hand pallet truck.

Steer axle installation - Reverse the removal procedure.

- The slots of the roll pins must face the direction of forward travel.

- Torque socket head screws to: MA = 385 Nm CAUTION: Do not swap hydraulic connections left and right!

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Workshop Manual R 7044 - 46

Steer axle fitted with a double acting steer cylinder Wheel hub - Removal and Dismantling 1 = axle beam 2 = stub axle 3 = radial sealing ring 4 = tapered roller bearing 5 = wheel hub 6 = split-pin (cotter pin) 7 = hub cap 8 = castle nut 9 = washer 10 = tapered roller bearing 11 = wheel bolt 12 = ball seat nut -

Slacken ball seat nuts (12) and remove wheel.

Pull hub cap (7) from wheel.

Remove split-pin (6).

Remove washer (9).

Withdraw the hub.

Remove radial sealing ring (3) then remove tapered roller bearings (4) and (10) from hub.

- If necessary, drive out of wheel hub outer races of tapered roller bearings (4) and (10).

Wheel hub - Reassembling and Installation - Apply a smear of grease to the sealing lips of the radial sealing ring. - Before re-assembling the hub, repack with grease F: cavity between inner race and bearing cage of tapered roller bearings, and the bearing spaces identified by an Von the drawing.

- To reassemble the hubs, reverse the procedure.

- Tighten castle nut (8) while rotating the wheel hub.

If necessary, slightly turn back the nut until the last castellation aligns with the split-pin hole for insertion of the split-pin. Torque loading: MA = 150 Nm

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Workshop Manual R 7044 - 46

Steer axle fitted with a double acting steer cylinder Checking the steering angles The steering angle must amount to 80° - 82°. To facilitate the measurement use the complementary angle for the setting. It should amount to 98° - 100°.

IMPORTANT: Ensure that the wheel lock is limited by the stop screws (1) and not by the cylinder stroke.

Wheel angle stop adjustment Right-hand bend

The wheel stop angle is limited by the stop screws (1).

- By operating on stop screws (1), set both steering angles to 80° - 82°.

- Check opposite angles.

- Check for adequate clearance between wheels and truck frame,

Left-hand bend

- Check that the wheel lock is not limited by the cylinder stroke.

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Workshop Manual R 7044 - 46

Steer axle fitted with a double acting steer cylinder Stub axle - Removal and Dismantling 1 = nut 2 = washer 3 = king pin 4 = plug 5 = stub axle 6 = hex. hd. screw 7 = nut 8 = spacing washer 9 = wiper ring 10 = tapered roller bearing 11 = grease nipple 12 = tapered roller bearing 13 = wiper ring 14 = 0 ring 15 = spacing washer - Remove the wheel.

- Press out the pin located between track rod and stub axle, - Slacken nut (1).

- Remove washer (2).

- Press the king pin (3) down through the stub axle and remove the king pin.

- Remove the stub axle from the axle.

- Remove from the stub axle: spacing washers, 0 ring, wiper rings and tapered roller bearings (items 8-15).

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Workshop Manual R 7044 - 46

Steer axle fitted with a double acting steer cylinder Stub axle - Reassembling and Installation 1 = nut 2 = washer 3 = king pin 4 = plug 5 = stub axle 6 = spacing washer 7 = wiper ring 8 = tapered roller bearing 9 = tapered roller bearing 10 = wiper ring 11 = 0 ring 12 = spacing washer 13 = pin - Install both tapered roller bearings (8 & 9) after having first repacked them with a sufficient amount of FL grade greasel - Apply a smear of FL grade grease to the sealing lips of the wiper rings (7 & 10).

- Install wiper rings (7 & 10), 0 ring (11) as well as both spacing washers (items 6 & 12).

- Install the stub axle into the axle beam.

- Drive in the king pin (3) from below after having first applied a light smear of oil to it. Pressing force 80 KN max.

- Fit the washer (2) into position on the king pin.

- Install a new nut (1) and tighten to a torque of: MA = 600 Nm. - Press the pin (13) into the track rod and secure with roll pins.

- Install wheel.

Lubricate the steer axle with FL grade grease.

Lubricating the steer axle with FL grade grease - Operate the linkage during steering.

- Using a grease gun, lubricate with FL grade grease the fittings with which the steer axle is equipped until a small amount of fresh grease oozes out at the lubricating points.

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Steer axle fitted with a double acting steer cylinder Track rod removal The steer axle is fitted with two track rods arranged between the steering cylinder and the two stub axles.

1 = stub axle 2 = piston rod 3 = sealing rings 4 = roll pins 5 = pin 6 = track rod 7 = ball joint - Remove the roll pins (4) - Using a press, press out the pins (5) Track rod installation Reverse the removal procedure Install pins cylinder end with a maximum press force of 50 kN and pins stub axle end with a maximum press force of 57 kN NOTE: Treat the pins with MoS 2 prior to installation.

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Steer axle fitted with a double acting steer cylinder Steering cylinder removal - Remove track rods.

- Disconnect hydraulic connections.

WARNING: Hydraulic oil may spill when disconnecting lines; be prepared for oil spillage!

- Slacken the four fixing screws (1).

Steering cylinder installation - Retighten the fixing screws (1).

Torque loading: MA =1050 Nm - Reconnect hydraulic connections.

CAUTION: Do not swap hydraulic connections.

- Install track rods.

IMPORTANT: For steering cylinder dismantling and reassembling refer to F.G. 06.

Lubricating the steer axle with grease Operate the linkage during greasing while the steer axle is off load.

Using a grease gun, lubricate with FL grade grease the 8 fittings with which the steer axle is equipped until a small amount of fresh grease oozes out at the lubricating points.

NOTE: When lubricating the upper bearing, the grease need not ooze out of the upper sealing ring, it may also escape from the bottom.

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Workshop Manual R 7044 - 46

Technical Data for Maintenance service Gearbox GR 80 Torque loading

Drive unit* mounting bolts M24x70 8.8 MA 660 Nm

Torque loading

Gear reduction box* mounting bolts M16x50 10.9 MA 275 Nm

Torque loading

Drive motor* mounting bolts M10x75 8.8 MA 46 Nm

Torque loading

Tachogenerator fixing screws M6x10 8.8 MA 9.5 Nm

Torque loading

Caliper fixing screws M12x30 8.8 MA 80 Nm

Torque loading

Cross member fixing screws MA 940 Nrn

Gearbox oil

SAE 90 Capacity: approx. 1.2 litres per gear reduction box

Grade of grease

lithium soap based grease

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Workshop Manual R 7044 - 46

Wheel Drive

The drive consists of a left and a right reduction gear (1& 2).

Drive motor (3A), gear reduction box (1& 2) and flange form an assembly.

Each drive unit is bolted to the truck frame by means of 8 bolts with tension washers and a flange..

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Workshop Manual R 7044 - 46

Intermediate flange

Item 1

Description Radial sealing ring 72x95x10 BA

2

Circlips DIN 472

3

Cylindrical roller bearings DIN 5412

4

Flange

5

Tension washer

6

Hex hd screw M 10x75 8.8

7

Wheel reduction gear

8

0-ring seal 180x4

9

Tension washer

10

Hex hd screw M 16x50 10.9

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Workshop Manual R 7044 - 46

Wheel reduction gear/ Frame

Flange

1. Hex hd bolt M24x85 8.8 MA = 660 Nm 2. Hex hd bob MA 940 Nm 3. Hex hd bolt M24x70 8.8 MA = 660 Nm 4. Hex hd bolt M24x50 10.9 MA = 940 Nm

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