Still Forklift R70-70 Series Service Repair Manual

Workshop ManualR 7044 -

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 alowertransverse web(2)are bolted dirctly on the frame.

Thefueltankispositionedwithintheright-handframe section, whereas the hydraulictankis housed within the left-hand frame section. Made of plastics, both tanks are slid in placeintothe framesection fromthe counterweightend.

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

10 = cross member

11 = hex hd screw M24x50 10.9

MA = 940 Nm

12 = tension washer

13 =lowertransverse 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

Should one or both of the frame sectionshave beenremoved, replacingmustbeeffectedin the sequence shownbelow.

1Fittheintermediateflangeintopositionontheframe and tighten the retaining screws by hand

2Bolt the counterweight on the frame. Do not fully tighten the bolts at this stage

3Assemble thelowertransversewebonto theframe andintermediateflange

4Fit the upper cross member into position. Tighten the retaining screws by hand

5Align the frame sections

6Tightenthecounterweightretainingboltstoatorque of MA= 660 N m

7Check spacing between both frame sections. should be 1080 ± 1 mm

8To replace the electric drive motors with their respective reduction gearremovecrossmember

9Assemble the lower transverse web with intermediateflangeandcrossmembertotheframe. 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

Workshop ManualR 7044 - 46

Technical Data for Maintenance Service

Steer axle

Wheel lock angle80-82°

Toe-in0±1 mm

Wheel camber0° Trail0°

Torque loading

Steer axle fitted with a single acting steer cylinder

Wheel hubMA=170 Nm

Axle bearingsMA =385 Nm

TrackrodMA =140 Nm

Eyebolt (bearing socket) for steer cylinderpiston rodMA =80 Nm

Steer axle fitted with a double acting steer cylinder

Wheel hubMA=150 Nm

Wheel nutsMA =640 Nm

Axle bearingsMA =385 Nm

Steercylinder fixingMA=1050 Nm

Nut on king pinMA =600 Nm

Lubricants

Wheel hubbearingsGrease Fto DIN 51825-KP2K-20, lithiumsoap based Grease Fto DIN 51825-KP2K-30, lithiumsoap based

Stub axle bearingsGrease FL,DIN 51825-KPF2N-20,lithiumsoap based

STILLIdent.No.148659

Workshop ManualR

Mechanical configuration of steer axle

The articulating steer axle suspended from the rear counterweightis mounted in a self-aligning bearing. The stub axles are supported in the axle beam on bushings and thrust bearings. Sleering is limited by stopscrewsontheaxlebeamrightandleft.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 preventrolling ofthe truck.Applythe handbrake.

-Disconnect hydraulic lines at steer cylinder. CAUTION:prepare foroilspillage.

-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 theforkendsofthehandpallettruck.Usinga1500 mmlong leverrod,drive axle bearing (1)outofthe 4 roll pins (2) and lower the axle onto the hand pallet truck.

Steer axle installation

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

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 screwAM 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:Steeraxle removal.

- Slacken hex nut (11)

- Remove hex hd screw (10)

- Remove hex hd screws (1)

-Removewashers(3)

- Drive outaxle bolt(5)

- Drive outbushings(4)ifnecessary

-Removebearingsupport(6)

Axle bearing - Reassembling

-Reversethedismantlingprocedure

-If necessary,compensate for end play in bearing supportby adding shims(7)(three different thicknesses are available as per partscataloque).

-Make sure the bushings are installed in the correctposition.

* the slot of the bushing may alternatively point in one or the other of the directios, as illustrated

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 seatnut(11)and remove wheel

-Removehubcap(10)

-Remove cotterpin(9)

-Removecastlenut(8)

--Remove wheel hub (5) If necessary, drive out of wheel hub outer races of tapered roller bearings (4)and(6)Withdrawtaperedrollers(4)andchevron seal (3) from the stub axle

Trail wheel hub - Reassembling

-Reversethedismantlingprocedure

-Before reassemblingthe wheel hub, firstfill cavity of tapered roller bearing and bearing cage with grease. Cavitiesshould 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 correctlythe lips side should face towards the axle baem

-Torque crown nut (8) to 170 Nm, then backoffthe nut until the next cotter pin hole appears

-Install cotter pin and lock

Workshop

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:

-Removecap(1)

-Remove cotterpin(2)

-Removecastlenut(3)

-Removewasher(4)

-Withdraweyebolt (7)

-Drivepin(13a)outofstubaxle(10)(protectthreads)

2. Dismantling at steering arm

-Remove cotterpin(2)

-Removecastlenut(3)

-Drive pin oftrack rod (13) out of steering arm (14)

Track rod installation

-Reversetheremovalprocedure

- Torque both castle nuts (3) to 140 Nm 02

Workshop ManualR

StubAxles - 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„7rackrodremoval“)

-Removehollowcap

-Remove grubscrew(11) (secured withLoctite)

-Drive king pin (18) outofsteer axle

-Removestub axle (10)fromsteer axle

-Driveoutbushings(17)

Stub Axles - Reassembling

-Tap bushings (17) in place with an installer. Make certain bushings are installed in their orginal position.The slotofthe bushings mustpointeither forward orbackwardasshowninthelowerdrawing

-Insertstubaxle(10)withthrustbearing(9)andshim (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)Maximumpermissable endplay

=< 0. 1 mm

-Press in the king pin (18) from below

-Refitcap (16)

-Install hallow screw (15)

-Apply Loctite242 to grubscrew (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

Fittingpositionofbushings (17)

* theslot ofthebushings (17)mayalternativelypoint in one or the other of the directions, as illustrated

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 hexhd bolt(4)

-Removewasher(5)

- Withdraw bearings(6) + (7) if necessary

Steering arm - Reassembling

-Reversethedismantling procedure

- Clean hex hd bolt(4) in a degreasing agent,apply Loctite 242 and tighten to a torque of 86 Nm

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

Steer cylinder removal

1.Remove from the stub axle:

1.1the eyebolt (6) - for disassembly see page 5 ofFunctional Group02 „Trackrod removal“

1.2Removingthe piston rod (7) fromthe eyebolt (6)

- slacken hex hd bolt (8)

- screw off piston rod (7) fromeyebolt

2.Removing the cylinder from the axle beam

- remove hexhd bolt(3)

-removewasher(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 ofremoval

Detail „Z“

Workshop ManualR

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Checking the steering angles

The steering angle must amount to 80° - 82°. To facilitate the measurement use the complomentary angle forthesetting.Itshouldamountto98°-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

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°

-Checkopposite angles.

-Checkforadequateclearancebetweenwheelsand truck frame.

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

Right-handbend

Left-handbend

Steer axle fitted with a double acting steer cylinder

Configuration of steer axle

The articulating steer axle suspended from the counterweightismountedin2 neoprene blocks.The stubaxlesaresupportedintheaxlebeamon tapered rollerbearings.Steering is limited by stopscrews 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! Riskoftipping!

-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 frontofthe axle.

-Removewheels

- Disconnect the hydraulic connections at steer cylinder.

-Remove the foursocket head screwswhich retain the steer axle in place.

CAUTION: Prepare for oil spillage when disconnectingthe hydraulic connectionsICatch 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 blocksplacedon theforkendsofthehand pallet truck.

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

Steer axle installation

-Reversetheremovalprocedure.

-The slots of the roll pins must face the direction of forwardtravel.

-Torque socket head screws to: MA = 385 Nm CAUTION:Donot swaphydraulic connections left and right!

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 rollerbearing

11 = wheel bolt

12 = ball seat nut

-Slacken ball seat nuts (12) and remove wheel.

-Pull hub cap (7) from wheel.

-Removesplit-pin(6).

-Removewasher(9).

-Withdraw the hub.

-Removeradialsealingring(3)thenremovetapered rollerbearings(4)and (10)fromhub.

-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-assemblingthehub, repack with grease F: cavity between inner race and bearing cage of tapered roller bearings, and thebearingspacesidentifiedbyanVonthedrawing.

-To reassemble the hubs,reverse the procedure.

- Tighten castle nut(8) while rotating the wheel hub. Ifnecessary, slightlyturn back the nut until the last castellationalignswiththesplit-pinholeforinsertion ofthe split-pin.Torque loading:

MA = 150 Nm

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 forthesetting.Itshould amountto98°-100°.

IMPORTANT: Ensurethatthewheellockislimited by the stop screws (1) and not by the cylinder stroke.

Wheel angle stop adjustment

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

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

-Checkopposite angles.

-Checkforadequateclearancebetweenwheelsand truck frame,

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

Right-handbend

Left-handbend

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 rollerbearing

11 = grease nipple

12 = tapered rollerbearing

13 = wiper ring

14 = ‘0’ ring

15 = spacing washer

-Removethewheel.

-Press out the pin located between track rod and stub axle,

-Slacken nut (1).

-Removewasher(2).

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

-Remove the stub axle from the axle.

-Remove from the stub axle:spacing washers, ‘0’ ring,wiperringsandtapered roller bearings (items8-15).

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 themwith 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

-Operatethe linkage duringsteering.

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

Track rod removal

Steer axle fitted with a double acting steer cylinder

The steer axle is fitted with two track rods arranged between thesteeringcylinderand thetwostubaxles.

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 50kN and pins stub axle end with a maximum press force of 57kN

NOTE: Treat the pins with MoS2 prior to installation.

Steer axle fitted with a double acting steer cylinder

Steering cylinder removal

- Remove track rods.

- Disconnecthydraulic connections.

WARNING: Hydraulicoilmayspillwhendisconnectinglines; 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 hydraulicconnections.

CAUTION: Do not swaphydraulic 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 amountoffresh grease oozesout atthe 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.

Workshop ManualR 7044 - 46

Technical Data for Maintenance service

Gearbox GR 80

Torqueloading Drive unit* mounting bolts M24x70 8.8 MA660 Nm

Torqueloading Gear reduction box* mounting bolts M16x50 10.9 MA 275 Nm

Torqueloading Drive motor* mounting boltsM10x75 8.8 MA 46 Nm

TorqueloadingTachogenerator fixing screws M6x108.8 MA9.5Nm

Torqueloading Caliper fixing screws M12x30 8.8 MA 80 Nm

Torqueloading Cross memberfixing screws MA 940 Nrn

GearboxoilSAE 90

Capacity:approx. 1.2 litres per gear reduction box

Gradeofgrease lithium soap based grease

The drive consistsofa leftand arightreduction gear (1&2).

Drivemotor(3A),gearreductionbox(1&2)andflange form an assembly.

Eachdrive unitis boltedtothe truckframe bymeans of 8 bolts with tension washers and a flange..

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.Hexhd bolt M24x50 10.9 MA = 940 Nm