Still r70 20 bis 45 fork truck service repair manual

STILL GmbH Stand: 08/2003 ( Ersatz für Stand: 03/1988 )
WORKSHOP MANUAL
R 70-20 bis 45
R 7012/13, R 7015/16, R 7023/24,
R 7041 - 43
Ident-No.: 164 729 (ex147 986, 145 221)

01
Workshop Manual R 7041 - 43, (R 7012/13 / 15/16 / 23/24)
Chassis Frame and Counterweight
01
1
2
3
4
1
2
Chassis Frame
The chassis frame is constructed of electrically
welded steel plate.
The fuel tank is positioned within the righthand
frame section, whereas the hydraulic tank is
housed within the left-hand frame section.
Counterweight
The removable rear counterweight is secured to the
frame weldment by 4 bolts.
1 = hex. hd. bolt M24 x 110, 8.8
DIN 933
Torque loading = 710 Nm
2 = locking ring
3 = spherical washer C25 DIN 6319
4 = ball cup D28 DIN 6319
Weight of the counterweight
7041 = 2200 kgs
7042 = 2570 kgs
7043 = 2910 kgs

02
Steer Axle
01
Contents Page
Technical Data for Maintenance Service 2
Steer Axle - Construction 3
Steer Axle removal & installation 3
Wheel Hub - Removal & Dismantling 4
Wheel Hub - Reassembling and Installation 4
Checking the steering angles 5
Wheel angle stop adjustment 5
Stub axle removal and installation 6
Track rod and steer cylinder bearing at stub axle 7
Track rod bearing on steering bell crank 7
Steer cylinder mounting at axle beam 8
Bell crank mounting 8

02
Technical Data for Maintenance Service
02
Functional Group 02
Steer axle
Wheel lock angle 80-82°
Toe-in 01 ± 1 mm
Wheel camber 0°
Trail 0°
Torque loadings for
Wheel hub MA = 470 Nm
Neoprene blocks MA = 195 Nm
Wheel nuts MA = 600 Nm
Lubricant
Wheel hub bearings lithium soap based grease
Stube axle king pin bearings lithium soap based grease

02
Steer axle
03
Steer axle - Construction
The articulating steer axle suspended from
the counterweight is mounted in neoprene blocks.
The stub axles are supported in the axle beam on
roller thrust bearings and bushes. Steering is limited
by stop screws on the stubs axles.
1 = axle beam
2 = fixing plates
3 = roll pin
4 = tension washer
5 = hex. hd. screw
6 = neoprene block
Steer axle removal
Caution:
Remove steer axle only wit mast in position on
the truck!
- Securely chock the front wheels to prevent rolling of
the truck
- Apply the parking brake
- Slacken steer wheel nuts
- J ack 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.
Caution: prepare for oil spillage!
- Remove the four hex. head screws M16 x 70 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 leverdrive 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 195 Nm
- Note:
Do not swap hydraulic connections left and right!

02
Steer axle
04
Wheel Hub - Removal and Dismantling
1 = axle beam
2 = stub axle
3 = radial seal
4 = tapered roller bearing
5 = wheel hub
6 = tapered roller bearing
7 = washer
8 = roll pin
9 = hubcap
10= nut
11 = ball seat nut
12= wheel bolt
- Slacken ball seat nuts (11) and remove wheel
- Pull hub cap (9) from wheel
- Slacken nut (10)
- Remove washer (7) together with roll pin (8)
- Withdraw the hub
- If necessary, drive out of wheel hub outer races of
tapered roller bearings (4) and (10)
Remove radial seal (3)
Wheel hub - Reassembling and Installation
- Apply a smear of grease to the sealing lips of the
radial seal
- Before re-assembling the hub, first fill cavity of
taperedrollerbearings andbearingcage withgrease
- The corresponding bearing spaces must be
repacked with grease at places identified by an X
on the drawing
- To reassemble the hubs, reverse the procedure
- Tighten nut (8) while rotating the wheel hub
Torque loading: MA= 470 Nm

02
Steer Axle
05
Linkskurve
= 82° +0/-2 Lenkeinschlag
Rechtskurve
1
Checking the steering angles
The steering angle ‘a’ must amount to 80° -82°. To
facilitate the measurement use the complementary
angle ß 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 82° - 2°
- Check opposite angles
- Check for adequate clearance between wheels and
truck frame
- Check that the wheel lock is not limited by the
cylinder stroke
a
a
ß
ß
Right-hand bend
Steering lock
Left-hand bend
a

02
Steer Axle
06
Stub axle king pin bearings
Removal:
Unscrew the three grease nipples (1)
Remove screws (2) from lower and upper ends of king
pin
Remove washers (3 & 14), roll pins (6 & 13) as well
as seals (5)
Unscrew grub screw (10)
Drive king pin (4) down, forcing out lower needle
bearings (7) and seal (8) at the bottom of the king
pin. Then drive out king pin into opposite direction.
Drive out upper needle bearings (7) and seal (8)
Remove stub axle (11) with thrust bearing (9) and
shims (12)
Installation:
Pack bearings with grease. apply a smear of
grease to the sealing lips of the seals before
installation!
Install needle bearings (7) andseals(8) into axle beam
Install stub axle (11) with thrust bearing (9) into axle
beam
Grease shims (12) before installation. Compensate
for any play by adding shims (12), making sure that
the thickest shim is placed bearing end
Install stub axle king pin (4), pressing it in at 8 kN
max.
Apply Loctite grade 243 to threads of grub screw (10)
and install grub screw
Install washers (3 & 14) with seals (5)
Install roll pins (6 & 13)
Install screws (2)
Install grease nipples (1)
Lubricate the stub axle with grease!

02
Steer Axle
07
Track rod and steer cylinder bearing at stub
axle
1 = hex. hd. screw M10 x 35, secured with
Loctite 243
2 = washer
3 = oil seal
4 = ball joint, press force: 4 kN max.
5 = roll pin 6 x 24
6 = completely screw in piston rod then screw
but by one turn
7 = oil seal
8 = oil seal
9 = pin, press force: 8 kN max.
Track rod bearing on steering bell crank
1 = circlip (retaining ring)
2 = pin, press into steering bell crank at 30 kN
max.
press into ball joint at 10 kN max.
3 = steering bell crank
4 = ball joint, press force: 4 kN max.
5 = V shaped rings
6 = washer

02
Steer Axle
08
Steer cylinder mounting at axle beam
1 = snap ring
2 = ball joint, press force: 2.6 kN
3 = roll pin
4 = hex. hd. bolt, secured with Loctite 243
5 = washer
6 = oil seal
7 = oil seal
8 = pin,
press into ball joint at 9 kN max.
press into axle beam at 68 kM max.
Bell crank mounting
1 = locking ring
2 = washer / shims
3 = needle bearing
4 = pin, press into axle beam at 42 M max.
5 = grease nipple
6 = snap ring
7 = washer (must always be fitted)
8 = oil seal

03
Power axle
01
Contents Page
Technical Data for Maintenance service 2
Power Axle / Description 3
Spur-type reduction gearbox / Sectional view 5
Power axle removal and installation 6
Wheel hub removal and installation 9
Half -shaft removal and installation 10

03
Technical Data for Maintenance service
02
Functional Group 03
Power axle type AE 40 - 02
Torque loadings frame/power axle MA = 1000Nm
Torque loadings axle housing/gear reduction box MA= 295Nm
End play toothed hollow shaft
+ 0.03 mm
- 0.06 mm
Torque loadings centring flange / wheel hub
ZS M 8 x 16 10.9 MA=35 Nm
Torque loadings oil drain plug MA = 70 Nm
Torque loadings half shaft ZS M 12 x 35 10.9 MA = 120 Nrn
Gearbox oil capacity: 9.5 litres checked with dipstick unscrewed and
pushed in as far as it will go and then withdrawn again
Grade of oil: SAE - 90 EP - 51512
Grade of grease lithium soap based grease with EP additive

03
Power Axle
03
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).
The long axle housing (3) with the double reduction
spur-type gearbox (1) are rigidly bolted to the frame
and the mast pivots are bolted to the half-shaft
housings.
1 = differential gear reduction box
2 = D.C. drive motor
3 = long half-shaft housing with cast-on
brake backplate
4 = fixing screws
5 = short half-shaft housing / gearbox half
with cast-on brake backplate
6 = mast pivots bolted to the half shaft housings

03
04
Power Axle
Spur-type reduction gearbox with differential assembly

03
Spur-type reduction gearbox with differential assembly
05
1 Gear case
2
3 dowel pin
4 allen screw
5 tapered roller bearing
6 differential
7 gear
8 roll pin
9 hex hd bolt
10 shim 145 x 130 x 0.5 -0.9
11 twered roller bearing
12 gear with shaft
13 shim 160 x 85 x 0.5 -0.9
14 circlip
15 connector
16 sealing ring
17 oil drain plug
18 lid
19 plug
20 driving dog
21 chevron seal
22 tapered roller bearing
23 toothed hollow shaft
24 ‘O’ring
25 shim 75 x 65 x 0.5 -0.8
26 ‘O’ring
27 chevron seal
28 cover
29 spring washer
30 hex hd bolt M 8 x 20 8.8

03
Power Axle
06
Power Axle removal
Remove mast assembly
Chock truck securely to prevent rolling
Drain oil at oil drain plug (2), catch oil in pan
Slacken wheelnuts
Remove wheels
Clearly mark the electric cables before disconnecting
them from the drive motor
Disconnect hydraulic brake lines at brake master
cylinder
Disconnect brake cables at the parking brake
With sling around power axle attach chain to overhead
hoist
Remove mounting bolts (3) right and left
Carefully manoeuvre the power axle clear of truck
Power Axle mounting
With the overhead hoist manoeuvre power axle into
frame
Insert the 16 mounting bolts with their 16 washers
but do not tighten at this stage
Torque all mounting bolts (3) to
MA 1000 Nm
Remove overhead hoist
Reconnect drive motor cables
Reconnect hydraulic brake lines to brake master
cylinder
Reconnect brake cables to parking brake Install
wheels (see FG. 04) Install mast (see FG. 20)
Checking oil level: Unscrew dipstick. push it in
as far as it will go and then withdraw again (do
not screw in for checking the oil level)
Oil capacity: 9.5 litres
Gearbox oil : SAE 90 EP - 51512 1 = oil filler neck with dipstick
2 = oil drain plug
3 = mounting bolts
4 = tension washers

03
Power Axle
07
Item Description
1 Spring washer DIN 137
2 Hex hd bolt M 8 x 20 8.8 MA = 23 Nm
3 Washer
4 Chevron seal A 45 x 62 x 8 P70
5 ‘0’ ring seal 37x2-P70
6 Tapered roller bearing
7 ‘0’ ring seal 74x3-P80
8 Lid
9 Allen screw M 12 x 50 - 10.9 MA = 120 Nm
10 Tapered roller bearing
11 Toothed hollow shaft
Power from the drive motor is transmitted via a
shaft with spline to the double reduction gears.
The pinion shaft in gearbox
is supported both sides on tapered roller bearings,
and the sealing between drive motor and gearbox
is with chevron seal.

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03
Power Axle
08
Adj usting instructions for supporting the toothed
hollow shaft on taper roller bearings
1. Assemble both taper roller bearings onto toothed
hollow shaft. After that determine dimension W
across taper roller bearing outer races.
2. Determine installation dimension „B“.
3. Determine centring collar length „C“ on cover.
4. Thickness of shims D = B - (minus)
(A + C + 0.06 mm)
5. Add or remove shims as per actual dimension =
„D“ + (plus) 0.03 mm (preload) up to - (minus)
0.06 mm (free play).
6. Assemble both taper roller bearings which must
be repacked with grease up to half of the max.
capacity In exceptional cases gearbox oil SAE
140 EP can be used as a substitute.
7. Using a fitting tool (mandrel), preassemble outer
race of taper roller bearing (opposite the cover).
8. Install toothed hollow shaft.
9. Using a fitting tool, pre-assemble by around 20
mm outer race of taper roller bearing (cover side).
10. Install layer of shims as per para. 5, and by
tightening the coverboltsevenlyin corner tocorner
sequence bring taper roller bearing outer race
into final position.

03
Wheel hub
09
Wheel hub removal
- J ack up truck securely from the side the removal is
performed or drain the oil from the reduction gearbox
if both sides of the truck are chocked.
- Remove the wheeinuts and withdraw the drive wheel.
- Remove the half -shaft (6) - see page 9.
- Remove the brake drum(1)after having first released
the parking brake.
- Remove the alien screws (7).
- Remove the centring flange (8).
- Remove hub (3).
Wheel hub installation
NOTE: If the wheel hub is not provided with wheel
studs (2), press new studs into the wheel hub
using a press.
- Tap both outer races of the taper roller bearings
(10 & 11) into the wheel hub.
- Grease inner race of taper roller bearing (10) and
insert it into wheel hub.
- Press radial seal (12) into wheel hub.
- Pack wheel hub with grease, and slide it on axle
housing.
- Grease inner race of taper roller bearing (9) and
tap until properly seated.
- Apply Loctite 572 to centring flange (8) and position
it on the axle housing (centring occurs
automatically on taper roller bearing), install alien
screws (7) and tighten to specified torque.
Torque loading: M A= 35 Nm
- Refer to page 10 for half-shaft installation.

03
Half -shaft removal and installation
10
Half-shaft removal
- J ack up truck securely from the side the removal
is performed or drain the oil from the axle.
- Remove wheeinuts.
- Remove drive wheel.
- Remove screws (1) securing half-shaft to hub.
- Using two of the screws, pull half-shaft (3) from
housing. Two appropriate tapholes exist in the
shaft flange.
- Carefully withdraw the half-shaft from the axle
housing.
Half-shaft installation
- Install chevron type sealing ring (2).
- Slide O-ring (4) on half -shaft.
- Carefully install half-shaft (3) into axle housing
and assemble it to bevel gear in differential. It
may be necessary to drive it in with a hammer
and a block of hardwood.
- Bolt half-shaft (3) and wheel hub (5) firmly
together.
- Torque loading MA = 120 Nm
- Follow same procedure for other halfshaf t.

Still r70 20 bis 45 fork truck service repair manual

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Still r70 20 bis 45 fork truck service repair manual