Still Forklift R70-15 Series Service Repair Manual

WORKSHOP - MANUAL R 70-15 / 16

R 7011 / 7031 Ident-No.: 1640726

(ex145 907)

STILL GmbH Stand: 8/1994 ( Ersatz für Stand:

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Workshop Manual R 7011(R 7031, R 7001)

01 Frame and Counterweight

Frame The welded steel frame is of unit construction and has a bolt-on cast iron counterweight.

The hydraulic oil tank serves as a frame crossmember between the leg and engine compartments.

The front cowl is bolted to the frame.

Counterweight The removable rear counterweight is secured to the frame by 3 bolts. (See sketch).

All the counterweight bolts should be torqued to 710 Nm. 1 = Hex hd bolt 2 = Ball cup 3 = Spherical washer 4 = Hex hd bolt 5 = Spring washer

M 24 x 85 DIN 933 DIN 6319 D 28 DIN 6319 C 25 M 24 x 60 DIN 933 DIN 127 A 24

Weight of the counterweight: 900 kgs

STILL GmbH Stand: 8/2004 ( Ersatz fĂźr Stand: 1986 )

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Workshop Manual R 7011(R 7031, R 7001)

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Technical Data for Maintenance Service Trail Axle Trail axle mounting bolts

MA = 195 Nm

Wheel hub bolts

MA = 22.6 Nm

Axial play of wheel hub

0.15 - 0.25 mm

Wheel lock angles

80 - 820 the complementary angle to 180° is measured

Press force for steer cylinder mounting pin

max. 68 kN

Press force for bellcrank mounting pin

max. 42 kN

STILL GmbH Stand: 8/2004 ( Ersatz fĂźr Stand: 1986 )

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Workshop Manual R 7011(R 7031, R 7001)

02 Trail/Steer Axle

Description The articulating steer axle suspended from the counterweight is mounted in neoprene blocks. King pins are mounted in needle bearings for easy steering.

Steering is limited by stop screws on the axle. Articulation is limited by stops on the counterweight.

Steering axle removal For steering axle removal, disconnect the power steer cylinder pipes and remove the cap screws (3) holding the fixing plates in position.

To install the steering axle, reverse the removal procedure.

Torque loading: MA = 195 Nm. Note: Do not interchange hyd. connections left and right!

Wheel hubs The wheel hubs are mounted on taper roller bearings. The wheel hub and the end of the axle are precision engineered, to eliminate the need for adjusting the bearing clearance by adding for removing shims.

Axial play = 0. 15 - 0.25 mm.

Wheel hub removal Pull hub cap (4) from wheel. Remove locking bolts (1) securing thrust washer (5). Next, remove thrust washer (5) together with roll pin (6). Remove the inner race (2) of outer taper roller bearing from the end of the axle and withdraw the wheel hub (7).

Wheel hub installation.

When installing the wheel hub (7) tighten the hex head locking bolt (1) while rotating the wheel hub.

Torque loading: MA = 22.6 Nm. Secure locking bolt (1) with Loctite 242.

Prior to assembly, apply grease between inner race and cage of taper roller bearing.

Only inner and outer races (2) of same make should be used.

When installing the wheel bearings, the corresponding bearings spaces must be repacked with grease, as shown in figure (3).

Before re-assembling the hub, carefully grease the sealing lip of the sealing ring (8).

Grade of lubricant to be used: Lithium soap based grease.

STILL GmbH Stand: 8/2004 ( Ersatz fĂźr Stand: 1986 )

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Workshop Manual R 7011(R 7031, R 7001)

Trail/Steer Axle Setting both steering angles The wheel lock is limited by the stop screw (1).

Note: Ensure that the wheel lock is limited by the stop screw and not by the cylinder stroke, and that there is sufficient clearance between the piston rod and the stub axle.

Checking the steering angles The steering angle á must amount to 80° -82°, see figure.

To facilitate the measurement use the complementary angle ß for the setting. It should amount to 98° - 100°.

Greasing the stub axle bearings Operate the linkage during greasing.

Note: In order to ensure that the bearings are sufficiently greased, the axle must not be off load, i. e. the truck should not be chocked up.

Right-hand bend

Left-hand bend

á = 80° - 82° steering lock

STILL GmbH Stand: 8/2004 ( Ersatz für Stand: 1986 )

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Workshop Manual R 7011(R 7031, R 7001)

02 Trail/Steer Axle

Stub axle king pin bearings Removal: Remove grub screw (1).

Using a chisel (or similar tool) open needle bearing at the top of the king pin.

Drive king pin down, forcing out bearing at the bottom of the king pin.

Then drive out king pin in the opposite direction.

Installation: Pack lower bearing (6) with grease, sparingly apply loctite grade 270 to the outside, and press it into its bore until flush.

Install oil seal (2).

The sealing lip must point away from the bearing.

Install stub axle with thrust bearing (3) into axle beam.

Compensate for any play by adding shims (4).

Max. permissible axial play = 0.1 mm.

Grease shims and machined surfaces.

Install oil seal (5).

The sealing lip must point away from the bearing.

Install stub axle king pin and lock with grub .screw (1 ).

Install grub screw (1), with thin coating of loctite grade 242.

Pack upper bearing (7) with grease, sparingly apply loctite grade 270 to the outside, and press it in.

STILL GmbH Stand: 8/2004 ( Ersatz fĂźr Stand: 1986 )

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Workshop Manual R 7011(R 7031, R 7001)

02 Trail/Steer Axle

Track rod and steer cylinder bearing at stub axle 1 2 3 4 5 6 7 8

= mounting/steer cylinder = grease nipple = oil seal = stub axle = track rod = bearing = washer = circlip

Track rod bearing on steering bell crank 1 2 3 4 5 6

= bearing inserted with Loctite 270 = pin = grease nipple = track rod = oil seal = steering bell crank

STILL GmbH Stand: 8/2004 ( Ersatz fĂźr Stand: 1986 )

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Workshop Manual R 7011(R 7031, R 7001)

02 Trail /Steer Axle

Detail ‘W’ Steer cylinder mounting at axle beam 1= 2= 3= 4 5 6 7 8

= = = = =

snap ring roll pin fillister head cap screw (secured with Loctite) washer oil seal ball joint oil seal pin

Press force: 68 kN at the maximum Detail “Y” Bellcrank mounting 1 2 3 4 5 6 7 8 9

= locking ring = washer = needle bearing = pin = oil seal = shim (quantity as required) = washer (must always be fitted) = grease nipple = snap ring

Press- force: 42 kN at the maximum

STILL GmbH Stand: 8/2004 ( Ersatz für Stand: 1986 )

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Workshop Manual R 7011(R 7031, R 7001)

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Technical Data for Maintenance Service Power Axle Torque loading

Power axle mounting bolts 195 Nm

Torque loading

Axle housing mounting bolts 120 Nm

Axial clearance

Hollow shaft: 0.05 mm at the maximum

Axial clearance

Wheel hub: 0.07 mm pre-load -

Axial clearance

Wheel hub: 0.21 mm slackness

Grade of grease

lithium soap based grease

Torque loading

Wheel hub/Slotted nut 180+20 Nm

Gearbox oil

Capacity: approx. 2 litres

Grade SAE - 80 MIL - L - 2105 API - GL 4 9

STILL GmbH Stand: 8/2004 ( Ersatz fĂźr Stand: 1986 )

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Workshop Manual R 7011(R 7031, R 7001)

03 Power Axle

Description The power axle consists of a double reduction spur-type gearbox (1) comprising differential assembly with two-bearing driving pinion, to which a D. C. electric motor (2) is flange mounted, as well as of a long axle housing (3) and an axle housing which is an integral part of the gear case (1).

STILL GmbH Stand: 8/2004 ( Ersatz fĂźr Stand: 1986 )

The long axle housing (3) with the double reduction spur-type gearbox (1) are rigidly bolted to the frame as a complete unit.

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Workshop Manual R 7011(R 7031, R 7001)

Power Axle Double reduction gear and differential

         

  

STILL GmbH Stand: 8/2004 ( Ersatz für Stand: 1986 )

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Workshop Manual R 7011(R 7031, R 7001)

03 Power Axle

1-2= gear case with integral axle housing 3 = cylindrical pin 4 = Allen head screw 5 = sealing ring 6 = screw plug (oil drain plug) 7 = grooved ball bearing 8 = differential 9 = gear 10 = hex hd screw 11 = roll pin 12 = taper roller bearing 13 = gear shaft 14 = shim 0.1, 0.3, 0.5, 1 mm 15 = circlip 16 = cover 17 = driving dog 18 = shaft sealing ring 19 = taper roller bearing 20 = toothed hollow shaft 21 = ‘0’ ring seal 22 = shim 0.1, 0.3, 0.5, 1 mm 23 = ring 24 = ‘0’ ring seal 25 = shaft sealing ring 26 = cover 27 = Allen head screw 28 = Allen head screw

STILL GmbH Stand: 8/2004 ( Ersatz für Stand: 1986 )

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Workshop Manual R 7011(R 7031, R 7001)

03 Power Axle

Axle housing installation Clean contact areas of gear case and axle housing.

Provide ‘O’ ring seal (2) with a smear of grease and place it on the recess of the axle housing (3). Next, assemble the axle housing with the gear case.

Apply loctite grade 270 to the 12 screws (4) and torque to 120 Nm.

STILL GmbH Stand: 8/2004 ( Ersatz für Stand: 1986 )

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Workshop Manual R 7011(R 7031, R 7001)

03 Power Axle

Half -shaft removal - Jack up truck securely from one side, otherwise drain gearbox oil - Remove wheel nuts - Remove drive wheel - Remove screws (10) securing shaft (7) to hub. Using two of the screws drive out the half shaft (7).

Two appropriate tapholes exist in the shaft flange - Remove shaft (7) Note: When carrying out repairs or maintenance operations on the half-shafts remove only one at a time.

Reason: Should both half-shafts (long and short shafts) be removed at the same time, the position of the half-shaft location inside the differential will be modified, making half-shaft installation impossible.

STILL GmbH Stand: 8/2004 ( Ersatz fĂźr Stand: 1986 )

Half -shaft installation - Clean sealing surface of half-shaft (7) and apply loctite grade 573 to sealing surface - Install shaft (7) - Torque shaft mounting screws to MA = 35 Nm - Replace drive wheel. Watch for correct alignment of holes for wheel brake adjustment - Torque wheel nuts to 195 Nm - Jack down the truck - Check half -shaft for leaks

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Workshop Manual R 7011(R 7031, R 7001)

03 Power Axle

Wheel hub removal - Jack up truck securely from one side (otherwise drain gearbox) - Remove half-shaft as described in section ‘Half -shaft removal’, page 9 - Remove brake drum (5) - Remove slotted nut (1) - Remove washer (2) Important: Note the position of the washer which is may be turned off at one side.

- Place fitting tool (self-made tool - see figure) into axle housing, and using a puller, pull wheel hub from axle housing.

- Inner race (9) of bearing can now be withdrawn from axle housing using puller.

STILL GmbH Stand: 8/2004 ( Ersatz für Stand: 1986 )

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Workshop Manual R 7011(R 7031, R 7001)

03 Power Axle

Wheel hub installation - Thouroughly clean wheel hub - Press both taper roller bearings complete only into wheel hub.

In the event of repairs of maintenance work on the wheel hub the taper roller bearings must always be replaced with new ones comprising a sealing ring (8).

Note: The taper roller bearings are provided with sealing rings which are installed at the factory with a special device. The taper roller bearings should therefore never be disassembled.

- Check grease filling of bearings, repack with grease if necessary. Grade of lubricant to be used: lithium soap based grease - Position wheel hub on axle housing - Place fitting tool (self-made tool - see figure) on outer bearing, and using a twoarmed claw puller or extractor slide hub with taper roller bearings on axle housing (puller claws behind brake anchor plate) Note: Do not hit or apply blows with a hammer, otherwise the sealing rings could fall off their locations - Fit washer (2) to axle housing (watch for correct fitting position) - Install new slotted nut and torque to 180+20 Nrn - Install brake drum (hole for wheel brake adjustment should align_with opening in wheel hub) - Axial clearance betw een 0.07 mm preloaded and 0.21 mm slackness - Install half -shaft (seepage 9)

STILL GmbH Stand: 8/2004 ( Ersatz fĂźr Stand: 1986 )

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Workshop Manual R 7011(R 7031, R 7001)

Power Axle Replacing the shaft sealing ring Remove the wheel nuts of the LH front wheel and pull wheel from the lift truck. 

By passing an Allen key through a hole in the frame loosen and remove screws securing tachogenerator to axle gearbox.

Remove tachogenerator together with driving dog.

Using a drawing point or similar tool remove shaft sealing ring (1) by pulling it in your direction.

Apply grease to new shaft sealing ring (1) -see sketch.

Lightly lubricate the borehole with oil.

Install shaft sealing ring (1) into the borehole provided to this end, and using a guide tube (see tool assembly drawing below) bring it into its correct position.

Note: Check driving dog (2) in hollow shaft (3) for correct press -in depth (15 mm) and truth.

Refit driving dog and tachogenerator. Refer to Functional Group 08 ‘Tachogenerator’.

Install the front wheel in reverse order of removal.

Torque wheel nuts to 195 Nm.

STILL GmbH Stand: 8/2004 ( Ersatz für Stand: 1986 )

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Workshop Manual R 7011(R 7031, R 7001)

Wheels and Tyres Synoptical Table on Tyres Pneumatic tyres Size

Track/mm

front rear

18x7-8 IC 11 16PR STD. 16x6-8 10PR STD.

897 882

front rear

18x7-8 IC 11 16PR 16x6-8 10PR

997 882

Mast

Tele Hi-Lo Triple

Tele Triple

O.L.H.*

mm

...2730 ...2530 ...1930 2731 ... 3230 1931 ... 3230

Superelastic (puncture- proof) tyres front rear

18x7-8 DIN 16x6-8 DIN

897 882

front rear

18x7-8 DIN 16x6-8 DIN

997 882

front rear

18x7-8 SIT 16x6-8 SIT

897 882

front rear

18x7-8 SIT 16x6-8 SIT

997 882

Tele Hi-Lo Triple

Tele Triple

Tele Hi-Lo Triple

Tele Triple

* Overall lowered height

Ball seat nut: Torque loading = 195 or 210 Nm

STILL GmbH Stand: 8/2004 ( Ersatz für Stand: 1986 )

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...2730 ...2530 ...1930 2731 ... 3230 1931 ... 3230 ...2730 ...2530 ...1930 2731 ... 3230 1931 ... 3230

Workshop Manual R 7011(R 7031, R 7001)

04 Wheels and Tyres

Pneumatic tyred wheel 1-6= Tyres front AB 1-3= Tyre, COMPL. 18x7-8 16PR 2 = Tube 180-8 VTL 3 = Flap 4 = Disk wheel without rings 5 = Side ring 6 = Lock ring 7 = Ball seat nut 8 = Spacer B 9 = Ball seat bolt B 11 - 16 = Tyres rear AB 11 - 13 = Tyre, COMPL. 16x6-8 10PR 12 = Tube 13 = Flap 14 = Disk wheel without rings 15 = Side ring 16 = Lock ring Note: Where the axle is fitted with spacers, ball seat type wheel nuts on spacer must be checked for correct torque at regular intervals to which end it is necessary to remove the wheels.

Torque loadings Ball seat type wheel nuts front and rear M14 x 1.5 MA: 195 Nm Ball seat type wheel bolts (for increased track width) M 14 x 24 Grade 10.9 MA: 195 Nm Important: Torque loadings for ball seat type wheel nuts/bolts: 1) without aftertreatment (black nuts/bolts) 210 Nm 2) galvanically aftertreated (bright nuts/bolts) 195 Nm

STILL GmbH Stand: 8/2004 ( Ersatz fĂźr Stand: 1986 )

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Workshop Manual R 7011(R 7031, R 7001)

04 Wheels and Tyres

Superelastic tyred wheel with lock rings 1--4= Tyres front AB 1 = Superelastic tyre 18x7-8 2 = Disk wheel without rings 3 = Side ring 4 = Lock ring 5 = Ball seat nut 6 = Spacer B 7 = Ball seat bolt B 10- 13 = Tyres rear AB 10 = Superelastic tyre 16x6-8 11 = Disk wheel without rings 12 = Side ring 13 = Lock ring Note: Where the axle is fitted with spacers, ball seat type wheel nuts on spacer must be checked for correct torque at regular intervals to which end it is necessary to remove the wheels!

Torque loadings Ball seat nuts front and rear M 14x 1,5 MA: 195 Nm Ball seat bolts (for increased track width) M 14 x 24 Grade 10.9 MA: 195 Nm Important: Torque loadings for ball seat nuts/bolts: 1) without aftertreatment (black nuts/bolts) 210 Nm 2) galvanically aftertreated (bright nuts/bolts) 195 Nm

STILL GmbH Stand: 8/2004 ( Ersatz fĂźr Stand: 1986 )

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Workshop Manual R 7011(R 7031, R 7001)

04 Wheels and Tyres

Superelastic tyred wheel without lock rings 1-2= Tyres front AB 1 = Superelastic tyre 18x7-8 2 = Disk wheel without rings 3 = Ball seat nut 4 = Spacer 5 = Ball seat bolt 10- 11 = Tyres rear AB 10 = Superelastic tyre 16x6-8 11 = Disk wheel without rings Note: Where the axle is fitted with spacers, ball seat type wheel nuts on spacer must be checked for correct torque at regular intervals to which end it is necessary to remove the wheels!

Torque loadings Ball seat nuts front and rear M 14x 115 MA: 195 Nm Ball seat bolts (for increased track width) M 14 x 24 Grade 10.9 MA: 195 Nm Important: Torque loadings for ball seat nuts/bolts: 1) without aftertreatment (black nuts/bolts) 210 Nm 2) galvanically aftertreated (bright nuts/bolts) 195 Nm

STILL GmbH Stand: 8/2004 ( Ersatz fĂźr Stand: 1986 )

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