Still r70 80 diesel fork truck service repair manual

01
Workshop manual 7087- 89
1
Table of contents Page
Chassis and counterweight 1
Jacking up the vehicle 2

4
6
2
5
7
1
3
01
Chassis and counterweight
3
The chassis is a welded construction.
The chassis and counterweight are bolted together
with 8 hexagon bolts (1) M24x180.
Bolt tightening torque(1) : 660 Nm
Weight of counterweights:
7087 - 4392kg
7088 / 7089 - 5418 kg
1 - SKS (8x) M24 x 180 8.8 660 Nm
2 - SKS (2x) M24 x 65 8.8 660 Nm
3 - SKS (12x) M24 x 50 10.9 939 Nm
4 - SKS (10x) M24 x 85 8.8 660 Nm
5 - SKS (2x) M27 x 170 10.9 940 Nm
6 - SKS (6x) M24 x 70 8.8 660 Nm
7 - SKS (4x) M24 x 50 10.9 930 Nm

Attention!
Before jacking up the vehicle, apply the parking
brake!
The fork truck must be jacked up for various
maintenance work. When jacking up the fork truck,
suitable measures must be taken to prevent the
truck slipping or tilting, e.g. wooden blocks.
Only jacks with sufficient bearing capacity must be
used and the fork truck must be jacked up only on
a level surface and secured to prevent it rolling.
Only jack up the fork truck at the points shown in
the diagrams, i.e. on the left or right of the mast
and at the counterweight.
When jacking up the fork truck at the mast, the
safety regulations for working on masts must be
observed.
01 Workshop manual 7087- 89
Jacking up the vehicle
4

1
02
Technical service data 
Steering axle design 3
Removing the steering axle 3
Fitting the steering axle 3
Removing the wheel hub 4
Fitting the wheel hub 4
Adjusting the steering angle 5
Checking the steering angle 5
Removing the stub axle 6
Fitting the stub axle 7
Greasing the running axle 7
Removing the tie rods 8
Fitting the tie rods 8
Removing the steering cylinder 9
Fitting the steering cylinder 9
Steering axle

2
Steering axle
Technical service data
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3
02
Steering axle
Steering axle design
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.
Steering limitation takes place via stop bolts in the
stub axle.
1 Axle body
2 Fixing plates
3 Hexagon bolt
4 Lock washer
5 Buffer elements
Removing the steering axle
CAUTION: Only remove steering axle with the mast
mounted! Risk of tilting!
- Apply the hand brake.
- Place wooden wedges under the front wheels to
prevent the vehicle from rolling.
- Loosen the wheel nuts on the steering axle
wheels.
- Jack up the vehicle as directed (see Group 01).
- Remove the wheels.
- Unscrew the hydraulic connections of the
steering cylinder.
CAUTION: When unscrewing the hydraulic
connections, hydraulic oil will discharge.
Collect the hydraulic oil and dispose of it in a
proper manner.
- Place a hand pallet truck or similar with timbers
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
- Tightenting torque of the 4 cheese head screws:
385 Nm
CAUTION: Take care not to confuse the left and
right hydraulic connections!

4
1
2
3
4
6
5
9
10
7
8
11
12
02
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
11 Wheel bolt
12 Nut
- Loosen the nuts (12) and remove the wheel.
- Remove the dust cap (7).
- Loosen the hexagon nut (8).
- Remove the washer (9) with the pin (6).
- Remove the wheel hub.
- Remove the taper roller bearings (4) and (10)
from the wheel hub; the seal (3) must be
removed for this purpose.
- If necessary, remove the outer rings of the
taper roller bearings (4) and (10).
Fitting the wheel hub
- Thoroughly grease the sealing lips of the
radial seal.
- Fill the taper roller bearings with grease F
between the inner ring and cage.
- Fill the bearing spaces with grease F at the
marked points (x).
- Fitting takes place in reverse order to
removal.
- Tighten the hexagon nut (8) while
continuously turning the wheel hub.
Tightening torque: MA
= 150 Nm
Steering axle

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

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

7
1
2
3
12
14
5
4
8
7
6
10
11
13
9
02
Steering axle
Fitting the stub axle
1 Hexagon nut
2 Washer
3 King pin
4 Plug
5 Stub axle
6 Spacer
7 Scraper ring
9 Spacer
11 Scraper ring
12 O-ring
13 Spacer
14 Bolt
- Fit the spacer (9) in the stub axle.
- Fit the two taper roller bearings (8+10).
Grease both bearings with grease FL!
- Thoroughly grease the sealing lips of the scraper
rings (7+11) with grease FL.
- Fit the scraper rings (7+11), both spacers (13, 6 )
and the O-ring (12).
- Insert the stub axle into the axle.
- Insert the king pin (3) from below, lightly oil the
pin.
- Fit the washer (2).
- Fit a new hexagon nut (1) and tighten with a
tightening torque of:
MA
= 600 Nm
- Press in the bolt (16) of the tie rod and secure with
pins.
- Mount the wheel.
- Grease the steering axle with grease FL.
- The steering must be operated while greasing.
- Grease the eight nipples of the steering axle with
grease FL, until gresh grease discharges at the
bearing points (see diagram on Page 8).

8
3
4
4
5
02
Removing the tie rods
The steering axle has two tie rods, which are seated
between the steering cylinder and the two stub axles.
1 Stub axle
2 Piston rod
3 Seals
4 Pins
5 Bolts
6 Tie rod
7 Ball socket
- Remove the pins (4)
- Press out the bolts (5)
Fitting the tie rods
- Fitting takes place in reverse order to removal.
Press in force of bolts on cylinder side:
max. 21 kN
Press in force of bolts on stub axle side:
max. 26 kN
Steering axle

9
2 2 2 2
02
Steering axle
Removing the steering cylinder
– Remove the tie rods.
– Unscrew the hydraulic connections and mark.
ATTENTION: Hydraulic oil discharges
– Loosen the four fixing bolts (1).
Fitting the steering cylinder
– Tighten the fixing bolts (1).
Tightening torque: MA
= 1050 Nm
– Screw on hydraulic connections.
ATTENTION: Do not confuse the hydraulic
lines.
– Fit the tie rods.
NOTE: See instructions for removing and
fitting the steering cylinder under Group 06.
Greasing the steering axle
– Relieve the steering axle while greasing and
operate the steering.
– Grease the eight nipples (2) of the steering axle
with grease FL, starting with the top nipple until
fresh grease discharges at the bearing points.
NOTE: While greasing the upper bearing, grease
may not necessarily discharge from the upper
seal. It can also discharge downwards.

Wheels and tyres
2
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8 m
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.
6 m
N
0
4
6

1
06
Technical data 2
Mode of operation 3
Functional description 3
Steering column 4
Steering unit 4
Priority valve 6
Steering cylinder 7
Steering

2
06
Technical service data
t
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a
M s
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4
1
8
–
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1
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0
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C
P
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R 0
/
5
+
0
0
1 r
a
b
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v
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a
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a
b
0
/
0
2
+
0
6
1
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T 7
1
0
8
B
2
5
1
0
4
S
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P r
a
b
4

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3
P
LS
CF
EF
LS
P
T
P R
L R
1
2
3
4
5
6
7
8
Rechts
Links
Fahrtrichtung
<----------
06
direction
right
left
Mode of operation
The vehicle has power assisted steering based on
the load sensing (LS) principle and acts on the
steering cylinder (7) at the steering axle.
A steering unit (3) is flanged to the bottom end of the
steering unit (2). It consists of a distributor valve and
a measuring pump. When the steering wheel is
operated, the measuring pump supplies the steering
system with oil, which is directly proportional to
rotation of the steering wheel. The distributor valve
supplies this oil to the required side of the steering
cylinder.
In LS systems, the steering and hydraulics are
supplied from a common pump unit (1). The
distribution of oil between both systems takes place
in the priority valve (4). The steering always has
priority, i.e. a sufficient quantity of oil is always
Steering
supplied to the steering appropriate to the respective
steering speed, independent of the load in the steering
system and hydraulics.
A smaller quantity of oil is required for steering than
for specific hydraulic functions. For this reason, the
pump unit operates at a slow speed during steering
with the hydraulics inactive.
In the event of failure of the oil flow, the steering unit
functions automatically as a handpump, so that the
vehicle can be steered manually (emergency steering).
1 – Pump 5 – Slider bank
2 – Steering column 6 – Hydraulic tank
3 – Steering unit 7 – Steering cylinder
4 – Prority valve 8 – Suction filter

4
LS
L R T P
2
1
06
Steering column/Steering unit
Steering column adjustment
The incliniation of the steering column can be
infinitely adjusted within a range of about 10° after
loosening the grip screw (2) (turning anticlockwise).
After adjusting the steering column to the required
position, it must be relocked by tightening the grip
screw.
Steering unit
The steering unit (1) is fixed to the steering column
bearing with four cheese-head screws.
The following valves are installed in the steering
unit, which are set to a fixed value by the
manufacturer:
Relief valve: 150 bar
Shock valve: 220 bar
ATTENTION: The valve settings must not be
altered.
Removing the steering unit
– Remove floor plate.
– Unscerw left inner covering.
– Unscrew rear steering column cover.
– Unscrew hydraulic connections T (tank), P
(pumps), L (left connection), R (right connection),
LS (control connection) and mark.
ATTENTION:
When unscrewing the hydraulic connections,
hydraulic oil will discharge. Collect the hydraulic
oil and dispose of in a proper manner.
– Loosen the four cheese-head screws and
remove handpump downwards.
While loosening the screws, the steering wheel
with steering column must be tilted forward and
back.

5
16 13
14
15
17
11
12
12
1
2
3
4
5
4
6
8
7
9
10
9
06
Fitting the steering unit
Fitting takes place in reverse order to removal.
ATTENTION:
It is important that the previously marked
hydraulic lines are screwed back into the same
position to prevent a risk of accident.
Repair of the steering unit
– In case of damage, the steering unit must be
replaced.
– Exception: Oil leakage
Available for this repair is a sealing set
Ident. No.:144694 consisting of:
1 x Lip seal (14)
1 x Dust seal (15)
7 x Washer (16)
3 x O-ring (17)
1 x Fitting instructions
NOTE:
For replacement of the lip seal and dust seal,
special tools of Messrs Danfoss are required.
– To stem union leaks at the steering unit
connections, seals are available from STILL Spare
Parts Service. However, the connection tightening
torques should previously be checked.
Steering unit
No. Description Remarks
1 Cheese-head screw MA = 46Nm
2 Washer
7 Steering column Tilt forward and back
Remove rear steering
column cover.
8 Union MA = 50Nm
9 Reducing union MA = 100 Nm
10 HP hose
11 Relief valve Installed in steering
unit.
MA = 50 ±1Nm

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