Still forklift r70 70 series service repair manual

STILL GmbH Stand: 03/2004 ( Ersatz für Stand: 8/1994 )
WORKSHOP - MANUAL
R 70-60 / 70 / 80
R 7044 - 46
Ident-No.: 164 732(ex146 592)

01
Chassis Frame
01STILL GmbH Stand: 01/2004 ( Ersatz für Stand: )
Workshop Manual R 7044 - 46
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.

01
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
MA = 660 Nm
9 = tension washer
10 = cross member
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

01
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 ± 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

02
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
Stub axle bearings Grease FL,DIN 51825-KPF2N-20, lithium soap
based
STILL Ident. No. 148659

02
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 beamright and left.Articulation
is limited by stops on the counterweight.
1 = axle bearing
2 = roll pin
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
- Installsteeraxle byreversingtheremoval procedure.
Torque hex hd bolts (4) to MA = 385 Nm

02
Steer Axle
Axle bearing - Dismantling
1 =hex hd screw M6x16
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

02
Steer Axle
Trail wheel hub - Dismantling
1 = stub axle
2 = washer
3 = chevron seal
4 = tapered roller bearing
5 = wheel hub
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
- 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

02
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 washer (4)
- Withdraw eyebolt (7)
- Drive pin (13a) out of stub axle (10) (protect threads)
2. Dismantling at steering arm
- 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

02
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)

02
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

02
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
8 = washer
9 = sealing ring
10 = pin
- Remove hex hd bolt (4)
- Remove washer (5)
- Withdraw bearings (6) + (7) if necessary
Steering arm - Reassembling
- Clean hex hd bolt (4) in a degreasing agent, apply
Loctite 242 and tighten to a torque of 86 Nm

02
Steer Axle
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
1. Remove from the stub axle:
1.1 the eyebolt (6) - for disassembly see page 5
of Functional Group 02 „Track rod removal“
1.2 Removing the piston rod (7) from the eyebolt
(6)
- slacken hex hd bolt (8)
- screw off piston rod (7) from eyebolt
Steer cylinder removal

02
Steer Axle
Detail „Z“
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

02
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
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.
- Check that the wheel lock is not limited by the
cylinder stroke.
Right-hand bend
Left-hand bend

02
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!

02
Wheel hub - Removal and Dismantling
1 = axle beam
2 = stub axle
3 = radial sealing ring
5 = wheel hub
6 = split-pin (cotter pin)
7 = hub cap
8 = castle nut
9 = washer
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

02
Right-hand bend
Left-hand bend
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
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,
- Check that the wheel lock is not limited by the
cylinder stroke.

02
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
11 = grease nipple
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).

02
Stub axle - Reassembling and Installation
1 = nut
2 = washer
3 = king pin
4 = plug
5 = stub axle
6 = spacing washer
7 = wiper ring
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.

02
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 MoS2
prior to
installation.

02
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.

03
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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03
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..

03
Intermediate flange
Item Description
1 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

03
Wheel reduction gear/ Frame
1. Hex hd bolt M24x85 8.8
MA = 660 Nm
2. Hex hd bob MA 940 Nm
MA = 660 Nm
MA = 940 Nm
Flange

Still forklift r70 70 series service repair manual

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